Home

Be sure the battery is fully charged

1. Terminal 1 Subthrottle Valve Actuator GY R 2 Unused 3 Unused 4 Fuel Pump Relay BR Y 5 Power Supply to Sensors BL 6 Power Supply to ECU from ECU Main Relay W G 7 Air Switching Valve R BL 8 Power Supply to ECU from Battery W BK 9 Oxygen Sensor Heater P BK 10 Injector 4 BL G 11 Injector 3 BL O 12 Subthrottle Valve Actuator V 13 Unused 14 Unused 15 Intake Air Temperature Sensor R BK 16 Intake Air Pressure Sensor 2 G W 17 Intake Air Pressure Sensor 1 Y BL 18 Radiator Fan Relay P BL 19 Vehicle down Sensor Y G 20 Crankshaft Sensor Y 21 Crankshaft Sensor Y BK 22 Speed Sensor P 23 Subthrottle Valve Actuator BK O 24 Subthrottle Valve Actuator G BL 25 Side Stand Switch G BK GC17558bEW2 FUEL SYSTEM DFI 3 19 DFI System 26 Main Throttle Sensor Y W 27 Subthrottle Sensor BL W 28 Unused 29 Water Temperature Sensor O 30 Ground for ECU BK BL 31 Warning Indicator Light LED Meter Unit BR R 32 Oxygen Sensor BL Y 33 Ground for Sensors G 34 Injector 2 BL R 35 Starter Button R BK 36 Injector 1 BL BK 37 Engine Stop Switch R BK 38 Stick Coil 4 BK G 39 Stick Coil 3 BK O 40 Stick Coil 1 BK 41 External Communication Line Immobilizer System KDS LG BK 42 Unused 43 Neutral Switch LG 44 Starter Lockout Switch R G 45 Unused 46 Immobilizer Amplifier V 47 Stick C
2. 58 4 Rear Caliper Disassembly pp Rear Caliper ASsembly aa Caliper Fluid Seal Damage Inspectigom Caliper Dust Seal Damage Front Caliper Dust Boot and Friction Boot Damage Inspection ZR800C Model Rear Caliper Dust Boot and Friction Boot Damage Caliper Piston and Cylinder Damage Front Caliper Holder Shaft Wear Inspection ZR800C 2 Rear Caliper Holder Wear Inspection pp Brake Pads cleats Aan ire et ea Ne Raed Front Brake Pad Removal 0 eene nennen nnne nnns Front Brake Pad Installation pp Rear Brake Pad Removal rd Ea erg te rie aede Rear Brake Pad Installation pp Brake Pad Wear Inspection 00 0071 0 60 00000060000 000 000000 Master Cylinder Hee M tert aba stri iat Reden Front Master Cylinder Removal pp Front Master Cylinder Installation idiot dni ne ERE e Rear Master Cylinder Removal cie Loi Leer Ree Reed diet dee Rear Master Cylinder Installation eene Front Master Cylinder Disassembly pp Rear Master Cylinder Disassembly 4 Master Cylinder Asse
3. GC17477FS1 e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with the fuel hose C both ends with the clamps D as shown Upside View E OApply soap and water solution to the areas F as shown OWatching the pressure gauge squeeze the pump lever G and build up the pressure until the pressure reaches the maximum pressure Injector Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi NOTICE During pressure testing do not exceed the maxi mum pressure for which the system is designed 8017478 52 C 3 124 FUEL SYSTEM Fuel Injectors OWatch the gauge for at least 6 seconds x If the pressure holds steady the fuel line is good x If the pressure drops at once or if bubbles are found in the area the fuel line is leaking Replace the delivery pipe assy injectors and related parts ORepeat the leak test and check the fuel line for no leak age e Install Fuel Outlet Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation e Start the engine and check for fuel leakage Fuel Injector Circuit GCci7520FW2 C 1 Ignition Switch 11 Battery 12 V 8 Ah 2 Engine Stop Switch 12 Starter Relay 3 Fuel Injector 1 13 Main Fuse 30 A 4 Fuel
4. feds 3 125 Free Play MS OS CHO 22 bee 3 125 Free Play Adjustmentin lg a RE aM 3 125 Gable Installation oie 3 125 Cable Lubrication 3 125 Throttle Body FS Sy 3 126 Idle Speed 3 126 Synchronization Inspection Adjustment 3 126 Throttle Body Assy Removal pp 3 126 Throttle Body Assy InstallatiQDi retra out here eor emer 3 129 Throttle Body Assy Disassembly pp 3 130 Throttle Body Assy Assembly ee poe ear er e ee aak 3 131 AIP CIC AMG 3 133 Air Cleaner Element Removal Installation pp 3 133 Air Cleaner Element Inspection ppp 3 133 Air Cleaner Oil Draining anto ere tor oe ote nde ERA TUM Iu Cl eu tM ne ES 3 133 Air Cleaner Housing tp eue trece evt peas Eat 3 133 Fuel lank Mm 3 134 Fuel Tank Removal iia sia repeti ener ed aet t b P eds 3 134 Fuel Tank Installation pp 3 136 Fuel Tank and Cap Inspection pp 3 138 Fuel Tank CIeanlrig x tack den Ete dura ind 3 138 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM
5. Camshaft Camshaft Chain Camshaft Removal Camshaft Installation Camshaft Camshaft Cap Wear Inspection pp Camshaft Runout Inspection Cam Wear Inspection Camshaft Chain Removal Cylinder Head Cylinder Compression Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp Inspection 5 16 5 17 5 17 5 17 5 19 5 19 5 19 5 20 5 20 5 20 5 21 5 22 5 22 5 22 5 23 5 23 5 24 5 24 5 26 Valve Clearance Inspection Valve Clearance Adjustment Valve Valve Installation Valve Guide Removal Valve Guide Installation Valve to Guide Clearance Measurement Wobble Cylinder Cylinder Remowval Cylinder Installation Piston Removal pp Piston Installation Cylinder Wear Inspection Piston Wear Inspection Piston Ring Piston Ring Groove Wear Inspection Piston Ring Groove Width 1 5 Piston Ring Thickness Inspection Piston Ring End Gap Inspection Throttle Body Holder
6. 2 14 System aaa 2 14 Air Cleaner Element Cleaning pp 2 14 Air Cleaner Element 2 14 Idle Speed 2 16 Idle Speed AdJUSlTienl ag Gee secede le exact eee Wenn sages 2 16 Throttle Control System Inspectigm cessent nennen nnns 2 16 Engine Vacuum Synchronization 2 17 PUG SV StS PIE 2 20 Fuel Hose 2 22 Cooling Syste 2 25 Coolant Level Inspection 2 25 Cooling Systems T 2 25 Coolant Charge RU A Ud 2 25 Water Hose and O ring 1201 intente entend nnns 2 28 Engine End 2 28 Valve Clearance Inspection 2 28 Valve Clearance Adjustment o aeneis o Ree 2 30 Air Suction System Damage Inspection pp 2 33 GUC LEM Aceh hb 2 33 Clutch Operation 2 33 Engine EUDrICa Ore eo reet haste del
7. 14 5 Steering 5 9 sannta 14 5 Steering edett 14 6 Stem Stem Bearing Removal pp 14 6 Stem Stem Bearing Installatiom 14 7 Steering Stem Bearing Lubrication 21 4 1 2 2 emen nnne 14 8 Steering Stem Warp Inspection pp 14 9 Stem Cap Deterioration Damage Inspection 14 9 FIANGIGD AR DITE REORUM 14 10 Handlebar Removal nie eet e e Rives even pe e eee elie 14 10 Handlebar Installation 2 14 10 14 2 STEERING Exploded View Exploded View STEERING 14 3 Torque No Fastener Navi Kati 1 Handlebar Holder Bolts 25 2 5 18 S 2 Rear View Mirror Locknut Upper 18 1 8 13 Lh View Mirror Nut Lower 30 3 1 22 4 Switch Housing Screws 3 5 0 36 31 5 Upper Front Fork Clamp Bolts 20 2 0 15 6 Steering Stem Head Bolt 108 11 0 79 7 7 Lower Handlebar Holder Nuts 34 3 5 25 R 8 Steering Stem Nut 27 2 8 20 9 Lower Front Fork Clamp Bolts 20 5 2 09 15 1 AL AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tighten torque G Apply grease L Apply a non permanent locking agent Lh Left hand Threads R
8. oe ee ls 910 9704081851 3 60 FUEL SYSTEM DFI Intake Air Temperature Sensor Service Code 13 e Turn the ignition switch off xIf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Intake Air Temperature Sensor Connector B R BK lead ECU terminal 15 C G lead ECU terminal 33 D x If the wiring is good check the intake air temperature sen sor resistance see Intake Air Temperature Sensor Resis tance Inspection GC17815ES1 Intake Air Temperature Sensor Resistance Inspection e Remove the intake air temperature sensor see Intake Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring
9. 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 3 38 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Actions chapter Firing incorrect Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Water or foreign matter in fuel Replace see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel injector clogged Inspect and repair
10. 0704218852 C 3 42 FUEL SYSTEM DFI Self Diagnosis e Push the left button A to display the odometer e Push the left button for more than two seconds The service code B is displayed on the LCD by the num ber of two digits e Any of the following procedures ends self diagnosis OWhen the service code is displayed on the LCD push the left button for more than two seconds The display will return to the previous display OWhen the ignition switch is turned off GT04220BS2 C FUEL SYSTEM DFI 3 43 Self Diagnosis Self Diagnosis Flow Chart Turn the ignition switch off Turn the ignition switch on Display the odometer and push the left button for more than two seconds Then self diagnosis mode starts i The service code s is displayed on the LCD Liquid Crystal Display Turn the ignition switch off Locate the problem with the service code table and inspect and repair the faulty system according to inspection procedure on all the service codes Turn the ignition switch on Make sure the yellow engine warning indicator light LED and or immobilizer warning symbol go off Run the engine for several minutes at idling and run the motorcycle at 30 km h 18 mph or above in order to confirm no problem END 0 17427 F 3 44 FUEL SYSTEM DFI Self Diagnosis Service Code Reading OThe service code s is displayed o
11. 9 mmn 1 Joint 9 Connector A 8 Front Right Turn Signal iz Front Left Turn Signal D D K Y BK Y Light 12V10W Meter Unit 1 ellow ABS Indicator Light LED 2 Yellow Engine Warning Indicator Light LED Fuse Box 1 3 Green Neutral Indicator ignition Fuse 15 Light LEB 2 Headlight Fuse 15 4 Blue High Beam Indicator 3 Brake Horn Fuse 7 Light LED 4 Turn Signal Relay Fuse 7 5A Green Left Turn Signal 5 ABS Fuse 30 Indicator Light LEB G reen Right Turn Signa Indicator Light LED Red Warning Indicator Light Battery Oil Pressure Water Temperature Immobilizer LED Speedometer Mileege Cruising Range Fuel Level Gauge Tachometer Mater Temperature Meter Odometer Trip Weter Clock Illumination Light LED arero Left Switch Housing LED Light Emitting Diode 1 Button 2 Turn Signal Switch 3 Hazard Switch 4 Dimmer Switch 5 Passing Button 6 Starter Lockout Switch TA H Light 1275 Headlight R Y Low aK 127558 998 E High 12v558 T Left City D Light 12V5W GIZA Relay Box Fuel Pump Relay Starter Circuit Relay 1 Radiator Fan Relay ABS 2 Headlight Circuit Relay Hydraulic 3 EGU Main Relay Unit 4 5 LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Switch Turn Signal Switch Dimmer Swi
12. Kawasaki Z800 ABS 7 4 gt p gt x 77 fe 1 f jj AA Y a Mets 26 2 mt 4 yp N 2 v A lt re N NN 2 S t XN n gt A T RON 2 a d a i Ame Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System a Ol I Appendix Z800 Z800 ABS Kawasaki Motorcycle service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan
13. After tightening the pulley bolt confirm whether pulley A is an angle shown 41 7 7 B OThis position is original position of the pulley NOTE OCorrect the position electrically after confirming the use is discontinued and there is no damage when differing from the angle of shown in the figure NOTICE 6617863651 Do not correct the pulley position with the tool forcibly The actuator damage will occur x If the pulley angle is wrong adjust the angle as follows OConnect 2 pins Connector 3 pins Connector OTurn the ignition switch on OConfirm the pulley turns clockwise and then counterclock wise OThe pulley stops at this side of the original position by the learning control OThe pulley returns to the original position 3 98 FUEL SYSTEM DFI Exhaust Butterfly Valve Actuator Service Code 63 ZR800A B Models x If the position is not within the specified angle above ad just the angle as follows ODisconnect 2 Pins Connector 3 Pins Connector OConnect the 12 V battery to the 2 pins connector termi nals Connect the battery to one terminal first and con nect to another terminal lightly to adjust the pulley position until it returns to the original position Pink lead terminal A Gray lead terminal Clockwise Pink lead terminal and Battery terminal Gray lead terminal and Battery terminal Counterclockwise Pink lead terminal and Batt
14. GS Fe 3 E SN f p RAM 6 A Sea BAN 2 g A N GCci7521FW2 C 1 Delivery Pipe Assy 2 Main Throttle Sensor 3 Subthrottle Sensor 4 Subthrottle Valve Actuator 5 Throttle Body Assy 6 Fuel Injectors Do not remove disassemble or adjust the main throttle sensor subthrottle sensor subthrottle valve actuator throttle link mechanism and throttle body assy because they are adjust or set surely at the manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy Throttle Body Assy FUEL SYSTEM DFI 3 131 e Remove the throttle body assy see Throttle Body Assy Removal e Cut the band A e Remove the delivery pipe assy mounting screws B to pull out the injectors from the throttle body assy together with the delivery pipe assy C NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the throttle body e Pull out the injectors A from the delivery pipe assy B NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy NOTICE Never drop the fuel injector especially on a hard surface Such a shock to the injector can damage it Throttle Body Assy Assembly e Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air e Replace the O rings A
15. 12V558 Headlight High 12 55 te Left City R BR Y Light 12V5W GIZA Front Left Turn Signal 6 12V10W Meter Unit ABS Indicator Light Yellow Engine Warning Indicator Light LED Green Neutral Indicator Light LEB Blue High Beam Indicator Light LED Green Left Turn Signal Indicator Light LEB Green Right Turn Signal Indicator Light LED Red Warning Indicator Light Battery Oil Pressure Water Temperature Immobilizer LED Speedometer Wileage Gruising Range Fuel Level Gauge Tachometer Water Temperature Meter dometer Trip Meter flock Ut tumination Light LED LED Light Emitting Diode LED Fuse Box 1 Ignition Fuse 15 2 Headlight Fuse 15 3 Brake Horn Fuse 7 4 Signal Relay Fuse 7 5 ABS Fuse 30 Left Switch Housing Relay Box Horn Button 1 Radiator Fan Relay ABS 2 Torn Signal Switch 2 Headlight Circuit Relay Hydraulic 3 Hazard Switch 3 EGU Main Relay Unit 4 Dimmer Switch 4 Fuel Pump Relay 2 Passing Button 5 Starter Circuit Relay Starter Lockout Switch LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard i Turn Signal Switch Dimmer Switch Starter Lockout witch Passing Button W2L0780AW5 C ELECTRICAL SYSTEM 16 23 Wiring Diagram ZR800B with GPS Unit Sub VETOEEI dain Sub Throttle throttle en ims Speed Actuator
16. 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nem ftlb Remarks Water Pump Impeller Bolt 9 8 1 0 87 Water Pump Cover Bolts 11 1 1 97 Coolant Drain Bolt Water Pump 11 1 1 97 in lb Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 Cylinder Head Cover Bolts 9 8 1 0 87 Camshaft Cap Bolts L 45 mm 12 1 2 106 in Ib Camshaft Cap Bolts L 40 mm 12 1 2 106 in Ib Spark Plugs 13 1 3 115 in Ib Front Camshaft Chain Guide Bolt Upper 25 2 5 18 Cylinder Head Bolts M10 ids Cylinder Head Jacket Plugs 21 6 2 20 15 9 Cylinder Head Bolts M6 12 1 2 106 Camshaft Chain Tensioner Mounting Bolts 11 1 1 97 Front Camshaft Chain Guide Bolt Lower 12 1 2 106 in Ib Rear Camshaft Chain Guide Bolt 25 2 5 18 Camshaft Chain Tensioner Cap Bolt 20 2 0 15 Throttle Body Assy Holder Bolts 13 1 3 115 in Ib Throttle Body Assy Holder Clamp Bolts 1 1 0 11 10 in Ib Coolant Drain Bolt Cylinder 9 8 1 0 87 Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 0 70 61 in Ib Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 0 50 43 in Ib Exhaust Butterfly Valve Cable Adjuster Locknuts 6 9 0 70 61 in Ib Exhaust Butterfly Valve Cover Bolt 11 1 1 97 in lb Muffler Body Mounting Bolts 34 3 5 25 Muffler Body End Cover Bolts 11 1 1 97 in Ib Muffler Body Cover Bolts 6 9 0 70 61 in Ib Exhaust Pipe Manifold Holder Nuts 17 1 7 13 Muffler Body Clamp Bolt 17 1 7 13 Clutch
17. xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Exhaust Butterfly Valve Actuator Sensor Connector B BL lead ECU terminal 5 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 8017598 51 3 84 FUEL SYSTEM Exhaust Butterfly Valve Actuator Sensor Service Code 34 ZR800A B Models Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE OBefore this inspection confirm the pulley A is original position see Exhaust Butterfly Valve Actuator Installa tion e Disconnect 2 pins Connector B 3 pins Connector C e Connect the harness adapter A between the 3 pins con nectors Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Connect a digital meter to the harness adapter leads Exhaust Butterfly Valve Actuator Sensor Output Voltage Connections to Adapter Digital Meter BL actuator Y lead Digital Meter BK BL actuator BK lead e Measure the output voltage at the 3 pins connector of the exhaust butterfly valve actuator when the pulley is original position e Turn the ignition switch on O
18. MR telco aria cata 16 30 A Roy ea 16 31 Precautloriss ec eres 16 34 acre qao M M 16 34 Charging Condition Inspection aot tob te tutti oen Mel alata Lima amate emat 16 34 Refreshing Chargen Charging Systemi asie t Alternator Cover Removal pp Alternator Cover Installation Stator Coil REMOVAL E ES T T Stator Coll Installation oreet te ree e ect ree Date a Eve P eun Alternator e e e e ai ee ed dan Alternator Rotor Charging voltage Inspection pp Alternator enne nennen nnne Regulator Rectifier Inspection ignition Eel SUSI RT Crankshaft Sensor Removal ener Crankshaft Sensor Installation pp 16 45 Crankshaft Sensor Inspectigom pp 16 45 Crankshaft Sensor Peak Voltage 16 46 Timing ee 16 46 Timing dioe pinu 16 46 Stick Coil Remioval ie tet eh Roe ELE LED EUER 16 47 Stick Coll InstallatiOn ioo 16 47 Stick Coil Inspection orecchie there pre
19. 0 5second 0 5second oh GP30227C81 0 3second am Hh LLU UU UU UU UU GP30229CS1 _ GP302320S1 o 16 100 ELECTRICAL SYSTEM Immobilizer System NOTE OTurn the ignition switch to ON with the registered igni tion key OCheck that the engine can be started using all regis tered ignition keys ELECTRICAL SYSTEM 16 101 Immobilizer System All Keys Initial Registration Flow Chart 2 Blinking Patterns and Number 0 2second 1 gu S econd 0 Ssecand gt 2 8P ECU checks first 0 second isecosd ignon key NOTE4 gt Pr 9 03 9 2 1864 gt 4 8h 0 Seecord 5 ife Red indicat and symbol blinking NOTES NOTE 1 Key Subsbtute Time Insert next key and turn it to ON within 15 seconds after previous key is tumed to OFF Amplifier O Time of Transmitting and Receiving Messages 3 ECU confirms the Immobilizer Amplifer Failure Pattern 1 8 i following Immobikzer Amplifier Failure Pattern 1 Second Ignition Key Collation Error Patiem 5 Registered Ignition Key is inserted Pattern 2 6 ECU confirms the following O Ignition Key or Not O Match the Unique Code O Not ignition Key 7 When the ECU registered is turned to OFF ECU keeps the power on for two seconds And then in two seconds after the key is turned to OFF ECU turns the pow
20. 3 72 3 2 FUEL SYSTEM DFI Vehicle down Sensor Installation pp 3 72 Vehicle down Sensor Input Voltage Inspection pp 3 73 Vehicle down Sensor Output Voltage Inspection pp 3 74 Subthrottle Sensor Service Code 32 sessi 3 76 Subthrottle Sensor Removal Adjustment eese 3 76 Subthrottle Sensor Input Voltage Inspection pp 3 76 Subthrottle Sensor Output Voltage Inspection pp 3 77 Subthrottle Sensor Resistance Inspection pp 3 79 Oxygen Sensor not activated Service Code 33 3 80 Oxygen Sensor Removal Installation sees 3 80 Oxygen Sensor InspeoctiQE tec ie eter ey oae enar pe d ean 3 80 Exhaust Butterfly Valve Actuator Sensor Service Code 34 ZR800A B Models 3 83 Exhaust Butterfly Valve Actuator Sensor Removal Installation 3 83 Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection 3 83 Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection 3 84 Exhaust Butterfly Valve Actuator Sensor Resistance 3 85 Immobilizer Amplifier Service Code 35 3 86 Antenna Resistance Inspection pp 3 86 Amplifier Input Voltage Inspection pp 3 86 Bl
21. GE15043BS1 C GE15028BS1 C GE15045BS1 C 5 28 ENGINE TOP END Valves Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F NOTICE Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Using the valve guide driver A and attachment B press and insert the valve guide in until the attachment surface C touches the head surface 13 3 13 5 mm 0 52 0 53 in D Special Tools Valve Guide Driver 57001 1564 Valve Guide Driver Attachment C 57001 1624 e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 4 57001 1274 T 2 m 22 ij SSS GE15046BS1 C ENGINE TOP END 5 29 Valves Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a rig
22. Remove Bolts A Bracket B ABS Hydraulic Unit C NOTICE The ABS hydraulic unit A has been adjusted and set with precision at the factory Do not try to dis assemble and repair the ABS hydraulic unit BRAKES 12 65 Anti Lock Brake System Equipped Models ABS Hydraulic Unit Installation Installation is the reverse of removal Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e When installing the hoses and pipes avoid sharp bend ing kinking flatting or twisting and run the hoses accord ing to Cable Wire and Hose Routing section in the Ap pendix chapter e Tighten Torque Brake Hose Banjo Bolts ABS Hydraulic Unit 33 N m 3 4 kgf m 24 ft lb e Run the lead correctly and connect the connector se curely OPull the lever A forward to connect the ABS hydraulic unit connector B e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage e Install the removed parts see appropriate chapters ABS Hydraulic Unit Inspection e Remove the ABS hydraulic unit see ABS Hydraulic Unit Removal e Visually inspect the ABS hydraulic unit Replace the ABS hydraulic unit if any of them are cracked or otherwise damaged e Visually inspect the connector terminals A Replace the ABS hydraulic unit or main harness if either of t
23. Replace it if necessary Spring Tension Inspection e Since a spring becomes shorter as it weakens check its free length A to determine its condition xIf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Spring Free Length ZR800A B Models Standard 252 5 mm 9 94 in Service Limit 247 5 mm 9 74 in Spring Free Length ZR800C D Models Standard 262 mm 10 3 in Service Limit 257 mm 10 1 in GM04801BS1 C GM04128BS1 C 8 04011851 C 13 36 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment ZR800A B Models e To adjust the rebound damping force turn the lower damping adjuster A OThe standard adjuster setting is the 1 1 4 turns out from the fully clockwise position Rebound Damping Force Adjustment Adjuster Damping Setting Load Road Speed Position Force 2 2 4 turns out Counterclockwise Clockwise 1 Softer Harder STD i 0 2 1 Seated position adjuster turned fully clockwise GMO5504BS1 C Spring Preload Adjustment ZR800A B Models e Remove the rear shock absorber from the frame see Rear Shock Absorber Removal e Loosen the locknut and turn o
24. Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 31 F Total Amount 2 8 L 3 0 US qt PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Fill the radiator up to the filler neck A with coolant NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Check the cooling system for leaks Tap the water hoses to force any air bubbles caught in side e Fill the radiator up to the filler neck with coolant e Fill the reserve tank up to the F full level line A with coolant and install the cap B e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down x If the coolant level is lower than the L low level line C add coolant to the F level line Do not add more coolant above the F level line e Install the removed parts see appropriate chapters 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Thermostat Housing A see Thermostat Removal in the Cooling System chapter Water Pump Cover B see Oil Pump Removal in the Engine Lubrication System chapter O rin
25. 3 5 Exploded View mm 5s ERE 2 Throttle Body Cover Mounting Bolts 0 41 35 3 Delivery Pipe Assy Mounting Screws 38 0 36 31 in Ib 4 Throttle Body Assy Holder Clamp Bolts 1 1 0 11 10 in Ib 5 Air Cleaner Duct Screws 3 8 0 39 34 in Ib 6 Air Duct Clamp Bolts 1 1 0 11 10 in Ib 7 Air Cleaner Housing Tapping Screws 1 2 0 12 11 in Ib 8 Air Cleaner Housing Mounting Bolts 9 8 1 0 87 in lb 9 Throttle Cable Decelerator 10 Throttle Cable Accelerator 11 Fuel Injectors 12 Air Switching Valve 13 Main Throttle Sensor 14 Subthrottle Sensor 15 Subthrottle Valve Actuator 16 Pad ZR800A B Models 17 Air Cleaner Element 18 Intake Air Temperature Sensor CL Apply cable lubricant EO Apply engine oil G Apply grease O Apply 2 stroke oil R Replacement Parts 3 6 FUEL SYSTEM DFI Exploded View Exploded View FUEL SYSTEM DFI 3 7 No Fastener pem Vehicle down Sensor Bolts 5 9 0 60 52 in lb 5 9 2 Throttle Cable Plate Bolt 0 60 52 in lb 3 Water Temperature Sensor 12 1 2 106 in Ib 4 Oxygen Sensor 44 4 5 32 5 Speed Sensor Bolt 12 1 2 106 in Ib 6 Crankshaft Sensor Bolts 5 9 0 60 52 in lb 7 Vehicle down Sensor 8 Intake Air Pressure Sensor 2 9 Intake Air Pressure Sensor 1 10 Stick Coils 11 ECU 12 Relay Box 13 Speed Sensor G Apply gre
26. L1 9114706851 12 54 BRAKES Anti Lock Brake System Equipped Models Step 2 e Disconnect the ABS hydraulic unit connector A and check the yellow ABS indicator light LED for function OThe yellow ABS indicator light LED should goes on when the ignition switch turned on x If the indicator does not goes on go to next step x If the indicator goes on go to step Step 2 1 e Disconnect the connector from the meter unit see Meter Unit Removal Installation in the Electrical System chap ter e Check for continuity between the terminal 13 BL Y A of the ABS hydraulic unit connector and a frame ground B x If there is continuity repair or replace the main harness x If there is no continuity replace the meter unit with a new one Step 3 e Check the voltage between the terminal 9 BK A and terminal 7 BR W B of the ABS hydraulic unit connector Special Tool Hand Tester 57001 1394 OThe battery voltage 10 16 V should not appear while the ignition switch turned off x If the battery voltage appeared repair or replace the main harness x If the battery voltage does not appear go to next step Step 4 e Check the voltage between the terminal 9 BK A and terminal 8 W BK B of the ABS hydraulic unit connector Special Tool Hand Tester 57001 1394 OThe battery voltage 10 16 V should not appear while the ignition switch turned off x If the battery v
27. TREEREN 4 15 Thermostat Removal ER Lt 4 15 Thermostat instalation esiis e ea A nennen nennen nnne nennen 4 15 Thermostat IrisDectlOn oett te trt rer V a eo EAT tn 4 16 Hose and Pipes ier ie rH REM TUER BRE AE SERE RENE 4 17 dtr e tela Raed Hema 4 17 HOSE INSPOCUOM pe HL 4 17 Water Temperature Sensor 99999 nnne nennen nnne nnne 4 18 Water Temperature Sensor Removal Installation pp 4 18 Water Temperature Sensor Inspection pp 4 18 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View i 2 Reserve Tank Bons os 10 srme 3 Thermostat Housing Screws 26 927 23mb 4 Thermostat Housing Ciamp Bt 69 tim S Water Temperature Sensor 12 12 iombe 6 Radiator Bos 07 ormb T Water Hose Clamp Screws 30 amb Radiator Bracket Mounting Bt 69 970 tim 9 Coolant Drain Bot Cylinder 98 19 srme Cylinder Fiting Mounting Bots n 11 orme 12 WaerPumpimpelerBot os 10 Water Pump Cover Bos n 14 orme 14 Coolant Drain Bot Water Pump 1 11 ormb G Apply grease HG Apply high temperature grease L Apply a non permane
28. 8017801 51 C FUEL SYSTEM 3 91 Stick Coils 1 2 3 4 Service Code 51 52 53 54 Turn the ignition switch off x If the input voltage is out of the standard check the wiring for continuity see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the input voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Stick Coil Circuit GCi7516FW2 Ignition Switch Engine Stop Switch Stick Coil 1 Stick Coil 2 Stick Coil 3 Stick Coil 4 ECU Joint Connector D Frame Ground 3 10 Engine Ground 11 Battery 12 V 8 Ah 12 Starter Relay 13 Main Fuse 30 A 14 Fuse Box 1 15 Ignition Fuse 15 A 16 Joint Connector C 00 3 92 FUEL SYSTEM DFI Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal Installation OThe radiator fan relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter Radiator Fan Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter xIf the radiator fan relay is normal check the wiring for
29. The engine gets extremely hot during normal oper ation and can cause serious burns Never touch a hot engine Measure the output voltage with the connector joined Output Voltage without Plugs Standard DC 0 2 V or less Turn the ignition switch off xIf the reading is out of the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connectors A Oxygen Sensor Connector B BL Y lead ECU terminal 32 C Glead ECU terminal 33 x If the wiring is good replace the sensor x If the reading is within the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 3 82 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 Oxygen Sensor Circuit BK BL B IU eed S S N NE 9 0100 GC17515FW2 1 Ignition Switch 10 Starter Relay 2 Water Proof Joint 2 11 Main Fuse 30 A 3 Oxygen Sensor 12 ECU Fuse 15 A 4 Joint Connector E 13 Relay Box 5 ECU 14 ECU Main Relay 6 Frame Ground 4 15 Fuse Box 1 7 Frame Ground 1 16
30. Water Proof Joint 1 Subthrottle Sensor Intake Air Pressure Sensor 2 Intake Air Pressure Sensor 1 Water Temperature Sensor Crankshaft Sensor 3 14 FUEL SYSTEM DFI System OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Chocolate O Orange W White DG Dark Green P Pink Y Yellow G Green Terminal Numbers of ECU Connectors ZR800A B Models Terminal 1 Subthrottle Valve Actuator GY R 2 Exhaust Butterfly Valve Actuator W R 3 Exhaust Butterfly Valve Actuator W BL 4 Fuel Pump Relay BR Y 5 Power Supply to Sensors BL 6 Power Supply to ECU from ECU Main Relay W G 7 Air Switching Valve R BL 8 Power Supply to ECU from Battery W BK 9 Oxygen Sensor Heater P BK 10 Injector 4 BL G 11 Injector 3 BL O 12 Subthrottle Valve Actuator V 13 Unused 14 Unused 15 Intake Air Temperature Sensor R BK 16 Intake Air Pressure Sensor 2 G W 17 Intake Air Pressure Sensor 1 Y BL 18 Radiator Fan Relay P BL 19 Vehicle down Sensor Y G 20 Crankshaft Sensor Y 21 Crankshaft Sensor Y BK 22 Speed Sensor P 23 Subthrottle Valve Actuator BK O 24 Subthrottle Valve Actuator G BL 25 Side Stand Switch G BK GC17558bEW2 FUEL SYSTEM DFI 3 15 DFI System 26 27 E
31. Battery 12 V 8 Ah Stater Relay Main Fuse 30 A Immobilizer Kawasaki Diagnostic System ECU Fuse 15A ECU Main Relay Relay Box Fuse Box 1 Ignition Fuse 15 A Red Warning Indicator Light LED Meter Unit Joint Connector C Immobilizer Antenna Immobilizer Amplifier ECU Communication Error Service Code 39 FUEL SYSTEM DFI 3 89 ECU Communication Line Inspection OWhen the data is not sent from the ECU to the meter unit for more than about 10 seconds the service code 39 is displayed OThe service code 39 is detected with meter unit Remove the ECU and meter unit check the wiring for continuity between main harness connector ODisconnect the ECU and meter unit connectors Wiring Inspection ECU Connector A Meter Unit Connector B BRIR lead ECU terminal 31 C x If the wiring is good check the meter unit see Electronic Combination Meter Unit Inspection in the Electrical Sys tem chapter x lf the meter unit is normal replace the ECU see ECU Removal Installation ECU Communication Line Circuit 80178030651 6C17439FW2 1 Meter Unit 2 Yellow Engine Warning Indicator Light LED 3 Frame Ground 1 4 3 90 FUEL SYSTEM DFI Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil 3 Service Code 53 Stick Coil
32. x If there is no continuity go to step 3 Step 2 1 e Disconnect the rear wheel rotation sensor connector e Recheck the continuity between the terminal 9 BK A and terminal 6 W G B of the ABS hydraulic unit con nector x If there is continuity repair or replace the main harness there is no continuity replace the rear wheel rotation sensor Step 3 e Connect the rear wheel rotation sensor connector e Check for continuity between the terminal 9 BK A and terminal 15 BK O B of the ABS hydraulic unit connec tor x If there is continuity go to next step x If there is no continuity go to step 4 Step 3 1 e Disconnect the rear wheel rotation sensor connector A e Recheck the continuity between the terminal 9 BK and terminal 15 BK O of the ABS hydraulic unit connector x If there is continuity repair or replace the main harness x If there is no continuity replace the rear wheel rotation sensor Step 4 e Disconnect the rear wheel rotation sensor connector A e Check for continuity between the terminal 6 W G B of the ABS hydraulic unit connector C and terminal 2 W G D of the rear wheel rotation sensor connector main har ness side xIf there is no continuity repair or replace the main har ness x If there is continuity go to next step GL14713BS1 GL14719BS1 9114720851 Anti Lock Brake System Equipped
33. 0 0028 in Service Limit 0 17 mm 0 0067 in Second Standard 0 02 0 05 mm 0 0008 0 0020 in Service Limit 0 15 mm 0 0059 Piston Ring Groove Width Inspection e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Top A Standard 0 83 0 85 mm 0 0327 0 0335 in Service Limit 0 93 mm 0 037 in Second B Standard 0 81 0 83 mm 0 0319 0 0327 in Service Limit 0 91 mm 0 036 in xIf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Inspection e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Top A Standard 0 78 0 79 mm 0 0307 0 0311 in Service Limit 0 71 mm 0 028 in Second B Standard 0 78 0 79 mm 0 0307 0 0311 in Service Limit 0 71 mm 0 028 in any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston GE16182BS1 GE16070781 GE16070881 C Cylinder Pistons ENGINE TOP END 5 39 Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder u
34. 3 5 kgf m 25 ft lb Tie Rod Nut 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Inspection Remove the rear shock absorber see Rear Shock Ab sorber Removal e Visually inspect the following items Oil Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing x lf it show any signs of damage replace it Rear Shock Absorber Scrapping ZR800A B Models A WARNING Pressurized nitrogen may explode when heated The rear shock contains nitrogen gas To avoid an explosion do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Drill the hole A of the reservoir tank using about 2 mm 0 08 in drillbit A WARNING Pressurized gas can cause injury Do not point the drill toward your face or body GM05507BS1 13 40 SUSPENSION Rear Shock Absorber ZR800C D Models A WARNING Since the rear shock absorber contains nitrogen gas do not incinerate the rear shock absorber with out first releasing the gas or it may explode Before a rear shock absorber is scrapped drill a hole at the point A shown to release the nitrogen gas com pletely Wear safety glasses when drilling the hole as the gas may blow out bits of drilled metal when the hole opens GM05498BS1 C SUSPENSION 13
35. Both Sides e For ABS equipped models remove the rear wheel rota tion sensor from the caliper bracket see Rear Wheel Ro tation Sensor Removal in the Brakes chapter Remove the drive chain A from the rear sprocket toward the left Move the rear wheel back and remove it NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Apply high temperature grease to the grease seal lips e Fit the collars on the both sides of the hub Left Side Collar A with Flange Right Side Collar B e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the swingarm stop B e Install the right wheel alignment indicator to the axle e Insert the axle from the right side of the wheel e Install the left wheel alignment indicator e Tighten Torque Rear Axle Nut 108 11 0 kgf m 79 7 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole DALLAS 4 e e SN gt 2 gt 2 4 LITT e GJ04249BS1 WHEELS TIRES 10 9 Wheels
36. G1050304 6105041751 6105011451 9 24 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods eMeasure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter Crankcase Main Bearing Inside Diameter Marks O or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks O 36 000 36 008 mm 1 4173 1 4176 in 36 009 36 016 mm 1 4177 1 4179 in e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B None 45 4 3 2 1 9105221851 6105041751 Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92028 1868 3 5 1 Brown 92028 1829 1 2 4 1 92028 1867 3 5 Black 92028 1828 1 2 4 92028 1866 3 5 F 92028 1866 x TUR 92028 1827 1 2 4 bearing inserts for Nos 1 2 4 journals oil groove respectively e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 9 25 Starter Motor Clutch Starter M
37. GC17589ES1 C GC17116BS1 C 3 52 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Main Throttle Sensor Circuit ve ae GC17428FW2 1 Main Throttle Sensor 2 Water Proof Joint 1 3 Water Proof Joint 2 4 ECU FUEL SYSTEM DFI 3 53 Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor 1 Removal Never drop the intake air pressure sensor espe cially on a hard surface Such a shock to the sensor can damage it Remove the fuel tank see Fuel Tank Removal e Disconnect the intake air pressure sensor 1 connector A e Remove the bolt A e Disconnect the vacuum hose A and remove the rubber damper B from the intake air pressure sensor 1 C Intake Air Pressure Sensor 1H Installation NOTE OThe intake air pressure sensor 1 is the same part as the intake air pressure sensor 2 e Installation is the reverse of removal OPosition the intake air pressure sensor 1 A between the projections B on the rubber damper e Install the rubber damper on the bracket C as shown e Tighten Torque Throttle Cable Plate Bolt 5 9 N m 0 60 kgf m 52 in Ib 7 930 P 3 54 FUEL SYSTEM DFI Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor 1 Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove the fuel tank see Fuel Tan
38. GT04218BS2 C With the engine stopped and turned in the self diagnosis mode the service code A is displayed on the LCD Liquid Crystal Display by the number of two digits If the problem is with the following parts the ECU can not recognize these problem Therefore the yellow engine warning indicator light LED does not go on and service code is not displayed LCD for Meter Unit Fuel Pump Fuel Pump Relay Fuel Injectors Stick Coil Secondary Wiring and Ground Wiring ECU Main Relay ECU Power Source Wiring and Ground Wiring LF FS 0704219852 C Troubleshooting the DFI System FUEL SYSTEM DFI 3 29 When the service code A is displayed for first ask the rider about the conditions B of trouble and then start to determine the cause C of problem As a pre diagnosis inspection check the ECU for ground and power supply the fuel line for no fuel leaks and for correct pressure The pre diagnosis items are not indicated by the engine warning indicator light LED Don t rely solely on the DFI self diagnosis function use common sense Even when the DFI system is operating normally the yel low engine warning indicator light LED goes on may be displayed under strong electrical interference Additional measures are not required Turn the ignition switch off to stop the indicator light If the yellow engine warning indicator light LED of the motorcycle brought in for repair still goes o
39. LED Light Emitting Diode 1 Button 1 Radiator Fan Relay ABs 2 Turn Signal Switch 2 Headlight Circuit Relay Hydraulic 3 Hazard Switch 3 EGU Main Relay Unit 4 Dimmer Switch 4 Fuel Pump Relay 5 Passing Button 5 Starter Circuit Relay 6 Starter Lockout Switch LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard i Turn Signal Switch Dimmer Switch Starter Lockout witch Passing Button W2L0708CW5 C ELECTRICAL SYSTEM 16 27 Wiring Diagram ZR800D Sub Bein Sub Throttle throttle Speed Actuator Sensor Intake Intake water Oxygen n 0 Switoh pace Air hir en Side Sensor Pressure Pressure Z Stand F bog uel Injectors Sensore2 Sensors ensor P 8 g e fe ge ge x dao ae ee 55 nr 5 Ti i9 5 5 1 Water arean ze Joint LI 9 Li HH s i E Se 3 JU tt v B B BK Y BK Y BK Y SSS SSS BK BL 8K BL BK Y P Joint onnector E ECU BK Y BK Y BK Y Joint BK Y 8K 0 w a Connector D 48 Rear Wheel Rotation Sensor Rear Right Turn Signal Kawasaki Self di
40. Left Switch Housing 1 Horn Button Torn Signal Hazard Switch Switch Passing Button 2 3 4 Dimmer Switch 5 8 Starter Lockout Switch Relay Box Radiator Fan Relay Headlight Circuit Relay EGU Main Relay Fuel Pump Relay Starter Circuit Relay Rano Horn Button Hazard Switch LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button Color BK W BK Y Color 0 GY sorer R BKBL Y Color Push Push DFF Push Released TERRI ERES W2L0705CW5 C ELECTRICAL SYSTEM 16 17 Wiring Diagram ZR800A without GPS Unit Sub yerest le dain Sub Thrott1e throttle a Speed Actuator o Sonso Senear Intake Oxygen Air Side Sensor Pressure Pressure stead Fuel uel Injectors Sensors EJ ensor dy TV g g bs fe Se 2x eee amok mem aoe TE EE Ses Mater proof aes a 1 Tuum Joint 1 H Li E F D BL Y WA EY ED LL amt 3 a Hearst Fem 9 EXER m CETT TEE BK Y BK Y BK BL Joint 8K BL BK Y onnector E P ECU BK Y 20 Joint BK Y BY Connector D Rear Right aK Y Turn Signa
41. Make Type Usable Engine Speed Fuel Pressure High Pressure Line Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage Resistance Intake Air Pressure Sensor 1 2 Input Voltage Output Voltage Intake Air Temperature Sensor Output Voltage Resistance Water Temperature Sensor Resistance Output Voltage Speed Sensor Input Voltage Output Voltage Vehicle down Sensor Input Voltage 1 100 50 r min rpm Dual throttle valve 34 mm 1 34 35 3 1 3 kPa 265 10 mmHg at idle speed DENSO Digital memory type with built in IC igniter sealed with resin 80 11 600 r min rpm 294 kPa 3 0 kgf cm 43 psi with engine idling In tank friction pump 50 mL 1 7 US oz or more for 3 seconds INP 288 Fine atomizing type with 8 holes About 11 7 12 3 at 20 C 68 F DC 4 75 5 25 V DC 0 995 1 025 V at idle throttle opening DC 4 05 4 48 V at full throttle opening for reference 4 6 DC 4 75 5 25 V DC 3 80 4 20 V at standard atmospheric pressure see this text for details About DC 2 25 2 50 V at 20 C 68 F 2 21 2 69 at 20 C 68 F About 0 322 kQ at 80 C 176 F see the Electrical System chapter About DC 2 80 2 97 V at 20 C 68 F DC 4 75 5 25 V About DC 0 05 0 09 V or DC 4 5 4 9 V at ignition switch ON and 0 km h DC 4 75 5 25 V Specifications FUEL SYSTE
42. Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Water temperature meter incorrect Water temperature meter broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Sub clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift ratchet assembly spring broken Shift ratchet assembly broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output
43. Step 1 1 e Disconnect the front wheel rotation sensor connector A e Recheck the continuity between the terminal 9 BK and terminal 8 W BK of the ABS hydraulic unit connector x lf there is continuity repair or replace the main harness xIf there is no continuity replace the front wheel rotation sensor Step 2 e Check for continuity between the terminal 9 BK A and terminal 6 W G B of the ABS hydraulic unit connector x If there is continuity go to next step x If there is no continuity go to step GL14713BS1 12 58 BRAKES Anti Lock Brake System Equipped Models Step 2 1 e Disconnect the rear wheel rotation sensor connector e Recheck the continuity between the terminal 9 BK A and terminal 6 W G B of the ABS hydraulic unit con nector x If there is continuity repair or replace the main harness x If there is no continuity replace the rear wheel rotation sensor Step 3 e Connect the front wheel rotation sensor connector e Check for continuity between the terminal 9 BK A and terminal 17 BK W B of the ABS hydraulic unit connec tor x lf there is continuity go to next step x If there is no continuity go to step 4 Step 3 1 e Disconnect the front wheel rotation sensor connector e Recheck the continuity between the terminal 9 BK A and terminal 17 BK W B of the ABS hydraulic unit con nector x If there is continuity repair or replace
44. TDC TIR 5 lt inch s kilometers per hour liter s liquid crystal display light emitting diode pound s meter s minute s millimeters of mercury miles per hour newton s ounce s pascal s horsepower pound s per square inch quart s revolution revolution s per minute second s top dead center total indicator reading volt s watt s ohm s COUNTRY AND AREA CODES AU BR SEA B2 Australia Brazil Southeast Asia B2 WVTA FULL UK WVTA FULL WVTA 78 2 WVTA Model Full Power WVTA Model Left Side Traffic Full Power WVTA Model 78 2 kW Power Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean
45. Throttle Body Holder Installation Muffler Body Remowval Muffler Body Installation Exhaust Pipe Removal Exhaust Pipe Installation Exhaust Butterfly Valve Cable Removal ZR800A B Models Exhaust Butterfly Valve Cable Installation ZR800A B Models 5 27 5 27 5 27 5 27 5 27 5 27 5 28 5 29 5 29 5 30 5 35 5 35 5 35 5 36 5 36 5 37 5 37 5 38 5 38 5 38 5 39 5 40 5 40 5 41 5 41 5 43 5 45 5 46 5 46 5 47 5 2 ENGINE TOP END Exploded View GE025618W5 C ENGINE TOP END 5 3 Exploded View ro m o uem sa nm Air Suction Valve Cover Bolts 87 in lb 9 8 1 0 S Cylinder Head Cover Bolts 87 Camshaft Cap Bolts L 45 mm 106 in Ib Camshaft Cap Bolts L 40 mm 106 in Ib Spark Plugs 115 in Ib Front Camshaft Chain Guide Bolt Upper 18 Cylinder Head Bolts M10 lt Cylinder Head Plugs 15 9 Cylinder Head Bolts M6 i 106 in Ib Camshaft Chain Tensioner Mounting Bolts 1 1 2 2 12 om 12 Rear Camshaft Chain Guide Bot 25 28 13 reine 5 2 3 4 5 6 7 8 9 10 1 15 Throttle Body Assy Holder Clamp Bolts 10 in Ib 16 Coolant Drain Bolt Cylinder 98 10 87inlb Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply
46. are noticed 9505117851 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Checkthat the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Outlet Hose B Fuel Intake Hose C Front D e Check that the outlet hose joints are securely connected OPush and pull A the hose joint B back and forth more than two times and make sure it is locked and does not come off Fuel Pump Side C Throttle Body Assy Side D A WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe x If it comes off reinstall the hose joint e Check that the intake hose A is onto the pipe fully and the clamps B are installed beyond the raised rib C 1 2 mm 0 039 0 079 in D 9505119851 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Draw the fuel out
47. d m ijf ex So ala PIC T Il dio 8 dur Ht pe om AN TIT x LL Fev L DU bs v AUL po E Oo m arpaTTHaex 2 ee 8017420FW5 C DFI System FUEL SYSTEM DFI 3 13 Part Names Oxygen Sensor Joint Connector E ECU Joint Connector D Exhaust Butterfly Valve Actuator Immobilizer Kawasaki Diagnostic System Connector Frame Ground 4 Frame Ground 3 Frame Ground 2 Frame Ground 1 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15 A Fuse Box 2 Radiator Fan Fuse 15 A Fuel Pump Relay Box Fuel Pump Relay ECU Main Relay Radiator Fan Relay Fuse Box 1 Ignition Fuse 15 A Meter Unit Tachometer Yellow Engine Warning Indicator Light Joint Connector C Immobilizer Antenna Immobilizer Amplifier Ignition Switch Engine Stop Switch Starter Button Fan Motor Stick Coil 1 Stick Coil 2 Stick Coil 3 Stick Coil 4 Air Switching Valve Vehicle down Sensor Intake Air Temperature Sensor Speed Sensor Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Subthrottle Valve Actuator Main Throttle Sensor Water Proof Joint 2
48. e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend x If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in 6105040451 6105040551 6105040651 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist Inspection e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance Inspection Measure connecting rod big end side clearance Olnsert a
49. rit pests tet oreet tbe detects veta Eee Pp tap a t ee tein EE ER TER pen 9 25 Starter Motor Clutch Removal Installation pp 9 25 Starter Motor Clutch Inspection pp 9 25 Starter Motor Clutch Disassembly pp 9 25 Starter Motor Clutch Assembly pate Fat petat edt tu sa eite 9 25 JiatismissiOriox ere 9 26 shift Pedal Remioval nir redo EHE errare Eee P 9 26 Shift Pedal Installation 9 26 External Shift Mechanism Removal 2 9 27 External Shift Mechanism Installation pp 9 27 External Shift Mechanism Inspection RN 9 28 Transmission Shaft 9 28 Transmission Shaft Installation pp 9 28 Transmission Shaft Disasserbly ose e doe deiode a aub uber 9 29 Transmission Shaft Assembly pp 9 30 Shift Drum and Fork 8 9 33 Shift Drum and Fork Installatiom enne 9 33 shift Druin Bisassembly o eqni ae ea ett eda Rec uec 9 33 Shift Drum ASSembly eet eee et bei e Eee seh ce 9 33 Shift Fork Bending inc ea OS 9 34 Shift Fork Gear Groove Wear Inspection pp 9 34 Shift Fork Guide Pin Drum Groove Wear Inspection pp 9 34 Gear Dog and Gear Dog Hole Damage Inspec
50. 1 Service Code 12 x If the wiring is good check the sensor for various vacuum Remove the intake air pressure sensor 1 A and discon nect the vacuum hose from the sensor e Connect an auxiliary hose B to the intake air pressure sensor 1 Temporarily install the intake air pressure sensor 1 OConnect a digital meter C vacuum gauge D the fork oil level gauge E and the measuring adapter to the intake air pressure sensor 1 Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter Y sensor Y BL lead Digital Meter sensor lead OTurn the ignition switch on OMeasure the intake air pressure sensor output voltage from various vacuum readings while pulling the handle 80104080852 of the fork oil level gauge OCheck the intake air pressure sensor output voltage us ing the following formula and chart Suppose Pg Vacuum Pressure Gauge of Throttle Body Local Atmospheric Pressure Absolute measured by a barometer Pv Vacuum Pressure Absolute of Throttle Body Vv Sensor Output Voltage V then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum Gauge Reading PI 70 cmHg Barometer Reading Vv 3 2 V Digital Meter Reading then Pv 70 8 62 cmHg Absolute Plot this Pv 62 cm
51. 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Radiator Cap Inspection Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Radiator Cap e Check the condition of the bottom A and top B valve seals and valve spring C x If any one of them shows visible damage replace the cap with a new one e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one Radiator Filler Neck Inspection e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Radiator Cap e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to functio
52. 15 9 0 135 US oz If necessary measure the oil level as follows OHold the inner tube vertically in a vise OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 ORemove the piston rod puller OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the outer tube to the oil ss Wy D GM04738BS1 6 04021251 C v Wy 7 6 04042851 6 04021351 C Front Fork SUSPENSION 13 23 Oil Level fully compressed without spring Standard Right Front Fork 106 2 mm 4 17 0 08 in from the top of the outer tube Left Front Fork 109 2 mm 4 29 0 08 in from the top of the outer tube NOTE OFork oil lever may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end C of the outer tube D OSet the gauge stopper E so that its lower side shows the oil level distance specified F OPull the handle slowly to pump out the excess oil until the oil no longer comes ou
53. 16 48 Stick Coil Primary Peak Voltage ode s mets va 16 48 Spark Plug Removal 16 49 Spark Plug Installation 16 49 Spark Plug Condition Inspection pp 16 49 Interlock Operation Inspection pp 16 49 ne 16 50 Electric Starter d o canted eels Aiea wee ve de cuneate es 16 53 Starter Motor Removal 16 53 Starter Motor 6 mm mnm rm rm nemen mene rni 16 53 16 2 ELECTRICAL SYSTEM Starter Motor Disassembly 16 53 Starter Motor Assembly eee 16 54 tt nb rene f Fr b La aa ret 16 55 Commutator Cleaning and Inspectionm 16 55 Armature InsSpectlOr 5 irte e ETE a ARR D APER En 16 56 Brush Lead 16 56 Brush Plate and Terminal Bolt 16 56 Starter Relay 25 ert rre tierna cec te pue epa driva dE PUEDEN REEL ERR ERN 16 57 Lighting EP 16 59 Headlight Beam Horizontal 16 59 Headlight Beam Vertical Adjustment 16 59 Headlight Bulb Replacem
54. 4 5 US gal Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower ZR800A B ZR800C D Maximum Torque ZR800A B ZR800C D Fuel System Starting System Ignition System Timing Advance Ignition Timing 3 0 m 9 8 ft 4 stroke DOHC 4 cylinder Liquid cooled 71 0 x 50 9 mm 2 80 x 2 00 in 806 cm 49 18 cu in 11 9 1 83 0 kW 113 PS at 10 200 r min rpm WVTA 78 2 78 2 kW 106 PS at 10 000 r min rpm 70 0 kW 95 2 PS at 9 500 r min rpm 83 0 N m 8 5 kgf m 61 16 at 8 000 r min rpm WVTA 78 2 80 5 8 2 kgf m 59 16 at 8 000 r min rpm 76 0 N m 7 7 kgf m 56 10 at 8 000 r min rpm FI Fuel Injection MIKUNI 34 EHDW x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter From 10 BTDC at 1 100 r min rpm to 37 BTDC at 5 000 r min rpm 1 12 GENERAL INFORMATION General Specifications Reduction Ratio Overall Drive Ratio Frame Type Caster Rake Angle Trail Front Tire Type Size Rim Size ltems ZR800AD BD CD DD Spark Plug CR9EK ND U27ETR Cylinder Numbering Method Left to right 1 2 3 4 Firing Order 1 2 4 3 Valve Timing Intake Open 38 BTDC Close 66 ABDC Duration 284 Exhaust Open 51 BBDC Close 25 ATDC Duration 256 Lubrication System Forced lubrication wet sump Engine Oil Type API SG SH SJ SL or S
55. A OWhen positioning 1 piston TDC at the end of the compression stroke Intake Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve A x If the valve clearance is not within the specified range first record the clearance and then adjust it 6507024851 OQ etm 9507131851 Ge LIII 9507132851 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions OBesides the standard shims in the valve clearance adjust ment charts the following additional shims maybe used Adjustment Shims Part Number Thickness 92180 0276 92180 0277 92180 0278 3 325 mm e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A BT EET 6507022851 ATUTI Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 31 VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE PART No 92180 MARK PRESENT SHIM THICKNESS mm 2 50 2 55 2 60 2 65 2 7012 75 2 80 2 8512 90 3 0013 05 3 10 3 15 3 2013 25 3 30
56. Actions chapter Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Unstable rough idling Fuel pressure too low or too high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Engine vacuum not synchronizing Intake air pressure sensor 1 trouble Inspect see chapter 3 Inspect and adjust see chapter 2 Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Intake air temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Main throttle sensor trouble Inspect see
57. Clutch Lever Clamp Bolts 11 1 1 97 in lb Oil Filler Plug 2 0 0 20 18 in Ib Clutch Cover Mounting Bolts 11 1 1 97 in lb Clutch Spring Bolts 8 8 0 90 78 in Ib Clutch Hub Nut 135 13 8 100 Engine Lubrication System Oil Jet Nozzle Bolts 6 9 0 70 Oil Filler Plug 2 0 0 20 Oil Filter 17 1 7 Oil Filter Holder 78 8 0 Oil Pressure Switch Terminal Bolt 2 0 0 20 Oil Pressure Switch 15 1 5 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Nem 16 Remarks Oil Passage Plugs 20 15 L Oil Pipe Holder Bolts 13 115 in Ib L Water Pump Cover Bolts 11 97 in lb Coolant Drain Bolt Water Pump 11 97 Water Pump Impeller Bolt 9 8 87 in lb Oil Pressure Relief Valve 15 11 L Oil Pan Bolts 15 11 Engine Oil Drain Bolt 30 22 Engine Removal Installation Front Engine Bracket Bolts 11 1 1 97 Upper Engine Bracket Bolts 44 4 5 32 S Subframe Bolts 25 2 5 18 S Adjusting Collar Locknuts 49 5 0 36 S Front Engine Mounting Bolts 44 4 5 32 S Upper Adjusting Collar 9 8 1 0 87 S Middle Engine Mounting Nut 44 4 5 32 S Rear Engine Bracket Bolts 25 2 5 18 S Lower Engine Mounting Nut 44 4 5 32 S Lower Adjusting Collar 4 9 0 50 43 in Ib S Engine Ground Cable Terminal Bolt 9 8 1 0 87 Crankshaft Transmission Oil Jet Nozzle Bolts 6 9 0 70 61 in Ib L Crankcase Bolts M6 12 1 2 106 in Ib S Crankcase Bolts M7 20 2 0 15 S Side Breather Plate Bolts 5 9 0 60 52 in Ib L Connecting Rod Big End Nuts uod lt lt MO Upper Brea
58. Clutch Springs F Clutch Spring Bolts G Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib Clutch Plate Assembly Length Standard 37 7 38 3 mm 1 48 1 51 in xIf the length is not within the specified range adjust the length see Clutch Plate Assembly Adjustment Clutch Plate Assembly Adjustment e Inspect the clutch plate assembly length and then re place the steel plate s which brings the length within the specified range e Remove Clutch Spring Bolts Clutch Springs Clutch Spring Plate e Replace the following steel plate s Thickness Part Number 1 4 mm 0 055 in 13089 1126 1 6 mm 0 063 in STD 13089 013 2 0 mm 0 079 in 13089 1073 NOTE ODo not use the steel plate of 1 4 mm 0 055 in and 2 0 mm 0 079 in thickness at the same time e Install the removed parts and inspect the clutch plate as sembly length Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib 8 06178 52 C 6 12 CLUTCH Clutch Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear Measure the thickness of each friction plate A at several points x If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 4 mm 0 094 in Clutch Plate W
59. ENGINE TOP END 5 47 e Remove Clamp A Exhaust Butterfly Valve Cable Upper Ends B e Remove Exhaust Butterfly Valve Cable Lower Ends see Muffler Body Removal Exhaust Butterfly Valve Cables Exhaust Butterfly Valve Cable Installation ZR800A B Models e Confirm whether pulley A is an angle as shown 41 7 7 B OThis position is original position of the pulley NOTE OCorrect the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown Do not correct the pulley position with the tool forcibly The actuator damage will occur x If the angle is wrong adjust the pulley see Exhaust But terfly Valve Actuator Installation in the Fuel System DFI chapter e Install the exhaust butterfly valve cable lower ends to the pulley of muffler body Close Cable Black A Open Cable White B e Install the muffler body see Muffler Body Installation e Run the exhaust butterfly valve cables to the inside of the clamp C e Install the exhaust butterfly valve cable upper ends to the pulley of actuator e Install the clamp D GE18176BS1 GE18180BS2 C 5 48 ENGINE TOP END Muffler e Stretch the open cable white A first by using the ad juster B OTurn the adjuster counterclockwise until the play of the open cable becomes no play Locknut of White C To keep the correct exhaust butterfly valve position
60. Electrolyte Filling Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name ZR800A B FTX9 BS NOTICE Each battery comes with its own specific elec trolyte container using the wrong container may overfill the battery with incorrect electrolyte which can shorten battery life and deteriorate battery per formance Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type NOTICE Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume A DANGER Sulfuric acid in battery electrolyte can cause severe burns To prevent burns wear protective clothing and safety glasses when handling electrolyte If the electrolyte comes in contact with your skin or eyes wash the area with liberal amounts of water and seek medical attention for more severe burns e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge e Remove the electrolyte container from the vinyl bag e Detach the strip
61. Final Drive chapter o 65118240 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection e If a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning of the O ring of the drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause de terioration and swelling of the O ring Immediately blow the chain dry with compressed air after clean ing Complete cleaning and drying the chain within 10 minutes e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe off any excess oil Oil Applied Areas A O rings B Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OClean the chain if it is dirty and lubricate it if it appears dry e Check the wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the
62. Flywheel Assembly 38 1 5 35 1 5 57001 1615 8 5716155 C 57001 1679 875716795 6 Rotor Holder 57001 1690 ST571690ST 6 Key Registration Adapter 57001 1746 ST5717468T 6 16 12 ELECTRICAL SYSTEM Special Tools and Sealant Liquid Gasket TB1211F 92104 0004 879200045 6 ELECTRICAL SYSTEM 16 13 Parts Location This page intentionally left blank 16 14 ELECTRICAL SYSTEM Parts Location osesTe P P Parts Location Meter Unit Ignition Switch Starter Lockout Switch Turn Signal Relay Stick Coils Spark Plugs Starter Motor Speed Sensor Frame Ground Fuse Box 2 Battery 12 V 8 Ah Relay Box Immobilizer Kawasaki Diagnostic System Connector ECU Fuse Box 1 Starter Relay Side Stand Switch Neutral Switch Alternator Regulator Rectifier Engine Ground Water Temperature Sensor Immobilizer Amplifier Front Brake Light Switch Vehicle down Sensor Air Switching Valve Radiator Fan Motor Crankshaft Sensor Oil Pressure Switch Oxygen Sensor Rear Brake Light Switch ELECTRICAL SYSTEM 16 15 16 16 ELECTRICAL SYSTEM Wiring Diagram ZR800A without GPS Unit Right Switch Housing 1 Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button 2 2
63. Intake Vehicle Air down Spark Plugs Sensor Sensor 1 2 3 4 otor as S S hir Stick Switching Soils Valve i 2 sta EE z 2 ze e 55 eS 50 0 5 ge Li 1 Immobilizer cil J Amplifier Antenna BKW i Joint eRe Connector BR K Meter Unit II Temperature mE isinin Joint Connector A Hm sj BK Y BK Y Front Right Turn Signal Light Right City Light 1275 Headlight R Y Low BK Y 12V558 Headlight dat High pes 1 1 12550 Left Gity D sw Light 12V5W GIZA Front Left Turn Signal 12V108 Meter Unit i Yellow Engine Warning Indicator Light LED 4 Green Left Turn Signal Indicator Light LED Green Right Turn Signa Indicator Light LED 6 Warning Indicator Light Battery il Pressure Water Temperature Immobilizer LED 7 Speedometer 8 Mileage Cruising Range 9 Fuel Level Gauge 10 Tachoneter 11 Nater Temperature Meter 12 0doneter Trip Meter 13 Clock 14 Il Iunination Light LED RELED Light Emitting Diode 2 6reen Neutral Indicator Fuse Box Light LED Ignition Fuse 3 Blue High Beam Indicator 2 Headlight Fuse Light LED 3 Brake Horn Fuse 7 4 Turn Signal 15 15 Relay Fuse 7 5
64. Kawasaki Rear Right Ec Turn Signal er LS fen 124108 L R Be Tail Brake BK Y BKZ Y 1e Light LED License Plats TE tis 12V5Y Rear Left E Turn Signal 6 vs 12V10w Joint Connector B Color Code e Green Light Blue Self diagnostic System Connector LeyBK BKAY WR ir vu OK Y R Fuel Fuel Starter X tevel Puan Rectifier sal ee P c Fuse Box 2 N 1 Fan Fuse 15A PIS 2 Meter Fuse 7 54 Battery Ground Starter 12V8Ah Pos Ground Wotor o Orange IGNITION SWITCH CONNECTIONS Pink Ignition Battery Signal RIGHT SWITCH HOUSING CONNECTIONS Purple ea R Red White 98052 07794 W2RO779AW5 C 16 20 ELECTRICAL SYSTEM Wiring Diagram ZR800B without GPS Unit Right Switch Housing 1 Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button Immobilizer Antenna BK w Front Wheel TI Intake Yehicle Air down Temperature Sensor Sensor 1 1 Horn Fan Spark Plugs FF 2 5A Hes 1 2 3 1 oter SS S S Air N Stick Switching 5 Soils Valve i n 5 55 5 Ps as 208 2 zz aR a 1 BK Y Innobi Y Amplifier PZBK Rotation Sensor tthe
65. LG Apply liquid gasket M Apply molybdenum disulfide grease R Replacement Parts SS Apply silicone sealant 16 8 ELECTRICAL SYSTEM Exploded View se A SA am x T NE GP026568W5 C ELECTRICAL SYSTEM 16 9 Exploded View s Diem 0 WRE 2 Starter Motor Cable Terminal Nut 0 50 43 in Ib 3 Starter Relay Bracket Bolts x 0 70 61 in Ib 4 Side Stand Switch Bolt 8 8 0 90 78 L 5 Regulator Rectifier Bracket Bolts 6 9 0 70 61 in Ib 6 Regulator Rectifier Bolts 6 9 0 70 61 in Ib 7 Spark Plugs 13 1 3 115 in Ib 8 Speed Sensor Bolt 12 1 2 106 in Ib 9 Engine Ground Cable Terminal Bolt 9 8 1 0 87 10 Fuel Level Sensor Bolts 6 9 0 70 61 in Ib L 11 Neutral Switch 15 1 5 11 12 Starter Relay 13 ABS Equipped Model 14 ZR800A B Models WVTA 78 2 and UK WVTA FULL Models ZR800C D Models WVTA FULL Model with Guard 15 Horn 16 Relay Box 17 ECU G Apply grease L Apply a non permanent locking agent R Replacement Parts 16 10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Model Name Capacity Voltage Gross Weight Electrolyte Volume Charging System Type Alternator Output Voltage Stator Coil Resistance Charging Voltage Regulator Rectifier Output Voltage Ignition System Crankshaft Sensor Resistance Crankshaft Sensor P
66. Pad C Flap Bracket D Flap E 9008041851 15 22 FRAME Fenders e Remove Screw A Washers B Rear Turn Signal Light Assembly C e Remove Screws A Washers B Dampers C License Plate Light Assembly D Flap E Flap Installation e Installation is the reverse of removal OCheck that the grommet A is in place on the flap bracket B ORun the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter OWhen installing the pad A position the leads B on the center of flap bracket C and align the edge of the pad with the these edge D of flap bracket OCheck that the pad A is in place on the bracket B OAlign the edge of the pad with the edge C of bracket G008039BS1 C 9008040851 Frame FRAME 15 23 Frame Inspection e Visually inspect the frame for cracks dents bending or warp Olf there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident resulting in injury or death If the frame is bent dented cracked or warped replace it 15 24 FRAME Side Stand Side Stand Removal Raise the rear wheel off the ground with the stand e Remove Side Stand Switch Bolt A Side Stand Switch B Spring C Side Stand Nut D Side Stand Bolt E Side Stand F Side Stand Installation e Apply grease to the sliding area
67. Radiator Upper Bolt Left D e Loosen the water hose clamp screw A e Disconnect the water hose B e Remove Radiator Upper Bolt Right C Radiator D NOTICE Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency e Remove Radiator Fan Mounting Bolts A Radiator Fan B Radiator COOLING SYSTEM 4 13 Radiator and Radiator Fan Installation e Installation is the reverse of removal e Install the rubber dampers A and radiator bracket collars B as shown Larger C Smaller D e Run the radiator fan motor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Radiator Bolts 6 9 N m 0 70 kgf m 16 in Ib Water Hose Clamp Screws 3 0 0 31 kgf m 27 in lb e Install the removed parts see appropriate chapter Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x lf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one GD071088W2 C 6007010451 C 4 14 COOLING SYSTEM Radiator When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m
68. Sonso Senear Intake Intake water Oxygen Air Air Side Sensor Pressure Pressure Z i Stand E bog uel Injectors Sensors Sensors ensor B i g g bs fe Se ge g 28 n Tar ds ds 059 Water proof 19 z Joint 1 E 1 Li L 1 FHH H H L B v B B D BL Y WA I TOE Ja ELL T3 Dee d I Joint onnector E ECU Joint Connector D Rear Wheel Rotation Sensor Rear Right Kawasaki Self diagnostic s F System BK Y 1L E Connector BRZY BL R BKZY BK Y Regulator Level Rectifier Alternator Sensor Pump a BK Y BK Y Fuse Box 2 Fuse 15 2 Meter Fuse 7 Emu te Joint Battery Ground Starter 12V8Ah Frame Ground Rear Exhaust Connector B Wotor rake Ligne Butterfly Valve Switch Actuator P BR W ABS Self diagnosis 85 Terminal Kawasaki Diagnosis System Sonnector Starter Relay 1 0 Fuse 15 2 Main Fuse 30 Turn Signal al Light 12V10W Tail Brake a Light LED License Plats TE tis 12V5Y Rear Left E Turn Signal 6 vs 12V10w Color Cod
69. TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance 0 13 0 38 mm 0 58 mm 0 0051 0 0150 in 0 023 in Connecting Rod Big End Bearing Insert Crankpin 0 041 0 071 mm 0 11 mm Clearance 0 0016 0 0028 in 0 0043 in Crankpin Diameter 34 984 35 000 mm 34 97 mm 1 3773 1 3780 in 1 3768 in Con rod Big End Inside Diameter Crankpin Diameter Bearing Insert None None Connecting Rod Bolt Stretch Crankshaft Runout Black Usable Range New Connecting Rod 0 24 0 36 mm 0 0094 0 0142 in Used Connecting Rod 0 20 0 32 mm 0 0079 0 0126 in Crankshaft Side Clearance 0 05 0 20 mm 0 0020 0 0079 in TIR 0 02 mm 0 0008 in or less Part Number 92139 1110 92139 1109 92139 1108 0 40 mm 0 0157 in TIR 0 05 mm 0 0020 in Specifications CRANKSHAFT TRANSMISSION 9 7 Item Standard Service Limit Crankshaft Main Bearing Insert Journal 0 020 0 044 mm 0 07 mm Clearance 0 0008 0 0017 in 0 0028 in Crankshaft Main Journal Diameter 32 984 33 000 mm 32 96 mm 1 2986 1 2992 in 1 2976 in 32 984 32 992 mm MS 1 2986 1 2989 in 1 32 993 33 000 mm EM 1 2989 1 2992 in 36 000 36 016 mm s 1 4173 1 4179 in 36 000 36 008 mm ES 1 4173 1 4176 in None 36 009 36 016 mm 1 4177 1 4179 in Marking None Crankcase Main Bearing Inside
70. Throttle Body Assy e Remove the throttle cable upper ends A e Remove Fuel Tank Bracket see Air Cleaner Element Replace ment in the Periodic Maintenance chapter Air Cleaner Housing Mounting Bolt A Both Sides e Loosen the air duct clamp bolts A Move B the air cleaner housing C backward and pull out the air ducts from the throttle body assy e Loosen the throttle body assy holder clamp bolts A and pull out the throttle body assy B backward Remove the throttle body assy to left side of motorcycle e After removing the throttle body assy stuff pieces of lint free clean cloth into the throttle body assy holders If dirt gets into the engine excessive engine wear and possible engine damage will occur Remove the throttle cable lower ends A from the throttle pulley Throttle Body Assy FUEL SYSTEM DFI 3 129 Throttle Body Assy Installation e Apply a thin coating of grease to the throttle cable lower ends e Fitthe accelerator cable end A and the decelerator cable end B into the throttle pulley e Install the throttle body assy holder clamp bolts in the di rection as shown Right Side A Left Side B Bolt Heads C e Fit the projections D of the holder into the holes in the clamps e Install the throttle body assy to the throttle body assy hold ers OApply a small amount of 2 stroke oil to the throttle body assy holder for easy installation e Tight
71. continuity see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Radiator Fan Relay Circuit 4 GCi7441FW2 C 1 Ignition Switch 10 Starter Relay 2 Joint Connector C 11 Main Fuse 30 A 3 Fan Motor 12 Fuse Box 2 4 Joint Connector E 13 Radiator Fan Fuse 15 A 5 ECU 14 Relay Box 6 Frame Ground 2 15 Radiator Fan Relay 7 Frame Ground 1 16 Fuse Box 1 8 Engine Ground 17 Ignition Fuse 15A 9 Battery 12 V 8 Ah Subthrottle Valve Actuator Service Code 62 FUEL SYSTEM DFI 3 93 Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the subthrottle valve actuator can damage it Subthrottle Valve Actuator Inspection NOTE OBe sure the battery is fully charged Remove the right throttle body cover see Throttle Body Assy Removal Turn the ignition switch on e Check to see that all the subthrottle valve lever A open and close smoothly e Turn the ignition switch off xIf the subthrottle valves do not operate check the sub throttle valve actuator resistance see Subthrottle Valve Actuator Resistance Inspection S
72. e Install the rebound damping adjuster rod A Right Front Fork Only Front Fork SUSPENSION 13 25 e Check the distance between the bottom end A of the top plug and rebound damping adjuster B with a pair of vernier caliper Right Front Fork Only 13 mm 0 51 in C e Replace the O ring A on the top plug B with a new one e Apply grease to the new O ring e Install the top plug on the piston rod and screw it e Holding the top plug with a wrench tighten the piston rod nut C against the top plug Torque Piston Rod Nuts 15 N m 1 5 11 ft Ib e Remove the fork spring stopper e Align the stoppers A of the top plug B with the grooves C of the clamp D and loosen the fork spring compres sor nut e Remove the fork spring compressor and clamps e Raise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation e Adjust the spring preload see Spring Preload Adjust ment e Adjust the rebound damping force see Rebound Damp ing Force Adjustment Right Front Fork Only Front Fork Oil Change ZR800C D Models Right Front Fork e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vice e Unscrew the top plug A out of the outer tube e Install the fork spring compressor as shown in the figure NOTE OSet the fork spring compressor so that the end of the handle A passes the upper side
73. e Tighten the bolts e Install the removed parts see appropriate chapters 9005041851 15 14 FRAME Fairings Lower Fairing Removal ZR800A B Models e Remove the bolts A e Clear the projection B and remove the lower fairing C Lower Fairing Installation ZR800A B Models e Check that the grommets A are in place on the lower fairing B and bracket e Insert the projection C into the hole D e Tighten Torque Lower Fairing Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb FRAME 15 15 Side Covers Side Cover Removal e Remove Seats see Rear Front Seat Removal Bolt A with washer e Pull the side cover B evenly outward to clear the projec tions C e Pull the side cover backward to clear the hook fasteners D and projections E 15 16 FRAME Side Covers Side Cover Installation e Check that the pads A and damper B are in place the side covers as follows Olnstall the adhesive surface of the damper to the adhesive surface of the pad Left Side Cover C Right Side Cover D 10 mm 0 39 in E View from F F E 7 SS 6006020812 C 4 2 a VK 2 VA 2 A 600602182 Side Covers FRAME 15 17 e Check that the grommets A and pad B are in place e Insert the projections C into the hole D e Fit the hook fasteners E e Insert the
74. e With the self diagnosis terminal connected to the ground check for continuity between the terminal 9 BK A and terminal 14 GY B of the ABS hydraulic unit connector x lf there is no continuity repair or replace the main har ness x lf there is continuity go to next step Step 5 e Jump the terminal 9 BK A and terminal 13 BL Y B at the ABS hydraulic unit connector using a jumper read C e Check the yellow ABS indicator light LED with the igni tion switch turned on x lf the indicator goes off replace the ABS hydraulic unit x If the indicator goes on go to next step Step 6 e Disconnect the connector from the meter unit see Meter Unit Removal Installation in the Electrical System chap ter e Check for continuity between the terminal 13 BL Y A of the ABS hydraulic unit connector B and terminal 9 BK C of the meter connector D xIf there is no continuity repair or replace the main har ness xIf there is continuity replace the meter unit with a new one Yellow ABS Indicator Light LED does not go on When the Ignition Switch turned on e Perform the Pre Diagnosis Inspection 1 e Check the system connectors for loose or poorly contact Step 1 e Check the meter fuse 7 5 A in the fuse box 1 for blown x If the fuse is blown replace the fuse x If the fuse is not blown go to next step E GL14703BS1 B 9114704851 1
75. oM RIGS RC TET 3 32 DFI System Troubleshooting aduer eruere ro ee Ove cedet 3 35 iB P Tr 3 40 Self Di gnosis OUIIITIG Te ect Pace dee Mea ape xor te oid debet 3 40 Self Diagnosis Procedures cedet enar nace uc cask idee ERA te 3 41 Service Code Reading roter re c aeter eee Rep ME FR s tek ODE 3 44 Service ros E 3 44 eru 3 46 Main Throttle Sensor Service Code 11 3 49 Main Throttle Sensor Removal AdjUStMent Ne 3 49 Main Throttle Sensor Input Voltage Inspection pp 3 49 Main Throttle Sensor Output Voltage Inspection pp 3 50 Main Throttle Sensor Resistance Inspection 3 51 Intake Air Pressure Sensor 1 Service Code 122 3 53 Intake Air Pressure Sensor 1 Removal pp 3 53 Intake Air Pressure Sensor 1 Installation pp 3 53 Intake Air Pressure Sensor 1 Input Voltage 3 54 Intake Air Pressure Sensor 1 Output Voltage 3 55 Intake Air Temperature Sensor Service Code 13 3 59 Intake Air Temperature Sensor Removal Installation pp 3 59 Intake Air Temperature Sensor Output Voltage Inspection pp 3 59 Intake Air Temperature Sensor Resistance Inspection pp 3 60
76. or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e Apply brake fluid to the cylinder bore e Replace the fluid seal A with a new one OApply silicone grease to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one if itis damaged 6105040251 Install the pad spring A e Apply silicone grease to the sleeve B e Install the rubber boot C and sleeve 9513181851 C e Install the pads see Rear Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Pad Wear Inspection e Remove the brake pads see Front Rear Brake Pad Re moval in the Brakes chapter Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Front Brake Pad C ZR800A B D Models Front Brake Pad D ZR800C Model Rear Brake Pad E Pad Lining Thickness Standard Front 4 0 mm 0 16 in Rear 5 0 mm 0 20 in Service Limit Front 1 mm 0 04 in Rear 1 5 mm 0 06 in Brake Light Switch Operation Inspection e Turn the ignition switch on e The brake light LED A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0
77. ore oR iow TION BATTERY O 9 Gr 1 Ignition Switch 10 Alternator 20 Headlight High 12 V 55 W 2 Tail Brake Light LED 11 Headlight Circuit Relay 21 Headlight Low 12 V 55 W 3 License Plate Light 12 12 Relay Box 22 Right City Light 12 V 5 W V5W 13 Passing Button 23 Frame Ground 1 4 Joint Connector B 14 Dimmer Switch 24 Joint Connector A 5 Frame Ground 4 15 Fuse Box 1 25 Blue High Beam Indicator 6 Main Fuse 30 A 16 Headlight Fuse 15 A Light LED 7 Engine Ground 17 Brake Horn Fuse 7 5 A 26 Meter Unit 8 Battery 12V 8 Ah 18 Frame Ground 2 9 Starter Relay 19 Left City Light 12 V 5W ELECTRICAL SYSTEM 16 63 Lighting System Turn Signal Light Bulb Replacement Remove the screw A and remove the lens B e Push and turn the bulb A counterclockwise and remove it e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 e Fit the projection A of the lens into the groove B of the turn signal light Tighten the screw Turn Signal Relay Inspection e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Left Side Fairing see Side Fairing Removal in the Frame chapter Turn Signal Relay A 16 64 ELECTRICAL SYSTEM Lighting System e Connect one 12 V battery and turn signal ligh
78. relay box and starter relay 3rd Check Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Side Stand Up Set the side stand on the ground then the engine will stop the engine does not stop inspect the neutral switch side stand switch and relay box x If their parts are normality replace the ECU IC Igniter Inspection OThe IC igniter is built in the ECU A e Refer to the following items Interlock Operation Inspection see Interlock Operation Inspection Ignition System Troubleshooting see Ignition System section ECU Power Supply Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter ELECTRICAL SYSTEM 16 51 Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good Ignition system wiring and connector Magoon Repair or replace inspection damaged part Good No good Spark plug inspection Replace spark plug Good No good Stick coil winding resistance inspection Replace stick coil Good 9998 Voltage is less specified value Inspect 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage Stick coil primary peak voltage inspection Good Stick coil
79. see Cable Wire and Hose Routing section in the Ap pendix chapter Torque Engine Ground Cable Terminal Bolt 9 8 N m 1 0 kgf m 87 in Ib NOTE OHold the mounting bolt at the right side of the frame not to turn when tightening the upper and lower engine mounting nuts at the left side of the frame 8 10 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the engine mounting bolts and nuts following the specified installing sequence O1st install the rear engine bracket A and tighten the bolts B temporarily O2nd install the left upper engine bracket C left subframe D and spherical washers E so that the spherical side faces inward and tighten the bolts F G H I temporar ily O3rd tighten the subframe bolts F G Torque Subframe Bolts F G 25 N m 2 5 kgf m 18 ft Ib O4th loosen the subframe bolt F and tighten the sub frame bolt F Torque Subframe Bolt F 25 N m 2 5 kgf m 18 ft Ib Obth loosen the subframe bolt and tighten the sub frame bolt G Torque Subframe Bolt G 25 N m 2 5 kgf m 18 ft Ib O6th tighten the subframe bolts H and upper engine bracket bolts I Torque Subframe Bolts H 25 N m 2 5 kgf m 18 ft Ib Upper Engine Bracket Bolts I 44 N m 4 5 kgf m 32 ft lb O7th insert the lower J and middle K engine mounting bolts O8th tighten the left front engine mounting bolt L Torque Front Engine Mounting Bolt L 4
80. start running Up In gear Pulled in LONNUS running Down Neutral Released Continue running Down Neutral Pulled in Cente running Does not start Down In gear Released Stops Does not start Stops Down In gear Pulled in If the side stand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Ignition Fuse 15 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Side Stand Switch see Switch Inspection in the Electri cal System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter x If the all parts are good condition replace the ECU see ECU Removal Installation the Fuel System DFI chap ter PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures Engine Stop Switch
81. that may allow fuel to leak and create the potential for a fire explosion To prevent fire or explosion from a damaged joint lock do not pry or excessively widen the joint lock ends when removing the fuel hose The joint lock has a retaining edge that locks around the housing e Pull B the fuel hose joint C out of the fuel outlet pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Close the fuel tank cap e Remove the fuel tank and place a it on a flat surface ODo not apply the load to the fuel outlet pipe of the fuel pump e Clean the pipe A e Cover the pipe and the hose joint B with the vinyl bags C to keep it clean Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Check that the dampers A and collars B are in place on the frame and the fuel tank xlf the dampers are damaged or deteriorated replace them GC09125BS1 C Fuel Tank FUEL SYSTEM DFI 3 137 e When installing the dampers A posi
82. 0 60 kgf m 52 in Ib e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket A to the crankshaft sensor lead grom met and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount Sealant Liquid Gasket TB1211F 92104 0004 e Apply high temperature grease to the switch terminal A to prevent rust ODo not protrude the grease from the rubber boot B e Install the oil pressure switch lead terminal securely Olnstall the lead terminal direction upward Torque Oil Pressure Switch Terminal Bolt 2 0 N m 0 20 kgf m 18 in Ib e Install the rubber boot e Install the removed parts see appropriate chapters e Replace the O ring in the crankshaft sensor cover A with a new one e Install Crankshaft Sensor Cover Clamp B e Tighten Torque Crankshaft Sensor Cover Bolts 11 N m 1 1 kgf m 97 in Ib Crankshaft Sensor Inspection e Remove the rightframe cover see Frame Cover Removal in the Frame chapter e Disconnect the crankshaft sensor lead connector A see Crankshaft Sensor Removal e Set the hand tester B to the x 10 O range and connect lead to the yellow lead and lead to the black lead in the connector Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance 376 564 Q x If there is more resistance than the specified value the coil
83. 1 22 120 5 30 3 1 22 120 5 Used Bolt Torque N m kgf m ft lb or Angle 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 30 3 1 22 100 5 GE14093BS1 61053408 5 5 26 ENGINE TOP END Cylinder Head e Install Front Camshaft Chain Guide A Rear Camshaft Chain Guide B New O rings C Collar D OApply grease to the new O ring e Tighten Torque Front Camshaft Chain Guide Bolt Upper E 25 N m 2 5 18 ft Ib Front Camshaft Chain Guide Bolt Lower F 12 N m 1 2 kgf m 106 in Ib Rear Camshaft Chain Guide Bolt G 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters Cylinder Head Warp Inspection e Clean the cylinder head Lay a straightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 GE14
84. 17 29 Cable Wire and Hose Routing G8091J1E G Clamps Hold the main harness Insert the projection of the clamp into the frame Fuse Box ABS Hydraulic Unit Lead ABS Equipped Models Battery Negative Cable Run the main harness to the outside of the clamp of the battery band Run the battery cable under the main harness Battery Positive Cable This read is ABS equipped models only Run the ECU lead under the relay box lead 17 30 APPENDIX Cable Wire and Hose Routing 8 09132 3 C 1 Thermostat Housing 2 Align the white paint of the water hose from thermostat housing to radiator with projection of the thermostat housing 3 Align the white paint of the water hose from cylinder head to thermostat housing with rib of the thermostat housing 4 Screw Heads 5 Clamps APPENDIX 17 31 Cable Wire and Hose Routing Ld 9 mE AMO N 2 S c N lt 2 CS NS ER OO GARY AT 7 f S 1 Clamps Install the clamp as shown 2 Align the white paint of the water hose from radiator to water pump with projection of the water pipe 3 Face the white paint position of the water hose to the upside 4 Viewed form A 17 32 APP
85. 39 in x lf it does not adjust the brake light switch e Remove Muffler Body Mounting Bolt A and Nut Footpeg Bracket Blots B PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e While holding the switch body turn the adjusting nut to adjust the switch Switch Body A Adjusting Nut B Light sooner as the body rises C Light later as the body lowers D NOTICE To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment x If it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri cal System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Front Brake Light Switch A see Switch Inspection in the Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Suspension Suspension System Front Forks Rear Shock Absorber Operation Inspec tion e Pump the forks down and up A 4 or 5 times and inspect the smooth stroke x If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter e Pump the seat down
86. 4 Service Code 54 Stick Coil Removal Installation e Refer to the Stick Coil Removal Installation in the Electri cal System chapter Stick Coil Primary Winding Resistance Inspection e Refer to the Stick Coil Inspection in the Electrical System chapter x If the reading is within the standard check the input volt age see Stick Coil Input Voltage Inspection Stick Coil Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Stick Coil Input Voltage Connections to ECU Connector For Stick Coil 1 Digital Meter BK lead terminal 40 Digital Meter BK Y lead terminal 54 For Stick Coil 2 Digital Meter BK G lead terminal 47 Digital Meter BK Y lead terminal 54 For Stick Coil 3 Digital Meter BK W lead terminal 39 Digital Meter BK Y lead terminal 54 For Stick Coil 4 Digital Meter BK O lead terminal 38 Digital Meter BK Y lead terminal 54 e Measure the input voltage to each primary winding of the stick coils with the engine stopped and with the connec tors joined e Turn the engine stop switch to run position e Turn the ignition switch on Input Voltage Standard Battery Voltage
87. 41 Swingarm Swingarm Removal e Remove Frame Covers see Frame Cover Removal in the Frame chapter Chain Cover see Drive Chain Removal in the Final Drive chapter Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter Remove Bolts A Screw B e Remove Bolts A Chain Cover B Rear Shock Absorber see Rear Shock Absorber Re moval e Unscrew the swingarm pivot shaft locknut A using the nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 13 42 SUSPENSION Swingarm e Remove Swingarm Pivot Shaft Nut A Swingarm Pivot Shaft B Swingarm Swingarm Installation e Replace the following parts with a new one Lower Shock Absorber Nut Upper Tie Rod Nut e Place the collar A on the stopper B inside the frame C e Insert the pivot shaft into the frame from the right side e Tighten the pivot shaft so that the clearance D between the collar and the frame come to 0 mm Right Side E e Loosen the pivot shaft once and tighten the pivot shaft securely Torque Swingarm Pivot Shaft 9 8 1 0 kgf m 87 in Ib e Tighten the pivot shaft locknut using the nut wrench Special Tool Swingarm Pivot Nut Wrench 57001 1597 Torque Swingarm Pivot Shaft Locknut 98 N m 10 kgf m 72 ft lb e Tighten Torque Swingarm Pivot Shaft Nut 108 N m
88. 7 7 Oil Pressure Gauge Adapter PT3 8 57001 1233 875712335 6 Liquid Gasket 1211 56019 120 875601205 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in the oil level inspection window NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not func tion properly the red warning indicator light LED and oil pressure warning symbol will blink If this blink stays on when the engine is running above idle speed stop the engine immediately and find the cause x If the oil level is too high remove the exce
89. 8 20000151 Fuse Element B Terminals C Blown Element D NOTE OA mass current flows to the battery according to the state of the battery which needs refreshing charge when the engine is turned causing main fuse blown out When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing Ne 17 2 Troubleshooting UIQ 17 40 17 2 APPENDIX Cable Wire and Hose Routing GBOGIISE 6 APPENDIX 17 3 Cable Wire and Hose Routing WN Meter Lead Run the meter lead to the front of the rubber cover Cover the city light lead connectors turn signal light lead connectors front wheel rotation sensor lead connector ABS equipped models with the rubber cover Main Harness Clamp Hold the right turn signal lead and right city light lead Right Turn Signal Lead Clamp Hold the left turn signal lead and left city light lead Right City Light Lead Head Light Leads Left City Light Lead Left Turn Signal Lead Clamp Hold the left switch housing lead and clutch cable Install the clamp near the clutch cable adjuster Clutch Cable Run the front brake hose between the bar of the meter bracket and front fork Clamp Hold the fron
90. A upward GM04734BS1 C e Install the collar A so that the cut side B faces down ward e Install the washer C on the collar e Install the clamps A as shown Special Tool Fork Spring Compressor 57001 1540 NOTE OSet the clamps so that the cutouts B do not fit the hole C of the washer D pull up the outer tube E to hold it by the clamps and then tighten the two bolts F The outer tube is used as a guide e Setthe fork spring compressor A front fork B protector and suitable jack e Lift up the suitable jack until the piston rod nut comes out Special Tool Fork Spring Compressor 57001 1771 Front Fork SUSPENSION 13 19 Hold up the fork piston rod puller e Insert the fork spring stopper A between the piston rod nut B and the holder C while holding up the fork piston rod puller D Special Tool Fork Spring Stopper 57001 1374 e Remove the fork piston rod puller e Install the rebound damping adjuster rod A Right Front Fork Only e Check the distance between the bottom end A of the top plug and rebound damping adjuster B with a pair of vernier caliper Right Front Fork Only 13 mm 0 51 in C e Replace the O ring A on the top plug B with a new one e Apply grease to the new O ring e Install the top plug on the piston rod and screw it e Holding the top plug with a wrench tighten the piston rod nut C against the top plug Torque Pisto
91. A of the side stand B e Replace the side stand nut C with a new one e Tighten the side stand bolt D first and then the side stand nut Torque Side Stand Bolt 29 N m 3 0 kgf m 21 ft Ib Side Stand Nut 44 N m 4 5 kgf m 32 ft Ib e Hook the spring E so that the long spring end faces up ward Olnstall the spring hook direction as shown e Install the side stand switch e Apply a non permanent locking agent to the thread of the side stand switch bolt and tighten it Torque Side Stand Switch Bolt 8 8 N m 0 90 kgf m 78 in Ib G020086BS1 C FRAME 15 25 Frame Cover Subframe Cover Removal Remove Side Cover see Side Cover Removal Bolts A with Washers e Clear the tabs B on the subframe cover C by pulling up the lower part of the subframe cover e Clear the tabs D on the subframe cover and remove the subframe cover Subframe Cover Installation e Check that the pads A are in place on the subframe cover B OAlign the edge of the pad with the line C and edge D of the subframe cover View from E E View from F F e Insert the tabs A into the slots B Olnsert the tabs C first then insert the remainder sequen tially e Tighten the bolts with washers e Install the removed parts see appropriate chapters 15 26 FRAME Frame Cover Frame Cover Removal e Check that the pads A are in place on the frame cover Left Frame Cover B Right Fram
92. B and can not be removed Lupo Pump Screen Fuel Filter Cleaning OThe pump screen A and fuel filter B are built into the pump and can not be cleaned or checked x If the pump screen or fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set Fuel Pump Relay Removal Installation OThe fuel pump relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter Fuel Pump Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter FUEL SYSTEM 3 119 Fuel Pump Fuel Pump Circuit DE Ga 6C17525FW2 C Ignition Switch Engine Stop Switch Frame Ground 1 Joint Connector E ECU Joint Connector D Frame Ground 3 Engine Ground Battery 12 V 8 Ah 10 Starter Relay 11 Main Fuse 30 A 12 ECU Fuse 15A 13 Fuel Pump 14 Relay Box 15 Fuel Pump Relay 16 Fuse Box 1 17 Ignition Fuse 15 A 18 Joint Connector C 5 3 120 FUEL SYSTEM Fuel Injectors Fuel Injector Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Fuel Injector Audible Inspection NOTE OBe sure the battery is fully charged e Start the engine and let it idle e Apply the tip of a screwdriver A to the fuel injector B Put the grip end onto your ear and listen whether the fuel injector is clicking or not
93. Be sure the adjusters are set equally OThe spring preload can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Adjuster Damping Position Force Good Low 1 13 14 SUSPENSION Front Fork Front Fork Removal Each Fork Leg e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Front Fender see Front Fender Removal in the Frame chapter Front Wheel see Front Wheel Removal the Wheels Tires chapter x Loosen the upper front fork clamp bolt A and fork top plug B beforehand if the fork leg is to be disassembled NOTE OLoosen the top plug after loosening the upper front fork clamp bolt e Loosen the lower front fork clamp bolts upper lower C e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork so that the length is 6 0 24 in A from the outside upper flat surface B of the steering stem head to upper surface C of the outer tube e Tighten Torque Lower Front Fork Clamp Bolts 20 5 N m 2 09 kgf m 15 1 ft lb Front Fork Top Plugs 22 5 N m 2 29 kgf m 16 6 ft Ib Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the top plug before tightening the upper front fork clamp bolt OTighten the t
94. C BK lead D Standard 11 7 15 5 at 20C 68 F x If the reading is out of the standard replace the sensor xIf the reading is within the standard check the power source voltage see Oxygen Sensor Heater Power Source Voltage Inspection Oxygen Sensor Heater Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Disconnect the oxygen sensor lead connector and con nect the harness adapter A between these connectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 e Connect a digital meter to the harness adapter lead Oxygen Sensor Power Source Voltage Connections to Adapter Digital Meter WG sensor BK lead Digital Meter Battery terminal e Measure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch on Power Source Voltage Standard Battery Voltage e Turn the ignition switch off xIf the reading is in specification but the problem still ex ists replace the ECU see ECU Removal Installation x If the reading is out of the standard check the following Oxygen Sensor Heater Fuse 10 A see Fuse Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in this section 80178140651 3 102 FUEL SYSTEM Oxygen Sensor Heater Service Code 67 xIf the fuse and wiring are good remove the ECU and c
95. Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder x If the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment e Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible e Remove the right subframe cover see Subframe Cover Removal in the Frame chapter e Slide the dust cover A at the clutch cable lower end out of place e Loosen both adjusting nuts B at the clutch cover as far as they will go e Pull the clutch outer cable C tight and tighten the adjust ing nuts against the clutch cover D e Slip the dust cover back onto place e Turn the adjuster at the clutch lever until the free play is correct e Push the release lever A toward the front of the motor cycle until it becomes hard to turn OAt this time the release lever should have the proper an gle shown 60 B x If the angle is wrong check the clutch and release parts for wear A WARNING Too much cable play can
96. D e Insert the projections E into the holes F and insert the tab G into the slot H e Install the ignition switch cover see Ignition Switch Cover Installation Middle Fairing Removal e Remove Seats see Rear Front Seat Removal Tank Cover see Tank Cover Removal Side Cover see Side Cover Removal Subframe Cover see Subframe Cover Removal Bolt A e Clear the projection B and hook fastener C and pull the middle fairing D backward to clear the hooks E Middle Fairing Installation e When installing the hook fastener A align the edge of the hook fastener with the lines B of the fuel tank C G005045BS1 C e Check that the pad A is in place on the middle fairing B G005046BS1 C Fairings FRAME 15 13 e Check that the grommet A is in place on the fuel tank e Insert the tabs B into the slots C e Fit the hook fasteners D e Insert the projection E into the hole F e Tighten the bolt e Install the removed parts see appropriate chapters Side Fairing Removal e Remove Middle Fairing see Middle Fairing Removal Bolts A Washer B Collar C e Clear the projections D and remove the side fairing E Side Fairing Installation e Check that the pad A is in place on the side fairing 10 mm 0 39 in B e Check that the grommets A are in place e Insert the projections B into the holes C e Install Collar A Washer B Bolts C
97. Diameter Marking Crankshaft Main Bearing Insert Thickness Brown 1 490 1 494 mm 0 0587 0 0588 in Black 1 494 1 498 mm 0 0588 0 0590 in Blue 1 498 1 502 mm 0 0590 0 0591 in Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92028 1868 3 5 92028 1829 92028 1867 92028 1828 1 Brown Black Po ne 92028 1866 N N BI bearing inserts for Nos 1 2 and 4 journals have an oil groove respectively Transmission Shift Fork Ear Thickness 5 9 6 0 mm 5 8 mm 0 232 0 236 in 0 228 in Gear Groove Width 6 05 6 15 mm 6 25 mm 0 238 0 242 in 0 246 in Shift Fork Guide Pin Diameter 6 9 7 0 mm 6 8 mm 0 272 0 276 in 0 268 in Shift Drum Groove Width 7 05 7 20 mm 7 3 mm 0 278 0 283 in 0 287 in 9 8 CRANKSHAFT TRANSMISSION Special Tools and Sealant Bearing Puller 57001 135 875701355 C Outside Circlip Pliers 57001 144 7570144ST C Bearing Puller Adapter 57001 317 7570317ST C Bearing Driver 32 57001 382 875703825 C Flywheel Holder 57001 1313 wy 15713138T C Liquid Gasket TB1216B 92104 1064 NS 879210645 Liquid Gasket TB1207B 92104 2068 M
98. Driver Set B 57001 1129 GJ06064BS2 C GJ06039BS1 C 6J06008BS1 C Hub Bearing WHEELS TIRES 10 17 e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 e Install the removed parts see appropriate chapters Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding xIf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J06008BS1 C 6J06002BS1 C FINAL DRIVE 11 1 Final Drive Table of Contents Exploded VIEW ieee oot ee E een 11 2 Ex 11 4 Special TOONS REE 11 5 Drive Odi LM 11 6 Drive Chain Slack Insp
99. End chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Air Suction Valves see Air Suction Valve Removal in the Engine Top End chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove the engine sprocket A see Engine Sprocket Removal in the Final Drive chapter e Disconnect Crankshaft Sensor Lead Connector and Oil Pressure Switch Lead Terminal see Crankshaft Sensor Removal in the Electrical System chapter Starter Motor Cable see Starter Motor Removal in the Electrical System chapter Alternator Lead Connector see Alternator Cover Re moval in the Electrical System chapter Neutral Switch Lead Connector B Side Stand Switch Lead Connector C Speed Sensor Lead Connector D Open the clamps E Remove the quick rivets A e Remove Front Engine Bracket Bolts A Horn B Front Engine Bracket C e Support the engine with a suitable stand A OPut a plank B onto the suitable stand for engine balance ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation Remove the right front engine mounting bolt A e Using the nut wrench A loosen the lock nut B Special Tool Engine Mount Nut Wrench 57001 1450 e Using the Hexagon Wrench turn the upper adjusting col
100. F ose wa P BK BKAY BK BL Joint BK BL Connector ECU HJ DA Joint Sannector D Rear Right Turn Signal Light 12VioW Tail Brake Light LEB SY Kawasaki Self diagnostic System Connector BL R BK BK BK A INI iii SIE B BE 15 n Regulator Rectifier Alternator License Plate Light 12V5W Y R ilr et Rear Left Turn Signal Light 12V10W R Y BLAR Fuse Box 2 1 Fan Fuse 15 2 Meter Fuse 7 Battery Ground Joint Starter 12V8Ah Frame Ground Rear Connector 8 C C d Motor Brake olor ode Light Starter Relay Switch Black 1 EGU Fuse 198 Blue oe ete Brown Blue 2 3 4 0 Orange Pink Purple R Red Ww White 88052 07070 W2RO707CW5 C 16 26 ELECTRICAL SYSTEM Wiring Diagram ZR800D Right Switch Housing 1 Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button 957 5 Intake Vehicle Air down Temperature Sensor Sensor 1 b eed Sark Plugs 2 5 dot 1 2 3 4 wF PY Pru Switchin
101. Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric starter For KLEEN do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner housing holder loose Air cleaner poorly sealed or missing Air cleaner clogged Compression high Carbon built up in combustion chamber 17 42 APPENDIX Troubleshooting Guide Engine load faulty Brake dragging Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Water temperature meter incorrect Water temperature meter broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble
102. Gasket TB1216B 92104 1064 e Install the new head cover gasket NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the cylinder head cover is applied e Install the cylinder head cover e Install the washer A with the metal side faces upward GE09054BS1 GE09084BS1 C GE09057BS1 5 18 ENGINE TOP END Cylinder Head Cover e Tighten the cover bolts following the specified tightening sequence Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters GE09058BS1 C Camshaft Chain Tensioner ENGINE TOP END 5 19 Camshaft Chain Tensioner Removal NOTICE This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Right Subframe Cover see Subframe Cover Removal in the Fra
103. If the reading is out of the standard replace the exhaust butterfly valve actuator xIf the reading within the standard but the problem still exists replace the ECU see ECU Removal Installation Exhaust Butterfly Valve Actuator Sensor Circuit 0 E 1 Water Proof Joint 1 2 Water Proof Joint 2 3 Exhaust Butterfly Valve Actuator 4 ECU 6GC17437FW2 3 86 FUEL SYSTEM DFI Immobilizer Amplifier Service Code 35 Antenna Resistance Inspection e Turn the ignition switch off e Remove the fuel tank see Fuel Tank Removal e Disconnect the antenna lead connector A e Measure the antenna resistance Antenna Resistance Connections BK lead BK W lead Standard About 3 0 4 6 Q x If the reading is out of the standard replace the antenna see Immobilizer System Parts Replacement in the Elec trical System chapter xIf the reading is within the standard check the wiring to the amplifier see wiring diagram in next section x If the wiring is good check the input voltage of the ampli fier see Amplifier Input Voltage Inspection Amplifier Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove the fuel tank see Fuel Tank Removal ODo not disconnect the connectors e Connect a digital meter to the amplifier connector A with needle adapter set Special Tool Needle Adapter Set 57001 1457 Amplifier Input Voltage Connect
104. If the seat width is within the specified range lap the valve to the seat as described below Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B GE15012281 GE15012381 C ENGINE TOP END 5 33 Valves eLapthevalve tothe seat once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance chapter GE15012081 C 5 34 ENGINE TOP END Valv
105. Ignition Fuse 15 A 8 Engine Ground 17 Joint Connector C 9 Battery 12 V 8 Ah FUEL SYSTEM DFI 3 83 Exhaust Butterfly Valve Actuator Sensor Service Code 34 ZR800A B Models Exhaust Butterfly Valve Actuator Sensor Removal Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator So the sensor itself can not be removed Remove the exhaust butterfly valve actu ator see Exhaust Butterfly Valve Actuator Removal Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove the fuel tank see Fuel Tank Removal e Disconnect the exhaust butterfly valve actuator sensor lead connector 3 pins connector and connect the har ness adapter A between these connector Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Connect a digital meter to the harness adapter leads Exhaust Butterfly Valve Actuator Sensor Input Voltage Connections to Adapter Digital Meter Y W actuator W lead Digital Meter BK BL actuator BK lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch off x If the reading is within the standard check the output volt age see Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection
106. Injector 2 14 ECU Fuse 15A 5 Fuel Injector 3 15 Relay Box 6 Fuel Injector 4 16 Fuel Pump Relay 7 Frame Ground 3 17 Fuse Box 1 8 Joint Connector D 18 Ignition Fuse 15A 9 ECU 19 Joint Connector C 10 Engine Ground Throttle Grip and Cables FUEL SYSTEM DFI 3 125 Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Cable Installation e Install the throttle cables in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the lower ends of the throttle cables in the throttle pulley on the throttle body assy after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Be sure the cables are routed correctly and properly adjusted Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter 3 126 FUEL SYSTEM Throttle Body Assy Idle Speed Inspection Adjustment e Refer to the Idle Speed Inspection Adjustment in the Pe riodic Maintenance chapter Synchronization Inspection Adjustment Refer t
107. Level Sensor Inspection x If the above items are good replace the meter assembly and or ECU GP170920 6 duty t TX100 50 i ETE 0V 8 17093052 16 82 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Fuel Level Sensor Line Self Diagnosis Mode Inspection NOTE OUsually when the open or short of the fuel level sensor circuit is detected it becomes the Fuel Level Sensor Line Self Diagnosis Mode OThe all segments of the fuel gauge and fuel warning sym bol A in the display will blink This function is Fuel Level Sensor Line Self Diagnosis Mode x If the meter enters the self diagnosis mode when the me ter is installed in the motorcycle check the fuel level sen sor see Fuel Level Sensor Inspection and wiring x If the fuel level sensor and wiring are good replace the meter assembly GP170650 6 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 83 Meter Circuit GP17096DW3 C Ignition Switch Speed Sensor Water proof Joint 1 Water proof Joint 2 Neutral Switch Water Temperature Sensor Crankshaft Sensor Oil Pressure Switch Joint Connector E ECU Frame Ground 1 Engine Ground Battery 12 V 8 Ah Main Fuse 30 A Starter Relay Meter Fuse 7 5 Fuse Box 2 Fuel Level Sensor ABS Hydraulic Unit Equipped Models Turn Signal Switc
108. Light LED 12 52 ABS Unit Solenoid Valve Inspection Service Code 13 14 17 18 21 12 55 ABS Solenoid Valve Relay Inspection Service Code 19 12 55 Front Rear Wheel Rotation Difference Abnormal Inspection Service Code 25 12 55 ABS Motor Inspection Service Code 35 12 56 Wheel Rotation Sensor Signal Abnormal Inspection Front Service Code 42 Rear Service Code 44 e RD cage Dee REA E ns ne coe FORM RR sa eo Rea ua 12 56 Front or Rear Wheel Rotation Sensor Wiring Inspection Service Code 43 12 57 Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 12 59 Power Supply Voltage Abnormal Inspection Service Code 52 Low Voltage Service Code 53 Migh Voltage jeier etaed tec 12 61 ABS Hydraulic Unit Internal Error Inspection Service Code 55 12 62 ABS Hydraulic Unit Removal 2 405 tette ipe drum erit 12 63 ABS Hydraulic Unit Installation Wee erred re Per 12 65 ABS Hydraulic Unit Inspection pp 12 65 Front Wheel Rotation Sensor Removal pp 12 66 Front Wheel Rotation Sensor Installation pp 12 66 Rear Wheel Rotation Sensor Remowval sss 12 66 Rear Wheel Rotation Sensor Installation pp 12 67 Wheel Rotation
109. Minnanna GP30228CS1 0 5second 0 5second GP30227C81 0 3second Qc Hh UUUUUUUUUUU GP30229CS1 ELECTRICAL SYSTEM 16 93 Immobilizer System e The ignition key 1 is successfully registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 2 times and stops for 1 second and then repeats this cycle to indicate successful regis tering of ignition key 1 e Turn to OFF and remove ignition key 1 OThe red warning indicator light LED and immobilizer warning symbol A blink to display the registration mode NOTE OTurn to OFF the ignition switch and wait for the period more than 15 seconds The registration mode automat ically ends and red warning indicator light LED and im mobilizer warning symbol go off OThis procedure has registered the registered ignition key and one ignition key OContinue the procedure to program the second and later keys e Insert the ignition key 2 to the ignition switch and turn it to ON Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted _ 0 5second 0 5second pope GP30227C81 GP302280S1 0 5second 0 5sec
110. No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2012 Kawasaki Heavy Industries Ltd First Edition 3 Sep 7 2012 LIST OF ABBREVIATIONS ABDC ABS AC Ah ATDC BBDC BDC BTDC C cmHg cu in DC DFI DOHC DOT ECU ampere s after bottom dead center antilock brake system alternating current ampere hour after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius centimeters of mercury cubic inch s direct current digital fuel injection double overhead camshaft department of transportation electronic control unit farad s degree s Fahrenheit foot feet gram s gallon s hour s horsepower s integrated circuit in km h L LCD LED Ib m min mmHg mph OZ Pa PS psi dt rpm
111. Operation Inspection First Step e Turn the ignition switch on Set the neutral position Turn the engine stop switch to stop position A e Push the starter button e The engine does not start x If the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop x If the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Spark Plug Condition Inspection e Remove the spark plugs see Spark Plug Replacement and visually inspect e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool x If the spark plug center electrode A and or side electrode B are corrected or damaged or if the insulator C is cracked replace the spark plug e Measure the gaps D with a wire type thickness gauge xIf the gap is incorrect carefully bend the side electrode with a tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in e Use the standard spark plug or its equivalent Spark Plug NGK CR9EK or ND
112. Release the brake D NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose e Install the diaphragm diaphragm plate and reservoir cap e Tighten Torque Front Master Cylinder Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten the bleed valve and install the rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines 9513339852 C 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove Upper F
113. Removal in the Brakes chapter e Remove Front Master Cylinder Reservoir Cap Screws A Reservoir Cap B Diaphragm Plate C Diaphragm D e Unscrew the locknut E and pivot bolt F and remove the brake lever e Pull the dust cover G out of place and remove the circlip H Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston assembly I e Replace Diaphragm D Dust Cover G Circlip H Piston Assembly l 8813335B 2 C Rear Master Cylinder Disassembly e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Remove the circlip A connector B and O ring C Special Tool Inside Circlip Pliers 57001 143 e Slide the dust cover D out of place and remove the cir clip E e Pull out the push rod assembly F e Remove the piston assembly G and return spring NOTICE Do not remove the secondary cup from the piston since removal will damage it e Replace Circlip A O ring C Circlip E Push Rod Assembly F Piston Assembly G 8513336852 C Diaphragm H Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause de
114. Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease 12 12 BRAKES Exploded View ABS Equipped Models 08102539845 C BRAKES 12 13 Exploded View No Fastener Remarks Brake Hose Banjo Bolts ABS Hydraulic Unit 33 Brake Hose Banjo Bolts 25 Rear Caliper Pin 27 Bleed Valve 69 in lb Rear Brake Pad Pin Plug 22 inlb Master Cylinder Mounting Bolts 25 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease o 12 14 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position 5 way adjustable to suit rider Non adjustable Non adjustable About 40 mm 1 57 in below footpeg top Brake Pads Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 5 mm 0 06 in Brake Discs Thickness Front 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Rear 5 8 6 2 mm 0 23 0 24 in 5 5 mm 0 22 in Runout TIR 0 15 mm 0 006 in or less TIR 0 3 mm 0 01 in Brake Fluid Grade DOT4 ABS Equipped Models Wheel Rotation Sensor Air Gap Front Rear 0 1 1 5 mm 0 004 0 059 in 0 1 1 5 mm 0 004 0 059 in BRAKES 12 15 Special Tools Hand Test
115. Replacement Parts S Follow the specified tightening sequence 14 4 STEERING Special Tools Head Pipe Outer Race Press Shaft Steering Stem Bearing Driver Adapter 41 5 57001 1075 57001 1345 ST571075ST C ST571345ST C Steering Stem Nut Wrench Head Pipe Outer Race Driver 55 57001 1100 57001 1446 ava 875711005 C 7571446ST C Steering Stem Bearing Driver 42 5 57001 1344 7571344ST C Steering STEERING 14 5 Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment Refer to the Steering Play Adjustment in the Periodic Maintenance chapter 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Bolts A Clamp B Clamp C ABS Equipped Models Bracket D Handlebars see Handlebar Removal Steering Stem Head see Steering Play Adjustment in the Periodic Maintenance chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Forks see Front Fork Removal in the Suspension chapter e Bend the claws A of claw washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 Remove the claw washer e Pushing up the stem base and remove the steering stem nut A with stem cap B Special Tool Steering Stem Nut Wrench C 57001 1100 e Remove Stee
116. U27ETR Spark Plug Replacement e Remove the stick coils see Stick Coil Removal in the Electrical System chapter e Remove the spark plugs using the 16 mm 0 63 in plug wrench A vertically SN N al SOS 9 9 99 9 9 99 yyy N IS gt SS 2222 N 6S17005BS1 C 2 62 PERIODIC MAINTENANCE Periodic Maintenance Procedures eReplace the spark plug with a new one Standard Spark Plug Type NGK CR9EK or ND U27ETR e Insert the new spark plug in the plug hole and finger tighten it first e Using the plug wrench A vertically tighten the plug The insulator of the spark plug may break if when the wrench is inclined during tightening Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib e Install the stick coils securely OBe sure the stick coils are installed by pulling up it lightly Others Chassis Parts Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Side Stand Points Lubricate with Grease Clutch Inner Cable Uppe
117. Water Temperature Sensor Service Code 14 3 62 Water Temperature Sensor Removal Installation pp 3 62 Water Temperature Sensor Output Voltage 3 62 Water Temperature Sensor Resistance 3 63 Intake Air Pressure Sensor 2 Service Code 16 3 64 Intake Air Pressure Sensor 2 Removal 3 64 Intake Air Pressure Sensor 2 3 64 Intake Air Pressure Sensor 2 Input Voltage 3 65 Intake Air Pressure Sensor 2 Output Voltage 3 66 Crankshaft Sensor Service Code 21 3 68 Crankshaft Sensor Removallnstallation 9 3 68 Crankshaft Sensor Resistance Inspection Ne 3 68 Crankshaft Sensor Peak Voltage Inspection essen 3 68 Speed Sensor Service Code 24 3 69 Speed Sensor Removal lnstallation pp 3 69 Speed Sensor Input Voltage Inspection pp 3 69 Speed Sensor Output Voltage Inspection pp 3 70 Vehicle down Sensor Service Code 31 7 3 72 Vehicle down Sensor Remowval esses eee eene em rene ener ene
118. a hammer or allowed to fall on a hard surface Be careful not to get water or mud on the ABS hy draulic unit e Drain the brake fluid from the front and rear brake lines ODrain the brake fluid through the bleed valve by pumping the brake lever and pedal e Remove Seats see Rear Front Seat Removal in the Frame chap ter Battery see Battery Removal in the Electrical System chapter Bolt A e Disconnect the ABS hydraulic unit connector B e Remove Exhaust Butterfly Valve Actuator ZR800B Model see Exhaust Butterfly Valve Actuator Removal in the Fuel System DFI chapter Rear Fender see Rear Fender Removal in the Frame chapter e Clean the ABS hydraulic unit NOTICE Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal installation Spread out a shop towel around the ABS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts e Remove the brake hose banjo bolts A while holding the ABS hydraulic unit B with a suitable plier C OCover the ABS hydraulic unit with a suitable rubber sheet D or thick cloth to prevent the damage 12 64 BRAKES Anti Lock Brake System Equipped Models e Remove the brake hose banjo bolts A while holding the ABS hydraulic unit B with a suitable plier C e Remove Bolt A ABS Hydraulic Unit Assembly B
119. adapter leads Oxygen Sensor Output Voltage Connections to Adapter Digital Meter BL Y sensor BL lead Digital Meter BR BK sensor W lead e Remove Fuel Tank see Fuel Tank Removal Air Suction Valve Covers see Air Suction Valve Re moval in the Engine Top End chapter Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter e Install the air suction valve covers see Air Suction Valve Installation in the Engine Top End chapter e Connect the air switching valve connector A e Install the suitable plugs A on the fitting of the air suction valve covers and shut off the secondary air 3 104 FUEL SYSTEM Oxygen Sensor Incorrect Output Voltage Service Code 94 e Remove the fuel outlet hose see Fuel Hose Replacement in the Periodic Maintenance chapter e Connect the following parts temporary Fuel Pump Lead Connector A Fuel Level Sensor Lead Connector B Extension Tube C Special Tool Extension Tube 57001 1578 e Start the engine and let it idle e Warm up the engine thoroughly until the radiator fan starts e Measure the output voltage with the connector joined Output Voltage with Plugs Standard DC 0 7 V or more e Next remove the plugs from the fittings A with idling A WARNING The engine gets extremely hot during normal oper ation and can cause serious burns Never touch a hot engine e Measure the out
120. adjust the open cable first Do not overstretch If the adjustment of the exhaust butterfly valve cables are incorrect the exhaust butterfly valve actuator does not operate correctly e Then stretch the close cable black D by using the ad juster E OTurn the adjuster counterclockwise until the play of the close cable becomes no play Locknut of Black F e Tighten Torque Exhaust Butterfly Valve Cable Adjuster Locknuts 6 9 N m 0 70 kgf m 61 in Ib e After installation cover the dust covers on the adjusters GE 81798W2 e After connecting the cables turn the ignition switch in and make sure that the pulley turns clockwise and counter clockwise then it returns clockwise slightly e Install the removed parts see appropriate chapters CLUTCH 6 1 Clutch Table of Contents Exploded ELM 6 2 ERR 6 4 Special Tool and 0 6 5 Clutch Lever and 222002 6 6 Clutch Lever Free Play InSpectiQFi nocent tinent nene ertet canvas da Spe sh 6 6 Clutch Lever Free Play Adjustment 0 2221 4 0010 6 6 Clutch Cable ce teo 6 6 Clutch Cable Installation aereo to ee te te tee aeri teret ot exe oo bee ode esa pec t Eee inta ord 6 6 Glutc
121. and replace damaged parts if necessary Incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder compression is lower than usable range Gas leakage around cylinder head Replace damaged check gasket and cylinder head warp Bad condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings 5 24 ENGINE TOP END Cylinder Head Cylinder Head Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal e Drain the coolant from the cylinder OPlace a container under the drain bolt A and remove it e Tighten the drain bolt with new gasket Torque Coolant Drain Bolt Cylinder 9 8 N m 1 0 kgf m 87 in Ib e Remove Crankshaft Sensor see Crankshaft Sensor Removal in the Electrical System chapter Front Camshaft Chain Guide Bolts A Front Camshaft Chain Guide B Rear Camshaft Chain Guide Bolt C Rear Camshaft Chain Guide D e Remove M6 Cylinder Head Bolts A M10 Cylinder Head Bolts B
122. are clogged remove the tank and drain it and then blow the breather free with compressed air Do not apply compressed air to the air vent holes C in the tank cap This could cause damage and clogging of the labyrinth in the cap Fuel Tank Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove Fuel Tank see Fuel Tank Removal Fuel Intake Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Pump see Fuel Pump Removal e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the fuel tank e Dry the tank with compressed air e Install Fuel Pump see Fuel Pump Installation Fuel Intake Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation COOLING SYSTEM 4 1 Cooling System Table of Contents 4 2 Coolant Flow 4 4 tete Rer dv ds 4 6 Special Tools 4 7 jura cEE 4 8 Coolant Deterioration INSPECTION 9
123. around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed OZR800A B D Models C OZR800C Model D 9105317851 9105320851 9105166851 C Calipers BRAKES 12 21 Caliper Dust Seal Damage Inspection e Check that the dust seals A are not cracked worn swollen or otherwise damaged x If they show any damage replace the dust seals with new ones Pistons B Fluid Seals C OZR800A B D Models D OZR800C Model E Front Caliper Dust Boot and Friction Boot Damage Inspection ZR800C Model e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged x If they show any damage replace it Rear Caliper Dust Boot and Friction Boot Damage Inspection e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged x If they show any damage replace it GLO5318BS1 9105321851 C GL05187BS1 C GLO5296BS1 C 12 22 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection e Visually inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scores or rusty OZR800A B D Models C OZR800C Model D Front
124. be on the adhesive coating area Dry them with a Clean cloth e Apply adhesive cement to the left side of the handlebars e Install the handlebar grip OWipe off any protruding adhesive cement e Apply a non permanent locking agent to the left handlebar weight screw and tighten it e Install the left switch housing OFit the projection A into a hole B in the handlebars e Tighten Torque Switch Housing Screws 3 5 0 36 kgf m 31 in Ib e Install the clutch lever see Clutch Lever Installation in the Clutch chapter e Install Throttle Grip Throttle Cable Tips A Right Switch Housing OFit the projection B into a hole C in the handlebars Torque Switch Housing Screws 3 5 N m 0 36 kgf m 31 in Ib e Apply a non permanent locking agent to the threads of the right handlebar weight screw and tighten it e Install the front master cylinder see Front Master Cylinder Installation in the Brake chapter e Run the lends cables and hose correctly see Cable Wire and Hose Routing section in the Appendix chap ter FRAME 15 1 Frame Table of Contents corn perite ie dert deel te pu Ro 15 2 D UE o MN 15 8 Rear Seat Remoyvalz RE e mee CEU 15 8 d o
125. bearings are identical e Install the stem A through the head pipe and install the ball bearing B and inner race C on it e Install Stem Cap D Steering Stem Nut E GNOS156BS1 C 14 8 STEERING Steering Stem e Settle the bearings in place as follows OTighten the steering stem nut with 55 Nm 5 6 kgf m 41 ft Ib of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a steering stem nut wrench A Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 27 N m 2 8 kgf m 20 ft Ib e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Install the stem head e Install the washer and temporary tighten the steering stem head bolt e Install the front forks see Front Fork Installation in the Suspension chapter NOTE OTighten the upper front fork clamp bolts first next the stem head bolt last the lower front fork clamp bolts OTighten the two lower front fork clamp bolts upper lower alternately two times to ensure even tightening torque Torque Upper Front Fork Clamp Bolts
126. but generally speaking the lower reading should be from zero to one half the scale ELECTRICAL SYSTEM 16 113 Relay Box Relay Box Internal Circuit GPi90108W2 C A Headlight Circuit Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Radiator Fan Relay 16 114 ELECTRICAL SYSTEM Fuse 30 A Main 15 A ECU Fuse Removal e Remove Left Side Cover see Side Cover Removal in the Frame chapter Starter Relay Cover A e Pull out the fuses A from the starter relay with needle nose pliers Fuse Box Fuse Removal e Remove the seats see Rear Front Seat Removal in the Frame chapter Unlock the hooks A to lift up the lids B Fuse Box 1 C Fuse Box 2 D e Pull the fuses A straight out of the fuse boxes with needle nose pliers Fuse Installation x If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage e Install the fuse box fuses on the original position as spec ified on the lid ELECTRICAL SYSTEM 16 115 Fuse Fuse Inspection e Remove the fuse see 30 Main 15 ECU Fuse Box Fuse Removal e Inspect the fuse element x lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A
127. by other than self diagnosis Check by self diagnosis If harness or connector is faulty If ABS part is faulty Repair or replace Check ABS parts NG Final inspection OK End GLI4011B F 12 44 BRAKES Anti Lock Brake System Equipped Models Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of condition the rider is dissatisfied with OTry to find out exactly what problem occurs under exactly what conditions by asking the rider know ing this information may help you reproduce the problem in the shop OThe diagnosis sheet will help prevent you from overlooking any keys so always use it Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Frequency Weather Mileage Phenomenon 1 Brake lever vibration or noise O Pedal vibration or noise Yellow ABS indicator light LED blinks Yellow ABS indicator light LED remains lit up O Braking distance too long O Abnormal brake lever movement 1 Abnormal pedal movement ABS not working ABS works but yellow ABS indicator light LED doesn t light up ABS operating too frequently Engine conditions at O At start up 1 After starting At 5 000 r min rpm or more problem Road conditions Slippery road O snow 1 gravel 1 other Rough surface Other High sp
128. can damage it Main Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove Left Throttle Body Cover see Throttle Body Assy Re moval e Disconnect the main throttle sensor connector and con nect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Main Throttle Sensor Input Voltage Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor G lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch off x If the reading is within the standard check the output volt age see Main Throttle Sensor Output Voltage Inspec tion OBO 6C17127BS1 3 50 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A lt Main Throttle Sensor Connector B BL lead ECU terminal 5 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and powe
129. changing oil Approx 450 mL 15 2 US oz After disassembly and completely dry 529 4 mL 17 9 0 135 US oz e Replace the O ring A on the top plug B with a new one Apply grease to the new O ring Screw on the piston rod rubber nut C fully to the piston rod D OScrew the piston rod rubber nut with the flat surface E facing upward Screw in the top plug stopped onto the piston rod Holding the top plug A with a wrench B tighten the piston rod rubber nut C against the top plug Torque Piston Rod Rubber Nut 15 N m 1 5 kgf m 11 416 e Rise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation Front Fork Disassembly e Remove the front fork see Front Fork Removal Drain the fork oil see Fork Oil Change 7 My D SUSPENSION 13 33 Front Fork e Separate the inner tube from the outer tube as follows OSlide up the dust seal A ORemove the retaining ring B from the outer tube OHolding the outer tube A by hand pull the inner tube B several times to pull out the outer tube e Remove the following parts from the inner tube Inner Tube Guide Busing A Outer Tube Guide Busing B Washer C Oil Seal D Retaining Ring E Dust Seal F Other than ZR800C D Models Left Front Fork e Hold the inner tube lower end in a vice e Using the fork cylinder holder A loosen the cylinder unit
130. chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Fuel pressure too low or too high Fuel pressure regulator trouble Fuel line clogged Poor acceleration Fuel pressure too low Water or foreign matter in fuel Fuel filter or pump screen clogged Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Inspect and repair see chapter 3 Inspect see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor 1 trouble Inspect see ch
131. code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect 3 46 FUEL SYSTEM DFI Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI ignition or immo bilizer system parts have troubles Service Output Signal Usable Codes Pars Range or Criteria Backups By If the main throttle sensor system fails the output voltage is out of usable 11 Output vorago wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method 1 If the intake air pressure sensor 1 system 12 fails the signal is out of the usable range Sensor 1 Pv 600 900 wiring short or open the ECU sets the DFI 9 jinthe a N method 2 Intake Air iake Air Temperature If the intake air temperature sensor system 13 Temperature 45 fails the signal is out of the usable Sensor wiring short or open the ECU sets Ta at 40 C If the water temperature sensor system fails Water Water Tenbarature the signal is out of the usable range wiring 14 Temperature Tw 30 r 120 C short or open the ECU sets Tw at 80 C Sensor When an radiator fan is turning on ECU sets Tw at 110 C If the intake air pressure sensor 2 system 16 D 2 fails the signal is out of the
132. discoloration or damage replace them as a set e Turn the bearing in the swingarm back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing 6GM062308W2 C Swingarm SUSPENSION 13 45 Swingarm Bearing Lubrication NOTE OSince the bearings are packed with grease and sealed lubrication is not required Chain Guide Inspection Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter 13 46 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal Squeeze the brake lever slowly and hold it with a band A e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Upper Tie Rod Nut and Bolt A Lower Tie Rod Nut and Bolt B Tie Rods C Tie Rod Installation e Apply grease to the inside of the oil seals e Install the tie rods so that the marked side faces A out side e Replace the tie rod nuts with new ones e Tighten Torque Tie Rod Nuts 59 N m 6 0 kgf m 44 ft Ib Rocker Arm Removal e Squeeze the brake lever slowly and hold it with a band e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Lower Rear Shock Absorber Nut and Bol
133. felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Install the clamp and screw e Tighten Torque Front Master Cylinder Reservoir Cap Screws 1 5 N m 0 15 13 e Tighten the bleed valve and install the rubber cap Torque Bleed Valves 7 8 0 80 kgf m 69 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage GLO9065BS2 C M C AE RO K 2 12 34 BRAKES Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below e Never reuse old brake fluid e Do not use fluid from a container that has been left unsealed or that has been open for a long time eDo not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to dete riorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid e Don t change the fluid in the rain or when a strong wind is blowing e Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the bra
134. flash point solvent should be used according to directions of the solvent manufacturer 6 020058 5 Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or 0 other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly 68020088 5 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol SN oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace AN parts if any has been found or if the part is be yond its service limit 680200968 5 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips cotter pins or self locking nuts must be rep
135. fuel pump have been clogged or stuck xIf the fuel pressure is much lower than specified check the following Fuel Line Leakage see Fuel Injector Fuel Line Inspec tion Amount of Fuel Flow see Fuel Flow Rate Inspection e After above checks measure the fuel pressure again e Remove the fuel pressure gauge hoses and adapter e Install Fuel Outlet Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation e Start the engine and check for fuel leakage Fuel Flow Rate Inspection A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the potential for serious burns Make sure the area is well venti lated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch off Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Wait until the engine cools down e Prepare a fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 e Remove the fuel tank bolt see Fuel Tank Removal 3 114 FUEL SYSTEM Fuel Line e Open the fuel tank cap A to lower the pressure in the tank e Remove the fuel outlet hose from the fuel pump see Fuel Tank Removal OBe sure to place a piece of cloth around t
136. go to the next step Not Verified OThe red warning indicator light LED and immobilizer warning symbol A blink to display the collation error refer to the following failure illustrations Immobilizer Amplifier Failure Registered Ignition Key Collation Error Turn the registered ignition key to OFF and remove the registered ignition key x If there are other registered ignition keys they should all do the procedure above OThe red warning indicator light LED and immobilizer warning symbol A blink continuously to display that the ECU is in the registration mode for 15 seconds NOTE Olnsert next key and turn it to ON within 15 seconds af ter previous key is turned to OFF and removed other wise registration mode will be ended and the red warn ing indicator light LED and immobilizer warning sym bol stop blinking OTo return to the registration mode start the registered ignition key s verification procedure This applies to all ignition key registration e Insert the ignition key 1 to the ignition switch and turn it to ON NOTE OKeep the other ignition key away from the immobilizer antenna 0 5second 0 5second oe deste ses GP30227C81 GP30228CS1 0 3second QOO UL GP30229CS1 0 5second 0 5second oe ESE py spes 8 302270651 16 86 ELECTRICAL SYSTEM Immobilizer System Olf there is any problem in the regi
137. it Air Switching Valve S eu foils ve R BK CI BK Y BK 0 BK 0 R BL BR BK BK Y Immobilizer Anplifier Immobilizer Antenna ES Joint Connector Meter Unit el iens Joint Connector A m sj BK Y Front Right IE Meter Unit i Yellow Engine Warning Indicator Light LED Fuse Box 2 Green Neutral Indicator ignition Fuse 15 Light LEB 2 Headlight Fuse 15 3 High Beam Indicator 3 Brake Horn Fuse 7 Light LED 4 Turn Signal Relay Fuse 7 5 4 Green Left Turn Signal Indicator Light LED reen Right Turn Signa Indicator Light LED Red Warning Indicator Light Battery Oil Pressure Water Temperature Immobilizer LED Speedometer Mileege Cruising Range Fuel Level Gauge Tachometer ater Temperature Meter dometer Trip Meter lock Illumination Light LED x 0 1 LED Light Emitting Diode 1 Button Turn sient EJF Light LE H 12V10 Right City Light 12V8N GIAE we ill Headlight Fuse Box 1 Low BK Y 12V558 or Headlight Lr 12v55 Left City D ery Light 12V5W GIZA Front Left Turn Signal 2 Left Switch Housi
138. it can be spun freely Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance see Balance Adjustment Balance Adjustment e f the wheel always stops one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used xIf the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct wheel balance e Permanently install the balance weight Balance Weight Removal e Insert standard tip screwdrivers A B between the rib C and the weight D as shown e Pry the balance weight with two screwdrivers and remove the balance weight e Discard the used balance weight NOTICE Do not tap the screwdrivers The rim could be dam aged Balance Weight Installat
139. link Length Standard Chain 20 30 mm 0 8 1 2 in 317 5 318 2 mm 12 50 12 53 in Up to 180 kg 397 Ib load rose 250 kPa 2 50 kgf cm 36 psi Rear Up to 180 kg 397 Ib load 290 kPa 2 90 kgf cm 42 psi Final Drive pedal travel Make ENUMA Type EK520MVXL2 Link 114 Links Brakes Brake Fluid Grade DOT4 Brake Pad Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 5 mm 0 06 in Brake Light Timing Front Pulled ON Rear ON after about 10 mm 0 39 in of Electrical System Spark Plug Type Gap NGK CR9EK or ND U27ETR 0 7 0 8 mm 0 028 0 031 in Special Tools Inside Circlip Pliers 57001 143 Steering Stem Nut Wrench 57001 1100 7570143ST C 875711005 C Pilot Screw Adjuster A 57001 1239 N 875712395 6 Oil Filter Wrench 57001 1249 7571249ST C PERIODIC MAINTENANCE 2 13 Vacuum Gauge 57001 1369 875713695 C Throttle Sensor Setting Adapter 57001 1538 7571538ST C Extension Tube 57001 1578 7571578ST C 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Air Cleaner Element Cleaning NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval A WARNING If dirt or dust is allowed to pass through i
140. molybdenum disulfide oil solution to the crankshaft main bearing inserts e Install the crankshaft with the camshaft chain A hanging on it Connecting Rod Removal Split the crankcase see Crankcase Splitting e Remove the connecting rod big end nuts A e Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions Remove the connecting rods from the crankshaft NOTICE Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins Connecting Rod Installation NOTICE To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D O or no mark 8105060181 If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Apply molybdenum disulfide oil solution A to the inner surfaces of upper and lower bearing inserts e Do not apply any grease or oil to the cap inside and cap insert outside B e Install the inserts so that their nails C are on the same
141. not at least 12 6 V repeat charging cycle OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 V repeat the charging cycle and load test If still below 12 6 V the battery is defective 16 34 ELECTRICAL SYSTEM Battery Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery NOTICE This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Gi
142. number of turns counted when first turned in This is to set the screw to its original position NOTE OA throttle body has different turns out of the bypass screw for each individual unit On setting the bypass screw use the turns out determined during disassem bly e Repeat the same procedure for other bypass screws Repeat the synchronization x If the vacuums are correct check the output voltage of the main throttle sensor see Main Throttle Sensor Output Voltage Inspection in the Fuel System DFI chapter Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y W lead Digital Meter W sensor lead Standard DC 0 995 1 025 V at idle throttle opening x If the output voltage is out of the standard check the in put voltage of the main throttle sensor see Main Throttle Sensor Input Voltage Inspection in the Fuel System DFI chapter Remove the vacuum gauge hoses and install the rubber caps on the original position Fuel System Fuel Hose Inspection fuel leak damage installation condition Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Re moval in the Fuel System DFI chapter and check the fuel hoses Replace the hose if any fraying cracks B or bulges C
143. of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells GP08135BS1 C ME02112BS1 GP08139BS1 C 16 32 ELECTRICAL SYSTEM Battery e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container e Check the electrolyte flow If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times NOTE OBe careful not to have the battery fall down Keep the container in place Don t remove the container from the battery the battery requires all the electrolyte from the container for proper operation NOTICE Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the container until it is completely empty e After filling let the battery sit for 20 60 minutes with the electrolyte container kept in place which is required for the electrolyte to fully permeate into the plates e Make sure that the container cells have emptied com pletely and re
144. of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact 8 15011951 C GE15012181 5 32 ENGINE TOP END Valves x If the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn NOTICE The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above x If the seat width is too wide make the 60 A grind de scribed below x
145. of the hole high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one Turn the bearing in the coupling back and forth A while checking for plays roughness or binding x If the bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Coupling Bearing Lubrication NOTE OSince the coupling bearing is packed with grease and sealed lubrication is not required Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket
146. of the joint pipe B with new ones e Apply engine oil to the new O rings and insert it to the delivery pipes C Olnsert the joint pipe so that the short side D faces right side OLeft and right delivery pipes are identical e Replace the O rings A of each injector B with new ones e Insert them to the delivery pipe assy C and confirm whether the injectors turn smoothly or not iron P eo P 3 132 FUEL SYSTEM Throttle Body Assy e Replace the dust seals A with new ones e Apply engine oil to the new dust seals e Install the injectors along with the delivery pipe assy to the throttle body Tighten Torque Delivery Pipe Assy Mounting Screws 3 5 0 36 kgf m 31 in Ib e Connect the subthrottle valve actuator connector and bind the harness with band e Install the throttle body assy see Throttle Body Assy In stallation Air Cleaner FUEL SYSTEM DFI 3 133 Air Cleaner Element Removal Installation e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A for tears or breaks xIf the element has any tears or breaks replace the ele ment Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water o
147. or Lost Part Ignition Ignition Keys Switch Amplifier ECU n Ignition Switch Amplifier Replacement Part Replacement Part Additional Replacement Part Immobilizer System Inspection e Refer to the Immobilizer Amplifier and Blank Key Detec tion section in the Fuel System DFI chapter 8 18655 52 16 106 ELECTRICAL SYSTEM Immobilizer System Immobilizer System Circuit GP30235CW3 C 5 Ignition Switch Joint Connector E ECU Immobilizer Kawasaki Diagnostic System Connector Frame Ground 1 Frame Ground 4 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15A ECU Main Relay Relay Box Fuse Box 1 Ignition Fuse 15 Red Warning Indicator Light LED Meter Unit Joint Connector C Immobilizer Antenna Immobilizer Amplifier ELECTRICAL SYSTEM 16 107 Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the switch housings and the ignition swit
148. position where the chain is tightest Measure the vertical movement chain slack A midway between the sprockets x If the chain slack exceeds the standard adjust it Chain Slack Standard 20 30 mm 0 8 1 2 in GK04060781 o 6812021BS1 o PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the axle nut B e Loosen the both chain adjuster locknuts C xIf the chain is too loose turn in the left and right chain adjusters D evenly xIf the chain is too tight turn out the left and right chain adjusters evenly and kick the wheel forward e Turn both chain adjusters evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the left wheel alignment indicator F should align with the same swingarm mark or position G that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned e Tighten Torque Chain Adjuster Locknuts 16 5 N m 1 68 kgf m 12 2 ft lb Rear Axle Nut 108 11 0 kgf m 79 7 ft lb e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do no
149. pp 3 108 FUEL SYSTEM DFI 3 3 DEI io iem EEUU 3 111 ECU Fuse Removal terere teg ag aee te ed re erre eg e a ret 3 111 EGU Fuse InstallatiOr 3 ettet hors tet cited et ete edi vt tn E eere o 3 111 ECU Fuse 3 111 ECU Main Relay Removal Installation pp 3 111 ECU Main Relay Inspection pp 3 111 BB 3 112 Fuel Pressure 3 112 Fuel Flow Rate 3 113 uu PT ML M 3 115 Fuel Pump RemioVal ete iat eun ere denen aere dee vie 3 115 Fuel Pump 3 116 Fuel Pump Operation Inspection pp 3 116 Fuel Pump Operating Voltage Inspection 4 3 117 Pressure Regulator Removal reb etre ede dane Rn EXPE dp adc d 3 118 Pump Screen Fuel Filter Cleaning pp 3 118 Fuel Pump Relay Removal Installation pp 3 118 etie Eo Ro eh Ee a b Ea tin t dee 3 118 EE 3 120 Fuel Injector Removal Installation pp 3 120 Fuel Injector Audible Inspection pp 3 120 Fuel Injector Resistance Inspection pp 3 120 Fuel Injector Power Source Voltage Inspection 3 121 Fuel Injector Output Voltage 3 122 Fuel Injector Fuel Line Inspection pp 3 123 Throttle
150. projections F into the holes C e Fit the grommet H on the bolt I e Tighten the bolt with washer 15 18 FRAME Seat Covers Seat Cover Removal e Remove Seats see Rear Front Seat Removal Bolts A e Pull the seat cover B backward to clear the hooks C Seat Cover Installation e Check that the pads A are in place on the seat cover e Check that the damper A is in place on the seat cover B e Insert the hooks C into the slots D on both sides e Install the removed parts see appropriate chapters FRAME 15 19 Fenders Front Fender Removal e Free the brake hoses A from the clamps B e Remove Bolts C with Washers Both Sides Front Fender D Front Fender Installation e Install the front fender to the front fork e Tighten Torque Front Fender Bolts 3 9 N m 0 40 kgf m 35 in Ib e Run the brake hose correctly see Cable Wire and Hose Routing section in the Appendix chapter Rear Fender Removal e Remove Seats see Rear Front Seat Removal Seat Cover see Seat Cover Removal Side Cover see Side Cover Removal Battery see Battery Removal in the Electrical System chapter ECU see ECU Removal in the Fuel System DFI chap ter Regulator Rectifier see Regulator Rectifier Inspection in the Electrical System chapter Bolts A Nuts B Remove the bolt A on both sides e Disconnect Left and Right Turn Signal Light Lead Connectors A License
151. pulling the rear of it up and Front Seat Installation e Insert the front seat hooks A under the slots B of the fuel tank bracket e Insert the hooks C into the seat holes D e Insert the bracket A into the hole B at the rear of front seat C while pushing down the rear part of the front seat e Tighten the bolts while pushing forward the rear part of the front seat FRAME 15 9 Fairings Upper Fairing Removal e Remove Bolts A Meter Cover B e Remove Bolts A Bracket B Remove the bolts C and pull out the upper fairing D forward Disconnect Headlight Lead Connectors A City Light Lead Connectors B Left and Right Turn Signal Light Lead Connectors C Remove the upper fairing D Upper Fairing Disassembly e Remove Upper Fairing see Upper Fairing Removal Headlight see Headlight Removal Installation in the Electrical System chapter Screws A Turn Signal Light Mounting Screws B Turn Signal Light Assembly C 0005042852 C 15 10 FRAME Fairings Upper Fairing Assembly Check the pads A are in place on the upper fairing e Installation is the reverse of removal 6G0050438W2 C Upper Fairing Installation e Connect City Light Lead Connectors Headlight Lead Connectors Left and Right Turn Signal Light Lead Connectors e Fit the projections A on the bracket into the holes B of the
152. see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI fuse blows Fuel pump bearings may wear Replace the fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Cracked or obstructed intake air pressure sensor 1 and 2 vacuum hose Inspect and repair or replace see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Subthrottle sensor trouble Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Subthrottle valve actuator trouble Knocking Fuel poor quality or incorrect Fuel change Use the gasoline recommended in Spark plug incorrect the Owner s Manual Replace it with the correct plug see chapter 2 Stick coil trouble Inspect see chapter 16 ECU trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 39 DFI S
153. segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection e Using the x 1 hand tester range measure the resis tance as shown Terminal Bolt and Positive Brush A Brush Plate and Negative Brush B Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has an open Replace the terminal bolt assembly and or the brush plate assembly Brush Plate and Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Brush Plate A Terminal Bolt and Right hand End Cover B Special Tool Hand Tester 57001 1394 x If there is any reading the brush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembly 8 11080851 C PUI P ELECTRICAL SYSTEM 16 57 Electric Starter System Starter Relay
154. sensor signal abnormal sensor or rotor missing too large clearance rotor tooth worn or missing Front or rear wheel rotation sensor wiring 43 wiring shorted or open connector bad ON connection Rear wheel rotation sensor signal abnormal 44 sensor or rotor missing too large ON clearance rotor tooth worn or missing Rear wheel rotation sensor wiring wiring 45 ON shorted or open connector bad connection 52 Power supply voltage abnormal ON low voltage 53 Annn an Power supply voltage abnormal ON high voltage 55 SLU ABS Hydraulic Unit Internal Error ECU ON operation abnormal In spite of the service code is not stored the yellow ABS Indicator Light LED does not go off when the 2 seconds later from the ignition switch turned on 12 52 BRAKES Anti Lock Brake System Equipped Models Yellow ABS Indicator Light LED Inspection Oln this model the yellow ABS indicator light LED A goes on or blinks by the control of the ABS hydraulic unit Yellow ABS Indicator Light LED Stays ON Error func tion after the ignition switch turned on No Service Code e Perform the Pre Diagnosis Inspection 1 e Check the system connectors for loose or poorly contact Step 1 e Check the ignition fuse 15 A A in the fuse box 1 for blown x If the fuse is blown replace the fuse xIf the fuse is not blown go to next step Step 2 e Measure the battery terminal volt
155. side of the fan motor and clutch cable Run the radiator overflow hose to the right side of the ignition switch main harness and throttle cables Run the fuel tank breather hose to the front of the fuel tank drain hose and reserve tank overflow hose Radiator Overflow Hose Bend the radiator overflow hose to the outside as shown Ignition Switch Lead 10 11 12 13 14 15 Immobilizer Antenna Lead Run the radiator overflow hose under the frame Clamp Hold the reserve tank overflow hose at the yellow tape position Turn Signal Light Relay Lead Left Right Switch Housing Lead Clamp Hold the left right switch housing lead at the white tape position Face the open side of the clamp to the upside Run the fuel tank breather hose and fuel tank drain hose to the front of the reserve tank bracket overflow hose and fuel tank drain hose Do not run the hoses in this space Stick Coil 1 Lead Run the stick coil 1 lead between the air switching valve hose and three hoses 17 20 APPENDIX Cable Wire and Hose Routing APPENDIX 17 21 Cable Wire and Hose Routing 17 18 Reserve Tank Overflow Hose Fuel Tank Drain Hose Fuel Tank Breather Hose Run the three hoses to the inside of the hook of the air cleaner housing Run the throttle position sensor lead through the hook of the air cleaner housing Throttle Position Sensor Connector Clamp Hold th
156. stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance Temperature Resistance kQ 20 4 F 18 80 2 37 0 32 F about 6 544 40 C 104 F 1 136 0 095 100 C 212 F 0 1553 0 0070 Reference Information Speed Sensor Removal Never drop the sensor especially hard surface Such a shock to the sensor can damage it e Remove Throttle Body Assy se Throttle Body Assy Removal in the Fuel System DFI chapter Connector A Speed Sensor Bolt B Speed Sensor C Speed Sensor Installation e Apply grease to the O ring A on the speed sensor B e Tighten Torque Speed Sensor Bolt 12 N m 1 2 kgf m 106 in Ib e Install the removed parts see appropriate chapters Speed Sensor Inspection e Refer to the Speed Sensor section in the Fuel System DFI chapter see Speed Sensor section in the Fuel Sys tem DFI chapter 8 18055 52 C ELECTRICAL SYSTEM 16 109 Switches and Sensors Oxygen Sensor Removal NOTICE Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it NOTICE Do not pull strongly twist or bend the oxygen sen sor lead This may cause the wiring open e Remove Right Frame Cover see Frame Cover Removal in the F
157. the air switching valve see Air Switching Valve Removal in the Engine Top End chapter e Set the hand tester A to the x 1 O range and connect it to the air switching valve terminals as shown Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 18 22 at 20 C 68 F x If the tester does not read as specified value replace it with a new one e Connect the 12 V battery A to the air switching valve terminals as shown e Blow the air to the intake air duct A and make sure does not flow the blown air from the outlet air duct B e Disconnect the 12 V battery e Blow the airto the intake air duct A again and make sure flow the blown air from the outlet air duct B x If the air switching valve does not operate as described replace it with a new one NOTE OTo check air flow through the air switching valve just blow through the air switching valve hose intake side C GE04030BS1 C GE04033BS1 C GE04031BS1 C lt 7 lt Se GE04032BS1 ELECTRICAL SYSTEM 16 67 Air Switching Valve Air Switching Valve Circuit 9 ore moy IGNITION S BR BATTERY Ge BR W BR W BK BL i GP18647BW3 C Ignition Switch Joint Connector E ECU Frame Ground 4 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15 A 10 ECU Mai
158. the battery is fully charged e Turn the ignition switch off e Remove the fuel tank see Fuel Tank Removal e Disconnect the water temperature sensor connector and connect the harness adapter A between these connec tors as shown Main Harness B Water Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the harness adapter leads Water Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor O lead Digital Meter BK sensor G lead e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch on Output Voltage Standard About DC 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine e Turn the ignition switch off x If the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17474FS1 C FUEL SYSTEM DFI 3 63 Water Temperature Sensor Service Code 14 xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Water Temperature Sensor Connector B O lead E
159. the connector A Remove the Immobilizer Amplifier B e Installation is the reverse of removal ECU Replacement NOTICE Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it NOTE OReplace the ECU according to the following procedure for the models with guards ORefer to the ECU section in the Fuel System DFI chap ter for the models without guards e Remove Seats see Rear Front Seat Removal in the Frame chap ter Seat Cover see Seat Cover Removal in the Frame chapter Battery see Battery Removal Relay Box see Relay Box Removal e Take out the ECU from rear fender hook e Remove the pad A 16 104 ELECTRICAL SYSTEM Immobilizer System e Using a small chisel A or other suitable tool remove the screws e Remove the upper guard A and lower guard B e Disconnect the connectors A Remove the ECU B e Check that the pad A and trim B are in place on the lower C and upper D guards GP18656BS2 C Immobilizer System ELECTRICAL SYSTEM 16 105 Connect the connectors to the ECU e Install the lower and upper A guards to the ECU NOTICE Do not pinch the leads e Tighten the new screws B using the Kawasaki genuine screws of which threads are coated with locking agent e Install the pads A over the guards as shown Registered Immobilizer Relational Parts Replacement Chart Failed
160. the fork spring compressor e Rise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation Left Front Fork e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vice e Unscrew the top plug A out of the outer tube e Holding the top plug A with a wrench B loosen the piston rod rubber nut C 13 30 SUSPENSION Front Fork e Using the fork piston rod stopper holder A remove the piston rod assy stopper B Special Tool Fork Piston Rod Stopper Holder 5700 1789 NOTE Olnstall the fork piston rod stopper holder so that the long side C faces upward e Remove Piston Rod Assy A Fork Spring B Spacer C e Hold the left front fork tube A upside down over a clean container B and drain the oil NOTE OPump the left front fork outer tube up and down to dis charge the fork oil e Insert the holder bar A into the axle hole of the front fork B Special Tool Bar 57001 1751 OPosition the bar left and right and evenly e Insert the lower end of the compression shaft A into the hole B of the holder bar Special Tool Fork Spring Compressor 57001 1587 Front Fork SUSPENSION 13 31 e Screw the adjust nut A onto the compression shaft as shown About 40 mm 1 57 in B e Screw the locknut C e Set the other side compression shaft same process e Install the spacer A with the flat
161. the main harness xIf there is no continuity replace the front wheel rotation sensor Step 4 e Disconnect the front wheel rotation sensor connector A e Check for continuity between the terminal 8 W BK B of the ABS hydraulic unit connector C and terminal 2 W BK D of the front wheel rotation sensor connector main harness side xIf there is no continuity repair or replace the main har ness x If there is continuity go to next step Step 5 e With disconnecting the front wheel rotation sensor con nector A check for continuity between the terminal 17 BK W B of the ABS hydraulic unit connector C and the 1 BK W terminal D of the front wheel rotation sen sor connector main harness side xIf there is no continuity repair or replace the main har ness x If there is continuity go to next step GL14715BS1 GL14715BS1 B 010006000 02009020 300 GL14717BS1 Anti Lock Brake System Equipped Models BRAKES 12 59 Step 6 e Connect the front wheel rotation sensor connector e Connect the 4 5 5 0 V DC power e g three AA dry battery in series A between the terminal 17 BK W B and terminal 8 W BK C of the ABS hydraulic unit connector to measure DC amperage Special Tool Hand Tester 57001 1394 OBe careful not to reverse connection of the DC power po larity OThe measure
162. thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Insert Crankpin Wear Inspection e Measure the bearing insert crankpin A clearance with plastigage B e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement After measurement replace the connecting rod bolts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 041 0 071 mm 0 0016 0 0028 in Service Limit 0 11 mm 0 0043 in 6105040781 9105236851 CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods x If the clearance is within the standard no bearing replace ment is required xIf the clearance is between 0 072 mm 0 0028 the service limit 0 11 mm 0 0043 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum i
163. to next step Step 2 e Check that there is iron or other magnetic deposits be tween the front or rear wheel rotation sensor A and sen sor rotor and the sensor rotor slots B for obstructions e Check the installation condition of the sensor for loose ness e Check the sensor tip and sensor rotor slots for deforma tion or damage e g chipped sensor rotor teeth x If the sensor and sensor rotor in bad condition clean or replace the faulty parts x If all items are correct go to next step 61147448 6 BRAKES 12 57 Anti Lock Brake System Equipped Models Step 3 e Check the front and rear tire wheel conditions for tire pres sure tire size types abnormal wear and deformations see Wheels Tires in the Periodic Maintenance chapter x If the tire and or wheel bad condition correct them if necessary and recheck x lf all items are good condition replace the ABS unit Front or Rear Wheel Rotation Sensor Wiring Inspection Service Code 43 OThis code is indicates there is a trouble in the front or rear wheel rotation sensor e Perform the Pre Diagnosis Inspection 1 and 2 e Check the system connectors for loose or poorly contact Step 1 e Disconnect the ABS hydraulic unit connector e Check for continuity between the terminal 9 BK A and terminal 8 W BK B of the ABS hydraulic unit connector x If there is continuity go to next step x If there is no continuity go to step 2
164. turn the ignition switch off OThe ABS parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OThe ABS parts cannot be disassembled Even if a fault is found do not try to disassemble and repair the ABS parts replace it OThe ABS has many brake lines pipes and leads And the ABS cannot detect problems with the conventional braking system brake disc wear unevenly worn brake pad and other mechanical faults To prevent trouble check the brake lines and pipes for correct routing and connection the wiring for correct routing and the brakes for proper braking power Be sure to check for fluid leak age and bleed the brake line thoroughly 12 40 BRAKES Anti Lock Brake System Equipped Models A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If any of the brake line fittings including the ABS hydraulic unit joint nuts or the bleed valve is opened at any time the air must be bled completely from the brake line If the brake lever has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately Do not ride the motorcycle with air in the brake line or the ABS could malfunction OThe yellow ABS indicator light LED A may light if th
165. usable range Sensor 2 Pa 60 900 wiring short or open the ECU sets Pa at 760 9 mmHg the standard atmospheric pressure 21 Crankshaft 2 5 If the crankshaft sensor fails the engine stops Sensor gna by itself at the 1 cranking Speed sensor must send 23 signals to the ECU at Speed the one rotation of the drive If the speed sensor system fails no signal 24 wiring short the speedometer shows The gear position is 0 decided by the signal of the speed sensor If the vehicle down sensor system has failures Vehicle Guite tValtade the output voltage is out of the usable range 31 down 0 fae 4 DAY wiring short or open the ECU shuts off the Sensor fuel relay the fuel injectors the ignition system If the subthrottle sensor system fails the output voltage is out of the usable range wiring 32 eee a short or open the ECU drive the subthrottle valve to the full closed position stops the current to the subthrottle valve actuator The oxygen sensor is 33 Oxygen 2 Pad If the oxygen sensor is not activated the ECU Sensor 9 P stops the feedback mode of the oxygen sensor voltage continuously to the ECU Self Diagnosis FUEL SYSTEM DFI 3 47 Parts Output Signal Usable Range or Criteria Backups by ECU Exhaust Butterfly Valve Actuator Sensor ZR800A B Models Output Voltage 0 1 4 9V If the exhaust butterfly valv
166. when the clock is setting clock is set at time of that time Check 7 Immobilizer Blinking Mode Inspection e Connect the leads in the same circuit as Check 1 e Disconnect the terminal 15 e Check that the red warning indicator light LED A starts blinking Immobilizer Blinking Mode e Push the left B and right C buttons more than 2 second within 20 seconds after the terminal 15 disconnected e Check that the red warning indicator light LED goes on 1 second and then the light goes off Immobilizer No Blink ing Mode NOTE OFor this inspection be sure the battery is 12 2 V or more Immobilizer Blinking Mode does not work when the battery voltage is less than 12 0 2 V du GP17809BS1 SR for N EPI ANNOS GP17810BS1 GP17073DS1 0170740 6 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 77 e Connect the terminal 15 to the battery terminal e And then disconnect the terminal 15 e Push the left A and right B buttons more than 2 second within 20 seconds after the terminal 15 disconnected e Check that the red warning indicator light LED C goes on 1 second and then the light starts blinking Immobilizer Warning Indicator Light Blinking Mode x If the meter function does not work replace the meter assembly Check 8 Green Left Turn Signal Indicator Light LED Inspection e Connect the leads in the s
167. 052 C GP1X910 6 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 81 Check 17 Trip Meter Inspection e Connect the leads in the same circuit as Check 15 e Set the TRIP mode A by pushing the left button B Raise the input frequency of the oscillator to see the result of odometer inspection x If the value indicated by the trip meter does not increase replace the meter assembly e When pushing the left button for more than two seconds check that the display changes 0 0 x If the display function does not change replace the meter assembly NOTE OThe integrated value of the odometer cannot be reset Check 18 Tachometer Inspection e Connect the leads in the same circuit as Check 1 e The engine speed rpm equivalent to the input frequency is indicated in the oscillator A if the square wave is input into terminal 6 Olndicates approximately 4 000 rpm if the input frequency is approximately 133 3 Hz xIf the meter function does not work replace the meter assembly Check 19 Other Inspection OThe following items are displayed while running AVERAGE CURRENT RANGE ECO Mark Water Temperature e When the above item is faulty indication check the follow ing items Wiring see Wiring Inspection ECU Communication Line see ECU Communication Line Inspection in the Fuel System DFI chapter Fuel Injectors see Fuel Injectors section in the Fuel Sys tem DFI chapter Fuel Level Sensor see Fuel
168. 094BS2 GE14038BS1 C Valves ENGINE TOP END 5 27 Valve Clearance Inspection Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove Cylinder Head see Cylinder Head Removal Valve Lifter and Shim OMark and record the valve lifter and shim locations so they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 21 B 57001 1272 Valve Installation e Replace the oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring White E Retainer F Split Keepers G Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head NOTICE Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 57001 1273
169. 1 57001 1400 7571394ST C 7571400ST C Peak Voltage Adapter 57001 1415 875714155 C Needle Adapter Set 57001 1457 Throttle Sensor Setting Adapter 57001 1538 8 5714578 C 7571538ST C Extension Tube 57001 1578 7571578ST C Fuel Pressure Gauge Adapter 57001 1593 7571593ST C FUEL SYSTEM DFI 3 25 Special Tools and Sealant Fuel Hose Measuring Adapter 57001 1607 57001 1700 ST571607ST C 875717005 Speed Sensor Measuring Adapter Liquid Gasket TB1211 57001 1667 56019 120 ST571667ST 875601205 Oxygen Sensor Measuring Adapter 57001 1682 875716825 3 26 FUEL SYSTEM DFI DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis DFI system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen cha
170. 11 0 kgf m 79 7 ft lb e Install the removed parts see appropriate chapters GMO6201BS1 C Swingarm SUSPENSION 13 43 Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collar A Oil Seals B Sleeve C Circlip D Right Side Special Tool Inside Circlip Pliers 57001 143 e Remove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover A 57001 1058 Swingarm Bearing Installation Replace the ball and needle bearings A with new ones e Install the ball and needle bearings so that the manufac turer s marks face out Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 528 B 57001 1610 Spacer 28 57001 1663 GM06228BS2 GM06229BS1 C GM06071BS1 C 13 44 SUSPENSION Swingarm e Install the needle bearings A ball bearing B and oil seals C position as shown Circlip D 23 5 0 4 mm 0 93 0 02 in E 6 0 4 mm 0 24 0 02 in F Swingarm Bearing Sleeve Inspection Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings A and ball bearing installed in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage If the needle bearing and sleeve B show any sings of abnormal wear
171. 20 3 2513 3013 35 3 4013 45 3 50 0 50 0 54 2 75 2 80 2 85 2 9012 95 3 0013 0513 1013 1513 20 3 25 3 30 3 0 55 0 59 eee 3 35 3 0 60 0 64 3 3 0 65 0 69 3 3 0 70 0 74 3 0 75 0 79 3 00 3 05 3 1013 15 3 20 3 25 3 30 3 35 3 40 3 4513 0 80 0 84 3 05 3 10 3 15 3 20 3 25 3 3013 35 3 40 3 45 3 50 0 85 0 89 3 10 3 15 3 20 3 25 3 3013 35 3 403 45 3 50 0 90 0 94 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 95 0 99 3 20 3 25 3 30 3 35 3 4013 45 3 50 1 00 1 04 3 253 3013 353 403 45 3 50 1 051 09 3 30 3 35 3 4013 45 3 50 1 1041 14 353 40 3 45 3 50 1 1524 19 403 48 3 50 INSTALL THE SHIM OF THIS THICKNESS mm 1 20 1 24 3 45 3 50 1 25 1 29 3 50 VALVE CLEARANCE MEASUREMENT 6807120BW3 C 1 Measure the clearance when engine is cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm Measured clearance is 0 47 mm Replace 2 95 mm shim with 3 15 mm shim 5 Remeasure the valve clearance and readjust if necessary PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Be sure to remeasure the clearance after selecting a shim according to the table If the clearance is out of the s
172. 20 N m 2 0 kgf m 15 ft Ib Steering Stem Head Bolt 108 N m 11 0 kgf m 79 7 ft lb Lower Front Fork Clamp Bolts 20 5 N m 2 09 kgf m 15 1 ft Ib AWARNING If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death Be sure the cables harnesses and hoses are routed properly and do not interfere with handlebar move ment see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter 6 05060451 C GNO5157BS1 STEERING 14 9 Steering Stem Steering Stem Warp Inspection e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem 8 05079851 Stem Cap Deterioration Damage Inspection Replace the stem if its oil seal A shows damage 14 10 STEERING Handlebar Handlebar Removal e Remove Clutch Lever Clamp Bolts A Clutch Lever Assembly B Left Switch Housing C Handlebar Weight D Handlebar Grip E e Remove Front Master Cylinder A see Front Master Cylinder Re moval in the Brakes chapter
173. 3 3513 4013 45 3 50 0 00 0 02 2 502 5512 60 2 65 2 7042 75 2 80 2 85 2 9012 95 3 00 3 05 3 10 3 15 3 2013 25 3 30 0 03 0 07 2 502 55 2 602 652 70 2 752 802 852 90 2 95 3 0013 05 3 10 3 15 3 2013 25 3 30 3 35 0 08 0 12 2 50 2 55 2 60 2 65 2 70 2 75 2 802 85 2 90 2 95 3 00 3 05 3 1013 15 3 20 3 2513 3013 35 3 40 0 13 0 14 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 852 90 2 95 3 00 3 053 10 3 15 3 2013 25 3 3013 35 3 40 3 45 0 1550 24 SPECIFIED CLEARANCE NO CHANGE REQUIRED o0 25 0 27 al 0 28 0 32 0 330 37 0 38 0 42 0 43 0 47 2 75 2 80 2 85 2 9012 95 3 00 3 05 3 10 3 15 3 20 3 p QN Example 0 48 0 52 2 80 2 85 2 90 2 95 3 00 3 05 3 103 15 3 2013 25 3 kK 0 53 0 57 2 85 2 90 2 95 3 0013 05 3 10 3 15 3 20 3 25 3 30 3 Lu 0 5850 62 LU 0 6350 67 0 680 72 lt 0 73 0 77 3 05 3 10 3 15 3 20 3 25 3 3013 3513 0 78 0 82 3 10 3 15 3 20 3 25 3 30 3 3513 403 LU 0 8350 87 3 15 3 20 3 25 3 30 3 353 40 3 45 3 50 o 3 203 25 22 0 88 0 92 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 93 0 97 3 25 3 30 3 35 3 40 3 45 3 50 LU 2 0 9851 02 30 3 35 3 40 3 43 3 50 e 1 031 07 3 35 3 4013 45 3 50 LU 1 08 1 12 3 40 3 4
174. 31 in Ib Upper Front Fork Clamp Bolts 20 2 0 15 Steering Stem Head Bolt 108 11 0 79 7 Lower Handlebar Holder Nuts 34 3 5 25 R Steering Stem Nut 27 2 8 20 Lower Front Fork Clamp Bolts 20 5 2 09 15 1 AL Frame Rear View Mirror Locknut Upper 18 1 8 13 Lh Rear View Mirror Nut Lower 30 3 1 22 Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib Front Fender Bolts 3 9 0 40 35 in Ib Footpeg Bracket Bolts 30 3 1 22 Side Stand Switch Bolt 8 8 0 90 78 in Ib L Side Stand Bolt 29 3 0 21 Side Stand Nut 44 4 5 32 R Lower Fairing Mounting Bolts 9 8 1 0 87 Lower Fairing Bracket Bolts 9 8 1 0 87 License Plate Light Mounting Screws 1 2 0 12 11 in Ib Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib Electrical System Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib Meter Mounting Screws 1 2 0 12 11 in Ib Meter Assembly Screws 0 43 0 044 3 8 in Ib Front Brake Light Switch Screw 1 2 0 12 11 in Ib License Plate Light Mounting Screws 1 2 0 12 11 in Ib Oxygen Sensor 44 4 5 32 Water Temperature Sensor 12 1 2 106 in Ib Stator Coil Bolts 12 1 2 106 in Ib L Alternator Rotor Bolt 155 15 8 114 Starter Motor Clutch Bolts 12 1 2 106 in Ib L 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks N m kgf m Timing Rotor Bolt 39 4 0 29 Starter Motor Mounting Bolts 11 1 1 97 in lb Crankshaft Sensor Cover Bolts 11 1 1 97 in lb Crankshaft Sensor Bolts 5 9 0 60 52 in lb Oil Pressure Swi
175. 4 N m 4 5 kgf m 32 ft lb O8th tighten the rear engine bracket bolts B Torque Rear Engine Bracket Bolts B 25 N m 2 5 kgf m 18 ft Ib O10th tighten the lower adjusting collar M until the clear ance between the engine and lower adjusting collar come to 0 mm Torque Lower Adjusting Collar M 4 9 N m 0 50 kgf m 43 in Ib O11th tighten the adjusting collar locknut N Torque Adjusting Collar Locknut N 49 N m 5 0 kgf m 36 ft Ib O12th tighten the lower O and middle P engine mounting nuts Torque Lower Engine Mounting Nut O 44 N m 4 5 kgf m 32 ft lb Middle Engine Mounting Nut P 44 N m 4 5 kgf m 32 ft lb O13th install the right upper engine bracket Q right sub frame R and spherical washers S so that the spherical side faces inward and tighten the bolts T U V W tem porarily O14th insert the right front engine mounting bolt X tem porarily O15th tighten the subframe bolts T U Torque Subframe Bolts T U 25 N m 2 5 kgf m 18 ft Ib ENGINE REMOVAL INSTALLATION 8 11 Engine Removal Installation O16th loosen the subframe bolt T and tighten the sub frame bolt T Torque Subframe Bolt T 25 N m 2 5 kgf m 18 ft Ib O17th loosen the subframe bolt U and tighten the sub frame bolt U Torque Subframe Bolt U 25 N m 2 5 kgf m 18 ft Ib O18th tighten the subframe bolts V and upper engine bracket bolts W Torque Subframe Bo
176. 4 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the fuel outlet hose with a new one Pull A the joint lock B fully as shown e Insert the fuel outlet hose joint A straight onto the deliv ery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and does not come off A WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe x If it comes off reinstall the hose joint e Run the fuel outlet hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter e Start the engine and check the fuel hose for leaks PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank A with the motorcycle held perpendicular Do not use the side stand x If the coolant level is lower than the L level line B un screw the reserve tank cap and add coolant to the F level line C L Low F Full For refilling add the specified mixture of coolant and soft
177. 42BS1 ian GLO8018BS1 o 12 32 BRAKES Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever or pedal has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake Remove Screws A Front Brake Reservoir Cap B Diaphragm Plate Diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir Slowly pump the brake lever several times until no air bubbles can be seen rising up throu
178. 5 ST571685ST 13 12 SUSPENSION Special Tools Bar 57001 1751 Fork Spring Compressor 57001 1771 8 5717515 6 875717715 6 Fork Piston Rod Stopper Holder 57001 1789 875717895 SUSPENSION 13 13 Front Fork Rebound Damping Force Adjustment ZR800A B Models Right Front Fork Only e To adjust the rebound damping force turn the rebound 9 damping adjuster A OThe standard adjuster setting is the 12th click from the fully clockwise position OThe damping force can be left soft for average riding But Csunterelockwise Clockwise it should be adjusted harder for high speed riding or riding Softer Harder with a passenger If the damping feels too soft or too stiff STD adjust it in accordance with the following table 26 12 1110 9 8 7 6 5 4 3 2 1 Rebound Damping Force Adjustment Adjuster Damping i Position Force Seated position adjuster turned fully clockwise Weak GM04799BS1 C Spring Preload Adjustment ZR800A B Models e Turn the spring preload adjuster A to change spring preload setting OThe standard adjuster setting is the 9 mm 0 4 in B from the fully counterclockwise position Adjuster Protrusion from top Standard 9 mm 0 4 in Usable Range 4 19 mm 0 16 0 75 in A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result
179. 5 3 50 1 13 1 17 3 45 3 50 gt 1 18 1 22 3 50 INSTALL THE SHIM OF THIS THICKNESS mm Measure the clearance when engine is cold Check present shim size Match clearance in vertical column with present shim size in horizontal column Install the shim specified where the lines intersect This shim will give the proper clearance Present shim is 2 95 mm Measured clearance is 0 45 mm Replace 2 95 mm shim with 3 20 mm shim 5 Remeasure the valve clearance and readjust if necessary GS07122BW3 C 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE PRESENT SHIM Example PART No 92180 MARK 4 95 THICKNESS mm 2 50 2 55 2 60 2 65 2 7012 752 802 85 2 902 95 3 00 3 05 3 1013 15 3 20 3 2513 30 3 35 3 40 3 45 3 50 0 00 0 04 0 05 0 09 75 73 2 80 2 2 2 2 3 0 10 0 14 2 0 15 0 19 290 0 20 0 21 80 2 8512 9042 95 0 22 0 31 SPECIFIED CLEARANCE NO CHANGE al 0 32 0 34 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 9513 003 05 3 1013 15 3 20 283 ada 39 3 40 3 49 3 50 S 0 3550 39 2 60 2 65 2 7012 75 2 80 2 85 2 80 2 9513 0013 0513 10 3 15 3 2013 253 30 3 35 3 40 3 45 3 50 0 40 0 44 2 65 2 7012 75 2 80 2 85 2 90 2 95 3 0013 0543 103 15 3
180. 6 79 Meter Gauge Indicator Unit Check 12 Yellow ABS Indicator Light LED Inspection Equipped Models e Connect the leads in the same circuit as Check 1 OThe yellow ABS indicator light LED goes on e Connect the terminal 10 to the battery terminal e Check that the yellow ABS indicator light LED A goes off xIf the indicator light LED does not go off replace the meter assembly Check 13 Red Warning Indicator Light LED Inspec tion Oil Pressure Warning e Connect the leads in the same circuit as Check 1 e Connect the terminal 1 to the battery terminal e Check that the oil symbol A and red warning indicator light LED B go on xIf the oil symbol and indicator light LED do not go on replace the meter assembly Check 14 Fuel Gauge Inspection e Connect the leads in the same circuit as Check 1 OThe all segments of the fuel gauge in the display will blink e Connect the variable rheostat A to the terminal 2 and the battery terminal GP17086DS1 C 17080 6 GP17088DS1 C 16 80 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Check that the segments number of the fuel level gauge A matches the resistance value of the variable rheostat OWhen the terminal 2 is connected 1 segment in the fuel level gauge should appear about every 15 seconds Display Segments 20 60 5 segments go on 110 3 segments go Variable Rheos
181. 7 A 20 N m 2 0 kgf m 15 ft Ib 6104134851 C 9 14 CRANKSHAFT TRANSMISSION Crankcase Splitting e Tighten the upper crankcase bolts in the order listed Torque Crankcase Bolts M8 A 27 N m 2 8 20 ft lb Crankcase Bolts M7 B C 20 N m 2 0 kgf m 15 16 Crankcase Bolts M6 D E F 12 N m 1 2 kgf m 106 in Ib L 85 mm 3 35 in B L 50 mm 1 97 in C L 90 mm 3 54 in D L 60 mm 2 36 in E L 40 mm 1 57 in F Clamps G e After tightening all crankcase bolts check the following items OWipe up the liquid gasket that seeps out around the crankcase mating surface OCrankshaft and transmission shafts turn freely OWhile spinning the output shaft gears shift smoothly from the 1st to 6th gear and 6th to 1st OWhen the output shaft stays still the gear can not be shifted to 2nd gear or other higher gear positions e Install the removed parts see appropriate chapters 6104262BS2 C CRANKSHAFT TRANSMISSION 9 15 Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see Crankcase Splitting Remove the crankshaft A Crankshaft Installation NOTICE If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply
182. 8 4 8 Coolant Level Inspection pp 4 8 Coolant Draining 4 8 COOLING ms 4 8 Pressure Testis 4 8 Cooling System lt lt echoes a 4 9 Coolant Reserve Tank Removal Installation 9 4 9 ET 4 10 Water Pump 601 800000000000000000000000000000000 ERa 4 10 Water Pump Installation pp 4 10 Water o ees PR a ai 4 10 Water Pump Impeller 4 10 Water Pump Impeller Inspection pp 4 10 Water Pump Housing Disassembly pp 4 10 Water Pump Housing Assembly mettons cea 4 11 Mechanical Seal 4 11 da 4 12 Radiator and Radiator Fan Removal pp 4 12 Radiator and Radiator Fan Installation pp 4 13 Radiator 4 13 Radiator Cap Inspection ort e o Pe nt 4 14 Radiator Filler Neck 4 14
183. 8 Valve Seat Cutter Holder 4 C 57001 1275 For Exhaust Valve Seat Valve Seat Cutter 45 524 5 57001 1113 Valve Seat Cutter 32 525 57001 1118 Valve Seat Cutter 60 525 57001 1328 For Intake Valve Seat Valve Seat Cutter 45 530 57001 1187 Valve Seat Cutter 32 530 57001 1120 Valve Seat Cutter 60 530 57001 1123 xIf the manufacturer s instructions are not available use the following procedure Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the fo
184. 8 BRAKES Master Cylinder Front Master Cylinder Removal Remove the banjo bolt A to disconnect the brake hose from the master cylinder see Brake Hose and Pipe Re moval Installation Unscrew the clamp bolts B and take off the master cylin der C as an assembly with the reservoir brake lever and brake switch installed e Disconnect the front brake light switch connectors D Immediately wash away any brake fluid that spills Front Master Cylinder Installation e Set the front master cylinder to match its mating surface A to the punch mark B of the handlebars e Tighten the upper clamp bolt first and then the lower clamp bolt Torque Front Master Cylinder Clamp Bolts 11 N m 1 1 kgf m 97 in lb Replace the washers that on each side of the hose fitting with new ones e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 16 Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage Rear Master Cylinder Removal e Remove the right frame cover see Frame Cover Removal in the Frame chapter e Disconnect the brake light switch connector A e Remove Bolts B Cover C e Remove the break hose banjo bolt A and disconnect the brake hose B from the rear master cylinder see Brake Hose and Pipe Removal Installation Immediately wash away any brake fluid that spills e Remove Rear Master Cylinder Mou
185. 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Assembly The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set e Using a high flash point solvent clean off the mating sur faces of the crankcase halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth Apply liquid gasket to the upper breather plate mating sur face A 1 mm 0 04 in or more thick and then install the upper breather plate 22 mm 0 87 in B Sealant Liquid Gasket TB1207B 92104 2068 NOTE OMake the application finish within 7 minutes when the liquid gasket to the mating surface of the upper breather plate is applied fit the plate and tighten the bolts just after application of the liquid gasket e Apply a non permanent locking agent to the threads of the upper breather plate bolts A and tighten them Torque Upper Breather Plate Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the breather hose A OAlign the white mark on the hose with the white mark on the pipe Olnstall the clamp B so that its head faces to right side Upper Breather Plate C 9104259851 C FN P 9104451851 C CRANKSHAFT TRANSMISS
186. ANIFOLD Honeycomb Type Catalyst P No 39178 0191 Mark 144 Honeycomb Type Catalyst P No 39178 189 Mark KHI M 150 Honeycomb Type Catalyst P No 39178 0192 Mark 145 MUFFLER BODY Non Catalyst P No 18091 0910 Mark KHI K 621 Non Catalyst P No 18091 0910 Mark KHI K 621 Non Catalyst P No 18091 0911 Mark KHI K 624 SPECIFICATION WVTA FULL UK WVTA FULL WVTA 78 2 AU SEA B2 BR WVTA FULL MODEL ZR800AD ZR800BD ZR800AD ZR800BD ZR800AD ZR800BD ZR800BD ZR800AD ZR800AD ZR800BD ZR800CD ZR800DD GE24919B F ENGINE TOP END 5 9 Exhaust System Manifold Mark Position A Honeycomb Type Catalyst Position A GE24956BS1 GE24921BS1 5 10 ENGINE TOP END Specifications ltem Standard Service Limit Camshafts Cam Height Exhaust 35 742 35 858 mm 1 4072 1 4117 in 35 64 mm 1 403 in Intake 35 942 36 058 mm 1 4150 1 4196 in 35 84 mm 1 411 in Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout 0 028 0 071 mm 0 0011 0 0028 in 23 950 23 972 mm 0 9429 0 9438 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less 0 16 mm 0 0063 in 23 92 mm 0 942 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Cylinder Head Warp Usab
187. Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter GE04117BS2 C 5 16 ENGINE TOP END Clean Air System Air Switching Valve Unit Test Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Hose Inspection Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve and air suction valve covers xIf they are not correct them Replace them if they are damaged Cylinder Head Cover ENGINE TOP END 5 17 Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Thermostat Housing see Thermostat Removal in the Cooling System chapter Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Air Suction Valve see Air Suction Valve Removal Cylinder Head Cover Bolts A Cylinder Head Cover Cylinder Head Cover Installation e Install Dowel Pins A Plug Hole Gaskets B e Replace the head cover gasket with a new one e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket A to the cylinder head as shown Sealant Liquid
188. CU ground and power supply trouble Inspect see chapter 3 ECU trouble No or little fuel in tank Fuel injector trouble Fuel pump not operating Fuel pump relay trouble Inspect and replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak Ene Stick coil shorted or not in good contact Inspect or reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 3 36 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes
189. CU terminal 29 C G lead ECU terminal 33 D PAL x If the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Resistance Inspection Water Temperature Sensor Resistance Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit GC17431FW2 1 Water Proof Joint 2 2 Water Temperature Sensor 3 ECU 3 64 FUEL SYSTEM DFI Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Removal Never drop the intake air pressure sensor 2 espe cially on a hard surface Such a shock to the sensor can damage it Remove the fuel tank see Fuel Tank Removal e Disconnect Water Temperature Sensor Connector Intake Air Pressure Sensor 2 Connector A Remove the intake air pressure sensor 2 B from the bracket e Disconnect the vacuum hose A and remove the rubber damper B from the intake air pressure sensor 2 C Intake Air Pressure Sensor 2 Installation NOTE OThe intake air pressure sensor 2 is the same part as the intake air pressure sensor 1 e Installation is basically the reverse of removal OPosition the intake air pressure sensor 2 A between the projections B on the rubber damper FUEL SYSTEM DFI 3 65 Intak
190. Caliper Holder Shaft Wear Inspection ZR800C Model The caliper body must slide smoothly on the caliper holder shaft A If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shaft are not badly worn or stepped and thatthe friction boot is not damaged x If the friction boot is damaged replace the friction boot To replace the friction boot remove the pads and the caliper holder x If the caliper holder shaft is damage replace the caliper holder GLO5319BS1 C GL05322BS1 9105168851 C GLO5185BS1 C Calipers BRAKES 12 23 Rear Caliper Holder Wear Inspection The caliper body must slide smoothly on the rear caliper pin bolt A and sleeve B If the body does not slide smoothly one pad will wear more than the other pad wear will increase and constant drag on the disc will raise brake and brake fluid temperature Check to see that the rear caliper pin bolt and the sleeve are not badly worn or stepped and that the rubber boots are not damaged x lf the rear caliper bolt is damaged replace the rear caliper pin bolt x If the sleeve is damaged replace the sleeve x If the rubber boots are damaged replace the rubber boot GLO5298BS1 12 24 BRAKES Brake Pads Front Brake Pad Removal ZR800A B D Models
191. Camshaft Chain any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 942 in x lf the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x If the clearance still remains out of the limit replace the cylinder head unit Camshaft Runout Inspection e Remove the camshafts see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown x If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in Cam Wear Inspection e Remove the camshafts see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 35 742 35 858 mm 1 4072 1 4117 in Intake 35 942 36 058 mm 1 4150 1 4196 in Service Limit Exhaust 35 64 mm 1 403 in Intake 35 84 mm 1 411 in Camshaft Chain Removal Split the crankcase see Crankcase Splitting in the Crank shaft Transmission chapter e Remove the camshaft chain A from the crankshaft sprocket GE11213BS1
192. Changing Oil Right Front Fork Left Front Fork After Disassembly and Completely Dry Right Front Fork Left Front Fork Fork Oil Level Fully compressed without fork spring below from the top of the outer tube Right Front Fork Left Front Fork Fork Spring Free Length Rear Shock Absorber Rebound Damper Setting ZR800A B Models 41 mm 1 6 in Atmospheric pressure Non adjustable 12th click from the 1st click of the fully clockwise position Usable range 0 26 clicks Adjuster protrusion is 9 mm 0 4 in Usable range 4 19 mm 0 16 0 75 in KHL 15 10 or equivalent Approx 405 mL 13 7 US oz 464 4 mL 15 7 0 135 US oz 469 4 mL 15 9 0 135 US oz 106 2 mm 4 17 0 08 in 109 2 mm 4 29 0 08 252 5 mm 9 94 in Service Limit 247 5 mm 9 74 in 41 mm 1 6 in Atmospheric pressure Non adjustable KHL 15 10 or equivalent Approx 410 mL 13 9 US oz Approx 450 mL 15 2 US oz 481 4 mL 16 3 0 135 US oz 529 4 mL 17 9 0 135 US oz 98 2 mm 3 86 0 08 in 262 mm 10 3 in Service Limit 257 mm 10 1 in 1 1 4 turns out from the fully clockwise position Usable range 0 2 2 4 turns out Specifications SUSPENSION 13 9 Item Standard Spring Preload Setting Position ZR800A B Models Standard Usable Range Spring Preload Setting Position ZR800C D Models Standard Usable Range Gas Pressure Spring l
193. Connections to Adapter L Digital Meter R pump Y R lead Digital Meter BK pump BK W lead e Measure the operating voltage with engine stopped and with the connector joined ea e Turn the engine stop switch run position e Turn the ignition switch on Operating Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch off x If the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Circuit Inspection in the Electrical System chapter x If the pump relay is normal check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf there is still no battery voltage check the ECU main relay and fuel pump relay see Relay Circuit Inspection in the Electrical System chapter xIf the main relay and pump relay are normal check the wiring for continuity see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is in specification but the pump does not op erate replace the fuel pump see Fuel Pump Removal In stallation 3 118 FUEL SYSTEM Fuel Pump Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump
194. Cylinder Head GE14091BS1 Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Install a new cylinder head gasket and dowel pins e Apply molybdenum disulfide oil solution to both sides A of the cylinder head bolt washers B and the threads of the head bolts C Cylinder Head ENGINE TOP END 5 25 e Tighten the M10 cylinder head bolts following the tighten ing sequence 1 101 OFirst tighten the bolts with 10 N m 1 0 kgf m 15 ft Ib of torque ONext in accordance with the following table tighten the bolts with the specified torque And using a torque angle gauge A tighten the bolts with the specified angle B cA 556 ju Order cjo o oO m o nN o 12 13 14 15 16 17 18 19 20 e Tighten the M6 cylinder head bolts as shown sequence 11 12 Torque Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 Cylinder Head Bolts M10 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 in Ib New Bolt Torque N m kgf m ft Ib or Angle 0 3 1 22 120 5 30 3 1 22 120 5 0 3 1 22 120 5 30 3 1 22 120 5 30 3 1 22 120 5 30 3 1 22 120 5 0 3 1 22 120 5 30 3 1 22 120 5 30 3
195. D to the harness adapter leads Vehicle down Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y G lead Digital Meter gt BK sensor lead e Hold the sensor vertically e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch on e Tilt the sensor 60 70 or more A right or left then hold the sensor almost vertical with the arrow mark pointed up B and measure the output voltage Output Voltage Standard With sensor tilted 60 70 or more right or left DC 0 65 1 35 V With sensor arrow mark pointed up DC 3 55 4 45 V NOTE Olf you need to test again turn the ignition switch off and then on e Turn the ignition switch off x If the reading is out of the standard replace the sensor GT04093BS1 C 80177860652 C Vehicle down Sensor Service Code 31 FUEL SYSTEM DFI 3 75 x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Vehicle down Sensor Connector B Y G lead ECU terminal 19 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Vehicle dow
196. Diameter 70 992 71 008 mm 2 7950 2 7956 in 71 11 mm 2 7996 in Piston Diameter 70 974 70 984 mm 2 7942 2 7946 in 70 82 mm 2 7882 in Piston Cylinder Clearance 0 008 0 034 mm 0 0003 0 0013 in Piston Ring Groove Clearance Top 0 04 0 07 mm 0 0016 0 0028 in 0 17 mm 0 0067 in Second 0 02 0 05 mm 0 0008 0 0020 in 0 15 mm 0 0059 in Piston Ring Groove Width Top 0 83 0 85 mm 0 0327 0 0335 in 0 93 mm 0 037 in Second 0 81 0 83 mm 0 0319 0 0327 in 0 91 mm 0 036 in Piston Ring Thickness Top 0 78 0 79 mm 0 0307 0 0311 in 0 71 mm 0 028 in Second 0 78 0 79 mm 0 0307 0 0311 in 0 71 mm 0 028 in Piston Ring End Gap Top 0 20 0 30 mm 0 0079 0 0118 in 0 6 mm 0 024 in Second 0 45 0 55 mm 0 0177 0 0217 in 0 9 mm 0 035 in 5 12 ENGINE TOP END Special Tools and Sealant Compression Gauge 20 kgf cm 57001 221 7570221ST C Valve Spring Compressor Assembly 57001 241 7570241ST C Piston Pin Puller Assembly 57001 910 7570910ST C Valve Seat Cutter 45 624 5 57001 1113 C 2 8 5711135 C Valve Seat Cutter 32 25 57001 1118 8 5711185 C Valve Seat Cutter 32 30 57001 1120 875711205 C Valve Seat Cutter 60 30 57001 1123 9 7571123ST C Valve Seat Cutter Holder Bar 57001 1128 BN 7571128ST C Valve
197. ECTRICAL SYSTEM 16 3 Exploded View This page intentionally left blank 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View Torque No Fastener e Remarks a Sina mens i vai 2 Meter Mounting Screws 0 12 11 in Ib 3 Meter Assembly Screws 0 43 0 044 3 8 in lb 4 Front Brake Light Switch Screw 1 2 0 12 11 in Ib 5 License Plate Light Mounting Screws 1 2 0 12 11 in Ib 6 Starter Lockout Switch L Apply a non permanent locking agent R Replacement Parts 16 6 ELECTRICAL SYSTEM Exploded View Exploded View ELECTRICAL SYSTEM 16 7 No Fastener N m Torque 1 Oxygen Sensor T A Water Temperature Sensor 106 in lb Stator Coil Bolts 106 in lb 114 2 3 4 Alternator Rotor Bolt 5 6 Starter Motor Clutch Bolts 12 1 2 106 in Ib L Timing Rotor Bolt 39 4 0 29 11 8 Crankshaft Sensor Cover Bolts 11 1 1 97 9 Crankshaft Sensor Bolts 5 9 0 60 52 in lb 10 Oil Pressure Switch Terminal Bolt 2 0 0 20 18 in Ib HG 11 Oil Pressure Switch 15 1 5 11 LG 12 Alternator Lead Holding Plate Bolt 12 1 2 106 in Ib L 13 Alternator Cover Bolts 15 1 5 11 14 Left Lower Fairing Bracket Bolts 11 1 1 97 in lb 15 Turn Signal Relay 16 Immobilizer Amplifer 17 ZR800A B Models G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent
198. ENDIX Cable Wire and Hose Routing GBO9155EW4 C 1 Meter Bracket 2 Front Brake Hose 3 Clamps Hold the front brake hose 4 ZR800A B D Models 5 ZR800C Model APPENDIX 17 33 Cable Wire and Hose Routing 8 09135 3 C 1 Run the rear brake hose to the inside of the mud guard 2 Damper 3 Rear Brake Hose 4 Hold the damper with the mud guard 5 Section A A 17 34 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 6B09138EW5 C APPENDIX 17 35 Cable Wire and Hose Routing Clamp Hold the front wheel rotation sensor lead Clamps Hold the front brake hose and front wheel rotation sensor lead at the white tape position of the front wheel rotation sensor lead 3 Clamps Hold the front brake hose 4 Meter Bracket 5 Front Wheel Rotation Sensor Lead 6 7 8 Nh Front Brake Hose Clamps Hold the ABS brake pipes Clamp Hold the ABS brake pipe 9 Clamp Hold the ABS brake hose 10 ABS Hydraulic Unit 11 Viewed from A 12 Touch the ABS brake pipe to the ABS hydraulic unit 13 Front Wheel Rotation Sensor 17 36 APPENDIX Cable Wire and Hose Routing ABS Equipped Models HT PI GB09139EW5 C APPENDIX 17 37 Cable Wire and Hose Routing AUN Clamp Hold the rear brake hose Run the rear brake hose of rear master cylinder under the clamp Clamps Hold the rear brake hoses so tha
199. FI 3 115 Fuel Pump Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the potential for serious burns Make sure the area is well venti lated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch off Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it e Draw the fuel out from the fuel tank with a commercially available electric pump Remove the fuel tank see Fuel Tank Removal careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down Remove the fuel intake hose A e Unscrew the fuel pump bolts B and take out the fuel pump C NOTICE Do not pull the leads of the fuel pump If they are pulled the lead terminals may be damaged e Discard the fuel pump gasket A 3 116 FUEL SYSTEM Fuel Pump Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air e Replace the fuel pump gasket with a new one e Check that the fuel pump
200. Fairing Removal in the Frame chapter Screws A and Clamps B Bracket C Screw D Bolts E and Clamps F Headlight Assy G e Installation is the reverse of removal City Light Bulb Replacement e Remove the upper fairing see Upper Fairing Removal in the Frame chapter e Remove the socket A with the bulb ELECTRICAL SYSTEM 16 61 Lighting System e Pull out the bulb A straight from the socket 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 e Replace the bulb with a new one e Install the socket securely Tail Brake Light LED Removal e Remove Rear Fender see Rear Fender Removal in the Frame chapter Flap see Flap Removal in the Frame chapter Tail Brake Light Mounting Screw A Tail Brake Light LED B Tail Brake Light LED Installation e Installation is the reverse of removal License Plate Light Bulb Replacement e Remove Screws A License Plate Light Cover B e Pull out the bulb A straight from the socket 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 e Replace the bulb with a new one 16 62 ELECTRICAL SYSTEM Lighting System e Insert the new bulb A into the socket B e Install the license plate light cover Headlight Tail Light Circuit
201. GE11012281 ENGINE TOP END 5 23 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 1 120 1 698 kPa 11 4 17 3 kgf cm 162 246 psi at 330 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib OThe following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to range damaged valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Remedy Action Remove the carbon deposits
202. GENERAL INFORMATION 1 1 General Information Table of Contents T Model IdentifICatiOn oi ep e e EE rte ren Gt er i agr ef e a General Specifications Unit Conversion Table 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en 9 S gine from accidentally turning over Disconnect the ground 2 qe AD cable first and then the positive When completed Wa with the service first connect the positive cable to the e 4 positive terminal of the battery then the negative ca A ble to the negative terminal DISASSEMBLY ASSEMBLY 68020248 5 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 6 020048 5 Solvent Use a high flash point solvent when cleaning parts High
203. Hg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal x If the reading is out of the usable range replace the sen sor x If the reading is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Intake Air Pressure Sensor 1 Service Code 12 FUEL SYSTEM DFI 3 57 Xo 7 2 ou 7 1 0 7 P4 7 2 P4 ME MS LUNA PN l 4 A 7 10 20 30 40 50 60 70 76 80 90 cmHg Ps W 1 1 1 20 40 60 80 101 32 120 kPa Ps ID 5T0 gt 5 68017120844 C ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Intake Air Pressure Sensor 1 Output Voltage V Digital Meter Reading 3 58 FUEL SYSTEM DFI Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor Circuit GO 1 Water Proof Joint 1 2 Water Proof Joint 2 3 Int
204. Hold the main harness Water Temperature Sensor Connector Clamp Hold the immobilizer antenna lead and ignition switch lead 17 10 APPENDIX Cable Wire and Hose Routing al A dE 0 N V L S V MTM 13 Ww 28 NS Es Ve FA ull 4 58091206 6 APPENDIX 17 11 Cable Wire and Hose Routing WN Run the clutch cable to the right side of the thermostat housing Clutch Cable Clamp Hold the fuel injector 4 lead Insert the projection of the clamp into the hole second from the right Run the fuel injector 1 lead between the air switching valve hose and other three hoses Intake Air Pressure Sensor 1 Connector Sub Throttle Valve Actuator Lead Connector Fuel Pump Lead Run the main harness between the pad and air cleaner housing Alternator Lead Pad Fuel Level Sensor Lead Insert the connectors to the pad from the bottom side Intake Air Temperature Sensor Connector Clamp Hold the exhaust butterfly valve actuator leads Insert the projection of the clamp into the frame Exhaust Butterfly Valve Actuator Connectors ZR800A B Models 17 12 APPENDIX Cable Wire and Hose Routing 6809121 6 APPENDIX 17 13 Cable Wire and Hose Routing 12 13 Left Turn Signal Light Lead License Plate Light Lead Right Turn Signal Light Lead Tail Bra
205. ION 9 11 Crankcase Splitting e Install the side breather plate A e Apply a non permanent locking agent to the threads of the side breather plate bolts B and tighten them Torque Side Breather Plate Bolts 5 9 N m 0 60 kgf m 52 in Ib 6104457BS1 e Replace the O rings A with new ones e Install the oil jet nozzles B e Apply a non permanent locking agent to the threads of oil jet nozzle bolts C e Tighten Torque Oil Jet Nozzle Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install Crankshaft see Crankshaft Installation Connecting Rods see Connecting Rod Installation Camshaft Chain A Transmission Shafts and Gears see Transmission Shaft Installation Dowel Pins B Shift Drum see Shift Drum and Fork Installation Shift Forks and Shift Rods see Shift Drum and Fork In stallation e Before fitting the lower case on the upper case check the following OBe sure to hang the camshaft chain on the crankshaft OCheck to see that the shift drum and transmission gears are in the neutral position 61048713 P 9 12 CRANKSHAFT TRANSMISSION Crankcase Splitting e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Liquid Gasket TB1216B 92104 1064 NOTE OEspecially apply a liquid gasket so that it shall be fill
206. Inspection e Remove Battery Negative Cable see Battery Removal Left Side Cover see Side Cover Removal in the Frame chapter e Disconnect the connector A e Remove the starter relay cover B e Disconnect the cable terminals A e Remove the Starter Relay B e Connect the hand tester A and 12 V battery B to the starter relay C as shown Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 range Criteria When battery is connected 0 O GP11202BS1 When battery is disconnected Q 16 58 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1 1 1 1 T b BK BL o BK Y BK Y GPi1242BW3 C lgnition Switch Engine Stop Switch Starter Button Neutral Switch Side Stand Switch Joint Connector E Joint Connector B Frame Ground 4 Frame Ground 1 Engine Ground 11 Battery 12 V 8 Ah Starter Relay Main Fuse 30 A Starter Motor Starter Circuit Relay Relay Box Starter Lockout Switch Fuse Box 1 lgnition Fuse 15 A Joint Connector C Lighting System ELECTRICAL SYSTEM 16 59 This motorcycle adopt the daylight system and have a headlight relay in the relay box The headlight does not go on when the ignition switch and the engin
207. M DFI 3 23 Item Standard Output Voltage Subthrottle Sensor Input Voltage Output Voltage Resistance Exhaust Butterfly Valve Actuator Sensor ZR800A B Models Input Voltage Output Voltage Resistance Immobilizer Antenna Resistance Exhaust Butterfly Valve Actuator ZR800A B Models Resistance Subthrottle Valve Actuator Resistance Input Voltage Oxygen Sensor Output Voltage Rich Output Voltage Lean Heater Resistance Throttle Grip and Cables Throttle Grip Free Play Air Cleaner Element With sensor tilted 60 70 or more right or left DC 0 65 1 35 V With sensor arrow mark pointed up DC 3 55 4 45 V DC 4 75 5 25 V DC 0 48 0 52 V at subthrottle valve full close position DC 3 65 4 38 V at subthrottle valve full open position 4 6 DC 4 75 5 25 V DC 3 46 3 76 V at pulley original position 4 6 About 3 0 4 6 O 5 200 for reference About 5 2 7 8 DC 8 5 12 5 V or DC 8 5 12 5 V and then about 0 V DC 0 7 V or more DC 0 2 or less 11 7 15 5 O at 20 C 68 F 2 3 mm 0 08 0 12 in Paper filter 3 24 FUEL SYSTEM DFI Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 Fork Oil Level Gauge 57001 1290 875701255 C 875712905 C Vacuum Gauge 57001 1369 225 222 7571369ST C Hand Tester 57001 1394 Throttle Sensor Setting Adapter
208. M with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 3 8 L 4 0 US qt Drive Train Primary Reduction System Type Gear Reduction Ratio 1 714 84 49 Clutch Type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear Ratios 1st 2 571 36 14 2nd 1 941 33 17 3rd 1 556 28 18 4th 1 333 28 21 5th 1 200 24 20 eth 1 095 23 21 Final Drive System Type Chain drive 3 000 45 15 5 633 at Top gear Tubular diamond 24 98 mm 3 86 in Tubeless 120 70ZR17 M C 58W J17M C x MT3 50 GENERAL INFORMATION 1 13 General Specifications Rear Tire Type Tubeless Size 180 55ZR17 M C 73W Rim Size J17M C x MT5 50 Front Suspension Type Telescopic fork Wheel Travel 120 mm 4 72 in Rear Suspension Type Swingarm uni trak Wheel Travel 137 mm 5 39 in Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12V8 Ah Headlight Type Semi sealed beam Bulb High Beam 12 55 2 Low Beam 12V 55 W Tail Brake Light LED Alternator Type Three phase AC Rated Output 30 1 A 14 0 V at 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country 1 14 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol km x 0 6214 mile mega M 1 000 000 2 ME ED kilo k 1 000 mm x 0 03937 in centi C 0 01 milli 0 001 Units of Torque mic
209. Models BRAKES 12 61 Step 5 e With disconnecting the rear wheel rotation sensor con nector A check for continuity between the terminal 15 BK O B of the ABS hydraulic unit connector C and terminal 1 BK O D of the rear wheel rotation sensor connector main harness side x lf there is no continuity repair or replace the main har ness x If there is continuity go to next step Step 6 e Connect the rear wheel rotation sensor connector e Connect the 4 5 5 0 V DC power e g three AA dry battery in series A between the terminal 15 BK O B and terminal 6 W G C of the ABS hydraulic unit connector to measure DC amperage Special Tool Hand Tester 57001 1394 OBe careful not to reverse connection of the DC power po larity OThe measured DC amperage should be within 3 17 mA x If measurement is abnormal replace the rear wheel rota tion sensor If measurement is normal replace the ABS hydraulic unit Power Supply Voltage Abnormal Inspection Service Code 52 Low Voltage Service Code 53 High Voltage Step 1 Measure the battery terminal voltage using a voltmeter A OThe battery voltage should be within 10 16 V x If the voltage is not within the specifications recharge or replace the battery x If the voltage within the specifications go to next step Step 2 e Check the ABS fuse 30A A in the fuse box 1 for blown xIf the ABS fuse is blown replace the fuse
210. N Exploded View 08102389845 C Exploded View CRANKSHAFT TRANSMISSION 9 5 No Fastener pone Remarks N m kgf m ft Ib 1 Shift Drum Bearing Holder Screw 5 9 0 60 52 in lb L 2 Shift Drum Bearing Holder Bolt 12 1 2 106 in lb L 3 Shift Drum Cam Holder Bolt 12 1 2 106 in lb L 4 Neutral Switch 15 1 5 11 5 Shift Lever Bolt 6 9 0 70 61 in lb 6 Gear Positioning Lever Bolt 12 1 2 106 in Ib 7 Shift Shaft Return Spring Pin 29 3 0 21 E 8 Tie Rod Locknuts 6 9 0 70 61 in lb 9 Shift Pedal Mounting Bolt 25 2 5 18 Apply engine oil G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent R Replacement Parts 9 6 CRANKSHAFT TRANSMISSION Specifications Connecting Rod Big End Inside Diameter Connecting Rod Big End Bearing Insert Thickness Marking None 34 984 34 992 mm 1 3773 1 3776 in O 34 993 35 000 mm 1 3777 1 3780 in 38 000 38 016 mm 1 4961 1 4967 in Marking None 38 000 38 008 mm 1 4961 1 4964 in O 38 009 38 016 mm 1 4964 1 4967 in Brown 1 475 1 480 mm 0 05807 0 05827 in Black 1 480 1 485 mm 0 05827 0 05846 in Blue 1 485 1 490 mm 0 05846 0 05866 in Connecting Rod Big End Bearing Insert Selection Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist
211. NING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc 12 26 BRAKES Brake Pads Rear Brake Pad Removal e Unscrew the pad pin plug A e Loosen the pad pin A e Unscrew the bolt B e Remove Pad Pin A Brake Pads B Rear Brake Pad Installation e Push the caliper piston in by hand as far as they will go e Install the outside pad A and insert the pad pin B as shown BRAKES 12 27 Brake Pads Set Inside Pad A Pad Pin B e Install the caliper see Caliper Installation e Tighten the pad pin and plug Torque Rear Brake Pad Pin 17 2 1 75 12 7 ft Ib Rear Brake Pad Pin Plug 2 5 N m 0 25 kgf m 22 in Ib A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 12 2
212. NOTE OThe number 39 is service code of Self Diagnosis see Fuel System chapter It is the service code of the meter communication line error OThe number 39 in the display and yellow engine warning indicator light LED disappear when the meter unit is connected to main harness of the normal motorcycle Check 3 Left Button Operation Check Connect the leads in the same circuit as Check 1 GP17083DS1 C 0 170680 4 557 Ls 1 70690 6 GP17083DS1 C 16 74 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e By pushing the left button A each time check that the display B changes as follows 000 gt TRIP A gt TRIP GP17959CN3 C x If the display function does not work replace the meter assembly 6 170700 6 Check 4 Mileage Indication Changing Check e Connect the leads in the same circuit as Check 1 e By pushing within 2 seconds the right button A each time check that the display B changes as follows xIf the display function does not work replace the meter assembly 6mm 6 Check 5 Unit Changing Check e Connect the leads in the same circuit as Check 1 GP17083DS1 C ELECTRICAL SYSTEM 16 75 Meter Gauge Indicator Unit e Set the ODO mode A by pushing the left button B e During the right button C pushing the unit of the speed D distance E and temperat
213. OA sound scope can also be used OThe click interval becomes shorter as the engine speed MB rises e Do the same for the other fuel injectors x If all the fuel injectors click at a regular intervals the fuel injectors are normal e Turn the ignition switch off If any fuel injector does not click check the fuel injector resistance see Fuel Injector Resistance Inspection Fuel Injector Resistance Inspection e Remove Fuel Tank see Fuel Tank Removal Fuel Outlet Hose see Fuel Hose Replacement in the Periodic Maintenance chapter e Disconnect the injector connector A e Connect a digital meter to the terminals of the injector B e Measure the fuel injector resistance Fuel Injector Resistance Connections For Fuel Injector 1 W R terminal For Fuel Injector 2 W R BLIR terminal For Fuel Injector 3 W R terminal For Fuel Injector 4 W R BL G terminal Standard About 11 7 12 3 at 20 C 68 F x If the reading is out of the standard replace the injector x lf the reading is within the standard check the power source voltage see Fuel Injector Power Source Voltage Inspection Fuel Injectors FUEL SYSTEM DFI 3 121 Fuel Injector Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Disconnect the injector connector and connect the har ness adapter A between these conn
214. OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch on or while the engine is run ning OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring ELECTRICAL SYSTEM 16 29 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc xIf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity OUse the wiring diagram to find the ends of t
215. Olncrease the charging voltage to a maximum voltage of EET 25 V if the battery will not accept current initially Charge A for no more than 5 minutes at the increased voltage then Omal check if the battery is drawing current If the battery will accept current decrease the voltage and charge by Y B the standard charging method described on the battery case If the battery will not accept current after 5 min 8 08022851 C utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 12 6 V or higher Good 12 0 lower than 12 6 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace 16 36 ELECTRICAL SYSTEM Charging System Alternator Cover Removal e Remove Left Frame Cover see Frame Cover Removal in the Frame chapter Left Lower Fairing see Lower Fairing Removal ZR800A B Models in the Frame chapter e Free the hoses A e Disconnect the alternator lead connector B e Remove the engine sprocket cover bolts A and bracket B e Open the clamps C e Place a suitable container under the alternator cover A e Remove Alternator Cover Bolts B Alternat
216. Plate Light Lead Connector B Tail Brake Light Lead Connector C e Pull out the rear fender D e Remove the flap assembly see Flap Removal 15 20 FRAME Fenders eRemove the seat lock cable tip A e Pull out the bracket B e Remove Bracket C Key Cylinder D Rear Fender Installation e Installation is the reverse of removal e Install the removed parts see appropriate chapters e Run the cables leads harness and hose correctly see Cable Wire and Hose Routing section in the Appendix chapter Rear Inner Fender Removal e Remove Bolts A Screw B Brake Hose Banjo Bolt of Rear Caliper Side see Brake Hose and Pipe Replacement in the Periodic Mainte nance chapter e For ABS equipped models remove the rear wheel rota tion sensor see Rear Wheel Rotation Sensor Removal in the Brakes chapter e Remove the rear inner fender C Rear Inner Fender Installation e Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Flap Removal e Remove Rear Fender see Rear Fender Removal Screw A with Washer Bracket B Nuts C Flap Assembly D FRAME 15 21 Fenders the bolts A e Remove Trims A Bracket B Remove the bolts A e Remove Bolts A License Plate Bracket B Pad C Flap Bracket D Remove For AU model Bolts A License Plate Bracket B
217. Pressure Battery REHIA Water Temperature Immobilizer Yellow B FI The self diagnosis system has two modes and can be switched to another mode by operating the meter unit User Mode The ECU notifies the rider of troubles in DFI system ig nition system and immobilizer system by lighting or blink ing the yellow engine warning indicator light LED A red warning indicator light LED B and warning symbol C when DFI ignition and immobilizer system parts are faulty and initiates fail safe function In case of serious troubles ECU stops the injection and ignition operations GT03073BS1 GT03074BS2 C FUEL SYSTEM DFI 3 41 Self Diagnosis Dealer Mode The LCD Liquid Crystal Display displays the service code s A to show the problem s which the above system has at the moment of diagnosis TIN GT04219BS2 Self Diagnosis Procedures NOTE OUse fully charged battery when conducting self diagnosis Otherwise the light LED and symbol do not light or blink Turn the ignition switch on OWhen a problem occurs with DFI system and ignition sys tem the yellow engine warning indicator light LED A goes on to alert the rider GT04217BS1 OWhen a problem occurs with immobilizer system equipped models the red warning indicator light LED A blinks and immobilizer warning symbol B is displayed on the LCD Liquid Crystal Display
218. Pump COOLING SYSTEM 4 11 Take the oil seal A out of the housing B with a hook Water Pump Housing Assembly Do not reuse the mechanical seal and oil seal e Apply high temperature grease to the oil seal lips A e Press the new oil seal into the housing with a bearing driver B until it stops at the bottom surface C of the housing Special Tool Bearing Driver Set 57001 1129 NOTICE Be careful not to damage the sealing surface of the mechanical seal Press the new mechanical seal into the housing with the oil seal driver A until its flange B touches the surface C of the housing Special Tool Oil Seal Driver 57001 1660 Mechanical Seal Inspection Remove the water pump impeller see Oil Pump Removal in the Engine Lubrication System chapter e Visually inspect the mechanical seal x If any one of the parts is damaged replace the mechani cal seal as a unit Rubber Seal A Impeller Sealing Seat Surface B Mechanical Seal C 6D06016BS1 C GD06017BS1 4 12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the side fairings see Side Fairing Removal in the Frame chapter e Disconnect the radiator fan motor lead connector A e Loosen the water hose clamp screw A e Disconnect the water hose B e Remove Radiator Lower Bolt C
219. R 879220685 C CRANKSHAFT TRANSMISSION 9 9 Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal in the Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Oil Pressure Switch Terminal see Oil Pressure Switch Removal in the Engine Lubrication System chapter Crankshaft Sensor see Crankshaft Sensor Removal the Electrical System chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Clutch see Clutch Removal in the Clutch chapter Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Oil Pan see Oil Pan Removal in the Engine Lubrication System chapter Oil Screen see Oil Pan Removal in the Engine Lubrica tion System chapter xIf the crankshaft is to be removed remove the pistons see Piston Removal in the Engine Top End chapter e Remove the upper crankcase bolts OFirst loosen the M6 bolts M6 Bolts A M7 Bolts B M8 Bolts C e Remove the lower crankcase bolts OFirst loosen the M7 bolts M7 Bolts A M9 Bolts B e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase 6104132851 C
220. Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No 2013 ZR800AD JKBZR800AADA00001 JKBZRCB10DDA00001 abii ZRB00BD JKBZR800ABDA00001 2013 ZR800CD JKBZR800CCDA00001 2013 ZR800DD JKBZR800CDDA00001 L1 This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1463 01 Printed in Japan
221. Remove Pad Pin A Pad Spring B Brake Pads C ZR800C Model e Remove the pad pin plug A e Loosen the pad pin A e Remove the caliper mounting bolts B e Remove the caliper with the hose installed e Remove Pad Pin A Brake Pads B Front Brake Pad Installation ZR800A B D Models e Push the caliper pistons in by hand as far as they will go e Install the outside pad A and insert the pad pin B as shown Brake Pads BRAKES 12 25 Set Inside Pad A Pad Spring B OPush down the pin holder C and insert the pad pin Torque Front Brake Pad Pin 17 2 N m 1 75 kgf m 12 7 ft Ib A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc ZR800C Model e Push the caliper pistons in by hand as far as they will go e Install the pad springs in its correct position e Install the outside pad A and insert the pad pin B as shown e Set Inside Pad A Pad Pin B e Install the caliper see Caliper Installation e Tighten the pad pin and plug Torque Front Brake Pad Pins 17 2 N m 1 75 kgf m 12 7 ft lb Front Brake Pad Pin Plugs 2 5 0 25 kgf m 22 in Ib A WAR
222. Right Switch Housing B Handlebar Weight C Throttle Grip D e When removing the lower handlebar holders remove the following parts Cotter Pin A Both Sides Lower Holder Nut B Both Sides Washer C Both Sides e Remove Handlebar Holder Bolts A Handlebar Holder B Handlebars C Lower Handlebar Holders D and Dampers If neces sary Handlebar Installation e Install the dampers A and lower handlebar holders B if removed e Align the punch mark C on the handlebars and the cor ner edge D on the lower handlebar holder Handlebar STEERING 14 11 e Put the upper handlebar holder A on the flat surface to confirm the installation direction Front B Rear C e When installing the lower handlebar holders install the upper handlebar holder A and handlebar holder bolts B temporarily as shown Front C Gap D Handlebars E Replace the lower handlebar holder nuts A with new ones e Install the washers B e Tighten Torque Lower Handlebar Holder Nuts 34 N m 3 5 kgf m 25 16 e Insert the cotter pins C from forward e Tighten the handlebar holder bolts following the tightening sequence 1 4 There will be a gap A at the rear part of the holder after tightening Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib 14 12 STEERING Handlebar e Using a high flash point solvent clean of any oil or dirt that may
223. Rims e Bend the cotter pin A over the nut B A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin GJ04250BS1 e Adjust the drive chain slack after installation see Drive Chain Slack Inspection in the Periodic Maintenance chap ter e For ABS equipped models install the rear wheel rotation sensor see Rear Wheel Rotation Sensor Installation in the Brakes chapter e Check the rear brake effectiveness A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc 10 10 WHEELS TIRES Wheels Rims Wheel Inspection e Raise the front rear wheel off the ground see Front Rear Wheel Removal Spin the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings see Hub Bearing Removal Installation e Inspect the wheel for small cracks dents bending or warp x If there is any damage to the wheel replace the wheel e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A a
224. SYSTEM DFI Exhaust Butterfly Valve Actuator Service Code 63 ZR800A B Models Exhaust Butterfly Valve Actuator Removal Never drop the exhaust butterfly valve actuator es pecially on a hard surface Such a shock to the ac tuator can damage it e Slide the dust covers A e Loosen the locknuts B and turn the adjusters C to give the cable plenty of play e Disconnect the connectors A e Remove Clamp A Exhaust Butterfly Valve Cables B Bolts C Exhaust Butterfly Valve Actuator D e Remove the pulley bolt while holding the pulley A with the suitable tool B NOTICE If the pulley bolt is removed without holding the actuator damage will occur e Remove the pulley from the actuator Exhaust Butterfly Valve Actuator Installation e Install the pulley A on the actuator so that the hole side B align with the groove C on the shaft OCheck that the groove on the shaft faces to the center of the screw D as shown Olf not adjust the position see the procedure on the next page FUEL SYSTEM DFI 3 97 Exhaust Butterfly Valve Actuator Service Code 63 ZR800A B Models e Install the pulley A on the actuator as shown Tighten the pulley bolt B while holding the pulley with the suitable tool C Torque Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 N m 0 50 kgf m 43 in Ib If the pulley bolt is tightened without holding the actuator damage will occur
225. Seat Cutter 45 530 57001 1187 7571187ST C Valve Spring Compressor Adapter 21 57001 1272 75712728T C ENGINE TOP END 5 13 Special Tools and Sealant Valve Guide Arbor 4 Valve Seat Cutter 60 525 57001 1273 57001 1328 875712735 C 7571328ST C Valve Guide Reamer 4 Valve Guide Driver 57001 1274 57001 1564 875712745 875715645 Valve Seat Cutter Holder 4 Valve Guide Driver Attachment C 57001 1275 57001 1624 875712755 875716248 Compression Gauge Adapter M10 x 1 0 Liquid Gasket TB1216B 57001 1317 92104 1064 875713175 ST921064ST 5 14 ENGINE TOP END Clean Air System Air Suction Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Side Fairings see Side Fairing Removal in the Frame chapter e Disconnect the hose A e Remove Thermostat Housing see Thermostat Removal in the Cooling System chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Air Suction Valve Cover Bolts A Both Sides e Disconnect the air switching valve connector B e Remove the air suction valve covers C with the air switching valve D e Remove the air suction valves Air Suction Valve Installation e Install the air suction valve A so that its wider side B of the reed valve case faces the front e Tighten Torque Air Suction Valve Cover Bo
226. Sensor Inspectionm pp 12 68 Wheel Rotation Sensor Air Gap Inspection pp 12 68 Wheel Rotation Sensor Rotor Inspection pp 12 69 ET Cin 12 69 et 12 69 56 1 5 ieee avn ee ieee 12 69 BRAKES 12 3 This page intentionally left blank 12 4 BRAKES Exploded View ZR800A Model e S T 8 Q Ga 08102533845 C BRAKES 12 5 Exploded View amma Pe 1 Brake Hose Banjo Bots 25 25 18 2 Front vaster Cyinder Reson Sows 18 015 mi 5 L5 From vaster Cynder Camp Bs arin E T Front atper Assembly 22 _ B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease p 5 ront brake ight Swier saw tim PETS 12 6 BRAKES Exploded View ZR800C Model GL025408W5 C BRAKES 12 7 Exploded View Brake Hose Banjo Bolts 25 2 5 18 Front Master Cylinder Reservoir Screws 1 5 0 15 13 in lb Brake Lever Pivot Bolt 1 0 0 10 89 inb 9 Front Brake Pad Pin Plugs 2 5 0 25 22inlb Front Brake Pad Pins 17 2 1 75 B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the s
227. Special Tool Fork Cylinder Holder 57001 1443 e Take the cylinder unit A out of the inner tube B ODo not disassemble the cylinder unit and inner tube 13 34 SUSPENSION Front Fork Front Fork Assembly Other than ZR800C D Models Left Front Fork e Using a high flash point solvent clean off any oil or dirt that may be on the adhesive coating area Dry them with a clean cloth e Apply adhesive ThreeBond TB1344N or equivalent to the threads of the cylinder unit A e Install the cylinder unit into the inner tube e Tighten the cylinder unit with the specified torque using the fork cylinder holder A and a suitable bar B Special Tool Fork Cylinder Holder 57001 1443 Torque Cylinder Unit 70 7 1 kgf m 52 ft Ib OTo tighten the cylinder unit with the specified torque pull the bar with 234 N 23 9 kgf 52 6 Ibf C force at the point of 300 mm 11 8 in D from the center E of the fork cylinder holder in the direction as shown e Replace the following parts with new one Oil Seal A Outer Tube Guide Bushing B Inner Tube Guide Bushing C Dust Seal D Retaining Ring E e Install the following parts onto the inner tube Dust Seal Retaining Ring Oil Seal Washer F Outer Tube Guide Bushing Inner Tube Guide Bushing e Insert the inner tube to the outer tube e Fit the new outer tube guide bushing A into the outer tube NOTE OWhen assembling the new outer tube guide bushing hold the wa
228. Supply Inspection Connections 1 Digital Meter Terminal 6 W G Digital Meter gt Battery terminal Digital Meter Terminal 8 W BK Digital Meter gt Battery terminal Ignition Switch OFF Terminal 6 W G 0 V Terminal 8 W BK Battery Voltage Ignition Switch ON Both Battery Voltage xIf the reading is out of the specification check the follow ing Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 10 A see Fuse Inspection in the Electrical System chapter ECU Main Relay see Relay Circuit Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in this sec tion x If ines wiring and relay are good replace the ECU see ECU Removal Installation GC17610ES1 3 110 FUEL SYSTEM ECU ECU Power Source Circuit 5 AAS Ignition Switch Frame Ground 1 Joint Connector E ECU Joint Connector D Frame Ground 4 Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15A Relay Box ECU Main Relay Fuse Box 1 Ignition Fuse 15 Joint Connector C GCi7519FW2 C DFI Power Source FUEL SYSTEM DFI 3 111 ECU Fuse Removal e Refer to the 30 A Main 10 A ECU Fuse Removal in the Electrical System chapter ECU F
229. System DFI Throttle Grip Free Play Idle Speed Bypass Screws Turn Out Throttle Body Vacuum Air Cleaner Element 2 3 mm 0 08 0 12 in 1 100 x50 r min rpm 35 3 1 3 kPa 265 10 mmHg at idle speed Paper filter Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Permanent type antifreeze Green Soft water 50 Coolant 50 35 31 2 8 L 3 0 US qt 0 22 0 31 mm 0 0087 0 0122 Exhaust in 0 15 0 24 mm 0 0059 0 0094 Intake in Clutch Clutch Lever Free Play 2 mm 0 08 0 12 in Engine Lubrication System Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 3 1 L 3 3 US qt when filter is not removed 3 4 L 3 6 US qt when filter is n removed 3 8 L 4 0 US qt when engine is completely dry Level Between upper and lower level lines Wait2 3 minutes after idling or running Wheels Tires Tread Depth Front 4 0 mm 0 16 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 5 5 mm 0 22 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air Pressure when Cold Drive Chain Slack Drive Chain Wear 20
230. T TRANSMISSION Transmission 1292 82 42 59 62 02 82 9209 6 072 67 90390141516001708 PON UP m 3 hi s 4909 1 e m pz X e eS E api Se at a So ooo e eee S i ea Lo ONS PIN AT 23 76409690 5 6969 626e969650269609909606 0 299999 999 9 92 2 Q 3 99 Gli3544BW3 C 1st Gear 32 Output Shaft Needle Bearing 17 Ball Bearing Circlip 18 Drive Shaft Bearing Outer Race 19 Nut Thrust Washer 30 mm 1 18 in 20 Collar 2nd Gear 21 Oil Seal Circlip 29 mm 1 14 in 22 Steel Ball Toothed Washer 35 mm 1 38 in 23 Washer Bushing 24 Bushing 6th Top Gear 25 Toothed Washer 34 mm 1 34 in Toothed Washer 31 mm 1 22 in 26 Circlip 33 mm 1 30 in 4th Gear 27 Bushing 3rd Gear 28 Toothed Washer oth Gear 29 Toothed Washer Bushing 30 Thrust Washer 31 mm 1 22 in Thrust Washer 33 mm 1 30 in 31 Needle Bearing CRANKSHAFT TRANSMISSION 9 33 Transmission Shift Drum and Fork Removal e Remove Lower Crankcase Half see Crankcase Splitting Transmission Shafts Gear Positioning Lever A see External Shift Mecha nism Removal Bolt B and Screw C Shift Drum Bearing Holder D e Pull out the shift rods E and take off the shift forks e Pull out the shift drum F Shift Drum and Fork Installation e Apply engine oil to the shift dru
231. T TRANSMISSION Transmission Shift Pedal Removal e Remove Shift Lever Bolt A Shift Lever B If the tie rod is removed from the shift pedal and shift lever note the following OThe following portions have left hand threads Locknut C of Shift Lever Side Ball Joint D of Shift Lever e Remove Shift Pedal Mounting Bolt E Shift Pedal F with Tie rod G Shift Pedal Installation e Apply grease to the sliding surface A on the shift pedal mounting bolt B e Install Washer C Tie Rod D and Shift Pedal E e Tighten Torque Shift Pedal Mounting Bolt 25 N m 2 5 kgf m 18 ft Ib e Align the punch mark A on the shift shaft with the slit B of the shift lever e Tighten Torque Shift Lever Bolt C 6 9 N m 0 70 kgf m 61 in Ib e After installation confirm that the shift pedal A is posi tioned as shown About 90 B x If the pedal position is different adjust it as follows OTo adjust the pedal position loosen the front locknut C left hand threads and rear locknut D and then turn the tie rod OTighten Torque Tie Rod Locknuts 6 9 N m 0 70 kgf m 61 in Ib CRANKSHAFT TRANSMISSION 9 27 Transmission External Shift Mechanism Removal Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Shift Lever see Shift Pedal Removal Clutch see Clutch Removal in the Clutch chapter Oil Pipe Holder Bolts A Oil Pipe Holders B Oil P
232. Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 17 018 57001 1609 Spacer 018 57001 1636 GM07030BS1 13 48 SUSPENSION Tie Rod Rocker Arm NOTE Olnstall the needle bearings so that the marked side faces in Needle Bearings A Oil Seals B Front C Right Side D Left Side E Rear Shock Absorber F Tie Rods G Rocker Arm H 7 5 mm 0 30 in I 5 0 0 4 mm 0 20 0 02 in J 5 5 mm 0 22 in K Rocker Arm Tie Rod Bearing Sleeve Inspection NOTICE 6 o Do not remove the bearings for inspection Re moval may damage them Q 5 2 e Visually inspect the rocker arm or tie rod sleeves A and needle bearings B e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring 07016881 inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of any of the nee dle bearings or sleeve replace the sleeve and needle bearings as a set Q Rocker Arm Tie Rod Bearing Lubrication NOTE OSince the bearings are packed with grease lubrication is not required STEERING 14 1 Steering Table of Contents ue ET 14 2 Special Tools sri 14 4 RCRUM 14 Steering nspectlonm
233. a Dry them with a clean cloth e Apply liquid gasket to the circumference of the alternator lead grommet and fit the grommet into the notch of the cover securely Sealant Liquid Gasket TB1211F 92104 0004 e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Shaft A Starter Idle Gear B e Hold the alternator rotor steady with the rotor holder A and stopper B e Remove the rotor bolt C and washer Special Tools Grip D 57001 1591 Stopper 57001 1679 Rotor Holder 57001 1690 16 38 ELECTRICAL SYSTEM Charging System e Using the flywheel puller A remove the alternator rotor B from the crankshaft Special Tool Flywheel Puller Assembly M38 1 5 M35 x 1 5 57001 1615 NOTICE Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Alternator Rotor Tapered Portion B e Apply a thin coat of molybdenum disulfide grease to the crankshaft C NOTE ODo not apply of molybdenum disulfide grease to the face D of the starter clutch gear x If the apply of molybdenum disulfide grease to the face of the starter clutch gear dry them with a clean cl
234. ads in order of the front Run the front brake hose through the clamp Clamp Hold the left turn signal lead Cover the city light lead connectors turn signal light lead connectors front wheel rotation sensor lead connector ABS equipped models with the rubber cover Left Turn Signal Lead Right Turn Signal Lead The left turn signal lead has the gray color connector 17 8 APPENDIX Cable Wire and Hose Routing 1 Throttle Cable Decelerator 2 Throttle Cable Accelerator 3 Main Harness 4 Run the throttle cables to the outside of the main harness and frame 5 Run the throttle cables under the main harness 50091196 APPENDIX 17 9 Cable Wire and Hose Routing 9 68091186 6 12 13 14 Run the ignition switch lead and immobilizer antenna lead between the frame and thermostat housing Fuel Tank Breather Hose Radiator Overflow Hose Fuel Tank Drain Hose Reserve Tank Overflow Hose Intake Air Pressure Sensor 2 Connector Do not bend the immobilizer amplifier lead near the immobilizer amplifier connector Run the immobilizer amplifier lead to the upside of the rubber cover Clamp Bend the clamp by 90 after the connectors are covered with rubber cover Radiator Fan Motor Lead Clamp Hold the immobilizer antenna lead ignition switch lead intake air pressure sensor lead and water temperature sensor lead Clamp
235. aft same process SUSPENSION 13 21 Front Fork Set the holder bar A and compression shafts B e Screw in the nuts A until the piston rod nut B comes out OHold up the top plug C while screwing in the nut e Insert the fork spring stopper A between the piston rod nut B and the clamp C while holding up the top plug D Special Tool Fork Spring Stopper 57001 1374 e Holding the piston rod nut with a wrench A remove the top plug B from the piston rod e Remove the fork spring compressor from the front fork e Remove Washer A Collar B Rebound Damping Adjuster Rod C Right Front Fork Only Fork Spring D GM04381BS1 C 13 22 SUSPENSION Front Fork e Screw the rod nut A onto the piston rod B as shown 12 mm 0 47 in or more C Drain the fork oil into a suitable container and remove the spring seat OUsing the piston rod puller A pump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 e Hold the fork tube upright press the inner tube A the piston rod all the way down e Pour in the type and amount of fork oil specified Recommended Oil KHL15 10 or equivalent Amount Per Side When changing oil Approx 405 mL 13 7 US oz After disassembly and completely dry Right Front Fork 464 4 mL 15 7 0 135 US oz Left Front Fork 469 4 mL
236. age using a voltmeter A OThe battery voltage should be within 10 16 V x If the voltage without specifications recharge or replace the battery x If the voltage within specifications go to next step Step 3 e Disconnect the ABS hydraulic unit connector e Check the voltage between the terminal 7 BR W A and terminal 9 BK B of the ABS hydraulic unit con nector Special Tool Hand Tester 57001 1394 OThe battery voltage 10 16 V should be appeared while the ignition switch turned on x If the battery voltage appeared go to step 4 x If the battery voltage does not appear go to next step Step 3 1 e Check the voltage between the terminal 7 BR W A of the ABS hydraulic unit connector and a frame ground Special Tool Hand Tester 57001 1394 OThe battery voltage 10 16 V should be appeared while the ignition switch turned on the battery voltage does not appear repair or replace the main harness x If the battery voltage appeared go to next step 8 08010851 C GL14702BS1 BRAKES 12 53 Anti Lock Brake System Equipped Models Step 3 2 e Check for continuity between the terminal 9 BK A of the ABS hydraulic unit connector and a frame ground B x lf there is no continuity repair or replace the main har ness x If there is continuity replace the ABS hydraulic unit Step 4
237. agnostic E Systen E Connector 54 55 5 zz 1 35 Er Starter 555555 Regulator Relay 5252525 Sensor Rectifier Alternator E Fuse Box 2 1 Fan Fuse 15A 2 Meter Fuse 7 54 Battery Ground 4 amp Joint Starter 12V8Ah Frame Ground Rear Connector B Motor Brake Light Switch Starter Relay 1 0 Fuse 15 2 Main Fuse 30 ABS Self diagnosis 85 Terminal Kawasaki Diagnosis System Connector aK Y aR Y R ak Y BK Y Light 12V10N Tail Brake Light LEO License Plate Light 12 5 Rear Left Turn Signal Light 12V10N Color Code Black Brown Green GY Gray LB Light Blue LG Light Green 0 Orange 98052 07086 Pink Purple R Red V violet w White Y Yellow W2R0708CW5 C 16 28 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them
238. ain Fuse 30 ABS Kawasaki Diagnosis System Connector Rear Right ee Turn Signal 128108 Tail Brake a Light LED License Plats TE tis 12V5Y Rear Left E Turn Signal 6 vs 12V10w Color Code Black Brown Green GY Gray LB Light Blue LG Light Green 0 Orange 98052 07066 Pink Purple R Red V violet w White Y Yellow W2R0706CW5 C 16 22 ELECTRICAL SYSTEM Wiring Diagram ZR800B with GPS Unit Rig Lig 1 2 3 arero Front Wheel Rotation Sensor GPS Unit H H 8K Y ov Immobi Amplifier BK Y EF i LL HL Right Switch Housing 1 Brake Light Switch 2 Engine Stop Switch 3 Starter Button oe Intake E Yehicle Air eY 0 doen Tenner stare ensor ensor aS pan Spark Plugs BR W ji 2 Wot 1 2 3 4 v N Stick Switching Coils Valve i ze H 55 NE gz 2 2 32 2 22 Front Right Torn sien E Tue E 12Vi0w 1 EE Immobilizer J Antenna E E 3 ii H 1 L uUi Lu 2 L tj ht City R BR Y ht 12V5W s am 1 HH Headlight R Y Low
239. airing see Upper Fairing Removal in the Frame chapter Brake Hose Banjo Bolts A e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hoses B temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e For ABS equipped models note the following e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Right Side Fairing see Side Fairing Removal in the Frame chapter Rear Fender see Rear Fender Removal in the Frame chapter ABS Hydraulic Unit see ABS Hydraulic Unit Removal in the Brakes chapter Bolts A Brackets B e Replace the brake hose and pipe as an assembly e There are washers on each side of the brake hose fit ting and unit side Replace them with new ones when installing e When installing the hoses avoid sharp bending kinking flatting or twisting and run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Fill the brake line after installing the brake hose see Brake Fluid Change PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly Remove the front master cylinder see Front Master Cylin der
240. ake Air Pressure Sensor 4 ECU FUEL SYSTEM DFI 3 59 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Removal Instal lation Never drop the intake air temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector A from the intake air temper ature sensor B e Pull out the intake air temperature sensor e Insert the intake air temperature sensor A into the grom met B Intake Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove the fuel tank see Fuel Tank Removal e Disconnect the intake air temperature sensor connector and connect the harness adapter A between these con nectors as shown Main Harness B Intake Air Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the harness adapter leads Intake Air Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor R BK lead Digital Meter BK sensor G lead e Measure the output voltage with the engine stopped and the connector joined e Turn the ignition switch on Output Voltage Standard About DC 2 25 2 50 V at intake air temperature 20 C 68 F NOTE OThe output voltage changes according to the intake air temperature
241. al System chapter Turn the engine stop switch off e The low beam and high beam headlights should stay go ing on x If the headlights and blue high beam indicator light LED does go off inspect or replace the following item Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter e Turn the ignition switch off e The headlights and blue high beam indicator light LED should go off Headlight Aiming Inspection Inspect the headlight beam for aiming xIf the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster A on the headlights in or out until the beam points straight ahead x lf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster A on the headlights in or out to adjust the headlight vertically NOTE high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Side Stand Switch Operation Inspection e Inspect the side stand switch A operation accordance to the following table Side Stand Switch Operation Gear Clutch Engine running running Up In gear Released Continue
242. al System chapter GT04217BS1 Warning Indicator Light LED Circuit BK Y BK BL GCi17518FW2 C 1 Meter Unit 2 Yellow Engine Warning Indicator Light LED 3 Frame Ground 1 4 Joint Connector E 5 ECU ECU FUEL SYSTEM DFI 3 107 ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle cannot clear the regulation ECU Identification ZR800A B Models Part Number A Specification WVTA FULL GB WVTA FULL SEA B2 AU 21175 0791 WVTA 78 2 21175 0833 BR 21175 0789 ECU Identification ZR800C D Models Part Number A 21175 0806 Specification WVTA FULL ECU Removal Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it NOTE ORefer to the Immobilizer System Parts Replacement in the Electrical System chapter for the models with guards e Remove the relay box see Relay Box Removal in the Electrical System chapter e Lift up the ECU A with rubber protector B e Disconnect the ECU connectors A e Remove the ECU B with Rubber Protector C 8017808 51 3 108 FUEL SYSTEM DFI ECU ECU Installation Connect the ECU connectors A e Install the ECU B in Rubber Protector C e Insert th
243. ame circuit as Check 1 e Connect the terminal 9 to the battery terminal e Check that the green left turn signal indicator light LED A goes on xIf the indicator light LED does not go on replace the meter assembly Check 9 Blue High Beam Indicator Light LED Inspec tion e Connect the leads in the same circuit as Check 1 e Connect the terminal 12 to the battery terminal GP17083DS1 C 6170750 6 6170770 6 GP17078DS1 16 78 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Check that the blue high beam indicator light LED A goes on x lf the indicator light LED does not go on replace the meter assembly Check 10 Green Right Turn Signal Indicator Light LED Inspection e Connect the leads in the same circuit as Check 1 e Connect the terminal 13 to the battery terminal e Check that the green right turn signal indicator light LED A goes on xIf the indicator light LED does not go on replace the meter assembly Check 11 Green Neutral Indicator Light LED Inspec tion e Connect the leads in the same circuit as Check 1 e Connect the terminal 11 to the battery terminal e Check that the green neutral indicator light LED A goes on xIf the indicator light LED does not go on replace the meter assembly 6 170790 170810 6 GP17082DS1 C ELECTRICAL SYSTEM 1
244. and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself xIf an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU GC17509FS1 C 6017029281 3 32 FUEL SYSTEM DFI Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Turn the ignition switch on Yellow engine warning indicator Yellow engine warning Red warning indicator light light LED do not go on or indicator light LED goes LED and Immobilizer Immobilizer warning symbol and on warning symbol blink red warning indicator light LED do not blink Conduct non self diagnosis Conduct self diagnosis Conduct self diagnosis inspection inspection DFI system inspection immobilizer system Conduct general fuel system inspection General fuel system throttle body assy air cleaner fuel tank etc Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what prob
245. and up A 4 or 5 times and inspect the smooth stroke xIf the shock absorber does not smoothly stroke or noise is found inspect the oil leak see Rear Shock Absorber Oil Leak Inspection 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absorber A for oil leakage x If the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x If the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter Tie Rod Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x If the tie rods A do not smoothly stroke or noise is found inspect the fasteners and tie rod bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter 65148915 P PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures Steering System Steering Play Inspection Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheels Tires chapter e With the front wheel pointing st
246. ank Key Detection Service Code 36 3 87 Ignition wenden nete ehe ette 3 87 ECU Communication Error Service Code 39 3 89 ECU Communication Line Inspection Nt 3 89 Stick Coils 1 2 3 4 Service Code 51 52 53 54 3 90 Stick Coil Removal lnstallatio e pner ice d nacen teta 3 90 Stick Coil Primary Winding Resistance Inspection pp 3 90 Stick Coil Input Voltage Inspection nnne nnns 3 90 Radiator Fan Relay Service Code 56 2 1 1 1212 1 1 1 2 122 44 24 4441 4 41 3 92 Radiator Fan Relay 3 92 Radiator Fan Relay Inspectigm nennen nennen nennen nbn nennen nnn 3 92 Subthrottle Valve Actuator Service Code 62 3 93 Subthrottle Valve Actuator Removal pp 3 93 Subthrottle Valve Actuator 3 93 Subthrottle Valve Actuator Resistance Inspection pp 3 93 Subthrottle Valve Actuator Input Voltage Inspection pp 3 94 Exhaust Butterfly Valve Actuator Service Code 63 ZR800A B Models 3 96 Exhaust Butterfly Valve Actuator 3 96 Exhaust Butterfly Valve Actuator Installation pp 3 96 Exhaust Butterfly Valve Actuator 3 98 Ex
247. apter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Stumble Fuel pressure too low Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 nspect see chapter 3 Subthrotte valve actuator rouble inspect see chapter 3 intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor rouble inspect see chapter 3 sug Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Fuel pressure too low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 2 S Intake air 1 trouble Intake air
248. area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want s
249. area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil pressure relief valve If cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts 6008060251 ENGINE LUBRICATION SYSTEM 7 11 Oil Pump Oil Pump Removal e Drain Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Remove the water pipe bolts A e Disconnect the water pipes B Remove Water Pump Cover Bolts A and Clamp Water Pump Cover B Remove Impeller Bolt A Washer Impeller B Water Pump Body C Oil Pump Cover Oil Water Pump Shaft Outer Rotor and Inner Rotor Oil Pump Installation e Install the outer rotor A into the crankcase e Install the pin B inner rotor C and oil water pump shaft D OTurn the pump shaft so that the slot E in its shaft fits onto the projection F of the pump drive gear shaft e Fit the pin A of the oil pump cover B into the hole C in the crankcase GG09081BS1 C 7 12 ENGINE LUBRICATION SYSTEM Oil Pump e Replace the O ring A with a new one e Apply gre
250. arp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 15 mm 0 0059 in or less Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A xIf any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 64 1 mm 2 52 in Service Limit 61 2 mm 2 41 in GF06060281 GF06060381 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents e delroro Tela V DET 7 2 Engine Onslow de dee ET 7 4 ee 7 6 Special Tools and 7 7 Engine Oiled 7 8 Oil Level INSpectiON aani 7 8 Engine Oil rene aa e ere eee eee 7 8 Oil Filter Replacement pp 7 8 elu E 7 9 Oil Pan Removalss 7 9 7 9 Oil Pressure Relief Valve 7 10 Oil Pressure Relief Valve Removal pp 7 10 Oil P
251. ase LG Apply liquid gasket R Replacement Parts 3 8 FUEL SYSTEM DFI Exploded View 6002595BW5 C Exploded View FUEL SYSTEM DFI 3 9 Fastener Torque fib Fuel Pump Bolts Fuel Level Sensor Bolts 10 6 9 0 70 61 inb L Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 0 70 61 in lb Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 0 50 43 in lb 5 ZR800A B Models L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 3 10 FUEL SYSTEM DFI DFI System DFI System 6C17422FW5 C DFI System FUEL SYSTEM DFI 3 11 ECU Battery 12 V 8 Ah Pressure Regulator Fuel Filter Water Temperature Sensor Intake Air Pressure Sensor 2 Intake Air Pressure Sensor 1 Fuel Flow Fuel Pump Delivery Pipe Assy Subthrottle Sensor Air Switching Valve Fuel Injectors Intake Air Temperature Sensor Air Flow Crankshaft Sensor Main Throttle Sensor Subthrottle Valve Actuator Speed Sensor Vehicle down Sensor Oxygen Sensor 3 12 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram ZR800A B Models 5555 BS 33 gt 555 37 2558 sralitf ilii PR e zi Dr rr BY7BL e BK BL
252. ase to the O ring e Install Pins B Water Pump Body C e Install the impeller A washer and bolt B e Tighten Torque Water Pump Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib e Replace the O rings C with new ones Apply grease to the O rings e Install the pins D and water pump cover e Tighten Torque Water Pump Cover Bolts 11 1 1 kgf m 97 in Ib e Install the upper water pipe A and lower water pipe B e Apply a non permanent locking agent to the threads of the water pipe bolts C and tighten them Torque Water Pipe Bolts 11 N m 1 1 97 in Ib Oil Pump Drive Gear Removal e Remove Clutch see Clutch Removal in the Clutch chapter Oil Pan see Oil Pan Removal Circlip A and Washer B Oil Pump Drive Gear C and Washer Special Tool Outside Circlip Pliers 57001 144 Oil Pump Drive Gear Installation e Apply molybdenum disulfide oil solution to the journal por tions A on the oil pump drive gear shaft B e Install the washers C D e Install the new circlip E into the groove of the oil pump drive gear shaft Special Tool Outside Circlip Pliers 57001 144 GG09098BS1 C ENGINE LUBRICATION SYSTEM 7 13 Oil Pressure Measurement Oil Pressure Measurement Remove the right lower fairing see Lower Fairing Re moval ZR800A B Models in the Frame chapter e Remove the oil passage plug and attach the adapter A and gauge B
253. bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebars shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar clamp bolt loose Steering stem nut loose Front rear axle runout excessive Engine mounting portions loose Handlebars pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent 17 44 APPENDIX Troubleshooting Guide Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery cable making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty
254. bolts and record the values to find the bolt stretch Connecting Rod A Mark here with a punch B Nuts C Fit micrometer pins into punch marks D e Tighten the big end nuts until the bolt elongation reaches the length specified in the table e Check the length of the connecting rod bolts x If the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in use Bolt Length after tightening Bolt Length before tightening Bolt Stretch Connect Usable Range of ing Rod Connecting Rod Assy Bolt Stretch Use the bolts Attached to DOM Bee 0 0094 0 0142 in new con rod Replace the Used _ bolts with new ones 0 20 0 32 mm New 0 0079 0 0126 in 2 Rotation Angle Method If you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method e Be sure to clean the bolts and nuts thoroughly with a high flash point solvent because the new bolts and nuts are treated with an anti rust solution A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the bolts nuts and connecting rods in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean them Immediately dry the bolts and nuts w
255. cessively high temperature Do not place any key close to magnet Do not place a heavy item on any key Do not grind any key or alter its shape Do not disassemble the plastic part of any key Do not drop the key and or apply any shocks to the key When an ignition key is lost the user should go to his dealer to invalidate the lost key registration in the ECU 10 When all ignition keys are lost the user should go to his dealer and have a new ECU installed and register the ignition keys GUT x 9 10 are strongly recommended to the customer to ensure security of the motorcycle Key Registration Case 1 When additional spare ignition key is required e Prepare a new spare ignition key e Cut the key in accordance with the shape of the current ignition key e Remove the rear seat see Rear Seat Removal in the Frame chapter e Remove the immobilizer Kawasaki diagnostic system connector cap A e Connect the key registration unit A and key registration adapter B as shown Immobilizer Kawasaki Diagnostic System Connector C Special Tools Key Registration Unit 57001 1582 Key Registration Adapter 57001 1746 Immobilizer System ELECTRICAL SYSTEM 16 85 Insert the registered ignition key to the ignition switch and turn it to ON Verified OThe red warning indicator light LED and immobilizer warning symbol A blink to display the registration mode
256. ch refer to the tables in the Wiring Diagram xIf the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Rear Brake Light Switch Connections Color BR BL When brake pedal is pushed down O o When brake pedal is released Side Stand Switch Connections Side Stand Switch Connections Color BK Y G W When side stand is down EE When side stand is up O O Neutral Switch Connections Neutral Switch Connections Color SW Terminal Ground When transmission is in neutral O o When transmission is not in neutral Oil Pressure Switch Connections Oil Pressure Switch Connections Color SW Terminal Ground When engine is running Engine lubrication system is in good condition 16 108 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection Remove the water temperature sensor see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter e Suspend the sensor A in a container of coolant so that the threaded portion is submerged e Suspend an accurate thermometer B with temperature sensing portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while
257. ck Brake System Equipped Models Erasing of Service Code Service Code Output Erase Completion lt gt Signal Blinks Yellow ABS Indicator Light LED ABS Self diagnosis Terminal 15 or more 1s or more 1s or more ABS Unit Erase Function lt Service Code Erase GL14730B 5 BRAKES 12 49 Anti Lock Brake System Equipped Models Self diagnosis Flow Chart Turn the ignition switch off and connect the ABS self diagnosis terminal to the frame ground The yellow ABS indicator light LED blinks to display the service code in 5 6 seconds after the ignition switch turned on Erase the service code memorized in the ABS hydraulic unit Start the self diagnosis mode to confirm that erasing has been completed Disconnect the ABS self diagnosis terminal from the frame ground ending the self diagnosis mode 1 With no service code is memorized drive at 30 km h 19 mph or more for one minute stop and try self diagnosis again Check the faulty point with the service code table and repair according to the Service Code Table Activate the ABS by driving the motorcycle at 30 km h 19 mph NG lit above in order to confirm that the is normal gt Repeat self diagnosis OK Unlit Activate the ABS at a safe place in order to confirm that it operates normally 2 End 1 The self diagnosis mode ends following When the ignition switch is OFF When th
258. ck for cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to the Coolant Level in the Periodic Maintenance chapter Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Remove the radiator cap and install a cooling system pressure tester A on the filler neck B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi NOTICE During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is all right the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump e Remove the pressure tester replenish the coolant and install the radiator cap e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter GDO5015BS1 C Coolant COOLING SYSTEM 4 9 Cooling System Flu
259. cuum is not within specifications adjust the by pass screws A Upside View B Special Tool Pilot Screw Adjuster A 57001 1239 e Adjust the each vacuum 1 4 to the standard value e Open and close the throttle valves after each measure ment NOTE ODo not turn the center adjusting screw C e Check the vacuums as before x If all vacuums are within the specification range finish the engine vacuum synchronization If any vacuum can not be adjusted within the specification replace the bypass screws 1 4 with new ones refer to the following procedure Remove the throttle body assy see Throttle Body Assy Removal in the Fuel System DFI chapter e Turn the bypass screw A with counting the number of turns until it seals fully but not tightly Record the number of turns e Remove Bypass Screw Spring B Washer C O ring D e Check the bypass screw hole in the throttle body for car bon deposits x If any carbons accumulate wipe the carbons off from the hole using a cotton pad penetrated with a high flash point solvent e Replace the bypass screw spring washer and O ring as a set e Turn in the bypass screw until it seats fully but not tightly Do not over tighten the bypass screw The tapered portion E of the bypass screw could be damaged 9505282851 4 9505283851 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures eBack out the same
260. d Remove the front fork from the fork spring compressor e Remove Washer A Collar B Rebound Damping Adjuster Rod C Right Front Fork only Fork Spring D GM04381BS1 C e Screw the rod nut A onto the piston rod B as shown 12 mm 0 47 in or more C GM04738BS1 e Drain the fork oil into a suitable container and remove the spring seat OUsing the piston rod puller A pump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 6M04021281 SUSPENSION 13 17 Front Fork e Hold the fork tube upright press the inner tube A the piston rod all the way down e Pour in the type and amount of fork oil specified Recommended Oil KHL15 10 or equivalent Amount Per Side When changing oil Approx 405 mL 13 7 US oz After disassembly and completely dry Right Front Fork 464 4 mL 15 7 0 135 US oz Left Front Fork 469 4 mL 15 9 0 135 US oz E 9 Wy D my Wy 8 04042851 C x If necessary measure the oil level as follows u OHold the inner tube vertically in a vise 3 OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 ORemove the piston rod puller 5 OWai
261. d DC amperage should be within 3 17 mA x If measurement is abnormal replace the front wheel ro tation sensor If measurement is normal replace the ABS hydraulic unit Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 OThis code is indicates there is a trouble in the rear wheel rotation sensor However the front and rear wheel rota tion sensor inspection should be performed if this code is indicated e Perform the Pre Diagnosis Inspection 1 and 2 e Check the system connectors for loose or poorly contact Step 1 e Disconnect the ABS hydraulic unit connector e Check for continuity between the terminal 9 BK A and terminal 8 W BK B of the ABS hydraulic unit connector x If there is continuity go to next step x If there is no continuity go to step 2 Step 1 1 e Disconnect the front wheel rotation sensor connector A e Recheck the continuity between the terminal 9 BK and terminal 8 W BK of the ABS hydraulic unit connector x lf there is continuity repair or replace the main harness xIf there is no continuity replace the front wheel rotation sensor LI LI LT LT LT LT LT LT LT 6500000 QOGGGCO 09 9114718851 12 60 BRAKES Anti Lock Brake System Equipped Models Step 2 Check for continuity between the terminal 9 BK A and terminal 6 W G B of the ABS hydraulic unit connector x If there is continuity go to next step
262. d and crankshaft coding Size Color B Con rod Big End Crankpin Inside Diameter Diameter Marking Marking Size Color Part Number Bearing Insert None None Black 92139 1109 O e Install the new inserts the connecting rod and check insert crankpin clearance with the plastigage Crankshaft Side Clearance Inspection e Insert a thickness gauge A between the crankcase main bearing and the crank web at the No 2 journal B to de termine clearance x If the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Crankshaft Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in Service Limit 0 40 mm 0 0157 in 6105060181 6105041781 6105019851 C CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods Crankshaft Runout Inspection Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in Crankshaft Main Bearing Insert Journal Wear Inspection e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly OD
263. d level in the brake reservoirs Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter 12 20 BRAKES Calipers Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Caliper Fluid Seal Damage Inspection The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage
264. d pull the stick coil A off the spark plug OTake out the stick coil 3 from between the frame and thermostat housing Remove the reserve tank bolts A with the clamp e Disconnect the air switching valve hose B for Stick Coil 2 e Disconnect the stick coil connectors e Pull the stick coil 1 D and 2 off the spark plugs OTake out the stick coil 2 from between the frame and thermostat housing Stick Coil Installation e Insert the stick coils e Be sure the stick coils are installed by pulling up it lightly e Connect the connectors NOTICE Do not tap the coil head while installing the coil e Run the hoses and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters 16 48 ELECTRICAL SYSTEM Ignition System Stick Coil Inspection Remove the stick coils see Stick Coil Removal e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 range and read the tester e Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 range and read the tester Stick Coil Winding Resistance Primary Windings 1 1 1 50 Secondary Windings 6 4 9 6 x If the tester does not read as specified replace the coil Stic
265. e e Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder A e Take off the plate holder e Set the plate holder B A and cutting and riveting pin B as shown e Turn the pin holder until riveting pin touches link pin e Turn the wrench clockwise until tip of riveting pin hits of link pin e Rivet it e Same work for the other link pin GK04026BS1 C Drive Chain FINAL DRIVE 11 9 e After staking check the staked area of the link pin for cracks e Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 7 6 0 mm 0 22 0 24 in Link Plates Outside Width Standard 17 25 17 45 mm 0 679 0 687 in x If the reading exceeds the specified length cut and rejoin the chain again Check Movement of the Rollers e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter e Install the removed parts see appropriate chapters GK04028BS1 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Remove Left Frame Cover see Frame Cover Removal in the Frame chapter Engine Sprocket Cover Bolts A Bracket B Engine Sprocket Cover C e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear bra
266. e Black Brown Green GY Gray LB Light Blue LG Light Green 0 Orange 98052 07804 Pink Purple R Red V violet w White Y Yellow W2RO780AWS C 16 24 ELECTRICAL SYSTEM Wiring Diagram ZR800C Immobi Amplifier CF Immobilizer Antenna Front Wheel Rotation Sensor Joint 9 Connector Meter Unit Joint Lj E 9 Connector sj Front Right Turn Signal BK Y Right Switch Housing l Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button Intake Yehicle Air down Sensor Sensor 1 1 Horn Fan Spark Plugs 5 2 Wot 1 2 3 4 on 9197 SS SS S Air N Switching Valve s MES T 5235 55 lt b 5 55 Temperature BK Y T BR Y i Light T2 i08 Right City Light 1275 Headlight R Y Low BK Y 127558 Headlight AT High 12551 e Left City D Light 12V5W GIZA Front Left Turn Signal T2 108 Meter Unit Yellow Engine Warning Indicator Light LED 2 Green Neutral Indicator Light LEB 3 Blue High Beam Indicator Light LED 4 Green Left Turn Signal Indicator Light LEB 5 6reen Right Turn Signa Indicator Light LED Red Wa
267. e tire pressure is incorrect a non recommended tire is in stalled or the wheel is deformed If the indicator light lights remedy the problem and clear the service code A WARNING Use of non recommended tires may cause malfunc tioning of ABS and can lead to extended braking distance resulting in an accident causing serious injury or death Always use recommended stan dard tires for this motorcycle GP170850 6 Anti Lock Brake System Equipped Models BRAKES 12 41 OThe yellow ABS indicator light LED may come on if the engine is run with the motorcycle on its stand and the transmission in gear If the indicator light comes on just turn the ignition switch off then clear service code 42 which indicates a Faulty front wheel rotation sensor OWhen the ABS operates the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal This is a normal condition It informs the rider that the ABS is operating normally OService codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit Therefore after maintenance work is finished be sure to erase the service codes Do not erase the service codes during troubleshooting Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work OBefore delivering the motorcycle to the customer be sure to erase any service codes which m
268. e Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Input Voltage Inspection NOTE OBe sure the battery is fully charged Turn the ignition switch off e Disconnect the intake air pressure sensor 2 connector and connect the measuring adapter A between these connectors Main Harness B Intake Air Pressure Sensor 2 C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Pressure Sensor 2 Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter BK sensor lead e Measure the input voltage with the engine stopped and 8700089851 2 with the connector joined e Turn the ignition switch on Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch off x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor 2 Output Voltage Inspection x If the reading is out of the standard remove the ECU check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A lt Intake Air Pressure Sensor 2 Connector B BL lead ECU terminal 5 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Ins
269. e Camp Bok a 29 1 ra Fontaxe e no Rearen We no 79 4 ABS Equipped Models G Apply grease HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 02 in or less TIR 1 0 mm 0 04 in Radial TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in Axle Runout 100 mm TIR 0 03 mm 0 0012 in or less TIR 0 2 mm 0 008 in 3 94 in Wheel Balance Balance Weights 10 g 0 35 oz or less 10 g 0 35 oz 20 g 0 71 oz 30 g 1 06 oz Rim Size Front J17M C x MT3 50 urs Rear J17M C x MT5 50 Tires Air Pressure when Cold Front Up to 180 kg 397 Ib load 250 kPa 2 50 kgf cm 36 psi Rear Up to 180 kg 397 Ib load Tread Depth Front Rear Standard Tire Front Size Make Type Rear Size Make Type 290 kPa 2 90 kgf cm 42 psi 4 0 mm 0 16 in 5 5 mm 0 22 in 120 70ZR17 MIC 58W DUNLOP SPORTMAX D214F J Tubeless 180 55ZR17 MIC 73W DUNLOP SPORTMAX D214 J Tubeless 1 mm 0 04 AT CH DE 1 6 mm 0 06 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in A WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death To e
270. e Cover C 9021005851 e When installing the grommet A face the thick side to ward the inside B of the left frame cover C 9021006851 e Remove Subframe Cover See Subframe Cover Removal Bolt A e Pull out the frame cover B and clear the projections C Frame Cover Installation e Check that the grommets A and damper B are in place e Insert the projections C into the holes D e Tighten the bolts e Install the removed parts see appropriate chapters Rear View Mirrors FRAME 15 27 Rear View Mirror Removal e Slide the dust cover A e Loosen the rear view mirror locknut upper B and re move the rear view mirror stay C from the rear view mir ror nut lower D OThe rear view mirror locknut upper and rear view mirror stay are left hand thread e Loosen the rear view mirror nut lower and remove it Rear View Mirror Installation e Tighten the rear view mirror nut lower A Torque Rear View Mirror Nut Lower 30 N m 3 1 kgf m 22 ft lb e Apply grease to the threads of the rear view mirror stay B NOTE OThe threads of the new rear view mirror stay applied with a grease e Tighten the rear view mirror stay until the fully position e Adjust the rear view mirror stay to assure the safe condi tions of the rear with the rider sitting on the motorcycle OThe rear view mirror locknut upper C and rear view mirror stay are left hand thread e Tig
271. e Frame chapter e Disconnect the connector A Remove Clamp A Bolts B Screw C Remove Clamp A Brake Hose Banjo Bolt B e Clear the brake hose C from the hole of the rear inner fender e Remove Chain Adjuster Locknut D Chain Adjuster E Clamp F Bolts G Rear Wheel Rotation Sensor H Rear Wheel Rotation Sensor Installation e Installation is the reverse of removal e Run the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Tighten Torque Chain Adjuster Locknut 16 5 N m 1 68 kgf m 12 2 ft lb 12 68 BRAKES Anti Lock Brake System Equipped Models Wheel Rotation Sensor Inspection Remove the front wheel rotation sensor A from the front fork Remove the rear wheel rotation sensor B from the caliper bracket e Visually inspect the wheel rotation sensors Replace the wheel rotation sensor if it is cracked bent or otherwise damaged Wheel Rotation Sensor Air Gap Inspection e Raise the front rear wheel off the ground see Front Rear Wheel Removal in the Wheels Tires chapter e Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly Thickness Gauge A Air Gap Standard Front 0 1 1 5 mm 0 004 0 059 in Rear 0 1 1 5 mm 0 004 0 059 in NOTE O The sensor air gap cannot be adjusted x If the air gap is not within the specification inspect the hub bearing s
272. e alternator lead side stand switch lead speed sensor lead and neutral switch lead Idle Adjusting Cable Run the reserve tank overflow hose to the inside of the water pipe 10 11 12 13 14 15 16 Clamp Hold the side stand switch lead and neutral switch lead Neutral Switch Lead Clamp Hold side stand switch lead Side Stand Switch Lead Hold the air cleaner drain hose with the clamp so that the hose is not blocked up at the corner Run the idle adjusting cable to the upside of the other hoses and leads Idle Adjusting Screw Run the fuel tank drain hose air cleaner drain hose and fuel tank breather hose in order from the outside Clamp Hold the air cleaner drain hose fuel tank drain hose and fuel tank breather hose in order from the front 17 22 APPENDIX Cable Wire and Hose Routing 7 AY 1 4 VIT VI i E t ca AN N NSS X SS 1 2 we 6809127 6 APPENDIX 17 23 Cable Wire and Hose Routing oo Sensor Lead Clamp Hold the crankshaft sensor oil pressure switch lead oxygen sensor lead order of the outside Run the rear brake switch lead to the outside of the exhaust butterfly valve cables Rear Brake Switch Lead Set the leads between two connectors Crankshaft Sensor Oil Pressure Switch Lead Clamp Hold the exhaust butterf
273. e and Pipe Removal In stallation NOTICE Immediately wash away any brake fluid that spills ZR800C Model e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose and Pipe Removal In stallation NOTICE Immediately wash away any brake fluid that spills Rear Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the rear caliper mounting bolt B and rear caliper pin bolt C and detach the caliper D from the disc e Unscrew the banjo bolt and remove the brake hose E from the caliper see Brake Hose and Pipe Removal In stallation NOTICE Immediately wash away any brake fluid that spills Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones BRAKES 12 19 Calipers Rear Caliper e Install Rubber Boot A Guide B e Fit the rear brake pads A to the guide B e Apply silicone grease to the rear caliper pin bolt e Tighten Torque Caliper Mounting Bolts Front 25 2 5 kgf m 18 ft lb Rear 22 N m 2 2 kgf m 16 ft lb Rear Caliper Pin Bolt 27 N m 2 8 kgf m 20 ft Ib Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Check the flui
274. e chapter Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter 12 30 BRAKES Master Cylinder Master Cylinder Inspection Visual Inspection e Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble the front and rear master cylinders see Master Cylinder Rubber Parts Replacement in the Peri odic Maintenance chapter e Check that there are no scratches rust or pitting on the inner wall A of each master cylinder and on the outside of each piston B If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D xIf a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups e Check the dust covers E for damage x If they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged x lf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Front Master Cylinder I Rear Master Cylinder J 9107171851 C GLO7172BS2 C Brake Disc BRAKES 12 31 Brake Disc Removal e Remove the wheels see Front Rear W
275. e dam aged OApply silicone grease to the dust seals and install them into the cylinders by hand e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Check the dust cover A and the friction boot B replace them with new ones if they are damaged e Apply a thin coat of silicone grease to the caliper holder shaft C and pin bolt D e Install the caliper holder e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly e Remove Rear Caliper see Rear Caliper Removal in the Brakes chapter Brake Pads see Rear Brake Pad Removal in the Brakes chapter 9513341851 6105040251 C PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Using compressed air remove the piston OCover the piston area with a wooden board A OBlow compressed air B into the hole for the banjo bolt to remove the piston A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston e Remove Dust Seal A and Fluid Seal B Bleed Valve C and Rubber Cap D Pad Spring E Rubber Boot F Sleeve G 9513180851 Rear Caliper Assembly e Clean the caliper parts except for the pads For cleaning the parts use only disc brake fluid isopropyl alcohol
276. e lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Exhaust Pipe Removal e Remove Oxygen Sensor see Oxygen Sensor Removal in the Electrical System chapter Muffler Body see Muffler Body Removal Exhaust Pipe Manifold Holder Nuts A Exhaust Pipe 5 46 ENGINE TOP END Muffler Exhaust Pipe Installation e Replace the exhaust pipe gaskets A and muffler body gasket with new ones and install them e Install the exhaust pipe B e Tighten the exhaust pipe manifold holder nuts C follow ing the specified tightening sequence ODo not deform the exhaust pipe gaskets e Tighten Torque Exhaust Pipe Manifold Holder Nuts C 17 N m 1 7 kgf m 13 ft Ib e Install Muffler Body see Muffler Body Installation Oxygen Sensor see Oxygen Sensor Installation in the Electrical System chapter e Thoroughly warm up the engine wait until the engine cools down retighten all the bolt and nuts e Install the removed parts see appropriate chapters OWhen installing run the each leads correctly see Cable Wire and Hose Routing section in the Appendix chapter GE181758W2 C Exhaust Butterfly Valve Cable Removal ZR800A B Models e Remove the right frame cover see Frame Cover Removal in the Frame chapter e Slide the dust covers A e Loosen the locknuts B and turn the adjusters C to give the cable plenty of play e Open the clamp D and free the cables Muffler
277. e motorcycle is driven while in the self diagnosis mode When the self diagnosis terminal disconnects 2 Apply brake suddenly at 30 km h 19 mph or more to confirm that the motorcycle stops smoothly and steady with pulsation on the brake lever and pedal GLI473IB F 12 50 BRAKES Anti Lock Brake System Equipped Models How to Read Service Codes OService codes are shown by a series of long and short blinks of the yellow ABS indicator light LED as shown below ORead 10th digit and unit digit as the yellow ABS indicator light LED blinks OWhen there are a number of faults a maximum of all service codes can be stored and the display will begin starting from the small number code entered OFor the display pattern first the smallest number code is shown next up to all service codes starting with the last one stored then the display is repeated from the smallest number code once again Service Service Service Service Service gt code 13 code 14 code 17 code 53 code 55 2 4 1 Olf there is no fault the yellow ABS indicator light LED lights as shown Repeat ON ABS Self diagnosis ABS Self diagnosis terminal is grounding Terminal ON 16 Yellow ABS indicator ON Goes on light LED function when service code is not stored ON Goes on r Yellow ABS indicator light LED function gt when
278. e output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear quickly C and pull it off upward disassemble the transmission e Remove the ball bearing A from drive shaft Special Tools Bearing Puller B 57001 135 Bearing Puller Adapter C 57001 317 e Discard the bearing iia 052 G113082B 5 6113048851 C 9 30 CRANKSHAFT TRANSMISSION Transmission Remove the collar A together with the ball bearing B from output shaft Special Tool Bearing Puller C 57001 135 e Discard the bearing Transmission Shaft Assembly e Install the new ball bearing A and collar B output shaft on the each shafts using the bearing driver Special Tool Bearing Driver 632 57001 382 Apply engine oil to the bushings ball bearings and shafts e Install the gear bushings A the shaft with their holes B aligned e Replace any circlips removed with new ones e Install the circlips A so that the opening B is aligned with a spline groove C 9113548851 9113549851 C 6113040851 6113010251 CRANKSHAFT TRANSMISSION 9 31 Transmission The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e Install the 3rd 4th gear onto t
279. e sensor system fails the output voltage is out of the usable range wiring short or open the ECU locks the exhaust butterfly valve at full open position near and it stops the current to the exhaust butterfly valve actuator Immobilizer Amplifier If the immobilizer system fails no signal wiring short or open the vehicle is no start and run Ignition Key The ignition key must use register key The ECU send the data for service code and key registration to the meter unit If the blank key or broken key is used the vehicle is no start and run Stick Coil 1 Stick Coil 2 The ECU sends signals output voltage continuously to the stick coil The ECU sends signals output voltage continuously to the stick coil If the stick coil 1 primary winding has failures no signal wiring short or open the ECU shuts off the injector 1 to stop fuel to the cylinder 1 though the engine keeps running If the stick coil 2 primary winding has failures no signal wiring short or open the ECU shuts off the injector 2 to stop fuel to the cylinder 2 though the engine keeps running Stick Coil 3 Stick Coil 4 The ECU sends signals output voltage continuously to the stick coil The ECU sends signals output voltage continuously to the stick coil If the stick coil 3 primary winding has failures no signal wiring short or open the ECU shuts off the injector 3 to stop fuel to t
280. e slits of the rubber protector to the projections D ECU Power Supply Inspection e Remove the relay box see Relay Box Removal in the Electrical System chapter e Visually inspect the ECU connectors If the connector is clogged with mud or dust blow it off with compressed air e Remove the ECU see ECU Removal e Visually inspect the terminals A of the ECU connectors x If the terminals of the main harness connectors are dam aged replace the main harness x If the terminals of the ECU connectors are damaged re place the ECU e Turn the ignition switch off e Disconnect the ECU connectors A e Set the hand tester B to the x 1 O range and check the following wiring for continuity Special Tool Hand Tester 57001 1394 ECU Grounding Inspection Connections 1 BK Y leads ECU terminal 30 53 or 54 Engine Ground Battery Terminal Battery Terminal Criteria Both 0 O x If no continuity check the connectors the engine ground lead or main harness and repair or replace them if nec essary 8017809 51 C ECU FUEL SYSTEM DFI 3 109 xIf the wiring is good check the power source voltage of the ECU NOTE OBe sure the battery is fully charged e Connect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Power
281. e stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Headlight Bulb Dust Cover A e Remove Hook A Headlight Bulb B When handling the quartz halogen bulb A never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution 16 60 ELECTRICAL SYSTEM Lighting System e Replace the headlight bulb e Fit the projection A of the bulb in the hollow B of the headlight e Install the hook A e Fit the dust cover A onto the bulb B firmly as shown Good C Bad D e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Removal Installation e Remove Upper Fairing see Upper
282. ead Digital Meter Frame Ground terminal Digital Meter W actuator V lead Digital Meter Frame Ground terminal IV Digital Meter Y actuator G BL lead Digital Meter Frame Ground terminal e Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard DC 8 5 12 5V or DC 8 5 12 5 V and then about 0 V e Turn the ignition switch off x If the reading is in specification but the actuator does not operate replace the throttle body assy x If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and actuator connectors Wiring Inspection ECU Connector A Subthrottle Valve Actuator Connector B GY R lead ECU terminal 1 C V lead ECU terminal 12 D BK O lead ECU terminal 23 E G BL lead ECU terminal 24 F xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17513FS1 C 8017803 51 FUEL SYSTEM DFI 3 95 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Circuit 2 of 2 55 fees 5 av 8017442 42 1 Subthrottle Valve Actuator 2 ECU 3 96 FUEL
283. eak Voltage Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Type Gap Sealed Battery FTX9 BS 12 V 8 Ah 12 6 V or more 3 0 kg 6 6 Ib 0 41 L 25 cu in Three phase AC 39 V or more at 4 000 r min rpm 0 05 0 6 O at 20 C 68 F 14 2 14 8 V 376 564 2 0 V or more 1 1 1 50 6 4 9 6 100 V or more NGK CR9EK or ND U27ETR 0 7 0 8 mm 0 028 0 031 Electric Starter System Starter Motor Brush Length Commutator Diameter 12 mm 0 47 in Service limit 10 mm 0 39 in 28 mm 1 10 in Service limit 27 mm 1 06 in Air Switching Valve Resistance 18 22 Q at 20 C 68 F Switches and Sensors Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance Fuel Level Sensor Resistance Full Position Empty Position ON after about 10 mm 0 39 in pedal travel When engine is stopped ON When engine is running OFF in the text 9 110 213 219 Q ELECTRICAL SYSTEM 16 11 Special Tools and Sealant Hand Tester 57001 1394 7571394ST C Peak Voltage Adapter 57001 1415 875714155 C Lead Wire Peak Voltage Adapter 57001 1449 7571449ST C Key Registration Unit 57001 1582 875715825 C Grip 57001 1591 7571591ST C Flywheel amp Pulley Holder 57001 1605 875716055 C
284. ean cloth e Apply liquid gasket to the threads of the oil pressure switch and tighten it Sealant Liquid Gasket TB1211 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib e Install the switch lead A as shown 45 B e Apply high temperature grease to the terminal e Tighten the terminal bolt Torque Oil Pressure Switch Terminal Bolt 2 0 N m 0 20 kgf m 18 in Ib 9013015851 C ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents EEE ON vee 8 2 Special E 8 4 Engirie Ete doter Da aou aM Pad 8 5 Engine 8 5 Ernigirie WS tall nd Me 8 9 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View Fastener Torque kgf m ud Ib 2 1 1 5 5 Front Engine Mounting Bolts S 6 Upper Adjusting Collar 9 8 to 87 P S 7 Middle Engine Mounting Nut 44 4 5 32 S 8 Rear Engine Bracket Bolts 25 2 5 18 S 9 Lower Engine Mounting Nut 44 4 5 32 S 10 Lower Adjusting Collar 4 9 0 50 43 in lb S 11 Engine Ground Cable Terminal Bolt 9 8 1 0 87 in lb S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION S
285. ease L Apply a non permanent locking agent LG Apply liquid gasket MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts W Apply water 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 00042478 5 Engine Oil Flow Chart ENGINE LUBRICATION SYSTEM 7 5 Camshaft Oil Oil Filter Oil Jet Crankshaft Oil Passage Oil Pressure Switch Breather Hose Drive Shaft Oil Passage Oil Pipe Main Oil Passage Output Shaft Oil Passage Oil Pump Oil Pressure Relief Valve Oil Screen Oil Blowby Gas 7 6 ENGINE LUBRICATION SYSTEM Specifications ltem Standard Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 3 1 L 3 3 US gt when filter is not removed 3 4 L 3 6 US gt when filter is removed 3 8 L 4 0 US gt when engine is completely dry Level Between upper and lower level lines Wait 2 3 minutes after idling or running Oil Pressure Measurement Oil Pressure 147 226 kPa 1 5 2 3 kgf cm 21 33 psi at 4 000 r min rpm Oil Temperature 90 C 194 F Special Tools and Sealant Outside Circlip Pliers 57001 144 7570144ST C Oil Pressure Gauge 10 kgf cm 57001 164 7570164ST C ENGINE LUBRICATION SYSTEM
286. ecial Tool Hand Tester 57001 1394 x lf the tester readings are not as specified or do not change smoothly according as the float moves up and down replace the sensor Fuel Level Sensor Resistance Standard Full position 9 11 O Empty position 213 219 O e Install a new gasket A on the fuel level sensor as shown Hollows B Front C e Apply a non permanent locking agent to the threads of the fuel level sensor bolts and tighten them Torque Fuel Level Sensor Bolts 6 9 N m 0 70 kgf m 61 in Ib GP18648BS1 C Relay Box ELECTRICAL SYSTEM 16 111 The relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal Never drop the relay box especially on a hard sur face Such a shock to the relay box can damage it e Remove Seat Cover see Seat Cover Removal in the Frame chapter Battery see Battery Removal Remove the band A and tool kit B Take out the immobilizer Kawasaki diagnostic system connector C with the pad e Disconnect the connector D e Remove the relay box E from the rubber protect F e Disconnect the connectors A e Remove the relay box B Relay Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit in this section xIf t
287. econdary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained n 6J05042BS1 C 10 16 WHEELS TIRES Hub Bearing Hub Bearing Removal e Remove the wheels see Front Rear Wheel Removal and take out the following Collars A Coupling B Out of rear hub Grease Seals C Front Wheel D Rear Wheel E e Use the bearing remover to remove the hub bearings A Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 20 x 922 B 57001 1293 Bearing Remover Shaft 13 C 57001 1377 Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Install the bearings by using the bearing driver set which does not contact the bearing inner race NOTE Olnstall the bearings so that the marked side faces out e Press in each bearing A right until they are bottomed Special Tool Bearing
288. ection 4 11 6 Drive Ghainoclack AGIUSUTIBYM e dba edere a tat esas 11 6 Wheel Alignment Inspection AdjUStMent e 11 6 Drive Chain Wear Inspection pp 11 6 Drive Chain L bricatiom nne nme e 11 6 Drive Chain Removal Installation pp 11 6 SPFOCKESt E EET 11 10 Engine Sprocket Removal iri roris tos e EAE meee 11 10 Engine Sprocket Installation secu edt 11 10 Rear Sprocket Removal sess nnne nnne nnne nnns 11 11 Rear Sprocket 11 11 Coupling 11 12 CouplngbBeanngji emaoval eden atadai 11 12 Coupling Bearing Installation 11 12 Coupling Bearing Inspection enere eae hu edente t cbe at et se Albun 11 13 Coupling Bearing Lubricatiori tree 11 13 Coupling Damper Inspection Sprocket Wear Inspection pp Rear Sprocket Warp Inspection RN 11 14 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View Fastener Engine Sprocket Cover Bolts Engine Sprocket Nut Chain Adjuster Locknuts Rear Axle Nut 5 Rear Sprocket Nuts 59 6 0 44 R HG Apply high temperature grease HO Apply heavy oil L Apply a non permane
289. ectors as shown Main Harness B Fuel Injector 1 C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the harness adapter leads Fuel Injector Power Source Voltage Connections to Adapter For Fuel Injector 1 2 3 4 Digital Meter gt R injector W R lead Digital Meter Battery terminal Measure the power source voltage with the engine stopped e Turn the engine stop switch to run position Turn the ignition switch on Power Source Voltage Standard Battery Voltage for 3 seconds and then 0 V Turn the ignition switch off x If the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Circuit Inspection in the Electrical System chapter x If the pump relay is normal check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf there is still no battery voltage check the ECU main relay and fuel pump relay see Relay Circuit Inspection in the Electrical System chapter x lf the main relay and pump relay are normal check the power source wiring see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is in specification c
290. ed up on the grooves NOTICE Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes e Fit the lower crankcase to the upper crankcase NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the crankcase half is applied fit the case and tighten the bolts just after application of the liquid gasket The 9 bolts A have a copper plated washer replace it with a new one e Apply molybdenum disulfide oil solution to the following Seating Surface C of Lower Crankcase and M9 Bolts Both Sides of Copper Plated Washers Threads of M9 Bolts 9104260851 9104458851 CRANKSHAFT TRANSMISSION 9 13 Crankcase Splitting e Tighten the M9 crankcase bolts following the tightening sequence 1 10 L 81 mm 3 19 in 1 6 L 95 mm 3 74 7 10 OFirst tighten the bolts with 10 N m 1 0 kgf m 89 ft Ib of torque ONext in accordance with the following table tighten the bolts with the specified torque And using a torque angle gauge A tighten the bolts with the specified angle Order aa Bolts TD 20 20 15 20 20 15 20 20 15 20 20 15 9 5 20 2 0 15 10 5 60 5 11 6 20 2 0 15 13 7 20 2 0 15 20 20 15 20 20 15 18 9 60 5 20 20 15 20 10 60 5 e Tighten Torque Crankcase Bolts M
291. ee Hub Bearing Inspection in the Wheels Tires chapter sensor installation condition and sensor see Wheel Rotation Sensor Inspection A e 6 147938 6 Anti Lock Brake System Equipped Models BRAKES 12 69 Wheel Rotation Sensor Rotor Inspection e Remove Wheels see Front Rear Wheel Removal in the Wheels Tires chapter Brake Disc Mounting Bolts A Sensor Rotor B Front Wheel C Rear Wheel D e Visually inspect the wheel rotation sensor rotor xIf the rotor is deformed or damaged chipped teeth A replace the sensor rotor with a new one x If there is iron or other magnetic deposits B remove the deposits Fuse Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter Fuse Installation e f a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage see Fuse Installation in the Electrical System chapter Fuse Inspection e Refer to the Fuse Inspection in the Electrical System chapter GL14006BS1 C GL14110BS1 SUSPENSION 13 1 Suspension Table of Contents Exploded VieW RUE RR UE RESTE UR R ance EET 13 2 me Wit eh 13 8 leor RRM 13 10 Front BORK de at tented Gevaert ees 13 13 Rebound Dam
292. eed cornering Driving 30 km h 19 mph or above Driving below 30 km h 19 mph When stopping When turning Gradual Abrupt Large brake lever stroke Large pedal stroke Driving conditions Brake application Other conditions BRAKES 12 45 Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 1 Replenish brake fluid Check brake fluid level in brake reservoir Check for brake fluid leakage Check brake lever and brake pedal function Repair brake line Repair or replace master cylinder Check brake pad and brake disc Replace faulty parts Front and rear wheels should rotate smoothly without brake drag Repair or replace brake system There shouldn t be a lot of play in the wheel bearing There shouldn t be excessive axle bending or disc runout Replace wheel bearing or axle 01147368 F 12 46 BRAKES Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 2 Check the yellow ABS indicator light LED Unlit Check the power source wiring and meter Does the yellow ABS indicator light LED light unit up with the ignition switch to ON Yes lit Drive at 30 km h 19 mph or above for one minute or more Yes When the motorcycle is running does the yellow ABS is normal ABS indicator light LED go off Count the number of times the yellow ABS indicator Ask the rider i
293. egistration 244 16 84 Immobilizer System Parts 16 102 Immobilizer System Inspection ps 16 105 neee lao KoT EE A ETTE E EATE 16 107 Brake Light Timing Inspection pp 16 107 Brake Light Timing Adjustment pp 16 107 Switch INSPECTION seene tete uve ae 16 107 Water Temperature Sensor Inspection 16 108 Speed Sensor Removal pp 16 108 Speed Sensor Installation esnie tee teer het E 16 108 Speed Sensor Inspection pp 16 108 Oxygen Sensor Removal insur lienn ie tel a DAE 16 109 Oxygen Sensor Installatighi uote ce Ee teria sak 16 109 Oxygen Sensor Inspeclion uisa brat ten aa dr 16 109 Fuel Level Sensor 16 110 Relay BOX es EE 16 111 Relay ET ntu es 16 111 Relay Circuit Inspection edu E 16 111 e Ha a 16 112 i r M 16 114 30 A Main 15 A ECU Fuse Removal 16 114 Fuse Box Fuse Removal 16 114 Fuse IrstallatlOls 16 114 EL
294. egulator Rectifier 00 00 5 16 44 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running This is to pre vent ECU damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the ECU Crankshaft Sensor Removal Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Right Frame Cover see Frame Cover Removal in the Frame chapter Right Lower Fairing see Lower Fairing Removal ZR800A B in the Frame chapter e Disconnect the crankshaft sensor lead connector A Open the clamp B e Slide out the rubber boot A e Remove Oil Pressure Switch Lead Terminal B Crankshaft Sensor Cover Bolts C with Clamp Crankshaft Sensor Cover D e Open the clamp E e Remove Crankshaft Sensor Bolts A Crankshaft Sensor B Ignition System ELECTRICAL SYSTEM 16 45 Crankshaft Sensor Installation e Run the crankshaft sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Crankshaft Sensor Bolts 5 9 N m
295. elow for correct bolt and nut usage Be careful not to overtighten the nuts The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods 1 Bolt Length Measurement Method e Be sure to clean the bolts nuts and connecting rods thoroughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the bolts nuts and connecting rods in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean them NOTICE Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely e Apply a small amount of molybdenum disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods e Install new bolts in the connecting rods 6105040451 9 18 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Dent both bolt head and bolt tip with a punch as shown Before tightening use a point micrometer to measure the length of new connecting rod
296. en Torque Throttle Body Assy Holder Clamp Bolts 1 1 Nm 0 11 kgf m 10 in Ib e Install the air duct clamp bolts in the direction as shown Left Side A Right Side B Bolt Heads C e Fit the projections D of the holder into the holes in the clamps e Install the air ducts to the throttle body assy OApply a small amount of 2 stroke oil to the throttle body assy holder for easy installation e Tighten Torque Air Duct Clamp Bolts 1 1 N m 0 11 kgf m 10 in Ib Air Cleaner Housing Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib 8017523 81 GC17524FS1 3 130 FUEL SYSTEM Throttle Body Assy e Apply a thin coating of grease to the throttle cable upper ends e Install the upper ends of the throttle cables in the grip e Fit the projection A of the right switch housing into the hole B of the handlebars e Turn the throttle grip and make sure thatthe throttle valves move smoothly and return by spring force e Run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e Tighten Torque Throttle Body Cover Mounting Bolts 4 0 N m 0 41 kgf m 35 in Ib e Adjust Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Throttle Body Assy Disassembly A
297. ength 175 2 mm 6 90 in Spring length 170 2 180 2 mm 6 70 7 09 in stronger to weaker 4th position 1st 7th position 980 kPa 10 kgf cm 142 psi Non adjustable 13 10 SUSPENSION Special Tools Inside Circlip Pliers 57001 143 7570143ST C Oil Seal amp Bearing Remover 57001 1058 7571058ST C Bearing Driver Set 57001 1129 7571129ST C Jack 57001 1238 7571238ST C Fork Oil Seal Driver 41 57001 1288 875712885 Fork Piston Rod Puller M12 x 1 25 57001 1289 Fork Oil Level Gauge 57001 1290 7571290ST C Fork Piston Rod Puller M10 x 1 0 57001 1298 7571298ST C Fork Spring Stopper 57001 1374 875713745 6 Fork Cylinder Holder 57001 1443 7571443ST Special Tools Hook Wrench T 3 2 R37 57001 1539 2 875715395 6 Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 7571587ST C Swingarm Pivot Nut Wrench 57001 1597 875715975 C Jack Attachment 7571608ST C SUSPENSION 13 11 Needle Bearing Driver 517 018 57001 1609 875716095 C Needle Bearing Driver 28 57001 1610 C amp O 8 5716105 C Spacer 18 57001 1636 mS 8757163697 C Spacer 28 57001 1663 ST571663ST Fork Spring Compressor 57001 168
298. ensor 1 Output Voltage Inspection e Measure the output voltage at the intake air pressure sen sor 1 in the same way as input voltage inspection note the following ODisconnect the intake air pressure sensor 1 connector and connect the measuring adapter A between these connectors Main Harness B Intake Air Pressure Sensor 1 C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the harness adapter leads Intake Air Pressure Sensor 1 Output Voltage Connections to Adapter Digital Meter Y sensor Y BL lead Digital Meter BK sensor G lead e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch on 0104078881 Output Voltage Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to local atmo spheric pressure e Turn the ignition switch off x If the reading is out of the usable range replace the sen sor x If the reading is within the usable range remove the ECU and check the wiring for continuity between main harness connector ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Intake Air Pressure Sensor 1 Connector B Y BL lead ECU terminal 17 C G lead ECU terminal 33 D 2077581051 3 56 FUEL SYSTEM DFI Intake Air Pressure Sensor
299. ent oie ete puc dad 16 59 Headlight Removal installation pp 16 60 City Light Bulb 16 60 Tail Brake Light LED Removal 16 61 Tail Brake Light LED Installation Due tat edt To Har tota cat sits cto 16 61 License Plate Light Bulb Replacement ppp 16 61 Turn Signal Light Bulb Replacement pp 16 63 Turn Signal Relay Inspection pp 16 63 Eea AVE I pm 16 66 Air Switching Valve Operation TeSst eese nennen nennen nnn 16 66 Air Switching Valve Unit TeSt rne orti reri ti ee te 16 66 16 68 Fan Motor Inspection iter t tt e e a eor ERN EE o E 16 68 Meter Gauge Indicator 16 70 Meter Unit Removal Installation 4 16 70 Meter Unit Disassembly ote cota Gr ted deste t m ett ee RA nage ttes 16 70 Meter Unit rrr sea Lee P de urit rate dai totius 16 70 Electronic Combination Meter Unit Inspection pp 16 71 Fuel Level Sensor Line Self Diagnosis Mode 16 82 Imm bilizer SY SUC Ms incen aaah 16 84 Operational Cautlons eite eren ehe eR IRE RE PR REX ERE GRE HR Reden dena di 16 84 Key R
300. er e Disconnect Battery Terminal see Battery Removal in the Electri cal System chapter Fuel Level Sensor Lead Connector A Fuel Pump Lead Connector B e Disconnect Fuel Tank Drain Hose A Fuel Tank Breather Hose B e Remove the fuel tank bolts C Fuel Tank FUEL SYSTEM DFI 3 135 e Open the fuel tank cap A to lower the pressure in the tank ODuring tank removal keep the tank cap open to release pressure in the tank This makes fuel spillage less e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump intake hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING Spilled fuel is flammable and can be explosive un der certain conditions The fuel can not be removed completely from the fuel tank Be careful for re mained fuel spillage e Be sure to place a piece of cloth around the fuel hose joint e Wipe off the dirt of the surface A around the connection using a cloth or a soft brush e Push the joint lock claws A with your fingers 6C09033BS1 C GC09124BS1 C 3 136 FUEL SYSTEM Fuel Tank Pull the joint lock A fully as shown Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock resulting in a loose or incomplete lock
301. er 57001 1394 12 16 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 40 mm 1 57 in C below top of footpeg x If it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when the push rod locknut has been loosened e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x If the length C shown is 69 1 mm 2 72 0 04 in the pedal position will be within the standard range e Tighten Torque Rear Master Cylinder Push Rod Locknut 17 2 1 75 kgf m 12 7 16 e Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Pedal Removal e Remove the right frame cover see Frame Cover Removal in the Frame chapter e Disconnect the rear brake light switch connector A e Remove Footpeg Bracket Bolt
302. er wise registration mode will be ended and the red warn ing indicator light LED and immobilizer warning sym bol go off OTo return to the registration mode start the registered ignition key verification procedure This applies to all ignition key registration e Insert the second ignition key to the ignition switch and turn it to ON NOTE OKeep the other ignition keys away from the immobilizer antenna 8 30228051 0 3second am Hh UUUUUUUUUUU GP30229CS1 gt LNA L GP302330S1 L_ 0 5second 0 5second GP30227C81 ELECTRICAL SYSTEM 16 99 Immobilizer System Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error The second ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 2 times and stops for 1 second and then repeats this cycle to indicate successful regis tration of second ignition key e Turn to OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends e The red warning indicator light LED A goes off 0 2second A GP30228CS1
303. er Installation Cylinder Wear Inspection e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown xIf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 70 992 71 008 mm 2 7950 2 7956 in Service Limit 71 11 mm 2 7996 in Piston Wear Inspection e Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton Piston Diameter Standard 70 974 70 984 mm 2 7942 2 9746 in Service Limit 70 82 mm 2 7882 in GE16061BS1 C GE16298BS1 GE16299BS1 C GE16300BS1 5 38 ENGINE TOP END Cylinder Pistons Piston Ring Piston Ring Groove Wear Inspection e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Top Standard 0 04 0 07 mm 0 0016
304. er off 0246 F 16 102 ELECTRICAL SYSTEM Immobilizer System Immobilizer System Parts Replacement Ignition Switch Replacement e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Side Fairings see Fairing Removal in the Frame chap ter e Disconnect the lead connectors A e Remove the steering stem head see Steering Play Ad justment in the Periodic Maintenance chapter e Using a punch A mark the punch mark at the center of broken Torx bolt head NOTE OMake the punch mark at center of the bolt head surely e Extend the punch mark with the 2 mm drill A In addition extend the punch mark with the 3 5 mm drill Lastly shave off the Torx bolt head with the 6 5 mm drill NOTE OBe sure to do not damage the lead wires and compo nent parts with a drill e Remove the ignition switch bolts A to separate the igni tion switch B and bracket C e Replace the ignition switch with a new one e Tighten the ignition switch bolts A Immobilizer System ELECTRICAL SYSTEM 16 103 e Tighten a new Torx bolt A until the bolt head B is broken C e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Register the more than two ignition keys see Key Regis tration Immobilizer Amplifier Replacement Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Disconnect
305. ery terminal Gray lead terminal and Battery terminal OConnect 2 Pins Connector 3 Pins Connector OTurn the ignition switch on OConfirm the pulley turns clockwise and then counterclock wise OThe pulley stops at this side of the original position by the learning control OThe pulley returns to the original position OTurn the ignition switch off x If the position is not within the specified angle above re place the exhaust butterfly valve actuator e Tighten Torque Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the close cable first and then open cable see Ex haust Butterfly Valve Cable Installation ZR800A B Mod els in the Engine Top End chapter Exhaust Butterfly Valve Actuator Inspection NOTE OBe sure the battery is fully charged e Remove the right side cover see Side Cover Removal in the Frame chapter e Turn the ignition switch on e Check to see the pulley A clockwise B and counter clockwise C smoothly OThe pulley turns clockwise and then counterclockwise and clockwise again e Turn the ignition switch off x If the pulley does not operate check the exhaust butter fly valve actuator resistance see Exhaust Butterfly Valve Actuator Inspection Resistance Inspection FUEL SYSTEM DFI 3 99 Exhaust Butterfly Valve Actuator Service Code 63 ZR800A B Models Exhaust Butterfly Valve Actuator Resistance Inspection e Turn
306. es Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area Outside Diameter Tool Vernier Caliper Purpose check seat outside diameter against specification Results Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase outside 32 Grind 522 of seat Tool 32 Cutter area to Purpose reduce outside specification Measure Seating Width diameter of seat Tool Vernier Caliper area to Purpose check seat width specification against specification Results 45 Grind Machinist s dye Tool 45 Cutter opera Purpose increase width of seat area beyond specification to increase outside diameter 60 Grind Tool 60 Cutter Purpose reduce seat Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve and valve seat area FINISHED check valve head for damage width to specification GEI5143B ENGINE TOP END 5 35 Cylinder Pistons Cylinder Removal e Remove the cylinder head see Cylinder Head Removal e Loosen the water hose clamp screw A e Remove Water Pipe Bolt B Water Pipe C and Water Hose Cylinder D Cylinder Installation NOTE Olf a new cylinder is used use new piston ring e Install the dowel pins A and new cylinder gasket B e Apply molybdenum disulfide oil solution to the cylinde
307. es upward If the meter unit is left upside down or sideways for a long time or dropped it will malfunction Do not short each terminals Check 1 Meter Unit Primary Operation Check e Using the auxiliary leads the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 16 OConnect the battery negative terminal to the terminal 8 e Connect the terminal 15 to the battery terminal 8 17061052 C GP17082DS1 C GP17083DS1 C 16 72 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e When the terminals are connected the meter unit dis plays the following OAII the LCD segments appear for about 1 second OThe red warning indicator light LED A and yellow en gine warning indicator light LED B go on for about 1 second OThe yellow ABS indicator light goes on C equipped models e About 3 seconds after the all fuel level gauge segments and fuel warning symbol start blinking A x If the fuel level gauge does not blink replace the meter assembly NOTE OThis meter unit has a failure detection function for open or short of the fuel level gauge When the fuel level gauge is open or short the meter unit alerts the rider by the all fuel level gauge segments blinks in the display OAbout 10 seconds after the yellow engine warning indi cator light LED A goes on and the LCD segments B C blink i
308. essed oil or grease seals unless removal is necessary Replace with new ones whenever removed L Press new oil seals with manufacture size marks facing out Make sure the seal is aligned properly when installing NS V 2 68020198 5 specified grease to the lip of seal before installing the seal Grease GBO2046BS1 C Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation 68020268 5 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri AH p TN cation points are called out throughout this manual apply A VAT a the specific oil or grease as specified e A x 68020218 5 Direction of Engine Rotation When rotating the crankshaft by hand the free play MN amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed r from output side UM 68020228 5 Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R wires must be connected to those of the same color e oar e GB020238 5 Instrument Use a meter that has en
309. ett eal aint ei Dialed 15 8 Front Seat RE lise a Seah pro eee ERR 15 8 Front Seatlnstallationz i oie tee tat ER eb e ata 15 8 PAINS 15 9 Upper Fairing 15 9 Upper Fairing ado Rte eee teo ep te eeu edes 15 9 Upper Fairing Asserbly one rd hh a rod te peces actes dep de eut 15 10 Upper Fairing Installation pp 15 10 Ignition Switch Cover Rernoval copiato thee reete edet de i ari ori et eee P eost 15 10 Ignition Switch Cover Installation pp 15 11 Tank Gover RerioVval idei A I Ae eed 15 11 Tank Gover Installatign cio tt tbe 15 11 Middle Fairing Removal 15 12 Middle F airing lastall ation santet epe 15 12 Side Fairing Removal 15 13 Side Fairing Installation is tuna Can pets 15 13 Lower Fairing Removal ZR800A B 15 14 Lower Fairing Installation ZR800A B Models RN 15 14 gt Pe ree ee Side CoveriREMOVAl ensen neiii Side Cover Installation 4 Seat Cover Removal Seat Cover Ins
310. etween the values given in the table the charging system is considered to be working normally xIf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output Charging System ELECTRICAL SYSTEM 16 41 e To check the alternator output voltage do the following procedures OTurn the ignition switch off ORemove the left frame cover see Frame Cover Removal in the Frame chapter ODisconnect the alternator lead connector A OConnect the hand tester as shown in the table 1 Special Tool Hand Tester 57001 1394 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage at 4 000 r min r
311. ew No Fastener Remarks Upper Front Fork Clamp Bolts Front Fork Top Plugs N Piston Rod Rubber Nut Piston Rod Assy Stopper Cylinder Unit Front Axle Clamp Bolt 9 Inner Tube ABS Equipped Models AD Apply adhesive see the text AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease R Replacement Parts 13 6 SUSPENSION Exploded View SUSPENSION 13 7 Exploded View Torque Remarks Nm kghm ftib Swingarm Pivot Shaft Nut 11 0 79 7 Swingarm Pivot Shaft Swingarm Pivot Shaft Locknut Rear Shock Absorber Nut Upper Rear Shock Absorber Nut Lower Rocker Arm Nut Tie Rod Nuts 8 ZR800C D Models G Apply grease R Replacement Parts No Fastener 13 8 SUSPENSION Specifications Item Standard Front Fork ZR800A B Models Per One Unit Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Right Front Fork Only Fork Spring Preload Setting Fork Oil Recommend Oil Amount When Changing Oil After Disassembly and Completely Dry Right Front Fork Left Front Fork Fork Oil Level Fully compressed without fork spring below from the top of the outer tube Right Front Fork Left Front Fork Fork Spring Free Length Front Fork ZR800C D Models Per One Unit Fork Inner Tube Diameter Air Pressure Fork Oil Recommend Oil Amount When
312. f the problem light LED blinks in the self diagnosis mode to find the happens again service code 61147378 F Self diagnosis Outline When the yellow ABS indicator light LED has blinked or come on the ABS hydraulic unit mem orizes and stores the service code for the service person to troubleshoot easily The service code memory is powered directly by the battery and cannot be canceled by the ignition switch The ABS hydraulic unit can memorize up to all service codes Further service codes are memorized after erasing the preceding all service codes If there is no fault the yellow ABS indicator light LED lights indicating that The ABS is normal Self diagnosis Procedures OBefore performing the self diagnosis procedures make sure that the yellow ABS indicator light LED A stays on to indicate any electrical problem occurring in the ABS system NOTE OUse a fully charged battery for performing self diagnosis procedure properly A insufficient battery may cause improperly result OThe self diagnosis procedures should be done with the motorcycle is stopped Anti Lock Brake System Equipped Models BRAKES 12 47 e The ABS hydraulic unit can be store the service codes including previous ones e To read out the current service code erase the stored service codes once prior reading the service code see Service Code Clearing Procedures Test ride the motorcycle with 30 km h 19 mph or more i
313. ffler Body Mounting Bolts K 34 N m 3 5 kgf m 25 ft lb GE18174BW3 C 5 44 ENGINE TOP END Muffler eAdjustthe exhaust butterfly cables see Exhaust Butterfly Valve Cable Installation e Thoroughly warm up the engine wait until the engine cools down retighten all the bolts and nut ZR800C D Models Replace the muffler body gasket A and nut B with new ones e Install the muffler body gasket until it is bottomed so that the inside chamfer side faces front C e Install the muffler body clamp D so that the insert the projection E into the clamp slit F e Install the muffler body G Olnstall the muffler body until it stops at the bottom surface of the exhaust pipe e Tighten Torque Muffler Body Clamp Bolt H 17 N m 1 7 kgf m 13 ft Ib Muffler Body Mounting Bolts I 34 N m 3 5 kgf m 25 ft lb GE18182BW3 C e Thoroughly warm up the engine wait until the engine cools down retighten all the bolts and nut ENGINE TOP END 5 45 Muffler e When installing the pads note the following Olnstall the pads A first Next install the pad B as shown Muffler Body Cover C e Install the muffler body cover A e Tighten Torque Muffler Body Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib L 27 mm 1 06 in B L 14 mm 0 55 in C 52 REEL 7 9 GE18184BS1 C e Install the removed parts see appropriate chapters OWhen installing run th
314. from the fuel tank with a commercially available electric pump Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Be sure to place a piece of cloth A around the fuel intake hose B e Remove Clamps C Fuel Intake Hose e Be sure to place a piece of cloth around the fuel hose joint e Wipe off the dirt of the surface A around the connection using a cloth or a soft brush e Push the joint lock claws A with your fingers GC09124BS1 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Pull the joint lock A as shown e Pull the fuel outlet hose joint B out of the delivery pipe e Clean the delivery pipe A e Cover the delivery pipe with the vinyl bag B to keep it clean 9505285851 e Install a new fuel intake hose A so that the white mark side B faces outlet pipe C of the fuel tank Fuel Pump D Bottom View E 9505126851 Fix the both ends of the fuel intake hose A with the clamps B as shown 1 2 mm 0 039 0 079 in C 9505123851 e Remove the vinyl bag on the pipe Check that there are no flaws burrs and adhesion of 9 foreign materials on the delivery pipe A 9505265851 2 2
315. g Valve i n Eom rt 4 5 5 55 50 3 5 55 BR W BK Y Immob Y Amplifier P 8K BK Immobilizer Antenna ES BK w Front Wheel Rotation Sensor L sms in Ld E H ELI 9 Connector A E Front Right iu d u Torn sient E ue OTE rae F 120108 Right City Light 12V8N BK Y Headlight R Y Low BK Y 127558 i High 12 55 te eee Left Gity R BR Y Light 12V5W GIZA Front Left Turn Signal 6 12V10W Meter Unit 1 ellow ABS Indicator Light LED 2 Yellow Engine Warning Indicator Light LED Fuse Box 1 3 Green Neutral Indicator ignition Fuse 15 Light LEB 2 Headlight Fuse 15 4 Blue High Beam Indicator 3 Brake Horn Fuse 7 Light LEO 4 Turn Signal Relay Fuse 7 5 5 reen Left Turn Signal 5 ABS Fuse 30 Indicator Light LEB 8 Groen Right Turn Signa Indicator Light LED 7 Red Warning Indicator Light Battery Oil Pressure Water Temperature Immobilizer LED 8 Speedometer 9 Wileage Cruising Range 10 fuel Level Gauge 11 Tachometer 12 Water Temperature Meter 13 Odometer Trip Weter 14 Clock 15 11 tumination Light LED Left Switch Housing Relay Box
316. g 22 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 319 mm 12 6 in A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain It is an endless type and should not be cut for installation Standard Chain Make ENUMA Type EK520MVXL2 Link 114 Links 6 04060651 C PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Chain Guide Wear Inspection e Remove Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter Footpeg Bracket Bolts A Left Footpeg Bracket B Chain Cover see Drive Chain Removal Installation in the Final Drive chapter e Remove the bolt A and chain guide B e Visually inspect the chain guide Replace the chain guide if it shows any signs of abnormal
317. garm Bearing Removal pp 13 43 Swingarm Bearing Installation pp 13 43 Swingarm Bearing Sleeve Inspection pp 13 44 Swingarm Bearing Lubrication pp 13 45 Chain Guide Inspection 13 45 Tie Rod Rocker ic e eee ete 13 46 TIG ROG REMOVE era 13 46 Tie Rod Installation n iei re e RR m ERRORES ERR RA ER ERE OR ERE ER FER D ER De RA ER A 13 46 Rocker Arm Removal Mae OR e aa ee PA DH Pie RENTE Qe Eo EL 13 46 Rocker Arm Installation pp 13 46 Tie Rod and Rocker Arm Bearing Removal seen eee 13 47 Tie Rod and Rocker Arm Bearing Installation esee 13 47 Rocker Arm Tie Rod Bearing Sleeve Inspection pp 13 48 Rocker Arm Tie Rod Bearing Lubrication 22 13 48 13 2 SUSPENSION Exploded View ZR800A B Models 6GM023798W5 C Exploded View SUSPENSION 13 3 No Fastener Upper Front Fork Clamp Bolts Front Fork Top Plugs Cylinder Units 70 Front Axle Clamp Bolt 20 7 Inner Tube ABS Equipped Models AD Apply adhesive see the text AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease R Replacement Parts Remarks 13 4 SUSPENSION Exploded View ZR800C D Models 077 022 2 600000 19004 ng To Gh om 0 GMO2381BWS C SUSPENSION 13 5 Exploded Vi
318. gh the fluid from the holes at the bottom of the reservoir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap A from the bleed valve on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container Brake Fluid BRAKES 12 33 Bleed the brake line and the caliper ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose e Install Diaphragm Diaphragm Plate Front Brake Reservoir Cap e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the brake fluid reservoir cap B clockwise C by hand until slight resistance is
319. gs C Hoses D e Apply soap and water solution to the new O rings and install them e Install the new hoses and tighten the clamps securely Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib Fill the coolant see Coolant Change Check the cooling system for leaks 85068078883 C Engine End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold room temperature e Remove Crankshaft Sensor Cover see Crankshaft Sensor Re moval in the Electrical System chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures e Position the crankshaft at 1 4 piston TDC TDC Mark A for 1 4 Pistons Timing Mark B Crankcase Halves Mating Surface e Using the thickness gauge A measure the valve clear ance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 22 0 31 mm 0 0087 0 0122 in Intake 0 15 0 24 mm 0 0059 0 0094 in NOTE OThickness gauge is horizontally inserted on the valve lifter Appropriateness A Inadequacy B Thickness Gauge C Horizontally Inserts D Cam E Valve Lifter F Hits the Valve Lifter Ahead G OWhen positioning 4 piston TDC at the end of the compression stroke Intake Valve Clearance of 2 and 4 Cylinders Exhaust Valve Clearance of 3 and 4 Cylinders Measuring Valve
320. h Left Dimmer Switch lgnition Fuse 15 A Fuse Box 1 Turn Signal Switch Right Meter Unit Joint Connector C Immobilizer Amplifier 16 84 ELECTRICAL SYSTEM Immobilizer System This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU If the code does not match ignition system injectors subthrottle valve actuator and exhaust butterfly valve actuator ZR800A B Models will not operate and the engine will not start Abstract e Do not keep more than one immobilizer key of any system on a key ring Jamming of the key code signal may occur and the operation of the system may be affected e The red warning indicator light LED will blink for a period of 24 hours once the ignition switch has been switched off and the key removed This blinking can be set to on or off as desired by holding the left and right buttons down for 2 seconds within 20 seconds of switching the ignition off e f all coded keys are lost the ECU and ignition switch will have to be replaced e The immobilizer system can not function until the ignition key code is registered in the ECU A total of five keys can be registered in the ECU at any one time Operational Cautions Do not put two keys of any immobilizer system on the same key ring Do not submerge any key in water Do not expose any key to ex
321. has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short necessitating replacement of the crankshaft sensor as sembly 16 46 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter A is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Remove the right frame cover see Frame Cover Removal in the Frame chapter e Disconnect the crankshaft sensor lead connector B see Crankshaft Sensor Removal e Set the hand tester C to the DC 10 V range e Connect the peak voltage adapter to the hand tester and crankshaft sensor leads in the connector Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Crankshaft Peak Voltage Sensor Lead Adapter Hand Tester Yellow lt Black Black i3 e Turn the ignition switch and engine stop switch on e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Cran
322. haust Butterfly Valve Actuator Resistance Inspection 3 99 Air Switching Valve Service Code 64 eee nennmenene nente nn 3 100 Air Switching Valve Removal Installation pp 3 100 Air Switching Valve Inspection erii erit Licet pe e n ERR ERR E YR RE 3 100 Oxygen Sensor Heater Service Code 67 0 4 412 4444 46 nnn 3 101 Oxygen Sensor Heater 3 101 Oxygen Sensor Heater Resistance 3 101 Oxygen Sensor Heater Power Source Voltage Inspection 3 101 Oxygen Sensor Incorrect Output Voltage Service Code 94 3 103 Oxygen Sensor Removal lnstallation pp 3 103 Oxygen Sensor MSPS COR DER ean ul e Padi te uat 3 103 Warning Indicator Light Step betae abet etaim ditas 3 106 Yellow Engine Warning Indicator Light LED Inspection pp 3 106 EQU usd tote tieu 3 107 EGU Identification er eei 3 107 utter de 3 107 ECU Installation 3 108 ECU Power Supply Inspection
323. he cylinder 3 though the engine keeps running If the stick coil 4 primary winding has failures no signal wiring short or open the ECU shuts off the injector 4 to stop fuel to the cylinder 4 though the engine keeps running Radiator Fan Relay When the radiator fan relay is OFF the relay is opened Subthrottle Valve Actuator Exhaust Butterfly Valve Actuator ZR800A B Models Air Switching Valve The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU The actuator operates open and close of the exhaust butterfly valve by the pulse signal from the ECU The air switching valve controls the flow of the secondary air by opening and shutting the solenoid valve If the subthrottle valve actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator If the exhaust butterfly valve actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator 3 48 FUEL SYSTEM DFI Self Diagnosis Service Output Signal Usable Codes Pare Range or Criteria Backups BY ECU Oxvaen The oxygen sensor heater If the oxygen sensor heater fails wiring short 67 2 raises temperature of or open the ECU stops the current to the Heater the sensor for its earlier heater and it stops the feedback mode of the activation oxygen sensor The oxygen senso
324. he brush plate aligns with the notch B of the end cover e Install the shim A on the armature shaft ELECTRICAL SYSTEM 16 55 Electric Starter System e Install the armature B among the brushes A e Align the line marks A of the end cover with the square mark B on the yoke e Align the line marks A of the yoke with the through bolt hole B in the end cover e Install the new O rings and tighten the bolts Gir Brush Inspection Measure the length of each brush A If any is worn down to the service limit replace the brush plate assembly B and the terminal bolt assembly C Starter Motor Brush Length D vd Standard 12 mm 0 47 in Ww Service Limit 10 mm 0 39 in k UU i A gun Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves 8 11061051 C 16 56 ELECTRICAL SYSTEM Electric Starter System eMeasure the diameter A of the commutator B x If the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between two
325. he camshaft chain tensioner body temporally see Camshaft Chain Tensioner Installation 8 11356 52 C e Install the camshaft caps e First tighten the all camshaft cap bolts evenly to seat the camshaft in place then tighten all bolts following the spec ified tightening sequence Torque Camshaft Cap Bolts L 45 mm 5 6 9 10 12 N m 1 2 kgf m 106 Camshaft Cap Bolts L 40 mm 1 4 7 8 11 20 12 N m 1 2 kgf m 106 in Ib e Install 8E11357B81 Camshaft Chain Tensioner see Camshaft Chain Ten sioner Installation Cylinder Head Cover see Cylinder Head Cover Instal lation 4p Ael di alee 4 EP eS AJ CP Py ert Camshaft Camshaft Cap Wear Inspection e Remove Camshaft Caps see Camshaft Removal e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft installed in the correct position e Measure each clearance between the camshaft journal and the camshaft cap using plastigage press gauge A e Tighten the camshaft cap bolts see Camshaft Installa tion GE11072BS1 C NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 0063 in 5 22 ENGINE TOP END Camshaft
326. he drive shaft with their oil holes aligned e Install the 6th gear bushing onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 6th gear onto the output shaft with their oil holes aligned e Install the 3rd 4th gear bushings onto the output shaft with their oil holes aligned NOTE OWhen the toothed washers 28 29 are assembled onto the output shaft note the following OWhen the tangs A of the toothed washer 29 shall be assembled they should be installed into the notch B of the toothed washer 28 see Page 9 32 D 6113132851 C e Fit the steel balls into the 5th gear holes in the output shaft 5th Gear A Output Shaft B Steel Balls C oy YA y Ky Do not apply grease to the balls to hold them in place This will cause the positive neutral finder mechanism to malfunction 9113543851 C OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 9 32 CRANKSHAF
327. he fork piston rod puller onto the end of the piston rod Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 e Pull the puller up above the outer tube top e Install the spring seat A with the flat surface B facing upward e Install the fork spring C with the smaller end D facing upward Install the spacer A so that the cut side B faces down ward e Set the fork spring compressor on the spacer A Special Tool Fork Spring Compressor 57001 1685 NOTE OSet the fork spring compressor so that the end of the handle B passes the upper side hole on the spacer by screwing the handle in the holder C to the bottom e While holding up the piston rod puller A by one person push down B the fork spring compressor and insert the fork spring stopper C between the piston rod nut D and the spacer E Special Tool Fork Spring Stopper 57001 1685 e Remove the piston rod puller GM04802BS1 GM04734BS1 C SUSPENSION 13 29 Front Fork e Replace the O ring A on the top plug B with a new one e Apply grease to the new O ring e Screw in the top plug stopped onto the piston rod e Holding the top plug A with a wrench B tighten the piston rod nut C against the top plug Torque Piston Rod Nut 20 N m 2 0 kgf m 15 ft Ib e While holding up the top plug A by one person push down B the fork spring compressor and pull out the fork spring stopper C e Remove
328. he fuel outlet pipe of the fuel pump A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Connect the prepared fuel hose A to the fuel outlet pipe e Secure the fuel hose with a clamp e Insert the fuel hose into the measuring cylinder B A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e Turn the engine stop switch to run position e Turn the ignition switch on OThe fuel pump should operate for 3 seconds and then should stop Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for 3 seconds ORepeat this operation several times Amount of Fuel Flow Standard 50 mL 1 7 US oz or more for 3 seconds e Turn the ignition switch off If the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation e Install the fuel tank see Fuel Tank Installation e Start the engine and check for fuel leakage Fuel Pump FUEL SYSTEM D
329. he harness adapter A between these connectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 e Connect a digital meter to the harness adapter leads Oxygen Sensor Output Voltage Connections to Adapter Digital Meter BL Y sensor BL lead Digital Meter BR BK sensor W lead e Remove Fuel Tank see Fuel Tank Removal Air Suction Valve Covers see Air Suction Valve Re moval in the Engine Top End chapter Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter e Install the air suction valve covers see Air Suction Valve Installation in the Engine Top End chapter e Connect the air switching valve connector A e Install the suitable plugs A on the fitting of the air suction valve covers and shut off the secondary air FUEL SYSTEM DFI 3 81 Oxygen Sensor not activated Service Code 33 Remove the fuel outlet hose see Fuel Hose Replacement in the Periodic Maintenance chapter Connect the following parts temporary Fuel Pump Lead Connector A Fuel Level Sensor Lead Connector B Extension Tube C Special Tool Extension Tube 57001 1578 e Start the engine and let it idle e Warm up the engine thoroughly until the radiator fan starts e Measure the output voltage with the connector joined Output Voltage with Plugs Standard DC 0 7 V or more Next remove the plugs from the fittings A with idling A WARNING
330. he lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary GP07084BS1 C 16 30 ELECTRICAL SYSTEM Battery Battery Removal e Turn the ignition switch off e Remove Seats see Rear Front Seat Removal in the Frame chap ter Band A Remove the Fuse Box B from the battery case e Take out the battery C from the battery case e Disconnect the negative cable A sure to disconnect the negative cable first e Slide out the positive terminal cap B and disconnect the positive cable C e Remove the battery Battery Installation e Turn the ignition switch off e Run the battery cables A outside the battery case B and under the main harness C D Projection on the Battery Case e Install the positive cable A first e Install the negative cable B e Apply a light coat of grease on the terminals to prevent corrosion e Cover the positive terminal with the red cap C e Place the battery in the original place so that the battery fits to the projection on the battery case e Install the removed parts see appropriate chapters Battery ELECTRICAL SYSTEM 16 31 Battery Activation
331. he terminals are cracked bent or otherwise damaged xIf the ABS hydraulic unit connector is clogged with mud or dust blow it off with compressed air 12 66 BRAKES Anti Lock Brake System Equipped Models Front Wheel Rotation Sensor Removal The wheel rotation sensor should be handled care fully never struck sharply as with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Clamp A e Disconnect the connector B e Remove Clamps A Bolts B Front Wheel Rotation Sensor C Front Wheel Rotation Sensor Installation e Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Rear Wheel Rotation Sensor Removal The wheel rotation sensor should be handled care fully never struck sharply as with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor Anti Lock Brake System Equipped Models BRAKES 12 67 e Remove Right Side Cover see Side Cover Removal in th
332. he tester does not read as specified replace the relay box 16 112 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection with the battery disconnected Tester Connection Tester Reading Q Headlight Relay 1 3 oo 7 6 ECU Main Relay 4 5 Fuel Pump Rel Be uel Pump Rela TUS 9 10 we 11 16 Starter Circuit Relay 11 12 17 20 Fan Relay 18 19 The actual reading varies with the hand tester used Relay Circuit Inspection with the battery connected Battery Connection Tester Tester Connection Reading Q ECU Main Relay Fuel Pump Relay Fan Relay Battery Tester Connection Tester Connection DC 25 V Range Reading V 9 O g v Starter Battery Circuit Relay WAS Voltage Apply positive lead Apply negative lead Diode Circuit Inspection Remove the relay box see Relay Box Removal e Check conductivity of the following pairs of terminals see Relay Box Internal Circuit in this section Diode Circuit Inspection 1 11 2 11 12 13 12 15 12 16 13 14 13 15 Tester Connection The resistance should be low one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes
333. heGableEubriGatlon nee Ss bot te teal teen dedu degunt et Bed s 6 6 Clutch Lever IMStallation 6 6 GIUTCH COVER TC 6 7 tenete aei RI itx devs cl Ra cR D e Fa NR PA 6 7 Clutch Cover Installation pp 6 7 Release Shaft Removal 2 6 7 Release Shaft Installation pt 6 8 Clutch Cover Disassembly pp 6 8 Clutch Cover ASSermbly rete ie 6 8 6 9 Le 6 9 CUteRSSLSUOn cece sects E chet debate dad 6 9 Clutch Plate Assembly Inspectionm cese nennen tnn nane 6 11 Clutch Plate Assembly Adjustment nennt 6 11 Clutch Plate Wear Damage Inspection pp 6 12 Clutch Plate Warp 6 12 Clutch Spring Free Length 6 12 6 2 CLUTCH Exploded View GF022128W5 C CLUTCH 6 3 Exploded View T No Fastener Remarks 97 in lb 5 Clutch Lever Clamp Bolts 0 20 18 in Ib 2 OilFiller Plug 3 Clutch Cover Mounting Bolts 11 1 1 97 in lb 4 Clutch Spring Bolts 8 8 0 90 78 in Ib 5 Clutch Hub Nut 135 13 8 100 R CL Apply cable lubricant EO Apply engine oil G Apply grease HG Apply high temperature grease L Apply a non
334. headlight e Tighten the bolts e Install Bracket Bolts Meter Cover Ignition Switch Cover Removal e Remove the bolts A e Clear the hooks B and tabs C and remove the ignition Switch cover D Fairings FRAME 15 11 Ignition Switch Cover Installation e Check that the pad A is in place on the ignition switch cover B 10 mm 0 39 in C e Fit the hooks A of the ignition switch cover B on the ribs C of the tank cover e Insert the pin D on the ignition switch cover into the hole E on the bracket e Insert the tabs A on the ignition switch cover into the slots B of the tank cover e Tighten the bolts C with the washers Tank Cover Removal e Remove the ignition switch cover see Ignition Switch Cover Removal e Clear the projections A tab B and hook fasteners C on the tank cover D e Pull the tank cover forward to clear the hook E Tank Cover Installation e When installing the hook fasteners A and pad B align the edge of the hook fasteners and pad with the lines C of the tank cover 5 mm 0 2 in D G005039BS1 15 12 FRAME Fairings e When installing the hook fasteners A align the edge of the hook fasteners with the lines B of the fuel tank e Check that the grommets A are in place on the fuel tank and tank cover e Insert the hook B on the fuel tank into the slot C of the tank cover e Fit the hook fasteners
335. heck the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Condition Inspection e Refer to the Spark Plug Condition Inspection in the Peri odic Maintenance chapter Interlock Operation Inspection e Raise the rear wheel off the ground with stand e Turn the engine stop switch on run position 1st Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Side Stand Down or Up OTurn the ignition switch on and push the starter button OThen the starter motor should not turn when the starter system circuit is normality xIf the engine is start inspect the starter lockout switch neutral switch and relay box 16 50 ELECTRICAL SYSTEM Ignition System 2nd Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Side Stand Up OTurn the ignition switch on and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality If the starter motor is not turn inspect the starter lockout switch side stand switch
336. heck the output voltage see Fuel Injector Output Voltage Inspection 80178820651 3 122 FUEL SYSTEM Fuel Injectors Fuel Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove the ECU see ECU Removal ODo not disconnect the ECU connector e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Fuel Injector Output Voltage Connections to ECU Connector For Fuel Injector 1 Digital Meter BL BK lead ECU terminal 36 Digital Meter gt Battery terminal For Fuel Injector 2 Digital Meter BL R lead ECU terminal 34 Digital Meter gt Battery terminal For Fuel Injector 3 Digital Meter BL O lead ECU terminal 11 Digital Meter gt Battery terminal For Fuel Injector 4 Digital Meter BL G lead ECU terminal 10 Digital Meter gt Battery terminal e Measure the output voltage with the engine stopped and with the connector joined e Turn the engine stop switch to run position e Turn the ignition switch on Output Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch off xIf the reading is in specification check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Remo
337. heck the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector Oxygen Sensor Connector B P BK lead ECU terminal 9 C xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 8017807 51 Oxygen Sensor Circuit BK BL r 4 907076 1 Ignition Switch 10 Starter Relay 2 Water Proof Joint 2 11 Main Fuse 30 A 3 Oxygen Sensor 12 ECU Fuse 15 A 4 Joint Connector E 13 Relay Box 5 ECU 14 ECU Main Relay 6 Frame Ground 4 15 Fuse Box 1 7 Frame Ground 1 16 Ignition Fuse 15 A 8 Engine Ground 17 Joint Connector C 9 Battery 12 V 8 Ah FUEL SYSTEM DFI 3 103 Oxygen Sensor Incorrect Output Voltage Service Code 94 Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Turn the ignition switch off e Remove the right frame cover see Frame Cover Removal in the Frame chapter e Disconnect the oxygen sensor lead connector 4 pins connector and connect the harness adapter A between these connectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 e Connect a digital meter to the harness
338. heel Removal in the Wheels Tires chapter e Remove the brake disc mounting bolts and take off the disc ORemove the sensor rotor ABS equipped models e Remove the gaskets Brake Disc Installation e Replace the gaskets with new ones e Install the brake disc on the wheel so that the marked side A faces out Olnstall the sensor rotor on the brake disc so that the marked side faces out ABS equipped models e Apply a non permanent locking agentto the threads of the front and rear brake disc mounting bolts B and tighten them Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 16 Brake Disc Wear Inspection e Measure the thickness of each disc A at the point where it has worn the most x If the disc has worn past the service limit replace it Measuring Area B Brake Discs Thickness Standard Front 4 8 5 2 mm 0 19 0 20 in Rear 5 8 6 2 mm 0 23 0 24 in Service Limit Front 4 5 mm 0 18 in Rear 5 5 mm 0 22 in Brake Disc Warp Inspection Raise the front rear wheel off the ground see Front Rear Wheel Removal in the Wheels Tires chapter OFor front disc inspection turn the handlebars fully to one side e Set up dial gauge against the disc A as shown measure disc runout while turning B the wheel by hand x If runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 15 mm 0 006 in or less Service Limit TIR 0 3 mm 0 01 in GL080
339. hole on the spacer B by screwing the handle in the holder C to the bottom Special Tool Fork Spring Compressor 57001 1685 13 26 SUSPENSION Front Fork e While holding up the top plug A by one person push down B the fork spring compressor and insert the fork spring stopper C between the piston rod nut D and the spacer E Special Tool Fork Spring Stopper 57001 1374 Holding the top plug A with a wrench B loosen the piston rod nut C Remove the top plug e While holding up the piston rod A by one person push down B the fork spring compressor and pull out the fork spring stopper C e Remove the fork spring compressor e Remove Spacer A Fork Spring B e Drain the fork oil into a suitable container and remove the spring seat OUsing the piston rod puller A pump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 6 04021251 Front Fork SUSPENSION 13 27 e Hold the fork tube upright press the outer tube A and the piston rod all the way down e Pour in the type and amount of fork oil specified Recommended Oil KHL15 10 or equivalent Amount When changing oil Approx 410 mL 13 9 US oz After disassembly and completely dry 481 4 mL 16 3 0 135 US oz x If necessary measure the oil level as follows OHold the inner
340. ht angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 17 mm 0 0035 0 0067 in Intake 0 03 0 11 mm 0 0012 0 0043 in Service Limit Exhaust 0 38 mm 0 015 in Intake 0 32 mm 0 013 in Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 21 6 21 8 mm 0 850 0 858 in Intake 26 4 26 6 mm 1 039 1 047 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Exhaust 0 5 1 0 mm 0 020 0 039 in Intake 0 5 1 0 mm 0 020 0 039 in GE15054BS1 C 8 15011752 C 5 30 ENGINE TOP END Valves Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar B 57001 112
341. hten the rear view mirror locknut upper Torque Rear View Mirror Locknut Upper 18 Nm 1 8 kgf m 13 ft lb e Install the dust cover D e Adjust the rear view mirror E by slightly moving only the mirror portion of the assembly Olnstallation and adjustment of the right side are common with those of the left side Follow the procedure specified at the left side ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents EXPlOdGd hore TET 16 3 Specifications a insi ER 16 10 Special Tools and Sealant cte te t o ett lige b S a ete ad 16 11 Parts Location i e o IR RU e era pene de a E RE MR Re ra dor E d 16 13 Wiring Diagram ZR800A without GPS Unity nnn 16 16 Wiring Diagram ZR800A with GPS Unit enne 16 18 Wiring Diagram ZR800B without GPS Unit mnn 16 20 Wiring Diagram ZR800B with GPS Unit emm 16 22 Wiring Diagram 2880006 ttu nr tr Op ede ette etre cr Aa by ders 16 24 Wiring Diagram ZR800D 52 xe eo tod nien b das He 16 26 Precautioris teca toc bri tado eo n Pv ate e deu vao ver eruat te A 16 28 Electrical VVIFIFIg i sse br RU RISO Deuce qut 16 29 Wiring InsSpectlofi or i oe oe elena bep o 16 29 M 16 30 Battery Removal RT 16 30
342. htening sequence Si Apply silicone grease Torque Cooling System Thermostat Bracket Bolt Reserve Tank Bolts Thermostat Housing Screws Thermostat Housing Clamp Bolt Water Temperature Sensor Radiator Bolts Water Hose Clamp Screws Radiator Bracket Mounting Bolt Coolant Drain Bolt Cylinder Water Pipe Bolts Cylinder Fitting Mounting Bolts 6 9 9 8 2 6 6 9 12 6 9 3 0 6 9 9 8 11 11 0 70 1 0 0 27 0 70 1 2 0 70 0 31 0 70 1 0 1 1 1 1 Fastener kgfm ft lb Remarks Fuel System DFI Throttle Cable Plate Bolt 5 9 0 60 52 in lb Throttle Body Cover Mounting Bolts 4 0 0 41 35 in lb Delivery Pipe Assy Mounting Screws 3 5 0 36 31 in lb Throttle Body Assy Holder Clamp Bolts 1 1 0 11 10 in Ib Air Cleaner Duct Screws 3 8 0 39 34 in lb Air Duct Clamp Bolts 1 1 0 11 10 in Ib Air Cleaner Housing Tapping Screws 1 2 0 12 11 in Ib Air Cleaner Housing Mounting Bolts 9 8 1 0 87 in lb Vehicle down Sensor Bolts 5 9 0 60 52 in lb Water Temperature Sensor 12 1 2 106 in Ib Oxygen Sensor 44 4 5 32 Speed Sensor Bolt 12 1 2 106 in Ib Crankshaft Sensor Bolts 5 9 0 60 52 in lb Fuel Pump Bolts 9 8 1 0 87 in lb L S Fuel Level Sensor Bolts 6 9 0 70 61 in lb L Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 0 70 61 in lb Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 0 50 43 in lb 61 in lb 87 23 in lb 61 in lb 106 in Ib 61 in lb 27 in lb 61 in lb 87 97 97
343. ight be stored in the ABS hydraulic unit Using the self diagnosis feature make sure that the yellow ABS indicator light LED lights A fully charged battery is a must for conducting reliable self diagnosis Test run the motorcycle at a speed of more than 30 km h 19 mph to see that the yellow ABS indicator light LED does not come on Finally test run the motorcycle at a speed of more than 30 km h 19 mph and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally the reaction force generated is felt in the brake lever and pedal This completes the final inspection ABS Troubleshooting Outline When an abnormality in the system occurs the yellow ABS indicator light LED lights up to alert the rider In ad dition the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self diagnosis mode the service code A is indicated by the number of times the yellow ABS indicator light LED blinks The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected Therefore after correcting the problem always erase the service codes and then run the self diagnosis pro gram to confirm normal signal output When due to a mal function the yellow ABS indicator light LED remains lit get a thorough understanding of the background before starting the repair work Ask the rider about
344. igital voltmeter A e Remove the battery see Battery Removal e Disconnect the battery terminals sure to disconnect the negative cable first e Measure the battery terminal voltage 808010851 NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage ELECTRICAL SYSTEM 16 35 Battery xIf the reading is 12 6 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 6 V or more Terminal Voltage V A Battery Charge Rate 96 B Refresh charge is required C Good D Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below 8 09001251 C Terminal Voltage 11 5 less than 12 6 V Standard Charge 0 9 A x 5 10 h see following chart Quick Charge 4Ax1h If possible do not quick charge If quick charge is done unavoidably do standard charge later on Charge Time h 11 8 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V Terminal Voltage less than 11 5 V 6P08023BS1 Charging Method 0 9 A 20 h NOTE
345. ignition switch OFF x If the reading is out of the standard replace the sensor x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Speed Sensor Connector B P lead ECU terminal 22 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17511FS1 C FUEL SYSTEM DFI 3 71 Speed Sensor Service Code 24 Speed Sensor Circuit GCi7512FW2 1 Speed Sensor 2 Water Proof Joint 1 3 Water Proof Joint 2 4 ECU 3 72 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 This sensor has a weight A with two magnets inside and sends a signal to the ECU But when the motorcycle banks 60 70 or more to either side in fact falls down the weight turns and the signal changes The ECU senses this change and stops the fuel pump relay the fuel injectors and the ignition system Hall IC B When the motorcycle is down the ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start To start the engine again raise the motorcycle turn the ignition switch off and then on Vehic
346. ile 2 38 Drive chain slack C Q every 1 000 km 600 mile 2 38 Drive chain wear C Q Q 2 40 Drive chain guide wear Q Q 2 41 Brakes Brake system 94119 19 Q Q Q 2 42 Brake fluid level 9405198 Q Q Q Q 2 43 Brake fluid front and rear G2 GY 2 44 Brake hose rubber parts of brake master GT every 48 000 km pe cylinder and caliper i 30 000 mile 2 48 Brake pad wear C Q Q Q Q 2 52 Brake light switch operation Q Q Q Q 2 52 Suspension Suspension system 9 1 Q 2 53 Steering Steering play Q4 Q Q Q 2 55 Steering stem bearings 2 2 56 Electrical System Electrical system 0 4 2 57 Spark plugs G 2 61 Others Chassis parts 4 2 62 Condition of bolts nuts and fasteners Q Q Q 2 64 Torque and Locking Agent PERIODIC MAINTENANCE 2 5 The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean AD Apply adhesive see the text AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease L Apply a non permanent locking agent Lh Left hand Threads LG Apply liquid gasket MO Apply molybdenum disulfide grease oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tig
347. ine Sprocket Removal For safety if the drive chain shall be replaced re place it using a recommended tool Recommended Tool Type EK Joint Tool 50 Brand ENUMA Body A Handlebar B Cutting and Riveting Pin C For Cutting D For Riveting E Plate Holder A F Plate Holder B G Gauge H GKO4016BS1 C Drive Chain FINAL DRIVE 11 7 e Grind A the pin head to make it flat e Set the cutting and riveting pin B as shown e Screw the pin holder until it touches chain pin e Be sure that the cutting pin hits center of chain pin e Screw the handlebar A into body e Turn the pin holder with wrench B clockwise to extract chain pin e Replace the link pin link plate and grease seals e Apply grease to the link pins A and grease seals B C e Engage the drive chain on the engine and rear sprockets e Insert the link pins in the drive chain ends e Install the grease seals e Install the link plate so that the mark D faces out e Push the link plate by hand or plier to fix it e n case of grease seals chain be sure to set the grease seals correctly e Set the plate holder A A and plate holder B B on the body GK04018BS1 C E GKO4019BS1 C GK04020BS1 C GK04021BS1 C 11 8 FINAL DRIVE Drive Chain e Fit the plate holder A to link plate e Turn the pin holder by hand until plate holder B touches the other link plat
348. ing and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE OMost countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Wheel Bearing Damage Inspection e Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebars all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel Spin B the front wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Raise the rear wheel off the ground with the stand see Rear Wheel Removal in the Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise xIf roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re moval Hub Bearing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the
349. inspect the chain 6J06002BS1 C GK05017BS1 C 11 14 FINAL DRIVE Sprocket Coupling Rear Sprocket Warp Inspection e Raise the rear wheel off the ground with the stand so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp x If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in GK05000BS1 C BRAKES 12 1 Brakes Table of Contents Exploded eater eerte eet ene de e rds Special TOS Brake Lever Brake Pedal ert tt orbe idoneae din ae Brake Lever Position Adjustment pp Brake Pedal Position Inspection pp Brake Pedal Position Adjustment pp Brake Pedal RBemoval itte tec eie Brake Pedal Installation pp sls Front Caliper Rear Caliper ROMOVal iss iiti ree rh hg a e a vere Er Dee FEY ELE EC seve Caliper Installation Front Caliper Disassemb y 3 6 adeo
350. ion e Check if the weight portion has any play on the blade A and clip B x lf it does discard it A WARNING Unbalanced wheels can create an unsafe riding condition If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Replace the loose balance weight Do not reuse used balance weight 6J04076BS1 C GJ04313BS1 6J04088BS1 C 10 12 WHEELS TIRES Wheels Rims Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0009 30 1 06 oz OBalance weights are available from Kawasaki dealers in 10 20 and 30 grams 0 35 0 71 and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weights more than 90 grams 3 17 oz If the wheel requires an excess bal ance weight disassemble the wheel to find the cause e Slip the balance weight A onto the rib B by pushing or lightly hammering C the clip D Left Side E Right Side F NOTE e Be sure to install the balance weight OCheck that the blade A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Left Side E Right Side F 6J04074BS1 C 6J04088BS1 C Tires WHEELS TIRES 10 13 Air Pressure Inspection Adjustment Refer to the Air Pressure In
351. ion Switch see Immobilizer System Parts Replace ment e Remove the immobilizer Kawasaki diagnostic system connector cap A Connect the key registration unit A and key registration adapter B as shown Immobilizer Kawasaki Diagnostic System Connector C Special Tools Key Registration Unit 57001 1582 Key Registration Adapter 57001 1746 e Connect New Ignition Switch Lead Connector A Current Immobilizer Antenna Lead Connector B NOTE OKeep the ignition switch more than 15 cm 5 9 in New Ignition Switch C Current Ignition Switch D e Insert the current registered ignition key A at the current ignition switch B e Insert the new ignition key 1 C to the new ignition switch D and turn it to ON wes Immobilizer System ELECTRICAL SYSTEM 16 91 OThe red warning indicator light LED and immobilizer warning symbol A blink 1 time and stops for 1 second and repeats this cycle Not Verified OThe red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure Registered Ignition Key Collation Error Turn to OFF and remove the new ignition key 1 NOTE Olnsert the next key and turn it to ON within 15 sec onds after previous key is turned to OFF and removed otherwise registration mode will be ended and the red warning indicator light LED and immobilizer warning symbol sto
352. ion noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly Warning Indicator Light Oil Pressure Warning Doesn t Go OFF Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn APPENDIX 17 43 Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner housing holder loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebars hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem
353. ions to Amplifier Connector Digital Meter BR W lead Digital Meter BK Y lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard Battery Voltage e Turn the ignition switch off x If the reading is out of the standard check the wiring see wiring diagram in next section x If the reading is within the standard check the wiring to ECU see wiring diagram in next section xIf the wiring is good replace the amplifier see Immobi lizer System Parts Replacement in the Electrical System chapter FUEL SYSTEM DFI 3 87 Blank Key Detection Service Code 36 e This code appears in the following conditions OThe transponder A in the ignition key is malfunction OWhen the spare key of unregistration is used OWhen the ignition key is registered in the registered ECU e Therefore the service code 36 will disappear when the above issue is solved Ignition Key Inspection e Register the ignition key correctly see Key Registration in the Electrical System chapter x If the service code 36 appears again the transponder the key is malfunction replace it 3 88 FUEL SYSTEM DFI Blank Key Detection Service Code 36 Immobilizer System Circuit GP30235CH3 C Ignition Switch Joint Connector E ECU nector Frame Ground 1 Frame Ground 4 Engine Ground
354. ip 57001 1591 Stopper 57001 1679 Rotor Holder 57001 1690 Torque Alternator Rotor Bolt 155 N m 15 8 kgf m 114 ft Ib e Apply a thin coat of molybdenum disulfide grease to the shaft A and install it and starter idle gear B e Install the alternator cover see Alternator Cover Installa tion GP09198BS1 C 16 40 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection e Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual alternator operating conditions e Take out the battery from the rear fender with the cables connected see Battery Removal e Check that the ignition switch is turned off and connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at var ious engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the headlight connector on the headlight unit The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging Voltage Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 2 14 8 V e Turn the ignition switch off to stop the engine and discon nect the hand tester x If the charging voltage is kept b
355. ipe C and O rings Remove the shift shaft assembly A while pulling out the shift mechanism arm B e Remove Oil Pump Drive Gear see Oil Pump Drive Gear Removal in the Engine Lubrication System chapter Gear Positioning Lever Bolt A Gear Positioning Lever B Collar and Spring External Shift Mechanism Installation e Install the gear positioning lever A as shown Spring B Collar C Gear Positioning Lever Bolt D e Tighten Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib e Apply grease to the new O rings on the oil pipe ends e Apply a non permanent locking agent to the threads of the oil pipe holder bolts and tighten them Torque Oil Pipe Holder Bolts 13 N m 1 3 kgf m 115 in Ib e Install the removed parts see appropriate chapters 9113330851 9 28 CRANKSHAFT TRANSMISSION Transmission External Shift Mechanism Inspection e Examine the shift shaft A for any damage x If the shaft is bent straighten or replace it x If the serration B are damaged replace the shaft x If the springs C are damaged in any way replace them x If the shift mechanism arm D is damaged in any way replace the shaft e Check the return spring pin A is not loose x If it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 29 N m 3 0 kgf m 21 ft Ib e Check the gear positioning lever B and its s
356. is defective Replace stick coil Voltage is zero No good or almost zero Inspect Replace bad parts or No good 1 Adapter connection is incorrect or inspect them with adapter is defective KAWASAKI Hand 2 Ignition switch and engine stop switch Tester 3 Crankshaft sensor peak voltage Replace bad parts ECU is defective Replace ECU GPI0280B F 16 52 ELECTRICAL SYSTEM Ignition System Ignition System Circuit pa a ee Hi Lid LL IL 2 St H HL 4 I Y R B Mi 3 3 1 Engine Stop Switch 11 Joint Connector E 21 Relay Box 2 Stick Coils 12 ECU 22 Starter Lockout Switch 3 Vehicle down Sensor 13 Frame Ground 1 23 Ignition Fuse 15 A 4 Speed Sensor 14 Frame Ground 4 24 Fuse Box 1 5 Main Throttle Sensor 15 Engine Ground 25 Joint Connector C 6 Subthrottle Sensor 16 Battery 12 V 8 Ah 26 Ignition Switch 7 Neutral Switch 17 Starter Relay 27 Spark Plugs 8 Crankshaft Sensor 18 Main Fuse 30 A 28 Water proof Joint 1 9 Side Stand Switch 19 ECU Fuse 15 A 29 Water proof Joint 2 10 Oxygen Sensor 20 ECU Main Relay Electric Starter System ELECTRICAL SYSTEM 16 53 Starter Motor Removal NOTICE Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor Remove the throttle body assy see Throttle Body Assy Rem
357. is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation LT TT Mw TTT eT LTT TET TTT ty 8017596 51 FUEL SYSTEM DFI 3 79 Subthrottle Sensor Service Code 32 Subthrottle Sensor Resistance Inspection e Turn the ignition switch off e Disconnect the subthrottle sensor connector e Connect a digital meter A to the subthrottle sensor con nector B e Measure the subthrottle sensor resistance Subthrottle Sensor Resistance Connections G lead C BL lead D Standard 4 6 x lf the reading is out of the standard replace the throttle body assy x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation 80177950651 Subthrottle Sensor Circuit 8 ae BL if 6C17435FW2 C 1 Subthrottle Sensor 2 Water Proof Joint 1 3 Water Proof Joint 2 4 ECU 3 80 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Turn the ignition switch off e Remove the right frame cover see Frame Cover Removal in the Frame chapter e Disconnect the oxygen sensor lead connector 4 pins connector and connect t
358. ith com pressed air after cleaning Clean and dry the bolts and nuts completely 6105040351 CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods e Apply a small amount of molybdenum disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods e Install new bolts in the connecting rods e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 5 OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly OTighten the hexagon nut by 2 corners OThe nuts can be tightened by using an angle torque gauge For details refer to Crankcase Assembly Connecting Torque Angle Rod Assy Bolt kgf m ft lb Attached to 18 1 8 13 Use the bolts new con rod 120 New attached to new con rod New 20 2 0 15 120 24 2 4 18 Replace the Used 120 Used bolts with new ones 25 2 5 18 1207 Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Inspection Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap
359. just the steering see Steering Play Adjustment GNO5157BS1 PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step e Turn the ignition switch on e The following lights should go on according to below table City Lights A go on Taillight LED B goes on License Plate Light C goes on Meter Panel LCD D goes on Green Neutral Indicator Light LED E goes on Oil Pressure Warning Symbol and Red Warning blink Indicator Light LED F Yellow ABS Indicator Light LED G ABS Equipped goes on Models x If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A and Brake Horn Fuse 7 5 A see Fuse Inspection in the Electrical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Electronic Com bination Meter Unit Inspection in the Electrical System chapter Meter Unit for Green Neutral Indicator Light LED see Electronic Combination Meter Unit Inspection in the Electrical System chapter Meter Unit for Red Warning Indicator Light LED see Electronic Combination Meter Unit Inspection in the Electrical System chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Ignition Switch see Switch Inspection in the Elec
360. k Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see Stick Coil Removal but do not remove the spark plugs e Measure the primary peak voltage as follows Olnstall the new spark plug A into each stick coil B and ground them onto the engine OConnect the peak voltage adapter C into the hand tester D which is set to the DC 250 V range OConnect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F Battery G Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter R to lead wire peak voltage adapter W Adapter BK to lead wire peak voltage adapter R 8 10011952 C GP10283BS1 C Ignition System ELECTRICAL SYSTEM 16 49 A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch and the engine stop switch on e Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one stick coil Stick Coil Primary Peak Voltage Standard 100 V or more e Repeat the test for the other stick coil xIf the reading is less than the specified value c
361. k Removal e Disconnect the intake air pressure sensor 1 connector and connect the measuring adapter A between these connectors Main Harness B Intake Air Pressure Sensor 1 C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the harness adapter leads Intake Air Pressure Sensor 1 Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter gt BK sensor lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch off x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor 1 Output Voltage Inspection the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A lt Intake Air Pressure Sensor 1 Connector B BL lead ECU terminal 5 C G lead ECU terminal 33 D MIDI xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation FUEL SYSTEM 3 55 Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure S
362. ke Light Lead Cover the turn signal light lead connectors and license plate light lead connector with the rubber cover Seat Lock Cable Clamp Hold the main harness Insert the projection of the clamp into the frame ABS Self Diagnosis System Connector ABS Equipped Models Kawasaki Diagnostic System Connector Run the seat lock cable under the ABS self diagnosis system lead ABS equipped models Kawasaki diagnostic system lead and rubber cover Run the leads under the bracket Guide Do not run the leads to the upside of the guide This figure is bad sample 17 14 APPENDIX Cable Wire and Hose Routing See a M 4 NN O S LA 6809122 6 APPENDIX 17 15 Cable Wire and Hose Routing Ignition Switch Lead Throttle Cable Accelerator Throttle Cable Decelerator Air Switching Valve Lead Run the radiator fan motor lead between the heat insulation rubber plate and engine bracket Radiator Fan Motor Lead Run the radiator fan motor lead under the clutch cable Clutch Cable Run the radiator fan motor lead under the water hose and air switching valve lead Immobilizer Antenna Lead Run the clutch cable to the right side of the thermostat housing Horn Lead Vehicle down Sensor Lead Clamp Hold the vehicle down sensor lead C
363. ke dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Throttle body assy holder loose Air cleaner housing holder loose Water or foreign matter in fuel Fuel to fuel injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance APPENDIX 17 41 Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous Throttle valve won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worn Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating
364. ke on Raise the rear wheel off the ground with the stand e Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter Remove the drive chain from the rear sprocket toward the right e Disengage the drive chain A from the engine sprocket B e Pull the engine sprocket off the output shaft C Engine Sprocket Installation e Replace the sprocket washer and axle cotter pin e Install the engine sprocket so that OUTSIDE letters A face outward e Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut e Tighten Torque Engine Sprocket Nut 167 Nm 17 0 kgf m 123 ft Ib NOTE OTighten the nut while applying the rear brake e After torquing the engine sprocket nut bend the one side of the washer over the nut FINAL DRIVE 11 11 Sprocket Coupling Be sure to install the dowel pins A e Install the engine sprocket cover A e Install the bracket B as shown and tighten the cover bolts C Torque Engine Sprocket Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib e Adjust the drive chain slack after installing the engine sprocket see Drive Chain Slack Adjustment in the Pe riodic Maintenance chapter Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter NOTICE Do not lay the wheel on the ground with the disc facing down This ca
365. ke parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause de terioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake e When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily e Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up im mediately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Hose BRAKES 12 35 Brake Hose and Pipe Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose and Pipe Inspection e Refer to the Brake Hose and Pipe Damage and Instal lation Condition Inspection in the Periodic Maintenance chapter 12 36 BRAKES Anti Lock Brake System Equipped Models Parts Location T 61147828 6 1 ABS Kawasaki Self diagnosis System Connector Fuse Box 1 Yellow ABS Indicator Light LED Front Wheel Rotation Sensor Rotor Front Wheel Rotation Sensor ABS Hydrau
366. ket Block the hose joint opening E during this operation if the caliper half has the opening Bolt F and Nut Push down G A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston OPull out the pistons by hand e Remove the dust seals A and fluid seals B e Remove the bleed valve C and rubber cap D e Repeat the previous step to remove the pistons from the other side of the caliper body 9513152851 9513337851 PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures Front Caliper Assembly ZR800A B D Models e Clean the caliper parts except for the pads For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply silicone grease to the dust seals and install them into the cylinders by hand e Replace the oil seal A e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the oil seal e Apply a non permanent locking agent to the threads of the front caliper assembly bolts and tighten them Tor
367. keys replacement is considered very rare case However if it is required the following is necessary NOTE OThe ECU must be replaced with a new one because the registered ignition key code that is registered in the current ECU can not be rewritten e Prepare a new ECU A 2 new ignition keys B NOTE OThe key registration unit is not required OAfter replacing the ECU be sure to register the 2 ignition keys If the 2 keys are not registered the engine can not be started e Insert the first ignition key into the ignition switch and turn it to ON rm Bp mm GP30232CS1 GP30823BS1 16 98 ELECTRICAL SYSTEM Immobilizer System Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure Ignition Key Collation Error e The first ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 1 time and stops for 1 second and the repeats this cycle to indicate successful registra tion of the first ignition key e Turn to OFF the first ignition key and remove it e The red warning indicator light LED and immobilizer warning symbol A blink to display the registration mode NOTE Olnsert next key and turn it to ON within 15 seconds af ter previous key is turned to OFF and removed oth
368. kshaft Sensor Peak Voltage Standard 2 0 V or more x If the tester reading is not specified one inspect the crank shaft sensor see Crankshaft Sensor Inspection Timing Rotor Removal e Remove the crankshaft sensor cover see Crankshaft Sensor Removal e Remove the timing rotor A OHolding the timing rotor with the flywheel amp pulley holder B and remove the rotor bolt C Special Tool Flywheel amp Pulley Holder 57001 1605 Timing Rotor Installation e Install the timing rotor A on the crankshaft B with their teeth C aligned e Holding the timing rotor with the flywheel amp pulley holder and tighten the bolt Torque Timing Rotor Bolt 39 N m 4 0 kgf m 29 ft Ib Special Tool Flywheel amp Pulley Holder 57001 1605 e Install the removed parts see appropriate chapters Ignition System ELECTRICAL SYSTEM 16 47 Stick Coil Removal Never drop the stick coils especially on a hard sur face Such a shock to the stick coils can damage it e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Side Fairings see Side Fairing Removal in the Frame chapter Remove the quick rivet A for Stick Coil 4 e Disconnect the stick coil connector and pull the stick coil 4 B off the spark plug Do not pry the connector part of the coil while re moving the coil e Remove Bolt C for Stick Coil 2 and 3 e Disconnect the stick coil connector an
369. l al Light 12 10W Tail Brake a Light LED ee H coo Frane Ground qus 1 Kawasaki I Self i diagnostic VL E System BK Y sac F Connector BKAY 16 iles Y BK BK m BK 2 BK Y PM Y R License Plate Light 12 58 OK BK Y LE 1 Rear Left Turn Signal Light 12V10N BRZY BK BK Y BRZY BL R B ii LA Fuel FUE H Starter Regulator Rai tevel PUMP Rectifier Alternator ee c Fuse Box 2 N BK BKZY BK Y 1 Fan Fuse 15 LIN 2 Meter Fuse 7 5A Battery Ground s 2 4 Joint Starter 12V8Ah rame Groun ear Exhaust Connector 6 6 4 Wotor Brake Butterfly olor ode Light valve Switeh Actuator Black Starter Relay 1 0 Fuse 15 2 Main Fuse 30 Brown Green GY Gray LB Light Blue 0 Orange Pink Purple R Red w White 98052 07050 W2RO705CW5 C 16 18 ELECTRICAL SYSTEM Wiring Diagram ZR800A with GPS Unit Right Switch Housing 2 Engine Stop Switch 3 Starter Button ev BR W BR BK Brzy BK Y Horn 2 2 Front Brake Light Switch Intake Vehicle Air down Temperatura Spark Plugs Sensor Sensor AT 3 5 S
370. laced with new ones whenever disassembled 68020108 5 Assembly Order 2 In most cases assembly order is the reverse of disassem TE od bly however if assembly order is provided in this Service cu Om i Manual follow the procedures given x S DE gt SS WX 2 4 68020118 S 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing performance Remo
371. lamp Hold the horn lead Insert the projection of the clamp into the frame Run the vehicle down sensor lead to the outside of the ABS brake pipes ABS equipped mod els Run the clutch cable under the vehicle down sensor lead and horn lead 17 16 APPENDIX Cable Wire and Hose Routing 1 Fuel Level Sensor Lead 2 Run the clutch cable through the clamp 3 Clutch Cable 4 Run the clutch cable under the vehicle down sensor lead and horn lead 5 Clamp Hold the horn lead Bend the clamp as shown 6 Horn Lead 7 Clamp Hold the horn lead 8 Horn 0809123E 6 APPENDIX 17 17 Cable Wire and Hose Routing GBOPIZ4E G 1 Fuel Tank Drain Hose 2 Reserve Tank Overflow Hose 3 Clamp Hold the reserve tank over flow hose fuel tank drain hose and fuel tank breather hose in order from the outside Hold the fuel tank breather hose at the tape position 4 Fuel Tank Breather Hose 5 Radiator Overflow Hose 17 18 APPENDIX Cable Wire and Hose Routing GB09125E 6 APPENDIX 17 19 Cable Wire and Hose Routing QI CN O 16 Run the left right switch housing lead and turn signal light relay lead between the reserve tank 17 18 19 20 Reserve Tank Overflow Hose Fuel Tank Drain Hose Fuel Tank Breather Hose Run the reserve tank over flow hose to the outside of the fuel tank drain hose as shown Run the radiator overflow hose to the left
372. lar A counterclockwise to make the gap between the en gine and upper adjusting collar e Remove the left front engine mounting bolt A e Remove Subframe Bolts A Both Sides Subframe B Both Sides Upper Engine Bracket Bolts C Both Sides Upper Engine Bracket D Both Sides Middle Engine Mounting Nut E and Bolt Lower Engine Mounting Nut F and Bolt Rear Engine Bracket Bolts G Rear Engine Bracket H 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Using the nut wrench A loosen the locknut B Special Tool Engine Mount Nut Wrench 57001 1450 e Using the Hexagon Wrench turn the lower adjusting col lar A counterclockwise to make the gap between the en gine and lower adjusting collar Disconnect the breather hose end A Remove the engine ground cable terminal bolt B Remove the drive chain A from the output shaft B e Using the stand take out the engine ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation Engine Installation e Support the engine with a suitable stand OPut a plank onto the suitable stand for engine balance e Screw the lower adjusting collar A to the frame e Screw the upper adjusting collar B to the subframe GH04184BS2 C e Hang the drive chain over the output shaft just before moving the engine into its final position in the frame e Run the breather hose and engine ground cable correctly
373. le Range 1 120 1 698 kPa 11 4 17 3 kgf cm 162 246 psi at 330 r min rpm 0 05 mm 0 002 in Valves Valve Clearance Exhaust Intake Valve Head Thickness Exhaust Intake Valve Stem Bend Valve Stem Diameter Exhaust Intake Valve Guide Inside Diameter Exhaust Intake Valve Valve Guide Clearance Wobble Method Exhaust Intake Valve Seat Cutting Angle Valve Seating Surface Width Exhaust Intake Outside Diameter Exhaust Intake Valve Spring Free Length Exhaust Intake 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 24 mm 0 0059 0 0094 in 1 0 mm 0 039 in 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 3 955 3 970 mm 0 1557 0 1563 in 3 975 3 990 mm 0 1565 0 1571 in 4 000 4 012 mm 0 1575 0 1580 in 4 000 4 012 mm 0 1575 0 1580 in 0 09 0 17 mm 0 0035 0 0067 in 0 03 0 11 mm 0 0012 0 0043 in 32 45 60 0 5 1 0 mm 0 020 0 039 in 0 5 1 0 mm 0 020 0 039 in 21 6 21 8 mm 0 850 0 858 in 26 4 26 6 mm 1 039 1 047 in 40 7 mm 1 602 in 40 7 mm 1 602 in 0 5 mm 0 020 in 0 25 mm 0 012 in TIR 0 05 mm 0 002 in 3 94 mm 0 155 in 3 96 mm 0 156 in 4 08 mm 0 161 in 4 08 mm 0 161 in 0 38 mm 0 015 in 0 32 mm 0 013 in 38 9 mm 1 531 in 38 9 mm 1 531 in ENGINE TOP END 5 11 Specifications Standard Service Limit Cylinder Pistons Cylinder Inside
374. le down Sensor A Ground Terminal G B Output Terminal Y G C Power Source Terminal BL D GC17355BS1 C Vehicle down Sensor Removal NOTICE Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Fuel Tank see Fuel Tank Removal Right Side Fairing see Side Fairing Removal in the Frame chapter e Disconnect the vehicle down sensor connector A Remove Vehicle down Sensor Bolts B and Bracket Vehicle down Sensor C Vehicle down Sensor Installation e The UP mark A of the sensor should face upward e Tighten Torque Vehicle down Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the sensor brackets GC17356BS1 C Vehicle down Sensor Service Code 31 FUEL SYSTEM DFI 3 73 Vehicle down Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Disconnect the vehicle down sensor connector and con nect the harness adapter A between these connectors as shown Main Harness B Vehicle down Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the har
375. leaner element A e Install a new element A so that flat side B faces forward e ZR800A B Models when installing the pad A align the edge of the pad with the rib B of the air cleaner duct G505CMA P 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Fit the tongue A of the air cleaner duct into the slot B of the air cleaner housing Tighten Torque Air Cleaner Duct Screws 3 8 N m 0 39 kgf m 34 in Ib Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebars to both sides A xlf handlebars movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Throttle Control System Inspection and Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions e Check the idle speed Idle Speed Standard 1 100 50 r min rpm x If the idle speed is out of the specified range adjust it Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the
376. lease Shaft see Release Shaft Removal Oil Seal A Needle Bearings B Oil Level Inspection Window Clutch Cover Assembly e Replace the needle bearings and oil seal with new ones NOTE Olnstall the needle bearings so that the manufacture s mark face out e Install the needle bearings A and oil seal B position as shown OPress the needle bearing until the bottom C OPress the needle bearing so that the bearing surface D is flush with the housing end of clutch cover E e Install the oil level inspection window until the bottom GF05025BS1 C GFO5018BS1 C CLUTCH 6 9 Clutch Clutch Removal e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with Thrust Bearing Pusher C Spring and Washer e Remove Friction Plates and Steel Plates Clutch Hub Nut A OHolding the clutch hub B remove the nut and washer Special Tool Clutch Holder C 57001 1243 e Remove Clutch Hub Spacer e Using the two 4 mm 0 16 in bolts A pull out the sleeve B needle bearing C and clutch housing D e Remove the spacer Clutch Installation e Install the following parts on the drive shaft Spacer A Needle Bearing B Sleeve C Clutch Housing D Spacer E Clutch Hub F Washer G Nut H GF06157BS2 C 6 10 CLUTCH Clutch Olnstall the spacer A so that the tapered side B faces inward Olnsta
377. lem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFI system problem or a general engine problem 0 17423 F FUEL SYSTEM DFI 3 33 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Mileage Environment when problem occurred Weather fine cloudy O rain snow O always O other Temperature O hot O warm cold O very cold O always O other Problem O chronic O often once frequency Road street highway O mountain road O uphill downhill C1 bumpy pebble Altitude normal O high about 1 000 m or more Motorcycle conditions when problem occurred Warning L1 Starts blinking about 3 seconds after from ignition switch ON and goes off after indicator light LED engine pressure becomes high enough with engine running O Starts blinking about seconds after from ignition switch ON and the FI warning symbol on the LCD starts blinking DFI system problem O Starts blinking about seconds after from ignition switch ON and the immobilizer warning symbol on the LCD starts blinking immobilizer system proble
378. len 2 34 Engine Oil 2 34 Oil ae ret tae p Cu 2 35 Whiels TIreg ice ot trier edd RR RR TR e aee SE MERE THER REN ME REUS XT E 23 Rev ver dr e dea gern 2 36 Air Pressu re InsSpectlOr oido Tete Ee Bere a Rue RE nt ta eie E e E 2 36 Wheels and likes Uh n RERO 2 36 Wheel Bearing Damage Inspection t epos ka a tior sates 2 37 SIME IBIQ Tee LT NUM 2 38 Drive Chain Lubrication Condition Inspection pp 2 38 Drive Chain Slack Inspection 4 2 38 Drive Chain SlackAdj stmerit n tee t cea de Lk ence en et eps dena tedden 2 39 Wheel Alignment Inspection ppp 2 40 Drive Chain Wear Inspection pp 2 40 Chain Guide Wear Inspection 22 2 22 0 2 000 0000000000000 0 0 2 41 2 42 2 42 Brake Fluid Level Inspectigon 88 nnne 2 43 Brake Fluid Gharige 2 2 44 Brake Hose and Pipe Replacement pp 2 46 Master Cylinder Rubber Parts Replacement pp 2 47 Caliper Rubber Parts 8 2 48 Brake Pad Wear Inspection pp 2 52 Brake Light Switch Ope
379. let pipe and delivery pipe e Secure the fuel hoses with the clamps e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to start the engine with the fuel hoses disconnected e Connect Fuel Pump Lead Connector Fuel Level Sensor Lead Connector e Turn the engine stop switch run position e Turn the ignition switch on OThe fuel pump should operate for 3 seconds and then should stop NOTE OAfter turning on the engine stop switch and ignition switch inspect the fuel leakage from the connected portion of the special tools NOTICE Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged Fuel Line FUEL SYSTEM DFI 3 113 e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure with Engine Idling Standard 294 kPa 3 0 kgf cm 43 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications Turn the ignition switch off x If the fuel pressure is much higher than specified replace the fuel pump because the fuel pressure regulator in the
380. lic Unit Rear Wheel Rotation Sensor Rear Wheel Rotation Sensor Rotor ABS Self diagnosis Terminal BRAKES 12 37 Anti Lock Brake System Equipped Models ABS System Wiring Diagram OL 5 1 Ignition Switch 12 ABS Self diagnosis Terminal 2 Front Brake Switch 13 ABS Hydraulic Unit 3 Rear Wheel Rotation Sensor 14 Fuse Box 1 4 Rear Brake Switch 15 ABS Fuse 30A 5 Frame Ground 5 16 Brake Hone Fuse 7 5 6 Frame Ground 1 17 Ignition Fuse 15 A 7 Engine Ground 18 Yellow ABS Indicator Light LED 8 Battery 12 V 8 Ah 19 Meter Unit 9 Starter Relay 20 Joint Connector C 10 Main Fuse 30 A 21 Front Wheel Rotation Sensor 11 ABS Kawasaki Self diagnosis System Connector OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Chooolate O Orange W White DG Dark Green P Pink Y Yellow G Green 12 38 BRAKES Anti Lock Brake System Equipped Models ABS Hydraulic Unit Terminal Names GLi4699BW2 C 2 Unused 3 Unused 4 Front and Rear Brake Light Switch Signal BL R 5 ABS Kawasaki Self diagnosis System Terminal P 6 Power Supply to Rear Wheel Rotation Sensor W G 7 Power Supply BR W 8 Power Supply to Front Wheel Rotation Sensor W BK 9 Ground BK 11 Unused 12 Unused 13 Yellow ABS Indicator Light BL Y 14 ABS Self diag
381. ll the spacer A so that the OUTSIDE mark B faces outward OReplace the clutch hub nut with a new one OHolding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 135 13 8 kgf m 99 6 ft lb e Install the friction plates and steel plates starting with a friction plate and alternating them NOTICE If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure Olnstall the last friction plate A fitting the tangs in the grooves in the housing as shown e Apply molybdenum disulfide grease to the pusher ends A and install the thrust bearing B pusher C spring D and washer E in the clutch spring plate F OApply engine oil to the needle bearing GF06040181 C S GF06158BS1 C Clutch CLUTCH 6 11 eAlign the mark A of the clutch spring plate B with the groove C of the clutch hub e Install Clutch Spring Plate Clutch Springs e Tighten Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the clutch cover see Clutch Cover Installation Clutch Plate Assembly Inspection e Inspect the friction plate thickness see Clutch Plate Wear Damage Inspection e Measure the length A of the clutch plate assembly as shown OAssemble Clutch Hub B Friction Plates C Steel Plates D Clutch Spring Plate E
382. llowing O achete etu ds Cutter angle B sadi aute Outer diameter of cutter C GE15133BS1 C 8 15011851 C Valves ENGINE TOP END 5 31 Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat
383. lts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters ENGINE TOP END 5 15 Clean Air System Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds for cracks folds warps heat damage or other damage xIf there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly x If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Air Switching Valve Removal e Remove Air Suction Valve Covers A see Air Suction Valve Re moval Hoses B Air Switching Valve C Never drop the air switching valve especially on a hardsurface Such a shock to the air switching valve can damaged it Air Switching Valve Installation e Install the air switching valve A with hose B as shown OAlign the white mark C of the hose and center line D of the air switching valve 30 40 E
384. lts V 25 N m 2 5 kgf m 18 ft Ib Upper Engine Bracket Bolts W 44 Nm 4 5 kgf m 32 ft lb O19th remove the right front engine mounting bolt X O20Sst tighten the upper adjusting collar Y until the clear ance between the washer and upper adjusting collar come to 0 mm Torque Upper Adjusting Collar Y 9 8 N m 1 0 kgf m 87 in Ib OLastly tighten the adjusting collar locknut Z and right front engine mounting bolt X Torque Adjusting Collar Locknut Z 49 N m 5 0 kgf m 36 ft lb Front Engine Mounting Bolt X 44 N m 4 5 kgf m 32 ft lb GH04183BW3 C 8 12 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the front engine bracket and horn e Tighten Torque Front Engine Bracket Bolts 11 N m 1 1 kgf m 97 in Ib e When installing the trim A note the following OTouch the trim to the horn bracket B e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant see Coolant Change in
385. ly valve cables Clamps Hold the crankshaft sensor oil pressure switch lead Clamps Hold the oxygen sensor lead Do not pull the oxygen sensor lead by force Oxygen Sensor ZR800A B Models 17 24 APPENDIX Cable Wire and Hose Routing APPENDIX 17 25 Cable Wire and Hose Routing Oo Run the intake air pressure sensor hose to the right side of the throttle cables Intake Air Pressure Sensor 1 Lead Throttle Cable Accelerator Throttle Cable Decelerator Run the main harness throttle cables and intake air pressure sensor hose in order from the upside Clamp Hold the intake air pressure sensor 1 fuel injector lead Insert the projection of the clamp into the frame Intake Air Pressure Sensor Hose Run the air switching valve hose between the main harness and intake air pressure sensor hose Fuel Level Sensor Lead 10 11 12 13 14 15 Run the fuel level sensor lead through the clamps Fuel Pump Lead Run the fuel pump lead through the bracket Sub Fuel Hose Position the mark rearward and face the mark to the front of this figure Rear 17 26 APPENDIX Cable Wire and Hose Routing GB09129E 6 APPENDIX 17 27 Cable Wire and Hose Routing ONDOABRWDNDN oo 11 12 Run the starter relay lead backward the hoses Starter Relay Lead Regulator Rectifier Lead Run the battery positive cable t
386. m L1 Starts blinking about 3 seconds after from ignition switch ON and about 10 seconds after the Fl warning symbol on the LCD starts blinking ECU communication error O Does not blink about seconds after ignition switch ON O light up ECU or meter unit replace Engine stalls O starter motor not rotating L1 starter motor rotating but engine do not turn over O starter motor and engine do not turn over O no fuel flow 0 no fuel in tank O no fuel pump sound no spark other right after starting O when opening throttle grip when closing throttle grip when moving off L1 when stopping the motorcycle O when cruising 3 34 FUEL SYSTEM DFI Troubleshooting the DFI System at low speed Poor running or no power at high speed Poor running O very low idle speed O very high idle speed O rough idle speed Oo battery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it backfiring afterfiring hesitation when acceleration engine oil viscosity too high brake dragging engine overheating clutch slipping other spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it spark plug incorrect replace it knocking fuel poor quality or incorrect use high octane gasoline brake dragging clu
387. m connector cap NOTE OTurn the ignition switch to ON with the registered igni tion key OCheck that the engine can be started using all regis tered ignition keys GP30232CS1 ELECTRICAL SYSTEM 16 89 Immobilizer System Spare Ignition Key Registration Flow Chart ECU checks NG iemmob zer amplifier 4NOTE1 Blinking Patterns and Number ECU checks registered NG 0 2second eg O Seecerd Seeeene gt 2 8 292192 243 teecene gt 3 9303297151 9393093 secerd 4 27 472979 193 01 4 20920 1 0 1 4 5 2 jarcente gt 6 O Connection of Ampl amp er Time of Transmitting and Receiving Signals 2 ECU confirms the folowing Immobilizer Amplifier Fadure Pattern 1 Ignition Key Collation Error Pattern 6 following Insert next key and turn it to within 15 seconds after previous key is turned to OFF Red warning indicator light and symbol banking Patter 4 5 Tum to OFF and remove igation key 2 3 Vacant Register Memory None Red warning indicator igh and symbol goes of ex F 16 90 ELECTRICAL SYSTEM Immobilizer System Case 2 When the ignition switch is faulty and to be replaced e Prepare a new ignition switch A and two new ignition keys B OThese parts are available as a set Prepare the current registered ignition key C e Remove Ignit
388. m forks and rods e Install the shift rods A noting the groove position OThe rods are identical OPosition the one with shortest ears B on the drive shaft and place the pin in the center groove in the shift drum C OThe two forks D on the output shaft are identical e Install the forks so that its 266 and 267 side faces clutch side e Apply a non permanent locking agent to the threads of the shift drum bearing holder bolt and screw and tighten them Torque Shift Drum Bearing Holder Bolt 12 N m 1 2 kgf m 106 in Ib Shift Drum Bearing Holder Screw 5 9 N m 0 60 kgf m 52 in Ib Shift Drum Disassembly Remove the shift drum see Shift Drum and Fork Re moval e While holding the shift drum with a vise remove the shift drum cam holder bolt Shift Drum Cam Holder Bolt A Dowel Pin B Shift Drum Assembly e Be sure to install the dowel pin e Apply a non permanent locking agent to the threads of the shift drum cam holder bolt and tighten it Torque Shift Drum Cam Holder Bolt 12 N m 1 2 kgf m 106 in Ib 9113333851 C 9 34 CRANKSHAFT TRANSMISSION Transmission Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A Shift Fork Gear Groove Wear Inspection Measure the thickness of the shift fork ears A and
389. may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket to the area A where the mating sur face of the crankcase touches the clutch cover gasket Sealant Liquid Gasket TB1211F 92104 0004 e Be sure that the dowel pins B are in position Replace the clutch cover gasket with a new one e Tighten Torque Clutch Cover Mounting Bolts 11 N m 1 1 kgf m 97 in Ib e Install the removed parts see appropriate chapters Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required Remove the clutch cover see Clutch Cover Removal e Pull the lever and shaft assembly straight out of the clutch cover 6 8 CLUTCH Clutch Cover Release Shaft Installation e Apply high temperature grease to the oil seal lips on the upper ridge of the clutch cover e Apply engine oil to the needle bearings in the hole of the clutch cover e Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft e Install the washer B and spring C e Insert the release shaft straight into the upper hole of the clutch cover NOTICE When inserting the release shaft be careful not to remove the spring of the oil seal e Fit the spring A as shown Viewed from Rear B Release Shaft C Clutch Cover D Clutch Cover Disassembly e Remove Re
390. mbly 4 cedo a Master Cylinder Inspection Visual cas Brake Dise REMOVAl cess iet Forte i eee et et agence Brake Disc Installation pp Brake Disc Wear Brake Disc Warp Inspectigom nennen nnne Brake Fl id m eer renti cedes e Pee o eene dede sed e vua ere aea e Brake Fluid Level Brake Fluid Charge odisea te Brake Line Blesdirig uo Een eot bem etta iN IT Brake Hose and Pipe Removallnstallation pp 12 2 BRAKES Brake Hose and Pipe 12 35 Anti Lock Brake System Equipped Models 12 36 ABS Servicing Precautions o ineat recu ruine cadit 12 39 ABS Troubleshooting Outline 3 12 41 Inquiries to RIdOr a ete ee lo ARE ERE en eee e ERREUR 12 44 Selr diagnosis Outlirie 5 debe aos cere te obtu be e buo deis pede n beds 12 46 Self diagnosis Procedures aus Mar tnt d opui vei nee et 12 46 Service Code Clearing Procedures eese 12 47 How to Read Service 22244 4 2 222 12 50 How to Erase Service Codes pp 12 50 Yellow ABS Indicator
391. me chapter Right Throttle Body Cover see Throttle Body Assy Re moval in the Fuel System DFI chapter Cap Bolt A Washer B Spring C Rod D Mounting Bolts E Camshaft Chain Tensioner F Camshaft Chain Tensioner Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Release the stopper B and push the push rod C into the tensioner body D e Install the tensioner body so that the stopper faces up ward e Tighten the tensioner mounting bolts A Torque Camshaft Chain Tensioner Mounting Bolts 11 N m 1 1 kgf m 97 in Ib e Install the rod spring and washer e Tighten the cap bolt B Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 kgf m 15 ft lb e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing 5 20 ENGINE TOP END Camshaft Camshaft Chain Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Crankshaft Sensor Cover see Crankshaft Sensor Re moval in the Electrical System chapter e Position the crankshaft at 1 4 piston TDC TDC mark A for 1 4 Pistons Timing Mark Crankcase Halves Mating Surface B e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts A Camshaft Caps B Camshafts C e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase The crankshaft ma
392. mea sure the width B of the gear grooves x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in x If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15 mm 0 238 0 242 in Service Limit 6 25 mm 0 246 in Shift Fork Guide Pin Drum Groove Wear Inspection e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove x If the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 268 in x If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 7 05 7 20 mm 0 278 0 283 in Service Limit 7 3 mm 0 287 in Gear Dog and Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113014551 9113334851 9113335851 C 9113336851 C WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded LETT 10 2 oc tnr Peu ede
393. molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 5 4 ENGINE TOP END Exploded View ZR800A B Models ENGINE TOP END 5 5 Exploded View mM AR Nm fib T Eras vave owning 69 orme Exhaust Butterfly Valve Actuator Pulley Bolt 0 50 43 in lb 3 Exhaust Butterfly Valve Cable Adjuster Locknuts x 0 70 61 in Ib 4 Muffler Body Mounting Bolts 34 3 5 25 5 Muffler Body End Cover Bolts 11 1 1 97 in Ib 6 Exhaust Butterfly Valve Cover Bolt 11 1 1 97 in lb 7 Muffler Body Cover Bolts 6 9 0 70 61 in Ib 8 Exhaust Pipe Manifold Holder Nuts 17 1 7 13 S 9 Muffler Body Clamp Bolt 17 1 7 13 R Replacement Parts S Follow the specified tightening sequence 5 6 ENGINE TOP END Exploded View ZR800C D Models GE02563885 C ENGINE TOP END 5 7 Exploded View Toque Remarks Nm kgfm ftib Lr mmesew wann sm 3s Muffler Body End Cover Bolts 97 3 Muffler Body Cover Bolts 6 9 0 70 61 in Ib 4 Exhaust Pipe Manifold Holder Nuts 17 1 7 13 S 5 Muffler Body Clamp Bolt 17 1 7 13 R Replacement Parts S Follow the specified tightening sequence 5 8 ENGINE TOP END Exhaust System Exhaust System M
394. move the container from the battery e Place the strip of caps A loosely over the filler ports press down firmly with both hands to seat the strip of caps into the battery don t pound or hammer When properly installed the strip of caps will be level with the top of the battery Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to the battery NOTE OCharging the battery immediately after filling can shorten service life j Se 7 e gue 8 09000751 C ME02114BS1 Hm LJ LJ ue 8 08012851 C 8 08010851 C Battery ELECTRICAL SYSTEM 16 33 Initial Charge e Newly activated sealed batteries require an initial charge Standard Charge 0 9 A x 5 10 hours x lf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO2 Yuasa MB 2040 2060 Christie C10122S xIf the above chargers are not available use equivalent one e Let battery sit 30 minutes after initial charge then check voltage using a voltmeter Voltage immediately after charging becomes temporarily high For accurate mea suring let the battery sit for given time NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used If voltage is
395. n a safety area to store the service code which correspond to the current problems e Remove the rear seat see Rear Seat Removal in the Frame chapter e Ground the self diagnosis terminal A Gray to a frame ground using a suitable auxiliary lead Keep the auxiliary lead ground during self diagnosis procedure e Turn the ignition switch on and read the service code see How to Read Service Code e To exit the self diagnosis mode remove the auxiliary lead from the self diagnosis terminal NOTE OThe grounding auxiliary lead must be removed after the self diagnosis procedure Service Code Clearing Procedures e Start the service code erase mode with the following pro cedure OThe erase mode starts when the ABS self diagnosis ter minal is disconnected from the frame ground after starting the self diagnosis mode OThe service code can be erased by grounding time for at least one second and ungrounding the ABS self diagnosis terminal three times or more within about 12 5 seconds after starting the erase mode and ground ing it OThe yellow ABS indicator light LED remains lit during the erase mode OAfter erasing the yellow ABS indicator light LED blinks two times and lights OOnce erasing is finished enter the self diagnosis mode again to confirm that the service codes have been erased If the ABS has been reset and all codes have been erased the yellow ABS indicator light LED lights 12 48 BRAKES Anti Lo
396. n check the ser vice code When the repair has been done the yellow warning indi cator light LED goes off But the service codes stored in memory of the ECU are not erased to preserve the prob lem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems When the motorcycle is down the vehicle down sensor operates and the ECU shuts off the fuel pump relay fuel in jectors and ignition system The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start When the starter button is pushed the yellow engine warning indicator light LED blinks but the service code is not displayed To start the engine again raise the motorcycle turn the ignition switch off and then ON Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them er 5 P aK NA Bete 8017425 81 C 3 30 FUEL SYSTEM DFI Troubleshooting the DFI System e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors A have seals B including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set C Insert the needle adap
397. n Relay 11 Relay Box 12 Fuse Box 1 13 Ignition Fuse 15 A 14 Joint Connector C 15 Air Switching Valve 16 Frame Ground 1 5 16 68 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Disconnect the radiator fan motor lead connector A e Using an auxiliary leads supply battery power to the fan motor x If the fan does not rotate the fan motor is defective and must be replaced ELECTRICAL SYSTEM 16 69 Radiator Fan System Radiator Fan Circuit a a Lii GPi5i29BW3 C Ignition Switch Joint Connector C Fan Motor Frame Ground 2 Water proof Joint 2 Water Temperature Sensor Frame Ground 1 Joint Connector E ECU 10 Engine Ground 11 Battery 12 V 8 Ah 12 Main Fuse 30 A 13 Starter Relay 14 Relay Box 15 Radiator Fan Relay 16 Fan Fuse 15 A 17 Fuse Box 2 18 Fuse Box 1 19 Ignition Fuse 15 A 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Unit Removal Installation e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter e Slide the dust cover A and disconnect the connector e Remove the meter unit by taking off the mounting screws B with the washers Do not drop the meter unit Place the meter unit so that it faces upward If the meter unit is left upside down or
398. n Rod Nuts 15 1 5 kgf m 11 ft Ib e Remove the fork spring stopper e Align the stoppers A of the top plug B with the grooves C of the clamp D and down the suitable jack e Remove the front fork from the fork spring compressor e Raise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation e Adjust the spring preload see Spring Preload Adjust ment e Adjust the rebound damping force see Rebound Damp ing Force Adjustment Right Front Fork Only GM04409BS1 C 13 20 SUSPENSION Front Fork If using the spring compressor 57001 1587 e Install the clamps A as shown NOTE OSet the clamps so that the cutout B of the upper side does not touch the tongue shape of stopper pull up the outer tube C to hold it by the clamps and then tighten the two bolts D The outer tube is used as a guide Special Tools Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 e Install the holders E to the clamps as shown e Insert the holder bar A into the axle hole of the front fork B Special Tool Bar 57001 1751 For Left Fork Leg OPosition the bar left and right and evenly e Insert the lower end of the compression shaft A into the hole B of the holder bar e Screw the adjust nut A onto the compression shaft as shown About 20 mm 0 79 in B e Screw the locknut C e Set the other side compression sh
399. n Sensor Circuit GC17595ES1 HO 6C17434FW2 1 Vehicle down Sensor 2 Water Proof Joint 1 3 Water Proof Joint 2 4 ECU 3 76 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C Subthrottle Sensor Removal Adjustment Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the subthrottle sen sor can damage it Subthrottle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Remove the left throttle body cover see Throttle Body Assy Removal e Disconnect the subthrottle sensor and connect the har ness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Subthrottle Sensor Input Voltage Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor G lead e Measure the input voltage with
400. n damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the rear sprocket nuts A e Remove the rear sprocket B Rear Sprocket Installation e Install the sprocket facing the tooth number marking A outward e Replace the rear sprocket nuts with new ones e Tighten Torque Rear Sprocket Nuts 59 N m 6 0 kgf m 44 ft Ib e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter 11 12 FINAL DRIVE Sprocket Coupling Coupling Installation e Apply high temperature grease to the following Coupling Grease Seal Lips A Coupling Internal Surface B Replace the O ring A with a new one e Apply grease to the O ring e Install the collar B Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers 57001 143 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 Coupling Bearing Installation e Replace the bearing with a new one e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 GK05040BS1 C GK05038BS1 C Sprocket Coupling FINAL DRIVE 11 13 Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end
401. n order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 34 984 35 000 mm 1 3773 1 3780 in Service Limit 34 97 mm 1 3768 in x If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 34 984 34 992 mm 1 3773 1 3776 in 34 993 35 000 mm 1 3777 1 3780 in A Crankpin Diameter Marks O or no mark 6105041781 6105040BS1 9 22 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Measure the connecting rod big end inside diameter mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 38 000 38 008 mm 1 4961 1 4964 in 38 009 38 016 mm 1 4964 1 4967 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark Select the proper bearing insert A in accordance with the combination of the connecting ro
402. n properly 6007013851 C GD07001BS1 C COOLING SYSTEM 4 15 Thermostat Thermostat Removal Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the side fairings see Side Fairing Removal in the Frame chapter e Loosen the water hose clamp screws A e Disconnect the water hoses B e Disconnect the immobilizer amplifier connector A and water temperature sensor lead connector B e Remove Radiator Cap Thermostat Bracket Bolt C e Disconnect the reserve tank hose D e Remove the thermostat housing E e Remove Thermostat Housing Screws A Cap B Thermostat 6009006851 C Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top e Apply grease to the new O ring e Install a new O ring into the housing e Tighten Torque Thermostat Housing Screws 2 6 N m 0 27 kgf m 23 in Ib e Run the hoses correctly see Cable Wire and Hose Rout 6009004851 ing section in the Appendix chapter e Tighten Torque Thermostat Bracket Bolt 6 9 N m 0 70 kgf m 61 in Ib Water Hose Clamp Screws 3 0 0 31 kgf m 27 in Ib e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter e Install the removed parts see appropriate chapters 4 16 COOLING SYSTEM Thermostat Thermostat Inspection Remove the thermostat see Thermostat Rem
403. n the LCD by the number of two digits OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order OThen after completing all codes the display is repeated until the ignition switch is turned OFF or left button is pushed for more than two seconds OFor example if three problems occurred in the order of 56 11 33 the service codes are displayed each two seconds from the lowest number in the order listed as shown below 11 gt 33 gt 56 gt 11 gt 33 gt 56 lt repeated GCi7514FW2 C Olf there is no problem or when the repair has been done yellow engine warning indicator light LED and or immobilizer warning symbol go off and service code is not displayed Service Code Erasing OWhen repair has been done yellow engine warning indicator light LED and or immobilizer warning symbol go off and service code is not displayed But the service codes stored in memory of the ECU are not erased to preserve the problem history In this model the problem history can not be erased Self Diagnosis FUEL SYSTEM DFI 3 45 Service Code Table Service Code System Problems 11 FI Main throttle sensor malfunction wiring open or short 12 Intake air pressure sensor 1 malfunction wiring open or short Intake air temperature sensor malfunction wiring open or short 44000 Water temperature
404. n the display x If the yellow engine warning indicator light LED does go on and or the LCD segments do not blink replace the meter assembly NOTE OThis meter unit has a failure detection function of the communication When the communication error was detected the meter unit alerts the rider by the yellow engine warning indicator light LED goes on and the LCD segments blinking in the display e Disconnect the terminal 15 OAII the LCD segments disappear OThe red warning indicator light LED A starts blinking see Abstract section in the Immobilizer System f the segments do not disappear replace the meter as sembly 0 170650 6 0 170670 6 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 73 Check 2 Meter Communication Line Service Code 39 Check e Connect the leads in the same circuit as Check 1 e Wait 10 seconds and the yellow engine warning indicator light LED goes on e Set the ODO mode A by pushing the left button B e Push the left button for more than 2 seconds e Check the following items OThe number 39 A in the display appear and yellow en gine warning indicator light LED B goes on e Push the left button for more than 2 seconds e Check the following items OThe display returns ODO mode from number 39 OThe yellow engine warning indicator light LED goes on x If the meter unit does not work replace the meter assem bly
405. nd Pipe Inspection in the Peri odic Maintenance chapter 4 18 COOLING SYSTEM Water Temperature Sensor The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to the water temperature sensor can damage it Water Temperature Sensor Removal Installation e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded Exhaust Specifications Special Tools and Sealant Clean Air System Air Suction Valve Remowval Air Suction Valve Installation Air Suction Valve Inspection Air Switching Valve Removal Air Switching Valve Installation Air Switching Valve Operation Air Switching Valve Unit Test Clean Air System Hose Cylinder Head Cylinder Head Cover Removal Cylinder Head Cover Installation Camshaft Chain Tensioner Camshaft Chain Tensioner Camshaft Chain Installation
406. nd radial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings see Hub Bearing Inspection If the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in A WARNING Damaged wheel parts may fail and cause an acci dent resulting in serious injury or death Never at tempt to repair a damaged wheel part If the wheel part is damaged it must be replaced with a new one Axle Inspection e Remove the front and rear axles see Front Rear Wheel Removal e Visually inspect the front and rear axle for damages x If the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout x If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 2 mm 0 008 in GJ04130BS1 GJ04043BS1 C WHEELS TIRES 10 11 Wheels Rims Balance Inspection Remove the front and rear wheels see Front Rear Wheel Removal e Support the wheel so that
407. ness adapter leads Vehicle down Sensor Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter BK sensor G lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch off x If the reading is within the standard check the output volt age see Vehicle down Sensor Output Voltage Inspec tion xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Vehicle down Sensor Connector B BL lead ECU terminal 5 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GT04091BS1 C GC17594ES1 C 3 74 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 Vehicle down Sensor Output Voltage Inspection e Remove the vehicle down sensor see Vehicle down Sensor Removal e Connect the harness adapter A to the vehicle down sen sor connectors as shown Special Tool Measuring Adapter 57001 1700 Main Harness B Vehicle down Sensor C e Connect a digital meter
408. ng in Relay Box Radiator Headlight Circuit Relay EGU Main Relay Fan Relay Fuel Pump Relay Starter Circuit Relay Rano 2 Turn Signal Switch 3 Hazard Switch 4 Dimmer Switch 5 Passing Button 6 Starter Lockout Switch LEFT SWITCH HOUSING C Horn Button Hazard Switch Turn Signal Switch ONNECTIONS Dimmer Switch Starter Lockout Switch Passing Button Color BK WBK Y Color o GY e Ler R BKBL Y Color Push Push DFF Push Released TERRI 1 2 210779 5 C ELECTRICAL SYSTEM 16 19 Wiring Diagram ZR800A with GPS Unit Sub throttle Main Sub Valve Throttle throttle Speed Actuator 6 Senior Sensor Intake serien qni Oxygen Air Air ees nk sige Sensor Pressure Pressure i las Fuel Injectors Sensorsz Sensors Sensor Sensor ace Switch t tl dae 1 1 fe ge ge 2 8 wed ruse Tu az iz Fui Water great 5 rs d Joint Ea i proof 2 ak D BL Y WA EN E m L1 a BK Y TIRAM im deine Jm pee Ecu BK Y BK Y P K Le dE HE HET EE wae i IL L5 BK Y 20 Joint BK Y BY Connector D 1 Frame
409. ng Inspection ECU Connector Crankshaft Sensor Connector B Y lead ECU terminal 20 C YIBK lead ECU terminal 21 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Crankshaft Sensor Circuit GC17473FS1 C D 0 Y Y BK Y 8K Y 1 Crankshaft Sensor 2 ECU GC17433FW2 C Speed Sensor Service Code 24 FUEL SYSTEM DFI 3 69 Speed Sensor Removal Installation e Refer to the Speed Sensor Removal Installation in the Electrical System chapter Speed Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Disconnect the speed sensor connector and connect the harness adapter A between these connectors Special Tool Speed Sensor Measuring Adapter 57001 1667 e Connect a digital meter to the harness adapter leads Speed Sensor Input Voltage Connections to Adapter Digital Meter BL sensor BL lead Digital Meter BK Y sensor G lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch off x If the reading is within the standard check the output volt age see Speed Sensor Output Voltage Inspec
410. nnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor 2 Connector B G W lead ECU terminal 16 C G lead ECU terminal 33 D xIf the wiring is good check the sensor for various vac uum see Intake Air Pressure Sensor 1 Output Voltage Inspection GC17589ES1 FUEL SYSTEM DFI 3 67 Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Circuit D 2 1 Water Proof Joint 1 2 Water Proof Joint 2 3 Intake Air Pressure Sensor 2 4 ECU 3 68 FUEL SYSTEM DFI Crankshaft Sensor Service Code 21 The crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Resistance Inspection e Refer to the Crankshaft Sensor Inspection in the Electrical System chapter x If the reading is within the standard check the peak volt age see Crankshaft Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Inspection e Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiri
411. nosis Terminal GY 15 Rear Wheel Rotation Sensor Signal Input BK O 16 Unused 17 Front Wheel Rotation Sensor Signal Input BK W 18 Power Supply to ABS Motor Relay R W Anti Lock Brake System Equipped Models BRAKES 12 39 ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system OThis ABS system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ABS hydraulic unit OTo prevent damage to the ABS parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground ODo not turn the ignition switch on while any of the ABS electrical connectors are disconnected The ABS hy draulic unit memorizes service codes not spray water on the electrical parts ABS parts con nectors leads and wiring Olf a transceiver is installed on the motorcycle make sure that the operation of the ABS system is not influenced by electric wave radiated from the antenna Locate the antenna as far as possible away from the ABS hydraulic unit OWhenever the ABS electrical connections are to be dis connected first
412. nsure proper handling and stability use only the recommended standard tires for replacement inflated to the standard pressure WHEELS TIRES 10 5 Special Tools Bearing Driver Set Bearing Remover Shaft 013 57001 1129 57001 1377 7571129ST C ST5713778T C Jack Jack Attachment 57001 1238 57001 1608 7 L 7571238ST C 7571608ST C Bearing Remover Head 20 x 22 57001 1293 7571293ST C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Front Caliper Mounting Bolts A Both Sides Front Caliper B Both Sides OZR800A B D Models C OZR800C Model D e For ABS equipped models remove the front wheel rota tion sensor see Front Wheel Rotation Sensor Removal in the Brake chapter e Loosen Front Axle Clamp Bolt A Front Axle B e Remove Lower Fairing see Lower Fairing Removal ZR800A B Models in the Frame chapter Oxygen Sensor see Oxygen Sensor Removal in the Electrical System chapter e Raise the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Pull out the axle to the right and drop the front wheel out of the forks NOTICE Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground WHEELS TIRES 10 7 Wheels Rims Front Wheel Installation NOTE OThe direction of the wheel rota
413. nt Connector E ECU Joint Connector D Immobilizer Kawasaki Diagnostic System Connector Frame Ground 4 Frame Ground 3 Frame Ground 2 Frame Ground 1 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15A Fuse Box 2 Radiator Fan Fuse 15 Fuel Pump Relay Box Fuel Pump Relay ECU Main Relay Radiator Fan Relay Fuse Box 1 Ignition Fuse 15 A Meter Unit Tachometer Yellow Engine Warning Indicator Light Joint Connector C Immobilizer Antenna Immobilizer Amplifier Ignition Switch Engine Stop Switch Starter Button Fan Motor Stick Coil 1 Stick Coil 2 Stick Coil 3 Stick Coil 4 Air Switching Valve Vehicle down Sensor Intake Air Temperature Sensor Speed Sensor Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Subthrottle Valve Actuator Main Throttle Sensor Water Proof Joint 2 Water Proof Joint 1 Subthrottle Sensor Intake Air Pressure Sensor 2 Intake Air Pressure Sensor 1 Water Temperature Sensor Crankshaft Sensor 3 18 FUEL SYSTEM DFI DFI System OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Chocolate O Orange W White DG Dark Green P Pink Y Yellow G Green Terminal Numbers of ECU Connectors ZR800C D Models
414. nt locking agent MO Apply molybdenum disulfide grease oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts W Apply water WL Apply soap and water solution or rubber lubricant col l DOD OOI DPI 4 4 COOLING SYSTEM Coolant Flow Chart Pp PI A 7 ae p pi e A uy SM 70 2464 3 O lt 8004168885 C COOLING SYSTEM 4 5 Coolant Flow Chart 1 Front 8 Radiator 2 Reserve Tank 9 Cylinder Head Jacket 3 Reserve Tank Overflow Hose 10 Cylinder Jacket 4 Reserve Tank Hose 11 Oil Filter 5 Radiator Cap 12 Water Pump 6 Thermostat Housing 13 Hot Coolant 7 Water Temperature Sensor 14 Cold Coolant Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro sion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is less than 55 C 131 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 58 62 C 136 144 F the thermostat opens and the coolant flo
415. nt locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack Standard Chain 20 30 mm 0 8 1 2 in Drive Chain Wear 20 link Length 317 5 318 2 mm 12 50 12 53 in 319 mm 12 6 in Make ENUMA Type EK520MVXL2 Link 114 links Sprockets Rear Sprocket Warp TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 7571129ST C 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter Drive Chain Removal installation e Remove Chain Cover Bolts A Chain Cover B Engine Sprocket Cover see Eng
416. nting Bolts C Footpeg Bracket Bolts D Muffler Body Mounting Bolt E and Nut Master Cylinder BRAKES 12 29 Remove Cotter Pin A Joint Pin B Bolt C Rear Master Cylinder D e Slide out the clamp E Pull off the reservoir hose lower end and drain the brake fluid into a container Rear Master Cylinder Installation e Install the reservoir hose lower end and Install the clamp e Tighten the bolt A e Replace the cotter pin B with a new one e Insert the cotter pin to the hole of the joint pin C and separate the cotter pin ends D e Install the footpeg bracket e Tighten Torque Footpeg Bracket Bolts 30 N m 3 1 kgf m 22 ft Ib Muffler Body Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib e Replace the washers that are on each side of the hose fitting with new ones e Install the brake hose OTouch the brake hose to the stopper of the rear master cylinder e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Install the cover e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage Front Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenanc
417. nto the throttle assy the throttle may become stuck pos sibly causing accident Replace the air cleaner ele ment according to the maintenance chart If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Remove the element see Air Cleaner Element Replace ment e Clean the element by tapping it lightly to loosen dust e Blow away the remaining dust by applying compressed air A from the outside to the inside from the clean side to the dirty side e Visually inspect the element for no tears or no breaks and inspect the sponge gasket B also x If the element or gasket has any tears or breaks replace the element Air Cleaner Element Replacement NOTE Oln dusty areas the element should be replaced more frequently than the recommended interval A WARNING If dirt or dust is allowed to pass through into the throttle assy the throttle may become stuck pos sibly causing accident Replace the air cleaner ele ment according to the maintenance chart NOTICE If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Bolts A Fuel Tank Bracket B Remove the air cleaner duct screws A Remove the air cleaner duct B backward e Discard the air c
418. nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at time maximum e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Install the stem head e Tighten Torque Steering Stem Head Bolt 108 N m 11 0 kgf m 79 7 ft lb Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft lb Check the steering again x If the steering is still too tight or too loose repeat the ad justment e Install the removed parts see appropriate chapters Steering Stem Bearing Lubrication e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage e Pack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Ad
419. o not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified Recommended Disc Brake Fluid Grade DOT4 e Follow procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake OT TT PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures e Level the brake fluid reservoir e Remove the reservoir cap diaphragm plate and di aphragm e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4
420. o not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Service Limit 0 07 mm 0 0028 in x If the clearance is within the standard no bearing replace ment is required x If the clearance is between 0 045 mm 0 0018 in and the service limit 0 07 mm 0 0028 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 32 984 33 000 mm 1 2986 1 2992 in Service Limit 32 96 mm 1 2976 in x If any journal has worn past the service limit replace the crankshaft with a new one xIf the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 32 984 32 992 mm 1 2986 1 2989 in 1 32 993 33 000 mm 1 2989 1 2992 in Crankshaft Main Journal Diameter Marks 1 or no mark
421. o the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the potential for serious burns Make sure the area is well venti lated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch off Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it e Remove Fuel Tank see Fuel Tank Removal Pad A e Disconnect the alternator lead connector A Open the clamp B and pull the alternator lead connector downward FUEL SYSTEM DFI 3 127 Throttle Body Assy e Remove Throttle Body Cover Mounting Bolt A Quick Rivet B Right Throttle Body Cover C e Remove Throttle Body Cover Mounting Bolt A Left Throttle Body Cover B e Remove the intake air pressure sensor 1 2 see Intake Air Pressure Sensor 1 2 Removal e Disconnect Air Switching Valve Hose Fuel Injector Connectors 1 4 A Subthrottle Valve Actuator Harness Connector B Main Throttle Sensor Connector C Subthrottle Sensor Connector D Open the clamp A e Remove Screws A Right Switch Housing B e 3 128 FUEL SYSTEM DFI
422. o the outside of the regulator rectifier lead Starter Motor Cable Battery Positive Cable Run the starter motor cable between the bracket and air cleaner housing Insert projection of the rear wheel rotation sensor connector into the frame ABS equipped mod els Run the rear wheel rotation sensor lead under the ABS brake pipes ABS equipped models Run the rear wheel rotation sensor lead to the inside of the exhaust butterfly valve cables ABS equipped models Battery Negative Cable Run the battery negative cable through the clamp Run the battery negative cable to the inside of the ABS brakes hose ABS equipped models ZR800A B Models 17 28 APPENDIX Cable Wire and Hose Routing 58091306 6 Run the regulator rectifier lead the outside of the battery positive cable Run the regulator rectifier lead under the cross pipe Battery Positive Cable Regulator Rectifier Lead Clamp Hold the regulator rectifier lead Insert the projection of the clamp into the frame Run the battery negative cable to the inside of the ABS brake hoses ABS equipped models Run the battery negative cable through the clamps Run the battery negative cable under the cross pipe Starter Motor Cable Run the air cleaner drain hose to the outside of the starter motor cable Air Cleaner Drain Hose APPENDIX
423. oil 2 BK R 48 Ground P 49 Ground BK Y 50 External Communication Line Immobilizer System KDS GY BL 51 Meter Unit Tachometer LB 52 Immobilizer Amplifier P BK 53 Ground for Fuel System BK Y 54 Ground for Ignition System BK Y KDS Kawasaki Diagnostic System 3 20 FUEL SYSTEM DFI DFI Parts Location Main Throttle Sensor A Subthrottle Sensor B Fuel Injectors 1 2 3 4 C Crankshaft Sensor A Oxygen Sensor B Ignition Key Transponder A Ignition Switch B Immobilizer Antenna C Yellow Warning Indicator Light LED D Stick Coils 1 2 3 4 A Air Switching Valve B Subthrottle Valve Actuator A Speed Sensor B LED FUEL SYSTEM DFI 3 21 DFI Parts Location Water Temperature Sensor A Intake Air Pressure Sensor 2 B Intake Air Pressure Sensor 1 C Immobilizer Amplifier D Vehicle down Sensor E Intake Air Temperature Sensor A Exhaust Butterfly Valve Actuator ZR800A B Models A Fuse Box 2 B Radiator Fan Fuse 15 A Fuse Box 1 C Ignition Fuse 15 A Battery 12 V 8 Ah D Relay Box A ECU Main Relay Radiator Fan Relay Fuel Pump Relay ECU B Immobilizer Kawasaki Diagnostic System Connector C Fuel Pump A 3 22 FUEL SYSTEM DFI Specifications Item Standard Digital Fuel Injection System Idle Speed Throttle Body Assy Throttle Valve Bore Throttle Body Vacuum Bypass Screws Turn Out ECU
424. oltage appeared repair or replace the main harness x If the battery voltage does not appear go to next step Step 5 e Check the voltage between the terminal 9 BK A and terminal 6 W G B of the ABS hydraulic unit connector Special Tool Hand Tester 57001 1394 OThe battery voltage 10 16 V should not appear while the ignition switch turned off x If the battery voltage appeared repair or replace the main harness x If the battery voltage does not appear replace the ABS hydraulic unit 9114707851 9114709851 9000900 2000 BUCO GL14708BS1 GL14710BS1 BRAKES 12 55 Anti Lock Brake System Equipped Models ABS Unit Solenoid Valve Inspection Service Code 13 14 17 18 OThese codes indicate there is a problem in the solenoid valves which integrated into the ABS Hydraulic Unit Therefore the solenoid valves cannot be checked directly e Check the system connectors for loose or poorly contact e In order to confirm a existing problem in the system erase the service code and then perform the pre diagnosis in spection 1 and 2 x If same service code is indicated again faulty solenoid valve in the ABS hydraulic unit Replace the ABS hy draulic unit x If the service code does not indicate ABS system is nor mal service code is not stored temporary failure ABS Solenoid Val
425. ond Ne GP30227C81 16 94 ELECTRICAL SYSTEM Immobilizer System Ignition Key Collation Error e The ignition key 2 is successfully registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 3 times and stops for 1 second and then repeat this cycle to indicate successful pro gramming of ignition key 2 e Turn to OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends e The red warning indicator light LED A goes off e Remove the key registration unit key registration adapter and install the immobilizer Kawasaki diagnostic system connector cap NOTE OTurn the ignition switch to ON with the registered igni tion key OCheck that the engine can be started using all regis tered ignition keys e Install the new ignition switch see Immobilizer System Parts Replacement Case 3 When the ECU is faulty and has to be replaced e Prepare a new ECU A and current registered ignition key s B NOTE OThe key registration unit is not required OAfter replacing the ECU be sure to register the 2 ignition keys If the 2 keys are not registered the engine can not be started 0 3second ULL 8 30229051 0 30 3 1second LLL GP30230C81 OHTE GP30232C81 GP30823BS1 ELECTRICAL SYSTEM 16 95 Immobilize
426. ont of the motorcycle e Free the clutch inner cable tip from the clutch release lever e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Operation Inspection in the Periodic Maintenance chapter e Install the removed parts see appropriate chapters Clutch Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the punch mark B e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Clutch Lever Clamp Bolts 11 1 1 kgf m 97 in Ib CLUTCH 6 7 Clutch Cover Clutch Cover Removal Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Right Subframe Cover see Subframe Cover Removal in the Frame chapter Right Lower Fairing see Lower Fairing Removal ZR800A B Models in the Frame chapter Clutch Cable Lower End A Clutch Cover Mounting Bolts B e Turn the release lever A toward the rear as shown and remove the clutch cover B About 90 C Clutch Cover Installation e Using a high flash point solvent clean off any oil or dirt that
427. or Cover Alternator Cover Installation e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Liquid Gasket TB1211F 92104 0004 e Check that dowel pins B are in place on the crankcase e Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 15 N m 1 5 kgf m 11 ft Ib e Run the alternator lead and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Charging System ELECTRICAL SYSTEM 16 37 Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolt A and Plate Alternator Lead Grommet B Stator Coil Bolts C Stator Coil D Stator Coil Installation e Apply a non permanent locking agent to the threads of the stator coil bolts and tighten them Torque Stator Coil Bolts 12 N m 1 2 kgf m 106 in Ib Secure the alternator lead with a holding plate e Apply a non permanent locking agent to the threads of the plate bolt and tighten it Torque Alternator Lead Holding Plate Bolt 12 N m 1 2 kgf m 106 in Ib e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating are
428. ors in the circuit are clean and tight and examine leads for signs of burning fraying short etc Deteriorated leads and bad connections can cause reappearance of problems and unstable operation of the DFI system If any wiring is deteriorated replace the wiring 9617572051 6017037351 Troubleshooting the DFI System FUEL SYSTEM DFI 3 31 e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the main harness or the subharness OIf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground
429. oth e Install the starter clutch gear A e Again clean the crankshaft tapered portion B and dry there Fit the woodruff key C securely in the slot in the crank shaft before installing the alternator rotor e Install the alternator rotor A while turning B the starter clutch gear C ELECTRICAL SYSTEM 16 39 Charging System e Using a cleaning fluid clean off any oil or dirt on the washer A and dry it with a clean cloth Install the washer NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque e Install the rotor bolt A and tighten it with 70 N m 7 0 kgf m 52 ft lb of torque Special Tools Grip B 57001 1591 Stopper C 57001 1679 Rotor Holder D 57001 1690 Remove the rotor bolt and washer e Check the tightening torque with flywheel puller Special Tool Flywheel Puller Assembly M38 1 5 M35 x 1 5 57001 1615 xIf the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly x If the rotor is pulled out with under 20 N m 2 0 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and washer and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Tighten the alternator rotor bolt while holding the alterna tor rotor steady with the rotor holder Special Tools Gr
430. otor Clutch Removal Installation e Refer to the Alternator Rotor Removal Installation in the Electrical System chapter Starter Motor Clutch Inspection e Remove Alternator Cover see Alternator Cover Removal in the Electrical System chapter Starter Idle Gear and Shaft e Turn the starter motor clutch gear A by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C x If the starter motor clutch does not operate as it should or if it makes noise go to the next step e Disassemble the starter motor clutch and visually inspect the clutch parts x If there is any worn or damaged part replace it NOTE OExamine the starter motor clutch gear as well Replace it if it worn or damaged Starter Motor Clutch Disassembly e Remove the alternator rotor see Alternator Rotor Re moval in the Electrical System chapter e Hold the alternator rotor with the flywheel holder A Special Tool Flywheel Holder 57001 1313 e Remove the starter motor clutch bolts B e Remove Starter Motor Clutch Housing A Starter Motor Clutch B 078162 P Starter Motor Clutch Assembly e Install the starter motor clutch to the housing so that the flange A fit to the housing groove B e Apply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 12 N m 1 2 kgf m 106 in Ib 9 26 CRANKSHAF
431. ough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GB02082BS1 C GENERAL INFORMATION 1 7 Model Identification ZR800AD Europe Left Side View 62038699 P ZR800AD Europe Right Side View 62038700 1 8 GENERAL INFORMATION Model Identification ZR800BD Europe Left Side View euo ZR800BD Europe Right Side View 62038702 GENERAL INFORMATION 1 9 Model Identification ZR800CD Left Side View ZR800CD Right Side View 1 10 GENERAL INFORMATION Model Identification ZR800DD Left Side View 62038707 ZR800DD Right Side View GENERAL INFORMATION 1 11 General Specifications ltems ZR800AD BD CD DD Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Curb Mass ZR800A ZR800B ZR800C ZR800D Front ZR800A ZR800B ZR800C ZR800D Rear ZR800A ZR800B ZR800C ZR800D Fuel Tank Capacity 2 100 mm 82 68 in 800 mm 31 50 in 1 050 mm 41 34 1 445 mm 56 89 in 150 mm 5 91 in 834 mm 32 83 in 229 kg 504 9 Ib 231 kg 509 4 Ib 226 kg 498 3 Ib 228 kg 502 7 Ib 116 kg 255 8 Ib 117 kg 258 0 Ib 114 kg 251 4 Ib 115 kg 253 6 Ib 113 kg 249 2 Ib 114 kg 251 4 Ib 112 kg 247 0 Ib 113 kg 249 2 Ib 17 L
432. oval the Fuel System DFI chapter e Slide back the rubber cap A Remove the starter motor cable terminal nut B e Remove the mounting bolts C Pull out the starter motor D Starter Motor Installation Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Replace the O ring A with a new one e Apply grease to the O ring e Tighten Torque Starter Motor Mounting Bolts 11 N m 1 1 kgf m 97 in lb e Install the starter motor cable e Tighten Torque Starter Motor Cable Terminal Nut 4 9 N m 0 50 kgf m 43 in Ib e Install the removed parts see appropriate chapters Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Remove the starter motor through bolts A and remove the both end covers B and pull the armature out of the yoke C 16 54 ELECTRICAL SYSTEM Electric Starter System OThe brush plate A and brushes come off with the right hand end cover 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 GP11116BS1 C Starter Motor Assembly e Replace the O rings A with new ones GP11117BS1 C e Install the brush plate so that the notch A of t
433. oval and inspect the thermostat valve A at room temperature x If the valve is open replace the thermostat with a new one To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 58 62 C 136 144 F A SS 6009000851 C 6009020252 C COOLING SYSTEM 4 17 Hose and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses see Cable Wire and Hose Routing sec tion in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre Bis vent the clamps from contacting the other parts Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in lb MN USS Hose Inspection e Refer to the Water Hose a
434. p blinking Verified OThe red warning indicator light LED and immobilizer warning symbol A blink to display the ECU is in the registration mode go to the next step L IL GP30233CS1 L 0 2second A GP30228CS1 0 3second A Be ULL GP30229CS1 0 5second 0 5second oh p GP30227C81 16 92 ELECTRICAL SYSTEM Immobilizer System e Disconnect the immobilizer antenna connector then con nect the antenna connector of the new ignition switch e Insert the ignition key 1 A again into the new ignition switch and turn it to ON NOTE Olnsert the next key and turn it to ON within 15 sec onds after previous key is turned to OFF and removed otherwise registration mode will be ended and the red warning indicator light LED and immobilizer warning symbol stop blinking OTo return to the registration mode start the registered ignition key verification procedure This applies to all ignition key registration OKeep other ignition keys away from the ignition switch Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error 0 2second A
435. pecial Tool Engine Mount Nut Wrench 57001 1450 875714505 C ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Support the rear part of the swingarm with a stand Squeeze the brake lever slowly and hold it with a band A A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine NOTICE Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Side Fairings see Side Fairing Removal in the Frame chapter Frame Covers see Frame Cover Removal in the Frame chapter Lower Fairings see Lower Fairing Removal ZR800A B Models in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Clutch Cable Lower End see Clutch Cable Removal in the Clutch chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Thermostat Housing see Thermostat Removal in the Cooling System chapter Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top
436. pecified range use the additional shim Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance e When installing the shim face the marked side toward the valve lifter At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation NOTICE Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage Apply engine oil to the valve lifter surface and install the lifter e Install the camshaft see Camshaft Installation in the En gine Top End chapter Recheck the valve clearance and readjust if necessary e Install the removed parts see appropriate chapters Air Suction System Damage Inspection e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the air switching valve hose A out of the air cleaner housing e Start the engine and run it at idle speed e Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose xIf there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test in the Electrical Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter
437. pecified tightening sequence Si Apply silicone grease 12 8 BRAKES Exploded View 6L02534BW5 C BRAKES 12 9 Exploded View Fastener N m 1 BekeHosBanoBols 25 2 Rear Master Cylinder Mounting Bots 25 _ 4 Rear Master Cylinder Push Rod Locknut 172 175 127 _ 6 Rear Brake Disc Mounting Bots 27 28 2 t T RearBrakePadPin 172 175 i27 8 Rear Brake Paa Pin Pug 25 025 in 9 BeedVave __ 08 DIN TO RewCalperMomdngBot 22 22 16 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease 12 10 BRAKES Exploded View ABS Equipped Models 6102538 5 C Exploded View BRAKES 12 11 Fastener N m Torque kgf m Remarks ft lb Brake Hose Banjo Bolts 25 2 5 1 5 Front Master Cylinder Reservoir Cap Screws Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Front Master Cylinder Clamp Bolts 6 Front Brake Light Switch Screw Brake Hose Banjo Bolts ABS Hydraulic Unit 8 Bleed Valves 7 8 9 Front Caliper Assembly Bolts 22 2 2 Front Caliper Mounting Bolts 25 2 5 Front Brake Pad Pins 5 9 11 17 2 0 15 0 10 0 60 1 1 0 12 0 80 1 75 69 Front Brake Disc Mounting Bolts 27 2 8 B Apply brake fluid L Apply a non permanent locking agent R
438. pection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17583bS1 3 66 FUEL SYSTEM DFI Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Output Voltage Inspection e Measure the output voltage at the intake air pressure sen sor 2 in the same way as input voltage inspection note the following ODisconnect the intake air pressure sensor 2 connector and connect the measuring adapter A between these connectors Main Harness B Intake Air Pressure Sensor 2 C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Pressure Sensor 2 Output Voltage Connections to Adapter Digital Meter gt Y sensor G W lead Digital Meter BK sensor lead e Measure the output voltage with the engine stopped and with the connector joined 6T040878S1 e Turn the ignition switch on Output Voltage Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg absolute NOTE OThe output voltage changes according to the local at mospheric pressure e Turn the ignition switch off x If the reading is out of the usable range replace the sen Sor xIf the reading is within the usable range remove the ECU and check the wiring for continuity between harness con nectors Special Tool Hand Tester 57001 1394 ODisco
439. permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence W Apply water 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Clutch Plate Assembly Length Friction Plate Thickness Friction and Steel Plate Warp Clutch Spring Free Length 37 7 38 3 mm 1 48 1 51 in 2 72 2 88 mm 0 107 0 113 in 0 15 mm 0 0059 in or less 64 1 mm 2 52 in 2 4 mm 0 094 in 0 3 mm 0 012 in 61 2 mm 2 41 in CLUTCH 6 5 Special Tool and Sealant Clutch Holder Liquid Gasket TB1211F 57001 1243 92104 0004 gt 7571243ST C 879200045 6 6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Removal e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Slide the dust cover A at the clutch cable lower end out of place e Loosen the nuts B and slide the lower end of the clutch cable to give the cable plenty of play e Screw in the adjuster e Line up the slots A in the clutch lever and adjuster B and then free the cable from the lever e Push the release lever toward the fr
440. pillage OWhen installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals 617036881 FUEL SYSTEM DFI 3 27 DFI Servicing Precautions Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose to burst Remove the fuel tank see Fuel Tank Removal and check the fuel hose Fuel Intake Hose A Fuel Outlet Hose B Replace the fuel hose if any fraying cracks or bulges are noticed Epica OTo maintain the correct fuel air mixture F A there must be no intake air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Torque Oil Filler Plug 2 0 N m 0 20 kgf m 18 in Ib 3 28 FUEL SYSTEM DFI Troubleshooting the DFI System Outline When a problem occurs with DFI system the yellow en gine warning indicator light LED A goes on to alert the rider GT04217BS1 When a problem occurs with immobilizer system the red warning indicator light LED A blinks and immobi lizer warning symbol B is displayed on the LCD when a problem occurs in the system
441. ping Force Adjustment ZR800A B Models Right Front Fork Only 13 13 Spring Preload Adjustment ZR800A B Models 13 13 Front Fork Removal Each Fork Leg pp 13 14 Eront Fork Installation nire rene ete te te ede t lve e pee n e eel eat 13 14 Front Fork Oil Change ZR800A B Models m 13 14 Front Fork Oil Change ZR800C D Models 13 25 Front Fork Disassembly a 13 32 Front Fork Assembly isiksi eer tela 13 34 Inner Tube Outer Tube Inspection 0 0000010001 13 35 Dust Seal 13 35 Spring TENSION Inspection ee TERI eO EN esr ute Lese ee dds He 13 35 Rear Shock Absorber esses eene aie Ee a ne nnne nnne e nene 13 36 Rebound Damping Force Adjustment ZR800A B 13 36 Spring Preload Adjustment ZR800A B Models se 13 36 Spring Preload Adjustment ZR800C D 13 37 Rear Shock Absorber 13 38 Rear Shock Absorber 13 39 Rear Shock Absorber 13 39 Rear Shock Absorber Scrapping RN 13 39 SWING AN esis vto EL Mas Ne te na Swingarm REMOVAL o erbe Roi i Swingarm Installation Swin
442. placement Intake Air Pressure Sensor 1 see Intake Air Pressure Sensor 1 Removal the Fuel System DFI chapter e Plug the vacuum hose end e Pull off the rubber caps A from the fittings of each throttle body Upside View B e Disconnect the air switching valve hose A from the air cleaner housing e Plug the air switching valve hose end and air cleaner housing fitting 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Connect a vacuum gauge special tool and hoses A to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 Connect a highly accurate tachometer B to one of the stick coil primary leads e Connect the following parts temporary Fuel Pump Lead Connector A Fuel Level Sensor Lead Connector B Extension Tube C Special Tool Extension Tube 57001 1578 e Start the engine and warm it up thoroughly Check the idle speed using a highly accurate tachometer A Idle Speed Standard 1 100 50 r min rpm x If the idle speed is out of the specified range adjust it with the adjusting screw see Idle Speed Adjustment Do not measure the idle speed by the tachometer of the meter unit e While idling the engine inspect the throttle body vacuum using the vacuum gauge B Throttle Body Vacuum Standard 35 3 1 3 kPa 265 10 mmHg at idle speed PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures If any va
443. plenty of play e Remove Muffler Body Cover Bolts A Muffler Body Cover B e Loosen the clamp bolt A Remove the mounting bolts B and nut and pull out the muffler body C backward from the exhaust pipe e Remove Exhaust Butterfly Valve Cover Bolt A Exhaust Butterfly Valve Cover B 5 42 ENGINE TOP END Muffler Loosen the locknuts A e Remove the exhaust butterfly valve cable lower ends B from the pulley C ZR800C D Models e Remove Muffler Body Cover Bolts A Muffler Body Cover B Loosen the clamp bolt A e Remove the mounting bolts B and nut and pull out the muffler body C backward from the exhaust pipe Muffler ENGINE TOP END 5 43 Muffler Body Installation ZR800A B Models Replace the muffler body gasket A and nut B with new ones e Install the muffler body gasket until it is bottomed so that the inside chamfer side faces rear C e Install the muffler body clamp D so that the insert the projection E into the clamp slit F e Install the exhaust butterfly valve cable see Exhaust But terfly Valve Cable Installation e Install the exhaust butterfly valve cover G e Tighten Torque Exhaust Butterfly Valve Cover Bolt H 11 N m 1 1 kgf m 97 in Ib e Install the muffler body I Olnstall the muffler body until it stops at the bottom surface of the exhaust pipe e Tighten Torque Muffler Body Clamp Bolt J 17 N m 1 7 kgf m 13 ft lb Mu
444. pm Reading Range Tester to Tester to 250 V AC One Black lead Another Black lead x If the output voltage shows the value in the table the al ternator operates properly xIf the output voltage shows a much lower reading than that given in the table stop the engine and inspect the stator coil resistance e Check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 Special Tool Hand Tester 57001 1394 ONote the readings total 3 measurements Table 2 Stator Coil Resistance at 20 C 68 F Tester Connections Reading Range Tester to Tester to One Black lead Another Black lead 0 05 0 6 Q x If there is more resistance than shown in the table or no hand tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x lf the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced 16 42 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection e Remove Regula
445. prevent clutch disengage ment and cause an accident resulting in serious in jury or death When adjusting the clutch or replac ing the cable be sure the upper end of the clutch outer cable is fully seated in its fitting or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment start the engine and check that the clutch does not slip and that it releases properly Engine Lubrication System Engine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine e Remove the engine oil drain bolt A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Replacement e Replace the drain bolt gasket B with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 30 N m 3 1 kgf m 22 16 e Pour in the specified type and amount of oil PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Recommended Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 SAE 20W 40 Capacity 3 1 L 3 3 US qt when filter is not saa removed SAE 10W 40 3 4 L 3 6 US qt when filter is removed Ls 3 8 L 4 0 US qt when engine is 20 10 0 10 20 30 40 0 LIII completely dry 509011851 NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requi
446. pring for breaks or distortion xIf the lever or spring are damaged in any way replace them e Visually inspect the shift drum cam C x If they are badly worn or if they show any damage replace it Transmission Shaft Removal Split the crankcase see Crankcase Splitting Remove the drive shaft A and output shaft B Transmission Shaft Installation Check to see that the set pins A and set rings B are in place 6113088BS1 C CRANKSHAFT TRANSMISSION 9 29 Transmission e Install the drive shaft and output shaft into the upper crankcase half e Apply engine oil to the bearings OThe bearing set pins and rings must match properly with the holes or grooves in the bearing outer races When they are properly matched there is no clearance A be tween the crankcase and the bearing outer races e Assemble the crankcase see Crankcase Assembly e Apply high temperature grease to the oil seal lips e Press in the oil seal A onto collar B so that the surface of the oil seal is flush with the counterbore bottom surface C of the crankcase Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the shafts Special Tool Outside Circlip Pliers 57001 144 e The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet th
447. put voltage with the connector joined Output Voltage without Plugs Standard DC 0 2 V or less e Turn the ignition switch off x If the reading is out of the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less check the following Fuel Pressure see Fuel Pressure Inspection Fuel Injector see Fuel Injectors section the fuel pressure and fuel injectors are good replace the sensor x If the reading is within the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation FUEL SYSTEM DFI 3 105 Oxygen Sensor Incorrect Output Voltage Service Code 94 9 Oxygen Sensor Circuit BK BL Ein 1888 49 9 OOO 6C17515FW2 C 1 Ignition Switch 10 Starter Relay 2 Water Proof Joint 2 11 Main Fuse 30 A 3 Oxygen Sensor 12 ECU Fuse 15 A 4 Joint Connector E 13 Relay Box 5 ECU 14 ECU Main Relay 6 Frame Ground 4 15 Fuse Box 1 7 Frame Ground 1 16 Ignition Fuse 15 A 8 Engine Ground 17 Joint Connector C 9 Battery 12 V 8 Ah 3 106 FUEL SYSTEM Warning Indicator Light LED Yellow Engine Warning Indicator Light LED Inspection Yellow Engine Warning Indicator Light LED A e Refer to the Electronic Combination Meter Unit Inspection in the Electric
448. que Front Caliper Assembly Bolts 22 N m 2 2 kgf m 16 ft lb e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Front Caliper Disassembly ZR800C Model e Remove Front Caliper see Front Caliper Removal in the Brakes chapter Brake Pads see Front Brake Pad Removal in the brakes chapter Caliper Holder e Using compressed air remove the pistons OCover the piston area with a clean thick cloth A OBlow compressed air B into the hole for the banjo bolt to remove the piston 8105040251 C 9513338851 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston OPull out the pistons by hand Remove the dust seals A and fluid seals B e Remove the bleed valve C and rubber cap D Front Caliper Assembly ZR800C Model e Clean the caliper parts except for the pads NOTICE For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they ar
449. r Up to 180 kg 397 Ib 290 kPa 2 90 kgf cm 42 psi Wheels and Tires Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from tread e Visually inspect the tire for cracks and cuts and replace the tire if necessary Swelling or high spots indicate inter nal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age x If any damage is found replace the wheel if necessary Tire Tread Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life 9096 worn So it is false economy and unsafe to use the tires until they are bald e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places x If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter 6J05007BS1 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Tread Depth Standard Front 4 0 mm 0 16 in Rear 5 5 mm 0 22 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in A WARNING Some replacement tires may adversely affect han dl
450. r bore e The piston ring openings must be positioned as shown The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Upper Oil Ring Steel Rail C Oil Ring Expander D Lower Oil Ring Steel Rail E Dent F 30 40 G Position the crankshaft at 2 3 piston TDC Prepare two auxiliary head bolts with their head cut Olnstall the two cylinder head bolts A diagonally in the crankcase e Install the cylinder block B Pistons C OFirst insert the 2 3 pistons and then rotate the crank shaft at 90 angle Olnsert the piston rings with your thumbs or the standard tip screwdriver 2 lt 2 2 9 S e 0 Neer 2 GE16091BS1 5 36 ENGINE TOP END Cylinder Pistons Piston Removal Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston e Remove the piston pins Special Tool Piston Pin Puller Assembly A 57001 910 e Remove the pistons Carefully spread the ring opening with your thumbs then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation e Apply molybdenum disulfide oil sol
451. r System e Replace ECU A see Immobilizer System Parts Replacement e Insert the current registered ignition key into the ignition switch and turn it to ON Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure 0 2second A GP30228CS1 Registered Ignition Key Collation Error 0 3second A Be ULL GP30229CS1 e The registered ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 1 time and stops for 1 second and the repeats this cycle to indicate successful registra tion of the registered ignition key 0 3second 1second A Bh E ire Sep 8 30233051 16 96 ELECTRICAL SYSTEM Immobilizer System e Turn to OFF the registered ignition key and remove it OThe red warning indicator light LED and immobilizer warning symbol A blink to display the registration mode NOTE Olnsert next key and turn it to ON within 15 seconds af ter previous key is turned to OFF and removed other wise registration mode will be ended and the red warn ing indicator light LED and immobilizer warning sym bol go off OTo return to the registration mode start the registered ignition key verification procedure This applie
452. r and Lower Ends A Throttle Inner Cable Upper and Lower Ends 6004040381 C PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant e With the cable disconnected at both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004011481 C 0004020152 C 2 64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Condition of Bolts Nuts and Fasteners Tightness Inspection e Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature xIf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new one
453. r harness con nector A GC17588bS1 3 78 FUEL SYSTEM Subthrottle Sensor Service Code 32 e Measure the output voltage with the engine stopped with the connector joined e Turn the ignition switch on Measure the output voltage when the subthrottle valve is completely closed by turning the lever A fully counter clockwise B Output Voltage Standard DC 0 48 0 52 V at subthrottle valve full close position DC 3 65 4 38 V at subthrottle valve full open position NOTE OTurn the lever clockwise confirm the output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 48 x 4 75 5 00 0 46 V 0 52 x 4 75 5 00 0 49 V Thus the valid range is 0 46 0 49 V e Turn the ignition switch off x If the reading is out of the standard check the subthrot tle sensor resistance see Subthrottle Sensor Resistance Inspection x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Subthrottle Sensor Connector B BL W lead ECU terminal 27 C G lead ECU terminal 33 D xIf the wiring
454. r must Oxygen send signals output Sensor voltage continuously to the ECU If the oxygen sensor output voltage is incorrect the ECU stops the feedback mode of the Oxygen sensor 94 Note 1 D J Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum vacuum sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method 2 a N Method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method This depends on the number of stopped cylinders Main Throttle Sensor Service Code 11 FUEL SYSTEM DFI 3 49 The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C Main Throttle Sensor Removal Adjustment Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the main throttle sen sor
455. r oil accumulated in the cleaner part e Visually check the drain hose A if the water or oil accu mulates xIf any water or oil accumulates in the hose remove the plug B from the drain hose and drain it A WARNING Oil on tires will make them slippery and can cause an accident and injury Be sure to reinstall the plug in the drain hose after draining Air Cleaner Housing Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Air Cleaner Drain Hose A e Disconnect the intake air temperature sensor connector e Pull B the air cleaner housing C forward and remove it from the frame 3 134 FUEL SYSTEM Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch off Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch off e Wait until the engine cools down e Remove Middle Fairing see Middle Fairing Removal in the Frame chapter Ignition Switch Cover see Ignition Switch Cover Re moval in the Frame chapt
456. r supply are good replace the ECU see ECU Removal Installation Main Throttle Sensor Output Voltage Inspection e Measure the output voltage at the main throttle sensor in the same way as input voltage inspection note the follow ing ODisconnect the main throttle sensor connector and con nect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y W lead Digital Meter BK sensor G lead e Start the engine and warm it up thoroughly e Check idle speed to ensure the throttle opening is correct Idle Speed Standard 1 100 50 r min rpm x lf the idle speed is out of the specified range adjust it see Idle Speed Inspection in the Periodic Maintenance chapter GC17588bS1 FUEL SYSTEM DFI 3 51 Main Throttle Sensor Service Code 11 e Turn the ignition switch off e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch on Output Voltage Standard DC 0 995 1 025 V at idle throttle opening DC 4 05 4 48 V at full throttle opening for reference NOTE OOpen the throttle confirm the output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading sho
457. r wheel rotation sensor to the inside of the exhaust butterfly valve cables Clamps Hold the rear brake hose and rear wheel rotation sensor lead Run the rear brake hose and rear wheel rotation sensor to the inside of mud guard Clamps Hold the rear wheel rotation sensor lead Run the rear wheel rotation sensor lead through the clamp Do not fit the rear wheel rotation sensor lead to the clamp after tightening the chain adjuster nut Rear Wheel Rotation Sensor ZR800A B Models 17 40 APPENDIX Troubleshooting Guide NOTE Stick coil trouble ORefer to the Fuel System chapter for most ECU trouble of DFI trouble shooting guide OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Gear position starter lockout or side stand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Engine Doesn t Start Starting Difficulty Starter motor not rotating Fuel air mixture incorrect Bypass screw maladjusted Ignition and engine stop switch not ON Starter lockout switch or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Ignition switch tro
458. raight ahead alternately tap each end of the handlebars The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pushing and pulling the forks x If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the leads and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Ignition Switch Cover see Ignition Switch Cover Re moval in the Frame chapter Handlebars see Handlebar Removal in the Steering chapter Meter Bracket Bolts A Meter Bracket B with Meter e Remove Steering Stem Head Bolt Plug A Steering Stem Head Bolt B e Loosen the upper front fork clamp bolts C e Remove the stem head D e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B and claw washer 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures eAdjust the steering Special Tool Steering Stem Nut Wrench A 57001 1100 x If the steering is too tight loosen the stem nut a fraction of a turn x If the steering is too loose tighten the stem
459. rame chapter Right Lower Fairing see Lower Fairing Removal ZR800A B Models in the Frame chapter Muffler Body Cover see Muffler Body Removal in the Engine Top End chapter e Disconnect the oxygen sensor lead connector A Free the lead from the clamps A e Remove the oxygen sensor B Oxygen Sensor Installation NOTICE Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B and filter holes C of the sensor to prevent oil contact Oil contami nation from hands can reduce sensor performance e Tighten fe gue P Torque Oxygen Sensor 44 N m 4 5 kgf m 32 ft Ib e Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Oxygen Sensor Inspection e Refer to the Oxygen Sensor Inspection in the Fuel System DFI chapter 16 110 ELECTRICAL SYSTEM Switches and Sensors Fuel Level Sensor Inspection Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Open the clamps A e Remove Bolts B Fuel Level Sensor C Check that the float moves up and down smoothly without binding It should go down under its own weight x If the float does not move smoothly replace the sensor Float in Full Position A Float in Empty Position B e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector B Sp
460. ration Inspection pp 2 52 Ue datio 2 53 Suspension ter pain ane Sonn ese s traded 2 53 2 2 PERIODIC MAINTENANCE Steering System isi ote teca atiis Dies Ree dE Steering Play Inspection pp Steering Play Adjustment pp Steering Stem Bearing Lubrication EIGCUIGAL TEM Lights and Switches Operation Inspection Headlight Aiming Inspection pp Side Stand Switch Operation Inspection Engine Stop Switch Operation Spark Plug Condition Spark Plug OINSS EE Chassis Parts Lubrication pp Condition of Bolts Nuts and Fasteners Tightness Inspection 2 55 2 55 2 55 2 56 2 57 2 57 2 59 2 60 2 61 2 61 2 61 2 62 2 62 2 64 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection Service at number of years shown or indicated odometer reading intervals whichever comes first For higher odometer readings repeat at the frequency interval established here C Service more frequentl
461. re 10 4 eM TP 10 5 Wheels RIIT S A emcee 10 6 Front Wheel Removal pp 10 6 Front Wheel 10 7 Rear Wheel Removal tertie eph g e e Le REA QE Mae bee 10 7 Rear Wheel Installation pp 10 8 Wheel Inspection PER TERT EG ERE RET 10 10 Axle Inspection t Ttc FUR R 10 10 Balance Inspection stent ctio ete etr pte 10 11 Balance Adjustment eese rte RM E dees 10 11 Balance Weight Removal 10 11 Balance Weight Installation b 10 11 Mcr 10 13 Air Pressure Inspection Adjustment enn 10 13 Tire Inspection erc EI IM Tire Installation te d e pde aeneus H b Bearg os tutte Hub Bearing PREMIO A LU BARS Aot Rute tau Pimp Loa ctas dente ase dd 10 16 Hub Bearing Installation pp 10 16 Hub Bearing Inspecti N 10 17 H b Bearing EUbri a O r chee data etn 10 17 10 2 WHEELS TIRES Exploded View 6402213885 C WHEELS TIRES 10 3 Exploded View ew EOC av
462. rements are fully formulated and provide adequate lubrication for both the engine and the clutch OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area e Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Replacement Drain the engine oil see Engine Oil Change Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 Replace the filter with a new one e Apply grease to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 17 N m 1 7 13 ft lb NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque e Pour in the specified type and amount of oil see Engine Oil Change 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels Tires Air Pressure Inspection e Remove the air valve cap e Measure the tire air pressure with an air pressure 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 e Install the air valve cap x Adjust the tire air pressure according to the specifications if necessary Air Pressure when Cold Front Up to 180 kg 397 Ib 250 kPa 2 50 kgf cm 36 psi Rea
463. ressure Relief Valve Installation pp 7 10 Oil Pressure Relief Valve Inspection pp 7 10 OI PUlTps seid dtd e teda tede diee ie etu pe ee Ret Erg 7 11 Oil Purnp Removal niri ERE Ee ether REO FO PA e ER HEURE EE 7 11 Oil Pump Installatiori ie oe dn 7 11 Oil Pump Drive Gear Removal nnne nennen 7 12 Oil Pump Drive Gear Installation 7 12 Oil Pressure Measurement 7 13 Oil Pressure Measurement pp 7 13 Oil Pressure Swit 2 7 14 Oil Pressure Switch Removal pp 7 14 Oil Pressure Switch Installation 7 14 7 2 ENGINE LUBRICATION SYSTEM Exploded View WF 7 ENGINE LUBRICATION SYSTEM 7 3 Exploded View No Fastener Torque N m kgf m 2 Oil Filler Plug 2 0 0 20 18 in Ib 3 Oil Filter 17 1 7 13 4 Oil Filter Holder 78 8 0 58 L 5 Oil Pressure Switch Terminal Bolt 2 0 0 20 18 in Ib HG 6 Oil Pressure Switch 15 1 5 11 LG 7 Oil Passage Plugs 20 2 0 15 L 8 Oil Pipe Holder Bolts 13 1 3 115 in Ib L 9 Water Pump Cover Bolts 11 1 1 97 in Ib 10 Coolant Drain Bolt Water Pump 11 1 1 97 in lb 11 Water Pump Impeller Bolt 9 8 1 0 87 12 Oil Pressure Relief Valve 15 1 5 11 L 13 Oil Pan Bolts 15 1 5 11 14 Engine Oil Drain Bolt 30 3 1 22 15 ZR800A B Models G Apply grease HG Apply high temperature gr
464. rging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A ODo not turn the ignition switch on while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes ODo not spray water the electrical parts DFI parts con nectors leads and wiring olf a transceiver is installed on the motorcycle make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected do not turn the igni tion switch on Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel s
465. ring Stem D Upper Ball Bearing Inner Race and Ball Bearing To remove the ball bearing outer races A pressed into the head pipe B insert a bar C into the recesses of head pipe and applying it to both recess alternately ham mer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones 8 05055 81 C Steering Stem STEERING 14 7 eRemovethe lower ball bearing inner race with its oil seal A which is pressed onto the steering stem with a suitable commercially available chisel B Stem Stem Bearing Installation Replace the bearing outer races with new ones e Apply grease to the outer races e Drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Head Pipe Outer Race Driver 55 B 57001 1446 e Replace the bearing inner races and oil seal with new ones e Apply grease to the oil seal e Install the oil seal A on the steering stem and drive the lower ball bearing inner race B applied the grease onto the stem Special Tools Steering Stem Bearing Driver 042 5 C 57001 1344 Steering Stem Bearing Driver Adapter 41 5 D 57001 1345 e Install the lower ball bearing A onto the stem e Grease the following Inner and Outer Races Lower and Upper Ball Bearings OThe lower and upper ball
466. rn Signal Light Mounting Screws 1 2 0 12 11 in Ib 4 Front Fender Bolts 3 9 0 40 35 in Ib Left hand Threads 15 4 FRAME Exploded View 6002606815 C FRAME 15 5 Exploded View Torque No Fastener Nem kgf m ftlb Remarks 1 Footpeg Bracket Bolts 30 3 1 22 2 Side Stand Switch Bolt 8 8 0 90 78 in Ib L 3 Side Stand Bolt 29 3 0 21 4 Side Stand Nut 44 4 5 32 R 5 Lower Fairing Mounting Bolts 9 8 1 0 87 6 Lower Fairing Bracket Bolts 9 8 1 0 87 7 ZR800A B Models G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 6 FRAME Exploded View FRAME 15 7 Exploded View No Fastener Remarks N m kgf m ft Ib 1 License Plate Light Mounting Screws 1 2 0 12 11 in Ib 2 Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib 3 AU Model 15 8 FRAME Seats Rear Seat Removal e Insert the ignition switch key A into the seat lock turning the key clockwise pulling the front part of the seat B up and pull the seat forward Rear Seat Installation e Insert the rear seat hook A into the bracket B of the frame e Insert the seat hook C into the latch hole D e Push down the front part of the seat until the lock clicks Front Seat Removal e Remove Rear Seat see Rear Seat Removal Bolt A Bracket B e Remove the front seat C by
467. rning Indicator Light Battery Oil Pressure Water Temperature Immobilizer LED Speedometer Mileage ruising Range Fuel Level Gauge 0 Tachometer l Water Temperature Meter 2 0dometer Trip Meter 3 Clock 4 1 lumination Light LED LED Light Emitting Diode F 1 2 3 4 zi H IAS use Box 1 R L Ignition Fuse 15 Headlight Fuse 15 Brake Horn Fuse 7 Turn Signal Relay Fuse 7 5 Relay Box Radiator Fan Relay Headlight Circuit Relay EGU Main Relay Left Switch Housing 1 Horn Button 2 Turn Signal Switch 3 Hazard Switch 4 Dinner 5 8 amun Switch Fuel Pump Relay Passing Button Starter Circuit Relay Starter Lockout Switch Horn Button SWITCH HOUSING CONNECTIONS Hazard Turn Signal Switch Dimmer Switch Starter Lockout witch Passing Button W2LO707CH5 C ELECTRICAL SYSTEM 16 25 Wiring Diagram ZR800C Sub Sub Throttle throttle Se Speed Actuator 9 Sensor Sensor intake Intake water Oxygen BL BK WR v BL z 55 2 dz Switch Air ir en Srank Side Sensor Pressure Pressure i Stand Fuel Injectors ensor u i Sensors Sensorsi Sensor T LUN i aa a g fi VERS T iss z EC ENT p E Water proof aes Joint H 7 ot AIL 3 A al AERA AL Hs rri
468. ro p 0 000001 Him ANDE 5 gh x 0 7376 ftlb N m x 8 851 in Ib Units of Mass 9 807 N m kg x 2 205 Ib kgf m x 7 233 g x 0 03527 02 kgf m x 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal IMP kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt IMP kgf cm 9807 kPa L 2 113 pint US kgf cm x 14 22 psi L A 1 816 pint IMP cmHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 oz IMP Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N 0 1020 kg kW x 1360 PS N x 0 2248 Ib kw x 1341 HP kg x 9 807 N PS x 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature ERA gee oF oF 32 68 104 248 284 40 20 320 20 140 40 C 20 5 40 i 267 489 i i 400 714 93 3 116 i 420 176 212 80 100 120 140 160 180 200 220 240 260 280 300 1140 138 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance 20 2 2 3 Torque and Locking debile 2 5 Specifications nic fr tert n Ra E QUE CER VER Y RE RUE EY YR EAT 2 11 2 13 Periodic Maintenance
469. rom tires frame engine or other painted parts Do not ingest coolant 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Remove the left lower fairing see Lower Fairing Removal ZR800A B Models in the Frame chapter e Place a container under the coolant drain bolt A then remove the drain bolt Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Remove the radiator cap A in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap OThe coolant will drain from the radiator and engine e Remove Left Side Fairing see Side Fairing Removal in the Frame chapter Reserve Tank Bolts A Clamp B e Turn over the reserve tank C remove the cap and pour the coolant into a suitable container e Install the reserve tank e Tighten Torque Reserve Tank Bolts 9 8 N m 1 0 kgf m 87 in Ib e Tighten the drain bolt with the gasket OReplace the drain bolt gasket with a new one Torque Coolant Drain Bolt Water Pump 11 Nm 1 1 kgf m 97 in Ib e When filling the coolant choose a suitable mixture ratio by referring to the coolant manufacturer s directions Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system
470. s Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Clamp Bolt Muffler Body Mounting Bolt and Nut Radiator Upper and Lower Bolts Subframe Bolts Wheels Front Axle Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Nut Brake Pedal Bolt Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Caliper Pin Bolt Rear Master Cylinder Mounting Bolts Suspension Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Locknut Swingarm Pivot Shaft Nut Tie Rod Nuts Rocker Arm Nut Steering Handlebar Holder Bolts Steering Stem Head Bolt Others Footpeg Bracket Bolts Front Fender Bolts Side Stand Bolt FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents Exploded VIeW ee eet hee eR epe he ON ANTE hae teense ae RED 3 4 DOE SUI pe rested pean 3 10 DEL Parts Location iie teat en tec b a RESP agents 3 20 Specifications ici er tek e RR CR ek ee a doer een e RR a e 3 22 Special Tools and Sealant i niece iet pori e e e epe noe A aO ee t e e RE e va en 3 24 DFI Servicing Precautions pp 3 26 DFIServieng Iecalto iuit undue tne ne petuo mime o a 3 26 Troubleshooting the DFI Systerr ait RR px ba Ree uin BER 3 28 OUTING E 3 28 Ore P TIT d
471. s B Muffler Body Mounting Bolt C and Nut BRAKES 12 17 Brake Lever Brake Pedal e Remove Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D Brake Pedal Bolt E Brake Pedal F Brake Pedal Installation e Apply grease to the inside of the bushing A e Install Washers B Bushing Brake Pedal C e Tighten Torque Brake Pedal Bolt D 8 8 0 90 kgf m 78 in Ib GLO4065BS1 C e Hook the return spring A on the brake pedal and footpeg bracket as shown Hook the rear brake light switch spring B on the switch and brake pedal as shown Replace the cotter pin with a new one e Insert the cotter C and bend the pin ends D e Install the footpeg bracket e Tighten Torque Footpeg Bracket Bolts 30 N m 3 1 kgf m 22 ft Ib Muffler Body Mounting Bolt 34 N m 3 5 kgf m 25 ft lb Check the brake pedal position see Brake Pedal Position Inspection 12 18 BRAKES Calipers Front Caliper Removal ZR800A B D Models e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc Do not loosen the caliper assembly bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hoses D from the caliper see Brake Hos
472. s noticed Tighten any brake hose banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolts ABS Unit ABS Equipped Models 33 3 4 24 ft Ib Inspect the brake hose routing If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road xIf the brake operation is insufficiency inspect the brake system A WARNING When test riding the vehicle be aware of surround ing traffic for your safety Brake Fluid Level Inspection Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebars when checking brake fluid level 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If the fluid level is lower than the lower level line fill the reservoir to the upper level line A Check that the brake fluid level in the rear brake reservoir A is above the lower level line B x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death D
473. s to all ignition key registration e Insert the other remaining registered ignition key to the ignition switch and turn it to ON NOTE OKeep the other ignition keys away from the immobilizer antenna Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error 0 5second 0 5second ae bere 8 302270651 GP302280S1 0 5second 0 5second a TE eV pe GP30227C81 0 3second QOO UU GP30229CS1 ELECTRICAL SYSTEM 16 97 Immobilizer System e The other remaining ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 2 times and stops for 1 second and then repeats this cycle to indicate successful regis tration of ignition key e Turn to OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends e The red warning indicator light LED A goes off NOTE OTurn the ignition switch to ON with the registered igni tion key OCheck that the engine can be started using all regis tered ignition keys Case 4 When all registered ignition keys are faulty or lost The all registered ignition
474. sensor malfunction wiring open or short Intake air pressure sensor 2 malfunction wiring open or short FI Crankshaft sensor malfunction wiring open or short FI Speed sensor malfunction wiring open or short FI Vehicle down sensor malfunction wiring open or short FI Subthrottle sensor malfunction wiring open or short FI Oxygen sensor inactivation wiring open or short FI Exhaust butterfly valve actuator sensor malfunction wiring open or short ZR800A B Models Immobilizer Immobilizer amplifier malfunction RT Blank key detection ECU communication error Stick coil 1 malfunction wiring open or short Stick coil 2 malfunction wiring open or short Stick coil 4 malfunction wiring open or short Radiator fan relay malfunction wiring open or short Subthrottle valve actuator malfunction wiring open or short Exhaust butterfly valve actuator malfunction wiring open or short ZR800A B Models 053 Stick coil 3 malfunction wiring open or short FI Air switching valve malfunction wiring open or short 27 Fl Oxygen sensor heater malfunction wiring open or short 94 Fl Oxygen sensor malfunction wiring open or short Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service
475. service code Main Sub 1 Main Sub is stored Code Code Code Code m te 3 2 2 The indicator display Service Code 13 Service Code 221 will repeat from the When Service Codes 13 and 22 stored first code Service Code Output Start Timing GL14732B 5 How to Erase Service Codes OEven if the ignition switch is turned off the battery or the ABS hydraulic unit are disconnected all service codes remain in the ABS hydraulic unit ORefer to the Service Code Clearing Procedure for the service code erasure BRAKES 12 51 Anti Lock Brake System Equipped Models Service Code Table Service Yellow ABS Indicator Code Light LED Stays on Error function after the ignition switch turned on Does not go on When the harness meter unit or ABS unit ignition switch turned on abnormal Problems Light State Main harness meter unit wheel rotation sensor s or ABS unit abnormal ON Rear intake solenoid valve trouble wiring JL IUUL oer shorted or open TL Rear outlet solenoid valve trouble wiring shorted or open Front intake solenoid valve trouble wiring shorted or open Front outlet solenoid valve trouble wiring shorted or open ABS solenoid valve relay trouble stuck relay ON or OFF Front rear wheel rotation difference abnormal substandard tire ABS motor trouble mechanical stuck Front wheel rotation
476. shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift ratchet assembly spring weak or bro ken Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Troubleshooting Guide Crankshaft runout excessive Engine mounting portions loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Exhaust butterfly valve cable loose ZR800A B Models Abnormal Drive Train Noise Clutch noise Clutch damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Wrong installation of outside friction plate Transmiss
477. sher against the new outer tube guide bush ing and tap the washer with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 641 57001 1288 e Install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 641 57001 1288 e Install the retaining ring and dust seal into the outer tube e Pour in the specified type of oil see Fork Oil Change Front Fork SUSPENSION 13 35 Inner Tube Outer Tube Inspection e Visually inspect the inner tube A x lf there is any damage replace the inner tube Since damage to the inner tube damages the oil seal and dust seal replace the oil seal and dust seal whenever the inner tube is replaced NOTICE If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Temporarily assemble the inner tube A and outer tube B and pump C them back and forth manually to check for smooth operation x If you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fall in use possibly causing an accident resulting in seri ous injury or death Replace a badly bent or dam aged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage
478. shing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound NOTICE Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the engine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal Installation e The coolant reserve tank is removed and installed dur ing coolant change see Coolant Change in the Periodic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Water Pump Removal Refer to the Oil Pump Removal in the Engine Lubrication System chapter Water Pump Installation e Refer to the Oil Pump Installation in
479. side and fit them into the recess of the connecting rod and cap Wrong application of oil and grease could cause bearing damage OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Remove debris and clean the surface of inserts e Install the cap on the connecting rod aligning the weight and diameter marks e Apply molybdenum disulfide oil solution MO to the threads and seating surfaces of the big end nuts and bolts e Install the crankshaft see Crankshaft Installation e Install each connecting rod on its original crankpin OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts The connecting rod bolts are designed to stretch when tightened Never reuse the connecting rod bolts See the table b
480. sideways for a long time or dropped it will malfunction e Installation is the reverse of removal e Run the cables leads and hose correctly see Cable Wire and Hose Routing section in the Appendix chap ter e Tighten Torque Meter Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Installation Caps A Meter Assembly Screws B e Separate the meter assembly A and upper meter cover B Meter Unit Assembly e Assembly the following parts Meter Assembly Upper Meter Cover e Tighten Torque Meter Assembly Screws A 0 43 N m 0 044 kgf m 3 8 in Ib e Replace the caps B with new ones and put them Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 71 Electronic Combination Meter Unit Inspection e Remove the meter unit see Meter Unit Removal Installa tion 1 Red Warning Indicator Light LED Ground 2 Fuel Level Sensor 3 Unused 4 Unused 5 Unused 6 Tachometer Pulse 7 Speed Sensor Pulse 8 Ground 9 Green Left Turn Signal Indicator Light LED 10 Yellow ABS Indicator Light LED Ground Equipped Models 11 Green Neutral Indicator Light LED Ground 12 Blue High Beam Indicator Light LED 13 Green Right Turn Signal Light LED 14 ECU Communication Line 15 Ignition 16 Battery Do not drop the meter unit Place the meter unit so that it fac
481. sing the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Top Standard 0 20 0 30 mm 0 0079 0 0118 in Service Limit 0 6 mm 0 024 in Second Standard 0 45 0 55 mm 0 0177 0 0217 in Service Limit 0 9 mm 0 035 in x lf the end gap of either ring is greater than the service limit replace all the rings GE16301BS1 5 40 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation e Apply grease to the new O rings A e Be sure to install the O rings e Install the holders B as shown Clamp C e Tighten Torque Throttle Body Assy Holder Bolts D 13 N m 1 3 kgf m 115 in Ib e Install the clamps E as shown and so that its hole fit on the projection F of the holder e Tighten Torque Throttle Body Assy Holder Clamp Bolts G 1 1 N m 0 11 kgf m 10 in Ib GE17054BS2 C ENGINE TOP END 5 41 Muffler A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Do not re move the muffler while it is hot Muffler Body Removal ZR800A B Models Remove the right frame cover see Frame Cover Removal in the Frame chapter e Slide the dust covers A Loosen the locknuts B and turn the adjusters C to give the cable
482. small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator 4 6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 F 2 8 L 3 0 US qt reserve tank full level including radiator and engine Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 13 18 psi Thermostat Valve Opening Temperature Valve Full Opening Lift 58 62 C 136 144 F 8 mm 0 31 in or more at 75 C 167 F COOLING SYSTEM 4 7 Special Tools Bearing Driver Set Oil Seal Driver 57001 1129 57001 1660 7571129ST C ST571660ST 6 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Remove the left side fairing see Side Fairing Removal in the Frame chapter e Visually inspect the coolant A in the reserve tank If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system xIf the coolant gives off an abnormal smell che
483. specified range Readjust if necessary Throttle Control System Inspection e Check that the throttle grip A moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Check the throttle grip free play B Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures x lf the free play is incorrect adjust the throttle cable as follows e Loosen the locknuts A B e Screw both throttle cable adjusters C D to give the throttle grip plenty of play e Turn the decelerator cable adjuster C until there is no play when the throttle grip play completely closed e Tighten the locknut A e Turn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B xIf the free play can not be adjusted with the adjusters replace the cable Engine Vacuum Synchronization Inspection NOTE OThese procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition e Situate the motorcycle so that it is vertical e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Fuel Outlet Hose see Fuel Hose Re
484. spection e Refer to the Air Switching Valve Unit Test in the Electrical System chapter xIf the air switching valve is normal check the wiring for continuity see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Air Switching Valve Circuit T GCi7517FW2 C 1 Ignition Switch 9 Starter Relay 2 Air Switching Valve 10 Main Fuse 30 A 3 Joint Connector E 11 ECU Fuse 15 A 4 ECU 12 Relay Box 5 Frame Ground 4 13 ECU Main Relay 6 Frame Ground 1 14 Fuse Box 1 7 Engine Ground 15 Ignition Fuse 15 A 8 Battery 12 V 8 Ah 16 Joint Connector C Oxygen Sensor Heater Service Code 67 FUEL SYSTEM DFI 3 101 Oxygen Sensor Heater Removal Installation The oxygen sensor heater is built in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heater Resistance Inspection e Turn the ignition switch off e Remove Right Frame Cover see Frame Cover Removal in the Frame chapter e Disconnect the oxygen sensor lead connector e Connect a digital meter A to the oxygen sensor lead con nector B e Measure the oxygen sensor heater resistance Oxygen Sensor Heater Resistance Connections BK lead
485. spection in the Periodic Main tenance chapter Tire Inspection Refer to the Wheel Tire Damage Inspection in the Peri odic Maintenance chapter Tire Removal e Remove Wheels see Front Rear Wheel Removal Valve Core Let out the air e To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges NOTICE Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure e Inspect the rim and tire and replace them if necessary e Clean the sealing surfaces ofthe rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary e Remove the air valve and discard it NOTICE Replace the air valve
486. ss oil using a syringe or some other suitable device xIf the oil level is too low add the correct amount of oil through the oil filter opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter ENGINE LUBRICATION SYSTEM 7 9 Oil Pan Oil Pan Removal Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Lower Fairings see Lower Fairing Removal ZR800A B Models in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Oil Pan Bolts A Clamps Bracket ZR800A B Models Oil Pan B and Gasket C Remove the oil pipe A oil pressure relief valve B oil screen C as necessary Oil Pan Installation e Clean the oil screen A e Install the oil screen so that the crankcase rib B fits the slot C of the oil screen e Apply grease to the O rings on the oil pipe x If the oil pressure relief valve was removed install it OAppl
487. ssary x If the all parts correct go to next step 12 56 BRAKES Anti Lock Brake System Equipped Models Step 3 e Measure the front and rear wheel rotation sensor air gaps see Wheel Rotation Sensor Air Gap Inspection If the air gap is not within the specification recheck the hub bearing sensor sensor rotor and sensor installation condition x If the air gap is within the specification replace the ABS hydraulic unit ABS Motor Inspection Service Code 35 e Perform the Pre Diagnosis Inspection 1 and 2 e Check the system connectors for loose or poorly contact e In order to confirm a existing problem in the system erase the service code and then recheck the yellow ABS indi cator light LED x If same service code is indicated again faulty ABS Motor in the ABS hydraulic unit Replace the ABS hydraulic unit x If the service code does not indicate ABS system is nor mal service code is not stored temporary failure Wheel Rotation Sensor Signal Abnormal Inspection Front Service Code 42 Rear Service Code 44 e Perform the Pre Diagnosis Inspection 1 and 2 e Check the system connectors for loose or poorly contact Step 1 e Measure the front or rear wheel rotation sensor air gap see Wheel Rotation Sensor Air Gap Inspection xIf the air gap is not within the specification recheck the hub bearing sensor sensor rotor and sensor installation condition x If the air gap is within the specification go
488. stration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error e The ignition key 1 is successfully registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 3 times and stops for 1 second and then repeats this cycle e Turn the ignition key 1 to OFF and remove the ignition key 1 OThe red warning indicator light LED and immobilizer warning symbol A blink to display the registration mode NOTE OTurn to OFF the ignition switch and wait for the period of 15 seconds or more The registration mode automat ically finishes and the red warning indicator light LED and immobilizer warning symbol will switch off OThis procedure registered the registered ignition key and one ignition key OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed GP30228CS1 0 5second 0 5second 8 302270651 0 3second Qu Hh UUUUUUUUUUU GP30229CS1 0 30 31second 8 30230051 0 0 5second M a ep GP30227C81 Immobilizer System ELECTRICAL SYSTEM 16 87 e Insert the ignition key 2 to the ignition switch and turn it to ON Olf
489. surface B facing up ward e Install the fork spring C with the smaller end D facing upward e Set the clamps A as shown Special Tool Fork Spring Compressor 57001 1540 e Tighten the two bolts B e Install the holders C to the clamps as shown Special Tool Fork Spring Compressor 57001 1587 e Using a high flash point solvent clean of any oil or dirt that may be on the adhesive coating area Dry them with a clean cloth e Apply adhesive ThreeBond TB1342 or equivalent to the threads of the piston rod assy stopper A e Install Piston Rod Assy B Piston Rod Assy Stopper e Screw the top plug C e Set the clamps A and compression shafts B 13 32 SUSPENSION Front Fork e Screw the nuts A onto the compression shafts B as shown About 15 mm 0 59 in C Screw the piston rod assy stopper D e Remove the following special tools Fork Spring Compressors Bar e Remove the top plug e Hold the inner tube lower end in a vice e Using the fork piston rod stopper holder A tighten the piston rod assy stopper B Special Tool Fork Piston Rod Stopper Holder 5700 1789 Torque Piston Rod Assy Stopper 17 5 N m 1 78 kgf m 12 9 ft Ib NOTE Olnstall the fork piston rod stopper holder so that the long side C faces upward e Pour in the type and amount of fork oil specified into the left front fork A Recommended Oil 15 10 or equivalent Amount When
490. switch The turn signal lights and green turn signal indicator light LED should go off x If the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Third Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight should go on x If the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse 15 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on e The blue high beam indicator light LED C should go on x If the high beam headlight and or blue high beam indicator light LED does not go on inspect or replace the following item Headlight High Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electric
491. t x If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above e Screw the fork piston rod puller onto the end of the piston rod Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 e Pull the puller up above the outer tube top e Install the spring seat A with the flat surface B facing upward e Install the fork spring C with the smaller end D facing upward e Install the collar A so that the cut side B faces down ward e Install the washer C on the collar GM04733BS2 C GM04734BS1 C 13 24 SUSPENSION Front Fork e Install the clamps A as shown Special Tools Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 NOTE OSet the clamps so that the cutouts B do not fit the hole C of the washer D pull up the outer tube E to hold it by the clamps and then tighten the two bolts F The outer tube is used as a guide e Set the holder bar A and compression shafts B Special Tool Bar 57001 1751 For Left Fork Leg e Screw in the fork compressor nut come out the piston rod nut OHold up the fork piston rod puller while screwing in the nut e Insert the fork spring stopper A between the piston rod nut B and the clamp C while holding up the fork piston rod puller D Special Tool Fork Spring Stopper 57001 1374 e Remove the fork piston rod puller
492. t worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Immobilizer system trouble Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Crankshaft sensor trouble Fuel air mixture incorrect Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Fuel to injector insufficient Fuel line clogged Throttle body assy holder loose Air cleaner housing holder loose Compression low Spark plug loose Troubleshooting Guide Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Camshaft cam worn Run on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery cable or ECU ground lead Carbon accumulating on valve seating sur face Engine overheating Other ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Bra
493. t A Lower Tie Rod Nut and Bolt B Rocker Arm Nut and Bolt C Rocker Arm D Rocker Arm Installation e Apply grease to the inside of the oil seals e Replace the following nuts with new ones Rocker Arm Nut Tie Rod Nut Rear Shock Absorber Nut Lower e Tighten Torque Rocker Arm Nut 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nuts 59 N m 6 0 kgf m 44 ft Ib Rear Shock Absorber Nut Lower 34 N m 3 5 kgf m 25 ft Ib SUSPENSION 13 47 Tie Rod Rocker Arm Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rods see Tie Rod Removal Rocker Arm see Rocker Arm Removal Sleeves A Oil Seals B Swingarm C see Swingarm Removal Remove the needle bearings D using a suitable tool GMO71188W2 Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearings and oil seals with new ones e Apply plenty of grease to the lips of the oil seals e Install the needle bearings and oil seals position as shown OScrew the needle bearing driver A into the driver holder B NOTE OFor a bearing of inner diameter 18 select the pressing side of the needle bearing driver according to its press ing depth Olnsert the needle bearing driver into the needle bearing C and press the needle bearing into the housing until the driver contacts the end surface of the housing Bearing Pressing Depth 5 5 mm 0 22 in D 5 0 mm 0 20 in E Spacer 18 F Thickness 0 5 mm 0 02 in Special
494. t align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut B A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin GJ04249BS1 C GJ04250BS1 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection e Check that the notch A on the left alignment indicator B aligns with the same swingarm mark or position C that the right alignment indicator notch aligns with x If they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned Drive Chain Wear Inspection e Remove the chain cover see Drive Chain Removal In stallation in the Final Drive chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain Lubricate the drive chain if it appears dry e Stretch the chain taut by hanging a 10 k
495. t brake hose and throttle cables Face the open side of the clamp down ward Brake Hose Left Switch Housing Lead Right Switch Housing Lead Throttle Cable Decelerator Throttle Cable Accelerator 17 4 APPENDIX Cable Wire and Hose Routing GBOSIIGE 6 APPENDIX 17 5 Cable Wire and Hose Routing Front Brake Hose Right Switch Housing Lead Throttle Cable Accelerator Throttle Cable Decelerator Do not twist the throttle cables Clutch Cable Left Switch Housing Lead Run the main harness front brake hose throttle cables and switch housing leads in order from the front 9 Main Harness 10 Run the throttle cables to the outside of the main harness 11 Hold the main harness with the clamp and insert the projection of the clamp into the bracket 12 Run the main harness between the throttle cables and switch housing lead 13 Clamp Hold the switch housing leads ONDOABRWDND 17 6 APPENDIX Cable Wire and Hose Routing 6809117 6 APPENDIX 17 7 Cable Wire and Hose Routing ON 10 11 12 Clamp Hold the right city light lead and right turn signal light lead Clamp Hold the left city light lead and left turn signal light lead Bend the clamps in the direction of arrows Horn Lead Clamp Hold the right turn signal lead Run the main harness front brake hose throttle cables and switch housing le
496. t the rear brake hose of the master cylinder is outside Clamp Hold the rear brake hose and rear wheel rotation sensor lead at the white tape position of the rear wheel rotation sensor lead Run the rear brake hose and rear wheel rotation sensor lead to the inside of the mud guard Insert the rear wheel rotation sensor lead to the slit without looking the white tape position Damper Rear Wheel Rotation Sensor Lead Rear Brake Hose Clamps Hold the rear wheel rotation sensor Run the rear wheel rotation sensor lead through the clamp Do not fit the rear wheel rotation sensor lead to the clamp after tightening the chain adjuster nut Rear Wheel Rotation Sensor Viewed from C Insert the rear wheel rotation sensor lead to the slit White Tapes Section A A Hold the damper with the mud guard Viewed from B Touch the ABS brake pipe to the ABS hydraulic unit ABS Hydraulic Unit 17 38 APPENDIX Cable Wire and Hose Routing ABS Equipped Models gt N 5 _ Ware A 0009136 6 1 Do not hold the front wheel rotation sensor with the clamp 2 Front Wheel Rotation Sensor 3 Clamp Hold the front wheel rotation sensor 4 Run the front brake hose through the clamp 5 Front Brake Hose APPENDIX 17 39 Cable Wire and Hose Routing ABS Equipped Models N 6809137E 6 Rear Wheel Rotation Sensor Lead Run the rea
497. t the spring preload OThe standard adjuster setting is 4th position Spring Preload Setting Standard Position 4th position Adjustable Range 1st to 7th position e f the compression of the spring is not suited to the op erating conditions adjust it to an appropriate position by referring to the table below Spring Preload Adjustment Adjuster Damping UE Load Road Driving Position Force Conditions Speed Hardness 1st Weak Soft Light Good Low T 1 T 1 1 7th Strong Hard Heavy Bad Highway e Install the removed parts see appropriate chapters Rear Shock Absorber Removal e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause an accident and injury e Remove Frame Covers see Frame Cover Removal in the Frame chapter Lower Shock Absorber Nut and Bolt A Lower Tie Rod Nut and Bolt B Rear Shock Absorber SUSPENSION 13 39 eRemove the upper shock absorber nut and bolt A Remove the shock absorber B from downside Rear Shock Absorber Installation Replace the rear shock absorber nuts upper and lower and tie rod nut with new ones e Tighten Torque Rear Shock Absorber Nuts Upper and Lower 34
498. t until the oil level settles 6304021381 OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the outer tube to the oil Oil Level fully compressed without spring Standard Right Front Fork 106 2 mm 4 17 0 08 in from the top of the outer tube Left Front Fork 109 2 mm 4 29 0 08 in from the top of the outer tube NOTE OFork oil lever may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end C of the outer tube D OSet the gauge stopper E so that its lower side shows the oil level distance specified F OPull the handle slowly to pump out the excess oil until the oil no longer comes out x If no oil is pumped out there is insufficient oil in the inner 0N04733b82 0 tube Pour in enough oil then pump out the excess oil as shown above 13 18 SUSPENSION Front Fork e Screw the fork piston rod puller onto the end of the piston rod Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 Pull the puller up above the outer tube top e Install the spring seat A with the flat surface B facing B upward e Install the fork spring C with the smaller end D facing
499. tallation 2 et Front Fender Remowval eee it ehe OE Front Fender Installation Rear Fender Removal eee et EE ER RES sin E EE REN Rear Fender Installation Rear Inner Fender Removal pp 15 20 Rear Inner Fender Installation pp 15 20 EP 15 20 15 22 15 23 esses E 15 23 DIGEST STAN mte TT TT ME 15 24 Side Stand Removal faves ines sdadesseeaiguecsd lduy sbeebs 15 24 Side Starnd InstallatUOn q io iere tae edic cael hal ite sanded he 15 24 DVR 15 25 Subtrame Cover REMOVAL e ne ree teet tee Mae teas ter eb utes Dan ratos 15 25 Subframe Cover Installation eene enne 15 25 Frame Cover Removals esc ty etn ete ede dede doeet ne ed 15 26 Frame Gover Installations eL E ee ss 15 26 Rear View MIMOS T UL m 15 27 Rear View Mirror Removal eene nnnnnn nennen nEn 15 27 Rear View Mirror Installation pp 15 27 15 2 FRAME Exploded View NDS Jey X Pa 6002605BW5 C Exploded View FRAME 15 3 No Fastener Torgne Remarks N m kgf m ft Ib 1 Rear View Mirror Locknut Upper 18 1 8 13 Lh 2 Rear View Mirror Nut Lower 30 3 1 22 3 Tu
500. tat Resistance 140 170 1 segment goes on 210 1 segment blinks xIf the display function does not work replace the meter assembly Check 15 Speedometer Inspection e Connect the leads in the same circuit as Check 1 e The speed equivalentto the input frequency is indicated in the oscillator A if the square wave is input into terminal 7 Olndicates approximately 60 km h if the input frequency is approximately 560 Hz Olndicates approximately 60 mph if the input frequency is approximately 904 Hz If the meter function does not work replace the meter assembly NOTE OThe input frequency of the oscillator adds the integrated value of the odometer OThe integrated value of the odometer cannot be reset Check 16 Odometer Inspection e Connect the leads in the same circuit as Check 15 e Set the ODO mode A by pushing the left button B e Raise the input frequency of the oscillator to see the result of this inspection OExample Indicates the increase of approximately 1 km h if the input frequency is approximately 525 Hz for one minute OExample Indicates the increase of approximately 1 mile if the input frequency is approximately 840 Hz for one minute x If the value indicated by the odometer does not increase replace the meter assembly NOTE OThe integrated value of the odometer cannot be reset GP170890 6 duty t TX100 50 T ace 0V 8 17090
501. tch Starter Lockout Switch Passing Button W2LO706CHS C ELECTRICAL SYSTEM 16 21 Wiring Diagram ZR800B without GPS Unit Speed Sensor Fuel Injectors Sub yerest le dain Sub Actuator Throttle throttle an Sensor Sensor ee Intake NeutralWater Switeh Tons Air Air en Side Sensor Pressure Pressure Z i Stand ensor Sensors Sensors Saitek H1 TV g E dae aet E o B Mater proof Bes 5 gt 1 Joint 1 e 1 Lii B v B B proof Joint 2 Joint onnector E ECU Joint Connector D Rear Wheel Rotation Sensor Kawasaki Self ABS Self diagnosis Terminal ir ir Y R diagnostic s F System BK Y 1L E Connector BKAY Alternator BRZY BL R BKZY BK Y Regulator Rectifier a BK Y BK Y Fuse Box 2 Fuse 15 2 Meter Fuse 7 Starter Wotor Joint Connector B 2 3 4 Frame Ground Battery Ground 12V8Ah Roar Brake Light Switch Actuator Exhaust Butterfly Starter Relay 1 0 Fuse 15 2 M
502. tch Terminal Bolt 2 0 0 20 18 in Ib HG Oil Pressure Switch 15 1 5 11 LG Alternator Lead Holding Plate Bolt 12 1 2 106 in Ib L Alternator Cover Bolts 15 1 5 11 Left Lower Fairing Bracket Bolts 11 1 1 97 in lb Starter Relay Cable Terminal Bolts 3 9 0 40 35 in Ib Starter Motor Cable Terminal Nut 4 9 0 50 43 in Ib Starter Relay Bracket Bolts 6 9 0 70 61 in Ib Side Stand Switch Bolt 8 8 0 90 78 in Ib L Regulator Rectifier Bracket Bolts 6 9 0 70 61 in Ib Regulator Rectifier Bolts 6 9 0 70 61 in Ib Spark Plugs 13 1 3 115 in Ib Speed Sensor Bolt 12 1 2 106 in Ib Engine Ground Cable Terminal Bolt 9 8 1 0 87 Fuel Level Sensor Bolts 6 9 0 70 61 in Ib L Neutral Switch 15 1 5 11 The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter Torque mm N m kgf m ft Ib 5 3 4 4 9 0 35 0 50 30 43 in Ib 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33 0 165 240 Specifications PERIODIC MAINTENANCE 2 11 Item Standard Service Limit Fuel
503. tch slipping engine overheating engine oil level too high engine oil viscosity too high other FUEL SYSTEM DFI 3 35 DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or Possible Causes Actions chapter Neutral starter lockout or side stand switch Inspect each switch see chapter 16 trouble Immobilizer system trouble Inspect see chapter 3 Vehicle down sensor operated Turn ignition switch off see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 E
504. ter inside the seal until the needle adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals e Make sure that measuring points are correct in the nector noting the position of the lock D and the lead color before measurement Do not reverse connections of a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition switch on and measure the voltage with the connector joined NOTICE Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts OAfter measurement remove the needle adapters and ap ply liquid gasket to the seals A of the connector B for waterproofing Sealant Liquid Gasket TB1211 56019 120 e Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connect
505. terioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures brake fluid to the new parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease to the followings Front Brake Lever Pivot Bolt Rear Dust Cover of Push Rod Assembly e Tighten Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib Front Master Cylinder Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib Caliper Rubber Parts Replacement Front Caliper Disassembly ZR800A B D Models e Loosen the front caliper pad pin A and banjo bolt B and tighten them loosely e Remove Front Caliper C see Front Caliper Removal in the Brakes chapter Brake Pads see Front Brake Pad Removal in the brakes chapter Front Caliper Assembly Bolts Oil Seal e Using compressed air remove the pistons One way to remove the pistons is as follows Olnstall a rubber gasket A and a wooden board B more than 10 mm 0 4 in thick on the caliper half and fas ten them together with a suitable bolt and nut as shown Leave one of the oil passages C open OLightly apply compressed air D to the oil passage until the pistons hit the rubber gas
506. terminal A and band B are in place Front C e Apply a non permanent locking agent to the threads of the fuel pump bolts e Tighten the fuel pump bolts to a snug fit following the tightening sequence as shown e Following the tightening sequence tighten the fuel pump bolts to the specified torque Torque Fuel Pump Bolts 9 8 N m 1 0 kgf m 87 in Ib e Tighten the pump bolts again to check the tightness in the order shown Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged e Turn the engine stop switch to run position e Turn the ignition switch on and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition switch off x If the pump does not operate as described above check the operating voltage see Fuel Pump Operating Voltage Inspection 80178200651 FUEL SYSTEM 3 117 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged Turn the ignition switch off e Remove the right subframe cover see Subframe Cover Removal in the Frame chapter e Disconnect the fuel pump lead connector and connect the harness adapter A between these connectors as shown Main Harness B Fuel Pump C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads Fuel Operating Voltage nds A 1
507. termine the fault using the self diagnosis function e Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part using the hand tester Special Tool Hand Tester 57001 1394 e Visually inspect the wiring for signs of burning or fraying x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage xIf the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the main harness B if necessary e Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests x If no abnormality is found in the wiring or connectors the ABS parts are the next likely suspects Check each part one by one x If an abnormality is found replace the affected ABS part GL14783BS1 BRAKES 12 43 Anti Lock Brake System Equipped Models ABS Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Conduct pre diagnosis inspection 1 2 Conduct self diagnosis Check
508. the Periodic Maintenance chapter GH04187BS1 CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded PLI 9 2 anan E 9 6 Special Tools and 9 8 Splitting mem 9 9 CralikCase S PIM E 9 9 GCrankcase ASSemlibly cedes e ber iene ae ated dora 9 10 Crankshaft and Connecting RODS 9 15 Crankshaft 9 15 Crankshaft Installation ERR deor e fe Rete Cae Tuer E REPERI DR 9 15 Connecting Rod Removal ui eie v MA ertet eta beaten id t 9 15 Connecting ROG Installation serere diaeta i ette taret chose diano bo det arse petet 9 15 Crankshaft Connecting Rod Cleaning nne 9 19 Connecting Rod Bend Inspection s etui i Ilocos eub ate ec ege aed 9 19 Connecting Rod Twist Inspectiom 9 20 Connecting Rod Big End Side Clearance 9 20 Connecting Rod Big End Bearing Insert Crankpin Wear Inspection 9 20 Crankshaft Side Clearance 9 22 Crankshaft Runout Inspectiom 9 23 Crankshaft Main Bearing Insert Journal Wear Inspectionm 9 23 5tarter Motot GIUtchi
509. the Engine Lubrica tion System chapter Water Pump Inspection Remove the left lower fairing see Lower Fairing Removal ZR800A B Models in the Frame chapter e Check the drainage outlet passage A at the bottom of the water pump body for coolant leaks If the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Re place the mechanical seal unit Water Pump Impeller Disassembly Assembly Remove the water pump impeller see Oil Pump Removal in the Engine Lubrication System chapter e The sealing seat and rubber seal may be removed easily by hand e Apply coolant around the surfaces of the rubber seal and sealing seat e Install the rubber seal A and sealing seat B into the impeller by pressing them by hand until the seat stops at the bottom of the hole e Install the water pump impeller see Oil Pump Installation in the Engine Lubrication System chapter Water Pump Impeller Inspection e Remove the water pump cover see Oil Pump Removal in the Engine Lubrication System chapter e Visually inspect the water pump impeller A x If the surface is corroded or if the blades are damaged replace the impeller Water Pump Housing Disassembly NOTICE Do not damage the hole wall of the water pump housing e Insert a bar A into the pump housing B and hammer evenly around the circumference of the mechanical seal bottom C 9006015851 C Water
510. the conditions B under which the problem occurred and try to determine the cause C Do not rely solely on the ABS self diagnosis function use common sense check the brakes for proper braking power and brake fluid level search for leaks etc GC17425FS1 C 12 42 BRAKES Anti Lock Brake System Equipped Models Even when the ABS is operating normally the yellow ABS indicator light LED may light up under the conditions listed below Turn the ignition switch off to stop the indicator light If the motorcycle runs without erasing the service code the light may light up again OAfter continuous riding on a rough road OWhen the engine is started with the stand raised and the transmission engaged and the rear wheel turns OWhen accelerating so abruptly that the front wheel leaves the ground OWhen the ABS has been subjected to strong electrical interference OWhen tire pressure is abnormal Adjust tire pressure OWhen a tire different in size from the standard size is being used Replace with standard size OWhen the wheel is deformed Replace the wheel Much of the ABS troubleshooting work consists of con firming continuity of the wiring The ABS parts are assem bled and adjusted by the manufacturer so there is no need to disassemble or repair them Replace the ABS hydraulic unit The basic troubleshooting procedures are listed below e Carry out pre diagnosis inspections as a preliminary in spection e De
511. the engine stopped and with the connector joined e Turn the ignition switch on Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch off x If the reading is within the standard check the output volt age see Subthrottle Sensor Output Voltage Inspection OBO 6C17127BS1 Subthrottle Sensor Service Code 32 FUEL SYSTEM DFI 3 77 xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Subthrottle Sensor Connector B BL lead ECU terminal 5 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Subthrottle Sensor Output Voltage Inspection e Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection note the fol lowing ODisconnect the subthrottle sensor connector and connect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Subthrottle Sensor Output Voltage Connections to Adapter Digital Meter R sensor BL W lead Digital Meter BK sensor G lead e Remove the fuel tank see Fuel Tank Removal e Disconnect the subthrottle valve actuato
512. the front and rear wheel rotation sensor air gaps see Wheel Rotation Sensor Air Gap Inspection x If the air gap is not within the specification correct the air gap accordingly x If the air is within the specification go to next step Step 2 e Check that there is iron or other magnetic deposits be tween the both wheel rotation sensor A and sensor ro tor and the sensor rotor slots B for obstructions e Check the installation condition of the sensor for loose ness e Check the sensor tip and sensor rotor slots for deforma tion or damage e g chipped sensor rotor teeth x If the sensor and sensor rotor in bad condition clean or replace the faulty parts x If all items are correct go to next step Step 3 e Checkthe front and rear tire wheel conditions for tire pres sure tire size types abnormal wear and deformations see Wheels Tires in the Periodic Maintenance chapter x If the tire and or wheel are in bad condition correct them to the normal condition x If there is no problem replace the ABS hydraulic unit 076006000100 yee B GL14711BS1 2 4 9114708851 61147448 6 Anti Lock Brake System Equipped Models BRAKES 12 63 ABS Hydraulic Unit Removal NOTICE The ABS hydraulic unit A has been adjusted and set with precision at the factory Therefore it should be handled carefully never struck sharply as with
513. the ignition switch off e Disconnect the exhaust butterfly valve actuator lead con nector 2 pins connector A e Set the hand tester to the x 1 O range and connect it to the exhaust butterfly valve actuator connector Special Tool Hand Tester 57001 1394 e Measure the exhaust butterfly valve actuator resistance Exhaust Butterfly Valve Actuator Resistance Connections P lead GY lead Standard Any Reading Resistance reference 5 200 Q xIf the reading is 0 or infinity Q replace the exhaust butterfly valve actuator x lf the reading is in specification remove the ECU and check the wiring for continuity between main harness con nectors ODisconnect the ECU and actuator connectors Wiring Inspection ECU Connector Exhaust Butterfly Valve Actuator Connector B WIR lead ECU terminal 2 C W BL lead ECU terminal 3 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 8017806 51 Exhaust Butterfly Valve Actuator Circuit O GC17443FW2 1 ECU 2 Exhaust Butterfly Valve Actuator 3 100 FUEL SYSTEM Air Switching Valve Service Code 64 Air Switching Valve Removal Installation e Refer to the Air Switching Valve Removal Installation in the Engine Top End chapter Air Switching Valve In
514. the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the following Intake Air Temperature Sensor Resistance Standard 2 21 2 69 at 20 C 68 F 60171008 About 0 322 at 80 C 176 F x If the reading is out of the standard replace the sensor x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation FUEL SYSTEM 3 61 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Circuit 6GCc17430FW2 C 1 Intake Air Temperature Sensor 2 Water Proof Joint 2 3 ECU 3 62 FUEL SYSTEM Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation Never drop the water temperature sensor especially a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Disconnect the connector A Remove the water temperature sensor B e Replace the gasket with a new one and tighten the water temperature sensor Torque Water Temperature Sensor 12 N m 1 2 kgf m 106 in Ib e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Water Temperature Sensor Output Voltage Inspection NOTE OBe sure
515. ther Plate Bolts 9 8 1 0 87 in lb L Starter Motor Clutch Bolts 12 1 2 106 in Ib L Oil Passage Plugs 20 2 0 15 L Oil Pipe Holder Bolts 13 1 3 115 in Ib L Crankcase Bolts M8 27 2 8 20 S Crankcase Bolts M9 L 95 mm i dd MO S Crankcase Bolts M9 L 81 mm cs 5 Shift Drum Bearing Holder Screw 5 9 0 60 52 in Ib Shift Drum Bearing Holder Bolt 12 1 2 106 in Ib L Shift Drum Cam Holder Bolt 12 1 2 106 in Ib L Neutral Switch 15 1 5 11 Shift Lever Bolt 6 9 0 70 61 in Ib Gear Positioning Lever Bolt 12 1 2 106 in Ib Shift Shaft Return Spring Pin 29 3 0 21 E Tie Rod Locknuts 6 9 0 70 61 in Ib 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Shift Pedal Mounting Bolt Wheels Tires Front Axle Clamp Bolt Front Axle Rear Axle Nut Final Drive N m 25 20 108 108 Remarks Engine Sprocket Cover Bolts 6 9 0 70 61 in Ib Engine Sprocket Nut 167 17 0 123 MO Chain Adjuster Locknuts 16 5 1 68 12 2 Rear Axle Nut 108 11 0 79 7 Rear Sprocket Nuts 59 6 0 44 R Brakes Brake Hose Banjo Bolts 25 2 5 18 Front Master Cylinder Reservoir Cap Screws 1 5 0 15 13 in Ib Brake Lever Pivot Bolt 1 0 0 10 8 9 in Ib Si Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Front Brake Light Switch Screw 1 2 0 12 11 in lb Front Master Cylinder Clamp Bolts 11 1 1 97 S Front Brake Disc Mounting Bolts 27 2 8 20 L Front Caliper Assembly Bolts 22 2 2 16 L Front Caliper Mo
516. there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error e The ignition key 2 is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blink 4 times and stops for 1 second and then repeats this cycle OThis procedure has registered the 2 ignition keys e Continue with the procedure to register an additional one ignition key NOTE OThe ECU can store up the five key codes Red Warning Indicator Light LED and Symbol Blink Indicator Indicator Light and Light and Remarks Symbol Blink Symbol Stop Ignition Key 3 5 times 1 second Repeat e Turn to OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends 0 2second a Gat d unnnnnnnnnnnrui 8 30228051 0 5second 0 5second E Er pr qp es GP30227C81 0 3second am Hh LULU UU UU UU UU GP30229CS1 0 30 30 30 3 0 30 30 3 1second A ote GP30231CS1 16 88 ELECTRICAL SYSTEM Immobilizer System e The red warning indicator light LED A goes off e Remove the key registration unit key registration adapter and install the immobilizer Kawasaki diagnostic syste
517. tick coil information use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Stick Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly
518. tion 9 34 9 2 CRANKSHAFT TRANSMISSION Exploded View Exploded View CRANKSHAFT TRANSMISSION 9 3 No Fastener Torque Remarks N m kgf m ft Ib 1 Oil Jet Nozzle Bolts 6 9 0 70 61 in Ib L 2 Crankcase Bolts M6 12 1 2 106 in Ib S 3 Crankcase Bolts M7 20 2 0 15 S 4 Side Breather Plate Bolts 5 9 0 60 52 in lb L 5 Connecting Rod Big End Nuts See the text lt lt MO 6 Upper Breather Plate Bolts 9 8 1 0 87 in lb L 7 Starter Motor Clutch Bolts 12 1 2 106 in Ib L 8 Oil Passage Plugs 20 2 0 15 L 9 Pipe Holder Bolts 13 1 3 115 in Ib L 10 Shift Drum Bearing Holder Screw 5 9 0 60 52 L 11 Shift Drum Bearing Holder Bolt 12 1 2 106 in Ib L 12 Crankcase Bolts M8 27 2 8 20 S 13 Bolts M9 L 95 mm See the text c MO S 14 Crankcase Bolts M9 L 81 mm See the text c MO S HG L LG M MO R S Follow the specified tightening sequence Apply engine oil Apply grease Apply high temperature grease Apply a non permanent locking agent Apply liquid gasket Apply molybdenum disulfide grease Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 Replacement Parts WL Apply soap and water solution or rubber lubricant 9 4 CRANKSHAFT TRANSMISSIO
519. tion xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Speed Sensor Connector B BL lead ECU terminal 5 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 8017510 51 3 70 FUEL SYSTEM DFI Speed Sensor Service Code 24 Speed Sensor Output Voltage Inspection e Raise the rear wheel off the ground with the stand e Measure the output voltage at the speed sensor in the same way as input voltage inspection note the following ODisconnect the speed sensor connector and connect the harness adapter A between these connectors Special Tool Speed Sensor Measuring Adapter 57001 1667 Speed Sensor Output Voltage Connections to Adapter Digital Meter gt BL Y sensor P lead Digital Meter BK Y sensor lead e Measure the output voltage with the engine stopped with the connector joined e Turn the ignition switch ON Output Voltage Standard About DC 0 05 0 09 V or DC 4 5 4 9 V at ignition switch ON and 0 km h NOTE ORotate the rear wheel by hand confirm the output volt age will be raise or lower e Turn the
520. tion A is shown by an arrow B on the wheel hub Check the wheel rotation mark on the front wheel install it e Apply high temperature grease to the grease seal lips e Fit the collars A on the both sides of the hub OThe collars are identical e Insert the front axle from the right side e Tighten Torque Front Axle 108 N m 11 0 kgf m 79 7 16 e Before tightening the axle clamp bolt A on the right front fork leg pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle NOTE OPut a block in front of the front wheel to stop moving e Tighten Torque Front Axle Clamp Bolt 20 N m 2 0 kgf m 15 ft Ib e Install the removed parts see appropriate chapters e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Wheel Removal e Raise the rear wheel off the ground with the stand A 10 8 WHEELS TIRES Wheels Rims e Remove Cotter Pin A Axle Nut B Washer Axle C from Right Side Wheel Alignment Indicator D
521. tion the thick side B to frame side C e Remove the vinyl bag on the pipe and fuel hose joint e Check the joint lock for deformation and wear x If the joint lock is deformed replace the fuel hose with a new one e Check that there are no flaws burrs and adhesion of foreign materials on the delivery pipe A e Apply engine oil to the pipe e Pull the joint lock A as shown e Insert the fuel outlet hose joint A straight onto the fuel outlet pipe until the hose joint clicks e Push the joint lock B until the hose joint clicks e Push and pull A the hose joint B back and forth more than two times and make sure it is locked and does not come off A WARNING Leaking fuel can cause a fire or explosion resulting in severe burns Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn t leak x If it comes off reinstall the hose joint e Connect the fuel pump fuel level sensor lead connectors and the battery terminal see Battery Installation in the Electrical System chapter GC09126BS1 C 9505265851 3 138 FUEL SYSTEM Fuel Tank Fuel Tank and Cap Inspection Open the tank cap e Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged e Check to see if the water drain pipe B in the tank are not clogged Check the tank cap breather also x If they
522. to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT3 8 57001 1233 Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately x If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 147 226 kPa 1 5 2 3 kgf cm 21 33 psi at 4 000 r min rpm Oil Temperature 90 C 194 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and install it Torque Oil Passage Plug 20 N m 2 0 kgf m 15 ft Ib 7 14 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Right Lower Fairing see Lower Fairing Removal ZR800A B Models in the Frame chapter Switch Cover A Switch Terminal Bolt B Oil Pressure Switch C Oil Pressure Switch Installation e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a cl
523. tor Rectifier Bracket Bolts A Regulator Rectifier Assembly B e Disconnect the connector A e Remove Regulator Rectifier Bolts B Regulator Rectifier C e Set the hand tester to the x 1 range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier x If the tester readings are not as specified replace the regulator rectifier Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit kQ Tester Lead Connection Terminal W BK2 BK3 BK Y W 2 5 25 2 5 25 2 5 25 3 3 67 2 5 25 2 5 25 Tester Lead Connection e Install the regulator rectifier e Tighten Torque Regulator Rectifier Bolts 6 9 N m 0 70 kgf m 61 in Ib Regulator Rectifier Bracket Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the removed parts see appropriate chapters GP09359B 5 ELECTRICAL SYSTEM 16 43 Charging System Charging System Circuit 1 BATTERY eS GP09360BW2 Ignition Switch Load Frame Ground 3 Engine Ground Battery 12 V 8 Ah Main Fuse 30 A Starter Relay Alternator R
524. trical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Yellow ABS Indicator Light LED ABS Equipped Mod els see Yellow ABS Indicator Light LED Inspection in the Brakes chapter e Turn the ignition switch off e The all lights should go off x If the light does not go off replace the ignition switch Second Step e Turn the ignition switch to hazard position 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Turn the turn signal switch A left or right position on The left or right turn signal lights B front and rear cording to the switch position should blink e The green turn signal indicator light LED C in the meter unit should blink x If the each light does not blink inspect or replace the fol lowing item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Green Turn Signal Light Indicator Light LED see Electronic Combination Meter Unit Inspec tion in the Electrical System chapter Turn Signal Relay Fuse 7 5 A see Fuse Inspection in the Electrical System chapter Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Push the turn signal
525. ts as indi cated and count how may times the lights blink for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not blink as specified replace the turn sig nal relay Testing Turn Signal Relay GP12040281 6 Load T The Number of T Blinking Times e Number of Turn c m Signal Lights Wattage W 1 5 10 140 250 2 20 75 95 Cycle s per minute Corrected to one light burned out Lighting System ELECTRICAL SYSTEM 16 65 Turn Signal Light Circuit ay BK Y BK Y GPi2640BW3 C 5 Ignition Switch Main Fuse 30 A Starter Relay Battery 12 V 8 Ah Engine Ground Rear Right Turn Signal Light 12 V 10 W Rear Left Turn Signal Light 12 V 10 W Joint Connector B Frame Ground 4 Turn Signal Relay Hazard Button Turn Signal Switch Turn Signal Relay Fuse 7 5 A Fuse Box 1 Frame Ground 2 Front Left Turn Signal Light 12 V 10 W Front Right Turn Signal Light 12 V 10 W Joint Connector A Green Right Turn Signal Indicator Light LED Green Left Turn Signal Indicator Light LED Meter Unit Frame Ground 1 16 66 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test e Remove
526. tube vertically in a vise OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 ORemove the piston rod puller OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the outer tube to the oil Oil Level fully compressed without spring Standard 98 2 mm 3 86 0 08 in from the top of the outer tube NOTE OFork oil level may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end C of the outer tube D OSet the gauge stopper E so that its lower side shows the oil level distance specified F OPull the handle slowly to pump out the excess oil until the oil no longer comes out x If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above i L7 Su My yy gt v Wy 7 6 04042851 6 04021351 C GM04733BS2 13 28 SUSPENSION Front Fork Screw on the rod nut A fully to the piston rod B e Screw t
527. uble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn t turn over Vehicle down sensor DFI coming off Immobilizer system trouble Starter clutch trouble Starter idle gear trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark spark weak Vehicle down sensor coming off Ignition switch not ON Engine stop switch turned to stop position Clutch lever not pulled in or gear not in neu tral Battery voltage low Immobilizer system trouble Spark plug dirty broken or gap malad justed Spark plug incorrect Stick coil shorted or not in good contact Air passage clogged Air cleaner clogged poorly sealed or miss ing Leak from oil filler cap crankcase breather hose or air cleaner drain hose Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly valve ben
528. ubthrottle Valve Actuator Resistance Inspection e Turn the ignition switch off e Disconnect the subthrottle valve actuator harness con nector A e Connect a digital meter to the subthrottle valve actuator harness connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections Y lead 1 P lead 2 G lead 3 BK lead 4 Standard About 5 2 7 8 Q xIf the reading is out of the standard replace the throttle body assy x If the reading is within the standard check the input volt age see Subthrottle Valve Actuator Input Voltage Inspec tion 6GC17168BS1 C 3 94 FUEL SYSTEM DFI Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch off e Disconnect the subthrottle valve actuator harness con nector and connect the harness adapter A between these connectors as shown Main Harness B Subthrottle Valve Actuator C Special Tool Measuring Adapter 57001 1700 e Connect the peak voltage adapter D and a digital meter E to the harness adapter leads Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Subthrottle Valve Actuator Input Voltage Connections to Adapter 1 Digital Meter R actuator GY R lead Digital Meter Frame Ground terminal Digital Meter BK actuator BK O l
529. unting Bolts 25 2 5 18 Front Brake Pad Pins 17 2 1 75 12 7 Front Brake Pad Pin Plugs 2 5 0 25 22 in lb Front Caliper Holder Pin Bolts 22 2 2 16 L Si Rear Master Cylinder Mounting Bolts 25 2 5 18 Brake Pedal Bolt 8 8 0 90 78 in Ib Rear Master Cylinder Push Rod Locknut 17 2 1 75 12 7 Rear Caliper Pin Bolt 27 2 8 20 Si Rear Brake Disc Mounting Bolts 27 2 8 20 L Rear Brake Pad Pin 17 2 1 75 12 7 Rear Brake Pad Pin Plug 2 5 0 25 22 in lb Rear Caliper Mounting Bolt 22 2 2 16 Brake Hose Banjo Bolts ABS Hydraulic Unit 33 3 4 24 Bleed Valves 7 8 0 80 69 in Ib Suspension Upper Front Fork Clamp Bolts 20 2 0 15 Front Fork Top Plugs 22 5 2 29 16 6 Piston Rod Nuts 15 1 5 11 Lower Front Fork Clamp Bolts 20 5 2 09 15 1 Cylinder Units 70 7 1 52 Front Axle Clamp Bolt 20 2 0 15 Piston Rod Nut 15 1 5 11 Piston Rod Rubber Nut 15 1 5 11 Torque and Locking Agent PERIODIC MAINTENANCE 2 9 Fastener Nem Torque ftlb Remarks Piston Rod Assy Stopper 17 5 1 78 12 9 AD Cylinder Unit 70 7 1 52 AD Swingarm Pivot Shaft Nut 108 11 0 79 7 Swingarm Pivot Shaft 9 8 1 0 87 Swingarm Pivot Shaft Locknut 98 10 72 Rear Shock Absorber Nut Upper 34 3 5 25 R Rear Shock Absorber Nut Lower 34 3 5 25 R Rocker Arm Nut 34 3 5 25 R Tie Rod Nuts 59 6 0 44 R Steering Handlebar Holder Bolts 25 2 5 18 S Rear View Mirror Locknut Upper 18 1 8 13 Lh Rear View Mirror Nut Lower 30 3 1 22 Switch Housing Screws 3 5 0 36
530. ure F change every time the left button is pushed within 2 seconds Km L Km h C MPG US mph F L 100Km Km h C MPG UK mph C GP17039DN3 C x If the meter function does not work replace the meter assembly Check 6 Clock Setting Check e Connect the leads in the same circuit as Check 1 e Set the ODO mode A by pushing the left button B e Push the left button for more than two seconds within 10 seconds connecting the terminal 15 OThe clock setting menu hour and minute C should blink e Push the right button D OThe hour display A starts blinking e By pushing the left button each time check that the hour display changes 6P170710 6 6P170020 6 GP17808BS1 C 16 76 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e By pushing the right button check that the hour display decides and minute display A starts blinking e By pushing the left button each time check that the minute display changes e By pushing the right button check that the hour and minute display start blinking e By pushing the left button check that the hour and minute display decide e When both hour and minute display is blinking by pushing the right button check that the hour display start blinking This blinking returns the hour setting display x If the display function does not work replace the meter assembly olf the terminal 15 disconnected
531. use Installation x If a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Fuse Installation in the Electrical System chapter ECU Fuse Inspection e Refer to the Fuse Inspection in the Electrical System chapter ECU Main Relay Removal Installation OThe ECU main relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter ECU Main Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter 3 112 FUEL SYSTEM Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove Fuel Tank see Fuel Tank Removal Fuel Outlet Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel out
532. ut the adjusting nut to free the spring Special Tool Hook Wrench T 3 2 R37 57001 1539 e To adjust the spring preload turn in the adjusting nut A to the desired position and tighten the locknut B Spring Length C Spring Preload Setting Standard Spring length 175 2 mm 6 90 in Usable Range Spring length 170 2 180 2 mm 6 70 7 09 in e Remove Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter Footpeg Bracket Bolts A Left Footpeg Bracket B Chain Cover see Drive Chain Removal Installation in the Final Drive chapter SUSPENSION 13 37 Rear Shock Absorber Remove Bolts A Screw B e To adjust the spring preload turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches A with the rear shock absorber attached the frame Special Tool Hook Wrench T 3 2 R37 57001 1539 x If the spring action feels too soft or too stiff adjust it Spring Adjustment Adjuster Damping Position Force 180 2 mm Weak Soft Light Good Low Setting Load Road Speed 7 09 in T T T T T T l l 170 2 mm 6 70 in Strong Hard Heavy Bad High e Install the removed parts see appropriate chapters Spring Preload Adjustment ZR800C D Models e Remove Bolts A Screw B 13 38 SUSPENSION Rear Shock Absorber e Using the hook wrench A turn the adjusting nut B to adjus
533. ution to the oil ring ex pander and install the oil ring expander A in the bottom piston ring groove so the ends B not butt together e Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom GE16180BS1 GE16181BS1 GE16060BS1 C Cylinder Pistons ENGINE TOP END 5 37 e Do not mix up the top and second ring e Install the top ring A so that the 1R mark B faces up e Install the second ring C so that the 2R mark D faces up OApply molybdenum disulfide oil solution to the piston rings NOTE Olf a new piston is used use new piston ring e Install the piston with its dent mark facing forward e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring compress it only enough to install it and no more NOTICE Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install the cylinder see Cylind
534. utput Voltage Standard DC 3 46 3 76 V at pulley original position e Turn the ignition switch off xIf the reading is out of the standard check the exhaust butterfly valve actuator sensor resistance see Exhaust Butterfly Valve Actuator Sensor Resistance Inspection x If the reading is within the standard remove the ECU check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Exhaust Butterfly Valve Actuator Sensor Connector B GY lead ECU terminal 28 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17599ES1 C FUEL SYSTEM DFI 3 85 Exhaust Butterfly Valve Actuator Sensor Service Code 34 ZR800A B Models Exhaust Butterfly Valve Actuator Sensor Resistance Inspection e Turn the ignition switch off e Disconnect the exhaust butterfly valve actuator sensor connector 3 pins connector A e Connect a digital meter B to the exhaust butterfly valve actuator sensor connector e Measure the exhaust butterfly valve actuator sensor re sistance 80178280651 Exhaust Butterfly Valve Actuator Sensor Resistance Connections W lead C BK lead D Standard 4 6 kO x
535. val Installation GC17612bES1 FUEL SYSTEM DFI 3 123 Fuel Injectors x If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and injector connectors Wiring Inspection ECU Connector A lt gt Fuel Injector Connector B For Fuel Injector 1 C BL BK lead ECU terminal 36 D For Fuel Injector 2 BL R lead ECU terminal 34 For Fuel Injector 3 BL O lead ECU terminal 11 For Fuel Injector 4 BL G lead ECU terminal 10 xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Fuel Injector Fuel Line Inspection e Remove Fuel Tank see Fuel Tank Removal Fuel Outlet Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage
536. ve Relay Inspection Service Code 19 e Perform the Pre Diagnosis Inspection 1 and 2 e Check the system connectors for loose or poorly contact Step 1 e Check the ABS fuse 30 A A in the fuse box 1 for blown x If the ABS fuse is blown replace the fuse x If the fuse is not blown go to next step Step 2 e Disconnect the ABS hydraulic unit connector e Check the voltage between the terminal 9 BK A and terminal 18 R W B of the ABS hydraulic unit connector O00907 69 Special Tool Hand Tester 57001 1394 Dace OThe battery voltage 10 16 should appear while the ignition switch turned on x lf the battery voltage does not appear repair or replace 114711881 the main harness x If the battery voltage appeared replace the ABS hydraulic unit Front Rear Wheel Rotation Difference Abnormal Inspection Service Code 25 e Perform the Pre Diagnosis Inspection 1 and 2 Step 1 e Check the front and rear tire wheel conditions for tire pres sure tire size types abnormal wear and deformations see Wheels Tires in the Periodic Maintenance chapter x If the tire and or wheel are bad condition correct them to the normal condition x If there is no problem go to next step Step 2 e Visually inspect the sensor rotor A for missing teeth or clogging with foreign matter see Wheel Rotation Sensor Rotor Inspection Clean or correct the parts if nece
537. ve a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water and seek medial at tention for more severe burns Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a d
538. ve old gaskets and clean the sealing surfaces thor oughly so that no gasket material or other material remains Install the new gaskets and replace the used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non Permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 68020128 5 GB020138 5 68020148 5 J 2 68020158 5 68020188 5 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be r pressed into place apply small amount of oil to the con D uua tact area Be sure to maintain proper alignment and use dai d smooth movements when installing gt GB020178 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is N absolutely necessary Replace with new ones whenever m removed Press bearings with the manufacturer and size MI marks facing out Press the bearing into place by putting RSs pressure on the correct bearing race as shown 2 B Bh B Pressing the incorrect race can cause pressure between Ic 5 A the inner and outer race and result in bearing damage 77 orem 68020188 5 Oil Seal Grease Seal Do not remove pr
539. water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts Cooling System Water Hose and Pipe Inspection coolant leak damage installation condition OThe high pressure inside the water hose can cause coolant to leak A or the hose to burst if the line is not properly maintained e Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in lb 6506005851 C Coolant Change A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant f
540. wear or damage e Install the removed parts see appropriate chapters e Tighten Torque Footpeg Bracket Bolts 30 N m 3 1 kgf m 22 ft Ib 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake System Brake Fluid Leak Brake Hose and Pipe Inspection e For ABS equipped models note the following e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Right Side Fairing see Side Fairing Removal in the Frame chapter e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A pipes B ABS equipped models and fittings C x If the brake fluid leaked from any position inspect or re place the problem part PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condi tion Inspection e For ABS equipped models note the following e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Right Side Fairing see Side Fairing Removal in the Frame chapter e Inspect the brake hoses pipes and fittings for deteriora tion cracks and signs of leakage g OThe high pressure inside the brake line cause fluid to leak A or the hose pipes ABS equipped models to burst if the line is not properly maintained Bend and twist the rubber hose while examining it Replace the hose and pipe ABS equipped models if any crack B bulge C or leakage i
541. whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi GJ05041BS1 6J05030781 6J05044BS1 C Tires WHEELS TIRES 10 15 e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Air Pressure Inspection in the Periodic Maintenance chap ter e Install the air valve cap e Adjust the wheel balance see Balance Adjustment Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for s
542. whenever the tire is replaced Do not reuse the air valve 6J05040BS1 C 10 14 WHEELS TIRES Tires e Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place NOTICE Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber OThe air valve is as shown Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B e Position the tire on the rim so that the air valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire e Center the rim in the tire beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces A WARNING Overinflating a tire can cause it to explode causing serious injury or death Be sure to install the valve core
543. wo lower front fork clamp bolts alternately two times to ensure even tightening torque e Install the removed parts see appropriate chapters e Adjust Spring Preload ZR800A B Models see Spring Preload Adjustment Front Fork Oil Change ZR800A B Models e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vise e Unscrew the top plug A out of the outer tube Front Fork SUSPENSION 13 15 e Install the clamps A as shown NOTE OSet the clamps so that the cutout B of the upper side does not touch the tongue shape of stopper pull up the outer tube C to hold it by the clamps and then tighten the two bolts D The outer tube is used as a guide Special Tool Fork Spring Compressor 57001 1540 e Set the spring compressor A and a suitable jack B as shown Special Tool Fork Spring Compressor 57001 1771 e Insert the projection of the protector A into the front fork bottom hole B e Set the front fork A under the holder B e Lift up the suitable jack and hold the front fork 13 16 SUSPENSION Front Fork e Lift up the suitable jack until the piston rod nut A comes out e Insert the fork spring stopper B between the piston rod nut and the holder C while holding up the top plug D Special Tool Fork Spring Stopper 57001 1374 e Holding the piston rod nut with a wrench A remove the top plug B from the piston ro
544. ws When the coolant temperature goes up beyond 100 C 212 F the radiator fan relay conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not suffi cient air flow such as at low speeds This increases up the cooling action of the radiator When the coolant temperature is below 97 5 C 208 F the fan relay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 13 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 13 18 psi When the engine cools down another
545. ws other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 985 x 4 75 5 00 0 936 V 1 015 x 4 75 5 00 0 964 V Thus the valid range is 0 936 0 964 V e Turn the ignition switch off x If the reading is out of the standard check the main throt tle sensor resistance see Main Throttle Sensor Resis tance Inspection x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness side connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Main Throttle Sensor Connector B Y W lead ECU terminal 26 C G lead ECU terminal 33 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Main Throttle Sensor Resistance Inspection e Turn the ignition switch off e Disconnect the main throttle sensor connector e Connect a digital meter A to the main throttle sensor connector B e Measure the main throttle sensor resistance Main Throttle Sensor Resistance Connections lead C G lead D Standard 4 6 x If the reading is out of the standard replace the throttle body assy x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation
546. xIf the fuse is not blown go to next step 909725899 GL14721BS1 01000507074 9114722851 12 62 BRAKES Anti Lock Brake System Equipped Models Step 3 e Disconnect the ABS hydraulic unit connector Check the voltage between the terminal 9 BK A and terminal 18 R W B of the ABS hydraulic unit connector Special Tool Hand Tester 57001 1394 OThe battery voltage 10 16 V should appear while the ignition switch turned on x If the battery voltage does not appear repair or replace the main harness x If the battery voltage appeared go to next step Step 4 Check the voltage between the terminal 9 BK A and terminal 7 BR W B of the ABS hydraulic unit connector Special Tool Hand Tester 57001 1394 OThe battery voltage 10 16 V should appear while the ignition switch turned on x If the battery voltage not appeared repair or replace the main harness x If the battery voltage does appear replace the ABS hy draulic unit ABS Hydraulic Unit Internal Error Inspection Service Code 55 OThis service code indicates there is an internal error for the ECU integrated with the ABS hydraulic unit regarding the wheel speed detection e Perform the Pre Diagnosis Inspection 1 and 2 Check the system connectors for loose or poorly contact Step 1 e Measure
547. xhaust Butterfly Valve Actuator Sensor GY Water Temperature Sensor O Ground for ECU BK BL Warning Indicator Light LED Meter Unit BR R Oxygen Sensor BL Y Ground for Sensors G Injector 2 BL R Starter Button R BK Injector 1 BL BK Engine Stop Switch R BK Stick Coil 4 BK G Stick Coil 3 BK O Stick Coil 1 BK External Communication Line Immobilizer System KDS LG BK Unused Neutral Switch LG Starter Lockout Switch R G Immobilizer Amplifier V Ground BK Y Stick Coil 2 BK R Ground P Unused External Communication Line Immobilizer System KDS GY BL Meter Unit Tachometer LB Immobilizer Amplifier P BK Ground for Fuel System BK Y Ground for Ignition System BK Y KDS Kawasaki Diagnostic System Main Throttle Sensor Y W Subthrottle Sensor BL W 3 16 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram ZR800C D Models zzzi Zlzz se22 323 zi 3 iz T TE LG BK aY BL IL ij S d mm 249 P 25 2 MI W 91 A 40 HII MI M CRIT 1 B DFI System FUEL SYSTEM DFI 3 17 Part Names Oxygen Sensor Joi
548. y a non permanent locking agent to the threads of the oil pressure relief valve and tighten it NOTICE Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 1 5 11 ft lb Replace the oil pan gasket with a new one e Install the clamps A as shown e Install the bracket ZR800A B Models B e Tighten Torque Oil Pan Bolts 15 N m 1 5 kgf m 11 ft Ib e Install the removed parts see appropriate chapters GG06028BS1 C GG06086BS1 C 7 10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Refer to the Oil Pan Removal Oil Pressure Relief Valve Installation Refer to the Oil Pan Installation Oil Pressure Relief Valve Inspection e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the oil pressure relief valve in a well ventilated
549. y be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Camshaft Installation e Be sure to install the following parts Plug Hole Gaskets A Dowel Pins B e Apply molybdenum disulfide oil solution to all cam parts and journals e If a new camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE OThe exhaust camshaft has a 1883 EX mark A and the intake camshaft has a 1182 IN mark B Be careful not to mix up these shafts 4974 I PY 151 dn BE Joe RUE Li o tof oo R qo 1079 4 PSS cm GE11210BS1 ENGINE TOP END 5 21 Camshaft Camshaft Chain e Position the crankshaft at 1 4 piston TDC e Pull the tension side exhaust side A of the chain taut to install the chain Neng ON e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown OThe timing marks of 1 4T must be aligned with the lower surface of crankcase of rear side B OThe timing marks must be aligned with the cylinder head upper surface C EX Mark D IN Mark E e Before installing the camshaft caps install t
550. y when operating in severe conditions dusty wet muddy high speed or frequent starting stopping O Emission Related Item Q Inspection Change or Replace Lubrication Odometer Reading B year x 1 T km 1 000 mile See A 18 24 6 a 8 e 11 4 15 2 Items Fuel System Q G every 36 000 km 22 500 mile Air cleaner element C O Idle speed Q Q 2 16 Throttle control system play smooth return no drag Q Q 2 16 Engine vacuum synchronization LL Q Q 2 17 Fuel system Q Fuel hoses Cooling System Coolant level o every 36 000 km Coolant water hose and O ring 22 500 mile gine Top End Valve clearance Q every 42 000 km 26 250 mile Air suction system UN RUNG Q Q 2 33 4 O Clutch operation play engagement disengagement gine Lubrication System Engine oil and oil filter C Wheels and Tires Tire air pressure Wheels and tires Wheel bearing damage 2 4 PERIODIC MAINTENANCE Pe riodic Maintenance Chart Odometer Reading B year 1 000 km x 1 000 mile See CA 1 6 12 18 24 Items 0 6 3 8 7 6 11 4 15 2 Final Drive Drive chain lubrication condition C Q every 600 km 400 m
551. ystem Troubleshooting Guide Symptoms or Possible Causes Actions chapter Intake air temperature sensor trouble Inspect see chapter 3 Miscellaneous Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Speed sensor trouble Inspect see chapter 3 Throttle valves will not fully open Inspect throttle cables and lever linkage see chapter 3 Engine overheating Water temperature sensor see Overheating of Troubleshooting Guide in crankshaft sensor or speed sensor trouble chapter 17 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 Air cleaner element clogged Clean element see chapter 2 Fuel pressure too high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 spect see chapter 3 Fuel too low Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Exhaust Smokes Excessively Black smoke ee 3 40 FUEL SYSTEM DFI Self Diagnosis Self Diagnosis Outline The self diagnosis system is monitoring the following mechanisms DFI System and Ignition System Immobilizer System The following warning indicator lights LED are used for symbols of below table LED Color Warning Indicator Symbols Oil

Be sure the battery is fully charged

Contents

Download Pdf Manuals

Related Search

Related Contents