KawasakiメーカーZ1000の使用説明書/サービス説明書
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Z1000 Motorcycle Service Manual.
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This quick refer ence guide will assi st you in locatin g a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black t ab on the edge at each table of contents page. •Refer to the secti onal table of contents for the exact pages to locate the spe- cific topic requir ed.
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Z1000 Motorcycle Service Manual All rights res erved. No parts of this publi cation may be reproduced, stored in a retr ieval system, or transmitt ed in any form or by any means, electronic mechanical.
LIST OF ABBREVIA TIO NS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternati ng current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center P.
EMISSION CONTROL I NFORMA TION T o protect the environment i n which we all l ive, Kawasaki has incor porated crankcase emis - sion (1 ) and exhaust emissi on (2) control systems in compliance wi th applicable regulat ions of the United Stat es Environmental Protec tion Agency and Californi a Air Resources Board.
WE RECOMMEND THA T ALL DEALERS OBSERVE THESE PROVISI ONS OF FEDERAL LA W , THE VIOLA TION OF WHICH IS PUNISHABLE BY CIVIL PENAL TIES NO T EXCEEDING $10,000 PE R VIOLA TION.
Foreword This manual is designed primarily for use by tra ined mechanics in a properly equipped shop. However , it contains enough det ail and basic in- formation to m ake it useful to the owner who de- sir es to perform hi s own basic maintenance and repair work.
NOTE ○ This note symbo l indic ates poin ts of par - ticul ar interest for more effi cient and con- venien t opera tion. • Indicates a procedural step or work to be done. ○ Indicates a proced ural sub-step or how t o do the work of the procedural step it follows.
GENERAL INFORMA T ION 1-1 1 General Information T able of Con tents Befor e S ervic ing .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...... .... ......... . 1-2 Model Identifi cation.
1-2 G ENER AL IN FORMA TIO N Before Servicing Before start ing to perform an inspection servi ce or carry out a disassembly and reassembly opera- tion on a motorcycl e, read the precautions gi ven below .
GENERAL INFORMA TION 1-3 Before Se rvicing Arran gement and Cle aning o f Removed Parts Disassembled parts are easy t o confuse. Arrange the parts accordi ng to the or der the parts were di sassembled and clean the par ts in order pri or to assembly .
1-4 G ENER AL IN FORMA TIO N Before Servicing Tighten ing Sequen ce Bolts, nuts, or screws must be tight ened according to the specif ied sequence to prev ent case warpage or deformation which can lead to malf unction. If the specifi ed tightening sequence is not indi cated, tighten t he fasteners a lternating diago nally .
GENERAL INFORMA TION 1-5 Before Se rvicing Press For items s uch as beari ngs or oil s eals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when instal ling.
1-6 G ENER AL IN FORMA TIO N Before Servicing Directio n of Engin e Rotati on When rotating the cranks haft by hand, the free play amount of rotating directi on will af f ect the adjus tment. Ro- tate the crankshaft t o positive dir ection (clockwise vi ewed from output side).
GENERAL INFORMA TION 1-7 Model Ident ification ZR1000–A1 Left Side View : ZR1000–A1 Right Side View:.
1-8 G ENER AL IN FORMA TIO N General S pecification s Items ZR1000–A1 ∼ Dimensions: Overall lengt h 2 080 mm (81.9 i n.) Overall width 770 mm (30.3 in. ) Overall height 1 055 mm (41.5 i n.) Wheelbase 1 420 mm (55. 9 in.) Road clearance 145 mm (5.7 in.
GENERAL INFORMA TION 1-9 General Specifica tions Items ZR1000–A1 ∼ Lubrication syst em Forced lubri cation (wet sump with cooler) Engine oil: Ty p e API S E, SF or SG API SH or S J with JASO MA Viscosi ty SAE10W-40 Capacity 3.8 L (4.0 US qt) Driv e T rain : Primary reduction system: Ty p e Gear Reduction ratio 1.
1-10 GENERAL INFORMA TION General S pecification s Items ZR1000–A1 ∼ T ail/brake l ight 12 V 0.5/3 .8 W (LED) (US, CA, Cal) 12 V 0.5/5W (LED) Alternator : T ype Three-phase AC Rated output 24 A/ 14 V @5 000 r/min (r pm) Specificati ons are subject to change wit hout notice, and may not apply to every count ry .
GENE RAL INFORMA TION 1-1 1 T e chnical Inform ation – Air Inlet System Subthrottle Contr ol System The ZR1000–A1 ∼ employs large bore throttle bodies to i ncrease power output. However , sudden changes in thrott le opening can cause hesit ation and jerky throt tle response wit h a single butterfl y valve in a larg e bore.
1-12 GENERAL INFORMA TION T echnical Informatio n – Air Inlet S ystem Operation The subthrottl e control system consists of the subth rottle valve, subthrottle valve actuator wit h a steppi ng motor built i n it, ECU, and subthrottle sensor . The subt hrottle valve is bui lt in the each throttle body .
GENERAL INFORMA T ION 1-13 T e chnical Info rmation – New I gnition Inte rlock Sidestand Outline The New Ignition Interl ock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand i s not li fted upward even t hough clutch lever pulled in, which dif fers from the trad itional one.
1-14 GENERAL INFORMA TION T echnical I nformation – T ail /Brake Lights Em ploying LE D Out lin e This model employs a tai l/brake li ght containing 21 Light Emit ting Diodes (LED).
GENERAL INFORMA T ION 1-15 T e chnical Informatio n – T ail/B rake Lights Employing LED The emitting c olor dif fers according t o the material s of semi-conductors .
1-16 GENERAL INFORMA TION T echnical I nformation - KLE EN (KA W A SAKI LOW EXHAU ST EMISS ION SYSTEM) Since the emission r egulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst prot ection system, according to eac h regulation of dif ferent countries.
GENERAL INFOR MA TION 1-17 Unit Conversio n T able Prefixes for Units: Prefix Symbol Power meg a M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 mill i m ×0 . 0 0 1 mic ro µ × 0.000001 Units o f Mass: k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume : L × 0.
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PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Con tents Periodic Maintenance Chart ..... ....... .. 2-2 T orque and Locking Agent ......... ........ 2-4 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 2-9 Spec ial T ools . ...
2-2 PERIODIC MAINTEN ANCE Periodic Main tenance Cha rt The scheduled maint enance must be done in accordance with this chart to kee p t he motorcy cle in good running condition. The initial maint enance is vita lly important and must not be neglect ed.
PERIODIC MAINTENANCE 2-3 Periodic Mainte nance Chart FREQUENCY Whichever 1 000 km *O D O M E T E R READING com es (600 mile) first 6 000 km → (4 000 mile) ↓ 12 000 km ( 7 500 m ile) 18 000 km (12 .
2-4 PERIODIC MAINTEN ANCE T orque and L ocking Agent The followi ng tables list the tight ening torque for the major fastene rs requiring use o f a non -perma nent locking agen t or liquid gasket. Letter s used i n the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads.
PERIODIC MAINTENANCE 2-5 T orq ue and Lock ing Agent T orque Fastener N·m kgf·m ft·lb Remarks Wa t e r p ump drain bolt 11 1.1 95 in·l b W ater pipe bolts 11 1.1 95 in·lb in/ou tlet Therm ostat housing ground bolt 7 0.7 61 in· lb Thermostat bracket bolt 7 0.
2-6 PERIODIC MAINTEN ANCE T orque and L ocking Agent T orque Fastener N·m kgf ·m ft·lb Remarks Engine Lubrication: Oil filler plug 1. 5 0.15 13 in·lb Engin e drain pl ug 20 2.0 14.5 Oil filt er (cartridge t ype, P/No.16097–1070) 26 2.7 20 R, EO Oil filt er (cartridge t ype, P/No.
PERIODIC MAINTENANCE 2-7 T orq ue and Lock ing Agent T orque Fastener N·m kgf·m ft·lb Remarks Wheels/Ti res: Front axle clamp bolt 34 3.5 25 Front axle 127 13 94 Rear axle nut 127 13 94 Fina l Drive: Engine sprocket nut 127 13 94 MO Eng ine sprocket cover bolt s 9.
2-8 PERIODIC MAINTEN ANCE T orque and L ocking Agent T orque Fastener N·m kgf ·m ft·lb Remarks Handle bar lower clamp nuts 34 3.5 25 Handlebar switch housi ng screws 3.4 0.35 30 in·l b Frame : Footpeg holder bolts 34 3.5 25 Muff ler mounting bolts 29 3.
PERIODIC MAINTENANCE 2-9 Specifications Item Standard Servic e Limit Fuel System: Throttle gri p free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Idle speed 1 100 ± 50 r/min (rpm) Bypass screws (turn o ut) 2 ± 1/4 (for ref erence) ––– Engine vacuum 32.
2-10 PERIODIC MAINTENANCE Specif ications Item Standard Service Limit Air pressure: (when cold) Front Up to 180 kg (396 lb) load: 250 kPa (2.5 kgf /cm², 36 psi) ––– Rear Up to 180 kg (396 lb) load: 290 kPa (2.9 kgf /cm², 41 psi) ––– Final Drive: D r i v ec h a i ns l a c k 20 ∼ 30 mm (0.
PERIODIC MAINTENANCE 2-1 1 Special T ools Steering Stem Nut Wrench: 57001–1100 Jack: 57001–123 8 Oil Filter Wren ch: 57001–124 9 Pilot Scre w Adjuster , C: 57001–1 292 Hand T ester : 57001–1.
2-12 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Fuel Sy stem (DFI) Fuel Hose and Connecti on Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’ s life witho.
PERIODIC MAINTENANCE 2-13 Periodic M aintenance P rocedures Throttl e Control System I nspection Throttle Gri p Play Inspecti on • Check the thrott le grip free pl ay [A]. If the f ree play i s incorr ect, adjust the t hrottle cable (see below). Throttle Grip Free Play Standard : 2 ∼ 3m m( 0 .
2-14 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Throttle Bore Cleaning • Check the thrott le bore for cleanliness as f ollows: ○ Remove the throttle body assy (see Fuel System (DFI) chapter). ○ Check the main throttl e valves and t hrottle bores [A] f or car bo n deposits by opening the main valves.
PERIODIC MAINTENANCE 2-15 Periodic M aintenance P rocedures Engine V acuum Synchr onizati on Inspectio n NOTE ○ These procedures are expl ained on the assumption that the inl et and ex haust systems of the en gine are i n good condition. • Situate the mo torcycle so that it is vertical.
2-16 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Install th e fuel tank (see Fuel System (DFI) chapter). • Start the engine and war m it up thoroughly . • Check t he idle s peed. T achometer [A] If the i dle speed is out of the specified range, adjust it.
PERIODIC MAINTENANCE 2-17 Periodic M aintenance P rocedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Speci al T ool - Pilot Sc rew A djuster , C: 570 01-1292 • Adjust the lowest vacuu m between #1 and #2 to the high- est of #1 and #2.
2-18 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Back out the same number of turns counted when first turned i n. This i s to set the s crew to it s original posit ion. NOTE ○ A throttle body has diff erent “turns out” of the bypass screw for each i ndividual unit.
PERIODIC MAINTENANCE 2-19 Periodic M aintenance P rocedures Air Cl eaner Eleme nt Cleani ng NOTE ○ In dusty areas, the element should be cleaned more freque ntly t han the recommended interv al. ○ After riding through rai n or on muddily roads, the ele- ment should be cleaned immediately .
2-20 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Clean the element by tapping it li ghtly to loosen dus t. • Blow away the remaining dust by applying compressed air [A] from the outsi de to the inside (from the clean side to the dirty side).
PERIODIC MAINTENANCE 2-21 Periodic M aintenance P rocedures ○ Disconnect t he hoses from t he separator , and remove the separator [A] from the motorcycle left si de. Front [B] ○ Visual ly inspect the separator for cracks and other dam- age. If the separator has any cracks or damage, replace it with a new one.
2-22 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator ca p [A] in two steps. First turn the cap co u nterclockwise to the fi rst stop. Then push and turn it further i n the same direction and remove t he cap.
PERIODIC MAINTENANCE 2-23 Periodic M aintenance P rocedures • Loosen the air bl eeder bolt [A] on the thermost at housing. Front [B] • Replenish the coolant into the radiato r until the coolant begins to flow out the air bleede r bolt hole (that is, all the remaining air is forced out) .
2-24 PERIODIC MAINTENANCE Periodic M aintenance Procedure s V alve Cl earance In spection NOTE ○ V alve clearance must be checked and adjuste d when the engine is cold (at room temperature).
PERIODIC MAINTENANCE 2-25 Periodic M aintenance P rocedures V alve Clearance Adj ustment • T o change the valve c learance, remove the camshaft chain tensioner , camshafts and valve li fters.
2-26 PERIODIC MAINTENANCE Periodic M aintenance Procedure s V AL VE CLEARANCE ADJUSTMENT CHART INLET V AL VE 1. Measure the clearance ( when engine is cold). 2. Check present shim size. 3. Match clearanc e in vertical column with present shim si ze in horiz ontal column.
PERIODIC MAINTENANCE 2-27 Periodic M aintenance P rocedures V AL VE CLEARANCE ADJUSTMENT CHART EXHAU ST V AL VE 1. Measure the clearanc e (when engine is cold) . 2. Check present shim size. 3. Match clear ance in vert ical column with present shim size in horizontal column.
2-28 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Clutch Clutch Adjust Inspection • Pull the clutch l ever just enough to tak e up the free play [A]. • Measure the gap between the lever and the lever holder . If the gap is too wide, the clutch m ay not release fully .
PERIODIC MAINTENANCE 2-29 Periodic M aintenance P rocedures Engine Lubrica tion System Engine Oil C hange • Sit uate the motorcycle so that it is vert ical after warming up the engine. • Rem ove th e eng ine d rain p lug [A ] to dra in the oil. ○ The oil in the oil filter can be draine d by removing the fil ter (see Oil Filter Change).
2-30 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Wheels /T ires Tire Inspection As the tire tread wears down, the tire becomes more sus- ceptible to punc ture and failure. An accepted estimat e is that 90 % of all tire failures occu r during the last 10 % of tread life ( 90 % worn).
PERIODIC MAINTENANCE 2-31 Periodic M aintenance P rocedures Air Pressure I nspection/ Adjustment • Remove the air valv e cap. • Measure the tire air pressure with an air pressur e gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
2-32 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • T ighten both chain adjuster locknuts securely . • T ighten the axle nut. T orq ue - Re ar Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb ) • T urn the wheel, measure the chain slack again at the tight- est positi on, and readjust if necessary .
PERIODIC MAINTENANCE 2-33 Periodic M aintenance P rocedures • Rotate the rear wheel to inspect the drive chain for dam- aged roller s, and loose pin s and links. If there is any irregul arity , replace the drive chain. Lubricate the drive chai n if it appears dry .
2-34 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Apply oil to the si des of the rollers so that oil wil l penetrate to the roll ers and bushings. Apply the oil to the O-rings so that th e O-r ings will be coated with oil. • Wipe off any excess oil.
PERIODIC MAINTENANCE 2-35 Periodic M aintenance P rocedures If it does not, adjust and inspect the brake light switch. • While holding the switch body , turn the adjusting nut [A] to adjust the switch. CAUTIO N T o avoid damaging the electrical connections in- side the switch, be sure t hat the switch body does not turn during adjustment.
2-36 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Master Cylinde r Inspection (V isual Inspection ) • Disassemble the front and rear master cylinder s. • Check t hat there are n o scratches, rust or pitti ng on the inner wall [A] of each master cylinder and on the outside of each piston [B].
PERIODIC MAINTENANCE 2-37 Periodic M aintenance P rocedures Level I nspection • Check that the brak e fluid level in t he front brake reser voir [A] is above the l ower level li ne [B]. NOTE ○ Hold the reservoir hor izontal by turning t he handlebar when checking brake flui d level.
2-38 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Level the brake flu id reservoir . • Remove the reservoir cap and diaphragm. • Remove the rubber cap fro m the bleed valve [A] on the caliper . • Attach a clear plastic hose [B] to the bleed valve, and run the ot her end of the hose into a cont ainer .
PERIODIC MAINTENANCE 2-39 Periodic M aintenance P rocedures Brake Line Bl eeding The brake fluid has a very low compression coef ficient so that almost all the movement of the brake l ever or pedal is transmit ted directly to t he caliper for braking action.
2-40 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Bleed the br ake line and the cal iper: ○ Repeat this operation unt il no more air can be seen com- ing out into t he plas tic hose. 1. Pump the brake lever until it becomes hard, and apply t h eb r a k ea n dh o l di t[ A ] .
PERIODIC MAINTENANCE 2-41 Periodic M aintenance P rocedures WA R N I N G When working with the disc brake, observe the pre- cautions listed bel ow . 1. Never reuse ol d brake fluid. 2. Do not use flu id from a container that has been left unsealed or tha t has been open for a long time.
2-42 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Suspension Front For k Oil Leak Chec k • V isually inspect t he front fork s [A] for oil leakage, scoring or scratches on the outer surface of t he inner tubes. Replace or repair any defective parts, if necessary .
PERIODIC MAINTENANCE 2-43 Periodic M aintenance P rocedures Steering Steer ing Inspe ction • Lif t the front wheel of f the ground using the jack. Speci al T ool - Jack: 57001–12 38 • With the front wheel pointing st raight ahead, alternately tap each end of the handlebar .
2-44 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Adjust the steering. Special T ool - S teering St em Nut Wrench: 57001– 1 100 [B] If the steering i s too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loos e, tighten the stem nut a fraction of a turn.
PERIODIC MAINTENANCE 2-45 Periodic M aintenance P rocedures • Unscrew the thermost at bracket bolt [A]. ○ If removing the spar k plug #2 or #3. • Disconnect: Stick C oil Connectors [ A] • Pul l out the stick coil # 1 [B] . • T ake out the camshaft posit ion sensor connector [C] f rom the bracket.
2-46 PERIODIC MAINTENANCE Periodic M aintenance Procedure s • Clean the spark plug, preferably in a s andblasting devi ce, and then clean of f any abrasive par ticles. The plug may also be cleaned using a high- flash point solvent and a wire brush or other tool.
PERIODIC MAINTENANCE 2-47 Periodic M aintenance P rocedures General Lu brication Lubri catio n • Bef ore lubricati ng each part, clean off any rusty spo ts with rust remover and wipe of f any grease, oil, dirt, or grime. • Lubricate the poi nts listed below with i ndicated lubri cant.
2-48 PERIODIC MAINTENANCE Periodic M aintenance Procedure s Nut, Bolt, and Fastener Tightness Tightne ss Inspection • Check the tightness of the bolts and nuts l isted here.
FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 3-3 DFI Pa rts Lo cat ion . .... ...... .... ....... .... ... 3 -8 DFI Wiring Diagr am .. ...... ...... ..... ...... .. 3-10 Spec ifica tions .
3-2 FUEL SYSTEM (DFI) ECU Install ation ... ...... ...... ...... ...... 3-71 ECU Power Supply Inspection ..... 3-72 DF I Pow er So urce .. ...... .... ...... .... ....... 3- 74 ECU Fuse Rem oval .. .... ...... .... ..... 3-7 4 ECU Fuse Install ation .
FUEL SYSTEM (DFI) 3-3 Exploded View Clifornia Evaporative Emission Control System 1. Canister 2. Separator 3. Right fitting of throt tle body #2 4. Right fitting of throt tle body #3 5. Canister purge hose (green) 6. Fuel return hose (left, red) 7. Fuel tank breather hose (right, blue) 8.
3-4 FUEL SYSTEM (DFI) Exploded View.
FUEL SYSTEM (DFI) 3-5 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Throttle cabl e plate bol t 6 0.6 52 in·lb 2 Throttle body cover bolts 7 0.7 61 in·lb 3 Throttle assy holder clamp bolt s 2 0.2 17 in·lb 4 Choke link holder screws 2.
3-6 FUEL SYSTEM (DFI) Exploded View.
FUEL SYSTEM (DFI) 3-7 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Inlet air pressur e sensor bolt 12 1.2 104 in·l b 2 W ater temperature sensor 25 2.5 18 3 V ehicle downsensor bolts 2 0.2 17 in·lb 4 Camshaft position sensor bolt 12 1.
3-8 FUEL SYSTEM (DFI) DFI Parts Locati on DFI: DFI Parts (this chapter) 8. ECU Fuse 15A 19. Turn Signal Relay F: Front 9. ECU ( DFI) 20. Subthrot tle Sensor (DFI) 1. W ater temperature 10. Stick Coi ls 21. Mai n Throttle Sensor (DFI) Sensor (DFI) 1 1.
FUEL SYSTEM (DFI) 3 -9 DFI Parts Location [1], [2], [1 0], [13], [22] and [24] are not included..
3-10 FUEL SYSTEM (DFI) DFI Wiring Diagr am.
FUEL SYSTEM (DFI) 3-1 1 DFI Wiring Diagram T erminal Names 1. Power Supply to Sensors (inlet air pr es- sure, a tmospheric pr essure, and throttle sensors) from ECU. 2. Main Throttle Sensor Signal 3. Subth rottle Sensor Signal f or ECU 4. Atmospheric P ressure Sensor Signal 5.
3-12 FUEL SYSTEM (DFI) Specif ications Item Standard Digital Fuel Inject ion System Idle Speed 1 100 ± 50 r/min (rpm) Throttl e Assy: Ty p e Four b arrel type Bore 38 mm (1 .
FUEL SYSTEM (DFI) 3- 13 Specifications Item Standard Det ect ion tim e Within 0.5 ∼ 1.0 sec. Output voltage with the sensor ti lted 60 ∼ 70° or more: 3.7 ∼ 4.4 V with sensor arrow mark pointed up: 0.4 ∼ 1.4 V Subthrottle Sens or: Non-adjustabl e and non-removal Input V oltage 4.
3-14 FUEL SYSTEM (DFI) Special T o ols Oil Pressure G auge: 57001–1 25 Carburetor Drai n Plug Wrench, Hex 3: 57001–1 269 Fork Oil Level Gauge: 57001–1 290 Hand T ester : 57001–1 394 Throttle S.
FUEL SYSTEM (DFI) 3- 15 DFI Servicing Precautions There are a number of important precaut ions that should be followed servi cing the DFI system. ○ This DFI system is designed t o be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V seale d battery as a power sour ce.
3-16 FUEL SYSTEM (DFI) DFI Servicin g Precautio ns ○ T o maintain the correct fuel/ai r mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oi l. Clutch Cover [B] Front [C] T orque - Oil Fill er Plug: 1.
FUEL SYSTEM (DFI) 3- 17 T ro ubleshooting th e DFI S ystem Outline When an abnormality in t he system occurs, t he FI indica- tor LED (Light Emitting Diode) l ight goes on to alert the r ider on the meter panel. In additi on, the condition of the problem is stored in the memory of t he ECU (electronic control unit ).
3-18 FUEL SYSTEM (DFI) T roubleshooting the DFI Sys tem ○ The DFI part connectors [A] have seal s [B], including the ECU. • Join th e connector and insert the needl e adapters (special tool) [C] inside the seal [B] from behind the connecto r until the adapter reac hes the terminal.
FUEL SYSTEM (DFI) 3- 19 T ro ubleshooting th e DFI S ystem • Pull each connecto r [A] apart and inspect i t for corrosion, dirt, and damage. If the connector i s corroded or dirty , clean it carefull y . If it is damaged, replace it. Connect the connector s securely .
3-20 FUEL SYSTEM (DFI) T roubleshooting the DFI Sys tem ○ There are two ways to i nspect the DFI system. One is voltage Check Method and the other is Resi stance Check Method . (V oltage Check Method) ○ This method is conducted by measuring the input voltage [B] to a sensor [A] firs t, and then the output volt age [C] from the sensor .
FUEL SYSTEM (DFI) 3- 21 T ro ubleshooting th e DFI S ystem DFI Diagnosis Flow Chart Inquiries t o Rider ○ Each rider reacts t o problems in dif ferent ways, so it is imp ortant to confir m what kind of symptoms the rider has encountered.
3-22 FUEL SYSTEM (DFI) T roubleshooting the DFI Sys tem Sample Dia gnosis Sh eet Rider name: Registration No. (license pl ate No.): Y ear of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred.
FUEL SYSTEM (DFI) 3- 23 T ro ubleshooting th e DFI S ystem Poor running □ choke lever pulled out fully (push it in fully) at low speed □ very low choke speed (adjust choke cable) □ very low idle.
3-24 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e NOTE ○ This is not an exhaustive list, giving every possibl e cause for each problem l isted. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
FUEL SYSTEM (DFI) 3- 25 DFI System T roubl eshooting G uide Symptoms or possible Causes Actions (chapter) Ignition and engine stop swi tches not ON Turn both switc hes ON . Clutch lever not pulled in and gear not in neutral wheth er sidestand up or not Pull the lever in and shi ft the gear in neutral.
3-26 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Symptoms or possible Causes Acti ons (chapter) Piston ring / groove clearan ce excessive Inspect and replace ( see chapter 5). Cylinder head gasket damaged Replace (see chapter 5). Cylinder head warped Inspect and replace ( see chapter 5).
FUEL SYSTEM (DFI) 3- 27 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) Atmospheric pressure sensor tr ouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapt er 3). Battery voltage low Inspect and charge ( see chapter 16).
3-28 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Symptoms or Possible Causes Actions (chapter) Subthrottle sensor t rouble I nspect (see chapter 3). Subthrottle val ve actuator trouble Inspect (see chapter 3) . W ater temperature sensor trouble Inspect ( see chapter 3).
FUEL SYSTEM (DFI) 3- 29 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) Spark plug d irty , broken or gap malad justed Clean spark plugs and adjust plug gap (see chapter 2). To o l o w fuel pressure Inspe ct (see chapter 3).
3-30 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Poor Running o r No Power at High Speed: Symptoms or Possible Causes Actions (chapter) Firing incorrect : Spark plug dirty , broken or maladjusted Cl ean spark plug and adjust plug gap (see chapter 2).
FUEL SYSTEM (DFI) 3- 31 DFI System T roubl eshooting G uide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Us e the gasoline recommended in the Owner ’s Manual) Change fuel (see chapter 3). Spark plug incorr ect Repla ce it with the correct plug (see chapter 16).
3-32 FUEL SYSTEM (DFI) DFI System T roublesh ooting Guid e Symptoms or Possible Causes Actions (chapter) T oo low fuel pressure Inspect fuel li ne and fuel pump (see chapter 3). W ater temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor tr ouble Inspect and replace (see chapter 3).
FUEL SYSTEM (DFI) 3- 33 Self-Diagnosis Self-diagnosis O utline The self-diagnosis syst em has three modes and can be switch ed t o another mode by gr ounding the self -diagnosis terminal.
3-34 FUEL SYSTEM (DFI) Self-Diagnos is • T o enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C ] aft er the lead i s fir st grounded, a nd then keep it grounded continu ously [D] for more than 2 sec onds.
FUEL SYSTEM (DFI) 3- 35 Self-Diagnosis.
3-36 FUEL SYSTEM (DFI) Self-Diagnos is H o wt oR e a dS e r v i c eC o d e s ○ Service codes are shown by a series of long and shor t blinks of the FI indicator LED light as shown below . ○ Read 10th digit and unit digit as the FI indi cator LED light blinks.
FUEL SYSTEM (DFI) 3- 37 Self-Diagnosis S e r v i c eC o d eT a b l e Servic e Code FI Indicator LED Light Problems 11 Main throttl e sensor malfunction, wiring open or short 12 Inlet ai r pressure sen.
3-38 FUEL SYSTEM (DFI) Self-Diagnos is Backu ps ○ The ECU takes the following measur es to prevent engine damage when the D FI or the ignition system parts have troub les. Service Codes Parts Output Signal Usable Range or Criteria B ackups by ECU 11 Mai n Throttle Sensor Main Throttle Sensor Output V oltage 0.
FUEL SYSTEM (DFI) 3- 39 Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by EC U 51 Stick Coil #1 (Ignition Coil)* The stick coil primary winding must send signals (output voltage) continuously to t he ECU.
3-40 FUEL SYSTEM (DFI) Main Throttle Se nsor (Servic e Code 1 1) Main Throttle Sensor Remov al/Adjustmen t CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set wit h precision at the fac tory . Never drop the sensor , especially on a hard surface.
FUEL SYSTEM (DFI) 3- 41 Main Thrott le Sensor (Service Co de 1 1 ) Output V oltag e Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspect ion, Note the follo wing . • Disconnect the main throttl e sensor (gray) [A] and con- nect the harness adapter [B] between these connect ors.
3-42 FUEL SYSTEM (DFI) Main Throttle Se nsor (Servic e Code 1 1) Resistance Inspection • T urn the ignition switch OFF . • Discon nect the mai n throttle sen sor connector . • Connect a digital meter [A] to the main throttle sensor connector [B].
FUEL SYSTEM (DFI) 3- 43 Inlet Ai r Pressure S ensor (Service Code 12 ) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the part can damage it.
3-44 FUEL SYSTEM (DFI) Inlet Air Press ure Sensor (Service Code 12) Out put Voltage Insp ectio n NOTE ○ The output voltage changes accor ding to the lo cal at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection.
FUEL SYSTEM (DFI) 3- 45 Inlet Ai r Pressure S ensor (Service Code 12 ) ○ T urn the ignition switch ON. ○ Measure the inl et air pressure sensor output volt age from various vacuum readings, while pull ing the handle of the fork oil level gauge. ○ Check the inlet air pr essure sensor output vol tage, using the following f ormula and chart.
3-46 FUEL SYSTEM (DFI) Inlet Air Press ure Sensor (Service Code 12) Pv = 24 ∼ 55 cmHg.
FUEL SYSTEM (DFI) 3- 47 Inlet Ai r Pressure S ensor (Service Code 12 ) Pv = 55 ∼ 86 c mHg Vv: Inlet Air Pressure Sensor Output V olt- age (V) (Digi tal Meter Reading) ID: Id ling TO: Thrott le Full .
3-48 FUEL SYSTEM (DFI) Inlet Ai r T em perature S ensor (Service Co de 13) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel T ank Removal). • Discon nect the connector [ A] from the inlet air tempera- ture sensor .
FUEL SYSTEM (DFI) 3- 49 Inlet Air T emperature Sensor (Service Code 13) Sensor Resistance Insp ection • Remove the inlet air temperature sensor (see t his sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat- sensitive port ion is submerged.
3-50 FUEL SYSTEM (DFI) W ater T em perature Sensor (Se rvice Code 14) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel T ank Removal). • Drain t he coolant about 200 mL (6.
FUEL SYSTEM (DFI) 3- 51 W ater T empe rature Sensor (Service Code 14) A. ECU D. W ater T em perat ure Sensor V . Coolant T emperature Gauge in T achometer Sensor Resistance Insp ection • Remove the water temperature sensor (see this se ction). • Refer to the Electri cal System chapter for w ater temper- ature sensor inspec tion.
3-52 FUEL SYSTEM (DFI) Atmosp heric Pressure Se nsor (Servic e Code 15) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it.
FUEL SYSTEM (DFI) 3- 53 Atmospheric Pr essure Sens or (Service Code 1 5) Output V oltag e Inspection • Measure the output voltage at the ECU in the same way as input voltag e inspection.
3-54 FUEL SYSTEM (DFI) Atmosp heric Pressure Se nsor (Servic e Code 15) V a: Atmospheric Pressure Sensor Output V oltage (v) ST : Standard of Sensor Output V oltage (v) UR: Usable Range of Sensor Output V oltage (v) H: Altitude (m or fee t) A.
FUEL SYSTEM (DFI) 3- 55 Crankshaft Sensor (S ervice Code 21) Start the engine and switc h the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosi s system does not detect dynamic condi- tion of the crankshaft sensor .
3-56 FUEL SYSTEM (DFI) Camshaft Positio n Sensor (Service Code 23) Start the engine and swi tch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the tim e of self-diagno sis. If the engine cannot be start ed, the self-diagno sis system does not detec t dynamic condi- tion of th e camshaft position sensor .
FUEL SYSTEM (DFI) 3- 57 Speed Sensor (Serv ice Code 2 4, 25) Speed Sensor Removal /Install ation • See the Switches and Sensors section in the Electrical System chapter . Speed Sen sor Inspe ction • See the Switches and Sensors section in the Electrical System chapter .
3-58 FUEL SYSTEM (DFI) Speed Sens or (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and spe ed sensor connector . Engine Sprocket Cover [C] • Connect a digital meter to the harness adapter leads.
FUEL SYSTEM (DFI) 3- 59 V e hicle-down Sensor (S ervice Code 31) Removal CAUTION Never drop the down-sensor , especially on a hard surface. Such a shock t o the sensor can damage it. • Remove: Connection and V ehicle-down Sensor [A] Bolts and W ashers [B] Front [C] Installation • The UP mark [A] of the sensor should f ace upward.
3-60 FUEL SYSTEM (DFI) V ehicle-down Sens or (Service Co de 31) • T urn the ignition switch OFF . • Remove the sensor . • Connec t a digital volt meter [A] to the con nector with nee- dle adapter set [B].
FUEL SYSTEM (DFI) 3- 61 V e hicle-down Sensor (S ervice Code 31) A. ECU S. ECU Main Relay T. I g n i t i o n S w i t c h a. ECU Fuse 15A b. V ehicle-down Sensor d.
3-62 FUEL SYSTEM (DFI) Subthrottle Se nsor (Servi ce Code 32) Subthrot tle Sensor Removal/Ad justment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set wit h precision at the fac tory . Never drop the sensor , especially on a hard surface.
FUEL SYSTEM (DFI) 3- 63 Subthrottle Sensor (Service Code 32) Output V oltag e Inspection • Remove the throttle body assy (see Thrott le Body Assy Removal). • Measure the output vol tage at the subthrott le sensor in the same way as input voltage inspect ion.
3-64 FUEL SYSTEM (DFI) Subthrottle Se nsor (Servi ce Code 32) Resistance Inspection • T urn the ignition switch OFF . • Discon nect the subt hrottle sens or connector . • Connect a digital meter [A] to the subthrot tle sensor con- nector [B]. • Measu re the subthr ottle sen sor resistance.
FUEL SYSTEM (DFI) 3- 65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53 , 54) Stick Coi l #1: Ignition Coil (Service Code 51) Stick Coi l #2: Ignition Coil (Service Code 52) Stick Coi l #3: Ignit.
3-66 FUEL SYSTEM (DFI) Stick Coils (#1, #2, # 3, #4: Service Code 51, 52 , 53, 54) A. ECU M. St ick Co ils N. Engine Stop Switch T . Ignition Switch X.
FUEL SYSTEM (DFI) 3- 67 Subthrottle V alve Actuator (S ervice Code 6 2) Subt hrott le V alv e Actua tor R emov al CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with preci sion at the factory . Never drop the actuat or , especially on a hard sur- face.
3-68 FUEL SYSTEM (DFI) Subthrottle V alve Actuator (Serv ice Code 62) Inpu t Voltage In spec tion NOTE ○ Be sure the batter y is fully charged. • T urn the ignition switch OFF .
FUEL SYSTEM (DFI) 3- 69 FI Indicator LED Light Inspection Flow Chart.
3-70 FUEL SYSTEM (DFI) FI Indicato r LED L ight LED Light In spection • Remove the meter unit (see Electr ical System chapter). • Using t wo auxiliary leads, supply batt ery power to the FI indicator LED light [A].
FUEL SYSTEM (DFI) 3- 71 ECU CAUTION Never drop the ECU, especially on a har d surface. Such a shock to the ECU can damage it. ECU Identi ficat ion ○ Most countries have t heir own regulati ons, so each ECU has d if ferent characteri stic. So, do not confuse ECU’ s with each other and use only the ECU’s for your cou ntry .
3-72 FUEL SYSTEM (DFI) ECU If the rubber protect or [A] is removed, install it. ECU [B] ECU P ower Supply Ins pec tion • V isually inspect the ter minals [A] of the ECU connectors. If the connector is clogged wit h mud or dust, blow it off with compressed air .
FUEL SYSTEM (DFI) 3- 73 ECU • Check the ECU power sourc e voltage with a digi tal meter [A]. ○ Position the terminal in accordance with terminal num bers of ECU connectors [B] in this chapter figure.
3-74 FUEL SYSTEM (DFI) DFI Power Sour ce ECU Fuse Removal • Refer to the Elec trical Syst em chapter for the ECU fuse rem ova l. ECU F use In stallat ion If a fuse fail s during operat ion, inspect the DFI sy stem to determine the c ause, and then replace it with a new fuse of proper amperage.
FUEL SYSTEM (DFI) 3- 75 Fuel Line Fuel P res sure In spec tion NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electr ical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to kno w symptom well.
3-76 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure wit h the engine idling. Fuel Pressure (idling) Standa rd: 310 kPa ( 3.2 kgf/cm² , 46 psi) NOTE ○ The gauge needle will fl uctuate. Read the pressure at the average of the maximum and mi nimum indicati ons.
FUEL SYSTEM (DFI) 3- 77 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. Front [B] • Be sure to place a piece of cloth around the f uel pump outlet hose. • Remove the fuel pump outlet hose [A] from the f uel pump [B] and the de livery pipe [C] (see Fu el Pump Removal).
3-78 FUEL SYSTEM (DFI) Fuel P ump Fuel Pump Removal CAUTION Never drop the fuel pump, especiall y on a hard sur- face. Such a shock to the pump can damage it .
FUEL SYSTEM (DFI) 3- 79 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Check that the fuel pump (–) terminal [A] and band [B] are in place. Front [C] • Apply a non-permanent locking agent to t he threads of the fuel pump bolts.
3-80 FUEL SYSTEM (DFI) Fuel P ump • Connect the hand tester ( 25 V DC) to the fuel pump con- nector [A] with needle adapter set. Front [ B] Special T oo ls - Hand T es ter: 57 001–13 94 Needle Ada pter Set: 57001 –1457 ○ Measure the operating v oltage with the engine stopped, and with the connector joined.
FUEL SYSTEM (DFI) 3- 81 Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay , especially on a hard surface. Such a shock to the rel ay can damage it. • Remove the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of the storage compartment.
3-82 FUEL SYSTEM (DFI) Fuel I njectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly . Audi ble In spect ion • Start the engine. • Apply the ti p of a screwdriver [ A] to the injector [C]. Put the grip end onto your ear , and listen whether the injector is clicki ng or not.
FUEL SYSTEM (DFI) 3- 83 Fuel Injectors Output V oltag e Inspection • T urn the ignition swi tch OFF . • Remove the ECU (see ECU section). • Connect a digital vo ltmeter [A] to the ECU connector [B] with the needle adapter set [C].
3-84 FUEL SYSTEM (DFI) Fuel I njectors Injector S ignal T est • Prepare two test li ght sets with male terminals as shown. Rating of Bulb [A ]: 12 V × 3 ∼ 3.4 W T erminal Width [ B]: 1.8 mm ( 0.071 in.) T erminal Thick ness [C]: 0.8 mm (0.031 in.
FUEL SYSTEM (DFI) 3- 85 Fuel Injectors Injector Resistance Inspectio n • Remove the fuel tank (see Fuel T ank Removal). • Disconnect the connect or from the injector [A] (see Throt- tle Body Assy Disassembly/Assembl y). • Measure the injector resist ance with the hand tester [B].
3-86 FUEL SYSTEM (DFI) Fuel I njectors • Check the injector fuel line for leakage as follows: ○ Connect a commercial ly availabl e vacuum/pressure pump [A ] to the nipple of the delivery pi pe [B] with a high-pressur e fuel hose [C] (both ends connected with the clamps [D]) as s hown.
FUEL SYSTEM (DFI) 3- 87 Fuel Injectors A. ECU K. Fuel Injectors N. Engine Stop Switch T. I g n i t i o n S w i t c h X. Ignition Fuse 10 A Y . Junction Box Z. Fuel Pump Relay (for fuel pump an injectors) d. Starter Relay e. Joint Connector C f. Sealed Battery j.
3-88 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle G rip Play In spection /Adjustme nt • Refer to the Throttle Control System Inspection i n the Pe- riodi c Maintenance chapter .
FUEL SYSTEM (DFI) 3- 89 Throttle Body Assy Idle Sp eed I nspe ction /Adj ustm ent • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Thrott le Bore Cl eaning • Refer to the Throttle Control Syst em Inspection in the Pe- riodic Maintenance chapter .
3-90 FUEL SYSTEM (DFI) Throttle Body Ass y • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cle aner Duct Clamp B olts [B] Special T ool - Carburetor Drain Plug Wrench, Hex 3: 57001–126 9 • Re.
FUEL SYSTEM (DFI) 3- 91 Throttle Body Assy • Remove the bolt [A] and the thrott le cable plate [B] f rom the throttle body front side. • Remove the t hrottle cab le lower ends from the t hrottle pulley .
3-92 FUEL SYSTEM (DFI) Throttle Body Ass y • Apply a t hin coating of grease t o the throttl e cable upper ends. • Insta l l the upper ends of the throttle cables in the grip (see Throttl e Body Assy R emoval) . • Fit the project ion [A] of the right swit ch housing into the hole [ B] of the handlebar ( front view).
FUEL SYSTEM (DFI) 3- 93 Throttle Body Assy CAUTION Never drop the injector , especially on a hard sur- face. Such a s hock to the injector can damage it. • Pull out [A ] the inject ors along wit h the deli very pipe [B]. If necessary , remove the injector s from the deli very pipe.
3-94 FUEL SYSTEM (DFI) Air C leaner Element Remova l/Instal lation • Refer to the Air Cleaner Element Cleaning in the Periodic Mainte nance chapter . Air Cle aner Oil D raini ng A drain hose is connected to the bottom of the air cleaner to drain water or oil acc umulated in the cleaner part .
FUEL SYSTEM (DFI) 3- 95 Fuel T ank Fuel T ank Removal WA R N I N G Gasoline is ext remely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventil ated and free from any source of flame or sparks; this includes any appliance with a pilot light.
3-96 FUEL SYSTEM (DFI) Fue l T ank • Be sure to place a piece of cloth [A] around the fuel hose pump outlet joint [ B]. • While p inching t he hose joint l ocks [C] wit h fingers, pull the joint out along the deliver y pipe. Front [D] W ARNING Be prep ared for fuel spill age; any spilled fuel must be completely wiped up immediatel y .
FUEL SYSTEM (DFI) 3- 97 Fuel T ank Fuel T ank Installa tion • Note the above W ARNING (see Fuel T ank Removal). • Route the hoses correct ly (see Appendix chapter ). • Check that the rubber dampers [ A] are on the frame and the fuel tank. Front [B] • Check that the dampers [A] are in place on the fuel t ank as well.
3-98 FUEL SYSTEM (DFI) Fue l T ank Fue l T ank an d Cap Inspect ion • V isually inspect t he gasket [A] on the tank cap for any damage . Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [ C] in the tank are not clogged.
FUEL SYSTEM (DFI) 3- 99 Evaporative Em ission Contr ol System Parts R emoval/In stallatio n WA R N I N G Gasoline is extremely fl ammable and can be ex- plosive under certai n conditions.
3-100 FUEL SYSTEM (DFI) Evaporative Emiss ion Control S ystem Sepa rator O pera tion T est W ARNING Gasoline is extremely flammable and can be ex- plosive unde r certain conditions.
COOLING SYSTEM 4- 1 4 Cooling System T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 4-2 Coola nt Fl ow Ch art .... ...... .
4-2 COOLING SYSTEM Exploded View.
COOLING SYSTEM 4- 3 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Radiator hose cla mp screws 2 0.2 17 in·lb 2 Thermostat air bleeder bolt 7.8 0.80 69 in·lb 3 Radiator fan bol ts 8.3 0.85 74 in·lb 4 Water pum p imp eller b olt 9.
4-4 COOLING SYSTEM Coolant F low Cha rt.
COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 2. W ater Pump 3. Cylinder Jacket 4. Cylinder Head Jacket 5. Thermostat Housing 6. Thermostat Air Bleeder Bolt 7. Radiator Cap 8. Radiator 9. Oil Filter 10. Outlet Hose 1 1. Inlet Hose 12. Oil Cooler 13.
4-6 COOLING SYSTEM Specif ications Item Standard Coolant provided when shipping: T ype (recommended) Permanent type of antifreez e (soft water and ethylene glycol plus c orrosion and rust inhi bitor c.
COOLING SYSTEM 4- 7 Special T ool Bear ing Dr iver Set: 57001–1129 Bearing Drive r: 57001–382 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20.
4-8 COOLING SYSTEM Coolant Coolant De terior ation Inspe ction • Remove the left side cover (see Frame chapter ). • V isual ly inspect the coolant [ A] in the reserve tank. Front [B] If whit ish cotton-li ke wafts ar e observed, aluminum par ts in the cooling system are corroded.
COOLING SYSTEM 4-9 Coolant Pressure T esting • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling sy stem pressure tes ter [A] on the filler neck [B]. NOTE ○ Wet the cap sealing surfaces wi th water or coolant to preve nt pressure leaks.
4-10 COOLING SYSTEM W ater Pum p Water Pump Removal • Refer to Oil Pump Removal in the Engine Lubri cation Sys- tem ch a pter . Wa t e r P u m p [ A ] Front [B] Water P um p Insta llati on • Refer to Oil Pump I nstallation i n the Engine Lubricat ion System chapter .
COOLING SYSTEM 4-1 1 W ater Pump • Be sure to repl ace the mechanical seal , oil seal, and O -ring wit h new ones because t hese parts wi ll be damaged by removal. • Apply plenty of high t emperature grease to the oil seal lips. • Apply oil to the outer circ um ference of the oil seal.
4-12 COOLING SYSTEM Radi ator Radiat or Removal W ARNING The radiator f an is connected directly to t he bat- tery . The radiat or fan may start even if the ignition switch is off. NEVER TOUCH THE RADIA TOR F AN UNTIL THE RADIA TOR F AN CONNECTOR IS DIS- CONNECTED.
COOLING SYST EM 4-13 Radiator • If necessary , remove: Radiator Fan Mounting Bolt s [A] Radiator Fan [B] Radi ator I nspe ction • Check the radiator core. If ther e are obstr uctions t o air flow , remove t hem. If the cor rugated fins [A] are deformed, carefull y straighten t hem.
4-14 COOLING SYSTEM Radi ator • Install the cap [A] on a coo ling system press ure tester [ B]. NOTE ○ Wet t he cap sea ling surfaces with water or coolant to prevent pressure leaks . • W atching the pressure gauge, pump the pressure tester to build up the pr essure until the relief valve opens: the gauge needle flicks downward.
COOLING SYST EM 4-15 Thermostat Ther mosta t Rem oval • Remove: Coolant : Drain about 200 mL Fuel T ank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt [ A] W ater T emperature Sensor Connector [ B] Three W ater Hoses [C] • Remove the thermostat housing [D].
4-16 COOLING SYSTEM Thermo stat • T o check valve opening t emperature, suspend the ther- mostat [A] in a cont ainer of water and raise the t empera- ture of the water . ○ The thermostat must be completel y submerged and must not touch the containe r sides or bottom.
COOLING SYST EM 4-17 Hose a nd Pip es Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses i n accordance wit h the Cable, Wire, and Hose Routing section in the Appendix chapter .
4-18 COOLING SYSTEM Radiator Fan Switch, Water T emp erature Sen sor CAUTION The fan switch or the water temper ature sensor should never be al lowed to fall on a hard sur face. Such a shock to their parts can damage t hem. Radiat or Fan Switch Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chap ter).
ENGINE TOP END 5-1 5 Engine T o p End T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 5-2 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 5-6 Special T ools and Sealant ........ ....... .. 5-8 Clean Air System .
5-2 ENGINE TOP END Exploded View.
ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Air suction val ve cover bolts 10 1.0 87 in·lb 2 Cylinder head cover bolts 10 1.0 87 in·lb 3 Camshaft cap bolts (L=45 mm) 12 1.2 104 in·lb 4 Camshaft cap bolts (L=40 mm) 12 1.
5-4 ENGINE TOP END Exploded View.
ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Coolant Drain Plug (Cylinder) 10 1.0 87 in·lb 2 Exhaust pipe manifol d holder nuts 17 1.7 12 3 Muffler body cl amp bolts 17 1.7 12 4 Muffler body mounting bolts and nuts 34 35 25 5 Crank shaft sensor cover bolt s 11 1.
5-6 ENGINE TOP END Specif ications Item Standard Servi ce Lim it Clean Air System: V acuum switch valve closing Open → Close pressure: 45 ∼ 53 kPa --- (340 ∼ 400 mmHg, 6.5 ∼ 7.7 psi) Cam shaf ts : Cam height: Exhaust 36.146 ∼ 36.254 mm 36.05 mm (1.
ENGINE TOP END 5-7 Specifications Item Standard Service L imit V alve/valve guide clearance (wobble method): Exhaust 0.09 ∼ 0.18 mm 0.40 mm (0.0 035 ∼ 0.0071 in.) (0 .016 in.) Inle t 0.03 ∼ 0.12 mm 0.33 mm (0.0 012 ∼ 0.0047 in.) (0 .013 in.) V alve seat cutting angle 45°, 3 2°, 60° -- - V alve seating sur face: Width: Exhaust 0.
5-8 ENGINE TOP END Special T oo ls and Sealant Compression Gauge: 57001–2 21 V alve S pring Com pressor Ass embly: 57001–2 41 Piston Pin Pul ler Assembly : 57001–9 10 V alve Seat C utter , 4 5° - 27.
ENGINE TOP END 5-9 Special T ools and S ealant V alve Spring Compressor Adapter , 22 : 57001–120 2 Spark Plug W rench, Hex 16: 57001–126 2 Fork Oil Level Gauge: 57001–129 0 Compression Ga uge Adapter , M10 × 1.0: 57001–131 7 V alve Guide Arbor , 4.
5-10 ENGINE T OP END Clean A ir System Air Suction V alve Removal • Remove: Fuel T a nk (see Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction V alve Cover Bolts [C] and Clamp Ai.
ENGINE T OP END 5-1 1 Clean Air System V acuum Switch V alve T est • Remove: Fuel T ank (see Fuel System (DFI) chapter) Va c u u m S w i t c h Va l v e • Connect a vacuum gauge [ A] and syringe [B] or f ork oil level gauge to the vacuum hoses as shown.
5-12 ENGINE T OP END Cylinder Head Cov er Cylin der He ad Cov er Re moval • Remove: Fuel T a nk (see Fuel System (DFI) chapter) V acuum Switch V alve and Hoses Stick Coils (see Electrical System chapter) Air Suc tion V alve Covers [A] • Remove the cylinder head cover bolts [A] and take of f the cove r .
ENGINE T OP END 5-13 Cylinder Head Cover • Install the washer [A] with the metal side faces upward. • T ighten: T orque - Cylind er Head Cov er Bolts [ B]: 10 N· m (1.
5-14 ENGINE T OP END Cams haft Chai n T ensi oner Camshaft Chain T ensioner Removal CAUTION This is a non-return type camshaft chain tensioner . The push rod does not return to its origi nal position once it moves out to take up camshaft chain slack.
ENGINE T OP END 5-15 Camshaft, Cam shaft Chain Camshaft Removal • Remove: Fuel T ank (see Fuel System (DFI) chapter) Stick Coil s (see Electr ical System) Cylinder Head Cover (see Cylinder Head Cover R e- moval) Pickup Coil Cover • Position the c rankshaft at #1, 4 p iston TDC.
5-16 ENGINE T OP END Camshaft, Camsh aft Chain • Apply engine oil to all cam parts and jour nals. • If a new camshaft is to be used, apply a thin coat of molyb- denum d isulfide gr ease to the cam surf aces. NOTE ○ The exhaust camshaft has a 030 EX mark [A] and the inlet camshaft has a 030 IN m ark [B].
ENGINE T OP END 5-17 Camshaft, Cam shaft Chain Camshaft, Camshaft Ca p Wear • Remove: Camshaft Chain Guide Camshaft Cap • Cut strips of plastigage to jour nal width. Place a strip on each journal parallel to t he camshaft instal led in the correct positi on.
5-18 ENGINE T OP END Camshaft, Camsh aft Chain Camshaft Chain Removal • Split the crankcase (s ee Crankshaft/T ransmission chap- ter). • Remove the camshaft chain [A] from the crankshaft sprocket.
ENGINE T OP END 5-19 Cylinder Head Cylinde r Compressi on Measuremen t NOTE ○ Use the battery which is fully charged. • W arm up the engine t horoughly .
5-20 ENGINE T OP END Cylinder He ad Cylind er Head Removal • Drain the coolant (see Cooling System chapter ). • Remove : Exhaust Pipes (see Exhaust Pipe Removal) Coolant Drain Bolt [A] (cylinder ).
ENGINE T OP END 5-21 Cylinder Head • Install: Front Camshaft Chain Guide [A] O-ring [B] Collar [C] • T ighten: T orque - Front C amshaft Chain Guide Bolt (Upper) [D]: 25 N·m ( 2.5 kg f·m, 18 f t·lb ) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m ( 1.
5-22 ENGINE T OP END Va l v e s V alve Cl earance In spection • Refer to the Engi ne T op End in the Per iodic Maintenance chapte r. V alve Clea rance Adjustm ent • Refer to the Engi ne T op End in the Per iodic Maintenance chapter . Valve Remova l • R emove the cylin der head (see Cylinder Head Removal).
ENGINE T OP END 5-23 V a lves V alve G uide Instal lation • Apply oil to the valve gui de outer surface before ins talla- tion. • Heat the area around the valv e guide hole to about 120 ∼ 150 °C (248 ∼ 302 °F). • Drive the valve gui de in from the top of the head using t he valve guide arbor .
5-24 ENGINE T OP END Va l v e s Valve Seat I nspe ction • Remove the valve (see V alve Removal). • Check t he valve seating sur face [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
ENGINE T OP END 5-25 V a lves Seat Cutter Operation Care: 1. This valve seat cutter is devel oped to grind the valve for repair . Therefore the cutter must n ot be used for other purposes than seat repair . 2. Do not drop or shock the val ve seat cutter , or the dia- mond particles may fall off.
5-26 ENGINE T OP END Va l v e s • Measure the outside diameter of the seating surface with a vernier ca liper . If the o utside diameter of the se ating surface is t oo small, repeat the 45° grind until the diamet er is within th e spec- ified range.
ENGINE T OP END 5-27 V a lves If the seat width is too wide, m ake the 60° [A] grind de- scribed below . If the seat width is within the specifi ed range, lap the valve to the seat as described below . • Grind the seat at a 60° angle until the seat width is within the specified range.
5-28 ENGINE T OP END Va l v e s.
ENGINE T OP END 5-29 Cylinder , Pistons Cylinde r Removal • Remove: Cylinder Head (see Cylinder Head Removal) Wa t e r H o s e [ A ] • Remove the cylinder [B]. Cyli nder Ins talla tion NOTE ○ If a new cylinder is used, use new piston ring. • Install the pins [A] and new cylinder gasket [B].
5-30 ENGINE T OP END Cylinder , Pistons • Remove the piston pin s. Special T oo l - Piston P in Puller Ass embly: 5700 1–910 [A] • Remove the pistons. • Carefull y spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it.
ENGINE T OP END 5-31 Cylinder , Pistons NOTE ○ If a new piston i s used, use new pist on ring. • Install the piston with i ts hollow facing forward. • Fit a n ew piston pin snap ring into the si de of the piston so that the ring opening [A] does n ot coincide with the slit [B] of the piston pi n hole.
5-32 ENGINE T OP END Cylinder , Pistons Piston Ring Groove Width • Measure the pi ston ring groove width. ○ Use a ve rnier caliper at several points around the pis ton. Piston Ring Groove Width Standa rd Service L imit T op [A] 0.83 ∼ 0.85 mm 0.
ENGINE T OP END 5-33 Throttle Body Holder Throttle Body Holder Insta llation • Be sure t o instal l the O-ri ngs [A]. • Install the c lamps [B] as shown and so t hat its hole fit on the project ion [C] of the holder . • T ighten: To r q u e- Throt tle Body Holder Bolts [D]: 1 2 N·m (1.
5-34 ENGINE T OP END Muffler W ARNING T o avoid a serious burn, do not remove the mufflers when the engine i s still hot. Wait until the muff lers cool down.
ENGINE T OP END 5-35 Muffler ○ Install the muff ler body clamp bolts as shown. [L] Upper Side [M] Ins ide [N] Connection Part Detail • Thoroughly warm up the engine, wait until the engi ne cools down, and retighten all the bolts and nuts.
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CLUTCH 6-1 6 Clutch T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 6-2 Spec ifica tions .. .... ...... .... ...... .... ...
6-2 CLUTCH Exploded View.
CLUTCH 6-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Clutch lever clamp bolts 7.9 0.8 69 in·lb S 2 Clutch cover bolts (L = 32 mm) 11 1.1 95 in·lb 3 Clutch cover bolts (L = 45 mm) 11 1.1 95 in·lb 4 Clutch cover bolts (L = 30 mm) 11 1.
6-4 CLUTCH Specif ications Item Standard S ervic e Lim it Clutch Lever Free Play 2 ∼ 3 m m (0.08 ∼ 0.12 in.) --- Clu tch : Clutch plate assembly 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 in.) -- - Fricti on plate t hickness 2.72 ∼ 2.88 m m (0.107 ∼ 0.1 13 in.
CLUTCH 6-5 Special T ools and S ealant Inside Circlip P liers: 57001–143 Clutch Holder: 57001–124 3 Kawasa ki Bond (Sili cone Seala nt): 56019–1 20.
6-6 CLUTCH Clutch L ever and Ca ble Clut ch L ever Fre e Play Ins pect ion • Refer to the Clutch Adjust Inspect ion in the Periodic Main- tenanc e chapter . Clutch Lever Free Play Adjustmen t • Refer to the Clutch Adjust Inspect ion in the Periodic Main- tenance chapter .
CLUTCH 6-7 Clutch C over Clutch Cover Removal • Remove: Engine Oil (drai n, see Engine Oil Change section in the Periodic Maintenance chapt er) Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B] Clutch Cable Bra cket [C] • T urn the release lever [A] toward the rear as shown, and rem ove the cl utch c over [B] .
6-8 CLUTCH Clutch Cover • Fit the spring [A] as shown. [B] Vi ewed from Rear [C] Rel ease Shaft [D] Clutch Cover Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings • Remove: Circlip.
CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (drai n, see Engine Oil Change section in the Periodic Maintenance chapt er) Clutch Cover ( see Clutch Cover Removal) Clutch Spring Bolts [A] Cl.
6-10 CLUTCH Clutch ○ Install the spacer [A] so that the tapered side [B] faces inwar d. ○ Install the washer [A] so that the OUT SIDE mark faces outward. ○ Replace the clutch hub nut wi th a new one. ○ Holding the clutch hub, tighten the cl utch hub nut.
CLUTCH 6-1 1 Clutch • Apply molybdenum disulfide greas e to the pusher ends [A] and install the pusher [B]. • Apply engine oi l to the needle beari ng [C] and instal l it. • Install the washer [D]. • Align the mark [A] of t he clutch spring pl ate [B] with the groove [C] of the clutch hub.
6-12 CLUTCH Clutch Clutch Plat e A ssembly Adj ustment • Inspect the clutch pl ate assembly length, and then re- place t he steel pl ate(s) whic h brings the length wi thin the specifi ed range. • Remove: Sprin gB o l t s Spring Holders Springs Spring Pl ate • Replace the f ollowing steel pl ate(s).
ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 7-2 Engin e Oil Fl ow Cha rt .
7-2 ENGIN E LUBRICA TION SYSTEM Exploded View.
ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Oil filler plug 1.5 0.15 13 in·lb 2 Engine drain plug 20 2.0 14.5 3 Oil filter (cart ridge type, P/No. 16097–1070) 26 2.7 20 EO, R 3 Oil filter (cart ridge type, P/No.
7-4 ENGIN E LUBRICA TION SYSTEM Engine Oi l Flow C hart.
ENGINE LUBRICA TION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oi l Passage 2. Oil Passage Hole in Alter nator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Fil ter 7. Oil Cooler 8. Oil Pr essure Switch 9.
7-6 ENGIN E LUBRICA TION SYSTEM Specif ications Item Standard Engine Oil: Ty p e API S E, SF or SG API SH or SJ with JASO MA Vi sc o s it y SA E 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filt er is removed) 3.
ENGINE LUBRICA TION SYSTEM 7-7 Special T ools and S ealant Oil Pressure Gauge , 10 kgf/cm²: 57001–164 Oil Press ure Gauge Adap ter , PT 3/8: 57001–123 3 Kawasa ki Bond (Sili cone Seala nt): 56019.
7-8 ENGIN E LUBRICA TION SYSTEM Engine Oil and Oil Filter W ARNING Motorcycle operation wit h insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear a nd may result in engine or t rans- mission seizure, accident , and injury .
ENGINE LUBRICA TION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drai n, see Periodic Maintenance chapter) Muff ler (see Engine T op End chapter) Oil Pan Bolts [A] Oil Pan [B] ○ Remove the oil pipe [A], oil pressure relief val ve [B] and oil screen [C] as necessary .
7-10 ENGINE LUBRICA TION SYSTEM Oil Pr essure Relief V alve Oil Pressure Relie f Valve Removal • See Oil Pan Removal. Oil Pressure Relief V alve Installation • See Oil Pan Instal lation.
ENGINE LUBRICA TION SYSTEM 7-1 1 Oil Pump Oil Pump Removal • Drain: Coolant (see Periodic Maintenance chapter) Engine Oil (see Periodi c Maintenance c hapter) • Remove: Wa t e r H o s e [ A ] W at.
7-12 ENGINE LUBRICA TION SYSTEM Oil Pu mp • Fit the pin [A] of the oil pump cover [B] into the hole [C] in the crankcase. • Instal l: Pins [A] W ater Pump Body [B] • Instal l: Impeller [A] and Bolt [B] • T ighten: T orque - Wate r Pump Impeller Bolt: 10 N·m (1.
ENGINE LUBRICA TION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Removal • Remove: Clutch (s ee Clutch chapter ) Oil Pan (see Oil Pan Removal) Circlip [A] and W asher [B] Oil Pump Drive Gear [C] Oil Pump Dri ve Gear Instal lation • Apply molybdenum disulf ide oil solution t o the journal por- tions [A] on the oil pump gear shaft [B].
7-14 ENGINE LUBRICA TION SYSTEM Oil Cooler Oil C ooler R em oval • Drain: Coolan t (see Per iodic Maintenance chapt er) Engine Oil (see Periodic Maintenance chapt er) • Remove: Oil Fil ter (see Pe.
ENGINE LUBRICA TION SYSTEM 7-15 Oil Pressure M easuremen t Oil Pressur e Measurement • Remove the oil passage plug, and at tach the adapter [A] and gauge [B] to the plug hole. Speci al T ools - Oil Pres sure Gau ge, 10 kgf/c m²: 57001–16 4 Oil Press ure Gauge Adap ter , PT 3/8: 57001 –1 233 • Start the engine and warm up the engine.
7-16 ENGINE LUBRICA TION SYSTEM Oil Pr ess ure S witc h Oil Pressure Switch Remova l • Remove: Engine Oil (drain, see Periodi c Maintenance chapter) Switch Cover [A] Switch T erminal [B] Oil Pre ssure Switch [C] Oil Pressure Switch Installation • Apply silicone seal ant to the threads of the oil pressure switch and tighten it.
ENGINE REMOV AL/INST ALLA TION 8-1 8 Engine Removal/Installation T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 8-2 Spec ial T ools .
8-2 ENGINE REM OV AL/INST ALLA TION Exploded View.
ENGINE REMOV A L/INST A LLA TION 8-3 Exploded View T orque No. Fastener N· m kgf·m ft·l b Remarks 1 Adj ustin g col lar loc knu t 49 5.0 36 S 2 Upper engine mounting bolts 44 4.5 32 S 3 Rear engine bracket bolt s 25 2.5 18 S 4 Front engine bracket bolts 44 4.
8-4 ENGINE REM OV AL/INST ALLA TION Special T o ols Carburetor Drain P lug Wrench, Hex3: 57001–1 269 Engine Mount Nut Wrench: 57001–14 50.
ENGINE REMOV A L/INST A LLA TION 8-5 Engine Remova l/Installation Engine Remova l • Support the rear part of the swingarm wi th a stand [A] . • Squeeze the brake l ever slowly and hol d it with a band [A]. WA R N I N G Be sure to hold the front brake w hen removing the engine, or the motorcycle may fall over .
8-6 ENGINE REM OV AL/INST ALLA TION Engine Removal/In stallation • Remove: Radiator Hose Clamp [ A] (Loosen) Radiat or Hose [B] Oil Cooler W ater Hose Clamp [C] (Loosen) Oil Cooler W ater Hose [D] R.
ENGINE REMOV A L/INST A LLA TION 8-7 Engine Remova l/Installation • Remove: Camshaft Position Sensor Connect or [A] Injector Har ness Connector [B] Coolant Reserve T ank [A] (see Cooling System chap.
8-8 ENGINE REM OV AL/INST ALLA TION Engine Removal/In stallation • Support the engine wi th a suitable st and [A]. ○ Put a plank [B] onto the sui table stand for engine bal ance.
ENGINE REMOV A L/INST A LLA TION 8-9 Engine Remova l/Installation • Using the Hexagon W rench, turn the adjusting col lar [A] counter clockwise t o mark the gap bet ween the engine and flame adjusting col lar . • Remove the drive chai n [A] from the output shaft [B].
8-10 ENGINE REMOV AL/IN ST ALLA TION Engine Removal/In stallation • Install the engine mounti ng bolts and nuts, following the specifi ed installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine i nto its final posi tion in the frame.
ENGINE REMOV AL/INST AL LA TION 8-1 1 Engine Remova l/Installation ○ Ninth, temporarily i nstall: Front Engine Brac ket [A] Front Right Engine Mounting Bolt [ B] ○ T enth, tighten the rear bracket bolts. T o rque - Rear Engin e Bracket Bo lts: 25 N·m (2.
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CRANKSHAFT/TR ANSMISSION 9-1 9 Crankshaft/T ransmission T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 9-2 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 9-6 Special T ools and Sealant ........ ....... .. 9-8 Crankcase Spli ttin g.
9-2 CRANKSHAFT/TRAN SMISSION Exploded View.
CRANKSHAFT/TR ANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf ·m ft·lb Remarks 1 Breather plate bolts 10 1.0 87 i n·lb L 2 Crankcase bolts ( M9, L=81 mm) 42 4.3 31 MO,S 3 Crankcase bolts ( M9, L=95 mm) 49 5.0 36 MO,S 4 Crankcase bolts (M8) 27 2.
9-4 CRANKSHAFT/TRAN SMISSION Exploded View.
CRANKSHAFT/TR ANSMISSION 9-5 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Shift pedal mounting bolt 34 3.5 25 L 2 Gear positioning lever bolt 12 1.2 104 in·lb 3 Shift shaft return spring pin 29 3.0 22 L 4 Shift drum cam holder bolt 12 1.
9-6 CRANKSHAFT/TRAN SMISSION Specif ications Item Standard Servi ce Lim it Crankshaft, Connecting Rods: Connecting rod bend --- TIR 0.2/100 mm (0.008/3.94 i n.) Connecting ro d twist --- TIR 0.2/ 100 mm (0.008/3.94 i n.) Connecting r od big end side clearance 0.
CRANKSHAFT/TRA NSMISSION 9-7 Specifications Item Standard Servi ce Limit Cranks haft runout TIR 0.0 2 mm (0.00 08 in.) or less TIR 0.05 mm (0.0020 in .) Crank shaft main bearing inser t/journal clearance 0.020 ∼ 0.044 mm 0.07 mm (0.0008 ∼ 0. 0017 in.
9-8 CRANKSHAFT/TRAN SMISSION Special T oo ls and Sealant Bear ing Puller: 57001–1 35 Bearing Puller Adapter: 57001–3 17 Kawasaki Bond (Silic one Sealant): 56019–12 0 Kawasaki Bond (Silic one Sea.
CRANKSHAFT/TRA NSMISSION 9-9 Crankcase Splitt ing Crankcase Splitt ing • Remove the engine (see Engine Removal /Installation chapter). • Set the engine on a clean surface and hol d the engine steady while parts are being removed.
9-10 CRANKSHAFT/T RANSMISSION Crankcase Sp litting • Apply liquid gasket to the breather plate mati ng surface [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, an d then install the bre ather plate. Sealant - Three Bond: 1207B • Apply a non-per manent locking agent to t he threads and tighten the bolt s [A].
CRANKSHAFT/T RANSMISSION 9-1 1 Crankcase Splitt ing • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealan t- K awasa ki Bo nd (Silico ne Sealant ): 92104 –1063 CAUTION Do not apply li quid gasket around the c rankshaft main bearing inserts, and oil passage holes.
9-12 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods Crankshaft R emoval • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A].
CRANKSHAFT/TR ANSMISSION 9-13 Crankshaft an d Connec ting Rods • Apply molybdenum disulf ide grease [A] to t he outer sur- face of the upper insert and the inner sur face of the con- necting rod big end. • Apply molybdenum disulfide o il [B] to the inner surfaces of upper and lower beari ng inserts.
9-14 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods (1) Bolt Length Measurement Method • Be sure to clean t he bolts, nuts, and connecting rods thorou ghly wit h a high-flash point solvent, because the new connecting rods, bolts, and nut s are treated wi th an anti-rust so lution.
CRANKSHAFT/TR ANSMISSION 9-15 Crankshaft an d Connec ting Rods (2) Rotati on Angle Method If you don’t have a point micrometer , you may tighten the nuts using the “Rotation Angle M ethod”.
9-16 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods Connecting Rod Ben d • Remove the connecting rod big end bearing inse rts, and reins t all the c onnecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod bi g end, and insert the arbor t hrough the connect- ing ro d big end.
CRANKSHAFT/TR ANSMISSION 9-17 Crankshaft an d Connec ting Rods Conn ecti ng Rod B ig End B eari ng Insert /Cra nkpin Wear • Measure the bearing ins ert/crankpin [B] clear ance with plastigage [A] . ○ T ighten the big end nuts t o the specified torque ( see Con- necting Rod Install ation).
9-18 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods Connecting Rod Big End Inside Diameter Marks None 38.000mm ∼ 38.0 08mm (1.496 1 ∼ 1.4964 i n.
CRANKSHAFT/TR ANSMISSION 9-19 Crankshaft an d Connec ting Rods Crankshaft Mai n B eari ng Insert/Journ al Wear • Using a plasti gage (press gauge) [A] , measure the bear- ing insert/jour nal [B] clearance. NOTE ○ Tighten the cr ankcase bolts to the specified torque (see Crankcase Assembly).
9-20 CRANKSHAFT/T RANSMISSION Crankshaft and Conn ecting Rods • Measure the main bear ing insi de diameter , and mark the upper crankcase half in accordance with the inside diam- eter . Crankcase Main Beari ng Inside Diamet er Marks : " " or no mark.
CRANKSHAFT/TR ANSMISSION 9-21 Starter Moto r Clutch Starter Motor Clutch Removal/Insta llation • Refer to the Alternat or Rotor Removal and Installati on in the Electrical System chapter . Starter Motor Clu tch Assembly • Be sure to instal l the one-way clutch [ A] so that its flange [B] fits in the holder r ecess [C].
9-22 CRANKSHAFT/T RANSMISSION T ransmission Shift Ped al Removal • Mark [A] the posit ion of the shift leve r [B] on the shift shaft so that it can be installe d later in the same posit ion.
CRANKSHAFT/TR ANSMISSION 9-23 T ra nsmission • Install the footpeg brack et [A]. • Apply a non-permanent locking agent to the footpeg bracket bolts [B]. • T ighten: T o rque - Footpeg br acket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffl er Mounting Bolt and Nut [C]: 29 N·m (3.
9-24 CRANKSHAFT/T RANSMISSION T ransmission • Remove: Gear Positionin g Lever Bolt [A] Gear Po sitioning Lever [B], Collar and spring External Sh ift Mechani sm Installati on • Install t he gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • T ighten: T orque - G ear Positioning Lever Bolt: 12 N·m (1.
CRANKSHAFT/TR ANSMISSION 9-25 T ra nsmission T ransmissi on Shaft Removal • Split the crank case (see Crankcase Splitting). • Remove the drive shaft [A] and output s haft [B]. T ransmission Sh aft Install ation • Check to see that the set pins [A] and set rings [B] are in place.
9-26 CRANKSHAFT/T RANSMISSION T ransmission • Remove the ball bear ing [A] fr om each shafts. Special T oo ls - Beari ng Puller: 57001– 135 [B] Bearin g Pulle r Adapter : 57001– 317 [C] • Discard th e bearing. T ransmission Shaft Assembly • Apply engine oil to t he sliding surfaces on the t ransmis- sion shafts, gears and bushi ngs.
CRANKSHAFT/TR ANSMISSION 9-27 T ra nsmission NOTE ○ When the toothed washers [ 28] [29] are asse mbled onto the output shaf t, note the foll owing. ○ When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [ B] of the toothed washer [28].
9-28 CRANKSHAFT/T RANSMISSION T ransmission 1. 1st G ear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (T op) Gear 7. T oothed Washer , 31 mm (1.2 2 in .) 8. Thrust W asher , 30 mm (1.18 in.) 9. Circli p 10. Circlip 1 1. Bushing 12. Bushing 13.
CRANKSHAFT/TR ANSMISSION 9-29 T ra nsmission Shift Dru m and Fo rk Installati on • Install the sh ift rods [ A], noting the gr oove position. The rods are identical. • Position the one wi th shortest ears [B] on the dr ive shaft and place the pin in the center gr oove in the shift drum [C].
9-30 CRANKSHAFT/T RANSMISSION T ransmission Sh ift Fork /Ge ar Gr oov e Wear • Measure the thi ckness of t he shift fork ear s [A], and mea- sur e th e w idth [B] of the gear grooves. If the thickness o f a shift fork ear is less than the service limit, the shift for k must be replaced.
WH EELS/ TIRES 1 0-1 10 Wheels/T ires T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 10- 2 Spec ifica tions .. .... ...... .
10-2 WHEELS/TIRES Exploded View.
WH EELS/ TIRES 1 0-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Rem arks 1 Front axle clamp bolt 20 2.0 15 2 Front axle 127 13 94 3 Rear axle nut 127 13 94 G: Apply grease. R: Replacement P arts WL: Apply soap and water solution or rubber lubr icant.
10-4 WHEELS/TIRES Specif ications Item Standard Ser vice Li mit Wheels (Rims): Rim runout: Axial --- TIR 0. 5 mm (0.020 in.) Radial --- TI R 0.8 mm (0.031 in.) Axle runout/100 mm (3.94 in.) TIR 0.05 m m (0.0020 in.) or less TIR 0.2 mm (0.008 in.) Wheel balance 10 g (0.
WH EELS/ TIRES 1 0-5 Special T ools Bear ing Dr iver Set: 57001–1129 Jack: 57001–123 8 Bearin g Remove r Head, 25 × 28 : 57001–1 346 Bearin g Remover Shaft , 13: 57001–1 377.
10-6 WHEELS/TIRES Wheels (Rim s) Front Wheel Removal • Remove: Brake C aliper Mounting Bolt s [A] • Loosen: Right Side Axle Clamp Bolt [A] Axle [B] • Raise the front wheel off the ground. Special T ool - J ack: 5 7001–1238 • Pull out the a xle to the right and drop t he front wheel out of the forks.
WHEELS/TIRES 10-7 Wheels (Rims) • T ighten the axle. T orque - Front Axle: 1 27 N·m (13 kgf·m, 94 ft·lb) • Before tig htening the clamp bolt on the r ight front fork leg, pump the front fork up and down 4 or 5 times to allow the right front fo rk leg to seat on the fr ont axle.
10-8 WHEELS/TIRES Wheels (Rim s) • Remove: Caliper Mounting Bolts [A] Calipe r[ B ] • Remove the drive chain [A] f rom the rear sprocket toward the lef t. • Move the rear wheel back and r emove the wheel from the rear caliper . • Remove the rear wheel.
WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WA R N I N G If the rear axle nut is not securely tightened or the cotter pin is not inst alled, an unsafe riding condi- tion may result. • Adjust the drive chai n slack after instal lation (see Final Drive chapter).
10-10 WHEELS/TIRES Wheels (Rim s) Axle Inspe ction • V isually inspect the f ront and rear axle for damages. If the a xle is damaged or bent, replac e it. • Place the axle in V blocks that are 100 mm (3. 94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfw ay between the blocks.
WHEELS/TIRES 10-1 1 Wheels (Rims) ( b )W h e nt h et i r ei s o nt h er i m . • Pry [A] the bal ance weight of f the rim flange usi ng a reg- ular tip scr ewdriver as shown in the figure. ○ Insert a tip of the screwdriver between the tire bead [B] and weight blade [C] until the end of the tip reaches the end of the weight blade.
10-12 WHEELS/TIRES Wheels (Rim s) • When required total weight ex ceeds 20 g (0.71 US oz), in- stall balance weight at bot h sides of rim flange as shown. Weight Sel ection: g (US oz) Requ ired T otal W eight : g( U So z ) O n eS i d e[ A ] Other Side [B ] 20 (0.
WHEELS/TIRES 10-13 Tir e s Air Pressure I nspection/ Adjustment • Refer to the Air Pr essure Inspecti on/Adjustment in the Pe- riodic Maintenance chapter .
10-14 WHEELS/TIRES Tire s • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal with a soap and wat er solution or rubber lubricant, and pull [B] the valve stem [A] thr ough the rim from the inside out until i t snaps into pl ace.
WHEELS/TIRES 10-15 Tir e s • Check to see that the rim lines [A] on both sides of the tire sidewalls are parall el with the rim fl anges. If the rim fl anges and tire sidewall r im lines are not parall el, remove the valve core. • Lubricate the rim flang es and tire beads.
10-16 WHEELS/TIRES Hub B earing Hub Bearing Remova l • Remove the wheel, and take out the following . Collar s Coupling (out of rear hub) Grease Seals Circli ps • Use the bearing remover to remove the hub bearings [ A]. CAUTION Do not lay the wheel on the ground with the di sc facing down.
FINAL DRIVE 1 1-1 11 Final Drive T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 1 1- 2 Spec ifica tions .. .... ...... ....
1 1-2 F INAL DRIVE Exploded View.
FINAL DRIVE 1 1-3 Exploded View T orque No. Fastener N·m kgf ·m ft·lb Remarks 1 Engine sprocket cover bolts 9.8 1.0 87 in·lb 2 Engine sprocket nut 127 13 94 MO 3 Rear sprocket nut 59 6.0 43 4 Engine sprocket cover damper bolts 6.9 0.7 61 in·lb L 5 Speed sensor bolt 6.
1 1-4 F INAL DRIVE Specif ications Item Standard Serv ice L imit Drive Chain: Chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) --- 20-link length 317 .5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard chain Make ENUMA --- Ty p e EK525UVXL2, Endless --- Link 1 12 link s --- Sprockets: Rear sprocket warp 0.
FINAL DRIVE 1 1-5 Special T ools Bear ing Dr iver Set: 57001–1129 Jack: 57001–1 238.
1 1-6 F INAL DRIVE Drive Chain Driv e Chain S lack Inspe ctio n • Refer to the Drive Chain Slack Inspection in the Peri odic Mainte nance chapter . Driv e Chain Sl ack Adjus tment • Refer to the Drive Chai n Slack Adjustment in the Peri odic Maintenance chapt er .
FINAL DRIVE 1 1-7 Drive Chain EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting and Riveti ng Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] pin head to make it flat. • Set cutting and riveti ng pin [B] as shown.
1 1-8 F INAL DRIVE Drive Chain • Set plate holde r (A) [A] and plate holder (B) [B] on the body . • Fit plate holder ( A) to link plate. • T urn pin holder by hand until plate holder (B) touches the other link plat e. • T urn pin holder by wrench clockwise until two pins of link come into groove of plate holder (A).
FINAL DRIVE 1 1-9 Drive Chain • T urn wrench clockwise until tip of riveting pin hi ts of li nk pin. • Rivet it. • Some work for the other link pi n. • After staking, check the staked area of the li nk pin for cracks. • Measure the outside di ameter [A] of the link pin and l ink plates outside width [ B].
1 1-10 FINAL D RIVE Sprocket, C oupling Engi ne Spr ocke t Rem oval • Remove: Speed S ensor [A] Connecto r Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor • Flatten out the b ended washer [ A]. • Remove the engine sprocke t nut [B] and washer .
FINAL DRIVE 1 1-1 1 Sprocket, C oupling Rear Sprocket Removal • Remove the rear wheel (see Wheels /T ires chapter) . CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the di sc. Place blocks under the wheel so that the disc does not touch the ground.
1 1-12 FINAL D RIVE Sprocket, C oupling • Replace the grease seal with a new one. • Press in the greas e seal so that the seal surf ace is flush with th e end of the hole.
FINAL DRIVE 1 1-13 Sprocket, C oupling Sprocket W ear Inspection • Visual ly inspect the engine and r ear sprocket teeth for wear and dam age. If the teeth are worn as il lustrated, repl ace the sprocket, and inspect t he drive chain wear (see Drive Chai n Wear Inspection).
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BRAKES 12-1 12 Brakes T able of Con tents Exploded V iew .......... ...... ...... ..... ...... .. 12-2 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 12-6 Special T ool ........ ...... ...... ...... ..... . ... .... 12-7 Brake Lever , Brake Pedal .
12-2 BRAKES Exploded View.
BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front caliper mounti ng bolts 25 2.5 18 2 Brake hose banj o bolt 25 2.5 18 3 Bleed valve 7.8 0.80 69 in·lb 4 Front caliper assembly bolts 22 2. 2 16 L 5 Front brake pad pin bolt 17 1.
12-4 BRAKES Exploded View.
BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear master cylinder push lod locknut 18 1.8 13 2 Rear caliper mounting bolts 25 2.5 18 3 Brake hose banj o bolts 25 2. 5 18 4 Bleed valve 7.8 0.80 69 in·lb 5 Rear master cylinder mounting bolts 25 2.
12-6 BRAKES Specif ications Item Standard Servi ce Limit Brake Lever , Brake Pedal: Brake lever position 5-way adjustable ( to suit rider) --- Brake lever free pl ay Non-adjustable --- Pedal free play Non-adj ustable --- Pedal positi on About 47 mm (1.
BRAKES 12-7 Special T ool Jack: 57001–123 8.
12-8 BRAKES Brake Lever , B rake Pedal Brake Lever P osition Adj ustment The brake lever adjust er has 5 positions so that the brake lever p osition can be adjusted to suit the operator’s hand. • Push the l ever forward an d turn the a djuster [A] to align the number wit h the arrow mark [B] on the lever holder .
BRAKES 12-9 Calipers Front Cali per Removal • Loosen the banjo bolt [A] at the brake hos e lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [ B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D].
12-10 BRAKES Calipers Cali per Ins tallation • Install t he caliper and brake hose lower end. ○ Replac e the washers on each side of hose fitting with new ones. • T ighten: T orque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf·m, 18 ft·lb) Caliper Mounting Bolts (Rear): 2 5 N·m (2.
BRAKES 12-1 1 Calipers WA R N I N G T o avoid serious injury , never place your fingers or palm in front of the piston. If y ou apply compressed air into the caliper , the piston may crush your hand or fingers. ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B].
12-12 BRAKES Calipers • Replace the fluid seal s [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them into the cyl inder s by hand. • Replace the dust seal s [B] with new ones i f they are dam- aged. ○ Apply brake fluid to t he dust seals, and install t hem into the cylinder s by hand.
BRAKES 12-13 Calipers Rear Caliper Assembly • Clean the calipe r parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol . • Install the bleed valve and rubber cap. T orque - Bleed V alve: 7.
12-14 BRAKES Calipers Cali per Pis ton a nd Cylin der D amag e • V isually inspect the pi ston [A] and cylinde r surfaces. Replac e the ca liper if t he cylinder and pi ston are badly scores or rusty . Front Caliper [B] Rear Ca liper [C ] Cali per H older S haf t Wear The caliper body must slide smoothly on the caliper holder shaft [D].
BRAKES 12-15 Brake Pads Front Bra ke Pad Removal • Remove: Mounting Bolts [A] • Remove: Pad Pin Bolt [A] P a dS p r i n g[ B ] Brake Pads [C] Fron t Brake P ad Inst allati on • Push the cali per pistons in by hand as f ar as they wi ll go. • Apply sili cone grease to the stopper ring [A].
12-16 BRAKES Brake Pads Rear Brake P ad Install ation • Push the cali per piston in by hand as f ar as it will go. • Insta l l: Brake Pads Pad Pin Clip • Install t he caliper ( see Caliper Instal lation).
BRAKES 12-17 Master Cylinde r Front Master Cyl inder Removal • Disconnect the front brake light switc h connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the maste r cylinder [C] (see Br ake Hose Removal/In- stallati on).
12-18 BRAKES Master Cylin der Rear Master Cylinder Re moval • Unscrew the brake hose banjo bolt [A] on the master c ylin- der (se e Brake Hose Removal/I nstallation). • Pull off t he reservoir hose lower end [B], and drain the brake flu id into a cont ainer .
BRAKES 12-19 Master Cylinde r Rear Master Cylinder Disasse mbly NOTE ○ Do not remove the push rod clevis for master cylinder disass embly since r emoval requires brake posit ion ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal).
12-20 BRAKES Brake Disc Brake Disc Remova l • Remove the wheel (see Wheels/T ires chapter). • Unscre w the mounting bolt s, and take off t he disc. Brake Disc Insta llati on • Install the brake di sc on the wheel so that the marked side [A] faces o ut.
BRAKES 12-21 Brake Fluid Brake Flui d Level Inspect i on • Refer to the Brake Flui d Level in the Peri odic Maintenance chapter . Brake Flu id Change • Refer to the Brake Flui d Change in the Periodic Mainte- nance chapter . Brake Line Bl eeding • Refer to the Brak e Line Bleeding in the Periodic Mainte- nance chapter .
12-22 BRAKES Brake Hose Brake Hose Removal /Install ation CAUTION Brake fluid quickl y ruins painted or plastic sur- faces; any spilled flui d should be completely wiped up imme diately with wet cloth. • When re moving t he brake hose, take care not t o spill the brake fluid on the pai nted or plastic part s.
SUSPENSION 13-1 13 Suspension T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 13- 2 Spec ifica tions .. .... ...... .... ...
13-2 SUSPENSION Exploded View.
SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb AL Front fork cl amp bolts (Upper): ZR1000–A2 ∼ 13 1.3 11 3 i n · l b 2 Front fork clamp bolts (Lower) 20 2. 0 15 AL Front fork cl amp bolts (Lower): ZR1000–A2 ∼ 30 3.
13-4 SUSPENSION Exploded View.
SUSPENSION 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear shock absorber nuts (upper and lower) 34 3.5 25 2 Swingarm pivot s haft nut 127 13 94 3 Swingarm pivot shaft loc knut 98 10 72 4 Rocker arm nut 34 3.5 25 5 T ie-rod nuts 59 6.
13-6 SUSPENSION Specif ications Item Standard Front Fork (per one unit): Fork inner tube outside diameter 41 mm (1.61 in.) Air Pressure Atmospheric press ure (Non-adjustabl e) Rebound damper setting 1.
SUSPENSION 13-7 Special T ools Oil Seal an d Bearin g Remover: 57001–105 8 Bear ing Dr iver Set: 57001–1129 Jack: 57001–123 8 Front Fork Oil S eal Driver: 57001–128 8 Fork Oil Level Gauge: 57 001–129 0 Fork Pi ston Rod P uller , M10 × 1.
13-8 SUSPENSION Front Fork Rebound Damping F orce Adjust ment (Onl y Right Fork Leg) • T o adju st the rebound damping force, turn the rebound damping adjuster [A] on t op of the right front fork leg to the desir ed position.
SUSPENSION 13 -9 Front F ork Front Fork Removal (each for k leg) • Remove: Front Wheel (see Wheels/T ires chapter .) Front Fender (see Frame chapter .) Windshield an d Bracket (see Frame chapter .) Inner Cover (see Frame chapt er .) Fairing and Bracket ( see Frame chapter .
13-10 SUSPENSION Front Fork Fork Oil C hange • Remove the front fork (see Front Fork Removal). ○ Tu r n t h e spring preload adjuster [A] countercl ockwise until the full y position. • Unscrew the t op plug [B] out of the inner tube. • A voiding the pins [A], set the front fork spring compressor set [B] on t he washer [C].
SUSPENSION 13-1 1 Front F ork • Drain the fork oil into a sui table contai ner . • Remove the fork spring [A]. ○ Pump the piston rod [B] up and down at least ten times to expel the oil from the fork . • Hold the fork tube upright, press the inner tube and the piston rod al l the way down.
13-12 SUSPENSION Front Fork Oil Level (fu lly compressed, without spri ng) Standard: R i g h tf o r kl e g 6 2±2m m ( 2 . 4 4± 0 . 0 8i n . ) Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil level may also be measured using the for k oil level gauge.
SUSPENSION 13-13 Front F ork • Check the O-ring on the top pl ug and replace it wit h a new one if damaged. • For the right for k leg, check the distance [C] between the bottom end [A] of the top pl ug and rebound damping ad- juster [B] with a pair of vernier cal iper .
13-14 SUSPENSION Front Fork ○ Holding the inner tube [A] by hand, pull the out er tube [B] several ti mes to pull out the outer tube. • Remove the inner tube guide bushing [A], outer tube guide bushing [B], washer [C], oil seal [D] from the i nner tube.
SUSPENSION 13-15 Front F ork • Install the cente ring plate on t he cylinder uni t. • Insert the cente ring plate and cylinder unit as a set into the inner tube. Cylinder Unit [A] and Center Ring Plate [C] for Right Fork Leg Cylinder Unit [B] and Center Ring Plate [C] for Left Fork Leg • Hold the front fork in a vise.
13-16 SUSPENSION Front Fork Spring T ension • Since a spring becomes shorter as it w eakens, check its free le ngth [A] to determine its co ndition. If the spring of eit her fork leg is shorter than the service limit, it must be replaced.
SUSPENSION 13-17 Rear Shock Absorber Rebound Damp ing Force Adjustment • T o adjust the rebound damping force, turn the rebound damping adjuster [A] to t he desired posit ion. ○ The standard adjust er setting f or an average-buil d rider of 68 kg (150 lb) wit h no passenger and no accessories 3/4 turns out of the f ully clockwise posi tion.
13-18 SUSPENSION Rear Shoc k Absorb er Special T oo ls - Hook Wrench: 57001–15 39 [A] Spring Adjustment Adju ster Dampi ng Positi on Force Setting Load Road Speed 193. 4 mm Wea k Soft Light Good Low (7.61 in.) ↑ ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓ ↓ 183.
SUSPENSION 13-19 Rear Shock Absorber • Remove the shock absorber [A] from upside. Rear S hock Ab sor ber Inst allatio n • T ighten: T orque - Re ar Shock Absorber Nuts : 34 N·m (3.5 kgf·m, 25 ft·lb) Rear S hock A bso rber Insp ectio n • Remove the rear shock absorber .
13-20 SUSPENSION Swingarm Swingarm Removal • Remove the muff ler bodies (see Engine T op End chapter .) • Raise t he rear wheel of f the ground with jack. Special T ool - J ack: 5 7001–1238 • Remove: Rear Wheel (see Wheels/T ires chapter .) Chain Cover (see Final Drive chapter .
SUSPENSION 13-21 Swingarm Swin garm In stallat ion • Apply plenty of grease to the ball bearing, needle bearings and grease seals, and add plenty of greas e to the grease nipple. • Install the collars [A]. ○ Place the right collar [A] on t he stopper [B] inside the frame [C].
13-22 SUSPENSION Swingarm • Remove the ball bear ing and needle b earings. Special T ool - Oil Sea l and Beari ng Remo ver: 57001–10 58 [A] Swingarm B earing Inst allati on • Apply plenty of grease to the ball bearing and needle bearings. • Install the needle bearings so that the manufacturer ’s marks face in.
SUSPENSION 13-23 Tie-Rod, R ocker Arm Ti e-Rod Removal • Remove the muf fler bodies (see Engi ne T op End chapter .) • Remove the side stand (see Frame c hapter .) • Using the jack, raise t he rear wheel off the ground. Speci al T ool - Jack: 57001–12 38 • Squeeze the brake l ever slowly and hol d it with a band [A].
13-24 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the needle bearings and oil seal li ps, and add grease to the grease nipple. • T ighten: T orque - Rocker Arm Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nut: 59 N·m (6.
STEERING 14-1 14 Steering T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 14- 2 Spec ial T ools . ...... .... ...... .... ..
14-2 STEERING Exploded View.
STEERING 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Steering stem nut 27 2.75 20 2 Steering stem head bolt 108 11 80 3 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb AL Front fork cl amp bolts (Upper): ZR1000–A2 ∼ 13 1.
14-4 STEERING Special T o ols Steer ing Stem Nut Wrenc h: 57001–1100 Bearin g Driver Se t: 57001–1129 Jack: 57001–1 238 Stee ring S tem Bear ing Dr iver : 57001–13 44 Steering Stem Bearing Dri.
STEERING 14-5 Steering Steer ing Inspe ction • Refer to the Steering Inspection in the Periodic Mainte- nance chapter . Steer ing Adjust ment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter .
14-6 STEERING Steerin g Stem Stem, Stem Bearin g Removal • Remove: Windsh ield and Bracket (see Frame chapter .) Inner Cover (see Fr ame chapter .) Fairing and Bracket (s ee Frame chapter .) Front W heel (see Wheels/T ires chapter .) Handlebar (see Handlebar Removal.
STEERING 14-7 Steering Stem • T o remove the bearing out er races [C] pressed into t he head pipe [B], insert a bar [A] into the rec esses [D] of head pipe, and applyi ng it to both recess alternatel y hammer it to drive the race out.
14-8 STEERING Steerin g Stem • Apply grease the lower ball bearin g [A] and install it onto the ste m. • Apply g rease to the upper ball bearing [ B] and inner race [C]. • Install t he stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it.
STEERING 14-9 Steering Stem NOTE ○ Tighten the fork upper clamp bolts first , next the stem head nut, last the fork lowe r clamp bolts. T orq ue - Steering S tem H ead Bolt : 108 N· m (1 1 kgf·m, 80 ft·lb) Front Fork Clamp Bolts (Upper): 8.8 N·m (0.
14-10 STEERING Handlebar Handle bar Removal • Remove: Clutch Lever Assembly [ A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right H andlebar Switch Housi ng [D] Handlebar Holder Bolts [E] • Remove the handlebar holder s [F] and then pull out the handle bar [G].
STEERING 14-1 1 Handlebar Rear V iew Mirror s Removal • Loosen the lower hexagonal area [ A] for tightening t o re- move the rear view mirror f rom the holder . CAUTIO N Do not force to t ighten and/or loosen t he upper hexagonal area (Adapter) [ B] with a pair of span- ners.
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FRAME 15-1 15 Frame T able of Con tents Exploded V iew .......... ...... ...... ..... ...... ...... ...... ........ ..... ...... ...... ........ ...... ..... ........ ...... ...... ...... .... . 15- 2 Seats .. .... ....... .... ...... .... ...... ....
15-2 FRAME Exploded View.
FRAME 15-3 Exploded View T orque No. Fastener N·m kgf· m ft·lb Remarks 1 Footpeg holder bolts 34 3.5 25 2 Muff ler mounting nuts 29 3.0 22 3 Side stand bolt 44 4.
15-4 FRAME Exploded View.
FRAME 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Windshield screws 0.35 ∼ 0.50 0.035 ∼ 0.050 3 ∼ 4i n · l b 2 Front fender bolts 3.
15-6 FRAME Exploded View.
FRAME 15-7 Seats Rear Seat Removal • Insert the i gnition switch ke y into the seat lock [A], turning the key countercl ockwise, pulling up on the rear of the seat [B], and pulling the seat backward. WA R N I N G The muffler surf ace is hot once the engine has been started.
15-8 FRAME Side C ov ers Side Cover Removal • Remove the bolt [A]. • Pull th e side cover [ B] evenly outward to clear the stop- pers. Side Cover Installation • Insert the t abs [A] into the h oles [B].
FRAME 15-9 Fairings Windshield Removal • Remove: Bolts [A] Windshield [B] Windshield Installation • Windshield Instal lation is the revers e of removal.
15-10 FRAME Fairings • Remove: Fairing Mountin g Bolts [A] (both side) Headli ght Connectors Fair ing Install ation • Fairing inst allation i s the revers e of removal.
FRAME 15-1 1 Seat Covers Seat Cover Removal • Remove: Seats Screws [A] • Push the central pin, and then remove the quick r ivets [A]. • Pull the front porti ons [A] of the seat cover outside [B], and then remove the seat cove r backward. Seat Cover Installation • Installat ion is r everse of removal.
15-12 FRAME Mud Gu ard Mud Guard Removal • Remove: Chain C over (see Final Drive chapter) Bolt [A] Clamp [B] • Lift up the mud guard [A], and t hen pull it out backward.
FRAME 15-13 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] Bolts [B] (both side) • Remove the front fender [C]. Front Fender Inst allation • Install the br ake hose clamps to the front fender hol es.
15-14 FRAME Fenders • Remove: Quick Rivets [A] Rear Fe nder Rear [B] Rear Fender Rear Inst allation • Put the pr ojection [A ] into the ho le [B]. • Put the projections [A ] into the holes [B].
FRAME 15-15 Frame Cover Frame Cover Removal • Remove: Bolts [A] Frame Cover [B] (both side).
15-16 FRAME Battery Case Battery Case Removal • Remove: Seats Seat Cover Rear Fender Assy Side Co vers Battery Left Side Screw [A] (wi th reserver tank) • Pull ou t the batt ery case [B] backward [C]. Battery Case In stallat ion • Put the battery case attachments [A] at the projections [B] on the frame.
FRAME 15-17 Side St and Side S tand Rem ova l • Raise the rear wheel of f the ground with the stand . • Remove: Muff ler (both side) Exhaust pip e Side Stand Switch Bol t [A] Side Stand Switch [B].
15-18 FRAME Fra me Fram e Insp ectio n • V isually ins pect the frame for cracks, de nts, bending, or warp. ○ If there is any damage to the frame, replace i t. W ARNING A repaired f rame may fail in use, possibl y causing an accident. If the frame is bent, de nted, cracked, or warped, replace it.
ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Con tents Parts Location. ...... ...... ...... ...... ..... ...... 16-3 Exploded V iew .......... ...... ...... ..... ...... .. 16-4 Spec ifica tions .. .... ...... .... .... ...... ..... ..... 16 -10 Special T ools and Sealant .
16-2 ELECTRICAL SYSTEM Fan M oto r Insp ecti on .... .... ...... ..... 16 -63 Meter , Gauge, Indicator Unit.... ...... .... 16-65 Meter Un it Re mova l ...... .... ...... ..... 16 -65 Meter , Gauge Disassembly ....... ... 16-65 Electronic Combination Meter Unit Inspection .
ELECTRICAL SYSTEM 16-3 Parts Lo cation [A] Starter Lockout Swit ch [B] Camshaft Position Sensor [C] Radiator Fan Switch [D] S tart er Mo tor [E] Alternator [F] Speed Sensor [G] Neutral Switch [H] Side.
16-4 ELECTRICAL SYSTEM Exploded View.
ELECTRICAL SYSTEM 16-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Meter mounting screws 1.2 0.12 11 i n · l b 2 T ail/brake li ght mounting screws 1.2 0.12 11 i n · l b 3 License plat e light mounting sc rews 1.2 0.12 11 i n · l b 4 Front brake light switch screw 1.
16-6 ELECTRICAL SYSTEM Exploded View.
ELECTRICAL SYSTEM 16-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater temperature sensor 25 2.5 18 SS 2 Spark plugs 13 1.3 11 5 i n · l b 3 Alternator lead holding plate bolts 11 1.1 95 in·lb L 4 Starter motor mounting bolts 11 1.
16-8 ELECTRICAL SYSTEM Exploded View.
ELECTRICAL SYSTEM 16-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Regulator/r ectifier bolt s 6.9 0.7 62 in·lb 2 Fuel level sensor bol ts 6.9 0.7 62 in· lb 3 Side stand s witch bolt 8.8 0.9 78 in·lb 4 Neutral switch 15 1.5 11 5 Speed sensor bolt 6.
16-10 ELECTRICAL SYSTEM Specif ications Item Standard Battery: Ty p e Sealed Battery Capacity 12 V 8 Ah Vo l t a ge 12.6 V or more Charging System: Ty p e Three–phase AC Alternator out put voltage 42 V or more Stator coil resist ance 0.3 ∼ 0.4 Ω Charging voltage 14.
ELECTRICAL SYSTEM 16-1 1 Special T ools and S ealant Hand T e ster: 57001–139 4 Flywheel Puller , M 38 × 1.5: 57001–140 5 Rotor Holder: 57001–154 3 Lead Wire- Peak V oltage A dapter: 57001–144 9 Kawasaki B ond (Silico ne Sealan t): 56 019–120 Rotor Pu ller , M 16/M18/ M20/M22 × 1 .
16-12 ELECTRICAL SYSTEM Wiring Diagram (U .S.A. and C anada).
ELECTRICAL SYSTEM 16-13 Wiring Diagram ( U.S.A. and Can ada).
16-14 ELECTRICAL SYSTEM Wiring Diagram (Au stralia).
ELECTRICAL SYSTEM 16-15 Wiring Diagram ( Australia).
16-16 ELECTRICAL SYSTEM Wiring Diagram (O ther than U.S .A., Canada, A ustralia, and Ma laysia).
ELECTRICAL SYSTEM 16-17 Wiring Diagram (Othe r than U.S.A., Ca nada, Aus tralia, and Mala ysia).
16-18 ELECTRICAL SYSTEM Wiring Diagram (M alaysia).
ELECTRICAL SYSTEM 16-19 Wiring Diagram (Mala ysia).
16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servi cing electri cal systems. Learn and ob- serve a ll the rules below . ○ Do not reverse the batter y lead connections. This will burn out the diodes on the el ectrical p arts.
ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B].
16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • V isually inspect the wir ing for signs of burning, fraying, etc. If any wiring is poor , replace the damag ed wiring. • Pull each connector [ A] apart and inspect it f or corrosion, dirt, and damage.
ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect t he battery cabl es or any other electrical connections when the igniti on switch is ON, as this could damage the ECU (Electronic Con- trol Unit) . Never reverse the connections of the battery , this could damage the ECU.
16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] seali ng the filler por ts [B] until just before use. • Check to see that there is no peel ing, tears or holes in the seal sheet on the top of the battery . • Place the bat tery on a level s urface.
ELECTRICAL SYSTEM 16-25 Battery • Fit the seal caps [A] tightly into the f iller ports until the seal caps are at the same level as t he top of the battery . NOTE ○ Do not h am mer . Press down evenly with both hands. CAUTION Once you installed the seal caps after filling the bat- tery , never remove it, nor add any water or elec- trolyte.
16-26 ELECTRICAL SYSTEM Battery Precauti ons 1) No need of topping–up No topp ing–up is necess ary in this batt ery until it ends its life under normal use. F orcibl y prying off the se aling plug t o add w ater is very d angero us. Never do that .
ELECTRICAL SYSTEM 16-27 Battery Interchang e The sealed battery can fully disp lay its performance only when combined with a pr oper vehicle electr ic system. Therefore, repl ace the sealed batter y only on a motor cycle which was origi nally equipped with th e sealed battery .
16-28 ELECTRICAL SYSTEM Battery T ermina l V oltage: 1 1.5 ∼ le ss than 12.6 V Standa rd Char ge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery T erminal V oltage (V) [A] Charge T im e (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do stan- dard charge later on.
ELECTRICAL SYSTEM 16-29 Charging System Altern ator Cover Remova l • Remove: Frame Cover Bolts [A] Left Frame Cover [B] Clamp (open) [A] Alternator Lead Connector [B] ○ For California m odel, remove the separator . • Place a suitable con tainer under the alternator cover [A], and remove the cover bolts [B].
16-30 ELECTRICAL SYSTEM Chargi ng System Stator Coil Inst allation • Apply a non-permanent locki ng agent to the stator coil bolts a nd tighten it . T orque - Stator Coil Bolts: 1 1 N·m (1.1 kgf·m, 95 in·l b) • Secure the al ternator lead with a holding plate, and tighten t he bolt.
ELECTRICAL SYSTEM 16-31 Charging System • Install t he starter gea r [A]. • Again, clean the crankshaft t apered portion [B] and dry there. • Fit the woodruff key [C] securel y in the slot in the crank- shaft before instal ling the alternat or rotor .
16-32 ELECTRICAL SYSTEM Chargi ng System • Apply a thin co at of molybdenum disulfi de grease to the shaft [A], and inst all it and starter idle gear [B].
ELECTRICAL SYSTEM 16-33 Charging System If there is more resistance t han shown in t he table, or no hand tester readi ng (infinity) for any two leads, the stator has an open lead and must be replac ed. Much less than this resistanc e means the stator is shorte d, and must be replaced.
16-34 ELECTRICAL SYSTEM Chargi ng System • Do the 1st st ep regulator ci rcuit test: ○ Connect the test li ght and the 12 V battery to t he regula- tor/ re ctifier as shown. ○ Check BK1, BK2, and BK3 terminal respectively . If the test l ight turns on, the regulator /rectifier i s defective.
ELECTRICAL SYSTEM 16-35 Charging System Chargi ng V oltage Insp ection • Check the battery conditi on (see Battery section). • W arm up the engine to obtain actual alternator operating conditions.
16-36 ELECTRICAL SYSTEM Chargi ng System Charging System Circuit 1. Ignition Sw itch 2. T o Starter C ircuit Relay 3. Alternator 4. Regulator/Recti fier 5.
ELECTRICAL SYSTEM 16-37 Ignition System WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engi ne is running, or you could receive a severe electri cal shock.
16-38 ELECTRICAL SYSTEM Ignition System Crankshaft S ensor Installa tion • Route the crankshaft sensor lead corr ectly (see Cable, Wire, a nd Hose Routing in Appendix chapter).
ELECTRICAL SYSTEM 16-39 Ignition System Cranks haft Se nsor Resis tance: 375 ∼ 565 Ω • Using the highest resistance range of the tester , m easure the resistance between the cr ankshaft sensor leads and chassis ground.
16-40 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal • Remove: Fuel T a nk (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) ○ Push th e tongue [B] upside and take out the connector from th e bra cket .
ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Posit ion Sensor Peak V oltage Inspecti on • Remove: Fuel T ank (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) • Set the hand tester [B] to t he 10 V DC range.
16-42 ELECTRICAL SYSTEM Ignition System • Remove the stick coi l harness [A] from the br acket. • Remove: Stick C oil Connector #4 [B] (di sconnect) Stick Coil #4 [C] Stick Coil Connector #3 [D] (.
ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil ( Ignition Co il togethe r with Spark Plug Cap) Inspectio n • Remove the stick coil s (see this chapter ). • Measure the primar y winding resi stance [A] as fol lows. ○ Connect the hand tester between t he coil terminals.
16-44 ELECTRICAL SYSTEM Ignition System W ARNING T o avoid extremely high volt age shocks, do not touch the spark plugs or tester connections. • T urn the ignition switch and the engine stop switch ON. • Pushing the sta rter button, turn the engine 4 ∼ 5 seconds with the t ransmission in neut ral to measure t he primary peak voltage.
ELECTRICAL SYSTEM 16-45 Ignition System Inte rlock O pera tion In sp ectio n • Remove: Seats (see Frame chapter) Junction Box (see this chapt er) ○ Do not disconnect the connect ors. 1st Check • Measure the terminal voltage of the G/BK lead in the junc- tion box connector [A] in accordance wit h the following procedure.
16-46 ELECTRICAL SYSTEM Ignition System IC Ignite r Inspecti on ○ The IC Igniter is bui lt in the ECU [A] . • Refer t o the Interl ock Operation Inspection, Ignition System T roubleshooting Chapter and Fuel System (DFI) chapter for ECU Inspection.
ELECTRICAL SYSTEM 16-47 Ignition System.
16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Sw itch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Stick Coils 6. Side Stand Switch 7. Crankshaft Sensor 8. Camshaft Position Sen- sor 9. Throttle Sensor 10. Neutral Switch 1 1.
ELECTRICAL SYSTEM 16-49 Electric Star ter System Starter M otor Removal CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Remove the mounting bolts [A]. • Pull out the starter motor [ B]. • Slide back the rubber cap [A].
16-50 ELECTRICAL SYSTEM Electric S tarter Sys tem ○ The brush plate [A] and brushes come off with the right–hand end c over [B]. • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate [C] from the right–hand end cover .
ELECTRICAL SYSTEM 16-51 Electric Star ter System • Align the l ine [A] marked on the yoke wi th the throug h bolt hole [B]. Brush Ins pection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the car bon brush holder assembly [B ] and the terminal bolt assembly [C].
16-52 ELECTRICAL SYSTEM Electric S tarter Sys tem NOTE ○ Even if the foregoi ng checks show the armatur e to be good, i t may be defective in some manner not readi ly detectable wi th the hand tester .
ELECTRICAL SYSTEM 16-53 Electric Star ter System • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Speci a l T ool - Hand T e ster : 57001– 1394 If the relay d oes not work as specified, t he relay is defec- tive.
16-54 ELECTRICAL SYSTEM Lighting Syst em This models adopt the day light system and ha ve a head- light relay in t he junction box. In these models, the head- light d oes not go on when the i gnition switch and the engine stop switch ar e first tur ned on.
ELECTRICAL SYSTEM 16-55 Lighting System Headli ght Bulb Replacement • Remove: Headlight Connector [ A] Headlight Bulb Dust Cover [ B] • Remove: Hook [A] Headlight Bulb [ B] CAUTION When handling the quartz–halogen bulb, never touch the glass port ion with bare hands.
16-56 ELECTRICAL SYSTEM Lighting Syst em • Fit the dust cover [A] with t he arrow mark upward onto the bulb [B] fi rmly as shown. Good [C ] Bad [D] Arrow Mark [E] • After i nstall ation, adjust the headlight aim (see this chap- ter).
ELECTRICAL SYSTEM 16-57 Lighting System • Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • Replace the bulb with a new one.
16-58 ELECTRICAL SYSTEM Lighting Syst em Headlight/T ail Light Circuit (US, CA, AS) Headlight/T ail Light Circuit (Other than US, CA, AS) US: U nited St ates of A me rica CA: Canada AS: Australia 1. Ignition Sw itch 2. Meter Ground 3. Alternator 4. Headlight Diodes 5.
ELECTRICAL SYSTEM 16-59 Lighting System T urn Signal Light Circuit US: U.S.A. m odel CA: Canada model MY : Malaysia m odel 1. Joint Connector D 2. Meter Unit 3. Right Tur n S ignal Indicator Light (LED) 4. Left T urn Signal Indicator Light ( LED) 5. Front R ight T urn Signal Light 6.
16-60 ELECTRICAL SYSTEM Lighting Syst em • Push and tur n the bulb [ A] counterclockwi se and remove it. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower groo ves [C] in the socket, and turn the bulb cl ockwise.
ELECTRICAL SYSTEM 16-61 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the up per and lower grooves [C] in t he socket, and turn the bulb cloc kwise. CAUTIO N The front turn signal/running positi on lights use a vibration resistant bulb.
16-62 ELECTRICAL SYSTEM Lighting Syst em • Unscrew the bolts [A] . • Loosen the bol ts [B]. • Unscrew the mounting s crews [A]. • Remove the tai l/brake light (LED) [B]. ○ Pull out the mount portion [C]. T a il/Brake Ligh t (LED ) Install ation • T ighten the tail/brake l ight mounting screws.
ELECTRICAL SYSTEM 16-63 Radiator Fan S ystem Fan System C ircuit Inspection • Disconnect th e lead connector [A] from the radi ator fan switch. • Using an auxiliar y wire [A], connect the radiator f an switch leads. If the fan rotates, inspec t the fan switch.
16-64 ELECTRICAL SYSTEM Radiator F an Syste m Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Joint Connector A 4. Joint Connector D 5. Meter Ground 6. Frame Ground 7. Joint Connector B 8. Junction Box 9. Fan Fuse 10A 10. Main Fuse 30A 1 1.
ELECTRICAL SYSTEM 16-65 Meter , Gauge, Indic ator Unit Met er Unit R emova l • Remove: Wind Sealed (see Fr ame chapter) • Slide the dust cover [A] and remove th e wiring connector [B]. • Remove the meter unit by taking of f the mounting screws [C] with the washers.
16-66 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit Electro nic Combin ation Mete r Unit Insp ection • Remove the meter uni t [A]. [1] Ignition [10] Batter y (+) [2] Fuel Reserv e Switch [1 1] Oi.
ELECTRICAL SYSTEM 16-67 Meter , Gauge, Indic ator Unit MODE AND R ESET BUTTON Operation Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Displ ay (LCD) S eg- ments Check".
16-68 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit • In the HOUR sett ing mode, press the RESET button to eff ect the MINUTE setting mode. ○ The min ute display flashes on t he display . • Press the MODE button to set the minute. • In the MINUTE s etting mode, press the RESET button to return to t he HOUR/MINUTE setting mode.
ELECTRICAL SYSTEM 16-69 Meter , Gauge, Indic ator Unit • If the osci llator is not avai lable, the speedo meter can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel of f the ground, using the jack. ○ T urn on the ignition switch.
16-70 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit W ater T emperature Meter Check: • Connect the 12 V battery and terminals in the same man- ner as s pecified in the "Liqui d Crystal Display (LCD) Seg- ments Check". • Connect the variabl e rheostat [A] to t he terminal [8] as shown .
ELECTRICAL SYSTEM 16-71 Meter , Gauge, Indic ator Unit Fuel Level Gauge Inspection: • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Connect a variable r heostat [A] to terminal [4] and [9] as shown.
16-72 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit • If the oscil lator is not availabl e, the tachometer can be checked as follows. ○ Connec t the 12 V battery and terminals in the same man- ner as specified in the "Liqui d Crystal Display (LCD) Seg- ments Check".
ELECTRICAL SYSTEM 16-73 Meter , Gauge, Indic ator Unit Right and Left T urn Signal Indicator Light (LED): For Right T urn Signal Indicator Light (LED) Battery Positive (+) T erminal to T erminal [13] .
16-74 ELECTRICAL SYSTEM Meter , Gauge, Ind icator Unit Meter Circuit 1. Right T urn Signal Indicator Light (LED) 2. High Beam Indicator Light (LED) 3. Neutral Indicator Light (LED) 4. Oil Pressure War ning Indicator Light (LED) 5. FI Indicator Light (LED) 6.
ELECTRICAL SYSTEM 16-75 Switches an d Sensors Brake Lig ht Timing Inspe ction • Refer to the Brakes i n the Periodic Maint enance chapter . Brake Lig ht Timing Adj ustment • Refer to the Brakes i n the Periodic Maint enance chapter .
16-76 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the connector [A]. • Remove the fan swit ch [B]. • Suspend the switch [A] in a container of coolant so that the temperature–s ensing projection and threaded port ion are submerged.
ELECTRICAL SYSTEM 16-77 Switches an d Sensors • Suspend the sensor [A] in a container of coolant so that the temperature- sensing projection [ E] and threaded por- tion [E] are submerged. • Suspend an accurate ther mometer [B] in the coolant. NOTE ○ The sensor and ther mometer must not touch the con- taine r side or bottom.
16-78 ELECTRICAL SYSTEM Switches and Sensors • Remove: Bolts [A] Speed S ensor Cover • Remove: Bolt [A] • T ake out the speed sensor [B]. • Connect the speed sensor connector [A] with the battery [B], 1 0 k Ω resistor [C] and hand tester [D] as shown.
ELECTRICAL SYSTEM 16-79 Switches an d Sensors Fuel L evel S enso r Ins pection • Remove: Fuel T ank (see Fuel System (DFI) chapter) • Ope n th e cla mps [ A]. • Remove: Bolts [B] Fuel Level Sensor [C] • Check that the float moves up and down smoothly without binding.
16-80 ELECTRICAL SYSTEM Switches and Sensors • Connect the test li ght [A] (12 V 3.4 W bulb a s ocket with leads) and th e 12 V battery [ B] to the fuel level sensor connec tor [C].
ELECTRICAL SYSTEM 16-81 Junction Box The junction box [A] has f uses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapt er). • Remove the junction box [A]. • Pull of f the connectors [A] f rom the junction box [B] .
16-82 ELECTRICAL SYSTEM Junction Bo x Starter Circu it/Headli ght Relay Inspe ction • Remove the junction box (see Junction Box Fuse Circuit Inspec tion). • Check conductivit y of the followi ng numbered terminals by connecting the hand tester and one 12 V battery to the junct ion box as shown.
ELECTRICAL SYSTEM 16-83 Junction Box Diode Circuit Inspection • Remove the junction box . • Check conductivi ty of the follo wing pairs of termi nals.
16-84 ELECTRICAL SYSTEM Fus e 30A Main Fuse Removal • Remove: Right S ide Cover (see Frame chapter) 30A Main Fuse Connect or [A] • Pull out the main fuse [B] from the starter relay with needle nose pl ier s. Junction Bo x Fuse Remo val • Remove the seats (see Frame chapter).
APP ENDI X 17- 1 17 Appendix T able of Con tents Cable , Wir e, a nd Hos e Rou ting ...... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... ...... .... ...... .... ...... ..... . 17-2 T roubleshooting Guide ......... ........... ....
17-2 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APP ENDI X 17- 3 Cable, Wire, and Hose Routing 1. Fixes by the left side cla mp of the tank. 2. T ank drain hose passes the side cover inst allation under the br acket. 3. Air cl e aner drain hose 4. Fuel tank drain hose 5. Cooling reserve tank hos e 6.
17-4 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APP ENDI X 17- 5 Cable, Wire, and Hose Routing 1. Clutch cable 2. Meter ground 3. Clamp ( Ignition switch connector) 4. Ignition swit ch connector 5. Inlet air pressure sensor 6. T o ign it ion coi l 7. Fan motor connector (Connect the con- nector on the inlet air pressur e sensor .
17-6 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APP ENDI X 17- 7 Cable, Wire, and Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Igniti o n switch connector 4. Meter ground (with thermostat) 5. Engine harness (Connect the harness on the cross pipe.
17-8 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APP ENDI X 17- 9 Cable, Wire, and Hose Routing 1. T ail light 2. Clamp 3. Atmosp heric pres sure sensor 4. T o ECU fuse 5. Junction Box 6. T o sel f-diagnosis indicat or terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10.
17-10 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APPENDIX 17-1 1 Cable, Wire, and Hose Routing 1. Clamp all the wires as shown in the encircled area. 2. Meter 3. T ake ou t the lead of the meter from the r ight side of the tie lap to connect with the meter . 4. Clutch cab le 5. Starter cable 6. T o fro nt left tur n signal light (Run the harn ess above the bolt for fairing i nstallation.
17-12 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APPENDIX 17-1 3 Cable, Wire, and Hose Routing 1. Clamp 2. Brake hose 3. Punch m ark 4. Run the brake hose through the inside of the frame. 5. T ight the bolt to the speci fied torque with t he stopper (for turni ng prevention) applied.
17-14 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APPENDIX 17-1 5 Cable, Wire, and Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head t o secure the coupler .) 2. Radiat or fan switch lead (Run the l ead through into the water hose.) 3. Cap 4. Catch cable (Run the cable through forwar d the water hose.
17-16 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APPENDIX 17-1 7 Cable, Wire, and Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Run the lead end till i t touches the boss of t he crankcase. 4. Install the exterior of the lead wit h staking area facing downward.
17-18 APPENDIX Cabl e, Wir e, and Hos e Ro utin g.
APPENDIX 17-1 9 Cable, Wire, and Hose Routing 1. Run the hose (cap – reserve) through upside of the throttle cabl e. 2. Run the hose (white) through into the th rottle cables . 3. Run the throttle body harness throttle upsi de of the hos e (white) and hose ( throttle – fitting) .
17-20 APPENDIX T roubleshooting Guide NOTE ○ Refer to the Fuel System chapt er for most of DFI t rouble shootin g guide. ○ This is not an exhaust ive list, giving every possible cause for each problem li sted. It is mea nt simply as a rough guide to assist the troubl eshooting for some of the more common difficul ties.
APPENDIX 17-2 1 T ro ubleshooting Guide Air cleaner duct loose Compression low: Spark p lug loose Cylinder head not suff iciently ti ghtened down No va lv e clear ance Cylinder , piston worn Piston ri.
17-22 APPENDIX T roubleshooting Guide Muffler overheati ng: For KLEEN, do not run the en gine even if with on ly one cylinder misfi ring or poor running (Request the nearest service fa- cility to corr.
APPENDIX 17-2 3 T ro ubleshooting Guide Abnormal Eng ine Noise: Knocking: IC igni ter in ECU trouble Carbon built up i n combustion chamber Fuel poor quality or incorrect Spark pl ug incorr ect Overhe.
17-24 APPENDIX T roubleshooting Guide Handling and /or Stability Unsatisfacto ry: Handle bar hard to turn: Cable routin g incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut to.
MODEL APPLICA TION Y ear Model Beginning Frame No. 2003 ZR1000–A1 JKAZRCA1 □ 3A000001 ZRT00 A–000001 JK AZRT00AAA000001 2004 ZR1000–A2 JKAZRCA1 □ 4A015001 JKAZRT00AAA015001 ZRT00 A–015001 □ :This digit in the frame number changes from one machine to another .
デバイスKawasaki Z1000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 Z1000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 Z1000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 Z1000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 Z1000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 Z1000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 Z1000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 Z1000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 Z1000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。
