Kawasaki Z1000 инструкция обслуживания

Z1000 Motorcycle Service Manual[...]

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This quick refer ence 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 with the black t ab on the edge at each table of contents page. •Refer to the secti onal table of contents for the exact pages to locate the spe- cific topic requir ed. Quick Refer[...]

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Z1000 Motorcycle Service Manual All rights res erved. No parts of this publi cation may be reproduced, stored in a retr ieval system, or transmitt ed in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the pr ior written permissi on of Quality Assurance Depart ment/Consumer Products and Machinery Company[...]

LIST OF ABBREVIA TIO NS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternati ng current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead c enter PS horsepower BTDC before top dead center psi pound(s) per squ are inch °C degree(s) Cel sius r revolu tion DC di[...]

EMISSION CONTROL I NFORMA TION T o protect the environment i n which we all l ive, Kawasaki has incor porated crankcase emis - sion (1 ) and exhaust emissi on (2) control systems in compliance wi th applicable regulat ions of the United Stat es Environmental Protec tion Agency and Californi a Air Resources Board. Addi- tionall y , Kawasaki has inco[...]

WE RECOMMEND THA T ALL DEALERS OBSERVE THESE PROVISI ONS OF FEDERAL LA W , THE VIOLA TION OF WHICH IS PUNISHABLE BY CIVIL PENAL TIES NO T EXCEEDING $10,000 PE R VIOLA TION. T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibi ts the fol lowing acts or the c ausing thereof: (1) The removal or rendering inoperative by any person other [...]

Foreword This manual is designed primarily for use by tra ined mechanics in a properly equipped shop. However , it contains enough det ail and basic in- formation to m ake it useful to the owner who de- sir es to perform hi s own basic maintenance and repair work. A basic knowledge of mechanic s, the proper use of tools, and workshop proce- du res [...]

NOTE ○ This note symbo l indic ates poin ts of par - ticul ar interest for more effi cient and con- venien t opera tion. • Indicates a procedural step or work to be done. ○ Indicates a proced ural sub-step or how t o do the work of the procedural step it follows. It also precedes the tex t of a NOTE. Indicates a conditional step or what ac ti[...]

GENERAL INFORMA T ION 1-1 1 General Information T able of Con tents Befor e S ervic ing .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...... .... ......... . 1-2 Model Identifi cation... ...... ...... ....... ...... ........ ........ ..... ........ ........ ...... ........ ......[...]

1-2 G ENER AL IN FORMA TIO N Before Servicing Before start ing to perform an inspection servi ce or carry out a disassembly and reassembly opera- tion on a motorcycl e, read the precautions gi ven below . T o facilitate act ual operations, notes , illustra- tions, photographs , cautions, and detailed descr iptions have b een included in ea ch chapt[...]

GENERAL INFORMA TION 1-3 Before Se rvicing Arran gement and Cle aning o f Removed Parts Disassembled parts are easy t o confuse. Arrange the parts accordi ng to the or der the parts were di sassembled and clean the par ts in order pri or to assembly . Storage of Remove d Parts After all the parts includi ng subassembly parts have been cleaned, stor[...]

1-4 G ENER AL IN FORMA TIO N Before Servicing Tighten ing Sequen ce Bolts, nuts, or screws must be tight ened according to the specif ied sequence to prev ent case warpage or deformation which can lead to malf unction. If the specifi ed tightening sequence is not indi cated, tighten t he fasteners a lternating diago nally . Tighten ing T orque Inco[...]

GENERAL INFORMA TION 1-5 Before Se rvicing Press For items s uch as beari ngs or oil s eals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when instal ling. Ball Be aring and Need le Beari ng Do not remove pressed ball or needle unless removal is absolu[...]

1-6 G ENER AL IN FORMA TIO N Before Servicing Directio n of Engin e Rotati on When rotating the cranks haft by hand, the free play amount of rotating directi on will af f ect the adjus tment. Ro- tate the crankshaft t o positive dir ection (clockwise vi ewed from output side). Electri cal Wire s A two-color wire i s identif ied first by th e primar[...]

GENERAL INFORMA TION 1-7 Model Ident ification ZR1000–A1 Left Side View : ZR1000–A1 Right Side View:[...]

1-8 G ENER AL IN FORMA TIO N General S pecification s Items ZR1000–A1 ∼ Dimensions: Overall lengt h 2 080 mm (81.9 i n.) Overall width 770 mm (30.3 in. ) Overall height 1 055 mm (41.5 i n.) Wheelbase 1 420 mm (55. 9 in.) Road clearance 145 mm (5.7 in.) Seat height 820 mm (32.3 i n.) Dry mass 198 kg (410.1 lb) Curb mass: Front 1 10 kg (242.6 lb)[...]

GENERAL INFORMA TION 1-9 General Specifica tions Items ZR1000–A1 ∼ Lubrication syst em Forced lubri cation (wet sump with cooler) Engine oil: Ty p e API S E, SF or SG API SH or S J with JASO MA Viscosi ty SAE10W-40 Capacity 3.8 L (4.0 US qt) Driv e T rain : Primary reduction system: Ty p e Gear Reduction ratio 1.714 (84/49) Clutch type Wet mult[...]

1-10 GENERAL INFORMA TION General S pecification s Items ZR1000–A1 ∼ T ail/brake l ight 12 V 0.5/3 .8 W (LED) (US, CA, Cal) 12 V 0.5/5W (LED) Alternator : T ype Three-phase AC Rated output 24 A/ 14 V @5 000 r/min (r pm) Specificati ons are subject to change wit hout notice, and may not apply to every count ry . (AU): Australia Model (US): U.S.A[...]

GENE RAL INFORMA TION 1-1 1 T e chnical Inform ation – Air Inlet System Subthrottle Contr ol System The ZR1000–A1 ∼ employs large bore throttle bodies to i ncrease power output. However , sudden changes in thrott le opening can cause hesit ation and jerky throt tle response wit h a single butterfl y valve in a larg e bore. Therefore two t hro[...]

1-12 GENERAL INFORMA TION T echnical Informatio n – Air Inlet S ystem Operation The subthrottl e control system consists of the subth rottle valve, subthrottle valve actuator wit h a steppi ng motor built i n it, ECU, and subthrottle sensor . The subt hrottle valve is bui lt in the each throttle body . The subthrot tle control system operates on [...]

GENERAL INFORMA T ION 1-13 T e chnical Info rmation – New I gnition Inte rlock Sidestand Outline The New Ignition Interl ock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand i s not li fted upward even t hough clutch lever pulled in, which dif fers from the trad itional one. Refer t o t[...]

1-14 GENERAL INFORMA TION T echnical I nformation – T ail /Brake Lights Em ploying LE D Out lin e This model employs a tai l/brake li ght containing 21 Light Emit ting Diodes (LED). The LED emits lumino us beams over a longer life span than thos e emi tted from a traditional electr ic heated bulb (more than 5 times longer), uses lower v oltage, e[...]

GENERAL INFORMA T ION 1-15 T e chnical Informatio n – T ail/B rake Lights Employing LED The emitting c olor dif fers according t o the material s of semi-conductors . Materials of Semi-Conductor and Emitting Color Materi als of Semi- Conduct or Emitting C olor GaAsP , GaAlAs Red GaP Gree n GaN Blue Ga: Galliu m As: Arsenic P: Phosphorus N: Nitrog[...]

1-16 GENERAL INFORMA TION T echnical I nformation - KLE EN (KA W A SAKI LOW EXHAU ST EMISS ION SYSTEM) Since the emission r egulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst prot ection system, according to eac h regulation of dif ferent countries. The muf fl er with built-in catalyst has the sam[...]

GENERAL INFOR MA TION 1-17 Unit Conversio n T able Prefixes for Units: Prefix Symbol Power meg a M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 mill i m ×0 . 0 0 1 mic ro µ × 0.000001 Units o f Mass: k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume : L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (i[...]

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PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Con tents Periodic Maintenance Chart ..... ....... .. 2-2 T orque and Locking Agent ......... ........ 2-4 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 2-9 Spec ial T ools . ...... .... ...... .... ...... ..... ..... 2-1 1 Periodic Maintenance Pro cedures..... 2-12 Fue l Syst[...]

2-2 PERIODIC MAINTEN ANCE Periodic Main tenance Cha rt The scheduled maint enance must be done in accordance with this chart to kee p t he motorcy cle in good running condition. The initial maint enance is vita lly important and must not be neglect ed. FREQUENCY Whichever 1 000 km *O D O M E T E R READ IN G comes (600 mile) firs t 6 000 km → (4 0[...]

PERIODIC MAINTENANCE 2-3 Periodic Mainte nance Chart FREQUENCY Whichever 1 000 km *O D O M E T E R READING com es (600 mile) first 6 000 km → (4 000 mile) ↓ 12 000 km ( 7 500 m ile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (20 000 mile) 36 000 km (24 000 mile) OPERA TION Every Clutch-adjus t † • • • • • • • Radi[...]

2-4 PERIODIC MAINTEN ANCE T orque and L ocking Agent The followi ng tables list the tight ening torque for the major fastene rs requiring use o f a non -perma nent locking agen t or liquid gasket. Letter s used i n the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. G: Apply grease to t he threads. MO: Apply molybd[...]

PERIODIC MAINTENANCE 2-5 T orq ue and Lock ing Agent T orque Fastener N·m kgf·m ft·lb Remarks Wa t e r p ump drain bolt 11 1.1 95 in·l b W ater pipe bolts 11 1.1 95 in·lb in/ou tlet Therm ostat housing ground bolt 7 0.7 61 in· lb Thermostat bracket bolt 7 0.7 61 in·lb Radi ator upper bolts 7 0.7 61 in ·l b Radiator lower bolts 7 0.7 61 in·[...]

2-6 PERIODIC MAINTEN ANCE T orque and L ocking Agent T orque Fastener N·m kgf ·m ft·lb Remarks Engine Lubrication: Oil filler plug 1. 5 0.15 13 in·lb Engin e drain pl ug 20 2.0 14.5 Oil filt er (cartridge t ype, P/No.16097–1070) 26 2.7 20 R, EO Oil filt er (cartridge t ype, P/No.16097–0002) 31 3.2 23 R, EO Oil cooler mounting bolt 76 7.8 56[...]

PERIODIC MAINTENANCE 2-7 T orq ue and Lock ing Agent T orque Fastener N·m kgf·m ft·lb Remarks Wheels/Ti res: Front axle clamp bolt 34 3.5 25 Front axle 127 13 94 Rear axle nut 127 13 94 Fina l Drive: Engine sprocket nut 127 13 94 MO Eng ine sprocket cover bolt s 9.8 1. 0 87 i n·lb Engine sprocket cover damper bolt 6.9 0.7 61 in·lb L Re ar spro[...]

2-8 PERIODIC MAINTEN ANCE T orque and L ocking Agent T orque Fastener N·m kgf ·m ft·lb Remarks Handle bar lower clamp nuts 34 3.5 25 Handlebar switch housi ng screws 3.4 0.35 30 in·l b Frame : Footpeg holder bolts 34 3.5 25 Muff ler mounting bolts 29 3.0 22 Side stand bolt 44 4.5 33 Side stand switch bolt 8. 8 0.9 78 i n·lb Windshield sc rews [...]

PERIODIC MAINTENANCE 2-9 Specifications Item Standard Servic e Limit Fuel System: Throttle gri p free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Idle speed 1 100 ± 50 r/min (rpm) Bypass screws (turn o ut) 2 ± 1/4 (for ref erence) ––– Engine vacuum 32. 7 ± 1.333 kPa (245 ± 10 mm Hg) Air cleaner element Pape r filte r Cooling System: Coolant: T yp[...]

2-10 PERIODIC MAINTENANCE Specif ications Item Standard Service Limit Air pressure: (when cold) Front Up to 180 kg (396 lb) load: 250 kPa (2.5 kgf /cm², 36 psi) ––– Rear Up to 180 kg (396 lb) load: 290 kPa (2.9 kgf /cm², 41 psi) ––– Final Drive: D r i v ec h a i ns l a c k 20 ∼ 30 mm (0.8 ∼ 1. 2 in .) ––– Drive chain (20-l i[...]

PERIODIC MAINTENANCE 2-1 1 Special T ools Steering Stem Nut Wrench: 57001–1100 Jack: 57001–123 8 Oil Filter Wren ch: 57001–124 9 Pilot Scre w Adjuster , C: 57001–1 292 Hand T ester : 57001–1 394 Spark Plug W rench (Owner’s T ool): 921 10–1 132[...]

2-12 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Fuel Sy stem (DFI) Fuel Hose and Connecti on Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’ s life without any maintenance, however , if the motorcycle is not properly handled, the high press ure in- side the fuel line can cause fuel to leak [A] or the h[...]

PERIODIC MAINTENANCE 2-13 Periodic M aintenance P rocedures Throttl e Control System I nspection Throttle Gri p Play Inspecti on • Check the thrott le grip free pl ay [A]. If the f ree play i s incorr ect, adjust the t hrottle cable (see below). Throttle Grip Free Play Standard : 2 ∼ 3m m( 0 . 0 8 ∼ 0.12 in.) • Check that the throttl e grip[...]

2-14 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Throttle Bore Cleaning • Check the thrott le bore for cleanliness as f ollows: ○ Remove the throttle body assy (see Fuel System (DFI) chapter). ○ Check the main throttl e valves and t hrottle bores [A] f or car bo n deposits by opening the main valves. If any carbon accumula tes, wip[...]

PERIODIC MAINTENANCE 2-15 Periodic M aintenance P rocedures Engine V acuum Synchr onizati on Inspectio n NOTE ○ These procedures are expl ained on the assumption that the inl et and ex haust systems of the en gine are i n good condition. • Situate the mo torcycle so that it is vertical. • Remove the fuel tank (see Fuel System (DFI) chapter). [...]

2-16 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Install th e fuel tank (see Fuel System (DFI) chapter). • Start the engine and war m it up thoroughly . • Check t he idle s peed. T achometer [A] If the i dle speed is out of the specified range, adjust it. CAUTION Do not measure the idl e speed by the tachometer of the m et er uni[...]

PERIODIC MAINTENANCE 2-17 Periodic M aintenance P rocedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Speci al T ool - Pilot Sc rew A djuster , C: 570 01-1292 • Adjust the lowest vacuu m between #1 and #2 to the high- est of #1 and #2. • Adjust the lowest vacu[...]

2-18 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Back out the same number of turns counted when first turned i n. This i s to set the s crew to it s original posit ion. NOTE ○ A throttle body has diff erent “turns out” of the bypass screw for each i ndividual unit. When setting t he bypass screw , use the “turns out” determ[...]

PERIODIC MAINTENANCE 2-19 Periodic M aintenance P rocedures Air Cl eaner Eleme nt Cleani ng NOTE ○ In dusty areas, the element should be cleaned more freque ntly t han the recommended interv al. ○ After riding through rai n or on muddily roads, the ele- ment should be cleaned immediately . WA R N I N G If dirt or dust is allowed to pass through[...]

2-20 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Clean the element by tapping it li ghtly to loosen dus t. • Blow away the remaining dust by applying compressed air [A] from the outsi de to the inside (from the clean side to the dirty side). • V isually inspect the el ement for no tears or no breaks and inspe ct the sponge gasket[...]

PERIODIC MAINTENANCE 2-21 Periodic M aintenance P rocedures ○ Disconnect t he hoses from t he separator , and remove the separator [A] from the motorcycle left si de. Front [B] ○ Visual ly inspect the separator for cracks and other dam- age. If the separator has any cracks or damage, replace it with a new one. ○ T o prevent the gasoli ne from[...]

2-22 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator ca p [A] in two steps. First turn the cap co u nterclockwise to the fi rst stop. Then push and turn it further i n the same direction and remove t he cap. ○ The coolant will drain f rom the radiator and eng[...]

PERIODIC MAINTENANCE 2-23 Periodic M aintenance P rocedures • Loosen the air bl eeder bolt [A] on the thermost at housing. Front [B] • Replenish the coolant into the radiato r until the coolant begins to flow out the air bleede r bolt hole (that is, all the remaining air is forced out) . • T ap the radiator hoses to force any air b ubbles cau[...]

2-24 PERIODIC MAINTENANCE Periodic M aintenance Procedure s V alve Cl earance In spection NOTE ○ V alve clearance must be checked and adjuste d when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter ) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Re- moval) • Position the cranks haft at 1,4[...]

PERIODIC MAINTENANCE 2-25 Periodic M aintenance P rocedures V alve Clearance Adj ustment • T o change the valve c learance, remove the camshaft chain tensioner , camshafts and valve li fters. Replace the shim with one of a dif ferent thickness. NOTE ○ Mark and record the val ve lifter and shim locat ions so they c an be reinstall ed in their or[...]

2-26 PERIODIC MAINTENANCE Periodic M aintenance Procedure s V AL VE CLEARANCE ADJUSTMENT CHART INLET V AL VE 1. Measure the clearance ( when engine is cold). 2. Check present shim size. 3. Match clearanc e in vertical column with present shim si ze in horiz ontal column. 4. Install the shim specifi ed where the lines int ersect. This shim will give[...]

PERIODIC MAINTENANCE 2-27 Periodic M aintenance P rocedures V AL VE CLEARANCE ADJUSTMENT CHART EXHAU ST V AL VE 1. Measure the clearanc e (when engine is cold) . 2. Check present shim size. 3. Match clear ance in vert ical column with present shim size in horizontal column. 4. Install t he shim specified wher e the lines inter sect. This shim wil l[...]

2-28 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Clutch Clutch Adjust Inspection • Pull the clutch l ever just enough to tak e up the free play [A]. • Measure the gap between the lever and the lever holder . If the gap is too wide, the clutch m ay not release fully . If the gap is too narrow , the clutch may not engage fully . In eit[...]

PERIODIC MAINTENANCE 2-29 Periodic M aintenance P rocedures Engine Lubrica tion System Engine Oil C hange • Sit uate the motorcycle so that it is vert ical after warming up the engine. • Rem ove th e eng ine d rain p lug [A ] to dra in the oil. ○ The oil in the oil filter can be draine d by removing the fil ter (see Oil Filter Change). Replac[...]

2-30 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Wheels /T ires Tire Inspection As the tire tread wears down, the tire becomes more sus- ceptible to punc ture and failure. An accepted estimat e is that 90 % of all tire failures occu r during the last 10 % of tread life ( 90 % worn). So it is fals e economy and unsafe to use the tires unt[...]

PERIODIC MAINTENANCE 2-31 Periodic M aintenance P rocedures Air Pressure I nspection/ Adjustment • Remove the air valv e cap. • Measure the tire air pressure with an air pressur e gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Adjust the t ire air press ure accordin[...]

2-32 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • T ighten both chain adjuster locknuts securely . • T ighten the axle nut. T orq ue - Re ar Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb ) • T urn the wheel, measure the chain slack again at the tight- est positi on, and readjust if necessary . • Insert a new c otter pin [A]. NOTE ○[...]

PERIODIC MAINTENANCE 2-33 Periodic M aintenance P rocedures • Rotate the rear wheel to inspect the drive chain for dam- aged roller s, and loose pin s and links. If there is any irregul arity , replace the drive chain. Lubricate the drive chai n if it appears dry . • Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chai[...]

2-34 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Apply oil to the si des of the rollers so that oil wil l penetrate to the roll ers and bushings. Apply the oil to the O-rings so that th e O-r ings will be coated with oil. • Wipe off any excess oil. Oil Applied Areas [A] O-ring [B] Brakes Brake Pad W ear Insp ection • Check the li[...]

PERIODIC MAINTENANCE 2-35 Periodic M aintenance P rocedures If it does not, adjust and inspect the brake light switch. • While holding the switch body , turn the adjusting nut [A] to adjust the switch. CAUTIO N T o avoid damaging the electrical connections in- side the switch, be sure t hat the switch body does not turn during adjustment. • Rem[...]

2-36 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Master Cylinde r Inspection (V isual Inspection ) • Disassemble the front and rear master cylinder s. • Check t hat there are n o scratches, rust or pitti ng on the inner wall [A] of each master cylinder and on the outside of each piston [B]. If a ma ster cylinder or piston shows any d[...]

PERIODIC MAINTENANCE 2-37 Periodic M aintenance P rocedures Level I nspection • Check that the brak e fluid level in t he front brake reser voir [A] is above the l ower level li ne [B]. NOTE ○ Hold the reservoir hor izontal by turning t he handlebar when checking brake flui d level. If the fluid level is l ower than the lower level line, fill t[...]

2-38 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Level the brake flu id reservoir . • Remove the reservoir cap and diaphragm. • Remove the rubber cap fro m the bleed valve [A] on the caliper . • Attach a clear plastic hose [B] to the bleed valve, and run the ot her end of the hose into a cont ainer . • Fill the reservoir wit [...]

PERIODIC MAINTENANCE 2-39 Periodic M aintenance P rocedures Brake Line Bl eeding The brake fluid has a very low compression coef ficient so that almost all the movement of the brake l ever or pedal is transmit ted directly to t he caliper for braking action. Air , however , is easily compressed. When air enters t he brake lines, brake lever or peda[...]

2-40 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Bleed the br ake line and the cal iper: ○ Repeat this operation unt il no more air can be seen com- ing out into t he plas tic hose. 1. Pump the brake lever until it becomes hard, and apply t h eb r a k ea n dh o l di t[ A ] . 2. Quick ly open and close [B] th e bleed valve whi le ho[...]

PERIODIC MAINTENANCE 2-41 Periodic M aintenance P rocedures WA R N I N G When working with the disc brake, observe the pre- cautions listed bel ow . 1. Never reuse ol d brake fluid. 2. Do not use flu id from a container that has been left unsealed or tha t has been open for a long time. 3. Do not mix two types and brands of fluid for use in the bra[...]

2-42 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Suspension Front For k Oil Leak Chec k • V isually inspect t he front fork s [A] for oil leakage, scoring or scratches on the outer surface of t he inner tubes. Replace or repair any defective parts, if necessary . Rear Shock Absor ber Oil Lea k Check • V isually inspec t the shock abs[...]

PERIODIC MAINTENANCE 2-43 Periodic M aintenance P rocedures Steering Steer ing Inspe ction • Lif t the front wheel of f the ground using the jack. Speci al T ool - Jack: 57001–12 38 • With the front wheel pointing st raight ahead, alternately tap each end of the handlebar . The front wheel should swing fully left and right from the for ce of [...]

2-44 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Adjust the steering. Special T ool - S teering St em Nut Wrench: 57001– 1 100 [B] If the steering i s too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loos e, tighten the stem nut a fraction of a turn. NOTE ○ T urn the stem nut 1/8 turn at time maximu[...]

PERIODIC MAINTENANCE 2-45 Periodic M aintenance P rocedures • Unscrew the thermost at bracket bolt [A]. ○ If removing the spar k plug #2 or #3. • Disconnect: Stick C oil Connectors [ A] • Pul l out the stick coil # 1 [B] . • T ake out the camshaft posit ion sensor connector [C] f rom the bracket. • Pul l out the stick coil # 2 [D] . CAU[...]

2-46 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Clean the spark plug, preferably in a s andblasting devi ce, and then clean of f any abrasive par ticles. The plug may also be cleaned using a high- flash point solvent and a wire brush or other tool. If the spark plug center electrode [A] and/or si de elec- trode [B] are cor roded or [...]

PERIODIC MAINTENANCE 2-47 Periodic M aintenance P rocedures General Lu brication Lubri catio n • Bef ore lubricati ng each part, clean off any rusty spo ts with rust remover and wipe of f any grease, oil, dirt, or grime. • Lubricate the poi nts listed below with i ndicated lubri cant. NOTE ○ Whenever the vehicle has bee n operated under wet o[...]

2-48 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Nut, Bolt, and Fastener Tightness Tightne ss Inspection • Check the tightness of the bolts and nuts l isted here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fastener s, check the tightness of them when the engine is cold (at room te[...]

FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 3-3 DFI Pa rts Lo cat ion . .... ...... .... ....... .... ... 3 -8 DFI Wiring Diagr am .. ...... ...... ..... ...... .. 3-10 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 3-12 Spec ial T ools . ...... .... ...... ....[...]

3-2 FUEL SYSTEM (DFI) ECU Install ation ... ...... ...... ...... ...... 3-71 ECU Power Supply Inspection ..... 3-72 DF I Pow er So urce .. ...... .... ...... .... ....... 3- 74 ECU Fuse Rem oval .. .... ...... .... ..... 3-7 4 ECU Fuse Install ation .... ...... ..... ... 3-74 ECU Fuse Ins pecti on .... .... ...... ..... 3- 74 ECU Main Relay Removal[...]

FUEL SYSTEM (DFI) 3-3 Exploded View Clifornia Evaporative Emission Control System 1. Canister 2. Separator 3. Right fitting of throt tle body #2 4. Right fitting of throt tle body #3 5. Canister purge hose (green) 6. Fuel return hose (left, red) 7. Fuel tank breather hose (right, blue) 8. Separator breather hose (blue) 9. Separator vacuum hose (whi[...]

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

FUEL SYSTEM (DFI) 3-5 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Throttle cabl e plate bol t 6 0.6 52 in·lb 2 Throttle body cover bolts 7 0.7 61 in·lb 3 Throttle assy holder clamp bolt s 2 0.2 17 in·lb 4 Choke link holder screws 2.1 0.21 18 in·lb 5 Delivery pipe screws 3.4 0.35 30 in·lb 6 Bypass screws 0.2 0.02 1.7 in· [...]

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

FUEL SYSTEM (DFI) 3-7 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Inlet air pressur e sensor bolt 12 1.2 104 in·l b 2 W ater temperature sensor 25 2.5 18 3 V ehicle downsensor bolts 2 0.2 17 in·lb 4 Camshaft position sensor bolt 12 1.2 104 in·l b 5 Cams h aft posit ion sensor rotor bolt 12 1.2 104 in·l b L 6 Air cleaner du[...]

3-8 FUEL SYSTEM (DFI) DFI Parts Locati on DFI: DFI Parts (this chapter) 8. ECU Fuse 15A 19. Turn Signal Relay F: Front 9. ECU ( DFI) 20. Subthrot tle Sensor (DFI) 1. W ater temperature 10. Stick Coi ls 21. Mai n Throttle Sensor (DFI) Sensor (DFI) 1 1. Throttle Body Assy 22. Ignition Switch 2. Inlet Air Pressure 12. Self-diagnosis T erminal 23. FI I[...]

FUEL SYSTEM (DFI) 3 -9 DFI Parts Location [1], [2], [1 0], [13], [22] and [24] are not included.[...]

3-10 FUEL SYSTEM (DFI) DFI Wiring Diagr am[...]

FUEL SYSTEM (DFI) 3-1 1 DFI Wiring Diagram T erminal Names 1. Power Supply to Sensors (inlet air pr es- sure, a tmospheric pr essure, and throttle sensors) from ECU. 2. Main Throttle Sensor Signal 3. Subth rottle Sensor Signal f or ECU 4. Atmospheric P ressure Sensor Signal 5. W ater T emperature Sensor Signal (+) 6.7. 8. – 9. Camshaft Position S[...]

3-12 FUEL SYSTEM (DFI) Specif ications Item Standard Digital Fuel Inject ion System Idle Speed 1 100 ± 50 r/min (rpm) Throttl e Assy: Ty p e Four b arrel type Bore 38 mm (1 .5 in.) ECU (Electronic Control Unit): Make Denso Ty p e Digital memory type, with buil t in IC ignit er , sealed with resin Usable engine speed 100 ∼ 1 1 1 60 r/m in (rpm ) [...]

FUEL SYSTEM (DFI) 3- 13 Specifications Item Standard Det ect ion tim e Within 0.5 ∼ 1.0 sec. Output voltage with the sensor ti lted 60 ∼ 70° or more: 3.7 ∼ 4.4 V with sensor arrow mark pointed up: 0.4 ∼ 1.4 V Subthrottle Sens or: Non-adjustabl e and non-removal Input V oltage 4.75 ∼ 5.25 V DC between BR an d BR/BK leads Output voltage at[...]

3-14 FUEL SYSTEM (DFI) Special T o ols Oil Pressure G auge: 57001–1 25 Carburetor Drai n Plug Wrench, Hex 3: 57001–1 269 Fork Oil Level Gauge: 57001–1 290 Hand T ester : 57001–1 394 Throttle Sensor Setting Adapter: 5 7001–1400 Fuel Pressure Gau ge Adapter: 57001–14 17 Needle A dapter Set : 57001–14 57 Throttle Sensor Setting Adapter: [...]

FUEL SYSTEM (DFI) 3- 15 DFI Servicing Precautions There are a number of important precaut ions that should be followed servi cing the DFI system. ○ This DFI system is designed t o be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V seale d battery as a power sour ce. ○ Do not reverse the batter[...]

3-16 FUEL SYSTEM (DFI) DFI Servicin g Precautio ns ○ T o maintain the correct fuel/ai r mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oi l. Clutch Cover [B] Front [C] T orque - Oil Fill er Plug: 1.5 N·m (0.15 kgf·m, 1 3 in·lb)[...]

FUEL SYSTEM (DFI) 3- 17 T ro ubleshooting th e DFI S ystem Outline When an abnormality in t he system occurs, t he FI indica- tor LED (Light Emitting Diode) l ight goes on to alert the r ider on the meter panel. In additi on, the condition of the problem is stored in the memory of t he ECU (electronic control unit ). Wit h the engine stopped and tu[...]

3-18 FUEL SYSTEM (DFI) T roubleshooting the DFI Sys tem ○ The DFI part connectors [A] have seal s [B], including the ECU. • Join th e connector and insert the needl e adapters (special tool) [C] inside the seal [B] from behind the connecto r until the adapter reac hes the terminal. Special T ool - Ne edle Ada pter Set: 57001 –1457 CAUTION Ins[...]

FUEL SYSTEM (DFI) 3- 19 T ro ubleshooting th e DFI S ystem • Pull each connecto r [A] apart and inspect i t for corrosion, dirt, and damage. If the connector i s corroded or dirty , clean it carefull y . If it is damaged, replace it. Connect the connector s securely . • Check the wiring for continuity . ○ Use the wiring di agram to fi nd the [...]

3-20 FUEL SYSTEM (DFI) T roubleshooting the DFI Sys tem ○ There are two ways to i nspect the DFI system. One is voltage Check Method and the other is Resi stance Check Method . (V oltage Check Method) ○ This method is conducted by measuring the input voltage [B] to a sensor [A] firs t, and then the output volt age [C] from the sensor . ○ Some[...]

FUEL SYSTEM (DFI) 3- 21 T ro ubleshooting th e DFI S ystem DFI Diagnosis Flow Chart Inquiries t o Rider ○ Each rider reacts t o problems in dif ferent ways, so it is imp ortant to confir m what kind of symptoms the rider has encountered. ○ T ry to find out exactly what p roblem occurred under exact ly what conditi ons by asking the rider; knowi[...]

3-22 FUEL SYSTEM (DFI) T roubleshooting the DFI Sys tem Sample Dia gnosis Sh eet Rider name: Registration No. (license pl ate No.): Y ear of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cl oudy , □ rain, □ snow , □ always, □ other: T emperature ?[...]

FUEL SYSTEM (DFI) 3- 23 T ro ubleshooting th e DFI S ystem Poor running □ choke lever pulled out fully (push it in fully) at low speed □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idl e speed □ battery volt age is low (char ge the battery ) □ spark plug l oose (tighte n it) □ spa[...]

3-24 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e NOTE ○ This is not an exhaustive list, giving every possibl e cause for each problem l isted. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○ The ECU may be involved in t he DFI electri cal and ignition sy stem troubles. If t[...]

FUEL SYSTEM (DFI) 3- 25 DFI System T roubl eshooting G uide Symptoms or possible Causes Actions (chapter) Ignition and engine stop swi tches not ON Turn both switc hes ON . Clutch lever not pulled in and gear not in neutral wheth er sidestand up or not Pull the lever in and shi ft the gear in neutral. Though clutch lev er pulled in, sidestand u p a[...]

3-26 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Symptoms or possible Causes Acti ons (chapter) Piston ring / groove clearan ce excessive Inspect and replace ( see chapter 5). Cylinder head gasket damaged Replace (see chapter 5). Cylinder head warped Inspect and replace ( see chapter 5). No valve clearance Adjust (see chapter 2). V alve g[...]

FUEL SYSTEM (DFI) 3- 27 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) Atmospheric pressure sensor tr ouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapt er 3). Battery voltage low Inspect and charge ( see chapter 16). Incorrect idle speed : W ater temperature sensor trouble Inspect[...]

3-28 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Symptoms or Possible Causes Actions (chapter) Subthrottle sensor t rouble I nspect (see chapter 3). Subthrottle val ve actuator trouble Inspect (see chapter 3) . W ater temperature sensor trouble Inspect ( see chapter 3). Atmospheric pressure sens or trouble Inspect (see chapter 3). Inlet a[...]

FUEL SYSTEM (DFI) 3- 29 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) Spark plug d irty , broken or gap malad justed Clean spark plugs and adjust plug gap (see chapter 2). To o l o w fuel pressure Inspe ct (see chapter 3). Fuel pump trouble Insp ect (see chapter 3). Main throttle sensor tr ouble Inspect (see chap[...]

3-30 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Poor Running o r No Power at High Speed: Symptoms or Possible Causes Actions (chapter) Firing incorrect : Spark plug dirty , broken or maladjusted Cl ean spark plug and adjust plug gap (see chapter 2). Spark plug cap trouble Inspect stick coil (see chapter 16). Spark plug cap shor ted or no[...]

FUEL SYSTEM (DFI) 3- 31 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Us e the gasoline recommended in the Owner ’s Manual) Change fuel (see chapter 3). Spark plug incorr ect Repla ce it with the correct plug (see chapter 16). Stick coil trouble Inspect (see chapter 16) . IC igni[...]

3-32 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Symptoms or Possible Causes Actions (chapter) T oo low fuel pressure Inspect fuel li ne and fuel pump (see chapter 3). W ater temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor tr ouble Inspect and replace (see chapter 3).[...]

FUEL SYSTEM (DFI) 3- 33 Self-Diagnosis Self-diagnosis O utline The self-diagnosis syst em has three modes and can be switch ed t o another mode by gr ounding the self -diagnosis terminal. User Mode: The ECU notifies the rider of troubles in DFI system and igniti on system by lighting the FI indic ator when DFI system and ignition syst em parts are [...]

3-34 FUEL SYSTEM (DFI) Self-Diagnos is • T o enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C ] aft er the lead i s fir st grounded, a nd then keep it grounded continu ously [D] for more than 2 sec onds. ○ Count the blinks of the LED light to read the servi ce code. Keep t h[...]

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

3-36 FUEL SYSTEM (DFI) Self-Diagnos is H o wt oR e a dS e r v i c eC o d e s ○ Service codes are shown by a series of long and shor t blinks of the FI indicator LED light as shown below . ○ Read 10th digit and unit digit as the FI indi cator LED light blinks. ○ When there are a number of problems, all the service c odes can be st ored and the[...]

FUEL SYSTEM (DFI) 3- 37 Self-Diagnosis S e r v i c eC o d eT a b l e Servic e Code FI Indicator LED Light Problems 11 Main throttl e sensor malfunction, wiring open or short 12 Inlet ai r pressure sensor malf unction, wiring open or short 13 Inlet air temperature sensor malfuncti on, wiring open or short 14 W ater temperature sensor malfunction, wi[...]

3-38 FUEL SYSTEM (DFI) Self-Diagnos is Backu ps ○ The ECU takes the following measur es to prevent engine damage when the D FI or the ignition system parts have troub les. Service Codes Parts Output Signal Usable Range or Criteria B ackups by ECU 11 Mai n Throttle Sensor Main Throttle Sensor Output V oltage 0.2 ∼ 4.8 V If the mai n throttle sen[...]

FUEL SYSTEM (DFI) 3- 39 Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by EC U 51 Stick Coil #1 (Ignition Coil)* The stick coil primary winding must send signals (output voltage) continuously to t he ECU. If the ignition pr imary winding #1 has failures ( no signal, wiring short or open), the ECU shuts of f the in[...]

3-40 FUEL SYSTEM (DFI) Main Throttle Se nsor (Servic e Code 1 1) Main Throttle Sensor Remov al/Adjustmen t CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set wit h precision at the fac tory . Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. Main Throttle S e[...]

FUEL SYSTEM (DFI) 3- 41 Main Thrott le Sensor (Service Co de 1 1 ) Output V oltag e Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspect ion, Note the follo wing . • Disconnect the main throttl e sensor (gray) [A] and con- nect the harness adapter [B] between these connect ors. Special T o[...]

3-42 FUEL SYSTEM (DFI) Main Throttle Se nsor (Servic e Code 1 1) Resistance Inspection • T urn the ignition switch OFF . • Discon nect the mai n throttle sen sor connector . • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measu re the main t hrottle sens or resistance. Main Throttle Sensor Resistance Conne ctions:[...]

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

3-44 FUEL SYSTEM (DFI) Inlet Air Press ure Sensor (Service Code 12) Out put Voltage Insp ectio n NOTE ○ The output voltage changes accor ding to the lo cal at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Inlet Air Pressure Sensor O utput V oltage Connections to ECU[...]

FUEL SYSTEM (DFI) 3- 45 Inlet Ai r Pressure S ensor (Service Code 12 ) ○ T urn the ignition switch ON. ○ Measure the inl et air pressure sensor output volt age from various vacuum readings, while pull ing the handle of the fork oil level gauge. ○ Check the inlet air pr essure sensor output vol tage, using the following f ormula and chart. Sup[...]

3-46 FUEL SYSTEM (DFI) Inlet Air Press ure Sensor (Service Code 12) Pv = 24 ∼ 55 cmHg[...]

FUEL SYSTEM (DFI) 3- 47 Inlet Ai r Pressure S ensor (Service Code 12 ) Pv = 55 ∼ 86 c mHg Vv: Inlet Air Pressure Sensor Output V olt- age (V) (Digi tal Meter Reading) ID: Id ling TO: Thrott le Full Open Pv: Throttle V acuum Pressure (absolute) ST : Standard of Sensor Output V oltage (v) Ps: Standard At mospheric Pressure ( abso- lute ) UR: Usabl [...]

3-48 FUEL SYSTEM (DFI) Inlet Ai r T em perature S ensor (Service Co de 13) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel T ank Removal). • Discon nect the connector [ A] from the inlet air tempera- ture sensor . • Pull out [B] t he [...]

FUEL SYSTEM (DFI) 3- 49 Inlet Air T emperature Sensor (Service Code 13) Sensor Resistance Insp ection • Remove the inlet air temperature sensor (see t his sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat- sensitive port ion is submerged. • Suspend a thermometer [ B] with the heat-sen sitive por- tion [C] loc[...]

3-50 FUEL SYSTEM (DFI) W ater T em perature Sensor (Se rvice Code 14) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel T ank Removal). • Drain t he coolant about 200 mL (6.76 US oz). • Disconnect th e sensor connector , and unscrew the[...]

FUEL SYSTEM (DFI) 3- 51 W ater T empe rature Sensor (Service Code 14) A. ECU D. W ater T em perat ure Sensor V . Coolant T emperature Gauge in T achometer Sensor Resistance Insp ection • Remove the water temperature sensor (see this se ction). • Refer to the Electri cal System chapter for w ater temper- ature sensor inspec tion.[...]

3-52 FUEL SYSTEM (DFI) Atmosp heric Pressure Se nsor (Servic e Code 15) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○ The atmospheric pressure sensor is the same part as the inl et air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring[...]

FUEL SYSTEM (DFI) 3- 53 Atmospheric Pr essure Sens or (Service Code 1 5) Output V oltag e Inspection • Measure the output voltage at the ECU in the same way as input voltag e inspection. Note the followi ng. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sens or Output V oltage Connections to ECU Meter (+) → G/W lead (t erm inal 4) Me[...]

3-54 FUEL SYSTEM (DFI) Atmosp heric Pressure Se nsor (Servic e Code 15) V a: Atmospheric Pressure Sensor Output V oltage (v) ST : Standard of Sensor Output V oltage (v) UR: Usable Range of Sensor Output V oltage (v) H: Altitude (m or fee t) A. ECU E. Atmospheric Pr essure Sensor[...]

FUEL SYSTEM (DFI) 3- 55 Crankshaft Sensor (S ervice Code 21) Start the engine and switc h the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosi s system does not detect dynamic condi- tion of the crankshaft sensor . In this case, turn off[...]

3-56 FUEL SYSTEM (DFI) Camshaft Positio n Sensor (Service Code 23) Start the engine and swi tch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the tim e of self-diagno sis. If the engine cannot be start ed, the self-diagno sis system does not detec t dynamic condi- tion of th e camshaft position sensor . In t[...]

FUEL SYSTEM (DFI) 3- 57 Speed Sensor (Serv ice Code 2 4, 25) Speed Sensor Removal /Install ation • See the Switches and Sensors section in the Electrical System chapter . Speed Sen sor Inspe ction • See the Switches and Sensors section in the Electrical System chapter . Input V oltage Ins pection NOTE ○ B e sure the battery is fully charged. [...]

3-58 FUEL SYSTEM (DFI) Speed Sens or (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and spe ed sensor connector . Engine Sprocket Cover [C] • Connect a digital meter to the harness adapter leads. Special T ool - Throttle Sensor Setting Adapter: 57001–140 0 ?[...]

FUEL SYSTEM (DFI) 3- 59 V e hicle-down Sensor (S ervice Code 31) Removal CAUTION Never drop the down-sensor , especially on a hard surface. Such a shock t o the sensor can damage it. • Remove: Connection and V ehicle-down Sensor [A] Bolts and W ashers [B] Front [C] Installation • The UP mark [A] of the sensor should f ace upward. T o rque - V e[...]

3-60 FUEL SYSTEM (DFI) V ehicle-down Sens or (Service Co de 31) • T urn the ignition switch OFF . • Remove the sensor . • Connec t a digital volt meter [A] to the con nector with nee- dle adapter set [B]. Special T ool - Ne edle Ada pter Set: 57001 –1457 V ehicle-down Sensor Output V oltage Connections to Sensor Meter ( +) → Y/G lead [ D][...]

FUEL SYSTEM (DFI) 3- 61 V e hicle-down Sensor (S ervice Code 31) A. ECU S. ECU Main Relay T. I g n i t i o n S w i t c h a. ECU Fuse 15A b. V ehicle-down Sensor d. Starter Relay f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A[...]

3-62 FUEL SYSTEM (DFI) Subthrottle Se nsor (Servi ce Code 32) Subthrot tle Sensor Removal/Ad justment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set wit h precision at the fac tory . Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. Subthrottl e Sensor Conn[...]

FUEL SYSTEM (DFI) 3- 63 Subthrottle Sensor (Service Code 32) Output V oltag e Inspection • Remove the throttle body assy (see Thrott le Body Assy Removal). • Measure the output vol tage at the subthrott le sensor in the same way as input voltage inspect ion. N ote the fol- lowing. • Disconnect the subthrott le sensor (black) [A] and (black) c[...]

3-64 FUEL SYSTEM (DFI) Subthrottle Se nsor (Servi ce Code 32) Resistance Inspection • T urn the ignition switch OFF . • Discon nect the subt hrottle sens or connector . • Connect a digital meter [A] to the subthrot tle sensor con- nector [B]. • Measu re the subthr ottle sen sor resistance. Throttle Se nsor Resistance Connections: BL lead [C[...]

FUEL SYSTEM (DFI) 3- 65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53 , 54) Stick Coi l #1: Ignition Coil (Service Code 51) Stick Coi l #2: Ignition Coil (Service Code 52) Stick Coi l #3: Ignition Coil (Service Code 53) Stick Coi l #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION Never drop the stick coils, especially on a ha[...]

3-66 FUEL SYSTEM (DFI) Stick Coils (#1, #2, # 3, #4: Service Code 51, 52 , 53, 54) A. ECU M. St ick Co ils N. Engine Stop Switch T . Ignition Switch X. Ignition Fuse 10 A Y. J u nction Box d. Starter Relay e. Joint Connector D f. Sealed Battery k. Ma in Fus e 30 A[...]

FUEL SYSTEM (DFI) 3- 67 Subthrottle V alve Actuator (S ervice Code 6 2) Subt hrott le V alv e Actua tor R emov al CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with preci sion at the factory . Never drop the actuat or , especially on a hard sur- face. Such a shock t o the actuator can damage it. Audibl [...]

3-68 FUEL SYSTEM (DFI) Subthrottle V alve Actuator (Serv ice Code 62) Inpu t Voltage In spec tion NOTE ○ Be sure the batter y is fully charged. • T urn the ignition switch OFF . • Remove the throttle body assy (see Throttle Body Assy Removal). • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the nee[...]

FUEL SYSTEM (DFI) 3- 69 FI Indicator LED Light Inspection Flow Chart[...]

3-70 FUEL SYSTEM (DFI) FI Indicato r LED L ight LED Light In spection • Remove the meter unit (see Electr ical System chapter). • Using t wo auxiliary leads, supply batt ery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: M eter Connector [C] (disconnec ted) Connection: BR/W Lead T erminal [1] o[...]

FUEL SYSTEM (DFI) 3- 71 ECU CAUTION Never drop the ECU, especially on a har d surface. Such a shock to the ECU can damage it. ECU Identi ficat ion ○ Most countries have t heir own regulati ons, so each ECU has d if ferent characteri stic. So, do not confuse ECU’ s with each other and use only the ECU’s for your cou ntry . Otherwise, the motor[...]

3-72 FUEL SYSTEM (DFI) ECU If the rubber protect or [A] is removed, install it. ECU [B] ECU P ower Supply Ins pec tion • V isually inspect the ter minals [A] of the ECU connectors. If the connector is clogged wit h mud or dust, blow it off with compressed air . Replace the main har ness if the ter minals of the main harness connectors are crack e[...]

FUEL SYSTEM (DFI) 3- 73 ECU • Check the ECU power sourc e voltage with a digi tal meter [A]. ○ Position the terminal in accordance with terminal num bers of ECU connectors [B] in this chapter figure. Battery [C] ECU P ower Source In spection Mete r betwe en T erminal 1 3 (W/Y) and Connections: Batte ry (–) T erminal between T erminal 43 (W/BK[...]

3-74 FUEL SYSTEM (DFI) DFI Power Sour ce ECU Fuse Removal • Refer to the Elec trical Syst em chapter for the ECU fuse rem ova l. ECU F use In stallat ion If a fuse fail s during operat ion, inspect the DFI sy stem to determine the c ause, and then replace it with a new fuse of proper amperage. • Refer to the Elec trical Syst em chapter for the [...]

FUEL SYSTEM (DFI) 3- 75 Fuel Line Fuel P res sure In spec tion NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electr ical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to kno w symptom well. ○ Be sure the battery is fully charge[...]

3-76 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure wit h the engine idling. Fuel Pressure (idling) Standa rd: 310 kPa ( 3.2 kgf/cm² , 46 psi) NOTE ○ The gauge needle will fl uctuate. Read the pressure at the average of the maximum and mi nimum indicati ons. If the f uel pressure is nor mal, the [...]

FUEL SYSTEM (DFI) 3- 77 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. Front [B] • Be sure to place a piece of cloth around the f uel pump outlet hose. • Remove the fuel pump outlet hose [A] from the f uel pump [B] and the de livery pipe [C] (see Fu el Pump Removal). Front [D] WA R N I N G Be prepared for fuel spill[...]

3-78 FUEL SYSTEM (DFI) Fuel P ump Fuel Pump Removal CAUTION Never drop the fuel pump, especiall y on a hard sur- face. Such a shock to the pump can damage it . W ARNING Gasoline is extremely flammable and can be explo- sive under cert ain conditions. Make sure the ar ea is well-ventilat ed and free from any source of flame or sparks; this includes [...]

FUEL SYSTEM (DFI) 3- 79 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Check that the fuel pump (–) terminal [A] and band [B] are in place. Front [C] • Apply a non-permanent locking agent to t he threads of the fuel pump bolts. • T ighten the fuel p um p bolts to a snug f it, following the tightening sequence shown. • Fo[...]

3-80 FUEL SYSTEM (DFI) Fuel P ump • Connect the hand tester ( 25 V DC) to the fuel pump con- nector [A] with needle adapter set. Front [ B] Special T oo ls - Hand T es ter: 57 001–13 94 Needle Ada pter Set: 57001 –1457 ○ Measure the operating v oltage with the engine stopped, and with the connector joined. • T urn the ignition swi tch ON.[...]

FUEL SYSTEM (DFI) 3- 81 Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay , especially on a hard surface. Such a shock to the rel ay can damage it. • Remove the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of the storage compartment. • Disconnect the connec tor . Front [B] Fuel Pu mp Re lay Ins[...]

3-82 FUEL SYSTEM (DFI) Fuel I njectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly . Audi ble In spect ion • Start the engine. • Apply the ti p of a screwdriver [ A] to the injector [C]. Put the grip end onto your ear , and listen whether the injector is clicki ng or not. ○ A sound scope [B] can also be used.[...]

FUEL SYSTEM (DFI) 3- 83 Fuel Injectors Output V oltag e Inspection • T urn the ignition swi tch OFF . • Remove the ECU (see ECU section). • Connect a digital vo ltmeter [A] to the ECU connector [B] with the needle adapter set [C]. Speci al T ool - Needl e Adap ter Set: 57001– 1457 Injector Output V oltage Connections to Injector #1 Meter ( [...]

3-84 FUEL SYSTEM (DFI) Fuel I njectors Injector S ignal T est • Prepare two test li ght sets with male terminals as shown. Rating of Bulb [A ]: 12 V × 3 ∼ 3.4 W T erminal Width [ B]: 1.8 mm ( 0.071 in.) T erminal Thick ness [C]: 0.8 mm (0.031 in. ) CAUTION Do not use larger terminals than specified above. A larg er terminal could damage the in[...]

FUEL SYSTEM (DFI) 3- 85 Fuel Injectors Injector Resistance Inspectio n • Remove the fuel tank (see Fuel T ank Removal). • Disconnect the connect or from the injector [A] (see Throt- tle Body Assy Disassembly/Assembl y). • Measure the injector resist ance with the hand tester [B]. Front [C] Speci al T ool - Hand T ester : 570 01–1394 Injecto[...]

3-86 FUEL SYSTEM (DFI) Fuel I njectors • Check the injector fuel line for leakage as follows: ○ Connect a commercial ly availabl e vacuum/pressure pump [A ] to the nipple of the delivery pi pe [B] with a high-pressur e fuel hose [C] (both ends connected with the clamps [D]) as s hown. T orque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 [...]

FUEL SYSTEM (DFI) 3- 87 Fuel Injectors A. ECU K. Fuel Injectors N. Engine Stop Switch T. I g n i t i o n S w i t c h X. Ignition Fuse 10 A Y . Junction Box Z. Fuel Pump Relay (for fuel pump an injectors) d. Starter Relay e. Joint Connector C f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A[...]

3-88 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle G rip Play In spection /Adjustme nt • Refer to the Throttle Control System Inspection i n the Pe- riodi c Maintenance chapter . Choke Lever Op eratio n ○ Do not use the choke lever except when the engine has a starti ng difficul ty like in cold weather (10 °C, 50 °F or be- low) or at hi[...]

FUEL SYSTEM (DFI) 3- 89 Throttle Body Assy Idle Sp eed I nspe ction /Adj ustm ent • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Thrott le Bore Cl eaning • Refer to the Throttle Control Syst em Inspection in the Pe- riodic Maintenance chapter . Engine V acuum Synchroniz ation Inspectio n/Adjustment • Refer to the[...]

3-90 FUEL SYSTEM (DFI) Throttle Body Ass y • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cle aner Duct Clamp B olts [B] Special T ool - Carburetor Drain Plug Wrench, Hex 3: 57001–126 9 • Remove: Right and Left Side Covers (s ee Frame chapter) Coolant Reserve T ank (see Coolant Change in the Peri- odic Maintenance c hapter) Starter Relay [...]

FUEL SYSTEM (DFI) 3- 91 Throttle Body Assy • Remove the bolt [A] and the thrott le cable plate [B] f rom the throttle body front side. • Remove the t hrottle cab le lower ends from the t hrottle pulley . • Remove: Choke Cable Upper End ( From choke lever) Choke Cable Lower End [A] Throttl e Body #2 [B] • After removing the thrott le body as[...]

3-92 FUEL SYSTEM (DFI) Throttle Body Ass y • Apply a t hin coating of grease t o the throttl e cable upper ends. • Insta l l the upper ends of the throttle cables in the grip (see Throttl e Body Assy R emoval) . • Fit the project ion [A] of the right swit ch housing into the hole [ B] of the handlebar ( front view). • T urn the throttle gri[...]

FUEL SYSTEM (DFI) 3- 93 Throttle Body Assy CAUTION Never drop the injector , especially on a hard sur- face. Such a s hock to the injector can damage it. • Pull out [A ] the inject ors along wit h the deli very pipe [B]. If necessary , remove the injector s from the deli very pipe. Replace the O-rigs of the indicators. If necessary , cut straps a[...]

3-94 FUEL SYSTEM (DFI) Air C leaner Element Remova l/Instal lation • Refer to the Air Cleaner Element Cleaning in the Periodic Mainte nance chapter . Air Cle aner Oil D raini ng A drain hose is connected to the bottom of the air cleaner to drain water or oil acc umulated in the cleaner part . • V isually check the drain h ose [A] if t he water [...]

FUEL SYSTEM (DFI) 3- 95 Fuel T ank Fuel T ank Removal WA R N I N G Gasoline is ext remely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventil ated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T urn the ignition switch OFF . Be prepared for fuel sp[...]

3-96 FUEL SYSTEM (DFI) Fue l T ank • Be sure to place a piece of cloth [A] around the fuel hose pump outlet joint [ B]. • While p inching t he hose joint l ocks [C] wit h fingers, pull the joint out along the deliver y pipe. Front [D] W ARNING Be prep ared for fuel spill age; any spilled fuel must be completely wiped up immediatel y . When the [...]

FUEL SYSTEM (DFI) 3- 97 Fuel T ank Fuel T ank Installa tion • Note the above W ARNING (see Fuel T ank Removal). • Route the hoses correct ly (see Appendix chapter ). • Check that the rubber dampers [ A] are on the frame and the fuel tank. Front [B] • Check that the dampers [A] are in place on the fuel t ank as well. Front [B] If the dampers[...]

3-98 FUEL SYSTEM (DFI) Fue l T ank Fue l T ank an d Cap Inspect ion • V isually inspect t he gasket [A] on the tank cap for any damage . Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [ C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank a[...]

FUEL SYSTEM (DFI) 3- 99 Evaporative Em ission Contr ol System Parts R emoval/In stallatio n WA R N I N G Gasoline is extremely fl ammable and can be ex- plosive under certai n conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated a nd free fr om any source of fl ame or sparks; this includes any appliance wi[...]

3-100 FUEL SYSTEM (DFI) Evaporative Emiss ion Control S ystem Sepa rator O pera tion T est W ARNING Gasoline is extremely flammable and can be ex- plosive unde r certain conditions. T urn the igniti on switch OFF . Do not smoke. Make sure the area is well-ventilat ed and free from any source of flame or sparks; this includes any appliance with a pi[...]

COOLING SYSTEM 4- 1 4 Cooling System T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 4-2 Coola nt Fl ow Ch art .... ...... .... ....... .... ...... .... ...... .... ....... .... ...... .... ...... .... ..... ...... .... ...[...]

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

COOLING SYSTEM 4- 3 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Radiator hose cla mp screws 2 0.2 17 in·lb 2 Thermostat air bleeder bolt 7.8 0.80 69 in·lb 3 Radiator fan bol ts 8.3 0.85 74 in·lb 4 Water pum p imp eller b olt 9.8 1.0 87 in·lb 5 W ater pump cover bolts 11 1.1 95 in·lb 6 W ater pump drain bol t 11 1.1 95 in?[...]

4-4 COOLING SYSTEM Coolant F low Cha rt[...]

COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 2. W ater Pump 3. Cylinder Jacket 4. Cylinder Head Jacket 5. Thermostat Housing 6. Thermostat Air Bleeder Bolt 7. Radiator Cap 8. Radiator 9. Oil Filter 10. Outlet Hose 1 1. Inlet Hose 12. Oil Cooler 13. Reserve T ank 14. Reserve T ank Hose 15. Reserve T ank Overflow Hose 16. Radiator Fan 17. W at[...]

4-6 COOLING SYSTEM Specif ications Item Standard Coolant provided when shipping: T ype (recommended) Permanent type of antifreez e (soft water and ethylene glycol plus c orrosion and rust inhi bitor chemicals for aluminum engines and radiat ors) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point – 35°C (– 31°F) T otal amount 2[...]

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

4-8 COOLING SYSTEM Coolant Coolant De terior ation Inspe ction • Remove the left side cover (see Frame chapter ). • V isual ly inspect the coolant [ A] in the reserve tank. Front [B] If whit ish cotton-li ke wafts ar e observed, aluminum par ts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rus ting. In eit[...]

COOLING SYSTEM 4-9 Coolant Pressure T esting • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling sy stem pressure tes ter [A] on the filler neck [B]. NOTE ○ Wet the cap sealing surfaces wi th water or coolant to preve nt pressure leaks. • Build up pressur e in the s ystem carefull y until[...]

4-10 COOLING SYSTEM W ater Pum p Water Pump Removal • Refer to Oil Pump Removal in the Engine Lubri cation Sys- tem ch a pter . Wa t e r P u m p [ A ] Front [B] Water P um p Insta llati on • Refer to Oil Pump I nstallation i n the Engine Lubricat ion System chapter . Water Pump I nsp ecti on • Check the drainag e outlet passage [A] at the bot[...]

COOLING SYSTEM 4-1 1 W ater Pump • Be sure to repl ace the mechanical seal , oil seal, and O -ring wit h new ones because t hese parts wi ll be damaged by removal. • Apply plenty of high t emperature grease to the oil seal lips. • Apply oil to the outer circ um ference of the oil seal. • Press the oil seal [A] into the water pump body [B] w[...]

4-12 COOLING SYSTEM Radi ator Radiat or Removal W ARNING The radiator f an is connected directly to t he bat- tery . The radiat or fan may start even if the ignition switch is off. NEVER TOUCH THE RADIA TOR F AN UNTIL THE RADIA TOR F AN CONNECTOR IS DIS- CONNECTED. TOUCHING THE F AN BEFORE THE CONNECTOR IS DISCONNECTED COUL D CAUSE INJUR Y FRO M TH[...]

COOLING SYST EM 4-13 Radiator • If necessary , remove: Radiator Fan Mounting Bolt s [A] Radiator Fan [B] Radi ator I nspe ction • Check the radiator core. If ther e are obstr uctions t o air flow , remove t hem. If the cor rugated fins [A] are deformed, carefull y straighten t hem. If the air pa ssages of the radiator c ore are blocked more tha[...]

4-14 COOLING SYSTEM Radi ator • Install the cap [A] on a coo ling system press ure tester [ B]. NOTE ○ Wet t he cap sea ling surfaces with water or coolant to prevent pressure leaks . • W atching the pressure gauge, pump the pressure tester to build up the pr essure until the relief valve opens: the gauge needle flicks downward. Stop pum ping[...]

COOLING SYST EM 4-15 Thermostat Ther mosta t Rem oval • Remove: Coolant : Drain about 200 mL Fuel T ank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt [ A] W ater T emperature Sensor Connector [ B] Three W ater Hoses [C] • Remove the thermostat housing [D]. Front [E] • Remove the screws [A], take off the cap [B], and take out the the[...]

4-16 COOLING SYSTEM Thermo stat • T o check valve opening t emperature, suspend the ther- mostat [A] in a cont ainer of water and raise the t empera- ture of the water . ○ The thermostat must be completel y submerged and must not touch the containe r sides or bottom. Suspend an ac- cur at e thermometer [B] in the water so that the heat sen- sit[...]

COOLING SYST EM 4-17 Hose a nd Pip es Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses i n accordance wit h the Cable, Wire, and Hose Routing section in the Appendix chapter . • Wet the int ernal diameter of both ends of the wate[...]

4-18 COOLING SYSTEM Radiator Fan Switch, Water T emp erature Sen sor CAUTION The fan switch or the water temper ature sensor should never be al lowed to fall on a hard sur face. Such a shock to their parts can damage t hem. Radiat or Fan Switch Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chap ter). • Remove the s[...]

ENGINE TOP END 5-1 5 Engine T o p End T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 5-2 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 5-6 Special T ools and Sealant ........ ....... .. 5-8 Clean Air System ........ ...... ...... ..... ...... 5-10 Air Su ction V a lve Re mova l .... ...... . 5- 10 Air Suc[...]

5-2 ENGINE TOP END Exploded View[...]

ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Air suction val ve cover bolts 10 1.0 87 in·lb 2 Cylinder head cover bolts 10 1.0 87 in·lb 3 Camshaft cap bolts (L=45 mm) 12 1.2 104 in·lb 4 Camshaft cap bolts (L=40 mm) 12 1.2 104 in·lb 5 Cylin der head bolts (M10 new bolts) 54 5. 5 40 MO, S (W asher) 5 Cylinder[...]

5-4 ENGINE TOP END Exploded View[...]

ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Coolant Drain Plug (Cylinder) 10 1.0 87 in·lb 2 Exhaust pipe manifol d holder nuts 17 1.7 12 3 Muffler body cl amp bolts 17 1.7 12 4 Muffler body mounting bolts and nuts 34 35 25 5 Crank shaft sensor cover bolt s 11 1.1 95 in· lb 6: "R" marked side faces [...]

5-6 ENGINE TOP END Specif ications Item Standard Servi ce Lim it Clean Air System: V acuum switch valve closing Open → Close pressure: 45 ∼ 53 kPa --- (340 ∼ 400 mmHg, 6.5 ∼ 7.7 psi) Cam shaf ts : Cam height: Exhaust 36.146 ∼ 36.254 mm 36.05 mm (1.4231 ∼ 1 .4273 in.) (1. 419 in.) Inlet 36.746 ∼ 36. 854 mm 36.65 mm (1.4467 ∼ 1 .4509 [...]

ENGINE TOP END 5-7 Specifications Item Standard Service L imit V alve/valve guide clearance (wobble method): Exhaust 0.09 ∼ 0.18 mm 0.40 mm (0.0 035 ∼ 0.0071 in.) (0 .016 in.) Inle t 0.03 ∼ 0.12 mm 0.33 mm (0.0 012 ∼ 0.0047 in.) (0 .013 in.) V alve seat cutting angle 45°, 3 2°, 60° -- - V alve seating sur face: Width: Exhaust 0.8 ∼ 1.2[...]

5-8 ENGINE TOP END Special T oo ls and Sealant Compression Gauge: 57001–2 21 V alve S pring Com pressor Ass embly: 57001–2 41 Piston Pin Pul ler Assembly : 57001–9 10 V alve Seat C utter , 4 5° - 27.5: 57001–11 14 V alve Se at Cutt er , 45° - 32: 57 001–1 1 15 V alve Seat C utter , 32° - 28: 57001–11 19 V alve Seat C utter , 32° - 3[...]

ENGINE TOP END 5-9 Special T ools and S ealant V alve Spring Compressor Adapter , 22 : 57001–120 2 Spark Plug W rench, Hex 16: 57001–126 2 Fork Oil Level Gauge: 57001–129 0 Compression Ga uge Adapter , M10 × 1.0: 57001–131 7 V alve Guide Arbor , 4.5: 57 001–133 1 V alve Seat Cutter Holder , 4.5 : 57001–1 330 V alve Guide R eamer , 4.5 [...]

5-10 ENGINE T OP END Clean A ir System Air Suction V alve Removal • Remove: Fuel T a nk (see Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction V alve Cover Bolts [C] and Clamp Air Suc tion V alve Cover [D] Air Suction V alve Air Suction V alve Install ation • Install the air suction valve [A] so that it s wider side [B] of t[...]

ENGINE T OP END 5-1 1 Clean Air System V acuum Switch V alve T est • Remove: Fuel T ank (see Fuel System (DFI) chapter) Va c u u m S w i t c h Va l v e • Connect a vacuum gauge [ A] and syringe [B] or f ork oil level gauge to the vacuum hoses as shown. Speci al T ool - Fork O il Level Gaug e: 5 7001–1 290 Air Flow [C] • Gradually rai se the[...]

5-12 ENGINE T OP END Cylinder Head Cov er Cylin der He ad Cov er Re moval • Remove: Fuel T a nk (see Fuel System (DFI) chapter) V acuum Switch V alve and Hoses Stick Coils (see Electrical System chapter) Air Suc tion V alve Covers [A] • Remove the cylinder head cover bolts [A] and take of f the cove r . Cylin der Hea d Co ver In stall ation •[...]

ENGINE T OP END 5-13 Cylinder Head Cover • Install the washer [A] with the metal side faces upward. • T ighten: T orque - Cylind er Head Cov er Bolts [ B]: 10 N· m (1.0 k gf·m , 87 in·lb)[...]

5-14 ENGINE T OP END Cams haft Chai n T ensi oner Camshaft Chain T ensioner Removal CAUTION This is a non-return type camshaft chain tensioner . The push rod does not return to its origi nal position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensi oner , do not take out the mounti ng bo[...]

ENGINE T OP END 5-15 Camshaft, Cam shaft Chain Camshaft Removal • Remove: Fuel T ank (see Fuel System (DFI) chapter) Stick Coil s (see Electr ical System) Cylinder Head Cover (see Cylinder Head Cover R e- moval) Pickup Coil Cover • Position the c rankshaft at #1, 4 p iston TDC. [A] TDC mark for #1, 4 Pistons [B] T iming Mark (crankcas e halves [...]

5-16 ENGINE T OP END Camshaft, Camsh aft Chain • Apply engine oil to all cam parts and jour nals. • If a new camshaft is to be used, apply a thin coat of molyb- denum d isulfide gr ease to the cam surf aces. NOTE ○ The exhaust camshaft has a 030 EX mark [A] and the inlet camshaft has a 030 IN m ark [B]. Be care ful not to mix up these shafts.[...]

ENGINE T OP END 5-17 Camshaft, Cam shaft Chain Camshaft, Camshaft Ca p Wear • Remove: Camshaft Chain Guide Camshaft Cap • Cut strips of plastigage to jour nal width. Place a strip on each journal parallel to t he camshaft instal led in the correct positi on. • Measure each c learance between the c amshaft journal and the camshaft cap using pl[...]

5-18 ENGINE T OP END Camshaft, Camsh aft Chain Camshaft Chain Removal • Split the crankcase (s ee Crankshaft/T ransmission chap- ter). • Remove the camshaft chain [A] from the crankshaft sprocket.[...]

ENGINE T OP END 5-19 Cylinder Head Cylinde r Compressi on Measuremen t NOTE ○ Use the battery which is fully charged. • W arm up the engine t horoughly . • Stop the engine. • Remove: Seats (see Frame chapter) Fuel T ank (see Fuel System (DFI) chapter) Stic k Coils Spark Plugs Owners T ool - Spark Plug Wrench, He x 1 6 • Attach the compres[...]

5-20 ENGINE T OP END Cylinder He ad Cylind er Head Removal • Drain the coolant (see Cooling System chapter ). • Remove : Exhaust Pipes (see Exhaust Pipe Removal) Coolant Drain Bolt [A] (cylinder ) • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft Position Sensor (see Elect rical System chap- ter) Camshafts (see Camsha[...]

ENGINE T OP END 5-21 Cylinder Head • Install: Front Camshaft Chain Guide [A] O-ring [B] Collar [C] • T ighten: T orque - Front C amshaft Chain Guide Bolt (Upper) [D]: 25 N·m ( 2.5 kg f·m, 18 f t·lb ) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m ( 1.2 kgf·m, 104 in ·lb) • Install: Rear Camshaft Chain Guide [F] • T ighten: T orqu[...]

5-22 ENGINE T OP END Va l v e s V alve Cl earance In spection • Refer to the Engi ne T op End in the Per iodic Maintenance chapte r. V alve Clea rance Adjustm ent • Refer to the Engi ne T op End in the Per iodic Maintenance chapter . Valve Remova l • R emove the cylin der head (see Cylinder Head Removal). • Remove the valve li fter and shim[...]

ENGINE T OP END 5-23 V a lves V alve G uide Instal lation • Apply oil to the valve gui de outer surface before ins talla- tion. • Heat the area around the valv e guide hole to about 120 ∼ 150 °C (248 ∼ 302 °F). • Drive the valve gui de in from the top of the head using t he valve guide arbor . The flange s tops the guide from going in t[...]

5-24 ENGINE T OP END Va l v e s Valve Seat I nspe ction • Remove the valve (see V alve Removal). • Check t he valve seating sur face [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside di ameter is too large or too small, repai r the seat (see Seat Repair). [...]

ENGINE T OP END 5-25 V a lves Seat Cutter Operation Care: 1. This valve seat cutter is devel oped to grind the valve for repair . Therefore the cutter must n ot be used for other purposes than seat repair . 2. Do not drop or shock the val ve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to appl y engine oil to the valve s ea[...]

5-26 ENGINE T OP END Va l v e s • Measure the outside diameter of the seating surface with a vernier ca liper . If the o utside diameter of the se ating surface is t oo small, repeat the 45° grind until the diamet er is within th e spec- ified range. Widen ed Width [A] of engagement by machi ning with 45° cutter Ground V olume [B] by 32° cutt [...]

ENGINE T OP END 5-27 V a lves If the seat width is too wide, m ake the 60° [A] grind de- scribed below . If the seat width is within the specifi ed range, lap the valve to the seat as described below . • Grind the seat at a 60° angle until the seat width is within the specified range. ○ T o make the 60° grind, fit 60° cutt er into the holde[...]

5-28 ENGINE T OP END Va l v e s[...]

ENGINE T OP END 5-29 Cylinder , Pistons Cylinde r Removal • Remove: Cylinder Head (see Cylinder Head Removal) Wa t e r H o s e [ A ] • Remove the cylinder [B]. Cyli nder Ins talla tion NOTE ○ If a new cylinder is used, use new piston ring. • Install the pins [A] and new cylinder gasket [B]. • Apply engine oi l to the cyli nder bore. • T[...]

5-30 ENGINE T OP END Cylinder , Pistons • Remove the piston pin s. Special T oo l - Piston P in Puller Ass embly: 5700 1–910 [A] • Remove the pistons. • Carefull y spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it. • Remove the 3-piece oil ring with your thumb s in the same manner [...]

ENGINE T OP END 5-31 Cylinder , Pistons NOTE ○ If a new piston i s used, use new pist on ring. • Install the piston with i ts hollow facing forward. • Fit a n ew piston pin snap ring into the si de of the piston so that the ring opening [A] does n ot coincide with the slit [B] of the piston pi n hole. ○ Apply molybdenum disulfide oil soluti[...]

5-32 ENGINE T OP END Cylinder , Pistons Piston Ring Groove Width • Measure the pi ston ring groove width. ○ Use a ve rnier caliper at several points around the pis ton. Piston Ring Groove Width Standa rd Service L imit T op [A] 0.83 ∼ 0.85 mm 0.9 3 mm (0.032 7 ∼ 0.0335 in.) (0.037 in.) Second [B] 0.82 ∼ 0.84 mm 0.9 2 mm (0.032 3 ∼ 0.033[...]

ENGINE T OP END 5-33 Throttle Body Holder Throttle Body Holder Insta llation • Be sure t o instal l the O-ri ngs [A]. • Install the c lamps [B] as shown and so t hat its hole fit on the project ion [C] of the holder . • T ighten: To r q u e- Throt tle Body Holder Bolts [D]: 1 2 N·m (1.2 kgf·m, 104 in ·lb ) Throttle Body Holder Clamp Screws[...]

5-34 ENGINE T OP END Muffler W ARNING T o avoid a serious burn, do not remove the mufflers when the engine i s still hot. Wait until the muff lers cool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolts [A] Muffl er Body Mounting Bolts [B] Muffler Body [ C] Exhaust Pipe Removal • Remove: Muffler Body Clamp Bolts [A] Exhaust Pipe Mani[...]

ENGINE T OP END 5-35 Muffler ○ Install the muff ler body clamp bolts as shown. [L] Upper Side [M] Ins ide [N] Connection Part Detail • Thoroughly warm up the engine, wait until the engi ne cools down, and retighten all the bolts and nuts.[...]

[...]

CLUTCH 6-1 6 Clutch T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 6-2 Spec ifica tions .. .... ...... .... ...... .... ....... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...... .... ...[...]

6-2 CLUTCH Exploded View[...]

CLUTCH 6-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Clutch lever clamp bolts 7.9 0.8 69 in·lb S 2 Clutch cover bolts (L = 32 mm) 11 1.1 95 in·lb 3 Clutch cover bolts (L = 45 mm) 11 1.1 95 in·lb 4 Clutch cover bolts (L = 30 mm) 11 1.1 95 in·lb 5 Clutch cover bol ts 11 1.1 95 in·lb 6 Oil fille r plug 1.5 0.15 13 in·lb 7 [...]

6-4 CLUTCH Specif ications Item Standard S ervic e Lim it Clutch Lever Free Play 2 ∼ 3 m m (0.08 ∼ 0.12 in.) --- Clu tch : Clutch plate assembly 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 in.) -- - Fricti on plate t hickness 2.72 ∼ 2.88 m m (0.107 ∼ 0.1 13 in.) 2.4 mm (0.094 in.) Fricti on and stee l plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012[...]

CLUTCH 6-5 Special T ools and S ealant Inside Circlip P liers: 57001–143 Clutch Holder: 57001–124 3 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20[...]

6-6 CLUTCH Clutch L ever and Ca ble Clut ch L ever Fre e Play Ins pect ion • Refer to the Clutch Adjust Inspect ion in the Periodic Main- tenanc e chapter . Clutch Lever Free Play Adjustmen t • Refer to the Clutch Adjust Inspect ion in the Periodic Main- tenance chapter . Cable Removal • S lide the dust cover [A] at the clutch cable lower end[...]

CLUTCH 6-7 Clutch C over Clutch Cover Removal • Remove: Engine Oil (drai n, see Engine Oil Change section in the Periodic Maintenance chapt er) Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B] Clutch Cable Bra cket [C] • T urn the release lever [A] toward the rear as shown, and rem ove the cl utch c over [B] . [C] about 90° Clutch Co[...]

6-8 CLUTCH Clutch Cover • Fit the spring [A] as shown. [B] Vi ewed from Rear [C] Rel ease Shaft [D] Clutch Cover Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings • Remove: Circlip [A] Special T ool - Inside Circ lip Pliers [B]: 5700 1–143 • Remove: Oil Level Gauge [C] Clutch Cover Assembly • Replace the needle bearings an[...]

CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (drai n, see Engine Oil Change section in the Periodic Maintenance chapt er) Clutch Cover ( see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Spr ings Clutch Spri ng Plate [B] (wi th thrust bearing and pusher [C]) • Remove: Fricti on Plates, Steel Plates Spring, Spring Seat Clutch Hub[...]

6-10 CLUTCH Clutch ○ Install the spacer [A] so that the tapered side [B] faces inwar d. ○ Install the washer [A] so that the OUT SIDE mark faces outward. ○ Replace the clutch hub nut wi th a new one. ○ Holding the clutch hub, tighten the cl utch hub nut. Special T ool - Cl utch Ho lder: 57 001–1243 T orque - Clutch Hub Nut: 135 N·m (14 k[...]

CLUTCH 6-1 1 Clutch • Apply molybdenum disulfide greas e to the pusher ends [A] and install the pusher [B]. • Apply engine oi l to the needle beari ng [C] and instal l it. • Install the washer [D]. • Align the mark [A] of t he clutch spring pl ate [B] with the groove [C] of the clutch hub. • Install the clut ch spring plate and spring, an[...]

6-12 CLUTCH Clutch Clutch Plat e A ssembly Adj ustment • Inspect the clutch pl ate assembly length, and then re- place t he steel pl ate(s) whic h brings the length wi thin the specifi ed range. • Remove: Sprin gB o l t s Spring Holders Springs Spring Pl ate • Replace the f ollowing steel pl ate(s). Part No. Thic kness 13089–107 3 2.0 m m ([...]

ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 7-2 Engin e Oil Fl ow Cha rt ...... .... ....... .... ...... .... ...... .... ....... .... ...... .... ...... .... .[...]

7-2 ENGIN E LUBRICA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Oil filler plug 1.5 0.15 13 in·lb 2 Engine drain plug 20 2.0 14.5 3 Oil filter (cart ridge type, P/No. 16097–1070) 26 2.7 20 EO, R 3 Oil filter (cart ridge type, P/No. 16097–0002) 31 3.2 23 EO, R 4 Oil cooler mounting bolt 76 7.8 56 EO 5 Oil pan bol[...]

7-4 ENGIN E LUBRICA TION SYSTEM Engine Oi l Flow C hart[...]

ENGINE LUBRICA TION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oi l Passage 2. Oil Passage Hole in Alter nator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Fil ter 7. Oil Cooler 8. Oil Pr essure Switch 9. Oil Pipe 10. Oil Pump 1 1. T o Drive Shaft 12. Oil Pipe 13. T o Output Shaf t 14. Drive S[...]

7-6 ENGIN E LUBRICA TION SYSTEM Specif ications Item Standard Engine Oil: Ty p e API S E, SF or SG API SH or SJ with JASO MA Vi sc o s it y SA E 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filt er is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level Between upper and l ower level lines Oil [...]

ENGINE LUBRICA TION SYSTEM 7-7 Special T ools and S ealant Oil Pressure Gauge , 10 kgf/cm²: 57001–164 Oil Press ure Gauge Adap ter , PT 3/8: 57001–123 3 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20 Oil Filter Wre nch: 57001–1 249[...]

7-8 ENGIN E LUBRICA TION SYSTEM Engine Oil and Oil Filter W ARNING Motorcycle operation wit h insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear a nd may result in engine or t rans- mission seizure, accident , and injury . Oil Level Inspect ion • Check that the engine oil level is between the upper [A] and lower [...]

ENGINE LUBRICA TION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drai n, see Periodic Maintenance chapter) Muff ler (see Engine T op End chapter) Oil Pan Bolts [A] Oil Pan [B] ○ Remove the oil pipe [A], oil pressure relief val ve [B] and oil screen [C] as necessary . Oil Pan Installation • Clean the oil scr een [A]. • Install th[...]

7-10 ENGINE LUBRICA TION SYSTEM Oil Pr essure Relief V alve Oil Pressure Relie f Valve Removal • See Oil Pan Removal. Oil Pressure Relief V alve Installation • See Oil Pan Instal lation. Oi l Pressure Relief V alve Inspect ion • Check to see if the val ve [A] slides smoothly when push- ing it i n with a wooden or other soft rod, and see i f i[...]

ENGINE LUBRICA TION SYSTEM 7-1 1 Oil Pump Oil Pump Removal • Drain: Coolant (see Periodic Maintenance chapter) Engine Oil (see Periodi c Maintenance c hapter) • Remove: Wa t e r H o s e [ A ] W ater P ipe Fittin g Bolt s [B] W ater Pipes [C] • Remove: W ater P ump Cover Bolts [A] Clamp [B] W ater Pum p Cover [C] • Remove: W ater Pump Impell[...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pu mp • Fit the pin [A] of the oil pump cover [B] into the hole [C] in the crankcase. • Instal l: Pins [A] W ater Pump Body [B] • Instal l: Impeller [A] and Bolt [B] • T ighten: T orque - Wate r Pump Impeller Bolt: 10 N·m (1.0 kgf·m, 87 in·lb) • Instal l: Pins [C] W ater Pump Cover an d Bolts T orq u[...]

ENGINE LUBRICA TION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Removal • Remove: Clutch (s ee Clutch chapter ) Oil Pan (see Oil Pan Removal) Circlip [A] and W asher [B] Oil Pump Drive Gear [C] Oil Pump Dri ve Gear Instal lation • Apply molybdenum disulf ide oil solution t o the journal por- tions [A] on the oil pump gear shaft [B]. • Install: W[...]

7-14 ENGINE LUBRICA TION SYSTEM Oil Cooler Oil C ooler R em oval • Drain: Coolan t (see Per iodic Maintenance chapt er) Engine Oil (see Periodic Maintenance chapt er) • Remove: Oil Fil ter (see Periodic Maintenance chapter) Wa t e r H o s e [ A ] Oil Cooler Mounting Bolt [B] and W asher Oil Coo ler [C] and W ater Hose Oil C ooler I nstalla tion[...]

ENGINE LUBRICA TION SYSTEM 7-15 Oil Pressure M easuremen t Oil Pressur e Measurement • Remove the oil passage plug, and at tach the adapter [A] and gauge [B] to the plug hole. Speci al T ools - Oil Pres sure Gau ge, 10 kgf/c m²: 57001–16 4 Oil Press ure Gauge Adap ter , PT 3/8: 57001 –1 233 • Start the engine and warm up the engine. • Ru[...]

7-16 ENGINE LUBRICA TION SYSTEM Oil Pr ess ure S witc h Oil Pressure Switch Remova l • Remove: Engine Oil (drain, see Periodi c Maintenance chapter) Switch Cover [A] Switch T erminal [B] Oil Pre ssure Switch [C] Oil Pressure Switch Installation • Apply silicone seal ant to the threads of the oil pressure switch and tighten it. Sealant - Kawasak[...]

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 REM OV AL/INST ALLA TION Exploded View[...]

ENGINE REMOV A L/INST A LLA TION 8-3 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Adj ustin g col lar loc knu t 49 5.0 36 S 2 Upper engine mounting bolts 44 4.5 32 S 3 Rear engine bracket bolt s 25 2.5 18 S 4 Front engine bracket bolts 44 4.5 32 S 5 Middle engine mounting nut 44 4.5 32 S 6 Lower engine mounting nut 44 4.5 32 S [...]

8-4 ENGINE REM OV AL/INST ALLA TION Special T o ols Carburetor Drain P lug Wrench, Hex3: 57001–1 269 Engine Mount Nut Wrench: 57001–14 50[...]

ENGINE REMOV A L/INST A LLA TION 8-5 Engine Remova l/Installation Engine Remova l • Support the rear part of the swingarm wi th a stand [A] . • Squeeze the brake l ever slowly and hol d it with a band [A]. WA R N I N G Be sure to hold the front brake w hen removing the engine, or the motorcycle may fall over . It could cause an accident and inj[...]

8-6 ENGINE REM OV AL/INST ALLA TION Engine Removal/In stallation • Remove: Radiator Hose Clamp [ A] (Loosen) Radiat or Hose [B] Oil Cooler W ater Hose Clamp [C] (Loosen) Oil Cooler W ater Hose [D] Radiato r Bolt [E] (Loosen) Radiator Bracket Bolt [F] • Disconnect Crankshaft Sensor Lead Connector ( see Electrical Sys- tem chapter) Stick Coil Har[...]

ENGINE REMOV A L/INST A LLA TION 8-7 Engine Remova l/Installation • Remove: Camshaft Position Sensor Connect or [A] Injector Har ness Connector [B] Coolant Reserve T ank [A] (see Cooling System chapter) Air Cleaner Housing Bolt [B] V acuum Switch V alve Hose [C] • Remove: V acuum Switch V alve T ube [A] Inlet Air Pr essure Sensor T ube [B] Thro[...]

8-8 ENGINE REM OV AL/INST ALLA TION Engine Removal/In stallation • Support the engine wi th a suitable st and [A]. ○ Put a plank [B] onto the sui table stand for engine bal ance. • Remove: Right and Lef t Engine Upper Mount ing Bolts [A] Front Engine Bracket Bolts [B] Front Engine Bracket [C] • Remove the middle and lower engine mounting nu[...]

ENGINE REMOV A L/INST A LLA TION 8-9 Engine Remova l/Installation • Using the Hexagon W rench, turn the adjusting col lar [A] counter clockwise t o mark the gap bet ween the engine and flame adjusting col lar . • Remove the drive chai n [A] from the output shaft [B]. • Down the rear portion of the engine a l ittl e and remove the engine groun[...]

8-10 ENGINE REMOV AL/IN ST ALLA TION Engine Removal/In stallation • Install the engine mounti ng bolts and nuts, following the specifi ed installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine i nto its final posi tion in the frame. ○ Second, insert the lower engine mounting bolt [A]. ○ Third [...]

ENGINE REMOV AL/INST AL LA TION 8-1 1 Engine Remova l/Installation ○ Ninth, temporarily i nstall: Front Engine Brac ket [A] Front Right Engine Mounting Bolt [ B] ○ T enth, tighten the rear bracket bolts. T o rque - Rear Engin e Bracket Bo lts: 25 N·m (2.5 kgf·m, 1 8 ft·lb) ○ Eleventh, tighten secur ely: Middle Engine Mounting Nut Lower Eng[...]

[...]

CRANKSHAFT/TR ANSMISSION 9-1 9 Crankshaft/T ransmission T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 9-2 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 9-6 Special T ools and Sealant ........ ....... .. 9-8 Crankcase Spli ttin g....... ...... ...... ..... .... 9-9 Cra nkcas e S plitti ng .... .... ......[...]

9-2 CRANKSHAFT/TRAN SMISSION Exploded View[...]

CRANKSHAFT/TR ANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf ·m ft·lb Remarks 1 Breather plate bolts 10 1.0 87 i n·lb L 2 Crankcase bolts ( M9, L=81 mm) 42 4.3 31 MO,S 3 Crankcase bolts ( M9, L=95 mm) 49 5.0 36 MO,S 4 Crankcase bolts (M8) 27 2.8 20 S 5 Crank case bolts (M7) 20 2.0 14.5 S 6 Crankcase bolts (M6) 12 1.2 104 in·l b S 7 [...]

9-4 CRANKSHAFT/TRAN SMISSION Exploded View[...]

CRANKSHAFT/TR ANSMISSION 9-5 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Shift pedal mounting bolt 34 3.5 25 L 2 Gear positioning lever bolt 12 1.2 104 in·lb 3 Shift shaft return spring pin 29 3.0 22 L 4 Shift drum cam holder bolt 12 1.2 104 in·lb L 5 Footpeg bracket bolts 34 3.5 25 L 6 Shift lever bolt 6.9 0.7 61 in·lb 7 T [...]

9-6 CRANKSHAFT/TRAN SMISSION Specif ications Item Standard Servi ce Lim it Crankshaft, Connecting Rods: Connecting rod bend --- TIR 0.2/100 mm (0.008/3.94 i n.) Connecting ro d twist --- TIR 0.2/ 100 mm (0.008/3.94 i n.) Connecting r od big end side clearance 0.13 ∼ 0.38 mm 0.58 mm (0.0051 ∼ 0.0150 in. ) (0.023 i n.) Connecting r od big end bea[...]

CRANKSHAFT/TRA NSMISSION 9-7 Specifications Item Standard Servi ce Limit Cranks haft runout TIR 0.0 2 mm (0.00 08 in.) or less TIR 0.05 mm (0.0020 in .) Crank shaft main bearing inser t/journal clearance 0.020 ∼ 0.044 mm 0.07 mm (0.0008 ∼ 0. 0017 in.) (0.0028 in.) Cran kshaft main journal di ameter: 32.984 ∼ 33.000 mm 32.96 mm (1.2986 ∼ 1. [...]

9-8 CRANKSHAFT/TRAN SMISSION Special T oo ls and Sealant Bear ing Puller: 57001–1 35 Bearing Puller Adapter: 57001–3 17 Kawasaki Bond (Silic one Sealant): 56019–12 0 Kawasaki Bond (Silic one Sealant): 92104–10 63[...]

CRANKSHAFT/TRA NSMISSION 9-9 Crankcase Splitt ing Crankcase Splitt ing • Remove the engine (see Engine Removal /Installation chapter). • Set the engine on a clean surface and hol d the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter) Clutch (s ee Clutch chapter ) External Shift Mechanism[...]

9-10 CRANKSHAFT/T RANSMISSION Crankcase Sp litting • Apply liquid gasket to the breather plate mati ng surface [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, an d then install the bre ather plate. Sealant - Three Bond: 1207B • Apply a non-per manent locking agent to t he threads and tighten the bolt s [A]. T orque - Breather Plate Bolts: 10 N·m (1.[...]

CRANKSHAFT/T RANSMISSION 9-1 1 Crankcase Splitt ing • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealan t- K awasa ki Bo nd (Silico ne Sealant ): 92104 –1063 CAUTION Do not apply li quid gasket around the c rankshaft main bearing inserts, and oil passage holes. • Fit the lower crankcase to the upper crankcase. [...]

9-12 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods Crankshaft R emoval • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Cra nksh aft Inst alla tion CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced wi th new ones, select the bear- ing insert s and check clearance wit h a plastig[...]

CRANKSHAFT/TR ANSMISSION 9-13 Crankshaft an d Connec ting Rods • Apply molybdenum disulf ide grease [A] to t he outer sur- face of the upper insert and the inner sur face of the con- necting rod big end. • Apply molybdenum disulfide o il [B] to the inner surfaces of upper and lower beari ng inserts. ○ The molybdenum disulfide oil is a mixture[...]

9-14 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods (1) Bolt Length Measurement Method • Be sure to clean t he bolts, nuts, and connecting rods thorou ghly wit h a high-flash point solvent, because the new connecting rods, bolts, and nut s are treated wi th an anti-rust so lution. W ARNING Clean the bolts, nuts, and connecti ng rods in [...]

CRANKSHAFT/TR ANSMISSION 9-15 Crankshaft an d Connec ting Rods (2) Rotati on Angle Method If you don’t have a point micrometer , you may tighten the nuts using the “Rotation Angle M ethod”. • Be sure to clean the bolts and nuts thor oughly with a high -flash poi nt solvent, because the new b olts and nuts ar e treated with an ant i-rust sol[...]

9-16 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods Connecting Rod Ben d • Remove the connecting rod big end bearing inse rts, and reins t all the c onnecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod bi g end, and insert the arbor t hrough the connect- ing ro d big end. • Select an arbor of[...]

CRANKSHAFT/TR ANSMISSION 9-17 Crankshaft an d Connec ting Rods Conn ecti ng Rod B ig End B eari ng Insert /Cra nkpin Wear • Measure the bearing ins ert/crankpin [B] clear ance with plastigage [A] . ○ T ighten the big end nuts t o the specified torque ( see Con- necting Rod Install ation). NOTE ○ Do not move the con necting rod a nd crankshaft[...]

9-18 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods Connecting Rod Big End Inside Diameter Marks None 38.000mm ∼ 38.0 08mm (1.496 1 ∼ 1.4964 i n.) 38.009 ∼ 38.0 16 mm (1 .4964 ∼ 1.4 967 in.) B i gE n dC a p[ A ] Connecting Rod [B] Weight Mar k, Alphabet [C] Diameter Mark (Around W eight Mark) [D]: “ ”o rn o mark • Select the[...]

CRANKSHAFT/TR ANSMISSION 9-19 Crankshaft an d Connec ting Rods Crankshaft Mai n B eari ng Insert/Journ al Wear • Using a plasti gage (press gauge) [A] , measure the bear- ing insert/jour nal [B] clearance. NOTE ○ Tighten the cr ankcase bolts to the specified torque (see Crankcase Assembly). ○ Do not turn the cranksha ft during clearance m eas[...]

9-20 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods • Measure the main bear ing insi de diameter , and mark the upper crankcase half in accordance with the inside diam- eter . Crankcase Main Beari ng Inside Diamet er Marks : " " or no mark. • T ight en the crankcase bolts t o the specifi ed torque (see Crankcase Assembly). N[...]

CRANKSHAFT/TR ANSMISSION 9-21 Starter Moto r Clutch Starter Motor Clutch Removal/Insta llation • Refer to the Alternat or Rotor Removal and Installati on in the Electrical System chapter . Starter Motor Clu tch Assembly • Be sure to instal l the one-way clutch [ A] so that its flange [B] fits in the holder r ecess [C]. • Apply a non-permanent[...]

9-22 CRANKSHAFT/T RANSMISSION T ransmission Shift Ped al Removal • Mark [A] the posit ion of the shift leve r [B] on the shift shaft so that it can be installe d later in the same posit ion. • Remove: Shift Lever Bolt [C] Shift L ever • Remove: Footpeg Bracket Bolts [A] Muffler Mount ing Bolt [B] Footpeg Bracket [C] • Remove the bolt [A], f[...]

CRANKSHAFT/TR ANSMISSION 9-23 T ra nsmission • Install the footpeg brack et [A]. • Apply a non-permanent locking agent to the footpeg bracket bolts [B]. • T ighten: T o rque - Footpeg br acket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffl er Mounting Bolt and Nut [C]: 29 N·m (3.0 kg f·m , 22 ft· lb) • Install the shift lever [A ], alignin[...]

9-24 CRANKSHAFT/T RANSMISSION T ransmission • Remove: Gear Positionin g Lever Bolt [A] Gear Po sitioning Lever [B], Collar and spring External Sh ift Mechani sm Installati on • Install t he gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • T ighten: T orque - G ear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) ?[...]

CRANKSHAFT/TR ANSMISSION 9-25 T ra nsmission T ransmissi on Shaft Removal • Split the crank case (see Crankcase Splitting). • Remove the drive shaft [A] and output s haft [B]. T ransmission Sh aft Install ation • Check to see that the set pins [A] and set rings [B] are in place. • Install the dr ive shaft and out put shaft into the upper cr[...]

9-26 CRANKSHAFT/T RANSMISSION T ransmission • Remove the ball bear ing [A] fr om each shafts. Special T oo ls - Beari ng Puller: 57001– 135 [B] Bearin g Pulle r Adapter : 57001– 317 [C] • Discard th e bearing. T ransmission Shaft Assembly • Apply engine oil to t he sliding surfaces on the t ransmis- sion shafts, gears and bushi ngs. • I[...]

CRANKSHAFT/TR ANSMISSION 9-27 T ra nsmission NOTE ○ When the toothed washers [ 28] [29] are asse mbled onto the output shaf t, note the foll owing. ○ When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [ B] of the toothed washer [28]. ○ Fit the steel balls int o the 5th gear holes in the o[...]

9-28 CRANKSHAFT/T RANSMISSION T ransmission 1. 1st G ear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (T op) Gear 7. T oothed Washer , 31 mm (1.2 2 in .) 8. Thrust W asher , 30 mm (1.18 in.) 9. Circli p 10. Circlip 1 1. Bushing 12. Bushing 13. Needle Bearing 14. Needle Bearing 15. Bearing Outer Race 16. Steel Bal l 17. Nut 18. Bushing 19.[...]

CRANKSHAFT/TR ANSMISSION 9-29 T ra nsmission Shift Dru m and Fo rk Installati on • Install the sh ift rods [ A], noting the gr oove position. The rods are identical. • Position the one wi th shortest ears [B] on the dr ive shaft and place the pin in the center gr oove in the shift drum [C]. ○ The two forks [D] on the output shaft are i dentic[...]

9-30 CRANKSHAFT/T RANSMISSION T ransmission Sh ift Fork /Ge ar Gr oov e Wear • Measure the thi ckness of t he shift fork ear s [A], and mea- sur e th e w idth [B] of the gear grooves. If the thickness o f a shift fork ear is less than the service limit, the shift for k must be replaced. Shift Fork Ear Thickness Standard: 5.9 ∼ 6.0 mm (0. 232 ?[...]

WH EELS/ TIRES 1 0-1 10 Wheels/T ires T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 10- 2 Spec ifica tions .. .... ...... .... ...... .... ....... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... [...]

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

WH EELS/ TIRES 1 0-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Rem arks 1 Front axle clamp bolt 20 2.0 15 2 Front axle 127 13 94 3 Rear axle nut 127 13 94 G: Apply grease. R: Replacement P arts WL: Apply soap and water solution or rubber lubr icant.[...]

10-4 WHEELS/TIRES Specif ications Item Standard Ser vice Li mit Wheels (Rims): Rim runout: Axial --- TIR 0. 5 mm (0.020 in.) Radial --- TI R 0.8 mm (0.031 in.) Axle runout/100 mm (3.94 in.) TIR 0.05 m m (0.0020 in.) or less TIR 0.2 mm (0.008 in.) Wheel balance 10 g (0.35 US oz) or less --- Balance weights 10 g (0.35 US oz) , 20 g (0.71 US oz), 30 g[...]

WH EELS/ TIRES 1 0-5 Special T ools Bear ing Dr iver Set: 57001–1129 Jack: 57001–123 8 Bearin g Remove r Head, 25 × 28 : 57001–1 346 Bearin g Remover Shaft , 13: 57001–1 377[...]

10-6 WHEELS/TIRES Wheels (Rim s) Front Wheel Removal • Remove: Brake C aliper Mounting Bolt s [A] • Loosen: Right Side Axle Clamp Bolt [A] Axle [B] • Raise the front wheel off the ground. Special T ool - J ack: 5 7001–1238 • Pull out the a xle to the right and drop t he front wheel out of the forks. CAUTION Do not lay the wheel down on on[...]

WHEELS/TIRES 10-7 Wheels (Rims) • T ighten the axle. T orque - Front Axle: 1 27 N·m (13 kgf·m, 94 ft·lb) • Before tig htening the clamp bolt on the r ight front fork leg, pump the front fork up and down 4 or 5 times to allow the right front fo rk leg to seat on the fr ont axle. NOTE ○ Put a block i n front of the fron t wheel to stop movin[...]

10-8 WHEELS/TIRES Wheels (Rim s) • Remove: Caliper Mounting Bolts [A] Calipe r[ B ] • Remove the drive chain [A] f rom the rear sprocket toward the lef t. • Move the rear wheel back and r emove the wheel from the rear caliper . • Remove the rear wheel. CAUTION Do not lay the wheel on the ground with the di sc facing down. This can damage or[...]

WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WA R N I N G If the rear axle nut is not securely tightened or the cotter pin is not inst alled, an unsafe riding condi- tion may result. • Adjust the drive chai n slack after instal lation (see Final Drive chapter). • Check the rear brake e ffecti veness. WA R N I N [...]

10-10 WHEELS/TIRES Wheels (Rim s) Axle Inspe ction • V isually inspect the f ront and rear axle for damages. If the a xle is damaged or bent, replac e it. • Place the axle in V blocks that are 100 mm (3. 94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfw ay between the blocks. T urn [C] the axle to mea- sure the runout. Th[...]

WHEELS/TIRES 10-1 1 Wheels (Rims) ( b )W h e nt h et i r ei s o nt h er i m . • Pry [A] the bal ance weight of f the rim flange usi ng a reg- ular tip scr ewdriver as shown in the figure. ○ Insert a tip of the screwdriver between the tire bead [B] and weight blade [C] until the end of the tip reaches the end of the weight blade. ○ Push the dr[...]

10-12 WHEELS/TIRES Wheels (Rim s) • When required total weight ex ceeds 20 g (0.71 US oz), in- stall balance weight at bot h sides of rim flange as shown. Weight Sel ection: g (US oz) Requ ired T otal W eight : g( U So z ) O n eS i d e[ A ] Other Side [B ] 20 (0.71) 1 0 (0.35) 10 (0 .35) 30 (1.06) 2 0 (0.71) 10 (0 .35) 40 (1.41) 2 0 (0.71) 20 (0 [...]

WHEELS/TIRES 10-13 Tir e s Air Pressure I nspection/ Adjustment • Refer to the Air Pr essure Inspecti on/Adjustment in the Pe- riodic Maintenance chapter . Tire Inspectio n • Refer to the T ire Inspection in the Periodic Maintenance chapter . Tire R emo val • Remove: Wheel (see Front Wheel Removal, R ear Wheel Re- moval) Disc (s) V alv e Core[...]

10-14 WHEELS/TIRES Tire s • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal with a soap and wat er solution or rubber lubricant, and pull [B] the valve stem [A] thr ough the rim from the inside out until i t snaps into pl ace. CAUTION Do not use engine oil or petroleum distilla tes to lu- brica te t he stem becau[...]

WHEELS/TIRES 10-15 Tir e s • Check to see that the rim lines [A] on both sides of the tire sidewalls are parall el with the rim fl anges. If the rim fl anges and tire sidewall r im lines are not parall el, remove the valve core. • Lubricate the rim flang es and tire beads. • Install the valve core and inflat e the tire agai n. • After the t[...]

10-16 WHEELS/TIRES Hub B earing Hub Bearing Remova l • Remove the wheel, and take out the following . Collar s Coupling (out of rear hub) Grease Seals Circli ps • Use the bearing remover to remove the hub bearings [ A]. CAUTION Do not lay the wheel on the ground with the di sc facing down. This can damage or warp the disc. Please blocks under t[...]

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

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

FINAL DRIVE 1 1-3 Exploded View T orque No. Fastener N·m kgf ·m ft·lb Remarks 1 Engine sprocket cover bolts 9.8 1.0 87 in·lb 2 Engine sprocket nut 127 13 94 MO 3 Rear sprocket nut 59 6.0 43 4 Engine sprocket cover damper bolts 6.9 0.7 61 in·lb L 5 Speed sensor bolt 6.9 0.7 61 in·lb L 6 Rear axle nut 127 13 94 7. Drive chain joint (ZR1000–A2[...]

1 1-4 F INAL DRIVE Specif ications Item Standard Serv ice L imit Drive Chain: Chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) --- 20-link length 317 .5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard chain Make ENUMA --- Ty p e EK525UVXL2, Endless --- Link 1 12 link s --- Sprockets: Rear sprocket warp 0. 4 mm (0.016 in.) or less 0.5 mm (0.[...]

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

1 1-6 F INAL DRIVE Drive Chain Driv e Chain S lack Inspe ctio n • Refer to the Drive Chain Slack Inspection in the Peri odic Mainte nance chapter . Driv e Chain Sl ack Adjus tment • Refer to the Drive Chai n Slack Adjustment in the Peri odic Maintenance chapt er . Wheel Alignmen t Inspection /Adjustment • R efer to th e Wheel Alignment Inspec[...]

FINAL DRIVE 1 1-7 Drive Chain EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting and Riveti ng Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] pin head to make it flat. • Set cutting and riveti ng pin [B] as shown. • Screw pin holder unti l it touches chai n pin. • Be sure that cut ting[...]

1 1-8 F INAL DRIVE Drive Chain • Set plate holde r (A) [A] and plate holder (B) [B] on the body . • Fit plate holder ( A) to link plate. • T urn pin holder by hand until plate holder (B) touches the other link plat e. • T urn pin holder by wrench clockwise until two pins of link come into groove of plate holder (A). • T ake of f plate hol[...]

FINAL DRIVE 1 1-9 Drive Chain • T urn wrench clockwise until tip of riveting pin hi ts of li nk pin. • Rivet it. • Some work for the other link pi n. • After staking, check the staked area of the li nk pin for cracks. • Measure the outside di ameter [A] of the link pin and l ink plates outside width [ B]. Link Pin Outside Diameter Standar[...]

1 1-10 FINAL D RIVE Sprocket, C oupling Engi ne Spr ocke t Rem oval • Remove: Speed S ensor [A] Connecto r Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor • Flatten out the b ended washer [ A]. • Remove the engine sprocke t nut [B] and washer . NOTE ○ When loosening the engine sprocket nut, hold the rear brake on[...]

FINAL DRIVE 1 1-1 1 Sprocket, C oupling Rear Sprocket Removal • Remove the rear wheel (see Wheels /T ires chapter) . CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the di sc. Place blocks under the wheel so that the disc does not touch the ground. • Remove the rear sprocket nuts [A]. • Remove the[...]

1 1-12 FINAL D RIVE Sprocket, C oupling • Replace the grease seal with a new one. • Press in the greas e seal so that the seal surf ace is flush with th e end of the hole. ○ Apply high temperature gr ease to the grease seal lips. Special T ool - Be aring Drive r Set : 57001–1 129 Couplin g Install ation • Grease th e following and ins tal[...]

FINAL DRIVE 1 1-13 Sprocket, C oupling Sprocket W ear Inspection • Visual ly inspect the engine and r ear sprocket teeth for wear and dam age. If the teeth are worn as il lustrated, repl ace the sprocket, and inspect t he drive chain wear (see Drive Chai n Wear Inspection). [A] Wor n T ooth (Engine Sprocket) [B] Wor n T ooth (Rear Sprocket) [C] D[...]

[...]

BRAKES 12-1 12 Brakes T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 12-2 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 12-6 Special T ool ........ ...... ...... ...... ..... . ... .... 12-7 Brake Lever , Brake Pedal ................ .. 12-8 Brake Lever Position Adjustment . 12-8 Brake Pedal Position Insp[...]

12-2 BRAKES Exploded View[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front caliper mounti ng bolts 25 2.5 18 2 Brake hose banj o bolt 25 2.5 18 3 Bleed valve 7.8 0.80 69 in·lb 4 Front caliper assembly bolts 22 2. 2 16 L 5 Front brake pad pin bolt 17 1.7 12 6 Brake lever pivot bolt 1.0 0.10 9i n · l b Si 7 Brake lever pivot bolt locknut 5.9[...]

12-4 BRAKES Exploded View[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear master cylinder push lod locknut 18 1.8 13 2 Rear caliper mounting bolts 25 2.5 18 3 Brake hose banj o bolts 25 2. 5 18 4 Bleed valve 7.8 0.80 69 in·lb 5 Rear master cylinder mounting bolts 25 2.5 18 6 Brake disc mounti ng bolts 27 2.8 20 L 7. Gasket (Before Frame No.[...]

12-6 BRAKES Specif ications Item Standard Servi ce Limit Brake Lever , Brake Pedal: Brake lever position 5-way adjustable ( to suit rider) --- Brake lever free pl ay Non-adjustable --- Pedal free play Non-adj ustable --- Pedal positi on About 47 mm (1.85 in.) below footpeg t op --- Brake Fluid: Grade DOT4 --- Brake Pads: Lining thicknes s: Front 4 [...]

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

12-8 BRAKES Brake Lever , B rake Pedal Brake Lever P osition Adj ustment The brake lever adjust er has 5 positions so that the brake lever p osition can be adjusted to suit the operator’s hand. • Push the l ever forward an d turn the a djuster [A] to align the number wit h the arrow mark [B] on the lever holder . ○ The di stance from the grip[...]

BRAKES 12-9 Calipers Front Cali per Removal • Loosen the banjo bolt [A] at the brake hos e lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [ B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. T ake out only the caliper mounti ng bolts for caliper r e- moval. Loosening the[...]

12-10 BRAKES Calipers Cali per Ins tallation • Install t he caliper and brake hose lower end. ○ Replac e the washers on each side of hose fitting with new ones. • T ighten: T orque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf·m, 18 ft·lb) Caliper Mounting Bolts (Rear): 2 5 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2[...]

BRAKES 12-1 1 Calipers WA R N I N G T o avoid serious injury , never place your fingers or palm in front of the piston. If y ou apply compressed air into the caliper , the piston may crush your hand or fingers. ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed v alve [C] a nd rubber cap [D]. ?[...]

12-12 BRAKES Calipers • Replace the fluid seal s [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them into the cyl inder s by hand. • Replace the dust seal s [B] with new ones i f they are dam- aged. ○ Apply brake fluid to t he dust seals, and install t hem into the cylinder s by hand. • Replace the O-rings [A] if t[...]

BRAKES 12-13 Calipers Rear Caliper Assembly • Clean the calipe r parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol . • Install the bleed valve and rubber cap. T orque - Bleed V alve: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Replace the flui d seal [A] with a new one. ○ Apply[...]

12-14 BRAKES Calipers Cali per Pis ton a nd Cylin der D amag e • V isually inspect the pi ston [A] and cylinde r surfaces. Replac e the ca liper if t he cylinder and pi ston are badly scores or rusty . Front Caliper [B] Rear Ca liper [C ] Cali per H older S haf t Wear The caliper body must slide smoothly on the caliper holder shaft [D]. If the bo[...]

BRAKES 12-15 Brake Pads Front Bra ke Pad Removal • Remove: Mounting Bolts [A] • Remove: Pad Pin Bolt [A] P a dS p r i n g[ B ] Brake Pads [C] Fron t Brake P ad Inst allati on • Push the cali per pistons in by hand as f ar as they wi ll go. • Apply sili cone grease to the stopper ring [A]. • Install: Brake Pads Pad Spring Pad Pin Bolts T o[...]

12-16 BRAKES Brake Pads Rear Brake P ad Install ation • Push the cali per piston in by hand as f ar as it will go. • Insta l l: Brake Pads Pad Pin Clip • Install t he caliper ( see Caliper Instal lation). W ARNING Do not attempt t o drive the motor cycle until a full brake pedal i s obtained by pumping the br ake pedal until the pads ar e aga[...]

BRAKES 12-17 Master Cylinde r Front Master Cyl inder Removal • Disconnect the front brake light switc h connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the maste r cylinder [C] (see Br ake Hose Removal/In- stallati on). • Remove the rear view mir ror (see Steering chapt er). • Unscrew the clamp bolts [A] , and [...]

12-18 BRAKES Master Cylin der Rear Master Cylinder Re moval • Unscrew the brake hose banjo bolt [A] on the master c ylin- der (se e Brake Hose Removal/I nstallation). • Pull off t he reservoir hose lower end [B], and drain the brake flu id into a cont ainer . • Loose n the master cyli nder mounting bol ts [C] lightl y . • Remove the cot ter[...]

BRAKES 12-19 Master Cylinde r Rear Master Cylinder Disasse mbly NOTE ○ Do not remove the push rod clevis for master cylinder disass embly since r emoval requires brake posit ion ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal). • Slide the dust cover on the push rod out of place, and remo ve the cir clip. ?[...]

12-20 BRAKES Brake Disc Brake Disc Remova l • Remove the wheel (see Wheels/T ires chapter). • Unscre w the mounting bolt s, and take off t he disc. Brake Disc Insta llati on • Install the brake di sc on the wheel so that the marked side [A] faces o ut. • Apply a non-permanent lock ing agent to the threads of the fron t and rear brake disc m[...]

BRAKES 12-21 Brake Fluid Brake Flui d Level Inspect i on • Refer to the Brake Flui d Level in the Peri odic Maintenance chapter . Brake Flu id Change • Refer to the Brake Flui d Change in the Periodic Mainte- nance chapter . Brake Line Bl eeding • Refer to the Brak e Line Bleeding in the Periodic Mainte- nance chapter .[...]

12-22 BRAKES Brake Hose Brake Hose Removal /Install ation CAUTION Brake fluid quickl y ruins painted or plastic sur- faces; any spilled flui d should be completely wiped up imme diately with wet cloth. • When re moving t he brake hose, take care not t o spill the brake fluid on the pai nted or plastic part s. • When removing the brake h ose, te[...]

SUSPENSION 13-1 13 Suspension T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 13- 2 Spec ifica tions .. .... ...... .... ...... .... ....... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...[...]

13-2 SUSPENSION Exploded View[...]

SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb AL Front fork cl amp bolts (Upper): ZR1000–A2 ∼ 13 1.3 11 3 i n · l b 2 Front fork clamp bolts (Lower) 20 2. 0 15 AL Front fork cl amp bolts (Lower): ZR1000–A2 ∼ 30 3.1 22 3 Front fork top plu gs 35 3. 6 26 4 Pi[...]

13-4 SUSPENSION Exploded View[...]

SUSPENSION 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear shock absorber nuts (upper and lower) 34 3.5 25 2 Swingarm pivot s haft nut 127 13 94 3 Swingarm pivot shaft loc knut 98 10 72 4 Rocker arm nut 34 3.5 25 5 T ie-rod nuts 59 6.0 43 G: Apply or a dd grease.[...]

13-6 SUSPENSION Specif ications Item Standard Front Fork (per one unit): Fork inner tube outside diameter 41 mm (1.61 in.) Air Pressure Atmospheric press ure (Non-adjustabl e) Rebound damper setting 1 turns out from the fully cloc kwise positi on (only right fork leg) (Usable Range: 0 ←→ 14 / 5 ∼ 2 2 /5 tur ns out) Fork spring preload set tin[...]

SUSPENSION 13-7 Special T ools Oil Seal an d Bearin g Remover: 57001–105 8 Bear ing Dr iver Set: 57001–1129 Jack: 57001–123 8 Front Fork Oil S eal Driver: 57001–128 8 Fork Oil Level Gauge: 57 001–129 0 Fork Pi ston Rod P uller , M10 × 1.0: 57001–1 298 Front Fork Spring Compres sor: 57001–1 338 Sock et Wrench: 57001–1 370 Hook Wrenc[...]

13-8 SUSPENSION Front Fork Rebound Damping F orce Adjust ment (Onl y Right Fork Leg) • T o adju st the rebound damping force, turn the rebound damping adjuster [A] on t op of the right front fork leg to the desir ed position. ○ The st andard adjuster setting f or the average-buil d rider of 68 kg (150 lb) wit h no passenger and no accessories i[...]

SUSPENSION 13 -9 Front F ork Front Fork Removal (each for k leg) • Remove: Front Wheel (see Wheels/T ires chapter .) Front Fender (see Frame chapter .) Windshield an d Bracket (see Frame chapter .) Inner Cover (see Frame chapt er .) Fairing and Bracket ( see Frame chapter .) Loosen the upper fork cl amp bolts [A] and fork top pl ug [B] before-han[...]

13-10 SUSPENSION Front Fork Fork Oil C hange • Remove the front fork (see Front Fork Removal). ○ Tu r n t h e spring preload adjuster [A] countercl ockwise until the full y position. • Unscrew the t op plug [B] out of the inner tube. • A voiding the pins [A], set the front fork spring compressor set [B] on t he washer [C]. Special T ool - F[...]

SUSPENSION 13-1 1 Front F ork • Drain the fork oil into a sui table contai ner . • Remove the fork spring [A]. ○ Pump the piston rod [B] up and down at least ten times to expel the oil from the fork . • Hold the fork tube upright, press the inner tube and the piston rod al l the way down. • Pour in the type and amount of fork oil specifie[...]

13-12 SUSPENSION Front Fork Oil Level (fu lly compressed, without spri ng) Standard: R i g h tf o r kl e g 6 2±2m m ( 2 . 4 4± 0 . 0 8i n . ) Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil level may also be measured using the for k oil level gauge. Special T ool - Fo rk Oil Leve l Gauge: 57001–1 2[...]

SUSPENSION 13-13 Front F ork • Check the O-ring on the top pl ug and replace it wit h a new one if damaged. • For the right for k leg, check the distance [C] between the bottom end [A] of the top pl ug and rebound damping ad- juster [B] with a pair of vernier cal iper . [C] 20 mm (0. 79 i n.) • Holding the top plug [A] wit h a wrench [B], tig[...]

13-14 SUSPENSION Front Fork ○ Holding the inner tube [A] by hand, pull the out er tube [B] several ti mes to pull out the outer tube. • Remove the inner tube guide bushing [A], outer tube guide bushing [B], washer [C], oil seal [D] from the i nner tube. Front Fork Assembly • Replace the following part s with new one. Oil Seal Guide Bushings B[...]

SUSPENSION 13-15 Front F ork • Install the cente ring plate on t he cylinder uni t. • Insert the cente ring plate and cylinder unit as a set into the inner tube. Cylinder Unit [A] and Center Ring Plate [C] for Right Fork Leg Cylinder Unit [B] and Center Ring Plate [C] for Left Fork Leg • Hold the front fork in a vise. • T orque the Allen bo[...]

13-16 SUSPENSION Front Fork Spring T ension • Since a spring becomes shorter as it w eakens, check its free le ngth [A] to determine its co ndition. If the spring of eit her fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spr in g and that of the remaini ng spring var y greatly , the remaining spr i[...]

SUSPENSION 13-17 Rear Shock Absorber Rebound Damp ing Force Adjustment • T o adjust the rebound damping force, turn the rebound damping adjuster [A] to t he desired posit ion. ○ The standard adjust er setting f or an average-buil d rider of 68 kg (150 lb) wit h no passenger and no accessories 3/4 turns out of the f ully clockwise posi tion. Reb[...]

13-18 SUSPENSION Rear Shoc k Absorb er Special T oo ls - Hook Wrench: 57001–15 39 [A] Spring Adjustment Adju ster Dampi ng Positi on Force Setting Load Road Speed 193. 4 mm Wea k Soft Light Good Low (7.61 in.) ↑ ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓ ↓ 183. 4 mm Strong Hard He avy Bad High (7.22 in.) Rear Shock Abso rber Removal • Using th[...]

SUSPENSION 13-19 Rear Shock Absorber • Remove the shock absorber [A] from upside. Rear S hock Ab sor ber Inst allatio n • T ighten: T orque - Re ar Shock Absorber Nuts : 34 N·m (3.5 kgf·m, 25 ft·lb) Rear S hock A bso rber Insp ectio n • Remove the rear shock absorber . • Visual ly inspect t he following it ems. Smooth Stroke Oil Leakage [...]

13-20 SUSPENSION Swingarm Swingarm Removal • Remove the muff ler bodies (see Engine T op End chapter .) • Raise t he rear wheel of f the ground with jack. Special T ool - J ack: 5 7001–1238 • Remove: Rear Wheel (see Wheels/T ires chapter .) Chain Cover (see Final Drive chapter .) Mud Guard (see Frame chapter .) Brake Hose Clamp [A] Lower Sh[...]

SUSPENSION 13-21 Swingarm Swin garm In stallat ion • Apply plenty of grease to the ball bearing, needle bearings and grease seals, and add plenty of greas e to the grease nipple. • Install the collars [A]. ○ Place the right collar [A] on t he stopper [B] inside the frame [C]. • Insert the pivot shaf t into the frame from the right side. •[...]

13-22 SUSPENSION Swingarm • Remove the ball bear ing and needle b earings. Special T ool - Oil Sea l and Beari ng Remo ver: 57001–10 58 [A] Swingarm B earing Inst allati on • Apply plenty of grease to the ball bearing and needle bearings. • Install the needle bearings so that the manufacturer ’s marks face in. • Install the ball bearing[...]

SUSPENSION 13-23 Tie-Rod, R ocker Arm Ti e-Rod Removal • Remove the muf fler bodies (see Engi ne T op End chapter .) • Remove the side stand (see Frame c hapter .) • Using the jack, raise t he rear wheel off the ground. Speci al T ool - Jack: 57001–12 38 • Squeeze the brake l ever slowly and hol d it with a band [A]. • Remove: Lower Rea[...]

13-24 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the needle bearings and oil seal li ps, and add grease to the grease nipple. • T ighten: T orque - Rocker Arm Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nut: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25 ft·l b) Ro[...]

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 Steering stem nut 27 2.75 20 2 Steering stem head bolt 108 11 80 3 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb AL Front fork cl amp bolts (Upper): ZR1000–A2 ∼ 13 1.3 11 3 i n · l b 4 Front fork clamp bolts (Lower) 20 2.0 15 AL Front fork cl amp bolts (Lower): Z[...]

14-4 STEERING Special T o ols Steer ing Stem Nut Wrenc h: 57001–1100 Bearin g Driver Se t: 57001–1129 Jack: 57001–1 238 Stee ring S tem Bear ing Dr iver : 57001–13 44 Steering Stem Bearing Driver Adapte r: 57001–13 45[...]

STEERING 14-5 Steering Steer ing Inspe ction • Refer to the Steering Inspection in the Periodic Mainte- nance chapter . Steer ing Adjust ment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter .[...]

14-6 STEERING Steerin g Stem Stem, Stem Bearin g Removal • Remove: Windsh ield and Bracket (see Frame chapter .) Inner Cover (see Fr ame chapter .) Fairing and Bracket (s ee Frame chapter .) Front W heel (see Wheels/T ires chapter .) Handlebar (see Handlebar Removal.) Steering St em Head Bolt Pl ug Steerin g Stem Head Bolt [A ] and W asher Steeri[...]

STEERING 14-7 Steering Stem • T o remove the bearing out er races [C] pressed into t he head pipe [B], insert a bar [A] into the rec esses [D] of head pipe, and applyi ng it to both recess alternatel y hammer it to drive the race out. NOTE ○ If either steering stem bearing is damaged, it is recom- mende d that both the upper and lower bearings [...]

14-8 STEERING Steerin g Stem • Apply grease the lower ball bearin g [A] and install it onto the ste m. • Apply g rease to the upper ball bearing [ B] and inner race [C]. • Install t he stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it. • Install the stem cap [D] and steering stem nut [E]. • Settle th[...]

STEERING 14-9 Steering Stem NOTE ○ Tighten the fork upper clamp bolts first , next the stem head nut, last the fork lowe r clamp bolts. T orq ue - Steering S tem H ead Bolt : 108 N· m (1 1 kgf·m, 80 ft·lb) Front Fork Clamp Bolts (Upper): 8.8 N·m (0.90 kgf·m, 78 in·lb) 13 N·m (1.3 kgf·m, 1 13 i n·lb): ZR1000– A2 ∼ Front Fork Cla mp Bo[...]

14-10 STEERING Handlebar Handle bar Removal • Remove: Clutch Lever Assembly [ A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right H andlebar Switch Housi ng [D] Handlebar Holder Bolts [E] • Remove the handlebar holder s [F] and then pull out the handle bar [G]. • Remove the cotter pins [A]. • Unscrew the mounting nuts[...]

STEERING 14-1 1 Handlebar Rear V iew Mirror s Removal • Loosen the lower hexagonal area [ A] for tightening t o re- move the rear view mirror f rom the holder . CAUTIO N Do not force to t ighten and/or loosen t he upper hexagonal area (Adapter) [ B] with a pair of span- ners. Disassembly of this a rea is Not A vailable. Non-permanent locking agen[...]

[...]

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

15-2 FRAME Exploded View[...]

FRAME 15-3 Exploded View T orque No. Fastener N·m kgf· m ft·lb Remarks 1 Footpeg holder bolts 34 3.5 25 2 Muff ler mounting nuts 29 3.0 22 3 Side stand bolt 44 4.5 33 4 Side stand switch bolt 8.8 0.9 78 in·lb G: Apply grease.[...]

15-4 FRAME Exploded View[...]

FRAME 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Windshield screws 0.35 ∼ 0.50 0.035 ∼ 0.050 3 ∼ 4i n · l b 2 Front fender bolts 3.9 0.4 34.7 in·lb L[...]

15-6 FRAME Exploded View[...]

FRAME 15-7 Seats Rear Seat Removal • Insert the i gnition switch ke y into the seat lock [A], turning the key countercl ockwise, pulling up on the rear of the seat [B], and pulling the seat backward. WA R N I N G The muffler surf ace is hot once the engine has been started. When operating the seat lock be careful not to touch the muffler or you m[...]

15-8 FRAME Side C ov ers Side Cover Removal • Remove the bolt [A]. • Pull th e side cover [ B] evenly outward to clear the stop- pers. Side Cover Installation • Insert the t abs [A] into the h oles [B]. • Install the bolt.[...]

FRAME 15-9 Fairings Windshield Removal • Remove: Bolts [A] Windshield [B] Windshield Installation • Windshield Instal lation is the revers e of removal. T orque - Windshield Screw: 0.35 ∼ 0.50 N ·m (0.035 ∼ 0 .050 kgf·m, 3 ∼ 4i n · l b ) Inner Cover Removal • Remove: Inner Cover Screws [A] (both side) Inner Cover [B] Inner Cover Inst[...]

15-10 FRAME Fairings • Remove: Fairing Mountin g Bolts [A] (both side) Headli ght Connectors Fair ing Install ation • Fairing inst allation i s the revers e of removal. Faring Bracket Remova l • Remove: Fair ing (see Fai ring Re moval) T urn Signal Lights (see Electrical System chapter) Meter Unit [A] (see Electrical System chapter) C lamp [B[...]

FRAME 15-1 1 Seat Covers Seat Cover Removal • Remove: Seats Screws [A] • Push the central pin, and then remove the quick r ivets [A]. • Pull the front porti ons [A] of the seat cover outside [B], and then remove the seat cove r backward. Seat Cover Installation • Installat ion is r everse of removal. • Put the projecti ons [A] into the gr[...]

15-12 FRAME Mud Gu ard Mud Guard Removal • Remove: Chain C over (see Final Drive chapter) Bolt [A] Clamp [B] • Lift up the mud guard [A], and t hen pull it out backward. Mud Guard Instal lation • Put the project ions [A] into t he grommets [B].[...]

FRAME 15-13 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] Bolts [B] (both side) • Remove the front fender [C]. Front Fender Inst allation • Install the br ake hose clamps to the front fender hol es. Rear F ender R ear Rem oval • Remove: Seats Seat Cover Canister (Calif ornia model only) Diodes [A] (pull out) Stop and T urn Si[...]

15-14 FRAME Fenders • Remove: Quick Rivets [A] Rear Fe nder Rear [B] Rear Fender Rear Inst allation • Put the pr ojection [A ] into the ho le [B]. • Put the projections [A ] into the holes [B]. • Install ation is reverse of removal.[...]

FRAME 15-15 Frame Cover Frame Cover Removal • Remove: Bolts [A] Frame Cover [B] (both side)[...]

15-16 FRAME Battery Case Battery Case Removal • Remove: Seats Seat Cover Rear Fender Assy Side Co vers Battery Left Side Screw [A] (wi th reserver tank) • Pull ou t the batt ery case [B] backward [C]. Battery Case In stallat ion • Put the battery case attachments [A] at the projections [B] on the frame.[...]

FRAME 15-17 Side St and Side S tand Rem ova l • Raise the rear wheel of f the ground with the stand . • Remove: Muff ler (both side) Exhaust pip e Side Stand Switch Bol t [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand In stallatio n • Apply gre ase to the sli ding area [ B] of the side st[...]

15-18 FRAME Fra me Fram e Insp ectio n • V isually ins pect the frame for cracks, de nts, bending, or warp. ○ If there is any damage to the frame, replace i t. W ARNING A repaired f rame may fail in use, possibl y causing an accident. If the frame is bent, de nted, cracked, or warped, replace it.[...]

ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Con tents Parts Location. ...... ...... ...... ...... ..... ...... 16-3 Exploded V iew .......... ...... ...... ..... ...... .. 16-4 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 16 -10 Special T ools and Sealant ........ ......... 16-1 1 Wiring Diagram (U.S.A. and Canada) 16-12 W[...]

16-2 ELECTRICAL SYSTEM Fan M oto r Insp ecti on .... .... ...... ..... 16 -63 Meter , Gauge, Indicator Unit.... ...... .... 16-65 Meter Un it Re mova l ...... .... ...... ..... 16 -65 Meter , Gauge Disassembly ....... ... 16-65 Electronic Combination Meter Unit Inspection .... ...... ...... ....... . .. 16-66 Switches and Sensors ....... ...... ...[...]

ELECTRICAL SYSTEM 16-3 Parts Lo cation [A] Starter Lockout Swit ch [B] Camshaft Position Sensor [C] Radiator Fan Switch [D] S tart er Mo tor [E] Alternator [F] Speed Sensor [G] Neutral Switch [H] Side Stand Switch [I] W ater T emperature Sensor [J] Batt ery [K] Junction Box [L] Front Brake Light Switch [M] S tick C oils [N] Crankshaft S ensor [O] R[...]

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

ELECTRICAL SYSTEM 16-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Meter mounting screws 1.2 0.12 11 i n · l b 2 T ail/brake li ght mounting screws 1.2 0.12 11 i n · l b 3 License plat e light mounting sc rews 1.2 0.12 11 i n · l b 4 Front brake light switch screw 1.2 0.12 11 i n · l b 5 Start er locknut switc h screws - - -[...]

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

ELECTRICAL SYSTEM 16-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater temperature sensor 25 2.5 18 SS 2 Spark plugs 13 1.3 11 5 i n · l b 3 Alternator lead holding plate bolts 11 1.1 95 in·lb L 4 Starter motor mounting bolts 11 1.1 95 in· lb 5 Stato r motor coil bol ts 11 1.1 95 in·lb 6 Alternator rot or bolt 11 0 11 80 [...]

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

ELECTRICAL SYSTEM 16-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Regulator/r ectifier bolt s 6.9 0.7 62 in·lb 2 Fuel level sensor bol ts 6.9 0.7 62 in· lb 3 Side stand s witch bolt 8.8 0.9 78 in·lb 4 Neutral switch 15 1.5 11 5 Speed sensor bolt 6.9 0.7 62 in·lb L 6 Speed sensor cover bolts 6.9 0.7 62 in· lb L 7 Regulator/[...]

16-10 ELECTRICAL SYSTEM Specif ications Item Standard Battery: Ty p e Sealed Battery Capacity 12 V 8 Ah Vo l t a ge 12.6 V or more Charging System: Ty p e Three–phase AC Alternator out put voltage 42 V or more Stator coil resist ance 0.3 ∼ 0.4 Ω Charging voltage 14.7 ± 0.5 V (regulator/r ectifier output voltage) Ignition System: Crankshaft s[...]

ELECTRICAL SYSTEM 16-1 1 Special T ools and S ealant Hand T e ster: 57001–139 4 Flywheel Puller , M 38 × 1.5: 57001–140 5 Rotor Holder: 57001–154 3 Lead Wire- Peak V oltage A dapter: 57001–144 9 Kawasaki B ond (Silico ne Sealan t): 56 019–120 Rotor Pu ller , M 16/M18/ M20/M22 × 1 .5: 57001–1 216 Flywheel and Pulley Holder: 57001–1 3[...]

16-12 ELECTRICAL SYSTEM Wiring Diagram (U .S.A. and C anada)[...]

ELECTRICAL SYSTEM 16-13 Wiring Diagram ( U.S.A. and Can ada)[...]

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

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

16-16 ELECTRICAL SYSTEM Wiring Diagram (O ther than U.S .A., Canada, A ustralia, and Ma laysia)[...]

ELECTRICAL SYSTEM 16-17 Wiring Diagram (Othe r than U.S.A., Ca nada, Aus tralia, and Mala ysia)[...]

16-18 ELECTRICAL SYSTEM Wiring Diagram (M alaysia)[...]

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

16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servi cing electri cal systems. Learn and ob- serve a ll the rules below . ○ Do not reverse the batter y lead connections. This will burn out the diodes on the el ectrical p arts. ○ Alway s check battery c ondition before c ondemning other parts [...]

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

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

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

16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] seali ng the filler por ts [B] until just before use. • Check to see that there is no peel ing, tears or holes in the seal sheet on the top of the battery . • Place the bat tery on a level s urface. • Remove the seal sheet. NOTE ○ A battery whose s ealing shee[...]

ELECTRICAL SYSTEM 16-25 Battery • Fit the seal caps [A] tightly into the f iller ports until the seal caps are at the same level as t he top of the battery . NOTE ○ Do not h am mer . Press down evenly with both hands. CAUTION Once you installed the seal caps after filling the bat- tery , never remove it, nor add any water or elec- trolyte. Init[...]

16-26 ELECTRICAL SYSTEM Battery Precauti ons 1) No need of topping–up No topp ing–up is necess ary in this batt ery until it ends its life under normal use. F orcibl y prying off the se aling plug t o add w ater is very d angero us. Never do that . 2) Refre shing charge If an engine wi ll not start, a horn sounds weak, or lamps are dim, it indi[...]

ELECTRICAL SYSTEM 16-27 Battery Interchang e The sealed battery can fully disp lay its performance only when combined with a pr oper vehicle electr ic system. Therefore, repl ace the sealed batter y only on a motor cycle which was origi nally equipped with th e sealed battery . Be careful, if a sealed battery i s installed on a motorcycle which had[...]

16-28 ELECTRICAL SYSTEM Battery T ermina l V oltage: 1 1.5 ∼ le ss than 12.6 V Standa rd Char ge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery T erminal V oltage (V) [A] Charge T im e (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do stan- dard charge later on. T erm inal [...]

ELECTRICAL SYSTEM 16-29 Charging System Altern ator Cover Remova l • Remove: Frame Cover Bolts [A] Left Frame Cover [B] Clamp (open) [A] Alternator Lead Connector [B] ○ For California m odel, remove the separator . • Place a suitable con tainer under the alternator cover [A], and remove the cover bolts [B]. • Pull the alternator cover outsi[...]

16-30 ELECTRICAL SYSTEM Chargi ng System Stator Coil Inst allation • Apply a non-permanent locki ng agent to the stator coil bolts a nd tighten it . T orque - Stator Coil Bolts: 1 1 N·m (1.1 kgf·m, 95 in·l b) • Secure the al ternator lead with a holding plate, and tighten t he bolt. ○ Apply a non-permanent locki ng agent to th e plate bolt[...]

ELECTRICAL SYSTEM 16-31 Charging System • Install t he starter gea r [A]. • Again, clean the crankshaft t apered portion [B] and dry there. • Fit the woodruff key [C] securel y in the slot in the crank- shaft before instal ling the alternat or rotor . • Install the alternator rotor [A] while turning [B] the starter clutch gear [C]. • Inst[...]

16-32 ELECTRICAL SYSTEM Chargi ng System • Apply a thin co at of molybdenum disulfi de grease to the shaft [A], and inst all it and starter idle gear [B]. • Insta l l the alternator cover (see Alternat or Cover Installa- tion). Alterna tor Inspectio n There are three types of alt ernator failure s: short, open (wire burned out), or loss in ro t[...]

ELECTRICAL SYSTEM 16-33 Charging System If there is more resistance t han shown in t he table, or no hand tester readi ng (infinity) for any two leads, the stator has an open lead and must be replac ed. Much less than this resistanc e means the stator is shorte d, and must be replaced. • Using the highest resistance range of the hand tester , mea[...]

16-34 ELECTRICAL SYSTEM Chargi ng System • Do the 1st st ep regulator ci rcuit test: ○ Connect the test li ght and the 12 V battery to t he regula- tor/ re ctifier as shown. ○ Check BK1, BK2, and BK3 terminal respectively . If the test l ight turns on, the regulator /rectifier i s defective. Repla ce it. If the test l ight does not turn on, c[...]

ELECTRICAL SYSTEM 16-35 Charging System Chargi ng V oltage Insp ection • Check the battery conditi on (see Battery section). • W arm up the engine to obtain actual alternator operating conditions. • Remove the seats (see Frame chapt er). • Check that the igniti on switch is turn ed off, and connect the hand tester [A] to the batt ery termin[...]

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

ELECTRICAL SYSTEM 16-37 Ignition System WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engi ne is running, or you could receive a severe electri cal shock. CAUTION Do not disconnect t he battery cabl es or any other electrical connections when the igniti on switch is on, or [...]

16-38 ELECTRICAL SYSTEM Ignition System Crankshaft S ensor Installa tion • Route the crankshaft sensor lead corr ectly (see Cable, Wire, a nd Hose Routing in Appendix chapter). • T ighten: T orque - Crankshaft Sensor Bolts: 5.9 N·m (0.6 kgf·m, 53 in·lb) • Apply sili cone sealant [A] to the cranks haft sensor lead grommet and crankcase halv[...]

ELECTRICAL SYSTEM 16-39 Ignition System Cranks haft Se nsor Resis tance: 375 ∼ 565 Ω • Using the highest resistance range of the tester , m easure the resistance between the cr ankshaft sensor leads and chassis ground. Any tester r eading less than i nfinity ( ∞ ) indicates a short, necessitating r eplacement of the crankshaft sensor as- se[...]

16-40 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal • Remove: Fuel T a nk (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) ○ Push th e tongue [B] upside and take out the connector from th e bra cket . • Remove: Camshaft Position Sensor Bolt [A] Camshaft Position Sensor [B] Cam sha[...]

ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Posit ion Sensor Peak V oltage Inspecti on • Remove: Fuel T ank (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) • Set the hand tester [B] to t he 10 V DC range. • Connect the peak voltage adapter [C] to the h and tester and Camshaft Position Sensor lea[...]

16-42 ELECTRICAL SYSTEM Ignition System • Remove the stick coi l harness [A] from the br acket. • Remove: Stick C oil Connector #4 [B] (di sconnect) Stick Coil #4 [C] Stick Coil Connector #3 [D] (di sconnect) • Disconnect: W ater T em perature Sensor Connector [A] Left Switch Housing Connect or [B] • Pull the main harness [C] upward and rem[...]

ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil ( Ignition Co il togethe r with Spark Plug Cap) Inspectio n • Remove the stick coil s (see this chapter ). • Measure the primar y winding resi stance [A] as fol lows. ○ Connect the hand tester between t he coil terminals. ○ Set the tester to the × 1 Ω range, and read the t ester . • Me[...]

16-44 ELECTRICAL SYSTEM Ignition System W ARNING T o avoid extremely high volt age shocks, do not touch the spark plugs or tester connections. • T urn the ignition switch and the engine stop switch ON. • Pushing the sta rter button, turn the engine 4 ∼ 5 seconds with the t ransmission in neut ral to measure t he primary peak voltage. • Repe[...]

ELECTRICAL SYSTEM 16-45 Ignition System Inte rlock O pera tion In sp ectio n • Remove: Seats (see Frame chapter) Junction Box (see this chapt er) ○ Do not disconnect the connect ors. 1st Check • Measure the terminal voltage of the G/BK lead in the junc- tion box connector [A] in accordance wit h the following procedure. ○ Insert the needl e[...]

16-46 ELECTRICAL SYSTEM Ignition System IC Ignite r Inspecti on ○ The IC Igniter is bui lt in the ECU [A] . • Refer t o the Interl ock Operation Inspection, Ignition System T roubleshooting Chapter and Fuel System (DFI) chapter for ECU Inspection.[...]

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

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

ELECTRICAL SYSTEM 16-49 Electric Star ter System Starter M otor Removal CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Remove the mounting bolts [A]. • Pull out the starter motor [ B]. • Slide back the rubber cap [A]. • Remove the starter motor ter minal nut [B]. Starter M otor Ins[...]

16-50 ELECTRICAL SYSTEM Electric S tarter Sys tem ○ The brush plate [A] and brushes come off with the right–hand end c over [B]. • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate [C] from the right–hand end cover . Starter Moto r Assembly • Install the brush plat e and brushes [A], and[...]

ELECTRICAL SYSTEM 16-51 Electric Star ter System • Align the l ine [A] marked on the yoke wi th the throug h bolt hole [B]. Brush Ins pection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the car bon brush holder assembly [B ] and the terminal bolt assembly [C]. Starter Motor Br ush Length Standard: 1[...]

16-52 ELECTRICAL SYSTEM Electric S tarter Sys tem NOTE ○ Even if the foregoi ng checks show the armatur e to be good, i t may be defective in some manner not readi ly detectable wi th the hand tester . If all other star ter motor and starter mot or circuit components check good, but the st arter motor still does not turn over or only turns over w[...]

ELECTRICAL SYSTEM 16-53 Electric Star ter System • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Speci a l T ool - Hand T e ster : 57001– 1394 If the relay d oes not work as specified, t he relay is defec- tive. Replace the relay . T estin g Rela y T ester R ange: ×1 Ω range Criteri a: W hen bat tery is [...]

16-54 ELECTRICAL SYSTEM Lighting Syst em This models adopt the day light system and ha ve a head- light relay in t he junction box. In these models, the head- light d oes not go on when the i gnition switch and the engine stop switch ar e first tur ned on. The headl ight comes on after the starter button is released and stays on until the ignition [...]

ELECTRICAL SYSTEM 16-55 Lighting System Headli ght Bulb Replacement • Remove: Headlight Connector [ A] Headlight Bulb Dust Cover [ B] • Remove: Hook [A] Headlight Bulb [ B] CAUTION When handling the quartz–halogen bulb, never touch the glass port ion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can red[...]

16-56 ELECTRICAL SYSTEM Lighting Syst em • Fit the dust cover [A] with t he arrow mark upward onto the bulb [B] fi rmly as shown. Good [C ] Bad [D] Arrow Mark [E] • After i nstall ation, adjust the headlight aim (see this chap- ter). Hea dligh t Rem oval/ Insta llati on • Remove: Fairing (see Fr ame chapter) • Disconnect the headlight conne[...]

ELECTRICAL SYSTEM 16-57 Lighting System • Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • Replace the bulb with a new one.[...]

16-58 ELECTRICAL SYSTEM Lighting Syst em Headlight/T ail Light Circuit (US, CA, AS) Headlight/T ail Light Circuit (Other than US, CA, AS) US: U nited St ates of A me rica CA: Canada AS: Australia 1. Ignition Sw itch 2. Meter Ground 3. Alternator 4. Headlight Diodes 5. T aillight Fuse 10A 6. Headlight Fuse 10A 7. Junction Box 8. High Beam Indicato r[...]

ELECTRICAL SYSTEM 16-59 Lighting System T urn Signal Light Circuit US: U.S.A. m odel CA: Canada model MY : Malaysia m odel 1. Joint Connector D 2. Meter Unit 3. Right Tur n S ignal Indicator Light (LED) 4. Left T urn Signal Indicator Light ( LED) 5. Front R ight T urn Signal Light 6. Front Left T urn Signal Light 7. Joint Connector A 8. Frame Groun[...]

16-60 ELECTRICAL SYSTEM Lighting Syst em • Push and tur n the bulb [ A] counterclockwi se and remove it. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower groo ves [C] in the socket, and turn the bulb cl ockwise. ○ T urn the bulb about 15° degr ees. For the U.S.A. and Canadian Models: • Unscrew the[...]

ELECTRICAL SYSTEM 16-61 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the up per and lower grooves [C] in t he socket, and turn the bulb cloc kwise. CAUTIO N The front turn signal/running positi on lights use a vibration resistant bulb. Replacement of the front turn signal /running position bulbs with a n[...]

16-62 ELECTRICAL SYSTEM Lighting Syst em • Unscrew the bolts [A] . • Loosen the bol ts [B]. • Unscrew the mounting s crews [A]. • Remove the tai l/brake light (LED) [B]. ○ Pull out the mount portion [C]. T a il/Brake Ligh t (LED ) Install ation • T ighten the tail/brake l ight mounting screws. T orque - T ail/Brake Light Mounting Screws[...]

ELECTRICAL SYSTEM 16-63 Radiator Fan S ystem Fan System C ircuit Inspection • Disconnect th e lead connector [A] from the radi ator fan switch. • Using an auxiliar y wire [A], connect the radiator f an switch leads. If the fan rotates, inspec t the fan switch. If the fan does not rotate, inspect t he following. Leads and Connectors Main Fuse an[...]

16-64 ELECTRICAL SYSTEM Radiator F an Syste m Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Joint Connector A 4. Joint Connector D 5. Meter Ground 6. Frame Ground 7. Joint Connector B 8. Junction Box 9. Fan Fuse 10A 10. Main Fuse 30A 1 1. Battery 12 V 8 Ah[...]

ELECTRICAL SYSTEM 16-65 Meter , Gauge, Indic ator Unit Met er Unit R emova l • Remove: Wind Sealed (see Fr ame chapter) • Slide the dust cover [A] and remove th e wiring connector [B]. • Remove the meter unit by taking of f the mounting screws [C] with the washers. CAUTION Place the meter or gauge so that the face is up. If a meter or gauge i[...]

16-66 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit Electro nic Combin ation Mete r Unit Insp ection • Remove the meter uni t [A]. [1] Ignition [10] Batter y (+) [2] Fuel Reserv e Switch [1 1] Oil Pres sure Warning [3] Unused Indica tor Lig ht (L ED) [4] Fuel Le vel Sens or Ground (–) [5] Neutral Indicato r Lig ht [12] S peed Senso r Su pply[...]

ELECTRICAL SYSTEM 16-67 Meter , Gauge, Indic ator Unit MODE AND R ESET BUTTON Operation Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Displ ay (LCD) S eg- ments Check". • Check that the display change to the ODO, TRIP , and CLOCK displays each tim e the MODE button [A] is pres[...]

16-68 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit • In the HOUR sett ing mode, press the RESET button to eff ect the MINUTE setting mode. ○ The min ute display flashes on t he display . • Press the MODE button to set the minute. • In the MINUTE s etting mode, press the RESET button to return to t he HOUR/MINUTE setting mode. • Press [...]

ELECTRICAL SYSTEM 16-69 Meter , Gauge, Indic ator Unit • If the osci llator is not avai lable, the speedo meter can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel of f the ground, using the jack. ○ T urn on the ignition switch. ○ Rotate the rear wheel by hand. ○ Check that the speedometer shows the speed. If the[...]

16-70 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit W ater T emperature Meter Check: • Connect the 12 V battery and terminals in the same man- ner as s pecified in the "Liqui d Crystal Display (LCD) Seg- ments Check". • Connect the variabl e rheostat [A] to t he terminal [8] as shown . • Check that the number of segments matches [...]

ELECTRICAL SYSTEM 16-71 Meter , Gauge, Indic ator Unit Fuel Level Gauge Inspection: • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Connect a variable r heostat [A] to terminal [4] and [9] as shown. • Check that the number of segment [B] matches the resis[...]

16-72 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit • If the oscil lator is not availabl e, the tachometer can be checked as follows. ○ Connec t the 12 V battery and terminals in the same man- ner as specified in the "Liqui d Crystal Display (LCD) Seg- ments Check". ○ Using an auxiliary wi re, quick open and connect the t er- min[...]

ELECTRICAL SYSTEM 16-73 Meter , Gauge, Indic ator Unit Right and Left T urn Signal Indicator Light (LED): For Right T urn Signal Indicator Light (LED) Battery Positive (+) T erminal to T erminal [13] For Left T urn S ignal Indicator Light (LED) Battery Positive (+) T erminal to T erminal [14] High Beam Indicator Light: Battery Positive (+) T ermina[...]

16-74 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit Meter Circuit 1. Right T urn Signal Indicator Light (LED) 2. High Beam Indicator Light (LED) 3. Neutral Indicator Light (LED) 4. Oil Pressure War ning Indicator Light (LED) 5. FI Indicator Light (LED) 6. Odometer/T rip Meter/Clock/Fuel Indicator 7. W ater T emperature G auge 8. Fuel Level Gauge[...]

ELECTRICAL SYSTEM 16-75 Switches an d Sensors Brake Lig ht Timing Inspe ction • Refer to the Brakes i n the Periodic Maint enance chapter . Brake Lig ht Timing Adj ustment • Refer to the Brakes i n the Periodic Maint enance chapter . Switch Inspection • Using a hand tester , check to see t hat only the con- nections shown in the table hav e c[...]

16-76 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the connector [A]. • Remove the fan swit ch [B]. • Suspend the switch [A] in a container of coolant so that the temperature–s ensing projection and threaded port ion are submerged. • Suspend an accurate t hermometer [B] in th e coolant so that the sensiti ve portions are located i [...]

ELECTRICAL SYSTEM 16-77 Switches an d Sensors • Suspend the sensor [A] in a container of coolant so that the temperature- sensing projection [ E] and threaded por- tion [E] are submerged. • Suspend an accurate ther mometer [B] in the coolant. NOTE ○ The sensor and ther mometer must not touch the con- taine r side or bottom. • Place the cont[...]

16-78 ELECTRICAL SYSTEM Switches and Sensors • Remove: Bolts [A] Speed S ensor Cover • Remove: Bolt [A] • T ake out the speed sensor [B]. • Connect the speed sensor connector [A] with the battery [B], 1 0 k Ω resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special T ool - Ha nd T est er: 57001 –1394 ?[...]

ELECTRICAL SYSTEM 16-79 Switches an d Sensors Fuel L evel S enso r Ins pection • Remove: Fuel T ank (see Fuel System (DFI) chapter) • Ope n th e cla mps [ A]. • Remove: Bolts [B] Fuel Level Sensor [C] • Check that the float moves up and down smoothly without binding. It shoul d go down under its own weight. If the float does not move smooth[...]

16-80 ELECTRICAL SYSTEM Switches and Sensors • Connect the test li ght [A] (12 V 3.4 W bulb a s ocket with leads) and th e 12 V battery [ B] to the fuel level sensor connec tor [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) → Blue Lead T erminal Battery (–) → BK/Y Lead T erminal If the test light t[...]

ELECTRICAL SYSTEM 16-81 Junction Box The junction box [A] has f uses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapt er). • Remove the junction box [A]. • Pull of f the connectors [A] f rom the junction box [B] . • Make sure all connector terminals a[...]

16-82 ELECTRICAL SYSTEM Junction Bo x Starter Circu it/Headli ght Relay Inspe ction • Remove the junction box (see Junction Box Fuse Circuit Inspec tion). • Check conductivit y of the followi ng numbered terminals by connecting the hand tester and one 12 V battery to the junct ion box as shown. ○ Refer to the Junction Box Internal Circui t. I[...]

ELECTRICAL SYSTEM 16-83 Junction Box Diode Circuit Inspection • Remove the junction box . • Check conductivi ty of the follo wing pairs of termi nals. Diode C ircuit Inspection Te s t e r Conn e ction 13–8, 13–9, 12 –1 1 , 12–14, 1 5–14, 1 6–14 The resistance should be low in one direction and more than ten times as much in the othe[...]

16-84 ELECTRICAL SYSTEM Fus e 30A Main Fuse Removal • Remove: Right S ide Cover (see Frame chapter) 30A Main Fuse Connect or [A] • Pull out the main fuse [B] from the starter relay with needle nose pl ier s. Junction Bo x Fuse Remo val • Remove the seats (see Frame chapter). • Unlock the hook to lift up t he lid [A]. • Pull the fuses [B] [...]

APP ENDI X 17- 1 17 Appendix T able of Con tents Cable , Wir e, a nd Hos e Rou ting ...... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... . 17-2 T roubleshooting Guide ......... ........... ............ ........... .............. .............. ........... .............. ........... 17-20[...]

17-2 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APP ENDI X 17- 3 Cable, Wire, and Hose Routing 1. Fixes by the left side cla mp of the tank. 2. T ank drain hose passes the side cover inst allation under the br acket. 3. Air cl e aner drain hose 4. Fuel tank drain hose 5. Cooling reserve tank hos e 6. Fixes by the swingarm clamp 7. Fuel level sensor 8. Fixes by the right sid e clamps two places o[...]

17-4 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APP ENDI X 17- 5 Cable, Wire, and Hose Routing 1. Clutch cable 2. Meter ground 3. Clamp ( Ignition switch connector) 4. Ignition swit ch connector 5. Inlet air pressure sensor 6. T o ign it ion coi l 7. Fan motor connector (Connect the con- nector on the inlet air pressur e sensor .) 8. Clam p 9. T o f uel pump 10. T o fuel level gauge and fuel res[...]

17-6 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APP ENDI X 17- 7 Cable, Wire, and Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Igniti o n switch connector 4. Meter ground (with thermostat) 5. Engine harness (Connect the harness on the cross pipe.) 6. W ater temperatur e sensor 7. Inlet air pressu re sensor 8. Cl[...]

17-8 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APP ENDI X 17- 9 Cable, Wire, and Hose Routing 1. T ail light 2. Clamp 3. Atmosp heric pres sure sensor 4. T o ECU fuse 5. Junction Box 6. T o sel f-diagnosis indicat or terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10. T o inlet air temperature sensor 1 1. Fan motor connector 12. Inle t ai[...]

17-10 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APPENDIX 17-1 1 Cable, Wire, and Hose Routing 1. Clamp all the wires as shown in the encircled area. 2. Meter 3. T ake ou t the lead of the meter from the r ight side of the tie lap to connect with the meter . 4. Clutch cab le 5. Starter cable 6. T o fro nt left tur n signal light (Run the harn ess above the bolt for fairing i nstallation.) 7. Run [...]

17-12 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APPENDIX 17-1 3 Cable, Wire, and Hose Routing 1. Clamp 2. Brake hose 3. Punch m ark 4. Run the brake hose through the inside of the frame. 5. T ight the bolt to the speci fied torque with t he stopper (for turni ng prevention) applied.[...]

17-14 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APPENDIX 17-1 5 Cable, Wire, and Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head t o secure the coupler .) 2. Radiat or fan switch lead (Run the l ead through into the water hose.) 3. Cap 4. Catch cable (Run the cable through forwar d the water hose.) 5. Air su cti on valve 6. W ater hose (Thermosta[...]

17-16 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APPENDIX 17-1 7 Cable, Wire, and Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Run the lead end till i t touches the boss of t he crankcase. 4. Install the exterior of the lead wit h staking area facing downward.[...]

17-18 APPENDIX Cabl e, Wir e, and Hos e Ro utin g[...]

APPENDIX 17-1 9 Cable, Wire, and Hose Routing 1. Run the hose (cap – reserve) through upside of the throttle cabl e. 2. Run the hose (white) through into the th rottle cables . 3. Run the throttle body harness throttle upsi de of the hos e (white) and hose ( throttle – fitting) . 4. Run the harness through u pside of the hose. 5. Throttle cable[...]

17-20 APPENDIX T roubleshooting Guide NOTE ○ Refer to the Fuel System chapt er for most of DFI t rouble shootin g guide. ○ This is not an exhaust ive list, giving every possible cause for each problem li sted. It is mea nt simply as a rough guide to assist the troubl eshooting for some of the more common difficul ties. Engine Does n’t Start, [...]

APPENDIX 17-2 1 T ro ubleshooting Guide Air cleaner duct loose Compression low: Spark p lug loose Cylinder head not suff iciently ti ghtened down No va lv e clear ance Cylinder , piston worn Piston ring bad (wor n, weak, broken, or sticki ng) Piston ring/ groove clearance excessive Cylinder head warped Cylinde r head gasket damaged V a l v es p r i[...]

17-22 APPENDIX T roubleshooting Guide Muffler overheati ng: For KLEEN, do not run the en gine even if with on ly one cylinder misfi ring or poor running (Request the nearest service fa- cility to correct it ) For KLE EN, do not push-start with a dead battery (Connect anoth er full-charged battery with j umper cables, and start the engin e using the[...]

APPENDIX 17-2 3 T ro ubleshooting Guide Abnormal Eng ine Noise: Knocking: IC igni ter in ECU trouble Carbon built up i n combustion chamber Fuel poor quality or incorrect Spark pl ug incorr ect Overheating Piston slap: Cylinde r/pi ston clearance excessiv e Cylinder , piston worn Connecting rod bent Piston pi n, pist on pin hole wor n V alve noise:[...]

17-24 APPENDIX T roubleshooting Guide Handling and /or Stability Unsatisfacto ry: Handle bar hard to turn: Cable routin g incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem beari ng damaged Steerin g st em bearing lubr ication inade- quate Steering stem bent Ti r e a i r pressure too low Handlebar sh[...]

MODEL APPLICA TION Y ear Model Beginning Frame No. 2003 ZR1000–A1 JKAZRCA1 □ 3A000001 ZRT00 A–000001 JK AZRT00AAA000001 2004 ZR1000–A2 JKAZRCA1 □ 4A015001 JKAZRT00AAA015001 ZRT00 A–015001 □ :This digit in the frame number changes from one machine to another . Part No.99924 -1310- 03 Printe d in Japan[...]