Kawasaki KX250F (2013) manual

KX250F Motorcycle Service Manual[...]

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This quick reference guide will assi st you in locatin g a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber wi th t he b lack tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Refere[...]

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KX250F Motorcycle Service Manual All right s reserved. No parts of t his publicat ion may be reproduced, stored in a retr ieval system, or transmitt ed in any f orm or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/ Motorcycle & Engine Company/Kawasaki[...]

LIST OF ABBREVIA TIONS A ampere(s) KDS Kawasaki Diagnostic System ABDC after bottom dead center km/h kilometers per hour AC alternatin g current Ll i t e r ( s ) Ah ampere hour lb pound(s) A TDC after top dead center LED Light E mitting Diode BBDC before bottom dead center mm e t e r ( s ) BDC bottom dead center min minute(s) BTDC before top dead c[...]

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his ow n basic maintenance and repair work. A basic knowledge of mechanic s, the proper use of tools, and workshop proce- dures must [...]

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GENERAL INFORMA TION 1-1 1 Gener al Information T able of Con tents Befor e S erv icing ...... .... .... ...... ..... .... .... .... .... .... ...... ..... .... .... .... .... .... ...... ..... .... .... .... .... .... ..... .... . 1-2 Model Identi fication. ...... ...... ...... ..... ...... ...... ...... ....... ...... ...... ...... ........ .....[...]

1-2 GEN ER AL INFO RMA TIO N Before Servicing Before st arting to per form an inspec tion servi ce or carry out a disassembly and reassembly opera- tion on a motorcycle, read t he prec autions given bel ow . T o facilitate actual operations , notes , ill ustra- tions, photographs, cautions, and detail ed descriptions have been included in each chap[...]

GENERAL INFORMA TION 1 -3 Before Servicing Storage of Removed Parts After all the parts includi ng subassembly parts have been cleaned, store the parts in a clean area. Put a clean clot h or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly . Insp ectio n Reuse of worn or damaged parts may lead t[...]

1-4 GEN ER AL INFO RMA TIO N Before Servicing Tightening T orque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. T ight en fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twic e-initi al tightening and final tightening with torque wrench. Forc e Use commo[...]

GENERAL INFORMA TION 1 -5 Before Servicing Ball Bearing a nd Needle Bearing Do not r emove pressed ball or needle unless removal is absolutely necessary . Replace with new ones whenever removed. P ress bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pre[...]

1-6 GEN ER AL INFO RMA TIO N Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of r otating direction will affe ct the adjustment. Ro- tate the crankshaft t o positive directi on (clockwise viewed from output side) . Ele ctric al Le ads A two-color lead is identif ied first by t he primary colo[...]

GENERAL INFORMA TION 1-7 Model Identification KX250ZD Left Side View KX250ZD Right Side View Frame Number Engine Number[...]

1-8 GEN ER AL INFO RMA TIO N General Specifications Item s KX250ZD Dimensions Overall Length 2 170 mm (85.43 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 270 mm (50.00 in.) Wheelbase 1 475 mm (58.07 in.) Road Clearance 330 mm (13.0 in.) Seat Height 945 mm (37.2 in.) Curb Mass: 106.2 kg ( 234.2 lb) (US, CA) 106.0 kg (233.7 lb) Front: 51.7 k[...]

GENERAL INFORMA TION 1 -9 General Specifications Items KX250ZD Drive T rain Primary Reduction System: Ty p e Gear Reduction Ratio 3.350 (67/20) Clutch T ype Wet multi disc, Manual T ransmission: Ty p e 5-speed, constant mesh, return shift Gear Ratios: 1st 2.142 (30/14) 2nd 1.750 (28/16) 3rd 1. 444 (26/ 18) 4th 1.235 (21/17) 5th 1.045 (23/22) Final [...]

1-10 GENERAL INFORMA TION Unit Conversion T able Prefixes for Units: Prefix Symbol Powe r mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mas s: 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 (IMP) L ×[...]

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Con tents Peri odic M ain te nance Cha rt .... ..... .... .... .... .... .... ....... .... .... .... .... .... .... .... ....... .... .... .... .... .... ..... ... 2-3 T orq ue a nd L ock ing A gen t ... .... ..... .... .... .... .... ...... ..... .... .... .... .... .... .... ....... .... .[...]

2-2 PERIODIC MAINTENANCE Bra kes ... .... ....... .... .... .... .... .... .... ..... ...... .... .... .... .... .... ..... ...... .... .... .... .... .... ..... ...... .... .... .... .... ... 2-3 9 Brake Lever and Pedal Adjustment ...... ...... ...... ..... ...... ........ ........ ...... ....... ...... ........ ........ .. 2-39 Brak e F luid L ev[...]

PERIODIC MAINTENANCE 2-3 Periodic M aintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycl e in good running condition. FREQUENCY OPERA TION Each race or 2.5 hours Every 3 races or 7.5 hours Every 6 race s or 15 hours Every 12 races or 30 hours See Page Spark plug - clean and inspect † • 2-81 Spark plu[...]

2-4 PERIODIC MAINTENANCE Periodic Maintenance Cha rt FREQUENCY OPERA TION Each race or 2.5 hours Every 3 races or 7.5 hours Every 6 races or 15 hours Every 12 race s or 30 hours See Page Wheels/ti res - inspect • 2-34 Rear sprocket - inspec t † • 2-38 Front fork - clean and inspect • 2-49 Front fork oil - c hange • 2-49 Rear shock absorbe[...]

PERIODIC MAINTENANCE 2-5 T or que a nd Loc king A gent T ighten all bolts and nuts to the proper torque using an accurate torque wrench. I f insufficien tly tightened, a bol t or nut may become damaged, strip an internal threa d, or break and then fall o ut. The following table lists the t ightening torque for the major bolts and nuts, and th e par[...]

2-6 PERIODIC MAINTENANCE T orque and Locking Agen t T orque Fastener N·m kgf·m ft·lb Remarks Camshaft Chain T ensioner Cap Bolt 20 2.0 15 Camshaft Chain T ensi oner Mounting Bolts 9.8 1.0 87 in·lb Clutch Right Engine C over Bolts 9.8 1.0 87 in·lb Clutch Cover Bol ts 9.8 1.0 87 i n·lb Oil F iller Plug 3.5 0.36 31 in·lb Clutch Hub Nut 98 10.0 [...]

PERIODIC MAINTENANCE 2-7 T or que a nd Loc king A gent T orque Fastener N·m kgf·m ft·lb Remarks Rear Axle Nut 108 11 . 0 79.7 Final Drive Rear Sprocket Nuts 34 3.5 25 R Brakes Brake Hose Banjo Bolts 25 2.5 18 Front Brake Reservoir Cap Screws 1. 5 0.15 13 in·lb Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S Brake Lever Pivot Bolt 5.9 0.6[...]

2-8 PERIODIC MAINTENANCE T orque and Locking Agen t T orque Fastener N·m kgf·m ft·lb Remarks Steering Handlebar Clamp B olts 25 2.5 18 AL, 2T Steering Stem Head Nut 98 10.0 72 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L Steering Stem Nut 4.9 0.50 43 in·lb T Handlebar Holder Nuts 34 3.5 25 R Front Fork Clamp Bolts (Lower) 22 2.2 16 AL Brake H[...]

PERIODIC MAINTENANCE 2-9 Specifications Item Standard S ervi ce Lim it Fuel System (DFI) Throttle Grip Free Play 2 ∼ 3 m m (0.08 ∼ 0.1 2 in .) ––– Idle Speed 2 050 ±50 r/min (rpm) ––– Air Cleaner Element Oil High quality foam air f ilter oil ––– Cooling System Coolant: T y pe (Recommended) Permanent type antifreeze ––– [...]

2-10 PERIODIC MAINTENA NCE Specification s Item Standard Service Limit Wheels/T ires Rim Runout (with tir e installed): Axial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm (0.0 8 in.) Radial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm (0.0 8 in.) T ires A ir P res sure (F ront /Rea r) 100 kPa (1.00 kgf/cm², 14 psi) ––– Standard Tire: Front: Size 80/[...]

PERIODIC MAINTENANCE 2-1 1 Specifications Item Standard S ervi ce Lim it Electrical System Spark Plug Gap 0. 8 ∼ 0.9 mm (0.031 ∼ 0.035 in.) –––[...]

2-12 PERIODIC MAINTENA NCE Special T o ols Inside Circlip Pliers : 57001- 143 Steer ing Stem N ut Wrench : 57001- 1 100 Jack: 57001- 1238 Fork Pis ton Rod Puller , M12 × 1.25: 57001- 1289 Fork Oil Level Gauge: 57001- 1290 Filler Ca p D river: 57001-1 454 Fork Spring Compressor: 57001-1 587 Jack At tachm ent: 57001-1 608 T o pP l u gW r e n c h ,5 [...]

PERIODIC M AINTENANCE 2-13 Special T ools Fork S pring Compressor: 57001-1 771[...]

2-14 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Fuel System (DF I) Fuel Hose and Connections Inspec tion ○ If the m otorcycle is not properly handled, the high pr es- sure inside t he fuel li ne can cause fuel to leak [A] or the hose burst. Remove the fuel tank (see Fuel T ank Re- moval in the Fuel System (DFI) chapter) and check the [...]

PERIODIC MAINTENANCE 2-15 Periodic M aintenan ce Procedures Throttle Body Cleani ng • Check the throttle bore for cleanliness as follo ws. ○ Remove the throttle body assy (see Throttle Body Assy Removal in t he Fuel System (DFI) chapter). ○ Check the throttle bore [A] at the throttle val ve for carbon deposits by opening the t hrottle valve. [...]

2-16 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Pull the fuel hose joint [A] out of the delivery pipe . W ARNIN G Fuel is fl ammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately . When the fuel hose is dis- connected, fuel[...]

PERIODIC MAINTENANCE 2-17 Periodic M aintenan ce Procedures • Remove the vinyl bag on each delivery pipe. • Check that there are no flaws, burrs, and adhesion of foreign material s on each delivery pipe [A]. • Replace the fuel hose with a new one. • Run the fuel hose correc tly (see Cable, Wire, and Hose Routing section in the Appendix chap[...]

2-18 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Push and pull [A] the fuel hose joint back and forth more than two times and make sure it is locked and does not com e off. Throttle Body Assy Side [B] Air Cleaner Side [C] W ARNIN G Leaking fuel can cause a fir e or explosion resulting in severe burns. Make sure the fuel hose joint i [...]

PERIODIC MAINTENANCE 2-19 Periodic M aintenan ce Procedures • Check the idle speed, using the engine revolution tester [A] for high accura cy . If the idle speed is out of specifi ed range, adjust it. Idle S peed Standard: 2 050 ± 50 r /min (rpm) Idle Speed Adjustment • Start the engine and warm it up thoroughly . • T urn the idle adjusting [...]

2-20 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Remove: Seat (see Seat Removal in the Frame chapter) Wing Bolt [A] Air Cleaner Element [B] • Stuf f a clean, lint-fr ee towel into the air cleaner duct so no dirt is allowed to enter the throttle body assy . • Wipe out the inside of the air cleaner housing with a clean damp t owel.[...]

PERIODIC MAINTENANCE 2-21 Periodic M aintenan ce Procedures • Apply grease to all connections and screw holes in the air cleaner housing and intake tract. • Install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a complete s eal. • Install the air cleaner element so that it[...]

2-22 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Co olant L evel In spec tion NOTE ○ Check the l evel when the en gine is cold (room or ambi- ent temperature). • Remove the right radiator shroud (see Radiator Shroud Removal in t he Frame chapter). • Lean the m otorcycle sli ghtly unti l the radiat or cap is level to the ground so t[...]

PERIODIC MAINTENANCE 2-23 Periodic M aintenan ce Procedures Coolant Deterioration Inspection • Visual ly inspect the coolant. If whitish cotton-l ike wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or st eel parts are rusting. In either case, flush the cooling system. If the coolant gives off a[...]

2-24 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Bring the piston to the TDC of the compression stroke to inspect the valve cl earance (the positi on at t he end of the compression stroke), when the cam lobe faces out side of the camshaft. ○ Place a wrench over the flywheel nut [A] and tur n it coun- terclock wise to align the TD C[...]

PERIODIC MAINTENANCE 2-25 Periodic M aintenan ce Procedures • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thick ness calculati on as follows. a+b–c=d [a] Present Shim Thickness [b] Measured V alve Clearance [c] Specified V alve Clearance (Mean V alue) Exhaust 0.195 mm Intake[...]

2-26 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Install the shim. ○ T urn the marked side [A] to upside. ○ Apply engine oil to the shi m to keep t he shim i n place during camshaft i nstallation. NOTICE Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causi ng ex- tensive engine damage. Do no[...]

PERIODIC MAINTENANCE 2-27 Periodic M aintenan ce Procedures • T ake a side- to-side and a front -to-back measurement as shown (total 6 measurements). ○ The cylinder wear is uneven in different places. 10 mm (0.39 in.) [A] 25 mm (0.98 in.) [B] 60 mm (2.3 6 in.) [C] Cylinder Inside Diameter Standard: 77.0 00 ∼ 77.012 mm (3 .0315 ∼ 3.0320 in.)[...]

2-28 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Silencer Wool Replacement • Remove: Right Side Cover (see Side Cover Removal in t he Frame chapter) Muffl er Body Cover Bolts [A] Muffler Mounting Bolt [ B] • Remove the m uffl er cover [A]. ○ T ap the bracket [B] with a plastic mallet [C] to separate the cover and pipe. • Replace [...]

PERIODIC MAINTENANCE 2-29 Periodic M aintenan ce Procedures Clutch Clutch Operation Inspection Clutch Lever (Clutch Cable) Free Play Inspecti on • Slide the clutch cabl e adjuster knob [A] out of place. • Check that the clutch cable upper end [B] is fully seated in the adjusting bolt [ C]. • Install the knob to original position. • Pull the[...]

2-30 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Measure the thickness [A] of the friction and at several points with vernier calipers. Friction Plate Thickness Standard: 2.72 ∼ 2.88 mm (0.107 ∼ 0.1 13 in .) Service Limit: 2.5 mm ( 0.10 in.) If th ey have worn past the serv ice limi t, replace them with new ones. • Place each f[...]

PERIODIC MAINTENANCE 2-31 Periodic M aintenan ce Procedures • Remove the engine oil drain bolt [A] from the bottom of the engine, and let the oil drain completely . NOTE ○ Hold th e motorcyc le upright so that the oil may drain completely . • Replace the drain bolt gasket with a new one. • Install the drain bolt with the gasket. • T ighte[...]

2-32 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Remove the oil filter [A]. • Replace the oil f ilter with a new one. • Apply grease to the gromm et [ A]. • Install the oil filter . ○ T urn the gro mm et to insi de. NOTICE Inside out installati on stop oi l flow , causing engine seizure. • Replace the oil filter c ap O-ring[...]

PERIODIC MAINTENANCE 2-33 Periodic M aintenan ce Procedures Crankshaft/T ransmission Crankshaft Inspecti on • Remove: Cylinder Head (see Cylinder Head Removal in the En- gine T op End chapter ) Cylinder (see Cyli nder Removal in the Engine T op End chapter) Piston (see Piston Removal in the Engine T op End chap- ter) • Make sure that the cranks[...]

2-34 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Tires In spe cti on • Remove any imbedded stones or other forei gn partic les from the tread. Repair or replace with a new one if necessary . • V isually inspect the tire for cracks and cuts. Replace the tire, if any damage are noticed. ○ Swelling or high spots indicate internal dama[...]

PERIODIC MAINTENANCE 2-35 Periodic M aintenan ce Procedures • Set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [A]. ○ The dif ference between t he highest and lowest dial read- ings is the amount of runout. • Set a dial gauge against the outer circumference of the rim, and rotate the rim to measur e[...]

2-36 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Stretch the chain taut by hanging a 10 kg (22 lb) weight [A] on the chain. • Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly , take measurements at several[...]

PERIODIC MAINTENANCE 2-37 Periodic M aintenan ce Procedures Drive C hain Slack Adjustment • Loosen the left and right chain adjust er locknuts [A]. • Remove the cotter pin [B] and loosen the rear axle nut [C]. If the chain i s too tight, back out the left and right chain adjusting bol ts [D] evenly , and push the wheel for ward until the chain [...]

2-38 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Drive Chain Lubrication ○ The chain should be lubricated with a l ubricant which wil l both prevent the exterior from rusting and also absorb shock and reduce fr icti on in the interior of the chain. If the chain is especially dirty , it should be washed in diesel oil or kerosene, and af[...]

PERIODIC MAINTENANCE 2-39 Periodic M aintenan ce Procedures Brakes Brake Lever and P edal Adjustment • Slide the dust cover [A]. • Adjust the brake lever to suit you. ○ Loosen the adjuster locknut [B ] and t urn the adjuster [C] to either side. • After adjustment, tighten the locknut. WA R N I N G An improperly adjusted brake could drag and[...]

2-40 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Brake Fluid Level Inspection • Check the brake fluid level in the front or rear brake reser- voir [A] and the front or rear reservoi r must be kept above the lower level l ine [B]. NOTE ○ Hold the reservoir hor izontal when checking brake fluid level. If the flui d level in front or re[...]

PERIODIC MAINTENANCE 2-41 Periodic M aintenan ce Procedures Brake Fluid Change WA R N I N G When working w ith the disc br ake, observe the pr e- cautions listed below . 1. Never reuse old brake fluid. 2. Do not use fl uid from a container t hat has been left unsealed or that has been open for a long time. 3. Do not mix two types and bra nds of flu[...]

2-42 PERIODIC MAINTENA NCE Periodic M aintenance Procedures NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid r eservoir . • Remove: Screws [A] Reservoir Cap [B] Diaphragm • Remove the rubber cap [A] on the bleed valve [B]. • Atta[...]

PERIODIC MAINTENANCE 2-43 Periodic M aintenan ce Procedures • Remove the clear plastic hose. • Install the diaphragm and reservoir cap. • T ighten: T orqu e - Front B rake Reservoir Cap S crews: 1.5 N ·m (0.1 5 kgf·m, 13 in·lb) • T ighten the bleed valve, and install the rubber cap. T orque - Caliper Bleed V alve: 7.8 N ·m (0.80 kgf·m,[...]

2-44 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Rear Master Cylinder Disassembly • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the B rakes chapter). NOTE ○ Do not remove the push rod clevi s since removal re- quires brake pedal position adjustment. • Remove the reservoir cap and diaphr agm , and pour the[...]

PERIODIC MAINTENANCE 2-45 Periodic M aintenan ce Procedures Caliper Rubber Parts Replaceme nt Front Caliper D isassembly • Remove: Front Caliper (see Caliper Removal in t he Brakes chap- ter) Brake Pads (see Brake Pad Removal in the Brakes chapter) • Separate the caliper holder [A] from the caliper [B]. • Remove the anti-rattle springs [C]. ?[...]

2-46 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Separate the caliper holder [A] from the caliper [B]. • Remove the anti-rattle springs [C]. • Using compressed air , remove the piston. ○ Cover the cali per opening with a clean heav y cloth [A]. ○ Remove the piston by l ightly applying compr essed air [B] to the hose joint ope[...]

PERIODIC MAINTENANCE 2-47 Periodic M aintenan ce Procedures • Replace the fluid seal(s) [A] with new ones. ○ Apply silicone grease t o the fluid seal(s), and install them into the cylinder(s) by hand. • Replace the dust s eal(s) [B] with new ones. ○ Apply brake fluid t o the dus t seal(s), and instal l them int o the cylinder(s) by hand. ?[...]

2-48 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Replace the friction boot [A] and dust boot [B] i f they are damaged. • Apply a thi n coat of PB C (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special hi gh-temperature, wat er-resistance gr ease). • Assemble the caliper and caliper hold[...]

PERIODIC MAINTENANCE 2-49 Periodic M aintenan ce Procedures Front Brake Hose • Remove: Brake Hose Clamp Bolts [A] Brake Hose Clamps [ B] Rear Br ake Hose • Remove: Bolts [ A] Caliper Guard [B] Screws [C] Brake Hose Clamp [D] • Remove: Screws [A] Brake Hose Clamp [B] Rear Master Cylinder Mounting Bolts [C] • Rem ove the front/rear brake hose[...]

2-50 PERIODIC MAINTENA NCE Periodic M aintenance Procedures Suspension Front Fork Inspection • V isually inspect the front fork for oil leakage, scoring or scratches on the outer sur face of the inner tubes [A]. • Holding the br ake l ever , pump the front fork down and up manually to check for smooth operation. If the fork shown damages or oil[...]

PERIODIC MAINTENANCE 2-51 Periodic M aintenan ce Procedures • Unscrew the le f t front f ork cylinder unit [A] from the outer tube [B]. Speci al T oo l - T op P lug Wrench, 50 mm [C]: 570 01-16 45 • Slowly slide down the outer tube. • Hold the left front for k tube [A] upside down over a clean container [B] and drain the oil. NOTE ○ Pump th[...]

2-52 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Compress the outer tube by hands and remove the ad- juster assembly from the axle holder part so that the lock- nut appear about 20 ∼ 30 m m (0.79 ∼ 1.2 in.). • Hold the l ocknut [A] with a wrench [B] and remove the left front fork adjuster assembly [C]. NOTE ○ Do not remove th[...]

PERIODIC MAINTENANCE 2-53 Periodic M aintenan ce Procedures • Holding the top plug wrench [A] with a vise, unscrew the left front fork base valve as sembly [B] on the fo rk cylinder unit [ C]. ○ Use a box wrench [D]. Speci al T ool - T op Plug Wrench , 5 0 mm: 5 7001-164 5 • Pull out the left front fork base valve assembly [A] from the fork c[...]

2-54 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Hold the left front fork cylin der unit [A] upright with the piston rod ful ly str etched. • Plug the oil hole [B] on the lef t f ront f ork c ylinder u nit with finger . • Pour the specifie d oil. Suspe nsion Oil - SHOW A S S-1 9 (1 L ) : 44091- 0009 Cylinder Unit Oil C apacity St[...]

PERIODIC MAINTENANCE 2-55 Periodic M aintenan ce Procedures • With t he piston rod [A ] appear about 20 mm (0. 79 in.) [B] from fully compressed, gently install the left front fork base valve assembly [C] slowly to the left front fork cylinder unit [D]. NOTE ○ Plug the oil hole [E] on the left front fork cylinder unit with finger . ○ While pu[...]

2-56 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Check the compressi on damping force setting to the soft- est. • Check the piston rod sliding surface for damage. • Drain the extra oi l from the l eft front fork cylinder unit oil hole [ A]. • Blow out t he extra oil from the oil hole of the left front fork cylinder unit with th[...]

PERIODIC MAINTENANCE 2-57 Periodic M aintenan ce Procedures • There should be no oil leak from the base valve assembly part [A] or bottom of t he cylinder [B]. If oi l leaks from the base valve assembly part or bottom of the cylinder , replace the cylinder unit. • Hold the left front for k cylinder unit on level ground. • Release the piston r[...]

2-58 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Replace the left front fork adjuster assembly O -ring [A] with a new one and apply specified fork oil to it. • Insert the push rod [B] into the piston rod [C]. • Install the left fr ont fork adjuster assembly [D] to the push rod. • Slowly turn the left front f ork adjuster assemb[...]

PERIODIC MAINTENANCE 2-59 Periodic M aintenan ce Procedures • Using the top plug wrench, unscrew the left front fork cylinder unit from the outer tube [A]. • Slowly slide down the outer tube. • Pour the specified fork oil into the left front fork outer tube. Suspen sion Oil - SHOW A SS-19 ( 1 L) : 44091- 0009 Outer T ube Oil Ca pacity Standar[...]

2-60 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • T emporarily install the right front fork spring adjuster unit [A] to the outer tube [B]. Special T ool - T op Plug Wrenc h, 5 0 mm [ C]: 57 001-1645 • Record the position of spring preload adjuster [A] and then turn [B] it to the hardest position. • Holding the top plug w rench [A[...]

PERIODIC MAINTENANCE 2-61 Periodic M aintenan ce Procedures When not usi ng the For k Spring Compressor (Special T ool: 57001-1771): • Compress the outer tube by hands and install the top plug wrench [A] between the axle holder bottom [B] and locknut [C]. Speci al T ool - T op Plug Wrench , 5 0 mm: 5 7001-164 5 WA R N I N G The fork spring applie[...]

2-62 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Inse rt th e hol der bar [A ] o f the fork sp rin g c omp ress or (special tool: 57001-1587) to the axle hole and secure it with the holde r [B] of the fork spring compressor (special tool: 57001-1771). Special T ools - Fork Spring Compresso r: 570 01-15 87 Fork Spring Compre ssor: 570[...]

PERIODIC MAINTENANCE 2-63 Periodic M aintenan ce Procedures • Hold the locknut [ A] with a wrench [ B] and remove the right front fork bottom plug [C]. NOTE ○ Do not remove the locknut from the piston rod. The piston rod may slide into the inner tube. NOTICE When loosening the locknut, the threads of the axle holder do not touch t he push rod. [...]

2-64 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • T ighten the locknut [A] fully . • Install the piston rod pulle r [A] to the threads on the piston rod end [B ]. Special T ool - Fork Pisto n Rod Pu ller , M12 × 1.25: 57001 -1289 • Install the following parts in the outer tube. Fork Spring [A] Spring Seat [B] Collar [C] Right Fro[...]

PERIODIC MAINTENANCE 2-65 Periodic M aintenan ce Procedures When not usi ng the For k Spring Compressor (Special T ool: 57001-1771): • Hold the axle holder part with a vise. ○ Protect the axle holder part with a soft jaws or heavy cloth when using a vise. WA R N I N G If the axle holder is not securely clamped, the fr ont fork assembly may come[...]

2-66 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Inse rt th e hol der bar [A ] o f the fork sp rin g c omp ress or (special tool: 57001-1587) to the axle hole and secure it with the holde r [B] of the fork spring compressor (special tool: 57001-1771). Special T ools - Fork Spring Compresso r: 570 01-15 87 Fork Spring Compre ssor: 570[...]

PERIODIC MAINTENANCE 2-67 Periodic M aintenan ce Procedures • Replace the O-ring [A] on the right front fork bottom plug with a new one and apply specified fork oil to it. • Slowly turn the right front fork bottom plug [ A] clockwi se until resistance is felt. Check the clearance between the locknut [B] and right front fork bottom plug for more[...]

2-68 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Hold the axle holder part with a vise. ○ Protect the axle holder part with a soft jaws or heavy cloth when using a vise. W ARNIN G If the axl e holder is not securely cl am ped, the front fork assem bly may come out of the vise when com- pressed, which could cause an accident resulti[...]

PERIODIC MAINTENANCE 2-69 Periodic M aintenan ce Procedures • H o l d i n gt h et o pp l u gw r e n c h[ A ]w i t hav i s e ,t i g h t e nt h e right front fork spring preload adjuster [B] on the right front fork spring adj uster unit [C] wit h a top plug wrench [D]. Speci al T ool s - T op Plug Wrench, 5 0 mm: 5 7001- 1645 T op P lug Wrench, 36 [...]

2-70 PERIODIC MAINTENA NCE Periodic M aintenance Procedures The torque of left front fork cylinder unit a nd right front fork spr ing adjuster unit are specifie d to 34 N·m (3. 5 kgf·m, 25 ft·lb), however , when you use the top plug wrench [A], reduce the torque to 90% of the speci fied value [31 N·m (3.1 kgf·m, 23 ft·lb)] due to the distance[...]

PERIODIC MAINTENANCE 2-71 Periodic M aintenan ce Procedures • Adjust the gas reservoir damping adjusters [A] to the soft- est posi tion. • Remove the adjuster assembly [B] and pump the rear s h o c kt od r a i nt h eo i l . • Using the hand press, push the reservoir cap [A]. • Remove: Circ lip [B] Reservoir Cap • T ap [A] the hole [B] in [...]

2-72 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • V isually i nspect t he piston [A], O-r i ng [B] , and oil seal as- sem bly [C] . If the piston, O-ring and oil seal assembly are badly scored, rusty or damaged, replace them. Piston Rod Assembly Disassembly/Assembly If necessary , disassembly and assembly the piston rod assembly as f [...]

PERIODIC MAINTENANCE 2-73 Periodic M aintenan ce Procedures • Wrap the threads [A] of the piston rod with tape. • Remove the oil seal assembly [B]. • Remove the O-ring [A] and spring [B]. • Remove the rebound rubber [A] out of its groove [B]. • Remove: Collar [ C] Spring Holder [D] Oil Seal [E] • Rem ove: Oil Seal [A] NOTICE T o avoid d[...]

2-74 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Remove: Stopper [ A] Damper [B] Damper Holder [C] • Inspect the piston rod slidi ng surface [A]. If the sliding surface i s scratches or distortion, replace it. • Hold the lower of the piston rod asse mbly in a vise with soft jaws or heavy cloth. • Make the threads of the piston [...]

PERIODIC MAINTENANCE 2-75 Periodic M aintenan ce Procedures • Rem ov e the tape fro m piston r od. • Install the pi ston assembly [A] so that the thick side of the stopper [B] f aces downward. NOTE ○ Be careful not to change the original positions. • Install the new piston rod locknut [C]. • T ighten: T orque - Piston Rod Locknut: 37 N·m[...]

2-76 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Pull up the gas reservoir ca p [A] against the circlip. 2.6 mm (0.1 in.) [ B] W ARNIN G Pressurized nitrogen gas can explode out of the shock reservoir cap if the circlip is not properly in- stalled, allowing oil and internal parts to burst out of the reservoir wi t h great force and c[...]

PERIODIC MAINTENANCE 2-77 Periodic M aintenan ce Procedures • Remount the upper portion of the shock absorber in a vise with soft jaws or heavy cloth. • Fill th e specifie d oil [A] into th e damping adjuster assem- bly hole. Suspen sion Oil - S HOW A SS-25 (1 L) : 45024- 0001 Rear Shock Absorber Oil Capacity Standard: approx. 380 mL (12.8 US o[...]

2-78 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Injec t t he n itr ogen gas u p to the 980 kPa (10.0 kgf/cm², 142 psi) pressure. W ARNIN G High pressure gas is dangerous and can explode, causing serious injury . T o avoid injur y , have a qual- ified mechanic pressurize the shock reservoir with nitrogen gas only . Do not use air or[...]

PERIODIC MAINTENANCE 2-79 Periodic M aintenan ce Procedures Steering Steering Inspection • Using the jack, raise t he front wheel off the ground. Speci al T ool s - Jac k: 5700 1-123 8 Jack Attac hment: 57001-1608 • With the front wheel pointing straight ahead, alternatel y nudge each end of the handlebars. ○ The front wheel should swing full[...]

2-80 PERIODIC MAINTENA NCE Periodic M aintenance Procedures • Loosen the front fork clamp bolts (upper) [A] on both sides. • Remove the steering stem head nut [B] and washer [ C]. • Remove the steering stem head [D]. • T urn the steering stem nut [A] with the steering stem nut wrench [B] to obtain the proper adjustment. If the steering is t[...]

PERIODIC MAINTENANCE 2-81 Periodic M aintenan ce Procedures Frame Frame Inspection • Clean the frame with steam cleaner . • Visual ly inspect the frame and rear frame f or cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WA R N I N G A repaired frame may fail in use, possibly causing an accident resulti ng in in[...]

2-82 PERIODIC MAINTENA NCE Periodic M aintenance Procedures General Lubricati on and Cable Inspection Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, di rt, or gri me. • Lubricate the points list ed below with i ndicated lubr icant. NOTE ○ Whenever the vehicle has been oper[...]

PERIODIC MAINTENANCE 2-83 Periodic M aintenan ce Procedures Cable Inspection • With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is f rayed [B], or if t he cable housing is kinked [C], r eplace the cable. Nut, Bolt, and Fastene r T[...]

2-84 PERIODIC MAINTENA NCE Periodic M aintenance Procedures If there are loose fasteners, retight en them to the spec- ified torque following the specified tightening sequence. Refer to the T orque and Locking Agent section in this chapter for torque specificati ons. For each fastener , first loosen it by 1/2 turn, then tighten it. If cotter pins a[...]

FUEL SYSTE M (DFI) 3- 1 3 Fuel System (DFI) T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 3-4 DFI Sy ste m .. .... .... ...... .... .... .... ..... .... .... ...... .... .... .... ..... .... .... ...... .... .... .... [...]

3-2 FUEL SYSTEM (DFI) Down str eam Injec tor R emo val ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... ..... .... .... ...... .... .... .... . 3-59 Down str eam Injec tor In stal lat ion ...... .... .... ...... .... ..... .... .... .... .... ...... .... ..... .... .... .... .... .... ...... . 3-59 Down str eam Injec tor A udi[...]

FUEL SYSTE M (DFI) 3- 3 This page int entionally left blank.[...]

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

FUEL SYSTEM ( DFI) 3-5 Exploded View To r q u e No. Fastener N·m kgf·m ft·lb Remarks 1 Throttl e Pulley Cover Bolts 3.4 0.35 30 in·lb 2 Throttl e Cable Bolts 3.0 0.31 27 in·lb 3 Throttl e Case Mounting Screws 3.8 0.39 34 in·lb 4 Air Cleaner Duct Clamp Bolt 2.0 0.20 18 in·lb 5 Deli ver y Joint Bolt 3.5 0.36 31 in·lb L CL: Apply cab le lubric[...]

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 W ater T em perature Sensor 12 1.2 106 in·lb 2 Gear Position Sw itch Screws 2.9 0.30 26 in·l b L AD: Apply adhesive. EO: A pply engi ne oil. G: Apply grease. S: Follow the specified tightening sequence. L: Apply a non-permanent locking agent. R: Replacement Par[...]

3-8 FUEL SYSTEM (DFI) DFI System DFI System[...]

FUEL SYSTEM ( DFI) 3-9 DFI System 1. Fuel T ank 2. Pressure Regulator 3. Fuel Pump 4. Intake Air Pressure Sensor 5. Downstream Inject or 6. Upstream Inject or 7. Intake Air T emperat ure Sensor 8. Air Cleaner Housing 9. Ignition Coil 10. V ehicle-down Sensor 1 1. Crankshaft Sensor 12. Throttle Sensor 13. W ater T emperature Sensor 14. Gear Position[...]

3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring D iagram[...]

FUEL SYSTEM (DFI) 3-1 1 DFI System Part Names 1. ECU 2. Self-diagnosis T erminal 3. Throttle Sensor 4. Intake Air Pressure Sensor 5. Downstream Inject or 6. Upstream Inject or 7. Intake Air T emperat ure Sensor 8. W ater T emperature Sensor 9. Frame Ground 1 10. Ignition Coil 1 1. Spark Plug 12. Frame Ground 2 13. Fuel Pump 14. V ehicle-down Sensor[...]

3-12 FUEL SYSTEM (DFI) DFI System T erminal Numbers of ECU Connectors T erminal Names 1. Power Supply to ECU : R/W 2. Unused 3. DFI Setting Data Selection 1: W/BL 4. Downstream Injector : BL/R 5. Unused 6. Ground for ECU : BK/Y 7. FI Warni ng Indicator Light: B L/W 8. Upstream Injector: BL/BK 9. Unused 10. Fuel Pump: P/BK 1 1. Ignition Coil: O 12. [...]

FUEL SYS TEM (DFI) 3-13 DFI P arts Location Kawasaki Diagnostic System Connector [A] ECU [B] FI W arning Indicator Light Harness Connector [C] Self-diagnosi s T erminal [D] V ehicle-down Sensor [A] Igniti on Coil [B] Intake Air Pressure Sensor [A] Downstream Injector [B] Ups tream Injector [A] Capacitor [A] Throttl e Sensor [B] W ater T emperature [...]

3-14 FUEL SYSTEM (DFI) DFI Parts Locati on Intake Air T emperature Sensor [A] Fuel Pump [A][...]

FUEL SYS TEM (DFI) 3-15 Specifications Item Standard Digital Fuel Inject ion System Idle Speed 2 050 ±5 0 r/min (rpm) Throttle Body A ssy: Throttle V alve S ingle throttle valve Bor e 43 mm (1.69 i n.) ECU: Make KEI HIN Ty p e Digital memory type, wit h built in IC i gniter , sealed with resi n Fuel Pressure 294 kPa (3.0 kgf/cm², 43 psi) with eng[...]

3-16 FUEL SYSTEM (DFI) Specification s Item Standard Throttle Grip and Cables Throt tle Gri p Free Play 2 ∼ 3 m m (0.08 ∼ 0.12 in.)[...]

FUEL SYSTEM (DFI) 3-17 Special T ools and Sealan t Oil Pressur e Gauge, 5 kgf /cm²: 57001-1 25 Fork Oil Level Gauge: 57001-1 290 V ac uum Gauge: 57001-1 369 Hand T est er: 57001-1 394 Filler Cap Drive r: 57001-1 454 Nee dle Adapt er Set: 57001- 1457 Fuel P ressure Gauge Adapter: 57001- 1593 Fuel Hose: 57001- 1607 Measuring Adapter: 57001- 1700 Liq[...]

3-18 FUEL SYSTEM (DFI) DFI Servicing Pre cautions DFI Servicing Precautions There are a number of important precaut ions that should be followed servicing the DFI system. ○ Connect these connectors until they click [A]. ○ Never any of the DFI electri cal connectors are discon- nected. The ECU memorizes service codes. ○ Do not spray water on t[...]

FUEL SYS TEM (DFI) 3-19 T roubles hooting th e DFI S ystem Outline When an abnormal i ty in the syst em occurs, the condition of the probl em is stored in the memory of the ECU (Elec- tronic Control U nit). With the engine stopped and conduct a self-di agnosis inspect ion, the service code is indicated by the number of times the orange FI warning i[...]

3-20 FUEL SYSTEM (DFI) T roubl eshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place volt age or resistance. ○ The DFI part co nnectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C]. Insert the [...]

FUEL SYS TEM (DFI) 3-21 T roubles hooting th e DFI S ystem • Pull each connectors [A] apart and inspect it for corro sion, dirt, and damage. If the c onnector is corroded or dirty , cl ean it car efully . If it is damaged, replace it. Connect them securely . • Check the wiring for continuity . ○ Use the wiring diagr am to find the ends of the[...]

3-22 FUEL SYSTEM (DFI) T roubl eshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each ri der reacts to pr oblems in dif ferent ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ T ry to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this [...]

FUEL SYS TEM (DFI) 3-23 T roubles hooting th e DFI S ystem Sample Diagnosis Sheet Rider name Model Engine No. Frame No. Date problem occurred Environment when probl em occurred. Weather □ fine, □ cloudy , □ rain, □ snow , □ always, □ other: T emperature □ hot, □ war m, □ cold, □ very cold, □ always Problem frequency □ chroni[...]

3-24 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshoot ing for some of the more common di f ficult ies in DFI system. ○ The ECU may be involved i n the DFI electrical and ignition system tr[...]

FUEL SYS TEM (DFI) 3-25 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) W ater temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Ins pect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Unstable (rough) idling: Fuel pressure too low or too high Inspect (see [...]

3-26 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Surge: Unstable fuel pressure Fuel pressure regulat or trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and replace fuel pump) (see chapter 3). Upstream/downstream inject or trouble Inspect (see chapter 3). W ater temperature s[...]

FUEL SYS TEM (DFI) 3-27 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) W ater temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Ins pect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Knocking: Fuel poor quality or incorrect Fuel change (Use the gasoline r[...]

3-28 FUEL SYSTEM (DFI) Self-Diagnos is Self-diagnosis Outline The self -diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU connected orange FI warning indicator light (LED) (option) goes on when DFI system and ignition system parts are faulty . In case of serious troubles[...]

FUEL SYS TEM (DFI) 3-29 Self-Diagnosis • Connect the power supply harness (option P/No. 2601 1 -0246) [A] to the capaci tor lead connector [B] of the main harness. • Connect the power supply harness (option P/No. 2601 1 -0246) to the 12 V battery [C]. • The orange FI warning indicator light (LED) will go on for 2 seconds for bulb inspec tion [...]

3-30 FUEL SYSTEM (DFI) Self-Diagnos is Self-Diagnosis Flow Chart[...]

FUEL SYS TEM (DFI) 3-31 Self-Diagnosis H o wt oR e a dS e r v i c eC o d e s ○ Service c odes are shown by a series of long and short blinks of the orange FI warning indicator light (LED) as shown below . ○ Read 10th digit and unit digit as the orange FI warning indicator light (LED) blinks. ○ When there a re a number of problems, all the ser[...]

3-32 FUEL SYSTEM (DFI) Self-Diagnos is Service Code T able Ser vice Codes Orange FI W arning Indicator Light (LED) Problems 11 Throttle sensor malfunction, wiring open or short 12 Intake air pressure sensor malfunction, wiring open or short 13 Intake air temperature sensor malfunction, wiring open or short 14 W ater temperature sensor malfunction, [...]

FUEL SYS TEM (DFI) 3-33 Self-Diagnosis Backups ○ The ECU takes t he following m easures to prev ent engi ne damage when th e DFI or the ignition system parts have troubles. Service Codes Par ts Output Signal Usable Range or Criteri a Backups by ECU 11 Throt tle Sensor Throttl e S ensor Output V oltage 0.58 ∼ 3.85 V If the throt tle sensor syste[...]

3-34 FUEL SYSTEM (DFI) Self-Diagnos is Not e: (1) D -J Method and α -N M ethod: When the engine load is light like at idling or low speed, the ECU determines the inject ion quantity by calculati ng from the throt tle vacuum (intake ai r pressur e sen- sor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-[...]

FUEL SYS TEM (DFI) 3-35 Throttle Sens or (Servic e Code 1 1) The throt t le sensor is a rotati ng variabl e resis tor that change output voltage according to throttle operating. The ECU senses this volt age cha nge and determines fuel injecti on quanti ty , and ign ition ti ming accordin g to engine rpm, and throttle opening. Input T erminal [ A] O[...]

3-36 FUEL SYSTEM (DFI) Throttle S ensor (Service Code 1 1) • Replace: Throttle Sensor Screw [A] Throttle S ensor [B] O-ring [C] • Apply engine oil to the new O-ring, and install it to t he new throttle sensor . • Engage the inner rotor groove [A] with the throttle shaft [B]. • Insert the throt tle sensor [A] into the throttle body . ○ Set[...]

FUEL SYS TEM (DFI) 3-37 Throttle Sens or (Servic e Code 1 1) • Adjust the sensor position so that the output voltage i s within the specified voltage range. Throttle S ensor Output V oltage Standard: DC 0.58 ∼ 0.62 V If the input voltage reading shows other than 5 V , calculate a valid output voltage range as follows: Exam ple: In the case of a[...]

3-38 FUEL SYSTEM (DFI) Throttle S ensor (Service Code 1 1) • Measure the input voltage with the engine stopped and with the connector j oined. Input V oltage Standard: DC 4.75 ∼ 5.25 V • Disconnect the power supply harness. If the reading is within the standard, check the output volt- age (see Throttl e Sensor Output V oltage Inspection). If [...]

FUEL SYS TEM (DFI) 3-39 Throttle Sens or (Servic e Code 1 1) • Refer to the Self-diagnosis Procedures, connect the 12 V battery to the main harness. • Measure the output v oltage with the engine stopped, and with the connector joined. Output V oltage Standard: DC 0.58 ∼ 0.62 V at idle throttle opening DC 3.65 ∼ 3. 85 V at full t hrottle ope[...]

3-40 FUEL SYSTEM (DFI) Throttle S ensor (Service Code 1 1) Throttle Sensor Resistanc e Inspection • Disconnect the throttle sensor connector . • Connect a digital meter [A] to the throttl e sensor connector [B]. • Measure the thrott le sensor resistance. Throttle Sensor Re sistance Connections: BL lead [C] ←→ BK lead [D ] Standard: 4 ∼ [...]

FUEL SYS TEM (DFI) 3-41 Intake Air Pressur e Se nsor (Service Code 12) Intake Air Pressure Sensor Removal NOTICE Never drop the intake air pressure sensor , espe- cially on a hard surface. Such a shock to the sensor can dam age it. • Remove: Fuel T ank (see Fuel T ank Removal) Fuel Hose (see Fuel Hose R eplacement in the Periodic Maintenance chap[...]

3-42 FUEL SYSTEM (DFI) Intake Air Press ure Sensor (Service Code 12) Intake Ai r Pressure Sensor Input Vol tage Inspection NOTE ○ Be sure the battery is fully charged. • Disconnect the intake air pr essure sensor connector and connect the measuring adapter [A] bet ween these con- nectors. Main Harness [B] Inta ke A ir P res sure Sensor [C] Spec[...]

FUEL SYS TEM (DFI) 3-43 Intake Air Pressur e Se nsor (Service Code 12) Intake Air P ressure Sensor Output V oltage Insp ectio n • Measure the intake air pres sure sensor output voltage in the same way as input voltage inspection. ○ Disconnect the i ntake air pressure sensor connector and connect the measuring adapter [A] between t hese con- nec[...]

3-44 FUEL SYSTEM (DFI) Intake Air Press ure Sensor (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor [A] and disconnect the vacuum hose from the sensor . • Connect an auxiliary hose [B] to the intake air pressure sensor . • T emporarily inst all the intake air pressure sensor[...]

FUEL SYS TEM (DFI) 3-45 Intake Air Pressur e Se nsor (Service Code 12) ID: Idlin g Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle V acuum Pressure (Absolute) ST : Standard of Sensor Output V oltage (V) TO: Throttl e Full Open UR: Usable Range of Sensor Output V oltage (V) Vv: Intake Air Pressure Sensor Output V oltage (V) (Digital Meter [...]

3-46 FUEL SYSTEM (DFI) Intake Air Press ure Sensor (Service Code 12) Intake Air Pressure Sensor Circuit 1. ECU 2. Intake Air Pressu re Sensor[...]

FUEL SYS TEM (DFI) 3-47 Intake Air T emperature Sens or (Service Code 13) Intake Air Te mperature Sensor Removal/Instal- lation NOTICE Never d rop the intake air temperature sensor , espe- cially on a hard surface. Such a shock to the sensor can dam age it. • Remove the rear frame with air cleaner housing ( see Rear Frame Removal in the Frame cha[...]

3-48 FUEL SYSTEM (DFI) Intake Air T emperature Se nsor (Service Code 13) • Measure the output voltage with the engine stopped and the connector joined. Output V oltage Standard: About DC 2.28 ∼ 3.43 V at int ake a ir temperat ure 20°C (68°F ) NOTE ○ The output voltage changes according to the intake air temperature. • Disconnect the power[...]

FUEL SYS TEM (DFI) 3-49 Intake Air T emperature Sens or (Service Code 13) Intake Air T emperature Sensor Circuit 1. ECU 2. Intake Air T emperat ure Sensor[...]

3-50 FUEL SYSTEM (DFI) W ater T emperatu re S ensor (Service Code 14) Water T emperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor , espe- cially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Draining in the Cooling System chapter). • Remove: Exhaust Pipe ( see Exh[...]

FUEL SYS TEM (DFI) 3-51 W ater T emperature Sen sor (Service Code 14) • Refer to the Self-diagnosis Procedures, connect the 12 V battery to the main harness. • Measure the output voltage with the engine stopped and the connector joined. Output V oltage Standard: About DC 2.80 ∼ 2.97 V at wat er tempera ture 20°C (68° F) NOTE ○ The output [...]

3-52 FUEL SYSTEM (DFI) W ater T emperatu re S ensor (Service Code 14) Water T emperature Sensor Inspection • Remove the water temperature sensor (see W ater T em- perature Sensor Removal/Installation). • Suspend the sensor [ A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged. • Suspend a the[...]

FUEL SYS TEM (DFI) 3-53 Crankshaft Sensor (S ervice Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaf t se nsor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Stator Coil Removal/Instal lation in the Elec- trical System chapter . Crankshaft Sensor Res istance Inspection •[...]

3-54 FUEL SYSTEM (DFI) Gear Po sition Switch (S ervice Code 25) Gear Position Switch Removal • Remove: Left Radiator Shroud (see Radiator Shroud R emoval in the Frame chapter ) Shift Pedal (see Shift Pedal Removal in the Crank- shaft/T r ansmission chapter) Engine Sprocket Cover and Drive Chain Guide ( see En- gine Sprocket Removal in the Final D[...]

FUEL SYS TEM (DFI) 3-55 Gear Position Switch (Se rvice Code 25 ) Gear Position Switch Inspection NOTE ○ Be sure the transmis sion mechanism is good condit ion. • Remove the left radiator shroud (see Radiator Shroud Re- moval i n the Frame chapter). • Disconnect the gear position switch lead connector [A]. • Set the hand tester [A] to the ×[...]

3-56 FUEL SYSTEM (DFI) V ehic le-down Sens or (Service Co de 31) When the m otorcycle is down, the engine stops according to the condition of the below table. Engine Speed Ti m e Engi ne Condit ion 2 500 rpm or les s After 30 s econds Stop 2 500 r pm or m ore After 3 seconds Sto p When the vehicle-down sensor is broken, the engine will stop at 3 se[...]

FUEL SYS TEM (DFI) 3-57 V ehicle -down Sensor (S ervice Code 3 1) • Measure the input voltage with the engine stopped and with the connector joined. Input V oltage Standard: DC 4.75 ∼ 5.2 5 V If the reading is within the standard, check the output volt- age (see V ehicle-down Sensor Output V oltage Inspec- tion). If the reading is out of the st[...]

3-58 FUEL SYSTEM (DFI) V ehic le-down Sens or (Service Co de 31) • Hold the sensor vert ically . • Refer to the Self-diagnosi s Procedures , connect the 12 V battery to the main harness. • Measure the output voltage with the engine stopped and with the connector j oined. ○ T ilt the sensor 55 ∼ 75° or more [A] right or left , then hold t[...]

FUEL SYS TEM (DFI) 3-59 Downstream Inje ctor (Service Code 41) NOTICE Never drop the downstream injector , especial ly on a hard surf ace. Such a shock to the downstr eam injector can damage it. Dow nstre am Inje cto r Remova l • Remove the throttle body assy (see Throttle Body Assy Removal). • Remove the delivery pipe mounting screw [A]. • R[...]

3-60 FUEL SYSTEM (DFI) Downst ream Injecto r (Service Cod e 41) • Fit the projections [A] on the delivery pipe to the hollows [B] of the throttle body assy . • T ighten the delivery pipe mounting screw [A]. • Install th e removed parts (see appropriate chapters) . Downstream Injector Audible Inspection • Remove: Left Radiator Shroud (see Ra[...]

FUEL SYS TEM (DFI) 3-61 Downstream Inje ctor (Service Code 41) • Connect a di gital meter to the t erminals i n downstream injector [A]. • Measure the downstream injector resistance. Downstr eam Injector Re sistanc e Connections: R/W terminal ←→ BL/R terminal Standard: About 1 1.7 ∼ 12.3 Ω at 20°C (68°F) If the reading is out o f the [...]

3-62 FUEL SYSTEM (DFI) Downst ream Injecto r (Service Cod e 41) Downstream I n jector Out put V oltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector . • Refer to the Self-diagnosi s Procedures , connect the 12 V battery to the main harness. • Using t he ne[...]

FUEL SYS TEM (DFI) 3-63 Downstream Inje ctor (Service Code 41) Downstream Fuel Line Inspection • Remove: Fuel T ank (see Fuel T ank Removal) Fuel Hose (see Fuel Hose R eplacement in the Periodic Maintenance chapter) ○ Place a piece of cloth around the fuel outlet pi pe of fuel pump and delivery pipe of throttl e body assy . • Check the dow ns[...]

3-64 FUEL SYSTEM (DFI) Downst ream Injecto r (Service Cod e 41) Downstream Injector Cir cuit 1. ECU 2. Downstream Inject or 3. Frame Ground 1 4. Capacitor[...]

FUEL SYS TEM (DFI) 3-65 Upstream Injector (S ervice Code 42) NOTICE Never dr op the upstream inject or , especially on a hard surface. Such a shock to the upstream injector can dam age it. Upstream Injector Removal • Remove: Rear Frame with Air Cleaner Housing (see Rear Frame Removal in t he Frame chapter) • Remove the delivery joint bolt [A]. [...]

3-66 FUEL SYSTEM (DFI) Upstream Injector (Service C ode 42) • Fit the projection [A] on the deli very pipe t o t he hol low [B] of the air cleaner housing. ○ Face the connector side to left side. • Apply a non-permanent locking agent to the threads of the delivery joint bolt [A]. • T ighten: T orque - Delivery Joint Bolt: 3.5 N·m (0.36 kgf[...]

[...]

3-68 FUEL SYSTEM (DFI) Upstream Injector (Service C ode 42) Upstream Injector Output V oltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector . • Refer to the Self-diagnosi s Procedures , connect the 12 V battery to the main harness. • Using t he needle adap[...]

FUEL SYS TEM (DFI) 3-69 Upstream Injector (S ervice Code 42) Upstream Injector Fuel Line Inspe ction • Remove: Fuel Hose (see Rear Frame Removal in the Frame chap- ter) ○ Place a piece of cloth around the delivery pipe of air cleaner housing. • Check the upstream inj ector fuel li ne for leakage as fol- lows: ○ Apply engine oil to the deliv[...]

3-70 FUEL SYSTEM (DFI) Upstream Injector (Service C ode 42) Upstream Injector Circui t 1. ECU 2. Upstream Injecto r 3. Frame Ground 1 4. Capacitor[...]

FUEL SYS TEM (DFI) 3-71 Fuel Pump (Service Code 46) Fuel Pump R emoval WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sur e the area is well-ventil ated and free from any source of fl ame or sparks; this includes any appliance with a pilot light. NOTICE Nev[...]

3-72 FUEL SYSTEM (DFI) Fuel Pump (Service Code 46) • Install the fuel pump [A] to the fuel tank. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Gradually tighten the f uel pump bolts evenly following the specifi ed tightening sequence [1 ∼ 6]. • Install th e removed parts (see appropriate chapters) . Fu el [...]

FUEL SYS TEM (DFI) 3-73 Fuel Pump (Service Code 46) • Measure the operating voltage with engine stopped and with the connector joined. Operat ing V oltage Stand ard: Battery V olt age If the readi ng is not battery voltage, check t he wiring for continuity (see Fuel Pump Circuit). If the wiring is good, check the ECU f or i ts ground and power su[...]

3-74 FUEL SYSTEM (DFI) Fuel Pump (Service Code 46) Fue l Pu mp Ci rcu it 1. ECU 2. Capacitor 3. Fuel Pump 4. Frame Ground 1[...]

FUEL SYS TEM (DFI) 3-75 Ignition Coil (Service Code 51) Ignition Coil Removal/Installation • Refer to the Igni tion Coil Removal/Inst allation in t he Elec- trical System chapter . Ignition Coil Primary Peak V oltage Inspection • Refer to the Ignition Coil P rimary Peak V oltage Check in the Electrical S ystem chapter . If the peak voltage is m[...]

3-76 FUEL SYSTEM (DFI) ECU ECU Identification ○ Most countries have their own regulations , so each ECU has di fferent characteris tic. So, do not confuse ECU wi th each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identif ication Part N umbe r [A] Specifica tion 21 175 -0782 US, CA 21 17[...]

FUEL SYS TEM (DFI) 3-77 ECU • Insert the slits [A] of the rubber protector to the ECU bracket. • Connect the E CU connector [B]. ECU Power Supply Inspection • Remove the number plate (see Number Plate Removal in the Frame ch apter). • Visual ly inspect the ECU connector . If the connector is clogged with mud or dust, blow it off with compre[...]

3-78 FUEL SYSTEM (DFI) ECU • Connect a digit al meter [A] to the ECU connector [B] with the needle adapter set. Special T ool - Needle Ada pter Set: 5 7001- 1457 ECU P ower Supply Inspection Connections: Digital Meter (+) → R/W lead (ECU ter minal 1 ) Digital Meter (–) → Ba ttery (–) T erminal Standard: When batter y i s n ot connecte d: [...]

FUEL SYS TEM (DFI) 3-79 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel T ank (see Fuel T ank Removal) Fuel Hose (see Fuel Hose R eplacement in the Periodic Maintenance chapter) ○ Be sure to place a pi ece of cloth around the fuel outlet pipe of the fuel pump and the deliver y pipe of the throttl[...]

3-80 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idli ng. Fuel Pressu re Standa rd: 294 kPa ( 3.0 kgf/cm² , 43 psi) with en gine idling NOTE ○ The gauge needle will fluctuate. Read the pressure at the aver age of the maximum and minimum i ndications. • Stop the engine. If the[...]

FUEL SYS TEM (DFI) 3-81 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the fuel hose fr om the fuel pump (see Fuel T ank Removal). ○ Be sure to place a pi ece of cloth around the fuel outlet pipe of t he fuel pump. WA R N I N G Fuel i s f lammable and explosive under cert ain con- ditions and can cause seve[...]

3-82 FUEL SYSTEM (DFI) Throttle Grip and Cable If the throttle grip has excessive free pl ay due to cable stretch or misadj ustment, t here will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play , the throttl e will be hard to control, and the idle sp[...]

FUEL SYS TEM (DFI) 3-83 Throttle Grip and Cable • Loosen the locknut [A] and bolts [B]. • Remove the cables [C] from the throttle body assy . • Free the tips [D] from the pulley . • Pull out the cables from the frame. • Lubricate the throttle cables (see Lubrication in the Peri- odic Maintenance chapter). • Apply grease to the throttl e[...]

3-84 FUEL SYSTEM (DFI) Throttle Body Ass y Idle Speed Inspection • Refer to the Idle Speed Inspec tion in the Periodic Main- tenance chapter . T h r o t t l eB o r eC l e a n i n g • Refer t o the Throttle Body Cleaning in the Periodic Main- tenance chapter . Throttle Body Assy Removal W ARNIN G Gasoline is extremely flamm able and can be ex- p[...]

FUEL SYS TEM (DFI) 3-85 Throttle Body Assy Throttle Bod y Assy Disassembly • Remove: Throttl e Body Assy (see Throttle Body Assy Removal) Intake Air Pressure Sensor [A] (see Intak e Air Pressure Sensor Removal) Downstream Injector [B] (see Dow nstream Injector R e- moval) Throttl e Sensor [C] (see Throt tle Sensor Replacement) Idle Adjustin g Sc [...]

3-86 FUEL SYSTEM (DFI) Air Cleaner Air Cle aner Housing Removal • Remove the rear frame (see Rear Frame Removal in the Frame chapter). • Remove the air cleaner housing bolts [A]. • T ake the air cleaner housing off the rear frame. Air Cleaner Hou sing Installation • Assemble the air cleaner housing (see Exploded View section). • Install t[...]

FUEL SYS TEM (DFI) 3-87 Fuel T ank Fue l T an k R emov al WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sur e the area is well-ventil ated and free from any source of fl ame or sparks; this includes any appliance with a pilot light. • Remove: Seat (see S[...]

3-88 FUEL SYSTEM (DFI) Fuel T ank When removing with standard tip screwdriver: • Insert the s tandard tip screwdri ver [A] into the slit [B] on the join t lo ck [C]. • T urn the driver to disconnect the joint lock. When removing with fingers: • Open and push up [A] the joint lock [B] with your fi ngers. NOTICE Prying or excessively widening t[...]

FUEL SYS TEM (DFI) 3-89 Fuel T ank • C l e a nt h ep i p e[ A ] . • Cover the pipe and hose joint [B] with the v inyl bags [C] to keep them clean. Fuel T ank Installation • Note the above W ARNING (see Fuel T ank Removal). • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in the A ppendix chapter). • Check that the da[...]

3-90 FUEL SYSTEM (DFI) Fuel T ank • Push and pull [A] the fuel hose joint back and forth more than two times, and make sure it is locked and does not com e off. W ARNIN G Leaking fuel can cause a fir e or explosion resulting in serious burns. Make sure the hose joint is in- stalled correct ly on the delivery pipe by sliding the join t. If it come[...]

COOLING SYSTEM 4- 1 4 Cooling System T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 4-2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... ..... ....[...]

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

COOLING SYSTEM 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Wate r Hose Clamp Screws 3.0 0.31 27 in·l b 2 Wa t e r P i p e B o l t 9.8 1.0 87 in·lb 3 Wate r Pump Cover Bolts (L = 55 mm) 9.8 1.0 87 in·lb L 4 Wate r Pum p Impeller Bolt 7.0 0.71 62 in·lb 5 Wate r Pump Cover Bolts (L = 30, 65 mm ) 9.8 1.0 87 in·lb 6 Coolant [...]

4-4 COOLING SYSTEM Specification s Item Standard Recommended Coolant Ty p e Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor c hemicals for aluminum engines and radiators) Color Green Mixed R atio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) T otal Am ount 1.2 L (1. 3 US qt) Radiator Radi[...]

COOLING SYSTEM 4- 5 Special T ool Bear ing Dri ver Set: 57001-1 129[...]

4-6 COOLING SYSTEM Coolan t Co olant L evel In spec tion • Refer to the Coolant Level Inspection in the Periodic Main- tenance chapter . Co olant Det erior atio n Inspec tion • Refer to the Coolant Deteriorat ion Inspection in the Peri- odic Maintenance chapter . Coolant Draining W ARNIN G Coolant can be extremely hot and cause severe burns, is[...]

COOLING SYSTEM 4-7 Coolant Coolant Filling NOTICE Use coolant contai ning corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’ s. Soft or disti lled water must be used wit h the antifreeze (see below for antifr eeze) in the cooling system. If hard water is used in the s[...]

4-8 COOLING SYSTEM Coolan t Cooling System Press ure T esting NOTICE During pressure testing, do not exceed the pres- sure for which the system i s des igned to work. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). • Remove the radiator cap, and install a cooling system pressure tester [A] and adapter [B] on the radiator filler neck [C].[...]

COOLING SYSTEM 4-9 Wa t e r P u m p Wate r Pump Cover Removal • Remove the oil filter (see Oil Filter Change in the Periodic Maintenance chapter). ○ Drain the engine oil from the water pump cover . • Drain the coolant (see Coolant D raining). • Remove the water pipe bolt [A], and disconnect the water pipe [B]. • Remove the water pump cove[...]

4-10 COOLING SYSTEM Wa t e r P u m p Impeller Removal • Remove: W ater Pump Cover (see W ater Pump Cover Removal) • Remove the impeller bolt [A] and take out the impeller [B] and washer . Impeller Install a tion • Install the washer [A] and impeller [B]. • T ighten: T orque - W ater Pump Impeller Bolt: 7.0 N·m (0.71 kgf·m, 62 in·lb) • [...]

COOLING SYS TEM 4-1 1 Wa t e r P u m p Water Pump Gear Installation • Press in the w ater pump gea r shaft [A] to the gear [B] until it is bottomed. • Apply grease to the w ater pump gear shaft. • Install the gear shaft from bearing side [C]. NOTICE Be sure to apply grease to the water pump shaft when installing. If it is installed dry , the [...]

4-12 COOLING SYSTEM Rad iat or Radiator Removal • Drain the coolant (see Coolant Draining). • Remove: Radiator Shrouds (see Radiator Shroud Removal in the Frame chapter) • Remove the capacitor [A] (see Capacit or Removal in the Electrical System chapter). • Loosen: W a te r Hos e Cla mp Screw s [B] • Slide the clamp [C]. • Pull the wate[...]

COOLING SY STEM 4-13 Radiator Radiator Installation • Install: Radiators W ashers Clutch Cable C lamps [A] (Left Side) • T ighten the radiator mounting bolts securely . • Run the overflow hose and water hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • T ighten: T orqu e - W ater Hose Clamp Screws: 3.0 N[...]

4-14 COOLING SYSTEM Rad iat or Radiator Cap Inspection • Check the top and bottom valve seals [A] of the radiat or cap, and the condition of the valve spring [B]. If any one of them shows visible damage, replace the cap. • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • Install the cap [A] on a cooli ng s[...]

ENGINE TOP E ND 5-1 5 Engine T op End T able of Con tents Exploded V iew .......... .......... ......... ...... 5-2 Spec ific ati ons ...... .... .... .... .... .... ..... ..... 5-6 Special T ools and Sealant ........ ....... . . 5-9 Cyli nder H ea d Co ver . ...... .... .... ..... .... . 5-1 2 Cylinder Head Cover Removal .... 5-12 Cylinder Head Co[...]

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

ENGINE TOP END 5-3 Exploded View To r q u e No. Fastener N·m kgf·m ft·lb Remarks 1 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb 2 Camshaft Cap B olts 9.8 1.0 87 in·lb MO, S 3 Plug 20 2.0 15 L 4 Cylinder Head Bolts ( M10) 44 4.5 32 MO, R, S 5 Auto-Decompress or Bolt 12 1.2 106 in·lb 6 Cylinder Head Bolts (M6) 12 1.2 106 in·lb S 7 Cylinder Bolt [...]

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

ENGINE TOP END 5-5 Exploded View G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. SS: Apply sil icone sealant.[...]

5-6 ENGINE T OP END Specification s Item Standard Service Limit Camshafts Cam Height: Exhaust 33.943 ∼ 34.057 mm (1.3 363 ∼ 1.3408 in.) 33.84 mm (1.332 in.) Inta ke 35.243 ∼ 35.357 mm (1.3 875 ∼ 1.3920 in.) 35.14 mm (1.383 in.) Camshaft Journal/Camshaft Cap Clearance 0.020 ∼ 0.062 mm (0.0 008 ∼ 0.0024 in.) 0.15 mm (0.0059 in.) Camshaft [...]

ENGINE TOP END 5-7 Specifications Item Standard S ervi ce Lim it V alve Seating Surface: Ou tside Diame ter : Exhaust 24.6 ∼ 24.8 mm (0.969 ∼ 0.976 in.) ––– Intake 30.6 ∼ 30.8 mm (1.205 ∼ 1.213 in.) ––– Width: Exhaust 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) ––– Intake 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) ––– V alve Spring F[...]

5-8 ENGINE T OP END Specification s V alve S tem D iameter V alve Stem Diameter [A] 45° [B] Va l v e S t e m B e n d Dial Gauge [A][...]

ENGINE TOP E ND 5-9 Special T ools and Sealan t Compression Gauge, 20 kgf/cm²: 57001-2 21 V alve Spring Compre ssor Assem bly: 57001-2 41 Piston Ring Compressor Grip: 57001-1 095 Piston Ring Compressor Belt, 67 ∼ 79: 57001-1 097 V alve Sea t Cutter , 45° - 27.5: 57001-1 1 14 V alve S eat Cutte r , 45° - 32 : 57001- 1 1 15 V alve S eat Cutte r [...]

5-10 ENGINE T OP END Special T oo ls an d Sealant Compr ession Gauge Adapter , M 10 × 1.0: 57001- 1317 V alve Seat Cutt er , 60° - 25: 57001- 1328 V alve Seat Cutter Holder , 4.5: 57001- 1330 V alve Guide Arbor , 4.5: 57001- 1331 V alve Guide Reamer , 4.5: 57001- 1333 V alve Se at Cutter , 60° - 33: 57001-1 334 Filler Ca p D river: 57001-1 454 V[...]

ENGI NE TOP END 5- 1 1 Special T ools and Sealan t V alve G uide Dr iver Attachment, F: 57001-1 722 Liqui d Gasket, TB1216 B: 92104- 1064[...]

5-12 ENGINE T OP END Cylinder Head Cov er Cylinder Head C over Removal • Remove: Fuel T ank (see Fuel T ank Rem oval in the Fuel System (DFI) chapter) Fuel Hose (see Fuel Hose Replacement in the P eriodic Maintenance chapter) Spark Plug Cap [A] Cylinder Head Cover Bolts [B] and W ashers Cylinder Head Cover [ C] • Remove the cylinder head cover [...]

ENGINE T OP END 5-13 Cylinder Head Cover • Install the cylinder head cover bolt washers with the metal side [A] upwards. • T ighten: T orque - Cylin der Head Cover Bolts [B]: 9.8 N·m (1 .0 kgf·m, 87 in·lb) • Install the r emoved parts (see appropr iate chapters) .[...]

5-14 ENGINE T OP END Cams haft Chain T ens ione r Camshaft Chain T ensioner Removal NOTICE This i s a non-return type camshaft chain tensioner . The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules l isted below: When removing the tensioner , do not take out the mounting bolt[...]

ENGINE T OP END 5-15 Camshafts Camshaft Removal • Remove: Cylinder Head C over (see Cylinder Head Cover Re- moval) T iming Inspection Cap [A] Flywheel Nut Cap [B] Speci al T ool - Filler Cap Driver : 5 7001-145 4 • Bring the piston to the TDC of the compres sion stroke. ○ Place a wrench over the flywheel nut [A] and turn it coun- terclockwis [...]

5-16 ENGINE T OP END Camshafts • Remove: Bolt [A] Auto-Decompressor [B] Spring [ C] Camshaft Installation • When installing the spring [A] on the auto-decompressor [B], put the spring end [C] onto the outside coil. • Install the auto-decompressor [A] in the exhaust camshaft. • T ighten: T orque - Auto-Decompressor Bol t [B]: 12 N·m (1.2 kg[...]

ENGINE T OP END 5-17 Camshafts • Bring the piston to the TDC. ○ Place a wrench over the flywheel nut [A] and turn it coun- terclockwis e to align the TDC mark [B] w ith the center of the groove [C] of the i nspection hole. • Engage the camshaft chai n with the camshaft sprockets. ○ Align the timing marks on the sprockets with the cylinder h[...]

5-18 ENGINE T OP END Camshafts • Install the dowel pins [ A] and positioning rings [B]. • Apply molybdenum disulfide oil solution to the threads and seating surface of the camshaft cap bolts. • T ighten all camshaft cap bolts evenly and lightly , and then tighten them with specified torque. ○ Follow the numbers [1 ∼ 8] of ti ghtening sequ[...]

ENGINE T OP END 5-19 Camshafts Camshaft C hain Removal • Remove: Camshafts (see C amshaft Removal) Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter) Lower Camshaft Chain G uide Bolt [A] Lower Cam shaft Chain Guide [B] • Disengage the camshaft chain [C] from the c rankshaft. Camshaft Chain Installation • Engage the camshaft ch[...]

5-20 ENGINE T OP END Camshafts Camshaft R unout Inspection • Remove the camshafts (see Camshaft Removal). • Set t he camshaft in a camshaft alignment jig or on V blocks. • Measure the runout with a dial gauge [A] at the specified place. If the runout exceeds the service limit, replace the camshaft. Camshaft Runout Standard : TIR 0.02 mm (0. 0[...]

ENGINE T OP END 5-21 Cylinder Head Cylinder Compression Measurement • W arm up the engine thoroughly . • Stop the engine. • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Spark Plug (see S park Plug Cleaning and Inspection in the Periodic Maintenance chapter) • Attach the compress ion gauge [A] and c ompression[...]

5-22 ENGINE T OP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Draining in the Cooling System chapter). • Remove: Fuel T ank (see Fuel T ank Rem oval in the Fuel System (DFI) chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Exhaust Pipe (see Exhaust Pipe Removal) • Re[...]

ENGINE T OP END 5-23 Cylinder Head Cylinder Head Installation • Install the front camshaft chain guide. ○ Fit the project i on [A] in the groove [B] of t he cylinder . ○ Insert the guide end [C] into the recess of the crankcase securely . NOTE ○ In this figure, the m agneto cover and flywheel has been removed for clari t y . • Replace the[...]

5-24 ENGINE T OP END Cylinder Head Cylinder Head War p Inspection • Refer to the Cylinder Head W arp Inspection in the Peri- odic Maintenance chapter .[...]

ENGINE T OP END 5-25 V alves V alve Clearance Inspect ion • Refer to the V alve Clearance Inspection in the Periodic Maintenance chapter . V alve Clea rance Adjustment • Refer to t he V alve Cl earance Adjustment in the Peri odic Maintenance chapter . V alve Removal • Remove the cylinder head (see Cylinder H ead Removal). • Remove the valve[...]

5-26 ENGINE T OP END Va l v e s V alve Installation NOTICE Do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. • V isually inspect the valve surface. If the surface is damaged, replace the valve. • Replace the oil seal [A] with a new one. • Apply a thin coat of molybde[...]

ENGINE T OP END 5-27 V alves V alve Guide Removal • Remove: V alve (see V alve Rem oval) Oil Seal Spring Seat • Heat the area around the valve guide up to 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head in oil and heat the oil. • Hammer lightly on the[...]

5-28 ENGINE T OP END Va l v e s • Ream the valve guide with valve guide reamer [A], even if the old guide is reused. ○ Always rotate the reamer clockwise. Special T ool - V alve Guide Re amer , 4.5: 570 01-1333 Valve/V alv e Guide Clear ance Meas urem en t (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by m[...]

ENGINE T OP END 5-29 V alves V alve Seat Inspection • Remove the valve (see V alve Removal). • Check the valve seati ng surface [A] between the valve [B] and valve seat [C]. • Measure the outside diameter [D] of the seating patter n on the valve seat. If the outside diameter is too l arge or too small, repair the seat (see Seat Repair) . V al[...]

5-30 ENGINE T OP END Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed t o grind the val v e f or repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to apply engi ne oil to the valve se[...]

ENGINE T OP END 5-31 V alves Widened Width [A] of engagement by machining with 45° cut ter Ground V olume [B] by 32° cutter 32° [C] Corr ect Width [D ] Ground V olume [E] by 60° cutter 60° [F] • Measure the outside diameter of t he seati ng surf ace wit h a vernier caliper . If the outside diameter o f the seating surface is too smal l, repe[...]

5-32 ENGINE T OP END Va l v e s If the seat width is too wide, make the 60° [A] grind de- scribed below . If the seat width is within the specified range, lap the valve to the seat as described below . • Grind the seat at a 60° angle un t il the seat wi dth is wit hin the specified r ange [B]. ○ T o make t he 60° grind, f it a 60° cutter in[...]

ENGINE T OP END 5-33 V alves[...]

5-34 ENGINE T OP END Cylinder and Pis ton Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Cam shaft Chain Guide [A] Cylinder Bolt [B] • T ap lightly up with a plastic mallet to separate the cylinder [C] from the crankcase. • Remove the cylinder base gasket. Piston Removal • Remove the cylinder (see Cylinder Remova[...]

ENGINE T OP END 5-35 Cylinder and Piston NOTE ○ The oil ring rails have no “top” or “bottom”. • Install the oil ring expander [A] i n the bottom piston ring groove so the ends [B] butt together . • Install the oil ring steel rails on both sides of the oil ring expander . ○ Spread the rail with your thumbs, but only enough to fit the[...]

5-36 ENGINE T OP END Cylinder and Pis ton • The piston ring openings must be positioned as shown. The openings of the oil ring st eel rails must be 15 ∼ 20° of angle from the opening of the oil ring expander . T o pR i n g[ A ] Upper Oil Ring Steel Rail [ B] Oil Ring Expander [C ] Lower Oil Ring Steel Rail [ D] • Apply engine oil to the cyli[...]

ENGINE T OP END 5-37 Cylinder and Piston Piston Ring Groove Width Inspection • Measure the groove width at sever al points around the piston with a vernier caliper . Piston Ring Groove Width Standard: To p 0 . 8 3 ∼ 0.85 mm (0.0327 ∼ 0.03 35 in.) Service Limit: T op 0.93 mm (0.037 in.) If any of the groove widths exceeds the s ervice limit, r[...]

5-38 ENGINE T OP END Cylinder and Pis ton Piston, Piston Pin, Connecting R od W e ar Inspection • V isually inspect the snap rings [A] still fitted in plac e. If the ring shows weakness or deformation, replace the ring. A lso if the pin hole groove shows excessive wear , replace the piston. • Measure the diameter of t he pist on pin [B] with a [...]

ENGINE T OP END 5-39 Throttle B ody As sy Ho lder Throttle Body Assy Holder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Throttl e Body Assy Holder Clamp Screw [A] ( Loosen) Throttle Body Assy Holder [B] and Holder Clamp Throttle Body Assy Holder Installation • Install: Throttl e Body Assy H older Throttle Body Assy Holder Clamp [...]

5-40 ENGINE T OP END Muffler W ARNIN G The muffler can become extremely hot during nor- mal operat ion and cause severe burns. Do not re- move th e muffler while it is hot. Mu ffler Bod y Remo val • Remove t he ri ght si de cover (see Side Cover Removal in the Frame chapter). • Loosen the muffler clamp bolt [A]. • Remove the mounting bolts [ [...]

CLUTCH 6-1 6 Clutch T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 6-2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... ..... .... ...... .... ....[...]

6-2 CLUTC H Exploded View[...]

CLUTCH 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Right Engine Cover Bol ts 9.8 1.0 87 in·l b 2 Clutch Cover Bolts 9.8 1.0 87 in·lb 3 Oi l Fi ller Plug 3.5 0.36 31 i n·lb 4 Clutch Hub Nut 98 10.0 72 R 5 Clutch Spring Bolts 9.0 0.92 80 in ·lb CL: Apply cab le lubricant. EO: A pply engi ne oil. G: Apply grease. M: Apply m[...]

6-4 CLUTC H Specification s Item Standard Service Limit Clutch Lever Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) ––– Clutch Fricti on Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.1 13 in.) 2.5 mm ( 0.10 in. ) Fricti on Plate W arp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.) Steel Plate W arp 0.15 mm (0.0059 in.) or less 0.3 mm ([...]

CLUTCH 6-5 Special T ools Inside Circli p Pliers: 57001-1 43 Bear ing Dri ver Set: 57001-1 129 Clut ch Holde r: 57001- 1243[...]

6-6 CLUTC H Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. W ARNIN G The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe durin[...]

CLUTCH 6-7 Clutch Lever and Cable • Align t he slit [A] of the a djusting nut to the slit [B] of the clutch lever . • Free the clutch cable upper end from the clutch lever . • T ake the cable off the cable holder [ A]. • T ake the cable lower end [B] of f the clutch rel ease lever [C]. NOTICE Do not remove the clutch release shaft unless it[...]

6-8 CLUTC H Clutch C over and Rig ht Engine Co ver Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Brake Pedal Bolt [A] Brake Pedal Ret urn Spring [B] • Remove the clutch cover bolt s [A ] and clutch cover [B]. Clut ch Cover I nstal la tio n • Replace the clutch cover gas [...]

CLUTCH 6-9 Clutch Cov er and Right Engine Cove r • Remove: Bolt [A] Right Engine Guard [B] • Remove: W ater Pump Cover (see W ater Pump Cover Removal in the Cooling System chapter) Clutch Cover Bolts [ A] Right Engine Cover Bolts [B] Right Engine Cover [ C] Right Engine Cover I nstallation • Install the dowel pins [A ]. • Replace the right [...]

6-10 CLUTCH Clutch C over and Rig ht Engine Co ver • Remove the vinyl tape from the kick shaft. • Instal l: W ater Pump Cover (see W ater Pump Cover Instal lation in the Cooling System chapter) Brake Pedal (see Brake Pedal Installation in the Brakes chapter) Oil Fi lter (see Oil Filter Change in the Periodic Mainte- nance chapter) Kick Pedal (s[...]

CLUTCH 6-1 1 Clutch Clutch Removal • Drain the engine oil ( see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] • Remove: Push Rod Holder Assembly [A] Steel Bal l Fricti on Plates [B] Steel Plates [C] • Hold the clutch [...]

6-12 CLUTCH Clut ch • Install the clutch housing [A]. ○ T urn the kickstarter idle gear and oil pump idle gear with a suitable tool [B] to fit in the clutch housing. • Instal l: Thrust W asher [A] Clutch Hub [B] • Hold the clutch hub with the clutch holder [A]. Special T ool - Clutc h Holder: 57001- 1243 • Install the toothed washer [B]. [...]

CLUTCH 6-13 Clutch • If a clutch part was replaced, install the standard adjusting washer (1. 5 mm t hickness) [A] of the push rod holder as- sembly , and check the rel ease lever position as explained later procedure. • Install the clutc h spring plate and clutch springs. • T ighten the clutch spring bolts while holding the c lutch housing w[...]

6-14 CLUTCH Clut ch Release Shaf t Removal • Remove: Clutch (see Clutch Removal) Clutch Cable Upper End ( see Clutch Cable Removal) • Remove the tip [A] of the clutch cable. • Pull out the release shaft assembly [B]. Release Shaft Insta llation • Apply engine oil to the needle bearings [A]. • Replace the oil seal [B] wit h a new one (see [...]

CLUTCH 6-15 Clutch Friction P late/Cl u tch Housing Cleara nce Insp ectio n • Measure the clearance between the tangs [ A] on the fric- tion plate and the finger s [B] of the clutch housi ng. If this c learance is excessiv e, the clutch will be noisy . If the clearance exceeds the service limit, replace the fric- tion pl ates. Friction Plate/Clut[...]

[...]

ENGINE L UBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 7-2 Lubricati on System Chart ....... ......... ........ ............ . .... ...... ........ ............ ......[...]

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·lb Remarks 1 Oil F ilter Cap Bolts 9.8 1.0 87 in·lb 2 Piston Oil Nozzle 2.9 0.30 26 in· lb 3 Breather Fitting 15 1.5 11 4 Oil Pump Idle G ear Shaft Screws 5.9 0.60 52 in· lb L 5 Oil Pum p Mounting B olts 7. 0 0.71 62 in·lb L 6 Engine Oil Dra in Bolt 20 2.0 15 EO:[...]

7-4 ENGINE LUBRICA TION SYSTEM Lubrication System Cha rt[...]

ENGINE LUBRICA TION SYSTEM 7 -5 Lubrication System Chart 1. Oil S creen (Scavenge) 2. Oil Shower to Tr ansmission 3. Piston O il Nozzle 4. Breather Hose 5. Oil Filter 6. Oil Screen (Feed) 7. Oil P ump (Scavenge) 8. Oil Pump ( Feed) 9. Kick Start er Idle Gear A: Crank Room Oil B: T ransmission Room Oil C: Blowby Gas D: Engine Oil[...]

7-6 ENGINE LUBRICA TION SYSTEM Specification s Item Standard Engine Oil Ty p e Castrol “POWER 1 R4 Racing” 5W -40 or API SG, SH, SJ, SL or SM wi th JASO MA, MA1 or MA2 Vi sc o s i t y SAE 10W -30, 10W-40, or 10W-50 Capacity 0.75 L (0.79 US qt) (when filter is not removed) 0.80 L (0.85 US qt) (when filter is removed) 1.00 L (1.06 US qt) (when en[...]

ENGINE L UBRICA TION SYSTEM 7-7 Special T ools Oil Pressur e Gauge, 5 kgf /cm²: 57001-1 25 Outside C irclip P liers: 57001-1 44 Oil Pressure Gauge Adapter , M6 × 1.0: 57001- 1664[...]

7-8 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter W ARNIN G V ehicle operation with insufficient, deterior ated, or contaminated engine oi l w ill cause accel erated wear and may result in engine seizure, accident, and injury . Check the oil level before each use and change the oil and filter according to the periodic maintenance chart. The [...]

ENGINE LUBRICA TION SYSTEM 7 -9 Engine Oil and O il Fil ter Oil Filter Replacement • Refer to the Oil Filter Replacement in the Periodic Main- tenance chapter . Oil Screen Cleaning and Inspection Oil Screen (Feed) • Split the crankcase (see Crankcase Disassembly in the Crankshaft/T ransmission chapter). • Remove the oil screen (feed) [A]. Lef[...]

7-10 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter Oil Screen (S cavenge) • Remove the magneto cover (see Magneto Cover Re- moval in t he Electrical System chapter). • Remove the oil screen (scavenge) [A]. • Clean the oil screen with a high flash-point solvent and remove any particles stuck to them. W ARNIN G Gasoline and low flash-poi[...]

ENGINE L UBRICA TION SYSTEM 7-1 1 Oil Pump Oil Pump Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Draining in the Cooling S ystem chapter) • Remove: Brake Pedal (see B rake Pedal Removal in the Brakes chapter) Kick Pedal (see Kick Pedal R emoval in the Crank- shaft/T ransmission c[...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pump • Disassemble the oil pump assembly . Pins [A] Oil Pump Cover [B] Inner [C] and Outer [D] Rotors (Feed) Oil Pump Body [E] Oil Pump Gear [F] Oil Pump Install ation • Apply moly bdenum disulfide grease to the shaft of the oil pump gear . • Apply engine oil to the inner and outer rotors. • Assemble: Oil[...]

ENGINE LUB RICA TION SYS TEM 7-13 Oil Pump • Apply engine oil t o the shaft of the oil pump idle gear [A]. • Install the oil pump idle gear . • T urn [B] the oil pump i dle gear to check that the oi l pump operates smoothly . • Replace the circli p [C] with a new one. • Install t he new circlip. Speci al T oo l - O utside Circlip Pli ers:[...]

7-14 ENGINE LUBRICA TION SYSTEM Oil Pressure Oil Pressure Measureme nt • Remove the water pump cover bolt. • Install the oil pressure gauge adapter [A] to the water pump cover . Special T ool - Oil Pressure G auge Adapter , M6 × 1.0 : 57001-1 664 • Attach the oil pressure gauge [A]. Special T ool - Oil Pr essure Gauge, 5 kgf/cm² : 57001-1 2[...]

ENGINE REMOV AL/INST ALLA TION 8-1 8 Engine Removal/Installation T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 8-2 Spec ial T ools . .... .... .... .... .... .... ....... .... .... .... .... .... .... ..... ...... ....[...]

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·lb Rem ark s 1 Upper Engine M ounting Bolts 49 5.0 36 S 2 Upper Engine Bracket Bolts 29 3.0 21 S 3 Middle Engine Bracket Nuts 29 3.0 21 R, S 4 Middle Engine Mounting Nut 49 5.0 36 R, S 5 Lower Engine Mounting N ut 49 5.0 36 R, S 6 Swingarm Pivot S haft N ut 98 10.[...]

8-4 ENGINE REMOV AL/INST ALLA TION Special T o ols Jack: 57001- 1238 Jack At tachm ent: 57001-1 608[...]

ENGINE REMOV AL/INST ALLA TION 8-5 Engine Re moval/Insta llation Engine Removal • Remove the engine guards. • Place the jack under the frame t o suppor t t he motorcycle. Speci al T ool s - Jac k: 5700 1-123 8 Jack Attac hment: 57001-1608 WA R N I N G When the swingarm pivot shaft is removed the swingarm and rear wheel assem bly will becom e de[...]

8-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Rear Frame ( see Rear Frame Removal in the Frame chapter) Exhaust Pipe ( see Exhaust Pipe Removal in the Engine To p E n d c h a p t e r ) Fuel T ank (see Fuel T ank Rem oval in the Fuel System (DFI) chapter) Radiators and Water Hoses (see Radiator Removal in the Cooling Sys[...]

ENGINE REMOV AL/INST ALLA TION 8-7 Engine Re moval/Insta llation • Disconnect the water temperature sensor connect or [A]. • Remove the following parts on both sides: Upper Engine Bracket Bolts [B] Upper Engine Mounting Bolts [C] and Nuts Upper Engine Brackets [D] • Remove: Middle Engine Bracket Bolts [A] and Nuts Middle Engine M ounting Bolt[...]

8-8 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Insert the swingarm pi vot shaft from the right side. • Install a ll engine bracket s, bolts and nuts temporari ly . ○ Insert the following bolts from left side: Middle Engine Mounting Bolt [A] Middle Engine Bracket Bolts [B] Lower Engine M ounting Bolt [C] • Install the s win[...]

CRANKSHAFT/TR ANSMISSION 9-1 9 Crankshaft/T ransmission T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 9-2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .[...]

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

CRANKSH AFT/TRANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf· m ft·l b Remarks 1 Primary Gear Nut 98 10.0 72 Lh, R 2 Reed V alve Screws 7.0 0.71 62 in·lb 3 Crankcase Bearing Retainer Screws 15 1.5 11 L 4 Piston Oil Nozzle 2.9 0.30 26 in·lb 5 Crankcase Bolts (L = 50 mm) 9.8 1.0 87 i n·lb S 6 Crankcase Bolt (L = 65 mm) 9.8 1.0 87 in?[...]

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

CRANKSH AFT/TRANSMISSION 9-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Kick Ratchet Guide Bolt 8.8 0.90 78 in·lb L 2 Kick Pedal Bolt 25 2.5 18 L 3 Shift Drum Cam Bolt 24 2.4 18 L 4 Gear Positioning Lever Nut 8.8 0.90 78 in·lb 5 Ratchet Plate Bolt 9.8 1.0 87 in·l b L, S 6 Ratchet Plate Screw 15 1.5 11 L, S 7 Shift Pedal B ol[...]

9-6 CRANKSHAFT/TRANSMISSION Specification s Item Standard Service L imit Crankshaft, Connecting Rod Connecting Rod Big End: Radial Clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.00055 in.) 0.06 mm (0.0024 in.) Side C learance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) 0.6 mm (0.02 in.) Crankshaft Runout TIR 0.03 mm (0.001 in.) or less TIR 0. 08 mm (0.00[...]

CRANKSHAFT/TR ANSMISSION 9-7 Special T ools and Sealan t Bearing P uller: 57001-1 35 Outside C irclip P liers: 57001-1 44 Bear ing Dri ver Set: 57001-1 129 Cran ksh aft Jig: 57001-1 174 Crank case Splitting T ool Assembly : 57001- 1362 Gear Hold er , m2.0: 57001- 1557 Liqui d Gaske t, TB 1216: 92104- 1063[...]

9-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Removal in the Engine Removal/Installat ion chapter). • Set the engi ne on clean surfac e while parts ar e being re- moved. • Remove: Piston (see Piston Removal in t he Engine T op End chap- ter) Right Engine Cover (see Right Engine Cove[...]

CRANKSH AFT/TRANSMISSION 9-9 Crankcase • Attach the crankcase splitting tool [A] to the left crankcase. ○ Adjust the gap with suitable collars or nuts [B]. Speci al T ool - Cran kcase S plittin g T o ol A ssembly: 5 7001 -1362 • T ighten the center bolt to split the crank case halves. ○ The front and rear portion of the crankcas e m ust be [...]

9-10 CRANKSHAFT/TRANSMISSION Crankcase • Support the crankcase bear ing boss with a suitable re- tainer [A]. • Install the new bearing [B] with a press and the bearing driver set [C]. Special T ool - Beari ng Driver Set : 57001 -1 129 NOTICE Support the crankcase bearing boss w hen the bear- ing is pressed, or the crankcase could be damaged. Le[...]

CRANKSHAFT/T RANSMISSION 9-1 1 Crankcase • Press the new output shaf t oil s eal [A] so that the oil seal surface is flush with the crankcase surface. ○ T urn the metal side to outside of the engine. • Press the new shift shaft oil seal [B] so that the oil seal surface is flush with the crankcase surface. Speci al T oo l - B earing Driver Se [...]

9-12 CRANKSHAFT/TRANSMISSION Crankcase • Press t he new shif t drum ball bearing [ A] and new output shaft bearing [ B] so t hat the sealed side [ C] faces outside of the engine. Special T ool - Beari ng Driver Set : 57001 -1 129 • Install the right crankc ase bearing retainers. ○ The right crankcase bear ing retainers ar e larger than left o[...]

CRANKSHAFT/TR ANSMISSION 9- 13 Crankcase • Install: Crankshaft (see Crankshaft Installation) T ransmission Shafts ( see T ransmission Shaft Ins talla- tion) • Install the oil screen (feed) [A] so that the shorter pipe side faces upward. • Position the connecting rod in BDC. • Install the crankshaft jig [B] bet w een the crankshaft fly- whee[...]

9-14 CRANKSHAFT/TRANSMISSION Crankcase • Install the gear posi tioning lever and shift drum cam (see External Shift Mechanism Installation). • Check to see that gears shift smoothly from 1st to 5th gear , and 5th to 1st while spinning the output shaf t. • Set the shift drum in the neutral position. • Replace the O-rings [A] on the output sh[...]

CRANKSHAFT/TR ANSMISSION 9- 15 Cran kshaf t Crankshaft Removal • Split the crankcase (see Cr ankcase Disassembly). • Remove the transmission shafts and shift drum (see T ransmission Shaft Removal). • Usi ng a pre ss , remove th e cr anks ha ft [A] fr om t he ri ght crankcase. If t he bearing stay on the c rankshaft when spl i tting the crankc[...]

9-16 CRANKSHAFT/TRANSMISSION Crankshaft • Carefull y align the oil passage hole in the right flywheel [A] with the one in the crankpin [B] at rebuildin g of the crankshaft. • Reassemble the crankshaf t according to the standard tol- erances in Specifications. ○ Connecting rod bend, twist (see Connecting Rod Bend Inspection , Connecting R od T[...]

CRANKSHAFT/TR ANSMISSION 9- 17 Cran kshaf t • First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass hammer . • Recheck the runout with a dial gauge and repeat the process until the r unout falls wi thin the service limi t. • Next, co rrect the vertical misalignment by either dr[...]

9-18 CRANKSHAFT/TRANSMISSION Crankshaft Connecting Ro d Bend Inspection • Remove the connecting rod. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connec t- ing rod big end. • Select an arbor [B] of the same diameter as t he piston pin and more than 105 mm ( 4.13 in. ) long, and i[...]

CRANKSHAFT/TR ANSMISSION 9- 19 T ransmi ssion T ransmission Shaft Removal • Split the crankcase (see Cr ankcase Disassembly). • Pull out th e shift rods [A], and remov e the shift forks [B]. • Remove the shift drum [C]. • Pull out the driv e shaft [D] and output shaft [E] t ogether . T ransmission Shaft Installati on • Apply engine oil to[...]

9-20 CRANKSHAFT/TRANSMISSION T rans mission Tra nsmission Shaft A ssembly • Apply engine oil liberally to the transmission shaft, gears and bearings. • Replace any circl ips that were removed with new ones. ○ Always i nstall the circli ps [A] so that the opening [B] is aligned with a spline groove [C], and install toothed wash- ers. T o insta[...]

CRANKSHAFT/TR ANSMISSION 9- 21 T ransmi ssion 1. Circlip ( Small) 2. T oothed Was her 3. Circlip (Large) 4. Ball Beari ng (Left Crankcase, One side sealed) 5. 2nd G ear (16T) 6. Bushing 7. 4th Gear (17T) 8. 3rd Gear (18T) 9. 5th Gear (22T) 10. Drive Shaft (1st Gear , 14T) 1 1. Ball Bearing ( Right Crankcase) 12. Output Shaft 13. Ball Bearing (Left [...]

9-22 CRANKSHAFT/TRANSMISSION T rans mission Shift Fork/Gear Groove Wear Inspection • Measure the thickness [A] of the s hift fork ear s, and mea- sure the width [B] of the gear grooves (with which the fork engages). Shift Fork Ear Thickness Standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) Service Limit: 4.8 mm (0. 189 in.) Gear Groove Width Standar[...]

CRANKSHAFT/TR ANSMISSION 9- 23 Primary Gear Primary Gear Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Clutch (see Clutch Removal in the Clutch chapt er) • T emporarily install the clutch housing [A], clutch hub [B], toothed washer and clutch hub nut [C]. • Hold the primary gear [D] with the gear [...]

9-24 CRANKSHAFT/TRANSMISSION External Shift Mec hanism Shift Ped al Removal • Remove: Shift Pedal Bolt [ A] Shift Pedal [B] Shift Pedal Installation • Install the shift pedal so that the slit [A] on the pedal aligns with the punch m ark [B] on the shift shaft. • T ighten: T orque - Shift Pedal Bolt [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Exte r[...]

CRANKSHAFT/TR ANSMISSION 9- 25 External Shift Mecha nism • Remove: Pin [A] Gear Positioning Lever [B] Collar [ C] Spring [D] External Shift Mechanism Install ation • Install: Pin [A] Spring [B] Collar [ C] Gear Positioning Lever [D] W asher • T ighten: T orque - Gear Positioning Lever Nut: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Hold the gear p[...]

9-26 CRANKSHAFT/TRANSMISSION External Shift Mec hanism • Install the s hift ratchet assembl y [A] and ratchet plate [B] as a set. • Apply a non-permanent locking agent to the ratchet plate screw and bolt. • T ighten: T orqu e - Ratchet P late Scr ew [C]: 15 N·m (1.5 kgf· m, 1 1 ft· lb) Ratchet P late Bolt [D]: 9.8 N·m (1.0 kgf·m, 87 i n?[...]

CRANKSHAFT/TR ANSMISSION 9- 27 External Shift Mecha nism • Check the shift ratchet assembly for any damage. If the r atchet [A], pawls [B], pins [C] or springs [D] ar e damaged in any way , replace them. • Visual ly inspect the shift drum cam [A]. If it is badly worn or if it shows any damage, r eplace it. • Check the gear positioning l ever [...]

9-28 CRANKSHAFT/TRANSMISSION Kickst arter Kick Pedal Removal • Remove: Kick P edal Bolt [A] and W asher Kick Pedal Assy [B ] Kick Pedal Installation • Install the kick pedal assy . ○ Put the pedal end [A] near the cylinder head cover m ating sur face [B] . • Apply a non-permanent locking agent to the threads of the kick pedal bolt. • Inst[...]

CRANKSHAFT/TR ANSMISSION 9- 29 Kickstarter Kick Shaf t Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Clutch (see Clutch Removal in the Clutch chapt er) Kickstart er Idle Gear [A] • Pull the spring end [B] out of the hole. • T urn the kick shaf t counterclockwise [C] and pull out the kickstart er a[...]

9-30 CRANKSHAFT/TRANSMISSION Kickst arter • Apply mol ybdenum disulfi de grease [A] to the kick gear , ratchet gear and kick shaft. • Replace the cir clips that were removed with new ones. Special T ool - Outside Circli p Pliers: 570 01-144 NOTE ○ When assembling the ratchet gear [A] onto the kick shaft [B], align the punch mark [C] on the ra[...]

CRANKSHAFT/TR ANSMISSION 9- 31 Bearings/Oil Seals Bear ing Rep lac eme nt NOTICE Do not remove the ball or needle bearings unless it is necessary . Removal may damage them. • Using a press or pu l ler , remove the ball bearing and/or needle bearings. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by h[...]

9-32 CRANKSHAFT/TRANSMISSION Bearin gs/Oil S eals • Inspect the needle beari ngs. ○ The rollers in a needle bearing normally wear very little, and wear is diffi cult t o measure. Instead of measuring, inspect the bearing f or abrasion, color change, or other damage. If ther e is any doubt as to the conditi on of a needle bear- ing, replac e it.[...]

WHEELS/TIRES 10-1 10 Wheels/T i res T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 10- 2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... ..... ...[...]

10-2 WHEELS/TIRES Exploded View[...]

WHEELS/TIRES 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Spoke Nipples Not less than 2.2 Not less than 0.22 Not less than 19 in·lb 2 Front Axle Nut 78 8.0 58 3 Front Axle Clamp Bolts 20 2.0 15 AL, S 4 Rear Axle Nut 108 11 . 0 79.7 AL: T ighten the two clamp bolts alter nately two times to ensure even tightening torque. HG[...]

10-4 WHEELS/TIRES Specification s Item Standard Service Limit Wheels (Rims) Rim Size: Front 21 × 1.60 ––– Rear 19 × 1.85 ––– Rim Runout: Axial TIR 1.0 mm (0 .04 in.) or l es s TIR 2.0 mm (0.08 in.) Radial TIR 1.0 mm (0 .04 in.) or l es s TIR 2.0 mm (0.08 in.) Axle Runout/100 mm (3.94 in.) T IR 0.03 mm (0.001 in.) or less TIR 0.2 mm (0[...]

WHEELS/TIRES 10-5 Special T ools Inside Circli p Pliers: 57001-1 43 Rim Protec tor: 57001-1 063 Bead Brea ker Assembly: 57001-1 072 Bear ing Dri ver Set: 57001-1 129 Jack: 57001-1 238 Bearin g R emover Head, 20 × 22: 57001- 1293 Bearin g R emover Head, 25 × 28: 57001- 1346 Bearin g Remover S haft, 13 : 57001- 1377 Jack Attachmen t: 57001- 1608[...]

10-6 WHEELS/TIRES Wheels (Rims) Fron t Wheel Rem ov al • Remo ve the a xl e nut [A ]. • Loosen the axle clamp bolts [B] on both sides. • Raise the front wheel off the ground with jack. Special T ools - J ack: 570 01-12 38 Jack Attach ment: 57001-1608 • Pull out the axle and remove the wheel. • Remove the collars [A] with caps [B] on both [...]

WHEELS/TIRES 10-7 Wheels (Rims) • Pump the front f ork up and down [A] 4 or 5 ti mes to ali gn both fork posit ions. NOTE ○ Put a block [B] in front of the wheel to stop moving. ○ Do not apply the front brake. • T ighten: T orque - Front Axle Clamp B olts (Right): 20 N·m (2.0 kgf·m, 15 ft·lb) NOTE ○ Tighten the two clamp bolts alternat[...]

10-8 WHEELS/TIRES Wheels (Rims) • Remove the cott er pin [A], rear axle nut [B] and washer [C]. • Pull out the axle [D], and remove the chain adjuster [E] on both sides. • Disengage the drive chain fr om the rear sprocket. • Remove the rear wheel. • Remove the collars [A] with caps [B] on both sides. NOTICE Do not lay the wheel on the gro[...]

WHEELS/TIRES 10-9 Wheels (Rims) • Install t he rear wheel. • Engage the drive chain with the rear sprocket. • Install the chain adjusters on the swingarm. Adjuster [A] (Left Side) Flat Adjuster [B] (Right Side) • Insert the ax l e from left side, and tighten the ax l e nut. T orqu e - Rear Axle Nut: 108 N·m (1 1.0 kgf·m, 79.7 ft·lb) • [...]

10-10 WHEELS/TIRES Wheels (Rims) Rim Installation Position • When installing the rim, set the rim f ollowing position. ○ The distance [A] from the brake disc seating sur face [B] of the front hub [C] to left end of the front rim [D] should be as follows. View from Front [E] Distance: 26.8 ± 0.5 mm (1.06 ±0.020 in.) ○ The distance [A] from t[...]

WHEELS/TIRES 10-1 1 Tir es Air Pressure Inspection/Adjustme nt • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter . Tir e Re m o v a l • Remove the wheel (see Front/Rear Wheel Removal). NOTICE Do not lay the wheel directly on the ground with the disc f acing down. This can damage or warp the disc. Place bloc[...]

10-12 WHEELS/TIRES Tire s • Break the beads away f rom bot h sides of the r im wit h the bead breaker [A]. Special T ool - Bead Breaker Assemb ly: 570 01-10 72 • Lubricate the ti re irons [A] (includ ed i n Bead Breaker As- sembly: 57001- 1072) and rim protectors [B] with soap and water solution or r ubber lubricant. Special T ool - Rim Pro tec[...]

WHEELS/TIRES 10- 13 Tir es • Position the tire on the rim so that the air valve [A] is at the tire balance mark [B] (the chalk mark made duri ng removal). ○ The new tire is no marked. • Insert the valve stem into the rim, and screw t he nut on loosely . • Fit t he rim protectors and use tire irons to install the tire bead. Speci al T ool s [...]

10-14 WHEELS/TIRES Hub Bearing Fron t Hub Bea ri ng Remova l • Remove: Front Wheel (see Front Wheel Removal) Grease Seals [A] • Use the b earing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the di sc facing down. This can damage or warp the disc. Place wooden blocks unde r the w heel so that t he disc d[...]

WHEELS/TIRES 10- 15 Hub Bearing • Using a suitable bar [ A], tap the around of the bearing inner race evenly to remove t he bearings [B]. Hub B ea ring In sta llat ion • Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compr essed ai r to prevent contamination of the bearings. • Replace the bearings w[...]

10-16 WHEELS/TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance canno t normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings ar e removed, they will need to be replaced with new ones. • T urn each bearing in the hub back and forth [A] while[...]

FINAL DRIVE 1 1-1 11 Final Drive T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 1 1-2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... ..... .... .[...]

1 1-2 FINAL DRIVE Exploded View[...]

FINAL DRIVE 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Rear Sprocket Nuts 34 3.5 25 R HO: Apply heavy oil. L: Apply a non-permanent locking agent. R: Replacement Parts[...]

1 1-4 FINAL DRIVE Specification s Item Standard Serv ic e Lim it Drive Chain Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) ––– Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make DAI DO ––– Ty p e DID 520DMA4 ––– Link 1 14 links ––– Sprocket Rear Sprocket W arp TIR 0 .4 mm (0. 01[...]

FINAL DRIVE 1 1-5 Special T oo l Outside Circlip Pliers: 57001-1 44[...]

1 1-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Dr ive C ha in S lac k Adju st me nt • Refer to the Drive Chain Sla ck Adjustment in the Periodic Maintenance chapter . Wheel A lignment Inspection • Check that the n otch [A] of the chain adjuster [B] a[...]

FINAL DRIVE 1 1-7 Drive Chain Drive Chain Installation • Fit the drive chain onto the sprocke ts. ○ Place the drive chain ends on the rear sprocket. • Install the master link [A] from the wheel side. • Install the link plat e [A] so that the mark faces out. • Install the clip [B] so t hat the c losed end [C] of the “U” pointed in the [...]

1 1-8 FINAL DRIVE Sprockets Engine Sprocke t Remova l • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Drive Chain Guide [C] • Remove: Circlip [A] Special T ool - Outside Circli p Pliers: 570 01-144 • Remove the engine s procket [B] f rom the dri ve chain [C]. Engine Sprock et I nstallation • Engage the drive chain [A] to[...]

FINAL DRIVE 1 1-9 Sprocket s • Remove: Rear Sprocket Bolts [A] and Nuts W ashers Rear Sprocket [B] Rear S pr ocke t Insta ll ation • Replace the rear sprocket nuts with new ones. • Install the rear sprocket [A] so that the marked side [B] faces out. • Install the rear sprocket bolts and washers. • T ighten: T orqu e - Rear Sproc ket N uts[...]

[...]

BRAKES 12-1 12 Brakes T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 12- 2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... ..... .... ...... .... [...]

12-2 BRAKES Exploded View[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Rem ark s 1 Brake Hose Banjo Bolts 25 2.5 18 2 Front Brake Reservoir Cap Screws 1.5 0.15 13 in· l b 3 Front Master Cylinder Clamp Bolts 8.8 0.90 78 in· l b S 4 Brake Lever Pivot Bolt 5.9 0.60 52 in· l b Si 5 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 i n·lb 6 Front Brake Disc Mo[...]

12-4 BRAKES Exploded View[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rem ark s 1 Brake Hose Banjo Bolts 25 2.5 18 2 Rear Brake Reservoir Cap Bolts 1.5 0.15 13 in·l b 3 Rear Master Cylinder Mounting Bolts 9.8 1.0 87 in·l b 4 Rear Master Cylinder Push Rod Lockn ut 17 1.7 13 5 Brake Pedal Bolt 25 2.5 18 G, L 6 Rear Caliper Holder Shaft 27 2.8 20 Si 7 R[...]

12-6 BRAKES Specification s Item Standard Service Limit Brake Lever Lever Free Play Adj ustable (to suit rider) ––– Brake Fluid Grade: Front DOT3 or DOT4 ––– Rear DOT3 or D OT4 ––– Brake Pads Lining Thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.) Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.) Brake Discs Thickness: Front 2.85 ∼ 3.15 [...]

BRAKES 12-7 Special T ools Jack: 57001-1 238 Jack Attachmen t: 57001- 1608[...]

12-8 BRAKES Brake Lever , Brake Peda l Brake Lever Play Adjustment • Refer to the Brake Lever and Pedal Adjustment in the Periodic M aintenance chapter . Br ake Ped al Positio n Adjus tm ent • Refer to the Brake Lever and Pedal Adjustment in the Periodic M aintenance chapter . Brake Pedal Removal • Remove: Cotter Pin [A] Joint Pin [B] W asher[...]

BRAKES 12-9 Brake Le ver , Brake Pedal • Replace the cotter pin w ith a new one. • Install the joint pin, washer and new cotter pin. • Bend the ends [A] of the cotter pin. • Check the brake pedal position (see Brake Lever and Pedal Adjustment in the Periodic Mai ntenance chapter).[...]

12-10 BRAKES Brake Fluid W ARNIN G 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 for a long time. 3. Do not mix two types and brands of fluid f or use in the brake. This lowers t he brake fluid boiling p[...]

BRAKES 12-1 1 Brake Fluid Brake Line B leeding The brake flui d has a very low compres sion coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air , however , is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in [...]

12-12 BRAKES Brake Fluid • Bleed the brake line and caliper as follows: ○ Repeat this oper ation until no more air can be seen com- ing out into the clear plastic hose. 1. Pump the brake lever until it beco m es hard, and apply the brake and hold it [ A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release [...]

BRAKES 12-13 Caliper Caliper Remov al Front Bra ke • Loosen the brake pad pin [A] before the caliper [B] re- moval if the caliper is to be disassembled. • Loosen the banjo bolt [C] so as not to spi ll brake fluid. NOTE ○ If the caliper is to be disassembled after removal and compressed air is not available, disassemble the caliper before brak[...]

12-14 BRAKES Caliper Caliper Installation • Install the br ake pad if it was r emoved (see Brake Pad Install ation). Front Brake • Install the caliper and tighten the bolts. T orque - Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 f t·lb) Rear Brake • Install the rear wheel and caliper (see Rear Wheel Instal- lation in the Wheels/T ir[...]

BRAKES 12-15 Caliper Fluid Seal Damage Inspection The fluid seal(s) [A] around the piston maintains the proper pad/disc clearance. If this seal is not in good condi- tion, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. • Replace the f luid seals under any of the following condi- tions. ○ [...]

12-16 BRAKES Caliper Caliper Piston and Cylinder Damage I nspection • V isually inspect t he piston(s) [A] and cylinder surfaces. Replace the ca liper if the cyli nder and piston are badly scores or rust y . Front Caliper [B] Rear Calipe r [C] Caliper Holder Shaft Wear Inspecti on The caliper body must slide smoothly on the c aliper holder shafts[...]

BRAKES 12-17 Brake Pad Brake Pad Removal Front Bra ke • Remove the pad pin [A]. • Rem ove the pis ton s ide p ad [B]. • Push the caliper holder toward the pi ston, and then re- move another pad [C]. Rear Brake • Remove: Pad Pin Plug [A] • Remove the pad pin [A]. • Rem ove the pis ton s ide p ad [B]. • Push the caliper holder toward th[...]

12-18 BRAKES Brake Pad • T ighten the brake pad pin. T orque - Brake Pa d Pin: 17 N·m (1.7 kgf·m, 13 ft·lb) Rear Brake Pad Pin Plug: 2.4 N·m (0.2 4 kgf·m, 21 in·lb) • Check the brake for good braking power , no brake drag, and no fluid leakage. W ARNIN G After servicing, it takes several applications of the brake lever or pedal before the[...]

BRAKES 12-19 Master Cylinder NOTICE Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely washed up imm ediately . Front Mas ter Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose upper end [B] from the master cylinder [C]. ○ When removing the brake hose, temporarily secure the en[...]

12-20 BRAKES Master Cylinder • The master cylinder clamp m ust be inst alled w ith the ar- row mark [A] upward. • T ighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. ○ There will be a gap at the lower mating surface of the clamp after tightening. T orque - Fr ont Master C ylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m, 7 8[...]

BRAKES 12-21 Master Cylinder • Replace the cotter pin w ith a new one. • Install the joint pin, washer and new cotter pin. • Bend the ends [A] of the cotter pin. • Check the brake pedal position (see Brake Lever and Pedal Adjustment in the Periodic Mai ntenance chapter). • Bleed the brake line (see Brake Line Bleeding). • Check the brak[...]

12-22 BRAKES Master Cylinder Master Cylinder Inspection (V isual Inspection) • Disassemble the front and rear master cylinders. • Check t hat ther e are n o scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B]. If a master cyli nder or piston shows any damage, replace them. • Inspect t[...]

BRAKES 12-23 Brake Disc Brake D isc Remov al • Remove the wheels (see Front/Rear Wheel Rem oval in the Wheels/T ires chapter). • Remove the mounting bolts, and take off the di sc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] f aces out. • Apply a non-permanent locking agent to t he thread s of th[...]

12-24 BRAKES Brake Hose Brake Hose Removal /Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter . Brake Hose Inspection • Refer to the Brake Hoses and Connections Inspection in the Periodic Maintenance chapter .[...]

SUSPENSION 13- 1 13 Suspension T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 13- 2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... ..... .... ...[...]

13-2 SUSPENSION Exploded View[...]

SUSPENSION 13 -3 Exploded View T orque No. Fastener N·m kgf ·m ft ·lb Remarks 1 Air P ressure Relief Screws 1.3 0.13 12 in·lb 2 Left Front Fork Base V alve Assembly 30 3.1 22 3 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L 4 Front Fork Clamp Bolts (Lower) 22 2.2 16 AL 5 Right Front Fork Spring Preload Adjuster 30 3.1 22 6 Left Front Fork Cylin[...]

13-4 SUSPENSION Exploded View[...]

SUSPENSION 13 -5 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Rear Shock Absorber Mounting Nut (Upper) 39 4.0 29 R 2 Rear Shock Absorber Mounting Nut (Lower) 34 3.5 25 R 3 T ie-Rod Mounti ng Nuts 59 6.0 44 R 4 Swingarm Pivot S haft Nut 98 10.0 72 R 5 Rocker Arm P ivot Nut 59 6.0 44 R 6 Gas Reservoir Dampin g Adjuster Assembly 29[...]

13-6 SUSPENSION Specification s Item Standard Service Limit Front Fork Air Pressure Atmospheric pressure ––– Rebound Damping A djustment (Left Fork only) (from the seated position adjuster turned fully clockwise) 10 clicks counterclockwise (EUR, BR) 12 clicks countercloc kwise (Adjustable Range) 20 ± 4 clicks Compression Damping Adjust m ent[...]

SUSPENSION 13 -7 Specifications Item Standard S ervi ce Lim it Low Speed Compression Damping Adjustment (from the seated position adjuster turn ed full y cloc kwis e) 12 clicks counterclockwise (Adjustable Range) 19 ± 6 clicks Gas Pressure 980 kPa (10.0 kgf/cm², 142 psi) ––– Tie-Rod, Rocker Arm Sleeve Outside Diameter: Ti e - R o d 19.987 ?[...]

13-8 SUSPENSION Special T o ols Oil Seal & B earing Rem over: 57001- 1058 Hook Wrench R37.5, R42: 57001- 1 101 Bearin g Drive r Se t: 57001- 1 129 Jack: 57001- 1238 Fork Oi l Seal Dri ver , 48: 57001-1 509 Hook Wrenc h T=3. 2 R37: 57001-1 539 Jack At tachm ent: 57001-1 608[...]

SUSPENSION 13 -9 Front Fork Air Pressure The standard ai r pressure in the front fork legs i s atmo- spheric pressure. Air pressur e in the fork legs increase with normal use, so the fork action stif fens during operation. R e- lease ai r pressure prior t o each r ace through the air pres- sure relief screw . • Place the jack under the frame so t[...]

13-10 SUSPENSION Front Fork Seated position [A]: adjust er turned fully clockwise. Comp ressio n Damp ing Ad just er Setti ng Standard: 8 click s [ B] (EUR, BR) 10 cl icks counterclockwise Softer (Counterclockwise) [C] Harder (Cloc kwise) [D] *: Although you can turn the adj uster beyond the ad- justable range, ef fecting no changes to damping forc[...]

SUSPENSION 13-1 1 Front Fork Seated position [A]: adjuster turned fully counterclock- wise. Spring Preload Adjuster Setting Standard: 15 clicks [B] (EU R, BR) 7 cli cks c loc kwis e Harder (Clo ckwise) [C] Softer (Counterclockwise) [D] *: Although you can turn the adjuster beyond the adjustable range, ef fecting no changes to spring preload, use it[...]

13-12 SUSPENSION Front Fork • Pull out the front fork downward with a twisting motion [A]. Front Fork Installation • Install the front fork. ○ The length [A] between the upper end [B] of the outer tube and steering stem head [C] is 5 mm (0.20 in.) . • Run the cables and hose according to the Cable, Wire, and Hose Routing section in t he App[...]

SUSPENSION 13- 13 Front Fork • Separate the inner tube [A] from the outer tube [B] as follo ws: ○ Slide up t he spring band [C]. ○ Slide up the dust seal [D]. ○ Remove the retaining ring [A] from the outer tube. ○ Grasp t he tubes and stroke the inner tube up an d down [A] several times. The shock t o fork seal separates the inner tube fr[...]

13-14 SUSPENSION Front Fork • When assembling the new outer tube bushings, washer and new oil seal [A], hold the oil seal against the new one, and tap the oil seal with the f ork oil seal driver [B] until it stops. Special T ool - Fork Oil S eal D river , 48: 5 7001-150 9 • Install the retainin g ring to t he outer tube. • Push the dust seal [...]

SUSPENSION 13- 15 Front Fork Adjuster Assembly Inspection • Inspect t he adjuster assembly [A] and push rod (left front fork only) [B] for damage. If they are damaged, replace them with new ones. • Replace the O-ring [C] on the adjuster assembly with a new one. Base V a lve Assembly Inspection • Inspect the threads portion [A] and spring [B] [...]

13-16 SUSPENSION Front Fork • T emporarily assemble the inner [A] and outer [B] tubes, and pump them back and forth manually to check for smooth operation. If you feel b inding or catching, the inner and outer tubes must be replac ed. W ARNIN G A straightened inner or outer fork tube may fall in use, possi bly causing an accident resulting in ser[...]

SUSPENSION 13- 17 Rear S hock Absorber T o suit to various riding conditions , the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional o ne. Also t he damping force can be adjusted easil y so changing oil viscosity unnecessary . Rebound D amping A djustment • T urn the rebound damping adjust er [A] [...]

13-18 SUSPENSION Rear Shock Absorb er • Adjust the high speed compression damping, turn the high speed compression dam ping adjuster with a wrench. If th e damping feels too soft or too stif f, adjust it in accor- dance with the following table. NOTICE Do not force the compression damping adjuster beyond the full y seated position, or the adjusti[...]

SUSPENSION 13- 19 Rear S hock Absorber Spring Preload Adjustment • Remove: Seat (see Seat Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter) Muff ler Body (see Muffler Body Removal in the Engine T op End chapte r) Rear Frame (see Rear Frame Removal in the Frame chapter) • Place the jack under th e frame so t[...]

13-20 SUSPENSION Rear Shock Absorb er Rear Shock Absorber Spring T ension Inspection • Since the spring becomes shorter as it weakens, check its free length [A] to determine its condition. Shock Absorber S pring Free Length Standard: 265 mm (10.4 in.) Service Limit: 260 mm (10.2 in.) If the free length falls below the service limit, replace the s[...]

SUSPENSION 13- 21 Rear S hock Absorber • Hold the upper end of the rear shock absorber in a vise with soft jaws [A] or a heavy cloth. • Using the hook wrenches [B], loosen the locknut [C] and turn the adjusting nut all w ay up. Speci al T ool s - Hook Wrench R3 7.5, R42: 57001 -1 101 Hook Wrench T=3. 2 R37 : 5 7001-153 9 • Slide the spring se[...]

13-22 SUSPENSION Rear Shock Absorb er Rear Shock Absorber Scrapping W ARNIN G Pressurized nitrogen may explode when heated. The rear shock contains nitrogen gas. T o avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve. • Remove the rear shock absorber (see Rear Shock Ab- sorber[...]

SUSPENSION 13- 23 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear W heel Rem oval in the Wheels/T i res chapter) Rear Flap (see Rear Flap Removal in the Frame chap- ter) Brake Pedal Bolt and Return Spring (see Brake Pedal Removal in the Br akes chapter) • Remove: Bolts [A] and Nuts Chain Guide Plate [B] Chain Guide [C] Screws [D] and B[...]

13-24 SUSPENSION Swingarm Swingarm Installa tion • Apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • Apply a non-permanent locking agent t o the chain slipper scr ews . • Install the chain sl ipper , and tighten the screws. • Replace with new ones: Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut • A[...]

SUSPENSION 13- 25 Swingarm Drive Chain G uide, Guide Roller , Chain Slipper Wear Inspection • Visual ly inspect the driv e chain guide [A] and replace it if excessively worn or damaged. • Visual ly inspect the upper and low er chain guide rollers [A] and replace them i f excessively worn or damaged. • Visual ly inspect the chain slipper [A] o[...]

13-26 SUSPENSION Tie-Rod, Rocker Arm Tie -Rod Removal • Place the jack under the frame so that the rear wheel is raised off the ground. Special T ools - J ack: 570 01-12 38 Jack Attach ment: 57001-1608 • Remove: Nut [A] Lower Chain Guide Roller [B] • Remove: Rear Ti e-Rod Mounting Bolt and N ut [A] Front T ie-Rod Mounting Bolt and Nut [B] T i[...]

SUSPENSION 13- 27 Tie-Rod, Rocker Arm • Remove: Rear Shock Absorber Bolt and Nut (Lower) [A] Rocker Arm Pivot Bolt and Nut [B] Rocker Arm [C] Rocker Arm Installation • Replace with new ones: Rear Shock Absorber M ounting Nut (Lower) Rocker Arm Pivot Nut T ie-Rod Mount ing Nut • Apply plenty of grease to t he needle bearings, oil seals and gre[...]

13-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Inst allation • Replace the needle bearings, oil seals and grease seals with new ones. • Apply plenty of grease to the oil seals, grease seals and needle bearings. NOTE ○ Install t he bearings so that the marked side faces out. ○ Install the oil seals so that the deep groov[...]

SUSPENSION 13- 29 Tie-Rod, Rocker Arm Needle Bearing Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect t he needle bearings installed i n the tie-r od and rocker arm. ○ The needle bearing normall y wear very little, and w ear is diff icult to measure. Instead of measuring, visually in- spect the b[...]

13-30 SUSPENSION Uni-T ra k Maintenance Uni-Trak Linkage Inspection • Refer to the Swingarm and U ni-T rak Linkage Inspection in the Periodic Maintenance chapter . Tie -Rod and Rocker Arm Sleeve W ear Inspe ction • Pull out the sleeves [ A] of the tie-rod and r ocker arm. • Measure the outside diameter of the sleeve. Sleeve O utside Di ameter[...]

STEERING 14-1 14 Steering T able of Con tents 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·lb Remarks 1 Handlebar Clamp Bolts 25 2.5 18 AL, 2T 2 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L 3 Steering Stem Head Nut 98 10.0 72 4 Handlebar Holder Nuts 34 3.5 25 R 5 Steering Stem Nut 4.9 0.50 43 in·lb T 6 Brake Hose Clamp Bolt 3.0 0.31 27 in·lb 7 Front Fork Clamp Bolts (Lo[...]

14-4 STEERING Special T o ols Bear ing Pu ller: 57001- 135 Steer ing Stem Be aring Dri ver: 57001- 137 Steerin g Stem Bearing Driver Adapter , 34 .5: 57001- 1074 Head Pip e Outer Race Press Shaf t: 57001- 1075 Head Pipe Out er R ace Driver , 51.5: 57001- 1076 Head Pipe Outer Race Driver , 54.5 : 57001-1 077 Steering Stem Nut Wrench: 57001-1 100 Hea[...]

STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter . Steering Adjustment • Refer to the Steering A djustment in the Periodic Mainte- nance chapter . Steering Stem, Stem Bearing Remova l • Remove: Number Plate [A] (see Number Plate Removal in the Frame chapter) Handlebar Pad [B] [...]

14-6 STEERING Steerin g • Remove the upper stem bearing inner race (tapered roller bearing) [A]. • Drive out the bear ing outer races from the head pipe. ○ Remove the outer races pressed into the head pipe, using the head pipe outer race remover [A], and hammer t he head pipe outer race remover to drive it out. Special T ool - He ad Pipe Oute[...]

STEERING 14-7 Steering • Replace the inner races with new ones. • Apply grease to the lower tapered roller bearing [A], and drive i t onto the stem with the steering stem bearing driver [B] and adapter [C]. Speci al T ools - St eering Stem Bearing Driver: 57 001-137 Steering Stem Bearing D river Adapter , 34.5: 57001-10 74 • Apply grease to t[...]

14-8 STEERING Steerin g • Install th e removed parts (see appropriate chapters) . T orque - Brake Hose Clamp Bolt: 3.0 N·m (0.31 kgf·m, 27 in·lb) W ARNIN G If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death. Be sure the cables, harnesses and hoses are routed properly and do not interfere w[...]

STEERING 14-9 Handlebars Handlebar Removal • Remove: Number Plate [A] (see Number Plate Removal in the Frame chapter) Handlebar Pad [B] Fuel T ank Breather Hose [C] • Remove: Clutch Lever Assembly [A] Engine Stop Switch [B] Band [C] Left Handlebar Grip [D] • Remove: Throttl e Grip Assy [A] (see Throttle Cable Replac ement in the Fuel System ([...]

14-10 STEERING Handlebars Handlebar Inst allation • Apply adhesive cement to the i nnermost area of the left handlebar grip and all-around inner surface of the left han- dlebar grip hol e entrance and also apply it to the roulet te area on the handlebars. • The lef t handlebar grip must be installed w ith the triangle mark [A] upward. ○ When [...]

STEERING 14-1 1 Handlebars • T ighten the handlebar clamp bolts [A]. ○ Equalize the front and rear gaps [B]. NOTE ○ Tighten the two clamp bolts alternatel y two t i mes to en- sure even ti ghtening torque. T orque - Handlebar Cla mp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install: Handlebar Pad [A] Fuel T ank Breather Hose [B] Number Plat [...]

[...]

FRAME 15-1 15 Frame T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 15- 2 Fram e ... ....... .... .... .... .... .... .... ....... .... .... .... .... .... .... ..... ...... .... .... .... .... .... ..... ...... .... ...[...]

15-2 FRAME Exploded View[...]

FRAME 15-3 Exploded View To r q u e No. Fastener N·m kgf ·m ft·l b Rem ark s 1 Footpeg Bracket Bolts (Upper) 54 5.5 40 L 2 Rear Frame Mounting Bolts 34 3.5 25 G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence.[...]

15-4 FRAME Fra me Frame Inspect ion • Refer to the Frame Inspection in the Periodic Mainte- nance chapter . Rear Frame Removal • Remove: Seat (see Seat Rem oval) Side Covers (see Side Cover Removal) Muffler Body (see Muffler Body Removal in t he Engine To p E n d c h a p t e r ) Rear Fender (see Rear Fender Removal) Rear Flap (see R ear Flap Re[...]

FRAME 15-5 Frame Engine Guards Removal • Remove the engine guards. Right Engine Guard [A] Left Engine Guard [B] Lower Engine Guard [C] Bolts [ D] Collars [E] Engine Guar d s Installa tion • Installat ion is the reverse of removal. ○ Fit the projection [A] of the right engine guard and hole [B] of the frame. ○ Fit the left engine guard simil[...]

15-6 FRAME Seat Seat Re mo val • Remove the side cover bolt [A] on both sides. • Spread [A] the side covers lightly . • T ake off the seat [B] backward [C]. Seat Inst allation • Install t he seat. ○ Insert the hooks [ A] of the seat under the flange coll ar [B] and brackets [C]. ○ T ake care not to dam age th e side covers with the brac[...]

FRAME 15-7 Side Covers Side Cov er Rem oval • Remove the bolts [A] a nd take off t he side cover [B]. ○ Clear the side cover tabs [C] from the air cleaner housing. Side Cov er Ins tallati on • Stick the pad [A] on the i nside of the right sid e cover . • Install the damper [B] securely . • Install the side covers. ○ Insert the t abs [A][...]

15-8 FRAME Radiator Shroud Radiator Shroud Removal • Remove: Bolts [A] Radiator Shroud [B] ○ Clear the radiator shroud tabs [C] from the air cleaner housing. Radiator Shroud Installation • Install the radiator shrouds. ○ Insert the tabs [A] of t he radiator s hroud into the slot s [B] of the air cleaner housing. • T emporarily i nstall th[...]

FRAME 15-9 Number Plate Number Pl ate Removal • Unlock the band [ A] of the number plate [B]. • Remove the bolt [C]. • Clear the project ions [D] and remove the number plate. Number Plat e Installat ion • Fit the holes [A] of t he number plate and projections [B] of the steering stem base. ○ Run the brake hose through the front of the num[...]

15-10 FRAME Fender Fron t Fender R emo val • Remove the bolts [A] and take off the f ront fender [B]. Front Fender Installation • T emporarily install the front bolts [A] first, and then the rear bolts [B ]. • T ighten all bolts securely . Rear Fender Removal/ Installation • R e m o v et h es i d ec o v e r s ( s e eS ide Cover Removal). ?[...]

FRAME 15-1 1 Footpegs Footpeg Removal • Remove: Cotter Pin [A] W asher [B] Pivot Pin [C] Spring [D] Footpeg [E] Footpeg Bracket Bolts [F] Footpeg Bracket [G] Footpeg Installation • Replace the cotter pin w ith a new one. • Apply a non-permanent locking agent to the footpeg bracket bolts [A]. • Install the foot peg bracket [B], and tight en [...]

[...]

ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Con tents Exploded V iew .......... .......... ......... ...... . ..... .......... ..... ...... ...... . ..... . ..... ......... ...... ...... ...... . ..... .. .... . 16- 2 Spec ific ati ons ...... .... .... .... .... .... ..... ...... .... .... .... .... ..... .... ...... .... .... .... .... .[...]

16-2 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYS TEM 16-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Regulator/Recti fier Nuts 10 1.02 89 in·lb R 2 Spark Plug 13 1.3 11 5 i n · l b 3 Flywheel N ut C ap 3.5 0.36 31 in·lb 4 Magneto Cover B olts 9.8 1.0 87 in·lb 5 T iming Inspection C ap 3.5 0.36 31 in·lb 6 Flywheel Nut 78.5 8.00 57.9 7 Stator Coil Bolts 9.8[...]

16-4 ELECTRICAL SYSTEM Specification s Item Standard Flywheel Magneto Magneto Output V oltage 37 V or more at 4 000 r/min (rpm) Stator Coil Resistance 0.4 ∼ 1.1 Ω at 20°C (68°F) Charging System Charging V oltage (Regulat or/Rectifier Output V oltage) 14.0 ∼ 14.5 V Capacitor Internal Resistance see text Ignition System Igniti on T iming 4° [...]

ELECTRICAL SYSTEM 16-5 Special T ools and Sealan t Roto r Pul ler , M16/ M18/ M20/M2 2 × 1.5: 57001-1 216 Ti ming Light: 57001-1 241 Hand T est er: 57001-1 394 Peak V oltage Adap ter: 57001-1 415 Filler Cap Drive r: 57001-1 454 Nee dle Adapt er Set: 57001- 1457 Flywh eel Puller , M2 8 × 1.0: 57001- 1471 Grip: 57001- 1591 Measuring Adapter: 57001-[...]

16-6 ELECTRICAL SYSTEM Special T oo ls an d Sealant Liquid Gasket, TB121 1F: 92104- 0004[...]

ELECTRICAL SYS TEM 16-7 Wiring Diagram This page int entionally left blank.[...]

16-8 ELECTRICAL SYSTEM Wiring Diagram[...]

ELECTRICAL SYS TEM 16-9 Wiring Diagram[...]

16-10 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electri cal systems. Learn and ob- serve all the rules below . ○ The electrical par ts should never be struck sharply , as with a hammer , or allowed to fall on a har d surface. Such a shock to the parts can damage them. ○ T o prevent da[...]

ELECTRICAL SYSTEM 16-1 1 Elec tric al Wir ing Wiring Inspection • Visual ly inspect the wiri ng for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connecto r [A] apart and inspect it for corro sion, dirt, and damage. If the c onnector is corroded or dirty , cl ean it car efully . If it is damaged[...]

16-12 ELECTRICAL SYSTEM Flywheel Magneto Magneto Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Left Radiator Shroud (see Radiator Shroud R emoval in the Frame chapter ) Shift Pedal (see Shift Pedal Removal in the Crank- shaft/T r ansmission chapter) • Disconnect the magneto lead [...]

ELECTRICAL SYSTEM 16-13 Flywheel Magneto • Hold the flywheel steady with the rotor holder [A], and remove the flywheel nut [B]. Speci al T ool s - G rip [C ]: 5700 1-1591 Rotor Hold er: 57001-1730 • Install the flywheel puller [A] to the flywheel. • Install the rotor puller [B] to the flywheel puller . • Remove the fly w heel from the crank[...]

16-14 ELECTRICAL SYSTEM Flywheel Magneto • Hold the flywheel steady with the rotor holder , and tighten the flywheel nut. Special T ools - G rip: 570 01-15 91 Rotor Hold er: 57001-17 30 T orque - Flywheel Nut: 78.5 N·m (8.00 kgf·m, 57.9 ft·lb) • Install the magneto cover (see Magneto Cover Inst alla- tion). Stator Coil Removal • Remove: Ma[...]

ELECTRICAL SYSTEM 16-15 Flywheel Magneto Flywheel Inspection There are three types of m agneto problems: shor t, open (lead burned out), or loss in flywheel magnetism. A short or open in one of the coil leads wil l result in either a low output, or no output at all. A loss in flywheel magnetism, which may be caused by dropping or hitting the flywhe[...]

16-16 ELECTRICAL SYSTEM Flywheel Magneto If there is more resist ance than shown in the table, or no hand test er reading (infini t y), the stator has an open lead and must be r eplaced. Much less than this resi stance means the stator is shorted, and must be replaced. • Using the highest resistance range of the hand tester , measure the res ista[...]

ELECTRICAL SYSTEM 16-17 Charging System Reg ulat or/R ecti fie r Remo val • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) • Open the clamp [A], and free the lead. • Slide the dust cover [B]. • Disconnect the re gulator/recti fier lead connector [C]. • Remove: Regulator/Rect ifier Nuts [A] Regulator/Rect ifie[...]

16-18 ELECTRICAL SYSTEM Charging System ○ Refer to the Self-diagnosis Procedures in the Fuel Sys- tem (DFI) chapter , connect t he 12 V battery to the main harness. • Connect the hand test er [A] to the battery t erminals [B] . Special T ool - Hand T ester: 5700 1-1394 • Start the engine, and note the voltage readings at various engine speeds[...]

ELECTRICAL SYSTEM 16-19 Charging System Regulat or/Rectif ier Resist ance (Unit: k Ω ) T est er (+) Lead Connect ion T ermi nal A B C D E A – ∞ ∞ ∞ ∞ B 6 ∼ 20 – 4 ∼ 12 4 ∼ 12 4 ∼ 12 C 4 ∼ 12 ∞ – ∞ ∞ D 4 ∼ 12 ∞ ∞ – ∞ (–)* E 4 ∼ 12 ∞ ∞ ∞ – (−)*: T ester ( −) Lead Connection • Install the reg[...]

16-20 ELECTRICAL SYSTEM Charging System Capacitor Inspection • Remove: Capacitor (see Capacitor Removal) • Set the hand tester to the × 1 k Ω range, connect the tester to the leads of the capacit or , and check the internal resis- tance the following table. Special T ool - Hand T ester: 5700 1-1394 NOTICE Use onl y Kawasaki Hand T ester 5700[...]

ELECTRICAL SYSTEM 16-21 Ignition Ti ming Ignition T iming Inspection • Remove the timing inspection cap [A]. Speci al T ool - Filler Cap Driver : 5 7001-145 4 • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer . Speci al T oo l - Timing Lig ht: 57001-1241 • Start the en gine and aim the ti min[...]

16-22 ELECTRICAL SYSTEM Ignition System Safety Ins tructions W ARNIN G The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Ignition Coil Removal • Disconnect the primary lead connector [A]. • Pull of[...]

ELECTRICAL SYSTEM 16-23 Ignition System Ignition Coil Inspection Measuring Arcing Distance The most accurate t est for deter m ining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3-needle method. • Remove the igniti on coil (see Ignit ion Coil Removal) . • Measure the arcing dist ance usin[...]

16-24 ELECTRICAL SYSTEM Ignition System Spark Plug Cleaning and Inspection • Refer to t he Spark Plug Cleaning and I nspection in the Periodic M aintenance chapter . Spark P lug Gap Inspecti on • Refer to t he Spark Plug Cleaning and I nspection in the Periodic M aintenance chapter . Ignition Coil Primary Peak V oltage Check • Remove the spar[...]

ELECTRICAL SYSTEM 16-25 Ignition System IC Igniter Inspec t ion ○ The IC igniter is built in the ECU. • Refer to the following items. Igniti on S ystem T roubleshooti ng (see Ignition System section) ECU Power Supply Inspection (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)[...]

16-26 ELECTRICAL SYSTEM Ignition System[...]

ELECTRICAL SYSTEM 16-27 Ignition System Crankshaft Sensor Peak Voltage Check • Disconnect the magneto lead connector (see Magneto Cover Removal ). NOTE ○ Measure the voltage with each lead connected cor- rectly . The c orrect value may not be obtained if disconnected. ○ Maintain the corr ect value of compression p ressure for the cylinder (Be[...]

16-28 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Disconnect the magneto lead connector (see Magneto Cover Removal). • Set the hand tester [A] to the × 10 Ω range and connect it to the Green/White [B] and White/Y ellow [C] leads in the connector . Special T ool - Hand T ester: 5700 1-1394 Crankshaf t Sensor R esistan ce [...]

ELECTRICAL SYSTEM 16-29 Ignition System • Check the wiri ng for conti nuity between the terminals of each connector referring the connector circu it. White Connector [A] Green Connector [B] Black Connector [C] Speci al T oo l - Han d T est er [D]: 57001-13 94 If the t ester does not read 0 Ω , t he connect or i s defective. Replace the connecto[...]

16-30 ELECTRICAL SYSTEM Switches Engine Stop Swit ch Inspection • Using the hand tester , check to see that the connections shown in the table have continuity (about z ero ohms). Special T ool - Hand T ester: 5700 1-1394 If the switch has an open or short, replace it with a new one. Engine Stop Switch Connection Gear Position Switch Removal • R[...]

APP ENDI X 17- 1 17 Appendix T able of Con tents Cabl e, W ire , a nd H ose R ou ting .... .... .... .... .... .... ....... .... .... .... .... .... .... ....... .... .... .... .... .... .... ....... . 17- 2 T roubleshooting Guide .............. . ......... . ......... ......... .......... .......... ........... . ......... .......... ......... ...[...]

17-2 APPENDIX Cab le, Wire , a nd Hose Routi ng 1. Front Brake Hose 2. Run the throttle cables inside of the number plate. 3. Throttle Cable (Acc eler ator ) 4. Throttle Cable (Decel erator) 5. Clutch Cable 6. Run the clutc h cable inside of the number plate. 7. Run the front brake hose outside of the num ber plate. 8. Band (H old the engine stop s[...]

APP ENDI X 17- 3 Cable, Wi re, and Hose R outing 1. Clutch Cable 2. Engine S top Switch Lead 3. Main Harness 4. Run the clutch cable outside of t he main harness. 5. Clamps (Firmly twist the clamp from near bolted point around the clutch cable.) 6. Throttle C ab les 7. Run the throttl e cables betw een the joint hose and radiator overflow hose. 8. [...]

17-4 APPENDIX Cab le, Wire , a nd Hose Routi ng 1. Engine Stop Switch Lead 2. Clamp (Hold the main harness and engine stop switch lead on the main harness at the white taped posit ion .) 3. Position the engine stop switch lead connector behind the clamp and between the main harness and frame. 4. Run the capac itor lead to the right side of the capa[...]

APP ENDI X 17- 5 Cable, Wi re, and Hose R outing 1. Clamp (Tur n the lock position to upward.) 2. Clamp (Tur n the lock position to upward.) 3. Run the main har ness and option lead over the capacitor lead. 4. Run the regul ator/recti fier lead as shown. 5. Run the regulator/rectif ier lead on the top position in t he clamp. 6. Run the ignit ion co[...]

17-6 APPENDIX Cab le, Wire , a nd Hose Routi ng[...]

APP ENDI X 17- 7 Cable, Wi re, and Hose R outing 1. Breather Hose 2. Downstream Lead 3. Throttle Sensor Lead 4. Install the upstream injector connector boot so that notch side faces inside. 5. Run the downstream lead and thrott le sensor lead over the throttle body assy r ear side. 6. Fuel Hose 7. Check the fuel hose position. If the fuel hose inte[...]

17-8 APPENDIX Cab le, Wire , a nd Hose Routi ng 1. Clamp (T wist t he cl amp on the mag neto l ead and gear posit ion swit ch lead at the gr ay taped position.) 2. Clamp ( T wist the clam p on the m agneto lead and gear position switch lead.) 3. Run the gear position s witch l ead inside of the gasket. 4. Do not pinch the gear posit ion swit ch lea[...]

APP ENDI X 17- 9 Cable, Wi re, and Hose R outing 1. Viewed Rear 2. Radiator O verflow Hose 3. Clamps 4. Joint Hose (T urn the blue paint to upside.) 5. Clamps (T urn the screw head to outs i de.) 6. Right R adiat or 7. W ater Pipe 8. Run the radiat or overflow hose in the front of the wate r hose and between the engine brackets. 9. Capac itor (Posi[...]

17-10 APPENDIX Cab le, Wire , a nd Hose Routi ng 1. Install the mesh protector side of the breather hose t o the engine. 2. Clamp (T urn the claw to the exhaust p ipe side.) 3. Clamp (Run the breather hose into the clamp.) 4. Breather Hose 5. Align the green paint to the stopper . 6. Stoppers 7. Align the red paint to the stopper . 8. Clamps (T urn[...]

APPENDIX 17-1 1 Cable, Wi re, and Hose R outing 1. T ouch the front brake hose fitting to the stopper . 2. Brake Hose 3. Clamp 4. Viewed A 5. Clamps[...]

17-12 APPENDIX Cab le, Wire , a nd Hose Routi ng 1. Brake Hose 2. Clamps 3. T ouch the rear b rake hose fi tting to the stopper . 4. Cotter Pin 5. Viewed A[...]

APPENDIX 17-13 T roublesh ooting Guide NOTE ○ Refer to the Fuel System (DFI) chapter f or most of DFI trouble shooting guide. ○ This is not an exhaustive list, giving every possible cause for each problem listed. I t is meant simply as a r ough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn ’t Start[...]

17-14 APPENDIX T roubl eshooting Guide Spark plug cap shorted or not in good con- tact Spark plug incorrect heat value ECU trouble Crankshaft sensor trouble Flywheel damage Ignitio n coil trouble Wiring connector not in good contact Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or miss- ing Air cleaner duct loose W ater or foreign[...]

APPENDIX 17-15 T roublesh ooting Guide Gear seized Gear positioning leve r operation trouble Shift drum broken Jumps out of gear: Shift fork ear worn, bent Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Gear positioning le ver spring weak or bro- ken Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines w[...]

17-16 APPENDIX T roubl eshooting Guide Steering stem bearing lubrication inade- quate Steering stem bent T ire air pressure too low Handlebars shakes or excessively vibrates: Ti r e w o r n Swingarm pivot bearings worn Rim w arped, or not balanced Spokes loose Wheel bearing worn Handlebar clamp bolt loose Steering stem head nut loose Front, rear ax[...]