Kawasaki Z750 manual

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This quick refer ence guide will assi st you in locating a desired topic or pr o- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black t ab on the edge at each table of conten ts page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic req uired. Quick Refer[...]

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Z750 All rights r eserved. No parts of this publ ication may be reproduced, stor ed in a retrieval system, or transmitted i n any form or by any means, electronic mechanical photocopyi ng, recording or other wise, without the prior wri tten permissio n of Quality A ssurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industr[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dea d center m meter(s) AC alternati ng current min minute( s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolu tion DC dire[...]

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contai ns enough detail and basic i n- formation t o make it useful to the owner who de- sires to perfor m his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures mus[...]

NOTE ○ This note symbo l indicat es points o f par - ticul ar interest f or more effici ent and con- venien t opera tion. • Indicates a procedural step or work t o be done. ○ Indicates a proc edural sub-step or how t o do the work of the procedural step i t follows. It also precedes the tex t of a NOTE. Indicates a c onditional step or what a[...]

GENERAL INFORMA TION 1-1 1 General Information T able o f Content s Befor e Servic ing ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ....... .......... . 1-2 Model Identif ication... ...... ....... ........ ........ ........ ....... ........ ........ ........ ....... ........ ....[...]

1-2 GENERAL INFORMA TION Before Servic ing Before start ing to perform an inspection servi ce or carry out a disassembly and reassembly opera- tion on a motorcycl e, read the precauti ons given below . T o facilitate actual operat ions, notes, illust ra- tions, photograph s, cautions, and detailed descr iptions have been i ncluded in each chapt er [...]

GENERAL INFORMA TION 1-3 Before Servicing Arrang emen t and Clea ning of Re moved Pa rts Disassembled parts ar e easy to confuse. Arrange the parts accor ding to the order the parts were disass embled and clean the par ts in order prior to assembly . Stor age of Removed Pa rts After all the parts including subassembly part s have been cleaned, stor[...]

1-4 GENERAL INFORMA TION Before Servic ing Tight ening S equen ce Bolts, nuts, or screws must be tight ened according to the specified sequence to pr event case warpage or deformati on which can lead to malf unction. If the specified t ightening sequence is not indicated, tighten the fasteners alt ernating diagonally . Tighte ning T orque Incorrect[...]

GENERAL INFORMA TION 1-5 Before Servicing Pres s For items such as bearings or oil seal s that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper al ignment and use smooth movements when install ing. Ball Bea ring and N eedl e Bearin g Do not remove pressed ball o r needle unless removal is absol[...]

1-6 GENERAL INFORMA TION Before Servic ing Directio n of Engine Rot ation When rotating the crank shaft by hand, the free play amount of rotati ng direction will af fect the adjustment. Ro- tate the crankshaft to positive direct ion (clockwise vi ewed from output side). Electri cal Wi res A two-color wire is identif ied first by the primary col or [...]

GENERAL INFORMA TION 1-7 Model Identificatio n ZR750–J1 Lef t Side View : ZR750–J1 Right Side V iew:[...]

1-8 GENERAL INFORMA TION General Sp ecifications Items ZR750–J1 Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 780 mm (30.7 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 425 mm (56.1 in.) Road clearance 165 m m (6.5 in.) Seat height 815 mm (32.1 in.) Dry m ass 195 kg (430.0 lb) Cu rb mass : Fron t 1 1 1 kg (244.8 lb) Rear 107 [...]

GENERAL INFORMA TION 1-9 General Specificati ons Items ZR750–J1 Viscosi ty SAE 10W-40 Capacity 3.8 L (4.0 US qt) Driv e T r ain: Primary reducti on system: Ty p e Gear Reduction rati o 1.714 (84/49) Clutch type W et multi disc T ransmission: Ty p e 6-speed, constant mesh, return shi ft Gear ratios: 1st 2.571 (36/14) 2nd 1.941 (33/17) 3rd 1.555 (2[...]

1-10 GENERAL INFORMA TION T echnical Infor mation – Air Inlet System Subthrottle Contr ol System The ZR750–J1 employs large bore thrott le bodies to increase power output. However , sudden changes in thrott le opening can cause hesitati on and jerky throttl e response with a single butt erfly valve in a large bore. Therefore two thrott le valve[...]

GENERAL INFOR MA TION 1-1 1 T ec hnical Information – Air In let System Operation The subthrottle cont rol system consists of the subthr ottle valve, subthrottle valve actuator wi th a stepping motor built in it, ECU, and subthrottle sensor . The subthrottl e valve is built in the each t hrottle body . The subthrottle control s ystem operates on [...]

1-12 GENERAL INFORMA TION T echnical In formation – New Igniti on Interlock Side stand Out lin e The New Ignit ion Inter lock Sidestand Syst em applied to ZR750–J1 models that cannot func tion if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which diff ers from the tradi tional one. Refer to the[...]

GENERAL INFORMA TION 1-13 T ec hnical Information – T ail/Brake Lights Emplo ying LED Outline This model employs a tail/brake light contai ning 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span t han those emitted f rom a traditional electric heated bulb (more than 5 times longer), uses lower voltage, expends lo[...]

1-14 GENERAL INFORMA TION T echnical In formation – T ail/Brake Light s Employing LED The emitting color dif fers according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materi als of Semi-C onductor Emitt ing Color GaAsP , GaAlAs Red GaP Gree n GaN Blue Ga: Ga llium As: Arsenic P: Phosphorus N: Nitrogen Al: [...]

GENERAL INFORMA TION 1-15 T ec hnical Information – KA W ASAKI LOW E XHAUST EMISSION S YSTEM Since the emission regulati ons become more severe, Kawasaki has adopted a type of simplified KA WASAKI LOW EXHAUST EMISSION SYS TEM (KLEEN), which have no catalyst protect ion sys- tem, according t o each regulation of dif ferent countries. The muffl er [...]

1-16 GENERAL INFORMA TION Unit Conver sion T able Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass: k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume: L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (i mp) L ×[...]

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able o f Content s Periodic M aint enance Chart .... .......... 2-2 T orque and Lock ing Agent ............... .. 2-5 Spec ifica tions .... ...... ...... ....... ...... ...... . 2-10 Spec ial T ools . ...... ...... ...... ....... ...... ..... 2- 12 Periodic Maintenance Procedur es..... 2-13 Fue l Sy[...]

2-2 PERIODIC MAINTENANCE Periodic Main tenance Chart The scheduled mai ntenance must be done i n accordance with thi s chart to keep the motorcycle i n good running condit ion. The initial maint enance is vitally important and must not be neglected. Periodic I nspection: FREQUENCY Whichever comes first * ODOMETER READING km × 1000 (mile × 1000) 1[...]

PERIODIC MAINTENANCE 2-3 Periodic Mainten ance Chart FREQUENCY Whichever comes first * ODOME TER READING km × 1000 (mile × 1 000) 1 6 12 18 24 30 36 See INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page Engine stop switch operati on year • • • — Fuel system (DFI): Air cleaner ele ment - clean # • 2–18 Throttle control syst em [...]

2-4 PERIODIC MAINTENANCE Periodic Main tenance Chart Periodic Repla cement Parts: FREQUENCY Whichever com es first * ODOMETER READING km × 1000 (mile × 1000) 1 12 24 36 48 See CHANGE/REPLACE ITEM Eve ry (0.6) (7.5) (15) (24) (30) Page Brake hoses 4 years • 2–36 Brake fluid ( front and rear) 2 years • • 2–32 Rubber parts of master cylind[...]

PERIODIC MAINTENANCE 2-5 T orq ue and Locking Ag ent The following tabl es list the tight ening torque for the major fas teners requiring use of a non -permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: AL: T ighten the two clamp bolts alte rnately two times to ensure even ti ghtening torque. G: Apply grease to[...]

2-6 PERIODIC MAINTENANCE T orque and Lo cking Agent T orque Fastener N·m kgf·m ft·lb Remarks W ater pump drain bolt 11 1.1 95 in·lb Water pipe bo lts 11 1.1 95 in·lb Thermostat housing gr ound bolt 7.0 0.70 61 in·lb Thermostat bracket bolt 7.0 0.70 61 in·lb Radiator upper bolts 7.0 0.70 61 in·lb Radiator lower bolts 7.0 0.70 61 in·lb Radia[...]

PERIODIC MAINTENANCE 2-7 T orq ue and Locking Ag ent T orque Fastener N·m kgf·m ft·lb Remarks Engine Lubricat ion: Oil fil ler plug 1.5 0.15 13 in·lb Engine oil dr ain bolt 20 2.0 14 Oil filter 31 3. 2 23 EO, R Holder mounting bolt 76 7.8 56 EO Oil pan bolts 11 1.1 95 in·l b Oil pipe holder bolts 13 1. 3 11 3 i n · l b L Oil pressure reli ef [...]

2-8 PERIODIC MAINTENANCE T orque and Lo cking Agent T orque Fastener N·m kgf·m ft·lb Remarks T i e-rod lock nuts 6.9 0.70 61 in·lb Neutral switch 15 1.5 11 Wheels/T ires: Front axle clamp bolt 34 3.5 25 Front axle 108 11 80 Rear axle nut 108 11 80 Final Drive: Engine sprocket nut 125 13 92 MO Engine sprocket cover bolts 9.8 1.0 87 in·lb Speed [...]

PERIODIC MAINTENANCE 2-9 T orq ue and Locking Ag ent T orque Fastener N·m kgf·m ft·lb Remarks Handlebar lower clamp nuts 34 3.5 25 Switch housing scr ews 3.5 0.36 31 in·l b Front fork c lamp bolts (Upper) 20 2.0 14 Front fork c lamp bolts (Lower) 20 2.0 14 AL Frame: Footpeg bracket bol ts 34 3.5 25 L Side stand bolt 44 4.5 33 Side stand switc h[...]

2-10 PERIODIC MAINTENANCE Specification s Item Standard S ervi ce Lim it Fuel System: Throttle grip f ree play 2 ∼ 3 mm (0.08 ∼ 0.12 in .) ––– Idle speed 1 100 ±50 r/min (rpm) ––– Bypass screws (turn out) 2 ±1/4 (for reference) ––– Engine vacuum 29.7 ±1.333 kPa (225 ±10 mmHg) ––– Air cleaner element Paper filter –?[...]

PERIODIC MAINTENANCE 2-1 1 Specifications Item Standard Servi ce Limit Air pressure: (when cold) Front Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) ––– Rear Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm², 42 psi) ––– Final Drive: Drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) ––– Drive chain 20-li nk length 317.[...]

2-12 PERIODIC MAINTENANCE Special T oo ls Steer ing Stem Nu t Wrench: 57001–1100 Jack: 57001–1 238 Oil Filter Wrench: 57001–1 249 Pilo t Scre w Adj uster , C: 57001–12 92 Hand T est er: 57001–13 94 Spark Pl ug Wr ench (Owner’s T ool): 921 10–1 146[...]

PERIODIC MAINTENANCE 2-13 Periodic Maint enance Proced ures Fuel System (DFI) Fuel Hose and Connect ion Inspection ○ The fuel hoses are desi gned to be used thr oughout the motorcycle’ s l ife wit hout any maintenance, however , if the motorcycle is not properly handled, the high pr essure in- side the fuel line can cause fuel t o leak [A] or t[...]

2-14 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures Throttle Control System Inspection Throttle Grip Play Inspecti on • Check the throttle gri p free play [A]. If the free pl ay is incorrect, adjust the throttle cable. Throttle Grip Free P lay Standard: 2 ∼ 3m m( 0 . 0 8 ∼ 0.12 in.) • Check that the thrott le grip moves smoothly fro[...]

PERIODIC MAINTENANCE 2-15 Periodic Maint enance Proced ures Idle Sp eed Ins pection • Start the engine and warm i t up thoroughly . • With the engi ne idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttl e cables may be improperly adjusted or incorrectl y routed or damaged. Be sure to correct any o[...]

2-16 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures • Install t he fuel tank (see Fuel System (DFI) chapter). • Start the e ngine and warm it up thoroughly . • Check the idle speed. T achometer [A] If the idle speed is out of the specif ied range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit. Wh[...]

PERIODIC MAINTENANCE 2-17 Periodic Maint enance Proced ures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Specia l T ool - Pilot Screw Adju ster , C: 5 7001–1292 • Adjust the lowest vac uum between #1 and #2 to the hi gh- est of #1 and #2. • Adjust the lowest va[...]

2-18 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures • Back out the same number of turns counted when first turned in. This is to set the screw to its original pos ition. NOTE ○ A throttle body has diff erent “turns out” of the bypass screw for each i ndividual unit. When setting the bypass screw , use the “turns out” determined [...]

PERIODIC MAINTENANCE 2-19 Periodic Maint enance Proced ures • Remove the fuel tank (see Fuel System (DFI) chapt er). • Remove the fuel tank bracket bol ts and bracket [A]. • Remove: Air Cleaner Duct Holder Screws [A] • Remove the air clean er duct holder [B] backwar d. • Clean the element by tapping it lightly t o loosen dust. • Blow aw[...]

2-20 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures Cooling System Radiator H ose and Conn ection Insp ection ○ The high pressure insi de the radiator hose can caus e coolant to l eak [A] or the hose to burst if the line is not properly mai ntained. Visually inspec t the hoses for signs of deterio ration. Squeeze the hoses. A hose should [...]

PERIODIC MAINTENANCE 2-21 Periodic Maint enance Proced ures • When filli ng the coolant, choose a suita ble mixture ratio by referring to t he coolant manufacturer’s direct ions. CAUTION Soft or distilled water must be used with the an- tifreeze in t he cooling system. If hard water is used in the system, it causes scale accumulation in the wat[...]

2-22 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures Engine T op End Air Su ction V alve Ins pectio n • Remove the air suction v alve (see Engine T o p End chap- ter). • V isually inspect the reeds for cracks, folds, warps, heat damage or other damage. If there is any doubt as to th e condition of the reeds [A], replace t he air suction [...]

PERIODIC MAINTENANCE 2-23 Periodic Maint enance Proced ures ○ When positioning #4 piston TDC at the end of the compression stroke: Inlet valve clearance of #2 and #4 cylind ers Exhaust valve clearance of #3 and #4 cylinders Measuring V alve [A] ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet valve clearance of #1 an[...]

2-24 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures • Slide the dust cover [A] at the clutch cable lower end out of place. • Loosen both adjust ing nuts [B] at the cl utch cover as far as they will go. • Pull the clutch outer cabl e [C] tight and tighten the adjust- ing nuts against the cover [D]. • Slip the rubber dus t cover back [...]

PERIODIC MAINTENANCE 2-25 Periodic Maint enance Proced ures NOTE ○ Although 10W-40 engine oil is the recommended oil for most condi tions, the oil viscosi ty may need t o be changed to accommodate atmospheric conditions in your riding area. Oil Fi lter Chan ge • Drain the engine oi l (see Engine O il Change) . • Remove the oil fi lter [A] wit[...]

2-26 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures Tr e a d D e p t h Front: Stand ard: 3.4 mm (0.1 3 in.) Service Limit: 1 mm (0.04 in.) 1.6 mm (0.06 in.) (A T , CH, DE ) Rear: Stand ard: 5.8 mm (0.2 3 in.) Service Limit: 2 mm (0.08 in.) (U p to 130 km/h (80 mph )) 3 mm ( 0.12 in.) (Over 130 km /h (80 mph)) W A RNING T o ensure safe handl[...]

PERIODIC MAINTENANCE 2-27 Periodic Maint enance Proced ures Final Drive Drive Chain Slack Inspection NOTE ○ Check the slack with the mot orcycle setting on i ts side stand. ○ Clean the chain i f it is dirty , and lubricate it if it appears dry . • Check the wheel alignment (see Wheel Ali gnment Inspec- tion). • Rotate the rear wheel to find[...]

2-28 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures • Bend the cott er pin [A] over t he nut. W A RNING If the rear axle nut is not securely tightened or the cotter pin i s not installed, an unsafe riding condi- tion may result. Drive Chai n W ear Inspect ion • Remove: Chain Cover Screws [A] Chain Cover [B] Mud Guard [C] (see Frame chap[...]

PERIODIC MAINTENANCE 2-29 Periodic Maint enance Proced ures Driv e Chain Lu bricati on • If a special lubricant is not available, a heavy oil such as SAE 90 is preferr ed to a lighter oi l because it will stay on the chain l onger and provide bet ter lubricat ion. • If the chain appear s especiall y dirty , clean it bef ore lubri- cation. CAUTI[...]

2-30 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures If it does not, adjust and inspect the brake light switch. • While holding the switch body , turn the adjusting nut [A] to adjust t he switch. CAUTION T o avoid damaging the electri cal connections in- side the swit ch, be sure that the swi tch body does not turn during adjustment. • R[...]

PERIODIC MAINTENANCE 2-31 Periodic Maint enance Proced ures Mas ter Cyl inder In spect ion (Visua l Insp ection ) • Remove the master cyli nders (see Brakes chapter ). • Disassemble the front and r ear master cylinders. • Check that there are no sc ratches, rust or pitting on the inner wall [A] of each m aster cylinder and on t he outside of [...]

2-32 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures Brake Fluid Le vel Inspection • Check that th e brake fluid l evel in the fr ont brake reservo ir [A] is ab ove the lower level l ine [B]. NOTE ○ Hold the reservoir hor izontal by turning the handl ebar when checking brake flui d level. If the fluid l evel is lower than the lower level[...]

PERIODIC MAINTENANCE 2-33 Periodic Maint enance Proced ures • Level the brake fluid reser voir . • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed val ve [A] on the caliper . • Attach a cl ear plasti c hose [B] to t he bleed valve, and run the other end of the hose int o a container . • Fill the reservoi r w[...]

2-34 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures B r a k eL i n eB l e e d i n g The brake flui d has a very low compression coeffici ent so that almost all the movement of the brake lever or pedal is transmitted di rectly to the cal iper for braking action. Air , however , is easily c ompressed. When air enters t he brake lines, brake l[...]

PERIODIC MAINTENANCE 2-35 Periodic Maint enance Proced ures • Bleed the brake line and the caliper: ○ Repeat this operati on until no more air can be seen com- ing out i nto the plast ic hose. 1. P ump the brake leve r until it becomes hard, and apply the brake and hold i t [A]. 2. Q uickly open and close [ B] the bleed valve while hold- ing th[...]

2-36 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures W A RNING When working with the disc brake, observe the pre- cautions listed below . 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open f or a long time. 3. Do not mix two types a nd brands of fluid for use in the brake. T[...]

PERIODIC MAINTENANCE 2-37 Periodic Maint enance Proced ures Suspension Front Fork Oi l Leak Check • Visual ly inspect t he front forks [ A] for oil l eakage, scoring or scratches on the inner surface of the inner tubes. Replace or repair any defective parts, if neces sary . Rear Shoc k Absorber Oil L eak C heck • Visual ly inspect the shock abs[...]

2-38 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures • Bend the claw washer tabs [A]. • Remove the steering st em locknut [B] and claw washer [C]. • Adjust the steeri ng. Special T ool - Steering Stem N ut Wrench: 5 7001–1 1 00 [B] If the steering i s too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loo[...]

PERIODIC MAINTENANCE 2-39 Periodic Maint enance Proced ures Electrical System Spark Pl ug Inspe ction • Remove: Fuel T ank (see Fu el System (DFI ) chapter) • Unscrew the thermostat br acket bolt [A]. • Disconnect: W ater T emperature Sen sor Connector [B] Left Switch Housi ng Connector [C] ○ If removing t he spark plug #2 o r #3. • Disco[...]

2-40 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures • Clean the spark plug, preferably in a sandbl asting device, and then clean of f any abrasive particles. The plug may also be cleaned using a high-fl ash point solvent and a wire brush or ot her suitable t ool. If the spark plug center electrode [A] and/or side electr ode [B] are correc[...]

PERIODIC MAINTENANCE 2-41 Periodic Maint enance Proced ures General Lubricatio n Lubri cation • Before lubric ating each part, clean off a ny rusty spots with rust remover and wipe off any greas e, oil, dirt, or grime. • Lubricate the po ints listed below wit h indicated l ubricant. NOTE ○ Whenever the vehicle has been operated under wet or r[...]

2-42 PERIODIC MAINTENANCE Periodic Ma intenance Proc edures Nut, Bolt, and Fastener Tightness Tight ness I nspec tion • Check the tightness of the bolts and nuts l isted here. Also, check to see that each cotter pin is in place and in good conditi on. NOTE ○ For the engine fa steners, check the tightness of them when the engine is cold (at room[...]

FUEL SYSTEM (DFI) 3 -1 3 Fuel System (DFI) T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 3-4 DFI Pa rts Loc atio n . ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ........[...]

3-2 FUEL SYSTEM (DFI) Senso r R esista nce I nspe ction . ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ........ ...... ....... 3-5 0 Atmospheric Pressure Sensor (Ser vice Code 15) ..... ............ .......... ......... ............ .......... ........ 3-51 Remo val ...... ...... ...... ...... ....... ...... ......[...]

FUEL SYSTEM (DFI) 3 -3 3 Fuel Pu mp R elay R emov al ... ...... ...... ...... ....... ...... ...... ........ ....... ...... ...... ...... ...... ....... ...... ... 3- 80 Fuel Pu mp R elay I nspe ction ... ...... ...... ...... ....... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ... 3- 80 Fuel Inje ctors . ...... ...... ..[...]

3-4 FUEL SYSTEM (DFI) Exploded View[...]

FUEL SYSTEM (DFI) 3 -5 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Throttle cable plat e bolt 6.0 0.60 52 in·lb 2 Throttle body assy holder clamp bolts 2.0 0.20 17 in·l b 3 Choke link holder screws 2.1 0.21 18 in·lb 4 Delivery pipe s crews 3.4 0.35 30 in·lb 5 Fuel pump bolts 9.8 1.0 87 in·lb L,S 6 Fuel level sensor bol ts [...]

3-6 FUEL SYSTEM (DFI) Exploded View[...]

FUEL SYSTEM (DFI) 3 -7 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Inlet air pressur e sensor bolt 12 1.2 104 in·l b 2 W ater t emperature sensor 25 2.5 18 3 V ehicle down sensor bolts 2.0 0.20 17 in·lb 4 Camshaft position sensor bolt 12 1.2 104 in·l b 5 Camshaft position sensor rotor bolt 12 1.2 104 in·lb L 6 Air cleaner d[...]

3-8 FUEL SYSTEM (DFI) DFI Parts L ocation DFI: DFI Parts (this chapt er) 1. W ater tem peratur e Sen- sor (DFI) 2. Inlet Air Pressure Sensor (DFI) 3. Injectors (DFI) 4. Fuel Pump (DFI) 5. Inlet Air T emperature Sensor (DFI) 6. Sealed Battery 7. Junction Box 8. ECU Fuse 15 A 9. ECU (DFI) 10. Stick Coils 1 1. Throttle Body Assy 12. Self-diagnosi s T [...]

FUEL SYSTEM (DFI) 3-9 DFI Parts Location [1], [2], [ 10], [13], [22] a nd [24] are not included.[...]

3-10 FUEL SYSTEM (DFI) DFI Wirin g Diagram[...]

FUEL SYSTEM (DFI) 3-1 1 DFI Wiring Diagram T erminal Names 1. Power Supply to Sensors 2. Main Throttle Sensor Signal 3. Subthrottl e Sensor Signal 4. Atmospheric Pressure Sensor Signal 5. W ater T emperature Senso r Signal (+) 6. Unused 7. Igniti on Switch Signal 8. Unused 9. Camshaft Position Sensor Signal (+) 10. Unused 1 1. Crankshaft Sensor Sig[...]

3-12 FUEL SYSTEM (DFI) Specification s Item Standard Digital Fuel Inject ion System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Ty p e Four barrel type Bore 34 mm (1.34 in.) ECU (Electronic Control Unit): Make Denso Ty p e Digital memory type, wit h built in IC ignit er , sealed with resin Usable engine speed 100 ∼ 12 240 r/min (rpm) Fuel Pr[...]

FUEL SYSTEM (DFI) 3-13 Specifications Item Standard Detection time Within 0.5 ∼ 1.0 sec. Output voltage with the sensor tilt ed 60 ∼ 70° or m ore: 3.7 ∼ 4.4 V with sensor arrow mark pointed up: 0.4 ∼ 1.4 V Subthrottl e Sensor: Non-adjustabl e and non-removal Input voltage 4.75 ∼ 5.25 V DC between BL and BR/BK leads Output voltage at i dl[...]

3-14 FUEL SYSTEM (DFI) Special T oo ls Oil Pressure Gauge: 57001–1 25 Fork Oil Level Gauge: 57001–1 290 Hand T est er: 57001–1 394 Thrott le Sens or Setting A dapter: 57001–1 400 Fuel Pressure Gauge Adapter : 57001–1 417 Needle Adapter Set: 57001–14 57 Throttle Sensor Setting Adapter: 57001–15 38 Sensor Harness Ada pter: 57001–15 61[...]

FUEL SYSTEM (DFI) 3-15 DFI Servicing P recautions DFI Servici ng Precaut ions There are a number of important prec autions that should be followed servi cing the DFI syst em. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed batt ery as a power source. ?[...]

3-16 FUEL SYSTEM (DFI) DFI Servicing Precaution s ○ Whenever the DFI electri cal connections are t o be discon- nected, fir st turn off the ignit ion SW (switch), and discon- nect the battery (–) t erminal. Do no t pull the lead, onl y the connector . Conversely , make sure that all the DFI elec- trical connect ions are firmly reconnected befor[...]

FUEL SYSTEM (DFI) 3-17 T ro ubleshooting the DF I System Outline Outline When an abnormality in t he system occurs, t he FI i ndica- tor LED (Light Emitti ng Diode) light goes on to aler t the rider on the meter panel. In addition, the condition of the problem is stored in the m emory of the ECU (electronic control uni t). With the engine stopped a[...]

3-18 FUEL SYSTEM (DFI) T roubleshooting the DFI Syste m ○ The DFI part connectors [A] have seal s [B], includin g the ECU. • Join the conn ector and insert the needle adapt ers (special tool) [C] ins ide the seals [B] from behind the connector until the adapte r reaches the terminal. Special T ool - Needle Ad apter Set: 57 001–1457 CAUTION In[...]

FUEL SYSTEM (DFI) 3-19 T ro ubleshooting the DF I System • Pull each connector [A] apar t and inspect it for corrosi on, dirt, and damage. If the connecto r is corroded or dirty , clean it carefully . If it is damaged, replace it. Connect the connectors sec urely . • Check the wiring for continuit y . ○ Use the wiri ng diagram to find the e n[...]

3-20 FUEL SYSTEM (DFI) T roubleshooting the DFI Syste m ○ There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resist ance Check Method. (V oltage Check Method) ○ This method is conducted by measuring the input volt age [B] to a sensor [A] fir st, and then the output voltage [C] from the sensor . ○ Someti[...]

FUEL SYSTEM (DFI) 3-21 T ro ubleshooting the DF I System DFI Diagnosis Flow Chart Inquiries to Rider Inquir ies to Rider ○ Each rider reac ts to problems in di fferent ways, so it is import ant to confirm what ki nd of symptoms the rider has encountered. ○ T ry to find out exactly what problem occurred under exactly what condi tions by asking t[...]

3-22 FUEL SYSTEM (DFI) T roubleshooting the DFI Syste m Sample Diagnosis She et Rider name: Registration No. (license plate No.): Y ear of initial regi stration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cl oudy , □ rain , □ snow , □ always, □ other: T emperature ?[...]

FUEL SYSTEM (DFI) 3-23 T ro ubleshooting the DF I System Poor running □ choke lever pulled out fully (push it in fully) at low speed □ very l ow choke speed (adjust choke cable) □ very low idle speed, □ very high id le speed, □ rough idle speed □ battery vol tage is low (charge t he battery) □ spark plug loose ( tighten it ) □ spark[...]

3-24 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guide DFI System T roubleshooting Guide NOTE ○ This is not an exhaustive list , giving every possible cause for each problem list ed. It is meant simply as a rough guide to ass ist the troubleshoot ing for s ome of the more common diff iculties. ○ The ECU may be involved i n the DFI electr ica[...]

FUEL SYSTEM (DFI) 3-25 DFI System T rouble shooting Guide Symptoms or possible Causes Actions (chapter) Starting techniqu e faulty When flooded, don’t crank engine wi th thrott le fully opened. No spark or spark weak : Ignition and engine stop swi tches not ON T urn both switches ON . Clutch lever not pulled in and gear not in neutral whether sid[...]

3-26 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guide Symptoms or possible Causes Actions (chapter) Cylinder , piston worn Inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapt er 5). Piston ri ng/groove clearance excessive Inspect and replace ( see chapter 5). Cylinder head gasket [...]

FUEL SYSTEM (DFI) 3-27 DFI System T rouble shooting Guide Symptoms or Possible Causes Actions (chapter) Inlet ai r temperature sens or trouble Inspect (s ee chapter 3). W ater temperature sensor trou ble Inspect (see chapter 3). Atmospheric pressure sensor troubl e Ins pect (see chapter 3). Fuel pressure too l ow or too high Inspect (see chapter 3)[...]

3-28 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sens or trouble Inspect (see chapter 3). Subthrottle sensor t rouble Inspect (see chapter 3). Subthrottle valve act uator trouble Inspect (see chapt er 3). W ater temperature sensor trouble Inspect (see chapter 3). Atmospheric press[...]

FUEL SYSTEM (DFI) 3-29 DFI System T rouble shooting Guide Symptoms or Possible Causes Actions (chapter) Spark plug dir ty , broken or gap mal adjusted Clean spark plugs and adjust plug gap (see chapter 2). T oo low fuel pressure Inspect (see chapter 3) . Fuel pump trouble Inspect (see chapter 3) . Main throttle sensor tr ouble Inspect (see chapter [...]

3-30 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guide Poor Runni ng or No P ower at High Speed: Symptoms or Possible Causes Actions (chapter) Firing incorrect : Spark plug dirty , broken or maladjusted Clean spark plug and adjust plug gap (see chapter 2). Spark plug cap trouble Inspect stick coil (see chapter 16). Spark plug cap shorted or not [...]

FUEL SYSTEM (DFI) 3-31 DFI System T rouble shooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasol ine recommended in the Owner ’s Manual) Change fuel (see chapter 3). Spark plug incorrect Replace it with the corr ect plug ( see chapter 16). Stick coil trouble Inspect (see chapter 1 6). IC ignite[...]

3-32 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guide Symptoms or Possible Causes Actions (chapter) T oo low fuel pressure Inspect fuel line and fuel pump (see chapter 3). W ater temperature sens or trouble Inspect and replace (see chapter 3). Inlet air temperatur e sensor trouble Inspect and repl ace (see chapter 3).[...]

FUEL SYSTEM (DFI) 3-33 Self-Diagn osis Self-diagn osis Outline Self-dia gnosis O utline The self-diagnos is system has three modes and can be switched to anot her mode by gr ounding the self -diagnosis term inal. User Mode: The ECU notifies t he rider of troubles in DFI system and ignition syst em by lighting the FI indicator when DFI system and ig[...]

3-34 FUEL SYSTEM (DFI) Self-Diagnosi s • T o enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after t he lead is first gro unded, and then keep it grounded conti nuously [D] for more than 2 seconds. ○ Count the blinks of the LED light to read the servi ce code. Keep the aux[...]

FUEL SYSTEM (DFI) 3-35 Self-Diagn osis[...]

3-36 FUEL SYSTEM (DFI) Self-Diagnosi s How to Re ad Service Codes How to Read Service Codes ○ Service codes are shown by a series of long and shor t blinks of the FI indi cator LED light as shown below . ○ Read 10th digit and unit digit as the FI indi cator LED light blinks. ○ When there are a number of problems, all the service codes can be [...]

FUEL SYSTEM (DFI) 3-37 Self-Diagn osis Service Code T abl e Servi ce Cod e T ab le Ser vic e Code FI Indicator LED Light Problems 11 Main throttle sensor malfu nction, wiring open or short 12 Inlet ai r pressure sensor malfunct ion, wiring open or short 13 Inlet air temperature sensor malfunction, wi ring open or short 14 W ater temperature sensor [...]

3-38 FUEL SYSTEM (DFI) Self-Diagnosi s Backup s Backups ○ The ECU takes the following measur es to prevent engine damage wh en the DFI or the ignit ion syste m parts have troubles. Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 11 Mai n Throttle Sensor Main Throttle Sensor Output V oltage 0.2 ∼ 4.8 V If the mai n thro[...]

FUEL SYSTEM (DFI) 3-39 Self-Diagn osis Service Codes Par ts Output Signal Usable Range or Criteria Backups by ECU 32 Subthrottle sensor Subthrottl e Sensor Output V oltage 0.15 ∼ 4.85 V If the s ubthrottle sensor system fa ils (the signal is out of the usable range, wiri ng short or open), the actuator locks sub throt tle valve at ful l open posi[...]

3-40 FUEL SYSTEM (DFI) Main Thro ttle Sensor (Service Code 1 1) Main Th rottle Senso r Rem oval/Adjustme nt CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set wi th precision at the factory . Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. Main Throttl e Se[...]

FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Serv ice Code 1 1) Output V oltage Inspectio n • Measure the output voltage at the main throt tle sensor in the same way as input voltage inspection, Note the follo wing. • Disconnect t he main throttl e sensor (g ray) [A] and c on- nect the harness adapter [B] between these connectors. Specia l T oo[...]

3-42 FUEL SYSTEM (DFI) Main Thro ttle Sensor (Service Code 1 1) Resistance Inspe ction • T urn the ignition switch OFF . • Disconnect the mai n throttle s ensor connector . • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main t hrottle s ensor resistance. Main Throttle Sensor Resistance Connections: BL[...]

FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Se nsor (Service Code 12) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel T ank (see Fuel System chapter) W ater T emperature Sensor Connector [A] Inlet Air Pr essure Sensor Bolt [ B] • Raise the inlet a ir pressure sensor [C] [...]

3-44 FUEL SYSTEM (DFI) Inlet A ir Pressure Senso r (Service Co de 12) Output V oltage Inspe ction NOTE ○ The output vol tage changes according to t he local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage ins pection. Note the followin g. Inlet Air Pressur e Sensor Output V o ltage Connections to[...]

FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Se nsor (Service Code 12) then Pv = Pl – Pg For example, suppose t he following dat a is obtai ned: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.2 V (digital volt meter reading) then P v= 7 0–8=6 2c m H g( a b s ) Plot this Pv (62 cmHg) at a point [1] on t he chart and draw[...]

3-46 FUEL SYSTEM (DFI) Inlet A ir Pressure Senso r (Service Co de 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output V olt- age (V) (Digital Meter Reading) ID: Idling Pv: Throttle V acuum Pressure (absolute) TO: Throttle Full Open Ps: Standard Atmospheric Pressure (abso- lute) ST : Standard of Sensor Output V oltage (v) UR: U sable Range [...]

FUEL SYSTEM (DFI) 3-47 Inlet Air T emperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can dam age it. • Remove the fuel tank (see Fuel T ank Removal). • Disconnect the connect or [A] from the inl et air tempera- ture sensor . • Pull out the inl et a[...]

3-48 FUEL SYSTEM (DFI) Inlet Air T em perature Sen sor (Service Co de 13) Sensor Resistance Inspection • Remove the inlet air temperat ure sensor (see this sec- tion). • Suspend the senso r [A] in a con t ainer of machine oil so that the h eat-sensitive por tion is submerged. • Suspend a thermometer [B] with the heat-sensi tive por- tion [C] [...]

FUEL SYSTEM (DFI) 3-49 W ater T e mperature Sensor ( Service Code 1 4) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can dam age it. • Remove the fuel tank (see Fuel T ank Removal). • Drain the coolant (see Cooling Syst em chapter). • Disconnect the sens or connector , and unscre[...]

3-50 FUEL SYSTEM (DFI) W ater T emp erature Sensor (Service Code 14) A. ECU D. W ater T em perature Sensor V . Coolant T emperature Gauge in T achometer Sensor Resistance Inspection • Remove the water temperature senso r (see this section). • Refer to the Electri cal System chapter for water t emper- ature sensor i nspection.[...]

FUEL SYSTEM (DFI) 3-51 Atmospheric Pre ssure Sensor (Ser vice Code 15) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can dam age it. NOTE ○ The atmospheric pr essure sensor is t he same part as the inlet air pressur e sensor except that the inlet air pressure sensor has the vacuum hose and differ ent wir[...]

3-52 FUEL SYSTEM (DFI) Atmosp heric Pressure Sensor ( Service Code 15) Output V oltage Inspe ction • Measure the output voltage at the ECU in the same way as input voltage ins pection. Note the followin g. Digital Met er [A] ECU Connector [B] Atmospheric Press ure Sensor Output V oltage Connections to ECU Meter ( +) → G/W lead ( terminal 4 ) Me[...]

FUEL SYSTEM (DFI) 3-53 Atmospheric Pre ssure Sensor (Ser vice Code 15) V a: Atmospheric Pressure Sensor O utput V oltage (v) ST : Standard of Sensor Output V oltage (v) H: Altitude (m or feet) UR: Usabl e Range of Sensor Output V oltage (v) A. ECU E. Atmospheric Pressure Sensor[...]

3-54 FUEL SYSTEM (DFI) Crankshaft Se nsor (Service Co de 21) Start the engine and swi tch the diagnosis mode to Dealer 1 mode to know a ll the problem t hat the DFI system h as at the time of self-dia gnosis. If the engine cannot be started, the self-dia gnosis system does not detec t dynamic condi- tion of the crankshaft sensor . In this case, tur[...]

FUEL SYSTEM (DFI) 3-55 Camshaft Position Senso r (Service Code 23) Start the engin e and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-di agnosis. If the engine cannot be start ed, the self-diagnosi s system does not detect dynamic condi- tion of the c am shaft posi tion sensor . In t[...]

3-56 FUEL SYSTEM (DFI) Speed Senso r (Service Code 24, 25) Sp eed Senso r Rem oval/I nstalla tion • See the Switches and Sensors section in the Electrical System chapter . Sp eed Sen sor Insp ecti on • See the Switches and Sensors section in the Electrical System chapter . Input V oltage Inspection NOTE ○ Be sure the bat tery is fully charged[...]

FUEL SYSTEM (DFI) 3-57 Speed Sen sor (Service Co de 24, 25 ) • Disconnect the speed sensor connect or [A] and connect the harness adapt er [B] between t he harness connect or and speed sensor connector . Engine Sprocket Cover [C] • Connect a digital meter to the harness adapter l eads. Specia l T ool - Throttle Sen sor Setting Ad apter: 57001?[...]

3-58 FUEL SYSTEM (DFI) V ehicl e-down Senso r (Service Code 31) Removal CAUTION Never drop the down-sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Connection and V ehicle-down Sensor [A] Bolts [B] Installation • The UP mark [A] of the sens or should face upward. T orqu e - V ehi cle-down Senso r Bol t[...]

FUEL SYSTEM (DFI) 3-59 V ehicle-d own Sensor (S ervice Code 31) • T urn the ignition swi tch OFF . • Remove the sensor . • Connect a digital volt meter [A] to the connector with nee- dle adapter set [ B]. Specia l T ool - Needle Adapt er Set : 57001–1 457 V ehicle-down Sensor Output V oltage Connections to Sensor Meter ( +) → Y/ G lead [ [...]

3-60 FUEL SYSTEM (DFI) V ehicl e-down Senso r (Service Code 31) A. ECU S. ECU Main Relay T . Ignition Switch a. ECU Fuse 15 A b. V ehicle-down Sensor d. Starter Relay f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A[...]

FUEL SYSTEM (DFI) 3-61 Subthrottle Sensor (Service Code 32) Subthr ottle Sensor Removal /Adjust ment CAUTION Do not remove or adjust the subthrot tle sensor [A] since it has been adjusted and set wit h precision at the factory . Never drop the sensor , especially on a hard surface. Such a shock to the sensor can dam age it. Subthrottle Sensor Conne[...]

3-62 FUEL SYSTEM (DFI) Subthrottle Se nsor (Service Cod e 32) Output V oltage Inspe ction • Remove the throttle body assy (see Thrott le Body Assy Removal). • Measure the output volt age at the subthrottl e sensor in the same way as input voltage ins pection. Note the fo l- lowing. • Disconnect the subthrott le sensor (black) [A] and (black) [...]

FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Resistance Inspection • T urn the ignition swi tch OFF . • Disconnect the subthrottle sensor connector . • Connect a digital meter [A] to the subthrott le sensor con- nector [B]. • Measure the subthrot tle sensor resist ance. Throttle Sensor Resistance Connections: BL le ad [C] ←[...]

3-64 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3 , #4: Service Cod e 51, 52, 53, 54) Stick Coil #1: Igniti on Coil (Service Code 51) Stick Coil #2: Igniti on Coil (Service Code 52) Stick Coil #3: Igniti on Coil (Service Code 53) Stick Coil #4: Igniti on Coil (Service Code 54) Removal/Installation CAUTION Never drop the stick coils, especially on a ha[...]

FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2, #3, # 4: Serv ice Code 51, 52, 53, 54) A. ECU M. Sti ck Coils N. Engine Stop Switch T . Ignitio n Switch X. Ignition Fus e 10 A Y . Junction Box d. Starter Relay e. Joint Connector C f. Sealed Battery k. Main Fuse 30 A[...]

3-66 FUEL SYSTEM (DFI) Subthrottle V alve Actuator (Serv ice Code 62) Subthrottle V alve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [ A] since it has been adjusted and set wit h precision at the factory . Never drop the actuator , especially on a hard sur- face. Such a shock to the actuat or can damage it. Audibl e Inspec[...]

FUEL SYSTEM (DFI) 3-67 Subthrottle V alve A ctuator (Service Code 62 ) Input V oltage In spection NOTE ○ Be sure the batt ery is f ully charged. • T urn the ignition swi tch OFF . • Remove the throt tle body ass y (see Thrott le Body Assy Removal). • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using th[...]

3-68 FUEL SYSTEM (DFI) FI Indicator LED L ight Inspection Flow Chart[...]

FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light LED Lig ht Inspe ction • Remove the meter uni t (see Elec trical System chapt er). • Using two auxili ary leads, supply battery power to t he FI indicator LED li ght [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection: B R / W L e a dT e r m i [...]

3-70 FUEL SYSTEM (DFI) ECU CAUTION Never drop the ECU, especial ly on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seats (see Frame c hapter) Junction Box [A] • T ake the ECU [A] out along w ith the harness. • Disconnect the ECU lead connector s [B]. ECU Installation • Connect the ECU connectors, noting the l[...]

FUEL SYSTEM (DFI) 3-71 ECU • With the ECU connectors [A] co nnected, check the fol- lowing ground lead for continuit y with the ignition switch OFF , using a tester and needl e adapter set. ECU Grounding Inspection 26, 50, o r 51 ( BK/Y) Te r m i n a l ←→ Batt ery (–) T ermin al: 0 Ω Engine Ground ←→ Ba tter y (–) T er minal : 0 Ω[...]

3-72 FUEL SYSTEM (DFI) ECU ECU Power Source Circuit A. ECU S. ECU Main Relay T . Ignition Switch a. ECU Fuse 15 A d. Starter Relay e. Joint Connector C f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A[...]

FUEL SYSTEM (DFI) 3-73 DFI Power Source ECU Fu se R emova l • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then r eplace it with a new fuse of proper amperage. • Refer to the Electrical System chapter for the ECU fuse i[...]

3-74 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspe ction NOTE ○ This inspec tion can det ermine which t rouble the DFI system has, mechanical or elec t rical trou ble. ○ It is prefera ble to measure the fuel pressure while run- ning the motorcycl e just when trouble occurred in order to kno w sym ptom w ell. ○ Be sure the bat tery is fully [...]

FUEL SYSTEM (DFI) 3-75 Fuel Line • Start the engine, and let it idl e. • Measure the fuel pressure with the engi ne idling. Fuel Pressure ( idling) S t a n d a r d : 3 1 0k P a( 3 . 2k g f / c m ² ,4 6p s i ) NOTE ○ The gauge needle will fluctuat e. Read the pressure at the average of the maximum and minimum indications. If the fuel pr essur[...]

3-76 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressur e in the tank. • Be sure to place a piece of cloth ar ound the fuel pump outlet hose. • Remove the fuel pump outlet hose [A] from the fuel pump [B] and t he delivery pipe [C] (see Fuel Pump Removal). Front [D] W A RNING Be prepared for fuel spill age; any spill[...]

FUEL SYSTEM (DFI) 3-77 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a har d sur- face. S uch a shock to the pump can damage it. W ARN ING Gasoline is ext remely flammable and can be explo- sive under certai n conditions. Make sure the area is well-ventil ated and free from any source of flame or sparks; this includes [...]

3-78 FUEL SYSTEM (DFI) Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Check that the fuel pump (–) te rminal [A] and band [B] ar e in place. Front [C] • Apply a non-permanent loc king agent to the threads of the fuel pump bolts. • T ighten the fuel pump bolts to a snug fit, following the tightening se quence shown. • Fol[...]

FUEL SYSTEM (DFI) 3-79 Fuel Pump • Connect the hand tester (25 V DC) t o the fuel pump con- nector [A] with needle adapt er set. Specia l T ools - Hand T ester: 5 7001–1394 Needle Adap ter Set: 5 7001–1457 ○ Measure the operat ing voltag e with the en gine stopped, and with t he connector joi ned. • T urn the i gniti on swi tch ON. ○ Th[...]

3-80 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay , especiall y on a hard surface. Such a shock to the relay can damage it. • Remove the seat cov er (see Frame chapte r). • Remove the fuel pump relay [A] from the tongue of the storage c ompartment. • Disconnect the connect or . Fuel Pump Relay Inspe ction ?[...]

FUEL SYSTEM (DFI) 3-81 Fuel Injectors Removal/Installation • Refer to t he Throttle Body Ass y Disassembly/Assembly . Audibl e Inspecti o n • Start the engine. • Apply the tip o f a screwdriver [A] to t he injector [C]. Put the grip end onto your ear , and listen whether the injector is clicking or not. ○ A sound scope [B] can also be used.[...]

3-82 FUEL SYSTEM (DFI) Fuel In jectors Output V oltage Inspe ction • T urn the ignition switch OFF . • Remove the ECU (see ECU sec tion). • Connect a digital voltmeter [A] to the ECU connector [B] with the needle adapt er set [C]. Special T ool - Needle Ad apter Se t: 57 001-1457 Injector Output V oltage Connections to Injector #1 Meter ( +) [...]

FUEL SYSTEM (DFI) 3-83 Fuel Injectors Injector Signal T est • Prepare two test light sets with male ter minals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W T erminal Width [B]: 1.8 mm (0.071 in.) T erminal Thickness [C]: 0.8 mm (0 .031 in.) CAUTION Do not use larger terminals than specified above. A larger terminal could damage the injector [...]

3-84 FUEL SYSTEM (DFI) Fuel In jectors Injector Resistance Inspection • Remove the fuel tank (see Fuel T ank Removal). • Disconnect the connect or from the injector [A] (see Throt- tle Body Assy Disassembly/ Assembly). • Measure the i njector resi stance with t he hand tester [B]. Special T ool - Hand T es ter: 57 001–1394 Injector Resi sta[...]

FUEL SYSTEM (DFI) 3-85 Fuel Injectors • Check the injector fuel li ne for leakage as follows: ○ Connect a commercially avail able vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressur e fuel hose [C] (both ends connected with the clamps [D]) as shown. T orque - F uel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in?[...]

3-86 FUEL SYSTEM (DFI) Fuel In jectors A. ECU K. Fuel Injectors N. Engine Stop Switch T . Ignition Switch X. Ignition Fuse 10 A Y . Junction Box Z. Fuel Pump Relay ( for fuel pump an injectors) d. Starter Relay e. Joint Connector C f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A[...]

FUEL SYSTEM (DFI) 3-87 Throttle Grip a nd Cables Throttl e Grip Play Inspe ction/Adj ustment • Refer to the Throttle Control Syst em Inspection in the Pe- riodic Maintenance chapte r . Chok e Lever O perat ion ○ Do not use the chok e lever except when the engine has a starting dif ficulty like in col d weather (10°C, 50°F o r below) or at hig[...]

3-88 FUEL SYSTEM (DFI) Throttle Bod y Assy Idle S peed In spect ion • Refer to the Idle Speed Inspecti on in the Per iodic Main- tenance chapter . Engine V acuum Synchroni zation Inspe ction/ Adjustment • Refer to the Engine V acuum S ynchroni zation Inspection in the Per iodic Maintenance chapt er . High Altit ude Performance Ad justment • A[...]

FUEL SYSTEM (DFI) 3-89 Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cleaner Duct Clamp Bol ts [B] • Remove: Right and Left Side Covers (see Frame chapter) Coolant Reserve T ank (see Cooling Syst em in the Peri- odic Maintenance chapter) Crankcase Breather Hose Right and Left Air Cleaner Housing Mounting Bolts [A] • Mo[...]

3-90 FUEL SYSTEM (DFI) Throttle Bod y Assy • Remove the bolt [A] and the t hrottle cable p late [B] from the throt tle body front s ide. • Remove the throttle cable lower ends from the throttl e pulley . • Remove: Choke Cable Upper End (From choke lever) Choke Cable Lower End [A] • After r emoving the throttl e body assy , stuff piec es of [...]

FUEL SYSTEM (DFI) 3-91 Throttle Body Assy • Apply a thin coating of grease to the throttl e cable upper ends. • Install the u pper ends of the throttl e cables in the grip. • Fit the projecti on [A] of the right switc h housing into the hole [B] of the handlebar . • T urn the throttle gri p and make sure that the throt tle valves move smoot[...]

3-92 FUEL SYSTEM (DFI) Throttle Bod y Assy CAUTION Never drop the injector , especially on a hard sur- face. Such a shock to the injector can damage it. • Pull out the i njectors along with the delivery pipe [ A]. If necessar y , remove the injector s from the deliver y pipe. Replace the O-r igs of the indicat ors. If necessary , cut straps and t[...]

FUEL SYSTEM (DFI) 3-93 Air Cleaner Elem ent Rem oval/ Insta llation • Refer to t he Air Cleaner Element Cleani ng in the Periodi c Maintenance chapter . Air Cle aner Oil Dr aining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. • Visual ly check the drain hose [A] if the water or[...]

3-94 FUEL SYSTEM (DFI) Fuel T ank Fuel T ank Removal W A RNING Gasoline is extremely flammable and can be explo- sive under cert ain conditions. Make sure the ar ea is well-ventilat ed and free from any source of flame or sparks; this incl udes any appli ance with a pilot light. Do not smoke. T urn the ignition switch OFF . Be prepared for fuel spi[...]

FUEL SYSTEM (DFI) 3-95 Fuel T ank • Be sure to place a piece of cl oth [A] around t he fuel hose pump outlet joint [B]. • While pinchi ng the hose joint locks [C] with fi ngers, pull the joint out along the delivery pipe. W ARN ING Be prepared for fuel spillage; any spill ed fuel must be com plet ely wip ed up im media tely . When the fuel hose[...]

3-96 FUEL SYSTEM (DFI) Fuel T ank • Insert the pump outlet hos e joint [A] strai ght onto the de- livery pipe [B] until the hose joint clicks [C]. Front [D] • Push and pull [A] the hose j oint [B] back and fort h more than two times and make sure i t is locked and doesn’t come of f. When the hose joint is correctly instal led, it should sli d[...]

COOLING SYSTEM 4 -1 4 Cooling System T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 4-2 Coola nt Flow Ch art ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...[...]

4-2 COOLING SYSTEM Exploded View[...]

COOLING SYSTEM 4 -3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Radiator hose c lamp screws 2.0 0.20 17 in·l b 2 Radiator fan bolts 8.3 0.85 74 in·lb 3 W ater pum p impeller bolt 9.8 1.0 87 in·l b 4 W ater pump cover bolts 11 1.1 95 in·l b 5 W ater pump drain bolt 11 1.1 95 in·lb 6 W ater pipe bolts 11 1.1 95 in·lb 7 Ther[...]

4-4 COOLING SYSTEM Coolant Flo w Chart[...]

COOLING SYSTEM 4 -5 Coolant Flow Ch art 1. Drain Bolt 2. W ater Pump 3. Cylinder Jacket 4. Cylinder Head Jacket 5. Thermostat Housing 6. Radiator Cap 7. Radiator 8. Oil Filter 9. Reserve T ank 10. Reserve T ank Hose 1 1. Reserve T ank Overflow Hose 12. Radiator Fan 13. W ater T em perat ure Sensor 14. Radiator Fan Switch 15. Hot Coolant 16. Cold Co[...]

4-6 COOLING SYSTEM Specification s Item Standard Coolant provided when shipping: T ype (recommended) Permanent type of antifreeze (soft water and ethyl ene glycol plus corrosion and rust inhibitor chemicals for alumi num engines and radiator s) Color Green Mixed ratio Sof t water 50%, coolant 50% Freezing point –35°C (–31°F) T otal amount 2.9[...]

COOLING SYSTEM 4 -7 Special T ools and Se alant Bearing Dr iver: 57001–382 Bear ing Drive r Set: 57001–1129 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20[...]

4-8 COOLING SYSTEM Coolant Coolant Deter ioratio n Inspection • Remove the left side cover (see Frame chapter ). • V isually inspect the coolant [A] in the reserve tank. If whit ish cotton-l ike wafts are obser ved, aluminum parts in the cooli ng system are cor roded. If the coolant is brown, iron or steel parts are rus ting. In either cas e, f[...]

COOLING SYSTEM 4-9 Coolant Pressure T esting • Remove the fuel tank (see Fuel System (DFI) chapt er). • Remove the radiat or cap, and install a cooling system pressure te ster [A] on the filler neck [B]. NOTE ○ Wet the cap sealing sur faces with water or coolant to prevent pressure leaks. • Build up pressur e in the system carefull y until [...]

4-10 COOLING SYSTEM W ater Pum p Wat er Pump Removal • Refer to the Oil Pump Removal in the Engine Lubrication System chapter . Wate r Pum p Insta llation • Refer to the Oil Pum p Install ation in t he Engine Lubrica- tion System chapt er . Wate r Pum p Inspec tion • Check the drainage outl et passage [A] at the bot tom of the water pump body[...]

COOLING SYSTEM 4-1 1 Wa t e r P u m p • T ake the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housin g Assembl y CAUTION Do not reuse the mechanical seal and oil seal. • Apply high temperat ure grease to t he oil seal lips [A] . • Press the new oi l seal into t he housing with a beari ng driver [B] unti l it stops at the b[...]

4-12 COOLING SYSTEM Radi ator Radiat or and Radiator Fan Removal W A RNING The radiator f an is connected directly to t he bat- tery . The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIA TOR F AN UNTIL THE RADIA TOR F AN CONNECTOR IS DIS- CONNECTED. TOUCHING THE F AN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE [...]

COOLING SYSTEM 4-13 Radiator Radia tor an d Radi ator Fan Insta llation • Installa tion is th e reverse of removal . • Install the radiat or bracket collar s [A] as shown. Rubber Damper [B] 30 ∼ 40° [C] Radiator [D] Bracket [E] • T ighten: T orq ue - Radiator L ower Bolts [F]: 7.0 N·m (0.70 kgf·m, 61 in·lb) Radiator Upper Bolts [G]: 7.0[...]

4-14 COOLING SYSTEM Radi ator • Install the cap [A] on a coolin g system pressure t ester [B]. NOTE ○ Wet the cap seali ng surfaces with water or coolant to prevent pressure leak s. • W atching the pressure gauge, pump t he pressure tes ter to build up the pr essure until the relief valve opens: the gauge needle f licks downward. Stop pumping[...]

COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Drain the cool ant (see Cooling Syst em in the Periodi c Maintenance chapter) . • Remove: Fuel T ank (see Fuel System (DFI ) chapter) Thermostat Bracket Bolt [A] Ground Lead [B] W ater T emperature Sensor Connector [C] Three W ater Hoses [D] • Remove the thermostat housing [E]. • Remove th[...]

4-16 COOLING SYSTEM Thermo stat • T o check valve opening t emperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water . ○ The thermostat must be co mpletely submerged and must not touch the cont ainer sides or bottom. Suspend an ac- curate ther mometer [B] in the water so that the heat sen- sitive[...]

COOLING SYSTEM 4-17 Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter . • Install the clamp [A] as near as possible to the hose e[...]

4-18 COOLING SYSTEM Radiator Fan Switch, Water T empe rature Sensor CAUTION The fan switch or the water temperatur e sensor should never be al lowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator Fan Swi tch Removal • Drain the c oolant (see Cooling Sy stem in the Periodic Maintenance c hapter). • Remove: Radia[...]

ENGINE TOP END 5-1 5 Engine T op End T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... 5-2 Spec ifica tions .... ...... ...... ....... ...... ...... . 5- 6 Spec ial T ools a nd Seala nt ...... ...... ..... 5- 8 Clean A ir System . ...... ...... ....... ...... ..... 5- 10 Air Suction V alve Removal ..... ...... 5-10 Air Su[...]

5-2 ENGINE T OP END Exploded View[...]

ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Air suction val ve cover bolts 9.8 1. 0 87 in·lb 2 Cylinder head cover bo lts 9.8 1.0 87 in·lb S 3 Camshaft cap bolts 12 1.2 104 in·lb S 4 Camshaft chain guide bolt s 12 1.2 104 in· lb S 5 Cylinder head bolts (M10 new bolts) 54 5.5 40 MO, S (W asher) 5 Cylinder [...]

5-4 ENGINE T OP END Exploded View[...]

ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf· m ft·l b Remarks 1 Coolant drain plug (cylinder) 9.8 1.0 87 in·l b 2 Exhaust pipe manifol d holder nuts 17 1.7 12 3 Muffler body cl amp bolt 17 1.7 12 4 Muffler bod y mounting bolt 30 3.0 22 5 Crankshaft sensor cover bolt s 11 1.1 95 in·lb 6. "1T" marked side faces up. 7.[...]

5-6 ENGINE T OP END Specification s Item Standard Service Limit Clean Air System: V acuum switch valve c lo sing Open → Close ––– pressure 41 ∼ 49 kPa (310 ∼ 370 mmHg, 6.0 ∼ 7.1 psi) Camshafts: Cam height: Exhaust 36.146 ∼ 36.254 mm (1.4231 ∼ 1.4273 i n.) 36.05 mm (1.419 in.) Inlet 36.746 ∼ 36. 854 mm (1.4467 ∼ 1.4509 in.) 36.[...]

ENGI NE TOP END 5 -7 Specifications Item Standard Servi ce Limit V alve spring free l ength: Exhaust 40.7 mm (1.602 in.) 38. 9 mm (1.531 in.) Inlet 40.7 mm (1.602 in.) 38.9 mm (1.531 in.) Cylinder , Pistons: Cylinder inside diameter: 68.400 ∼ 68.412 mm (2.6929 ∼ 2.6934 in.) 68.50 mm (2.6969 in.) Piston diameter 68.345 ∼ 68.360 mm (2.6907 ∼ [...]

5-8 ENGINE T OP END Special T ool s and Sealant Compress ion Gauge: 57001–2 21 V alve S pring Comp ressor Ass embly: 57001–2 41 Piston Pin Pull er Assembly: 57001–9 10 V alve S eat Cutter , 45° - 24: 57001–11 13 V alve Seat Cutter , 45° - 27.5: 57001–11 14 V alve Seat C utte r , 32° - 25: 57001–11 18 V alve Seat C utte r , 32° - 28:[...]

ENGINE TOP END 5-9 Special T ools and Se alant V alve Guide Reamer , 4: 57001–127 4 V alve Seat Cutter Holder , 4: 57001–127 5 Fork Oil Level Gauge: 57001–129 0 Compression Gau ge Adapter , M10 × 1.0: 57001–131 7 V alve Seat Cutt er , 60° - 25: 57001–1 328 V alve Seat Cutt er , 60° - 27: 57001–1 409 Spark Plug Wre nch (Owner ’ s T [...]

5-10 ENGINE T OP END Clean Ai r System Air Sucti on V alve Removal • Remove: Fuel T ank (see Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction V alve Cover Bol ts [C] and Clamp Air Suction V alve Cover [D] Air Suction V alve Air Sucti on V alve Install ation • Install t he air suct ion valv e [A] so that its w ider side [B] [...]

ENGINE T OP END 5-1 1 Clean Air System V acuum Switch V alve T est • Remove: V acuum Switch V alve (see V acuum Switch V alve Re- mova l) • Connect a vacuum gauge [ A] and syri nge [B] or fork oil level gauge to the vacuum hoses as shown. Specia l T ool - Fork Oil Le vel Gauge: 57001–1 290 Air F lo w [C] • Gradually raise the vacuum (lower [...]

5-12 ENGINE T OP END Cylinder H ead Cover Cylinder Head Cover Remova l • Remove: Fuel T ank (see Fuel System (DFI) chapter) V acuum Switch V alve and Hoses Stick Coil s (see Electrical System chapter) Air Sucti on V alve Covers [ A] • Remove the cylinder head cover bolts [A] and tak e off t he cove r . Cylinder He ad Cover Instal lation • Rep[...]

ENGINE TOP END 5-13 Cylinder Hea d Cover • T ighten the cover bolts fol lowing the spec ified tighteni ng sequence. T orque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the r emoved parts (s ee appropriate chapters ).[...]

5-14 ENGINE T OP END Camshaft Cha in T e nsioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type camshaft chain tensioner . The push rod does not return to its original posi tion once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensi oner , do not take out the mounting bolt[...]

ENGINE TOP END 5-15 Camshaft, Camshaft C hain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- mova l) Pickup Coil Cover • Position the crankshaft at #1, 4 piston TDC. TDC m ark [A] for #1, 4 Pistons T i ming Mark (crankc ase halves mating surface) [B] • Remove: Camshaft Chain T ensioner (see Camshaft Chain T en- si[...]

5-16 ENGINE T OP END Camshaft, Camsha ft Chain • Position the crankshaf t at #1, 4 piston TDC. • Pull the tensio n side (exhaust side ) [A] of the chain taut to inst all the chain. • Engage the camshaft chain wit h the camshaft sprockets so that t he timing marks on the sprockets are positio ned as shown. ○ The timing marks of #1, 4T m ust [...]

ENGINE TOP END 5-17 Camshaft, Camshaft C hain If any clearance exceed s t he servi ce limit, measure the diameter of each camshaft journal with a micrometer . Camshaft Journal Diameter Standard : 23.950 ∼ 23.972 mm (0.942 9 ∼ 0.9438 in.) Service Limit: 23 .92 mm (0.942 in.) If the camshaf t journal diameter i s less than the s ervice limit, rep[...]

5-18 ENGINE T OP END Cylinder Hea d Cylinder Compr ession Measuremen t NOTE ○ Use the battery which is fully char ged. • W arm up the engine thoroughly . • Stop the engine. • Remove: Seats (see Frame c hapter) Fuel T ank (see Fuel System (DFI) chapter) Stic k Coils Spark Plugs Owner ’s T ool - Spark Plu g Wrench, 16 mm: 921 10 –1 146 ?[...]

ENGINE TOP END 5-19 Cylinder Head Cylinde r Head Removal • Drain the coolant (see Cooling Syst em chapter). • Remove: Exhaust Pipes (see Exhaust Pi pe Removal) Coolant Drain Bolt [ A] (cylinder) • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- mova l) Camshaft Position Sensor (see Elect rical System chap- ter) Camshafts (see Camshaf[...]

5-20 ENGINE T OP END Cylinder Hea d • Instal l: Front Camshaft Chain Guide [A] O-ring [B] Collar [C] • T ighten: T orque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower ) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) • Install the removed parts (see appropri ate chapters) . Cylinde[...]

ENGINE TOP END 5-21 V al ves V a lve Cleara nce Ins pection • Refer to the E ngine T op End in the P eriodic Maintenance chapter . V alve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and recor d the valv e lifter and shim locations so t hey can be install ed in their original pos[...]

5-22 ENGINE T OP END Va l v e s V alve Guide Installati on • Apply oil to the val ve guide outer surface befor e installa- tion. • Heat the area around the valve gui de hole to about 120 ∼ 150°C (248 ∼ 302°F) . • Drive the valve guide in fr om the top of the head using the valve gu ide arbor . The flange stops the guide f rom going in t[...]

ENGINE TOP END 5-23 V al ves V alve Seat Inspe ction • Remove the valve (see V alve Removal). • Check the valve seating surface [A] between the valv e [B] and valve seat [C]. ○ Measure the outsi de diameter [D] of the seat ing pattern on the valve seat. If the outsi de diameter is too large or to o small, repair the seat (see Seat Repair) . V[...]

5-24 ENGINE T OP END Va l v e s Seat Cutter Operation Care: 1. This valve seat cutter is devel oped 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 valv e seat cutter , or the dia- mond particl es may fall of f. 3. Do not fail to appl y engine oil to the val ve [...]

ENGINE TOP END 5-25 V al ves • Measure the outside diamet er of the seating surface wi th a vernier caliper . If the outsi de diameter of the seat ing surface is too s mall, repeat the 45° gr ind until the di ameter is wit hin the spec- ified range. Widened Width [A] of engagement by machining wi th 45° cutter Ground V olume [B] by 32° cutter [...]

5-26 ENGINE T OP END Va l v e s If the seat width is t oo wide, make the 60° [A] grind de- scribed bel ow . If t he seat width i s withi n the speci fied range, lap the valve to the seat as described below . • Grind the seat at a 60° angle until the seat width is within the specif ied range. ○ T o make the 60° grind, fit 60° cutter int o th[...]

ENGINE TOP END 5-27 V al ves[...]

5-28 ENGINE T OP END Cylinder , Piston s Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Wa t e r H o s e [ A ] • Remove the cylinder [B]. Cylinder Inst allati on NOTE ○ If a new cylinder is used, use new piston ring. • Install t he dowel pins [A] and new cylinder gasket [B]. • Apply engine oil to the cyli nder bore. [...]

ENGINE TOP END 5-29 Cylinder , Pis tons • Remove the piston pin s. Specia l T ool - Piston Pin P uller Assembl y: 57001–910 [ A] • Rem ove the pis tons. • Carefully spread the ri ng opening with your thumbs and then push up on the opposite side of t he ring [A] to remove it. • Remove the 3- piece oil r ing with your thumbs in the same man[...]

5-30 ENGINE T OP END Cylinder , Piston s NOTE ○ If a new pi ston is used, use new piston ri ng. • Install the piston with i ts marking hollow facing for ward. • Fit a new piston pin snap r ing into the side of the pist on so that the ring opening [A] does not coincide with the s lit [B] of the pist on pin hole. ○ Apply molybdenum disulfi de[...]

ENGINE TOP END 5-31 Cylinder , Pis tons Piston Rin g, Piston Ring Groo ve Wear • Check for uneven groove wear by ins pecting the ring seat - ing. The rings should fit perfectly parall el to groove surfaces . If not, replace th e piston and all the piston rings. • With the piston ri ngs in their grooves, make several mea- surements with a thickn[...]

5-32 ENGINE T OP END Cylinder , Piston s Piston Ring E nd Gap • Place the pi ston ring [A] i nside the cyli nder , using the pis- ton to locate the ri ng squarely in place. Set it close to the bottom of the cyl inder , where cylinder wear is low . • Measure the gap [B] between the ends of the ring with a thickness ga uge. Piston Ring End Gap To[...]

ENGINE TOP END 5-33 Throttle Body Holder Throt tle Bo dy Holde r Insta llation • Be sure to instal l the O-rings [A]. • Install the clamps [B] as shown and so that its hole fit on the projecti on [C] of the holder . • T ighten: T orque - T hrottle Body H older B olts [D]: 13 N·m (1.3 kgf·m, 1 13 in·lb) Throttle Bo dy Assy Hold er Clamp Bo [...]

5-34 ENGINE T OP END Muffler W A RNING T o avoid a serious burn, do not remove the muffl er when the engine is still hot. Wait until t he muffler cool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolt [A] Muffler Body Mounti ng Bolt [B] • Pull the muff ler body backward. Exhaust Pipe Removal • Remove: Radiator Lower Bolt (see Cooli[...]

ENGINE TOP END 5-35 Muffler ○ Install the muf fler body clamp bolt as shown. Upper Side [H] Ou tside [I] • Thoroughly warm up t he engine, wait until the engine cools down, and retighten all the bolts and nuts.[...]

[...]

CLUTCH 6-1 6 Clutch T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 6-2 Spec ifica tions .... ...... ...... ....... ...... ...... ...... ...... ....... ...... ........ ...... ....... ...... ...... ...... ...... ....... . [...]

6-2 CLUTCH Exploded View[...]

CLUTCH 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Clutch lever clamp bolts 7.8 0.80 69 in·l b S 2 Clutch cover mounting bolts 11 1.1 95 in·lb 3 Oil fille r plug 1.5 0.15 13 in·lb 4 Clutch spri ng bolts 8.8 0.90 78 i n·lb 5 Clutch hub nut 135 14 100 R CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. M: [...]

6-4 CLUTCH Specification s Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3 m m (0.08 ∼ 0.12 in .) ––– Clutch: Clutch plate assembly 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.) ––– Fricti on plate thickness 2. 72 ∼ 2.88 mm (0.107 ∼ 0.1 13 in.) 2.4 mm (0.094 in.) Friction and steel plate warp 0.2 mm (0.008 in.) or l ess 0.3 mm ([...]

CLUTCH 6-5 Special T ool a nd Sealant Clutch Holder: 57001–124 3 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20[...]

6-6 CLUTCH Clutch L ever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch in the Periodic Maint enance chapter . Clutch Lever Free Play Adjustment • Refer to the Clutch in the Periodic Maint enance chapter . Cable Removal • Slide the dust cover [A] at the clutch cable lower end out of place. • Loosen the nut s [B], and slid[...]

CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Adjustment The adjuster has 5 positions so tha t the clutch lever posi- tion can be adjusted to suit the operator ’ s hand. • Push the lever forward and turn t he adjuster [ A] to align the number with the arrow mark [B] on the lever holder . ○ The distance from the grip to the l ever is minimum [...]

6-8 CLUTCH Clutch Cover Clutch Cover Removal • Remove: Engine Oil (drain, see Engine Lubric ation S ystem in t he Periodic Maintenance chapter ) Clutch Cable Lower End [A] Clutch Cover Mounting Bol ts [B] • T urn the release lever [A] toward the rear as shown, and r e m o v et h ec l u t c hc o v e r[ B ] . About 90° [C] Clutch Cover Installat[...]

CLUTCH 6-9 Clutch Cover • Fit the spri ng [A] as shown. Viewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings • Remove: Cir cli p [A] Oil Level Gauge [B] Clutch Cover Assembly • Replace the needl e bearings and oil seal with new ones. NOTE ○ Install the needle bearings so t[...]

6-10 CLUTCH Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Lubric ation S ystem in t he Periodic Maintenance chapter ) Clutch Cover (see Clut ch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plat e [B] (wit h thrust bearing and pusher [C], spring and washer) • Remove: Frictio n Plates, Steel Plates Spring, S[...]

CLUTCH 6-1 1 Clutch ○ Install the spacer [A] so that the tapered side [B] f aces inw ard. ○ Install the washer [A] so that the OUTSIDE mark faces outward. ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, ti ghten the clutch hub nut. Specia l T ool - Clutch H older: 570 01–1243 T orque - Clutc h Hub Nut: 135 N·m (14 [...]

6-12 CLUTCH Clutch • Apply molybdenum disul fide grease to the pusher ends [A] and install the bearing [B], pusher [ C], spring [D] and washer [E] in the clutch spr ing plate [F]. ○ Apply engine oil to the needle bearing. • Install the clut ch spring plate, springs and spring holders, and tighten t he clutch spri ng bolts. T orque - Clutch Sp[...]

CLUTCH 6-13 Clutch Clutch Pla te, Wear , Damage In spection • Visual ly inspect the friction and steel plates for si gns of seizure, overheatin g (discoloration), or uneven wear . • Measure the thickness of each friction plate [ A] at several points. If any plates show signs of damage, or if they have worn past the service li mit, replace them [...]

[...]

ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 7-2 Engin e Oil Flo w Char t.... ....... ...... ...... ...... ...... ....... ...... ...... ........ ....... ......[...]

7-2 ENGINE LUBRICA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Oil filler plug 1.5 0.15 13 in·l b 2 Engine oil drain bol t 20 2.0 14 3 Oil f ilt er 31 3.2 23 EO, R 4 Holder mounting bolt 76 7.8 56 EO 5 Oil pan bolts 11 1.1 95 in·lb 6 Oil pipe holder bolts 13 1.3 11 3 i n · l b L 7 Oil p ressu re relie f valve 15 [...]

7-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow C hart[...]

ENGINE LUBRICA TION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Oil Passage Hole in Alter nator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Filter 7. Oil Pressure Switch 8. Oil Pipe 9. Oil Pump 10. T o Drive S haft 11 . O i l P i p e 12. T o Output Shaft 13. Drive Shaft Oil Pass[...]

7-6 ENGINE LUBRICA TION SYSTEM Specification s Item Standard Engine Oil: Ty p e API SE, SF or SG API SH or SJ wi th JASO MA V iscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when fi lter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level Between upper and lower level lines Oil Pressur[...]

ENGINE LUBRICA TION SYSTEM 7-7 Special T ools and Se alant Oil Pressure Gauge , 10 kgf/cm²: 57001–164 Oil Press ure Gauge Adapter , PT3/8 : 57001–123 3 Oil Filter Wrench: 57001–1 249 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20[...]

7-8 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil F ilter W A RNING Motorcycle operati on with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seiz ure, accident, and injury . Oil Le vel Inspec tion • Check that the engine oi l level is between the upper [A] and lower[...]

ENGINE LUBRICA TION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Engine Lubri cation System in the Periodic Maintenance chapt er) Exhaust Pipe Assy and Muf fler Body (see Engine T op End chapter) Oil Pan Bo lt s [A] Oil P an [B ] Oil Pan Installation • Clean the oil screen [A] . • Install the oi l screen so that the cra[...]

7-10 ENGINE LUBRICA TION SYSTEM Oil Pressure Relief V alve Oil Pressure Relief V alve Removal • See Oil Pan Removal. Oil Pr essure Relie f V alve Install ation • See Oil Pan Ins tallat ion. Oil Pre ssure Reli ef V alve Inspect ion • Check to see if the val ve [A] slides smoothly when push- ing it in with a wooden or other sof t rod, and see i[...]

ENGINE LUBRICA TION SYSTEM 7-1 1 Oil Pump Oil Pump Removal • Drain: Coolant (see Cooli ng System in the Periodic Mainte- nance chapter) Engine Oil (see Engine Lubr ication System i n the Peri- odic Maintenance chapter) • Remove: Water Pip e Bolts [ A] Water Pipes [B ] • Remove: W ater Pump Cover Bolts [A] Cla mp [B ] W ater Pump Cover [C] •[...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pu mp • Instal l: Pins [A] W ater P ump Body [B] • Instal l: Impeller [A], W asher and Bolt [B] • T ighten: T orque - Water Pump Impeller Bolt: 9 .8 N·m (1.0 kgf·m, 87 in·lb) • Instal l: Pins [C] W ater Pump C over and Bolts T orqu e - Water Pump Cover Bolts: 1 1 N·m (1.1 kgf·m, 95 in·lb) • Instal[...]

ENGI NE LUBRICA TIO N SYST EM 7-13 Oil Pressure Me asurement Oil Pressu re Measurement • Remove the oil passage pl ug, and attach the adapter [A] and gauge [B] to the plug hole. Special T ools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pre ssure Gaug e Adapter , PT 3/8: 57001–1 233 • Start the engine and warm up th e engine. • Run t[...]

7-14 ENGINE LUBRICA TION SYSTEM Oil Press ure Switch Oil Pressure Switch Removal • Remove: Engine Oil (drain, see Engine Lubric ation S ystem in t he Periodic Maintenance chapter ) Switch Cover [A] Switch T erminal [B] O i lP r e s s u r eS w i t c h[ C ] Oil Pressure Switch Installation • Apply silicone sealant to the t hreads of the oil press[...]

ENGINE REMOV AL/INST ALLA TI ON 8-1 8 Engine Removal/Installation T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 8-2 Spec ial T ool ... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... .....[...]

8-2 ENGINE REMOV AL /INST ALLA TION Exploded View[...]

ENGINE REMOV AL/INST ALLA TION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Adjusting coll ar locknut 49 5.0 36 S 2 Upper engine mounting bolts 44 4.5 33 S 3 Rear engine bracket bolts 25 2.5 18 S 4 Front engine bracket bolts 44 4.5 33 S 5 Middle engine mounting n ut 44 4.5 33 S 6 Lower engine mounting nut 44 4.5 33 S 7 Engin[...]

8-4 ENGINE REMOV AL /INST ALLA TION Special T o ol Engine Mount Nut Wrench: 57001–1 450[...]

ENGINE REMOV AL/INST ALLA TION 8-5 Engine Removal/ Installation Engine Remo val • Support the rear part of the swi ngarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. W ARN ING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over . I t could cause an accident and injury . CAUTIO[...]

8-6 ENGINE REMOV AL /INST ALLA TION Engine Remov al/Installation • Remove: Camshaft Positi on Sensor Connector [A] Injector Harness Connector [B] • Remove the vacuum switch valve hose f rom the air cleaner housing. • Remove: Breather Hose End [A] Engine Ground Cabl e T erminal Bolt [B] • Support the engine wi th a suitable st and [A]. ○ P[...]

ENGINE REMOV AL/INST ALLA TION 8-7 Engine Removal/ Installation • Remove the middle a nd lower engine m ounting nut s [A] and bolts. • Remove: Rear Engine Bracket B olts [B] Rear Engine Bracket [C] • Using the nut w rench [ A], loosen the locknut [B]. Specia l T ool - Engine M ount Nut Wrenc h: 57 001–1450 • Using the Hexagon Wr ench, tur[...]

8-8 ENGINE REMOV AL /INST ALLA TION Engine Remov al/Installation • Install the engine mounting bolts and nuts, following the specified i nstallin g sequence. ○ First, hang the drive chain over the output shaft just before moving the engine i nto its final position in the frame. ○ Second, insert the lower engine mountin g bolt [A]. ○ Third, [...]

ENGINE REMOV AL/INST ALLA TION 8-9 Engine Removal/ Installation ○ T enth, temporari ly install : Front Engine Bracket [C] Right Upper Engine Mounting Bolt [A] Front Engine Bracket Bolts [ B] ○ Eleventh, ti ghten the right upper engine mounting bolt. ○ Lastly , tighten th e front engine brac ket bolts. T orque - Right Upper Engine Mounting Bol[...]

[...]

CRANKSHAFT/TRA NSMISSION 9-1 9 Crankshaft/T ransmission T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... 9-2 Spec ifica tions .... ...... ...... ....... ...... ...... . 9- 6 Spec ial T ools a nd Seala nt ...... ...... ..... 9- 9 Crank case S plit ting.. ...... ....... ...... ....... 9- 10 Cra nkcase Sp littin g ....... .[...]

9-2 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRA NSMISSION 9-3 Exploded View T orque No. Fastener N· m kgf·m ft·lb Re ma rks 1 Breather plate bolts 9.8 1.0 87 in·lb L 2 Crankcase bolts (M9, L = 81 mm) 42 4.3 31 MO, S 3 Crankcase bolts (M9, L = 95 mm) 42 4.3 31 MO, S 4 Crankcase bolts (M8) 27 2.8 20 S 5 Crankcase bolts (M7) 20 2.0 14 S 6 Crankcase bolts (M6) 12 1.2 104 in·lb S [...]

9-4 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRA NSMISSION 9-5 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Shift pedal mounting bolt 34 3.5 25 L 2 Gear positioning lever bolt 12 1.2 104 i n·lb 3 Shift shaft r eturn spring pin 29 3.0 22 L 4 Shift drum cam hol der bolt 12 1.2 104 in·lb L 5 Footpeg bracket bolts 34 3.5 25 L 6 Shift lever bol t 6.9 0.70 61 in·lb[...]

9-6 CRANKSHAFT/TRANSMISSION Specification s Item Standard Service L imit Crankshaft, Connecting Rods: Connecting rod bend ––– TIR 0.2/100 mm (0.008/3.94 i n.) Connecting rod twist ––– TIR 0.2/100 mm (0.008/3.94 i n.) Connecting rod bi g end side clearanc e 0.13 ∼ 0.38 mm 0.58 mm (0.0051 ∼ 0.0150 in. ) (0.023 in. ) Connecting rod bi [...]

CRANKSHAFT/TRAN SMISSION 9-7 Specifications Item Standard Service Limit Crankshaft side clearance 0.05 ∼ 0.20 m m 0.40 mm (0.0020 ∼ 0.0079 i n.) (0.0157 in.) Crankshaft runout TIR 0.02 mm (0.0008 in.) or less TIR 0.05 mm (0.0020 in.) Crankshaft main bearing inser t/journal clearanc e 0.020 ∼ 0.044 mm 0.07 mm (0.0008 ∼ 0.0017 i n.) (0.0028 i[...]

9-8 CRANKSHAFT/TRANSMISSION Specification s Item Standard Service L imit Shift fork guide pin diameter 6.9 ∼ 7.0 mm 6.8 mm (0.272 ∼ 0.276 i n.) (0.268 i n.) Sh ift drum g roov e width 7.05 ∼ 7.20 mm 7.3 mm (0.278 ∼ 0.283 i n.) (0.287 i n.)[...]

CRANKSHAFT/TRA NSMISSION 9-9 Special T ools and Se alant Bearing Puller: 57001–135 Bearing Puller Adapter: 57001–317 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20 Kawasa ki Bond (Sili cone Seala nt): 92104–1 066[...]

9-10 CRANKSHAFT/T RANSMISSION Crankcase Spl itting Crankcase Splitting • Remove the engine (see Engine Remov al/Installat ion chapter). • Set the engine on a clean surf ace and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electric al System chapter) Clutch (see Clutch chapter) External Shif t Mechanis[...]

CRANKSHAFT/T RANSMISSION 9-1 1 Crankcase Splittin g • Apply liq uid gasket t o the breather p l ate mati ng surface [A] 1 to 1. 5 mm (0.04 to 0.06 i n.) thick, and then inst all the breather plate. Sealant - Three Bond: 1207B • Apply a non-permanent locking agent to the threa ds and tighten t he bolts [ A]. T orque - Breather Plate Bolts: 9.8 N[...]

9-12 CRANKSHAFT/T RANSMISSION Crankcase Spl itting • Apply liquid gasket [A] to the mating surface of the lower crankcase half . Sealant - Kawas aki Bond (Silicone S ealant): 92104–1066 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. • Fit the lower crankcase to the upper cra nkcase. • A[...]

CRANKSHAFT/TRANSMISSION 9-13 Crankshaft an d Connecting R ods Crankshaft Removal • Split the crankcase (see Crankcase Splitt ing). • Remove the crankshaft [A]. Crankshaft Inst allation CAUTION If the crankshaft, bearin g inserts, or crankcase halves are replaced wit h new ones, select the bear- ing inserts and check clearance with a plastigage [...]

9-14 CRANKSHAFT/T RANSMISSION Crankshaft and Conne cting Rods • Apply molybdenum disul fide grease [A] t o the outer sur- face of the upper insert and the inner surf ace of the con- necting r od big end. • Apply molybdenum di sulfide oil [ B] to the inner sur faces of upper and lower bearing inserts . ○ The molybdenum disulfide o il is a mixt[...]

CRANKSHAFT/TRANSMISSION 9-15 Crankshaft an d Connecting R ods (1) Bolt Length Measurement Method • Be sure to clean the bol ts, nuts, and connecting rods thoroughly with a high-fl ash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust sol ution. W ARN ING Clean the bolts, nuts, and connecti ng rods in a [...]

9-16 CRANKSHAFT/T RANSMISSION Crankshaft and Conne cting Rods (2) Rotation Angl e Method If you don’t have a point micrometer , you may tighten the nuts using the “Rot ation Angle Method”. • Be sure to clean the bol ts and nuts thoroughly with a high -flash point solvent , because the new bolts and nut s are treated wit h an anti-rust solut[...]

CRANKSHAFT/TRANSMISSION 9-17 Crankshaft an d Connecting R ods Connecti ng Rod Bend • Remove the connecting rod big end bearing inser ts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect - ing rod big end, and ins ert the arbor through the connect- ing rod big end. • Select an arbo r of th[...]

9-18 CRANKSHAFT/T RANSMISSION Crankshaft and Conne cting Rods Connectin g Rod Big End Bea ring Insert /Crankpin Wear • Measure the bearin g insert/crankpin [ B] clearance wit h plasti gage [A]. • T ighten the big end nuts to the specified torque (see Con- necting R od Installati on). NOTE ○ Do not move the connecting rod and crankshaft during[...]

CRANKSHAFT/TRANSMISSION 9-19 Crankshaft an d Connecting R ods • Measure the connecting rod big end inside diameter , and mark each connecti ng rod big end in accordance with the inside diameter . • T ighten the connecting rod big end nuts to the specified torque (see Connecti ng Rod Installation). NOTE ○ The mark already on the big end s houl[...]

9-20 CRANKSHAFT/T RANSMISSION Crankshaft and Conne cting Rods Crankshaft Run out • Measure the crankshaft runout. If the measurement exceeds the serv ice limit, replace the crankshaft . Crankshaft Runout Standard : TI R 0.02 mm (0 .0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in. ) Cran kshaf t Main B earing Insert/ Journal We ar • Usin[...]

CRANKSHAFT/TRANSMISSION 9-21 Crankshaft an d Connecting R ods • Measure the main bearing inside diameter , and mark the upper crankcase half in accordance wit h the inside di am- eter . Crankcase Main Bearing Inside Diameter Marks : " " or no mark. • T ighten the crankcase bolts to t he specified t orque (see Crankcase Assembly). NOTE[...]

9-22 CRANKSHAFT/T RANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Install ation in the Electri cal System chapter . Star ter Mo tor C lutch In spect ion • Remove: Alternator Cover (see Electrical System chapter) Starter Idle Gear • T urn the starter motor clutch gear [A] b[...]

CRANKSHAFT/TRANSMISSION 9-23 T ran smission Shift Pedal Removal • Mark [A] the position of the shif t lever [B] on the shift shaft so that it can be inst alled later in the same posi tion. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Footpeg Bracket Bolts [A] Footpeg Bracket [B] • Remove the bolt [A], foot peg [B] and shift pedal [C[...]

9-24 CRANKSHAFT/T RANSMISSION T ransmissio n • Install the footpeg bracket [A]. • T ighten: T orque - Footpeg Bracket Bolts [B]: 34 N·m (3.5 kgf·m, 25 ft·lb) • Install the shift lever [A], aligning the mark (previ ously marked). • T ighten: T orque - Shift Lever Bolt: 6.9 N·m (0.70 k gf·m, 61 in·lb) • Install t he shift pedal [B] as[...]

CRANKSHAFT/TRANSMISSION 9-25 T ran smission • Remove: Gear Positioning Lever Bolt [ A] Gear Positioning Lever [B], Coll ar and Spring Exte rnal Sh ift Mech anism I nstalla tion • Install the gear positioning lever [A] as shown. Spr in g [B] Co llar [C] Bol t [D] • T ighten: T orque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 104 in·l[...]

9-26 CRANKSHAFT/T RANSMISSION T ransmissio n T ransmissi on Shaft Removal • Split the c rankcase (see Crankc ase Splitting). • Remove the drive shaft [A] and output shaft [B]. T ransmissi on Shaft Install ation • Check to see that the set pins [A] and set rings [B] are in place. • Install the drive shaft and out put shaft i nto the upper cr[...]

CRANKSHAFT/TRANSMISSION 9-27 T ran smission • Remove the ball bearing [A] from each shafts . Specia l T ools - Bearin g P uller: 57001 –135 [B] Bearing Pull er Adapte r: 57001–317 [C] • Discard the bearing. T ransmission Shaft Assembly • Apply engine oil to the bushings, ball bearings and shaf ts. • Install the gear bushings [A] on the [...]

9-28 CRANKSHAFT/T RANSMISSION T ransmissio n NOTE ○ When the toothed washers [28] [29] are assembled onto the output shaft , note the foll owing. ○ When the tangs [A] of the t oothed washer [29] shall be assembled, they shoul d be install ed into the not ch [B] of the to othed washer [28] (see Page 9–29). • Fit the st eel balls i nto the 5t[...]

CRANKSHAFT/TRANSMISSION 9-29 T ran smission 1. 1st Gear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (T op) Gear 7. T oothed W asher , 31 mm (1.22 in.) 8. Thrust Washer , 30 mm (1.18 in.) 9. Circlip 10. Circlip 1 1. Bushing 12. Bushing 13. Needle Bearing 14. Needle Bearing 15. Bearing Outer Race 16. Steel Ball 17. Nut 18. Bushing 19. Bush[...]

9-30 CRANKSHAFT/T RANSMISSION T ransmissio n Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Spli tting) T ransmission Shafts External Shif t Mechanism (see Extern al Shift Mecha- nism Removal) Bolt [A] and Screw [B] Shift Drum Bearing Holder [C] • Pull out the shi ft rods [D] , and take off the shift forks. • Pull o[...]

CRANKSHAFT/TRANSMISSION 9-31 T ran smission Shif t Fork Bendi ng • Visual ly inspect the shift forks, and replace any for k that is bent. A bent fork could cause dif ficulty in shifting, or al low the transmission to jump out of gear when under power . 90° [A] Shif t Fork/Gear Groo ve Wear • Measure the thickness of the shift fork ear s [A], a[...]

[...]

WHEELS/TIRES 10-1 10 Wheels/T ires T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 10-2 Spec ifica tions .... ...... ...... ....... ...... ...... ...... ...... ....... ...... ........ ...... ....... ...... ...... ...... .[...]

10-2 W HEEL S/TI RES Exploded View[...]

WHEELS/TIRES 10-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Front axle clamp bolt 34 3.5 25 2 Front axle 108 11 80 3 Rear axle nut 108 11 80 G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubr icant.[...]

10-4 W HEEL S/TI RES Specification s Item Standard Se rvice Lim it Wheels (Rims): Rim runout: Axial ––– TI R 0.5 mm (0.020 in.) Radial ––– TI R 0.8 mm (0.031 in.) Axle runout/ TIR 0.05 mm (0.0020 in.) or less TI R 0.2 mm 100 mm (3.94 in.) (0.008 in.) Wheel balance 10 g (0.35 oz. ) or less ––– Balance weights 10 g (0.35 oz.), 20 g [...]

WHEELS/TIRES 10-5 Special T ools Bear ing Drive r Set: 57001–1129 Jack: 57001–123 8 Bearin g Remover Head, 20 × 22: 57001–1 293 Bearin g Remover S haft, 13: 57001–1 377[...]

10-6 W HEEL S/TI RES Wheels (Rim s) Front Wheel Removal • Remove: Brake Caliper Mounting Bol ts [A] • Loosen the fr ont axle clamp bolt [A]. • Remove the front axle [B]. • Raise the front wheel off the ground. Special T ool - Jack: 5 7001–1238 • Pull out the axle to the right and drop the front wheel out of the forks. CAUTION Do not lay[...]

WHEELS/TIRES 1 0-7 Wheels (Rims) • T ighten the front axle. T orque - F ront Axle: 108 N·m (1 1 kgf·m, 8 0 ft·lb) • Before tightening the cl amp bolt on the right front fork leg, pump the front fork up a nd down 4 or 5 times to all ow the right fr ont fork leg to seat on the fr ont axle. NOTE ○ Put a block i n front of the front wheel to s[...]

10-8 W HEEL S/TI RES Wheels (Rim s) • Remove: Caliper Mounting Bolts [A] Caliper [B] • Remove the drive chain [A] f rom the rear sprocket toward the lef t. • Move the rear wheel back and remove the wheel from the rear caliper . • Remove the rear wheel. CAUTION Do not lay the wheel on the ground wit h the disc facing down. This can damage or[...]

WHEELS/TIRES 1 0-9 Wheels (Rims) • Bend the cotter pin [A] over the n ut. W ARN ING If the rear axle nut is not securely tightened or the cotter pin is not inst alled, an unsafe riding condi- tion may result. • Adjust the drive chain sla ck after installation (see Final Drive chapter). • Check the rear brake ef fectiveness. W ARN ING Do not a[...]

10-10 WHEELS/TIRES Wheels (Rim s) Axle Inspe ction • Remove the front and rear axl es. • V isually inspect the f ront and rear axle for damages. If the axle is damaged or bent, repl ace it. • 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. T urn [C] [...]

WHEELS/TIRES 10-1 1 Wheels (Rims) CAUTION When removing the balance weight, do not touch the brake disc. The disc could be damaged. Do not tap the screwdrivers. The rim could be dam- aged. Balan ce Weight Inst allation • Check if the weight port ion has any play on the cli p. If it does, discard it. W ARN ING If the balance weight has any play on[...]

10-12 WHEELS/TIRES Tire s Air P ressur e Insp ection • Refer to the Air Pressur e Inspection in the Periodic Main- tenance chapter . Tire Inspecti on • Refer to the T ire Wear I nspection in t he Periodic Mai nte- nance chapter . Tire Removal • Remove: Wheel (see Front Wheel Removal, Rear Wheel Re- moval) Disc(s) V alve Core (let out the air)[...]

WHEELS/TIRES 10-13 Tir e s • Install a ne w valve in the rim. ○ Remove the valve cap, lubricate the stem seal with a soap and water soluti on or rubber lubricant, and pull [B] the valve stem [A] through the ri m from the inside out until it snaps into plac e. CAUTION Do not use engine oil or petrol eum distillates to l u- bricate the stem becau[...]

10-14 WHEELS/TIRES Tire s • Check to see that the r im lines [A] on both sides of the ti re sidewalls are parallel with the rim flanges. If the rim fla nges and tire sidewall ri m lines are not parallel, remove the valve core. • Lubricate t he rim flanges and tire beads. • Install the valve core and inflate t he tire agai n. • After t he ti[...]

WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the f oll owing. Co llars Coupling (out of rear hub) Grease Seals Cir cli p • Use the bearing remover to re move the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Please blocks under t h[...]

[...]

FINAL DRIVE 1 1-1 11 Final Drive T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 1 1-2 Spec ifica tions .... ...... ...... ....... ...... ...... ...... ...... ....... ...... ........ ...... ....... ...... ...... ...... ..[...]

1 1-2 F INAL DRIVE Exploded View[...]

FINAL DRIVE 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Engine sprocket cover bolts 9.8 1.0 87 in·lb 2 Engine sprocket nut 125 13 92 MO 3 Rear sprocket nuts 59 6.0 43 4 Speed sensor cover bolts 6.9 0.70 61 in·lb L 5 Speed sensor bolt 6.9 0.70 61 in·lb L 6 Rear axle nut 108 11 80 G: Apply grease. HO: Apply heavy oil. L:[...]

1 1-4 F INAL DRIVE Specification s Item Standard Se rvice L imit Drive Chain: Chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 i n.) ––– 20-link l ength 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard chain Make ENUMA ––– Ty p e EK520MVXL ––– Link 1 12 lin ks ––– Sprockets: Rear sprocket warp 0.4 mm (0.016 in.) or l[...]

FINAL DRIVE 1 1-5 Special T ools Bear ing Drive r Set: 57001–1129 Jack: 57001–1 238[...]

1 1-6 F INAL DRIVE Driv e Chain Driv e Chain Slac k Inspec tion • Refer to the Drive Chain Slack Inspect ion in the Periodic Maintenance chap ter . Drive Chain Sl ack Adjustment • Refer to the Drive Chai n Slack Adjustment in the Peri odic Maintenance chap ter . Drive Chai n W ear Inspect ion • Refer to the Drive Chain Wear I nspection in the[...]

FINAL DRIVE 1 1-7 Drive Chain Drive Chai n Replacemen t • Remove: Chain Cover (see Drive Chain Removal) Engine Sprocket Cover (see Engine Sprocket Removal) EK JOINT TOOL #50 Body [A] Handlebar [B] C u t t i n g&R i v e t i n gP i n[ C ] For Cutting [D] For R ivet in g [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] pin h[...]

1 1-8 F INAL DRIVE Driv e Chain • Replace the link pin, link pl ate and grease seals. • Apply grease to the link pins [A] and grease seals [B] [C]. • Engage the drive chain on the engine and rear sprockets. • Insert the li nk pins in the drive chain ends. • Install the grease seal s [C]. • Install the link plate so that the mark [D] fac[...]

FINAL DRIVE 1 1-9 Drive Chain • T urn pin holder until riveti ng pin touches link pin. • T urn wrench clock wise until tip of rivet ing pin hits of link pin. • Rivet it. • Some work for the other link pin. • After staki ng, check the stake d area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link pla[...]

1 1-10 FINAL DRIVE Sprocket, Co upling Engine Spro cket Removal • Remove: Speed Sensor Connector [A] Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer . NOTE ○ When loosening the engine s procket nut, hold t he rear brake on. • U[...]

FINAL DRIVE 1 1-1 1 Sprocket, Coupling Rear Sprocket Rem oval • Remove the rear wheel (see Wheels/T ires chapter). CAUTION 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. • Remove the rear sprock et nuts [A]. • Remove the r[...]

1 1-12 FINAL DRIVE Sprocket, Co upling • Replace the grease seal with a new one. • Press in the gr ease seal so that the seal surface is f lush with the end of the hol e. ○ Apply high temperature grease to the grease seal l ips. Special T ool - Bearing Dr iver Set : 5700 1–1 129 Coupli ng Installation • Grease the fol lowing and instal l [...]

FINAL DRIVE 1 1-13 Sprocket, Coupling Sprocket Wear Insp ection • Visual ly inspect the engine an d rear sprocket teeth for wear and damage. If the teeth are worn as ill ustrated, replace the spro cket, and inspect the drive chain wear (see Drive Chain W ear Inspection) . Worn T ooth (Engine Sprocket) [A] Worn T ooth (Rear Sprocket) [B] Direction[...]

[...]

BRAKES 12-1 12 Brakes T able o f Content s Exploded V iew .... ...... ...... ....... ...... ...... 12-2 Spec ifica tions .... ...... ...... ....... ...... ...... . 1 2-6 Special T ool ........ ...... ...... ..... ........ . ... .. 12-7 Brake Lever , Brake Pedal .............. .... 12-8 Brake Lever Position Adjustment . 12-8 Brake Pedal Position Ins[...]

12-2 BRAKES Exploded View[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front caliper mounting bolts 34 3.5 25 2 Brake hose banjo bolts 25 2.5 18 3 Bleed valve 7.8 0.80 69 in·l b 4 Brake lever pivot bolt 1.0 0.10 9i n · l b Si 5 Brake lever pivot bolt locknut 5.9 0.60 52 in·l b 6 Front brake di sc mounting bolts 27 2. 8 20 L 7 Front brake li[...]

12-4 BRAKES Exploded View[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear master cylinder push rod locknut 18 1.8 13 2 Rear caliper mounting bolts 25 2.5 18 3 Brake hose banjo bolts 25 2.5 18 4 Bleed valve 7.8 0.80 69 in·l b 5 Rear master cylinder mounting bolts 25 2.5 18 6 Rear brake disc mounting bolts 27 2.8 20 L B: Apply brake fluid. G:[...]

12-6 BRAKES Specification s Item Standard Se rvice Lim it Brake Lever , Brake Pedal: Brake lever position 5-way adjustable (to suit rider) ––– Brake lever free play Non-adjust able ––– Pedal free play Non-adjustable ––– Pedal position About 47 mm (1.85 in.) below footpeg top ––– Brake Fluid: Grade DOT4 ––– Brake Pads: [...]

BRAKES 12-7 Special T ool Jack: 57001–123 8[...]

12-8 BRAKES Brake Lever , B rake Pedal Brake Lever P osition Adjustmen t The brake lever adjuster has 5 posit ions so that the brake lever positi on can be adjusted to suit the operator ’s hand. • Push the l ever forward and turn the adjust er [A] to al ign the number wit h the arrow mark [B] on the lever holder . ○ The distance from the grip[...]

BRAKES 12-9 Calipers Front Cal iper Removal • Loosen the banjo bolt [A] at the brak e hose lower end, and tighten it loos ely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bol t and remove the brake hoses [ D] from the cal iper (see Br ake Hose Removal/Inst allation). CAUTION Immedia[...]

12-10 BRAKES Calipers Front Caliper Disassembly • Remove: Front Caliper (see Caliper Removal) Brake Pads and Springs ( see Brake Pad Removal) • Using compressed ai r , remove the pistons. ○ Cover the piston area with a clean, thick c loth [A]. ○ Blow compressed air [B] into the hole f or the banjo bolt to remove the pi ston. W A RNING T o a[...]

BRAKES 12-1 1 Calipers • Replace the fluid seal s [A] with new ones. ○ Apply brake fluid to the flui d seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged. ○ Apply brake fl uid to the dust s eals, and install them i nto the cylinders by hand. • Apply brake fluid to the outsi[...]

12-12 BRAKES Calipers Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning t he parts, use only disc brake fluid, isopropyl alcohol, or ethyl al cohol. • Install the bleed valve and rubber cap. T orqu e - Ble ed V al ve: 7.8 N·m (0.80 kgf· m, 69 in·lb) • Replace the fluid seal [A] with a new one. ○ Ap[...]

BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage • Visual ly inspect the pi ston [E] and cylinder surfaces. Replace the cal iper if the cylinder and pist on are badly scores or rusty . Fluid Seal [A] Dust Seal [B] Rubber Boot [C] Front Caliper [J] Rear Caliper [K] Calipe r Holder S haft W ear The caliper body must slide smoot hly on the c[...]

12-14 BRAKES Brake Pad s Front Brake Pad Remova l • Remove the caliper from the disc. • Draw out the holder shaft pi n [A], and take off t he holder shaft [B]. • Remove the pad [C] on the piston side. • Push the holder [D ] towards the piston, and remove the pad of the other side [E] from the holder shaft [F]. Fron t Brake Pad I nstalla tio[...]

BRAKES 12-15 Master Cylinder Front Master Cyli nder Removal • Disconnect the front brake light s witch connectors [A] . • Remove the banjo bolt [B] t o disconnect the brake hose from the master cy linder [C] (see Br ake Hose Removal/In- stallati on). • Unscrew the clamp bolts [A], and take of f the master cylin- der as an assembly with the re[...]

12-16 BRAKES Master Cylind er Rear Master Cylin der Removal • Unscrew the brake hose banjo bolt [A] on the master c ylin- der (see Brake Hose Removal /Installati on). • Pull off the reservoir hose lower end [B], and drain the brake fl uid into a cont ainer . • Loosen the master cylinder mounti ng bolts [C] lightly . • Remove the cotter pin [...]

BRAKES 12-17 Master Cylinder Rear Master Cylin der Disassem bly NOTE ○ Do not remove t he push rod c levis for mast er cylinder disassembly since removal requires brake position ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal). • Slide the dust cover on the push rod out of place, and remove the circlip. •[...]

12-18 BRAKES Brake Disc Brake Disc Remova l • Remove the wheel (see Wheels/T ires chapter). • Unscrew the mounting bol ts, and take off t he disc. Brake Disc Insta llati on • Install the brake disc on the wheel so that the marked side [A] faces out. • Apply a non-permanent loc king agent to the threads of the fr ont and rear brak e disc mou[...]

BRAKES 12-19 Brake Fluid Brake F luid Leve l Inspectio n • Refer to the Brakes i n the Periodic Maint enance chapter . Brake Fluid Ch ange • Refer to the Brakes i n the Periodic Maint enance chapter . Brake L ine Ble eding • Refer to the Brakes i n the Periodic Maint enance chapter .[...]

12-20 BRAKES Brake Hose Brake Hose Removal /Install ation CAUTION Brake fluid quickly ruins pai nted or plastic sur- faces; any spilled flui d should be completely wiped up immediately with wet cloth. • When removing t he brake hose, take care not to s pill the brake flui d on the painted or plasti c parts. • When removing the brak e hose, temp[...]

SUSPENSION 13-1 13 Suspension T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 13-2 Spec ifica tions .... ...... ...... ....... ...... ...... ...... ...... ....... ...... ........ ...... ....... ...... ...... ...... ......[...]

13-2 SUSPENSION Exploded View[...]

SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf· m ft·l b Remarks 1 Front fork clamp bolt s (Upper) 20 2.0 14 2 Front fork clamp bolt s (Lower) 20 2. 0 14 AL 3 Front fork top plugs 25 2.5 18 4 Front fork bottom Allen bo lts 30 3.1 22 L 5 Front axle clamp bol t 34 3.5 25 6. Right fork leg 7. Left fork leg AL: T ighten the two clamp bol[...]

13-4 SUSPENSION Exploded View[...]

SUSPENSION 13-5 Exploded View To r q u e No. Fastener N·m kgf· m ft·l b Remarks 1 Rear shock absorber nuts (upper and lower) 34 3.5 25 2 Swingarm pivot shaft nut 108 11 80 3 Swingarm pivot shaft locknut 98 10 72 4 Rocker arm nut 34 3.5 25 5 T ie-rod bolts 59 6.0 43[...]

13-6 SUSPENSION Specification s Item S tandard Front Fork (per one unit): Fork inner tube outside diamet er 41 mm (1.61 in.) Air Pressure Atmospheri c pressure (Non-adjustabl e) Fork spring sett ing Non-adjustable Damper setting Non-adjustabl e Fork oil viscosit y KA Y ABA KHL34-G10 Fork oil capacity 452 ±4 mL (15.28 ±0.135 US oz.) (completely dr[...]

SUSPENSION 13-7 Special T ools Fork Cylinder Holder Handle: 57001–183 Fork Cylinder Holder Adapter: 57001–105 7 O i lS e a l&B e a r i n gR e m o v e r : 57001–105 8 Bear ing Drive r Set: 57001–1129 Jack: 57001–123 8 Fork Oil Seal Dr iver: 57001–1 288 Fork Oil Level Gauge: 57001–1 290 Hook Wrench: 57001–1 539 Swingarm pivot Nut [...]

13-8 SUSPENSION Front Fork Front Fork Remova l • Remove: Front Wheel (see T ires/Wheels chapter) Front Fender (see Frame chapt er) Fairing (see Fr ame chapter) Loosen the hand lebar bolt, upper fork clamp bol t and fork top plug bef ore-hand if the for k leg is to be d isassembled. NOTE ○ Loosen the t op plug aft er loosenin g the upper fork cl[...]

SUSPENSION 13-9 Front Fork • Hold the outer t ube vertically i n a vise and compress the fork comple tely . • W ait until the oil level stabil izes. • Use the fork oil lev el gauge [A] to measure the distance between the top of the inner tube to the oil level . Specia l T ool - Fork Oil Le vel Gauge: 57001–1 290 ○ Set the oil l evel gauge[...]

13-10 SUSPENSION Front Fork • Remove the cylinder unit [A], washer , and the spring [B] from the inner tube. • Remove the following f rom the top of the outer t ube: Dust Seal [A] Reta ining Ring [ B] • Separate the in ner tube [A] from the outer tube [B] . NOTE ○ From the compressed stat e, firmly pull down the outer tube a few ti mes towa[...]

SUSPENSION 13-1 1 Front Fork Front For k Assembly • Check the top plug O-ring and replace it with a new one. • Replace the foll owing parts with new ones: Re taining R ing [A] Dust Seal [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Fork Bottom Allen Bolt Gasket [F] • Install the gui de bushing on the en d of the inner tube.[...]

13-12 SUSPENSION Front Fork Inner T ube/Ou ter T ube Inspection • V isually inspect the i nner tube [A] and repair any nicks or rust by usin g an oil stone. If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal slip, replace t he oil seal whenever the inner tube i s repaire d or replaced. CAU[...]

SUSPENSION 13-13 Rear Shock Absorber Rebo und Dam ping For ce Adjustm ent • T urn the damper adjuster [A] to ad just the rebo und damp- ing. ○ Align the numbered mar k [B] of the adjuster . ○ The standard adjuster setting for average-build ri der of 68 kg (150 I b) with no pas senger and no access ories is position "2". If the dampe[...]

13-14 SUSPENSION Rear Shoc k Absorber • Remove: Lower Shock Absorber Nut [A] Lower Shock Absorber Bolt [B] • Remove: Upper Shock Absorber Nut [A] Upper Shock Absorber Bolt [B] • Remove the shock absor ber [A] from upside. Rear Shock Absorbe r Installati on • T ighten: T orque - Rear Shock Absorbe r Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear[...]

SUSPENSION 13-15 Swingarm Swingarm Removal • Raise the rear wheel off the ground with jack. Specia l T ool - Jack: 57001 –1238 • Remove: Chain Cover (see Final Drive chapter) Mud Guard (see Frame chapter) Brake Hose Clamp [A] Rear Wheel (see W heels/ T ires chapter) Lower Shock Absorber Nut and Bolt [A] Upper T ie-rod Nut and Bolt [B] • Rem[...]

13-16 SUSPENSION Swingarm Swingar m Installat ion ○ Place the collar [A] on the stopper [B] inside the frame [C]. • Insert the p ivot shaft int o the frame fr om the right side. • T ighten the pivot shaft so t hat the clearance [ D] between the colla r and the f rame c ome to ze ro mm. • T ighten: T orque - S wingarm Pivot Shaft Nut : 1 08 [...]

SUSPENSION 13-17 Swingarm Swingar m Bearin g Install ation • Install the needl e bearings so t hat the manufacturer’s marks face in. • Install the ball beari ng so that the manufacturer’s marks faces out. Specia l T ool - Bearing Dr iver S et: 57001 –1 129 [ A] Swingar m Bearing, Sl eeve Inspection CAUTION Do not remove the bearings for i[...]

13-18 SUSPENSION Tie-rod, Rock er Arm Tie-ro d Remov al • Remove the side stand ( see Frame chapter). • Using the jack, rai se the rear wheel off t he ground. Special T ool - Jack: 5 7001–1238 • Squeeze the brak e lever slowly and hold it with a band [A]. • Remove: Lower Rear Shock Absorber Bolt and Nut [A] Upper and Lower T ie-rod Nuts a[...]

SUSPENSION 13-19 Tie-rod, Rocker Ar m Rock er Arm/T ie-rod Be aring, S leeve In spect ion • Visual ly inspect the rocker arm/tie-rod s leeves and needle bearings. • The rollers in a needle bearing normally wear very li ttle, and wear is diffi cult to measure. Instead of measuring, inspect the beari ng for abrasion, color change, or other damage[...]

[...]

STEERING 14-1 14 Steering T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 14-2 Spec ial T ools ... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... [...]

14-2 STEERING Exploded View[...]

STEERING 14-3 Exploded View T orque No. Fastener N·m kgf· m ft·l b Remarks 1 Steering stem nut 27 2.8 20 2 Steering stem head bolt 108 11 80 3 Front fork clamp bolts (Upper) 20 2.0 14 4 Front fork clamp bolts (Lower) 20 2.0 14 AL 5 Handlebar clamp bolts 25 2.5 18 S 6 Handlebar lower clamp nuts 34 3.5 25 7 Switch housing screws 3.5 0.36 31 in·lb[...]

14-4 STEERING Special T oo ls Steer ing Stem Nu t Wrench: 57001–1100 Bearing D river Set: 57001–1129 Jack: 57001–1 238 Stee ring St em Bear ing Dri ver: 57001–13 44 Stee ring Ste m Bearin g Driver Ad apter : 57001–13 45[...]

STEERING 14-5 Steering Steeri n g Inspecti on • Refer to the Steeri ng in the Periodi c Maintenance chapter . Steer ing Adjus tment • Refer to the Steeri ng in the Periodi c Maintenance chapter .[...]

14-6 STEERING Steerin g Stem Stem , Stem B earing Re moval • Remove: Inner Cover (see Frame chapter ) Fairing and Bracket (see Fr ame chapter) Front Wheel (see Wheels/T i res chapter) Handlebar (see Handlebar Removal) Steering Stem Head Bolt Plug Steering Stem Head Bolt [A] and W asher Front Fork Clamp B olts (Lower) (Loosen) Steering Stem H ead [...]

STEERING 14-7 Steering Stem Stem, Stem Beari ng Installa tion • Replace the bear ing outer rac es with new ones . • Apply grease to the outer races, and drive t hem into the head pipe at the same t ime. Specia l T ool - Bearing Dr iver S et: 57001 –1 129 [ A] • Replace the bearing inner r aces and oil seal with new ones. • Apply grease t [...]

14-8 STEERING Steerin g Stem • Install t he claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it t ouches the claw washer . • T ighten the stem locknut clockwise until the claws are aligned with t he grooves (rangi ng from 2nd to 4th) o[...]

STEERING 14-9 Handlebar Handleb ar Removal • Remove: Handlebar Holder Plugs Clutch Lever Assembly [A] Left Handlebar Swit ch Housing [B] Front Brake Master Cyli nder [C] Right Handlebar Switch Housing [D] Handlebar Holder Bolts [E] • Remove the handlebar holder [F] and then pull out the handlebar . • Remove the cotter pins [A]. • Remove the[...]

[...]

FRAME 15-1 15 Frame T able o f Content s Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ........ ...... ........ ..... . ..... 15-2 Seats .. ....... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... ..[...]

15-2 FRAME Exploded View[...]

FRAME 15-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Footpeg bracket bolt s 34 3.5 25 L 2 Side stand bracket bolts 49 5.0 36 3 Side stand bolt 44 4.5 33 4 Side stand switch bolt 8.8 0.90 78 in·l b G: Apply grease. L: Apply a non-permanent locking agent.[...]

15-4 FRAME Exploded View[...]

FRAME 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front fender brac ket bolts 8. 8 0. 90 78 in·lb L 2 Front fender bolt s 3.9 0.40 35 in·lb[...]

15-6 FRAME Exploded View[...]

FRAME 15-7 Seats Rear Seat Removal • Insert the i gnition switch k ey into the seat lock [A], t urning the key clockwis e, pulling up on the rear of the seat [B], and pulling the seat backward. Rear S eat Inst allation • Slip the rear seat hooks [A] into the hollow-cubic bracket [B] on the fr ame. • Insert t he seat latch [ C] i nto the latch[...]

15-8 FRAME Side Covers Side Cover Remova l • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the s top- pers. Side Cover Installa tion • Insert the t abs [A] into the holes [B]. • Install the bolt.[...]

FRAME 15-9 Fairings Inner Cover Re moval • Remove: Inner Cover Screws [A] and W ashers Inner Cover [B] Inner Cover In stallat ion • Fit the proj ection [A] on the inner cover [B] into the hole [C] in the fairing. • Install the washer s and inner cover screws. Fairin g Remo val • Remove: Fairing Mounti ng Bolts [A] (both side) Headlight Conn[...]

15-10 FRAME Seat Covers Seat C over R emova l • Remove: Seats Screws [A] • Push the centr al pin, and then r emove the quic k rivets [A]. • Pull the front porti ons [A] of the seat cover outside [B], and then remove the seat cover backward. Seat Cover Inst allation • Install ation is reverse of removal. • Put the project ions [A] into t h[...]

FRAME 15-1 1 Mud Guard Mud Guard Removal • Remove: Chain Cover (see Final Drive chapter) Bol t [A] Cla mp [B ] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Install ation • Put the projecti ons [A] into th e grommets [B].[...]

15-12 FRAME Fenders Fron t Fen der Re moval • Remove: Front Wheel (see Wheels/T i res chapter) Brake Hose Clamps Front Reflecto r Bolts [A] Bolts [B] (both side) • Remove the front fender [C]. Front Fender I nstallati on • Apply a non-permanent loc king agent to the threads of the bra cket b olts . • T ighten: T orque - Front Fe nder Bracke[...]

FRAME 15-13 Fenders • Remove: Quic k Rive ts [A] Rear Fender Rear [B] Rear Fender Rear Insta llation • Put the projection [A] into the hole [B]. • Put the projections [A] i nto the holes [B]. • Installa tion is rever se of removal.[...]

15-14 FRAME Frame Cover Fram e Cov er Rem oval • Remove: Bolts [A] Frame Cover [B] (both side)[...]

FRAME 15-15 Battery Case Battery Case Removal • Remove: Seats Seat Cover Rear Fender Assy Sid e Cov ers Bat ter y Reserver T ank Screws • Pull out the battery case [A] backward. Battery Case Installation • Put the battery case attachments [A] at the proj ections [B] on the frame.[...]

15-16 FRAME Side S tand Side Stand Remo val • Raise the rear wheel of f the ground with the stand. • Remove: Side Stand Switch Bolt [A ] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Insta llati on • Apply grease to the sliding area [B] of the side stand [ A]. • T ighten the bolt and lock [...]

FRAME 15-17 Rear View Mirrors Rear V iew Mirror s Removal • Loosen the lower hexagonal area [ A] for tightening to r e- move the rear view mirror f rom the holder . CAUTION Do not force to tighten and/or loosen the upper hexagonal area (Adapter) [B] wit h a pair of span- ners. Disassembly of this ar ea is Not A vailable. Non-permanent locking age[...]

15-18 FRAME Frame Frame Inspecti on • V isually i nspect the f rame for c racks, dents, bending, or warp. ○ If there is any damage to the frame, replace i t. W A RNING A repaired f rame may fail in use, possibly causi ng an accident. If the frame is bent, dented, cracked, or warped, replace it.[...]

ELECTRICAL SYSTEM 16-1 16 Electrical System T able o f Content s Part s Locati on.. ...... ...... ....... ...... ...... ...... ........ ....... ...... ...... ...... ...... ....... ...... ...... ...... ...... ........... . 16-3 Exploded V iew .... ...... ...... ..... ........ ...... ........ ....... . ... ...... ........ ...... ....... ...... ......[...]

16-2 ELECTRICAL SYSTEM Spark P lug In stalla tion .. ....... ...... ...... ...... ...... ......... ...... ...... ...... ....... ...... ...... ...... ...... ....... .... 16 -4 4 Spark P lug In spect ion ..... ....... ...... ...... ...... ...... ....... ...... ...... ...... ....... ...... ...... ...... ...... ....... .... 16 -44 Spark P lug G ap Insp[...]

ELECTRICAL SYSTEM 16-3 Parts Location 1. Starter Lockout Switch 2. Camshaft Position Sen- sor 3. Radiator Fan Switch 4. Starter Motor 5. Alternator 6. Speed Sensor 7. Neutral S witch 8. Side Stand Switch 9. W ater T emperature Sen- sor 10. Battery 1 1. Junction Box 12. Fr ont Brake Light Switch 13. Stick Coils 14. Crankshaft Sensor 15. Rear Brake L[...]

16-4 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Meter mounting screws 1.2 0.12 10 in·l b 2 T ail/bra ke light mounting screws 1.2 0.12 10 in·lb 3 License plate l ight mounting screws 1. 2 0.12 10 in· lb 4 Front brake light swi tch screw 1.0 0. 10 9i n · l b 5 Starter locknut s witch screws – – – L 6 [...]

16-6 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater temperature senso r 25 2.5 18 SS 2 Spark plugs 13 1.3 11 3 i n · l b 3 Alternator lead holding plate bolt 11 1.1 95 in·lb L 4 Starter motor mounting bolts 11 1.1 95 in·lb 5 Stator coil bolts 11 1.1 95 in·lb 6 Alternator rot or bolt 11 0 11 81 7 Starter[...]

16-8 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Regulator/r ectifier bolt s 6.9 0. 70 61 in·lb 2 Fuel level sensor bolts 6.9 0.70 61 in· lb 3 Side stand switch bolt 8.8 0. 90 78 in·lb L 4 Neutral switc h 15 1.5 11 5 Speed sensor bolt 6.9 0.70 61 in·lb L 6 Speed sensor cover bolts 6.9 0.70 61 in·l b L 7 Re[...]

16-10 ELECTRICAL SYSTEM Specification s Item Standard Battery: Ty p e Sealed Battery Capacity 12 V 8 Ah Vo l t a g e 12.6 V or more Charging System: Ty p e Three-phase AC Alternat or output volt age 42 V or more Stator coil resist ance 0.3 ∼ 0. 4 Ω Charging voltage 14.7 ±0.5 V (regulator/r ectifier output vol tage) Ignition System: Crankshaft [...]

ELECTRICAL SYSTEM 16-1 1 Special T ools and Se alant Rotor Pu ller , M16/M 18/M20/M2 2 × 1.5 : 57001–121 6 Flywheel & Pulle y Holder : 57001–134 3 Hand T e ster : 57001–139 4 Flywheel Puller , M38 × 1.5 : 57001–140 5 Lead Wire-P eak V oltage Adapter : 57001–144 9 Needle Adapter : 57001–1 457 Harness Adapter : 57001–1 542 Rotor H[...]

16-12 ELECTRICAL SYSTEM Wiring Diagram (C anada)[...]

ELECTRICAL SYSTEM 16-13 Wiring Diagram (Can ada)[...]

16-14 ELECTRICAL SYSTEM Wiring Diagram (Au stralia)[...]

ELECTRICAL SYSTEM 16-15 Wiring Diagram (Austr alia)[...]

16-16 ELECTRICAL SYSTEM Wiring Diagram (Other t han Canada, Austr alia and Malaysia)[...]

ELECTRICAL SYSTEM 16-17 Wiring Diagram (O ther than Canada, Au stralia and Malaysia)[...]

16-18 ELECTRICAL SYSTEM Wiring Diagram (Ma laysia)[...]

ELECTRICAL SYSTEM 16-19 Wiring Diagram (Mala ysia)[...]

16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that ar e musts when s ervicing elect rical systems. Learn and ob- serve all the rules below . ○ Do not reverse the batter y lead connections. This will burn out the di odes on the electrical parts. ○ Always check battery condition before condemning other parts of a[...]

ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [ B][...]

16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • V isually inspect the wir ing for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector i s corroded or dirty , clean it carefully . If it is damaged, replac[...]

ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connect ions when the ignition switch is ON, as this could damage t he ECU (Electronic Con- trol Unit). Never reverse the connections of the battery , this could damage the ECU. • Remove: Seats (see Frame Chapter) • Disconnect th[...]

16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] sealing the fille r ports [B] until just before use. • Check to see that ther e is no peeling, tears or hole s in the seal sheet on the top of the battery . • Place the bat tery on a level surface. • Remove the seal sheet. NOTE ○ A battery whose seal sheet has[...]

ELECTRICAL SYSTEM 16-25 Battery • Fit the seal cap [A] tightly into the f il ler ports until t he seal caps are at the same level as t he top of the battery . NOTE ○ Do not hammer . Press down evenly w it h both hands. CAUTION Once you installed the seal caps aft er filling t he bat- tery , never remove it, nor add any water or el ec- trolyte. [...]

16-26 ELECTRICAL SYSTEM Battery Precauti ons 1) No need of topping–up No topping–up is necessary i n this battery unti l it ends its life under normal use. F orc ibly prying off the se at cap to add w ater is very da ngerous. Neve r do that. 2) Refreshing charge If an engine wil l not start, a horn sounds weak, or lamps are dim, it indicates th[...]

ELECTRICAL SYSTEM 16-27 Battery Interchang e The sealed batter y can fully displ ay its perfo rmance only when combined with the pr oper vehicle elect ric system. Therefore, replace a sealed batte ry only on a motorcycl e which was originall y equipped with a sealed battery . Be careful, if a sealed batt ery is installed on a motorcycl e which had [...]

16-28 ELECTRICAL SYSTEM Battery T erminal V oltage: 1 1.5 ∼ less than 12.6 V Standard Charge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery T erminal V oltage (V) [A] Charge T ime (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do stan- dard charge later on. T erminal V o lt[...]

ELECTRICAL SYSTEM 16-29 Charging System Alter nator Cover R emoval • Remove: Left Frame Cover (see Frame chapter) Clamp (open) [A] Alternator Lead Connector [B] • Place a suitable container under the alternator cover [A], and remove the cover bolts [B] . • Pull the alternator cover outside. Alter nator Cover Inst allation • Apply silicone s[...]

16-30 ELECTRICAL SYSTEM Chargin g System Stator Co il Installation • Apply a non-permanent loc king agent to the threads of the stator coil bolt s and tighten them. T orque - S tator Coil Bolts: 1 1 N·m (1.1 kgf·m, 95 in·lb) • Secure the al ternator lead with a hol ding plate, and tighten t he bolt. ○ Apply a non-permanent locking agent to[...]

ELECTRICAL SYSTEM 16-31 Charging System • Install the starter gear [A]. • Again, clean the crankshaft taper ed portion [B] and dr y there. • Fit the woodruf f key [C] securel y in the slot i n the crank- shaft before instal ling the alternat or rotor . • Install the alternator rot or [A] while turn ing [B] the sta rter clutch gear [C]. • [...]

16-32 ELECTRICAL SYSTEM Chargin g System • Apply a thin c oat of molybdenum disulfide grease to the shaft [A], and inst all it and starter i dle gear [B]. • Install t he alternator cover (see Alternator Cover Inst alla- tion). Alternator Inspe ction There are three ty pes of alternator fail ures: short, open (wire burned out), or loss in rot or[...]

ELECTRICAL SYSTEM 16-33 Charging System If ther e is more resi stance than shown in the table, or no hand tester readi ng (infinity ) for any two leads, the stator has an open lead and must be replaced. Much less than this resi stance means the stato r is shorted, and must be replaced. • Using the highes t resistance ran ge of the hand tes ter , [...]

16-34 ELECTRICAL SYSTEM Chargin g System • Do the 1st s tep regulator ci rcuit test: ○ Connect the test li ght and the 12 V batt ery to the regula- tor/re ctifier as shown. ○ Check BK1, BK2, and BK3 terminal respectively . If the test l ight turns on, the regulato r/rectifi er is defective. Replace it. If the test light does not turn on, cont[...]

ELECTRICAL SYSTEM 16-35 Charging System Char ging V oltage I nspec tion • Check the battery conditi on (see Battery secti on). • W arm up the engine to obtain act ual alternator operati ng conditions. • Remove the seats (see Frame chapter). • Check that the igniti on switch is turned of f, and connect the hand tester [A] to the battery term[...]

16-36 ELECTRICAL SYSTEM Chargin g System Charging System Circuit 1. Ignition Switch 2. T o Starter Circuit Relay 3. Alternator 4. Regulator/Recti fier 5. Joint Connector C 6. Battery 12 V 8 Ah 7. Main Fuse 30 A 8. Load[...]

ELECTRICAL SYSTEM 16-37 Ignition System W ARN ING The ignition system produces extremely high volt- age. D o not touch the spark plugs or stick coils while the engi ne is running, or you could r eceive a severe electr ical shock. CAUTION Do not disconnect the battery cables or any other electrical connect ions when the ignition switch is on, or w h[...]

16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inst allation • Route the crankshaft sens or lead correctly (s ee Cable, Wire, and Hose Routing in Appendix chapt er). • T ighten: T orque - Cranksh aft Senso r Bolt s: 5.9 N·m (0 .60 kg f·m, 52 in·lb) • Apply silicone seal ant [A] to the crankshaft s ensor lead grommet and crankcas[...]

ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor In spection • Remove: Right Frame Cover (see Frame chapter) Crankshaft Sensor Lead Connector [A] • Set the hand tester to the × 100 Ω range and connect (+) lead to the yel low/black lead and ( –) lead to the black l ead in the connector . Specia l T ool - Hand T e ster: 5 7001– 13[...]

16-40 ELECTRICAL SYSTEM Ignition System Timin g Roto r Remov al • Remove the crankshaf t sensor cover (s ee Crankshaft Sensor Removal) • Remove th e timing rot or [A]. ○ Holding the timing rotor w ith the fl ywheel & pulley holder [B] and remove the bolt [C]. Special T ool - Flywheel & Pu lley Holde r : 57001–134 3 Timing Rotor I ns[...]

ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Positi on Sensor Inspect ion • Remove: Fuel T ank (see Fuel System (DFI ) chapter) Camshaft Position Sensor Lead Connector [A] (disc on- nect) • Set the hand tester t o the × 10 Ω range and connec t it to the yellow and bl ack leads in the connect or . Specia l T ool - Hand T ester : 5 7001–[...]

16-42 ELECTRICAL SYSTEM Ignition System Stic k Coil (I gniti on Coil t ogeth er with S park Pl ug Cap ) Removal • Remove the fuel tank (see Fuel System (DFI) chapter ). • Remove the thermostat brack et bolt [A]. • Disconnect: W ater T emperature Sensor C onnector [B] Left Switch Hous ing Connector [C] ○ If removing the stic k coil #2 or #3.[...]

ELECTRICAL SYSTEM 16-43 Ignition System Stick Coi l (Ignition Coi l together with Spar k Plug Cap) Inspection • Remove the stick c oils (see this chapter ). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between t he coil terminals . ○ Set the tester t o the × 1 Ω range, and read the tester . • Measu[...]

16-44 ELECTRICAL SYSTEM Ignition System W A RNING T o avoid extremely high voltage shocks, do not touch the spark plugs or tester connecti ons. • T urn the ignition switch and the engine stop switch ON. • Pushing the st arter button, tur n the engine 4 ∼ 5 seconds with the t ransmission in neut ral to measure t he primary peak vo ltage. • R[...]

ELECTRICAL SYSTEM 16-45 Ignition System Interl ock Operati on Inspecti on • Remove: Seats (see Frame chapter) Junction Box (see this chapter ) ○ Do not disconnect the connect ors. 1st Check • Measure the terminal voltage of t he G/BK lead in the junc- tion box connector [A] in accordance w ith the following procedure. ○ Insert the nee dle a[...]

16-46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC Igniter i s built in th e ECU [A]. • Refer to the Interl ock Operation Inspecti on, Igniti on System T roubleshooting chapter and Fuel System (DFI) chapter for ECU Inspection.[...]

ELECTRICAL SYSTEM 16-47 Ignition System[...]

16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Stick Coils 6. Side Stand Switch 7. Crankshaft Sensor 8. Camshaft P osit ion Sen- sor 9. Throttle Sensor 10. Neutral Switch 1 1. Junction Box 12. Ignition Fuse 10 A 13. Starter Lockout Switch 14. Diode 15. ECU[...]

ELECTRICAL SYSTEM 16-49 Electric Starte r System Star ter Motor Removal CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Slide back the rubber cap [A]. • Remove the starter motor terminal nut [B]. • Remove the mounting bolt s [A]. • Pull out the starter mo tor [B]. Starter Mo tor Ins[...]

16-50 ELECTRICAL SYSTEM Electric Starter Syste m ○ The brush plate [A] and brushes come of f with the right -hand end cover [B]. • Remove the terminal locknut [A] and terminal bolt [B], and then remove t he brush with the brush plate [C] from the right- hand end cover . Star ter Mo tor As semb ly • Install the brush p late and brushes [A], an[...]

ELECTRICAL SYSTEM 16-51 Electric Starte r System • Align the line [A] marked on the yoke wit h the through bolt hole [B]. Brush I nspection • Measure the length [A] of each brush. If any is worn down t o the service l imit, replace the ca rbon brush holder assembl y [B] and the terminal bol t assembly [C]. Starter Motor Brush Length Stand ard: [...]

16-52 ELECTRICAL SYSTEM Electric Starter Syste m NOTE ○ Even if the f oregoing checks show the armatur e to be good, it may be defective in some manner not readily detectable wi th the hand tester . If all other starter motor and starter motor circuit components check good, but the starter motor st ill does not turn over or onl y turns over weakl[...]

ELECTRICAL SYSTEM 16-53 Electric Starte r System • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Specia l T ool - Hand T ester : 5 7001–1394 If the rel ay does not work as specified, the rel ay is defec- tive. Replace the relay . T es ting Relay T ester R ang e: × 1 Ω range Criteria : When b attery is co[...]

16-54 ELECTRICAL SYSTEM Lighting System This models adopt the day light system and have a head- light relay in t he junction box. In these m odels, the head- light does not go on when the igni tion switch and the engine stop switch ar e first turned on. The headlight comes on after the starter button is released and stays on until the ignition swit[...]

ELECTRICAL SYSTEM 16-55 Lighting System • Fit the projecti on [A] of the bulb in the hollow [B ] of the headlight. • Install the hook [C]. • Fit the dust cover [A] with the arrow mark upward onto the bulb [B] firmly as shown. Good [C] Bad [ D] Arr ow Ma rk [E ] • After installat ion, adjust the headlight aim (see this chap- ter). Headlight [...]

16-56 ELECTRICAL SYSTEM Lighting System City Ligh t Bulb Repl acement ( Europea n Model) • Remove the fairi ng (see Frame chapter). • Pull out the socket [A] together with the bulb. • Pull the bulb [A] out of the socket. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater watt age t[...]

ELECTRICAL SYSTEM 16-57 Lighting System Headlight/T ail Light Circuit (CA, AS) Headlight/T ail Light Circuit ( Other than CA, AS) AS: Australia CA: Canada 1. Ignitio n Switch 2. Meter Ground 3. Alternator 4. Headlight Diodes 5. T aillight Fuse 10 A 6. Headlight Fuse 10 A 7. Junction Box 8. High Beam Indicator Light (LED) 9. Joint Connector D 10. Ci[...]

16-58 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit CA: Canada model MY : M alaysia model 1. Joint Connector D 2. Meter Unit 3. Right T urn Signal Indica- tor Light (LED) 4. Left Turn Signal Indicator Light (LED) 5. Front Right T urn Signal Light 6. Front Left T urn Signal Light 7. Joint Connector A 8. Frame Ground 9. Hazard Button 1[...]

ELECTRICAL SYSTEM 16-59 Lighting System • Push and turn the bulb [A] counterclockwis e and remove it. • Insert the new bulb [A] by aligning its upper and lower pins [B] with th e upper and lower grooves [C] in t he socket, and turn the bulb cl ockwise. ○ T urn the bulb about 15°. For the Canadian Model: • Unscrew the screw [A]. • Unscrew[...]

16-60 ELECTRICAL SYSTEM Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the s ocket, and turn th e bulb c lockwis e. T urn Signa l Relay Inspect ion • Remove: Seats (see Frame c hapter) Upper Seat Cover (see Frame chapter) T urn S ignal Relay [A] • Connect one 12 V bat[...]

ELECTRICAL SYSTEM 16-61 Lighting System • Unsc rew the bo lts [A]. • Unscrew the mounting scr ews [A]. • Remove the tail /brake light (LED) [B]. ○ Pull out the mount port ion [C]. T ail/Brake Light (LED) Installation • T ighten the tail/brake light mountin g screws. T orque - T a il/Brake Light Mounting Screws: 1.2 N·m (0.1 2 kgf·m, 10 [...]

16-62 ELECTRICAL SYSTEM Radiator F an System Fan System Circuit Inspection • Disconnect the le ad connector [A] from the radiat or fan switc h. • Using an auxiliary wi re [A], connect the radiat or fan switch leads. If the fan rotates, i nspect the fan switch. If the fan does not rot ate, inspect the following. Leads and Connectors Main Fuse an[...]

ELECTRICAL SYSTEM 16-63 Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Joint Connector A 4. Joint Connector D 5. Meter Ground 6. Frame Ground 7. Joint Connector B 8. Junction Box 9 . F a nF u s e1 5A 10. Main Fuse 30 A 1 1. Battery 12 V 8 Ah[...]

16-64 ELECTRICAL SYSTEM Meter , Gaug e, Indicator U nit Meter Unit Removal • Remove: Fairing (see Fr ame chapter) • Slide the dust cov er [A] and remove the wiring connec tor [B]. • Remove the meter unit by taking of f the mounting screws [C] with the washers. CAUTION Place the meter or gauge so that the face is up. If a meter or gauge is l e[...]

ELECTRICAL SYSTEM 16-65 Meter , Gauge, Indicator Uni t Elect ronic C ombi nation M eter U nit Insp ecti on • Remove the meter unit [A]. [1] Igni tion [10 ] Ba ttery (+ ) [2] Fuel Reser ve Switch [1 1] Oil Pres sure W arning [3] U nused Ind icator Light (LE D) [4] Fuel Lev el Sensor Ground (–) [5] N eutral In dicator Li ght [12] Speed Sensor S u[...]

16-66 ELECTRICAL SYSTEM Meter , Gaug e, Indicator U nit MODE AND RESET BUTTON Operati on Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liqu id Crystal Display (LCD) Seg- ments Check". • Check that the display change t o the ODO, TRIP , and CLOCK displays each t ime the MODE button [A] is pre[...]

ELECTRICAL SYSTEM 16-67 Meter , Gauge, Indicator Uni t • In the HOUR setting mode, press the RESET button to eff ect the MINUTE setting mode. ○ The minute dis play flashes on the display . • Press the MODE button to set the minute. • In the MINUTE setti ng mode, press the RESET button to return to t he HOUR/MINUTE setting mode. • Press th[...]

16-68 ELECTRICAL SYSTEM Meter , Gaug e, Indicator U nit • If the oscill ator is not available, the speedometer can be checked as f ollows. ○ Install the meter unit. ○ Raise the rear wheel of f the ground, using the jack. ○ T urn on the ignition s witch. ○ Rotate the rear wheel by hand. ○ Check that the speedometer shows the speed. If th[...]

ELECTRICAL SYSTEM 16-69 Meter , Gauge, Indicator Uni t W ater T em perature Meter Check: • Connect the 12 V battery and t erminals in t he same man- ner as specified in the "Liquid Crystal Displ ay (LCD) Seg- ments Check". • Connect the variable rheostat [A] to the termi nal [8] as shown. • Check that the number of segments matches [...]

16-70 ELECTRICAL SYSTEM Meter , Gaug e, Indicator U nit Fuel Level Gauge Inspection: • Connect the 12 V battery and terminals in the same man- ner as speci fied in the “Liqui d Crystal Displ ay (LCD) Seg- ments Check”. • Connect a variable r heostat [A] to termi nal [4] and [9] as shown. • Check that the number of segment [B] matches the [...]

ELECTRICAL SYSTEM 16-71 Meter , Gauge, Indicator Uni t • If the oscil lator is not avai lable, the tachometer can be checked as follows. ○ Connect the 12 V battery and t erminals in t he same man- ner as specified in the "Liquid Crystal Displ ay (LCD) Seg- ments Check". ○ Using an auxiliar y wire, quick open and connect the ter- min[...]

16-72 ELECTRICAL SYSTEM Meter , Gaug e, Indicator U nit Right and Left T urn Signal Indicator Light (LED): For Right T urn Signal Indicator Light (LED) Battery Positi ve (+) T erminal to T erminal [13] For Left T urn Signal Indi cator Light (LED) Battery Positi ve (+) T erminal to T erminal [14] High Beam Indicator Light: Battery Positi ve (+) T er[...]

ELECTRICAL SYSTEM 16-73 Meter , Gauge, Indicator Uni t Meter Circuit 1. Right T urn Signal Indica- tor Light (LED) 2. High Beam Indicator Light (LED) 3. Neutral Indicator Light (LE D) 4. Oil Pressure W arning In- dicator Li ght (LED) 5. FI Indi cator Light (LED) 6. Odometer/T rip Meter/ Clock/Fuel Indicator 7. W ater T emperature Gauge 8. Fuel Leve[...]

16-74 ELECTRICAL SYSTEM Switches a nd Sensors Brake Light T iming Inspect ion • Refer to the Brake s in the Periodic Maintenan ce chapter . Bra ke Light Timi ng Adjus tment • Refer to the Brake s in the Periodic Maintenan ce chapter . Switch Inspection • Using a hand tes ter , check to see that only the con- nections shown i n the table have [...]

ELECTRICAL SYSTEM 16-75 Switches and Se nsors • Rem ove th e fan switc h [A]. • Suspend the switch [A] in a container of coolant so that the temperature–sensi ng projection and threaded porti on are submerged. • Suspend an accurate t hermometer [B] in the coo lant so that the sensit ive portions are locat ed in almost the same depth. NOTE ?[...]

16-76 ELECTRICAL SYSTEM Switches a nd Sensors • Suspend the sensor [A] in a contai ner of coolant so that the temperatur e-sensing proj ection [E] and threade d por- tion [E] are submerged. • Suspend an accurate thermometer [B] in the coolant. NOTE ○ The sensor and t hermometer must not touc h t he con- tainer side or bottom. • Place the co[...]

ELECTRICAL SYSTEM 16-77 Switches and Se nsors • Remove: Bol ts [A ] Speed Sensor Cover • Remove: Bol t [A] • T ake out t he speed sensor [B]. • Connect the speed sens or connector [A] with t he battery [B], 10 k Ω re sistor [C] and hand tester [D] as shown. • Set the tester t o the DC 25 V range. Specia l T ool - Hand T ester : 5 7001?[...]

16-78 ELECTRICAL SYSTEM Switches a nd Sensors Fuel Level Senso r Inspection • Remove: Fuel T ank (see Fuel System (DFI) chapter) • Open the clamps [A]. • Remove: Bolts [B] Fuel Level Sensor [C] • Check that t he float moves up and down smoothly without binding. It should go down under its own weight. If the float does not move smoothly , re[...]

ELECTRICAL SYSTEM 16-79 Switches and Se nsors • Connect the test light [ A] (12 V 3.4 W bulb a socket with leads) and t he 12 V battery [B] to the fuel l evel sensor connector [C]. Connections: Battery (+) → 1 2 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) → Blue Lead T ermin al Battery (–) → BK/Y Lead T ermi nal If the test light[...]

16-80 ELECTRICAL SYSTEM Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box [A]. • Pull of f the connectors [A] from the j unction box [B]. • Make sure all connector terminals are [...]

ELECTRICAL SYSTEM 16-81 Junction Box Starter C ircuit/Headl ight Rela y Inspe ction • Remove the junct ion box (s ee Junction Box Fuse Circuit Inspection) . • Check conductivi ty of the foll owing numbered terminal s by connecting t he hand tester and one 12 V battery to the junction box as shown. ○ Refer to the Junction Box Int ernal Circuit[...]

16-82 ELECTRICAL SYSTEM Junction Box Diode Circuit Inspection • Remove the junction box. • Check conductiv ity of the fol lowing pairs o f terminals. Diode Circui t Inspection Te s t e r Connectio n 13-8, 13-9, 12 -1 1, 12 -14, 15-14, 16 -14 The resist ance should be low i n one direction and more than ten times as much in the other di rection.[...]

ELECTRICAL SYSTEM 16-83 Fuse 30 A Mai n Fuse R emova l • Remove: Right Side Cover ( see Frame chapter ) 30 A Main Fuse Connector [A] • Pull out t he main fuse [B] from the starter relay wit h needle nose pliers. Junction Box Fus e Removal • Remove the seats (see Frame chapter). • Unlock the hook t o lift up the l id [A]. • Pull the f uses[...]

16-84 ELECTRICAL SYSTEM Fuse Fuse Inspection • Remove the fus e (see Fuse Removal) . • Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the af fected circui t. If the amperage is equal to or greater than the fuse rati ng, check the wiring and related components for a sho[...]

APPENDIX 17-1 17 Appendix T able o f Content s Cable , Wire, a nd Hos e Rout ing .... ...... ...... ...... ....... ...... ...... ...... ....... ...... ...... ...... ...... ....... ...... ... 17 -2 T roubleshooting Guide ...... .......... ............ ........... ............ .......... ........... ............ ............ ......... .. 17-18[...]

17-2 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-3 Cable, Wire, a nd Hose Routing 1. Fixes by the left side cl amp of the tank. 2. Run the tank drain hose unde r the bracket for the side cover . 3. Air cleaner drain hose 4. Cooling reserve tank hose (Run the hose inside the under ring.) 5. Fuel tank drain hose 6. Fixes by the swingarm clamp 7. Fuel level sensor 8. Fixes by the right s[...]

17-4 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-5 Cable, Wire, a nd Hose Routing 1. Clutch cable 2. Meter ground 3. Clamp (Ignition switch connector) 4. Ignition swit ch connector 5. Inlet air pressure sensor 6. T o ignition coil 7. Fan motor connector (Connect the con- nector on t he inlet air pr essure sensor .) 8. Clamp 9. T o fuel pump 10. T o fuel level gauge and fuel reserve sw[...]

17-6 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-7 Cable, Wire, a nd Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat brac ket) 3. Ignition switch connect or 4. Meter ground 5. Engine harness 6. W ater t emperatur e sensor 7. Inlet air pressure sensor 8. Clamp 9. T o pickup coil and oil pressure swi tch 10. T o fuel [...]

17-8 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-9 Cable, Wire, a nd Hose Routing 1. T ail light 2. Clamp 3. Atmospheric pressure sensor 4. T o ECU fuse 5. Junction Box 6. T o self-diagnosis indicator terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reser ve switch 10. T o inlet air temperature sensor 1 1. Fan m otor connector 12. Inlet air pre[...]

17-10 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-1 1 Cable, Wire, a nd Hose Routing 1. Clamp the position of branch harness and front r ight turn signal light lead. 2. Run the meter harness into the hole of cover . 3. Meter 4. Set the cover to cover all of the connector . 5. Clamp the right and left switch housing lead and front left turn sign al light lead. 6. T o left switch housing[...]

17-12 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-13 Cable, Wire, a nd Hose Routing 1. Clamp 2. Brake hose 3. Run the brake hose thr ough the inside of the reservoir hose. 4. T ight the bolt to the specified torque wi th the stopper (for t urning preventi on) applied. 5. Seat lock 6. Seat lock cable[...]

17-14 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-15 Cable, Wire, a nd Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap c enter and bolt head to secure the coupler .) 2. Fan switch horn lead 3. Cap 4. Clutch cable (Run the cable through forward the water hose.) 5. Air suction valve 6. W ater hose (Thermostat – Radiator) 7. W ater hose (Head – Ther mostat[...]

17-16 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-17 Cable, Wire, a nd Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the b racket. 3. Install the lead upward. 4. Pickup coil and oil pressure swi tch (Run the cable t hrough inner si de from the start er lead.) 5. Install the exterior of the lead wit h staking area facing downward. 6. Battery negative cable (Run t[...]

17-18 APPENDIX T roubleshooting Guide NOTE ○ Refer to the Fuel System chapter for most of DFI trouble shooting guide. ○ This is not an exhaust ive list, giving every possible cause for each problem list ed. It is meant simply as a rough guide to assist the troubleshoot ing for some of the more common difficult ies. Engine Doesn ’t Start, Star[...]

APPENDIX 17-19 T rou bleshooting Guide Air cleaner duct loose Compression low: Spark plug loose Cylinder head not suf ficiently ti ghtened down No valve clearance Cylinder , piston worn Piston ring bad ( worn, weak, broken, or sticking) Piston ring/ groove clearance exces sive Cylinder head warped Cylinder head gasket damaged V alve spring br oken [...]

17-20 APPENDIX T roubleshooting Guide Engine load fault y: Clutch slipping Engine oil level too high Engine oil vis cosity too high Drive trai n trouble Brake dragging Lubrication i nadequate: Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect: W ater temperature gauge broken W ater temperature sensor br oken Coolant inco[...]

APPENDIX 17-21 T rou bleshooting Guide Engine mount loose Crankshaft beari ng worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket , guide worn Air suction valve damaged V acuum switch valve damaged Alternator rot or loose Catalytic convert er melt down due to muf fler overheating (KLEEN) Abnormal Drive T rain[...]

17-22 APPENDIX T roubleshooting Guide Rear shock adjustment too soft Front fork , rear shock absorber sp ring weak Rear shock absorbe r oil leaking Brake Doesn’t Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pa d Brake fluid deter iorated Primary or secondary cup damaged in master cylinder Master cylind[...]

MODEL APPLICA TION Y ear Model Beginning Frame No. 2004 ZR750–J1 JKAZRDJ1 □ 4A000001 ZR750J–000001 JKAZR750JJA000001 □ :This digit in the frame number changes from one machine to another . Part No.99924-1 323-01 Printed in Japan[...]