KawasakiメーカーER-6n (2006)の使用説明書/サービス説明書
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ER-6n Motorcycle Service Manual http://mototh.com.
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This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required.
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ER-6n Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical pho.
LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa .
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work.
NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con - venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows.
GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification.........................
1-2 G ENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the preca utions given below .
GENERAL INFORMA TION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly .
1-4 G ENERAL INFORMA TION Before Servicing Tightening Sequence Generally , when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
GENERAL INFORMA TION 1-5 Before Servicing Press For items s uch as bearin gs or oil seals that must be pressed into place, apply small amount of oil to the con- tact area.
1-6 G ENERAL INFORMA TION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified.
GENERAL INFORMA TION 1-7 Model Identification ER650A6F/ ER650A6S Left Side Vi ew ER650A6F/ ER650A6S Right Side View ER650A6F: Australia, Malaysia ER650A6S: Europe http://mototh.
1-8 G ENERAL INFORMA TION General Specifications Items ER650A6F/ER650A6S Dimensions Overall Length 2 100 mm (82.7 in.) Overall Width 760 mm (29.9 in.) Overall Height 1 095 mm (43.1 in.) Wheelbase 1 405 mm (55.3 in.) Road Clearance 140 mm (5.5 in.) Seat Height 785 mm (30.
GENERAL INFORMA TION 1-9 General Specifications Items ER650A6F/ER650A6S Vi scosity SAE 10W-40 Capacity 2 . 4L( 2 . 5U Sq t ) Drive T rain Primary Reduction System: Ty p e Gear Reduction Ratio 2.095 (88/42) Clutch T ype Wet multi disc T ransmission: Ty p e 6-speed, constant mesh, return shift Gear Ratios: 1st 2.
1-10 GENERAL INFORMA TION General Specifications Items ER650A6F/ER650A6S Headlight: Ty p e Semi-sealed beam Bulb 1 2V5 5W×2 / 5 5W( H i / L o ) T ail/Brake Light 12 V 5/21 W Alternator: Ty p e Three-phase AC Rated Output 24 A/14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country .
GENERAL INFORMA TION 1-1 1 T echnical Informati on - Cassette T ype T ran smission Cassette T ype T ransmission The transmission of the current model is unable to be removed without disassembling upper and lower crankcase halves.
1-12 GENERAL INFORMA TION T echnical Information - Inlet Air Pressure Sensor Atmospheric pressure sensor and camshaft position sensor are not equipped with the ER650A. As a substitute of these sensors above, the ER650A recognizes atmospheric pressure and intake stroke of #1 by the signal of inlet air pressure sensor .
GENERAL INFORMA TION 1-13 Unit Conversio n T able Prefixes fo r Un its: Prefix Symbol Power mega M ×1 0 0 0 0 0 0 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass: k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units o f V olume: L × 0.
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PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic M aintenance Chart ........................................................................................... ........ 2-3 T orque and Locking Agent .........................
2-2 PERIODIC MAINTENANCE Steering P lay Inspection ................................................................................................ ... 2-35 Steering P lay Adjustment.....................................................................
PERIODIC M AINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
2-4 PERIODIC MAINTENANCE Periodic Main tenance Chart FREQUENCY Whichever comes first * ODOMETER READING ×10 0 0k m (× 1 000 mile) 1 6 12 18 24 30 36 INSPECTION Every (0.
PERIODIC M AINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever comes first * ODOMETER READING × 1 000 km (× 1 000 mile) 1 12 24 36 48 CHANGE/REPLACE ITEM Every (0.
2-6 PERIODIC MAINTENANCE T orque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: AL: T ighten the two clamp bolts alternately two times to ensure even tightening torque.
PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Clutch Upper Cap on Clutch Cover 3.9 0.40 35 in·lb Lower Cap on Clutch Cover – – – Hand-tighten Oil Filler Plug – – – Hand-tighten Clutch Cover Mounting Bolts 9.
2-8 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Oil Pressure Switch 15 1.5 11 SS Oil Passage Plug 20 2.0 15 L Gear Positioning Lever Bolt 12 1.2 106 in·lb L Shift Shaft Return Spring pin 29 2.9 22 L Shift Drum Cam Bolt 12 1.
PERIODIC MAINTENANCE 2-9 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Rear Shock Absorber Nut 59 6.0 44 Swingarm Pivot Shaft Nut 108 11 . 0 80 Steering Front Fork Clamp Bolts (Lower) 20 2.0 15 AL Front Fork Clamp Bolts (Upper) 20 2.
2-10 PERIODIC M AINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks T iming Rotor Bolt 40 4.1 30 W ater T emperature Sensor 12 1.2 106 in·lb The table below , relating tightening torque to thread diameter , lists the basic torque for the bolts and nuts.
PERIODIC M AINTENANCE 2-1 1 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 13 0 0± 5 0r / m i n( r p m ) ––– Bypass Screws (T urn Out) 0 ∼ 3 1/2 (for reference) ––– Engine V acuum 35.
2-12 PERIODIC M AINTENANCE Specifications Item Standard Service Limit Final Drive Drive Chain Slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) ––– Drive Chain Wea r (20-link Length) 317.
PERIODIC M AINTENANCE 2-13 Special T ools Inside Circlip P l ie r s: 57001-143 Steering Stem Nut Wrenc h: 57001-1 100 Jack: 57001-1238 Oil Filter Wrench: 57001-1249 Extension T ube: 57001-1578 Pilot Screw Adjuster , E: 57001-1603 Jack Attachment: 57001-1608 http://mototh.
2-14 PERIODIC M AINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose Inspection (fuel leak, damage, installatio n condition) ○ The fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance.
PERIODIC MAINTENANCE 2-15 Periodic Maintena nce Procedures If necessary , adjust the throttle c able as follows. • Loosen the locknut [A] at the upper end of the accelerator cable. • T urn the adjuster [B] in completely so as to give the throttle grip plenty of play .
2-16 PERIODIC M AINTENANCE Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately .
PERIODIC MAINTENANCE 2-17 Periodic Maintena nce Procedures WA R N I N G Clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.
2-18 PERIODIC M AINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly . • Check the idle speed. T achometer [A] • Open and close the throttle. If the idle speed is out of the s pecified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit.
PERIODIC MAINTENANCE 2-19 Periodic Maintena nce Procedures • Repeat the same procedure for other bypass screws. • Repeat the synchronization. If the vacuums are correct, check the output voltage of the m ain throttle sensor (see Main Throttle Sensor Output V oltage Inspection in the Fuel System (DFI) chapter).
2-20 PERIODIC M AINTENANCE Periodic Maintenance Procedures Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
PERIODIC MAINTENANCE 2-21 Periodic Maintena nce Procedures • Check the valve clearance when the pistons are at TDC. ○ The pistons are numbered beginning with the engine left side.
2-22 PERIODIC M AINTENANCE Periodic Maintenance Procedures V alve C learance M easurin g Positi o n #2 Piston TDC at End of Compression Stroke → Inlet valve clearances of #2 piston, and Exhaust valve clearances of #2 piston If the v alve clearance is not with in the specified range, first record the clearance, and adjust it.
PERIODIC MAINTENANCE 2-23 Periodic Maintena nce Procedures V AL VE CLEARANCE ADJUSTMENT CHART INLET V A L V E 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column.
2-24 PERIODIC M AINTENANCE Periodic Maintenance Procedures V AL VE CLEARANCE ADJU STMENT CHART EXHAU ST V A L VE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column.
PERIODIC MAINTENANCE 2-25 Periodic Maintena nce Procedures Clutch Clutch Operation Inspection • Pull the c lutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder . If the gap is too wide, the clutch may not release fully .
2-26 PERIODIC M AINTENANCE Periodic Maintenance Procedures Wheel/Tire Damage In spection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary .
PERIODIC MAINTENANCE 2-27 Periodic Maintena nce Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/T ires chapter). • T urn the handlebar all the way to the right or left.
2-28 PERIODIC M AINTENANCE Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. • Wipe off any excess oil.
PERIODIC MAINTENANCE 2-29 Periodic Maintena nce Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, i f the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.
2-30 PERIODIC M AINTENANCE Periodic Maintenance Procedures Drive Chain W ear Inspection • Remove: Chain C over (see Swingarm R emoval in the S uspension chapter) • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links.
PERIODIC MAINTENANCE 2-31 Periodic Maintena nce Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. If the brake fluid leaked from any position, inspect or r e- place the problem part.
2-32 PERIODIC M AINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
PERIODIC MAINTENANCE 2-33 Periodic Maintena nce Procedures Brake Pad Wear Inspection • Check the lining thickness [A] of the pads in each caliper . If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
2-34 PERIODIC M AINTENANCE Periodic Maintenance Procedures Suspensions Front Fo rks/Rear Shock Absorber Operation Inspection • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
PERIODIC MAINTENANCE 2-35 Periodic Maintena nce Procedures Steering System Steering Play Inspection • Raise the front wheel off the ground with jack. Special T ools - Jack: 57001-1238 Jack Attachment: 57001-1608 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar .
2-36 PERIODIC M AINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special T ool - Steering Stem N ut Wrench [A]: 57001-1 100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
PERIODIC MAINTENANCE 2-37 Periodic Maintena nce Procedures Electrical System Spark P lug Condition Inspectio n • Remove the spark plugs (see Spark Plug Replacement).
2-38 PERIODIC M AINTENANCE Periodic Maintenance Procedures Lights and Switches Operation I nspectio n First Step • T urn on the ignition switch. • The following lights should go on according to below table.
PERIODIC MAINTENANCE 2-39 Periodic Maintena nce Procedures Third Step • T urn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. • The turn signal indicator light (LED) [C] in the meter unit should flash.
2-40 PERIODIC M AINTENANCE Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (LED) [C] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.
PERIODIC MAINTENANCE 2-41 Periodic Maintena nce Procedures NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations.
2-42 PERIODIC M AINTENANCE Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Ele.
PERIODIC MAINTENANCE 2-43 Periodic Maintena nce Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant.
2-44 PERIODIC M AINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
PERIODIC MAINTENANCE 2-45 Periodic Maintena nce Procedures Replacement Parts Air Cleaner Element Replacement • Refer to the Air Cleaner Element Cleaning. Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine.
2-46 PERIODIC M AINTENANCE Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil C hange). • Remove the oil filter [A] with the oil filter wrench [B]. Special T ool - Oil Filter Wrench: 57001-1249 • Replace the filter with a new one.
PERIODIC MAINTENANCE 2-47 Periodic Maintena nce Procedures • Install the new fuel hose. • Insert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks.
2-48 PERIODIC M AINTENANCE Periodic Maintenance Procedures • Put [A] the projection [B] on the reserve tank into the hole [C] on the frame bracket, and place the reserve tank on the right side of frame. • Place a container under the water pump drain bolt [A], then remove the drain bolt.
PERIODIC MAINTENANCE 2-49 Periodic Maintena nce Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer ’s directions. CAUTION Soft or distilled water must be used with the an- tifreeze in the cooling system.
2-50 PERIODIC M AINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
PERIODIC MAINTENANCE 2-51 Periodic Maintena nce Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately .
2-52 PERIODIC M AINTENANCE Periodic Maintenance Procedures • Level the brake fluid reservoir . • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed valve [A] on the caliper . • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container .
PERIODIC MAINTENANCE 2-53 Periodic Maintena nce Procedures Master Cylinder Rubb er Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container .
2-54 PERIODIC M AINTENANCE Periodic Maintenance Procedures • Apply brake fluid to the new parts and to the inner wall of the cylinder . • T ake care not to scratch the piston or the inner wall of the cylinder . • T ighten the brake lever pivot bolt and locknut.
PERIODIC MAINTENANCE 2-55 Periodic Maintena nce Procedures • Replace the fluid seals [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them into the cylinders by hand. • Replace the dust s eals [B] with new ones if they are dam- aged.
2-56 PERIODIC M AINTENANCE Periodic Maintenance Procedures Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap.
PERIODIC MAINTENANCE 2-57 Periodic Maintena nce Procedures • Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench [A]. Owner ’ s T ool - Spark Plug Wrench , 16 mm: 921 10-1 132 • T ighten: T orque - Spark Plugs: 15 N·m (1.
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FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) T able of Contents Exploded View ................................................................................................................ ........ 3-4 DFI System .......................................
3-2 FUEL SYSTEM (DFI) Sensor Resistance Inspection .......................................................................................... 3-53 Crankshaft Sensor (Service Code 21) ....................................................................
FUEL SYSTEM (DFI) 3-3 Pump Screen, Fuel Filter Cleaning ................................................................................... 3-86 Fuel Injectors ...........................................................................................
3-4 FUEL SYSTEM (DFI) Exploded View http://mototh.com.
FUEL SYSTEM (DFI) 3-5 Exploded View T orque No. Fastener N·m kgf· m ft·lb Remarks 1 Fuel Pump Bolts 9.8 1.0 87 in·lb L, S 2. FI Indicator LED Light 3. Throttle Cable (Accelerator) 4. Throttle Cable (Decelerator) 5. Throttle Body Assy 6. Injectors CL: Apply cable lubricant.
3-6 FUEL SYSTEM (DFI) Exploded View http://mototh.com.
FUEL SYSTEM (DFI) 3-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater T emperature Sensor 12 1.2 106 in·lb 2 Speed Sensor Bolt 7.8 0.80 66 in·lb L 3 Oxygen Sensor (Europe Model) 44.1 4.50 32.5 4. Inlet Air Pressure Sensor 5. Air Switching V alve 6.
3-8 FUEL SYSTEM (DFI) DFI Sys tem DFI System http://mototh.com.
FUEL SYSTEM (DFI) 3-9 DFI System 1. Ignition Switch 2. Starter Lockout Switch 3. Starter Relay 4. T achometer 5. FI Indicator Light (LED) 6. Inlet Air Pressure Sensor 7. Spark Plug 8. Crankshaft Sensor 9. Injector 10. Main Throttle Sensor 1 1. Delivery Pipe 12.
3-10 FUEL SYSTEM (DFI) DFI Sys tem DFI System Wiring Diagram http://mototh.com.
FUEL SYSTEM (DFI) 3-1 1 DFI System Part Name 1. Oxygen Sensor (Europe Model) 2. Crankshaft Sensor 3. Inlet Air T emperature Sensor 4. W ater T emperature Sensor 5. W ater-proof Joint E 6. Injectors 7. V ehicle-down Sensor 8. W ater-proof Joint D 9. Inlet Air Pressure Sensor 10.
3-12 FUEL SYSTEM (DFI) DFI Sys tem T erminal Names 1. Subthrottle V alve Actuator Drive Signal 2 2. Subthrottle V alve Actuator Drive Signal 1 3. W ater T emperature Warning Light Signal 4. Unused 5. Oxygen Sensor Signal 6. Speed Sensor Signal 7. Main Throttle Sensor Signal 8.
FUEL SYSTEM (DFI) 3-13 DFI Parts Location DFI: Digital Fuel Injection Parts 1. FI Indicator Light LED (DFI) 2. Ignition Switch 3. Throttle Body Assy 4. Inlet A ir T emperature Sensor 5. Injectors 6. Fuel Pump 7. Relay Box (ECU Main Relay , Fuel Pump Relay , Radiator Fan Relay) 8.
3-14 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Assy: Ty p e T wo barrel type Bore 38 mm (1.
FUEL SYSTEM (DFI) 3-15 Specifications Item Standard Output V oltage with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Subthrottle Sensor: Non-adjustable and non-removal Input V oltage 4.75 ∼ 5.
3-16 FUEL SYSTEM (DFI) Special T ools and Sealant Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Fork Oil Level Gauge: 57001-1290 Hand T ester: 57001-1394 Throttle Sensor Setting Adapter #1: 57001-1400 Pea.
FUEL SYSTEM (DFI) 3-17 Special T ools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120 http://mototh.com.
3-18 FUEL SYSTEM (DFI) DFI Servicing Precau tio ns DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source.
FUEL SYSTEM (DFI) 3-19 DFI Servicing Precautions ○ T o maintain the correct fuel/air 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 oil. Clutch C over [B] T orque - O il Filler Plug: Hand-tighten http://mototh.
3-20 FUEL SYSTEM (DFI) T roubleshooti ng the DFI S ystem Outline Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
FUEL SYSTEM (DFI) 3-21 T roubleshooting the DFI System ○ The DFI part connectors [A] have seals [B], including the ECU. • Join the connector and insert the needle adapters [C] inside the seals [B] from behind the connector until the adapter reaches the terminal.
3-22 FUEL SYSTEM (DFI) T roubleshooti ng the DFI S ystem • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the c onnector i s corroded or dirty , clean it carefully . If it is damaged, replace it. Connect the connectors securely .
FUEL SYSTEM (DFI) 3-23 T roubleshooting the DFI System ○ There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (V oltage Check Method) ○ This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor .
3-24 FUEL SYSTEM (DFI) T roubleshooti ng the DFI S ystem DFI Diagnosis Flow Chart Inquiries to Rider Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered.
FUEL SYSTEM (DFI) 3-25 T roubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Y ear of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred.
3-26 FUEL SYSTEM (DFI) T roubleshooti ng the DFI S ystem □ clutch slipping □ other □ spark plug loose (tighten it) □ spark plug dirty , broken, or gap maladjusted (remedy it) Poor running or n.
FUEL SYSTEM (DFI) 3-27 DFI System T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possi ble cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
3-28 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or possible Causes Actions (chapter) Clutch lever not pulled in and gear not in neutral whether sidestand up or not Pull the lever in and shift the gear in neutral.
FUEL SYSTEM (DFI) 3-29 DFI System T roubleshooting Guide Symptoms or possible Causes Actions (chapter) No valve clearance Adjust (see chapter 2). V alve guide worn Inspect and replace (see chapter 5). V alve spring broken or weak Inspect and replace (see chapter 5).
3-30 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-31 DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Loose terminal of battery (–) lead or engine ground lead Inspect and repair (see chapter 16). Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see chapter 16).
3-32 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). W ater temperature sensor trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-33 DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle body assy O-ring damaged Replace (see chapter 3). Fuel tank air vent obstructed Inspect and repair (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3).
3-34 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Drive train trouble Inspect drive chain (see chapter 2) and sprockets (see chapter 1 1). Camshaft cam worn Inspect and replace (see chapter 5). Air switching valve trouble Inspect and replace (see chapter 5).
FUEL SYSTEM (DFI) 3-35 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outlin e The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal.
3-36 FUEL SYSTEM (DFI) Self-Diagnosis • T o enter the s elf-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
FUEL SYSTEM (DFI) 3-37 Self-Diagnosis http://mototh.com.
3-38 FUEL SYSTEM (DFI) Self-Diagnosis H o wt oR e a dS e r v i c eC o d e s How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below . ○ Read 10th digit and unit digit as the FI indicator light (LED) blinks.
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis S e r v i c eC o d eT a b l e Service Code T able Service Code FI Indicator LED Light Problems 11 Main throttle sensor malfunction, wiring open or short 12 Inlet .
3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups Backups ○ The ECU takes the following measures to prev ent engine damage w hen the DFI or the ignition system parts have troubles. Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 11 Main Throttle Sensor Main Throttle Sensor Output V oltage 0.
FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 51 Stick Coil #1 (Ignition Coil)* The stick coil primary winding must send signals (output voltage) continuously to the ECU.
3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 1 1) Main Throttle Sensor Removal/Adj ustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory . Never drop the sensor , especially on a hard surface.
FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 1 1) Output V oltage Inspection • Measure the output voltage at the m ain throttle sensor in the same way as input voltage inspection, Note the following. • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 1 1) Resistance Inspection • T urn the ignition switch OFF . • Disconnect the main throttle sensor connector . • Connect a digital m eter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance.
FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Left C enter Fairing (see Center Fairing Removal in the Frame c hapter) • Disconnect the inlet air pressure sensor connector [A] and the vacuum hose [B].
3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sens or (Service Code 12) Output V oltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection.
FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (V acuum gauge reading) Pl = 70 cmHg (V arometer r eading) Vv = 3.
3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sens or (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output V oltage (V) (Digital Meter Reading) Pv: Throttle V acuum Pressure (Absolut.
FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. W ater-proof Joint E 3. W ater-proof Joint D 4.
3-50 FUEL SYSTEM (DFI) Inlet Air T emperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel T ank Removal). • Disconnect the connector [A] from the inlet air tempera- ture sensor .
FUEL SYSTEM (DFI) 3-51 Inlet Air T emperature Sensor (Service Code 13) Sensor Resistance I nspectio n • Remove the inlet air temperature sensor . • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.
3-52 FUEL SYSTEM (DFI) W ater T emperature Sensor (Service Code 14) Water T emperature Sensor Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
FUEL SYSTEM (DFI) 3-53 W ater T emperature Sensor (Service Code 14) W ater T emperatu re Sensor Circuit 1. ECU 2. W ater T emperature Sensor 3. W ater-proof Joint E 4. Meter Unit Sensor Resistance I nspectio n • Remove the water temperature sensor (see W ater T em- perature Sensor Removal/Installation).
3-54 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch 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-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor .
FUEL SYSTEM (DFI) 3-55 Speed Sensor (Service C ode 24, 25) Speed Sensor Removal/Installation • See the Switches and Sensors section in the Electrical System chapter . Speed Sensor Inspection • See Speed Sensor Inspection section in the Electrical System chapter .
3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector and connect the harness adapter [A] between the harness connector and speed sensor connector . • Connect a digital meter to the harness adapter leads.
FUEL SYSTEM (DFI) 3-57 V e hicle- down Sensor (Service Co de 31) V ehicle-down Sensor Removal CAUTION Never drop the down-sensor , especially on a hard surface.
3-58 FUEL SYSTEM (DFI) V ehicle-down Sensor (Service Code 31) • Remove the sensor . • Connect a digital volt meter [A] to the connector with nee- dle a dapter set [B].
FUEL SYSTEM (DFI) 3-59 V e hicle- down Sensor (Service Co de 31) V ehicle-down Sensor Circuit 1. ECU 2. W ater-proof Joint E 3. V ehicle-down Sensor 4.
3-60 FUEL SYSTEM (DFI) Subthrottle Sensor ( Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory . Never drop the sensor , especially on a hard surface.
FUEL SYSTEM (DFI) 3-61 Subthrottle Sensor (Service Code 32) Subthrottle Sensor O utput V oltage Insp ection • Remove the fuel tank (see Fuel T ank Removal). • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection.
3-62 FUEL SYSTEM (DFI) Subthrottle Sensor ( Service Code 32) Subthrottle Sensor Resistance Inspection • T urn the ignition switch OFF . • Disconnect the subthrottle sensor connector . • Connect a digital meter [A] to the subthrottle sensor con- nector [B].
FUEL SYSTEM (DFI) 3-63 Oxygen Sensor-not activated (S ervice Code 33) - Europe Model Oxygen Se nsor Remo val/In stallation • Refer to Switches and Sensors section in the Electrical System chapter . Oxygen Sensor Inspection • W arm up the engine thoroughly until the radiator fan starts.
3-64 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (S ervi ce Code 33) - Euro pe Model • Measure the output voltage of the sensor with the con- nector joined. Oxygen Sensor Output V oltage (without Plugs) Standard: 0.2 V or less If the reading is within range (with plugs: 0.
FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2: Service Code 51, 52) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur- face.
3-66 FUEL SYSTEM (DFI) Stick Coils (#1, #2: Service Code 51, 52) Stick Coil Circuit 1. ECU 2. W ater-proof Joint C 3. Stick Coils 4. Engine Stop Switch 5. Ignition Switch 6. Ignition Fuse 10 A 7. Main Fuse 30 A 8. Battery 9. Frame Ground 10. Joint Connector http://mototh.
FUEL SYSTEM (DFI) 3-67 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Radiator fan relay is bult in the relay box. • Remove the relay box (see Relay Box Removal in the Electrical System chapter). Radiator Fan Relay Inspection • See Relay Circuit Inspection in the Electrical System chapter .
3-68 FUEL SYSTEM (DFI) Subthrottle V alve Actuator (Service Code 62) Subthrottle Valve Actuator Remo val CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory . Never drop the actuator , especially on a hard sur- face.
FUEL SYSTEM (DFI) 3-69 Subthrottle V alve Actuator (Service Code 62) Subthrottle V alve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • T urn the ignition switch OFF . • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
3-70 FUEL SYSTEM (DFI) Air Switching V alve (Service Code 64) Air Switching V alve R emoval/Insta llation • Refer to Clean Air System section in the Engine T op End chapter . Air Switching Valve Inspection • Refer to Air Switching V alve section in the Electrical Sys- tem chapter .
FUEL SYSTEM (DFI) 3-71 Oxygen Sensor Heater (Servi ce Code 67) - Europe Model Oxygen Sensor Hea ter Removal/Installation The oxygen sensor heater is bult in the oxygen sensor . So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
3-72 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Servi ce Code 67) - Europe Model Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor 3. W ater-proof Joint E 4. W ater-proof Joint D 5. Oxygen Sensor Heater Fuse 10 A 6. Main Fuse 30 A 7. Battery 8. Frame Ground 9.
FUEL SYSTEM (DFI) 3-73 Oxygen Sensor-Incorrect Output V olta ge (Service Code 94) - Europe Model Oxygen Se nsor Remo val/In stallation • Refer to Oxygen Sensor Removal/Installation in the Elec- trical System chapter . Oxygen Sensor Inspection • W arm up the engine thoroughly until the radiator fan starts.
3-74 FUEL SYSTEM (DFI) Oxygen Sensor-Incorrect Output V ol tage (Service Code 94) - Europe Model • Measure the output voltage of the sensor with the con- nector joined. Oxygen Sensor Output V oltage (without Plugs) Standard: 0.2 V or less If the reading is within range (with plugs: 0.
FUEL SYSTEM (DFI) 3-75 FI Indicator Light (LED) Inspection Flow Chart http://mototh.com.
3-76 FUEL SYSTEM (DFI) FI Indicator Light (LED) FI Indica tor Light (LED) Inspection • Remove the m eter unit (see Meter Unit Removal i n the Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator light (LED) [A].
FUEL SYSTEM (DFI) 3-77 ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seat (see Seat Removal in the Frame chapter) Grab Ra.
3-78 FUEL SYSTEM (DFI) ECU ECU Power Su pply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air . Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged.
FUEL SYSTEM (DFI) 3-79 ECU ECU Power Source Circuit 1. ECU 2. W ater-proof Joint C 3. Ignition Switch 4. W ater-proof Joint A 5. ECU Main Fuse 15 A 6. ECU Main Relay 7. Relay Box 8. Main Fuse 30 A 9. Battery 10. Frame Ground 1 1. Joint Connector http://mototh.
3-80 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well.
FUEL SYSTEM (DFI) 3-81 Fuel Line • T urn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop. CAUTION Do not drive the fuel pump without the fuel in the fuel tank. • Measure the fuel pressure with the engine stopped. Fuel Pressure Right after Ignition Switch ON, with pump running: Standard: 323 kPa (3.
3-82 FUEL SYSTEM (DFI) Fuel Line Fuel Flow Rate Inspection NOTE ○ Be sure the battery is fully charged. W ARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
FUEL SYSTEM (DFI) 3-83 Fuel Line CAUTION Do not drive the fuel pump without the fuel in the fuel tank. • Measure the discharge for 3 seconds with the plastic hose filled with fuel.
3-84 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it.
FUEL SYSTEM (DFI) 3-85 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • T ighten the fuel pump bolts to a snug fit, tighten them alternating diagonally . T orque - Fuel Pump Bolts: 9.
3-86 FUEL SYSTEM (DFI) Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set. Special T ools - Hand T ester: 57001-1394 Needle Adapter Set: 57001-1457 ○ Measure the operating voltage with the engine stopped, and with the connector joined.
FUEL SYSTEM (DFI) 3-87 Fuel Pump Fuel Pump Circuit 1. ECU 2. W ater-proof Joint C 3. Engine Stop Switch 4. Ignition Switch 5. Ignition Fuse 10 A 6. Fuel Pump Relay 7. Relay Box 8. Main Fuse 30 A 9. Battery 10. Frame Ground 1 1. Fuel Pump http://mototh.
3-88 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly . Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end onto your ear , and listen whether the injector is clicking or not.
FUEL SYSTEM (DFI) 3-89 Fuel Injectors Fuel Inje ctor Output Voltage Inspection • T urn the ignition switch OFF . • Remove the ECU (see ECU Power Supply Inspection). • Connect a digital voltmeter [A] to the ECU connector [B] with the needle adapter set [C].
3-90 FUEL SYSTEM (DFI) Fuel Injectors • Remove the fuel tank (see Fuel T ank Removal). • Remove the air cleaner housing ( see Air Cleaner Housing Removal) • Remove connectors for injector [A]. • Connect each test light set [B] to the injector sub harness connector [C].
FUEL SYSTEM (DFI) 3-91 Fuel Injectors Injector Unit T est • Use two leads [A] and the same test light set [B] as in “Injector Signal T est”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V Battery [D] CAUTION Be sure to connect the bulb in series.
3-92 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit 1. ECU 2. Fuel Injectors 3. W ater-proof Joint C 4. Engine Stop Switch 5. Ignition Switch 6. Ignition Fuse 10 A 7. Fuel Pump Relay (for fuel pump and injec- tors) 8. Relay Box 9. Main Fuse 30 A 10.
FUEL SYSTEM (DFI) 3-93 Throttle Grip a nd Cables Throttle Grip F ree Play Inspection • Refer to Throttle Control System Inspection in the Peri- odic Maintenance c hapter . Throttle Grip Free Play Adjustment • Refer to Throttle Control System Inspection in the Peri- odic Maintenance c hapter .
3-94 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to Idle Speed Inspection in the Periodic Mainte- nance c hapter . Engine V acuum Synchronization Inspection/Adjust- ment • Refer to Engine V acuum Synchronization Inspection in the Periodic Maintenance chapter .
FUEL SYSTEM (DFI) 3-95 Throttle Body Assy • Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play . • Remove the right switch housing and take out the acceler- ator cable upper end [A] and the decelerator cable upper end [B].
3-96 FUEL SYSTEM (DFI) Throttle Body Assy • Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley . • Check fuel leakage from the throttle body assy . W ARNING Fuel spilled from the carburetors is hazardous. • Apply a thin coating of grease to the throttle cable upper ends.
FUEL SYSTEM (DFI) 3-97 Throttle Body Assy • Remove: Screws [A] Delivery Pipe [B] Fuel Injectors [C] Throttle Body Assy Assembly ○ Replace the O-rings [A] and seals [B] with the new ones. • Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air .
3-98 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to Air Cleaner Element Replacement in the Periodic Maintenance chapter . Air C leaner Element Insp ection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter).
FUEL SYSTEM (DFI) 3-99 Air Cleaner • Unscrew the bolts [A] and remove the air cleaner housing [B]. Air C leaner Housing Installation • Install the clamp on the hose [A] so that its pinch heads [B] face the right. • Install the clamp on the breather hose [C] so that its pinch heads [D] face the front.
3-100 FUEL SYSTEM (DFI) Fuel T ank Fuel T ank Removal W ARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
FUEL SYSTEM (DFI) 3-101 Fuel T ank • Be sure to place a piece of cloth [A] around the fuel hose joint. • Insert a minus screw driver [B] into the slit [C]on the joint lock. • T urn [A] the driver to disconnect the joint lock [B]. • Pull [C] the fuel hose joint out [D] of the outlet pipe.
3-102 FUEL SYSTEM (DFI) Fuel T ank • Be sure that the trim seal [A] is on the fuel tank. Reverse Side of Fuel T ank [B] Side Cover [C] Approx. 17 mm (0.67 in.) [D] Front [E] • Insert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks.
FUEL SYSTEM (DFI) 3-103 Fuel T ank Fuel T ank Cleaning WA R N I N G Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.
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COOLING SYSTEM 4-1 4 Cooling System T able of Contents Exploded View ................................................................................................................ ........ 4-2 Coolant Flow Chart .....................................
4-2 COOLING SYSTEM Exploded View http://mototh.com.
COOLING SYSTEM 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Radiator Hose Clamp Screws 2.0 0.20 17 in·lb 2 Water Pump Impeller Bolt 9.8 1.0 87 in·lb 3 Water Pump Cover Bolts 9.8 1.0 87 in·lb 4 Water Pump Drain Bolt 7.0 0.70 62 in·lb 5 Thermostat Housing Bolts 9.
4-4 COOLING SYSTEM Coolant Flow Chart http://mototh.com.
COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to prot ect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes.
4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping T ype (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor c hemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point − 35°C ( − 31°F) T otal Amount 1.
COOLING SYSTEM 4-7 Special T ools Bearing Driver Set: 57001-1 129 Oil Seal Driver: 57001-1660 http://mototh.com.
4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right center fairing cover (see Center Fairing Removal in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator .
4-10 COOLING SYSTEM Wa t e r P u m p Wat er Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Loosen the clamp and remove the radiator hose [A] from the water pump cover [B]. • Remove the water pump cover bolts [C].
COOLING SYSTEM 4-1 1 W ater Pump • Install the water pump cover , being careful of the two dowel pins [A]. T orque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Mechanical Seal Inspectio n • Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- c a ls e a la sau n i t .
4-12 COOLING SYSTEM Wa t e r P u m p Impeller Assembly • Clean the sliding surface of the mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion.
COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left/Right Center Fairing (see Center Fairing.
4-14 COOLING SYSTEM Radiator Radiator an d Radiator Fan Installation • Install the grommet [A] so that its large side faces the front. • Install the radiator [B] to the frame. ○ Align [C] the p rojection on the radiator with the hole o n the frame.
COOLING SYSTEM 4-15 Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • W atching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward.
4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left Center Fairing (see Center Fairing Removal in the Frame c hapter) Thermostat Hosing Bolts [A] Thermostat Hosing [B] • Pull the thermostat [A] out of the cylinder head.
COOLING SYSTEM 4-17 Thermostat • T o check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water . ○ The thermostat must be completely submerged and must not touch the container sides or bottom.
4-18 COOLING SYSTEM Hose and 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 (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter).
COOLING SYSTEM 4-19 W ater T emperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water T emperature Sensor Removal/In stallatio n • Refer to Water T emperature Sensor Removal/Installation in the Fuel System (DFI) chapter .
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ENGINE TOP END 5-1 5 Engine T op End T able of Contents Exploded View ................................... 5-2 Specifications .................................... 5-7 Special T ools and Sealant ................. 5-9 Clean Air System ...................
5-2 ENGINE TOP END Exploded View http://mototh.com.
ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Suction V alve Cover Bolts 9.8 1.0 87 in·lb 2 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb 3 Camshaft Cap Bolts 12 1.2 106 in·lb S Cylinder Head Bolts (M10 New Bolts) 54 5.
5-4 ENGINE TOP END Exploded View http://mototh.com.
ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Cylinder Bolt (M8) 27.5 2.8 20 MO,S 2 Cylinder Nut (M10) 49 5.0 36 MO,S 3 Cylinder Bolts (M6) 12 1.2 106 in·lb S 4 Exhaust Pipe Manifold Holder Nuts 17 1.7 12 5 Muffler Body Mounting Bolt (Front) 20 2.
5-6 ENGINE TOP END Exploded View Silencer [C] with H ole [A] for Oxygen Sensor [B] http://mototh.com.
ENGINE TOP END 5-7 Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 35.843 ∼ 35.957 mm (1.41 1 1 ∼ 1.415 6 in.) 35.74 mm (1.4071 in.) Inlet 36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.) 36.44 mm (1.4346 in.) Camshaft Journal, Camshaft Cap Clearance 0.
5-8 ENGINE TOP END Specifications Item Standard Service Limit V alve Spring Free Length: Exhaust 41.91 mm (1.650 in.) 40.3 mm (1.587 in.) Inlet 41.9 1 mm (1.650 in.) 40.3 mm (1.587 in.) Cylinder , Pistons Cylinder Inside Diameter 82.994 ∼ 83.006 mm (3.
ENGINE TOP END 5-9 Special T ools and Sealant Compression Gauge, 20 kgf/cm²: 57001-221 V alve Spring Compressor Assembly: 57001-241 Va l v e S e a t C u t t e r, 4 5 ° - 35: 57001-1 1 16 Va l v e S .
5-10 ENGINE TOP END Special T ools and Sealant Compression Gauge Adapter , M10 × 1.0: 57001-1317 V alve Seat Cutter Holder , 4.5: 57001-1330 V alve Guide Arbor , 4.
ENGINE TOP END 5-1 1 Clean Air System Air Suction V alve Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing R emoval .
5-12 ENGINE TOP END Clean A ir System Air Switching Valve Installation • Install the vacuum switch valve so that the vacuum fitting [A] faces left side. • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
ENGINE TOP END 5 -13 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing R emo.
5-14 ENGINE TOP END Camshaft Chain T ensioner Camshaft Chain T ensioner Remo val CAUTION This is a non-return type camshaft chain tensioner . The push rod does not return to its original position once it moves out to take up camshaft chain slack.
ENGINE TOP END 5 -15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) • Position the crankshaft as follows.
5-16 ENGINE TOP END Camshaft, Camshaft Chain • Apply m olybdenum disulfide oil solution to all cams [A] journals [B] and thrust blocks [C] with × marks. • If a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces.
ENGINE TOP END 5 -17 Camshaft, Camshaft Chain ○ The timing marks must be aligned with the cylinder head upper surface [C]. EX mark [D] (Between #1 Pin and #2 Pin) IN mark [E] (Between #31 Pin and #3.
5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft and Sprocket Assembly ○ The inlet and exhaust s prockets are identical. • Install the sprockets so that the m arked (“IN” and “EX”) side faces to the right side. CAUTION Inlet sprocket must use “IN” marked bolts holes [A].
ENGINE TOP END 5 -19 Camshaft, Camshaft Chain Camshaft Runout • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown. If the runout exceeds the service limit, replace the shaft.
5-20 ENGINE TOP END Cylinder Head Cylinder Compression Measure men t NOTE ○ Use the battery which is fully charged. • W arm up the engine thoroughly .
ENGINE TOP END 5 -21 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Carbon accumulation.
5-22 ENGINE TOP END Cylinder Head • Firstly remove the M6 cylinder head bolts and M6 cylinder bolts [A]. • Secondly , remove the M8 bolts [B]. • Thirdly , remove the M10 nut [C].
ENGINE TOP END 5 -23 Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sides of washers and the threads of bolts and nut. M10 Cylinder Head Bolts [B] M10 Cylinder Nut [C] M8 Cylinder Bolt [D] • T orque the all the bolts and nut following the tightening sequence [1 ∼ 8].
5-24 ENGINE TOP END Cylinder Head • T ighten the M6 cylinder head bolts and M6 cylinder bolts [A]. T orque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder B olts (M 6): 12 N·m (1.2 kg f· m, 106 i n ·lb) • Install the front camshaft chain guide [A].
ENGINE TOP END 5 -25 Va l v e s V alve Clearance Inspection • Refer to V alve Clearance Inspection in the Periodic Main- tenance c hapter . V alve Clearance Adjustment • Refer to V alve Clearance Adjustment in the Periodic Maintenance chapter . V alve Removal • Remove cylinder head (see Cylinder Head Removal).
5-26 ENGINE TOP END Va l v e s V a lve Guide In stallation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor .
ENGINE TOP END 5 -27 Va l v e s V alve Seat Inspection • Remove the valve (see V alve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
5-28 ENGINE TOP END Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off.
ENGINE TOP END 5 -29 Va l v e s • Measure the outside diameter of the seating surface with a vernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
5-30 ENGINE TOP END Va l v e s If the seat width is too wide, make the 60° or 55° [A] grind described below . If the seat width is within the specified range, lap the valve to the seat as described below . • Grind the seat at a 60° or 55° angle until the seat width is within the specified range.
ENGINE TOP END 5 -31 Va l v e s http://mototh.com.
5-32 ENGINE TOP END Cylinder , Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Horn • Remove: Front Engine Mounting Bolts (Both Side) [A] (see Engine Removal in the En.
ENGINE TOP END 5 -33 Cylinder , Pistons • Remove the piston pins. Special T ool - Piston Pin Puller: 57001-156 8 [A] Piston Pin Puller Adapter C: 57001-1657 [D] Center Bolt [B] Shall of Piston [C] • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it.
5-34 ENGINE TOP END Cylinder , Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its marking hollow facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the s lit [B] of the piston pin hole.
ENGINE TOP END 5 -35 Cylinder , Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings.
5-36 ENGINE TOP END Cylinder , Pistons Piston Ring End Gap • Place the piston ring [A] insid e the cylinder , using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder , where cylinder wear is low . • Measure the gap [B] between the ends of the ring with a thickness gauge.
ENGINE TOP END 5 -37 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown and so that their projec- tions fit [C] on the holes of the holders. ○ Be sure that the clamp bolt heads [D] face outwards.
5-38 ENGINE TOP END Muffler W ARNING T o avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Right Frame Cover (see Frame Cover Removal in the Frame c hapter) • Remove the bolts and lift up the right footpeg stay [A].
ENGINE TOP END 5 -39 Muffler Muffler Body and Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muf fler body connection gasket [B] with new ones and install them. ○ Install the muffler body connection gasket until it is bot- tomed so that the chamfer side [C] feces muffler body [D].
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6-2 CLU TCH Exploded View http://mototh.com.
CLUTCH 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Cap on Clutch Cover 3.9 0.40 35 in·lb 2 Lower Cap on Clutch Cover – – – Hard-tighten 3 Oil Filler Plug – – – Hard-tighten 4 Clutch Cover Mounting Bolts 9.8 1.
6-4 CLU TCH Specifications Item Standard Service L imit Clutch Lever Free Play 2 ∼ 3m m( 0 . 0 8 ∼ 0.12 in.) ––– Clutch Friction Plate Thickness 2.92 ∼ 3.08 mm (0.1 15 ∼ 0.121 in.) 2.8 m m (0.1 10 in.) Friction Plate W arp 0.15 mm (0.16 in.
CLUTCH 6-5 S p e c i a lT o o la n d S e a l a n t Clutch Holder: 57001-1243 Kawasaki Bond (Silicone Sealant): 92104-0004 http://mototh.com.
6-6 CLU TCH Clutch Lever and Cable Clutch Leve r F ree Play Inspection • Refer to Clutch Operation Inspection in the Periodic Main- tenance chapter . Clutch Lever Free Play Adjustment • Refer to Clutch Operation Inspection in the Periodic Main- tenance chapter .
CLUTCH 6-7 Clutch Lever and Cabl e Clutch Lever Installation • Install the clutch lever so that the mating surface [B] of the clutch lever clamp is aligned with the punch mark [A]. • T ighten the upper clamp bolt first, and then the lower clamp bolt.
6-8 CLU TCH Clutch Cover Clutch Cover Removal • Remove: Engine Oil (drain, see Engine Oil Change in the Periodic Maintenance chapter) Right Frame Cover (see Frame Cover Removal in the Frame c hapter.
CLUTCH 6-9 Clutch Cover Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary . If re- moved, the oil seal replacement may be required. • Remove the clutch cover (see Clutch Cover R emoval).
6-10 CLUTCH Clutch Cover • Remove the oil level gauge [A]. Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Install the needle bearings [A] and oil seal [B] position as shown.
CLUTCH 6-1 1 Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Spri.
6-12 CLUTCH Clutch • Be sure that the spacer [A] is in position. • Insert the following on the drive shaft. Clutch Housing [A] with Chain [B] and Sprocket [C] Sleeve [D] • Align [E] the hole on the oil pump sprocket with the oil pump shaft. • Install the following parts on the drive shaft.
CLUTCH 6-13 Clutch • Install the friction plates and steel plates, starting with a friction plate and alternating them. CAUTION If new dry friction plates and steel plates are in- stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
6-14 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the s ervice limit, it must be replaced. Clutch Spring Free Length Standard: 33.6 mm (1.32 in.) Service Lim it: 32 .
ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Contents Exploded View ................................................................................................................ ........ 7-2 Engine Oil Flow Chart............
7-2 ENGINE L UBRICA TION SYSTEM Exploded View http://mototh.com.
ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Oil Drain Bolt 20 2.0 15 2 Filter Plate Bolts 9.8 1.0 87 in·lb L 3 Oil Filter 17.2 1.75 13 EO, R 4 Holder Mounting Bolt 25 2.5 18 L 5 Oil Pan Bolts 12 1.
7-4 ENGINE L UBRICA TION SYSTEM Engine Oil Flow Chart http://mototh.com.
ENGINE LUBRICA TION SYSTEM 7-5 Engine Oil Flow Chart http://mototh.com.
7-6 ENGINE L UBRICA TION SYSTEM Specifications Item Standard Engine Oil Ty p e API SE, SF or SG API SH, SJ or SL with JASO MA Vis c os i t y SAE 10W-40 Capacity: 1.7 L (1.8 US gt) (when filter is not removed) 1.9 L (2.0 US gt) (when filter is removed) 2.
ENGINE LUBRICA TION SYSTEM 7-7 Special T ools and Sealant Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter , PT3/8 × 19/in.: 57001-1233 Oil Filter Wrench: 57001-1249 Kawasaki Bond (Silicone Sealant): 56019-120 http://mototh.
7-8 ENGINE L UBRICA TION SYSTEM Engine Oil and Oil F ilter W ARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury .
ENGINE LUBRICA TION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine To.
7-10 ENGINE LUBRICA T ION SYSTEM Oil Pan Oil Pan Installation • Apply grease to the O-rings on the oil pipes [A]. • Install the oil pipe plate [B] s o that its guide portion [C] fits the breather pipe [D] as shown. • Apply a non-permanent locking agent to the oil pipe plate bolt.
ENGINE LUBRICA TION S YSTEM 7-1 1 Oil Pressure Relief V alve Oil Pressure Relief V alve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation.
7-12 ENGINE LUBRICA T ION SYSTEM Oil Pump Oil Pump Remo val • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Clutch (see Clutch Removal in the Clutch cha.
ENGINE LUBRICA TION SYSTEM 7-13 Oil Pump Oil Pump Installation • Apply molybdenum disulfide grease to the portion [A] of the oil pump shaft, as shown.
7-14 ENGINE LUBRICA T ION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole.
ENGINE LUBRICA TION SYSTEM 7-15 Oil Pressure Switch Oil Pressure Switch Removal • Remove or drain: Engine Oil (see Engine Oil Change in the Periodic M ain- tenance chapter) Switch Cover [A] Switch T.
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ENGINE REMOV AL/INST ALLA TION 8-1 8 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................ ........ 8-2 Engine Removal/Installation .
8-2 ENGINE REMOV AL/INST ALLA TION Exploded View http://mototh.com.
ENGINE REMOV AL/INST ALLA TION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Mounting Bracket Bolts 25 2.5 18 2 Front Engine Mounting Bolts 44 4.5 32 3 Rear Engine Mounting Nuts 44 4.5 32 4. Engine Mounting Brackets 5. Collar http://mototh.
8-4 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it w ith a band [A]. W ARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over .
ENGINE REMOV AL/INST ALLA TION 8-5 Engine Removal/Installation • Disconnect the crankshaft sensor lead connector [A]. • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine To p E n d c h .
8-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Remove the shift pedal [A] (see Shift Pedal Removal in the Crankshaft/T ransmission chapter).
ENGINE REMOV AL/INST ALLA TION 8-7 Engine Removal/Installation • T ighten: T orque - Rear Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 32 ft·lb) Font Engine Mounting Bolts: 44 N·m (4.
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CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/T ransmission T able of Contents Exploded View ................................... 9-2 Specifications .................................... 9-6 Special T ools and Sealant ................. 9-9 Crankcase Splitting.
9-2 CRANKSHAFT/TRANSMISSION Exploded View http://mototh.com.
CRANKSHAFT/TRANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Connecting Rod Big End Nuts see T ext ← ← ← 2 T iming Rotor Bolt 40 4.1 30 3 Oil Plate B olts 9.8 1.0 87 in·lb L 4 Breather Plate Bolts 9.8 1.0 87 in·lb L 5 Shift Shaft Return Spring Pin 29 2.
9-4 CRANKSHAFT/TRANSMISSION Exploded View http://mototh.com.
CRANKSHAFT/TRANSMISSION 9-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Gear Positioning Lever Bolt 12 1.2 106 in·lb L 2 Transmission Case Bolts 20 2.0 15 3 Shift Drum Cam Bolt 12 1.2 106 in·lb L 4 Shift Drum Bearing Holder Screw 4.
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend ––– TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod T wist ––– TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Clearance 0.012 ∼ 0.036 mm (0.0005 ∼ 0.0014 in.) 0.07 mm (0.0028 in.
9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase Bearing Bore Diameter: 31.000 ∼ 31.016 mm (1.2205 ∼ 1.2228 in.) ––– Marking: ○ 31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.) ––– None 31.009 ∼ 31.016 mm (1.
CRANKSHAFT/TRANSMISSION 9-9 Special T ools and Sealant Outside Circlip Pliers: 57001-144 Kawasaki Bond: 92104-1064 Bearing Driver Set: 57001-1 129 http://mototh.
9-10 CRANKSHAFT/TRANSMISSION Crankcase Sp litting Crankcase Splitting • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder (see Cylinder Removal in the Engine .
CRANKSHAFT/TRANSMISSION 9-1 1 Crankcase Splitting If the oil pie is to be removed, follow the next procedure. ○ Unscrew the bolts [A] and remove the oil pipe [B]. ○ Prepare a 5 mm rod [B], and insert it to the hole of the upper crankcase half. ○ Remove the oil pipe [A], tapping [C] the rod as shown.
9-12 CRANKSHAFT/TRANSMISSION Crankcase Sp litting • Press and insert [A] the new needle bearing [B] for the shift drum until it is bottomed. Special T ool - Bea rin g Drive r Set: 570 0 1-1 129 • Press and insert [C] the new needle bearing [D] for the shift shaft so that the bearing surface is flush with the end of the hole.
CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Install the crankshaft assembly and the balancer shaft as- sembly on the upper crankcase half. ○ Align [A] the timing m ark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.
9-14 CRANKSHAFT/TRANSMISSION Crankcase Sp litting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially , apply a liquid gasket carefully so that it shall be filled up on the grooves.
CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. ○ Insert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half.
9-16 CRANKSHAFT/TRANSMISSION Crankcase Sp litting • T ighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the M9 bolts [1, 2] L= 1 13 mm (4.45 in.) with washers. T orque - Crankcase Bolts (M9): 44 N·m (4.
CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rod s Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A].
9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Installation CAUTION T o minimize vibration, the connecting rods should have the same weight mark.
CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rod s • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. NOTE ○ Install each connecting rod so that its oil jet [A] faces the exhaust side (the front [B]) (see Engine Oil Flow Chart in the Engine Lubrication System chapter).
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CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rod s • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil to the following: Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Con-rods • First, tighten the nuts to the specified torque.
9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod T wist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.
CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rod s If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Side Clearance • Insert a thickness gauge [A] between the crankcase main bearing and the crank web at the No. 2 journal [B] to determine clearance. If the clearance exceeds the service limit, replace the crankcase halves as a set.
CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rod s Crankshaft Main Journal Diameter Standard: 37.984 ∼ 38.000 mm (1.4954 ∼ 1.496 1 in .) Service Limit: 37.96 mm (1.4945 in.) If any journal has worn past the service limit, replace the crankshaft with a new one.
9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install the new inserts in the crankcase halves and check insert/journal clearance with the plastigage.
CRANKSHAFT/TRANSMISSION 9-27 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert.
9-28 CRANKSHAFT/TRANSMISSION Balancer If either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it.
CRANKSHAFT/TRANSMISSION 9-29 T ransmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] Shift Pedal Installation • Align the mark [A] on the shift shaft with the slit [B] on the shift lever . • T ighten the shift lever bolt securely .
9-30 CRANKSHAFT/TRANSMISSION T ransmission • Remove: Clutch (see Clutch Removal in the Clutch chapter) Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Spacer , W asher and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown.
CRANKSHAFT/TRANSMISSION 9-31 T ransmission • When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing until it is bottomed.
9-32 CRANKSHAFT/TRANSMISSION T ransmission • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way , replace them. • Visually inspect the shift d rum cam [B]. If they are badly worn or if they show any damage, replace it.
CRANKSHAFT/TRANSMISSION 9-33 T ransmission T ransmission Assy Disassembly • Remove the transmission assy (see T ransmission Assy Removal) • Remove the following from the transmission case [A].
9-34 CRANKSHAFT/TRANSMISSION T ransmission • Install the following on the transmission case [A]. Shift Drum [B] Pin [C] Shift Drum Cam [D] ○ Align the pin with the hole on the shift drum cam. • Apply a non-permanent locking agent to the shift drum cam bolt and torque it.
CRANKSHAFT/TRANSMISSION 9-35 T ransmission • Install the gear positioning lever ( see External Shift Mech- anism Installation). • Install the shift rod plate. T orque - Shift Rod Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Set the gear positioning lever to the neutral position [A].
9-36 CRANKSHAFT/TRANSMISSION T ransmission • Install the transmission assy on the crankcase (see T rans- mission Assy Installation). • Press in the oil seal [A] onto collar [B] so that the surface of the oil seal is flush with the surface [C] of the crankcase.
CRANKSHAFT/TRANSMISSION 9-37 T ransmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear , and the l argest one is 6th gear . Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
9-38 CRANKSHAFT/TRANSMISSION T ransmission 1. 1st Gear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (T op) Gear 7. Ball Bearing 8. Bushing 9. T oothed Washer , 34 mm (1.34 in.) 10. Circlip 1 1. Bushing 12. Thrust Washe r , 30 mm (1.18 in.) 13.
CRANKSHAFT/TRANSMISSION 9-39 T ransmission Shift Drum and Fork Removal • Remove the transmission assy (see T ransmission Assy Removal). • Remove the shift forks [A] and shift drum [B] (see T rans- mission Assy Disassembly). Shift D rum and Fork Installation • Refer to T ransmission Assy Assembly and Installation.
9-40 CRANKSHAFT/TRANSMISSION T ransmission Shift Fork Guide Pin/Drum Groove Wear • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
CRANKSHAFT/TRANSMISSION 9-41 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary . Removal may damage them. • Using a press or puller , remove the ball bearing and/or needle bearings.
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WHEELS/TIRES 10-1 10 Wheels/T ires T able of Contents Exploded View ................................................................................................................ ........ 10-2 Specifications .........................................
10-2 WHEELS/TIRES Exploded View http://mototh.com.
WHEELS/TIRES 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Axle 108 11 . 0 80 2 Front Axle Clamp Bolt 34 3.5 25 3 Rear Axle Nut 108 11 . 0 80 G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.
WHEELS/TIRES 10-5 Special T ools Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Bearing Remover Head, 20 × 22: 57001-1293 Bearing Remover Shaft, 13: 57001-1377 Jack Attachment: 57001-1608 http://mototh.
10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] • Loosen: Axle Clamp Bolt [A] • Remove the f ront axle [B]. • Remove the lower fairing (see Lower Fairing Removal in the Frame chapter).
WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. • Insert the front axle, and tighten the axle.
10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with stand [A]. • Remove: Brake Caliper Mounting Bolts [A] Rear Brake Caliper [B] • Remove: Cotter P in [A] Axle Nut [B] Wa s h e r [ C ] Axle [D] with W asher • Remove the drive chain [A] from the rear sprocket toward the left.
WHEELS/TIRES 10-9 Wheels (Rims) • Engage the drive chain w ith the rear sprocket. • Install the caliper bracket [A] onto the swingarm stop [B]. • Insert the axle from the right side of the wheel, and tighten t h ea x l en u t . T orque - Rear Axle Nut: 108 N·m (1 1.
10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground with jack. Special T ools - Jack: 57001-1238 Jack Attachment: 57001-160 8 • Spin the wheel lightly , and check for roughness or binding. If roughness or binding is found, replace the hub bearings.
WHEELS/TIRES 10-1 1 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely . • Spin the wheel lightly , and mark [A] the wheel at the top when the wheel stops.
10-12 WHEELS/TIRES Wheels (Rims) Balance Weight Part Number Wei g ht 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0009 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.
WHEELS/TIRES 10-13 Tir e s Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance c hapter . Tire Inspecti on • Refer to the Wheel/T ire Damage Inspection in the Peri- odic Maintenance c hapter .
10-14 WHEELS/TIRES Tir e s • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
WHEELS/TIRES 10-15 Tir e s • Check to see that the rim lines [A] on both sides of the tire sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. • Lubricate the rim flanges and tire beads.
10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required. http://mototh.
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FINAL DRIVE 1 1-1 11 Final Drive T able of Contents Exploded View ................................................................................................................ ... ..... 1 1-2 Specifications .........................................
11 - 2 F I N A L D R I V E Exploded View http://mototh.com.
FINAL DRIVE 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Sprocket Nut 125 12.7 92 MO 2 Rear Axle Nut 108 11 . 0 80 3 Rear Sprocket Nuts 59 6.0 44 4 Speed Sensor Bolt 7.8 0.80 69 in·lb L 5 Speed Sensor Bracket Bolts 9.8 1.
11 - 4 F I N A L D R I V E Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) ––– Drive Chain Wear (20-link Length) 317.
FINAL DRIVE 1 1-5 Special T ools Inside Circlip P l ie r s: 57001-143 Bearing Driver Set: 57001-1 129 http://mototh.com.
11 - 6 F I N A L D R I V E Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Drive Chain Slack Adjustment • Refer to the Drive C hain Slack Adjustment in the Periodic Maintenance chapter .
FINAL DRIVE 1 1-7 Drive Chain • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. • Screw the handlebar [A] into body . • T urn the pin holder with wrench [B] clockwise to extract chain pin.
11 - 8 F I N A L D R I V E Drive Chain • Fit the plate holder (a) to link plate. • T urn the pin holder by hand until plate holder (b) touches the other link plate. • T urn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a).
FINAL DRIVE 1 1-9 Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter Standard: 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Link Plates Outside Width Standard: 17.
1 1-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Remove: Speed Sensor Bracket Bolts [A] Speed Sensor Bracket [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer .
FINAL DRIVE 1 1-1 1 Sprocket, Coupling Engine Sprocket Insta lla tion • Replace the sprocket washer and axle cotter pin. • Install the engine sprocket [A] so that “OUTSIDE” letters face outward. • Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine sprocket nut.
1 1-12 FINAL DRIVE Sprocket, Coupling Coupling Installation • Apply high-temperature grease to the coupling grease seal lips [A]. • Apply grease to the coupling internal surface [B]. • Grease the following. Wheel Flange Portion [A] O-ring [B] • Install the collar [C].
FINAL DRIVE 1 1-13 Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole.
1 1-14 FINAL DRIVE Sprocket, Coupling Rear Spro cket W arp Inspection • Raise the rear wheel off the ground with stand so that it will turn freely . • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
BRAKES 12-1 12 Brakes T able of Contents Exploded View ................................... 12-2 Specifications .................................... 12-6 Special T ools ..................................... 12-7 Brake Lever , Brake Pedal ..............
12-2 BRAKES Exploded View http://mototh.com.
BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Bleed V alve 7.8 0.80 69 in·lb 2 Brake Hose Banjo Bolts 25 2.5 18 3 Brake Lever Pivot Bolt 1.0 0.10 9i n · l b Si 4 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb 5 Front Brake Disc Mounting Bolts 27 2.
12-4 BRAKES Exploded View http://mototh.com.
BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Bleed V alve 7.8 0.80 69 in·lb 2 Brake Hose Banjo Bolts 25 2.5 18 3 Brake Pedal Bolt 8.8 0.90 78 in·lb 4 Rear Brake Disc Mounting Bolts 27 2.8 20 L 5 Rear Caliper Mounting Bolts 25 2.
12-6 BRAKES Specifications Item Standard Service Limit Brake Lever , Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) ––– Brake Lever Free Play Non-adjustable ––– Pedal Free Play Non-adjustable ––– Pedal Position About 40 mm (1.
BRAKES 12-7 Special T ools Inside Circlip P l ie r s: 57001-143 Jack: 57001-1238 Jack Attachment: 57001-1608 http://mototh.com.
12-8 BRAKES Brake Lever , Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator ’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder .
BRAKES 12-9 Brake Lever , Brake Pedal Brake Pe dal Remo val • Remove: Frame Cover (see Frame Cover Removal in the Frame chapter) Bolts [A] Right Footpeg Stay [B] • Remove: Cotter P in [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the mounting bolt [E] and take out the brake pedal.
12-10 BRAKES Brake Lever , Brake Pedal • Install the right footpeg stay , and tighten the bolts. T orqu e - Footp eg Stay Bolts: 3 4 N ·m (3.5 kg f·m , 25 ft·lb) ○ Depress the brake pedal [A] and then align the bolts holes of the master cylinder [B].
BRAKES 12-1 1 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation).
12-12 BRAKES Calipers Front Caliper Disassembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter . Front Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter .
BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty . Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A].
12-14 BRAKES Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Draw out the holder shaft pin [A], and take off the holder shaft [B].
BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose Removal/In- stallation).
12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose Removal/Installation). • Unscrew the master cylinder mounting bolts [A]. • Remove the cotter pin [B]. NOTE ○ Pull off the joint pin while pressing down the brake pedal.
BRAKES 12-17 Master Cylinder Master Cylinder Inspe ction • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
12-18 BRAKES Brake Disc Brake Disc Removal • Remove the w heel (see Front/Rear Wheel Removal in the Wheels/T ires chapter). • Unscrew the mounting bolts, and take off the disc. • Remove the gaskets. Brake Disc Installa tion • Replace the gaskets with new ones.
BRAKES 12-19 Brake Fluid Brake Fluid Level Inspectio n • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter . Brake Flui d Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter .
12-20 BRAKES Brake Fluid • Bleed the brake line and the caliper . ○ Repeat this operation until no more air can be seen com- ing out into the plas tic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while hold- ing the brake applied.
BRAKES 12-21 Brake Fluid WA R N I N G When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a c ontainer that has been left unsealed or that has been open for a long time. 3.
12-22 BRAKES Brake Hose Brake Hose R emo val/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter . Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the P eriodic Maintenance chapter .
SUSPENSION 13-1 13 Suspension T able of Contents Exploded View ................................................................................................................ ........ 13-2 Specifications ..............................................
13-2 SUSPENSION Exploded View http://mototh.com.
SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Axle Clamp Bolt 34 3.5 25 2 Front Fork Bottom Allen Bolts 30 3.1 22 L 3 Front Fork Clamp Bolts (Lower) 20 2.0 15 AL 4 Front Fork Clamp Bolts (Upper) 20 2.0 15 5 Front Fork T op Plugs 25 2.
13-4 SUSPENSION Exploded View http://mototh.com.
SUSPENSION 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Shock Absorber Bolt 59 6.0 44 2 Rear Shock A bsorber Nut 59 6.0 44 3 Swingarm Pivot Shaft Nut 108 11 .
13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner T ube Outside Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Fork Spring Setting Non-adjustable Damper Setting Non-adjustable Fork Oil: Vis c os i t y KA Y ABA KHL34-G10 or equivalent Amount approx.
SUSPENSION 13-7 Special T ools Inside Circlip P l ie r s: 57001-143 Fork Cylinder Holder Handle: 57001-183 Fork Cylinder Holder Adapter: 57001-1057 Oil Seal & Bearing Remover: 57001-1058 Bearing D.
13-8 SUSPENSION Special T ools Spacer , 28: 57001-1663 http://mototh.com.
SUSPENSION 13-9 Front F ork Front Fork Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/T ires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Loosen the upper fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled.
13-10 SUSPENSION Front Fork • Compress [A] the fork [B] upside down to draw out the oil into the suitable container [C]. • Pour in the specified amount of oil. Fork Oil Vi scosity: KA Y ABA KHL34-G10 or equivalent Amount (Per Side): When changing oil: approx.
SUSPENSION 13-1 1 Front F ork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Remove the top plug [A] with O-ring, take out the collar [B], fork spring seat [C], and fork spring [D]. • Drain the fork oil (see Front Fork Oil Change).
13-12 SUSPENSION Front Fork • Remove the following from the inner tube. Inner Guide Bushing [A] Outer Guide Bushing [B] Wa s h e r [ C ] Oil Seal [D] • Remove the cylinder base [A] from the bottom of the outer tube. Front Fork Assembly • Check the top plug O-ring and replace it with a new one.
SUSPENSION 13-13 Front F ork • Apply non-permanent locking agent to the threads of the bottom Allen bolt [A]. • Hold the front fork horizontally in a vise [B]. • Hold the cylinder unit [C] with the special tools and tighten the bottom Allen bolt to secure the cylinder in place.
13-14 SUSPENSION Front Fork Fork Spring Inspection • Measure the free length [A] of the fork spring [B]. If the measured length is shorter than the service limit, the spring must be replaced.
SUSPENSION 13-15 Rear Shock Absorber Spring Preload Adjustment • Using the hook wrench [A], turn the adjusting nut [B] to adjust the spring preload. ○ The standard adjuster setting for average-build rider of 68 kg (150 Ib) with no passenger and no accessories is 3rd position.
13-16 SUSPENSION Rear Shock Absorber • Remove: Upper Shock Absorber Bolt [A] Lower Shock Absorber Nut and Washer Lower S hock Absorber Bolt [B] • Remove the shock absorber [C] from backward. Rear Sh ock Absorber Installation • Installation is the reverse of removal.
SUSPENSION 13-17 Swingarm Swingarm Removal • Remove: Chain Cover Bolts [A] and Cover [B] • Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Frame Covers (see Frame Cover Remo.
13-18 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] Special T ool - In s ide Circlip Pliers : 570 01-143 • Remove the ball bearing and needle bearings.
SUSPENSION 13-19 Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown. Circlip [D] 25 mm (0.98 in.) [E] 17 mm (0.67 in.) [F] 1 mm (0.04 in.) [G] 0.5 mm (0.02 in.) [H] 1 mm (0.04 in.) [I] 23.5 mm (0.93 in.) [J] 6 mm (0.
13-20 SUSPENSION Swingarm • T urn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If the bearing play , roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage.
STEERING 14-1 14 Steering T able of Contents Exploded View ................................................................................................................ ........ 14-2 Special T ools ..................................................
14-2 STEERING Exploded View http://mototh.com.
STEERING 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fork Clamp Bolts (Lower) 20 2.0 15 AL 2 Front Fork Clamp Bolts (Upper) 20 2.0 15 3 Handlebar Holder Bolts 25 2.5 18 S 4 Left Switch Housing Screws 3.5 0. 36 31 in·lb 5 Right Switch Housing Screws 3.
14-4 STEERING Special T ools Steering Stem Nut Wrench: 57001-1 100 Bearing Driver Set: 57001-1 129 Steering Stem Bearing Driver , 42.5: 57001-1344 Steering S tem Bearing Driver Adapter , 41 .
STEERING 14-5 Steering Steering Inspection • Refer to the Steering P lay Inspection in the Periodic Main- tenance c hapter . Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter .
14-6 STEERING Steering Stem Stem, Stem Bearing Re mova l • Remove: Front Wheel (see Front Wheel Removal in the Wheels/T ires chapter) Headlight Assy (see Headlight Removal/Installation in the Electr.
STEERING 14-7 Steering Stem • Remove the lower bearing inner race [A] which is pressed onto the steering stem with a suitable commercially avail- able chisel [B]. Stem, Stem Beari ng Installation • Replace the bearing outer races with new ones. • Apply grease to the outer races, and drive them into the head pipe at the same time.
14-8 STEERING Steering Stem • Settle the inner races in place as follows. ○ T ighten the steering stem nut with 39 N·m ( 4.0 kgf·m, 29 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly . Afterward tighten it again with specified torque using a stem nut wrench [A] in the direction shown.
STEERING 14-9 Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem. Stem Cap Deterioration, Damage Replace the stem cap if its oil seal [A] shows damage.
14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Switch Housing [B] Left Handlebar Weight [C] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- .
STEERING 14-1 1 Handlebar • Install the clutch lever (see Clutch Lever Installation in the Clutch chapter). • Apply adhesive cement to the inside of the left handlebar grip. • Apply a non-permanent locking agent to the left handlebar weight bolt.
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FRAME 15-1 15 Frame T able of Contents Exploded View ................................................................................................................ ........ 15-2 Seat ..................................................................
15-2 FRAME Exploded View http://mototh.com.
FRAME 15-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Footpeg Stay Bolts 34 3.5 25 2 Sidestand Bolt 44 4.5 33 3 Sidestand Switch Bolt 8.8 0.90 78 in·lb L G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts http://mototh.
15-4 FRAME Exploded View http://mototh.com.
FRAME 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fender Bolts 3.9 0.40 35 in·lb 2 Front Fender Bracket Bolts 8.8 0.90 78 in·lb L L: Apply a non-permanent locking agent.
15-6 FRAME Exploded View http://mototh.com.
FRAME 15-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Grab Rail Mounting Bolts 25 2.5 18 2 Lower Fairing Mounting Bolts 8.8 0.90 78 in·lb http://mototh.
15-8 FRAME Seat Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Seat Installation • Slip the seat hook [A] under the brace [B] on the fuel tank bracket.
FRAME 15-9 Fairings Lower Fairing Removal • Remove the mounting bolts [A] and lower fairing [B]. Lower Fairing Installation • Install the lower fairing, and tighten the mounting bolts. T orque - Lower Fairing, Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Center Fairing Removal • Remove the mounting bolts [A].
15-10 FRAME Fairings • Connect the turn signal lead connector . • Insert the projections [A] into the holes [B]. • Install the mounting bolts. Upper Fairing Removal • Remove: Headlight Assy (s.
FRAME 15-1 1 Fairings Inner Fairing Removal • Remove: Center Fairings (see Center Fairing Removal) Mounting Screws [A] Inner Fairing [B] Inner Fairing Installation • T ighten the mounting screws. • Install the center fairings (see Center Fairing Installation).
15-12 FRAME Side Covers Side Cover Removal • Remove the seat (see Seat Removal). • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the stop- pers. Side Cover Installation • Insert the tabs [A] into the holes [B]. • T ighten the bolt.
FRAME 15-13 Seat Covers Seat Cover Removal • Remove: Seat (see Seat Removal) Bolts [A] Grab Rails [B] Screw Rivets [C] • Push the central pin, and then remove the quick rivets [A]. • Pull the front and rear portions of the seat cover outside, and then remove the seat covers.
15-14 FRAME Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] Bolts [B] with Collar (Both Side) • Remove the front fender [C]. Front Fender Installation • T ighten: T orque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) • Install the brake hose clamps to the front fender holes.
FRAME 15-15 Fenders Rear Fender Front Removal • Remove: Rear Fender Rear (see Flap and Rear Fender Rear Re- moval) Battery (see Battery Removal in the Electrical System chapter) Relay Box (see Relay.
15-16 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending or warp. ○ If there is any damage to the frame, replace it. W ARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
FRAME 15-17 Sidestand Sidestand Remov al • Raise the rear wheel off the ground with stand. • Remove: Frame C over (see Frame Cover Removal) Bolts [A] Footpeg Stay [B] • Remove: Sidestand Switch .
15-18 FRAME Frame C over Frame Cover Removal • Remove the bolt [A]. • Pull the frame cover [B] outward to clear the stoppers. Frame Cover Installation • Insert the projections [A] into the holes [B].
FRAME 15-19 Rear View Mirrors Rear V iew Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to re- move the rear view mirror from the holder . CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [B] with a pair of span- ners.
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ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Contents Exploded View ................................................................................................................ ........ 16-3 Specifications ................................
16-2 ELECTRICAL SYSTEM IC Igniter Inspection ....................................................................................................... ... 16 -40 Electric Starter System ...................................................................
ELECTRICAL SYSTEM 16-3 Exploded View Dummy Page http://mototh.com.
16-4 ELECTRICAL SYSTEM Exploded View http://mototh.com.
ELECTRICAL SYSTEM 16-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 License Plate Light Cover Screws 0.90 0.090 8i n · l b 2 License Plate Light Mounting Screws 1.2 0.12 11 i n · l b 3 Meter S crews 1.2 0.12 11 i n · l b http://mototh.
16-6 ELECTRICAL SYSTEM Exploded View http://mototh.com.
ELECTRICAL SYSTEM 16-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Brake Light Switch Screw 1.2 0.12 11 i n · l b 2 Left Switch Housing Screws 3.5 0.36 31 in·l b 3 Right Switch Housing Screws 3.5 0.36 31 in·lb 4 Starter Motor Cable T erminal Nut 6.
16-8 ELECTRICAL SYSTEM Exploded View http://mototh.com.
ELECTRICAL SYSTEM 16-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Alternator Cover Bolts 9.8 1.0 87 in·lb 2 Alternator Lead Holding Plate Bolt 9.8 1.0 87 in·lb L 3 Alternator Rotor Bolt 155 15.8 11 4 MO 4 Crankshaft Sensor Bolts 6.
16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Ty p e Sealed Battery Model Name YTX12-BS Capacity 12 V 10 Ah V oltage 12.8 V or more Charging System Ty p e Three-phase AC Alternator Output V oltage 42 V or more at 4 000 r/min (rpm) Stator Coil Resistance 0.
ELECTRICAL SYSTEM 16-1 1 Special T ools and Sealan ts Hand T ester: 57001-1394 Flywheel Puller Assembly , M38 × 1.5/M35 × 1.5: 57001-1405 Peak V oltage Adapter: 57001-1415 Lead Wire - Peak V oltage .
16-12 ELECTRICAL SYSTEM Parts Location 1. Air Switching V alve 2. Alternator 3. Battery 12 V 10 Ah 4. Crankshaft Sensor 5. ECU (Electric Control Unit) 6. Fan Motor 7. Front Brake Light Switch 8. Fuse Box with ECU Main Fuse 9. Ignition Switch 10. Meter Unit 1 1.
ELECTRICAL SYSTEM 16-13 Parts L ocation Dummy Page http://mototh.com.
16-14 ELECTRICAL SYSTEM Wiring Diagram http://mototh.com.
ELECTRICAL SYSTEM 16-15 Wiring Diagram http://mototh.com.
16-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts.
ELECTRICAL SYSTEM 16-17 Precautions Male Connectors [B] http://mototh.com.
16-18 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
ELECTRICAL SYSTEM 16-19 Battery Battery Removal • Remove: Seat (see Seat Removal in the Frame chapter) • Disconnect the negative (–) cable [A]. • Slide out the positive (+) terminal cap [B] and then discon- nect the positive (+) cable. CAUTION Be sure to disconnect the negative (–) cable first.
16-20 ELECTRICAL SYSTEM Battery • Remove the electrolyte container from the vinyl bag. • Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery . NOTE ○ Do not pierce or otherwise open the s ealed cells [B] of the electrolyte container .
ELECTRICAL SYSTEM 16-21 Battery Initial Charge • Place the strip [A] of caps loosely over the filler ports. • Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 A × 5 ∼ 10 hours If using a recommended battery charger , follow the charger ’s instructions for newly activated sealed battery .
16-22 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. F orcibly prying off the seal cap to add water is very dangerous. N ever do that. 2) Refreshing charge.
ELECTRICAL SYSTEM 16-23 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Seat (see Seat Removal in the Frame chapter) Battery Cable Cap (see Battery Removal) • Disconnect the battery terminals.
16-24 ELECTRICAL SYSTEM Battery T erminal V oltage: 1 1.5 ∼ less than 12.8 V Standard Charge 1.2 A × 5 ∼ 10 h (see following chart) Quick Charge 5A×1h CAUTION If possible, do not quick charge. If quick charge is done unavoidably , do standard charge later on.
ELECTRICAL SYSTEM 16-25 Charging System Alternator Cover Removal • Remove: Lower Fairing (see Lower Fairing Removal i n the Frame chapter) Alternator Lead Connector [A] • Place a suitable container under the alternator cover [A], and remove the cover bolts [B].
16-26 ELECTRICAL SYSTEM Charging System Stator Coil Installation • Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. T orq ue - Stator C o il Bolts : 12 N ·m (1.2 kgf·m , 106 in·lb) • Secure the alternator lead with a holding plate, and tighten the bolt.
ELECTRICAL SYSTEM 16-27 Charging System • Install the starter gear [A] and washer [B]. • Again, clean the crankshaft tapered portion [C] and dry there. • Install the alternator rotor [A] while turning [B] it c ounter- clockwise. • Install the washer [A].
16-28 ELECTRICAL SYSTEM Charging System • Apply a thin coat of molybdenum disulfide grease to the shafts [A], and install them. • Install the torque limiter [B] and starter idle gear [C]. • Install the alternator cover (see Alternator Cover Installa- tion).
ELECTRICAL SYSTEM 16-29 Charging System If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced.
16-30 ELECTRICAL SYSTEM Charging System Regulator Circuit Check T o test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ∼ 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
ELECTRICAL SYSTEM 16-31 Charging System Charging V oltage Inspection • Check the battery condition (see Charging Condition In- spection). • W arm up the engine to obtain actual alternator operating conditions. • Remove the seat (see Seat Removal in the Frame chap- ter).
16-32 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. W ater-proof Joint C 5. Main Fuse 30 A 6.
ELECTRICAL SYSTEM 16-33 Starter Motor Clutch Starter M otor Clutch Removal/Installa tion • Refer to the Alternator Rotor Removal/Installation. Starter Motor Clutch Inspection • Remove: Alternator Cover (see A lternator Cover Removal) Starter Idle Gear and T orque Limiter Shafts • T urn the starter motor clutch gear [A] by hand.
16-34 ELECTRICAL SYSTEM Ignition System W ARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock.
ELECTRICAL SYSTEM 16-35 Ignition System Crankshaft Sensor Installation • Route the crankshaft sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • T ighten: T orq u e - Cra nkshaft S en s or Bolts: 6.0 N ·m (0.
16-36 ELECTRICAL SYSTEM Ignition System • Pushing the starter button, turn the engine 4 ∼ 5s e c - onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. • Repeat the measurement 5 or more times. Crankshaft Sensor Peak V oltage Standard: 1.
ELECTRICAL SYSTEM 16-37 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). • Measure the primary winding resistance [A] as follows.
16-38 ELECTRICAL SYSTEM Ignition System W ARNING T o avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • T urn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
ELECTRICAL SYSTEM 16-39 Ignition System Interlock Operation Inspe ction • Raise the rear wheel off the ground with stand. 1st Check • Start the engine to the following conditions. Condition T ransmission Gear → 1st Posi tion Clutch Lever → Release Sidestand → Down or Up ○ T urn the ignition switch ON and push the starter button.
16-40 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC igniter is built in the ECU [A]. • Refer to the Interlock Operation Inspection, Ignition Sys- tem T roubleshooting chart and Fuel System (DFI) chapter for ECU Power Supply Inspection.
ELECTRICAL SYSTEM 16-41 Ignition System http://mototh.com.
16-42 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Spark Plugs 4. Stick Coils 5. W ater-proof Joint C 6. Sp eed Sen sor 7. Subthrottle Sensor 8. Main Throttle Sensor 9. W ater-proof Joint D 10. V ehicle-down Sensor 1 1.
ELECTRICAL SYSTEM 16-43 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Remove the fuel tank (see Fuel T ank Removal in the Fuel System (DFI) chapter).
16-44 ELECTRICAL SYSTEM Electric Starter System • Remove: T erminal Locknut and W ashers O-ring • Remove the brush plate assy [A] from the yoke [B]. • Remove the brush plate [A] from the plate cover [B]. NOTE ○ Do not remove the negative carbon brushes form the brush plate.
ELECTRICAL SYSTEM 16-45 Electric Starter System • Align the lines [A] on the yoke with the end cover lines [B]. • T ighten the through bolts. T orque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) Brush Inspection • Measure the length of each brush [A].
16-46 ELECTRICAL SYSTEM Electric Starter System NOTE ○ Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester.
ELECTRICAL SYSTEM 16-47 Electric Starter System • Disconnect the connector [A]. • Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D].
16-48 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. W ater-proof Joint B 3. Starter Lockout Switch 4. Ignition Fuse 10 A 5. Fuse Box 6. Starter Circuit Relay 7. Relay Box 8. Starter Motor 9. Starter Relay 10.
ELECTRICAL SYSTEM 16-49 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
16-50 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] with the “T op” mark upward onto the bulb [B] firmly as shown. Good [C] Bad [D] To p M a r k [ E ] • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).
ELECTRICAL SYSTEM 16-51 Lighting System Headlight Removal/Installation • Remove: Mounting Bolts [A] • Disconnect the headlight connectors [A] and city light con- nector [B]. • Remove the headlight assy . • Remove the upper fairings (see Upper Fairing Removal in the Frame chapter).
16-52 ELECTRICAL SYSTEM Lighting System License Pla te Light Bulb Replacement • Remove: Screws [A] License Plate Light Cover [B] • Push and turn the bulb counterclockwise and remove it. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
ELECTRICAL SYSTEM 16-53 Lighting System Headlight/T ail Light Circuit 1. Ignition Switch 2. W ater-proof Joint A 3. W ater-proof Joint B 4. Position Light 5. Headlight (High Beam) 6. Headlight (Low Beam) 7. Dimmer Switch 8. Passing Switch 9. Headlight Relay 10.
16-54 ELECTRICAL SYSTEM Lighting System • Push and turn the bulb [A] counterclockwise and remove it. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
ELECTRICAL SYSTEM 16-55 Lighting System T urn Signal Light Circuit 1. Meter Unit 2. W ater-proof Joint A 3. W ater-proof Joint B 4. Front Right T urn Signal Light 5. Front Left T urn S ignal Light 6. T urn Signal Relay 7. Hazard Button 8. T urn Signal Switch 9.
16-56 ELECTRICAL SYSTEM Air Switching V alve Air Switch ing Valve Operation T est • Remove the fuel tank (see Fuel T ank Removal in the Fuel System (DFI) c hapter). • Pull the air switching valve hose [A] out of the air cleaner base. • T ake the air switching valve hose end outside of the frame.
ELECTRICAL SYSTEM 16-57 Air Switching V alve • Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air duct [B]. • Disconnect the 12 V battery . • Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air duct [B].
16-58 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor . If the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Circuit 1.
ELECTRICAL SYSTEM 16-59 Meter , Gauge, Indicator Unit Meter Unit Removal • Remove: Headlight Assy (see Headlight Removal/Installation) Screws [A] and Cover [B] • Slide the dust cover [A] and remove the connector [B]. • Remove the meter unit by taking off the mounting screws [C] with the washers.
16-60 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A] (see Meter Unit Removal).
ELECTRICAL SYSTEM 16-61 Meter , Gauge, Indicator Unit ○ When the terminals are connected, all the LCD segments [A] and LED warning lights [B] appear (FI w arning light appear for two seconds). If the LCD segments and LED warning lights will not ap- pear , replace the meter assembly .
16-62 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit • In the HOUR/MINUTE setting mode, press the RESET button again to effect the HOUR setting mode. ○ The hour display flashes on the display . • Press the MODE button to set the hour . • In the HOUR setting mode, press the RESET button to effect the MINUTE setting mode.
ELECTRICAL SYSTEM 16-63 Meter , Gauge, Indicator Unit • If the oscillator is not available, the speedometer can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel off the ground with stand. ○ T urn on the ignition switch. ○ Rotate the rear wheel by hand.
16-64 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit • If the oscillator is not available, the tachometer can be checked as follows. ○ Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”.
ELECTRICAL SYSTEM 16-65 Meter , Gauge, Indicator Unit Fuel Level W arning Indictor Light (LED) Battery Negative (–) T erminal to T erminal [9] High Beam Indicator Light (LED) Battery Positive (+) T .
16-66 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 2. Frame Ground 3. Meter Unit 4. W ater-proof Joint B 5. ECU Fuse 15 A 6. Ignition Fuse 10 A 7. Fuse Box 8. Main Fuse 30 A 9. Battery 12 V 10 Ah 10. Frame Ground 1 1.
ELECTRICAL SYSTEM 16-67 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance c hapter . Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance c hapter .
16-68 ELECTRICAL SYSTEM Switches and Sensors Water T emperature Sensor Inspection • Remove the water temperature sensor (see Removal/In- stallation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] and threaded por- tion [C] are submerged.
ELECTRICAL SYSTEM 16-69 Switches and Sensors Speed Sensor Inspection • Remove the speed sensor (see Speed Sensor Removal). • Connect the speed sensor connector [A] with the battery [B], 10 k Ω resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range.
16-70 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Insp ection (Europe Models) • Refer to the Oxygen Sensor Inspection in the Fuel System (DFI) chapter . F u e lR e s e r v eS w i t c hI n s p e c t i o n • Fill the fuel tank with fuel. • Close the fuel tank cap s urely .
ELECTRICAL SYSTEM 16-71 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) • T ake out the relay box [A] and disconnect the connectors [B].
16-72 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery connect ed) Battery Connecti on (+) (–) Te s t e r Connection Te s t e r Reading ( Ω ) 2-1 1 1-3 0 ECU Main Relay 4-5 7.
ELECTRICAL SYSTEM 16-73 Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay http://mototh.
16-74 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Cover (see Starter Relay Inspection) Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers.
ELECTRICAL SYSTEM 16-75 Fuse Fuse Installation • If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. • Install the fuse box fuses on the original position as spec- ified on the lid.
http://mototh.com.
APPENDIX 17-1 17 Appendix T able of Contents Cable, Wire, and Hose Routing ...................................................................................... ........ 17-2 T roubleshooting Guide ....................................................
17-2 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Clamp (From the on sequentially , through the lef t switch housing lead, ignition switch lead and main harness.) 2. Left Switch Housing Lead Connector 3. Clamp (Insert the clamp from air cleaner side.) 4.
17-4 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Relay Box 2. Main Harness 3. Clamp (Insert the clamp in the bracket.) 4. Battery Negative Cable 5. Battery Positive Cable 6. ECU Connectors 7. Clamp 8. Clamp 9. T ail Light Connector 10. License Plate Light Connector 1 1.
17-6 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Inlet Pressure Sensor 2. T urn Signal Relay 3. Clamp (Insert the clamp in the frame.) 4. Horn Lead 5. T o the W ater T emperature Sensor 6. Oxygen Sensor Lead Connector 7. Clamp (Through the sidestand switch lead and oxygen sensor lead in the clamp.
17-8 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Radiator Fan Connector 2. Clamp (Through the main harness and radiator fan lead, and insert the clamp in the frame.) 3. Through the horn lead between water pipe and frame. 4. T o Front Left T urn Signal Light 5.
17-10 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-1 1 Cable, Wire, and Hose Routing 1. Clamp (Through the right switch housing lead, and insert the clamp in the frame.) 2. Clutch Cable 3. Throttle Cables 4. Clamp 5. Right Switch Housing Lead 6. Clamp (Insert the clamp in the bracket.) 7. Clamp (Insert the clamp in the frame.
17-12 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Crankshaft Sensor Lead Connector 2. Clamp (Insert the clamp in the bracket.) http://mototh.com.
17-14 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-15 Cable, Wire, and Hose Routing 1. T ail Light Connector 2. License Plate Light Connector 3. Rear Right Turn Signal Light Connector 4. Rear Left Turn Signal Light Connector 5. Clamp (Insert the clamp in the rear fender rear .) 6. Clamp (Insert the clamp in the rear fender rear .
17-16 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Throttle Cables 3. Headlight (LO) Connector 4. Headlight (HI) Connector 5. Brak e Hose 6. Clamp 7. Ignition Switch Lead 8. Main Harness 9. Left Switch Housing Lead 10. Clutch Cable 1 1.
17-18 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Clamp 2. Clamp 3. Clamp 4. Clamp (Clamp the main harness, subthrottle sens or lead and subthrottle valve actuator lead to the delivery pipe.) 5. Ground Lead 6. Clamp 7. Subthrottle Sensor Lead Connector 8.
17-20 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Regulator/Rectifier Lead 2. Clamp (Insert the clamp in the frame.) 3. Rear Brake Light Switch Lead Connector 4. Through the rear brake light switch lead and vehicle-down sensor lead from the front side of the rear shockabsorber installation part.
17-22 APPENDIX Cable, Wire, and Hose Routing http://mototh.com.
APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Clamp (Insert the clamp in the front fender .) 2. Brak e Hose 3. Clamp http://mototh.com.
17-24 APPENDIX Cable, Wire, a nd Hose Routing http://mototh.com.
APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Clamp http://mototh.com.
17-26 APPENDIX T roubleshooting Guide NOTE ○ Refer to the Fuel System chapter for most of DFI trouble shooting guide. ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX 17-27 T roubleshooting Guide Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder , piston worn Piston ring bad (worn, weak, broken, or .
17-28 APPENDIX T roubleshooting Guide Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Gauge incor.
APPENDIX 17-29 T roubleshooting Guide Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve da.
デバイスKawasaki ER-6n (2006)の購入後に（又は購入する前であっても）重要なポイントは、説明書をよく読むことです。その単純な理由はいくつかあります：
Kawasaki ER-6n (2006)をまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはKawasaki ER-6n (2006)の技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Kawasaki ER-6n (2006)の取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Kawasaki ER-6n (2006)で得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Kawasaki ER-6n (2006)を既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はKawasaki ER-6n (2006)の不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Kawasaki ER-6n (2006)に関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちKawasaki ER-6n (2006)デバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
