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Vulcan 1600 Nomad Service Manual

1. GLO7020482 C 12 18 BRAKES Brake Discs Brake Disc Removal e Remove the wheel see Front Rear Wheel Removal in the Wheels Tires chapter e Unscrew the mounting bolts A and take off the disc Brake Disc Installation e Install the brake disc A on the wheel so that the marked side B faces out e Apply a non permanent locking agent to the threads of the brake disc bolts C e Tighten Torque Front Brake Disc Bolts 27 N m 2 8 kgf m 20 ft Ib Rear Brake Disc Bolts 27 N m 2 8 kgf m 20 ft lb Brake Disc Wear e Measure the thickness of each disc A at the point where it has worn the most Measuring Area B Replace the disc if the sliding surface has worn past the service limit Brake Discs Thickness Standard Front 4 8 5 2 mm 0 19 0 20 in Rear 6 8 7 2 mm 0 27 0 28 in Service Limit Front 4 5 mm 0 18 in Rear 6 0 mm 0 24 in Brake Disc Warp e Jack up the motorcycle so that the wheel is off the ground see Front Rear Wheel Removal in the Wheels Tires chapter OFor front disc inspection turn the handlebar fully to one side e Set up a dial gage against the disc A as shown and mea sure disc runout while turning B the wheel by hand x If the 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 aosa P GLO80101S81 GLO8O11BS1
2. Tester Connection Tester Reading Q Tester Connection Tester Reading Q 1 1A 0 1A 8 co 1 2 2 8 co 3A 4 3A 8 co 6 5 6 2 co 6 10 6 3A co 6 7 17 3A co 6 17 0 Starter Circuit Headlight Relay Inspection e Remove the junction box e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the junction box as shown see Junction Box Internal Circuit in this section Alf the tester does not read as specified replace the junc tion box 16 98 ELECTRICAL SYSTEM Junction Box Relay Circuit Inspection with the battery disconnected Tester Tester Connection Reading Q Headlight Relay E 13 9 Tester Tester Connection Reading Q Starter Circuit Relay The actual reading varies with the hand tester used Apply tester positive lead Apply tester negative lead Relay Circuit Inspection with the battery connected Battery Tester Tester Reading Connection Connection Reading Q Headlight Relay 9 13 0 Starter Circuit lA O Noirs Relay 13 11 The actual reading varies with the hand tester used Apply tester positive lead Apply tester negative lead Diode Circuit Inspection e Remove the junction box e Check conductivity of the following pairs of terminals see Junction Box Internal Circuit in t
3. GC17705BW2 1 ECU 2 Crankshaft Sensors 3 Joint Connector 2 FUEL SYSTEM DFI 3 63 Vehicle down Sensor Service Code 31 Removal CAUTION Never drop the down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal in this chapter e Remove the bolts A and take out the covers B e Remove Bracket Nut A Inlet Air Pressure Sensor Bolt B e Remove the bracket nuts A and pull the vehicle down sensor B with the bracket C out of the frame e Unscrew the screws A and disconnect the connector B e Remove the vehicle down sensor C 3 64 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 Installation e Install the vehicle down sensor assy A in the original po sition The arrow mark B on the sensor must be on the front and point upward e Do not install the sensor upside down e Tighten the sensor bracket nuts C securely Front D e Install the Fuel Tank see Fuel Tank Installation in this chapter WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situations like leaning over in a turn with the po tential for an accident resulting in injury or death Ensure that the down sensor is held in place by the bracket and its bolt as shown 6017218BS2 C V
4. ELECTRICAL SYSTEM 16 69 Automatic Turn Signal Canceling System Turn Signal Control Relay Inspection CAUTION Never drop the turn signal control relay especially on a hard surface Such a shock to the unit can damage it e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Reservoir Tank see Coolant Change in the Periodic Maintenance chapter e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how many times the lights flash for one minute Turn Signal Control Relay Connector A Turn Signal Lights B 12 V Battery C x lf the lights do not flash as specified replace the turn sig nal control relay Testing Turn Signal Control Relay Inspection 6P14000351 Load The Number of x Tum Signal Lights Wattage W Flashing Times c m GEES 140 250 42 46 75 95 Cycle s per minute corresponds to one light burned out and the other lights stay ON NOTE OEven if the foregoing checks show the turn signal con trol relay to be good it may be defective in some man ner especially for automatic turn signal canceling op eration not readily detectable with above checks If all other checks are good replace the turn signal control relay Turn Signal Light Removal Installation e For front turn signal light removal remove the headlight unit see Headlight Removal in th
5. Headlight Beam Horizontal Adjustment Headlight Beam Vertical Adjustment A A 16 62 Headlight Bulb Replacement 16 62 Headlight Body Removal 16 63 City Light Bulb Replacement Other than US CA and AU 16 64 Tail Brake Light Removal Installa lei E 16 64 Tail Brake Light Bulb Replacement eea 16 64 Licence Plate Light Bulb Hepnlacement 16 65 Automatic Turn Signal Canceling AN 16 67 Wiring Inspection 16 67 Distance Sensor Inspection 16 68 16 2 ELECTRICAL SYSTEM Turn Signal Control Relay Inspection accio deg erd Turn Signal Light Removal Installation Turn Signal Light Bulb Replacement Radiator Fan System Fan System Circuit Inspection Fan Motor Inspection Oil Pressure Warning System Oil Pressure Light Delay Unit Removal coooooccccccnccnncccnncconccnnncs Oil Pressure Light Delay Unit Inspechon n nneeseeeeeeeeeeeeeeeeeeen Meter Gauge Meter Unit Removal eeeeeaenn Meter Unit Installation Meter Unit Disassembly Meter Unit Assembly Meter Unit Inspection LED Light Inspection Indicator Light Inspection Water Temperature Warning System Water Temperature Warning System Check Switch and Gensors Fuel Level Sensor I
6. BRAKES 12 19 Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e 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 Be sure to bleed the air from the brake line when ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is almost the same as for the front brake e Remove the reservoir cap and fill the reservoir with fresh specified brake fluid to the upper level line in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes A at the bottom of the reservoir e Remove the rubber cap from the bleed valve A on the front caliper B e Attach a clear plastic ho
7. GE11000481 5 38 ENGINE TOP END Cylinder Head 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 Do not drop or shock the valve seat cutter or the diamond particles may fall off Do not fail to apply engine oil to the valve seat cutter be fore grinding the seat surface Also wash off ground parti cles sticking to the cutter with washing oil CAUTION Do not use a wire brush to remove the metal par ticles from the cutter It will take off the diamond particles 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 During operation wash off any ground particles sticking to the cutter with washing oil After use wash it with washing oil and apply thin layer of engine oil before storing Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter A into the holder B and slide it into the valve guide e Press down lightly on the handle and turn it right or left C Grind the seat surface only until it is smooth CAUTION 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 HLA c
8. e Visually inspect the bearing in the front and final gear cases for abrasion color change or other damage Alf there is any doubt as to the condition of the bearing replace it Needle Bearing Inspection CAUTION Do not remove the needle bearing in the final gear case for inspection Removal may damage them e Check the needle bearings in the front and final gear cases OThe rollers in the needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage Alf there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged BRAKES 12 1 Brakes Table of Contents Exploded VIS Wi iii asia tere rd Reade ee Patent edad a Re E tnt 12 2 DPOCITICATIONS ac HAL A aes hs caste de dde nu a doen c OO 12 6 Special TO A A el na cede eege eg EE 12 7 Brake Lever Brake Pedal ii 12 8 Brake Lever Position AUS MEE tt ti ta o 12 8 Brake Pedal Position AGjUSIMENE sn near le nd ebe 12 8 Brake Pedal Removal si 12 9 Brake Pedal I stallati n sssne amsn ane la 12 10 Call iii id dan 12 11 Front Caliper REMOvVal msi Oasis 12 11 Rear Caliper Hemoval ses 12 11 Caliper Installation sumisa an arde 12 11 Front CallperDiSasSeraDiV EE 12 12 Fron
9. GP24005B 3 Ignition Switch Junction Box Turn Signal Control Relay Fuse 10 A Turn Signal Control Relay Meter Unit Distance Sensor Turn Signal Indicator Light Front Left Turn Signal Light Front Right Turn Signal Light 10 Rear Left Turn Signal Light 11 Rear Right Turn Signal Light 12 Turn Signal Switch 13 Joint Connector 1 14 Joint Connector 2 15 Main Fuse 30 A 16 Battery J O O1 ND A ELECTRICAL SYSTEM 16 73 Radiator Fan System A WARNING The radiator fan is connected directly to the battery The fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES Fan System Circuit Inspection e Remove Bolts A Regulator Rectifier Bracket B e Disconnect the radiator fan switch connector A e Using an auxiliary lead A connect the radiator fan switch connector B Radiator Fan Switch C x lf the fan rotates inspect the fan switch see Radiator Fan Switch Inspection in this chapter Alf the fan does not rotate inspect the following Leads and Connectors Main Fuse 30 A and Fan Fuse 15 A see Fuse Inspection in this chapter Fan Motor see Fan Motor Inspection in this section Fan Motor Inspection e Disconnect the connector A from the radiator fan swi
10. e Remove Thermostat Housing see Thermostat Removal in the Cooling System chapter Left Air Cleaner Base see Left Air Cleaner Housing Re moval Installation in this chapter Right Air Cleaner Base see Right Air Cleaner Housing Removal in this chapter Spark Plug Lead Holder Bolts A Spark Plug Lead Holder B and Spark Plug Caps C Throttle Body Assy Holder Bolts D Throttle Body Assy Holder E Front F e Disconnect Throttle Sensor Connector A Vacuum Hose B From Inlet Air Pressure Sensor Vacuum Hose C Between Vacuum Switch Valve and Throttle Body Assy 3 96 FUEL SYSTEM DFI Throttle Body Assy e Disconnect the front and rear injector connectors A Front B e Remove the following from the choke cable holder A Screw B Choke Cable Plate C e While pushing the choke lever A forward remove the cable housing from the choke cable holder B and the inner cable out of the holder slit C e Take off the lower end D from the choke lever Front E e Remove the screws A and take off the right switch hous ing B e Remove the accelerator cable end A and decelerator cable end B at the throttle grip FUEL SYSTEM DFI 3 97 Throttle Body Assy e Remove the cable clip A e Turn the throttle pulley B as shown and pull out the ac celerator cable housing C from the cable holder D e Return the pulley and pull out the decelerator cable hous ing E from
11. 10 8 WHEELS TIRES Wheels Rims Rear Wheel Removal e Using the jack A and attachment jack B under the frame pipe ribs C lift the rear wheel D OFF the ground until the front wheel E touches the ground Special Tools Jack 57001 1238 Attachment Jack 57001 1398 CAUTION Be sure to put the front wheel ON the ground when GJ04111BS1 removing the rear wheel or the motorcycle may fall over The motorcycle could be damaged Be sure to put the front wheel ON the ground when removing the rear wheel or the motorcycle may fall over It could cause an accident and injury e Squeeze the brake lever slowly and hold it with a band A CAUTION Be sure to hold the front brake when removing the rear wheel or the motorcycle may fall over The motorcycle could be damaged A WARNING Be sure to hold the front brake when removing the rear wheel or the motorcycle may fall over It could cause an accident and injury e Remove Left and Right saddlebags see saddlebag Removal in the Frame chapter Rear Fender see Rear Fender Removal in the Frame chapter e Loosen the left and right muffler clamp bolts e Remove the left and right muffler stay mounting bolts A e Lower the left and right mufflers B WHEELS TIRES 10 9 Wheels Rims e Remove Bolts A Both Sides Saddlebag Stay Lower B e Remove Caliper Mounting Bolts A Caliper B e Remove
12. Inside Oil Pipe Removal e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove Oil Pipe Clamp Bolt A Oil Pipe Holder Bolt B e Remove the inside oil pipe C from the right crankcase e Remove the oil return pipe clamp bolt A and oil return pipe B e Remove the oil separator A e Remove Oil Pipe Clamp Bolts A Oil Pipe Holder Bolt B e Remove the inside oil pipe C and the oil return pipe D from the left crankcase E OPull out the large size fittings F first and remove the small size fitting G upward e Remove the bolt A and the oil baffle B 7 12 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Inside Oil Pipe Installation e Check that the oil pipe fitting O rings A are in good con dition e Apply grease to the O rings before installation Oil Pipe B Fitting C e Install the inside oil pipe A separator B and the oil re turn pipe C to left crankcase D as shown ODo not apply silicone sealant to the groove of the grommet and the mating surface of the grommet E OApply silicone sealant to the crankcase mating surface F of the separator Sealant Three Bond TB1207B OApply a non permanent locking agent to the oil pipe holder bolt G oil return pipe clamp bolt H oil pipe clamp bolts I and oil baffle bolt J Olf the oil nozzles K are removed install them 6G090398 2 C Torque Oil Pi
13. LE e Apply molybdenum disulfide grease to the oil seal lips and install the washer A and the oil seal B into the outer tube OFace the flat side C of the seal upward Special Tool Front Fork Oil Seal Driver D 57001 1219 e Install Retaining Ring Dust Seal GM0402068S1 SUSPENSION 13 13 Front Fork e Apply a non permanent locking agent to the threads of the Allen bolt and screw the Allen bolt into the bottom of the outer tube e Hold the front fork horizontally in a vise A e Hold the cylinder unit B with the special tools and tighten the Allen bolt C Special Tools Fork Cylinder Holder Handle D 57001 183 Fork Cylinder Holder Adapter E 57001 1057 Torque Front Fork Bottom Allen Bolt 30 N m 3 1 kgf m 22 ft lb e Pour in the specified type of oil see Fork Oil Change Each Fork Leg in this section e Install Fork Spring A Washer B Spacer C Top Plug D with O ring E e Install the front fork see front fork Installation in this sec tion Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage Alf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced CAUT
14. e Watch the gauge for at least 6 seconds Alf the pressure holds steady the system is good x If the pressure drops at once or if bubbles are found in the area the line is leaking Perform the following as necessary ORetighten the fuel hose clamps D Torque Fuel Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib OReplace O ring and Seal Ring of Injectors G ORepeat the leak test and check the fuel line for no leak age e Install the fuel outlet hose see Fuel Tank Installation in this chapter e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Fit the fuel hose joint 2 A onto the pipe for delivery joint until the joint clicks B Olnsert the hose joint 2 straight along the pipe Front C 6017224BS2 C 3 70 FUEL SYSTEM DFI Fuel Injectors 1 2 Service Code 41 42 e Push and pull A the fuel hose joint 2 B back and forth more than two times and make sure it is locked and doesn t come off When the fuel hose joint 2 is correctly installed it should slide on the delivery pipe about 5 mm 0 2 in A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak e Install the fuel tank see Fuel Tank Installation in this chap ter and connect the battery terminal Audible Inspection e Remove the left air cleaner housing see Left Air Cleane
15. BK Y Lead Terminal lf the test light turn on the reserve switch is defective Replace the fuel level sensor e Remove Fuel Level Sensor see Fuel Level Sensor Inspection in this section e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel level sensor lead connector as shown 12 V Battery A Test Light B Fuel Level Sensor Connector C Fuel Reserve Switch D x lf the test light doesn t light replace the fuel level sensor NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel level sensor is removed Leave the fuel reserve switch with leads for inspection connected for few minutes 6P18050BS1 Speed Sensor Removal e Remove Alternator Outer Cover see Alternator Outer Cover Re moval in this chapter Speed Sensor Lead Connector A Band B Bolt C Speed Sensor D Speed Sensor Installation e Apply grease to the O ring A on the speed sensor e Apply a non permanent locking agent to the threads of the speed sensor mounting bolt e Tighten Torque Speed Sensor Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb ELECTRICAL SYSTEM 16 93 Switch and Sensors Speed Sensor Inspection e Remove the speed sensor see Speed Sensor Removal in this section e Connect the speed sensor connector A with a battery B 10 kQ resistor C and hand tester D as shown e Set th
16. Camshafts Camshaft Sprocket Installation e Use the sprocket marked F for the front camshaft A and the sprocket marked R for the rear camshaft B e Apply a non permanent locking agent to the camshaft sprocket bolts and tighten them to the specified torque Torque Camshaft Sprocket Bolts 15 N m 1 5 kgf m 11 ft Ib Camshaft Rocker Case Wear 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 and the rocker case using plastigage NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap e Apply molybdenum disulfide oil solution to the threads and seating surface of M12 nuts and both sides of wash ers OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Tighten the rocker case nuts and bolts temporarily follow ing the tightening sequence shown and then tighten them to the specified torque Torque M12 Rocker Case Nuts 1 4 78 N m 8 0 kgf m 58 ft lb M8 Rocker Case Nuts 5 8 25 N m 2 5 kgf m 18 ft lb Rocker Case Bolts 9 10 8 8 N m 0 90 kgf m 78 in Ib Inlet Side A GE11020281 GE20010281 ENGINE TOP END 5 29 Camshafts e Remove the rocker case again and measure the plasti gage width A to de
17. Canister Face the white mark left Separator Rear Oil Hose Separator Inlet Run these hoses on the left of the main harness Front APPENDIX 17 21 Cable Wire and Hose Routing Lin AT Wy 7 d Si hl 2 a L gA Dz ZA A N SZ Ee NL SYA d Q NY RES 9 NON ZY SC IN i E rr 6809720844 C 1 Left Handlebar Switch 9 Run the throttle cables in 16 Horn Leads Connectors side the clutch hose 17 Starter Cable 2 Accessory Lead Connec 10 Run the throttle cables in 18 Clamp Fit it into the en tors side the head pipe cover gine mount bracket and 3 Headlight Body 11 Head Pipe Cover clamp the left and right 4 Front Left Turn Signal 12 Plastic Snap on Clamps regulator rectifier leads Light Lead Connectors Fit them into the frame 19 Horn 5 Front Right Turn Signal pipe 20 Starter Motor Light Lead Connectors 13 Put the clutch hose into 21 Front Regulator Rectifier 6 Main Harness the hole of the head pipe 22 White Mark Position it 7 Right Handlebar Switch cover here Connectors 14 Water Baffle Plats 23 Run the clutch hose in the 8 Clutch Hose 15 Fuel Tank Water Drain bracket with white mark Hose outside 17 22 APPENDIX Cable Wire and Hose Routing 24 Side stand Switch Leads Run the lead through the front and rear hooks and hold them with the snap on clamp a bit tight behind the side stand bracket Welded Clamp Left Fr
18. Crankshaft Web Length Standard 96 85 96 95 mm 3 813 3 817 in Service Limit 96 6 mm 3 80 in x If the length measurement is smaller than the service limit replace the crankshaft Otherwise replace the crankcase halves as a set CAUTION The right and left crankcase halves are machined at 6105061BS1 the factory in the assembled state so they must be replaced as a set 9 28 CRANKSHAFT TRANSMISSION Primary Gear Primary Gear Removal e Remove Clutch Cover see Clutch Cover Removal in the Clutch chapter Starter Clutch Gear see Crankcase Disassembly in this chapter e Using the gear holder A to loosen the primary gear bolt B Special Tool Gear Holder m2 0 57001 1557 e Remove Clutch see Clutch Removal in the Clutch chapter Bolts A e Remove the water pump chain guide B and water pump idle shaft holder C from the right crankcase e Remove the primary gear bolt A water pump drive sprocket B idle shaft C and idle shaft sprocket D Water Pump Chain E OStuff the cloth F on the holes of the crankcase so that the pin close not drop into the crankcase bottom e Pull the primary gear A out of the crankshaft and take the pin B out of the idle shaft Primary Gear Installation e Fit the primary gear A with the boss B facing toward the engine inside CRANKSHAFT TRANSMISSION 9 29 Primary Gear e Fit the pin A into the slot B
19. Fuel pressure regulator trouble Inspect and replace see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Ignition coil trouble Inspect see chapter 16 Compression Low Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 Cylinder piston worn Inspect and replace see chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 Valve guide worn or stem seal damaged Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on seating surface Inspect and replace see chapter 5 KACR compression release cam sticks open Inspect and repair or replace see chapter 5 Inspect and replace see chapter 5 Inspect and repair or replace see chapter 5 Hesitation le O Too low fuel pressure Inspect see chapter 3 Clogged fuel line Inspect and repair see chapter 3 Cracked or obstructed inlet air pressure sensor Inspect and repair or replace see chapter 3 hose Fuel pump trouble Inspect see chapter 3 Fuel injector troub
20. Torque Fastener Nem kgf m ftlb Remarks Electrical System Alternator Cover Bolts 11 1 1 97 in lb Alternator Inner Cover Bolts 11 1 1 97 in lb Alternator Outer Cover Assembly Bolts 6 9 0 70 61 in lb Alternator Outer Cover Bolts 6 9 0 70 61 in lb WL Alternator Outer Cover Damper Bolts 6 9 0 70 61 in lb L Alternator Outer Cover Joint Bolts 6 9 0 70 61 in lb L Alternator Rotor Bolt 78 8 0 58 MO Alternator Stator Bolts 13 1 3 115 ml L Crankshaft Sensor Lead Holder Bolt 2 9 0 30 26 in lb L Crankshaft Sensor Screws 2 9 0 30 26 in lb Front Brake Light Switch Screw 1 2 0 12 11 in lb Fuel Level Sensor Mounting Bolts 6 9 0 70 61 in lb L Fuel Pump Mounting Bolts 9 8 1 0 87 in lb S Headlight Rim Screws 2 9 0 30 26 in lb Headlight Unit Bracket Screws 1 0 0 10 8 9 in lb L Inside Starter Holder Bolts 11 1 1 97 in lb L Neutral Switch 15 1 5 11 Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Screw 1 5 0 15 13 in lb G Radiator Fan Bolts 8 3 0 85 73 in lb Radiator Fan Switch 18 1 8 13 Regulator Rectifier Bolts 6 5 0 66 57 in lb Rotor Bolt Cap 1 5 0 15 13 in lb Side Stand Switch Mounting Bolt 8 8 0 90 78 in lb L Spark Plugs 18 1 8 13 Speed Sensor Mounting Bolt 9 8 1 0 87 in lb L Stater Lockout Switch Screw 1 2 0 12 11 in lb Stater Motor Assembly Bolts 4 9 0 50 43 in lb Stater Motor Mounting Bolts 11 1 1 97 in lb Stater Motor Terminal Locknut 11 1 1 97 in lb Stater Motor Terminal Nut 4 9 0 50 43 in lb Stator Lead Holder Screw 11 1 1 97 in lb L T
21. 80 g 2 8 oz 90 g 3 2 oz One Side A 10 g 0 4 oz 10 g 0 4 oz 20 g 0 7 oz 20 g 0 7 oz 30 g 1 1 oz 30 g 1 1 oz 20 g 0 7 oz 20g 0 7 oz 20 g 0 7 oz 20g 0 7 oz 20 g 0 7 oz 30g 1 1 oz Weight Selection Other Side B 10 g 0 4 oz 10 g 0 4 oz 20 g 0 7 oz 20 g 0 7 oz 30 g 1 1 oz 30 g 1 1 oz 20 g 0 7 oz 20g 0 7 oz 20 g 0 7 oz 20g 0 7 oz GJ04114BS1 10 16 WHEELS TIRES Tires Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection in the Periodic Main tenance chapter Tire Inspection e Refer to the Wheel Tire Damage Inspection in the Peri odic Maintenance chapter Tire Removal e Remove the following Wheel see Front Rear Wheel Removal in this chapter Brake Disc see Brake Disc Removal in the Brakes chap ter 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 Valve Stem 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 CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a commercially avail
22. Alf a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage DFI Fuse Inspection e Remove the fuse see DFI Fuse Removal in this section e Inspect the fuse element x lf it is open 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 rat ing check the wiring and related components for a short circuit Housing A Fuse Element B and Blown Element D Terminals C GP20000181 CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Do not use a fuse rated for other than amperage and voltage specified in the Wiring Diagram DFI Main Relay Removal CAUTION Never drop the relay especially on a hard surface Such a shock to the relay can damage it e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Coolant Reservoir Tank see Coolant Change in the Pe riodic Maintenance chapter e Remove the DFI main relay A and disconnect the con nector Front B DFI Main Relay Inspection e Remove the DFI main relay see DFI Main Relay Removal in this section e Connect the hand tester A and one 12 V battery B to the relay connector C as shown Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch
23. BR BK lead D Standard 4 6kQ x If the reading is out of the range replace the throttle sen sor along with the throttle body x lf the reading is within the range but the problem still exists the ECU is suspect Replace the ECU 6017023881 FUEL SYSTEM DFI 3 47 Throttle Sensor Service Code 11 y y pa ei g g g g E z 2 Gd 3 g g a S ES ZS S a E z S ES ei y E e S a e tes z e e o CN e we e e a GC17700BW2 1 ECU 2 Throttle Sensor 3 48 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the part can damage it e Remove the fuel tank see Fuel Tank Removal in this chapter e Disconnect the inlet air pressure sensor connector A e Unscrew the inlet air pressure sensor bolt B and remove the sensor C e Disconnect the vacuum hose from the sensor Front D Installation NOTE OThe inlet air pressure sensor is the same part as the atmospheric pressure sensor except for a vacuum hose and different wiring e Route the vacuum hose correctly see Cable Wire and Hose Routing section in the Appendix chapter Make sure it doesn t get pinched or kinked e Install the inlet air pressure sensor A OThe stopper B must not be on the sensor holder C Rear View D e Tighten the inlet air pressure sens
24. Cable Wire and Hose Routing OONOARWN A Fuel Tank Ignition Coil for Rear Spark Plugs Fuel Tank Water Drain Hose Run the hose over the cooling hose Plastic Snap on Clamps Rear Brake Light Switch and Radiator Fan Leads Right Frame Pipe Plastic Snap on Clamp Rear Brake Light Switch Lead Rear Brake Light Switch Clutch Hose Left Frame Pipe Choke Knob and Cable Horn Fit the clamp position with the choke knob Permissible valve within 10 mm 0 4 in Clamp Welded Clamps 10 30 mm 0 4 1 2 in Clamp Fuel Tank Breather Hose Except California Model Marking Position here Run the fuel tank breather hose between the bracket and the right frame pipe Holder Swingarm Pivot Cross Pipe Run the hose in front of swingarm pivot and cross pipe Clamp Coolant Reserve Tank Overflow Hose Front 17 4 APPENDIX Cable Wire and Hose Routing as are w E lt CE a Se SE x Sg S gt A e SE 9 D V 26 3 25 ji OTL ae ies g D ms Ne ER OS 3 9 D 9 eD 9 CO eD eI eI 9 lt Ggs Ze i KS A S OI aia D 9 AA LD oO Ob S APPENDIX 17 5 Cable Wire and Hose Routing GBO9311BH3 Right Rear Spark Plug Lead Left Rear Spark Plug Lead Inlet Air Pressure Hose Ignition Coil for Rear Spark Plugs
25. Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main tenance 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 radiator filler neck B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leakage e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 17 8 psi CAUTION 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 17 8 psi e Watch the gauge for at least 6 seconds x lf the pressure holds 93 kPa 0 95 kgf cm 13 5 psi or more the system is all right x lf the pressure drops and no external source is found check for internal leakage Droplets in the engine oil indi cate internal leakage Check the cylinder head and cylin der gaskets and the water pump e Remove the pressure tester replenish the coolant and install the radiator cap COOLING SYSTEM 4 9 Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator W
26. Incorrect Tooth Contact Patterns Example 1 e Increase the thickness of the drive gear shim s by 0 05 mm 0 002 in and or increase the thickness of the driven gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Heel A Bottom B Top C Toe D Drive Gear E Driven Gear F 6Ko8001252 C 6K09013BS2 C FINAL DRIVE 11 37 Front Bevel Gears Incorrect Tooth Contact Patterns Example 2 e Decrease the thickness of the drive gear shim s by 0 05 mm 0 002 in and or decrease the thickness of the driven gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Heel A Bottom B Top C Toe D Drive Gear E Driven Gear F GKO9014BS2 C Bevel Gear Inspection e Visually check the bevel gears for scoring chipping or other damage k Replace the bevel gears as a set if either gear is dam aged Cam Damper Inspection e Visually inspect the spring A cam follower B damper cam C and output shaft D x Replace the damaged parts 6K09012BS1 11 38 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Replacement e Using the bearing driver set or the oil seal and bearing remover remove the bearings Special Tools Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 NOT
27. Starter system wiring open or shorted Inspect the wiring see chapter 16 Ignition switch trouble Inspect and replace see chapter 16 Engine stop switch trouble Inspect and repair or replace see chapter 16 Main 30 A or ignition fuse blown Inspect and replace see chapter 16 Starter motor rotating but engine doesn t turn over inspect See chapter 9 inspect see chapter 9 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Connecting rod big end seizure Inspect and replace see chapter 9 Crankshaft seizure Inspect and replace see chapter 9 Transmission gear or bearing seizure Inspect and replace see chapter 9 Inspect and replace see chapter 9 Balancer bearing seizure Inspect and replace see chapter 9 No fuel flow No or little fuel in tank Supply fuel see Owner s Manual Fuel pump not rotating Inspect see chapter 3 Fuel injector trouble Inspect and replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Engine flooded Spark plug dirty broken or gap maladjusted Clean spark plugs and a
28. 0 kgf cm O psi T T T T y y y de SE Hard Heavy Bad 3 0 kgf cm 43 psi e Adjust the air pressure NOTE OCheck and adjust the air pressure when the rear shock absorbers are cold room temperature 13 16 SUSPENSION Rear Shock Absorber Air Type e Raise the rear wheel A off the ground using the jack B and the attachment jack C Special Tools Jack 57001 1238 Attachment Jack 57001 1398 gt N gt en RES AAN O SOC AS ES e Take off each air valve cap A on the right and left shock absorbers Front B e Check the air pressure with the air pressure gauge NOTE ODo not use tire gauges for checking air pressure They may not indicate the correct air pressure because of air leakage that occur when the gauge is applied to the valve GMO5036BS1 OTo lower the air pressure push the valve core in slightly To raise the pressure inject air through the valve with a tire pump Change the air pressure within the range spec ified in the preceding table to suit various riding condi tions CAUTION Inject air little by little so that air pressure does not rise rapidly Air pressure exceeding 490 kPa 5 0 kgf cm 71 psi may damage the oil seal Try to set the air pressure of the right and left shock absorbers as equally as possible WARNING Be sure to adjust the air pressure within the usable range Pressure too high can produce a hazardous rid
29. Caliper Rubber Parts Replacement Spark Plug Replacement snsneseeeeeeeseeeeeeeeeeeeee Final Gear Case Oil Change Clutch Hose and Pipe Replacement Clutch Fluid Change ss cc Clutch Master Cylinder Rubber Parts Replacement nnssenesenereerrrrrrrrrrrrrrrrrrrrrrrrrrrens Clutch Slave Cylinder Piston Seal Replacement 2 32 2 32 2 34 2 36 2 37 2 37 2 37 2 38 2 40 2 40 2 41 2 42 2 43 2 44 2 47 2 48 2 48 2 50 2 51 2 55 2 56 2 56 2 57 2 58 2 59 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 FREQUENCY Whichever ODOMETER READING comes gt x 1 000 km first x 1 000 mile See 4 1 6 12 18 24 30 36 Page INSPECTION Every 0 6 4 7 5 12 15 20 24 Fuel System Air cleaner element clean e o 2 16 Throttle control system play smooth Sar return no drag inspect y Idle speed inspect Fuel leak fuel hose and pipe inspect Fuel hose and pipe damage inspect Cooling System Coolant level inspect Coolant leak radiator hose and pipe inspect Radiator hose damage inspect Radiator hose installation condition inspect Evaporative Emission Control
30. E VULCAN 1600 NOMAD EH Kawasaki VN1600 CLASSIC TOURER 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 NIO BIO IN e0 O0 o NI IO A AON lech Appendix VULCAN 1600 NOMAD Kawasaki VN1600 CLASSIC TOURER 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 Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan 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 witho
31. Final Gear Case see Final Gear Case Removal in this chapter Propeller Shaft see Propeller Shaft Removal in this sec tion e Wipe the old grease off the propeller shaft sliding joint and pinion joint e Pack the propeller shaft sliding joint with 20 mL 0 68 US oz of high temperature grease A Sliding Joint B Propeller Shaft C e Install Propeller Shaft see Propeller Shaft Installation in this section Final Gear Case see Final Gear Case Installation in this chapter Propeller Shaft Inspection e Check that the universal joint A works smoothly without rattling or sticking x lf it does not work smoothly the needle bearings of the universal joint are damaged Replace the propeller shaft assy with a new one e Visually inspect the bearing of the shaft and the wear of the splines B at the rear end of the shaft x lf it is bent at all replace the propeller shaft assy Do not attempt to straighten a bent shaft Sliding Joint Inspection e Visually inspect the internal splines B of the propeller shaft sliding joint A x If they are badly worn or chipped replace the joint with a new one 6S12023BS1 FINAL DRIVE 11 25 Front Bevel Gears Front Gear Case Removal a e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Rear Shift Lever A see External Shift Mechanism Re moval in the Crankshaft Transmission chapter OThe speed sensor conne
32. GS11000BS1 6S11022BS1 PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures 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 Alf any measurement is less than the service limit re place the tire see Tire Removal and Installation in the Wheels Tires chapter Tread Depth Standard Front 4 5 mm 0 18 in Rear 7 2 mm 0 28 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 1 in Over to 130 km h 80 mph Wheel Bearing Damage Inspection e Using a jack and attachment raise the front wheel off the ground see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebar all the way to the left or right e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel e Spin B the front wheel lightly and check for smoothly turn roughness binding or noise Alf roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Hub Bearings Inspection in the Wheels Tires chapter e Using a jack and attachment raise the rear wheel off the ground 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 tur
33. 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 OTo prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running 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 leads 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 too 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 OWire Color Co
34. Oil Baffle Fitting Left Crankcase Right Air Cleaner Housing Crankcase Breather Hose Oil Separating Chambers Right Crankcase Oil Return Pipes 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Situate the motorcycle so that it is vertical e Check that the engine oil level is between the upper A and lower B levels in the gauge Clutch Cover C NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait 2 3 minutes 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 2 3 minutes until the oil settles CAUTION 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 function properly the oil pressure warning light will light If this light 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 excess oil using a syringe or some other suitable device
35. R Replacement Parts CO 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend gt TIR 0 2 100 mm 0 08 3 94 in Connecting Rod Twist TIR 0 2 100 mm 0 08 3 94 in Connecting Rod Big End Side Clearance 0 16 0 46 mm 0 7 mm 0 006 0 018 in 0 03 in Connecting Rod Big End Bearing 0 026 0 057 mm 0 10 mm Insert Crankpin Clearance 0 0010 0 0022 in 0 004 in Crankpin Diameter 54 981 55 000 mm 54 97 mm 2 1646 2 1654 in 2 164 in Marking None O Connecting Rod Big End Bore Diameter Marking None O Connecting Rod Big End Bearing Insert Thickness Brown Black Blue 54 981 54 991 mm 2 1646 2 1650 in 54 992 55 000 mm 2 1650 2 1654 in 58 000 58 020 mm 2 2835 2 2842 in 58 000 58 010 mm 2 2835 2 2839 in 58 011 58 020 mm 2 2839 2 2842 in 1 483 1 487 mm 0 0584 0 0585 in 1 487 1 491 mm 0 0585 0 0587 in 1 491 1 495 mm 0 0587 0 0589 in Connecting Rod Big End Bearing Insert Selection Con Rod Big End Bore Diameter Crankpin Diameter Bearing Insert Marking Marking Size Color Part Number None O Brown 92028 1476 None None Black 92028 1475 O O O None Blue 92028 1474 Crankshaft Side Clearance 0 05 0 55 mm 0 75 mm 0 002 0 020 in 0 030 in Crankshaft Web Length 96 85 96 95 mm 96 6 mm 3 813 3 817 in
36. Smooth Stroke B Oil Leakage see Rear Shock Absorber Oil Leak Inspec tion in the Periodic Maintenance chapter Crack or Dent A If there is any damage to the rear shock absorber one unit feels weaker than the other replace both shock absorbers as a set e Visually inspect the rubber bushings C Alf they show any signs of damage replace them 6M05093BS1 6M05094BS1 13 18 SUSPENSION Rear Shock Absorber Air Type e Visually inspect the shock absorber sleeves A and nee dle bearings B e The roller in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing in the shock absorber 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 sleeves replace the sleeves and needle bearings as a set Rear Shock Absorber Scrapping e Remove the rear shock absorber see Rear Shock Ab sorber Removal in this section A WARNING Since the rear shock absorber contains air do not incinerate the rear shock absorber without first re leasing the air or it may explode Before a rear shock absorber is scrapped remove the air valve A GMO5095BS1 SUSPENSION 13 19 Swingarm Swingarm Removal e Using the jack A and attachment jack B under the frame pipe ribs C lift the rear wheel D OFF the ground until the front wheel E to
37. ping it during removal or installation Do not drop the HLA or hit it sharply If it is dam aged the plunger will not operate smoothly HLA Air Bleeding e Remove the HLA see HLA Removal in this section e Fill a container with engine oil e Prepare a thumbtack and cut its needle to 2 1 2 3 mm 0 0827 0 0906 in long A Grind its cutting edge B smooth e Push in the check valve of the HLA D with the needle of the tack C and move the plunger up and down in the oil bath Alf the plunger sinks into the HLA body repeat the air bleeding procedure and then push the plunger After air bleeding if the plunger sinks into the HLA body again replace the HLA CAUTION Do not push the check valve in more than 2 1 2 3 mm Pushing too deep may cause the damage of the HLA HLA Installation e Check that the HLA plunger is not damaged Alf the plunger does damage replace the HLA HLA Body A O ring B Plunger Spring C Pivot Plunger D Check Valve E Check Valve Spring F 6E210601S1 TRE ASS e d GE21060281 e Air bleed the HLA see HLA Air Bleeding in this section e Soak a rocker arm A in engine oil and then insert the HLA B into the rocker arm OBe careful not to tip the rocker arm having the HLA and not to allow engine oil to leak out of the HLA 5 26 ENGINE TOP END Camshafts Camshaft Removal e Remove Rocker Case Covers
38. 0 242 in Service Limit 6 25 mm 0 246 in 6113022BS1 Shift Fork Guide Pin Drum Groove Wear e Measure the diameter of each shift fork guide pin B and measure the width A of each shift drum groove lf the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 7 9 8 0 mm 0 311 0 315 in Service Limit 7 8 mm 0 307 in Alf any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 8 05 8 20 mm 0 317 0 323 in Service Limit 8 30 mm 0 327 in 6113023BS1 Gear Dog and Gear Dog Hole Damage e Visually inspect the gear dogs A and gear dog holes B x Replace any damaged gears or gears with excessively worn dogs or dog holes 6113024BS1 9 38 CRANKSHAFT TRANSMISSION Ball Bearing Needle Bearing and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearing outer race NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a blowtorch This will warp the case Soa
39. 0 8 GP05054BW5 C ELECTRICAL SYSTEM 16 21 Wiring Diagram Australia Junction Box Ignition Fuse 104 Horn Fuse 104 Taillight Fuse 104 Headlight Fuse 104 Accessory Fuse 10A Radiator Fan Fuse 154 Turn Signal Fuse 104 Starter Circuit Relay Headlight Relay CET uo Right Handlebar Switches i Front Brake Light Switch 2 Engine Stop Switch Crankshaft 3 Starter Button Sensor Kawasaki Diagnostic 1 22 Spark Plugs System Gonnector Ignition Self Coils diagnosis a gt Termina Electronic Control Unit gt E BL BR BR R K Ks Kee KAR Joint Connector 2 BK Y License Plate Light 12 5 Tail Brake Lights 12421 5 Rear Right Turn Signa Light 124218 4 Rear Left Turn Signal Light 12 21 5 Rear Accessory Connectors DEI Fuse LO Di BK Y BK Y BKW WR DEI Relay Wain Relay Color Gode BK Black BL Blue oR Brown Digital Fuel Injection System Fuel r chocolate ue 1 Fuel Injector 1 6 Inlet Air Temperature Sensor pi ee Fuel Injector 2 7 Water Temperature Sensor ar EES Throttle Sensor 5 Inlet Air Pressure Sensor e Green 9 o OH Y R Starter Motor ISG Valve 2 Atmospheric Pressure Sensor ay Gray 186 Valve i 10 Vehicle down Sensor Light Green
40. 1 with the red paint mark on the top ISC Hose 2 with the blue paint mark F on the top Power Source Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Power Source Voltage Inspection of the fuel pump e Turn the ignition switch OFF e Remove the right air cleaner cover see Right Air Cleaner Housing Removal in this chapter e Connect a digital voltmeter A to the connectors B of each ISC valve Power Source Voltage at ISC Valve Connector Connections to ISC Valve 1 2 Meter WIR Lead Terminal Meter Battery Terminal e Measure the power source voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Power Source Voltage at ISC Valve Connector Standard Battery Voltage 12 5 V or more e Turn the ignition switch OFF x If there is no battery voltage check the DFI power source circuit see DFI Power Source Circuit in the DFI Power Source section Alf the reading is normal the power supply voltage is nor mal Check the output voltage 6017046BS1 3 88 FUEL SYSTEM DFI ISC Valves Output Voltage Inspection e Check the output voltage at the connectors A of the ISC Valves e Remove the right air cleaner cover see Right Air Cleaner Housing Removal this chapter Special Tool Hand Tester B 57001 1394 Output Voltage of ISC Valves Connections for ISC Valve 1 C Te
41. 11 1 1 97 in lb LH Shift Shaft Return Spring Pin 39 4 0 29 L Starter Clutch Bolt 85 8 7 63 MO Starter Clutch Coupling Bolts 15 1 5 11 L Water Pump Chain Guide Bolt 8 3 0 85 73 in lb Water Pump Chain Guide Spring Hook Bolt 2 9 0 30 26 in lb Water Pump Drainage Hose Fitting 9 8 1 0 87 in lb Water Pump Impeller Bolt 8 8 0 90 78 in lb LH Wheels Tires Front Axle Clamp Bolts Front Axle Shaft Front Brake Disc Bolts Muffler Stay Mounting Bolts Rear Axle Nut Rear Brake Disc Bolts Tire Air Valve Nuts Final Drive Bearing Retainer Bolts Front Gear Bearing Retainer Bolt Final Gear Damper Cam Nut Drive Gear Nut Driven Gear Assy Mounting Bolts 18 Driven Gear Bolt 89 Final Gear Case Cover Bolt M10 25 Final Gear Case Cover Bolt M8 17 Final Gear Case Drain Plug Final Gear Case Mounting Nut S 25 Front Gear Case Bolts M8 21 Front Gear Case Bolts M6 106 in Ib Neutral Switch a 11 Oil Nozzle Front 26 in lb Oil Nozzle Right 13 Oil Pipe Banjo Bolts 106 in Ib Pinion Gear Nut 96 Speed Sensor Mounting Bolt d 87 in lb 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Brakes Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Pedal Clamp Bolt Front Brake Disc Bolts Front Brake Hose Banjo Bolt Front Brake Light Switch Screw Front Brake Reservoir Cap Screw Front Caliper Bleed Valves Front Caliper Mounting Bolts Front Footboard Bracket Bolts Front Master Cylinder Clam
42. 85 the ECU locks ignition timing into the ignition Vacuum Sensor Absolute Vacuum Pv 63 mmHg 860 mmHg timing at full throttle open position and sets the DFI in the D J method 1 x If the inlet air pressure sensor system fails the signal Pv is out of the usable range wiring short or open the ECU sets the DFI in the a N method 1 Inlet Air Tempera ture Sensor Water Tem perature Sensor Inlet Air Temperature Ta 47 C 178 C Water Temperature Tw 28C 161 C x If the inlet air temperature sensor fails the signal is out of the usable range wiring short or open the ECU sets Ta at 45 C x If the water temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Tw at 86 C Atmo spheric Pressure Sensor Crankshaft Sensor 1 Absolute Atmospheric Pressure Pa 63 mmHg 860 mmHg Either crankshaft sensor must send signals output voltage Crankshaft Sensor 2 8 or more times continuously to the ECU x If the atmospheric pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets Pa at 760 mmHg the standard atmospheric pressure x If either crankshaft sensor generates 8 or more signals the ECU runs the engine by the signal of the good crankshaft sensor but neither crankshaft sensors generate signals the engine stops by itself Vehicle down Sensor F
43. Alphabet C Diameter Mark Around Weight Mark D O or no 6105055851 mark CAUTION If the connecting rods bearing inserts or crank shaft are replaced with new ones select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the inside A of the big end bearing inserts OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 Alf bearing inserts are replaced install them as follows ODo not apply molybdenum disulfide oil solution to the out side B of the inserts or the inside C of the connecting rod and cap Olnstall the inserts so that their nails D are on the same side and fit into the recess of the connecting rod and cap 9 24 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods 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 Dowel Pin G Connecting Rod Bolts H e Install the cap on the connecting rod aligning the weight and diameter marks e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil solution MO to the threads seati
44. B The gasket C comes off e Discard the gasket ODo not remove or adjust the following parts These parts are set at the factory and cannot be readjusted CAUTION Adjustment of some of these parts could result in poor performance requiring replacement of the throttle body Throttle Sensor A Turning the sensor body could spoil the ignition timing and injection quantity Front View B Throttle Stop Screw A Tampering with this screw could spoil the idling performance since the screw sets the gap be tween the throttle valves and the throttle bore with throttle grip closed Rear View B Choke Lever Stop Screw A This screw sets the throttle valve opening when the choke knob is pulled fully Tampering with the screw could cause malfunction of the choke lever Throttle Cable Holder B This is sold with a throttle body as a unit Rear View C Throttle Valve and Throttle Shaft They are not allowed to remove because of diffi culty of removal FUEL SYSTEM DFI 3 101 Throttle Body Assy e Remove the delivery joint and injectors see Injector Re moval in this chapter e Open the butterfly valves A and wipe any carbon off the throttle bores B around the valves using a piece of lint free cloth penetrated with a high flash point solvent e Clean the bores C of the inlet manifold D as well e Blow away dirt or dust from the throttle body and the inlet manifold by applying co
45. Bearing Remover Head 420 x 22 57001 1293 T5712938T 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove the front fender see Rear Fender Removal in the Frame chapter e Unscrew the front brake caliper mounting bolts A and remove the brake calipers B with the hose installed e Loosen Front Axle Clamp Bolts A Front Axle B OUsing the jack A and the attachment jack B under the frame pipe ribs C and a commercially available jack D under the engine E lift the front wheel F OFF the ground until the rear wheel G touches the ground Special Tools Jack 57001 1238 Attachment Jack 57001 1398 CAUTION Be sure to put the rear wheel ON the ground when 8515028851 removing the front wheel or the motorcycle may fall over The motorcycle could be damaged A WARNING Be sure to put the rear wheel ON the ground when removing the front wheel or the motorcycle may fall over It could cause an accident and injury e Unscrew the axle to the right and drop the front wheel A out of the fork CAUTION Do not lay the wheel directly 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 WHEELS TIRES 10 7 Wheels Rims Front Wheel Installation e Apply grease to the seal lips e Fit the collars A on the both side of the hub OThe collars are ident
46. C the left side cover slightly forward and remove it Left Side Cover Installation e Put the front stoppers A into the grommets B first then put the rear stopper into the grommet e Turn the ignition switch key A counterclockwise until the key slot is horizontal B to secure the left side cover Right Side Cover Removal e Remove the screw A CAUTION Be careful not to scratch the right side cover sur face with the rear exhaust pipe B during removal or installation e Cover the rear exhaust pipe with a shop towel and pull the right side cover evenly outward to clear the stoppers Right Side Cover Installation e Put the stoppers A into the grommets B e Tighten the screw FRAME 15 11 Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation e Remove the mounting bolts A on both sides to separate the fender from the front fork e Move the fender forwards with the wheel installed and remove it Rear Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation e Remove Rear Seat see Rear Seat Removal in this chapter Front Seat see Front Seat Removal in this chapter Left and Right Saddlebags see Saddlebag Removal in this chapter Tandem Grip see Tandem Grip Removal in this chapter e Remove the left and right rear fender covers A e Remo
47. Choke Cable Clamp To Right Front Spark Plug Plastic Clamps Right Air Cleaner Base Vacuum switch valve hose to the right air cleaner base Throttle Sensor White Marks faced upwards Left Front Spark Plug Lead Ignition Coil for Front Spark Plugs Plastic Clamp Left Air Cleaner Housing Clamp Front Oil Hose Fuel Pump Outlet Hose Grommet California Model only Clamp Radiator Inlet Hose Rear Coolant Hose Front Coolant Hose Reserve Tank Hose Without Mark Throttle Cables Upper Decelerator Lower Accelerator Plastic Clamp Align the clamp with the mark faced upward Rear oil hose into the rear rocker case cover Canister Purge Hose Green for Califor nia Model Air Suction Valve Front Vacuum Switch Valve Hose Rear Vacuum Switch Valve Hose Run the crankcase breather hose over the vacuum switch valve Wire Clamps Face the tab as shown Vacuum Switch Valve Rear Rocker Case Cover Vacuum Hose to Throttle Body Front 17 6 APPENDIX Cable Wire and Hose Routing Y YU AE a SAA dE Ke Kee e EE VW ich AN TS a Lee eee a Var AC AS a ee ON Ke Wer WA 1 Ignition Coil for Front Spark Plugs 11 Radiator 2 Inlet Air Pressure Sensor Hose 12 Fuel Pump Outlet Hose 3 Front Coolant Hose 13 Clamp 4 Vacuum Switch Valve Hose vacuum 14 Clamp 5 Radiator Inlet Hose 15 Crankca
48. G Apply grease LH Left hand threads R Replacement Parts SS Apply silicone sealant Kawasaki Bond 56019 120 4 4 COOLING SYSTEM Specifications Coolant provided when shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure 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 C 31 F 2 3 L 2 4 US qt Reserve tank full level including radiator and engine 93 123 kPa 0 95 1 25 kgf cm 13 5 17 8 psi Thermostat Valve Opening Temperature Valve Full Opening Lift 58 62 C 136 144 F 8 mm 0 3 in or more 75 C 167 F COOLING SYSTEM 4 5 Special Tools and Sealant Bearing Driver Set 57001 1129 ST5711298T Bearing Remover Shaft 9 57001 1265 ST5712658T Bearing Remover Head 410 x 12 57001 1266 ST5712668T Kawasaki Bond Silicone Sealant 56019 120 ST5601208ST 4 6 COOLING SYSTEM Coolant Flow Chart 1 Water Pump 2 Water Jacket 3 Cylinder Head 4 Water Pipe 5 Water Hose 6 Radiator Cap 7 Thermostat 8 Reserve Tank Hose 9 Radiator 10 Radiator Fan 11 Throttle Body Assy 12 Front 13 Cold Coolant 14 Hot Coolant 15 Reserve Tank 16 Reserve Tank Overflow Hose 6D04008BW4 COOLING SYSTEM 4 7 Coolant F
49. Hand Tester Fuel Hose 57001 1394 57001 1607 ST5713948T ST571607ST Filler Cap Driver Kawasaki Bond Silicone Sealant 57001 1454 56019 120 ST5714548T ST5601208ST FUEL SYSTEM DFI 3 21 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OTo maintain the correct fuel air mixture F A there must be no inlet air leaks in the DFI system Be sure to install the oil filler cap A after filling the engine oil using the filler cap driver B Clutch Cover C Front D Special Tool Filler Cap Driver 57001 1454 Torque Oil Filler Cap 1 5 N m 0 15 kgf m 13 in Ib 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 lead connections This will damage the ECU ODo not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running Otherwise surge damages the con nector terminals or the DFI parts OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen charging 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 th
50. Rating of Bulb C 12 V x 3 3 4 W 12 V Sealed Battery D CAUTION Be sure to connect the bulb in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current 6017024481 e Connect the test light set to the injector E as shown e Open and connect F the end of the wire to the battery terminal repeatedly The injector should click x If the injector does not click replace the injector If the injector clicks check the wiring again If the wiring is good replace the injector may be clogged or ECU 123456 7 8 91011 12 13 14 15 18 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 tail IE GC17707BW3 C 1 ECU 7 Battery 2 Junction Box 8 Fuel Injector 1 3 Ignition Fuse 10 A 9 Fuel Injector 2 4 Ignition Switch 10 DEI Main Relay 5 Stater Relay 11 DFI Fuse 15 A 6 Main Fuse 30 A 3 74 FUEL SYSTEM DFI Fuel Pump Service Code 45 Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To
51. Reon IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS Orange Front Brake Light Switoh Engine Stop Switch Starter Button Pink Color BK BK Golor R Y R Color BK R Purple Brake teve orr rreef Feliea tn oe run Loge push ege por rea w Mito L CL ste GPOSOSSBWS C Fero 99052 11710 16 22 ELECTRICAL SYSTEM Wiring Diagram Other than United States Canada and Australia Radiator Fan Switch Ignition e A emperature on Switch Radiator gy aber Fan OFF Rear Brake fore Light OI BI Si Switch Oil Pressure Warning R BR R Light Delay Unit H vie Y BL R EN Bk BK Y Speed Sensor P LE R H Laron 10 8k LE R LE R LEA wey BK Y BK Y alle CHE T vun H BR R HH We Ltb R Y R Y He LG LG GY GY 6 6 R BK R BK rit O E Front Right 4 En Turn Signal Gi Light 12421N Front Left i e Turn Signal ile Light 12V214 joint HE Connector 1 H H es IM CTI m la es E a a 7 ii a z CO 00000 Front Accessory E 50 Connectors w e R BK Headlight R BK 12V60 55 BK Y D i D BK Y BK Y BK Y BK Y BK Y Bk Y TITI Fi DI Bx Y wey BK Y Di Speedometer Unit 1 Odometer Trip Meter Clock Liquid Crystal Display 2 Speedometer 55 a e Frame ess rare 3 Fuel Meter EE Gi S
52. able tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING To ensure safe handling and stability use only the standard tires for replacement inflated to the stan dard pressure Use the same manufacturer s tires on both front and rear wheels e Inspect the rim and tire and replace them if necessary e Clean the sealing surfaces of the 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 CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve GJO5006BS1 WHEELS TIRES 10 17 Tires Olnsert the new air valve in the front and rear wheel rim Valve Cap A Valve Body B Valve Nuts C Valve Washer D Rim E Valve Grommet F Coupling Damper Side Left Side G ORemove the valve cap valve nuts valve washer and in sert the valve stem through the rim from the inside out Torque Tire Air Valve Nuts 1 5 N m 0 15 kgf m 13 in lb e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads CAUTION Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of the tire e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rot
53. ail ii aky 1 16 ser 1 16 wB Joint Connector 2 BK Y BK Y BK Y BK Y BK Y DZ BK Y DZ Bx Y DZ Bx Y Bx Y Bx Y Bx Y BL Y LL 1 License Plate Light i2V5 2 Tail Brake Lights 12421 5 Se 3 Rear Right Turn Signal Light 124210 4 Rear Left Turn Signal Light 124210 5 Rear Accessory Connectors DEI Fuse BL R WR DR Y N BR BK BL N BR HO BK Y BR Y BR R WR YAR T OI BK Y RI OH MUR WAR WIR ay WIR P DFI Wain Relay BL R BL G We Yn BR BK D I Color Code ek T sis pee Bwe BR Brown CH Chocolate DM Hi ep el ep eh Digital Fuel Injection System Fuel 1 Fuel Injector 1 B Inlet Air Temperature Sensor POS 2 Fuel Injector 2 7 Water Temperature Sensor LES Derk Green Starter 3 _Throttle Sensor 8 Inlet Air Pressure Sensor a Green Motor 4 180 Valve 2 9 Atmospheric Pressure Sensor ay tray 5 0 156 Valve 1 1 Vehicle down Sensor LB Light Blue te ight treen ye LENITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button 98052 1172 GPOSOS7BWS C 16 24 ELECTRICAL SYSTEM Servicing Precautions There are a number of important precautions that should be followed servicing electrical systems
54. 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 satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 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 12 22 BRAKES Brake Hoses Brake Hose Removal Installation CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 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 hose A 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 There are washers B on each side of the brake hose fitting Replace them with new ones when installing e Tighten the banjo bolts C on the hose fittings Torque Front Brake Hose Banjo Bolts 34 N m 3 5 kgf m 25 ft lb Rear Brake Hose Banjo Bolts 34 N m 3 5 kgf m 25 ft lb e When installing the hoses A avoid sharp bending kink ing flattening or twisting and route the hoses according to Cable Wire an
55. binding If roughness or binding is found replace the hub bearings e Inspect the front and rear axles for damage see Axle In spection in this section Alf the axle is damaged or bent replace it e Inspect the wheel for small cracks dents bending or warp Alf there is any damage to the wheel replace the wheel 10 12 WHEELS TIRES Wheels Rims e Remove the wheel and support it without the tire by the axle e Measure the rim runout radial A and axial B with a dial gauge x If the rim runout exceeds the service limit check the hub bearings Replace them if they are damaged x lf the problem is not due to the bearings replace the wheel Rim Runout Service Limit Axial 0 5 mm 0 02 in Radial 0 8 mm 0 03 in Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Visually inspect the front and rear axles for damage 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 Standard TIR 0 05 mm 0 002 in or less Service Limit TIR
56. displayed when a short wave form such as the one show in the diagram is input Example An input frequency of 720 Hz will display about 60 mph An input frequency of 450 Hz will display about 60 km h x If the meter does not function correctly replace the meter unit Alf an oscillator is unavailable check the speedometer as follows Olnstall the meter unit See Meter Unit Installation in this section OUse the jack and the attachment jack to lift the rear wheel see Rear Wheel Removal in the Wheels Tires chapter Special Tools Jack 57001 1238 Attachment Jack 57001 1398 OTurn the ignition switch ON OTurn the rear wheel by hand to see if the speedometer shows the vehicle speed that corresponds to the wheel rotation x If it does not show properly inspect the speed sensor and speed sensor power supply voltage Alf the speed sensor and speed sensor power supply volt age are normal replace the meter unit ama B TA FU VD a GP17094BS1 Duty 50 OV GP17095BS2 C 16 84 ELECTRICAL SYSTEM Meter Gauge Speed Sensor Power Supply Voltage Inspection e Connect the leads in the same circuit as for the LCD Seg ment Inspection Check 2 e Set the hand tester A to DC25 V check the voltage be tween terminal 10 and battery negative lead Connections Hand Tester Terminal 10 Hand Tester Battery Negative Terminal Special Tool
57. e Install the flange B and the seal in the direction shown Face the ribs C of the flange and the smaller diameter end upwards OThe seal should be centered on the flange e Tighten the inlet manifold bolts D to a snag fit 6017226851 e First tighten the throttle body assy holder bolts A secondly the inlet manifold bolts B and spark plug lead holder bolts C to the specified torque Torque Throttle Body Assy Holder Bolts 11 N m 1 1 kgf m 97 in lb Inlet Manifold Bolts 12 N m 1 2 kgf m 104 in Ib Spark Plug Lead Holder Bolts 11 N m 1 1 kgf m 97 in lb e Install the lower ends of the throttle cables in the throttle pulley Accelerator Cable A and Decelerator Cable B e Run the throttle cables correctly see Cable Wire and Hose Routing section in the Appendix chapter e Stake C the cable clip D on the throttle cable holder E Rear View F e Install the lower end of the choke cable in the choke lever e Apply a non permanent locking agent to the threads of the choke cable plate screw Torque Choke Cable Plate Screw 2 9 N m 0 30 kgf m 26 in 1b e Run the choke cable correctly see Cable Wire and Hose Routing section in the Appendix chapter and check that the choke knob moves smoothly 6017228BS1 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 rig
58. 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 GJ04113BS1 Alf proper balance has been achieved permanently install the balance weight Balance Weight Part Number Weight grams 41075 0014 10 0 4 oz 41075 0015 20 0 7 oz 41075 0016 30 1 1 oz NOTE OBalance weights are available from Kawasaki Dealers in 10 20 and 30 gram 0 4 0 7 and 1 1 oz sizes An imbalance of less than 10 grams 0 4 oz will not usually affect running stability ODo not use four or more balance weights more than 90 gram 3 2 oz Ifthe wheel requires an excess balance weight remove and disassemble the wheel to find the cause Balance Weight Removal Ee a When the tire is not on the rim e Push A the blade portion toward the outside with a reg ular tip screw driver and slip the weight off the rim flange e Discard the used balance weight GJ04116BS1 10 14 WHEELS TIRES Wheels Rims b When the tire is on the rim e Pry A the balance weight off the rim flange using a reg ular tip screw driver as shown in the figure Olnsert a tip of the screw driver between the tire bead B and weight blade C until the end of the tip reaches the end of the weight blade OPush the driver grip toward the tire so that the balance weight slip
59. eet e le EE 11 6 Special TOS oi A vitor haan eh ones 11 7 Final Gear Case and OH 11 9 Oil LOVESl INSPSCHOM iia eieiei area et ae diver eege be 11 9 OIGAN eege att pita alineada 11 9 Final Gear Case Removal eet 11 9 Final Gear Case Installations nesi a a a e ah 11 9 Final Gear Case Disassembly nissan ne dite Ae ENER See 11 9 Final Gear Case ASOMO EE 11 11 Pinion Gear Removal sise 11 13 Pinion Gear Installation A rai 11 14 Pinion Gear Bearing Preload Adjustment 11 16 Bevel Gear Inspechon sirar Nerei ai eE EE EEEE L E EE A R EE 11 18 Pinion Gear Joint Inspection 11 18 Final Bevel Gear Adu Mei a hadas 11 18 Backlas Nie ee LEE Tooth Contact Adjustment Propeller Na EE Propeller Shaft Hemoval re tnre nn AEEA EEEE EEEEEEEEEEEEEEEEEEEEEEEEEE EEEE EEEE EEEE Propeller Shawt Installation seen a a O Aa RaR 11 23 Propeller Shaft Joint Lubrication ooccccccccccncccncninonennninnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnenininninnn 11 24 Propeller Shaft Inspection ssssssssennernnenrrtnnntnnntnn rnnr nran annn nnnn nannan nnan an nannan n Ennn n Ennn 11 24 Sliding Joint NS pec O EE 11 24 Front Bevel Gein ren e te en a ae E EES 11 25 Front Gear Case Removal 11 25 Front Gear Case Installation neee 11 25 Front Gea
60. gine wear and possibly engine damage will occur e Remove Allen Bolt and Washer A Left Air Cleaner Cover B e Remove the element A e Push a clean lint free towel into the lower air cleaner duct to keep dirt or other foreign material from entering e Replace the air cleaner element with a new one e Install a new element A with the smaller gasket B side facing outside CAUTION Use only the recommended air cleaner element Kawasaki part number 11013 1305 Using another air cleaner element will wear the engine prema turely or lower the engine performance PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Engine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine e Remove the engine oil drain plug A and drain the oil e Remove Oil Screen Plug A Right Side e Remove the oil screen A the spring B and the washer C e Clean the oil screen with a high flash point solvent and remove any particles stuck to it e Clean the screen thoroughly whenever the engine oil is changed WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Che
61. ing Removal in this section Throttle Body Assy see Throttle Body Assy Removal in this chapter e Remove Oil Hose Clamps A Lower Air Cleaner Duct B Air Cleaner Duct Holder C Torque Air Cleaner Duct Holder Bolts 10 N m 1 0 kgf m 89 in Ib FUEL SYSTEM DFI 3 105 Fuel Tank Fuel Tank Removal Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To avoid fire do not remove the fuel tank when the engine is still hot Wait until it cools down To make fuel spillage minimum draw the fuel out from the fuel tank with a pump as much as possible when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn both ignition switch and engine stop switch OFF e Wait until the engine cools down e Open the fuel tank cap A to lower the pressure in the tank and draw the fuel out from the fuel tank with a com mercially available pump A WARNING The fuel cannot be removed completely from the fuel tank Be careful for remained fuel spillage e Remove the Allen bolts A and take out the meter cover B e Disconnect the meter A and ignition switch B connec tors EOI
62. punched mark on the pedal e Tighten the clamp bolt Torque Shift Pedal Clamp Bolt 29 N m 3 0 kgf m 21 ft Ib e Install the left front footboard see Front Footboard Re moval Installation in the Frame chapter External Shift Mechanism Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Alternator Cover A see Alternator Outer Cover Re moval in the Electrical System chapter Front and Rear Shift Levers B Front Gear Case C see Front Gear Case Removal in the Final Drive chapter e Remove the shift shaft A while pushing B the shift mechanism arm C towards the shift shaft e Unscrew the bolt D and remove the gear set lever E and its spring F CRANKSHAFT TRANSMISSION 9 31 Transmission External Shift Mechanism Installation e Install the gear set lever A and the spring B in the crankcase and tighten the bolt C Torque Gear Set Lever Bolt 11 N m 1 1 kgf m 97 in Ib e Install the shift mechanism arm assy Be sure to install the washer D onto the shift shaft e Install the front gear case see Front Gear Case Installa tion in the Final Drive chapter e Install Alternator Cover see Alternator Cover Removal Instal lation Front and Rear Shift Levers Olnstall the rear shift lever A on the shift shaft so that the punched mark on the shaft is aligned B with the slot of the rear shift lever e Loosen the locknuts C and tur
63. rings Replace the compression release unit Cylinder Head Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Rocker Cases see Rocker Case Removal in this chap ter Camshafts see Camshaft Removal in this chapter Spark Plug Retainers see Front Camshaft Chain Re moval in this chapter OThe camshaft chain comes off e Remove Air Suction Valves A see Air Suction Valve Removal in this chapter Cooling Pipes with Hoses B 5 34 ENGINE TOP END Cylinder Head e Remove the cylinder head nuts A e Take the cylinder head off the cylinder NOTE ODo not remove the coolant drain plug B yet Cylinder Head Installation OThe front cylinder head A has an F mark while the rear cylinder head B has an R mark Be careful not to mix them up Front C CAUTION The cylinder head and rocker case are machined in the assembled state so they must be used as a set e Replace the cylinder head gasket with a new one e Tighten the cylinder head nuts temporarily These nuts are tightened to the specified torque after installing rocker case installation e Apply grease to the O ring A e Pull the camshaft chain up the chain tunnel insert the spark plug retainer B through the chain loop and tighten it Special Tool Hexagon Wrench Hex 27 57001 1210 Torque Spark Plug Retainer 12 N m 1 2 kgf m 104 in Ib e Install Spark
64. the arbor B varies from being parallel with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x 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 08 3 94 in 6105040681 6105040781 CRANKSHAFT TRANSMISSION 9 25 Crankshaft Connecting Rods Connecting Rod Big End Side Clearance e Measure the side clearance B of the connecting rod big end A Olnsert a thickness gauge between the big end and either crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 16 0 46 mm 0 006 0 018 in Service Limit 0 7 mm 0 03 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 Wear e Remove the big end cap and place a strip of plastigage on the crankpin A e Apply molybdenum disulfide oil solution to the threads and seating surface of the big end nuts OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Tighten the big end nuts to the specified torque to com press the plastigage and measure the plastigage width B to determine
65. to the ECU connector B us ing two needle adapters C Special Tool Needle Adapter Set 57001 1457 Water Temperature Sensor Output Voltage Connections to ECU Meter gt O lead terminal 7 Meter gt BR BK lead terminal 11 e Measure the output voltage of the sensor with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard 3 38 V at coolant temperature 25 C 77 F lf the output voltage is normal but there is still trouble check the sensor resistance x lf the output voltage is about 4 8 V the ECU is normal Remove the fuel tank and check the wiring between the ECU and the sensor e Turn the ignition switch OFF x If the output voltage is not about 4 8 V and out of the spec ified remove the fuel tank and check the wiring between the ECU and the water temperature sensor for continuity x lf the wiring is good check the water temperature sensor resistance e Remove the needle adapters and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connector GC17721BS1 FUEL SYSTEM DFI 3 57 Water Temperature Sensor Service Code 14 Resistance Inspection e Remove the water temperature sensor see Removal in this section e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded porti
66. using a press and two thickness gauges C which are overlapped to about 2 5 mm 0 10 in e Cut the sheet with scissors into four strips D of gum or clay as shown 7 mm 0 276 in E 4 mm 0 157 in F e Remove the clutch see Clutch Removal in this chapter e Place the inner clutch hub spring holder assy A the outer clutch hub B and the clutch plates friction and steel plates C on blocks D ODo not support the spring holder E with the blocks 6FO80019S1 6F13000281 6 16 CLUTCH Clutch e Apply a soap and water solution to the strips This is to separate the strips easily from the clutch spring plate and clutch hub when removing strips e Place these four strips A on the raised surface B of the outer clutch hub in a criss cross pattern as shown e Install the clutch spring plate C and a block D OWhile noting the positions of the spline teeth E fit the clutch spring plate into the outer clutch hub smoothly Be careful not to move these strips e Press F the block until the clutch plates G seat closely CAUTION Do not press the block too much This could dam age the clutch parts The maximum press force is 100 kg GF13000382 C e Remove the clutch spring plate e Peel off these strips with a thin bladed screwdriver O e Measure the pressed thickness A of each strip with vernier calipers OThe thickness represents
67. 0 2 mm 0 008 in Wheel Balance OTo improve stability and decrease vibration at high speed the front and rear wheels must be kept balanced e Check and balance the wheels when required or when a tire is replaced with a new one Balance Inspection e Remove the wheel see Front Rear Wheel Removal in this section e Support the wheel so that it can be spun freely e 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 FA A PIS eres OR E ER ROSSER fr red z FE 604061252 C GJ04043BS1 GJ04112BS1 WHEELS TIRES 10 13 Wheels Rims Balance Adjustment e f the wheel always stops in one position provisionally at tach a balance weight A to the rim flange at the marking using adhesive tape Use only the genuine balance weights 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 Alf 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
68. 0004 ST9200048T ELECTRICAL SYSTEM 16 17 Special Tools and Sealants Dummy Page 16 18 ELECTRICAL SYSTEM Wiring Diagram United States and Canada Radiator lrenir1on eae Fan Switch lenition Berrea te Temperature Switch mrion Re Radiator ne Switch Fan Rear Horn Brake 12V4 0A TT trike BK Y DI So Switch Gil Pressure Warning R BR R Light Delay Unit w a ji Y BL R LR e BR BL BK Y vee DI R BL BL HA BK Y Speed Sensor P L6 R if am A Ho 10 BK O LE R VS in i Le E BK Y HOON 1 5 GE P Mi TI OO tie AAA ATAR A BEER DEER Sr G R BK EEE Front Accessory E Fl H Connectors W BL Gg R BK Headlight R BK HHAH 12V60 55 Bk Y H RZY D B PR DEE i Signal Running e td er Position Lights BK Y peda k 12V21 5 pt piee L 1 EEN Se ALS EE RP DE EN PL 1 2 CR PRES CE Signal Running OEA Ht tt tt Position Lights 12421 5 a ed le i BE Il Connector 1 H LC ay ay BK Y BK Y LU BK Y BK Y dei BK Y I D z ER aK Y ER Speedometer Unit 1 Odometer Trip Meter Clock Liquid Crystal Display Se w e Ee eee 2 Speedometer 3D ef me A Frame SSS gt gt 3 Fuel Meter EE gt Ground PET 4 Illuminator LED i S23 25 5 Fuel Indicator LED Pieds 7 7 See er 6 Water Temperature Warning FI S S Sierre ae Oil Pressure Warning Indicator
69. 11 Clutch Cover Removal eiii iii re thd ie dai tadas 6 11 Clutch Cover Instala WEE iere eebe Eden 6 11 Clutch Remains ad ica adds acid 6 12 Clutch RECHT le EE 6 13 Inner Clutch Hub Disassembly EE 6 14 Spring Plate Gap Measurement 6 15 Spring Plate Gap Adjustment icono e diri 6 16 Friction and Steel Plate Wear and Damage Inspection eeeseeeeeeeeeeeeeeeeeeeneeees 6 17 Friction or Steel Plate Warp seen 6 17 Clutch Spring Height Measurement 6 17 Clutch Housing Finger Inspection EE 6 17 Outer Clutch Hub Spline Inspection 6 18 Cam Damper Inspection sise 6 18 6 2 CLUTCH Exploded View 6F02055BW5 C CLUTCH 6 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Clutch Cover Bolts 11 1 1 97 mb 2 Clutch Damper Cover Bolts 9 8 1 0 87 in lb L 3 Clutch Damper Plate Bolts 9 8 1 0 87 in lb EO 4 Clutch Hose Banjo Bolt Upper 25 2 5 18 5 Clutch Hose Banjo Bolt Lower 25 2 5 18 6 Clutch Hub Nut 145 14 8 107 MO Clutch Lever Pivot Bolt d 0 10 8 9 mb SI ES Clutch Lever Pivot Bolt Locknut 0 60 9 Clutch Master Cylinder Clamp Bolts 1 1 Clutch Reservoir Cap Screws E 0 15 Clutch Slave Cylinder Bleed Valve 0 80 Clutch Slave Cylinder Bolts 0 70 Oil Filler Cap 0 15 Starter Lockout Switch Screw 0 12 15 Clutch Slave Cylinder 16 Starter Lockout Switch 17 Cup point side faces outside EO Apply engine oil L Apply a non permanent locking agen
70. 205 Ib g x 0 03527 OZ Units of Volume L x 0 2642 gal US L x 0 2200 gal imp L x 1 057 qt US L x 0 8799 qt imp L x 2 113 pint US L x 1 816 pint imp mL x 0 03381 oz US mL x 0 02816 oz imp mL x 0 06102 cu in Units of Force N x 0 1020 kgf N x 0 2248 Ib kg x 9 807 N kg x 2 205 Ib Units of Temperature F 5 F 40 N m x 0 1020 N m x 0 7376 N m x 8 851 kgf m x 9 807 kgf m x 7 233 kgf m x 86 80 Units of Pressure kPa x 0 01020 kPa x 0 1450 kPa x 0 7501 kgf cm x 98 07 kgf cm x 14 22 cmHg x 1 333 Units of Speed km h x 0 6214 Units of Power kW x 1 360 kW x 1 341 PS x 0 7355 PS x 0 9863 40 C 9 N m ft lb in lb kgf cm psi cmHg kPa psi kPa mph PS HP kW HP 68 104 176 212 248 284 80 100 120 140 160 180 200 220 240 260 280 300 40 60 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Torque anid LOCkinG Agenta cion cae Gis aa cto diane ston ner aio dn meee 2 6 eene te TEE 2 13 Special OO EE 2 15 Periodic Maintenance Proc dures e di 2 16 A A 2 16 Air Cleaner Element Cleaning is 2 16 Throttle Control System Inspection sn ias 2 16 Idle Speed Inspection ss 2 17 idie Speed ET 2 17 Choke Knob Operation sise 2 18 Fuel Hose Inspection Fuel Leak Damage Installation Condi
71. 4 9 N m 0 50 kgf m 43 in Ib e Install the front fork inner covers A Torque Front Fork Inner Cover Bolts 4 0 N m 0 40 kgf m 35 in Ib e Install the fork legs B and push it up C tightly against the stem bottom e Temporarily tighten the front fork clamp bolts lower D GNO5050BS2 e Install Steering Stem Head A with Handlebar Holder O ring B Washer C Stem Head Nut D e Temporarily tighten the front fork clamp bolts upper E GNO5047BS1 14 12 STEERING Steering Stem OCheck that the top end A of the inner tube is flush with the upper surface B of the steering stem head Otherwise reinstall the fork leg e Tighten the front fork clamp bolts upper and then the stem head nut and finally the front fork clamp bolts lower Torque Front Fork Clamp Bolts Upper 29 N m 3 0 kgf m 22 ft lb Steering Stem Head Nut 88 N m 9 0 kgf m 65 ft Ib Front Fork Clamp Bolts Lower 29 N m 3 0 kgf m 22 ft lb NOTE OTighten the two front fork clamp bolts lower alternately two times to ensure even tightening torque e Install the removed parts see appropriate chapters e Check and adjust the following items after installation Steering see Steering Play Inspection in the Periodic Maintenance chapter Throttle Cables see Throttle Grip Free Play Adjustment in the Fuel System DFI chapter Headlight Aim see Headlight Beam Horizontal and ver tical Adjustmen
72. 55 BRL Front Left Turn Signal Light 12421 6 6 BK Y OO Front Right e ay Turn Signal CI Light 124218 Joint Connector 1 6 se Ga ee a E BX Y BX Y BX Y BK Y BK Y gt BRIY gt Speedometer Unit x EER 1 Odometer Trip Meter Clock Liquid Grystal Display AN E RE 2 Speedometer Dr esclbsess A Frame de Del Meter org TLL 25 e Ground uminator i Sa 25 5 Fuel Indicator LED Did H amp Water Temperature Warning FI S Dil Pressure Warning Indicator LED 2e M Le gt 7 Mode Switch IS Neutral Oil B Reset Switch Switch Pressure du 9 High Beam Indicator Light 12V1 12 Switeh S 10 Turn Signal Indicator Light 12V1 12 ld Neutral Indicator Light 12 1 124 Fuel Level LED Light Emitting Diode Sensor 2 0FF on Oo 0 ZF Side Stand Left Handlebar Switches Switch 1 Starter Lockout Switch E 1 2 Horn Button oe 3 Dimmer Switch sarea 4 Turn Signal Switch Switch LEFT HANDLEBAR SWITCH CONNECTIONS Sterter Lockout Switch Horn Button Dimmer Switch Turn Signal Switch Color BK R BK Color BK IBK Y Color R Y BL R BK Color G D GY IBK Y R Push omo Lo omo L ommo To Released TL best Y HI Y BK Y BK BK BK BK HEI Y BK Y BK BR Y U aR Y Y Y BK Y D BR BK BK BK Alternator Regulator Regulator Alternator 2 Rectifier Rectifier 1 Front Rear Lo YAR xr Turn Signal 9 Control Relay
73. A e Tighten the primary gear bolt while holding the alternator rotor steady with the flywheel holder Special Tool Flywheel Holder 57001 1410 Torque 143 N m 14 5 kgf m 107 ft lb e Push the starter clutch gear B in and turn it clockwise C and install it e Apply molybdenum disulfide oil solution to the threads and seating surface of the starter clutch bolt D and tighten it to the specified torque while holding the primary gear bolt OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 Torque Starter Clutch Bolt 85 N m 8 7 kgf m 63 ft lb OBe sure to install the washer E onto the torque limiter gt gem P CRANKSHAFT TRANSMISSION 9 21 Crankcase e Apply engine oil to the gasket A of the oil filter before installation 6605040251 e Tighten the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 18 Nm 1 8 kgf m 13 ft lb e Apply silicone sealant to the threads of the oil pressure switch C and tighten it to the specified torque Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb e Install Shift Mechanism see External Shift Mechanism Instal lation in this chapter Stater Motor see Starter Motor Installation in the Elec trical System chapter Oil Hoses see Oil Hose Ins
74. A from the pins B on the bracket CAUTION Never drop the meter unit especially on a hard sur face Such a shock to the unit can damage it Place the speedometer so that the face is up If the meter is left upside down or sideways for any length of time it will malfunction 16 78 ELECTRICAL SYSTEM Meter Gauge Meter Unit Installation e Install Meter Unit A Damper B D 22 mm 0 87 in Damper C 16 mm 0 63 in Bracket D Damper E D 24 mm 0 94 in Washers F Steel Nuts G Bolts H L 12 mm 0 47 in Cover I Meter Cover J Washers K Nylon Bolts L L 10 mm 0 39 in Meter Unit Disassembly e Remove the meter unit see Meter Unit Removal in this section e Remove Screws A Upper Meter Cover B e Remove Screws A Holder B e Remove the grommet C from the lower meter cover D SEI P NOTE OThe water temperature warning LED light oil pressure warning LED light and FI indicator LED light can not be exchanged ELECTRICAL SYSTEM 16 79 Meter Gauge e Turn out the socket A counterclockwise OThese sockets are for the high beam indicator light turn signal indicator light and neutral indicator light Meter Unit Assembly e Insert the bulb A so that the projections B align with the grooves C in the panel and turn in the socket clockwise Ima P e Fit the grommet A in the lower meter cover e Install Holder B Screws
75. Adapter M12 x 1 25 57001 1183 can also be used OValve Seat Cutter 32 633 57001 1199 can also be used instead of Valve Seat Cutter 32 35 57001 1121 ENGINE TOP END 5 15 Clean Air System Air Suction Valve Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Vacuum Switch Valve see Vacuum Switch Valve Re moval in this section e Unscrew the mounting bolts A and remove the front air suction valve cover B e Remove the front air suction valve e Unscrew the mounting bolts A and remove the rear air suction valve cover B e Remove the rear air suction valve Air Suction Valve Installation e Replace the gaskets with new ones e Install each air suction valve so that its wider side A of the reed faces left Rear Air Suction Valve B e Tighten Torque Air Suction Valve Cover Bolts 7 4 N m 0 75 kgf m 65 in Ib Air Suction Valve Check e Remove the air suction valve see Air Suction Valve Re moval in this chapter e Visually inspect the reeds for cracks folds warps heat damage or other damage x If 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 e f there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly
76. Balancer Shaft B Inside Oil Pipe C and Oil Return Pipe D see Inside Oil Pipe Removal in the Engine Lubrication System chapter Oil Baffle E Transmission Assy F see Transmission Removal in this chapter Shift Forks G and Shift Rod H Shift Drum Assy I e Remove the following from the right crankcase Inside Oil Pipe A and Oil Return Pipe B see Inside Oil Pipe Removal in the Engine Lubrication System chapter Oil Separator C Oil Pump D see Oil Pump Removal in the Engine Lu brication System chapter Water Pump Chain Guide E CAUTION Do not remove the bearings and the oil seals unless it is necessary Removal may damage them Crankcase Assembly CAUTION The left and right crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set e With 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 Support the crankcase bearing boss with a suitable re tainer A e Using a press and the bearing driver set C install a new bearing B or and race by pushing the bearing outer race until it bottoms out CAUTION Support the crankcase bearing boss when pushing the bearing otherwise the crankcase could be dam aged 6104020351 e Press the three needle bearings with manufacturer s marks f
77. Clutch Line Bleeding in the Clutch chapter e Remove the clear plastic hose e Install the reservoir cap e Tighten the bleed valve and install the rubber cap Torque Clutch Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib Clutch Slave Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Master Cylinder Rubber Parts Replacement e Remove the clutch master cylinder see Clutch Master Cylinder Removal in the Clutch chapter e Remove the reservoir cap A and diaphragm B and pour the clutch fluid into a container e Unscrew the locknut C and pivot bolt D and remove the clutch lever E e Pull the dust cover F out of place and remove the circlip G Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston assy H primary cup I piston J secondary cup K and return spring L e Replace Piston Assy Dust Cover Diaphragm Circlip CAUTION Do not remove the secondary cup from the piston since removal will damage it e Check the parts of the clutch master cylinder see Clutch Master Cylinder Inspection in the Clutch chapter x If any part shows signs of damage replace it e Before assembly clean all parts including the master cylinder with clutch fluid or alcohol CAUTION Use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning parts Do not use any other fluid for cleaning these
78. Coolant 50 35 C 31 F 2 3 L 2 4 US qt Engine Top End Valve Clearance Clutch Clutch Fluid Grade Clutch Lever Free Play Engine Lubrication System Engine Oil Type Viscosity Capacity Level Non adjustable hydraulic lash adjusters DOT4 Non adjustable API SE SF or SG API SH or SJ with JASO MA SAE 10W 40 2 9 L 3 1 US qt when filter is not removed 3 1 L 3 3 US qt when filter is removed 3 5 L 3 7 US qt when engine is completely disassembled and dry Between upper and lower level lines Wait 2 3 minutes after idling or running Tires Tread Depth Front Air Pressure When Cold Front Rear BRIDGESTONE EXEDRA G721 4 5 mm 0 18 in BRIDGESTONE EXEDRA G722 G 7 2 mm 0 28 in Up to 185 kg 408 Ib load 225 kPa 2 25 kgf cm 32 psi Up to 185 kg 408 Ib load 280 kPa 2 8 kgf cm 40 psi 1 mm 0 04 in 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 1 in 2 14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Final Gear Case Oil Grade Viscosity Oil Level Amount Brakes Brake Fluid Grade Brake Pad Lining Thickness Front Rear Brake Light Timing Front Rear Electrical System Spark Plug Type API Service Classification GL 5 hypoid gear oil When above 5 C 41 F SAE90 When below 5 C 41 F SAE80 Filler opening bott
79. E Spark Plugs A ISC Valve 2 for Rear Cylinder B Inlet Air Temperature Sensor C ISC Valve 1 for Front Cylinder D Rear Brake Light Switch E Starter Relay and Maine Fuse 30 A A Turn Signal Control Relay B DFI Maine Relay C Oil Pressure Light Delay Unit D Junction Box E Diode A in main harness DFI Fuse 15 A B Self diagnosis Terminal C ECU Electronic Control Unit D Battery E 16 4 ELECTRICAL SYSTEM Electrical Parts Location Atmospheric Pressure Sensor A Ignition Coil 1 B Frame Ground Terminal C Spark Plugs D Injectors E Horn A Radiator Fan B Water Temperature Switch C Radiator Fan Switch D Starter Motor E Regulator Rectifiers F Alternator G Crankshaft Sensors H Side stand Switch I Speed Sensor A Engine Ground Terminal B Neutral Switch C Oil Pressure Switch D ELECTRICAL SYSTEM 16 5 Electrical Parts Location Dummy Page 16 6 ELECTRICAL SYSTEM Exploded View 6P021838W5 C ELECTRICAL SYSTEM 16 7 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Alternator Cover Bolts 11 1 1 97 in lb 2 Alternator Inner Cover Bolts 11 1 1 97 in lb 3 Alternator Outer Cover Assembly Bolts 6 9 0 70 61 in lb 4 Alternator Outer Cover Bolts 6 9 0 70 61 in lb WL 5 Alternator Outer Cover Damper Bolts 0 70 61 in lb L 6 Alternator Outer Cover Joint Bolts 0 70 61 in De
80. Engine oil level too low Engine oil viscosity too low Camshaft bearing portion worn Crankshaft bearings worn Oil pressure switch damaged Oil pressure switch lead damaged Relief valve stuck open O ring at the oil pipe in the crankcase dam aged 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 Choke knob left pulled out Brown smoke Air cleaner duct loose Air cleaner O ring damaged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect 17 32 APPENDIX Troubleshooting Guide Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm sleeve or pivot bearings worn Wheel rim warped or not balanced Wheel bearing worn Handlebar nuts loose Steering stem head nut loose Front rear axle runout excessive Handlebar pulls to one side Frame bent Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and or left front fork oil level incorrect Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock ab
81. In addition the condition of the problem is stored in the memory of the ECU electronic control unit 6017204BS1 With the engine stopped and turned in the self diagnosis mode the service code A is indicated by the number of times the Fl indicator LED light blinks When due to a malfunction the Fl indicator LED light and FI symbol remains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause Don t rely solely on the DFI self diagnosis function use common sense First conduct a self diagnosis inspection and then a non self diagnosis The non self diagnosis items are not indi cated by the Fl indicator LED light GC17729BS1 Even when the DFI system is operating normally the Fl indicator LED light and Fl symbol may light up under strong electrical interference No repair needed Turn the ignition switch OFF to stop the indicator light and Fl symbol When the FI indicator LED light and Fl symbol go on and the motorcycle is brought in for repair check the service codes When the repair has been done the LED light and FI symbol do not go on OThere are two ways to inspect the DFI system One is Voltage Check Method and the other is Resistance Check Method Voltage Check Method OThis method is conducted by measuring the input voltage B to a sensor A first and then the output voltage C from the sensor OSometime this method can detect
82. Inspection A WARNING This inspection may produce sparks Keep the bat tery and the meter unit away from the fuel tank Alf the LED light is abnormal replace the meter unit Alf the Fl indicator LED light is normal the wiring or ECU has trouble Check the wiring see next diagram If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection in this chap ter 6017214BS1 CN LENITION QS C BATTERY ol os CT RES Tairi Ji Irate 2 Je GC17710BW2 ECU Junction Box Ignition Fuse 10 A Ignition Switch Meter Unit Fl Indicator LED Light Starter Relay Main Fuse 30 A Battery 1 2 3 4 5 6 7 8 9 3 82 FUEL SYSTEM DFI ECU ECU Identification OMost countries have their own regulations so each ECU has different characteristic of fuel injection according to each country So do not confuse ECU s with each other and use only the ECU s for your country Otherwise the motorcycle could not clear the emission regulation ECU Identification Models Type A Part No B CA and US F8T97373 21175 0048 EUR F8T37974 21175 0078 AU F8T97373 21175 0048 AU Australia Model CA Canada Model EUR Europe Model US United States Model ECU Removal CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove the front seat s
83. L J Alternator Stator Bolts Alternator Rotor Bot e ot s fo 115 in lb L Crankshaft Sensor Lead Holder Bolt 26 in lb L 11 Inside Stator Holder Bolts o Crankshaft Sensor Screws 26 in lb 1 1 97 in lb L 12 Neutral Switch 13 Regulator Rectifier Bolts 65 0 66 57inlb 14 Rotor Bolt Cap 13 in lb 15 Spark Plugs 16 Speed Sensor Mounting Bolt 98 17 Stator Lead Holder Screw 8 Timing Inspection Cap 0 15 87 in lb L 97 in lb L 13 in lb Regulator Rectifier Apply engine oil Apply high temperature grease L Apply a non permanent locking agent Apply molybdenum disulfide oil solution to the threads mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 SI SS WL Apply silicone grease Apply silicone sealant Kawasaki Bond 92104 0004 Apply a soap and water solution or rubber lubricant 16 8 ELECTRICAL SYSTEM Exploded View 6P02184BW5 C ELECTRICAL SYSTEM 16 9 Exploded View No Fastener Torque N m Remarks kgf m ft lb Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Screw 1 5 0 15 13 in Ib G Radiator Fan Bolts 8 3 0 85 73 in lb Radiator Fan Switch 18 1 8 13 Water Temperature Sensor 18 1 8 13 SS OI AJOINJ gt Water Temperature Switch 7 8 0 80 69 in lb SS Atmospheric Pressure Sensor DEI
84. L Right Air Cleaner Cover Allen Bolt 16 1 6 12 Spark Plug Lead Holder Bolts 11 1 1 97 in lb Throttle Body Assy Holder Bolts 11 1 1 97 in lb Water Temperature Sensor 18 1 8 13 Ss Cooling System Radiator Drain Bolt 2 2 0 22 19 in lb Radiator Fan Bolts 8 3 0 85 73 in lb Radiator Fan Switch 18 1 8 13 Water Hose Clamp Screws 2 5 0 25 22 in lb Water Pipe Bolts 11 1 1 97 in lb Water Pump Air Bleeder Bolt 11 1 1 97 in lb Water Pump Cover Bolts 11 1 1 97 in lb Water Pump Drain Bolt 11 1 1 97 in lb Water Pump Impeller Bolt 8 8 0 90 78 in lb LH Water Temperature Sensor 18 1 8 13 SS PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Torgue Remarks N m kgf m ft Ib Water Temperature Switch 7 8 0 80 69 in lb SS Engine Top End Air Suction Valve Cover Bolts 7 4 0 75 65 in lb Camshaft Chain Guide Bolts 11 1 1 97 in lb L Camshaft Chain Guide Retainer Bolts 11 1 1 97 in lb L Camshaft Sprocket Bolts 15 1 5 11 L Chain Tensioner Cap 20 2 0 15 S Chain Tensioner Lockbolts 4 9 0 50 43 in lb S Chain Tensioner Mounting Bolts 11 1 1 97 in lb S Cylinder Head Nuts 25 2 5 18 S Cylinder Nuts 25 2 5 18 S Exhaust Pipe Cover Clamp Screws 6 9 0 70 61 in lb Muffler Stay Mounting Bolts 25 2 5 18 Oil Hose Flange Bolts 9 8 1 0 87 in lb Plugs 20 2 0 15 L Premuffler Chamber Bolts 29 3 0 21 Rocker Case Bolts 8 8 0 90 78 in lb S Rocker Case Cover Bolts 8 8 0 90 78 in lb S Rocker Case Nuts M12 78 8 0 58 MO S Rocker Case Nuts M
85. Never drop the starter motor especially on a hard surface Such a shock to the motor can damage it Starter Motor Installation CAUTION 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 GPIB P e Replace the O ring A with a new one e Apply a small amount of engine oil to the O ring Torque Starter Motor Mounting Bolts 11 N m 1 1 kgf m 97 in lb Starter Motor Terminal Nut 4 9 N m 0 50 kgf m 43 in lb Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal in this section e Take off the starter motor assembly bolts A and remove both end covers B and pull the armature out of the yoke ELECTRICAL SYSTEM 16 57 Starter Motor e Take the positive carbon brushes B out of the brush hold ers A e Take off the brush plate C with brush wire from the yoke e Unscrew the terminal locknut B and remove the terminal bolt A e Take the positive carbon brushes and wire assy C out of the yoke GP12000381 NOTE ODo not remove the negative carbon brushes A from the brush plate B Starter Motor Assembly e Holding the springs A with plastic washers B insert the brushes OFit the brush wire into the holder groove e Align the tang C wit
86. P 3 106 FUEL SYSTEM DEI Fuel Tank e Remove the bolts A and take out the meter unit B CAUTION Place the meter so that the face is up If a meter is left upside down or sideways for any length of time it will malfunction e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank Bolts A e Disconnect the battery terminal e Disconnect Fuel Pump Connector 2 pin A Fuel Level Sensor Connector 3 pin B NOTE ODuring tank removal keep the fuel tank cap A open to release pressure in the fuel tank This makes fuel Spillage less e Draw the fuel out from the fuel tank with a commercially available pump OPut the soft plastic hose A into the drain pipe B and draw the fuel out FUEL SYSTEM DFI 3 107 Fuel Tank e Prepare rubber hoses of the inside diameter 5 5 8 mm 0 20 0 23 in e g Rubber Tube Part No 92191 1272 x L 80 mm 3 1 in and make plug hoses A of the rubber hose with one end tied with a wire B e Raise the rear of the tank up and disconnect the hoses on the bottom e Plug these pipes C with plug hoses to prevent fuel spillage e Disconnect the fuel drain hose A Front B e Prepare a rubber hose of the inside diameter 7 3 7 5 mm 0 29 0 30 in e g Part No 92191 1264 x L 100 mm 3 9 in and make a plug hose A with one end tied with a wire B e Raise the fuel tank A up and mak
87. Plugs see Spark Plug Installation in the Electrical System chapter Camshafts see Camshaft Installation in this chapter Rocker Cases see Rocker Case Installation in this chapter Air Suction Valves see Air Suction Valve Installation in this chapter e Tighten Torque Cylinder Head Nuts 25 N m 2 5 kgf m 18 ft lb Cylinder Nuts 25 N m 2 5 kgf m 18 ft lb Water Pipe Bolts 11 N m 1 1 kgf m 97 in Ib ENGINE TOP END 5 35 Cylinder Head Cylinder Head Warp e e Remove the cylinder head see Cylinder Head Removal in this chapter e Lay astraightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straight edge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If they cylinder head is warped more than the service limit replace it Alf they 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 Valve Clearance Adjustment NOTE OSince the hydraulic lash adjusters constantly maintain zero clearance it is not necessary to inspect or adjust the valve clearance Valve Removal e Remove the cylinder head see Cylinder Head Removal in this section e Swing open the rocker arm e Using the valve spring compressor assembly remove the valve Special Tools Valve Spri
88. Preload Measurement with Spring Scale e Hold the bearing housing in a vise so that the gear shaft axis is vertical e Hook C the spring scale B on the driven gear holder A at a point 200 mm 7 9 in D apart from the center of the gear shaft e Apply force to the handle horizontally and at a right angle to it Special Tool Driven Gear Holder m2 57001 1027 QP S 6K09011BS1 Alf the preload is out of specified range replace the bear ing collar and or spacer To increase preload decrease the stack length of the collar and spacer To decrease preload increase the stack length of the collar and spacer Change the stack length a little at a time e Recheck the bearing preload and readjust if necessary Collars for Preload Adjustment Spacers for Preload Adjustment Length mm Part Number Thickness mm Part Number 22 8 0 898 in 92027 1152 1 70 0 0669 in 92025 1072 22 9 0 902 in 92027 1153 1 72 0 0677 in 92025 1073 23 0 0 906 in 92027 1154 1 74 0 0685 in 92025 1074 23 1 0 909 in 92027 1155 1 76 0 0693 in 92025 1075 23 2 0 913 in 92027 1156 1 78 0 0701 in 92025 1076 23 3 0 917 in 92027 1157 1 80 0 0709 in 92025 1077 23 4 0 921 in 92027 1158 23 5 0 925 in 92027 1159 23 6 0 929 in 92027 1160 23 7 0 933 in 92027 1161 23 8 0 937 in 92027 1162 23 9 0 941 in 92027 1163 24 0 0 945 in 92027 1164 24 1 0 949 in 92027 1165 11 34 FINAL D
89. Removal OThe pressure regulator A is built into the fuel pump B and cannot be removed Pump Screen Fuel Filter Cleaning OThe pump screen A and fuel filter B are built into the pump and cannot be cleaned or checked Alf the pump screen or fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set Operation Inspection NOTE OBe sure the battery is fully charged OJust listen to the pump sound in the fuel tank to confirm pump operation 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 Alf the pump does not work as described above inspect the power source voltage GC10028BS1 GC10029BS1 GC10030BS1 3 76 FUEL SYSTEM DFI Fuel Pump Service Code 45 Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the front seat see Front Seat Removal in the Frame chapter e Connect the hand tester 25 V DC B to the fuel pump connector A with two needle adapters C Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Pump Operating Voltage at Pump Connections to Pump Connectors Tester Y R Lead D Tester BK W Lead E e Measure the operating voltage with the engine stopped and with the connector joined e Turn the ignit
90. SYSTEM Meter Gauge e Push the mode button A to CLOCK e Push the reset button B more than 2 seconds then the display turns to the HOUR MINUTE mode C Oln the HOUR MINUTE mode the numbers flash on the display e Check that the flashing number changes to the HOUR or MINUTE display each time the reset button is pushed HOUR MINUTE e HOUR MINUTE x If the display does not work replace the meter unit e Check that the time can be set x If the time cannot be set replace the meter unit Clock Setting e In the HOUR MINUTE mode push the reset button again to effect the HOUR setting mode OThe hour display flashes on the display e Push the mode button to set the hour e In the HOUR mode push the reset button once to effect the MINUTE setting mode OThe minute display flashes on the display e Push the mode button to set the minute 6P17091BS2 C 6P17092BS1 6P17093BS1 ELECTRICAL SYSTEM 16 83 Meter Gauge e Set the minute push the reset button to return to the HOUR MINUTE mode ePush the mode button to complete the time setting process OThe clock starts counting the seconds as soon as the mode button is pushed Speedometer Inspection e Connect the leads in the same circuit as for the LCD Seg ment Inspection check 2 e Connect the oscillator A to the terminal 11 The vehi cle speed that corresponds to the input frequency will be
91. Service Code 41 Fuel Injector 2 Rear Fuel Injector for Rear Cylinder Service Code 42 CAUTION Never drop the injector especially on a hard sur face Such a shock to the injector can damage it Injector Removal Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Disconnect the battery lead ter minal Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Check to see that the battery lead terminal is discon nected e Remove Fuel Tank see Fuel Tank Removal in this chapter Front and Rear Injector Connectors A e Remove the fuel hose joint 2 A from the pipe for the delivery joint and take out the fuel hose assy outlet hose B e Unscrew the delivery joint screw A and bolts B and lift up the delivery joint C with the injectors D e Remove the injectors from the delivery joint 3 68 FUEL SYSTEM DFI Fuel Injectors 1 2 Service Code 41 42 Injector Installation OThe front and rear injectors are the same e Replace the seal A and O ring B with new ones and install them onto the injector C e Apply engine oil to the O ring and install them onto the injector CAUTION To avoid air and fuel leak be careful not
92. Taillight Lead Connec tor Self Diagnosis Terminal Put these connectors into the alternator outer cover Front Turn Signal Light Leads Connect them in the headlight body Run the front turn signal light leads into the holes of the bracket Left Handlebar Switch Leads Connect them in the headlight body Straps Right Handlebar Switch Leads 17 26 APPENDIX Cable Wire and Hose Routing 1 2 3 ont 00 Y 9 10 Main Harness Starter Motor Lead Fuel Tank Filler Drain Hose Except Cali fornia Model Engine Ground Lead Run it downward Coolant Reserve Tank Overflow Hose Coolant Reserve Tank Hose from the ra diator cap to the coolant reserve tank To the inside of the alternator outer cover Through the alternator outer cover to the starter motor To the engine ground Crankcase Ko ER tm 6809725844 To the crankcase backward lower clamp Junction Box Lead ECU Main Relay Turn Signal Control Unit Insert the band attached main harness Band Fix the main harness and frame joint part only California model run the green hose inside the band Oil Pressure Light Delay Unit Coolant Reserve Tank Hose Run the up per side of the frame bracket Holder APPENDIX 17 27 Cable Wire and Hose Routing 5 LATIN gt AGR eu z E lt lt e y 6899726844 C 20 Insert the sub harness connector to the frame 21
93. Torque Alternator Inner Cover Bolts 11 N m 1 1 kgf m 97 in lb e Move the engine into its original position and tighten the engine mounting bolts Torque Engine Mounting Bolts and Nuts 44 N m 4 5 kgf m 32 ft lb e Install the removed parts see appropriate chapters Alternator Rotor Removal e Remove the alternator cover see Alternator Cover Re moval Installation in this section e Hold the alternator rotor A steady with the flywheel holder B and remove the rotor bolt C Special Tool Flywheel Holder 57001 1410 e Take the alternator rotor washer and ratchet off the crankshaft 16 36 ELECTRICAL SYSTEM Charging System Alternator Rotor Installation e Install the alternator rotor A while fitting the alignment notch B of the splines onto the alignment tooth C e Apply molybdenum disulfide oil solution to the threads of the alternator rotor bolt OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Tighten Torque Alternator Rotor Bolt 78 N m 8 0 kgf m 58 ft lb e Install the alternator cover see Alternator Cover Re moval Installation in this section Alternator Outside Stator Removal e Remove the alternator cover A see Alternator Cover Removal Installation in this section e Remove the crankshaft sensors B see Crankshaft Sen sor Removal in this chapter e Unscrew the Allen bolts C and take t
94. Vehicle down Sensor Connector 22 Vehicle down Sensor 23 Throttle Cables 24 Right Handlebar Switch Lead 25 Head Pipe Cover 26 Plastic Snap on Clamps 15 mm Rear Brake Light Switch and Radiator Fan Leads 27 Plastic Snap on Clamps 15 mm Rear Brake Light Switch 28 Right Regulator Rectifier 29 Rear Brake Light Switch 30 Front 17 28 APPENDIX Troubleshooting Guide NOTE ORefer to Fuel System chapter for most of DFI troubleshooting 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 Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter lockout switch or neutral switch trou ble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter clutch trouble Vehicle down sensor coming off Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Balancer bearing seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line c
95. Viscosity SAE 10W 40 Capacity 2 9 L 3 1 US qt when filter is not removed 3 1 L 3 3 US qt when filter is removed 3 5 L 3 7 US qt when engine is completely disassembled and dry Level Wait 2 3 Minutes After Idling or Between upper and lower level lines Running Oil Pressure Measurement Oil Pressure 2 000 r min rpm Oil 340 440 kPa 3 5 4 5 kgf cm 50 64 psi Temperature 90 C 194 F ENGINE LUBRICATION SYSTEM 7 5 Special Tools and Sealant Oil Pressure Gauge 5 kgf cm Kawasaki Bond Silicone Sealant 57001 125 56019 120 ST5701258T ST5601208ST Oil Pressure Gauge Adapter PT 1 8 57001 1033 ST5710338T 7 6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 6G04004B 5 ENGINE LUBRICATION SYSTEM 7 7 Engine Oil Flow Chart gt i J O O1 ND A Oil Flow 1 30 Blowby Gas Oil Screen Oil Pump Relief Valve Oil Filter Bypass Valve Oil Pressure Switch Inside Oil Pipe Banjo Bolts of Right Crankcase Rear Outside Oil Hoses HLA Oil Filter Rocker Shafts Rocker Arms HLA Hydraulic Lash Adjuster Camshafts Outside Oil Pipe Front Gear Case Inside Oil Pipe Crankshaft Alternator Rotor Oil Nozzle Front Piston Drive Shaft Output Shaft Rear Piston Front Rocker Case Rear Rocker Case Inside Oil Pipe Fittings
96. WVTA FULL H VN1600 D1H Control Information Full Full Power H Honeycomb Type Catalyst GB United Kingdom Model GE02156B F 5 8 ENGINE TOP END Exploded View Chamber Mark Position A Silencer Mark Position A ENGINE TOP END 5 9 Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Closing Pressure Open Close 49 3 65 3 kPa 370 490 mmHg Camshafts Cam Height Exhaust Inlet Camshaft Rocker Case Clearance 25 17 Camshaft Journal Diameter 25 17 Rocker Case Bearing Inside Diameter 25 17 Camshaft Runout Rocker Arm Inside Diameter Rocker Shaft Diameter Cylinder Head Cylinder Compression Usable Range Cylinder Head Warp Valve Valve Clearance Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet 33 487 33 601 mm 1 3184 1 3229 in 33 805 33 919 mm 1 3309 1 3354 in 0 020 0 062 mm 0 0008 0 0024 in 0 016 0 055 mm 0 0006 0 0022 in 24 959 24 980 mm 0 9826 0 9835 in 16 966 16 984 mm 0 6680 0 6687 in 25 000 25 021 mm 0 9843 0 9851 in 17 000 17 021 mm 0 6693 0 6701 in TIR 0 02 mm 0 0008 in or less 16 000 16 018 mm 0 6299 0 6306 in 15 966 15 984 mm 0 6286 0 6293 in 340 590 kPa 3 5 6 0 kg cm 50 85 psi 300 r min rpm with electric starter Non adjust
97. and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains wha
98. and remove the hoses C e Unscrew the bolts and remove the water pipes D and O rings E e Apply grease to the new O ring and install the water pipes e Torque the water pipe bolts F Torque Water Pipe Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the new radiator hose and tighten the hose clamps securely Torque Water Hose Clamp Screws 2 5 N m 0 25 kgf m 22 in Ib e Fill the coolant see Coolant Change in this chapter e Check the cooling system for leaks GS06026BW3 C 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 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 hose A temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Install new brake hoses and pipes e Immediately wash away any brake fluid that spills e There are washers B on each side of the brake hose fitting Replace them with new ones when installing e Tighten the banjo bolts C on the hose fittings Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 0 ft Ib e When installing the hoses A avoid sharp bending kink ing flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in
99. and replace see chapter 3 Compression low Spark plug loose Reinstall see chapter 16 Tighten see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on the seating surface KACR compression release cam sticks open Inspect and repair or replace see chapter 5 engine stalls when moving off FUEL SYSTEM DFI 3 37 DEI System Troubleshooting Guide Symptoms or Possible Causes Actions detailed reference HLA hydraulic lash adjuster damaged worn Inspect and replace see chapter 5 seizure or spring broken Knocking Fuel poor quality or incorrect Use high octone gasoline recommended in the Owner s Manual Ignition coil trouble Inspect see chapter 16 IC igniter in ECU trouble spect see chapter 16 i nlet air temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Miscellaneous Throttle valves won t fully open Inspect throttle cable and lever linkage see chapter 3 Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 Clutch slipping Inspect friction plate
100. 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 Electrical System chapter Suspension Front Forks Rear Shock Absorber Operation Inspection 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 e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the shock absorber does not smoothly or noise is found inspect the oil leak see Rear Shock Absorber Oil Leak Inspection in this chapter or shock absorber mounting condition 6S 138248 P PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Front Fork Oil Leak Inspection e Remove the bolts A on both sides and then slide the front fork inner covers downward e Visually inspect the front forks A for oil leakage scoring or scratches on the outer surface of the inner tubes x Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection e Remove the Saddlebags see Saddlebag Removal in the Frame chapter e Visually inspect the shock absorbers A for oil leakage x If they are oil leaked one unit feels weaker than the other replace both shock absorber as a set see Rear Shock Absorber Removal and Installation
101. check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 25 0 35 mm 0 010 0 014 in Second 0 40 0 55 mm 0 016 0 022 in Oil 0 30 0 90 mm 0 012 0 035 in Service Limit Top 0 7 mm 0 03 in Second 0 9 mm 0 04 in Oil 1 2 mm 0 05 in x lf the end gap of either ring is greater than the service limit replace all the rings GE160707S1 GE160708S1 GE160140S1 ENGINE TOP END 5 47 Mufflers Exhaust Pipe Removal A WARNING To avoid a serious burn do not remove the exhaust pipe or muffler when the engine is still hot Wait until the muffler cools down e Loosen the clamp screws A on the rear exhaust pipe cover B e Detach the clamps C by sliding it up e Remove the rear exhaust pipe cover e Loosen the clamp screw A e Detach the clamp B by sliding it forward e Remove the lower front exhaust pipe cover C by sliding it forward e Loosen the clamp screws A e Detach the clamps B by sliding them up or forward e Remove the front exhaust pipe co
102. drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Brake Pad Removal e Remove the rear caliper with the hose installed see Rear Caliper Removal in this chapter e Remove Snap Pin A Pad Pin B 1 7 k r 12 14 BRAKES Brake Pads e Remove the jaw side pad A and then remove the piston side pad B Jaw C Rear Brake Pad Installation e Before installation clean the pads with a high flash point solvent e Push A the caliper pistons in by hand as far as they will go e Be sure to install the snap pin for the caliper A WARNING Do not attempt to ride the motorcycle until a full pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first application of the lever or pedal if this is not done Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter BRAKES 12 15 Master Cylinder Front Master Cylinder Removal e Disconnect the front brake light switch connectors A e Draw out the brake fluid from the reservoir with a means like the fork oil level gage e Pull the bolt caps out e Remove the banjo bolt B to disconnect the brake hose from the master cylinder see Brake Hose Removal In stallation
103. e Apply molybdenum disulfide grease to the rocker shafts e Install the rocker arms C and retaining springs D on each rocker shaft as shown These retaining springs are the same OThe rocker arm E of the exhaust side F next to the chain tunnel is different from the others OBe careful not to tip the rocker arm and not to allow the oil to leak out of HLA e Tighten the rocker shafts to the specified torque Torque Rocker Shafts 25 N m 2 5 kgf m 18 ft lb e Apply silicone sealant A to the rocker case mating sur face and the outer circumference of the plugs as shown Sealant Kawasaki Bond Silicone Sealant 92104 0004 ODo not apply silicone sealant around the camshaft bear ing e Apply molybdenum disulfide oil solution to the threads and seating surface of M12 nuts and both sides of wash ers OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Tighten the rocker case nuts and bolts temporarily follow ing the tightening sequence shown and then tighten them to the specified torque Torque M12 Rocker Case Nuts 1 4 78 N m 8 0 kgf m 58 ft lb M8 Rocker Case Nuts 5 8 25 N m 2 5 kgf m 18 ft lb Rocker Case Bolts 9 10 8 8 N m 0 90 kgf m 78 in Ib Inlet Side A 6E20000BS1 5 24 ENGINE TOP END Rocker Case e Replace the HLA oil filters A with new ones e After installing the rocke
104. f DZ j BK Y i License Plate Light 12V5 2 Tail Brake Lights 12421 5 3 Rear Right Turn Signal Light 12 21 4 Rear Left Turn Signal Light 124218 5 Rear Accessory Y R H Y R Connectors pri Starter DFI GEN Relay Main Relay Ce Color Code Fuel Digital Fuel Injection System Ee 1 Fuel Injector 1 6 Inlet Air Temperature Sensor p d DG Dark Green 2 Fuel Injector 2 7 Water Temperature Sensor Starter 3 Throttle Sensor 8 Inlet Air Pressure Sensor GB cren Rotor 4 186 Valve 2 0 Atmospheric Pressure Sensor 5 150 Valve 1 10 Vehicle down Sensor e Sr EE IGNITION SWITCH CONNECTIONS parties ter tome falls renta Front Brake Light Switch Engine Stop Switch Starter Button Color ak Bk color e Y R Color e BK R Brake Lever OFF Free Pulled In RUN Push 98052 1165D RIGHT HANDLEBAR SWITCH CONNECTIONS GPOSOS3BWS C 16 20 ELECTRICAL SYSTEM Wiring Diagram Australia Radiator Fan Horn 12V4 0A d BK Y Dil Pressure Warning R BR R Light Delay Unit HM 6 Y BL R DA BK Y Speed Sensor P LO R oun Leien EH H BK Bk Y BL Radiator Fan Switch Hater Temperature Em Switch CH Di Rear Brake Light BK BK E Switch Sai iil A 0606600 ee Front Accessory E Gonnectors M i It R BK Headlight a BK 12V60
105. for damage or signs of deteriora tion OThese hoses should not be hard and brittle nor should be soft or swollen x Replace it if any cracks or swelling are noticed e Check that the hoses are securely connected 7 14 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Breather Drain Cleaning OThe air cleaner drain hose is provided beneath the right air cleaner housing and catches the water or oil from the crankcase breather hose Usually water or oil does not collect at the bottom In the event that rain water is drawn in through the air cleaner or if engine oil is blown back drain the housing e Remove the left air cleaner housing see Left Air Cleaner Housing Removal in the Fuel System DFI chapter e Remove the drain plug A from the air cleaner drain hose B to drain the water or breather e Install the plug on its original position A WARNING Be sure to reinstall the plug in the drain hose after draining Oil on tires will make them slippery and can cause an accident and injury ENGINE LUBRICATION SYSTEM 7 15 Oil Pressure Oil Pressure Measurement e Slide out the rubber boot A e Disconnect the oil pressure switch lead B from the ter minal screw C e Unscrew the oil pressure switch D NOTE OMeasure the oil pressure after the engine is warmed up e Attach the oil pressure gauge B and adapter C to the switch hole Oil Pressure Switch A Special Tools Oil Pressur
106. four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion 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 x 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 GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing DE 1 2 Model Identifications a aa ainda 1 7 General Gpechfications 1 9 Unit Conversion dable iii ees 1 12 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 att
107. ignition fuse blown Inspect and replace see chapter 16 Fuellair mixture incorrect Air cleaner clogged poorly sealed or missing Clean or reinstall see chapter 3 Leak from oil filler cap crankcase breather hose Inspect and repair or replace see chapter 3 or air cleaner drain hose Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Throttle sensor trouble Inspect see chapter 3 Fuel pressure may be low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 nspect see chapter 3 Inlet air temperature sensor rouble Inspect see chapter 3 Water temperature sensor trouble Inspet see chapter 3 Compression low Cylinder head not sufficiently tightened down 3 32 FUEL SYSTEM DFI DEI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Cylinder piston worn Inspect and replace see chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 Valve guide
108. ignition switch e The headlights and high beam indicator light should go off Headlight Aiming Inspection e Inspect the headlight beam for aiming xlf 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 headlight with a screwdriver in or out until the beam points straight ahead OTurn the adjuster clockwise to face the headlight to the left x lf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster A in the headlight in or out with a screwdriver to adjust the headlight vertically OTurn the adjuster clockwise to face the headlight up GS17044BS1 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures NOTE OON 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 OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 0 in drop at 7 6 m 24 93 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 50 mm 2 0 in A Center of Brightest Spot B 7 6 m 24 93 ft C GP12172BS1 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Si
109. in in height The sliding range is within 50 mm 2 0 in to suit the rider s preference e Loosen the upper and lower bolts B on both sides and slide the windshield up or down e Check to see that the position marks C are in the same relative position on both sides e Tighten the bolts securely e Loosen the subwindshield bolts A on both sides and slide the subwindshield B up or down so the clearance C is 10 mm 0 4 in between the subwindshield lower edge and the headlight body e Tighten the subwindshield bolts Windshield Removal CAUTION Be careful not to damage the surface of the wind shield e Remove the upper and lower bolts A on both sides and remove the windshield B FRAME 15 21 Windshield Windshield Assembly Installation CAUTION Be careful not to damage the surface of the windshield e Install the following with the bolts and nuts to the windshield A Outer Center Plate B and Damper C Inner Center Plate D and Damper E Left and Right Outer Plates F Left and Right Stays G and Dampers H Washers I OThe left outer plate has an L mark on its back and the right outer plate an R mark front view 60160018W2 C e Insert the subwindshield A between the windshield B and the dampers C e Install the left and right inner plates A and dampers B between the windshield C and left and right outer plates D e First tigh
110. in Ib OA D 4 14 COOLING SYSTEM Radiator A WARNING The radiator fan is connected directly to the bat tery The radiator fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES Radiator Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Cover Bolts A Cover B Front C e Pry the plastic clamps A e Remove Nut A Radiator Fan Motor Connector B ET PRP tine e Remove Radiator Hose Clamps A Radiator Hoses B COOLING SYSTEM 4 15 Radiator e Remove the mounting bolt A e Lift up the radiator to clear the stoppers e Remove the radiator CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency e Remove Radiator Fan Bolts A Radiator Fan B GD07030BS1 Radiator Installation e Be sure to install the radiator fan ground lead terminal A Torque Radiator Fan Bolts 8 3 N m 0 85 kgf m 73 in Ib GDO7031BS1 e Fit the radiator stoppers A into the left and right grom A Kc mets B a e Install the pump inlet hose and position the hose clamp j 2 Lo see Water P
111. in the Suspension chapter e Install the Saddlebags see Saddlebag Installation in the Frame chapter Swingarm Pivot Lubrication e Remove the swingarm see Swingarm Removal in the Suspension chapter e Clean the old grease out of the bearings e Apply grease to the inner surface of the needle bearings A e Apply a thin coat of grease to the lips B of the grease seals e Install the swingarm see Swingarm Installation in the Suspension chapter 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering System Steering Play Inspection e Check steering as follows OUse the jack A the attachment jack B under the frame pipe ribs C and a commercially available jack D under the engine E to lift the front wheel F OFF the ground until the rear wheel G touches the ground Special Tools Jack 57001 1238 Attachment Jack 57001 1398 OWith the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully right and left 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 OFeel for steering looseness by pushing and pulling A the fork 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 Be sure the wires and cables are properly routed OThe bea
112. into its original position in the frame e Tighten Torque Downtube Bolts 59 N m 6 0 kgf m 44 ft Ib Engine Mounting Nuts 44 N m 4 5 kgf m 33 ft lb Engine Mounting Bracket Bolts 25 N m 2 5 kgf m 18 ft lb e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation e Connect the engine ground lead A down to the engine as shown Torque Engine Ground Terminal Bolt 7 8 N m 0 80 kgf m 69 in Ib e Install the removed parts see appropriate chapters e Adjust the throttle cables see Throttle Grip Free Play Ad justment in the Fuel System DFI chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter e Adjust the idling see Idle Speed Inspection in the Periodic Maintenance chapter e Check the clutch operation e Check the brake effectiveness A WARNING Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this is not done CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded Views far fas
113. is normal and the ECU is sus pect Check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter e Remove the inlet air pressure sensor D and disconnect the vacuum hose from the sensor e Connect an auxiliary hose E to the inlet air pressure sen sor e Temporarily install the inlet air pressure sensor OConnect a commercially available digital meter A the needle adapters F vacuum gauge B and the fork oil level gauge C to the inlet air pressure sensor Front G Special Tools Fork Oil Level Gauge 57001 1290 Needle Adapter Set 57001 1457 Digital Meter Connections Meter W BL lead of Inlet Air Pressure Sensor Meter BR BK lead of Inlet Air Pressure Sensor OTurn the ignition switch ON OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge Olnspect the inlet air pressure sensor output voltage using the following formula and charts for Pv 24 55 cmHg and 55 86 cmHg 6017197BS2 C FUEL SYSTEM DFI 3 51 Inlet Air Pressure Sensor Service Code 12 Suppose Pg Vacuum gauge of Throttle Assy PI Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum absolute of Throttle Assy Vv Sensor Output Voltage v then Pv Pl Pg For example suppose the following data is obtained in the chart of the next page Pg 8 cmHg vacuum gauge rea
114. kgf m 4 3 7 8 in lb 3 0 4 0 N 0 30 0 50 kg 0 6 1 0 Ib FINAL DRIVE 11 7 Special Tools Outside Circlip Pliers Driven Gear Holder m2 57001 144 57001 1027 ST5701448T Bearing Puller Oil Seal 8 Bearing Remover 57001 158 57001 1058 ST570158ST ST5710588T Bearing Puller Adapter Bearing Driver Set 57001 317 57001 1129 ST570317ST ST5711298T Bearing Driver 32 Pinion Gear Holder m1 9 57001 382 57001 1165 T5703828T Damper Cam Holder Final Gear Case Holder 57001 1025 57001 1250 ESS 11 8 FINAL DRIVE Special Tools Drive Shaft Holder 57001 1407 FINAL DRIVE 11 9 Final Gear Case and Oil Oil Level Inspection e Refer to the Oil Level Inspection in the Periodic Mainte nance chapter Oil Change e Refer to the Oil Change in the Periodic Maintenance chapter Final Gear Case Removal Alf the final gear case is to be disassembled drain the final gear case oil see Oil Change in the Periodic Maintenance chapter e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter e Remove the left rear shock absorber A from its studs by taking off the nuts e Remove the final gear case by taking off the nuts B The spring comes off with the case NOTE Olf the final gear case is full of oil place the case so that the breather hole C is on top Final Gear Case Installation e Lubricate th
115. limiter to protect the regulator rectifier from excessive current Do not use an ammeter instead of a test light 16 42 ELECTRICAL SYSTEM Charging System e Do the 1st step regulator circuit test OConnect the test light and the 12 V battery to the regula tor rectifier as shown OCheck BK1 BK2 BK3 terminals respectively x If the test light turns on the regulator rectifier is defective Replace it x lf the test light does not turn on continue the test e Do the 2nd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the 1st step regulator circuit test OApply 12 V to the BK R terminal OCheck BK1 BK2 and BK3 terminals respectively x If the test light turns on the regulator rectifier is defective Replace it Olf the test light does not turn on continue the test e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the 1st step regulator circuit test OMomentarily apply 24 V to the BK R terminal by adding a 12 V battery OCheck BK1 BK2 and BK3 terminals respectively CAUTION Do not apply more than 24 volts If more than 24 volts is applied the regulator rectifier may be dam aged Do not apply 24 V more than a few seconds If 24 volts is applied for more than a few seconds the regulator rectifier may be damaged lf the test light does not light w
116. list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease to the threads L Apply a non permanent locking agent to the threads LH Left hand threads M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution The molybdenum disulfide oil solution is a mixture of the engine oil and molybdenum disulfide grease weight ratio 10 1 O Apply oil to the threads and seating surface R Replacement parts S Tighten the fasteners following the specified sequence SI Apply silicone grease ex PBC grease SS Apply silicone sealant ST Stake the fasteners to prevent loosening WL Apply a soap and water solution or rubber lubricant Torque Fastener ES Kern DI Remarks Fuel System Air Cleaner Duct Holder Bolts 10 1 0 89 in lb Choke Cable Plate Screw 2 9 0 30 26 in lb E Fuel Pump Mounting Bolts 9 8 1 0 87 in lb L S Inlet Air Temperature Sensor Nut 7 8 0 80 69 in lb Inlet Manifold Bolts 12 1 2 104 in lb ISC Pipe Holder Bolts 11 1 1 97 in lb Left Air Cleaner Base Bolt 11 1 1 97 in lb Left Air Cleaner Base Screws 2 2 0 22 19 in lb L Left Air Cleaner Cover Allen Bolt 16 1 6 12 Right Air Cleaner Allen Bolts 11 1 1 97 in lb Right Air Cleaner Base Bolt 11 1 1 97 in lb Right Air Cleaner Base Screws 2 2 0 22 19 in lb
117. make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove the fuel tank see Fuel Tank Removal in this 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 Remove the fuel pump inlet hose e Unscrew the fuel pump bolts A and take out the fuel pump B and gasket e Discard the fuel pump gasket CAUTION Do not pull the leads C of the fuel pump If they are pulled the lead terminals may be damaged Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air GC10027BS1 e Replace the fuel pump gasket A with a new one GC10034BS1 FUEL SYSTEM DFI 3 75 Fuel Pump Service Code 45 e Check that the fuel pump terminals 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 shown e Following the tightening sequence tighten the pump bolts to the specified torque Torque Fuel Pump Mounting 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 Pressure Regulator
118. motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained m
119. mounts loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Vacuum switch valve damaged Alternator rotor loose Catalytic converters melt down due to muf fler overheating KLEEN Balancer gear worn or chipped Balancer shaft position maladjusted Balancer bearing worn Balancer shaft coupling rubber damper damaged Water pump chain sprocket worn Abnormal Drive Train Noise Clutch noise Clutch rubber damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Rear wheel coupling damaged Final gear case oil level too low or oil too thin Insufficient grease in propeller shaft joint 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 Master cylinder damaged Other noise Bracket nut bolt etc not properly mounted or tightened Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged
120. new one and install the gaskets aligning the holes with the crankcase water passages B e Be sure to install the dowel pins C e Using the piston ring compressor assembly A with the chamfered side B upward install the cylinder block C Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 995 108 57001 1358 OThe front cylinder A has an F mark and the rear cylinder B has an R mark Be careful not to mix them up Pe FX Front C L f 4 gt e Insert the chain guide into the cylinder OThe front chain guide for the front cylinder has an F mark A and the front chain guide for the rear cylinder has an R mark B Be careful not to mix up these chain guides since the front chain guide for the rear cylinder is longer 6E16029BS1 5 44 ENGINE TOP END Cylinders Piston e Install the front cylinder in the same way OPosition the front piston at TDC OTighten the cylinder nuts temporarily These nuts are tightened to the specified torque after rocker case instal lation Cylinder Wear 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 three locations total of six measure ments shown in the figure x lf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 70 mm
121. of the water pump drive sprocket boss and install the sprockets e Install Dowel Pins A Washer B Pulling the chain guide C and install the idle shaft holder D e Install the clutch see Clutch Installation in the Clutch chapter Torque Idle Shaft Holder Bolts 8 3 N m 0 85 kgf m 73 in Ib e Apply molybdenum disulfide oil solution to the threads and seating surface and tighten the primary gear bolt A while holding the primary gear B with the gear holder C OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 Special Tool Gear Holder m2 0 57001 1557 Torque Primary Gear Bolt 145 N m 14 5 kgf m 107 ft lb 9 30 CRANKSHAFT TRANSMISSION Transmission Shift Pedal Removal e Remove the left front footboard see Front Footboard Re moval Installation in the Frame chapter e Unscrew the rear shift pedal clamp bolt A and take off the rear shift pedal B e Unscrew the front shift pedal clamp bolt C and pull out the front shift pedal D Shift Pedal Installation e For the front shift pedal install the shift pedal A so that the punched mark on the shaft is aligned B with the punched mark on the shaft e Tighten the clamp bolt Torque Shift Pedal Clamp Bolt 29 N m 3 0 kgf m 21 ft Ib e For the rear shift pedal install the shift pedal A so that the punched mark on the shaft is aligned B with the
122. parts Gasoline motor oil or any other petroleum distil late will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off com pletely and will eventually deteriorate the rubber used in the cylinder e Apply clutch fluid to the parts removed and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Install the push rod with the dust seal fitted into the groove OThe push rod round end must be faced inwards Torque Clutch Lever Pivot Bolt 1 0 N m 0 10 kgf m 8 9 in Ib Clutch Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in lb e Install the clutch master cylinder see Clutch Master Cylin der Installation in the Clutch chapter GSO8020BS2 C PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement e Remove the alternator outer cover see Alternator Outer Cover Removal in the Electrical System e Loosen the banjo bolt A at the clutch pipe lower end and tighten it loosely e Unscrew the slave cylinder bolts B and detach the slave cylinder with the pipe installed from the engine e Pump the clutch lever until the piston comes out of the cylinder e Unscrew the banjo bolt and remove the slave cylinder C CAUTION Immediately wash away any clutch fluid that spills It may damage painted surfaces NOTE Olf the clutch slave cylind
123. rear wheel A off the ground using the jack B and the attachment jack C Special Tools Jack 57001 1238 Attachment Jack 57001 1398 Ne Ze SES SIA j SP A e Remove the alternator outer cover see Alternator Outer re a Cover Removal in the Electrical System chapter Y es ree e Disconnect the side stand switch lead connector A e Remove Side Stand Switch Bolt A Spring B Side Stand Bolt C Side Stand D Side Stand Installation e Apply grease to the contact surface of the frame and side stand e Install Side Stand A Side Stand Mounting Bolt B and Nut C e Tighten the bolt and lock them with the nut Torque Side Stand Mounting Nut 44 N m 4 5 kgf m 33 ft lb e Hook the spring D so that face the long spring end up ward Olnstall the spring hook direction as shown e Install the side stand switch OApply a non permanent locking agent to the side stand switch mounting bolt F e Tighten Torque Side Stand Switch Mounting Bolt 8 8 N m 0 90 kgf m 78 in lb e Check that the side stand switch mounting bolt and nut is not loosening e Run the side stand switch lead correctly see Cable Wire and Hose Routing section in Appendix chapter e Install the alternator outer cover see Alternator Outer Cover Installation in the Electrical chapter G002010BS2 15 20 FRAME Windshield Windshield Height Adjustment OThe windshield A can be adjusted within 45 mm 1 8
124. seal has an adhe sive coated body do not apply a liquid gasket to the exterior surface of the body ds T Cl de 2x e d f ns frowns 74 4 12 COOLING SYSTEM Water Pump e Press A the mechanical seal B by using a suitable 28 mm socket C and a bearing driver D until its flange touches the step E Gap F Special Tool Bearing Driver Set 57001 1129 x If the coolant still leaks through the drainage outlet hose the seal and ball bearings is probably damaged Replace the mechanical seal ball bearings and oil seal by splitting the crankcase e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove the water pump impeller see Water Pump Re moval in this section e Pull out the water pump shaft from the inside of the right crankcase e Take the bearing A out of the right crankcase using the bearing remover Special Tools Bearing Remover Shaft B 57001 1265 Bearing Remover Head 410 x 12 C 57001 1266 e Using a thin bladed screwdriver pry out the oil seal e Press out the mechanical seal A and ball bearing B from the inside of the right crankcase with the bearing driver set C Special Tool Bearing Driver Set 57001 1129 OBe sure to replace the mechanical seal oil seal O ring and ball bearings with new ones because these parts will be damaged by removal e Apply plenty of high temperature grease to the oil seal lips e Apply oil
125. should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut as shown B e Tighten the left and right muffler clamp bolts and stay mounting bolts Torque Muffler Stay Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Visually inspect the tire for stuck any grease A x If any grease have stuck to the surface of the tire wash the tire clean with soap and water solution e Check the rear brake effectiveness A WARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done P IMO7000BS1 HJ07002BS1 WHEELS TIRES 10 11 Wheels Rims Wheel Coupling Removal e Remove the rear wheel see Rear Wheel Removal in this section e Remove the coupling retaining ring A e Remove the wheel coupling B with a bearing puller if necessary Wheel Coupling Installation e Replace the O ring A and the retaining ring B e Grease the following O ring Bosses C of Rear Drum Hub e Install Rubber Damper D Coupling E Retaining Ring Wheel Inspection e Raise the front or rear wheel off the ground Special Tools Jack 57001 1238 Attachment Jack 57001 1398 e Spin A the wheel lightly and check for roughness or
126. shown Timing Marks A F mark B Cylinder Head Upper Surface C Front D OPull the front side exhaust side of the chain taut to install the camshaft Olnstall the front chain tensioner see Camshaft Chain Ten sioner Installation in this chapter The timing marks must be aligned with the cylinder head upper surface e Next install the rear camshaft OCheck to be sure that the front camshaft chain timing is correct OTurn the crankshaft counterclockwise A e Align the R mark A TDC mark for the rear piston with the middle of the notch B 310 turn from the front piston TDC e Engage the rear camshaft sprocket with the camshaft chain as shown Timing Marks A and R Mark B Cylinder Head Upper Surface C Front D OPull the front side inlet side of the chain taut to install the camshaft e Install the rear chain tensioner and check the front rear chain timing again OThe timing marks must be aligned with the cylinder head upper surface and positioned as shown after chain ten sioner installation e Install Rocker Cases see Rocker Case Installation in this chapter Rocker Case Covers see Rocker Case Cover Installa tion in this chapter Special Tool Filler Cap Driver 57001 1454 Torque Timing Inspection Cap 1 5 N m 0 15 kgf m 13 in Ib Rotor Bolt Cap 1 5 N m 0 15 kgf m 13 in Ib a GE11012781 GE11012881 5 28 ENGINE TOP END
127. 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 WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen 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 No fire should be drawn near the battery or no terminals should have the tightening loos ened 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 Get medial attention if severe ELECTRICAL SYSTEM 16 31 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle elec tric system Therefore replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery Be careful if the 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 digital meter A e Remove the front seat see Front Seat Removal in the Frame chapte
128. ted eee ai ii ieee eGo 4 10 Water Pump Installation 4 10 Water Pump Inspection ss 4 11 Mechanical Seal Replacement cccccccccccecececececeeeceeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeteeeeneees 4 11 Rad lato niece A AAA a AA PS eres RE EA iene a 4 14 Radiator Removal sorier A de ren ln ner Ar mt tetes 4 14 Radiator Installation ennnen tenerne ennnen ennan nennen nen 4 15 Radiator INSPSCON i deed eege ENEE A 4 15 Radiator Cap Inspection ss 4 16 Radiator Filler Neck Inspection 4 16 ale EE 4 17 Thermostat Removals 5 ege Zeches EE ee wig EE 4 17 Thermostat Installaton ss 4 17 Thermostat Inpec tasca A A Seley 4 17 A GE 4 18 Hose Installation iii A waived nee Aes 4 18 FIOSE RO 4 18 4 2 COOLING SYSTEM Exploded View 6D02038BW5 C COOLING SYSTEM 4 3 Exploded View No Fastener e Remarks N m kgf m ft Ib 1 Radiator Drain Bolt 2 2 0 22 19 in 1b 2 Radiator Fan Bolts 8 3 0 85 73 in lb 3 Radiator Fan Switch 18 1 8 13 4 Water Hose Clamp Screws 2 5 0 25 22 in lb 5 Water Pipe Bolts 11 1 1 97 in lb 6 Water Pump Air Bleeder Bolt 11 1 1 97 in lb 7 Water Pump Cover Bolts 11 1 1 97 in lb 8 Water Pump Drain Bolt 11 1 1 97 in lb Water Pump Impeller Bot 23 090 78imb LH 10 12 Ball Bearing 13 Double Seal Bearing 14 Mechanical Seal 15 Oil Seal 16 Radiator 17 Radiator Cap 18 Thermostat
129. the backlash related parts are replaced or the driven gear bolt is loosened even if the purpose is not to replace the parts be sure to check and adjust the bearing preload the bevel gear backlash and tooth con tact by replacing shims Preload Adjustment e Install the driven gear assy and tighten the driven gear nut to the specified torque Torque Driven Gear Bolt 120 N m 12 2 kgf m 89 ft Ib ODo not install the oil seal and O ring and do not stake the bolt until the correct bearing preload is obtained CAUTION To start with choose a shim or collar so that the bearings are just SNUG with NO play and also with NO preload Any overpreload on the bearings could damage the bearings e Apply a little engine oil to the bearings and turn the gear shaft more than 5 turns to allow the bearings to seat e Measure the bearing preload Bearing preload is defined as a force or torque which is needed to start the gear shaft turning Preload for Driven Gear Bearing Using Torque Wrench 0 5 0 9 N m 0 05 0 09 kgf m 4 3 7 8 in Ib Using Spring Scale 3 0 4 0 N 0 30 0 50 kg 0 6 1 0 Ib NOTE OPreload can be measured either with a spring scale or a beam type torque wrench When measured with a spring scale the preload is designated by force N kg lb and when measured with a torque wrench it is des ignated by torque N m kgf m in 1b FINAL DRIVE 11 33 Front Bevel Gears
130. the battery case into the stopper A of the frame e Install the removed parts see appropriate chapters FRAME 15 15 Tool Box Tool Box Removal e Remove the left side cover see Left Side Cover Removal in this chapter e For California model remove the band A and canister B e Unscrew the bolts C e Pull the tool box D out 15 16 FRAME Footboard Front Footboard Removal Installation e Remove Footboard Bracket Bolts A Left Front Footboard B e Tighten Torque Front Footboard Bracket Bolts 34 N m 3 5 kgf m 25 ft lb e Remove Footboard Bolts A Spring B Right Front Footboard C e Install the spring A as shown Right Front Footboard B Rear View C 6014002BS1 Front Footboard Disassembly e Remove the left front footboard see Front Footboard Re moval installation in this section e Remove Spring A Circlip B Pin C Sebi P e Remove the right front footboard see Front Footboard Removal Installation in this section e Remove Circlip A Pin B FRAME 15 17 Footboard Front Footboard Assembly e Replace the circlip A with a new one e Install Left Front Footboard Damper B Left Front Footboard C Bank Sensor D Bank Sensor Bolts E e Insert the pin F from the front side of the footboard bracket G e Install the new circlip e Install the spring H hook direction as shown e Replace the
131. the bearing insert crankpin clearance see Camshaft Rocker Case Wear in the Engine Top End chapter Torque Connecting Rod Big End Nuts 59 N m 6 0 kgf m 44 ft lb ODo not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Crankpin Clearance Standard 0 026 0 057 mm 0 0010 0 0022 in Service Limit 0 10 mm 0 004 in Alf the clearance is within the standard no bearing insert replacement is required Alf the clearance is between 0 057 mm 0 0022 in and the service limit 0 10 mm 0 004 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure G105061181 105056BS1 6105041751 9 26 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods x If the clearance exceeds the service limit measure the diameter of the crankpin A Crankpin Diameter Standard 54 981 55 000 mm 2 1646 2 1654 in Service Limit 54 97 mm 2 1642 in x If the crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameter is not less than the ser vice limit but does not coincide with the original diameter marking on the crankshaft make a new mark on it Crankpin Diameter Marks None 54 981 5
132. the cable holder e Remove the decelerator cable end F and the accelerator cable end G from the throttle pulley B e Pinch the lock of the fuel hose joint 2 A with fingers pull the joint 2 out along the pipe for delivery joint and take out the fuel hose assy B Front C e Unscrew the inlet manifold bolts A Inlet Manifold B Front C e Take out the throttle body assy A from the right side while tilting it up OBe careful not to damage dent nick flaw and crack the flange mating surface and the plastic parts ODo not drop the throttle body assy especially on a hard surface A WARNING The throttle body assy should never be allowed to fall Throttle may become stuck possibly causing an accident e Stuff a piece of lint free clean cloth into the throttle body assy and the inlet ports of the cylinder heads to keep dirt out of the engine If dirt or dust is allowed to pass through into the throttle bore the throttle may become stuck possi bly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur 3 98 FUEL SYSTEM DFI Throttle Body Assy Throttle Body Assy Installation e Install the lower air cleaner duct between cylinders e Replace the flange seal A with a new one e With a high flash point solvent clean off the flange sur face of the cylinder head and wipe dry
133. the hand tester A to the connector as shown in the table ONote the resistance readings Stator Coil Resistance Reading Range Tester to Tester to One black lead Another black lead 0 33 0 49 Q x If there is more resistance than shown in the table or no hand tester reading infinity the stator has an open wire 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 A Any hand tester reading less than infinity indicates a short necessitating stator replacement Alf the stator coil has 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 ORepeat the test for the other black leads ORepeat the test for the inside alternator connector 6P090207S1 6P09020851 16 40 ELECTRICAL SYSTEM Charging System Regulator Rectifier Removal e Remove Alternator Outer Cover see Alternator Outer Cover Re moval in this section Regulator Rectifier Lead Connectors A e Remove Regulator Rectifier Bolts A Regulator Rectifiers B Regulator Rectifier Installation e Run the regulator rectifier leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Tigh
134. the pinion gear steady with the pinion gear holder A The difference between the highest and the lowest gage reading is the amount of backlash OMeasure backlash at three locations equally spaced on the splines Final Bevel Gear Backlash 0 10 0 20 mm 0 0039 0 0079 in at ring gear hub splines x lf the backlash is out of the limit replace the ring gear shims To increase backlash increase the thickness of the shim s To decrease backlash decrease the thick ness of the shim s Change the thickness a little at a time e Recheck the backlash and readjust as necessary GKO7010281 FINAL DRIVE 11 21 Final Gear Case and Oil Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth with a high flash point solvent e Apply checking compound to 4 or 5 teeth of the pinion gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact e Hold the pinion gear assembly with the final gear case holder A Special Tool Final Gear Case Holder 57001 1250 Torque Final Gear Case Mounting Nuts 34 N m 3 5 kgf m 25 ft lb e Turn the pinion gear for one re
135. the upper and lower outer races which are press fitted into the frame head pipe clean of grease and dirt e Visually check the outer races and the rollers x If the rollers or races are worn or if either race is dented replace both races and all the roller bearings as a set see Stem Bearing Installation in the Steering chapter e Pack the upper and lower tapered roller bearings in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem and adjust the steering see Steering Stem Installation in the Steering chapter and Steering Play Adjustment in this chapter 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation First Step e Turn on the ignition switch e The following lights should go on according to below table Models United canada Europe Aus States tralia Position Lights A goes on goes on City Light B goes on Taillight C goes on goes on goes on goes on Licence Plate Light D goes on goes on goes on goes on Meter Panel LCD E goes on goes on Neutral Indicator LED F goes on goes on goes on goes on FI Indicator LED G goes on goes on goes on goes on goes on goes on goes on goes on Fuel Level Warning about about about about Indicator LED H 2 sec 2 sec 2 sec 2 sec onds o
136. tightening Special Tool Spark Plug Wrench Hex18 57001 1024 Torque Spark Plugs 18 N m 1 8 kgf m 13 ft Ib e Install the spark plug caps securely OBe sure the spark plug caps are installed by pulling up it lightly 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Gear Case Oil Change e Remove the left saddlebag see Saddlebag Removal in the Frame chapter e Warm up the oil by running the motorcycle so that the oil will pick up any sediment and drain easily Stop the motorcycle and turn the ignition switch OFF e Place an oil pan beneath the final gear case and remove the filler cap and drain plug A WARNING When draining or filling the final gear case be care ful that no oil gets on the tire spoke or rim Clean off any oil that inadvertently gets on them with a high flash point solvent e After the oil has completely drained out install the drain plug with a new gasket Torque Final Gear Case Drain Plug 8 8 N m 0 90 kgf m 78 in Ib e Fill the final gear case with the specified oil and quantity Final Gear Case Oil Amount 200 mL 6 76 US oz Grade API GL 5 hypoid gear oil Viscosity When above 5 C 41 F SAE 90 When below 5 C 41 F SAE 80 NOTE OThe term GL 5 indicates a quality and additive rating A GL 6 rated hypoid gear oil can also be used e Be sure the O ring is in place and install the filler plug e Install the left saddlebag see
137. to get dirt or dust on the O ring Be careful not to damage the O ring e Apply engine oil to the O ring A and install each injector B into the delivery joint C e Check that there is no dirt or dust on the injector seating surface A of the inlet manifold B e Check that the two dowel pins C are in place in the inlet manifold e Fit the end of the injector into the delivery joint D and install them into the inlet manifold B e Align the projection A on the delivery joint B with the hole C of the left side bracket D e Fit A the connectors B of the injector into the bracket recesses C e Tighten the delivery joint screw and bolts securely FUEL SYSTEM DFI 3 69 Fuel Injectors 1 2 Service Code 41 42 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 a high pressure fuel hose C both ends connected with clamps D as shown Torque Fuel Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib OApply a soap and water solution to the areas E shown OWatching the pressure gauge squeeze the pump lever F 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 CAUTION During pressure testing do not exceed the maxi mum pressure for which the system is designed
138. to the driven gear and their bearings Such a shock could damage the driven gear and or bearings Damper Cam Removal e Remove the front gear case see Front Gear Case Re moval in this section e Remove the circlip A and needle bearing B of the output shaft Special Tool Outside Circlip Pliers 57001 144 e Remove the crankcase bearing upper retainer bolts C and retainer D e Insert a bolt 612 mm L 100 mm 0 47 in L 3 94 in A into the engine mounting bolt hole e Unscrew the damper cam nut B using a damper cam holder C special tool and deep socket wrench Special Tool Damper Cam Holder 57001 1025 e Apply a non permanent locking agent to the threads of the retainer bolts e Install the upper retainer Torque Bearing Retainer Bolts 11 N m 1 1 kgf m 97 in Ib Damper Cam Installation e Replace the damper cam nut with a new one e Insert the bolt 12 mm L 100 mm 40 47 in L 3 94 in A into the engine mounting bolt hole e Apply molybdenum disulfide oil solution to the threads and seating surface of the damper cam nut OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Tighten the damper cam nut B to the specified torque Special Tool Damper Cam Holder 57001 1025 Torque Damper Cam Nut 195 N m 20 0 kgf m 144 ft Ib 11 30 FINAL DRIVE Front Bevel Gears e Install Needl
139. to the outer circumference of the oil seal e Press the oil seal A into the hole from the inside of the right crankcase with the bearing driver set so that the spring side of the seal lips is toward the inside of the crankcase Special Tool Bearing Driver Set 57001 1129 e Press the oil seal in until the seal end is even with step B of the hole as shown OUse the bearing driver which has a larger diameter than the oil seal e Press in each ball bearing C with its manufacturer s mark facing out until it bottoms out yi II d GD06011181 GD06011281 GD06020481 COOLING SYSTEM 4 13 Water Pump e Press A the mechanical seal B by using a suitable 28 mm socket C and a bearing driver D until its flange touches the step E Gap F e Install the water pump shaft from the inside of the right crankcase Special Tool Bearing Driver Set 57001 1129 e Clean both sliding surfaces of a new mechanical seal with a high flash point solvent e g ethyl alcohol and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication e Apply coolant to the surface of the rubber seal A and sealing seat B and press the rubber seal and sealing seat into the impeller by hand until the seat bottoms out e Tighten the water pump impeller bolt by turning the bolt counterclockwise Torque Water Pump Impeller Bolt 8 8 N m 0 90 kgf m 78
140. turn then tighten it x If cotter pins are damaged replace them with new ones 6004011481 6004020152 C PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Bolt Nut and Fastener to be checked Wheels Front Axle Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin Front and Rear Fender Mounting Bolts Final Drive Final Gear Case Mounting Nuts Brakes Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Caliper Holder Bolt Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Suspension Front Fork Clamp Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Steering Stem Head Nut Handlebar Clamp Bolts Engine Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Shift Pedal Bolts Muffler Stay Mounting Bolts Exhaust Pipe Holder Nuts Clutch Master Cylinder Clamp Bolts Clutch Lever Pivot Nut Radiator Mounting Bolt Radiator Bracket Bolts Others Side stand Bolt and Nut Front and Rear Footboard Bracket Bolts Tandem Grip Mounting Bolts Downtube Bolts Windshield Bolts Saddlebag Bolts 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident CAUTION If dirt gets through into the engine excessive en
141. upward ISC Valve 1 for Rear Cylinder ISC Valve 2 for Front Cylinder ISC Valve Hose 2 Red Mark ISC Valve Hose 1 Blue Mark ISC Valve 1 G Y W R Leads ISC Valve 2 G BL W R Leads 120 Front Air Flow 17 10 APPENDIX Cable Wire and Hose Routing APPENDIX 17 11 Cable Wire and Hose Routing Rear View 1 Fuel pump with the fuel filter and screen belt in 2 Fuel Pump Bolts 3 Fuel Hose Joint Delivery Joint 4 Fuel Tank 5 O ring 6 Left Air Cleaner Cover 7 Fuel Hose Joint Fuel Pump 8 Fuel Pump Outlet Hose 9 Fuel Injector 2 Inlet Manifold Injector Lead 2 Injector Lead 1 White Tape Connector Black Frame Pipes Atmospheric Pressure Sensor Lead Inlet Air Pressure Sensor Lead White Tape Connector Natural Water Temperature Sensor Lead Bend before install Run the lead inlet air temperature sensor and ISC valve leads inside the rocker case cover Inlet Air Temperature Sensor and ISC Valve Leads Breather Hose Grommet Right Air Cleaner Base Strap Fuel Pump Outlet Pipe Pressure Regulator Throttle Cables Vacuum Switch Valve Hose Inlet Air Pressure Sensor Hose Rear View Front 17 12 APPENDIX Cable Wire and Hose Routing 6809713845 C APPENDIX 17 13 Cable Wire and Hose Routing J O O1 BR ND A Rea
142. x lf the oil level is too low add the correct amount of oil through the oil filler 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 Pump and Oil Line Oil Pump Removal e Remove the engine see Engine Removal in the Engine Removal Installation chapter e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove the oil pump mounting bolts A and take off the pump B out of the right crankcase e Unscrew the relief valve C if necessary e Remove Circlip A Washer B Pump Shaft C Pump Gear D Oil Pump Installation e Note the position of the oil pump shaft tang A and turn the pump gear shaft so that the tang fits into the slot B of the oil pump gear e Replace the O rings C with new ones if they are dam aged e Be sure to install the dowel pins D e Tighten Torque Oil Pump Mounting Bolts 11 N m 1 1 kgf m 97 in Ib e Check that the oil pump gear turns smoothly in t
143. 0 35 22 1 192 31 26 0 965 28 29 0 781 25 32 Shaft 2 619 15 21 x 33 9 3 105 Top gear Grade API Service Classification GL 5 Hypoid gear oil Viscosity SAE90 above 5 C SAE80 below 5 C Capacity 200 mL 6 76 US oz Frame Type Tubular double cradle Caster Rake Angel 32 Trail 184 mm 7 24 in Front Tire Type Tubeless Size 150 80 16 M C 71H Rear Tire Type Tubeless Size 170 70B16 M C 75H Front Suspension Type Telescopic fork Wheel travel 150 mm 5 91 in Rear Suspension Type Swingarm Shock absorber Wheel travel 99 mm 3 90 in GENERAL INFORMATION 1 11 General Specifications Items VN1600 D1 Brake Type Front Dual disc Rear Single disc Electrical Equipment Battery Capacity 12 V 18 Ah Headlight Type Semi sealed beam Bulb 12 V 60 55 W quartz halogen Tail Brake Light 12 V 5 21 W Alternator Type Three phase AC twin rotor Rated output 42 A x 14 V 6 000 r min rpm Specifications subject to change without notice and may not apply to every country AU Australia CA Canada CAL California US United States of America 1 12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Mass Prefix Symbol Power mega M x 1000 000 kilo k x 1000 centi c x 0 01 milli m x 0 001 micro u x 0 000001 Units of Length km x 0 6214 m x 3 281 mm x 0 03937 Units of Torque mile kgf m ft Ib in Ib kg x 2
144. 0 04 in Brake Fluid Level Inspection e Check that the brake fluid level in the front brake reservoir A is above the lower B level line NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level x If the fluid level is lower than the lower level line fill the reservoir to the upper level line A in the reservoir B GL10020181 GLO6010281 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Check that the brake fluid level in the rear brake reservoir A is between the upper B and the lower C level lines x If the fluid level is lower than the lower level line fill the reservoir to the upper level line OUse extra heavy duty brake fluid only from a container marked DOT4 OBrake fluid of DOT4 is installed in the brake system when shipped A WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter e Install the front brake reservoir cap Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e Follow the procedure below to install the rear brake reser voir cap correctly OFirst tighten the rear brake reservoir cap B clockwise C by hand until the resistan
145. 0 04 in 3 75 6 25 kQ 2 2 V or more 2 0 V or more 380 560 Q 1 0 mm 0 04 in Non measurable and non adjustable 12 mm 0 47 in Service limit 8 5 mm 0 33 in 28 mm 1 10 in Service limit 27 mm 1 06 in FULL position 3 5 Q EMPTY position 213 219 O ON after about 10 mm 0 4 in pedal travel When engine is stopped ON When engine is running OFF ELECTRICAL SYSTEM 16 15 Specifications Item Standard Radiator Fan Switch Resistance Rising Temperature Falling Temperature Water Temperature Switch Resistance Rising Temperature Falling Temperature From OFF to ON 102 108 C 212 226 F From ON to OFF 97 103 C 207 217 F ON Less than 0 5 Q OFF More than 1 MQ From OFF to ON 113 117 C 235 243 F From ON to OFF 108 C 226 F temperature less than ON temperature ON Less than 0 5 Q OFF More than 1 MQ e Refer to the Fuel System DFI chapter for specifications of DFI parts 16 16 ELECTRICAL SYSTEM Special Tools and Sealants Spark Plug Wrench Hex 18 Flywheel Holder 57001 1024 57001 1410 Jack Peak Volt Adapter 57001 1415 ST571238ST ST571415ST Timing Light Filler Cap Driver 57001 1241 57001 1454 T5712418T ST5714548T Hand Tester Kawasaki Bond Silicone Sealant 57001 1394 56019 120 ST5713948T ST5601208ST Attachment Jack Kawasaki Bond Silicone Sealant 57001 1398 92104
146. 1 17 Final Gear Case and Oil Preload Adjustment e To increase preload decrease the thickness of the size of the shim s To decrease preload increase the thickness of the shim s e Change the thickness a little at a time e Re adjust the bearing preload and re adjust if necessary Shims for Preload Adjustment Thickness Part Number 0 1 0 004 in 92025 1219 0 2 0 008 in 92025 1220 0 3 0 012 in 92025 1221 0 5 0 020 in 92025 1222 0 6 0 024 in 92025 1223 0 7 0 028 in 92025 1224 0 8 0 031 in 92025 1225 0 9 0 035 in 92025 1226 1 0 0 040 in 92025 1227 1 30 0 051 in 92025 1214 1 32 0 052 in 92025 1215 1 34 0 053 in 92025 1216 1 36 0 054 in 92025 1217 1 38 0 0543 in 92025 1218 Standard H WT SI ZA NN DT RA ee d Gees XXX OS Se Ge LL WN TY E KA R 5 G A KA WE a SA lt A SS A KA SG SA SY SSS SY ES 3535 SS RSR SS RSR A A GKOGOOIBW2 1 Washer A Before Tightening 2 Shim s B After Tightening 3 Pinion Gear Joint C Initial Clearance 4 Bearing Housing D Under No Preload 5 Tapered Roller Bearing E No Clearance 6 Tapered Roller Bearing F Under Preload 11 18 FINAL DRIVE Final Gear Case and Oil Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or o
147. 15 1 5 11 L 4 Chain Tensioner Cap 20 2 0 15 S 5 Chain Tensioner Lockbolts 4 9 0 50 43 ml S 6 Chain Tensioner Mounting Bolts 11 1 1 97 in lb S 25 18 S 25 w 5 9 KACR Kawasaki Automatic Compression Release Unit 10 R marked side faces up 11 RN marked side faces up 12 Each circle mark points to the front side L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight 10 1 R Replacement Parts S Follow the specific tightening sequence 5 6 ENGINE TOP END Exploded View ENGINE TOP END 5 7 Exploded View Torque No Fastener Remarks j Nm kgf m ft lb 1 Exhaust Pipe Cover Clamp Screws 6 9 0 70 61 in lb 2 Muffler Stay Mounting Bolts 25 2 5 18 3 Premuffler Chamber Bolts 29 3 0 21 4 Rocker Shafts 25 2 5 18 M 5 Front Exhaust Pipe 6 Rear Exhaust Pipe 7 Left Muffler 8 Right Muffler 9 Premuffler Chamber 10 HLA Hydraulic Lash Adjusters EO Apply engine oil M Apply molybdenum disulfide grease R Replacement Parts WL Apply a soap and water solution or rubber lubricant Exhaust System SHOMBER SILENCER ITEM NAME ORG PRODUCT Non Catalyst U S A VN1600 D1 Honeycomb Type U S A CALIF VN1600 D1L CANADA VN1600 D1 P No 18091 0199 P No 18004 0004 Mark KHI K 372 AUSTRALIA VN1600 D1 Mark KHI M 099 EPA Noise Emission WVTA FULL H VN1600 D1H GB
148. 2 2 0 22 19 in Ib L 4 Left Air Cleaner Cover Allen Bolt 16 1 6 12 5 Right Air Cleaner Allen Bolts 11 1 1 97 in lb 6 Right Air Cleaner Base Bolt 11 1 1 97 in lb 19 in lb N Y N E Right Air Cleaner Base Screws Right Air Cleaner Cover Allen Bolt Spark Plug Lead Holder Bolts Throttle Body Assy Holder Bolts Water Temperature Sensor 00 9 12 Air Cleaner Drain Hose 13 Air Cleaner Duct Holder 14 Air Cleaner Element 15 Crankcase Breather Hose 16 Left Air Cleaner Base 17 Right Air Cleaner Base 18 Right Spark Plug Lead Holder 19 Throttle Body Assy 20 Vacuum Switch Valve L Apply a non permanent locking agent alxiaj o 0 SS Apply silicone sealant Kawasaki Bond 56019 120 CA Canada Model CAL California Model US United States Model ajaloo _ Co _ N 97 mb 97 mb 13 3 6 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 7 Exploded View Torque No Fastener Nem kgfm ft lb Remarks 1 Choke Cable Plate Screw 2 9 0 30 26 in lb L 2 Fuel Pump Mounting Bolts 9 8 1 0 87 in lb L S 3 Inlet Air Temperature Sensor Nut 7 8 0 80 69 in lb 4 Inlet Manifold Bolts 12 1 2 104 in lb 5 ISC Pipe Holder Bolts 11 1 1 97 in lb 6 Spark Plug Lead Holder Bolts 11 1 1 97 mb 7 Throttle Body Assy Holder Bolts 11 1 1 97 mb Atmospheric Pressure Sensor Battery Case Choke Cable Delivery Joint DEI Main R
149. 2 76 in B 20 mm 0 79 in C Cylinder Inside Diameter Standard 102 000 102 012 mm 4 0157 4 0162 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 102 10 mm 4 020 in or 0 05 mm 0 002 in difference between any two measurements Piston Wear e Measure the outside diameter A of each piston 5 mm 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 101 942 101 957 mm 4 0135 4 0140 in Service Limit 101 79 mm 4 007 in Piston Cylinder Clearance e Subtract the piston diameter from the cylinder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 043 0 070 mm 0 0017 0 0028 in x lf the piston cylinder clearance is less than the specified range use a smaller piston made within the standard di ameter or increase the cylinder inside diameter within the standard diameter by honing x lf the piston cylinder clearance is greater than specified range use a larger piston made within the standard di ameter x lf only a piston is replaced the clearance may exceed the standard slightly But it must not to be less than the minimum of the clearance in order to avoid piston seizure SQ GE16013681 GE16013781 ENGINE TOP END 5
150. 25 1786 0 7 0 028 in 92180 0012 0 8 0 031 in 92025 1787 0 8 0 031 in 92180 0013 0 9 0 035 in 92025 1788 0 9 0 035 in 92180 0014 1 0 0 039 in 92025 1789 1 0 0 039 in 92180 0015 1 2 1 2 0 047 in 92025 1790 0 047 in 92180 0016 11 20 FINAL DRIVE Final Gear Case and Oil Backlash Adjustment e Clean any dirt and oil off the bevel gear teeth with a high flash point solvent CAUTION Do not install the O ring or oil seals during adjust ment e Install the pinion gear bearing housing with the primary shim 1 0 mm 0 04 in thickness e Hold the pinion gear steady with the pinion gear holder A and tighten the final gear case mounting nuts to the specified torque Special Tool Pinion Gear Holder m1 9 57001 1165 Torque Final Gear Case Mounting Nuts 34 N m 3 5 kgf m 25 ft lb e Install the ring gear assy with the primary shim 1 0 mm 0 04 in thickness and tighten the cover bolts to the specified torque Torque Final Gear Case Cover Bolts M10 34 N m 3 5 kgf m 25 ft lb M8 23 N m 2 3 kgf m 17 ft lb OCheck the backlash during tightening of the cover bolts and stop tightening them immediately if the backlash dis appears Then change the ring gear shim to a thicker one e Mount a dial gage D on a vise so that the tip of the gage is against the splines of the ring gear hub e To measure the backlash turn the ring gear hub B back and forth C while holding
151. 27 2 8 20 L 3 Rear Brake Hose Banjo Bolts 34 3 5 25 4 Rear Caliper Bleed Valves 7 8 0 80 69 in lb 5 Rear Caliper Holder Bolt 64 6 5 47 6 Rear Caliper Mounting Bolts 34 3 5 25 7 Rear Master Cylinder Mounting Bolts 25 2 5 18 8 Rear Master Cylinder Push Rod Locknut 18 1 8 13 HD rom Apply brake fluid Apply grease Apply a non permanent locking agent Replacement Parts Apply silicone grease or PBC grease 12 6 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position No 1 Non adjustable Non adjustable About 110 mm 4 3 in height from pedal top to footpeg top 5 way adjustable Brake Fluid Grade DOT4 EE Brake Pads Pad Lining Thickness Front 4 5 mm 0 18 in 1 mm 0 04 in Rear 7 0 mm 0 28 in 1 mm 0 04 in Brake Discs Thickness Front Rear Runout 4 8 5 2 mm 0 19 0 20 in 6 8 7 2 mm 0 27 0 28 in TIR 0 15 mm 0 006 in or less 4 5 mm 0 18 in 6 0 mm 0 24 in TIR 0 3 mm 0 01 in BRAKES 12 7 Special Tool Inside Circlip Pliers 57001 143 ST5701438T 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align
152. 3 80 in Crankshaft Runout TIR 0 02 mm TIR 0 05 mm 0 0008 in or less 0 002 in CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Crankshaft Main Bearing Journal Clearance 0 025 0 052 mm 0 10 mm 0 0010 0 0020 in 0 004 in Crankshaft Main Journal Diameter 54 986 55 000 mm 54 96 mm 2 1648 2 1654 in 2 164 in Crankcase Main Bearing Bore Diameter 55 025 55 038 mm 55 07 mm 2 1663 2 1668 in 2 168 in Transmission Shift Fork Ear Thickness 5 9 6 0 mm 5 8 mm 0 23 0 24 in 0 23 in Gear Shift Fork Groove Width 6 05 6 15 mm 6 25 mm 0 238 0 242 in 0 246 in Shift Fork Guide Pin Diameter 7 9 8 0 mm 7 8 mm 0 311 0 315 in 0 307 in Shift Drum Groove Width 8 05 8 20 mm 8 30 mm 0 317 0 323 in 0 327 in 9 8 CRANKSHAFT TRANSMISSION Special Tools and Sealant Outside Circlip Pliers 57001 144 ST5701448T Bearing Driver Set 57001 1129 ST5711298T Oil Filter Wrench 57001 1249 T5712498T Flywheel Holder 57001 1313 wy ST571313ST Flywheel Holder 57001 1410 Gear Holder m2 0 57001 1557 ST5715578T Kawasaki Bond 92104 1064 ST9210648T CRANKSHAFT TRANSMISSION 9 9 Crankcase Crankcase Disassembly e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Engine see Engine Removal in the Engine Removal I
153. 4 991 mm 2 1646 2 1650 in O 54 992 55 000 mm 2 1650 2 1654 in Crankpin Diameter Mark O mark or no mark B e Apply molybdenum disulfide oil solution to the threads and seating surface of the big end nuts OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Temporarily install the big end cap and tighten the big end nuts to the specified torque Torque Connecting Rod Big End Nuts 59 N m 6 0 kgf m 44 ft lb e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter OThe mark already on the big end should almost coincide with the measurement because of little wear Connecting Rod Big End Inside Diameter Marks None 58 000 58 010 mm 2 2835 2 2839 in O 58 011 58 020 mm 2 2839 2 2842 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark around weight mark D O or no mark e Select the proper bearing insert A identified by the size color B in accordance with the combination of the con necting rod and crankshaft coding Big End Bearing Insert Selection Con rod Big End Bore Diameter Marking None Brown 92028 1476 Crankpin Diameter f Mark Size Color Part Number Bearing Insert 92028 1475 e Install the new inserts in the connecting rod and check insert crankpin clearance w
154. 45 Cylinders Piston Cylinder Boring and Honing OThere is an oversize piston available The oversize piston requires oversize rings Oversize Piston and Rings 0 5 mm 0 02 in oversize e Before boring a cylinder A first measure the exact di ameter of the oversize piston and then according to the standard clearance in the Specifications determine the rebore diameter However if the amount of boring nec essary would make the inside diameter greater than 0 5 mm 0 02 in the cylinder block must be replaced OCylinder inside diameter must not vary more than 0 01 mm 0 0004 in at any point OBe wary of measurements taken immediately after boring since the heat affects cylinder diameter Oln the case of rebored cylinder and oversize piston the service limit for the cylinder is the diameter that the cylin der was bored to plus 0 1 mm 0 004 in and the service limit for the piston is the oversize piston original diameter minus 0 15 mm 0 0059 in If the exact figure for the re bored diameter is unknown it can be roughly determined by measuring the diameter at the base of the cylinder Piston Ring Piston Ring Groove Wear 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
155. 7001 1241 e Start the engine and aim the timing light at the ignition timing mark on the alternator rotor e Run the engine at the speeds specified and note the align ment of the ignition timing marks Ignition Timing Engine speed r min rpm Hole notch A aligns with 950 F or R mark B on alternator rotor F Mark for Front Cylinder R Mark for Rear Cylinder e Repeat the test for the rear cylinder using the rear ignition coil lead x If the ignition timing is incorrect check the crankshaft sen sor see Crankshaft Sensor Inspection in this section Alf the crankshaft sensor are normal check the ECU see ECU Power Supply in the Fuel System DFI chapter Interlock Operation Inspection e Raise the rear wheel off the ground see Rear Wheel Re moval in the Wheels Tires chapter e Remove the right side cover see Right Side Cover Re moval in the Frame chapter ODo not disconnect the connectors A 16 52 ELECTRICAL SYSTEM Ignition System 1st Check e Measure the terminal voltage of the R W lead in the junc tion box connector A in accordance with the following procedure OSet the tester B to the 10 V DC range connect it to the R W lead and frame ground C Connection Tester Terminal R W Lead Terminal Tester Terminal Frame Ground Condition Transmission Gear 1st Position Clutch Lever Release Side Stand Down OTurn the ignition switch on ORe
156. 8 25 2 5 18 S Rocker Shafts 25 2 5 18 M Rotor Bolt Cap 1 5 0 15 13 in lb Spark Plug Retainers 12 1 2 104 in lb Spark Plugs 18 1 8 13 Timing Inspection Cap 1 5 0 15 13 in lb Water Pipe Bolts 11 1 1 97 in lb Clutch Clutch Cover Bolts 11 1 1 97 in lb Clutch Damper Cover Bolts 9 8 1 0 87 in lb L Clutch Damper Plate Bolt 9 8 1 0 87 in lb EO Clutch Hose Banjo Bolt Upper 25 2 5 18 Clutch Hose Banjo Bolt Lower 25 2 5 18 Clutch Hub Nut 145 14 8 107 MO Clutch Lever Pivot Bolt 1 0 0 10 8 9 in lb SI Clutch Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Clutch Master Cylinder Clamp Bolts 11 1 1 97 in lb S Clutch Reservoir Cap Screws 1 5 0 15 13 in lb Clutch Slave Cylinder Bleed Valve 7 8 0 80 69 in lb Clutch Slave Cylinder Bolts 6 9 0 70 61 in lb L Oil Filler Cap 1 5 0 15 13 in lb Starter Lockout Switch Screw 1 2 0 12 11 in Ib Engine Lubrication System 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks Oil Drain Plug i 15 Oil Filter 13 EO R Oil Filter Pipe 18 Ss Oil Hose Banjo Bolt E 87 in lb Oil Hose Flange Bolts E 87 in lb Oil Hose Nozzle 26 in lb LH Oil Nozzles 26 in lb Oil Pipe Clamp Bolts d 97 in lb L Oil Pipe Holder Bolts 97 in lb L Oil Pressure Switch 11 Ss Oil Pressure Switch Terminal Screw 13 in lb G Oil Pump Mounting Bolts i 97 in lb Oil Return Pipe Clamp Bolts 97 in lb L Oil Screen Plug 15 Relief Valve d 11 L Engine Removal Installation Downtube Bol
157. 8 Attachment Jack 57001 1398 CAUTION Be sure to put the rear wheel on the ground when removing the front fork or the motorcycle may fall over The motorcycle could be damaged Be sure to put the rear wheel on the ground when removing the front fork or the motorcycle may fall over It could cause an accident and injury e Remove Windshield see Windshield Removal in the Frame chapter Headlight Body see Headlight Body Removal in the Electrical System chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter e Remove Bolts A Both Sides Left and Right Windshield Brackets B Front Fork Center Cover C ES er 6M04134BS1 GS15023BS1 13 10 SUSPENSION Front Fork e Remove Bolts A and Washers Brake Hose Clamp B Front Turn Signal Light Bracket C e Loosen the front fork clamp bolt upper A and fork top plug B before hand if the fork leg is to be disassembled NOTE OLoosen the fork top plug after loosening the front fork clamp bolt upper e Remove Front Fork Clamp Bolts A Front Fork B Front Fork Installation e Install the fork so that the top end A of the inner tube is flush with the upper surface B of the steering stem head bracket e Tighten Torque Front Fork Clamp Bolts Lower 29 N m 3 0 kgf m 21 ft lb Front Fork Top Plug 22 N m 2 2 kgf m 16 ft lb NOTE GM04256BS1 C OTighten the t
158. 8 Steering Stem LEET e cias 14 11 Steering Stem Wal EE 14 12 Steering Stem Bearing DEE 14 13 A A AE AREE ae ete Lam den iaeia 14 13 Siem B arind Installation tasa ane Ad ds hd 14 13 Stem Bearing LUDMGAMON ed Ate EE 14 14 Stem Cap Deterioration Damage 14 14 14 2 STEERING Exploded View STEERING 14 3 Exploded View Torque No Fast R k o astener Nem kgf m Pe emarks 1 Front Fork Clamp Bolts Upper 29 3 0 22 2 Front Fork Clamp Bolts Lower 29 3 0 22 AL 3 Handlebar Clamp Bolts 34 3 5 25 O S 4 Handlebar Holder Nuts 34 3 5 25 5 Steering Stem Head Nut 88 9 0 65 6 Steering Stem Nut 4 9 0 50 43 mb S AD Apply adhesive AL Tighten the two front fork clamp bolts lower alternately two times to ensure even tightening torque G Apply grease O Apply 2 stroke oil R Replacement Parts S Follow the specific tightening sequence 14 4 STEERING Special Tools Head Pipe Outer Race Press Shaft Jack 57001 1075 57001 1238 a IZ ST571075ST N ei ST571238ST Head Pipe Outer Race Driver 54 5 Steering Stem Bearing Driver 42 5 57001 1077 57001 1344 ST571077ST C ST571344ST Steering Stem Nut Wrench Steering Stem Bearing Driver Adapter 41 5 57001 1100 57001 1345 2 e D 7571100ST Head Pipe Outer Race Remover ID gt 37 mm Attachment Jack 57001 1107 57001 1398 ST571107ST STEERING 14 5 Handlebar Handleba
159. 9 OCODE DEDRA ARDEO 22090 290000 G1132088 4 C Circlip 20 mm 0 79 in Needle Bearing Thrust Washer 22 3 mm 0 88 in Three Circlips 628 mm 1 10 in 2nd Gear 5th Top Gear Bushing 5th Gear Two Splined Washers 28 5 mm 1 12 in 3rd Gear 4th Gear 1st Gear Drive Shaft Output Shaft 2nd Gear Three Splined Washers 30 3 mm 1 20 in Three Circlips 29 mm 1 14 in 5th Top Gear 3rd Gear Bushing 3rd Gear Steel Balls 4th Gear Washer 25 5 mm 1 00 in 1st Gear Washer 625 5 mm 1 00 in Needle Bearing Circlip 625 mm 0 98 in Align gear or bushing oil holes with the shaft holes CRANKSHAFT TRANSMISSION 9 37 Transmission Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bend A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear under load 90 A A 6113014581 Shift Fork Gear Groove Wear e Measure the thickness of the shift fork ears A and 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 23 0 24 in Service Limit 5 8 mm 0 23 in Alf 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
160. A in the final gear case cover clean with compressed air e Apply a non permanent locking agent to the threads of each stud and install them to the case if they were re moved e Reinstall the original ring gear shim s to keep the gear backlash and the tooth contact unchanged OWhen final gear case parts are replaced the final bevel gear must be adjusted see Backlash Adjustment and Tooth Contact Adjustment in this section e Apply a non permanent locking agent to the threads of the final gear case cover bolts e Tighten Torque Final Gear Case Cover Bolts M10 34 N m 3 5 kgf m 25 ft lb M8 23 N m 2 3 kgf m 17 ft lb e Insert the pinion gear assembly into the final gear hous ing OReinstall the pinion gear assembly shim s to keep the gear backlash and the tooth contact unchanged GKO70108S1 FINAL DRIVE 11 13 Final Gear Case and Oil Pinion Gear Removal e Pry open the staking A on the pinion gear nut B e Unscrew the nut A while holding the pinion gear assem bly B with the pinion gear holder C Special Tool Pinion Gear Holder m1 9 57001 1165 e Remove Washer A Shim s B Pinion Gear Joint C with the O ring D Pinion Gear E with the Tapered Roller Bearing F e Drive out the bearing outer race from the bearing housing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 e Drive out the tapered roller bearing A in the bearing housing B
161. B OSpin the 4th gear quickly C and pull it off upward Transmission Assembly e Refer to the transmission assembly illustration on ahead e Align each gear oil hole with the drive shaft oil hole when installing the 3rd gear 9 and the 5th gear 6 e Align each oil hole with the output shaft oil hole when installing the 3rd gear 17 bushing 18 and the 5th gear 16 CAUTION Do not apply grease to the steel balls to hold them in place This will cause the positive neutral finder mechanism to malfunction e Fit the three steel balls A into the holes B of the output 4th gear C and then install the gear on the output shaft so that the steel balls align with the recesses D in the shaft OAfter assembling the 4th gear with steel balls in place on the output shaft check the ball locking effect that the 4th gear does not come out of the output shaft when moving it up and down by hand fi 9 KX hes RN d O EN Y SO 6113204BS1 AS LO AE 6113082B S CRANKSHAFT TRANSMISSION 9 35 Transmission e Replace any circlip A that were removed with new ones e Install the circlips so that the opening B is aligned with a spline groove C 6111000381 9 36 CRANKSHAFT TRANSMISSION Transmission 40 ODOMOOOU 2 mT TH D E OO JO O1 P Go A ENS Sy Bon A CD CD DOOU
162. BA G10 SAE 10W 20 or equivalent Amount per side When changing oil approx 440 mL 14 8 US oz After disassembly and completely dry 513 4 mL 17 3 0 1 US oz e Waitfor about five minutes so that any suspended air bub bles can surface e Measure the oil level using the fork oil level gauge A Special Tool Fork Oil Level Gauge 57001 1290 OSet the gauge stopper B so that its lower side shows the oil level distance specified C Olnsert the gage tube into the inner tube D and position the stopper across the top of the inner tube E OPull the handle slowly to draw out the excess oil until no more oil comes up the tube lf no oil is drawn out from the beginning there is not enough oil in the fork Pour in some more oil then draw out the excess Front Fork Oil Level fully compressed without fork spring Standard 135 2 mm 5 31 0 08 in from the top of the inner tube 6M04134BS1 6M04030351 GM04013682 C SUSPENSION 13 9 Front Fork e Install Fork Spring A Washer B Spacer C Top Plug D with O ring E e Install the front fork see Front Fork Installation in this sec tion Front Fork Removal e Using the jack A and attachment jack B under the frame pipe ribs C and a commercially available jack D under the engine E lift the front wheel F OFF the ground until the rear wheel G touches the ground Special Tools Jack 57001 123
163. Baffle 26 Water Pump Drainage Hose 27 Apply a non permanent locking agent to the tap end of this stud only 28 Do not apply any oil EO Apply engine oil L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1064 LH Left hand Threads MO Apply molybdenum disulfide oil solution to the threads and the seating surface mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant Three Bond TB1207B 9 4 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque No Fastener eg kafin ftIb Remarks 1 Damper Cam Nut 195 20 0 144 MO R 2 Gear Set Lever Bolt 11 1 1 97 in lb 3 de Shaft Holder Bolts 8 3 0 85 73 in lb 4 Rear Shift Lever Clamp Bolt 12 1 2 104 in lb 5 Shift Drum Cam Bolt Se 11 L 6 ani Pedal Clamp ho N LT shit Red tocknt Fon a a Shit Rod Locknut Rear a arin 710 Water Pump Chain Guide Bolt 83 085 Tain 11 Water Pump Chain Guide Spring Hook Bok 29 030 2mb 13 Drive Shaft 14 Output Shaft 15 Align the punch marks 16 Align the punch mark with the slit EO Apply engine oil L Apply a non permanent locking agent LH Left hand Threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1
164. Battery e Put the battery holder A on the battery e Tighten the nuts B securely e Connect Fuel Pump Connector 2 pin C Fuel Level Sensor Connector 3 pin D Battery Lead Connector E Rear Turn Signal Taillight Lead Connector F e Install DFI Fuse G Front Seat see Front Seat Installation in the Frame chapter Battery Activation Electrolyte Filling e 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 for VN1600 D1 FTZ16 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance CAUTION 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 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 of caps A from the container
165. 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 the headlight rim screws A on both sides e Pull the headlight unit A and drop it out e Pull the headlight connector B e Remove the headlight dust cover C e Push the hook A to unlock ELECTRICAL SYSTEM 16 63 Lighting System e Take out the bulb A CAUTION When handling the quartz halogen bulb 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 OClean off any contamination that inadvertently gets on the bulb with alcohol or a soap and water solution e Replace the headlight bulb e Fit the dust cover A with the TOP mark B upward onto the bulb C firmly as shown Good D Bad E e Tighten Torque Headlight Rim Screws 2 9 N m 0 30 kgf m 26 in Ib e After installation adjust the headlight aim see Headlight Beam Horizontal Vertical Adjustment in this section Headlight Body Removal e Remove the headlight rim screws A on both sides e Pull the headlight unit B and drop it out e Remove Rubber Cover A Clamp B Connectors C e Remove the headlight body bolts A then take off the b
166. Brakes chapter e Pull out the caliper holder A e Insert a wooden board A 5 mm 0 2 in thick inside the caliper opening e Pump the brake pedal until the pistons B push the wooden board 6L05040351 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the board and pull out the pistons A by hand OThese pistons can also be removed by disconnecting the hose and applying compressed air to the hose joint open ing using the same wooden board But be careful not to put your fingers or palm inside the caliper opening during work To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the pistons may crush your hand or fingers CAUTION Immediately wash away any brake fluid that spills e Remove Anti Rattle Spring A Dust Seals B and Fluid Seals C Rubber Friction Boots D Bleed Valves E and Rubber Caps F Rear Caliper Assembly e Tighten the bleed valve Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Olt is recommended that the fluid seal piston seal which is removed be replaced with a new one e Replace the dust seals A if they are damaged e Install the fluid seal B Either side of the seal may face outboard e Install the antirattle spring A in the caliper as shown e Apply brake fluid to the cylinders pistons and fluid seals p
167. C e Tighten the band D as shown 16 80 ELECTRICAL SYSTEM Meter Gauge Meter Unit Inspection LCD Segment Inspection e Remove the meter unit see Meter Unit Removal in this section CAUTION Do not drop the meter unit Such a shock to the meter unit can damage it Place the meter facing up If a meter is left upside down or sideways for any length of time it will malfunction A Meter Unit Lead Connector 1 Neutral Indicator Light 2 Fl Indicator LED Light 3 Oil Pressure Warning LED Light 4 Water Temperature Warning LED Light 5 Speed Signal for Turn Signal Control Relay 6 Unused 7 Battery 8 Ignition Neutral Indicator Light and Illumination 9 Battery High Beam Indicator Light and IIlumi nation 10 Speed Sensor Supply Voltage 11 Speed Sensor Signal 12 Fuel Level Sensor Signal 13 Right Turn Signal Indicator Light 14 Left Turn Signal Indicator Light 15 Fuel Level Warning Indicator LED Light 16 High Beam Indicator Light CAUTION Do not short each terminals When inspecting the meter unit be sure to connect each connections Check 1 e Using the auxiliary leads connect a 12 V battery A to the meter unit lead connector terminals Connections Battery Positive Terminal Terminal 7 Battery Negative Terminal Terminal 9 OWhen the terminals are conn
168. C17211B F 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 problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe 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 3 28 FUEL SYSTEM DFI Troubleshooting the DEI System Sample Diagnosis Sheet Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Mileage Environment when problem occurred Weather O fine D cloudy O rain O snow O always O other Temperature O hot O warm O cold O very cold O always ne O chronic O often O once Road O street 0 highway O mountain road O uphill 0 downhill 0 bumpy O pebble O normal O high about 1 000 m 3 281 ft or more Motorcycle conditions when problem occurred Fl indicator O light up immediately after ignition switch ON and goes off after engine oil LED light pressure is high enough with engine running normal O lights up immediately after ignition switch ON and stays on after engine oil pressure is high enough with engine running DFI problem O lights up immediately after ignition switch ON but goes off after about 10 seconds though en
169. CU e Turn off the ignition switch e Remove the front seat see Front Seat Removal in the Frame chapter e Disconnect Fuel pump Connector A Fuel Level Sensor Connector B Battery Lead Connector C Rear Turn Signal Taillight Lead Connector D e Remove DFI Fuse E Nuts F Battery Holder G e Slide the black and red caps out e Disconnect the negative cable A from the battery first and then the positive cable B from the battery CAUTION Be sure to disconnect the negative cable first Pull the battery C out of the case Clean the battery using a solution of baking soda and water Be sure that the wire connections are clean Battery Installation e Visually inspect the surface of the battery container lf any sings of cracking or electrolyte leakage from the sides of the battery e Face the terminal forward A and put the battery into the battery case CAUTION Do not install the battery backwards e Connect the positive cable B red cap to the terminal first and then the negative cable C black cap to the terminal e Apply a light coat of grease on the terminals to prevent corrosion e Cover the terminals with the black and red caps CAUTION If each battery cable is not correctly disconnected or connected sparks can arise at electrical connec tions causing damage to electrical and DFI parts 16 28 ELECTRICAL SYSTEM
170. Cable Wire and Hose Routing section in the Appendix chapter e Install the frame ground lead A to the rear mounting bolt of the ignition coil 1 16 46 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection e Remove the ignition coils see Ignition Coil Removal in this chapter e Measure the arcing distance with a commercially avail able coil tester A to check the condition of the ignition coil B e Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug terminal to the tester in the manner prescribed by the manufacturer and mea sure the arcing distance 3 Needle Arcing Distance Standard 6 mm 0 2 in or more To avoid extremely high voltage shocks do not touch the coil body or leads x If the distance reading is less than the specified value the ignition coil or spark plug caps are defective e To determine which part is defective measure the arcing distance again with the spark plug caps removed from the ignition coil Remove the caps by turning them counter clockwise x If the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap x lf the coil tester is not available the coil can be checked for a broken or badly shorted winding with the hand tester Special Tool Hand Tester 57001 1394 NOTE OThe hand tester cannot detect layer shorts a
171. Caliper Holder Bolt A Axle Nut Cotter Pin B Axle Nut C OPull the silencer out side and straighten the cotter pin e Pull out the axle and slide the rear wheel A toward the right B to disengage the wheel from the final gear case e Move the rear wheel back C and remove it CAUTION Do not lay the wheel directly 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 grease to the grease seal of the wheel e Apply grease to the ring gear hub splines A of the final gear case B e Insert the collars C on both sides of the hub 10 10 WHEELS TIRES Wheels Rims e Insert the axle A from the left side of the rear wheel e Slide the rear wheel to the left side and engage the ring gear hub splines with the wheel coupling hub splines e Pull the axle little and install the caliper holder e Tighten Torque Rear Axle Nut 108 N m 11 0 kgf m 80 ft Ib Rear Caliper Holder Bolt 64 N m 6 5 kgf m 47 ft Ib Rear Caliper Mounting Bolts 34 N m 3 5 kgf m 25 ft lb A WARNING If the axle nut is not securely tightened an unsafe riding condition may result 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
172. D Readings 0 Q x If no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary G017730BS2 3 84 FUEL SYSTEM DFI ECU e Check the power source voltage of the ECU with a digital meter A Battery B in the Frame Special Tool Needle Adapter Set 57001 1457 HCH 30 ECU Power Source Inspection Meter Connection between 30 W R Terminal and Battery GC Terminal Ignition Switch OFF 0 V Ignition Switch ON Battery Voltage 12 5 V or more GC17726BS1 x lf the digital meter does not read as specified check the following Power Source Wiring see wiring diagram of DFl Power Source section in this chapter DFI Fuse 15 A see DFI Fuse Inspection in this chapter DFI Main Relay see DFI Main Relay Inspection Ignition Fuse 10 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter x If the inspection checks good the ECU is damaged Re place the ECU The ECU itself cannot be checked or ser viced FUEL SYSTEM DFI 3 85 DFI Power Source D I Fuse Removal e Remove the front seat see Front Seat Removal in the Frame chapter e Pull the lock A and open the lid B e Pull out the DFI fuse C from the case with needle nose pliers Front D
173. Disassembly ASSeEMDIy oooooooocccccccccocononoonnccncccnnnanononcnncnnnnnnnnnnn nn cn nnnnnnnnannnnnnnnno 9 33 Transmission Dis ase e ascii a a o des 9 34 Transmission ASS ss al ere 9 34 Shift Fork Bending sario 9 37 Shift Fork Gear Groove Wear sis fn dre er dun tem A aaea lens s 9 37 Shift Fork Guide Pin Drum Groove Wear 9 37 Gear Dog and Gear Dog Hole Damage su 9 37 Ball Bearing Needle Bearing and Oil Seal 9 38 Ball Bearing and Outer Race Replacement ooccoooocccc cccccccononononcncncnnnnnnnnoncnnnnnnnnnnnnn nn nncnnnnnns 9 38 Ball and Needle Bearing Wear 9 38 Oil Seal Inspector eri 9 39 9 2 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Bearing Retainer Bolts 11 1 1 97 in lb L 2 Camshaft Chain Guide Bolts 11 1 1 97 in lb L 3 Clutch Push Rod Guide Bolts 11 1 1 97 in lb L 4 Connecting Rod Big End Nuts 59 6 0 44 MO 5 Crankcase Bolt M10 L 115 mm 39 4 0 29 S 6 Crankcase Bolts M10 L 105 mm 39 4 0 29 S 7 Crankcase Bolts M6 L 80 mm 11 1 1 97 in lb S 8 Crankcase Bolts M6 L 70 mm 11 1 1 97 in lb S 9 Crankcase Bolts M6 L 40 mm 11 1 1 97 in lb S Crankcase Bolts M8 S 10 S 85 i 20 2 26 nb 8 9 0 1 2 1 S 145 i 85 2 Starter Clutch Coupling Bolts 15 22 Water Pump Drainage Hose Fitting 9 8 23 Left Crankcase 24 Right Crankcase 25 Oil
174. Do not remove the push rod clevis A for master cylin der disassembly since removal requires brake pedal po sition adjustment e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Remove the reservoir cap B plate C and diaphragm D e Slide the dust cover E on the push rod out of place and remove the circlip F Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop e Take off the piston assy G piston H primary cup I secondary cup J and return spring K e Replace Piston Assy Dust Cover Brake Hose L Diaphragm O ring M Circlips a GS13098BS2 C GS13099BS2 PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION 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 deterioration 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 e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care not to scratch the piston or the
175. Do not try to start the engine with the fuel hoses disconnected FUEL SYSTEM DFI 3 91 Fuel Line e Turn the ignition switch ON The fuel pump will turn for 3 seconds and then stop e Measure the fuel pressure with the engine stopped Fuel Pressure right after Ignition Switch ON with pump running Standard 304 kPa 3 1 kgf cm 44 psi after 3 seconds from Ignition Switch ON with pump stopped Standard 280 kPa 2 9 kgf cm 41 psi residual fuel pressure The system should hold the residual pressure about 30 seconds e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure idling Standard 304 kPa 3 1 kgf cm 44 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications Alf the fuel pressure is normal the fuel circulation system fuel pump pressure regulator and oil passage is no faults Check the DFI electronic control system injectors sensors crankshaft sensors and ECU x lf the fuel pressure is much higher than the specified check the following Delivery Pipe Clogging Injector Clogging Alf the fuel pressure is much lower than specified check the following Fuel Pump for Operation Check the sound of the pump Fuel Line Leakage or Clogging Amount of Fuel Flow see Fuel Flow Rate Inspection in this section x If the fuel pressure is much lower than specified and if inspection abov
176. E Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a blowtorch This will warp the case Soak the case in oil and heat the oil e Install a new needle bearing A with the marked side fac ing out until it bottoms out using the bearing driver set B This prevents bearing damage Special Tool Bearing Driver Set 57001 1129 e Using a press and the bearing driver set A install a new ball bearing until it stops at the bottom of the case Special Tool Bearing Driver Set 57001 1129 Ball Bearing Wear CAUTION Do not remove the bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it GKO0902068S1 6114060581 6114010181 FINAL DRIVE 11 39 Bearing and Oil Seal Tapered Roller Bearing Inspection CAUTION Do not remove the tapered roller bearing for inspec tion Removal may damage them
177. E 10 4 Special TOONS E 10 5 Wheels CD 10 6 Front Wheel Removal 2 ceccceccceeeceeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeneeeeseeeneeeseeeseeeeeeess 10 6 Front Wheel Installation ss 10 7 Rear Wheel Removal see 10 8 Rear Wheel Installation o a a a a ai 10 9 Wheel Coupling Removal culta eet 10 11 Wheel Coupling Installation siii in daa dh latente tele ne te ed dns 10 11 Wheel Inspector alias Axle INSD CtiOn viii di Wheel Balance nitrato EE dE Balance Inspection di adidas cl engageieren ent Balance Weight Removal A A E Air Pressure Inspection Adjustment 10 16 WIS INS PSCUON aa A ac sve te 10 16 Tir REMOVAL Etc a A Ai als 10 16 A EE 10 16 TIPE heet sisi essaie sante het Nine KEE ED ebe Auer Aere 10 18 Hub Bearings Wheel El ne CEET 10 19 Hub Bearings Removal aaa 10 19 PUB Bearings Stell AMO EE 10 19 Hub Glen EE 10 20 Hub Bearings Ree Te EE 10 20 10 2 WHEELS TIRES Exploded View 6J02056BW5 C WHEELS TIRES 10 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Front Axle Clamp Bolts 29 3 0 21 AL 2 Front Axle Shaft 108 11 0 80 3 Rear Axle Nut 108 11 0 80 4 Tire Air Valve Nuts 1 5 0 15 13 in lb AL Tighten the two front axle clamp bolts alternat
178. E Z Ground ar De 4 llluminator LED i S22 23 5 Fuel Indicator LED H Beets yyy tee 8 Mater Temperature Warning FI Pase SS Oil Pressure Warning Indicator LED SL gee LE z ER eux 7 Mode Switch 28 See Noes Neutral Oil aaa gas 8 Reset Switch Switch Pressure E 9 High Beam Indicator Light 12V1 1 Switch feat EM 10 Turn Signal Indicator WEE eexSSS perse 11 Neutral Indicator Light 12V1 12 Fuel za RER Level LED Light Emitting Diode FL Sensor H i L JL Za on Alternator Regulator Regulator Alternator S Rectifier Rectifier 000 L sise Front Rear Stand Left Handlebar Switches 4 Switch 18 1 Starter Lockout Switch Eusi Y R 2 Horn Button ele Did Turn Signal 3 Dimmer Switch Reserve D Control Relay 4 Turn Signal Switch Switch dee LEFT HANDLEBAR SWITCH CONNECTIONS starter Lockout Seiten Horn Button GP05056BW5 C ELECTRICAL SYSTEM 16 23 Wiring Diagram Other than United States Canada and Australia Junction Box 1 Ignition Fuse 104 6 Radiator Fan Fuse 15A 2 Horn Fuse 10A 7 Turn Signal Fuse 104 E A 3 Taillight Fuse 104 8 Starter Circuit Relay Right Handlebar Switches 4 Headlight Fuse 10A 9 Headlight Relay 1 Front Brake Light Switch 5 Accessory Fuse 10A 2 Engine Stop Switch Crankshaft 8 Starter Button Sensor 3 S Kawasaki 1 2 Diagnostic ae sii Plugs System Connector lenition selt Coils diagnosis me Terminal o Electronic Control Unit Ll 201
179. Hand Tester 57001 1394 x If the voltage is less than 6 V replace the meter unit ODO Meter Inspection e Connect the leads in the same circuit as for the Speedometer Inspection e Push the mode button to ODO A e Raise the input frequency of the oscillator to quickly see the result of this inspection x If the value indicated by the odo meter does not increase replace the meter unit TRIP Meter Inspection e Connect the leads in the same circuit as for the Speedometer Inspection e Push the mode button to TRIP A e Rise the input frequency of the oscillator to quickly see the result of this inspection x If the value indicated by the trip meter does not increase replace the meter unit Fuel Level Gauge Inspection e Connect the leads in the same circuit as for the LCD seg ment inspection Check 2 e Connect a variable rheostat A to the terminal 12 and battery negative lead as shown e Check that the number of segments B matches the re sistance value of the variable rheostat OWhen terminal 12 is connected one segment should ap pear about 10 15 seconds Resistance Q Number of Segments 50 5 100 3 210 1 Resistance values are standard and they have tolerance x If this indicator function does not work replace the meter unit GP17096BS1 GP17098BS1 GP17099BS2 C ELECTRICAL SYSTEM 16 85 Meter Gauge LED Light Inspe
180. ION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump 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 B may fail in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and in spect the other tube carefully before reusing it GM040138S1 6M04134BS1 GM04282BS1 GM04283BS1 13 14 SUSPENSION Front Fork Dust Seal Inspection x Inspect the dust seal A for any signs of deterioration or damage Replace them if necessary GM040625S1 Spring Tension e Since the spring becomes shorter as it weakens check its free length A to determine its condition x lf the spring of either fork leg is shorter than the service limit it must be replaced x lf the length of a replacement spring and that of the re maining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability 6M04011651 Spring Free Length Standard 393 9 mm 15 50 in Service Limit 386 mm 15 2 in SUSPENSION 13 15 Rear Shock Absorber Air Type Rebound Damping A
181. If the output voltage is normal check the output voltage for vacuum see Inlet Air Pressure Sensor section in this chapter If the output voltage changes within the usable range as vacuum changes the sensor is normal and the ECU is suspect Check the ECU for its ground and power supply e Turn the ignition switch OFF and remove the needle adapters e Apply silicone sealant the seals of the connector for wa terproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connector 3 60 FUEL SYSTEM DFI Atmospheric Pressure Sensor Service Code 15 O 1234567 8 91011 1213 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 GC17704BW2 C 1 ECU 2 Atmospheric Pressure Sensor x If you need to check the atmospheric pressure sensor for various altitudes other than sea level check the output voltage as follows ODetermine the local altitude elevation x If you know the local atmospheric pressure using a barometer substitute the atmospheric pressure for Pv Throttle Vacuum in the inlet air pressure sensor chart See Output Voltage Inspection in the Inlet Air Pressure Sensor section OGet the usable range of the atmospheric pressure sensor output voltage in the same way as Output Voltage Inspection of the inlet air pressure sensor and check if Va output voltage is within the usable range or not If you know the local altitude use the following c
182. Inspection e Whenever the radiator or water hoses are removed or in accordance with the Periodic Maintenance Chart check the radiator or water hoses and their connections Refer to the Radiator Hose Inspection Coolant Leak Damage Installation Condition in the Periodic Maintenance chap ter ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded VIE Seege egen 5 2 KACR Kawasaki Automatic Specifications 5 9 Compression Release Special Tools and Sealants 5 12 Inspection 5 31 Clean Air System 5 15 Cylinder Head cocaina 5 32 Air Suction Valve Removal 5 15 Cylinder Compression Air Suction Valve Installation 5 15 Measurement 5 32 Air Suction Valve Check 5 15 Cylinder Head Removal 5 33 Vacuum Switch Valve Removal 5 16 Cylinder Head Installation 5 34 Vacuum Switch Valve Installation 5 16 Cylinder Head Warm 5 35 Vacuum Switch Valve Operation Valve Clearance Adjustment 5 35 RK TE 5 16 Valve Removal 5 35 Vacuum Switch Valve Unit Test 5 16 Valve Installation 5 35 Clean Air System Hose Valve Guide Removal 5 36 Inspechon neneeeeeeeeeneeeeeeee 5 17 Valve Guide Installation 5 36 Camshaft Chain Tensioner 5 18 Valve Guide Wear Wobble Camshaft Chain Tension
183. KSHAFT TRANSMISSION 9 19 Crankcase e Apply a non permanent locking agent to the threads of the chain guide bolts and chain guide retainer bolt e Install Rear Camshaft Chain A Lower Chain Guide B Front Chain Guide Retainer C Rear Chain Guide D Torque Camshaft Chain Guide Bolts 11 N m 1 1 kgf m 97 in lb Camshaft Chain Guide Retainer Bolt 11 N m 1 1 kgf m 97 in Ib e Install Water Pump Sprocket A with Shaft B Chain C 6104079BS1 e Install Washer A Idle Shaft Sprocket B OFit the pin C into the slots D of the idle shaft sprocket 6104080BS1 e Install the primary gear A with the boss B facing toward the engine inside e Install Pin A Idle Shaft Sprocket B Water Pump Drive Sprocket C and Chain D Dowel Pins E OStuff the cloth on the holes of the crankcase so that the pin does nat drop into the crankcase bottom 61048312 P 9 20 CRANKSHAFT TRANSMISSION Crankcase e Install Idle Shaft Holder A and Water Pump Chain Guide B as shown Torque Idle Shaft Holder Bolts 8 3 N m 0 85 kgf m 73 in 1b e Fit the alignment tooth A of the splines of the right bal ancer onto the alignment notch B of the balancer shaft e Install the collar A copper washer B and needle bear ing C in the order listed OThe copper washer must be on the collar e Install the starter torque limiter D e Install the primary gear bolt
184. LED So Re eee Lie Wak GE Gm s sus 7 Mode Switch Ss Ze partes eutra i aoe eme B Reset Switch Switch Pressure a High Beam Indicator Light 12V1 12W Switch 10 Turn Signal Indicator Light 12V1 12 1i Neutral Indicator Light 12V1 12 Fuel Te rein Level LED Light Emitting Diode Sensor TI er on y Alternator Regulator Regulator Alternator Rectifier Rectifier ooo o E Side PED ee Gi DI Stand Left Handlebar Switches Switch 1 Starter Lockout Switch Fuel Y R 2 Horn Button Se BK Y Turn Signal 3 Dimmer Switch Se 9 Control Relay 4 Turn Signal Switch Switch LEFT HANDLEBAR SWITCH CONNECTIONS Color Clutch Lever Released Pulled in 6P050528W5 C ELECTRICAL SYSTEM 16 19 Wiring Diagram United States and Canada Junction Box 1 lgnition Fuse 104 Radiator Fan Fuse 15A 2 Horn Fuse 104 7 Turn Signal Fuse 104 Right Handlebar Switch 2 Taillight Fuse 104 8 Starter Circuit Relay eech 4 Headlight Fuse 104 9 Headlight Relay 2 Engine Stop ee Crankshaft 5 Accessory Fuse 104 3 Starter Button Sensor Kawasaki Diagnostic ai 2 Connector T Ignition Neu gr Al Coils diagnosis 1 asi terminal Let Sees Electronic Control Unit LIL oat RW tE 1 O NE BK Y Joint Connector 2 BK Y mA BK Y eur BK Y DAD BK Y DAP BK Y BK Y DZ BK Y
185. LG R O R G BK G BK 6 Bk LG R G R BK Y BK Y LE BR R BR R l fic R Y R Y d HH EE all o A E cr EH M m H CT EE ceases L e E o ere oo ES JN 5 GE BATTERY QS ros D 09 BK Y R lt r CATE 7R HN BL W 7R G BL W R Sun W R P HI o 78 GI JE du W R E E T il R BK BL OL f 60176938W5 C FUEL SYSTEM DFI 3 15 DFI Wiring Diagram DFI and Electrical Parts DFI DFI Parts ECU Electronic Control Unit DFI Self diagnosis Terminal Engine Stop Switch Starter Button Ignition Coils Crankshaft Sensors Joint Connector 2 Speed Sensor Interlock Diodes 10 Starter Circuit Relay 11 Ignition Fuse 10 A 12 Junction Box 13 LCD Liquid Crystal Display 14 Speedometer 15 Fl Indicator LED Light DFI 16 MODE Button 17 RESET Button 18 Ignition Switch 19 Stater Relay 20 Main Fuse 30 A 21 Sealed Battery 22 Fuel Pump DFI 23 Fuel Injector 1 DFI 24 Fuel Injector 2 DFI 25 Throttle Sensor DFI 26 DFI Fuse 15 A for ECU Injectors Fuel Pump DFI Main Relay and ISC Valves 27 ISC Valve 2 DFI 28 ISC Valve 1 DFI 29 Inlet Air Temperature Sensor DFI 30 Water Temperature Sensor DFI 31 Inlet Air Pressure Sensor DFI 32 Atmospheric Pressure Sensor DFI 33 Vehicle down Sensor DFI 34 DFI Main Relay for ECU Injectors Fuel Pump and ISC
186. Line Bleeding in this chapter e Check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done 12 12 BRAKES Calipers 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 Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Caliper Fluid Seal Damage 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 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 replac
187. Main Relay ECU Electronic Control Unit Horn Inlet Air Pressure Sensor Inlet Air Temperature Sensor Junction Box Oil Pressure Light Delay Unit Starter Relay Turn Signal Control Relay Vehicle Down Sensor Apply grease Apply Silicone Sealant Kawasaki Bond 56019 120 16 10 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 11 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Front Brake Light Switch Screw 1 2 0 12 11 ml 2 Fuel Level Sensor Mounting Bolts 6 9 0 70 61 in lb L 3 Fuel Pump Mounting Bolts 9 8 1 0 87 in lb 4 Side Stand Switch Mounting Bolt 8 8 0 90 78 in lb L 5 Starter Lockout Switch Screw 1 2 0 12 11 in lb 6 Starter Motor Se Bolts 0 50 1 in 1b 10 Starter Relay EO Apply engine oil L Apply a non permanent locking agent S Follow the specific tightening sequence R Replacement Parts 16 12 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 13 Exploded View No Fastener E Remarks N m kgf m ft Ib 1 Headlight Rim Screws 2 9 0 30 26 in lb 2 Headlight Unit Bracket Screws 1 0 0 10 8 9 in lb L 3 Tail Brake Light Assembly Screws 1 2 0 12 11 mb 4 Tail Brake Light Lens Screws 1 2 0 12 11 mb 5 Tail Brake Light Mounting Nuts 5 9 0 60 52 in lb 6 Turn Signal Light Lens Screws 1 0 0 10 8 9 in lb 7 Turn Signal Light Mounting Screws 69 070 6
188. Make sure they do not get pinched or kinked e Route hoses with a minimum of bending so that the air or vapor will not be obstructed Canister Installation eRun the purge hose green A above the canister breather hose blue B through the hole C into the tool case D ODo not run these hoses side by side on the battery side of the canister This prevents hoses from being flattened when installing the left side cover e Install the canister and the left side cover see Left Side Cover Installation in the Frame chapter e Face the white mark E left as shown Canister Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance Chapter Separator Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance Chapter GSO5000BS1 3 112 FUEL SYSTEM DFI Evaporative Emission Control System Hose Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance Chapter Separator Operation Test A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF e Remove Front Seat see Front Seat Removal in the Frame chap ter Left Side Cover see Left Side Cover Removal in th
189. NOTE OFor the rear brake caliper A bleed the brake line for two bleed valves B 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 GLO9017BS2 C GS13024B S BRAKES 12 21 Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do 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 deteriorate Don t leave the reservoir cap off A for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing 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 deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake When handing the disc pads or disc
190. ODIC MAINTENANCE Periodic Maintenance Procedures Choke Knob Operation ODo not use the choke knob except when the engine has a starting difficulty like in cold weather 10 C or below or at high altitude The DFI system has an automatic choke system using ISC valves a water temperature sensor and an atmospheric pressure sensor which provide start ability NOTE OPull the choke knob A fully when using The choke lever B doesn t work with the choke knob halfway Front C OWhen flooded do not crank the engine with the throt tle fully opened This promotes engine flooding because more fuel is supplied automatically by the DFI system Fuel Hose Inspection Fuel Leak Damage Installation Condition OThe fuel hoses are designed to be used throughout the motorcycle s life without any maintenance however if the motorcycle is not properly handled the high pressure in side the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly e When installing route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses wi
191. OFor the handlebar switches and the ignition switch refer to the tables in the Wiring Diagram x If 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 Color BR BL When brake pedal is pushed down OO When brake pedal is released Side Stand Switch Connections Color G BK When side stand is down Neutral Switch Connections Color SW Terminal Ground When transmission is in neutral OO When transmission is not in neutral Oil Pressure Switch Connections Color SW Terminal Ground When engine is running Engine lubrication system is in good condition ELECTRICAL SYSTEM 16 97 Junction Box The junction box A has fuses B relays and diodes y The relays and diodes can not be removed Junction Box Fuse Circuit Inspection e Remove the right side cover see Right Side Cover Re moval in the Frame chapter e Remove the junction box e Pull off the connectors from the junction box e Make sure all connector terminals are clean and tight and none of them have been bent Clean the dirty terminals and straighten slightly bent ter minals e Check conductivity of the numbered terminals with the hand tester see Junction Box Internal Circuit in this sec tion x If the tester does not read as specified replace the junc tion box Fuse Circuit Inspection
192. OTE OThe output voltage changes according to the local at mospheric pressure e Check the output voltage of the sensor at the ECU con nector A Special Tool Needle Adapter Set 57001 1457 Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter W BL lead terminal 29 Meter BR BK lead terminal 11 e Measure the output voltage with the engine stopped and with the connector joined Needle Adapters B e Turn the ignition switch ON Output Voltage at ECU Usable Range 3 74 4 26 V DC at the standard atmospheric pressure 101 32 kPa or 76 cmHg absolute x If the output voltage is at about 4 8 V the ECU is normal Remove the fuel tank and check the wiring between the ECU and the sensor x If the output voltage is at about 4 8 V and out of the usable range remove the fuel tank and check the wiring If the wiring is good check the sensor itself as follows e Turn the ignition switch OFF and remove the needle adapters e Apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connector GC17719BS1 3 50 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 x If the output voltage is normal check the inlet air pressure sensor itself OCheck the output voltage for vacuum as follows If the output voltage changes within the usable range as vac uum changes the sensor
193. RIVE Front Bevel Gears Bearing Preloading Mechanism EN X SX NN NN NN NN NN NN NN NN AAA LLILL L 1111 Z GK09017BW2 C Bearing Housing Tapered Roller Bearing Spacer Collar Tapered Roller Bearing Before Tightening After Tightening Under No Preload Initial Clearance Under Preload No Clearance TM MOUODFARWNR Backlash Adjustment e Clean any dirt and oil off bevel gear teeth with a high flash point solvent e Install the drive gear with the primary shim 1 0 mm 0 04 in thickness and tighten the nut to the specified torque Torque Drive Gear Nut 265 N m 27 0 kgf m 195 ft lb NOTE ODo not stake the head of the nut until both backlash and tooth contact adjustments are finished e Install the driven gear assy in the front gear case with the primary shim 1 0 mm 0 04 in thickness and tighten the mounting bolts to the specified torque Torque Driven Gear Assy Mounting Bolts 25 N m 2 5 kgf m 18 ft lb OCheck backlash during tightening of the mounting bolts and stop tightening them immediately if the backlash dis appears Then change the shim to a thicker one FINAL DRIVE 11 35 Front Bevel Gears e Install a holder A with 6 mm bolts and nuts on the front gear case to mount a dial gage e Set up a dial gage against a drive gear tooth to check gear backlash The gage stem must be in line with the direction of tooth travel e To measu
194. Rear Cover E GE19001BS1 5 22 ENGINE TOP END Rocker Case Rocker Case Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Rocker Case Covers see Rocker Case Cover Removal in this chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter e Remove the timing inspection cap A and rotor bolt cap B Special Tool Filler Cap Driver C 57001 1454 e Turn the crankshaft counterclockwise A and align the F mark TDC mark for front piston B with the middle of the notch C e Remove Oil Hose Flange Bolt A Oil Hose B e Remove the camshaft chain tensioner see Camshaft Chain Tensioner Removal in this chapter e Remove the rocker case bolts A smaller nuts B and then larger nuts C e Using the pry points A take the rocker case out of the cylinder head ENGINE TOP END 5 23 Rocker Case e Unscrew the rocker shafts A and take the rocker arms B out of the rocker case e Take out the oil filters if necessary e Remove the lash adjuster if necessary see HLA Removal in this chapter CAUTION The cylinder head and rocker case are machined in the assembled state so they must be used as a set Be careful not to mix them up for front and rear cylinders Rocker Case Installation e Replace the O rings A with new ones and install them on the rocker shaft B
195. SAA 7 N Ee S77 OEE a S SR DU 7 Y bf ae er E PIARD AR r AAA A 7 Ov SR lt gt O Q ISS K SS SS g I oe Se bei his Si RS GE LE BW E bf COLES Le gt S RREY alt CAE ASIS E GKO6005B 2 Studs Pinion Gear Shim s O ring Oil Seal Tapered Roller Bearings Pinion Gear Bearing Housing Pinion Gear Retainer Bolt Stud Needle Bearing Small Ring Gear Oil Seal Needle Bearing 6K06004BS1 11 12 FINAL DRIVE Final Gear Case and Oil e Replace the needle bearings A with new ones e Apply a hypoid gear oil to the roller parts of the needle bearings B qf Vat 6K06007BS1 NOTE Olnstall the bearing so that the marked side faces out OPress in the bearings until they are bottomed Special Tool Bearing Driver Set 57001 1129 e Install the snapring B secure e Apply a non permanent locking agent to the bearing re tainer bolt C e Install the washer D and the bearing retainer bolt Torque Bearing Retainer Bolt 6 9 N m 0 70 kgf m 61 in Ib e Apply a thin coat of high temperature grease to the oil seal lip of the ring gear oil seal e Install the ring gear oil seal with its spring A facing inward using a suitable driver until the face of the seal is even B with the end of the hole GKO40008S1 e Blow the breather hole
196. SION Crankcase e Turn the crankshaft counterclockwise A and align the alignment tooth B with the middle of the crankcase rib C This makes the front piston set to its top dead center e Install the crankshaft balancer gear D while fitting the alignment notch of the splines onto the alignment tooth OAligning the balancer gear marks line mark E with the front piston on its top dead center e Install Alternator Inside Stator A see Alternator Inside Stator Installation in the Electrical System chapter Alternator Rotor B Olnstall the alternator rotor while fitting the alignment notch C of the splines onto the alignment tooth D OBe sure to align the balancer gear mark with the alternator mark shorter line mark A while keeping the front piston on its top dead center Top Mark for Rear Piston B Longer Mark Top Mark for Front Piston C Longer Mark e Apply molybdenum disulfide oil solution to the threads and the seating surface of the left balancer gear bolt and alternator rotor bolt OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Holding the alternator rotor steady with the flywheel holder A Special Tool Flywheel Holder 57001 1410 e Install the ratchet B e Tighten Torque Left Balancer Gear Bolt C 85 N m 8 7 kgf m 63 ft lb Alternator Rotor Bolt D 78 N m 8 0 kgf m 58 ft lb CRAN
197. Saddlebag Installation in the Frame chapter Clutch Hose and Pipe Replacement OSince the clutch hose is the same as the brake hose refer to the Brake Hose Replacement in this chapter for clutch hose and Pipe Replacement PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures Clutch Fluid Change e Level the clutch fluid reservoir and remove the reservoir cap e Remove the alternator outer cover see Alternator Outer Cover Removal in the Electrical System chapter and the rubber cap from the bleed valve on the clutch slave cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh fluid e Change the clutch fluid as follows 1 Open B the bleed valve using a wrench 2 Pump the clutch lever and hold C it 3 Close D the bleed valve 4 Release E the clutch lever ORepeat this operation until fresh fluid comes out from the plastic hose or the color of the fluid changes OCheck the fluid level in the reservoir often replenishing it as necessary NOTE Olf the fluid in the reservoir runs completely out any time during fluid changing the bleeding operation must be done over again from the beginning since air will have entered the line A WARNING Do not mix two brands of fluid e After changing the fluid check the clutch for good clutch power and no fluid leakage x If necessary bleed the air from the lines see
198. Since the clutch fluid is the same as the brake fluid refer to the Brake Fluid Level Inspection in this chapter for fur ther details Torque Clutch Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib A WARNING Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Mixing different types and brands of fluid lowers the fluid boiling point and could cause the clutch to be ineffective It may also cause the rubber clutch parts to deteriorate Clutch Fluid Leak Clutch Hose and Pipe e Apply the clutch lever and inspect the clutch fluid leak from the clutch hose A and fitting x lf the clutch fluid leaked from any position inspect or re place the problem part Clutch Hose Damage and Installation Condition Inspection e The high pressure inside the clutch line can cause fluid to leak A or the hose to burst if the line is not properly maintained Bend and twist the rubber hose while exam ining it x Replace it if any fraying cracks B or bulges C are no ticed e Check that the hoses are securely connected and banjo bolts are tightened correctly Torque Clutch Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e When installing the clutch hose route the hoses accord ing to Cable Wire and Hose Routing section in the Ap pendi
199. System CAL Evaporative emission control system function inspect Air Suction System Air suction system damage inspect Clutch and Drive Train Clutch operation play disengagement engagement inspect Clutch fluid level inspect Clutch fluid leak inspect Clutch hose damage inspect Clutch hose installation condition inspect Final gear case oil level inspect Wheels and Tires Tire air pressure inspect Wheel tire damage inspect Tire tread wear abnormal wear inspect Wheel bearing damage inspect year e e e 2 25 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart Brake pad wear inspect Brake hose installation condition inspect Brake fluid level inspect year 6 months FREQUENCY Whichever ODOMETER READING comes yy x 1 000 km first x 1 000 mile See 1 6 12 18 24 30 36 Page INSPECTION Every 0 6 4 7 5 12 15 20 24 Brake System Brake fluid leak brake hose and pipe year e a E a E z 2 25 inspect Brake hose and pipe damage inspect year Brake operation effectiveness play no drag inspect year Brake light switch operation inspect Suspensions Front forks rear shock absorber Steering stem bearings lubricate 2 years operation damping and smooth stroke e e e 2 28 inspect Front forks rear shock a
200. Terminal The same as No 10 Power Source Ground for Diagnosis Tool Power Supply to Sensors Inlet Air Pressure Atmospheric Pressure And Throttle Sensors from ECU Com Line B Fuel Pump Signal Injector 2 Signal Injector 1 Signal ISC Valve 1 Signal Ignition Control Circuit Ground to Battery Terminal Ignition Coil 2 Signal Ignition Coil 1 Signal 3 18 FUEL SYSTEM DFI Specifications Item Standard Throttle Grip Free Play 2 3 mm 0 08 0 12 in Air Cleaner Element Paper filter DFI System Make Idle Speed Throttle Body Assy Type x Bore ECU Electronic Control Unit Type Usable Engine Speed ISC Valves Maximum Air Flow Rate Solenoid Resistance Fuel Pressure High Pressure Line Right after Ignition Switch ON After Pump Runs 3 seconds and Stops With Engine Idling Pressure Regulator Regulated Fuel Pressure Throttle Sensor Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Atmospheric Pressure Sensor Inlet Air Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Resistance Water Temperature Sensor Resistance Vehicle down Sensor Detection Angle Detection Time Mitsubishi Electric 950 50 r min rpm Two barrel type x 36 mm 1 4 in Digital memory type with built in IC igniter sealed with resin 100 5 900 r min rpm Idle Sp
201. Terminals 3 and 4 Testing Relay Tester range 1 Q range Criteria When battery is connected 0 Q When battery is disconnected Q Alf the relay does not work as specified replace the relay 3 86 FUEL SYSTEM DFI DFI Power Source DFI Power Source Circuit O 12345 6 7 8 91011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 CD TON PARK IGNITION Oot TAIL rate Jos co GC17709BW3 C ECU Junction Box Ignition Fuse 10 A Ignition Switch Starter Relay Main Fuse 30 A Battery Fuel Pump Fuel Injector 1 10 Fuel Injector 2 11 ISC Valves 2 12 ISC Valves 1 13 DFI Main Relay Actuators Fuel Pump Fuel Injectors 1 and 2 ISC Valves 1 and 2 14 DFI Fuse 15 A 15 Joint Connector 2 HN O O1 UN FUEL SYSTEM DFI 3 87 ISC Valves Removal Installation CAUTION Never drop the ISC valves especially on a hard sur face Such a shock to the valve can damage it OThe ISC valves are removed during right air cleaner hous ing removal see Right Air Cleaner Housing Removal in this chapter OThe ISC valve itself is the same for front and rear but wiring is different Be careful not to reverse the leads ISC Valve 1 A G Y WIR leads B ISC Valve 2 C G BL W R leads D Front E e Install the ISC hoses as shown ISC Hose
202. Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Calipers Purpose check seat O D against spec Too small 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seat Width Tool Vernier Calipers Purpose check seat width against spec Too narrow Too wide 45 Grind Tool 45 Cutter Purpose increase width of seat area beyond spec to increase O D Machinist s dye on seat 55 Grind Tool 55 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage ENGINE TOP END 5 41 Cylinders Piston Cylinder Removal e Remove the cylinder head see Cylinder Head Removal in this chapter e Remove the coolant drain plug A and drain the coolant from the cylinder e Pull out the front camshaft chain guide B e Remove the cylinder nuts C e Tap lightly up the cylinder with a plastic mallet to separate from the crankcase e Remove the cylinder base gasket 4 PA Piston Removal e Remove the cylinder block see Cylinder Removal in this section e Place a piece of clean cloth under the piston and remove the piston pin snap rings A from the outside of each pis to
203. Valves 35 Frame Ground OONDABRWDND 3 16 FUEL SYSTEM DFI DFI Wiring Diagram Terminal Numbers of ECU Connectors O O U O O 112131415161718191011121314151617181920 21122 e 24 25126 21128 Se 32 3314 39 36 3188 d B 43 FUEL SYSTEM DFI 3 17 DFI Wiring Diagram Terminal Names 1 2 1 2 3 _ 2ADOOMNDOA for Front Cylinder for Rear Cylinder Starter Lockout Switch Signal Interlock Circuit Signal Self diagnosis Signal Generated by grounding this terminal and shown by FI indicator LED light Tachometer Signal Electric Starter Button Signal Water Temperature Sensor Power Source for Diagnosis Tool ECU Power Source Circuit Ground to Battery Terminal Ground of Inlet Air Temperature Water Temperature Inlet Air Pressure Atmospheric Pressure and Throttle Sensors Neutral Switch DFI Main Relay Solenoid Ground in ECU Crankshaft Sensor 2 Signal Crankshaft Sensor 1 Signal Com Line A Fl Indicator LED Light Signal ISC Valve 2 Signal Ignition Control Circuit Ground to Battery Terminal Vehicle down Sensor Signal Throttle Sensor Signal Speed Sensor Signal Atmospheric Pressure Sensor Signal Inlet Air Pressure Sensor Signal Power Supply to ECU ISC Valves Injectors and Fuel Pump Vehicle down Sensor Inlet Air Temperature Sensor ECU Power Source Circuit Ground to Battery
204. a fault of the ECU ORefer to the each Sensor Inspection section for detail in this chapter e Use a fully charged battery and a digital meter D which can be read two decimal places voltage or resistance Y W BR BK BL W 6017715BS2 FUEL SYSTEM DFI 3 23 Troubleshooting the DFI System OThe DFI part connectors A have seals B including the ECU except for ISC valves e Join the connector A and insert the needle adapter spe cial tool C inside the seal B from behind the connector until the adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 CAUTION 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 con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of the hand tester or 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 CAUTION 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 silicone sealant to the seals A of the connector B for waterproofing Sealant Kawa
205. able Auto adjuster 0 9 1 1 mm 0 03 0 04 in 0 9 1 1 mm 0 03 0 04 in TIR 0 01 mm 0 0004 in or less 6 955 6 970 mm 0 2738 0 2744 in 6 965 6 980 mm 0 2742 0 2748 in 33 39 mm 1 315 in 33 71 mm 1 327 in 0 15 mm 0 0059 in 0 14 mm 0 0055 in 24 93 mm 0 981 in 16 94 mm 0 667 in 25 08 mm 0 987 in 17 08 mm 0 672 in TIR 0 1 mm 0 004 in 16 05 mm 0 632 in 15 94 mm 0 628 in 0 7 mm 0 03 in 0 5 mm 0 02 in TIR 0 05 mm 0 002 in 6 94 mm 0 273 in 6 95 mm 0 274 in 5 10 ENGINE TOP END Specifications Item Standard Service Limit Valve Guide Inside Diameter Exhaust 7 000 7 015 mm 7 08 mm 0 279 in 0 2756 0 2762 in Inlet 7 000 7 015 mm 7 08 mm 0 279 in Valve Valve Guide Clearance Wobble Method 0 2756 0 2762 in Exhaust 0 08 0 15 mm 0 35 mm 0 014 in 0 003 0 006 in Inlet 0 05 0 13 mm 0 33 mm 0 013 in 0 002 0 005 in Cam Height Camshaft Journals and Runout GE02000381 Cam Height maximum A Valve Head Thickness GEO20005S1 Valve Head Thickness A Valve Stem Diameter B 45 C 25 mm 0 984 in A 17 mm 0 669 in B Valve Stem Bend E GEO20006S1 ENGINE TOP END 5 11 Specifications Item Standard Service Limit Valve Seat Surface Valve Seat Cutting Angle Ou
206. ach side of the clutch hose fitting e Tighten the clutch hose banjo bolt Torque Clutch Hose Banjo Bolt Upper 25 N m 2 5 kgf m 18 ft lb e Replenish the clutch fluid into the reservoir and bleed the clutch line see Clutch Line Bleeding in this chapter e Check that the clutch line has proper fluid pressure and no fluid leakage Clutch Master Cylinder Disassembly Assembly e Refer to the Clutch Master Cylinder Rubber Parts Re placement in the Periodic Maintenance chapter 6 8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Inspection e Disassemble the clutch master cylinder see Clutch Mas ter Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter CAUTION Do not remove the secondary cup from the piston since removal will damage it e Check that there are no scratches rust or pitting on the inside of the master cylinder A and on the outside of the piston B x lf the master cylinder or piston shows any damage re place them e Inspect the primary cup C and secondary cup D If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups e f fluid leakage is noted at the clutch lever the piston as sembly should be replaced to renew the cups e Check the dust cover E for damage e If it is damaged replace it e Check that the relief and supply ports are not plugged x lf the small relief port becomes plugged
207. acing out into holes on the right side of the right crankcase Push the needle bearing outer race until the face of the bearing is even with the end of the hole using a driver Special Tool Bearing Driver Set 57001 1129 9 14 CRANKSHAFT TRANSMISSION Crankcase e Apply a non permanent locking agent to the threads of e the bearing retainer bolt e Install the bearing retainer A Torque Bearing Retainer Bolts 11 N m 1 1 kgf m 97 in Ib Bearings B Race C Left Crankcase D e Apply silicone sealant A to the step of the oil separating chamber B in the left crankcase C Sealant Three Bond TB1207B e Apply a non permanent locking agent to the threads of the oil baffle bolt F e Install the oil baffle D on the chamber Front E Torque Oil Baffle Bolt 11 N m 1 1 kgf m 97 in Ib e Apply a non permanent locking agent to the threads of the bearing retainer bolts e Install the bearing retainers A Torque Bearing Retainer Bolts 11 N m 1 1 kgf m 97 in Ib Bearings B Race C Right Crankcase D e Install the following in the left crankcase Transmission Assy and Shift Drum Assy see Transmis sion Installation in this chapter Shift Fork and Shift Rod see Transmission Installation in this chapter Oil Pipe and Oil Return Pipe see Inside Oil Pipe Instal lation in the Engine Lubrication System chapter e Apply engine oil to the transmission gears ball bearings shift drum and cran
208. ad Connections Adapter R Adapter BK Front Ignition Coil BK gt Ground Rear Ignition Coil BK G gt Ground 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 or more times for one ignition coil Ignition Coil Primary Peak Voltage Standard Front 208 V or more Rear 192 V or more e Repeat the test for the other ignition coil x lf the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection in this section Crankshaft Sensors see Crankshaft Sensor Inspection in this section lf the ignition coils and crankshaft sensors are normal check the ECU see ECU Power Supply Inspection in the Fuel System DFI chapter ELECTRICAL SYSTEM 16 49 Ignition System Crankshaft Sensor Removal e Remove the alternator cover A see Alternator Cover Removal Installation in this chapter e Unscrew the holder bolt B and take off the crankshaft sensor lead holder C e Unscrew the screws D and take off the crankshaft sen sors with the grommet E Crankshaft Sensor Installation e Refer to the Alternator Stator Installation in this chapter Crankshaft Sensor Inspection e Remove
209. ad the voltage Interlock Operation Voltage Standard 4V or more x If the voltage is lower than the standard inspect the side stand switch starter lockout switch gear position switch and junction box x lf their parts are normality replace the ECU x lf the voltage is standard push the starter button OThen the starter motor should not turn when the starter system circuit is normality x If the starter motor turned ECU is defective Replace the ECU 2nd Check e 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 e Set the side stand on the ground then the engine will stop x If whichever may not be stopped inspect the gear posi tion switch starter lockout switch side stand switch and junction box x lf their parts are normality replace the ECU ELECTRICAL SYSTEM 16 53 Ignition System IC Igniter Inspection OThe IC igniter is built in the ECU A Damper B Battery Case C Groove D Front E e Refer to the Fuel System DFI chapter for ECU Inspec tion 16 54 ELECTRICAL SYSTEM Ignition System IC igniter in ECU Troubleshooting Beginning Inspect ECU and crankshaft sensors Do above inspections prove that IC igniter in ECU and crankshaft sensors are good Replace Does engine still ope
210. ail Brake Light Assembly Screws 1 2 0 12 11 in lb Tail Brake Light Lens Screws 1 2 0 12 11 in lb Tail Brake Light Mounting Nuts 5 9 0 60 52 in lb Timing Inspection Cap 1 5 0 15 13 in lb Turn Signal Light Lens Screws 1 0 0 10 8 9 in lb Turn Signal Light Mounting Screws 6 9 0 70 61 in lb Water Temperature Sensor 18 1 8 13 SS Water Temperature Switch 7 8 0 80 69 in lb SS 2 12 PERIODIC MAINTENANCE Torque and Locking Agent 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 dia mm EE N m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 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 PERIODIC MAINTENANCE 2 13 Specifications Item Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Air Cleaner Element 2 3 mm 0 08 0 12 in 950 50 r min rpm Paper filter Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount Permanent type antifreeze Green Soft water 50
211. ame Pipe Starter Motor Lead ECU Fit it into the battery case behind the case rib on the bottom Five Clamps Install the alternator outer cover and make sure the sheath of the harness is inside the cover 31 32 33 34 35 36 37 Front 39 6B097218W4 C Connect the ignition primary lead connec tor as shown Main Harness Strap main harness and California purge hose green Rear Turn Signal Taillight Lead Connec tor Sealed Battery Headlight Connector Run the rear harness under the pipe Left Side APPENDIX 17 23 Cable Wire and Hose Routing GBOS399BW4 Snap on Straps Front Brake Hose Holders Front Brake Hose Assembly Front Brake Calipers Handlebar Grommets Brake Hose Joint Run the front brake hose through the steering stem bracket Clamp Front SAN A eS a _ 17 24 APPENDIX Cable Wire and Hose Routing 6809723845 C APPENDIX 17 25 Cable Wire and Hose Routing LN A vat Le LS 4 tn DD S RE Gg EH A T SES SS SS iS Sis SS a CAS gt SSS h SER SC El M S UA SITS Main Harness Run it into the headlight body and inside the brake hose Throttle Cables Front Brake Hose Rear Brake Light Switch Connector BR BL leads under the radiator fan connec tor Radiator Fan Connector BK Y Y W BR W lead over the brake light switch con
212. 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 GP08020481 6P08003BS1 6P090006S1 ELECTRICAL SYSTEM 16 29 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 Y A 6P090007S1 e Check the electrolyte flow x 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 e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION 6P090008S1 Removal of the container before it is completely empty can shorten the service life ofthe battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery e Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum perf
213. and the oil seal C using the bearing driver set D Special Tool Bearing Driver Set 57001 1129 XXXXA 6K06003BS1 11 14 FINAL DRIVE Final Gear Case and Oil Pinion Gear Installation e The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact They must be re placed as a set e Check the tapered roller bearing see Tapered Roller Bearing Inspection in this chapter e Apply a hypoid gear oil to the roller bearings e Drive the tapered roller bearing A into the pinion gear housing B using the bearing driver set C Special Tool Bearing Driver Set 57001 1129 6K06011BS1 e Drive the tapered roller bearing outer race A into the pinion gear housing B using the bearing driver set C Special Tool Bearing Driver Set 57001 1129 e Insert the pinion gear A Olnstall the pinion gear with the tapered roller bearing as B one unit e Check the O ring C on the pinion gear joint D for any kind of damage x Replace it if necessary e Apply a hypoid gear oil to the O ring e Install the pinion gear joint shim s E and washer F FINAL DRIVE 11 15 Final Gear Case and Oil e Replace the pinion gear nut with a new one e Apply molybdenum disulfide oil solution to the threads and seating surface of the pinion gear nut OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease wit
214. ankshaft sensor peak voltage Replace Replace bad parts Peak voltage measurement is repeated 5 or more times Inspect 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Battery voltage 3 Crankshaft sensor peak voltage ECU is defective Replace bad parts or inspect the with KAWASAKI Hand Tester GP10090B F ELECTRICAL SYSTEM 16 45 Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plugs ignition coils or spark plug high tension cables while the engine is running or you could receive a severe electrical shock CAUTION 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 prevent IC igniter damage in the ECU Do not install the battery backwards The negative side is grounded This is to prevent damage to the IC igniter in the ECU and the diodes Ignition Coil Removal e Remove fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Remove Clamps A Primary Leads Ignition Coil Mounting Nuts B Frame Ground Lead C Ignition Coil 1 D Front E e Remove Clamps A Primary Leads Ignition Coil Mounting Nuts B Ignition Coil 2 C Front D Ignition Coil Installation e Connect the primary leads to the ignition coil terminals and run the high tension cables according to the
215. ard Bracket Bolt A Front Guard Bolt B Front Guard C e Tighten Torque Front Footboard Bracket Bolt 34 N m 3 5 kgf m 25 ft lb Rear Guard Removal e Remove Saddlebag see Saddlebag Removal in this chapter Rear Guard Bolt Upper A Rear Guard Bolt Cap and Bolt Middle B Rear Guard Bolts Lower C Rear Guard D 15 26 FRAME Rear View Mirrors Rear View Mirror Removal Other than European Model e Loosen the locknut A e Turn the rear view mirror stay B counterclockwise to re move the rear view mirror from the holder C Rear View Mirror Removal European Model e Loosen the lower hexagonal area A e Turn the rear view mirror stay B counterclockwise to re move the rear view mirror from the holder C CAUTION Do not force to tighten and or loosen the upper hexagonal area adapter A with a pair of span ners or wrench Disassembly of this area is not possible Non permanent locking agent B is already applied to the threads of this inner area Forcible loosening may damage the adapter and or the turning mechanism of the stay C Rear View Mirror Installation Other than European Model e Loosen the locknut all the way up e Screw the mounting area of the rear view mirror A into the holder B all the way then back it two turns out e Turn the stay to assure visibility to the rear with the rider sitting on the motorcycle and tighten the locknut C se cur
216. ase Disassembly in the Crankshaft Transmission chapter Primary Gear see Primary Gear Removal in the Crank shaft Transmission chapter e Remove Lower Chain Guide Bolts A Lower Chain Guide B e Take out the rear camshaft chain C GE16028BS1 ENGINE TOP END 5 31 Camshafts Rear Camshaft Chain Installation e Apply a non permanent locking agent to the threads of the chain guide bolts and tighten them to the specified torque Torque Camshaft Chain Guide Bolts 11 N m 1 1 kgf m 97 in Ib e Install the spark plug retainer see Front Camshaft Chain Installation in this section e Install the removed parts see appropriate chapters KACR Kawasaki Automatic Compression Release Inspection ODue to the simplicity of the KACR no periodic mainte nance is needed There are only two symptoms of prob lems with the KACR mechanism compression is not re leased during starting and compression is released dur ing running OThe cylinder compression is not released during starting abnormal the pin A stays within the cam B and will not push up the exhaust rocker arm e Remove the KACR unit and visually inspect the spring C x lf the spring is damaged deformed or missing replace the spring e Remove the spring and move the weights D back and forth Alf the weights do not move smoothly all the way replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rock
217. astener Nm kgf m ft lb Remarks 1 Rear Footboard Bracket Bolts 25 2 5 18 2 Tool Box 3 Battery Case 4 Front Fender 5 Rear Fender 6 Front Seat 7 Rear Seat G Apply grease 15 6 FRAME Exploded View FRAME 15 7 Exploded View No Fastener senate Remarks N m kgf m ft Ib 1 Tandem Grip Mounting Bolts 25 2 5 18 2 Saddlebags 3 Windshield 4 Trim other than US Canada and Australia 15 8 FRAME Special Tools Attachment Jack 57001 1398 Jack 57001 1238 o e Di E Ei N ba e H Di FRAME 15 9 Seats Rear Seat Removal e Remove the rear seat bolt A and move the rear seat backwards B and remove it Rear Seat Installation e Slip the hook A of the rear seat into the bracket B on the rear fender e Tighten the rear seat bolt Front Seat Removal e Remove the rear seat see Rear Seat Removal in this section e Remove the front seat bolt A e Pull the front seat B backwards and up then remove it Front Seat Installation e Insert the hook A of the seat under the fuel tank bracket e Tighten the front seat bolt e Install the rear seat see Rear Seat Installation in this sec tion Front B 15 10 FRAME Side Covers Left Side Cover Removal e Insert the ignition switch key A into the left side cover and turn the key clockwise until the key slot is vertical e Pull B the rear part of the left side cover push
218. ate Thickness Standard 3 3 3 5 mm 0 13 0 14 in Service Limit 3 1 mm 0 12 in Friction or Steel Plate Warp 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 lf any friction plate is warped over the service limit re place it and measure the spring plate gap and adjust it if necessary Alf any steel plate is warped over the service limit replace it with a new one of the same thickness Friction or Steel Plate Warp Standard 0 2 mm 0 008 in or less Service Limit 0 3 mm 0 01 in Clutch Spring Height Measurement e Measure the height B of the clutch spring A x If the spring height is less than the service limit it must be replaced Clutch Spring Height Standard 4 3 mm 0 17 in Service Limit 4 0 mm 0 16 in Clutch Housing Finger Inspection e Visually inspect the fingers A of the clutch housing where the tangs B of the friction plates hit them x If they are badly worn or if there are groove cuts where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged and measure the spring plate gap and adjust it if necessary GFO606028S1 GF13010781 6F13000BS1 6 18 CLUTCH Clutch Outer Clutch Hub Spline Ins
219. ater Temperature Warning Indicator LED Light Connections Battery Negative Lead to Terminal 4 OThe water temperature warning indicator LED light A and symbol B in the LCD should go on x lf the LED light and or symbol do not go on replace the meter unit 6P17102BS2 C 6P17103BS2 C ELECTRICAL SYSTEM 16 87 Meter Gauge Indicator Light Inspection e Connect the leads in the same circuit as for the LCD Seg ments Inspection Check 2 Neutral Indicator Light e Connect the lead to the terminal 1 and battery negative lead Neutral Indicator Light Connections Battery Negative Lead to Terminal 1 OThe neutral indicator light A should go on Alf the indicator light does not go on inspect the bulb e Check conductivity of the bulb with the hand tester x If the bulb is open replace the bulb x Even if the bulb is replacement but the indicator light does not go on replace the meter unit GP17104BS2 C 16 88 ELECTRICAL SYSTEM Meter Gauge Turn Signal Indicator Light e Connect the lead to the terminal 13 and 14 as follows Neutral Indicator Light Connections Battery Positive Lead to Terminal 13 Battery Negative Lead to Terminal 14 or Battery Positive Lead to Terminal 14 Battery Negative Lead to Terminal 13 OThe turn signal indicator light A should go on x If the ind
220. ation Pivots Lubricate with Motor Oil Rear Brake Rod Joint Points Lubricate with Grease Throttle Inner Cable Upper Ends A Clutch Lever Pivot Apply silicone grease Brake Lever Pivot Apply silicone grease Brake Pedal Pivot Side stand 6004040351 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cable Lubricate with Cable Lubricant Choke 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 Bolts Nuts and Fastener 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 x lf 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 in this chapter For each fastener first loosen it by 1 2
221. ation Direction B OThe front rim is no right and left distinction Olnstall the rear tire on the rim so that the damper faces left e Position the tire on the rim so that the valve A is at 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 commer cially 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 Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life 6J04017BS1 GJO5003BS1 GJO5005BS1 10 18 WHEELS TIRES Tires e Check to see that the bead lines A on both sides of the tire sidewalls are parallel with the rim flanges x lf the rim flanges and tire sidewall bead lines are not par allel 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 stan
222. ator with coolant see Coolant Change in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat see Thermostat Removal in this section and inspect the thermostat valve at room tem perature Alf the valve is open replace the valve with a new one e To check valve opening temperature suspend the ther mostat A and an accurate thermometer B in a container of water with the heat sensitive portions C in almost the same depth NOTE OThe thermostat must be completely submerged and the thermostat and thermometer must not touch the con tainer sides or bottom e Gradually raise the temperature of the water while stirring the water gently for even temperature Alf the measurement is out of the range replace the ther mostat Thermostat Valve Opening Temperature 58 62 C 136 144 F GD09020282 C 4 18 COOLING SYSTEM Hoses 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 Install the clamps A as near as possible to the hose end to clear the raised rib on the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts Torque Water Hose Clamp Screws 2 5 N m 0 25 kgf m 22 in lb ZL SSS aO 6D100201S1 Hose
223. be Removal in the Frame chap ter but remove the downtube with the right front foot board and rear master cylinder left installed e Unscrew the clutch cover bolts 18 A e Using the pry points A take the cover B off the crankcase NOTE ODO not remove the damper cover C Clutch Cover Installation e Replace the clutch cover gasket with a new one e Tighten Torque Clutch Cover Bolts 11 N m 1 1 kgf m 97 in Ib L 35 mm 1 3 in A L 30 mm 1 2 in B L 25 mm 1 0 in C e Install the removed parts see appropriate chapters 6 12 CLUTCH Clutch Clutch Removal NOTE OUse an air impact wrench for removal of the clutch hub nut e Remove the clutch cover see Clutch Cover Removal in this section e Remove the retaining ring A using a cutout portion C and take the operating plate B out of the clutch assem bly Screw Driver D e Remove Washer A Spring Plate Pusher B Needle Bearing Washer e Unscrew the clutch hub nut A by using an air impact wrench e Take the clutch spring B and the clutch spring holders C out of the clutch hub e Take the back torque limiter springs A and the clutch spring plate out of the clutch housing e Take the friction steel plate A and outer clutch hub B out of the clutch housing CLUTCH 6 13 Clutch e Take the inner clutch hub A collar B washer C and clutch housing D out of the crankca
224. bly 5 49 Rear Camshaft Chain Removal 5 30 Chamber Identification 5 50 Rear Camshaft Chain Installation 5 31 5 2 ENGINE TOP END Exploded View A BNO SILA SS IIA SITAS CSS 6E021408W5 C ENGINE TOP END 5 3 Exploded View No Fastener Torque Remarks N m kgf m ft lb 1 Air Suction Valve Cover Bolts 7 4 0 75 65 in lb 2 Plugs 20 2 0 15 L 3 Rocker Case Cover Bolts 8 8 0 90 78 in lb S 4 Rocker Case Bolts 8 8 0 90 78 in lb S 5 Rocker Case Nuts M12 78 8 0 58 MO S 6 Rocker Case Nuts M8 25 2 5 18 S 7 Spark Plug Retainers 12 1 2 104 in lb 8 9 10 AD EO G L MO R S Follow the specific tightening sequence SS Apply silicone sealant Kawasaki Bond 92104 0004 Air Suction Valves HLA Hydraulic Lash Adjuster Oil Filters Vacuum Switch Valve Apply adhesive Apply engine oil Apply grease Apply a non permanent locking agent Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 Replacement Parts 5 4 ENGINE TOP END Exploded View ENGINE TOP END 5 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Camshaft Chain Guide Bolts 11 1 1 97 in lb L 2 Camshaft Chain Guide Retainer Bolts 11 1 1 97 in lb L 3 Camshaft Sprocket Bolts
225. bsorber oil leak year o e e 2 29 inspect Swingarm pivot lubricate e 2 29 Steering System Steering play inspect year e e e e 2 30 Electrical System Lights and switches operation inspect Headlight aiming inspect Side stand switch operation inspect year year year Engine stop switch operation inspect Others Chassis parts lubricate Bolts and nuts tightness inspect year year For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping CAL California Model PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever ODOMETER READING come x 1 000 km first x 1 000 mile y CHANGE REPLACE ITEM Air cleaner element Engine oil Fuel hose Coolant Radiator hose and O ring Brake hose and pipe Brake fluid Rubber parts of master cylinder and caliper Spark plug Final gear case oil Clutch hose and pipe Clutch fluid Clutch slave cylinder piston seal For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping 2 6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables
226. by using a bearing driver e First press each right bearing A in until it bottoms out Special Tool Bearing Driver Set B 57001 1129 e Next install the following New Circlip Distance Collar Left Bearing 6J06060651 605000451 10 20 WHEELS TIRES Hub Bearings Wheel Bearings OReplace the circlips with new ones Special Tool Inside Circlip Pliers 57001 143 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 Hub Bearings Inspection OSince the hub bearings are made to extremely close tol erance the clearance cannot 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 x 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 Hub Bearings Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J05000581 GJ060305S1 FINAL DRIVE 11 1 Final Drive Table of Contents EXploded BEE 11 2
227. ce 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 rear brake reser voir body A Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road Alf the brake operation is insufficiency inspect the brake system A WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety Brake Light Switch Operation e Turn on the ignition switch e The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures x lf it does not adjust the brake light switch 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 Bottom View E CAUTION 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 item Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light Bulb see Tail Brake Light Removal in the Electrical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System
228. circlip A with a new one e Install Right Front Footboard Damper B Right Front Footboard C Bank Sensor D Bank Sensor Bolts E e Insert the pin F from the front side of the footboard bracket G e Install the new circlip Rear Footboard Removal Installation e Remove Allen Bolts A Rear Footboard B e Tighten Torque Rear Footboard Bracket Bolts 25 N m 2 5 kgf m 18 ft Ib Rear Footboard Disassembly e Remove the rear footboard see Rear Footboard Re moval in this section e Remove Circlip A Pin B Rear Footboard Assembly e Replace the circlip A with a new one e Install Left Rear Footboard Damper B Left Rear Footboard C Left Rear Footboard Cover D Cover Bolt E e Install the spring F and spring cap G from the rear side of the left rear footboard e Insert the pin H from the front side of the footboard bracket I e Install the new circlip 6014003BS1 G014005BS1 15 18 FRAME Footboard e Replace the circlip A with a new one e Install Right Rear Footboard Damper B Right Rear Footboard C Right Rear Footboard Cover D Footboard Cover D Cover Bolt E e Install the spring G and spring cap F from the front side of the right rear footboard e Insert the pin H from the front side of the right front foot board e Install the new circlip GO14006BS1 FRAME 15 19 Side Stand Side Stand Removal e Raise the
229. ck the screen carefully for any damage holes and broken wires Alf the screen is damaged replace it e Be sure to put in the oil screen with the rubber gasket end inside e Replace the screen plug O ring with new one Torque Oil Screen Plug 20 N m 2 0 kgf m 14 ft lb OThe oil in the filter can be drained by removing the filter see Oil Filter Replacement in this chapter e Replace the drain plug gasket with a new one Torque Engine Oil Drain Plug 20 N m 2 0 kgf m 14 ft lb Oil Filter 18 N m 1 8 kgf m 13 ft lb 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the oil filler cap A with the filler cap driver B and pour in the specified type and amount of oil Clutch Cover C Special Tool Filler Cap Driver 57001 1454 Torque Oil Filler Cap 1 5 N m 0 15 kgf m 13 in Ib Engine Oil Type API SE SF or SG SAE 20W 50 API SH or SJ with JASO MA SAE Dowd 20W 40 Viscosity SAE 10W 40 SAE 10W 50 ae Amount 2 9L 3 1 US qt when filter is not removed 3 1 L 3 3 US qt when filter is removed SAE 10W 30 I I I 3 5 L 3 7 US qt when engine is completely 20 10 0 10 20 30 40 0 disassembled and dry 4 14 32 50 68 86 oun 6S09010BS1 C NOTE 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 Oil Filter Replacement e Dra
230. coils e Remove the needle adapters e Apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connector GC17724BS1 3 80 FUEL SYSTEM DFI FI Indicator LED Light Inspection Flow Chart SE i Repair or replace Turn the ignition switch ON the meter or wiring Does the LED light No unlit Check the LED light oil go on pressure switch and the wiring Yes goes on Run the engine with idling Yes goes off eae Does the LED light go off DFI and ignition systems are considered to be normal o stays on Does the LED light go off No stayed on DFI and ignition systems after 10 20 seconds are abnormal Turn the ignition switch OFF Turn the ignition switch OFF End of inspection Go to self diagnosis DFI and ignition systems Ask the rider if the problem are normal occurs again Yes occurs Replace the ECU GC17212B F FUEL SYSTEM DFI 3 81 FI Indicator LED Light The Fl indicator LED light A goes ON when the igni tion switch is turned ON and the LED light goes OFF when the engine oil pressure is high enough the engine is run ning This is to ensure that the Fl indicator LED light has not burned out and the DFI system and the ignition system function properly LED Light Inspection e Refer to the Meter Gauge section in the Electrical System chapter for LED Light
231. ction e Connect the leads in the same circuit as for the LCD Seg ments Inspection Check 2 Fuel Level Warning Indicator LED Light e Connect an about 30 Q resistor A to the terminal 15 and battery negative lead Fuel Level Warning Indicator LED Light Connections Battery Negative Lead to Terminal 15 OThe fuel level warning indicator LED light B should go on Alf the fuel level warning indicator LED light does not go on replace the meter unit Oil Pressure Warning Indicator LED Light and LCD Symbol e Connect the lead to the terminal 3 and battery negative lead Oil Pressure Warning Indicator LED Light Connections Battery Negative Lead to Terminal 3 OThe oil pressure warning indicator LED light A and sym bol B in the LCD should go on Alf the LED light and or symbol do not go on replace the meter unit Bi ole i 4O GP17100BS2 C 6P17101BS2 C 16 86 ELECTRICAL SYSTEM Meter Gauge FI Indicator LED Light and LCD Symbol e Connect the lead to the terminal 2 and battery negative lead FI Indicator LED Light Connections Battery Negative Lead to Terminal 2 OThe FI indicator LED light A and symbol B in the LCD should go on If the LED light and or symbol do not go on replace the meter unit Water Temperature Warning Indicator LED Light and LCD Symbol e Connect the lead to the terminal 4 and battery negative lead W
232. ction wiring open 21 JULITIL Crankshaft sensor 1 malfunction wiring open or short 22 JULIUL Crankshaft sensor 2 malfunction wiring open or short 31 JUULTL Vehicle down sensor malfunction wiring open or short 41 JUUULIL Injector 1 malfunction wiring open or short 42 JUUULJUL Injector 2 malfunction wiring open or short 45 JUUU LIU UU UU Fuel pump malfunction wiring open or short 54 A Ignition coil primary winding 1 malfunction wiring open or short 52 aaa Ignition coil primary winding 2 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 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 1 for Front Cylinder 2 for Rear Cylinder FUEL SYSTEM DFI 3 43 Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI electronical or the ignition system parts have troubles Service Output Signal Usable Codes Parts Range or Criteria Backups by ECU x If the throttle sensor system fails the signal is out of the usable range wiring short or open Throttle Throttle Valve Opening ha Ar Eeer 11 Sensor Angle a 4
233. ction Box Ignition Fuse 10 A Ignition Switch Main Fuse 30 A Battery 16 90 ELECTRICAL SYSTEM Water Temperature Warning System Water Temperature Warning System Check The water temperature warning LED light goes on when the ignition switch is turned on and goes off soon to ensure that its circuit functions properly and the warning LED light has not burned out The warning LED light also goes on whenever the coolant temperature rises to 113 117 235 243 F when the motorcycle is in operation If it stays on stop the engine and check the coolant level in the reserve tank after the engine cools down e Remove Bolts A Regulator Rectifier Bracket B e Inspect the water temperature warning LED light and the system wiring OTurn on the ignition switch ODisconnect the water temperature switch lead A then ground it to the frame or engine using an auxiliary lead If the water temperature warning LED light is lit inspect the water temperature switch B see Water Temperature Switch Inspection in this chapter Replace the switch if damaged If the warning LED light is not lit check the warning LED light and wiring ELECTRICAL SYSTEM 16 91 Switch and Sensors Fuel Level Sensor Inspection gt e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter e Open the clamps A e Remove Bolts B Fuel Level Sensor C e Check that the float moves up and down smoothly with
234. ction in this chapter for re moval installation of the throttle cables and choke cable Cable Lubrication and Inspection e Whenever the choke cable or the throttle cables are re moved or in accordance with the Periodic Maintenance Chart lubricate the these cables Refer to the General Lubrication in the Periodic Maintenance Chapter OUse a commercially available pressure cable lubricator to lubricate these cables OWith the cable disconnected at both ends the cable should move freely in the cable housing FUEL SYSTEM DFI 3 95 Throttle Body Assy Idle Speed Check e Refer to the Idle Speed Inspection in the Periodic Main tenance Chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance Chapter High Altitude Performance Adjustment OAny modification is not necessary in this model since the atmospheric pressure sensor senses pressure change due to high altitude and the ECU compensates the change Throttle Body Assy Removal e Remove the fuel tank see Fuel Tank Removal in this chapter Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately
235. ctive or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective ELECTRICAL SYSTEM 16 39 Charging System Alternator Inspection There are three types of alternator failures short open lead burned out or loss in rotor magnetism A short or open in one of the stator coil lead 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 leav ing it near an electromagnetic field or just by aging will re sult in low output e To check the alternator output voltage do the following procedures ORemove the alternator outer cover and disconnect the outside alternator connector A OConnect the hand tester to the outer as shown Special Tool Hand Tester 57001 1394 OStart the engine ORun it at 3 000 rpm of the engine speed ONote the voltage readings Alternator Output Voltage Tete T Range Tester to Tester to 3 000 rpm 250 V AC One black lead Another black lead 60 90 V x If the output voltage shows the value in the table the alter nator operates properly and the regulator rectifier is dam aged A much lower reading than the value in the table indicates that the alternator is defective ORepeat the test for the other black leads Hand Tester A e Check the stator coil resistance as follows OStop the engine OConnect
236. ctor B is disconnected during engine removal Se e Unscrew the front gear case bolts C and remove the de front gear case D GKOSO19BS1 OThe cam follower A and the damper spring B come off with the gear case e Check that the shift shaft oil seal and replace it if dam aged Front Gear Case Installation e Tighten the front gear case bolts as follows OTighten the bolt 1 and bolt 2 alternately until contact to the mating surface of the left crankcase OTighten the bolts in the order shown Torque M8 Front Gear Case Bolts 1 5 29 N m 3 0 kgf m 21 ft lb M6 Front Gear Case Bolts 6 11 12 N m 1 2 kgf m 104 in Ib e Install the removed parts see appropriate chapters GK09020BS2 Front Gear Case Disassembly e Remove Front Gear Case see Front Gear Case Removal in this section Cam Follower A Damper Spring B Rubber Boot C 11 26 FINAL DRIVE Front Bevel Gears e Remove the driven gear assy mounting bolts A and pry the assy B off the case ORaise the driven gear using the following pry points A e Remove the drive gear assy as follows OPry off the gear case cap A with a tool OPry open the drive gear nut A with a small chisel Olnstall Damper Spring Cam Follower B OUnscrew the drive gear nut while holding the drive gear shaft with the drive shaft holder C special tool Front Gear Case D Socket Wrench E Vise F Special To
237. d Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change in the Periodic Maintenance chap ter SUSPENSION 13 1 Suspension Table of Contents Exploded Vi Wir A what Rata RE Ae a he ie ne 13 2 Specifications ici dag A Genin idence 13 6 Special Tol EE 13 7 Front FORK cil TE 13 8 Fork Oil Change Each Fork Leg 48488848 einen tiennent 13 8 Front Fork Removals ia eaaa aa iii 13 9 Front Fork Installation 13 10 ProntFork EE Le A Ath dian baa ea eee Aue 13 11 Front FOCA SOM E 13 12 Inner Tube Outer Tube Inspection se 13 13 Dust Seal Inspechon a a a aa a a a e a Aa Ea aaa Ra aa E eaaa ATE a aaa 13 14 Spring TORSO ia sedate ess een e E veel AAA A S a 13 14 Rear Shock Absorber Air Type sise 13 15 Rebound Damping Adjustment coco a era 13 15 PUPP PSS SURG Ad SUMO nt sli diia 13 15 Rear Shock Absorber Removal sise 13 16 Rear Shock Absorber Installation 13 17 Rear Shock Absorber Inspection rre erener ene 13 17 Rear Shock Absorber Scrapping ococccicccininnniconoconccnn cnn cnn 13 18 EELER TERRES CE EE EE Swingarm ReMOVA euer nn atic ee dt en Big Radiat ct ae Swingarm Installation Swingarm le RE EE 13 20 Swingarm Bearing INStallAton 22 2 Jesse scecoeecuvetsdecq
238. d replace see chapter 16 Engine oil level too high Repair see chapter 7 Spark plug dirty broken or gap maladjusted Clean spark plugs and adjust plug gap see chapter 2 Stumble inspect See chapter 3 Inspect see chapter 3 inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and repair fuel line 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 Clean spark plugs and adjust plug gap see chapter 2 inspect ses chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 FUEL SYSTEM DFI 3 35 DEI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Inspect and replace see chapter 5 Inspect and replace see chapter 5 er fre inspect see chapter 3 Run on dieseling S Ignition switch trouble Inspect and replace see cha
239. d stop air flow Spring A Diaphragm B Valve C Low Vacuum D Secondary air flows E GE04020581 6E04023BS1 ENGINE TOP END 5 17 Clean Air System x If the vacuum switch valve does not operate as described replace it with a new one NOTE OTo check air flow through the vacuum switch valve just blow through the air cleaner hose C Vacuum Switch Valve Closing Pressure Open Close Standard 49 3 65 3 kPa 370 490 mmHg High Vacuum A Secondary air cannot flow B Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the right air cleaner base vacuum switch valve throttle body and air suction valve covers x lf they are not correct them Replace them if they are damaged 6E04024BS1 5 18 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type cam 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 sio
240. dard 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 Tire Air Pressure Inspection in the Periodic Maintenance chapter e Install the air valve cap e Install the brake disc A so that the marked side B faces out e Apply a non permanent locking agent and tighten the brake disc bolts C Torque Front Brake Disc Bolts 27 N m 2 8 kgf m 20 ft Ib Rear Brake Disc Bolts 27 N m 2 8 kgf m 20 ft lb e Adjust the wheel balance A WARNING Check and balance the wheel when a tire is replaced with a new one New tires are slippery and may cause loss of control and injury A break in period of 160 km 100 mile is necessary to establish nor mal tire traction During break in avoid sudden and maximum braking and acceleration and hard cor nering 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 secondary damage not visible from exter
241. de Stand Switch Operation Inspection e Inspect the side stand switch A operation accordance to below table Side stand Switch Operation Side Gear Clutch Engine Endine Run Stand _ Position Lever Start 9 Continue running Continue GIW P Neutral Pulled in Starts y running Neutral Released Starts Doesn t Continue Released start running Continue running Down Neutral Released Starts Continue running Down Neutral Pulled in Starts Continus running Down Released POERI Stops start Down Pulled in Doesnt Stops start x 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 10 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 Control Relay see Starter Relay Inspection in the Electrical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Starter Control Relay see Electrical System cha
242. decelerator cable C until there is no play OTighten the locknut against the adjuster OTurn the adjuster of the accelerator cable D until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster Idle Speed Inspection e Start the engine and warm it up thoroughly OAt first the engine will run fast to decrease warm up time fast idle OGradually the fast idle will lower to a certain RPM auto matically This is the idle speed e With the engine idling turn the handlebar to both sides x lf handlebar 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 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 e Check the idle speed x If the idle speed is out of the specified range adjust it see Idle Speed Adjustment in this chapter Idle Speed Standard 950 50 r min rpm Idle Speed Adjustment e Start the engine and warm it up thoroughly OWait until fast idle speed lowers to a certain value 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 specified range Readjust if necessary Front B 2 18 PERI
243. dem Grips B e Tighten Torque Tandem Grip Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Frame Inspection e Visually inspect the frame A for cracks dents bending or warp x If there is any damage to the frame replace it A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it G009018BS1 ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Electrical Parts Location Exploded View Specifications noo0aannanennneeeaeaenne Special Tools and Sealants Wiring Diagram United States and Wiring Diagram Other than United States Canada and Australia Servicing Precautons Electrical Wiring Wiring Inspection A soda Se Battery Removal s s s Battery Installation Battery Activation Precautions ici a ter ln Le E Charging Condition Inspection Refreshing Charge Charging System Alternator Outer Cover Removal Alternator Outer Cover Installation ss messnssiestass Alternator Cover Removal Instal Alternator Cover Assembly Alternator Inner Cover Removal Alternator Inner Cover Installation Alternator Rotor Removal Alternator Rotor Installation Alternator Outside Stator Removal Alternator Outside Stator Installation Alter
244. des BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Light green W White DG Dark green O Orange Y Yellow ELECTRICAL SYSTEM 16 25 Servicing Precautions OElectrical Connectors Female Connectors A Male Connectors B GPO070003S1 16 26 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If 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 e Check that the connectors are not loose e Check the wiring for continuity OUse the wiring diagram to find the ends of the wire which is suspected of being a problem OConnect the hand tester between the ends of the wires Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range and read the tester x If the tester does not read 0 Q the lead is defective Re place the wire or the wiring harness B if necessary GPO7000BS1 ELECTRICAL SYSTEM 16 27 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch in ON as this could damage the ECU Electronic Con trol Unit Never reverse the connections of the battery this could damage the E
245. ding between any two 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 Alf there is any reading at all the armature has a short and the starter motor must be replaced Special Tool Hand Tester 57001 1394 GP110608S1 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 mo tor components 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 Assy Inspection e Using the x 1 Q hand tester range measure the resis tance as follows Terminal Bolt and Positive Brushes A Brush Plate and Negative Brushes B Plastic C OThe reading should be zero Alf there is not close to zero ohms the brush lead has an open Replace the terminal bolt assembly and the brush holder assembly 16 60 ELECTRICAL SYSTEM Starter Motor 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 Negative Brush Holders B Terminal Bolt and Yoke C OThe reading should be infinite Q x lf there is any reading the brush holder assembly and or terminal bol
246. ding PI 70 cmHg barometer reading Vv 3 2 V digital volt meter reading then Pv 70 8 62 cmHg abs Plot this Pv 62 cmHg 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 04 3 49 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 Pv 24 55 cmHg IS LTE EE La 0 ES A EM cmHg 40 45 50 5 25 30 35 kPa 32 35 40 50 60 70 73 ID lt gt TO gt Pv abs GC170349 3 3 52 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Pv 55 86 cmHg a Pv abs 115 6017035083 ID Idling Ps Standard Atmospheric Pressure absolute Pv Throttle Vacuum absolute ST Standard of Sensor Output Voltage v TO Throttle Full Open UR Usable Range of Sensor Output Voltage v Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading FUEL SYSTEM DFI 3 53 Inlet Air Pressure Sensor Service Code 12 123456 7 8 910111213 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 GC17701BW2 C 1 ECU 2 Inlet Air Pressure Sensor 3 54 FUEL SYSTEM DFI Inlet Air Temperature Sensor Service Code 13 Removal Installation CAUTION Nev
247. djust plug gap see chapter 2 Starting technique faulty When flooded don t crank engine with throttle fully opened FUEL SYSTEM DFI 3 31 DEI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter No spark or spark weak Ignition and engine stop switches not ON Turn both switches ON Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral whether side stand up or not and gear not in neutral whether gear in neutral or not inspect see chapter 3 inspect see chapter 3 Inspect and charge see chapter 16 Spark plug dirty broken or gap maladjusted Clean spark plug and adjust plug gap see chapter 2 Spark plug cap or high tension wiring trouble Inspect the ignition coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect the cap see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Neutral starter lockout or side stand switch Inspect each switch see chapter 16 trouble Crankshaft sensor trouble Inspect see chapter 16 Ignition coil trouble Inspect see chapter 16 Ignition switch shorted Inspect and replace see chapter 16 Engine stop switch shorted Inspect and repair or replace see chapter 16 Starter system wiring shorted or open Inspect and repair or replace see chapter 16 Main 30 A or
248. djustment The rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions The numbers on the adjuster show the setting position e Turn the adjuster A until the desired number B OThe standard adjuster setting is No II for an average build rider of 68 kg 150 Ib with no passenger and no acces sories Alf the damper setting feels too soft or too stiff adjust it in accordance with the following table Rebound Damping Adjustment Adjuster Damping on Setting Load Road Speed Position Force Weak Soft Light Good Low Il 1 1 1 1 1 II y II Strong Hard Heavy Bad High A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Air Pressure Adjustment The air pressure in the rear shock absorbers can be ad justed for different road and loading conditions The following table shows an example of air pressure ad justment To obtain stable handling and a suitable ride ad just the air pressure as indicated The standard air pressure is atmospheric pressure for an average build rider of 68 kg 150 Ib with no passenger and no accessories Ordi narily the heavier the total load becomes the higher the air pressure should be set Air Pressure Adjustment Air Pressure Setting Load Road Atmospheric Pressure Soft Light Good
249. e Frame chapter e Connect the hoses to the separator e Disconnect the breather hose from the separator and in ject about 20 mL 0 68 US oz of gasoline A into the separator B through the hose fitting e Disconnect the evaporative fuel return hose C from the fuel tank D e Run the open end of the return hose into the container level with the tank top E e Start the engine and let it idle x If the gasoline in the separator comes out of the hose the separator works well If it does not replace the separator with a new one FUEL SYSTEM DFI 3 113 Evaporative Emission Control System GC130188 4 C Fuel Tank White Hose Vacuum Throttle Body Green Hose Purge Lower Air Cleaner Duct Canister Band for Canister Inlet Red Hose Rear Return Fitting Band for Separator 12 Bracket 13 Separator 14 Blue Hose Breather 15 Blue Hose Front Breather PANA Or a XX ao COOLING SYSTEM 4 1 Cooling System Table of Contents EXPO WA 4 2 eet le TEE 4 4 Special Tools and Sealant aenn nentee eneee 4 5 Coolant Flow Carts ici dree SCENE dadd 4 6 A O 4 8 Coolant Deterioration Inspechon ss 4 8 Coolant Level Inspechon sis 4 8 Coolant DraininN tai dis 4 8 All EE 4 8 Pressure Testing 0d 4 8 Cooling System FISHING sess ae quon en Nan a iria 4 9 E e ENEE 4 10 Water PUMp Re MOV alain aa eerie
250. e Bearing A Circlip B Front Gear Case see Front Gear Case Installation in this chapter Special Tool Outside Circlip Pliers 57001 144 Front Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load the tapered roller bearings must be properly preloaded Also the backlash the distance one gear will move back and forth without moving the other gear and tooth contact pattern of the bevel gears must be cor rect to prevent the gears from making noise and being dam aged Above three adjustments are of critical importance and must be carried out in the correct sequence and method OPreload adjustment is necessary whenever the driven gear bolt 2 loosened even if the purpose is not to replace the parts FINAL DRIVE 11 31 Front Bevel Gears D Ih IZAN D d MAN GE ja A SR ES d SIAN a E A di VS WARNES KS SS SK y SOS SS Sab EN JN Fad LS el Backlash related Parts 1 Drive Gear 2 Driven Gear Bolt 3 Drive Gear Shim s 4 Ball Bearing 5 Drive Gear Shaft 6 Front Gear Case 7 Driven Gear 8 Tapered Roller Bearing 9 Driven Gear Shim s 10 Driven Gear Bearing Housing 11 Driven Gear Joint Preload related Parts 12 Collar Preload Adjustment 13 Spacer Preload Adjustment 14 Tapered Roller Bearing 11 32 FINAL DRIVE Front Bevel Gears Front Bevel Gear Adjustment a OWhen any of
251. e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter GP18020282 C GP18141BS1 ELECTRICAL SYSTEM 16 95 Switch and Sensors Water Temperature Switch Inspection e Remove the water temperature switch e Suspend the switch A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend an accurate thermometer B with heat sensitive portions C located in almost the same depth NOTE OThe switch 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 the oil gently for even temperature e Using the hand tester measure the internal resistance of the switch across the terminal and the body at the tem peratures shown in the table x If the measurement is out of the range replace the switch Water Temperature Switch Resistance ORising temperature aP18020352 From OFF to ON at 113 117 C 235 243 F OFalling temperature From ON to OFF at 108 C 226 F temperature less than ON temperature ON Less than 0 5 Q OFF More than 1 MQ 16 96 ELECTRICAL SYSTEM Switch and Sensors Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms
252. e Finger tighten the clutch slave cylinder bolts e Remove the band from the clutch lever and release the clutch lever Geo P GF10004BS1 6 10 CLUTCH Clutch Slave Cylinder e Tighten Torque Clutch Slave Cylinder Bolts A 6 9 N m 0 70 kgf m 61 in Ib OPut the clamp B together the clutch slave cylinder bolt and bend along the slave cylinder with the end of the clamp straight to the engine side as shown in the figure This clamp is to prevent the edge of the slave cylinder from damaging the wire not to clamp the wire e Replace the washers on each side of the clutch hose fit ting with new ones e Tighten the banjo bolt C to the specified torque Torque Clutch Hose Banjo Bolt Lower 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the master cylinder reservoir and bleed the air in the clutch line e Check the clutch operation Clutch Slave Cylinder Disassembly Assembly e Refer to the Clutch Slave Cylinder Piston Seal Replace ment in the Periodic Maintenance chapter CLUTCH 6 11 Clutch Clutch Cover Removal e Raise the rear wheel off the ground see Rear Wheel Re moval in the Wheels Tires chapter e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Right Front Guard see Front Guard Removal Installa tion in the Frame chapter Front Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Downtube see Downtu
253. e Fuel Tank Removal in this chapter e Disconnect the atmospheric pressure sensor connector A e Remove the sensor nut B e Remove the atmospheric pressure sensor C Front D Installation NOTE OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except for different wiring and no hose e Install the atmospheric pressure sensor A OThe stopper B must not be on the sensor holder C Rear View D e Tighten the atmospheric pressure sensor nut securely e Install the fuel tank see Fuel Tank Installation in this chap ter GC17698BS1 Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the throttle sensor or the inlet air pressure sensor e Turn the ignition switch OFF e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Connect a digital meter A to the connector B using two needle adapters C Special Tool Needle Adapter Set 57001 1457 GC17717BS1 Atmospheric Pressure Sensor Input Voltage Connections to ECU Meter gt BL W lead terminal 35 Meter gt BR BK lead terminal 11 e Measure the input voltage to the sensor with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard 4 75 5 25 V DC e Turn the ignition switch OFF x
254. e Gauge 5 kgf cm 57001 125 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e 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 oil pressure relief valve and or crankshaft bearing wear and con rod big end bearing insert wear im mediately x If the reading is much higher than the standard check the oil screen first and the oil passages for dirt or clogging Also replace the oil filter Oil Pressure Standard 340 440 kPa 3 5 4 5 kgf cm 50 64 psi 2 000 r min rpm oil temperature 90 C 194 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns from hot engine oil that will drain through the oil passage when the plug is re moved e When installing the oil pressure switch apply silicone sealant to the threads of the switch and tighten it to the specified torque Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb e Apply grease to the oil pressure switch terminal screw Torque Oil Pressure Switch Terminal Screw 1 5 N m 0 15 kgf m 13 in lb e Connect the oil pressure switch lead and slide back the rubber boot to the original position 7 16 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Inspection e Remove the relief Valve see O
255. e 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 CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly 5 16 ENGINE TOP END Clean Air System Vacuum Switch Valve Removal e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Pull off the hoses A and take out the vacuum switch valve B Vacuum Switch Valve Installation e Install the vacuum switch valve A so that the inlet vac uum hose B faces rear side e Route the hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Vacuum Switch Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Vacuum Switch Valve Unit Test e Remove the vacuum switch valve see Vacuum Switch Valve Removal in this section e Connect a commercially available vacuum gauge A and syringe B or fork oil level gauge to the vacuum hoses as shown Special Tool Fork Oil Level Gauge 57001 1290 Air Flow C e Gradually raise the vacuum lower the pressure applied to the vacuum switch valve and check the valve opera tion When the vacuum is low the vacuum switch valve should permit air to flow When the vacuum raises to valve closing pressure it shoul
256. e checked for a broken or badly shorted winding with the hand tester special tool NOTE OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Disconnect the crankshaft sensor lead connector e Set the hand tester A to the x 100 Q range and wire it to the crankshaft sensor lead connector B Connections Tester Connections Front Crankshaft Sensor BRIX lt gt BK Rear Crankshaft Sensor BKR lt gt BKW x If there is more resistance than the specified value the coil has an open wire and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance Standard 380 560 Q 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 assy 6P110006S1 ELECTRICAL SYSTEM 16 51 Ignition System Ignition Timing Inspection e Remove the alternator outer cover see Alternator Outer Cover Removal in this chapter e Remove the timing inspection cap A Special Tool Filler Cap Driver 57001 1454 e Attach the timing light A to the front ignition coil lead in the manner prescribed by the manufacturer Special Tool Timing Light 5
257. e checks out good replace the fuel pump assy the fuel filter may be clogged and measure the fuel pressure again x If the residual pressure 260 280 kPa drops at once the high pressure fuel line could be leaking e Remove the fuel pressure gauge and adapter e Run the fuel hoses in accordance with the Cable Wire and Hose Routing section in the Appendix chapter 3 92 FUEL SYSTEM DFI Fuel Line e Fit the fuel hose joint 2 A onto the pipe for delivery joint until the joint clicks B Olnsert the hose joint straight along the pipe Front C e Push and pull A the fuel hose joint 2 B back and forth more than two times and make sure it is locked and doesn t come off When the fuel hose joint 2 is correctly installed it should slide on the delivery pipe about 5 mm 0 2 in A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn both ignition switch and engine stop switch OFF e Wait u
258. e 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 fault codes ODo not spray water on the electrical parts DFI parts con nectors leads and wiring Never water a vehicle with connectors unplugged because seals don t work and ter minals could corrode OTo prevent corrosion and deposits in the fuel system do not add any fuel antifreeze chemicals to fuel OWhen any fuel hose is disconnected do not turn on the ignition switch 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 spillage GC170368S1 3 22 FUEL SYSTEM DFI Troubleshooting the DEI System Outline When an abnormality in the system occurs the Fl indica tor LED light A and Fl symbol B go on to alert the rider on the meter panel
259. e oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts ST Stake the fasteners 11 4 FINAL DRIVE Exploded View GKO2074BW5 C FINAL DRIVE 11 5 Exploded View Final Gear Case No Fastener LT Bearing Retainer Bot Final Gea 69 oro etme 4 Final Gear Case Drain Pug JL 68 090 78mb 75 Final Gear Case Mounting nus 35 s gt 127 HG Apply high temperature grease HO Apply hypoid gear oil L Apply a non permanent 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 ST Stake the fasteners 11 6 FINAL DRIVE Specifications Item Standard Final Gear Case Oil Grade API GL 5 hypoid gear oil Viscosity When above 5 C 41 F SAE90 When below 5 C 41 F SAE80 Oil Level Filler opening bottom Amount 200 mL 6 76 US oz Final Bevel Gear Backlash 0 10 0 20 mm 0 0039 0 0079 in at ring gear hub splines Preload for Pinion Gear Bearing Torque Wrench Spring Scale 0 6 1 0 N m 0 06 0 10 kgf m 5 2 8 7 in Ib 3 0 5 0 N 0 30 0 50 kg 0 7 1 1 Ib Propeller Shaft Joint Grease 20 mL 0 68 US oz high temperature grease Front Bevel Gear Backlash 0 10 0 15 mm 0 004 0 006 in at gear tooths Preload for Front Bevel Gear Bearing Torque Wrench Spring Scale 0 5 0 9 N m 0 05 0 09
260. e propeller shaft joint see Propeller Shaft Joint Lubrication in this chapter e Install the spring so that the smaller diameter end A faces toward the final gear case e Fit the pinion gear splines into the propeller shaft joint while turning the ring gear hub A e Tighten the final gear case mounting nuts to the specified torque Torque Final Gear Case Mounting Nuts 34 N m 3 5 kgf m 25 ft lb x lf the final gear case oil was drained fill the case with oil see Oil Change in the Periodic Maintenance chapter e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter Final Gear Case Disassembly e Remove the final gear case see Final Gear Case Re moval in this section e Using 6 mm 0 2 in bolts A with 10 mm 0 4 in pitch threads jack up the pinion gear assembly B e Remove the pinion gear assembly and shim s C from the final gear case 11 10 FINAL DRIVE Final Gear Case and Oil e Remove the final gear case cover bolts A e Use three tapped holes B to lift the ring gear assy from the gear case The shim s comes off with the assy NOTE ODo not disassemble the ring gear assy ring gear ring gear hub and final gear case cover but the oil seal can be removed e To remove the ring gear oil seal A heat the ring gear assy in an oil bath to 120 150 C 248 302 F then pry out the oil seal with an awl or other tool Be careful not to scratch the s
261. e seating pattern on the valve seat with vernier calipers x If the outside diameter is too large or too small repair the seat see Valve Seat Repair in this section Valve Seat Surface Outside Diameter Standard Exhaust 28 9 29 1 mm 1 14 1 15 in Inlet 31 9 32 1 mm 1 25 1 26 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with vernier calipers Good F Alf the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair in this section Valve Seat Surface Width Standard Exhaust 0 5 1 0 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder 7 B 57001 1126 Valve Seat Cutter Holder Bar C 57001 1128 For Exhaust Valve Seat Valve Seat Cutter 45 p35 57001 1116 Valve Seat Cutter 32 635 57001 1121 or 32 633 57001 1199 Valve Seat Cutter 55 635 57001 1247 For Inlet Valve Seat Valve Seat Cutter 45 440 57001 1496 Valve Seat Cutter 32 438 5 57001 1122 Valve Seat Cutter 55 438 5 57001 1497 OThe marks stamped on the back of the cutter A represent the following O E Cutter Angle B DINO Outer Diameter of Cutter C If the manufacturer s instructions are not available use the following procedure GE15011782 C
262. e sure that the shop towel B is around the fuel hose joint 1 C e A person should pinch the hose joint locks D with fingers disconnect the joint E and plug the tank outlet pipe with the plug hose Front F A WARNING Immediately wipe up fuel that spills 6009020451 6C09036BS1 3 108 FUEL SYSTEM DFI Fuel Tank e Close the fuel tank cap e Remove the fuel tank from the vehicle and place it on a flat surface CAUTION For California model if gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capacity is greatly reduced If the canister does become contaminated replace it with a new one e For California Model note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground For California model be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air California Model OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel lea
263. e tester to the DC 25 V range Special Tool Hand Tester 57001 1394 e Trace A the speed sensor surface with the screw driver OThen the tester indicator should flick B x lf the tester indicator does not flick replace the speed sensor Front Brake Light Switch Inspection e Refer to the Brake Light Switch Operation in the Periodic Maintenance chapter Rear Brake Light Switch Check Adjustment e Refer to the Brake Light Switch Operation in the Periodic Maintenance chapter Radiator Fan Switch Removal CAUTION Never drop the fan switch especially on a hard sur face Such a shock to the part can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Disconnect the fan switch connector see Fan System Cir cuit Inspection in this chapter e Unscrew the radiator fan switch A from the radiator Radiator Fan Switch Installation e Tighten Torque Radiator Fan Switch 18 N m 1 8 kgf m 13 ft Ib e Fill the coolant and bleed the air from the cooling system see Coolant Change in the Periodic Maintenance chap ter GP18070451 S DC25V 6P180701S1 TA AY ANG GP18140BS1 16 94 ELECTRICAL SYSTEM Switch and Sensors Radiator Fan Switch Inspection e Remove the fan switch from the radiator see Radiator Fan Switch Removal in this section e Suspend the switch A in a container of machine oil so that the heat sens
264. e the dust seal B as well Also replace all seals every other time the pads are changed Front Caliper G Rear Caliper H Caliper Dust Boot and Friction Boot Damage e Check that the dust boot C and friction boot D are not cracked worn swollen or otherwise damaged e f they show any damage replace it Caliper Piston and Cylinder Damage e Visually inspect the piston E and cylinder surfaces x Replace the caliper if the cylinder and piston are badly scored or rusty Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts If the body does not slide smoothly one pad will wear more than the other and constant drag on the disc may cause the temperature of the discs or the brake fluid to increase e Visually inspect that the caliper holder shafts F are not badly worn or bent x lf the caliper holder shafts are damaged replace the en tire caliper assembly GLO5119BS1 BRAKES 12 13 Brake Pads Front Brake Pad Removal y e Remove the front caliper with the hose installed see Front Caliper Removal in this chapter e Remove Snap Pin A Pad Pin B e Remove the jaw side pad A and then remove the piston side pad B Jaw C Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the brake pads e Install the pad pin and snap pin A The snap pin must be outside of the pads Do not attempt to
265. e times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 volts repeat the charging cycle and load test If still below 12 6 volts the battery is defective 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 a 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 this chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION 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 Give 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
266. ealing surface on the ring gear hub CAUTION Do not heat the case with a blowtorch This will warp the case e Remove the snap ring A and pull out the needle bearing B x lf the small ring gear oil seal C is damaged remove it using the oil seal and bearing remover ORemove the small ring gear oil seal if damaged Special Tool Oil Seal 8 Bearing Remover D 57001 1058 e Unscrew the bearing retainer bolt A and washer B e Pull out the needle bearing C Special Tool Oil Seal amp Bearing Remover 57001 1058 6K070104S1 GKO70105S1 FINAL DRIVE 11 11 Final Gear Case and Oil Final Gear Case a VAS ME 6 ZA ct ms ol i WAL MH GY f A WAZA Pinion Gear Nut Washer Shim s for Preload Pinion Gear Joint O ring Ring Gear Hub Ring Gear Oil Seal Ball Bearing Final Gear Case Cover 10 Cover Mounting Bolts 11 Ring Gear Shim s 12 Ring Gear OMNMAOARWD Final Gear Case Assembly OThe ring gear and pinion gear are lapped as a set in the factory to get the best tooth contact They must be in stalled as a pair and never replace one without the other e Press the small ring gear oil seal A until it bottoms out with its spring B facing inward Special Tool Bearing Driver Set 57001 1129 e Apply a thin coat of high temperature grease to the oil seal lip 7 8 9 9 XA ASC SELLY
267. ear Master Cylinder Disassembly e Refer to the Brake Master Cylinder Rubber Parts Re placement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Brake Master Cylinder Rubber Parts Re placement in the Periodic Maintenance chapter Master Cylinder Inspection e Disassemble the front and rear master cylinders see Brake Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter CAUTION SET Do not remove the secondary cup from the piston RARE since removal will damage it 6L07003BS1 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 Alf a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D Alf a cup is worn damaged softened rotted or swollen the piston assy should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston assy should be replaced to renew the cups i e Check the dust covers E for damage NAIL Alf they are damaged replace them e Check the piston return spring 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 J Rear Master Cylinder K
268. earing preload is obtained CAUTION To start with choose a shim or shims so that the bearings are just SNUG with NO play but also with NO preload Any over preload on the bearings could damage the bearings e Apply a little hypoid gear oil to the bearings and turn the gear shaft more than 5 turns to allow the bearings to seat e Measure the bearing preload Bearing preload is defined as the force or torque which is needed to start the gear shaft turning Preload for Pinion Gear Bearing Using Torque Wrench 0 6 1 0 N m 0 06 0 10 kgf m 5 2 8 7 in Ib Using Spring Scale 3 0 5 0 N 0 30 0 50 kg 0 7 1 1 Ib NOTE OPreload can be measured either with a spring scale or a beam type torque wrench When measured with a spring scale the preload is designated by force N kg lb and when measured with a torque wrench it is des ignated by torque N m kgfm in b Using Spring Scale e Hook the spring scale A on the handle at the point 200 mm 7 87 in B from the center of the gear shaft e Hold the bearing housing in a vise so that the gear shaft axis is vertical e Apply force to the handle horizontally and at a right angle to it Special Tool Pinion Gear Holder m1 9 C 57001 1165 x lf the preload is out of the specified range replace the shims under the flat washer and re check the preload Refer to the next paragraph to select suitable shims 6K06000BS1 FINAL DRIVE 1
269. echanics 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 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 e 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 t
270. ecially on a hard surface Such a shock to the ignition coil can dam age it e See Ignition Coil Removal Installation of the Ignition Sys tem section in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Connect a digital meter A as shown using two needle adapters B Special Tool Needle Adapter Set 57001 1457 Ignition Coil Input Voltage at ECU Connections for Ignition Coil 1 Meter BK lead terminal 44 Meter Battery Terminal Connections for Ignition Coil 2 Meter BK G lead terminal 43 Meter Battery Terminal e Measure the input voltage to each primary winding of the ignition coils with the engine stopped and with the con nectors joined e Turn the ignition switch ON Input Voltage at ECU Standard Battery Voltage 12 5 V or more x lf the reading is out of the standard check the ECU for its ground and power supply see ECU Power Supply In spection in this chapter x If the reading is good remove the fuel tank and check the wiring between the ECU and the primary lead terminals at the ignition coils x If the wiring is good crank the engine and check the peak voltage of the ignition coils see Ignition Coil Primary Peak Voltage in the Electrical System chapter in order to check the primary
271. ect the cap see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Ignition coil trouble Inspect see chapter 16 Fuel mixture incorrect Choke knob left pulled out Push in see chapter 3 Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Throttle body assy loose Reinstall see chapter 3 Throttle body assy O ring damaged Replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI Pump bearings may wear Replace the pump fuse blows see chapter 3 Fuel pump trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Throttle sensor malfunction Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Cracked or obstructed inlet air pressure sensor Inspect and repair or replace see chapter 3 hose Injector clogged Visually inspect
272. ected the speedometer nee dle momentary points to the last reading and then return to the 0 position x If the needle function does not work replace the meter unit GP17086BS1 6P17087BS1 ELECTRICAL SYSTEM 16 81 Meter Gauge Check 2 e Using the auxiliary lead connect the battery positive ter minal to terminal 8 e Verify that all the LCD segments the letters and num bers of the liquid crystal display to appear for 3 seconds and the speedometer needle momentary points to the last reading and then return to the 0 position Then the clock or meters operates normally depending on the mode se lected e Disconnect the terminal 8 e Verity that all the LCD segments and symbols disappear x lf the display function does not work replace the meter unit Mode Button Operation Checks e Connect the lead in the same circuit as for the LCD Seg ment Inspection Check 2 e Check that the display A changes to the CLOCK ODO and TRIP display each time the mode button B is pushed CLOCK ODO gt TRIP x If the display does not work replace the meter unit e Push the mode button A to TRIP and push the reset button B more than 2 seconds The display shows 0 0 x If the display does not show 0 0 replace the meter unit GP17088BS1 GP17089BS1 GP17090BS1 16 82 ELECTRICAL
273. edal Posi tion Adjustment in this chapter e Unscrew the brake hose banjo bolt A on the master cylin der e Loosen the master cylinder mounting bolts B e Unscrew the front footboard bracket bolts C e Remove Cotter Pin A Joint Pin B Rear Master Cylinder Mounting Bolts C e Slide the reservoir hose lower end clamp A e Pull out the reservoir hose lower end B and drain the brake fluid into a container Rear Master Cylinder Installation e Replace the cotter pin with a new one e Insert the cotter pin A to the hole of the joint pin B and separate C the cotter pin ends e Use a new flat washer on each side of the brake hose fitting e Tighten Torque Front Footboard Bracket Bolts 34 N m 3 5 kgf m 25 ft lb Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Rear Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft lb e Bleed the brake line see Brake Line Bleeding in this chapter e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done BRAKES 12 17 Master Cylinder Front Master Cylinder Disassembly e Refer to the Brake Master Cylinder Rubber Parts Re placement in the Periodic Maintenance chapter R
274. ee Front Seat Removal in the Frame chapter e Disconnect Fuel Pump Connector A Fuel Level Sensor Connector B Battery Lead Connector C Rear Turn Signal Taillight Lead Connector D e Remove DFI Fuse E Nuts F Battery Holder G e Pull the ECU A out along with the harness x If necessary push the lock and disconnect the ECU con nectors GC17055BS1 FUEL SYSTEM DFI 3 83 ECU ECU Installation e Connect the ECU connector e Fit the ECU A in behind the left side rib C of the battery case B until the ECU bottoms Front D ECU Power Supply Inspection e Remove the ECU see ECU Removal in this section e Visually inspect the terminals of the ECU connector Alf the connector is clogged with mud or dust blow it off with compressed air x Replace the main harness if the terminals A of the main harness connectors are cracked bent or otherwise dam aged Replace the ECU if the terminals of the ECU connector are cracked bent or otherwise damaged e With the ECU connector A joined check the following ground leads for continuity with the ignition switch OFF using a digital meter B Battery C in the Frame Special Tool Needle Adapter Set 57001 1457 ECU Grounding Inspection Meter Connections 10 20 32 or 42 BK Y Es Battery Terminal Terminal 42 Engine Ground Terminal bask Battery Terminal
275. ee Fuel Tank Removal in the Fuel System DFI chapter Cover Bolts A Cover B Front C e Remove Nut A Rear Brake Light Switch Connector B e Remove the front exhaust pipe see Exhaust Pipe Re moval in the Engine Top End chapter e Pry the plastic clamps A e Remove the regulator rectifier bracket bolt A FRAME 15 29 Downtube e Supper the engine with a commercially available stand A e Remove Bolt B Rear Brake Reservoir Cover C Right Front Footboard Bracket Bolt D e Remove the rear brake reservoir A e Pry the plastic clamp B e Remove the right front footboard C by taking off the bolt D with brake pedal and rear master cylinder installed e Remove Engine Mounting Bracket Bolts E Downtube Bolt Caps and Bolts F e Take off the brake hose A from the clamps B Downtube Installation e Run the brake hose inside the downtube and clamp it e Put left and right stoppers A of the radiator into the grom mets B of the downtube e Tighten Torque Downtube Bolts 59 N m 6 0 kgf m 44 ft Ib Engine Mounting Bracket Bolts 25 N m 2 5 kgf m 18 ft lb Front Footboard Bracket Bolts 34 N m 3 5 kgf m 25 ft lb 15 30 FRAME Frame Tandem Grip Removal Installation e Remove the left and right saddlebags see Saddlebag Re moval in this chapter e Remove Bolts A Both Sides Back Rest B e Remove Tandem Grip Mounting Bolts A Both Sides Left and Right Tan
276. eed Control Valve or Fast Idle Solenoid Valve 75 7 L 19 8 1 8 US gal min 13 6 20 4 Q 304 kPa 3 1 kgf cm 44 psi with fuel pump running 280 kPa 2 9 kgf cm 41 psi with fuel pump stopped 304 kPa 3 1 kgf cm 44 psi with fuel pump running 294 4 9 kPa 3 00 0 05 kgf cm 43 0 73 psi 4 75 5 25 V DC between BL W and BR BK leads 0 584 0 604 V DC between Y W and BR BK leads 4 29 4 59 V DC between Y W and BR BK leads 4 6 KQ between BL W and BR BK leads 4 75 5 25 V DC 3 74 4 26 V DC at standard atmospheric pressure 5 4 6 6 kQ at 0 C 32 F 2 26 2 86 KQ at 20 C 68 F 0 29 0 39 kQ at 80 C 176 F 2 162 3 112 kQ at 20 C 68 F 0 785 1 049 kQ at 50 C 122 F 0 207 0 253 kQ at 100 C 212 F More than 45 5 for each bank Within 0 5 1 0 second FUEL SYSTEM DFI 3 19 Specifications Item Standard Fuel Injectors Type Static Injection Quantity Nozzle Type x Diameter Resistance Fuel Pump Type Discharge INP 281 273 0 289 8 mL 9 23 9 80 US oz min One spray type with 4 holes 11 7 12 3 Q at 20 C 68 F Friction pump 67 mL 2 27 US oz or more for 3 seconds 3 20 FUEL SYSTEM DFI Special Tools and Sealant Oil Pressure Gauge 5 kgf cm Needle Adapter Set 57001 125 57001 1457 ST5701258T ST571457ST C Fork Oil Level Gauge Fuel Pressure Gauge Adapter 57001 1290 57001 1593 ST571290ST ST571593ST
277. eeeeeeeeeeeeeeeeeeseeeeeeeeeeesenenaess 2 27 Brake Light Switch Operation EE 2 27 SUSPENSION Hassett eae era iene eee eee ne a ee 2 28 Front Forks Rear Shock Absorber Operation Inspection sssssseesseesseesseerreesreeereeerrereeene 2 28 Front Fork Oil Leak Inspection 2 29 Rear Shock Absorber Oil Leak Inspection ee cece eeeeeeeeee eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 29 Swingarm Pivot Lubrication 2 sc eveeessace ce cavemen io 2 29 Steering SY SSM RE 2 30 Steering Play Inspection E 2 30 Steering Play AUSTIN EE 2 30 Stem Bearing LUbTICAION ici ee tee 2 31 2 2 PERIODIC MAINTENANCE Electrical SVT atinada elo Lights and Switches Operation Headlight Aiming Inspection cece Side Stand Switch Operation Inspection Engine Stop Switch Operation Inspection RN Chassis Parts Lubrication Bolts Nuts and Fastener Tightness Inspection Replacement Parts cccccccececeeeceeeeeeeeeeeeeeeeetees Air Cleaner Element HReplacement Engine Oil CHANGO EE Oil Filter Replacement ssnssnnseeeseeeeeeeeeeeeeeeereeeeen Fuel Hose Replacement Coolant Changements Radiator Hose and O ring Replacement Brake Hose and Pipe Replacement Brake Fluid Change gega iebegedz eege erg AEe taste Brake Master Cylinder Rubber Parts Replacement o oooccccccccnccnccnncnnnncnnnnnnnnnnnninnninnninnnios
278. eelbase 1 690 mm 66 5 in Road Clearance 150 mm 5 91 in Seat Height 720 mm 28 3 in Dry Mass 350 kg 675 Ib Curb Mass Front 164 kg 362 Ib Rear 213 kg 470 lb Fuel Tank Capacity 20 L 5 3 US gal Fuel Unleaded and high octane gasoline see VN1600 D1 Owner s Manual 3 5 m 11 5 ft 4 stroke SOHC V2 cylinder Liquid cooled 102 x 95 mm 4 02 x 3 74 in 1 552 mL 94 70 cu in 9 0 1 49 kW 67 PS 4 700 r min rpm CA CAL US 127 N m 12 95 kgf m 93 7 ft lb 2 700 r min rpm CA CAL US DFI Digital Fuel Injection System Electric starter Battery and coil transistorized Electronically advanced digital From 5 BTDC 950 r min rpm 25 BTDC 4 500 r min rpm NGK DPR6EA 9 or ND X20EPR U9 Front to Rear 1 2 1 2 22 BTDC 66 ABDC 268 66 BBDC 26 ATDC 272 Forced lubrication wet sump 1 10 GENERAL INFORMATION General Specifications Items VN1600 D1 Engine Oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 3 5 L 3 7 US qt when engine is completely disassembled and dry Drive Train Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd Ath 5th Final Drive System Type Reduction Ratio Overall Drive Ratio Final Gear Case Oil Primary Reduction System Gear 1 517 85 56 Wet multi disc 5 speed constant mesh return shift 2 500 40 16 1 59
279. eeth on the driven gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use this for checking the bevel gears 11 36 FINAL DRIVE Front Bevel Gears e Turn the driven gear for 3 or 4 revolutions in the drive and reverse coast directions while creating a drag on the drive gear e Check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth and little closer to the toe of the tooth x If the tooth contact pattern is incorrect replace the shim s at the driven gear and shim s at the driven gear follow ing the examples shown Then erase the tooth contact patterns and check them again Also check the back lash every time the shims are replaced Repeat the shim change procedure as necessary NOTE Olf the backlash goes out of standard range after chang ing shims correct the backlash before checking the tooth contact pattern Olt is OK to pack two shims Do not pack three or more shims Heel A Bottom B Top C Toe D Drive Gear E Driven Gear F
280. ef Valve Inspeccion rl in tr aline ee 7 16 7 2 ENGINE LUBRICATION SYSTEM Exploded View 6002056BW5 C ENGINE LUBRICATION SYSTEM 7 3 Exploded View No Fastener ge kgEm ft lb Remarks 1 Oil Baffle Bolt 11 1 1 97 in lb L 2 Oil Drain Plug 20 2 0 15 3 Oil Filter 18 1 8 13 EO R 4 Oil Filter Pipe 25 2 5 18 SS 5 Oil Hose Banjo Bolt 9 8 1 0 87 in lb 6 Oil Hose Flange Bolts 9 8 1 0 87 in lb 7 Oil Hose Nozzle 00 Oil Nozzles Oil Pipe Clamp Bolts Oil Pipe Holder Bolts 11 1 1 97 in lb Oil Pressure Switch 15 1 5 Oil Pressure Switch Terminal Screw 1 5 0 15 13 in lb Oil Pump Mounting Bolts Oil Return Pipe Clamp Bolts Oil Screen Plug Relief Valve _ N gt 17 Crankcase Breather Hose 18 HLA Oil Filters 19 Oil Baffle 20 Oil Return Pipes 21 Oil Screen 22 Oil Separator Smaller side goes first 23 To Right Air Cleaner Base EO Apply engine oil G Apply grease L Apply a non permanent locking agent LH Left hand Threads R Replacement Parts SS Apply silicone sealant to the threads of the oil pressure switch Kawasaki Bond 56019 120 SS Apply silicone sealant to the threads of the oil filter pipe Three Bond TB1401B SS Apply silicone sealant to the left crankcase mating surface of the separator Three Bond TB1207B 7 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE SF or SG API SH or SJ with JASO MA
281. ehicle down Sensor Inspection NOTE OBe sure the battery is fully charged e Take out the vehicle down sensor A see Removal in this section ODo not disconnect the connector B e Connect a digital volt meter C to the connector natural 3 pin using two needle adapters D Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Power Source Voltage Connections to Sensor Meter BR lead E Meter CH BK Y lead F e Turn the ignition switch ON and measure the power source voltage with the connector joined Output Voltage at Sensor Standard Battery Voltage 12 5 V or more GC17727B82 e Turn the ignition switch OFF x If there is no battery voltage check the DFI power source circuit see DFI Power Source Circuit in the DFI Power Source section FUEL SYSTEM DFI 3 65 Vehicle down Sensor Service Code 31 x If the power source is normal check the output voltage of the sensor e Connect a digital volt meter A to the connector natural 3 pin using two needle adapters B Vehicle down Sensor Output Voltage Connections to Sensor Meter Y G lead E Meter CH BK Y lead F e Turn the ignition switch ON and measure the output volt age with the connector joined OTilt the sensor 40 50 or more C right or left then hold the sensor almost vertical D with the arrow mark pointed up and measure the output voltage Output Voltage at Sensor S
282. elay ECU Electronic Control Unit Fuel Tank Injector 1 for Front Cylinder Injector 2 for Rear Cylinder Inlet air Pressure Sensor Inlet Air Temperature Sensor Inlet Manifold ISC Valve 2 for Front Cylinder ISC Valve 1 for Rear Cylinder O ring Right Air Cleaner Base Seal Throttle Body Throttle Cable Accelerator Throttle Cable Decelerator Vehicle down Sensor Apply cable lubricant Apply grease Apply a non permanent locking agent Replacement Parts Follow the specified tightening sequence 3 8 FUEL SYSTEM DFI DFI System gt lt 7 pal Ir ss A FUEL SYSTEM DFI 3 9 DFI System 1 2 ECU Electronic Control Unit Crankshaft Sensor 1 Crankshaft Sensor 2 Pressure Regulator Throttle Sensor Atmospheric Pressure Sensor Inlet Air Pressure Sensor Water Temperature Sensor Inlet Air Temperature Sensor Fl Indicator LED Light Fuel Filter Delivery Joint Injector 1 Injector 2 Fuel Pump ISC Valve 2 Front Side ISC Valve 1 Rear Side Vehicle down Sensor Fuel Tank Alternator Rotor Sealed Battery Left Air Cleaner Housing Right Air Cleaner Housing Lower Air Cleaner Duct Thermostat Housing Throttle Valves Fuel Flow Air Flow Speed Sensor Fuel Hose Joint Fuel Pump Side Fuel Hose Joint Delivery Joint Side for Front Cyli
283. eld Assembly Installation 15 21 Deflector Removal 15 22 Deflector Assembly 0aaaanaaa 15 22 Travel Trunk and Saddlebags 15 23 Lid Unlatching 15 23 Lid RE e Un eh ns 15 23 Saddlebag Removal 15 23 Saddlebag Installation 15 23 CE EE 15 25 Front Guard Removal Installation 15 25 Rear Guard Removal 15 25 Rear View Mirrors 15 26 Rear View Mirror Removal Other than European Model 15 26 Rear View Mirror Removal European Model 15 26 Rear View Mirror Installation Other than European Model 15 26 Rear View Mirror Installation European Model 15 27 Downtube 15 28 Downtube Removal Downtube Installation FTG E Tandem Grip Removal Installa ll EE 15 30 Frame Inspection 15 30 15 2 FRAME Exploded View FRAME 15 3 Exploded View Torque No Fastener Nom kgf m ft lb Remarks 1 Downtube Bolts 59 6 0 44 2 Engine Mounting Bracket Bolts 25 2 5 18 3 Front Footboard Bracket Bolts 34 3 5 25 4 Side Stand Nut 44 4 5 32 G Apply grease WL Apply a soap and water solution or rubber lubricant 15 4 FRAME Exploded View Alo AA A je al Y EY 6002133845 C FRAME 15 5 Exploded View Torque No F
284. ely e Adjust the rear view mirror by slightly moving only the mirror portion of the assembly Olnstallation and adjustment of the left side are common with the those of right side Follow the procedure speci fied at the right side 6022000BS1 FRAME 15 27 Rear View Mirrors Rear View Mirror Installation European Model e Screw the mounting area of the rear view mirror A into the holder B all the way and tighten the lower hexagonal area C securely CAUTION Do not force to tighten and or loosen the upper hexagonal area adapter A with a pair of span ners or wrench Disassembly of this area is not possible Non permanent locking agent B is already applied to the threads of this inner area Forcible loosening may damage the adapter and or the turning mechanism of the stay C 6022000BS1 e Turn the stay A to assure visibility to the rear with the rider sitting on the motorcycle e Adjust the rear view mirror B by slightly moving only the mirror portion of the assembly Olnstallation and adjustment of the left side are common with the those of right side Follow the procedure speci fied at the right side 15 28 FRAME Downtube Downtube Removal e Raise the rear wheel A off the ground using the jack B and the attachment jack C Special Tools Jack 57001 1238 nn Attachment Jack 57001 1398 Se A PA NN PES AN SS e Remove Fuel Tank s
285. ely two times to ensure even tightening torque G Apply 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 SE TIR 0 5 mm 0 02 in Radial SE TIR 0 8 mm 0 03 in Axle Runout 100 mm TIR 0 05 mm 0 002 in or less TIR 0 2 mm 0 008 in Wheel Balance 10 g 0 4 oz or less Balance Weights 10 g 0 4 oz 20 g 0 7 oz 30 g 1 1 oz Tires Air Pressure When Cold Front Up to 185 kg 408 Ib load 225 kPa 2 25 kg cm 32 psi Rear Up to 185 kg 408 Ib load 280 kPa 2 80 kg cm 40 psi Tread Depth Front 4 5 mm 0 18 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 7 2 mm 0 28 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 1 in Standard Tires Make Type Size Front BRIDGESTONE EXEDRA G721 150 80 16 M C 71H Rear BRIDGESTONE EXEDRA G722 G 170 70B 16 M C 75H AT Austria CH Switzerland DE Germany A WARNING Use the same manufacturer s tires on both front and rear wheels WHEELS TIRES 10 5 Special Tools Inside Circlip Pliers Bearing Remover Head 25 x 28 57001 143 57001 1346 W 7570143ST Bearing Driver Set Bearing Remover Shaft 613 57001 1129 57001 1377 ST5711298T ST5713778T Jack Attachment Jack 57001 1238 57001 1398 ST5712388ST
286. ention 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 wires from the battery to prevent the engine Gi E from accidentally turning over Disconnect the ground wire AOA D gt first and then the positive When completed with the Go Y C ITE a service first connect the positive wire to the positive 8 p d ae terminal of the battery then the negative wire to the neg AA los ative terminal DISASSEMBLY ASSEMBLY 020248 S Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 00200 S Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 68020058 S Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or 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 al
287. er Method 5 36 Removal orinda ti ahs 5 18 Valve Seat Inspection 5 37 Camshaft Chain Tensioner Valve Seat Repair 5 37 Installation 5 18 Cylinders Piston 5 41 Rocker Case Cover 5 20 Cylinder Removal 5 41 Rocker Case Cover Removal 5 20 Piston HRemoval 5 41 Rocker Case Cover Installation 5 20 Cylinder Piston Installation 5 41 Rocker Case Cover Assembly 5 21 Cylinder Wear 5 44 Rocker Case 5 22 Piston Wear 5 44 Rocker Case Removal 5 22 Piston Cylinder Clearance 5 44 Rocker Case Installation 5 23 Cylinder Boring and Honing 5 45 Rocker Arm Assembly 5 24 Piston Ring Piston Ring Groove HLA Remova 5 25 Wales ciar Din ed 5 45 HLA Air Bleeding 5 25 Piston Ring Groove Width 5 46 HLA Installation 5 25 Piston Ring Thickness 5 46 Camshafts ic nico cia 5 26 Piston Ring End Gap 5 46 Camshaft Removal 5 26 M fflers saisissant 5 47 Camshaft Installation 5 26 Exhaust Pipe Removal 5 47 Camshaft Sprocket Installation 5 28 Muffler HRemova 5 48 Camshaft Rocker Case Wear 5 28 Exhaust Pipe Muffler Installation 5 48 Front Camshaft Chain Removal 5 29 Chamber Removal Installation 5 49 Front Camshaft Chain Installation 5 30 Chamber Assem
288. er arm if necessary Stopper E OThe cylinder compression is released while the engine is running abnormal the pin A stays out the cam B and pushes up the exhaust rocker arm e Remove the spring C and move the weights D back and forth x If the weights do not move easily from the retracted po sition replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary Stopper E GE22020181 GE22020281 5 32 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE OBe sure the battery is fully charged e Warm up the engine thoroughly e Stop the engine e Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole Do not remove the other spark plug only the plug lead e For the other cylinder remove both spark plugs Special Tool Spark Plug Wrench Hex 18 A 57001 1024 e Using 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 A 57001 221 Compression Gauge Adapter M12 x 1 25 B 57001 1018 or 57001 1183 Cylinder Compression Usable Range 340 590 kPa 3 5 6 0 kg cm 50 85 psi 300 r min rpm OThe compression gauge adapter 57001 1183 can also be used e Repeat the measurement for the other cylinder e In
289. er drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the right air cleaner base see Right Air Cleaner Housing Removal in this chapter e Disconnect the connector A from the inlet air tempera ture sensor and unscrew the nut B e Remove the inlet air temperature sensor Torque Inlet Air Temperature Sensor Nut 7 8 Nm 0 80 kgf m 69 in lb Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the inlet air temperature e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Connect a digital meter A to the ECU connector B us ing two needle adapters C Special Tool Needle Adapter Set 57001 1457 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter P lead terminal 31 Meter gt BR BK lead terminal 11 e Measure the output voltage of the sensor with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard 2 4 V at inlet air temperature 25 C 77 F e Turn the ignition switch OFF lf the output voltage is normal but there is still trouble check the sensor resistance x lf the output voltage is about 4 8 V the ECU is normal Remove the right air cleaner base and check the wiring between the ECU and the sensor x If the output voltage is not about 4 8 V and ou
290. er is removed and left alone the piston will be pushed out by spring force e Remove Se de Spring C NS Y H GSO8019BS1 e Replace the piston seal with a new one e Before assembly apply clutch fluid to the outside of the piston and the piston seal e Install the piston seal as shown Cylinder A Piston B Piston Seal C Spring D GF1001038S1 FUEL SYSTEM DFI 3 1 Fuel System DEI Table of Contents Exploded View 3 4 Crankshaft Sensor Inspection DPS yc coi 3 8 Vehicle down Sensor Service Code DFI Parts Location 3 10 Ol VE 3 63 DFI Wiring Diagoram 3 14 Removal voii tc 3 63 Specifications 3 18 Installaton 3 64 Special Tools and Sealant 3 20 Vehicle down Sensor Inspection 3 64 DFI Servicing Precautions 3 21 Fuel Injectors 1 2 Service Code Troubleshooting the DFI System 3 22 A AZ A 3 67 Et E 3 22 Injector Removal 3 67 Inquiries to Rider 3 27 Injector Installation 3 68 DFI System Troubleshooting Guide 3 30 Audible Inspection 3 70 Self Diagnosis A 3 39 Power Source Voltage Inspection 3 70 Self diagnosis Procedures 3 39 Output Voltage Inspection 3 71 Service Code Reading 3 40 Injector Signal Test 3 72 Service Code Erasing 3 41 Injector Resistance Inspection 3 72 Thro
291. ernator leads and then the grommet D for the crankshaft sensor leads with the round mark E up e Pull F the alternator leads and crankshaft sensor leads G outside the alternator cover and reduce the slack of leads inside the cover as possible in order to prevent contact with the rotor e Apply silicone sealant to the mating surface I of the grommet Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Connect the outside alternator connector BK leads to the connector Y leads of the regulator rectifire Alternator Inside Stator Removal e Remove Alternator Rotor see Alternator Rotor Removal in this section Alternator Inner Cover see Alternator Inner Cover Re moval in this section e Unscrew the inside stator holder bolts A and take the inside stator B and holder C off the left crankcase Ki GPO9011BS2 C 16 38 ELECTRICAL SYSTEM Charging System Alternator Inside Stator Installation e Apply a non permanent locking agent to the threads of the inside stator holder bolts e Install the inside stator with the BK leads on the left crankcase Torque Inside Stator Holder Bolts 11 N m 1 1 kgf m 97 in Ib e Apply silicone sealant to the grommet and fit it into the notch of the alternator inner cover Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Connect the inside alternator connector BK leads to the connector Y BK leads of the regulator rectifier Chargi
292. eutral finder operates properly While spinning C the output shaft A using an air impact wrench gears shift smoothly from the 1st 2nd 5th gear and 5th 4th 1st When the output shaft stays still the gear can be shifted to only the 1st gear or neutral It should not be shifted to the 2nd gear or other higher gear positions Shift Drum B e Apply a non permanent locking agent to the shift shaft return spring pin D and tighten it Torque Shift Shaft Return Spring Pin 39 N m 4 0 kgf m 29 ft lb e Set the gear set lever to the neutral position Shift Drum Cam A Gear Set Lever B Neutral Position C Spring D e Set the spring end to the crankcase as shown E Torque Gear Set Lever Bolt 11 N m 1 1 kgf m 97 in Ib 6104076BS1 e Install the balancer dampers A so that each damper hole B is positioned alternately e Install the left balancer A on the balancer shaft in the engine left side while fitting the alignment tooth B onto the alignment notch C of the splines e Install the left balancer gear bolt e Apply a non permanent locking agent to the threads of the chain guide bolts and chain guide retainer bolt e Install Front Camshaft Chain A Lower Chain Guide B Front Chain Guide Retainer C Rear Chain Guide D Torque Camshaft Chain Guide Bolts 11 N m 1 1 kgf m 97 in lb Camshaft Chain Guide Retainer Bolt 11 N m 1 1 kgf m 97 in Ib 9 18 CRANKSHAFT TRANSMIS
293. gine oil pressure is high enough with engine running DFI problem unlights LED light ECU or its wiring fault sometimes lights up probably wiring fault Starting starter motor not rotating difficulty starter motor rotating but engine doesn t turn over starter motor and engine don t turn over no fuel flow O no fuel in tank O no fuel pump sound pj pa ajaja o engine flooded do not crank engine with throttle opened which promotes engine flooding Engine stops Poor running at low speed O no spark O choke knob is not pulled fully when using the knob pull it fully when using O other O right after starting O when opening throttle grip O when closing throttle grip O when moving off O when stopping the motorcycle O when cruising O other O choke knob left pulled out fully push it in fully O very low fast idle speed O very low idle speed O very high idle speed O rough idle speed O battery voltage is low charge the battery O spark plug loose tighten it O spark plug dirty broken or gap maladjusted adjust it O backfiring O afterfiring O hesitation when acceleration FUEL SYSTEM DFI 3 29 Troubleshooting the DFI System Poor running or no power at high speed engine oil viscosity too high brake dragging engine overheating clutch slipping choke knob left pulled out fu
294. h a weight ratio 10 1 e Using the pinion gear holder A tighten the pinion gear nut B Special Tool Pinion Gear Holder m1 9 57001 1165 Torque Pinion Gear Nut 127 N m 13 0 kgf m 94 ft Ib OCheck the pinion gear bearing preload see Preload Ad justment in this chapter e Remove Pinion Gear Nut Washer Shim s Pinion Gear Joint with the O ring Pinion Gear with the Tapered Roller Bearing e Replace the oil seal with a new one e Drive the oil seal A using the bearing driver set B Special Tool Bearing Driver Set C 57001 1129 e Apply a thin coat of high temperature grease to the oil seal lip e Reinstall the above removed parts OStake A the pinion gear nut with a punch CAUTION When staking the nut be careful not to apply shock to the pinion gear and its bearing Such a shock could damage the pinion gear and or bearing 11 16 FINAL DRIVE Final Gear Case and Oil Pinion Gear Bearing Preload Adjustment Preload Measurement e Check and adjust the bearing preload in the following case OWhen any of the parts listed below are replaced with new ones Tapered Roller Bearings Bevel Gears Bearing Housing Pinion Gear Joint OWhen the pinion gear nut is loosened even if the purpose is not to replace the parts e Assemble the pinion gear bearing housing and tighten the pinion gear nut to the specified torque Oil seal instal lation is not required until the correct b
295. h the terminal bolt D e Put the armature A among the brushes and remove the plastic washers B 16 58 ELECTRICAL SYSTEM Starter Motor e Fit the tang A of the brush plate into the left end cover groove B e Apply a thin coat of grease to the oil seal B in the right end cover A e Apply a thin coat of grease to the left bearing A e Fit shims onto the right end cover OThe line on the yoke should align A with the line on the left cover Torque Starter Motor Assembly Bolts 4 9 N m 0 50 kgf m 43 in lb Brush Inspection e Measure the length A of each brush x If any is worn down to the service limit replace the carbon brush holder assy B and the terminal bolt assy C Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 8 5 mm 0 33 in ELECTRICAL SYSTEM 16 59 Starter Motor Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves 6P11061081 e Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 Q hand tester range measure the resis tance between any two commutator segments A x lf there is a high resistance or no rea
296. hart For example Suppose the local altitude is 1 300 m 4 200 ft and the sensor output voltage Va is 3 3 V Plot this H 1 300 m at a point 1 on the following 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 2 3 64 V Plot Va 3 3 V on the vertical line Point 3 Results In the chart Va is within the usable range and the sensor is normal FUEL SYSTEM DFI 3 61 Atmospheric Pressure Sensor Service Code 15 10000 ft H Altitude m or feet SL Sea Level 0 m ST Standard of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v Va Atmospheric Pressure Sensor Output Voltage v 3 62 FUEL SYSTEM DFI Crankshaft Sensors 1 2 Service Code 21 22 Crankshaft Sensor 1 for Front Cylinder Service Code 21 Crankshaft Sensor 2 for Rear Cylinder Service Code 22 Crankshaft Sensor Removal Installation e See Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft sensors have no power source and when the engine stops the crankshaft sensors generates no signals e Remove the alternator outer cover and check the wiring for continuity using the following diagram e Crank the engine and measure the peak voltage of the crankshaft sensors see Crankshaft Sensor Inspection in the Electrical System chapter in order to check the coils
297. he automatic turn signal canceling system esia P Fourth Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight should go on Alf the low beam headlight does not go on inspect or re place the following item Headlight Beam Bulb see Headlight Bulb Replacement in the Electrical System chapter Headlight Fuse 10 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 ste F 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Set the dimmer switch to high beam position e The high beam headlight should go on e The high beam indicator light A should go on x If the high beam headlight and or high beam indicator light does not go on inspect or replace the following item Headlight Bulb see Headlight Bulb Replacement in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter e Turn off the engine stop switch e The low beam and high beam headlights should stay go ing on x If the headlights and high beam indicator light 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 off the
298. he bottom of the saddlebag into the dampers A in the saddlebag stay lower e Fit the hook A behind the bag B into the catch C on the saddlebag stay upper D At this point the bag is free to move on the mounts 15 24 FRAME Travel Trunk and Saddlebags e Open the lid see Lid Unlatching in this section and tighten the bag bolts A Washer s B Saddlebag C Saddlebag Stay upper D Front E e Close the lid see Lid Latching in this section x If the lid does not work properly adjust the bag clearance to mount the bag snugly without being distorted e Remove the bag bolts G e Lightly push the bag A towards the upper stay B and measure each bag clearance E between the boss C and damper D with a thickness gauge x If both clearances are 1 0 mm 0 04 in or less standard clearance the bag can be mounted snugly and the lid may be locked x If either clearance is more than 1 0 mm 0 04 in when the other clearance is 0 mm insert the washer s F as shown to get the standard clearance e Install the bag and bag bolts and tighten the bolts se curely e Open and close the lid several times to check for smooth operation Be sure the lid latches and locks securely x If the lid does not work properly remove the bag bolts and readjust the clearance GO15000BS1 6015010181 FRAME 15 25 Guards Front Guard Removal Installation e Remove Front Footbo
299. he fuel pump and the fuel level sensor connec tors and the battery lead terminal Fuel Tank and Cap Inspection 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 breather pipe B in the tank is not clogged x If the breather pipe is clogged blow the breather free with compressed air Alf the tank cap breather is clogged replace the tank cap Front C CAUTION Do not apply compressed air to the air vent holes D in the tank cap This could damage and clog the labyrinth in the cap 3 110 FUEL SYSTEM DFI Fuel Tank Fuel Tank Cleaning WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the tank e Remove the fuel tank see Fuel Tank Removal in this chapter e Remove the fuel pump from the fuel tank see Fuel Pump Removal in this chapter e Fill the fuel tank with some high flash point solvent and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the tank e Dry the tank with compressed air e Install the fuel pump on the fuel tank see Fuel Pump In stallation in this chapter e Install the fuel tank see Fuel Tank Installation in this chap ter FUEL SYSTEM DFI 3 111 Evaporative Emi
300. he left side of the right crankcase e Apply a non permanent locking agent to the threads of the relief valve and install it Torque Relief Valve 15 N m 1 5 kgf m 11 ft lb Oil Hose Removal E WFA Y az CA Bee E e e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Rocker Case Covers see Rocker Case Cover Removal in the Engine Top End chapter Oil Hose Flange Bolts A Front B 7 10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line e Remove Oil Hose Banjo Bolt A Front Oil Hose B Front Oil Hose C Oil Hose Installation e Run the front oil hose over the rear oil hose as shown Olnsert the rear oil hose A first ONext insert the front oil hose B ORun both oil hoses between the rocker case and the rocker case cover Torque Oil Hose Flange Bolts 9 8 N m 1 0 kgf m 87 in Ib e Hook the front oil hose to the clamps C e Fit the clamp D as shown 6609018BS2 C e Install each bottom end of the oil hoses on the right crankcase behind the rear cylinder as shown Front Oil Hose A Rear Oil Hose B Front C OFace the paint marks D rearward e Replace the copper washers on each side of the banjo bolt with new ones Torque Oil Hose Banjo Bolt E 9 8 N m 1 0 kgf m 87 in lb e Install the removed parts see appropriate chapters EE of VY OF 6G09017BS2 C ENGINE LUBRICATION SYSTEM 7 11 Oil Pump and Oil Line
301. he right end of the balancer shaft Needle Bearing B Collar C Copper Washer D Starter Clutch E e Unscrew the primary gear bolt A while holding the alter nator rotor steady with the flywheel holder OThe primary gear can be removed with the engine in the frame Special Tool Flywheel Holder 57001 1410 e Take the end of the spring A off the hook and unscrew the bolts B e Remove the idle shaft holder C and chain guide D from the right crankcase OThe idle shaft holder can be removed with the engine in the frame OPushing the idle shaft E remove the holder e Remove the washer A e Take out the water pump drive sprocket B chain C and idle shaft sprocket D as a set e Take the idle shaft E out of the crankcase OThe idle shaft has two pins e Pull the primary gear A out of the crankshaft e Remove the idle shaft sprocket B with the flat washer from the water pump chain C CRANKSHAFT TRANSMISSION 9 11 Crankcase e Remove Lower Chain Guide Bolts A Lower Chain Guide B Rear Camshaft Chain C Rear Chain Guide Bolts D Rear Chain Guide E Front Chain Guide Retainer Bolt F Front Chain Guide Retainer G e Loosen the left balancer gear bolt A using the flywheel holder B OThe left balancer gear bolt has right hand threads Special Tool Flywheel Holder 57001 1410 e Remove the alternator rotor bolt C and the alternator rotor D e Remove the alte
302. he shift drum bearing holder bolts e Install Shift Drum Bearing Holder A Bolts B Torque Shift Drum Bearing Holder Bolts 11 N m 1 1 kgf m 97 in Ib e Apply engine oil to the shift rod the shift forks and Trans mission gears Shift Drum Disassembly Assembly e Remove the shift drum assy A see Transmission Re moval in this section e Remove Cotter Pin B Pin C Drive Shaft Shift Fork No 292 Drive Shaft D e Disassemble the shift drum assy as shown Shift Drum Cam Bolt A Pin Plate B Pin C Cam D Bearing E Shaft Drum F G113203BS1 9 34 CRANKSHAFT TRANSMISSION Transmission e Be sure to face the number to the right and insert the cotter pin A of the drive shaft shift fork B from the right as shown Shift Drum C Pin D Bearing E Cam F Pin Plate G e Apply a non permanent locking agent to the threads of the shift drum cam bolt H Torque Shift Drum Cam Bolt 15 N m 1 5 kgf m 11 ft lb Transmission Disassembly e Remove the transmission shafts see Transmission Re moval in this section e Using the circlip pliers special tool remove the circlips and disassemble the transmission shaft Special Tool Outside Circlip Pliers 57001 144 OThe 4th gear A on the output shaft has three steel balls for the positive neutral finder mechanism e Remove the 4th gear as follows OSet the output shaft in a vertical position holding the 3rd gear
303. he stator D off the alternator cover Alternator Outside Stator Installation e Apply a non permanent locking agent to the threads of the alternator stator bolts e Install the stator A with the BK leads on the alternator cover B Torque Alternator Stator Bolts 13 N m 1 3 kgf m 115 in 1b e Apply a non permanent locking agent to the threads of the stator lead holder screw e Install the stator lead holder C and tighten the screw D Torque Stator Lead Holder Screw 9 8 N m 1 0 kgf m 87 in 1b 6P09073BS1 ELECTRICAL SYSTEM 16 37 Charging System e Set up the dampers A and crankshaft sensor holders B to the pickup coils C e Install the crankshaft sensors as shown OCrankshaft sensor A with shorter leads BK and BK Y for 1 front OCrankshaft sensor B with longer leads BK W and BK R for 2 rear Torque Crankshaft Sensor Screws 2 9 N m 0 30 kgf m 26 in Ib e Apply a non permanent locking agent to the threads of the crankshaft sensor lead holder bolt ORun the longer crankshaft sensor leads over the shorter crankshaft sensor leads above the alternator leads Torque Crankshaft Sensor Lead Holder Bolt 2 9 N m 0 30 kgf m 26 in Ib e Apply silicone sealant to the sides H of the grommets as shown and fit the grommets into the notch of the alterna tor cover Sealant Kawasaki Bond Silicone Sealant 92104 0004 OFirst install the grommet C for the alt
304. he taillight and license plate light should go on x If the light does not go on inspect or replace the following item Ignition Switch see Switch Inspection in the Electrical System chapter Third Step e Turn on the turn signal switch A left or right position e The left or right turn signal lights B front and rear ac cording to the switch position should flash e The turn signal indicator light C in the meter unit should flash x lf the each light does not flash inspect or replace the following item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Turn Signal Light Indicator Bulb see Meter Unit Assem bly in the Electrical System chapter Turn Signal Control Relay Fuse 10 A see Fuse Inspec tion in the Electrical System chapter Turn Signal Switch see Turn Signal Switch Electrical System chapter Turn Signal Control Relay see Turn Signal Control Re lay Inspection Electrical System chapter Harness see Wiring Inspection in the Electrical System Inspection in the chapter e Push the turn signal switch e The turn signal lights and indicator light should go off x lf the light does not go off inspect or replace the following item Turn Signal Switch see Turn Signal Switch Inspection in the Electrical System chapter Turn Signal Control Relay see Turn Signal Control Re lay Inspection in the Electrical System chapter NOTE ORefer to the Electrical system chapter for t
305. hem 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 per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace 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 020158 S 020168 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount
306. hen 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 considerably 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 CAUTION 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 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Water Hose Clamp A Water Hose B Front C e Remove Water Pump Cover Bolts A Water Pump Cover B e Remove Impeller Bolt A Impeller B NOTE OThe impeller bolt has left hand threads Turn the bolt clockwise and remove it Water Pump Installation e Tighten the water pump impeller bolt by turning the bol
307. hen 24 V is applied mo mentarily to the BK R terminal the regulator rectifier is defective Replace it x lf the regulator rectifier passes all the tests described it may still be defective If the charging system still does not work properly after checking all the components and the battery test the regulator rectifier by replacing it with a known good unit e Repeat the test for another regulator rectifier 6P100004S1 GP100005S1 6P10000681 ELECTRICAL SYSTEM 16 43 Charging System Charging System Circuit GPOSO56BH3 Ignition Switch Alternator 2 inside stator Regulator Rectifier 2 Alternator 1 outside stator Regulator Rectifier 1 Battery Joint Connector 2 Main Fuse 30 A Starter Relay Load 16 44 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition Malfunctioned engine Ignition system wiring and connector inspection Spark plug inspection No good __ Repair or replace No good Replace Plug cap inspection Good No good Replace Voltage is less than the Ignition coil primary peak voltage inspection specified value Good No good Voltage is OK Voltage is zero or almost zero Ignition coil is defective Inspect Adapter connection is incorrect or adapter is defective Ignition switch and engine stop switch Battery voltage Cr
308. his section Diode Circuit Inspection 13 8 13 9 12 11 12 14 15 14 16 14 x The resistance should be low in 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 junction box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale Tester Connection ELECTRICAL SYSTEM 16 99 Junction Box Junction Box Internal Circuit TJOD 9 000060 Gig GI A Accessory Fuse 10 A B Fan Fuse 15A C Turn Signal Fuse 10 A D Horn Fuse 10 A E Ignition Fuse 10 A F Headlight Fuse 10 A G Headlight Relay H Headlight Diodes Starter Diode J Starter Circuit Relay K Interlock Diodes L Taillight Fuse 10 A GP19005B 2 16 100 ELECTRICAL SYSTEM Fuse Main Fuse Removal e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Coolant Reservoir Tank see Coolant Change in the Pe riodic Maintenance chapter e Remove the starter relay A e Pull out the main fuse B from the starter relay with needle nose pliers Junction Box Fuse Removal e Remove the right side cover see Right Side Cover Re moval in the Frame chapter e Unlock the hook to lift up the lid A e Pull the fuses B straight out of the junct
309. hrottle Cable see Throttle Body Assy Removal in the Fuel System DEI chapter Front and Rear Exhaust Pipes see Exhaust Pipe Re moval in the Engine Top End chapter Alternator Outer Cover see Alternator Outer Cover Re moval in the Electrical System chapter Radiator see Radiator Removal in the Cooling System chapter Thermostat Housing see Thermostat Removal in the Cooling System chapter Ignition Coil 1 and 2 see Ignition Coil Removal in the Electrical System chapter Left and Right Front Guards see Front Guard Re moval Installation in the Frame chapter 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Right Spark Plug Lead Holder A Throttle Body Assy Holder B Engine Ground Terminal C e Remove Throttle Sensor Connector A Inlet Air Pressure Sensor Hose B e Remove Injector Connectors A Fuel Hose B Connector C e Remove Horn A Choke Knob B e Disconnect Regulator Rectifier Lead Connectors A Alternator Lead Connectors B Crankshaft Sensor Lead Connector C Side Stand Switch Lead Connector D Speed Sensor Lead Connector E Oil Pressure Switch Neutral Switch Connector F ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Remove Bracket Bolts A Clutch Hose Bracket B Clutch Slave Cylinder Bolts C Clutch Slave Cylinder D see Clutch Slave Cylinder Re moval in the Clutch chapter e Remove Bracket Bolts A Regulator Rec
310. hroughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color 65020238 GENERAL INFORMATION 1 7 Model Identification VN1600 D1 US and Canada Left Side View VN1600 D1 US and Canada Right Side View Soe P 1 8 GENERAL INFORMATION Model Identification VN1600 D1 Europe Left Side View 098163 P VN1600 D1 Europe Right Side View 09816 P GENERAL INFORMATION 1 9 General Specifications Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plugs Cylinder Numbering method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Items VN1600 D1 Dimensions Overall Length 2 515 mm 99 02 in Overall Width 1 040 mm 40 9 in AU 990 mm 39 in Overall Height 1 460 mm 57 5 in Wh
311. ht switch housing into the hole B of the handlebar e Turn the throttle grip and make sure that the throttle valves move smoothly and return by spring force e Check the throttle grip free play see Throttle Control Sys tem Play Inspection in the Periodic Maintenance chapter A WARNING Operation with an incorrectly routed cable could re sult in an unsafe riding condition FUEL SYSTEM DFI 3 99 Throttle Body Assy e Fit the fuel hose joint 2 A onto the pipe for delivery joint until the joint clicks B Olnsert the hose joint straight along the pipe Front C e Push and pull A the fuel hose joint 2 B back and forth more than two times and make sure it is locked and doesn t come off When the fuel hose joint 2 is correctly installed it should slide on the delivery pipe about 5 mm 0 2 in A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak e Install the removed parts see appropriate chapters Throttle Body Assy Disassembly Assembly e Remove the throttle body assy see Throttle Body Assy Removal in this section e Unscrew two bolts A and pull out the ISC pipe 1 B and ISC pipe 2 C from the hoses D Bottom View E e Remove the three throttle body flange bolts A 3 100 FUEL SYSTEM DEI Throttle Body Assy e Split the throttle body assy into the throttle body A and the inlet manifold
312. hts flicker at regular intervals the injector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection Olnjector signals can be also confirmed by connecting the hand tester x 10 V AC instead of the test light set to the injector main harness female connector Crank the en gine with the starter motor and check to see if the needle oscillates at regular intervals Special Tool Hand Tester 57001 1394 x If the test light doesn t flicker or the tester needle doesn t oscillates check the wiring and connectors again If the wiring is good the ECU is suspect Replace the ECU Injector Resistance Inspection e Remove the fuel tank see Fuel Tank Removal in this chapter e Disconnect the connector from the injector A see Injec tor Removal in this chapter e Measure the injector resistance with a digital meter B Front C Injector Resistance Connections to Injector Meter Meter 1 WIR BL R Terminal 2 WIR gt BL G Terminal Standard 11 7 12 3 Q at 20 C 68 F x If the reading is out of the range perform the Injector Unit Test x lf the reading is normal perform the Injector Unit Test for confirmation 6017024281 6017024381 FUEL SYSTEM DFI 3 73 Fuel Injectors 1 2 Service Code 41 42 Injector Unit Test e Use two wires A and the same test light set B as in Injector Signal Test
313. ic Maintenance chap ter CLUTCH 6 7 Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi tion 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 Clutch Master Cylinder Removal e Disconnect the starter lockout switch connector A e Draw out the clutch fluid from the reservoir with a means like the fork oil level gauge e Remove the banjo bolt B to disconnect the clutch hose from the master cylinder e Unscrew the clamp bolts C and take off the master cylin der D as an assembly with the clutch reservoir clutch lever and starter lockout switch installed CAUTION Clutch fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Clutch Master Cylinder Installation OThe master cylinder clamp must be installed with the rear view mirror boss A upward e Set the clutch master cylinder B to match its mating sur face C to the punch mark D of the handlebar e Tighten the upper clamp bolt E first and then the lower clamp bolt F There will be a gap at the lower part of the clamp after tightening Torque Clutch Master Cylinder Clamp Bolts 11 N m 1 1 kgf m 97 in lb e Use a new flat washer on e
314. ic lash adjuster damaged worn seizure or spring broken HLA oil passage clogged Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Throttle body assy loose APPENDIX 17 29 Troubleshooting Guide Choke knob left pulled out Throttle body assy O ring damage Air cleaner duct loose Air cleaner O ring damaged Fuel pump trouble 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 warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface KACR sticks open engine stalls when mov ing off HLA seizure Backfiring when deceleration Vacuum switch valve broken Air suction valve trouble Other IC igniter in ECU trouble Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too high Brake dragging Engine overheating Clutch slipping Air suction valve trouble Vacuum switch valve trouble Poor Running or No Power at H
315. ical e Insert the axle from the right side of the wheel e Tighten the axle Torque Front Axle Shaft 108 N m 11 0 kgf m 80 ft lb e Before tightening the clamp bolts on the right fork leg pump the forks up and down A 4 or 5 times to allow the right fork leg to find a neutral position on the front axle NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block in front of the wheel to stop it from moving e Tighten the axle clamp bolts A to the specified torque Torque Front Axle Clamp Bolts 29 N m 3 0 kgf m 21 ft Ib NOTE OTighten the two front axle clamp bolts alternately two times to ensure even tightening torque e Check the clearance B between the front axle collar C and the right fork leg D The clearance between the front axle collar and the right fork leg should be between 1 05 EE 3 19 mm 0 041 0 124 in x If the clearance is out of this range remove the front wheel again and check the axle wheel hub and other related parts for damage e Tighten the caliper mounting bolts Torque Front Caliper Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e Check the front brake effectiveness A WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done
316. icator LED light doesn t go on and no fault codes can be displayed Fl Indicator LED Light ISC Valves DFI Main Relay Ignition Coil Secondary Wiring check the internal resistance see Electrical System chapter ECU Power Source Wiring and Ground Wiring see ECU Inspection in this chapter OFor example if two problems of 12 and 15 occur the service code 12 and 15 are shown as follows FUEL SYSTEM DEI 3 41 Self Diagnosis Fl Indication starts Indicator Fault Codei2 Fault Codei2 10th digit Unit digit ON LED Light Fault Code12 Fault Code15 66170262w1 OEach service code is continuously repeated three times until the ignition switch is turned OFF Code12 3times Code15 3times Code12 3times m gt Second Service Code Erasing OWhen the repair has been done the LED light will not show fault codes any more But even if the repair has been done the ignition switch is turned OFF or the battery is disconnected all the fault codes remain in the ECU which need not be absolutely erased 3 42 FUEL SYSTEM DFI Self Diagnosis Service Code Table Service e FI Indicator LED Light Problems 1 a A G Throttle sensor malfunction wiring open or short elmmn l Vacuum sensor malfunction wiring open or short 13 E AECH Inlet air temperature sensor malfunction wiring open or short Hi Water temperature sensor malfunction wiring open or short EA A Te a pressure sensor malfun
317. icator light does not go on inspect the bulb e Check conductivity of the bulb with the hand tester x If the bulb is open replace the bulb x Even if the bulb is replacement but the indicator light does not go on replace the meter unit GP17105B83 o High Beam Indicator Light e Connect the lead to the terminal 16 and battery positive lead High Beam Indicator Light Connections Battery Positive Lead to Terminal 16 OThe high beam indicator light A should go on x lf the indicator light does not go on inspect the bulb e Check conductivity of the bulb with the hand tester x If the bulb is open replace the bulb x Even if the bulb is replacement but the indicator light does not go on replace the meter unit 6P17106BS2 C ELECTRICAL SYSTEM 16 89 Meter Gauge Meter Unit Circuit Meter Unit Odometer Trip Meter Clock LCD Speedometer Fuel Meter Illuminator LED Fuel Indicator LED Water Temperature Warning Fl Oil Pressure Warning Indicator LED Mode Button Reset Button High Beam Indicator Light Turn Signal Indicator Light Neutral Indicator Light Speed Sensor Joint Connector 2 GP17107B 3 Fuel Level Sensor Fuel Reserve Switch Turn Signal Control Relay Frame Ground Water Temperature Switch Oil Pressure Warning Light Delay Unit Neutral Switch Electronic Control Unit Jun
318. if the old guide is reused OTurn the reamer in a clockwise direction until the reamer turns freely in the guide Never turn the reamer counter clockwise or it will be dulled OOnce the guides are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 47 57001 162 Valve Guide Wear Wobble Method Olf a small bore gauge is not available inspect the valve guide wear by measuring the valve to guide clearance with the wobble method as indicated below The reading is not actual valve to guide clearance because the mea suring point is above the guide 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 to valve guide clearance e Repeat the measurement in a direction at a right angle 90 to the first x If the reading exceeds the service limit replace the guide Valve to Guide Clearance Wobble Method Standard Exhaust 0 08 0 15 mm 0 003 0 006 in Inlet 0 05 0 13 mm 0 002 0 005 in Service Limit Exhaust 0 35 mm 0 014 in Inlet 0 33 mm 0 013 in GE15011681 ENGINE TOP END 5 37 Cylinder Head Valve Seat Inspection e Remove the valve see Valve Removal in this section e Check the valve seat surface A between the valve B and valve seat C OMeasure the outside diameter D of th
319. igh Air suction valve trouble Vacuum switch valve trouble Catalytic converters melt down due to muf fler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect IC igniter in 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 17 30 APPENDIX Troubleshooting Guide For KLEEN do not start the engine under misfire due to spark plug fouling or poor connection of the spark plug For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine IC igniter in ECU trouble Fuel air mixture incorrect Throttle body assy loose Throttle body assy O ring damage Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner O ring damaged Air cleaner clogged Compression high Carbon built up in combustion chamber KACR sticks close Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too high Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Water temperature warning system incorrect Water tem
320. igh Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel air mixture incorrect Choke knob left pulled out Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Air cleaner O ring damaged Water or foreign matter in fuel Throttle body assy loose Throttle body assy O ring damage Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble 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 Valve not seating properly valve bent worn or carbon accumulation on the seating surface KACR sticks open engine stalls when mov ing off HLA seizure Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Be sure to use high octane gasoline recommended by Owner s Manual Spark plug incorrect IC igniter in ECU trouble Miscellaneous Throttle valves won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too h
321. il Pump Removal in this chapter e Check to see if the valve slides smoothly when pushing it in with a wooden or other soft rod and see if it comes back to its seat by spring pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance lf 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 Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent Valve A Spring B x If cleaning does not solve the problem replace the relief valve as an assembly The relief valve is precision made with no allowance for replacement of individual parts 6608060281 ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents leie 210 AE 8 2 Special TOS genee Annies ee eat eas at sien teva eee EA Aaa 8 4 Engine Removal MstalatO EE 8 5 Engine REMOVAL AAA ATA A et 8 5 Engine Install de EE 8 8 8 2 ENGINE REMOVAL INSTALLATION Exploded View 6H02053BW5 C ENGINE REMOVAL INSTALLATION 8 3 Exploded View No Fastener ee Remarks N m kgf m ft Ib 1 Downtube Bolts 59 6 0 44 2 E
322. in the engine oil see Engine Oil Change in this chap ter e Remove the oil filter A with the oil filter wrench B and discard the oil filter Special Tool Oil Filter Wrench 57001 1249 NOTE OThe filter has an oil filter bypass valve which can not be removed e Replace the oil filter with a new one e Apply engine oil to the gasket A of the new filter before installation e Tighten the filter with the oil filter wrench Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 18 N m 1 8 kgf m 13 ft lb e Pour in the specified type and amount of oil see Engine Oil Change in this chapter 6605040281 PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Fuel Hose Replacement e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Disconnect the 2 fuel injector connector A e Pinch the lock of the fuel hose joint 2 with fingers dis connect the joint A and take out the fuel hose assy B Front C A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage e Replace the fuel hose with a new one e Fit the fuel hose joint 2 A onto the pipe for delivery joint until the joint clicks B Olnsert the hose joint straight along the pipe Fron
323. in this chapter e Remove the clamp bolt caps e Unscrew the clamp bolts C and take offthe master cylin der as an assembly with the reservoir brake lever and brake switch installed CAUTION Immediately wash away any brake fluid that spills Front Master Cylinder Installation e Set the front master cylinder A to match its mating sur face B to the punched mark C of the handlebar OThe master cylinder clamp must be installed with the rear view mirror boss A faced upward e Tighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in lb e Install the clamp bolt caps e Use a new flat washers A on each side of the brake hose fitting e Tighten the brake hose banjo bolt B Torque Front Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft lb e Replenish the fluid in the reservoir and bleed the brake line see Bleeding the Brake Line in this chapter e Check the brake for good braking power no brake drag and no fluid leakage 078140 P o7et4t P 12 16 BRAKES Master Cylinder Rear Master Cylinder Removal e Remove the brake fluid reservoir cover see Brake Pedal Position Adjustment in this chapter e Draw out the brake fluid from the reservoir with a means like the fork oil level gage e Remove the brake fluid reservoir see Brake P
324. inding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm 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 set lever spring weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise Knocking IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Be sure to use high octane gasoline recommended in Owner s Manual Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn APPENDIX 17 31 Troubleshooting Guide Connecting rod bent Piston pin piston pin hole worn Valve noise Engine not sufficiently warmed up after HLA installation HLA damaged worn seizure or spring bro ken HLA aeration due to low oil level Air in HLA Metal chips or dust jammed in HLA Engine operated in red zone Valve spring broken or weak Camshaft bearing portion worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine
325. ing condition Only air or nitrogen gas can be used Never inject oxygen or any kind of explosive gas Rear Shock Absorber Removal e Lift the rear wheel off the ground using the jack and the attachment jack Special Tools Jack 57001 1238 Attachment Jack 57001 1398 SUSPENSION 13 17 Rear Shock Absorber Air Type e Squeeze the brake lever slowly and hold it with a band A CAUTION Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over The motorcycle could be damaged 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 the left and right saddlebags see Saddlebag Re moval in the Frame chapter e Remove the nuts A lock washers and flat washers from both ends of the rear shock absorber B e Pull the rear shock absorber off the frame Rear Shock Absorber Installation e Install the sleeve A so the flange side faces inside e Install the rear shock absorber so that the air valve B faces forward C e Tighten the rear shock absorber nuts D to the specified torque Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 ft Ib e Install the left and right saddlebags see Saddlebag In stallation in the Frame chapter Rear Shock Absorber Inspection e Remove the rear shock absorbers A e Visually inspect the following items
326. ing surface of the right crankcase B Sealant Kawasaki Bond 92104 1064 ODo not apply liquid gasket to the area C around the hole of the oil screen ODo not drop liquid gasket into the oil passage D OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out around the mating surface especially around the area E NOTE OMake the application finish within 30 minutes when the liquid gasket to the mating surface of the right crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket e Tighten the crankcase bolts as follows OLightly tighten all the bolts to a snug fit OTighten the M8 and M10 bolts in the order shown and then tighten the M6 bolts to the specified torque Torque M8 Crankcase Bolts 1 6 21 N m 2 1 kgf m 15 ft lb M10 Crankcase Bolts 7 9 39 N m 4 0 kgf m 29 ft Ib Front A Torque M6 Crankcase Bolts 11 N m 1 1 kgf m 97 in Ib L 80 mm 3 1 in A L 70 mm 2 8 in B L 40 mm 1 6 in C Front D e After tightening all the crankcase bolts check the follow ing items OWipe up the liquid gasket that seeps out around the crankcase mating surface OTurn the right crankcase down and check that the drive shaft and output shaft turn freely 6104013BS1 G104180BS1 CRANKSHAFT TRANSMISSION 9 17 Crankcase OCheck that the positive n
327. ing up through the fluid from the holes at the bottom of the reser voir This bleeds the air from the master cylinder end of the line NOTE OTap the clutch hose lightly going from the lower end to the upper end and bleed the air off at the reservoir e Attach a clear plastic hose A to the bleed valve on the clutch slave cylinder and run the other end of the hose into a container e Bleed the clutch line as follows Pump the clutch lever a few times until it becomes hard and then hold it applied B Quickly open and close C the bleed valve Release D the clutch lever Check the fluid level in the reservoir often replenishing it as necessary NOTE Olf 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 en tered the line ORepeat this operation until no more air can be seen com ing out into the plastic hose A WARNING Do not mix different grades and brands of fluid Torque Clutch Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib Clutch Slave Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Clutch Hose Removal Installation OSince the clutch hose is the same as the brake hose re fer to the Brake Hoses section in the Brakes chapter for clutch hose removal or installation Clutch Hose and Connection Check e Refer to the Clutch Hose Damage and Installation Condi tion Inspection Check in the Period
328. inner wall of the cylinder CAUTION Do not remove the secondary cup from the piston since removal will damage it e Tighten the brake lever pivot bolt and the locknut Silicone Grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Dust Cover Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 8 7 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib Caliper Rubber Parts Replacement Front Caliper Disassembly e Remove Front Caliper see Front Caliper Removal in the Brakes chapter Cotter Pin A Pin B Pads C e Push the piston in e Remove Pad Springs A Caliper Holder B 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Using compressed air remove the piston A WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers Olnsert a wooden board A 5 mm 0 2 in thick inside the caliper opening OApply compressed air B to the banjo bolt hole to allow the pistons C to protrude and stop at the wooden board ORemove the wooden board and pull out the piston by hand x If compressed air is not available with the brake hose still attached apply the brake lever to remove the pistons The remaining process is as described above e Remove Dust Seals A Fluid Seals Piston Seals B Frict
329. ion Damage Replace the stem cap if its grease seal A shows dam age FRAME 15 1 Frame Table of Contents Exploded View 15 2 Special Tools 15 8 A EE 15 9 Rear Seat Removal 15 9 Rear Seat Installation 15 9 Front Seat Removal 15 9 Front Seat Installation 15 9 Side COVERS e aiaa ri 15 10 Left Side Cover Removal 15 10 Left Side Cover Installation 15 10 Right Side Cover Removal 15 10 Right Side Cover Installation 15 10 Ele Sia tes seu 15 11 Front Fender Removal 15 11 Rear Fender Removal 15 11 Rear Fender Installation 15 12 Battery EE 15 13 Battery Case Removal 15 13 Battery Case Installation 15 14 TOOLBOX adi 15 15 Tool Box Removal 15 15 Footboard aeaa 15 16 Front Footboard Removal Instal E Idien fer et A eke 15 16 Front Footboard Disassembly 15 16 Front Footboard Assembly 15 17 Rear Footboard Removal Installa TI OW ies en secteur cd 15 17 Rear Footboard Disassembly 15 17 Rear Footboard Assembly 15 17 Side Stand 15 19 Side Stand Removal 15 19 Side Stand Installation 15 19 Windshield WEE 15 20 Windshield Height Adjustment 15 20 Windshield Removal 15 20 Windshi
330. ion Boot C Bleed Valve CAUTION Immediately wash away any brake fluid that spills Front Caliper Assembly e Clean all parts other than the outer and inner pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol E e Install the bleed valve A and the rubber cap B Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib 6L050401S1 e Replace the fluid seals A with new ones apply brake fluid to them and install them in the caliper body Either side of the fluid seal may face outboard e Check the dust seals B and replace them with new ones if they are damaged 6L05040281 PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons A into the cylinders e Check the friction boot B and dust boot C and replace them with new ones if they are damaged e Apply a thin coat of silicon grease to the holder shafts D and the holder holes e Install the pad springs A e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wash the caliper with water to remove brake fluid and wipe it off Rear Caliper Disassembly e Remove the rear caliper with the hose installed see Rear Caliper Removal in the Brakes chapter e Remove the pads see Rear Brake Pad Removal in the
331. ion SW ON then start self diagnosis mode by pushing the meter buttons Fl indicator LED light blinks to display the fault code The LCD FI characters are displayed Locate the problem with the fault code table and inspect and repair DFI or ignition system according to inspection procedure on fault code 11 to 52 End the self diagnosis mode then remove the auxiliary wire v Make sure the FI indicator LED light and FI symbol do not go ON 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 Service Code Reading OService codes are shown by a series of long and short blinks of the FI indicator LED light as shown below ORead 10th digit and unit digit as the FI indicator LED light blinks OWhen there are a number of problems all the fault codes can be stored and the display will be gin starting from the lowest number service code in the numerical order Then after completing all codes the display is repeated until the ignition switch is turned OFF OFor example if four problems occurred in the order of 31 15 41 12 the fault codes are displayed from the lowest number in the order listed 12 gt 15 31 41 12 gt 15 31 41 gt repeated Olf there is no problem or when the repair has been done no service code is shown If the problem is with the following parts the ECU cannot memorize these problems the Fl ind
332. ion box with nee dle 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 junction box fuses on the original position as specified on the lid Fuse Inspection e Remove the fuse see Main Fuse Junction Box Fuse Re moval in this section e Inspect the fuse element x lf it is down 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 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 CAUTION Do not use a fuse rated for other amperage and volt age specified in the wiring diagram Installation of a fuse with a higher rating may cause damage to wiring and components and a fuse of a lower rat ing will soon blow again GP20000181 APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose ROUTE eee east 17 2 Troubleshooting Guide viciado iia 17 28 17 2 APPENDIX Cable Wire and Hose Routing lt d LAR z A a 7 il SH Y A MM 6809707845 C APPENDIX 17 3
333. ion switch ON OThe tester needle should indicate battery voltage for 3 seconds and then 0 V Operating Voltage at Pump Connector Standard Battery Voltage 12 6 V or more for 3 seconds and then 0 V x lf the reading stays on battery voltage and never shows 0 V Check the ECU and DFI main relay x lf the voltage is in specification but the pump doesn t work replace the pump x If there is still no battery voltage check the DFI main relay see DFI Main Relay Inspection in this chapter e After inspection remove the needle adapter and apply silicone sealant to the seal of the connector for water proofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of Fuel Pump Connector GC10008BS1 FUEL SYSTEM DFI 3 77 Fuel Pump Service Code 45 Power Source Voltage Inspection NOTE OBe sure the battery is fully charged WAR K x a e Remove the front seat see Front Seat Removal in the Frame chapter e Connect a digital meter A to the fuel pump connector B 2 pin using the needle adapter C Special Tool Needle Adapter Set 57001 1457 O GC10007BS1 Pump Power Source Voltage Connections to Pump Connector Tester Y R lead D Tester Battery Terminal E e Measure the power source voltage with the engine stopped and with the pump connector joined e Turn the ignition switch ON Power Source Voltage at Pump Connect
334. ir temperature sensor trouble Inspect and replace see chapter 3 FUEL SYSTEM DFI 3 39 Self Diagnosis Self diagnosis Procedures OWhen a problem occurs with the DFI system the Fl indi cator LED light A and Fl symbol B go on 6017204BS1 e Remove the front seat see Front Seat Removal in the Frame chapter e Ground A the self diagnosis terminal B yellow lead to the battery terminal C using a wire D e Turn the ignition switch ON e Push the MODE button A and display the odo meter e Push the RESET button B for more than two seconds The LCD FI characters C are displayed e Count the blinks of the LED light D to read the service code NOTE OUse a fully charged battery when conducting X self diagnosis Otherwise the LED light blinks very 9017205881 slowly or doesn t blink OKeep the self diagnosis female connector grounded during self diagnosis using a wire e Any of the following procedures conditions ends self diagnosis OWhen pushing the RESET button more than 2 seconds and 2 seconds passed OWhen the ignition switch is turned to OFF OPushing the MODE button and the trip meter is displayed OWhen the ECU receives the speed sensor signal 3 40 FUEL SYSTEM DFI Self Diagnosis Turn the ignition SW switch OFF Connect the self diagnosis female connector to the battery lead connector using an auxiliary wire Turn the ignit
335. irt gets through into the engine excessive en gine wear and possibly engine damage will occur Air Cleaner Element Cleaning e Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance Chapter Left Air Cleaner Housing Removal Installation e Remove Air Cleaner Element see Air Cleaner Element Removal in this section Air Cleaner Base Bolts A and Screws B e Remove the air cleaner base C OBe careful not to lose the air cleaner base mounting nuts A These nuts and lower air cleaner duct are sold as a unit e Apply a non permanent locking agent to the threads of the air cleaner base screws Torque Left Air Cleaner Base Bolts 11 N m 1 1 kgf m 97 in 1b Left Air Cleaner Base Screws 2 2 N m 0 22 kgf m 19 in lb Left Air Cleaner Cover Allen Bolt 16 N m 1 6 kgf m 12 ft lb FUEL SYSTEM DFI 3 103 Air Cleaner Right Air Cleaner Housing Removal e Remove Allen Bolt and Washer A Right Air Cleaner Cover B e Remove ISC Valve Hoses A ISC Valve Lead Connectors B Air Cleaner Allen Bolts C and Screws D Air Cleaner Base Bolt E Choke Knob F e Remove Air Cleaner Base A Inlet Air Temperature Sensor Connector B ISC Valve Leads C Crankcase Breather Hose D Air Cleaner Drain Hose E separate from the base A Vacuum Switch Valve Air Hose F OBe careful not to lose the air cleaner base mounting nuts G These nuts and lower air cleaner duct are sold as a
336. is chapter e Disconnect the connectors A 16 70 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System e Remove Front Turn Signal Light Bracket Bolts A Front Turn Signal Light Assy B e For rear turn signal light removal remove the rear fender see Rear Fender Removal in the Frame chapter e Turn over the rear fender and remove the cover bolts A and cover B e Disconnect the connectors A e Remove the rear turn signal light bracket bolts B e Remove the rear turn signal light assy from the rear fender e Remove the turn signal light mounting screws A e Remove the turn signal light B from the bracket C e Tighten Torque Turn Signal Light Mounting Screws 6 9 N m 0 70 kgf m 61 in Ib Turn Signal Light Bulb Replacement e Remove the turn signal light lens screw A and take off the lens B ELECTRICAL SYSTEM 16 71 Automatic Turn Signal Canceling System e Push the bulb A in the socket and turn the bulb counter clockwise B e Replace the bulb with a new one e Insert the new bulb A by aligning the pins B with the groove in the walls of the socket C e Fit the projection A in the recess B of the lens e Tighten Torque Turn Signal Light Lens Screws 1 0 N m 0 10 kgf m 8 7 in Ib 16 72 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Turn Signal Cancelling System Circuit TIE sn 16 G BK Y
337. ishaasotedigalctacenselsadelsedh laaninticeiacestasenegens 13 21 Swingarm Bearing Sleeve Inspection 13 21 Grease Seal and Needle Bearing Lubrication uu 13 21 13 2 SUSPENSION Exploded View D Gm oD OH D 000 Gi mM O 2e 6M021178W5 C SUSPENSION 13 3 Exploded View Torque No Fastener Nem kgfm Pe Remarks 1 Front Axle Clamp Bolts 29 3 0 21 AL 2 Front Fork Bottom Allen Bolts 30 3 1 22 L 3 Front Fork Clamp Bolts Upper 29 3 0 21 A Front Fork Clamp Bolts Lower 29 3 0 21 AL 5 Front Fork Inner Cover Bolts 4 0 0 40 35 in lb 6 Front Fork Top Plugs 22 2 2 16 AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 4 SUSPENSION Exploded View SUSPENSION 13 5 Exploded View Torque No Fast R k O astener Nom kgfm itib emarks 1 Rear Shock Absorber Nuts 34 3 5 25 2 Swingarm Pivot Shaft 127 13 0 94 G G Apply grease WL Apply a soap and water solution or rubber lubricant 13 6 SUSPENSION Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Diameter Fork Spring Setting Air Pressure Rebound Damper Setting Fork Oil Type Amount When Changing Oil After Disassembly and Completely Dry Fork Oil Level Fully Compres
338. iston seals and push the pistons into the cylinders by hand Take care that neither the cylinder nor the piston skirt gets scratched GLO5010BS1 PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e Replace the caliper holder shaft rubber friction boot A and dust boot B if they are damaged e Apply a thin coat of silicone or PBC grease to the caliper holder shafts C and holder holes Silicone or PBC grease is a special high temperature water resistance grease e Install the pads see Rear Brake Pad Installation in the Brakes chapter Spark Plug Replacement e Remove Fuel Tank for Rear Spark Plug see Fuel System chap ter Spark Plug Caps A e Remove the spark plug using the 18 mm 0 7 in plug wrench vertically Special Tool Spark Plug Wrench Hex18 57001 1024 CAUTION The insulator A of the spark plug may break if when the wrench is inclined during loosening Inclined Spark Plug Wrench B Contact Spark Plug and Plug Wrench C Bad D Vertically Spark Plug Wrench E Good F 6P10132BS1 e Replace the spark plug with a new one Standard Spark Plug Type NGK DPR6EA 9 or ND X20EPR UP e Insert new spark plug in the plug hole and finger tighten it first e Using the plug wrench A vertically tighten the plug CAUTION The insulator of the spark plug may break if when the wrench is inclined during
339. ith the plastigage 6105057BS1 6105055BS1 6105041751 CRANKSHAFT TRANSMISSION 9 27 Crankshaft Connecting Rods Crankshaft Runout e 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 0 002 in 6105058BS1 Crankshaft Main Bearing Journal Wear e Measure the diameter A of the crankshaft main journal Crankshaft Main Journal Diameter Standard 54 986 55 000 mm 2 1648 2 1654 in Service Limit 54 96 mm 2 164 in If any journal has worn past the service limit replace the crankshaft with a new one e Measure the main bearing bore diameter A in the crankcase halves Crankcase Main Bearing Bore Diameter Standard 55 025 55 038 mm 2 1663 2 1668 in Service Limit 55 07 mm 2 168 in Alf they are any signs of seizure damage or excessive wear replace the crankcase halves as a set FT 6105060881 Crankshaft Side Clearance e Measure the crankshaft side clearance Crankshaft Side Clearance Standard 0 05 0 55 mm 0 002 0 020 in Service Limit 0 75 mm 0 030 in Clearance A Crankcase B Crankshaft C 6105061281 Alf the clearance is greater than the service limit measure the crankshaft web length A to see whether the crank shaft or the crankcase is faulty
340. itive portion and threaded portion are submerged e Suspend an accurate thermometer B with heat sensitive portions C located in almost the same depth NOTE OThe switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using the hand tester special tool measure the internal resistance of the switch across the terminals at the tem peratures shown in the table x If the measurement is out of the range replace the switch Fan Switch Resistance ORising temperature From OFF to ON at 102 108 C 212 226 F OFalling temperature From ON to OFF at 97 103 C 203 217 F ON Less than 0 5 O OFF More than 1 MQ Water Temperature Switch Removal CAUTION The water temperature switch should never be al lowed to fall on a hard surface Such a shock to the part can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Disconnect the switch connector see Water Temperature Warning System Inspection in this chapter e Remove the water temperature switch A from the radia tor Water Temperature Switch Installation e Apply silicone sealant to the threads of the water temper ature switch Sealant Kawasaki Bond Silicone Sealant 59019 120 Torque Water Temperature Switch 7 8 N m 0 80 kgf m 69 in Ib
341. jack to lift the rear wheel see Rear Wheel Removal in the Wheel Tires chapter Special Tools Jack 57001 1238 Attachment Jack 57001 1398 e Set the hand tester to the DC25 V range and connect it to the LB lead terminal A and battery terminal B as shown Connections Hand Tester LB Lead Terminal Hand Tester Battery Terminal e Remove all the spark plugs and shift the gear into 1st e Turn the rear wheel slowly to see that the tester s pointer fluctuates repeated by reading 0 5 V and 12 V x lf the tester s pointer fluctuates distance sensor is nor mal x If the tester s pointer does not fluctuate inspect the speed sensor and turn signal control relay If the speed sensor and control relay are good replace the digital meter as sembly Turn Signal Switch Inspection e Open the headlight housing see Headlight Body Re moval in this chapter e Unplug the 9 pin connectors that leads to the left handle bar switch e Check the turn signal switch connections according to the table x If the switch has an open circuit or a short it can be disas sembled for repair The contact surfaces may be cleaned but no internal parts are available for replacement x lf any parts are not repairable the left handlebar switch must be replaced as a unit Turn Signal Switch Connections Color G O GY BKIY Y R L left e eo OFF push R right e ___ e ___
342. jector Connectors Terminal 30 Injector 1 Terminal WIR Terminal 30 Injector 2 Terminal WIR Terminal 40 Injector 1 Terminal BL R Terminal 39 Injector 2 Terminal BL G x If the wiring is good inspect the resistance of the injectors see Injector Resistance Inspection in this section e Remove the needle adapter e Apply silicone sealant to the seals of the ECU connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connectors 3 72 FUEL SYSTEM DFI Fuel Injectors 1 2 Service Code 41 42 Injector Signal Test e Prepare two test light sets with male terminals as shown Rating of Bulb A 12 V x 3 3 4 W Terminal Width B 1 8 mm 0 07 in Terminal Thickness C 0 8 mm 0 03 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main har ness connector female leading to harness repair or replacement Be sure to connect bulbs in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Remove the fuel tank see Fuel Tank Removal in this chapter e Plug the fuel hose ends e Remove connectors for injector A e Connect each test light set B to the injector main harness connector C e Connect the battery lead terminal e While cranking the engine with the starter motor watch the test lights lf the test lig
343. k to disconnect Join the connector and fit it into the slit of the bracket Ignition Switch Speedometer Fuel Level Sensor Con nector Main Harness Fuel Pump Run the fuel level sensor lead between the fuel pump and the fuel pump outlet pipe Fuel Tank Breather Hose Mark Position here GB09715BW4 C Fuel Tank Bottom View Two Recesses Position here Fuel Level Sensor Lead Inside of Fuel Tank Fuel Pump Outlet Pipe Clamps Clamp Fuel Pump Lead Press the clamps Raise the lock to disconnect Front Top 17 16 APPENDIX Cable Wire and Hose Routing I Neel yO O H N I gt E AN WO O o a 19 are 6B09716BW5 C APPENDIX 17 17 Cable Wire and Hose Routing gt gt 1 Vacuum Pulsation Bypass Air Flow For Front Cylinder For Rear Cylinder Top View Rear View Bottom View Delivery Joint Fuel Injector 2 Fuel Injector 1 ISC Hose 1 Blue Mark Throttle Sensor Vacuum Hose to Inlet Air Pressure Sensor Inlet Manifold ISC Hose 2 Red Mark ISC Pipe 1 ISC Pipe 2 Throttle Cable Holder Choke Lever Stop Screw Throttle Pulley Idle Adjusting Screw Throttle Stop Screw Throttle Body Throttle Body Assy ISC Pipe Damper Throttle Cable Decelerator Throttle Cable Accelerator Position the whi
344. k the case in oil and heat the oil e Using a press and the bearing driver set A install the new bearing or outer race until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball and Needle Bearing Wear CAUTION Do not remove the ball bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x lf there is any doubt as to the condition of a needle bear ing replace it 6114060581 6114010181 CRANKSHAFT TRANSMISSION 9 39 Ball Bearing Needle Bearing and Oil Seal Oil Seal Inspection e Inspect the oil seal Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents EXPO Views as 10 2 elen e le E
345. kage Fuel Tank Installation e Read the above WARNING e Route the hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e For California Model note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground OConnect the hoses according to the diagram ofthe system see the last page of this chapter or Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not get pinched or kinked ORoute hoses with a minimum of bending so that the air or vapor will not be obstructed FUEL SYSTEM DFI 3 109 Fuel Tank e Check that the rubber dampers A are in place x lf the dampers are damaged or deteriorated replace them ORemove the plug hoses and 98 mm 0 03 in plug then quickly install the fuel hoses one by one e Be sure the hoses are clamped securely to prevent leak age e Insert the fuel hose joint 1 A straight onto the tank outlet pipe B until the hose joint clicks C Front D e Push and pull A the hose joint B back and forth more than two times and make sure it is locked and doesn t come off When the hose joint is correctly installed it should slide on the delivery pipe about 5 mm 0 2 in Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak x lf it does not slide reinstall the hose joint e Connect t
346. kshaft main bearing e Insert the left crankshaft tapered end the longer end into the left crankcase OThe left shaft B of the crankshaft A is longer than the right shaft C SI P CRANKSHAFT TRANSMISSION 9 15 Crankcase e Install the balancer shaft A so that the flanged side B faces downward toward the left crankcase e Check to see that the following parts are in place in the left crankcase Transmission Assy A and Shift Drum Assy B Shift Fork C and Shift Rod D Crankshaft E Front Connecting Rod F Right Rear Connecting Rod G Left Balancer Shaft H Dowel Pins I O ring J Oil Baffle K Oil Pipe L Oil Return Pipe M e Install the following in the right crankcase Inside Oil Pipe and Oil Return Pipe see Inside Oil Pipe Installation in the Engine Lubrication System chapter Oil Separator see Inside Oil Pipe Installation in the En gine Lubrication chapter Oil Pump see Oil Pump Installation in the Engine Lubri cation System chapter e Install the water pump chain guide A OBe sure to install the collar B in the bolt hole Torque Water Pump Chain Guide Bolt 8 3 N m 0 85 kgf m 73 in Ib e Check to see that the following parts are in place in the right crankcase Oil Pipe A Oil Pump B Oil Separator C Oil Return Pipe D Water Pump Chain Guide E 9 16 CRANKSHAFT TRANSMISSION Crankcase e Apply liquid gasket A to the mat
347. l Throttle Body Assy Installation Throttle Body Assy Disassembly Assembly NAC Air Cleaner Element Removal 3 90 3 90 3 92 3 94 3 94 3 94 3 94 3 94 3 94 3 94 3 95 3 95 3 95 Air Cleaner Element Cleaning 3 102 Left Air Cleaner Housing Removal Installation 3 102 Right Air Cleaner Housing Removal neneanennnnoeenenenenn 3 103 Right Air Cleaner Housing Installation 3 103 Lower Air Cleaner Duct Removal Installation 3 104 Fue Tank diese Re tenant ieee 3 105 Fuel Tank Removal 3 105 Fuel Tank Installation 3 108 Fuel Tank and Cap Inspection 3 109 Fuel Tank Cleaning 000000aaaeeaaa 3 110 Evaporative Emission Control SYSTEM cinc iii 3 111 Parts Removal Installation 3 111 Canister Installation 3 111 Canister Inspection 3 111 Separator Inspection 3 111 Hose Inspection 3 112 Separator Operation Test 3 112 FUEL SYSTEM DFI 3 3 Dummy Page 3 4 FUEL SYSTEM DFI Exploded View 6002154BW5 C FUEL SYSTEM DFI 3 5 Exploded View Torque No Fastener Nem kgfm ft lb Remarks 1 Air Cleaner Duct Holder Bolts 10 1 0 89 in lb 2 Left Air Cleaner Base Bolt 11 1 1 97 in lb 3 Left Air Cleaner Base Screws
348. l 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 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings Oil seals Grease seals circlips or cotter pins must be replaced with new ones whenever disassembled Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given 68020088 S 680200 8 68020108 Zo Za E gt e MO 22 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 t
349. lation ici iaa 12 18 Brake Disc Wear seen 12 18 Brake DISC Walp 20 A a hate ee et a Ea 12 18 ELCH e EE 12 19 Brake Fluid Level Inspechon EEEE EEEE EEEEEEEEEEEEEE AEAEE EEEE EEEn E EEEE 12 19 Brake Fluid Change aiii 12 19 Brake Line Bleeding ieina rd 12 19 Brake HOSeS gai e Aaa 12 22 Brake Hose Removal Installation 0 cceccceccsecceeeceseceeeneeceeeeeeeeeeeseceeeeeeeeeseeeeeeenesaeenaees 12 22 12 2 BRAKES Exploded View BRAKES 12 3 Exploded View Torque No Fast R k o astener Nem Kofi a emarks 1 Brake Lever Pivot Bolt 1 0 0 10 8 9 in lb Sl 2 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 3 Front Brake Disc Bolts 27 2 8 20 L 4 Front Brake Hose Banjo Bolts 34 3 5 25 5 Front Brake Light Switch Screw 1 2 0 12 11 ml 6 Front Brake Reservoir Cap Screws 1 5 0 15 13 in lb 7 Front Caliper Bleed Valves 7 8 0 80 69 in lb 8 Front Caliper Mounting Bolts 34 3 5 25 9 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S 10 Hose Holders U S A and Canada Models B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence SI Apply silicone grease or PBC grease 12 4 BRAKES Exploded View IN WW e AF S 2 BRAKES 12 5 Exploded View Torque No Fastener Nem kgfm Pe Remarks 1 Brake Pedal Clamp Bolt 25 2 5 18 2 Rear Brake Disc Bolts
350. le Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 3 34 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Throttle sensor malfunction Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Loose injector connectors Remedy see chapter 3 Crankshaft sensor trouble Inspect and repair or replace see chapter 16 Ignition coil trouble Inspect and repair or replace see chapter 16 Loose terminal of battery lead or engine Inspect and repair see chapter 16 ground lead Delay of ignition timing Inspect pickup coil and IC igniter in ECU see chapter 16 Poor acceleration Choke knob left pulled out Push in see chapter 3 Too low fuel pressure Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Clogged fuel filter Inspect see chapter 3 and replace fuel pump Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 mn Le Le lA Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Ignition coil trouble Inspect an
351. lf the reading is less than the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter x If the reading is within the standard range check the sen sor output voltage FUEL SYSTEM DFI 3 59 Atmospheric Pressure Sensor Service Code 15 e Remove the needle adapters e Apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connector Output Voltage Inspection NOTE OThe output voltage changes according to the local at mospheric pressure x Check the output voltage of the sensor at the ECU con nector A Needle Adapters B Special Tool Needle Adapter Set 57001 1457 GC17722BS1 Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter gt BL Y lead terminal 28 Meter BR BK lead terminal 11 e Measure the output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Usable Range 3 74 4 26 V DC at the standard atmospheric pressure 101 32 kPa or 76 cmHg abs Alf the output voltage is about 4 8 V the ECU is normal Remove the fuel tank and check the wiring between the ECU and the sensor Alf the output voltage is not about 4 8 V and out of the usable range remove the fuel tank and check the wiring If the wiring is good check the sensor itself as follows x
352. light Body see Headlight Body Removal in the Electrical System chapter Front Wheel see Front Wheel Removal in the Tires Wheels chapter e Remove Bolts A Both Sides Left and Right Windshield Brackets B Front Fork Center Cover C e Remove Bolts A Brake Hose Clamp B Turn Signal Rights Bracket C STEERING 14 9 Steering Stem e Remove Bolts A Both Sides Front Fork Rear Covers B e Remove Bolt A Cable Bracket B e Remove Bolts A Headlight Body Stay B e Remove Brake Hose Banjo Bolt A Brake Hose B e Remove the brake hose joint bolt A 14 10 STEERING Steering Stem e Remove Handlebar Holder Bolt Cap and Bolts A Handlebar B e Remove Steering Stem Head Nut A Washer B e Loosen the front fork clamp bolts upper C e Remove O ring A Steering Stem Head B with Handlebar Holder e Loosen the front fork clamp bolts lower A e Remove the fork legs B e Remove Bolts A Both Sides Front Fork Inner Covers B STEERING 14 11 Steering Stem e Remove Claw Washer A Steering Stem Nut B Stem Cap C O ring D NOTE OBe sure to remove the O ring for removal of the steering stem e Pull out the steering stem E from the bottom Steering Stem Installation e Install Steering Stem A Bearing B New O ring C Stem Cap D Stem Nut E Claw Washer F e Tighten Torque Steering Stem Nut
353. light delay unit A Oil Pressure Light Delay Unit Inspection e Disconnect the lead A of the oil pressure switch B and ground C it to the engine using an auxiliary wire e Turn the ignition switch D ON x If the oil pressure warning LED light E in the meter unit is lit check the oil pressure switch connections see Switch Inspection in this chapter Alf the warning LED light is not lit check the warning LED light and wiring see Meter Unit Inspection in this chapter Alf the LED light and wiring are good replace the oil pres sure light delay unit F 6P26002BS1 16 76 ELECTRICAL SYSTEM Oil Pressure Warning System e Turn the ignition switch ON e Ground the oil pressure switch lead to the engine then the oil pressure warning LED light should be lit with a delay e Measure this delay time from grounding of the switch lead to lighting of the warning LED light Lighting Delay Time Standard about 3 seconds x lf the lighting delay time is out of the standard too far replace the oil pressure light delay unit ELECTRICAL SYSTEM 16 77 Meter Gauge Meter Unit Removal e Remove Bolts A and Washers Meter Cover B e Remove Cover A Ignition Switch Lead Connector B Meter Unit Lead Connector C e Remove the connector D from the bracket e Remove Bolts A Meter Unit B with Bracket e Remove Nuts A and Washers e Pull out the meter unit
354. lly push it in fully 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 gjajaja paja a aja papa pa jojo po o clutch slipping engine overheating engine oil level too high engine oil viscosity too high other 3 30 FUEL SYSTEM DFI DEI 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 OThe ECU may be involved in the DFI electrical and ignition system troubles If these 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 Engine Doesn t Start Starting Difficulty Symptoms or Possible Causes Actions chapter Starter motor not rotating Ignition and engine stop switches not ON Turn both switches ON Starter lockout switch or neutral switch trouble Inspect see chapter 16 Starter motor trouble Inspect see chapter 16 Battery voltage low Inspect and charge see chapter 16 Starter relays not contacting or operating Inspect the starter relay see chapter 16 Starter button not contacting Inspect and replace see chapter 16
355. logged Engine flooded Clean spark plugs and adjust plug gaps Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood be cause more fuel is supplied automatically by DFI No spark spark weak Vehicle down sensor coming off Ignition switch not ON Engine stop switch turned off Clutch lever not pulled in and gear not in neutral whether side stand up or down Though clutch lever pulled in side stand up and gear not in neutral Battery voltage low Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect IC igniter in ECU trouble Neutral starter lockout or side stand switch trouble Crankshaft position sensor trouble Ignition coil trouble Ignition switch or engine stop switch shorted Wiring shorted or open Fuse blown Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing 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 Valve not seating properly valve bent worn or carbon accumulation on the seating surface KACR compression release cam sticks open engine stalls when moving off HLA hydraul
356. low Chart 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 as coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is below 58 62 C 136 144 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 flows When the coolant temperature goes up beyond 100 110 C 212 230 F the radiator fan switch conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 97 103 C 207 217 F the fan switch 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 exce
357. ls just off the ground Frame Pipe Rib C e Support the front part of the engine bottom D using a commercially available jack E Special Tools Jack 57001 1238 Attachment Jack 57001 1398 e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Alternator Outer Cover see Alternator Outer Cover Re moval in this section Alternator Cover see Alternator Cover Removal Instal lation in this section Alternator Rotor see Alternator Removal in this section Front and Rear Exhaust Pipe see Exhaust Pipe Re moval in the Engine Top End chapter GPO9111BS1 GPO9109BS1 ELECTRICAL SYSTEM 16 35 Charging System e Remove the front engine mounting bolt A e Loosen the rear engine mounting bolt B e Disconnect the alternator lead connector C e Lift up A the front part of the engine using the jack until the lower part of the alternator inner cover clears the lower frame B NOTE OTurn the propeller shaft so that the engine can be raised as high as possible e Pull out the shift shaft C from the alternator inner cover e Unscrew the bolts D and take off the alternator inner cover E Alternator Inner Cover Installation e Replace the gasket with a new one e Apply silicone sealant to the grommet and fit it into the notch of the alternator inner cover Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the alternator inner cover
358. ly inspect the one way clutch coupling and starter clutch gear for damage x lf there is any worn or damaged surface in the following parts replace it Sliding Surface B and Cage of One way Clutch Sliding Surface C of Starter Clutch Gear Sliding Surface A of Coupling Starter Torque Limiter Check e Remove the torque limiter see Crankcase Disassembly in this section and visually inspect it x lf the limiter has wear discoloration or other damage replace it as a set Gear A Friction Plates B Spring C Pinion D 61048120 P 6107001BS1 If A VE Ly GE 6110010181 CRANKSHAFT TRANSMISSION 9 23 Crankshaft Connecting Rods Connecting Rod Removal e Remove the crankshaft see Crankcase Disassembly in this chapter e Remove the connecting rod big end nuts and take off the rod and cap along with the bearing inserts from the crankshaft A NOTE OMark and record the locations of the connecting rods B So and their big end caps C with the bearing inserts left 8 attached so that they can be installed in their original positions CAUTION To prevent damage to the crankpin surfaces do not allow the connecting rod bolts to bump against the crankpins Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark
359. measurement is within the specified check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter e Clean off machine oil that inadvertently gets on the sen sor especially on the terminals with a high flush point sol vent 123456789101112131415161718 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 BR B P BR BK P BK Fs GC17702BW2 1 ECU 2 Inlet Air Temperature Sensor 3 56 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the thermostat housing A see Thermostat Re moval in the Cooling System chapter e Disconnect the sensor connector B and unscrew the water temperature sensor C Sealant Kawasaki Bond Silicone Sealant 56019 120 Threads of Water Temperature Sensor Torque Water Temperature Sensor 18 N m 1 8 kgf m 13 ft lb e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the coolant temperature in the engine e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Connect a digital meter A
360. move the tapered roller bearing which is pressed onto the driven gear shaft with the bearing puller and adapter Special Tools Bearing Puller 57001 158 Bearing Puller Adapter 57001 317 Driven Gear Assembly O TP e Replace the driven gear bolt with a new one OThe drive and driven gears are lapped as a set at the fac tory to get the best tooth contact They must be replaced as a set SSP SSS IVY e Be sure to check and adjustthe bearing preload the bevel by gear backlash and tooth contact see Front Bevel Gear We 777 wa UE Adjustment in this section e Drive the tapered roller bearing inner race B onto the driven gear shaft C using the bearing driver A Special Tool Bearing Driver 432 57001 382 GkO60012S1 e After completing the bearing preload adjustment re assemble the driven gear assy OUsing the bearing driver set press the oil seal in until the face of the seal is level with the end of the bearing housing hole Special Tool Bearing Driver Set 57001 1129 FINAL DRIVE 11 29 Front Bevel Gears OApply molybdenum disulfide oil solution to the threads and the seating surface of the driven gear bolt OTighten the driven gear bolt to the specified torque Torque Driven Gear Bolt 120 N m 12 2 kgf m 89 ft lb OStake A the driven gear bolt to prevent it from loosening CAUTION When staking the bolt be careful not to apply shock
361. mpressed air CAUTION Do not immerse the throttle body or throttle assy in a high flash point solvent for cleaning This could damage the throttle sensor on the throttle body e Before assembly visually inspect the mating surfaces A for any damage like dent nick rust flaw and crack e Nick or rust damage can sometimes be repaired by using emery paper first No 200 then 400 to remove sharp edges or raised areas x If the damage is not repairable replace the throttle body and or the inlet manifold to prevent leakage e With a high flash point solvent clean off the mating sur faces and wipe dry e Be sure to install the dowel pins B e Fit the new gasket C into the groove Be careful not to pinch the gasket between the mating surfaces e Tighten the flange bolts evenly e Turn the throttle pulley A to check that the throttle valves B move smoothly and return by spring force x lf the throttle valves do not move smoothly replace the throttle body 3 102 FUEL SYSTEM DFI Air Cleaner Air Cleaner Element Removal e Remove Allen Bolt and Washer A Left Air Cleaner Cover B e Remove the element A e Push aclean lint free towel into the lower air cleaner duct to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the throttle assy the throttle may become stuck possi bly causing an accident CAUTION If d
362. n CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall GE16020381 e Using the piston pin puller assembly remove the piston pins Special Tools Piston Pin Puller Assembly A 57001 910 Piston Pin Puller Adapter B 57001 1211 e Remove the piston GE160605S1 e Carefully spread the ring opening with your thumbs and 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 GE16060681 Cylinder Piston Installation O NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander 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 6E16013081 5 42 ENGINE TOP END Cylinders Piston e Do not mix up the top ring and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 45 F of angle from the opening of the top ring Top Ring A Seco
363. n stallation chapter Water Pump see Water Pump Removal in the Cooling System chapter Rocker Case Covers see Rocker Case Cover Removal in the Engine Top End chapter Rocker Cases see Rocker Case Removal in the Engine Top End chapter Cylinder Heads see Cylinder Head Removal in the En gine Top End chapter Cylinder Blocks see Cylinder Removal in the Engine Top End chapter Pistons see Piston Removal in the Engine Top End chapter Clutch Cover see Clutch Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Front Gear Case see Front Gear Case Removal in the Final Drive chapter Damper Cam see Damper Cam Removal in the Final Drive chapter Alternator Cover see Alternator Cover Removal Instal lation in the Electrical System chapter Alternator Inner Cover see Alternator Inner Cover Re moval in the Electrical chapter e Remove the shift shaft A while pushing B the shift mechanism arm C towards the shift shaft e Unscrew the bolt D and remove the gear set lever E and its spring F e Remove the shift shaft return spring pin G e Pull the starter clutch gear A out of the starter clutch OThe starter clutch gear can be removed with the engine in the frame e Unscrew the starter clutch bolt B while holding the pri mary gear bolt C e Remove the washer D 9 10 CRANKSHAFT TRANSMISSION Crankcase e Take out the torque limiter A e Remove the following from t
364. n roughness binding or noise If roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Hub Bearings Inspection in the Wheels Tires chapter and coupling Brakes System Brake Fluid Leak Brake Hose and Pipe e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A and fitting Alf the brake fluid leaked from any position inspect or re place the problem part Gvy03001181 65118049 P 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Damage and Installation Condition Inspection e Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings Brake Pad Wear Inspection e Remove the brake pads see Front and Rear Brake Pad Removal in the Brakes chapter e Check the lining thickness A of the pads in each caliper x lf the lining thickness of either pad is less than the ser vice limit B replace both pads in the caliper as a set see Front and Rear Brake Pad Installation in the Brakes chapter Pad Lining Thickness Standard Front 4 5 mm 0 18 in Rear 7 0 mm 0 28 in Service Limit 1 mm
365. n Puller Assembly 57001 162 57001 910 ST5709108ST Valve Guide Arbor 7 Compression Gauge Adapter M12 x 1 25 57001 163 57001 1018 Compression Gauge 20 kgf cm Spark Plug Wrench Hex 18 57001 221 57001 1024 T5702218T Valve Spring Compressor Assembly Piston Ring Compressor Grip 57001 241 57001 1095 T5702418T Valve Spring Compressor Adapter 28 2 Valve Seat Cutter 45 635 57001 243 57001 1116 ST5710958T ST5711168T ENGINE TOP END 5 13 Special Tools and Sealants Valve Seat Cutter 32 635 Piston Pin Puller Adapter 414 57001 1121 57001 1211 ST5711218T T5712118T Valve Seat Cutter 32 638 5 Valve Seat Cutter 55 435 57001 1122 57001 1247 STO00000ST Valve Seat Cutter Holder 67 Fork Oil Level Gauge 57001 1126 57001 1290 d ST5711268T ST5712908T Valve Seat Cutter Holder Bar Piston Ring Compressor Belt 695 4108 57001 1128 57001 1358 ST5711288T Hexagon Wrench Hex 27 Filler Cap Driver 57001 1210 57001 1454 7571454ST 5 14 ENGINE TOP END Special Tools and Sealants Valve Seat Cutter 45 640 Kawasaki Bond Silicone Sealant 57001 1496 56019 120 ST5714968T ST560120ST Valve Seat Cutter 55 38 5 Kawasaki Bond Silicone Sealant 57001 1497 92104 0004 ST571497ST ST9200048T OCompression Gauge
366. n the lower and front exhaust pipe cover clamp lower screws A with they are head inclined at 50 B or less to horizontal as shown This prevents the screw from touching ground when banking Torque Exhaust Pipe Cover Clamp Screws 6 9 N m 0 70 kgf m 61 in lb e First tighten all the bolts and nuts to a snug fit e Secondary tighten the exhaust pipe holder nuts evenly e Finally tighten the rest of the mounting bolts and clamp bolts securely e Thoroughly warm up the engine wait until the engine cools down and retighten all the clamp bolts Chamber Removal Installation e Remove Front and Rear Exhaust Pipes see Exhaust Pipe Re moval in this section Left and Right Mufflers see Muffler Removal in this sec tion Left Chamber Bolts A e Take out the premuffler chamber B e Tighten Torque Premuffler Chamber Bolts 29 N m 3 0 kgf m 21 ul Chamber Assembly e Apply a soap and water solution or rubber lubricant to the surface of the rubber bushings and install them into the brackets of the chamber as shown Top View Rubber Bushings A 24 8 mm 0 98 in with a raised ring B Rubber Bushings C 625 3 mm 1 0 in without raised ring Zs P GE18020881 5 50 ENGINE TOP END Mufflers Chamber Identification OThe this models have a premuffler chamber Identification No KHI M 099 with a honeycomb type catalytic con verter and without any catalyst protection system Do not mix up
367. n the shift rod D so that the outside length E of the locknuts is 112 1 mm 4 4 0 04 in OThe rear locknut has left hand threads Torque Shift Rod Locknut Front 11 N m 1 1 kgf m 97 in Ib Shift Rod Locknut Rear 11 N m 1 1 kgf m 97 in Ib Rear Shift Lever Clamp Bolt 12 N m 1 2 kgf m 104 in Ib e Install Engine see Engine Installation in the Engine Re moval Installation chapter Shift Pedal see Shift Pedal Installation in this section External Shift Mechanism Inspection e Examine the shift shaft A for any damage Alf the shaft is bent straighten or replace it Alf the serrations B are damaged replace the shaft x lf the springs C D are damaged in any way replace them x lf the shift mechanism arm E is damaged in any way replace the arm e Check the return spring pin A is not loose x lf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 39 N m 4 0 kgf m 29 ft lb e Check the gear set lever B and its spring C for breaks or distortion x lf the lever or spring is damaged in any way replace it e Visually inspect the shift drum pins pin holder and pin plate x If they are badly worn or if they show any damage replace them 9 32 CRANKSHAFT TRANSMISSION Transmission Transmission Removal N WA Nu e Remove the engine see Engine Removal in the Engine Removal Installati
368. nal 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 GJO5004BS1 WHEELS TIRES 10 19 Hub Bearings Wheel Bearings Hub Bearings Removal e Remove the wheel and take out the following Collars Grease Seals A Circlips B Coupling C Out of Rear Hub Front Hub D Rear Hub E Special Tool Inside Circlip Pliers 57001 143 e Use the bearing remover to remove the hub bearings A 6J06003BS2 C CAUTION Do not lay the wheel directly 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 Special Tools Bearing Remover Shaft 13 B 57001 1377 Bearing Remover Head 25 x 428 C 57001 1346 for Front Hub Bearing Remover Head 20 x 22 C 57001 1293 for Rear Hub Hub Bearings Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub with compressed air to pre vent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings
369. nator Inside Stator Removal Alternator Inside Stator Installation Charging Voltage Inspection Alternator Inspection Regulator Rectifier Removal Regulator Rectifier Installation Regulator Rectifier Inspection Regulator Inspection Ignition Gvstem Ignition Coil Removal 16 33 16 33 16 34 16 34 16 35 16 35 16 36 16 36 16 40 16 41 Lighting System Ignition Coil Installation 16 45 Ignition Coil Inspection 16 46 Spark Plug Removal 16 47 Spark Plug Installation 16 47 Spark Plug Cleaning Inspection 16 47 Ignition Coil Primary Peak Vie Ee 16 47 Crankshaft Sensor Removal 16 49 Crankshaft Sensor Installation 16 49 Crankshaft Sensor Inspection 16 49 Ignition Timing Inspection 16 51 Interlock Operation Inspection 16 51 IC Igniter Inspection 16 53 Starter Motor 16 56 Starter Motor Removal 16 56 Starter Motor Installation 16 56 Starter Motor Disassembly 16 56 Starter Motor Assembly 16 57 Brush Inspection 16 58 Commutator Cleaning and Inspection 16 59 Armature Inspection 16 59 Brush Assy Inspection 16 59 Brush Plate and Terminal Bolt Inspection Starter Relay Inspection
370. nd Ring B Oil Ring Steel Rails C Oil Ring Expander D Circle mark E must be faced toward the engine front Opening Positions G e Face the circle mark A on each piston toward the front side B OThe front and rear pistons are the same but they should be installed in their original positions CAUTION Incorrect installation of the piston could cause pis ton seizure and result in severe engine damage 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 e Apply molybdenum disulfide oil solution to the outer sur face of the piston pin OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 OWhen installing the piston pin snap ring compress it only enough to install it and no more e Apply molybdenum disulfide oil solution to the cylinder bore e Apply molybdenum disulfide oil solution to the front and rear of the piston skirt e Install the rear cylinder first with the rear piston at TDC GE16060481 GE16100BS1 GE16101BS1 6E160134S1 ENGINE TOP END 5 43 Cylinders Piston NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance in this section and use new piston ring e Replace the cylinder base gasket A with a
371. nd shorts resulting from insulation breakdown under high voltage e Measure the primary winding resistance as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 Q range and read the tester e Measure the secondary winding resistance as follows ORemove the plug caps by turning them counterclockwise OConnect the tester between the spark plug High Tension cables OSet the tester to the x 1 kQ range and read the tester Measure primary winding resistance A Measure secondary winding resistance B Ignition Coil C Ignition Coil Winding Resistance Primary Windings 1 9 2 90 Secondary Windings 18 28 KQ x If the tester does not read as specified replace the coil OTo install the plug cap turn it clockwise ELECTRICAL SYSTEM 16 47 Ignition System Spark Plug Removal e Remove the spark plug caps e Remove the spark plugs using the 18 mm 0 7 in plug wrench Special Tool Spark Plug Wrench Hex 18 57001 1024 Spark Plug Installation e Insert the spark plug vertically into the plug hole with the plug installed in the plug wrench A e Tighten the plugs Special Tool Spark Plug Wrench Hex 18 57001 1024 Torque Spark Plugs 18 N m 1 8 kgf m 13 ft Ib e Fit the plug caps securely Spark Plug Cleaning Inspection e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may al
372. nd the tensioner cap B OSet the spring end into the hollow C of the cap e Tighten the tensioner cap to the specified torque Torque Chain Tensioner Cap 20 N m 2 0 kgf m 15 ft lb e Remove the lockbolt A and check to be sure that the larger spring clicks then install the lockbolt Torque Chain Tensioner Lockbolt 4 9 N m 0 50 kgf m 43 in Ib 5 20 ENGINE TOP END Rocker Case Cover Rocker Case Cover Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Vacuum Switch Valve see Vacuum Switch Valve Re moval in this chapter e Remove the bolts A and take off the cover B from the rocker case e Take out the oil filter springs A and HLA oil filters B Rocker Case Cover Installation e Replace the HLA oil filters A with new ones e Install the oil filter springs B e After installing the rocker case fill the oil reservoir C with engine oil e Replace the cover gasket D with a new one e Tighten the cover bolts E to the specified torque follow ing the tightening sequence Dowel Pins F Inlet Side G Torque Rocker Case Cover Bolts 8 8 N m 0 90 kgf m 78 in 1b GE19000BS2 C ENGINE TOP END 5 21 Rocker Case Cover Rocker Case Cover Assembly e Apply adhesive to the rubber dampers A and install them on the rocker case cover as shown Olnsert the projections B of the dampers to the holes C of the cover Front Cover D
373. nder for Rear Cylinder 3 10 FUEL SYSTEM DFI DFI Parts Location FUEL SYSTEM DFI 3 11 DFI Parts Location D OO OO P amp ND n DH DFI Parts Front Atmospheric Pressure Sensor DFI Water Temperature Sensor DFI Ignition Coils Ignition Switch see next page Starter Motor Water Temperature Switch Regulator Rectifier Crankshaft Sensors Alternator Side stand Switch Neutral Switch Oil Pressure Switch Fuel Pump DFI see next page Vehicle down Sensor DFI ECU DFI DFl Fuse 15A Sealed Battery Junction Box Starter Relay Turn Signal Control Unit DEI Main Relay Oil Pressure Light Delay Unit ISC Valve 2 DFI for Front Cylinder ISC Valve 1 DFI for Rear Cylinder Inlet Air Temperature Sensor DFI Injectors DFI Inlet Air Pressure Sensor DFI Fl Indicator LED Light DFI see next page Throttle Sensor DFI Rear Brake Light Switch Radiator Fan Radiator Fan Switch Delivery Joint DFI Pump Screen see next page Fuel Filter see next page Fuel Tank Reverse Side 3 12 FUEL SYSTEM DFI DFI Parts Location FUEL SYSTEM DFI 3 13 DFI Parts Location 3 14 FUEL SYSTEM DFI DFI Wiring Diagram Sal a ho l e DAIN IL WE BK BK Y BK W BK R K BK P
374. nds onds onds 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 Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Meter Unit Inspec tion in the Electrical System chapter Meter Unit for Neutral Indicator LED see Meter Unit In spection in the Electrical System chapter Meter Unit for Fuel Level Warning Indicator LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Fl Indicator LED see Meter Unit Inspec tion in the Electrical System chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Ignition Fuse 10A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Headlight Fuse 10A see Fuse Inspection in the Electri cal System chapter Harness see Wiring Inspection in the Electrical System chapter e Turn off the ignition switch e The all lights should go off x lf the light does not go off replace the ignition switch GS17045BS1 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Second Step e Turn the ignition switch to P Park position e T
375. nector Plastic Snap on Clamp Radiator Fan and Rear Brake Light Switch Leads Inlet Air Pressure Sensor Connector Plastic Snap on Clamp Rear Brake Light Switch Lead Ignition Coil Primary Lead Connectors for Rear Cylinder Inlet Air Temperature Sensor and ISC Valve Leads Water Temperature Sensor Connector Throttle Sensor Connector Clutch Hose Horn Lead Choke Knob Frame Ground Terminal Ignition Coil Primary Lead Connectors for Front Cylinders Atmospheric Pressure Sensor Connector Harness Clamp Fit it into the frame pipe Throttle Cables Injector 2 Connector Rear Injector 1 Connector Front Main Harness Bracket Fit the straps into the frame pipe White Tape for Identification 40 41 43 44 45 46 47 48 49 Front 6B09724BW2 C Battery Lead from engine ground lead Oil Pressure Light Delay Unit ECU Main Relay Turn Signal Control Unit Starter Relay Batter Positive Terminal White Tape Align it with the grommet Starter Motor Lead Battery negative Lead Connector Fuel Pump Connector ECU Connector ECU Main Fuse Fuel Level Sensor Connector Plastic Snap on Clamp Run the self diagnosis accessory and rear har ness Battery Holder Fit the fuel pump fuel level sensor connectors ECU main Fuse and plastic snap on clamp Accessory Lead Connectors Female 42 Rear Turn Signal
376. ner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the cam chain timing and damage the valves e For the front chain tensioner remove the lower air cleaner duct and left air cleaner base holder see Air Cleaner sec tion in the Fuel System DFI chapter OThe procedure to remove the front chain tensioner is as follows e Loosen the lockbolt A and remove the tensioner cap B e Remove the tensioner mounting bolts C and take off the chain tensioner e For the rear chain tensioner A removal is the same as for the front chain tensioner Camshaft Chain Tensioner Installation CAUTION Be sure to install the camshaft chain tensioner after camshaft chain is timed e Push the stopper A to release the ratchet and push the push rod B into the tensioner body GE10010581 ENGINE TOP END 5 19 Camshaft Chain Tensioner e Install the larger spring A and then the ball bearing assy B OFit the ball bearing assy into the body until it bottoms out using a thin bladed screwdriver GE10010681 e Screw in the lockbolt A finger tight to hold the ball bear ing assy temporarily e Install the retainer B e Install the tensioner body A and tighten the mounting bolts B to the specified torque Torque Chain Tensioner Mounting Bolts 11 N m 1 1 kgf m 97 in 1b e Install the smaller spring A a
377. ng Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 28 2 B 57001 243 Valve Installation e Replace the stem 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 A and Stem Oil Seal B Spring Seats C Inner Spring D and Outer Spring E Retainer F and Split Keepers G Closed Coil End H GE15011581 5 36 ENGINE TOP END Cylinder Head Valve Guide Removal e Remove the valve stem oil seal and spring seats 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 Special Tool Valve Guide Arbor 7 57001 163 CAUTION Do not heat the cylinder head with a blowtorch This will warp the head Soak the cylinder head in engine oil and heat the oil 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 in the engine oil e Drive the valve guide in from the top of the head using the valve guide arbor The flange stops the guide from going in too far Special Tool Valve Guide Arbor 7 57001 163 e Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer A even
378. ng Voltage Inspection e Check the battery condition see Charging condition In spection in this chapter e Warm up the engine to obtain actual alternator operating conditions e Remove the front seat see Front Seat Removal in the Frame chapter e Check that the ignition switch is turned off and connect the hand tester to the battery as shown in the table Special Tool Hand Tester 57001 1394 Battery Charging Voltage Range Tester to Tester to 3 000 rpm 25VDC Battery Battery 14 2 15 2 V e Turn on the ignition switch and start the engine and note the voltage readings at various engine speeds with the headlight turned on and then turned off To turn off the headlight disconnectthe headlight connector in the head light unit The readings should show nearly battery volt age 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 e Turn off the ignition switch to stop the engine and discon nect the hand tester x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally x If the output voltage is much higher than the values spec ified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x lf the battery voltage does not rise as the engine speed increases then the regulator rectifier is defe
379. ng dust by applying compressed air A from the inside to the outside from the clean side to the dirty side e Visually check the element for no tears or no breaks and check the sponge gasket B also x If the element or gasket has any tears or breaks replace the element e Install the left air cleaner cover Torque Left Air Cleaner Cover Allen Bolt 16 N m 1 6 kgf m 12 ft lb Throttle Control System Inspection Throttle Grip Play Inspection e Check the throttle grip free play A x lf the free play is incorrect adjust the throttle cables Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from close to full open and the throttle closes quickly and completely in all steering positions by the return spring x If the throttle grip doesn t return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed doesn t change x If the idle speed increases check the throttle grip free play and the cable routing PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e f necessary adjust the throttle cable as follows OLoosen the locknuts A and screw the adjusters B all the way in so as to give the throttle grip plenty of play OTurn out the adjuster of the
380. ng surfaces of the big end nuts and threads of con rod bolts e Tighten the big end nuts to the specified torque Torque Connecting Rod Big End Nuts 59 N m 6 0 kgf m 44 ft lb 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 e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap 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 more than 105 mm 4 13 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on a 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 08 3 94 in Connecting Rod Twist e With the big end arbor A still on the V block C hold the connecting rod horizontally and measure the amount that
381. ng the left side cover Olnstall the canister and the left side cover see Left Side Cover Installation in the Frame chapter OFace the white mark E left as shown e Check the liquid vapor separator as follows ODisconnect the hoses from the separator and remove the separator A from the motorcycle right side Front B OVisually inspect the separator for cracks and other dam age x If the separator has any cracks or damage replace it with a new one OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORoute the hoses according to Cable Wire and Hose Routing section in the Appendix chapter Refer to the di agram of the evaporative emission control system in the Fuel System chapter too OWhen installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses with a minimum of bending so that the emission flow will not be obstructed GSO5001BS1 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Air Suction System Air Suction System Damage Inspection e Pull the vacuum switch hose A out of the right air cleaner base e Start the engine and run it at idle speed e Plug the vacuum switch hose end with
382. ngine Mounting Bracket Bolts 25 2 5 18 3 Engine Mounting Nuts 44 4 5 33 WL Apply a soap and water solution or rubber lubricant 8 4 ENGINE REMOVAL INSTALLATION Special Tools Jack Attachment Jack 57001 1238 57001 1398 ST5712388ST ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Support the rear part of the frame on the jack A and the attachment jack B Special Tools Jack 57001 1238 Attachment Jack 57001 1398 OFit the ribs C of the frame into the groove of the attach ments e Squeeze the brake lever slowly and hold it with a band A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION 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 Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Battery Cables see Battery Removal in the Electrical System chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Left Air Cleaner Housing see Left Air Cleaner Housings Removal Installation in the Fuel System DFI chapter Right Air Cleaner Housing see Right Air Cleaner Hous ings Removal in the Fuel System DFI chapter T
383. nnectors in the circuit are clean and tight and examine wires for signs of burning fraying short etc Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system x If any wiring is deteriorated replace the 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 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 OSet the tester to the x 1 Q range and read the tester x lf the tester does not read 0 Q the lead is defective Re place the lead GC17716BS2 GC17059BS1 FUEL SYSTEM DFI 3 25 Troubleshooting the DFI System Olf both ends of a harness A are far apart ground B the one end C using an auxiliary wire D and check the continuity between the end E and the ground F This enables 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 and it must be repaired or re placed e Narro
384. nspection Fuel Reserve Switch Inspection Speed Sensor Removal 16 92 Speed Sensor Installation 16 92 Speed Sensor Inspection 16 93 Front Brake Light Switch Inspechon snesneeeeeeeeeeeeeeeeeen 16 93 Rear Brake Light Switch Checki Adiustmment 16 93 Radiator Fan Switch Removal 16 93 Radiator Fan Switch Installation 16 93 Radiator Fan Switch Inspection 16 94 Water Temperature Switch Removal neneannnnnnneenenenenn 16 94 Water Temperature Switch Installation 16 94 Water Temperature Switch Inspection 16 95 Switch Inspection 16 96 Junction Box 16 97 Junction Box Fuse Circuit Inspechon nnsnoneeeeeeeeeeeeeeeeeeen 16 97 Starter Circuit Headlight Relay Inspechon nsseeneneeeeeeeeeereeeeen 16 97 Diode Circuit Inspection 16 98 USO chet A ter 16 100 Main Fuse Removal 16 100 Junction Box Fuse Removal 16 100 Fuse Installation 16 100 Fuse Inspechon 16 100 ELECTRICAL SYSTEM 16 3 Electrical Parts Location Left Handlebar Switches A Starter Lockout Switch B Ignition Switch C Front Brake Light Switch D Right Handlebar Switches E Meter Unit F Fuel Pump with Fuel Reserve Switch G Water Temperature Sensor A Inlet Air Pressure Sensor B Vehicle down Sensor C Throttle Sensor D Ignition Coil 2
385. nstallation 3 83 Resistance Inspection 3 57 ECU Power Supply Inspection 3 83 Atmospheric Pressure Sensor DFI Power Source 3 85 Service Code 15 3 58 DFI Fuse Removal 3 85 Removal 3 58 DFI Fuse Inspection 3 85 Install tiON cocos ni 3 58 DFI Main Relay Removal 3 85 Input Voltage Inspection 3 58 DFI Main Relay Inspection 3 85 Output Voltage Inspection 3 59 ISG Valves iia 3 87 Crankshaft Sensors 1 2 Service Removal Installation 3 87 Code 21 22 ls ot 3 62 Power Source Voltage Inspection 3 87 Crankshaft Sensor Output Voltage Inspection 3 88 Removal Installation 3 62 Resistance Inspection 3 88 3 2 FUEL SYSTEM DFI Fuel Lime Fuel Pressure Inspection Fuel Flow Rate Inspection Throttle Grip and Cables Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment Choke Knob Operation Choke Cable Free Play Inspechon nnna Cable Removal Installation Cable Lubrication and Inspection Throttle Body Assy Idle Speed Check Idle Speed Adjustmen t High Altitude Performance ee d EE Throttle Body Assy Remova
386. ntil the engine cools down e Open the fuel tank cap A to lower the pressure in the tank Front B FUEL SYSTEM DFI 3 93 Fuel Line e Prepare a plastic hose of the inside diameter 7 5 mm 0 30 in x L about 400 mm 15 7 in and a measuring cylinder e Remove Front Seat see Front Seat Removal in the Frame chap ter Meter Cover see Fuel Tank Removal in this chapter Fuel Tank Bolts e Raise the fuel tank e Stuff a clean shop towel around the fuel outlet hose joint OWhile pinching the locks of the hose joint 1 with fingers disconnect the joint see Fuel Tank Removal in this chap ter and insert the plastic hose A quickly onto the tank outlet pipe e Secure the plastic hose with a clamp B e Run the other side of the plastic hose into the measuring cylinder C e Temporarily install the fuel tank and close the fuel tank cap A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e With the engine stopped turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop Repeat this several times until the plastic hose is filled with fuel e Measure the discharge for 3 seconds with the plastic hose filled with fuel Amount of Fuel Flow Standard 67 mL 2 27 US oz or more for 3 seconds x If the fuel flow is much less than the specified check the battery condition see Charging Condition Inspection in the Electrical S
387. o the specified torque while holding the primary gear A with the gear holder B Torque Clutch Hub Nut 145 N m 14 8 kgf m 107 ft lb Special Tool Gear Holder 57001 1557 e The spring plate pusher A into the clutch hub Squeeze the clutch lever slowly and hold it with a band Olnstall the needle bearing B and the washer onto the pusher e Pushing A the operating plate B into the clutch hub and insert the retaining ring C by hand e Install the clutch cover see Clutch Cover Installation in this section Inner Clutch Hub Disassembly e Remove the inner clutch hub see Clutch Removal in this section e Using a press A and the clutch spring compressor B push the damper spring holder C to remove the retaining ring D Special Tools Clutch Spring Compressor 57001 1162 Inside Circlip Pliers E 57001 143 CLUTCH 6 15 Clutch e Remove Retaining Ring A Spring Holder B Damper Spring C Spring Holder D Spacer E Damper Cam F Inner Clutch Hub G Spring Plate Gap Measurement Insufficient spring plate gap will cause the engine brak ing effect to be more sudden resulting in rear wheel hop On the other hand if the spring plate gap is excessive the clutch may slip or the clutch lever may feel spongy or pul sate when pulled e Prepare sheet gum chewing gum or about 5 g 0 176 oz clay A e Make an about 2 5 mm 0 10 in thick sheet B of gum or clay
388. ockwise and release it It should lock in position e Tighten Torque Tail Brake Light Lens Screws 1 2 N m 0 12 kgf m 11 in Ib Licence Plate Light Bulb Replacement e Remove the licence plate light lens screws A and take off the lens B e Remove the wedge base type bulb A pull the bulb straight out of the socket B CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value 16 66 ELECTRICAL SYSTEM Lighting System Headlight Tail Light Circuit ON PARK ol LO le J O O1 ND A BK Y Ignition Switch Alternator Headlight Relay Headlight Fuse 10 A Taillight Fuse 10 A Junction Box High Beam Indicator Light Headlight License Plate Light Tail Brake Lights Frame Ground Joint Connector 2 Joint Connector 1 Dimmer Switch Starter Relay Main Fuse 30 A Battery Running Position Lights US and Canada Models City Light Other than US Canada and Australia Models GP12087BH3 ELECTRICAL SYSTEM 16 67 Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn But motorcycles turn with a bank additionally and so have a smaller steer angle This makes difficult to adopt an automobile type turn signal canceling system becau
389. ody B 16 64 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement Other than US CA and AU US United States Model CA Canada Model AU Australia Model e Remove the headlight unit see Headlight Body Removal in this section e Pull out the socket A together with the bulb e Remove the wedge base type bulb A pull the bulb straight out of the socket B e Replace the bulb with a new one CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value Tail Brake Light Removal Installation e Remove the rear fender see Rear Fender Removal in the Frame chapter e Turn over the rear fender and remove the cover bolts A and cover B e Disconnect the tail brake light lead connector A e Remove the nuts B e Remove the tail brake light from the rear fender e Tighten Torque Tail Brake Light Mounting Nuts 5 9 N m 0 60 kgf m 52 in Ib Tail Brake Light Bulb Replacement e Unscrew the screws A in the taillight lens e Pull the lens B off ELECTRICAL SYSTEM 16 65 Lighting System e Push the bulb A in turn it counterclockwise B and pull it out e Replace the bulb with a new one e With the front pin A up and the rear pin B down insert the new bulb by aligning the front pin with the left groove C in the walls of the socket D e Push the bulb in turn it cl
390. of oil to the con S is tact area Be sure to maintain proper alignment and use gt Gp i 8 smooth movements when installing CD Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is E absolutely necessary Replace with new ones whenever Det removed Press bearings with the manufacturer and size N A pa N marks facing out Press the bearing into place by putting FT Sy SS pressure on the correct bearing race as shown AB Gh iF J Pressing the incorrect race can cause pressure between fe 5 At the inner and outer race and result in bearing damage gt 77 L 65020188 S Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed H Lt GS Press new oil seals with manufacture and size marks facing WK out Make sure the seal is aligned properly when installing SK y 6602018 S Apply specified grease to the lip of seal before installing the seal Grease 6B02046BS1 Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation GB02026B S 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 cation points are called out t
391. ol Drive Shaft Holder 57001 1407 GK09020282 C FINAL DRIVE 11 27 Front Bevel Gears e Pull off the drive gear shaft A the drive gear B and shim s C e Remove the bearing holder D from the gear case e Remove the drive gear shaft ball bearing E using the bearing driver set Front F Special Tool Bearing Driver Set 57001 1129 GKO90103S1 Front Gear Case Assembly OThe drive and driven gear are lapped as a set in the fac tory to get the best tooth contact They must be replaced as a set e Press the drive gear B slowly with the driver A onto the shaft C Special Tool Bearing Driver 632 57001 382 e Apply a non permanent locking agent to the threads of the bearing retainer bolts Torque Bearing Retainer Bolts 8 8 N m 0 90 kgf m 78 in Ib ESOO br SOS A TD LO Ex yy L VE PZZZZ7Z7 6K09009BS1 e Be sure to check and adjust the bearing preload the bevel gear backlash and tooth contact when any of the back lash related parts are replaced see Front Bevel Gear Ad justment in this section e After completing all adjustment reassemble the front gear case OReplace the drive gear nut with a new one OApply molybdenum disulfide oil solution to the threads and seating surface of the nut and tighten it to the speci fied torque to settle the bearings in place OLoosen the nut completely and retighten it to the specified
392. om 200 mL 6 76 US oz 4 5 mm 0 18 in 7 0 mm 0 28 in Pulled ON ON after about 10 mm 0 39 in of pedal travel NGK DPR6EA 9 ND X20EPR U9 1 mm 0 04 in 1 mm 0 04 in AT Austria Model CH Switzerland Model DE Germany Model PERIODIC MAINTENANCE 2 15 Special Tools Inside Circlip Pliers Oil Filter Wrench 57001 143 57001 1249 ST570143ST ST571249ST Steering Stem Nut Wrench Attachment Jack 57001 1100 57001 1398 ST571100ST Jack Filler Cap Driver 57001 1238 57001 1454 ST5714548T ST5712388ST 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Air Cleaner Element Cleaning NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately e Remove Allen Bolt and Washer A Left Air Cleaner Cover B e Remove the element A e Push aclean lint free towel into the lower air cleaner duct to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Clean the element by tapping it lightly to loosen dust e Blow away the remaini
393. om the outer tube ORemove the retaining ring B from the outer tube 6M040141S1 OUse the fork outer tube weight A to separate the outer tube B from the inner tube C OHolding the inner tube by hana pull the outer tube several times to pull out the inner tube Special Tool Fork Outer Tube Weight 57001 1218 OTake out the cylinder base out of the outer tube GmMO40308 S 13 12 SUSPENSION Front Fork e Remove the inner tube guide bushing A outer tube guide bushing B washer C and oil seal D from the inner tube 6M04117BS1 Front Fork Assembly e Replace the following parts with new ones after removal Dust Seal A Retaining Ring B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Bottom Allen Bolt Gasket F GM04281BS1 e Put the cylinder unit A with the spring into the inner tube B protruding from the inner tube and install the cylinder base C onto the bottom end of the cylinder unit Olnstall the cylinder base with the tapered end D up e Install the inner tube cylinder unit and cylinder base as a set into the outer tube 6M040311S1 e Install the new guide bushing A with a used guide bush ing B on it by tapping the used guide bushing with fork oil seal driver C until it stops OThe split D of the bushing should face toward the side E of the vehicle Special Tool Front Fork Oil Seal Driver 57001 1219
394. on and adjust it if necessary e Check the rear brake light switch operation and adjust the switch if necessary see Brake Light Switch Operation in the Periodic Maintenance chapter BRAKES 12 11 Calipers Front Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B CAUTION Do not loosen the caliper assembly bolt C Take out only the caliper mounting bolts for caliper re moval Loosening the caliper assembly bolts will cause brake fluid leakage Immediately wash away any brake fluid that spills e Take off the caliper e Unscrew the banjo bolt and remove the brake hose from the caliper Rear Caliper Removal e Remove Right Saddlebag see Saddlebag Removal in the Frame chapter Caliper Mounting Bolts A Brake Hose B Rear Caliper C Caliper Installation e Install the caliper and brake hose lower end OReplace the washer on each side of hose fitting with new ones e Tighten the caliper mounting bolts and banjo bolt Torque Front Caliper Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Rear Caliper Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Front Brake Hose Banjo Bolts 34 N m 3 5 kgf m 25 ft lb Rear Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft lb e Check the fluid level in the brake reservoirs see Brake Fluid Level Inspection in the Periodic Maintenance chap ter e Bleed the brake line see Brake
395. on are 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 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 table Water Temperature Sensor Resistance Standard 2 162 3 112 kQ at 20 C 68 F 0 785 1 049 kQ at 50 C 122 F 0 207 0 253 kQ at 100 C 212 F x If the measurement is out of the range replace the sensor x If the measurement is within the specified check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter e Clean off machine oil that inadvertently gets on the sen sor especially on the terminals with a high flush point sol vent GC17030482 C o 123 4 5 6 7 8 91011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 GC17703BW2 1 ECU 2 Water Temperature Sensor 3 58 FUEL SYSTEM DFI Atmospheric Pressure Sensor Service Code 15 Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank se
396. on can determine which trouble the DFI system has mechanical or electrical trouble Olt is preferable to measure the fuel pressure while run ning the motorcycle when the trouble has occurred in order to know symptom well OBe sure the battery is fully charged e Remove the fuel tank see Fuel Tank Removal in this chapter e Disconnect the 2 fuel injector connector A e Pinch the lock of the fuel hose joint 2 with fingers dis connect the joint B and take out the fuel hose assy C Front D A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage e Install the fuel pressure gauge adapter A special tool and Fuel Hoses B special tool between the fuel tank outlet pipe C and the inlet pipe D to the delivery joint E OPut the fuel pressure gauge adapter outside the frame e Connect the pressure gauge F special tool to the fuel pressure gauge adapter Fuel Tank G Fuel Pump H Front I Fuel Flow Special Tools Fuel Pressure Gauge Adapter 57001 1593 Fuel Hoses 57001 1607 Oil Pressure Gauge 57001 125 e Connect the 2 fuel injector connector e Temporarily install the fuel tank e Connect Fuel Pump Connector 2 pin Battery Lead Terminal A WARNING GC17731BS2 C
397. on chapter e Split the crankcase see Crankcase Disassembly in this chapter e Remove the crankshaft see Crankcase Disassembly in this chapter e First remove the oil pipe A see Inside Oil Pipe Removal in the Engine Lubrication System chapter and then re move the shift drum bearing holder bolts and holder B e Pull out the shift rod C and take the shift forks D out of the output shaft 4th gear Output Shaft E Drive Shaft F Shift Drum Assy G e Align the shift drum cam A with the cutoff B of the left crankcase by turning the shift drum e Take out the transmission shafts A and shift drum assy B as a set e Separate the drive and output shafts shift drum and shift forks Transmission Installation e Install the drive and output shafts shift drum assy and output shaft 5th gear shift fork as a set Drive Shaft Assy A Output Shaft Assy B Shift Fork Drive Shaft 3rd Gear C and Shift Drum Assy D Shift Fork No 270 Output Shaft 5th Gear E CRANKSHAFT TRANSMISSION 9 33 Transmission e Install Shift Fork No 293 Output Shaft 4th Gear A Shift Rod B OEach output shaft shift fork has an identification number Do not confuse them e Install the shift forks with each number faced left as shown Shift Fork No 270 5th Gear A Shift Fork No 293 4th Gear B Front C 6113020BS1 e Apply a non permanent locking agent to the threads of t
398. op plug before tightening the front fork clamp bolt upper OTighten the two front fork clamp bolts lower alternately two times to ensure even tightening torque e Tighten Torque Front Fork Clamp Bolt Upper 29 N m 3 0 kgf m 21 ft lb SUSPENSION 13 11 Front Fork e Install the removed parts see appropriate chapters e Check the front brake effectiveness after installation A WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Front Fork Disassembly GC Set e Remove the front fork see Front Fork Removal in this section E e Drain the fork oil see Fork Oil Change in this section OThe following parts are removed during draining the fork oil Top Plug D with O ring E Spacer C Washer B Fork Spring A 6M04134BS1 e Hold the front fork horizontally in a vise A e Stop the cylinder unit B from turning by using the special tools e Unscrew the Allen bolt C and take the gasket out of the bottom of the outer tube Special Tools Fork Cylinder Holder Handle D 57001 183 Fork Cylinder Holder Adapter E 57001 1057 e Take the cylinder unit out of the inner tube 6M04013851 e Separate the inner tube from the outer tube as follows ORemove the dust seal A fr
399. or Standard Battery Voltage 12 5 V or more Fuel Pump F x lf the reading is good the power source voltage is normal Inspect operating source voltage see Operating Voltage Inspection in this chapter Alf the reading is incorrect check the following Battery Main Fuse 30 A see Fuse Inspection in the Electrical System chapter DFI Fuse 15 A see DFI Fuse Inspection this chapter Ignition Fuse 10 A in Junction Box see Fuse Inspection in the Electrical System chapter DFI Main Relay see DFI Main Relay Inspection in this chapter Wiring for Fuel Pump Power Source see next page Vehicle down Sensor see vehicle down Sensor Inspec tion in this chapter 3 78 FUEL SYSTEM DFI Fuel Pump Service Code 45 123456 7 8 91011 12 13 14 15 18 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 BR Y BK BR R ae CR o NIP ARK renrionlos BR JBATTERY Q On ignition OT TAILi TON TAIL2 IE GC17708BW3 C ECU Junction Box Ignition Fuse 10 A Ignition Switch Starter Relay Main Fuse 30 A Battery Fuel Pump DEI Main Relay DFI Fuse 15 A _ FUEL SYSTEM DFI 3 79 Ignition Coils 1 2 Service Code 51 52 Ignition Coil 1 Ignition Coil for Front Cylinder Service Code 51 Ignition Coil 2 Ignition Coil for Rear Cylinder Service Code 52 Removal Installation CAUTION Never drop the ignition coils esp
400. or Hose Inspection Coolant Leak Damage Installation Condition OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained 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 x 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 2 5 N m 0 25 kgf m 22 in lb 6S06000BS1 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Evaporative Emission Control System Inspection CAL e Inspect the canister as follows ORemove the left side cover see Left Side Cover Removal in the Frame chapter ORemove the band A and take out the canister B OVisually inspect the canister for cracks and other damage x lf the canister has any cracks or bad damage replace it with a new one NOTE OThe canister is designed to work well through the motor cycle s life without any maintenance if it is used under normal conditions ORun the purge hose green A above the canister breather hose blue B through the hole C into the tool case D ODo not run these hoses side by side on the battery side of the canister This prevents hoses from being flattened when installi
401. or nut securely e Install the fuel tank see Fuel Tank Installation in this chap ter Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspec tion of the throttle sensor or the atmospheric pressure sensor e Turn the ignition switch OFF e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Connect a digital meter A to the connector B using two needle adapters C Special Tool Needle Adapter Set 57001 1457 Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter BL W lead terminal 35 Meter gt BR BK lead terminal 11 SCH a lt ALL LILELLE 11 Zei GC17697BS1 GC17717BS1 FUEL SYSTEM DFI 3 49 Inlet Air Pressure Sensor Service Code 12 e Measure the input voltage to the inlet air pressure sensor with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard 4 75 5 25 V DC e Turn the ignition switch OFF x lf the reading is less than the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter If the ground and power supply are good the ECU is suspect Replace the ECU x If the reading is within the standard range check the sen sor output voltage Output Voltage Inspection N
402. orcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Catalog or 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 e 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 ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains
403. ormance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 60 minutes after filling Initial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial charge Standard Charge 1 8 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 Optimate Ill 6P08019BS1 Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 Alf the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 6 volts repeat charging cycle 16 30 ELECTRICAL SYSTEM Battery e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery 6P090009S1 NOTE OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at thre
404. ospheric pressure sensor e Turn the ignition switch OFF e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Connect a digital meter A to the connector B using two needle adapters C Special Tool Needle Adapter Set 57001 1457 Throttle Sensor Input Voltage Connections to ECU Connector Meter BL W lead terminal 35 Meter CH gt BR BK lead terminal 11 e Measure the input voltage to the throttle sensor with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard 4 75 5 25 V DC e Turn the ignition switch OFF x lf the reading of input voltage is less than the standard check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter x If the input voltage is within the standard range remove the fuel tank and check the wiring from the ECU to the throttle sensor for continuity x If the wiring is good check the output voltage of the throt tle sensor Output Voltage Inspection e Start the engine and warm it up thoroughly e Check idle speed to make sure the throttle opening is cor rect Idle Speed Standard 950 50 r min rpm Alf the idle speed is out of the specified range adjust the idle speed see Idle Speed Inspection in the Periodic Maintenance chapter e Turn off the ignition switch GC17717BS1 3 46 FUEL SYSTEM DFI Thro
405. ould not work and the cylinder head must be re placed e Measure the outside diameter A of the seat surface seat O D with vernier calipers x If the seat O D is too small repeat the 45 grind B until the diameter is within the specified range Ground Voluum C NOTE ORemove all pittings or flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seat surface This makes seat surface dis tinct and 32 and 55 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x If the seat O D is too large make the 32 grind described below 14800 P GE15020681 ENGINE TOP END 5 39 Cylinder Head 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 CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding GE15020781 e Grind the seat at a 32 angle A until the seat O D B is within the specified range x If the seat O D is within the specified range measure the seat width as described below e To measure the seat width use vernier calipers to mea sure the width C of the 45 angle portion of the seat at seve
406. out 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 Float Arm Stoppers C e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector B Black Yellow C White Yellow D Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Alf 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 E 3 5Q Empty position 213 219 O e Install a new gasket A on the fuel tank B as shown C Hollows D Front Side e Apply a non permanent locking agent to the threads of the level sensor mounting bolts and tighten it Torque Fuel Level Sensor Mounting Bolts 6 9 N m 0 7 kgf m 61 in lb Fuel Reserve Switch Inspection e Fill the fuel tank with fuel e Close the fuel tank cap surely e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Level Sensor Lead Connector A e Connect the test light B 12 V 3 4 W bulb in a socket with leads and the 12 V battery C to the fuel level sensor lead connector 6P18049BS1 16 92 ELECTRICAL SYSTEM Switch and Sensors Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side LB Lead Terminal Battery
407. ove the right front footboard bracket bolts C and footboard bolts D and turn over the footboard bracket E e Remove ES Rear Master Cylinder Mounting Bolts A S gt a AR 7 Brake Pedal Return Spring B jf a WA gt Apy Brake Switch Return Spring C E i U e e Unscrew the brake pedal clamp bolt A e Pull out the brake lever B with the master cylinder in stalled 12 10 BRAKES Brake Lever Brake Pedal e Pull out the brake pedal A from the right footboard bracket B Brake Pedal Installation e Apply grease to the brake pedal shaft e Install the pedal shaft A so that the punched mark on the shaft is aligned B with the punched mark on the brake lever C e Install Brake Pedal Return Spring Brake Switch Return Spring e Tighten Torque Brake Pedal Clamp Bolt 25 N m 2 5 kgf m 18 ft Ib Front Footboard Bracket Bolts 34 N m 3 5 kgf m 25 ft lb Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Replenish the fluid in the reservoir and bleed the brake line see Brake Line Bleeding in this chapter e Check the brake for proper braking power no brake drag and no fluid leakage A WARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done e Check the brake pedal positi
408. p Bolt Rear Brake Disc Bolts Rear Brake Hose Banjo Bolts Rear Caliper Bleed Valves Rear Caliper Holder Bolt Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension 1 0 5 9 25 27 34 1 2 1 5 7 8 34 34 8 8 27 25 7 8 64 34 25 18 Torque 0 10 0 60 2 5 2 8 3 5 0 12 0 15 0 80 3 5 3 5 0 90 2 8 2 5 0 80 6 5 3 5 2 5 1 8 8 9 in lb 52 mb 18 20 25 11 in lb 13 mb 69 in lb 25 25 78 in lb 20 18 69 mb 47 25 18 13 Remarks SI Front Axle Clamp Bolts 29 3 0 21 AL Front Fork Bottom Allen Bolts 30 3 1 22 L Front Fork Clamp Bolts Upper 29 3 0 21 Front Fork Clamp Bolts Lower 29 3 0 21 AL Front Fork Inner Cover Bolts 4 0 0 40 35 in lb Front Fork Top Plugs 22 2 2 16 Rear Shock Absorber Nuts 34 3 5 25 Swingarm Pivot Shaft 127 13 0 94 Steering Front Fork Clamp Bolts Upper 29 3 0 21 Front Fork Clamp Bolts Lower 29 3 0 21 AL Handlebar Clamp Bolts 34 3 5 25 O S Handlebar Holder Nuts 34 3 5 25 Steering Stem Head Nut 88 9 0 65 Steering Stem Nut 4 9 0 50 43 in lb S Frame Downtube Bolts Engine Mounting Bracket Bolts Front Footboard Bracket Bolts Rear Footboard Bracket Bolts Side Stand Nut Side Stand Switch Mounting Bolt Tandem Grip Mounting Bolts 59 25 34 25 44 8 8 25 6 0 2 5 3 5 2 5 4 5 0 90 2 5 44 18 25 18 32 78 in lb 18 PERIODIC MAINTENANCE 2 11 Torque and Locking Agent
409. pe Holder Bolt 11 N m 1 1 kgf m 97 in Ib Oil Return Pipe Clamp Bolt 11 N m 1 1 kgf m 97 in Ib Oil Pipe Clamp Bolt 11 N m 1 1 kgf m 97 in Ib Oil Baffle Bolt 11 N m 1 1 kgf m 97 in Ib Oil Nozzles 3 0 N m 0 30 kgf m 26 in Ib ENGINE LUBRICATION SYSTEM 7 13 Oil Pump and Oil Line e Install the inside oil pipe A separator B and the oil return pipe C to the right crankcase D ODo not apply silicone sealant to the groove of the grommet and the mating surface of the grommet E Olnstall the separator so that it s smaller side F faces in side OApply a non peramanet locking agent to the oil pipe holder bolt G oil return pipe clamp bolt H and oil pipe clamp bolts I Olf the oil nozzle J is removed install it OThe oil hose nozzle K has left hand threads 6009043BW2 C Torque Oil Pipe Holder Bolt 11 N m 1 1 kgf m 97 in Ib Oil Return Pipe Clamp Bolts 11 N m 1 1 kgf m 97 in lb Oil Pipe Clamp Bolt 11 N m 1 1 kgf m 97 in Ib Oil Hose Nozzle 3 0 N m 0 30 kgf m 26 in Ib Oil Nozzle 3 0 N m 0 30 kgf m 26 in Ib e Install the removed parts see appropriate chapters Blowby Gas System Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the oil reserve tank and right air cleaner base x If they are not correct them e Inspect the breather hoses A breather pipe B and the air cleaner drain hose
410. pe Outer Race Driver 54 5 B 57001 1077 GNO70108S1 e Replace the stem bearing inner races with new ones e Apply grease to the lower inner race A and drive it onto the stem base Special Tools Steering Stem Bearing Driver 42 5 B 57001 1344 Steering Stem Bearing Driver Adapter 41 5 C 57001 1345 e Install the steering stem see Steering Stem Installation in this chapter NOTE ODo not install the O rings yet e Settle the bearings in place as follows OTighten the stem nut to 78 N m 8 0 kgf m 58 ft lb of torque To tighten the steering stem nut to the specified torque hook the wrench on the stem nut and pull the wrench at the hole by 440 N 45 0 kg 99 Ib force in the direction shown Special Tool Steering Stem Nut Wrench A 57001 1100 180 mm 7 1 in B Force C GNO70109S1 14 14 STEERING Steering Stem Bearing OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged e Remove the stem nut e Install the O rings and adjust the steering see Steering Play Adjustment in the Periodic Maintenance chapter Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib Stem Bearing Lubrication e In accordance with the Periodic Maintenance Chart lubri cate the steering stem bearings Refer to the Stem Bear ing Lubrication in the Periodic Maintenance chapter Stem Cap Deteriorat
411. pection e Visually inspect where the teeth B on the steel plates wear against the splines A of the outer clutch hub x If there are notches worn into the splines replace the outer clutch hub Also replace the steel plate with a new one of the same thickness if their teeth are damaged Cam Damper Inspection e Disassemble the clutch see Inner Clutch Hub Disassem bly in this section e Visually inspect the damper cam A damper spring B and cam follower C x Replace any damaged parts GF13011281 GF130108S1 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents EXPO WA 7 2 eene te TEE 7 4 Special Tools and Sealant taent enee 7 5 E gine a Flow Sa ita Men ad nt are AA day ne tu da nas 7 6 Engine Oil and Ou Ple caida llora ent este rentre tetes storm 7 8 Oil Level Inspection see 7 8 Engine Oil Change sert sn es o ie ed ne 7 8 Oil Filter Replacement sienne 7 8 Oil Pump and Oil Line e eii dada 7 9 Oil Pump ReMOVAI NENNEN idad 7 9 Oil Pump Installation ciel 7 9 Oil Hose Removal sise 7 9 Oil Hose Installation EE 7 10 Inside Oil Pipe Removal seen 7 11 Inside Oil Pipe Installation 7 12 Blowby Gas System Inspection EE 7 13 Breather Drain Cleaning 00 A a o 7 14 Oil Pressure adi A AS sta fa etre ven ut ttes 7 15 Oil Pressure Measurement sie 7 15 R li
412. perature warning light broken Water temperature switch 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 Radiator fan switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Cooling system component incorrect Radiator fan switch trouble Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Spring plate free play maladjustment Clutch spring broken or weak Clutch slave cylinder trouble Clutch hub or housing unevenly worn Clutch master cylinder trouble Clutch not disengaging properly Clutch plate warped or too rough Spring plate free play maladjustment Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch slave cylinder trouble Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch fluid leakage Clutch fluid deteriorated Clutch master cylinder primary or sec ondary cup damaged Clutch master cylinder scratched inside Air in the clutch fluid line 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 set lever b
413. 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 nee dle 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 5 17 8 psi x lf the cap holds too much pressure or cannot hold the specified pressure replace it with a new one Radiator Filler Neck Inspection e Remove the radiator cap see Coolant Change in the Pe riodic Maintenance chapter 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 function properly Front B 6D070107S1 COOLING SYSTEM 4 17 Thermostat Thermostat Removal e Drain the coolant about 200 mL 6 8 US oz e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Water Hoses A Bracket Bolts B Water Temperature Sensor Connector C e Remove the thermostat housing D along with the bracket Front E e Remove the bolts A take off the cap B and take out the thermostat Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top e Install a new O ring into the housing e Fill the radi
414. pter Harness see Wiring Inspection in the Electrical System chapter x lf the all parts are good condition replace the ECU In Gear Pulled in Starts PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch A to stop position e Push the start 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 gt j trical System chapter SIS P Second Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to run position e Push the start 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 Electrical System chapter Alf the engine stop switch is good condition replace the ECU 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 c
415. pter 16 Engine switch trouble Inspect and repair or replace see chapter 16 Fuel injector trouble Inspect see chapter 3 Engine overheating see Overheating of Troubleshooting Guide see chapter 17 Other Engine oil viscosity too high Change see chapter 2 Inspect tightness of bolts and nuts see chapter 2 or bearing wear see chapter 11 Final gear case oil viscosity too high Change see chapter 2 Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 Engine overheating see Overheating of Troubleshooting Guide in chapter 17 Vacuum switch valve trouble Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine wires for signs of burning or fraying see chapter 3 Drive train trouble 3 36 FUEL SYSTEM DFI DEI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions detailed reference Spark plug dirty broken or maladjusted Clean spark plug and adjust plug gap see chapter 2 Spark plug cap or high tension wiring trouble Inspect plug cap and ignition coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or insp
416. pump A OLoosen the air bleeder bolt B until the coolant seeps out around the bolt then tighten it Torque Water Pump Air Bleeder Bolt 11 N m 1 1 kgf m 97 in Ib e Tap the radiator hoses to force any air bubbles caught inside e Fill the radiator up to the filler neck A with coolant e Install the radiator cap 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Fill the reservoir tank up to the F full level line A with coolant and install the cap e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter e Start the engine and warm it up thoroughly until the radi ator fan turns on and then stop the engine e Check the coolant level in the reserve tank several times while the engine is cooling down and replenish as nec essary lf the coolant level is lower than the L level line add coolant to the F level line CAUTION Do not add more coolant above the F level line PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Thermostat Housing A with Bracket B see Thermostat Removal in the Cooling System chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Right Side Cover see Right Side Cover Removal in the Frame chapter e Loosen the radiator hose clamps
417. r e Disconnect the battery terminals see Battery Removal in this section gt lt j CAUTION RS Be sure to disconnect the negative cable first soldado dde e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage Alf the reading is 12 6 V or more no refresh charge is re quired however ifthe 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 B Refresh charge is required C Good D Refreshing Charge e Remove the battery A see Battery Removal in this sec tion e Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Never remove seal cap B even at charging Never add water Charge with current and time as stated below ieee 16 32 ELECTRICAL SYSTEM Battery Terminal Voltage 11 5 less than 12 6 V Standard Charge 1 8 A x 5 10 h see following chart E Quick Charge 9Ax1h E CAUTION so If possible do not quick charge If quick charge is gt done unavoidably do standard charge later on 11 6 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 Charging Method 1 8A x 20 h NOTE Olncrease the cha
418. r Housing Removal in this chapter e Start the engine e Apply the tip of a screwdriver A to the injector C Put the grip end onto your ear and listen whether the injector is clicking or not OA sound scope B can also be used e Do the same for the other injector Front D x lf all the injectors click at a regular intervals the injec tors are good The trouble may be related to the fuel line requiring fuel pressure inspection see Fuel Pressure In spection in this chapter OThe click interval becomes shorter as the engine speed rises x If either injector doesn t click the DFI circuit or the injector is suspect Perform Power Source Voltage Inspection first Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the reserve tank see Coolant Change in the Pe riodic Maintenance chapter e Connect a digital meter A to the DFI main relay connec tor B using the needle adapter C Battery D in the frame Special Tool Needle Adapter Set 57001 1457 Injector Power Source Voltage at DEI Main Relay Connections Meter W R Lead Terminal E Meter gt Battery Terminal e Measure the power source voltage of the injector with the engine stopped and with the connectors joined e Turn the ignition switch ON Power Source Voltage at DEI Main Relay Standard Battery Voltage 12 5 V or more QT S E ck OUR KI
419. r 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Throttle body assy loose Reinstall see chapter 3 Replace see chapter 3 Choke knob left pulled out Push in see chapter 3 Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Thermostat trouble Inspect and replace see chapter 4 Inlet air temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Unstable rough idling ISC valve trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 33 DEI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Throttle sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Fuel pressure too low or too high inspect see chapter 3 Incorrect ide speed Engine statis easly IL l l Throttle sensor trouble engine stops when Inspect see chapter 3 opening the throttle Fuel pressure too low or too high Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3
420. r Case Disassembly 2228 anillos lada ica iba 11 25 Front Goal Case Us EE 11 27 Den sar Disass embly sta e Ee 11 28 Driven Gear Assembly siii arras 11 28 Damper Cam ne 11 29 Damper Cam Installation 11 29 Front Bevel Gear EIST ii 11 30 Preload Adjustment 11 32 Preload Measurement with Spring Scale ss 11 33 Backlash AdIUSMeNt cri dial ratita sydccceeecpagtedhetasatarn tee 11 34 Tooth Contact AG USIMOEN EE 11 35 Bevel Gear Inspechon tnnt EAAEEEEEEEEEEREEEAEEEEEEEAEEEEEEEEEEEEn EEEE EEEE 11 37 Cam Damper Inspection sise 11 37 B aring and Oil Seal e dali a RSA nd dune duree dE 11 38 Ball or Needle Bearing HReplacement rn nncnnnnns 11 38 Ball Bearing Wear si ee oia 11 38 Tapered Roller Bearing Inspechon eent 11 39 Needle Bearing Inpec EE 11 39 Oil Seal Inspection 11 39 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View Front Gear Case 090 78 inb 2 Damper Cam Mile 200 m vor 3 Drive Gear Nut LA Driven Gear Assy Mounting Bolis 25 25 18 5 Driven Gear Bolt 12 104 im e Neutral Switch 15 15 n o 9 Oil Nozzle Front 2 9 0 30 26 in lb 10 Oil Nozzle Right 18 1 8 13 11 Oil Pipe Banjo Bolts 12 1 2 104 in Ib 12 Speed Sensor Mounting Bolt 9 8 1 0 87 in lb L 13 Drive Gear Shaft 14 Output Shaft EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engin
421. r Fender Grommets Five Clamps Rear Fender Harness Plastic Cover Run the rear fender harness into the cut of plastic cover Connector for Licence Plate and Tail Brake Lights License Plate Light Tail Brake Light Snap on Strap White Mark of Rear Fender Harness Position here Rear Left Turn Signal Light Rear Right Turn Signal Light Bracket Connector of Rear Left Turn Signal Light The female plug is fitted into bracket Connector of Rear Right Turn Signal Light The female plug is fitted into bracket Press by hands Clamp the rear fender harness with these clamps and press each end of clamps by hands against the rear fender Rear View Front 17 14 APPENDIX Cable Wire and Hose Routing EONS NO We EES A S K N E E WY A HA EN al 7 FS Left Regulator Rectifier Connector Inside Alternator Connector Crankshaft Sensor Connector Oil Pressure Switch Neutral Switch Con nector Speed Sensor Connector Outside Alternator Connector Right Regulator Rectifier Connector 6B09714BW4 C Side stand Switch Connector Starter Motor Lead Speed Sensor Strap Speed Sensor Lead Insert the oil pressure neutral switch leads and side stand switch leads in this order between the alternator cover and the clutch slave cylinder APPENDIX 17 15 Cable Wire and Hose Routing N OOA Ignition Switch Connector Push the loc
422. r Removal e Cut the straps e Remove Clutch Master Cylinder A see Clutch Master Cylinder Removal in the Clutch chapter Left Handlebar Switch Housing B e Remove the left grip end cap A from the handlebar B OThe left grip end cap has left hand threads e Remove the left grip C GNO6024BS1 e Remove Front Brake Master Cylinder A see Front Master Cylin der Removal in the Brakes chapter Right Handlebar Switch Housing B Throttle Grip C e Remove the handlebar clamp bolt caps e Unscrew the handlebar clamp bolts A and remove the handlebar B from the stem head Handlebar Installation e Apply 2 stroke oil to the threads of the handlebar clamp bolts e Install the handlebar clamp A together with the handle bar so that the cut side B on the clamp points at the rear e Tighten the handlebar clamp bolts C OTighten the clamp bolts front first and then the rear If the handlebar clamp is correctly installed there will be no gap at the front and a gap at the rear after tightening Torque Handlebar Clamp Bolts 34 N m 3 5 kgf m 25 ft lb 14 6 STEERING Handlebar e The front half of the right handlebar switch housing A has a small projection B Fit the projection into the small hole C in the handlebar e Set the left handlebar switch housing A to match its mat ing surface B to the punched mark C of the handlebar e Install the handlebar switch housings e Ins
423. r case fill the oil reservoir B with engine oil e Tighten Torque Oil Hose Flange Bolts 9 8 N m 1 0 kgf m 87 in Ib e Tighten the cylinder head nuts A and cylinder nuts B to the specified torque Torque Cylinder Head Nuts 25 N m 2 5 kgf m 18 ft Ib Cylinder Nuts 25 N m 2 5 kgf m 18 ft lb Rocker Cases C Cylinder Heads D Cylinders E Special Tool Filler Cap Driver 57001 1454 Torque Timing Inspection cap 1 5 N m 0 15 kgf m 13 in 1b Rotor Bolt Cap 1 5 N m 0 15 kgf m 13 in Ib e Install Throttle Body Assy see Throttle Body Assy Installation in the Fuel System DFI chapter Rocker Case Covers see Rocker Case Cover Installa tion in this section Engine see Engine Installation in the Engine Re moval Installation chapter Rocker Arm Assembly e Prepare a flat end bar A and a block B with a recess C e Press the oil chamber D for the HLA into the rocker arm end E until the chamber end is even with the step F of the hole Olnstall the oil chamber as shown so that the air bleed hole G is placed within 120 degrees H This makes HLA bleeding easier GE20010381 GE20010482 C ENGINE TOP END 5 25 Rocker Case HLA Removal e Remove the rocker arms see Rocker Case Removal in this section e Pull the HLA hydraulic lash adjuster B out of the rocker arm A with fingers CAUTION Be careful not to damage or deform an HLA by tap
424. r 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 x Adjust the tire air pressure according to the specifications if necessary Air Pressure When Cold Up to 185 kg 408 Ib 225 kPa 2 25 kgf cm 32 psi Front Rear Up to 185 kg 408 Ib 280 kPa 2 8 kgf cm 40 psi A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure Use the same man ufacture s tires on both front and rear wheels NOTE OMost countries may have their own regulations requiring a minimum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is re placed with a new one see Balance Inspection in the Wheels Tires chapter Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of damage Swelling or high spots indicate internal damage requiring tire replacement Tire Tread Wear Abnormal 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 90 worn So it is false economy and unsafe to use the tires until they are bald
425. ral places around the seat Ground Voluum D Alf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then measure the seat O D x If the seat width is too wide make the 55 grind described below e To make the 55 grind fit 55 cutter into the holder and slide it into the valve guide e Turn the holder while pressing down lightly e Grind the seat at a 55 angle A until the seat width B is within the specified range x If the seat width is within the specified range lap the valve to the seat as described below GE15012381 e Lap the valve to the seat once the seat width and O D 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 GE11000681 e The seat 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 5 40 ENGINE TOP END Cylinder Head Valve Seat Repair START Machinist s dye on seat 45 Grind
426. rate poorly Replace crankshaft sensors Does engine still operate poorly 1 IC igniter in ECU or crankshaft sensor is damaged 2 Even if the preceding checks show good it may be defective in some manner not readily detectable with peak voltage adapter or hand tester Replace damaged part Does engine still operate poorly Replace part which was not replaced above Does engine still operate poorly Trouble may be caused by other ignition system parts or engine itself 0091B F ELECTRICAL SYSTEM 16 55 Ignition System Ignition System Circuit O1 E N O Ignition Switch Engine Stop Switch Starter Button Spark Plugs Ignition Coil 1 front cylinder Ignition Coil 2 rear cylinder Crankshaft Sensor 1 front cylinder 8 Crankshaft Sensor 2 rear cylinder DFI Fuse 15 A DFI Main Relay Frame Ground Vehicle down Sensor Throttle Sensor Electronic Control Unit Joint Connector 2 Main Fuse 30 A GP10092B 4 Battery Junction Box Ignition Fuse 10 A Starter Circuit Relay Interlock Diodes Starter Lockout Switch Side Stand Switch Diode Neutral Switch 16 56 ELECTRICAL SYSTEM Starter Motor Starter Motor Removal e Remove chapter Starter Motor Bolts A e Remove the starter motor terminal nut A and cable B CAUTION
427. re the backlash move the drive gear back and forth C while holding B the driven gear steady with a tool The difference between the highest and lowest gage readings is the amount of backlash Sa ae x lf the backlash is not within the limit replace the gear gk080006 tif shim s at the drive and or driven gear To increase back lash increase the thickness of the shim s To decrease backlash decrease the thickness of the shim s Change the thickness a little at a time e Recheck the backlash and readjust as necessary NOTE Olt is OK to pack two shims Do not pack three or more shims Front Bevel Gear Backlash at gear tooths 0 10 0 15 mm 0 004 0 006 in Shims for Drive Gear Shims for Driven Gear Thickness mm Part Number Thickness mm Part Number 0 15 0 006 in 92025 1688 0 1 0 039 in 92025 1826 0 5 0 020 in 92025 1689 0 15 0 006 in 92025 1818 0 6 0 023 in 92025 1690 0 5 0 020 in 92025 1819 0 7 0 028 in 92025 1691 0 6 0 023 in 92025 1820 0 8 0 031 in 92025 1692 0 7 0 028 in 92025 1821 0 9 0 035 in 92025 1693 0 8 0 031 in 92025 1822 1 0 0 039 in 92025 1694 0 9 0 035 in 92025 1823 1 1 0 043 in 92025 1695 1 0 0 039 in 92025 1824 1 2 0 047 in 92025 1696 1 2 0 047 in 92025 1825 Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth with a high flash point solvent e Apply checking compound to 4 or 5 t
428. rging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge forno more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D ee A CANN 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 0 lower than 12 6 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace ELECTRICAL SYSTEM 16 33 Charging System Alternator Outer Cover Removal e Remove Left Front Footboard see Front Footboard Removal In stallation in the Frame chapter Front and Rear Shift Pedals see Shift Pedal Removal in the Crankshaft Transmission chapter e Unscrew the bolts A and take off the alternator outer cover B Alternator Outer Cover Installation e First insert the upper edge A of the alternator outer cover under the left crankcase ribs B This prevents the rib failure e Apply a soap and water solution or rubber lubricant to the body of the alterna
429. ring groove clearance Piston Ring Groove Clearance Standard Top 0 050 0 090 mm 0 0020 0 0035 in Second 0 030 0 070 mm 0 0012 0 0028 in Service Limit Top 0 19 mm 0 0075 in Second 0 17 mm 0 0067 in x If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both GE160138S1 GE16020881 5 46 ENGINE TOP END Cylinders Piston Piston Ring Groove Width e Measure the width of the top A and second B ring grooves OUse vernier calipers at several points around the piston Piston Ring Groove Width Standard Top 1 24 1 26 mm 0 049 0 050 in Second 1 22 1 24 mm 0 048 0 049 in Service Limit Top 1 34 mm 0 053 in Second 1 32 mm 0 052 in x lf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness e Measure the thickness of the top A and second B rings OUse a micrometer to measure at several points around the ring Piston Ring Thickness Standard Top 1 17 1 19 mm 0 046 0 047 in Second 1 17 1 19 mm 0 046 0 047 in Service Limit Top 1 10 mm 0 043 in Second 1 10 mm 0 043 in x If 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
430. rings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Remove the stem head see Steering Stem Removal in the Steering chapter e Remove the claw washer e Adjust the stem nut A with the stem nut wrench B by tightening to the specified torque Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib e Install the stem head see Steering Stem Installation in the Steering chapter e Tighten the following in the order listed Torque Stem Head Nut 88 N m 9 0 kgf m 65 ft lb Front Fork Clamp Bolts Upper 29 N m 2 9 kgf m 21 ft lb ORun the throttle cables brake hose and clutch hose in accordance with the Cable Wire and Hose Routing sec tion in the Appendix chapter e Check and adjust the steering and throttle cables after installation A WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done GS15023BS1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Stem Bearing Lubrication e Remove the steering stem see Steering Stem Removal in the Steering chapter e Using a high flash point solvent wash the upper and lower tapered roller bearings A in the cages and wipe
431. rnator inside stator see Alternator Inside Stator Removal in the Electrical System chapter e Take the balancer drive gear A e Remove the left balancer gear bolt e Take the balancer gear B washer and left balancer off the balancer shaft as a set e Remove Lower Chain Guide Bolts A Lower Chain Guide B Front Camshaft Chain C Rear Chain Guide Bolts D Rear Chain Guide E Front Chain Guide Retainer Bolt F Front Chain Guide Retainer G e Pull the water pump sprocket A with it s chain B and shaft C 9 12 CRANKSHAFT TRANSMISSION Crankcase e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 e Remove the oil pressure switch C e Remove Oil Hoses see Oil Hose Removal in the Engine Lubrica tion chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter e Remove the right crankcase bolts M8 Bolts 5 A sea O OBe sure to remove this bolt B oa E Front C G104183BS1 e Remove all the left crankcase bolts in the order listed M6 Bolts 14 A M8 Bolt 1 B M10 Bolts 3 C Front D G104184BS1 e Turn the left crankcase down e Lift up the right crankcase OUsing the pry points split the crankcase halves Pry Point Front A Pry Point Rear B CRANKSHAFT TRANSMISSION 9 13 Crankcase e Remove the following from the left crankcase Crankshaft A
432. rward and take it off CAUTION Do not tap the swingarm pivot shaft when removing or installing Push or pull the pivot shaft while turn ing the shaft Tapping on the shaft could damage the needle bearings in the swingarm Swingarm Installation e Apply grease to the needle bearings and grease seals e Apply grease to the threads A of the swingarm pivot shaft Torque Swingarm Pivot Shaft 127 N m 13 0 kgf m 94 ft lb e Move the swingarm up and down A to check for abnor mal friction and push and pull B it to check for bearing play e Install Right Rear Shock Absorber see Rear Shock Absorber Installation in this chapter Final Gear Case see Final Gear Case Installation in the Final Drive chapter Rear Wheel see Rear Wheel Installation in the Wheels Tires chapter e Install the removed parts see appropriate chapters e After installing the swingarm replenish the brake fluid into the reservoir and bleed the brake line see Brake Line Bleeding in the Brakes chapter Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal in this chapter Propeller Shaft see Propeller Shaft Removal in the Final Drive chapter Left and Right Sleeves A Left and Right Grease Seals B SUSPENSION 13 21 Swingarm e Remove the needle bearings using the oil seal amp bearing remover A Special Tool Oil Seal amp Bearing Remover 57001 1058 e Replace the bearings and sleeve
433. s for wear see chapter 6 Engine overheating see Overheating of Troubleshooting Guide in chapter 17 Engine oil level too high Repair see chapter 7 Engine oil viscosity too high Change see chapter 3 Drive train trouble Inspect tightness of bolts and nuts see chapter 2 or bearing wear see chapter 11 Final gear case oil viscosity too high Change see chapter 2 Camshaft cam worn Inspect and replace see chapter 5 Vacuum switch valve trouble Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Catalytic converters melt down due to muffler Replace muffler see chapter 5 overheating KLEEN Exhaust Smokes Excessively White smokes Piston oil ring worn Inspect and replace see chapter 5 Cylinder worn Inspect and replace see chapter 5 Valve oil seal damaged Replace see chapter 5 Valve guide worn Replace the guide see chapter 5 Engine oil level too high Repair see chapter 7 Black smoke Air cleaner clogged Clean see chapter 3 Choke knob left pulled out Push in see chapter 3 Brown smoke 3 38 FUEL SYSTEM DFI DEI System Troubleshooting Guide Symptoms or Possible Causes Actions detailed reference Air cleaner O ring damaged Replace see chapter 3 Too low fuel pressure Inspect see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet a
434. s off the rim flange e Discard the used balance weight Balance Weight Installation e Check if the weight portion has any play on the brade and clip plate x lf it does discard it If the balance weight has any play on the rim flange the blade and or clip have been stretched Replace the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition e Lubricate the balance weight blade tire bead and rim flange with a soap and water solution or rubber lubricant This helps the balance weight slip onto the rim flange CAUTION Do not lubricate the tire bead with engine oil or pe troleum distillates because they will deteriorate the tire e Install the balance weight on the rim OSlip the weight on the rim flange B by pushing or lightly hammering A the weight in the direction shown in the figure Tire Bead C Blade D e Check that the blade A and weight B seat fully on the rim flange C and that the clip D is hooked over the rim ridge E and reaches rim flat portion GJ04117BS1 GJ04118BS1 GJ04119BS1 WHEELS TIRES 10 15 Wheels Rims e When required total weight exceeds 20 g 0 7 oz install balance weight at both sides of rim flange as shown Required Total Weight 10 g 0 4 oz 20 g 0 7 oz 30 g 1 1 oz 40 g 1 4 oz 50 g 1 8 oz 60 g 2 1 oz 70 g 2 5 oz
435. s with new ones e Remove the other side bearing in the same manner Swingarm Bearing Installation e Apply plenty of grease to the needle bearings and sleeve e Be sure to install the needle bearings so that the man ufacturer s marks are faced out This prevents bearing damage e Position the bearings A as shown using a suitable bear ing driver in the bearing driver set Sleeves B Grease Seals C 5 mm 0 2 in D Special Tool Bearing Driver Set 57001 1129 Swingarm Bearing Sleeve Inspection CAUTION Do not remove the needle bearings for inspection Remove may damage them e Visually inspect the swingarm 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 inspect the bearing in the swingarm for abrasion color change or other damage Alf 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 Grease Seal and Needle Bearing Lubrication e Refer to the Swingarm Pivot Lubrication in the Periodic Maintenance chapter STEERING 14 1 Steering Table of Contents Exploded VW aida 14 2 Special TOS iaa 14 4 eebe eege EE 14 5 Handlebar une EE 14 5 Handlebar Installation cial iria ataco coda 14 5 le E 14 7 SIGSMMG Me 14 7 Steering Ausente 14 7 O Meat lhe hee dace 14 8 Steering Stem Removal cios a A RRA 14
436. saki Bond Silicone Sealant 56019 120 Seals of Connector 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 6017045BS1 6017037351 3 24 FUEL SYSTEM DFI Troubleshooting the DEI System Resistance Check Method OThis method is simple No need for a fully charged battery and the needle adapter Just do the following especially when a sensor A is suspect e Turn the ignition switch OFF and disconnect the connec tors e Inspect the sensor resistance using a digital meter see each Sensor Inspection in this chapter e Inspect the wiring and connections B for continuity using the hand tester C special tool analog tester rather than a digital meter Special Tool Hand Tester 57001 1394 x lf the sensor the wiring and connections are good in spect the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter If the ground and power supply are good the ECU is suspect Replace the ECU 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 co
437. se e Pull the needle bearing A sleeve B and thrust washer C off the drive shaft Clutch Installation When replacing any one of the following parts check the spring plate gap see Spring Plate Gap Measurement in this section Spring Plate A Friction Plates B Steel Plates C GF13010181 e When installing the clutch housing mesh the oil pump drive gear A with the oil pump gear B so that the pump gear turns smoothly CAUTION If new dry steel or friction plates are installed ap ply engine oil to the surfaces of each plate to avoid clutch plate seizure e Install the friction plates and steel plates starting with a friction plate and alternating them e First install the friction plates fitting their tangs in the deeper grooves A and finally the outermost friction plate B in the shallower grooves C 6 14 CLUTCH Clutch e Install the clutch spring holder outer A on the spring holder B and convex direction of outside C on the spring holder D e Apply grease to the back torque limiter springs E and install the each direction them on the spring holder as shown Clutch Hub Nut F for Reference e Apply molybdenum disulfide oil solution to the threads and seating surface of the clutch hub nut OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Tighten the clutch hub nut t
438. se C to the bleed valve and run the other end of the hose into a container 12 20 BRAKES Brake Fluid e 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 lever and hold it A 2 Quickly open and close B the bleed valve while holding the brake lever applied 3 Release the brake lever 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 Repeat the above steps for the other caliper e Remove the clear plastic hose e Tighten Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Front Brake 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 the 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
439. se Breather Tube 6 Thermostat Housing 16 Clamp 7 Radiator Cap 17 Vacuum Switch Valve 8 Coolant Reserve Tank Hose 18 To Front Cylinder Head 9 Rear Coolant Hose 19 Elbow Joint 10 Rear Oil Hose APPENDIX 17 7 Cable Wire and Hose Routing Ka A 1 20 Front Oil Hose 21 Right Air Cleaner Base 22 Radiator Outlet Hose 23 To Rear Cylinder Head 24 Water Temperature Sensor 25 Align the mark with the clamp end 26 White Marks on the Coolant Hoses 27 Water Pipes 28 Wire clamp with the tab on the left 29 Main Harness Bracket 30 Coolant Reserve Tank 38 39 6899710844 C Coolant Reserve Tank Overflow Hose Clamp Holder Rear Vacuum Switch Valve Hose Front Vacuum Switch Valve Hose Vacuum switch valve hose to the right air cleaner base Note each position and direction of the clamp bolts Install the ignition coil lead as shown Front APPENDIX 17 9 Cable Wire and Hose Routing OONOABRWN TOp Locate the glued joint of the gasket within the angle Gasket Right Air Cleaner Cover Allen Bolt Clamp Inlet Air Temperature Sensor and ISC Valve Leads Inlet Air Temperature Sensor and ISC Valve Leads Vacuum Switch Valve Hose O ring Right Air Cleaner Base Grommet Lower Air Cleaner Duct between 1 and 2 Cylinders Elbow joint connected to crankcase breather hose Inlet Air Temperature Sensor ISC Valve Inlets Mark faced
440. se of inaccurate operation in motorcycles So motorcycles adopt time amp distance counting system The canceling system consists of a battery turn signal control relay distance sensor and turn signal switch When the turn signal switch is pushed onto the right or left the turn signals start flashing and the control relay starts counting off 8 seconds At the end of this time the control relay starts calculating distance traveled using pulses from the distance sensor in the speedometer The control relay keeps working even after the tern signal switch was released and returned to the neutral position by spring force When the motorcycle has traveled an additional 65 meters 213 foots the control relay shuts off the current turns off the turn signal lights and resets itself x If the turn signal canceling system does not function properly first check all the wiring connections carefully e Secondly inspect the distance sensor e Thirdly inspect the turn signal switch in the left handlebar switch e Lastly check the turn signal control relay Wiring Inspection e Connect all the connectors e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Coolant Reservoir Tank see Coolant Change in the Pe riodic Maintenance chapter e Remove the turn signal control relay A e Pull off the 6 pin connector of the relay the 9 pin and 4 pin meter connectors in the headlight housing and the 9 pin left handlebar s
441. sed Without Fork Spring below from the top of the Inner Tube Fork Spring Free Length Rear Shock Absorber Rebound Damper Set Air Pressure Standard Usable Range p43 mm 1 7 in Non adjustable Atmospheric pressure Non adjustable Non adjustable KAYABA G10 SAE 10W 20 or equivalent Approx 440 mL 14 8 US oz 513 4 mL 17 3 0 1 US oz 135 2 mm 5 31 0 08in 393 9 mm 15 50 in Service Limit 386 mm 15 2 in Nol of 4 positions Atmospheric Pressure Atmospheric Pressure 290 kPa 3 0 kgf cm 43 psi SUSPENSION 13 7 Special Tools Fork Cylinder Holder Handle Front Fork Oil Seal Driver 57001 183 57001 1219 Fork Cylinder Holder Adapter Jack 57001 1057 57001 1238 0 Oil Seal amp Bearing Remover Fork Oil Level Gauge 57001 1058 57001 1290 ST5712388ST ST571058ST ST5712908T Bearing Driver Set Attachment Jack 57001 1129 57001 1398 ST571129ST Fork Outer Tube Weight 57001 1218 ST5712188ST 13 8 SUSPENSION Front Fork Fork Oil Change Each Fork Leg e Remove the front fork see Front Fork Removal in this section e Hold the outer tube vertically in a vise e Remove Top Plug D with O ring E Collar C Washer B Spring A e Pour out the fork oil A with the fork upside down e Hold the outer tube vertically in a vise e Fill the front fork with the specified oil Fork Oil Type KAYA
442. see Rocker Case Cover Removal in this chapter Rocker Cases see Rocker Case Removal in this chap ter e Remove the camshaft B along with the KACR A ORemove the camshaft plug C e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase CAUTION The crankshaft may 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 chain and sprocket Camshaft Installation OThe front camshaft A and rear camshaft B are different The rear camshaft has a groove C e Install the KACR on each camshaft OThe front KACR A and rear KACR B are different inside view Do not confuse these KACRs e Fit the pin A into the notch B and install the KACR C onto the camshaft D e Apply molybdenum disulfide oil solution to all cam parts including their journals OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Remove the timing inspection cap and check that the F mark aligns with the middle of the notch front piston TDC see Camshaft Removal in this section x If necessary align them ENGINE TOP END 5 27 Camshafts e First install the front camshaft OEngage the front camshaft sprocket with the camshaft chain as
443. so be cleaned using a high flash point solvent and a wire _ RRELL LLL RS ERRATA ROSS brush or other tool NZ x lf the spark plug center electrode A and or side elec AA trode B are corroded or damaged or if the insulator C y is cracked replace the plug AUG e Use the standard spark plug or its equivalent e Measure the gap D with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode with a tool to obtain the correct gap Spark Plug Gap 0 8 0 9 mm 0 03 0 03 in GP10012681 Ignition Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Remove all the spark plug caps but do not remove the spark plugs e Install new spark plugs into all the spark plug caps and ground them onto the engine 16 48 ELECTRICAL SYSTEM Ignition System e Install a commercially available peak voltage adapter A into the hand tester B e Connect the adapter between the ignition coil primary wire terminal and the engine ground with the primary lead left connected Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Brand KOWA SEIKI Olnsert the adapter probe into the terminal of the primary lead C ECU D Battery E Ignition Coil F New Spark Plug G Special Tool Hand Tester 57001 1394 Hand Tester Range DC 1 000 V Primary Le
444. sorber adjustment too hard Tire air pressure too high Front fork bent 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 mas ter cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No JKBVNKD1015A000001 or 2005 VN1600 D1 JKBVNT60ADA013001 O This digit in the frame number changes from one machine to another BE amp Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1343 01 Printed in Japan
445. ss 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 5 17 8 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 5 17 8 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to from a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Remove the right side cover see Right Side Cover Re moval in the Frame chapter e Visually inspect the coolant A in the reservoir tank x 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 flash the cooling system lf the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system
446. ssion Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the run ning engine or stores the vapors in a canister when the en gine is stopped Although no adjustments are required a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF CAUTION If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one e To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Be sure to plug the return hose to prevent fuel spilling before fuel tank removal A WARNING When removing the fuel tank be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air e Connect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter
447. stall the spark plugs Torque Spark Plugs 18 N m 1 8 kgf m 13 ft lb ENGINE TOP END 5 33 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us able range Problem Cylinder compression is higher than usable range Cylinder compression is lower than usable range Diagnosis Carbon buildup on piston and in combustion chamber possibly due to damaged valve stem valve guide stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Remedy Action Remove the carbon deposits and replace damaged parts if necessary Replace the gasket with a standard part Damaged or missing compression release cam spring Replace the spring Compression release weights do not move smoothly Gas leakage around cylinder head Bad condition of valve seats valves and valve springs HLA seizure Incorrect piston cylinder clearance Piston seizure Bad condition of piston ring and or piston ring grooves Compression release weights do not move smoothly Replace the compression release unit Replace damaged gasket and check cylinder head warp Repair them if necessary Replace the HLA Replace the piston and or cylinder Inspect the cylinder and liner and replace repair the cylinder and or piston as necessary Replace the piston and or the piston
448. ster WIR lead Tester G Y lead Connections for ISC Valve 2 D Tester WIR lead Tester G BL lead e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Output Voltage at ISC Valve Reading The needle points battery voltage 12 5 V or more and 11 seconds later 0 V x If the reading is incorrect check the resistance of the ISC valve see Resistance Inspection in this chapter x If the reading of the resistance is normal check the wiring for continuity see next page x If the wiring is normal check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter Resistance Inspection e Disconnect the connectors from the ISC valve e Measure the resistance between the terminals of the ISC valve with a digital meter ISC Valve Solenoid Resistance 1 2 Standard 13 6 20 40 x If the reading is out of the standard range replace the ISC valve GC17047BS1 FUEL SYSTEM DFI 3 89 ISC Valves Jon iGNITION Qo BATTERY Qo qa ILL TAIL Jee mail Ou Go GC17711BW3 C ECU Junction Box Ignition Fuse 10 A Ignition Switch Starter Relay Main Fuse 30 A Battery ISC Valve 2 ISC Valve 1 DFI Main Relay DFI Fuse 15 A n 3 90 FUEL SYSTEM DFI Fuel Line Fuel Pressure Inspection NOTE OThis inspecti
449. t M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence SI Apply silicone grease or PBC grease 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid Grade DOT4 provided when shipping EE Clutch Lever Position No 1 to suit rider 5 way adjustable Clutch Lever Free Play Non adjustable SE Clutch Clutch Spring Free Height 4 3 mm 0 17 in 4 0 mm 0 16 in Spring Plate Gap Usable Range 1 95 2 45 mm 0 077 0 096 in EE Friction Plate Thickness 3 3 3 5 mm 0 13 0 14 in 3 1 mm 0 12 in Friction or Steel Plate Warp 0 2 mm 0 008 in or less 0 3 mm 0 01 in CLUTCH 6 5 Special Tools Inside Circlip Pliers Gear Holder 57001 143 57001 1557 ST5701438ST ST571557ST Clutch Spring Compressor 57001 1162 6 6 CLUTCH Clutch Fluid Clutch Fluid Level Inspection e Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter Clutch Fluid Change e Refer to the Clutch Fluid Change in the Periodic Mainte nance chapter Clutch Line Bleeding e Remove the alternator outer cover see Alternator Outer Cover Removal in the Electrical System chapter e With the reservoir cap off slowly pump the clutch lever several times until no air bubbles can be seen ris
450. t C e Push and pull A the fuel hose joint 2 B back and forth more than two times and make sure it is locked and doesn t come off When the fuel hose joint 2 is correctly installed it should slide on the delivery pipe about 5 mm 0 2 in A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak x If it comes off reinstall the hose joint e Connect the 2 fuel injector connector e Run the fuel hose in accordance with the 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 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change A WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Since coolant is harmful to the human body do not use for drinking e Place a container under the radiator drain bolt A then remove the drain bolt e 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 coolan
451. t counterclockwise Torque Water Pump Impeller Bolt 8 8 N m 0 90 kgf m 78 in 1b e Replace the water pump cover gasket with a new one e There are aluminum gasket A on rear side of the water pump cover B Replace them with new ones when in stalling Front C Torque Water Pump Cover Bolts 11 N m 1 1 kgf m 97 in 1b 6D06022BS1 COOLING SYSTEM 4 11 Water Pump e Insert the pump inlet hose until the hose end A touches the pump inlet step B e Tighten the hose clamp screw securely Torque Water Hose Clamp Screw 2 5 N m 0 25 kgf m 22 in Ib Water Pump Inspection e Check the water pump drainage outlet hose A at the bottom of the water pump for coolant leakage x lf the mechanical seal is damaged the coolant leaks through the seal and drain through the passage Replace the mechanical seal e Visually inspect the impeller A Alf the surface is corroded or if the blades are damaged replace the impeller Mechanical Seal Replacement e Remove the water pump impeller see Water Pump Re moval in this section e Pry the mechanical seal flange off with a small chisel A e Pull the mechanical seal out of the right crankcase with needle nose pliers Discard the mechanical seal CAUTION Be careful not to damage the water pump shaft and the inner sealing surface of the crankcase e Replace the mechanical seal with a new one NOTE OSince the replacement mechanical
452. t Caliper ASOMO 12 12 Rear Caliper Disassembly ito idilio its 12 12 Rear Caliper ASse EE 12 12 Caliper Fluid eelere sel mean eeh 12 12 Caliper Dust Boot and Friction Boot Damage 12 12 Caliper Piston and Cylinder Damage serrana dra 12 12 Caliper Holder Shaft Wear 12 12 IR Brake Pads iii al ein ee RE ts 12 13 Front Brake Pad Removal 12 13 Front Brake Pad Installation 12 13 Rear Brake Pad Removal ccecccecceee eee e cece cece eeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeneeeseeeeeeeneeeeeeenes 12 13 Rear Brake Pad Installation e aiai 12 14 Brake Pad Wear Inspection EEEE EEEE EEEE 12 14 Master Cy Wir it AA A AA cay AAA ete ta ae 12 15 Front Master Cylinder Removal sien 12 15 Front Master Cylinder Installation is 12 15 Rear Master Cylinder Removal usd bi 12 16 Rear Master Cylinder Installation 12 16 Front Master Cylinder DiSassemDIy 2 hausse dde 12 17 Rear Master Cylinder Disassembly nn nncnncncnnnnnn nn nrcnnnnnnnn 12 17 Master Cylinder Asset oeste nt ne a nd a ariran 12 17 Master Cylinder Inspection cuore 12 17 Brake DISCS 0004 veces Alike A I ee Me A Se dee dE A EA 12 18 Brake Disc Removal sise 12 18 Brake Disc Instal
453. t assembly have a short Replace the brush holder assembly and the terminal bolt assembly Starter Relay Inspection e Remove the right side covers see Right Side Cover Re moval in the Frame chapter e Remove the coolant reserve tank then the starter relay e Connect the hand tester A and 12 V battery B to the starter relay C as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 Q range Criteria When battery is connected gt 0 Q When battery is disconnected Q GP12184BS1 ELECTRICAL SYSTEM 16 61 Starter Motor Electric Starter Circuit Ignition Switch Engine Stop Switch Starter Button Junction Box Starter Circuit Relay Ignition Fuse 10 A Starter Lockout Switch Side Stand Switch Diode Neutral Switch Starter Motor Starter Relay Main Fuse 30 A Battery Joint Connector 2 GP11032B 3 16 62 ELECTRICAL SYSTEM Lighting System This model adopts the daylight system and has a head light relay in the junction box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on when the engine starts running and stays on even if the engine stalls The headlight goes out when the ignition switch is turned off It also goes out while the starter button is depressed Headlight
454. t in the Electrical System chapter e Check the front brake effectiveness WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done Steering Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem GM04256BS1 GNO5053BS1 STEERING 14 13 Steering Stem Bearing Stem Bearing Removal e Remove the steering stem see Steering Stem Removal in this chapter e Drive out the bearing outer races from the head pipe Special Tool Head Pipe Outer Race Remover ID gt 37 mm A 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races be replaced with new ones GNO70106S1 e Remove the lower inner race A which is pressed onto the steering stem using a chisel Grease Seal B Tap here C GNO70107S1 Stem Bearing Installation e Replace the bearing outer races with new ones e Apply grease to the outer races and drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Head Pi
455. t is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the
456. t of the spec ified remove the right air cleaner base check the wiring between the ECU and the inlet air temperature sensor x lf the wiring is good check the sensor resistance e Remove the needle adapters and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connector GC17720BS1 FUEL SYSTEM DEI 3 55 Inlet Air Temperature Sensor Service Code 13 Resistance Inspection e Remove the inlet air temperature sensor see Re moval Installation in this section e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are 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 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 table Inlet Air Temperature Sensor Resistance Standard 5 4 6 6 kQ at 0 C 32 F 2 26 2 86 kQ at 20 C 68 F 0 29 0 39 kQ at 80 C 176 F 6017030182 C A If the measurement is out of the range replace the sensor x If the
457. t will drain from the radiator and engine Front B e Remove the water pump drain bolt A The remaining coolant will drain from the water pump B OPlace a conduit under the drain hole of the pump cover The conduit leads to a container Front C e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Coolant Reservoir Tank Bolts A PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures e Turn over the reservoir tank A remove the cap B and pour the coolant into a suitable container e Install the reservoir tank CAUTION Soft or distilled water must be used with the an tifreeze see Specifications in this chapter in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 2 3 L 2 4 US qt e Tighten the drain bolts Torque Radiator Drain Bolt 2 2 N m 0 22 kgf m 19 in Ib Water Pump Drain Bolt 11 N m 1 1 kgf m 97 in Ib e Fill the coolant into the radiator NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions OFill in the coolant slowly so that it can expel the air from the engine and radiator e Check the cooling system for leaks e Bleed the air from the water
458. tall Clutch Master Cylinder see Clutch Master Cylinder In stallation in the Clutch chapter Front Brake Master Cylinder see Front Master Cylinder Installation in the Brakes chapter e Apply adhesive the inside the left grip A e Insert the left grip until punched mark B in the handlebar e Check and adjust the throttle cables see Throttle Control System Inspection in the Periodic Maintenance chapter and rear view mirrors SI P GNO6021BS1 STEERING 14 7 Steering Steering Check e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment e Refer to the Steering Play Adjustment in the Periodic Maintenance chapter 14 8 STEERING Steering Stem Steering Stem Removal e Using the jack A and attachment jack B under the frame pipe ribs C and a commercially available jack D under the engine E lift the front wheel F OFF the ground until the rear wheel G touches the ground Special Tools Jack 57001 1238 Attachment Jack 57001 1398 CAUTION Be sure to put the rear wheel on the ground when removing the steering or the motorcycle may fall over The motorcycle could be damaged GS15023BS1 Be sure to put the rear wheel on the ground when removing the steering or the motorcycle may fall over It could cause an accident and injury e Remove Windshield see Windshield Removal in the Frame chapter Head
459. tallation in the Engine Lu cubration chapter e Install the removed parts see appropriate chapters Starter Clutch Disassembly e Remove the starter clutch assy see Crankcase Disas sembly in this section e Remove the Allen bolts A with the balancer mass B held with the flywheel holder C Special Tool Flywheel Holder 57001 1313 6048318 P e Pull the coupling A out of the right balancer B e Take the one way clutch C out of the coupling 6107000BS1 9 22 CRANKSHAFT TRANSMISSION Crankcase Starter Clutch Assembly e Install the one way clutch A so that its groove B faces outward and its flange C fits between the right balancer D and the coupling E e Apply a non permanent locking agent to the threads of the coupling bolts and tighten them to the specified torque Torque Starter Clutch Coupling Bolts 15 N m 1 5 kgf m 11 ft lb Special Tool Flywheel Holder 57001 1313 Starter Clutch Inspection e Remove the starter clutch gear A and torque limiter then reinstall the starter clutch gear into the starter clutch e Turn the starter clutch to both side OWhen viewed from the right side of the engine the clutch should turn clockwise B freely but should not turn coun terclockwise C x If the starter clutch does not operate as it should or if it makes noise disassemble the starter clutch x If one way clutch A installation is wrong reinstall it x Visual
460. tandard with sensor tilted 40 50 or more right or left 3 7 4 4 V with sensor arrow mark pointed up 0 4 1 4V NOTE Olf you need to test again turn the ignition switch OFF and then ON e Turn the ignition switch OFF e Remove the needle adapters and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of Vehicle down Sensor Connector x lf the output voltage is out of the specified replace the vehicle down sensor x lf the output voltage is normal the wiring is suspect Check the wiring If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection in this chapter GC17728BS2 3 66 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 12345673910111213141518 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 BR Y Y BK BR R P OCN an JBATTERY Ql On BK Y d IGNITION OT TAILI QT GCi7706B 3 TAIL2 IE ECU Junction Box Ignition Fuse 10 A Ignition Switch Frame Ground Starter Relay Main Fuse 30 A Battery Vehicle down Sensor 10 DFI Main Relay 11 DFI Fuse 15 A 12 Joint Connector 2 HN O O1 UN FUEL SYSTEM DFI 3 67 Fuel Injectors 1 2 Service Code 41 42 Fuel Injector 1 Front Fuel Injector for Front Cylinder
461. tch B e Using an auxiliary lead C supply battery power to the fan motor x lf the fan does not rotate the fan motor is defective and must be replaced Battery D GP15023BS1 16 74 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 6P15024BW2 C 1 Radiator Fan 2 Radiator Fan Switch 3 Junction Box 4 Fan Fuse 15 A 5 Main Fuse 30 A 6 Battery ELECTRICAL SYSTEM 16 75 Oil Pressure Warning System Motorcycle operation with low engine oil level even if it is higher than the lower level line will cause oil level change when sudden acceleration or deceleration and may lead flicker of the oil pressure warning light because of too rapid response of the oil pressure switch To improve this operation the oil pressure light delay unit is adopted which prevents flicker of the oil pressure warning light by delaying its lighting Oil Pressure Warning System Circuit GP26003B 2 1 Ignition Switch 6 Battery 2 Junction Box 7 Oil Pressure Switch 3 Ignition Fuse 10 A 8 Meter Unit 4 Oil Pressure Light Delay Unit 9 Oil Pressure Warning LED Light 5 Main Fuse 30 A Oil Pressure Light Delay Unit Removal e Remove Coolant Reservoir Right Side Cover see Right Side Cover Removal in the Frame chapter Coolant Reservoir Tank see Coolant Change in the pe riodic Maintenance chapter e Pull the connectors out of the oil pressure
462. te citada 9 2 Specifications EE 9 6 Special Tools and Sealant rnent nnee 9 8 Cr o do 9 9 Grankcase Disassembly EE 9 9 Crankcase ASSOMDIY EE 9 13 Starter e BIEN le EE 9 21 Startet E le EE 9 22 Starter Clutch Inspechon ss 9 22 Starter Torque Limiter Check 9 22 CrankshaltCONRSCUNO Re EE 9 23 Connecting Rod Removal coins ec 9 23 Connecting Rod Installation EE 9 23 Crankshaft Connecting Rod Cleammg nono nnnnnnnnnannnnnnnnnn 9 24 Connecting Rod EE 9 24 Connecting Rod TWISEs E 9 24 Connecting Rod Big End Side Clearance neieeeeeeeeeiitteteeeiiirrrttesssrtrintnnssssrtrrrerenent 9 25 Connecting Rod Big End Bearing Wear 9 25 Crankshaft RUNOUt cenit ee cee eee AA ae ee OR ee dys AA ee AA 9 27 Crankshaft Main Bearing Journal Wear 9 27 Crankshaft Side Clara ni iii EE Ee 9 27 giele 9 28 Primary Gear Removal iii diia 9 28 Primary Gear Installations ee esta ane ne et tn dre men qi nee 9 28 TTANSMISSION fess rence tele reed ele nana pe RE E Ae EEEE EA ne date ne ent aa E age lanta tenace nee tte rates 9 30 Shi Pedal Removal eta de chad ae athena o de ee nt en gain dur ce 9 30 Shift Pedal Installation dd 9 30 External Shift Mechanism Removall ste italia 9 30 External Shift Mechanism Installation 9 31 External Shift Mechanism Inspechon nn 9 31 Transmission Remo alocado socia dales cated parta A pis 9 32 Transmission Installation ari A A AA e ER 9 32 Shift Drum
463. te marks here Cable Clip Stake the cable clip on the throttle cable holder Rubber Plug except California Front 17 18 APPENDIX Cable Wire and Hose Routing m tl pa x HA ITA IN lt Tl E 6899717844 C 1 Rear Brake Caliper 2 Hose Holders 3 Rear Brake Hose 4 Hose White Marks Position here 5 Hose Clamps 6 Run the brake hose between the engine mounting bracket bosses and the oil filter and then along the downtube towards the front 7 Oil Filter APPENDIX 17 19 Cable Wire and Hose Routing 0 star LS FRE 6899718844 C Rear Brake Reservoir Rear Master Cylinder Brake Pedal Bend both ends of the cotter pin as shown Clevis Rear Brake Reservoir Cover Downtube Swingarm Cotter Pin Rear Brake Disc Front Sech ok kee ckt Sch Sch oct w 00 Y O O1 P Go OO 17 20 APPENDIX Cable Wire and Hose Routing Throttle Body Assy Throttle Cable Decelerator Throttle Cable Accelerator Front Oil Hose Grommet Fuel Pump Outlet Hose Separator Vacuum Hose White Fuel Tank Breather Pipe Filler Drainpipe 90 00 97 OLR IN 10 Fuel Tank Breather Hose Blue Rear 11 Fuel Tank Return Hose Red Front 12 Fuel Tank 13 Main Harness 6899719844 C Run the hoses through the hole Plug Separator Breather Hose Blue Lower Air Cleaner Duct Canister Purge Hose Green
464. ten Torque Regulator Rectifier Bolts 6 5 N m 0 66 kgf m 57 in lb ELECTRICAL SYSTEM 16 41 Charging System Regulator Rectifier Inspection e Remove the alternator outer cover see Alternator Outer Cover Removal in this section BK W BK e Check the rectifier resistance as follows e Disconnect the regulator rectifier connector BK R BK e Connect the hand tester special tool to the regulator rec tifier as shown in the table and check the resistance in BK BL BK both directions of each diode in the rectifier following the table x The resistance should be low in one direction and more ine than ten times as much in the other direction If any two wires are low or high in both directions the rectifier is defective and the regulator rectifier must be replaced NOTE OThe actual tester reading varies with the hand tester used and the individual rectifier but generally speak ing the lower reading should be from zero to one half the scale Rectifier Circuit Inspection Connections Tester No Reading Tester to Tester to Range BK1 BK BL o0 BK W x 100 NE or 1 2 scale BK1 x 1000 BK2 BK3 BK1 BK2 co BK3 e Repeat the test for another regulator rectifier Regulator Inspection OTo test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also as a current
465. ten all the bolts and nuts to a snug fit and finally tighten them evenly e Pull the subwindshield all the way up 15 22 FRAME Windshield e For the European Model install the trim A to around the windshield e Install the trim caps B to the end of the trim e Install the windshield A on the brackets with the bolts e Set the windshield all the way down and tighten the bolts B securely Deflector Removal e Remove Bolts A Deflector B Deflector Assembly e Assemble the following with the bolts A and nuts B Left Stay C Right Stay D Left E and Right F Deflectors Left Deflector Bracket G Right Deflector Bracket H Washers I GO16000BS1 FRAME 15 23 Travel Trunk and Saddlebags Lid Unlatching e Insert the ignition key into the lid lock A turn the key counterclockwise B and pull the knob C outward The lid will open Lid Latching e While pulling the knob A up close the lid B release the knob and then turn the key clockwise C e Pull the knob to make sure the lid is locked CAUTION Do not slam the lid shut Otherwise the lid will not latch and could damage Saddlebag Removal e Open the lid A see Lid Unlatching in this section e Unscrew the bolts B e Close the lid see Lid Latching in this section e Lift the saddlebag C to clear the bottom stoppers and remove the bag Saddlebag Installation e Fit the stoppers on t
466. termine the clearance between each journal and the rocker case Measure the maximum plas tigage width Camshaft Rocker Case Clearance Standard p25 0 020 0 062 mm 0 0008 0 0024 in p17 0 016 0 055 mm 0 0006 0 0022 in Service Limit p25 0 15 mm 0 0059 in p17 0 14 mm 0 0055 in Alf any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard p25 24 959 24 980 mm 0 9826 0 9835 in p17 16 966 16 984 mm 0 6680 0 6687 in Service Limit p25 24 93 mm 0 981 in p17 16 94 mm 0 667 in x If 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 and rocker case CAUTION The rocker case and cylinder head are machined in the assembled state so they must be replaced as a set Front Camshaft Chain Removal e Remove Front Camshaft see Camshaft Removal in this section Spark Plug see Spark Plug Removal in the Electrical System chapter Spark Plug Retainer A Special Tool Hexagon Wrench Hex 27 B 57001 1210 e Remove Alternator Inner Cover see Alternator Inner Cover Re moval in the Electrical System chapter Alternator Inside Stator Alternator Inside Stator Re moval in the Electrical System chapter Crankshaft Balancer Gear see Crankcase Disassembl
467. tern shown above Heel A Bottom B Top C Toe D FINAL DRIVE 11 23 Propeller Shaft Propeller Shaft Removal e Remove Final Gear Case see Final Gear Case Removal in this chapter Swingarm see Swingarm Removal in the Suspension chapter e Remove the propeller shaft from the front driven gear joint OTurn the propeller shaft so that the lockpin access hole A in the propeller shaft comes outside OMove back the propeller shaft and slip the propeller shaft off the driven gear joint while pushing on the lockpin Propeller Shaft A Universal Joint B Lockpin C Spring D Driven Gear Joint E e Remove the circlip B from the rear end of the propeller shaft A using a circlip pliers e Remove the washer C and pull out the propeller shaft sliding joint D Propeller Shaft Installation e Check the O ring A on the rear end of the propeller shaft for any kind of damage and replace it if necessary e Lubricate the propeller shaft joint see Propeller Shaft Joint Lubrication in this section e After connecting the propeller shaft to the driven gear joint pull the propeller shaft rearward to check that the shaft is secured in place by the lockpin e Install Swingarm see Swingarm Installation in the Suspension chapter Final Gear Case see Final Gear Case Installation in this chapter GK08010182 C 11 24 FINAL DRIVE Propeller Shaft Propeller Shaft Joint Lubrication e Remove
468. th a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked 6003020281 PERIODIC MAINTENANCE 2 19 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 with the motor cycle held upright The coolant level should be between the F full level and the L low level In the photo the right side cover has been removed for clarity Front A Reserve Tank B F Level C L Level D Alf the coolant level is lower than the L level remove the right side cover and the reserve tank cap then add coolant to the F level CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum engine parts In an emergency soft water can be added but the diluted coolant must be returned to the cor rect mixture ratio within a few days If coolant must be added often or the reserve 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 Radiat
469. the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change in this chapter Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is almost the same as for the front brake e Level the brake fluid reservoir e Remove Reservoir Cap A Plate B Diaphragm C GS13000BS1 PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Remove the rubber cap from the bleed valve A on the front caliper B e Attach a clear plastic hose C 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 as follows ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes Open the bleed valve A Apply the brake and hold it B Close the bleed valve C 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 BROWN e Remove the clear plastic hose e Install the front brake reservoir cap e Tighten the bleed valves and install the r
470. the alternator outer cover see Alternator Outer Cover Removal in this chapter e Remove all the spark plug caps but do not remove the spark plugs e Disconnect the crankshaft sensor lead connector A e Connect a commercially available peak voltage adapter A to the hand tester B Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Brand KOWA SEIKI Special Tool Hand Tester 57001 1394 e Insert the adapter probes into the connector C of the crankshaft sensor D as shown Connections Adapter Adapter R BK Front Crankshaft Sensor BKIY lt BK Rear Crankshaft Sensor BKIR gt BK W GP110005S1 16 50 ELECTRICAL SYSTEM Ignition System NOTE OBe sure the battery is fully charged Hand Tester Range DC 10 V 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 crankshaft sensor peak voltage e Repeat the measurements 5 or more times for one crank shaft sensor e Repeat the test for the other crankshaft sensor Crankshaft Sensor Peak Voltage Standard Front 2 2 V or more Rear 2 0 V or more x If the reading is less than the specified value replace the crankshaft sensor x If the reading is normal check the ECU see ECU Power Supply Inspection Fuel System DEI chapter x lf the peak voltage adapter is not available the coil can b
471. the clutch will drag Blow the ports clean with compressed air e Check the piston return spring for any damage x lf the spring is damaged replace it 6FO9002BS1 CLUTCH 6 9 Clutch Slave Cylinder Clutch Slave Cylinder Removal e Remove Alternator Outer Cover see Alternator Outer Cover Re moval in the Electrical System chapter Banjo Bolt A Clutch Slave Cylinder Bolts B Slave Cylinder C CAUTION Immediately wash away any clutch fluid that spills It may damage painted surfaces e Perform the following if the clutch slave cylinder is to be removed but not disassembled CAUTION If the clutch slave cylinder is removed and left alone the piston will be pushed out by spring force and the clutch fluid will drain out ORemove the clutch slave cylinder with the pipe installed OPush A the piston into the cylinder as far as it will go OApply the clutch lever A slowly and hold it with a band B NOTE OHolding the clutch lever keeps the piston from coming out Clutch Slave Cylinder Installation e Apply molybdenum disulfide grease to the flat end A of the push rod B e Install the push rod so that the flat end faces in Cup Point C e Replace the spacer D of the clutch slave cylinder with a new one e Install the spacer so that the stepped side E faces out ward e Apply a non permanent locking agent to the threads of the clutch slave cylinder bolts F
472. the injector 1 to stop fuel to the cylinder 1 continuously to the though the engine keeps running ECU The ignition coil primary x If the ignition primary winding 2 has failures no lanition Coil winding must send signal wiring short or open the ECU shuts off g 2 signals output voltage the injector 2 to stop fuel to the cylinder 2 Note continuously to the ECU though the engine keeps running 1 When the engine load is light like at idling or low speed the ECU determines injection quan tity by calculating from throttle vacuum inlet air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method low speed mode As engine speed increases and the engine load turns middle to heavy the ECU determines injection quantity by calculating from throttle opening throttle sensor output voltage and engine speed This method is called a N method high speed mode FUEL SYSTEM DFI 3 45 Throttle Sensor Service Code 11 Removal Adjustment CAUTION Do not remove or adjust the throttle sensor A since it has been adjusted and set with precision at the factory Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspec tion of the inlet air pressure sensor or the atm
473. 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 Adjustment e Check that the brake pedal A is in the correct position Pedal Position Standard About 110 mm 4 3 in B height from pedal top to footboard top C NOTE OUsually it s not necessary to adjust the pedal position but always adjust it when push rod locknut has been loosened Olf the push rod length cannot be adjusted by turning the clevis the brake pedal may be deformed or incorrectly installed e Unscrew the brake fluid reservoir cover bolt A and re move the brake fluid reservoir cover B e Unscrew the reservoir bolt A and take off the brake fluid reservoir B BRAKES 12 9 Brake Lever Brake Pedal e Remove the right front footboard bracket bolts A and turn over the footboard bracket B e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position Alf the length C is 80 1 mm 3 1 0 04 in the pedal position will be within the standard range e Tighten Torque Rear Master Cylinder Push Rod Locknut 18 N m 1 8 kgf m 13 ft Ib Front Footboard Bracket Bolts 34 N m 3 5 kgf m 25 ft lb Brake Pedal Removal e Remove the brake fluid reservoir A see Brake Pedal Position Adjustment in this section e Loosen the rear master cylinder mounting bolts B e Rem
474. the spring plate gap ARES SSZ Spring Plate Gap XX XD XxX Usable Range 1 95 2 45 mm 0 077 0 096 in NOTE GF13000481 Oln case of rear wheel hop adjust the spring plate gap a bit larger and in case of clutch slip or spongy clutch lever adjust the gap a bit smaller within the usable range Spring Plate Gap Adjustment x If the plate gap is out of the usable range change one of the steel plates A to a thicker or thinner one to get the correct gap OUse the standard steel plates 2 0 mm 0 079 in thick x 6 7 plates and the adjustment steel plate 1 6 or 2 3 mm 0 063 or 0 090 in thick x 0 1 plates total 7 plates Steel Plates Thickness Part Number 1 6 mm 0 063 in 13089 1080 2 0 mm 0 079 in STD 13089 1075 2 3 mm 0 090 in 13089 1081 CAUTION If new friction or steel plates are installed apply en gine oil to the surfaces of each plate to avoid clutch plate seizure GF130005S1 CLUTCH 6 17 Clutch Friction and Steel Plate Wear and Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear Alf any plates show signs of damage replace the plates e Measure the thickness of the friction plates A at several points x If they have worn past the service limit replace the friction plate and measure the spring plate gap and adjust it if necessary Friction Pl
475. ther damage Replace the bevel gears as a set if either gear is dam aged Pinion Gear Joint Inspection e Visually inspect the splines A of the pinion gear joint x If they are badly worn or chipped replace the joint with a new one Also inspect the propeller shaft sliding joint Final Bevel Gear Adjustment OThe backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged e After replacing any of the backlash related parts be sure to check and adjust the backlash and tooth contact of the bevel gears First adjust backlash and then tooth con tact by replacing shims OThe amount of backlash is influenced by the ring gear position more than by the pinion gear position OTooth contact locations is influenced by pinion gear posi tion more than by ring gear position 6K06006BS1 FINAL DRIVE 11 19 Final Gear Case and Oil Backlash Related Parts GKOGO12BH3 1 Pinion Gear Bearing Housing 2 Pinion Gear Shim s 3 Pinion Gear Assy 4 Ring Gear Assy 5 Ring Gear Shim s 6 Final Gear Case Ring Gear Shims for Backlash Adjustment Pinion Gear Shims for Tooth Contact Adjustment Thickness mm Part Number Thickness mm Part Number 0 15 0 006 in 92025 1783 0 15 0 006 in 92180 0009 0 5 0 020 in 92025 1784 0 5 0 020 in 92180 0010 0 6 0 024 in 92025 1785 0 6 0 024 in 92180 0011 0 7 0 028 in 920
476. this chamber with the other type chamber espe cially with a non catalyst chamber The motorcycle could not clear the emission regulation Exhaust Gas Flow Premuffler Chamber A Honeycomb Type Catalytic Converter B Inlet C from Rear Exhaust Pipe Inlet D from Front Exhaust Pipe Premuffler Chamber Outlet E ORefer to the VN1500 G H Service Manual Part No 99924 1241 for more information about the KLEEN theory maintenance and handling precautions including the secondary air injection system GE18020482 C CLUTCH 6 1 Clutch Table of Contents Exploded Views is 6 2 elen e le EE 6 4 Special TOS E Clutch Elida a A cd Clutch Fluid Level Inspection Clutch Fl id G ange cuore feed te EE Clutch Line Bleeding EE Clutch Hose Removal Installation wnccesssim fceccsaeystsecketeceve ane ces es Clutch Hose and Connection Check sn 6 6 Clutch Master Cylinder iia A AA A a de 6 7 Clutch Lever Adjustment esni bare nt Re litio 6 7 Clutch Master Cylinder Removal sinus 6 7 Clutch Master Cylinder Installation cuina 6 7 Clutch Master Cylinder Disassemblvi esembhy 6 7 Clutch Master Cylinder Inspection assistant eege EES 6 8 Clutch Slave Cylinder cirio da mette 6 9 Clutch Slave Cylinder Removal vicodin redil deb 6 9 Clutch Slave Cylinder Installation 6 9 Clutch Slave Cylinder Disassembly Assembly 6 10 Re WER 6
477. tifier Bracket B Starter Motor Terminal Nut C e Remove Brake Reservoir Cover Bolt A Brake Reservoir Cover B e Support the engine with a commercially available stand A e Remove Engine Mounting Nut B Engine Mounting Bracket Bolts C Both Sides Downtube Bolt Cap and Bolts D e Remove the downtube E with the right front footboard and rear master cylinder installed e Remove Engine Mounting Nuts A Engine Mounting Bracket Bolts B Both Sides 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Disengage the propeller shaft from the engine OPull off the rubber boot A and push on the lockpin B a little with a pin OMove the engine forward C to free it from the rear pro peller shaft e Remove the engine A from the motorcycle right side Engine Installation e Support the engine with a commercially available stand and move them inside the frame in the reverse order of removal e Install the rubber boot A on the rear end of the front bevel gear case e Fit the spring B into the front bevel gear joint e Put the lockpin C into the front bevel gear joint e Apply a thin coat of high temperature grease to the driven gear joint and to the propeller shaft joint e Push on the lockpin A and move back the engine to en gage the front bevel gear joint with the propeller shaft joint e Insert the rear mounting bolt from the left side of the en gine to set the engine
478. tin 8 City Light Other than US Canada and Australia Models 9 Other than US and Canada Models 10 US and Canada Models 11 US Model 12 Canada Model 13 Australia Model 14 Other than US Canada and Australia Models L Apply a non permanent locking agent 16 14 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name FTZ16 BS Capacity 12 V 18 Ah Voltage 12 6 V or more Charging System Alternator Type Three phase AC with delta connection and rare earth Battery Charging Voltage Alternator Output Voltage No Load Stator Coil Battery Charging Coil Resistance Regulator Rectifier Type Resistance Ignition System Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Front Rear Spark Plug Spark Plug Gap Spark Plug Cap Resistance Crankshaft Sensor Crankshaft Sensor Peak Voltage Front Rear Crankshaft Sensor Resistance Crankshaft Sensor Air Gap Electric Starter System Starter Motor Brush Length Commutator Diameter Switch And Sensor Fuel Level Sensor Resistance Rear Brake Light Switch Timing Engine Oil Pressure Switch Resistance single magnet rotor 14 2 15 2 V 3 000 r min rpm 60 90 V 3 000 r min rpm 0 33 0 49 O Load dumping regulator with full wave rectifier in the text 6 mm 0 2 in or more 19 290 18 28 KQ 208 V or more 192 V or more 0 8 0 9 mm 0 03
479. tion 2 18 CO Sy SUC Riles EEE me mnt tee Le en ut 2 19 Coolant Level Inspection ss 2 19 Radiator Hose Inspection Coolant Leak Damage Installation Condition 2 19 Evaporative Emission Control System him eee tes 2 20 Evaporative Emission Control System Inspection CAL 2 20 Alir SUCTION SM dps 2 21 Air Suction System Damage Inspection 2 21 Clutch and Drive Train 2 21 Clutch Operation Inspechon a r a aa aaaea Tea r SaS 2 21 Clutch Fluid Level Inspection seen 2 22 Clutch Fluid Leak Clutch Hose and Pipe tr setilnennentnle 2 22 Clutch Hose Damage and Installation Condition Inspection 2 22 Final Gear Case Oil Level Inspection oocooocccciciciciciconocononcconcnonnnrnnnonnno nono nnnn nn nnnnrnnnn nn names 2 23 nee lee 2 24 Tire Air Pressure Inspection sense 2 24 Wheel Tire Damage Inspection ne 2 24 Tire Tread Wear Abnormal Wear Inspection 0 nnnnnnsooanannnnnnennesennnnnnornsnsnnrnnensesnnenrnnnne 2 24 Wheel Bearing Damage Inspection 2 cccccccccsceceececeeceeeseeeseeseeneceeeeeeeesseeenseeeesenereneesens 2 25 Brakes Sic ds 2 25 Brake Fluid Leak Brake Hose and Pipe ss 2 25 Brake Hose Damage and Installation Condition Inspechon 2 26 Brake Pad Wear Inspections cicl n denied 2 26 Brake Fluid Level Inspechon nnan nnnnnnnnnn nannan Anann nn nnen amenna 2 26 Brake Operation Inspection ccccccccceccececeeeceeeeceeeceeeeeeeeeeee
480. tor outer cover bolts C for easy installation and tighten them Torque Alternator Outer Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib Front D e Install Front and Rear Shift Pedals see Shift Pedal Installation in the Crankshaft Transmission chapter Left Front Footboard see Front Footboard Removal In stallation in the Frame chapter 6P090117S1 Alternator Cover Removal Installation e Remove the alternator outer cover see Alternator Outer Cover Removal in this section e Disconnect the crankshaft sensor lead connector A and alternator lead connector B 16 34 ELECTRICAL SYSTEM Charging System e Remove Alternator Cover Bolts A Bracket B Alternator Cover C e Replace the gasket with a new one e Apply silicone sealant to the area A to the crankshaft sensor wire grommet B Stator Lead Grommet C Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Tighten the Alternator cover bolts Torque Alternator Cover Bolts 11 N m 1 1 kgf m 97 in Ib Alternator Cover Assembly e Install each shift shaft grease seal A with the lip B facing inside the alternator cover C until the seal side is even D with the end of the hole e Apply a little high temperature grease on the lips E Alternator Inner Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Using the jack A and the attachment jack B raise the front and rear whee
481. torque Torque Drive Gear Nut 265 N m 27 0 kgf m 195 ft lb OStake the nut to secure it in place CAUTION When staking the nut be careful not to apply shock to the shaft and its bearing Such a shock could damage the shaft and or bearing e Install the shim A e Install the driven gear assy so that the pry ribs B and machined surfaces C align e Tighten the driven gear assy mounting bolts to the speci fied torque Torque Driven Gear Assy Mounting Bolts 25 N m 2 5 kgf m 18 ft lb 11 28 FINAL DRIVE Front Bevel Gears x lf the oil pipe A was removed use a new flat washer on each side of the fittings and tighten the banjo bolts to the specified torque OTighten the front banjo bolt B first then the rear banjo bolt C e Install the rear shift lever D aligning the lever slit E with the punch mark of the shaft Torque Oil Pipe Banjo Bolts 12 N m 1 2 kgf m 104 in Ib Rear Shift Lever Clamp Bolt 12 N m 1 2 kgf m 104 in lb 6K090401S1 Driven Gear Disassembly e Holding the driven gear joint with the driven gear holder A in a vise unscrew the driven gear bolt B Special Tool Driven Gear Holder m2 57001 1027 6K090205S1 e Remove the driven gear joint A with the O ring B e Remove the driven gear from the bearing housing e Remove the oil seal from the housing with a hook and pull the tapered roller bearing out of the housing e Re
482. ts 59 6 0 44 Engine Ground Terminal Bolt 7 8 0 80 69 in lb Engine Mounting Bracket Bolts 25 2 5 18 Engine Mounting Nuts 44 4 5 32 Crankshaft Transmission Bearing Retainer Bolts 11 1 1 97 in lb L Camshaft Chain Guide Bolts 11 1 1 97 in lb L Camshaft Chain Guide Retainer Bolts 11 1 1 97 in lb L Clutch Push Rod Guide Bolts 11 1 1 97 in lb L Connecting Rod Big End Nuts 59 6 0 44 MO Crankcase Bolt M10 L 115 39 4 0 29 S Crankcase Bolts M10 L 105 39 4 0 29 S Crankcase Bolts M6 L 80 11 1 1 97 in lb S Crankcase Bolts M6 L 70 11 1 1 97 in lb S Crankcase Bolts M6 L 40 11 1 1 97 in lb S Crankcase Bolts M8 21 2 1 15 S Damper Cam Nut 195 20 0 144 MO R Frame Ground Bracket Bolt 11 1 1 97 in lb L Gear Set Lever Bolt 11 1 1 97 in lb Idle Shaft Holder Bolt 8 3 0 85 73 in lb Left Balancer Gear Bolt 85 8 5 63 MO Oil Baffle Bolt 11 1 1 97 in lb L Oil Drain Plug 20 2 0 15 Oil Filter 18 1 8 13 ft lb EO R Oil Hose Nozzle 2 9 0 30 26 in lb LH Oil Nozzles 2 9 0 30 26 in lb Oil Pressure Switch 15 1 5 11 SS PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener Nem kgfm ftlb Remarks Oil Return Pipe Clamp Bolts 11 1 1 97 in lb L Primary Gear Bolt 145 14 5 107 MO Rear Shift Lever Clamp Bolt 12 1 2 106 in Ib Shift Drum Bearing Holder Bolts 11 1 1 97 in lb L Shift Drum Cam Bolt 15 1 5 11 L Shift Pedal Clamp Bolt 29 3 0 21 Shift Rod Locknut Front 11 1 1 97 in lb Shift Rod Locknut Rear
483. tside Diameter Exhaust Inlet Width Exhaust Inlet Valve Spring Free Length Outer EX IN Inner EX IN Cylinder Piston Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Oversize Piston And Rings Piston Ring Groove Clearance Top Second Piston Ring Groove Width Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil 45 32 55 28 9 29 1 mm 1 14 1 15 in 31 9 32 1 mm 1 25 1 26 in 0 5 1 0 mm 0 02 0 04 in 0 5 1 0 mm 0 02 0 04 in 44 76 mm orange 1 762 in 39 82 mm orange 1 568 in 102 000 102 012 mm 4 0157 4 0162 in 101 942 101 957 mm 4 0135 4 0140 in 0 043 0 070 mm 0 0017 0 0028 in 0 5 mm 0 02 in 0 050 0 090 mm 0 0020 0 0035 in 0 030 0 070 mm 0 0012 0 0028 in 1 24 1 26 mm 0 049 0 050 in 1 22 1 24 mm 0 048 0 049 in 1 17 1 19 mm 0 046 0 047 in 1 17 1 19 mm 0 046 0 047 in 0 25 0 35 mm 0 010 0 014 in 0 40 0 55 mm 0 016 0 022 in 0 30 0 90 mm 0 012 0 035 in 43 2 mm 1 70 in 38 3 mm 1 51 in 102 10 mm 4 020 in 101 79 mm 4 007 in 0 19 mm 0 0075 in 0 17 mm 0 0067 in 1 34 mm 0 053 in 1 32 mm 0 052 in 1 10 mm 0 043 in 1 10 mm 0 043 in 0 7 mm 0 03 in 0 9 mm 0 04 in 1 2 mm 0 05 in 5 12 ENGINE TOP END Special Tools and Sealants Valve Guide Reamer 47 Piston Pi
484. ttle Sensor Service Code 11 e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Connect a digital meter A to the connector B using the needle adapters C Special Tool Needle Adapter Set 57001 1457 Throttle Sensor Output Voltage Connections to ECU Connector Meter Y W lead terminal 26 Meter BR BK lead terminal 11 CAUTION Insert the needle adapter straight along the lead in the connector to prevent short circuit between ter minals GC17718BS1 e Measure the output voltage of the sensor with the engine stopped and with the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard 0 584 0 604 V DC at idle throttle opening 4 29 4 59 V DC at full throttle opening x If the output voltage is normal replace the ECU x lf the reading is out of the standard range inspect the throttle sensor resistance e After throttle sensor inspection remove the needle adapters and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of ECU Connector Resistance Inspection e Turn the ignition switch OFF e Disconnect the throttle sensor connector e Connect a digital meter A to the throttle sensor connector B e Measure the throttle sensor resistance Throttle Sensor Resistance Connections BL W lead C
485. ttle Sensor Service Code 11 3 45 Injector Unit Test 3 73 HemovallAdiustrmment 3 45 Fuel Pump Service Code 45 3 74 Input Voltage Inspection 3 45 Fuel Pump Removal 3 74 Output Voltage Inspection 3 45 Fuel Pump Installation 3 74 Resistance Inspection 3 46 Pressure Regulator Removal 3 75 Inlet Air Pressure Sensor Service Pump Screen Fuel Filter A E EE 3 48 Cleaning EE 3 75 Removal 3 48 Operation Inspection 3 75 Installation 3 48 Operating Voltage Inspection 3 76 Input Voltage Inspection 3 48 Power Source Voltage Inspection 3 77 Output Voltage Inspection 3 49 Ignition Coils 1 2 Service Code Inlet Air Temperature Sensor Service D 14 OL A A duly Shes 3 79 Code ds tod 3 54 Removal Installation 3 79 Removal Installation 3 54 Input Voltage Inspection 3 79 Output Voltage Inspection 3 54 Fl Indicator LED Light 3 80 Resistance Inspection 3 55 LED Light Inspection 3 81 Water Temperature Sensor Service ECU ld 3 82 Code Alt en ee 3 56 ECU Identification 3 82 Removal Installation 3 56 ECU Removal 3 82 Output Voltage Inspection 3 56 ECU I
486. ubber caps Torque Caliper Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in lb e Follow the procedure below to install the rear brake reser voir cap correctly OFirst tighten the rear brake reservoir cap B clockwise C by hand until the resistance is felt fully then tighten the cap an additional 1 6 turn D while holding the rear brake reservoir A body GS13108BS2 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures OFor the rear brake caliper A change the brake fluid for two bleed valves B 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 see Brake Line Bleeding in the Brakes chapter Brake Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the reservoir cap A plate B and diaphragm C e Unscrew the locknut D and pivot bolt E and remove the brake lever e Pull the dust cover F out of place and remove the circlip G Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston assy H piston I primary cup J secondary cup K and return spring L e Replace Piston Assy Dust Cover Diaphragm Circlip Rear Master Cylinder Disassembly NOTE O
487. uches the ground Special Tools Jack 57001 1238 Attachment Jack 57001 1398 e Squeeze the brake lever slowly and hold it with a band A CAUTION Be sure to hold the front brake when removing the swingarm or the motorcycle may fall over The mo torcycle could be damaged A WARNING Be sure to hold the front brake when removing the swingarm or the motorcycle may fall over It could cause an accident and injury e Remove Left and Right Saddlebags see Saddlebag Removal in the Frame chapter Rear Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Front Exhaust Pipe Cover see Exhaust Pipe Removal in the Engine Top End chapter Swingarm Pivot Cap A e Before removing the swingarm unscrew the banjo bolt A on the rear caliper B OTemporarily 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 Detach the rear brake hose C from the holders D on the swingarm CP M VA Z A Ge CANS Te Por Tl Ly AS e L Sg y 7 d gt 3 y 13 20 SUSPENSION Swingarm e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Final Gear Case see Final Gear Case Removal in the Final Drive chapter Right Rear Shock Absorber see Rear Shock Absorber Removal in this chapter e Unscrew the pivot shaft A and pull it out while turning e Pull the swingarm B rea
488. uel Injector 1 Fuel Injector 2 Vehicle down Sensor Output Voltage signal Vd 0 2V 4 6V The injector must send signals output voltage 16 or more times continuously to the ECU The injector must send signals output voltage 16 or more times continuously to the ECU x If the vehicle down sensor system has failures the output voltage Vd is out of the usable range wiring short or open the ECU shuts off the fuel pump the fuel injectors and the ignition system x lf the injector 1 fails signals less than 16 times wiring short or open the ECU shuts off the signal to the injector Fuel is not supplied to the cylinder 1 though the engine keeps running x If the injector 2 fails signals less than 16 times wiring short or open the ECU shuts off the signal to the injector Fuel is not supplied to the cylinder 2 though the engine keeps running Fuel Pump The pump must send signals output voltage continuously to the ECU x If the fuel pump fails no signals to ECU wiring short or open the ECU shuts off the pump and then the engine stops because of fuel pressure drop 3 44 FUEL SYSTEM DFI Self Diagnosis Service Output Signal Usable Codes Parts Range or Criteria Packups RECU The ignition coil primary If the ignition primary winding 1 has failures no ignition Coil winding must send signal wiring short or open the ECU shuts off 51 9 1 signals output voltage
489. ump Installation in this chapter e Tighten the hose clamp screw securely Torque Water Hose Clamp Screws 2 5 N m 0 25 kgf m 22 in lb Radiator Inspection e Remove the radiator see Radiator Removal in this sec tion e Check the radiator core x If there are obstructions to air flow remove them xlf the corrugated fins A are deformed carefully straighten them Alf 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 6D070104S1 4 16 COOLING SYSTEM Radiator CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage 1 Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core 2 Hold the steam gun perpendicular C not oblique D to the core surface and run the steam gun fol lowing the core fin direction Radiator Cap Inspection e Remove the radiator cap see Coolant Change in the Pe riodic Maintenance chapter e Check the condition of the top and bottom valve seals of the radiator cap x If any one of them shows visible damage replace the cap Bottom Valve Seal A Top Valve Seal B Valve Spring C 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 leakage e Watching the pressure gauge pump the
490. unit Right Air Cleaner Housing Installation e Check to see that the seals A B and the ISC pipe O rings C are in place e Apply a non permanent locking agent to the threads of the right air cleaner base screws e Tighten Torque Right Air Cleaner Base Bolt D 11 N m 1 1 kgf m 97 in lb Right Air Cleaner Allen Bolts E 11 N m 1 1 B o kgf m 97 in lb Right Air Cleaner Base Screws F 2 2 N m 0 22 kgf m 19 in Ib 3 104 FUEL SYSTEM DFI Air Cleaner x If the air cleaner drain hose A has been removed with it attached to the right air cleaner base pull the drain hose off the right air cleaner base Remove the left air cleaner base and insert the drain hose under the lower air cleaner duct e Install the inlet air temperature sensor A the ISC valve 1 B ISC valve 2 C and the crankcase breather hose D Torque Inlet Air Temperature Sensor Nut E 7 8 N m 0 80 kgf m 69 in Ib OThe ISC valve 1 is connected to W R and G Y leads and the hose F marked red OThe ISC valve 2 is connected to W R and G BL leads and the hose G marked blue OThe ISC valve 1 and 2 are the same parts Top Marks H Torque Right Air Cleaner Cover Allen Bolt 16 N m 1 6 kgf m 12 ft lb Lower Air Cleaner Duct Removal Installation e Remove Left Air Cleaner Housing see Left Air Cleaner Housing Removal Installation in this section Right Air Cleaner Housing see Right Air Cleaner Hous
491. ut 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 2004 Kawasaki Heavy Industries Ltd First Edition 1 Oct 31 2004 M LIST OF ABBREVIATIONS A ampere s Ib pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current r min rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s mass W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency
492. ve Allen Bolts A Both Sides Bolts B Both Sides Left and Right Saddlebag Stays Upper C e Disconnect the rear turn signal and tail brake lead con nector A and pull off the female connector along with the strap B e Remove the rear fender bolts C 15 12 FRAME Fenders e Remove the rear fender bolts A on both sides e Remove the rear fender B rearwards Rear Fender Installation e Installation is reverse of removal note the following OPut the grommet A of the rear fender into the stopper B of the frame OBe sure the harness in place see Cable Wire and Hose Routing section in the Appendix chapter FRAME 15 13 Battery Case Battery Case Removal e Remove Front Seat see Front Seat Removal in this chapter Battery see Battery Removal in the Electrical System chapter ECU see ECU Removal in the Fuel System DFI chap ter Rear Fender see Rear Fender Removal in this chapter Coolant Reservoir Tank see Coolant Change in the Pe riodic Maintenance chapter e Pull the following upwards Oil Pressure Light Delay Unit A DFI Main Relay B Turn Signal Control Unit C Starter Relay D e Remove the bolts A Front B e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Screws A Rear View B e Remove the battery case A towards the rear B 15 14 FRAME Battery Case Battery Case Installation e Put the grommet B of
493. ver C e Loosen the front exhaust pipe clamp bolt A e Remove the front exhaust pipe holder nuts B e Take off the front exhaust pipe C F4 1112 5 48 ENGINE TOP END Mufflers e Loosen the left chamber bolt e Remove Right Chamber Bolt A Rear Exhaust Pipe Holder Nuts B e Loosen the rear exhaust pipe clamp bolt C e Pull the upper end of the rear exhaust pipe outward and twist clockwise a little and then take off the rear exhaust pipe D Muffler Removal e Remove Left and Right Saddlebag see Saddlebag Removal in the Frame chapter Lower Front Exhaust Pipe Cover Right Muffler only see Exhaust Pipe Removal in this section Muffler Stay Mounting Bolts A Both Sides e Loosen the left and right muffler clamp bolts B e Move the left and right muffler C backward and remove it Exhaust Pipe Muffler Installation e Replace the exhaust pipe holder gasket A with new ones e Replace the exhaust pipe and muffler flange gasket A with new ones e Install the exhaust pipe and muffler pipe clamps B with its bolt downward e Tighten Torque Premuffler Chamber Bolts C 29 N m 3 0 kgf m 21 ft lb Muffler Stay Mounting Bolts 25 N m 2 5 kgf m 18 ft lb GE18032BS2 ENGINE TOP END 5 49 Mufflers e Install the lower front exhaust pipe cover A OFit the two plastic tabs B of the front lower exhaust cover into the slots C in the lower muffler D e Tighte
494. volution B back and forth while creating a drag on the ring gear hub C e Remove the ring gear assy and pinion gear assy to check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe x If the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as necessary NOTE Olf the backlash is out of the standard range after changing the pinion gear shim s replace the ring gear shim s to correct the backlash before checking the tooth contact pattern 11 22 FINAL DRIVE Final Gear Case and Oil Correct Tooth Contact Pattern No adjustment is required GKO6015B 1 C Heel A Bottom B Top C Toe D Incorrect Tooth Contact Patterns Example 1 GKO6016B 1 C ODecrease the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pattern shown above Heel A Bottom B Top C Toe D Incorrect Tooth Contact Patterns Example 2 G6KO6017B 1 C Olncrease the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pat
495. w down suspicious locations by repeating the con tinuity tests from the ECU connectors Alf 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 Alf an abnormality is found replace the affected DFI part Alf no abnormality is found in the wiring connectors and DFI parts replace the ECU OThe following diagnosis flow chart illustrates the above procedures OWire Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Light green W White DG Dark green O Orange Y Yellow OElectric Connectors Female Connectors A 6017029281 GPO70002 1 3 26 FUEL SYSTEM DFI Troubleshooting the DEI System Male Connectors B GPO070003S1 FUEL SYSTEM DFI 3 27 Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs General fuel system throttle body assy air cleaner fuel tank etc Confirm problems Gather information from rider Does Fl indicator LED light and Fl symbol go on NO unlit YES goes on Conduct self diagnosis inspection Conduct non self diagnosis inspection Inquiries to Rider e Refer to the next sample diagnosis chart Conduct general fuel system inspection G
496. witch connector under the fuel tank e Make sure all connector terminals are clean and tight and none of them have been bent OClean the dirty terminals and straighten slightly bent ter minals e Check conductivity or voltage of the numbered terminals with the hand tester OThe terminal numbers are shown in the wiring diagram of Turn Signal Canceling System Special Tool Hand Tester 57001 1394 Wiring Inspection Connectors ee Tester Reading Connection Turn Signal Control Relay 1 8 lt gt Distance Sensor 3 7 Turn Signal Control Relay 2 11 00 lt gt Left Handlebar Switch 3 9 4 10 Turn Signal Control Relay 6 Battery Voltage lt gt Battery Battery with IG Switch ON 0 V with IG Switch OFF IG Switch Ignition Switch 16 68 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System x If any one of the hand tester readings shows an improper values check the wiring and connections of the turn sig nal switch distance sensor and turn signal control relay Check the turn signal control relay see Turn Signal Con trol Relay Inspection in this section if all of them turn out good Distance Sensor Inspection Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Coolant Reservoir Tank see Coolant Change in the Pe riodic Maintenance chapter e Remove the turn signal control relay A ODo not disconnect the connector B e Use the jack and the attachment
497. worn Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on seating surface KACR compression release cam sticks open Inspect and repair or replace see chapter 5 Engine stalls when moving off HLA hydraulic lash adjuster damaged worn Inspect and replace see chapter 5 seizure or spring broken HLA oil passage clogged Inspect and repair or replace see chapter 5 Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak Battery voltage low Inspect and charge see chapter 16 Spark plug dirty broken or gap maladjusted Clean spark plugs and adjust plug gap see chapter 2 Spark plug cap or high tension wiring trouble Inspect the ignition coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect the cap see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Ignition coil trouble Inspect see chapter 16 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Clean element or inspect sealing see chapter 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapte
498. x chapter Replace the hose if it has been sharply bent or kinked 6FO8000BS1 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Final Gear Case Oil Level Inspection A WARNING Motorcycle operation with insufficient deterio rated or contaminated oil causes accelerated wear and may result in seizure of the pinion and ring gears Seizure can lock the rear wheel and skid the rear tire with consequent less of control e Support the motorcycle perpendicular to the ground e Remove the left saddlebag see Saddlebag Removal in the Frame chapter e Loosen the left muffler clamp bolt e Remove the left muffler stay mounting bolts A e Lower the left muffler B e Unscrew the filler cap A using the filler cap driver B Special Tool Filler Cap Driver 57001 1454 e The oil level A should come to the bottom of the filler opening x lf it is low first check the final gear case for oil leakage remedy it if necessary and add oil through the filler open ing Use the same type and brand of oil that is already in the final gear case e Install the filler cap Special Tool Filler Cap Driver 57001 1454 e Tighten the left muffler clamp bolts and muffler stay mounting bolts Torque Muffler Stay Mounting Bolts 25 N m 2 5 kgf m 18 ft lb 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel and Tires Tire Air Pressure Inspection e Measure the tire ai
499. y GC17725BS1 FUEL SYSTEM DFI 3 71 Fuel Injectors 1 2 Service Code 41 42 Alf the power source voltage is incorrect check the DFI power source see DFI Main Relay Inspection in this chapter Alf the DFI power source is good check the ECU for its ground and power supply see ECU Power Supply In spection in this chapter Alf the ground and power supply of the ECU are good the ECU is suspect Replace the ECU Alf the power source voltage is normal check the output voltage of the injector Output Voltage Inspection e Remove the ECU see ECU Removal in this chapter ODo not disconnect the ECU connector e Measure the output voltage of the injector at the ECU con nector in the same way as power source voltage inspec tion Needle Adapter A Special Tool Needle Adapter Set 57001 1457 GC17723BS1 Injector Output Voltage at ECU Connections for Injector 1 Meter gt BL R lead terminal 40 Meter Battery Terminal Connections for Injector 2 Meter BL G lead terminal 39 Meter gt Battery Terminal Output Voltage at ECU Standard Battery Voltage 12 5 V or more Alf the output voltage is normal perform Injector Signal Test x If the output voltage is out of the standard turn the ignition switch OFF remove the fuel tank and check the injector wiring for continuity Injector Wiring Inspection ECU Connector In
500. y in the Crankshaft Transmission chapter Lower Chain Guide Bolts A Lower Chain Guide B e Take out the front camshaft chain C 5 30 ENGINE TOP END Camshafts Front Camshaft Chain Installation e Apply a non permanent locking agent to the threads of the chain guide bolts and tighten them to the specified torque Torque Camshaft Chain Guide Bolts 11 N m 1 1 kgf m 97 in lb e Install Crankshaft Balancer Gear see Crankcase Assembly in the Crankshaft Transmission chapter Alternator Inside Stator see Alternator Inside Stator In stallation in the Electrical System chapter Alternator Inner Cover see Alternator Inner Cover In stallation in the Electrical System chapter e Apply grease to the O ring A e Pull the camshaft chain up the chain tunnel insert the spark plug retainer B through the chain loop and tighten it Special Tool Hexagon Wrench Hex 27 57001 1210 Torque Spark Plug Retainer 12 N m 1 2 kgf m 104 in Ib e Install Spark Plug see Spark Plug Installation in the Electrical System chapter Front Camshaft see Camshaft Installation in this sec tion Rear Camshaft Chain Removal e Remove Rear Camshaft see Camshaft Removal in this section Spark Plug see Spark Plug Removal in the Electrical System chapter Spark Plug Retainer see Front Camshaft Chain Re moval in this section Clutch see Clutch Removal in the Clutch chapter Starter Clutch Gear see Crankc
501. your finger and feel vacuum pulsing in the hose x If there is no vacuum pulsation check the hose line for leak If there is no leak check the vacuum switch valve see Vacuum Switch Valve Unit Test in the Engine Top End chapter e Apply a soap and water solution or rubber lubricant to the end of the vacuum switch hose A and put the hose into the right air cleaner base B with the white mark C faced forward until the white mark aligns with the top of the grommet D Clutch and Drive Train Clutch Operation Inspection e With the engine idling make sure that there is no noise or abnormally heavy feeling when pulling A in the clutch lever fully Also make sure that the shift lever operates smoothly e When moving off the motorcycle by releasing the clutch lever gradually make sure that the clutch does not slip and that the clutch engages smoothly x lf the clutch operation is insufficiency inspect the clutch system A WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Level Inspection e Hold the clutch fluid reservoir horizontal e Check that the clutch fluid level of the clutch reservoir is between the lower A and the upper B level lines x If the fluid level is lower than the lower level line fill the reservoir to the upper level line in the reservoir O
502. ystem chapter If the battery is good re place the fuel pump e After inspection connect the fuel hoses and install the fuel tank see Fuel Tank Installation in this chapter e Start the engine and check for no fuel leakage GC17780BS2 3 94 FUEL SYSTEM DFI Throttle Grip and Cables Throttle Grip Free Play Inspection e Refer to the Throttle Control System Check in the Periodic Maintenance Chapter Throttle Grip Free Play Adjustment e Loosen the locknuts A and screw the adjusters B all the way in so as to give the throttle grip plenty of play e Turn out the adjuster of the decelerator cable C until there is no play e Tighten the locknut against the adjuster e Turn the adjuster of the accelerator cable D until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Choke Knob Operation e Refer to the Choke Knob Operation in the Periodic Main tenance chapter Choke Cable Free Play Inspection OChoke cable free play cannot be adjusted e Check that the choke inner cable slides smoothly by pulling and pushing the choke knob lightly x If there is any irregularity or the choke lever doesn t work when the choke knob is pulled fully replace the choke cable Cable Removal Installation OSee Throttle Body Assy se

Vulcan 1600 Nomad Service Manual

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