Home

ZX600-J

Contents

1. 040 490047 9 2 3 49 5 9 49 0 5 A Accessory Fuse 10 A G Headlight Relay B Fan Fuse 10 H Headlight Diodes C Turn Signal Relay Fuse 10 A Starter Diode D Horn Fuse 10 A J Starter Circuit Relay E Ignition Fuse 10 A K Interlock Diodes F Headlight Fuse 10 L Taillight Fuse 10 A 15 76 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal e Remove Seats see Frame chapter Starter Relay and 30 A Main Fuse Connector A Pull out the main fuse B from the starter relay with needle nose pliers Junction Box Fuse Removal e Remove the seats see Frame chapter Unlock the hook to lift up the lid A e Pull the fuses B straight out of the junction box with nee dle nose pliers C Headlight Fuse Fuse Installation fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage Install the junction box fuses on the original position as specified on the lid Fuse Inspection e Remove the fuse see Fuse Removal Inspect the fuse element x If it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAU
2. 7571405ST C 7571449ST C 1 36 GENERAL INFORMATION Special Tools and Sealant Engine Mount Nut Wrench 57001 1450 ST571450ST Needle Adapter Set 57001 1457 OA 5157145751 C Flywheel amp Pulley Holder 57001 1605 Throttle Sensor Setting Adapter 57001 1521 7571521ST C 5157160551 C Kawasaki Bond Silicone Sealant 56019 120 5156012051 C Kawasaki Bond Liquid Gasket Gray 92104 1063 879210635 C GENERAL INFORMATION 1 37 Cable Wire and Hose Routing lt la 2 2 2 6809061384 Choke Cable Clutch Cable Throttle Cables Front Fork Coolant Reserve Tank Hose Coolant By pass Hose To Main Harness Air Intake Duct Turn Signal Light Lead Run the clutch cable over the coolant hoses Clamp 12 City Light Lead 13 Brake Hose 1 2 3 4 5 6 7 8 9 1 38 GENERAL INFORMATION Cable Wire and Hose Routing 68090814 3 o NO Meter Lead Headlight Turn Signal Light Lead Headlight Relay Lead Left Handlebar Switch Lead Right Handlebar Switch Lead Ignition Switch Lead Front Fork Radiator Fan Motor Lead Radiator Fan Switch Lead Stick Coil Lead Main Harness Alternator Lead Throttle Sensor Lead Speed Sensor Lead Engine Ground Frame Ground Fuel Pump Regulato
3. 15 18 Precautions e Q 15 19 Electrical cose n dto attesa but hae ind Staats 15 21 Wiring ANS PO eis e 15 21 Battery 15 22 leren Le UE 15 22 Electrolyte Filing enean haie ode eia Gates Des ee ECL 15 22 EIERE EE 15 23 Precautions E 15 23 15 24 Charging Condition Blo De EE 15 24 9242153 Tc 15 25 ET Hee EE 15 27 Alternator Cover Fetter 15 27 Alternator Cover Installation 2 cette iret e prete deter cua 15 27 Stator Coil Mecca Mtem 15 27 Stator Goll Installation 15 27 Alternator Rotor 5 wale 15 28 Alternator Rotor Installation WEE 15 28 15 Alternator Inspection sitet toi rrr eee sa Pete 15 29 Regulator Rectifier 15 30 Charging Voltage Inspectloni 4 2 ric e utet tee eol e be de rad deus 15 32 e le E eue 15 35 Crankshaft Sensor Removal re ee iter teet woe last ever ote ee E 15 36 Crankshaft Sensor Installation su auem ens libata enema inier Rocca edat a 15 37 Crankshaft Sensor
4. Impeller Bolt A Impeller B Water Pump Body A Oil Pump Cover B Oil Water Pump Shaft C Outer Rotor D and Inner Rotor NOTE OThe oil water pump assembly can easily be removed by installing water pump cover bolt E into the oil water pump shaft and pulling them Oil Pump Installation Install the outer rotor A in to the crankcase Install the pin B inner rotor C and oil water pump shaft D OTurn the pump shaft so that the slot E in its shaft fits onto the projection F of the pump drive gear shaft e Fit the pin A of the oil pump cover B into the hole C in the crankcase 6009011451 o 6 10 ENGINE LUBRICATION SYSTEM Oil Pump e Install Pins A Water Pump Body B Impeller A and Bolt B Tighten Torque Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib Install Pins C Water Pump Cover D Apply a non permanent locking agent to the threads of the water pump cover bolts and tighten them Torque Water Pump Cover Bolts 12 N m 1 2 kgf m 104 in Ib Oil Pump Drive Gear Removal e Remove Clutch see Clutch chapter Oil Pan see Oil Pan Removal Circlip A and Washer B Special Tool Outside Circlip Pliers 57001 144 Oil Pump Drive Gear C Oil Pump Drive Gear Installation e Install the circlip A into the groove B of the oil pump drive gear shaft Special Tool Outside Circlip Pliers 57001 144 ENG
5. E ass ta 15 68 Brake Light Timing eren mete oder gere 15 68 SWITCH INSPECTION EE 15 68 Radiator Fan Switch Inspection esses 15 69 Water Temperature Sensor Inspection 15 70 Throttle Sensor 9 15 70 Throttle Sensor Inspection 15 70 Throttle Sensor Position 2220 201 15 71 Speed Sensor INSPECHON ET 15 72 Meise c 15 73 Junction Box Fuse Circuit Inspechon 15 73 Starter Circuit Headlight Relay 15 73 Diode Circuit Inspection i 15 74 Pm 15 76 30 A Main Fuse 15 76 Junction Box Fuse HRemoval 15 76 GE UE e ns a a a 15 76 ELECTRICAL SYSTEM 15 3 Exploded View 6202060414 1 Crankshaft Sensor 2 IC Igniter 3 Stick Coils T1 5 9 N m 0 60 52 in lb T2 12 N m 1 2 kgf m 104 in Ib 13 N m 1 3 kgfm 113 in Ib T4 44 N m 4 5 33 ft lb L Apply a non permanent locking agent SS Apply silicone sealant 15 4 ELECTRICAL SYSTEM Exploded View 6202060514 1 Starter Lockout Switch 5 120 12 kgf m 87 ft lb 2 Oil Pressure Switch T6 1 0 N m 0 1 kgf m 9 in Ib
6. oR ech Air Vent Filter Align the mark on the hose with the mark on the filter Carburetors Air Cleaner Housing Fit the projection of the housing in the re cess of the air duct Vacuum Switch Valve Through the stick coil lead Stick Coil Lead Coolant Reserve Tank Hose To Coolant Reserve Tank 6809061984 C To Radiator Install the clamps with the baffle plate Baffle Plate Vacuum Hose Vacuum Hose Fitting Plug Fuel Tank Drain Hose Clamp Air Vent Filter Hose Cylinder Head Cover Ground Lead Run the hose through the hole of the fender 1 44 GENERAL INFORMATION Cable Wire and Hose Routing Front Brake System Rear Brake System 6 79 E S aN Brake Hose Joint Front Brake Reservoir Front Brake Master Cylinder Clamp Installed to the front fender Front Brake Caliper Clamp Clamp Rear Brake Caliper Rear Brake Master Cylinder Rear Brake Reservoir The brake hose shall be installed so that the white mark on it faces to outside A Cable Wire and Hose Routing GENERAL INFORMATION 1 45 Evaporative Emission Control System California Model 6809062184 P GO A N Vacuum Valve To Air Vent Filter Carburetor Vent Hose Carburetor Vent Hoses Fitting 3 Way Carburetor Vent Hose To 3 Way Fitting
7. 2 2 2 1 31 Cable Wire and Hose Roullng rre terrier nte P 1 37 Cable Wire and Hose Routing 2 600 4 1 47 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following 1 2 4 6 7 Dirt Before removal and disassembly clean the motorcycle Any dirt entering the engine will shorten the life of the motorcycle For the same reason before installing a new part clean off any dust or metal filings Battery Ground Disconnect the ground cable from the battery before performing any disassembly operations on the motorcycle This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the leads from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive cable to the positive terminal of the battery Installation A
8. 8 18 Crankshaft Removal 8 9 External Shift Mechanism Crankshaft Installation 8 9 72 8 18 Connecting Rod Removal 8 9 External Shift Mechanism Connecting Rod Installation 8 9 Installation 8 18 Crankshaft Connecting Rod External Shift Mechanism Cleaning codicc 8 12 8 19 Connecting Rod Bend Inspection 8 12 Transmission Shaft Removal 8 19 Connecting Rod Twist Inspection 8 13 Transmission Shaft Installation 8 19 Connecting Rod Big End Side Transmission Shaft Disassembly 8 20 Clearance Inspeciton 8 13 Transmission Shaft Assembly 8 20 Connecting Rod Big End Shift Drum and Fork Removal 8 21 Bearing Insert Crankpin Wear Shift Drum and Fork Installation 8 22 8 13 Shift Drum Disassembly 8 22 Crankshaft Side Clearance Shift Drum Assembly 8 22 8 15 Shift Fork Bending Inspection 8 22 Crankshaft Runout Inspection 8 15 Shift Fork Gear Groove Wear Crankshaft Main Bearing Inspechon 8 23 Insert Journal Wear Inspection 8 15 Shift Fork Guide Pin Drum Starter Motor Clutch 8 17 Groove Wear Inspection 8 23 Starter Motor Clutch Gear Dog and Gear Dog
9. 10 10 Engine Sprocket ne 10 10 Engine Sprocket Installatigris siae ete eee ehe cease epi eni npe Ss 10 10 Rear Sprocket Rear Sprocket Installation Coupling Installation eere ee ete Fou a dre n e non demus Coupling Bearing ee RE 10 11 Coupling Bearing Installation 2 nore ed e re rele E ees sees 10 12 Coupling Bearing tO toos fateor Es 10 12 Coupling Bearing Lubrication 1 det ia gr Re eege 10 12 Coupling Damper Inspechon 10 12 Sprocket Wear 10 13 Rear Sprocket Warp 10 13 10 2 FINAL DRIVE Exploded View T1 6 9 N m 0 7 61 in Ib T2 12 N m 1 2 kgf m 104 59 N m 6 0 kgf m 43 ft lb T4 127 N m 13 0 kgf m 94 ft lb G Apply grease HO Apply heavy oil L Apply a non permanent locking agent O Apply oil R Replacement Parts FINAL DRIVE 10 3 Specifications Item Standard Service Limit Drive Chain Chain Slack 30 35 mm 1 18 1 38 in 20 Link Length 317 5 318 2 mm 12 50 12 53 in 323 mm 12 72 in Standard Chain Make ENUMA EK525MVXL Endless ZX600 J1 J3 EK525UVXL2 Endless ZX600 J4 US EK525UVXL2 Endless ZX600 J6F CA Link 108 l
10. 2 20 Choke Cable Installation 2 7 Fuel Tank Installation 2 20 Choke Cable Lubrication and Fuel Tank Inspection 2 21 Inspection BEE 2 7 Fuel Tank Cleaning 2 21 2 8 Fuel Tap 2 21 Idle Speed Inspection 2 8 Fuel Tap Installation 2 22 Idle Speed Adjustment 2 8 Fuel Tap Inspection 2 22 Synchronization Inspection 2 8 Fuel Pump Fuel Filter 2 23 Synchronization Adjustment 2 9 Fuel Pump Fuel Filter Removal 2 23 Service Fuel Level Inspection 2 9 Fuel Pump Fuel Filter Installation 2 23 Service Fuel Level Adjustment 2 10 Fuel Pump Inspection 2 23 Fuel System Cleanliness Fuel Filter Inspection 2 23 Inspection sss 2 11 Evaporative Emission Control System Carburetor Removal 2 11 California Model 2 24 Carburetor Installation 2 12 Parts Removal Installation 2 24 Carburetor Disassembly 2 13 Hose Inspection 2 24 Carburetor Assembly 2 14 Separator Inspection 2 24 Carburetor Separation 2 14 Separator Operati
11. 6 13 Oil Pressure Switch Removal 6 13 Oil Pressure Switch Installation cesse 6 13 6 2 ENGINE LUBRICATION SYSTEM Exploded View 68602094844 C T1 1 5 0 15 kgfm 13 in lb Hand T8 25 2 5 18 ft lb Tight T9 31 3 2 kgf m 23 ft lb T2 2 0 N m 0 20 kgf m 17 EO Apply engine oil 9 8 N m 1 0 kgf m 87 in Ib G Apply grease T4 12 N m 1 2 kgf m 104 in Ib L Apply a non permanent locking agent T5 15 N m 1 5 11 ft lb R Replacement Parts 6 20 N m 2 0 14 5 ft lb SS Apply silicone sealant T7 78 N m 8 0 58 ft lb W Apply water ENGINE LUBRICATION SYSTEM 6 3 Engine Oil Flow Chart KE r E E a D 6604060184 1 Oil Pan 12 Drive Shaft 2 Oil Screen 13 Output Shaft 3 Oil Pump 14 Oil Pressure Switch 4 Oil Pressure Relief Valve 15 Cylinder Head 5 Oil Filter 16 Camshaft Cap 6 Oil Cooler 17 Camshaft 7 Crankshaft 18 Oil Passage 8 To Connecting Rod Journals 19 Oil Pipe 9 Starter Clutch Gear 20 Oil Drain Plug 10 Alternator Rotor 21 Oil Nozzles 11 Starter Clutch Oil Passage Hole 6 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil ZX600 J1 J2 ZX600 J3 Grade API SE SF or SG lt SH SJ SL with JASO MA Viscosity SAE 10W 40 10W 50 20W 40 or 2
12. Radiator Fan Switch 18 1 8 13 Water Temperature Sensor 7 8 0 80 69 in Ib 55 Impeller Bolt 9 8 1 0 87 in lb Water Pump Cover Bolts 12 1 2 104 in Ib L Thermostat Housing Cover Bolts 5 9 0 60 52 mb Water Hose Fitting Bolts 11 1 1 95 in Ib Engine Top End Spark Plugs 13 1 3 113 in Ib Air Suction Valve Cover Bolts 12 1 2 104 in Ib L Cylinder Head Cover Bolts 9 8 1 0 87 Camshaft Chain Tensioner Mounting Bolts 12 1 2 104 in Ib Camshaft Cap Bolts 12 1 2 104 in Ib Camshaft Chain Guide Bolts Upper 12 1 2 104 in Ib Cylinder Head Bolts 10 49 5 0 36 Washer 6 12 1 2 104 in Ib S Cylinder Head Jacket Plugs Right 15 1 5 11 L Cylinder Head Jacket Plugs Upper Left 20 2 0 14 5 L Engine Side Cover Bolts 12 1 2 104 in Ib Camshaft Chain Guide Bolt Crankcase 25 2 5 18 Carburetor Holder Bolts 12 1 2 104 in Ib 1 26 GENERAL INFORMATION Torque and Locking Agent Fastener Jorgue Remarks N m kgf m ft Ib Baffle Plate Bolts 9 8 1 0 87 in lb L Muffler Body and Exhaust Pipe Connecting 45 4 5 33 Nuts Exhaust Pipe Mounting Bolt 34 3 5 25 Clutch Clutch Cover Bolts 12 1 2 104 in lb L 2 Front Clutch Cover Damper Bolts 5 9 0 60 52 in lb L Clutch Spring Bolts 8 8 0 90 78 Clutch Hub Nut 137 14 101 R Engine Lubrication System Oil Filler Plug 1 5 or 0 15 or 13 in Ib or Hand Tight Hand Tight Hand Tight Engine Drain Plug 20 2 0 14 5 Oil Filter Cartridge type 31 3 2 23 R O Oil Cooler
13. Remove the coolant valve on the engine left side e Inspect the coolant valve A at room temperature x the valve is closed replace the valve with a new one OTo check valve opening just blow through the valve Valve Closing Temperature for reference Standard 70 C 158 F or more at 25 kPa 0 25 kg cm 3 6 psi GC060610S1 C 2 18 FUEL SYSTEM Air Cleaner Element Removal e Remove Seats see Frame chapter Fuel Tank see Fuel Tank Removal Upper Housing Mounting Bolts A Upper Housing B Remove the following parts as a unit Upper Plastic Holder A Element B Lower Plastic Holder C e Put a clean lint free towel on the air cleaner housing to keep dirt or other foreign material from entering WARNING If dirt or dust is allowed to pass through into the car buretors the butterfly valves may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Element Installation Install the element unit A with the foam element side gray facing up Element Cleaning and Inspection Clean the element in a well ventilated area and make sure that there are no sparks or flame any where near the working area Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element Remove the air cleane
14. Replace the O ring B with a new one e After draining install the drain screw with the O ring Torque Vacuum Valve Drain Screw 1 0 N m 0 10 kg m 9 in Ib e Using a vacuum gauge and fork oil level gauge inspect the vacuum valve operation see Vacuum Switch Valve Test in Engine Top End chapter Special Tool Fork Oil Level Gauge 57001 1290 OWhen applying vacuum 1 5 cmHg to the vacuum sens ing fitting A air flows from pipe B to pipe C and vice versa OWhen stopping applying vacuum air flows from pipe B to pipe D and vice versa x If the vacuum valve does not operate as described re place it with a new one CAUTION Do not use compressed air during the valve check or the vacuum valve may be damaged Vacuum lt 1 5 Hg No Vacuum t Air flows COOLING SYSTEM 3 1 Cooling System Table of Contents Exploded EE ee de TEE Coolant Flow En In EE GOOLE ee Rar M Coolant Deterioration 9 98 Coolant Level nnns 3 6 Coolant Drainirig te e aiu 3 6 TRE 3 7 Pressure Testing mm 3 8 Cooling System FIUSHING 3 9 Coolant Filter Cleaning eats 3 9 Water PUM e 3 10 Water P
15. 0 25 22 1 with white washer 4 9 N m 0 50 kg m 43 with black washer California 6602060684 Specifications FUEL SYSTEM 2 5 Item Standard Throttle Grip And Cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in Choke Cable Free Play 2 3 mm 0 08 0 12 in Carburetors Make Type Main Jet Main Air Jet Jet Needle Pilot Jet Slow Jet Pilot Air Jet Slow Air Jet Pilot Screw Turns Out Starter Jet Idle Speed Carburetor Synchronization Vacuum Service Fuel Level Float Height CA Canada US United States MIKUNI BDSR 36 x 4 1 4 155 2 3 157 5 45 5E110 54 1 Other than US CA 1 4 5E18 3 2 3 5E19 3 12 5 125 3 turns out 35 1300 50 r min rpm Less than 2 7 kPa 2 cmHg difference between any two carburetors 20 2 1 mm 0 80 0 04 in below the mark on the carburetor body 7 2 mm 0 28 0 08 in Special Tools Carburetor Drain Plug Wrench Hex 3 57001 1269 Fuel Level Gauge 57001 1017 Fork Oil Level Gauge 57001 1290 as required Pilot Screw Adjuster A 57001 1239 2 6 FUEL SYSTEM Throttle Grip and Cables Throttle Grip Play Inspection Throttle Grip Free Play Inspection e Check the throttle grip free play A x If the free play is incorrect adjust the throttle cable Throttle Grip Free Play Standard 2 3 0 08 0 12 in Check that the throttle grip moves smoothly fr
16. 3 15 3 20 3 25 3 30 3 35 3 40 3 45 SPECIFIED CLEARANCE NO CHANGE REQUIRED 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 315 3 20 3 25 3 30 3 38 3 40 3 45 3 50 2 80 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 REESE PESE sas ERES imam 0 00 0 05 0 06 0 10 0 11 0 19 0 20 0 24 N 0 30 0 34 Example 0 40 0 44 0 45 0 49 0 50 0 54 0 60 0 64 0 65 0 69 0 70 0 74 0 75 0 79 0 80 0 84 2 x 2 Ko lt gt o z lt H gt a lt gt INSTALL THE SHIM OF THIS THICKNESS mm 1 Measure the clearance when engine is cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 3 05 mm 0 120 in Measured clearance is 0 35 mm 0 014 in Replace 3 05 mm 0 120 in shim with 3 25 mm 0 128 in shim 5 Remeasure the valve clearance and readjust if neces sary 4 22 ENGINE TOP END Valves VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE PRESENT SHIM Example VALVE CLEARANCE MEASUREMENT PART 92180 1014 1016 1018 1020 1022 1024 1026 1028 1030 1032 103411036 1038 1040 1042 10441046 1048 1050 10
17. Brake fluid level Inspect T month e e e e Clutch adjust Inspect 1 month Radiator hoses connections Inspect T Brake fluid change 2 years e Brake master cylinder cup and dust cover replace Coolant change 2 years Caliper fluid seal and dust seal replace 4 years Steering stem bearing lubricate 2 years Coolant filter clean year 1 12 GENERAL INFORMATION Periodic Maintenance Chart Other than United States and Canada Models Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here Replace add adjust clean or torque if necessary GENERAL INFORMATION 1 13 Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION The ZX600J have catalytic converters The secondary air injection system A helps Kawasaki keep motorcycle exhaust gases below the established emission regulation limits This system draws air into the exhaust ports dilutes and burns harmful ingredients in the exhaust gas in order to reduce them This allows the carburetor to be set at a reasonable setting position without adjusting it much leaner so engine performance and actual riding performance are not spoiled But under the trend that the emission regulation becomes more severe Kawasaki has adopted two catalytic converte
18. EE e dee e eI 5 7 Clutch Plate Assembly 22 2 rette tci 5 9 Clutch Plate Assembly Adjustment eene 5 10 Clutch Plate Wear Damage Inspection 5 10 Clutch Plate Warp Inspechon nere nnn nnne nnn 5 10 Clutch Spring Free Length Measurement eese 5 11 5 2 CLUTCH Exploded View 1 Clutch Lever Pivot Nut T1 5 9 N m 0 60 52 in Ib T2 8 8 N m 0 90 78 in Ib T3 12 N m 1 2 kgf m 104 in Ib T4 137 N m 14 kgf m 101 16 5 1 5 Nem 0 15 kgf m 13 in Ib or Hand Tight CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts W Apply water 620210284 C CLUTCH 5 3 Specifications Standard Service Limit Item Clutch Lever Free Play Clutch Friction Plate Thickness Friction and Steel Plate Warp Clutch Spring Free Length 82 1 mm 3 23 in Clutch Plate Assembly Length 37 7 38 3 mm 1 48 1 51 in 2 3 mm 0 08 0 12 in cwm 2 72 2 88 mm 0 107 0 113 in 2 2 mm 0 087 in 0 2 mm 0 008 in or less 0 3 mm 0 012 in 78 0 mm 3 07 in Special Tool Clutch Holder 57001 1243 Sealant Kawasaki Bond Silicone Sealant 56019 120 5 4 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection e Pull the clutch lever just enough to take up the f
19. 16 8 APPENDIX Nut Bolt and Fastener Tightness Tightness Inspection Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x If there are loose fasteners retorque them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Front Axle Nut Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts 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 Nut Uni Trak Link Nuts Steering Steering Stem Head Nut Handlebar Mounting Bolts Engine Engine Mounting Bolts Exhaust Pipe Mounting Bolt Muffler Mounting Nut Exhaust Pipe Holder Nuts Muffler Body and Exhaust Pipe Connecting Bolts Clutch Lever Pivot Nut Others Sidestand Mounting Bolt Footpeg Mounting Bolts Footpeg Bracket Mounting Bolts Fr
20. 6J06006BS1 C 6J06007BS1 C 9 16 WHEELS TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones Turn each bearing in the hub back and forth A while checking for plays roughness or binding bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J06002BS1 C FINAL DRIVE 10 1 Final Drive Table of Contents e leie Ee WE 10 2 Specifications E 10 3 E 10 4 Drive Chain Slack Inspection 000000006000 000000 10 4 Drive Chain Slack Adjustment sii eren odas eite exte 10 4 Wheel Alignment Inspection Adjustment 10 4 Drive Chain Wear Inspection 10 5 Drive Chain Lubrtcatton 9 10 5 Drive EN TEE 10 6 Drive Chain Installation mmm meer nennen nennen 10 6 Drive Chain Replacement ZX600 J4 US ZX600J6F 10 7 Sprocket Co pling iced decente re kk e deeds PD D ed Og
21. EEO cms mmo ommo a Pulled in Q W221968AW5 6 15 8 ELECTRICAL SYSTEM Wiring Diagram United States and Canada ZX600 J3 ight Handlebar Switches Front Brake Light Switch Engine Stop Switch Starter Button 00 R Radiator Fan T Switch D BL BL BK ter sl BL BL W BK BK Y gt 542252 Radiator Fan o8 past 2 LK BATTERY 9 D H 5 iti Switch TGRTTIOR CS GY 3252 gnition Swite TAIL R BL Triad TAIL 95951 R 5 D TAIL3 6221 06 0 6 High Beam Indicator Light 12V1 1 Meter Assembly Left Turn Signal Indicator EIE Right Turn Signal Indicator R BK Light 12V1 1W er Neutral Indicator Light 12V1 1W 011 Pressure Warning Light 12V1 1 Tachometer Light 12V0 7W Tachometer Sp dom er amp Tachometer Li t 1 1 et h 2V1 1 e R BL BK Y L6 P NE a BL Y peed Sensor P 5 1 BK Y R R BK Y BK Y HA Ee p A ese F e Frame Ground Speedometer Speedometer Light 12V0 7W BK BL T Water Temperature Warning Light LED ight Headlight 2V60 55W BK W BK Y 8 0 ay R BK R Y BL Y Y 8 LG 5522 2550 xt 2 955 i23 mx Left Headlight 12V60 55W w 8
22. Fitting Carburetor Vent Hose To Canister Yellow Vacuum Switch Valve 10 11 Vacuum Hose Vacuum Hose 13 14 15 Band 17 18 19 Vacuum Hoses To 2 3 Carburetor Holder Fitting 4 Way Vacuum Hose To 1 Car buretor Holder Separator Purge Hose 3 Way Fit ting to Canister Green Fitting 3 Way Return Hose To Fuel Tank Breather Hose To Canis ter Blue Breather Hose To Fuel Tank Drain Hose Clamp Air Cleaner Clamp Pickup Coil Cover Clamp Plug Clamp 1 46 GENERAL INFORMATION Cable Wire and Hose Routing 7 6 Eg eI n lt Fuel Tank Return Hose To Fuel Tank Red Breather Hose To Fuel Tank Blue Through the cut portion of Rear Fender Band Band Canister Carburetor Vent Hose Yellow Breather Hose Blue 10 11 12 13 the leads through the rear fender 15 16 68809870844 C Purge Hose Green To Right Turn Signal Light Canister Headlight Fuse notch Run the leads over the canister hoses Run the turn signal lead inside of the can ister hoses GENERAL INFORMATION 1 47 Cable Wire and Hose Routing ZX600 J4 Evaporative Emission Control System California Model ALR ie Fo De 2 88096208844 C 1 2 3 4 5 6 CON Main Harness 10 Fu
23. 3 Front Brake Light Switch T7 1 5 0 15 kgf m 13 in Ib 4 Neutral Switch T8 34 N m 3 5 kgf m 25 ft lb T1 3 4 0 35 kgf m 30 in Ib G Apply grease or engine oil T2 12 N m 1 2 kgf m 104 in Ib L Apply a non permanent locking agent 6 9 0 70 61 in Ib M Apply molybdenum disulfide grease T4 15 N m 1 5 11 ft lb SS Apply silicone sealant ELECTRICAL SYSTEM 15 5 Exploded View 6202060614 1 Turn Signal Relay 2 Water Temperature Sensor 3 Fan Switch 4 Side Stand Switch 5 Headlight Relays 6 Rear Brake Light Switch T1 7 8 N m 0 80 69 in Ib T2 18 N m 1 8 kgf m 13 16 9 8 N m 1 0 87 in Ib T4 8 8 N m 0 90 78 in Ib L Apply a non permanent locking agent SS Apply silicone sealant 15 6 ELECTRICAL SYSTEM Wiring Diagram United States and Canada ZX600 J1 J2 Radiator Switch Fan BL W BL BK BL BK BL W BK Y dir Radiator past ETI BATTERY 92 tte Ignition Switch TAIL TAIL OO R 1 2 3 ight Handlebar Switches Front Brake Light Switch Engine Stop Switch Starter Button AT 1 c 42 Model T HI 5 gt 2522542 etre BATTERY 92 o3 163195 Speedomete amp Tachometer Light 12Vi iW Speedometer
24. CAUTION Immediately wash away any brake fluid that spills Front Master Cylinder Installation e Set the front master cylinder to match its mating surface A to the punch mark B of the handlebar e The master cylinder clamp must be installed with the ar row mark C upward e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 0 90 kgf m 78 in Ib ZX600J1 J6F 11 1 1 97 in Ib ZX600J7F e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 e Bleed the brake line see Bleeding the Brake Line Check the brake for good braking power no brake drag and no fluid leakage Rear Master Cylinder Removal e Unscrew the brake hose banjo bolt A on the master cylin der see Brake Hose Removal Installation e Pull off the reservoir hose lower end B and drain the brake fluid into a container e Remove the cotter pin C and joint pin D NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts E and take off the master cylinder F and master cylinder cover G 11 14 BRAKES Master Cylinder Rear Master Cylinder Installation Replace the cotter pin with a new Replace the w
25. GENERAL INFORMATION 1 19 Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION Do not run overspeed limiter too much from the standpoint to protect the engine Overspeed limiter has a protection system that applies ignition cut method and fuel cut method together Conventional system applies fuel on method e Do not run the engine even if only one cylinder has a misfire or has unstable running In this case request the nearest service facility to correct it If you have no choice but running by yourself keep engine rpm as low as possible and try to finish running at the shortest period e When the battery is dead do not push start Connect another full charged battery with jumper ca bles and start the engine 5 Additional Information 1 Secondary Air Injection System The mechanism is simple and power loss is minimum because the system uses the vacuum pres sure created by exhaust pulses The secondary injection air helps the fuel air mixture burn more completely Primary air means air which flows through the inlet pipe As the exhaust valve opens and the burned fuel passes the exhaust valve a stream of fresh air is introduced through the air suction valve This fresh air burns the unburned gas and converts the carbon monoxide CO and hydrocarbons HC into harmless carbon dioxide CO2 and water H20 1 2 O2 gt CO O2 CO H20 The secondary air injection system consists of a vacuum switch valve
26. Olnstall the meter unit ORaise the rear wheel off the ground using the jack OTurn on the ignition switch ORotate the rear wheel by hand OCheck that the speedometer shows the speed x If the speedometer does not work check the speed sen sor electric source voltage and speed sensor GP17060481 U Push DUTY 50430 Less than 0 8 17060751 15 66 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Speed Sensor Electric Source Check Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check Set the hand tester to the DC25 V range and connect it to the terminals 2 and 4 x If the voltage is less than 7 V replace the meter unit CAUTION Do not short the terminals 2 4 and 4 5 Odometer Check Check the odometer with the speedometer in the same way x If value indicated in the odometer is not added replace the meter unit Trip Meter Check Check the trip meter with the speedometer in the same way x If value indicated in the trip meter is not added replace the meter unit Check that when the ODO TRIP button is pushed for more than two seconds the figure display turns to 0 0 x If the figure display does not indicate 0 0 replace the me ter unit Water Temperature Meter Check Connect the 1
27. e Lubricate the rim flanges and tire beads Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Tire Inspection Install the brake disc s so that the marked side faces out see Brakes chapter e Adjust the wheel balance 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 external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained 6J05004BS1 C Hub
28. o9 BR Brown A Chocolate Dare Green h Starter Relay European model with Honeycomb Catalytic Converter only Green 9 Grange Pink PU Purple rea RIGHT HANDLEBAR SWITCH CONNECTIONS Headlight Switch Front Brake Light Switch Engine Stop Switch Starter Button Color R W R BL BL BL Y Color BK BK Color Color BK R BK R IGNITION SWITCH CONNECTIONS g Button Ignition Battery lgnition Tail Tai 12 L er fef err voce es Brake Lever Pulled In 98051 1898B 1899B 221898885 C 15 14 ELECTRICAL SYSTEM Wiring Diagram Malaysia Right Handlebar Switches 1 Front Brake Light Switch Radiator Fan 2 Engne Stop Switch Switch 3 Starter Button n BL W 117 BL BK H BL BK BK Y S9 zz l Radiator Fan len mand cm BR lt BR SEN calo Ignition Switch 1 ay DL 1 Got sc R BL 0 R BATTERY x TAILS 66 0 0 Ra High Beam Indicator Meter Assembly Light 12Vi 1W Left Turn Signal BR W Light 12 Right Tu R BK Light 12 en Neutral 5 Light 12 BL R Gil Pres vn Tachomet BK LG DEER IE el
29. 1 1 1 1 13 7 Steering Stem Warp Inspection 13 7 27 LEE 13 8 Handlebar Removal 23 52 25 1 2 0 a 13 8 Handlebar Installation Mesa dein ete 13 8 Handlebar Holder Removal ipt 13 8 Handlebar Holder 13 9 13 2 STEERING Exp loded View 2 2m d 8 5 0 35 kgf m 30 4 9 N m 0 5 kgf m 36 in Ib 9 8 N m 1 0 87 in lb 20 N m 2 0 kgf m 14 5 ft lb 25 2 5 kgf m 18 ft lb 34 3 5 kgf m 25 ft lb 49 5 0 kgf m 36 ft lb 15 1 5 kgf m 11 ft lb Apply adhesive Apply grease Apply a non permanent locking agent 68802060244 C STEERING 13 3 Specifications Special Tools Steering Stem Nut Wrench 57001 1100 Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 55 57001 1446 Head Pipe Outer Race Driver 647 57001 1447 Steering Stem Bearing Driver 542 5 57001 1344 Steering Stem Bearing Driver Adapter 41 5 57001 1345 Jack 57001 1238 13 4 STEERING Steering Steering Inspection e Lift the front wheel off the ground using the jack Special Tool Jack 57001 1238 With the front wheel pointing straight ahead alternately tap each end o
30. COOLING SYSTEM 3 7 Coolant e Remove Lower Fairing see Frame chapter Radiator Cap A e Place a container under the drain plug A at the bottom of the water pump cover B Drain the coolant from the radiator and engine by remov ing the drain plug e Remove Lower Fairing see Frame chapter Hose A Mounting Screws B and Reserve Tank C Collar and Idle Speed Adjusting Screw Bracket D Remove the cap and pour the coolant into a container Coolant Filling e Remove Lower Fairing see Frame chapter Tighten the drain plug Torque Drain Plug 9 8 N m 1 0 kgf m 87 in Ib e Fill the radiator up to the radiator filler neck A with coolant and install the radiator cap NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Fill the reserve tank up to the full level line with coolant and install the cap CAUTION Soft or distilled water must be used with the an tifreeze see below for antifreeze in the cooling sys tem If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system 6005010351 C 8005010851 C 3 8 COOLING SYSTEM Coolant Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 31 F Total Amount 2 31 2 43 US qt NOTE OChoose a suitable mixture rati
31. Drive Chain FINAL DRIVE 10 9 Set the plate holder B A and the cutting and rivetting pin B as shown e Turn the pin holder until the rivetting pin touches the link pin Turn the wrench clockwise until the tip of rivetting pin con tact with the link pin Rivet it Repeat the same procedure for the other link pin e After staking check the staked area of the link pin for cracks Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 6 6 0 mm 0 22 0 24 in Link Plates Outside Width Standard 19 85 20 00 mm 0 78 0 79 in If the reading exceeds the specified length cut and rejoin the chain again Check Movement of the Rollers Adjust the drive chain slack after installing the chain GK04026BS1 GK04028BS1 10 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Remove Speed Sensor Bolt A Speed Sensor B Engine Sprocket Cover Bolts C Engine Sprocket Cover D e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 Loosen the drive chain see Slack Adjustment Remove the drive chain from the rear sprocket toward the right e Disengage the drive chain A from
32. Kawasaki Ninja ZX 6R 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 Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Electrical System gt c Mille Or B Oo Kawasaki Ninja ZX 6R Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp Machinery Group 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 without prior notice and without incurring an obligation to make such changes
33. Rare Magnet Material Sintered metal made from mainly neodium Nd ferric magnet Fe and boron B Main Characters Rare magnet used and assembled in the alternator for the ZX600 J model has six 6 times higher performance than that of the traditional use ferrite magnet This allows the alternator to reduce its mass and weight to the large extent In addition to above mentioned there s no use to worry about the future lackage of rare magnetic resources such as samarium cobalt GENERAL INFORMATION 1 25 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads LG Apply grease to the threads Lh Left hand threads M Apply molybdenum disulfide grease O Apply oil to the threads and seating surface R Replacement parts S Tighten the fasteners following the specified sequence SS Apply silicone sealant St Stake the fasteners to prevent loosening Fuel System Vacuum Valve Drain Screw 1 0 0 10 9 in Ib Fuel Tap Bolts 4 9 0 50 43 in lb with black washer Fuel Tap Bolts 2 5 0 25 22 in lb with white washer Cooling System Water Hose Clamp Screws 2 0 0 20 17 in lb Coolant By pass Fitting 9 8 1 0 87 L Coolant Drain Plug Water Pump 9 8 1 0 87 Coolant Drain Plugs Cylinder 9 8 1 0 87
34. ZX600 J1 J3 To adjust the compression damping force turn the com pression damping adjuster A until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 9th click from the 1st click of the fully clockwise position ZX600 J4 US ZX600J6F CA e To adjust the compression damping force turn the re bound damping adjuster A up to the specified turns OThe standard adjuster setting for the overage build rider of 68 kg 150 Ib and with no passenger and accessories is 2 turns out from fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Counterclockwise Clockwise Sof ter Harder STD 1211109 8 Seated position adjuster turned fully clockwise GM04060351 Front Fork SUSPENSION 12 7 OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Compression Damping Force Adjustment soting Speed Weak Soft Low T High A 12 clicks ZX600 J1 J3 3 turns out ZX600 J4 US ZX600J6F CA B 1 click ZX600 J1 J3 Fully clockwise position Z
35. yellow red lead it would be a red yellow lead if the colors were reversed Unless instructed otherwise electrical leads must be connected to leads of the same color Two Color Electrical Lead cross section Color Indicated on the Lead Color Indicated on the Wiring Diagram Red Lead Strands Yellow Red Yellow Red 08802069841 C 1 4 GENERAL INFORMATION Before Servicing 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteri orated performance replace the damaged parts GENERAL INFORMATION 1 5 Model Identification ZX600 J1 Left Side View ZX600 J1 Right Side View 1 6 GENERAL INFORMATION General Specifications Items ZX600 J1 J2 ZX600 J3 Dimensions Overall Length 2 030 mm 79 9 in PN 2 060 mm 81 1 in Overall Width 730 mm 28 7 in lt Overall Height 1 175 mm 46 3 in Wheelbase 1 400 mm 55 1 in Road Clearance 145 mm 5 70 in Seat Height 820 mm 32 3 in Dry Ma
36. 4 23 4 24 4 24 4 25 4 25 4 30 4 30 4 30 4 30 4 31 4 32 4 32 4 32 4 33 4 33 4 33 4 34 4 34 4 35 4 35 4 35 4 36 4 36 4 2 ENGINE TOP END Exploded View 1 Closed coil end faces downward T1 9 8 1 0 kgf m 87 in Ib T2 12 Nem T3 13 T4 15 Nem 5 25 Nem 6 20 T7 49 OQ 1 2 kgf m 104 in Ib 1 3 113 in lb 1 5 kgf m 11 ftIb 2 5 kgf m 18 ft lb 2 0 kgf m 14 5 ft lb 5 0 kgf m 36 ft lb T8 7 8 N m 0 80 69 in Ib EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant ENGINE TOP END 4 3 Exploded View GE02204884 C 1 R marked side face up T2 12 1 2 kgf m 104 in Ib 2 RN marked side face up 34 N m 3 5 kgf m 25 ft lb 3 A marking hollow facing forward T4 45 N m 4 5 33 ft lb 4 Exhaust Pipe Mounting Bolt EO Apply engine oil 5 Exhaust Pipe Holder Nuts L Apply a non permanent locking agent 6 Muffler Mounting Nut R Replacement Parts T1 9 8 N m 1 0 kgf m 87 in Ib 4 4 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Closing Pressure Open Close 57 65 kPa 430 490 mmHg Camshafts Cam Height Exhaust Inlet Camshaft Journal Camshaft Cap Clearance
37. 7571017ST C Oil Seal amp Bearing Remover 57001 1058 7571058ST C 1 32 GENERAL INFORMATION Special Tools and Sealant Head Pipe Outer Race Press Shaft 57001 1075 ST571075ST C Steering Stem Nut Wrench 57001 1100 5157110051 C Hook Wrench R37 5 R42 57001 1101 ST571101ST C Valve Seat Cutter 32 528 57001 1119 ST571119ST C Valve Seat Cutter 32 30 57001 1120 5157112051 C Valve Seat Cutter 60 030 57001 1123 7571123ST C Valve Seat Cutter 45 627 5 57001 1114 875711145 C Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 45 532 57001 1115 ST571115ST C 7571128ST C Bearing Driver Set 57001 1129 7571129ST C Special Tools and Sealant Valve Spring Compressor Adapter 20 57001 1154 J 7571154ST C Valve Spring Compressor Adapter 22 57001 1202 5157120251 C Fork Outer Tube Weight 57001 1218 7571218ST C Front Fork Oil Seal Driver 57001 1219 5157121951 6 57001 1238 7571238ST C GENERAL INFORMATION 1 33 Pilot Screw Adjuster A 57001 1239 7571239ST C Clutch Holder 57001 1243 gt 875712435 C Oil Filter Wrench 57001 1249 7571249ST C Spark Plug Wrench Hex 16 57001 1262 5157126251 C Carburetor Dra
38. Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout 34 345 34 453 mm 1 352 1 356 in 35 146 35 254 mm 1 384 1 388 in 0 038 0 081 mm 0 0015 0 0032 in 23 940 23 962 mm 0 9425 0 9434 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less 34 24 mm 1 348 in 35 04 mm 1 380 in 0 17 mm 0 0067 in 23 91 mm 0 941 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Cylinder Head Warp usable range 950 1 450 kPa 9 7 14 8 kgf cm 138 210 psi 350 r min rpm Valves Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve Valve Guide Clearance Wobble Method Exhaust 0 22 0 31 mm 0 0087 0 0122 in 0 11 0 19 mm 0 0043 0 0075 in 1 0 mm 0 04 in 0 5 mm 0 02 in TIR 0 01mm 0 0004 in or less 3 955 3 970 mm 0 1557 0 1563 in 3 975 3 990 mm 0 1565 0 1571 in 4 000 4 012 mm 0 1575 0 1580 in 4 000 4 012 mm 0 1575 0 1580 in 0 10 0 18 mm 0 004 0 007 in 0 6 mm 0 024 in 0 25 mm 0 010 in TIR 0 05 mm 0 002 in 3 94 mm 0 155 in 3 96 mm 0 156 in 4 08 mm 0 161 in 4 08 mm 0 161 in 0 35 mm 0 014 in Specifications ENGINE TOP END 4 5 Stand
39. Grease Seals C Sleeve D Circlip right side E Special Tool Inside Circlip Pliers 57001 143 Remove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover 57001 1058 A Swingarm Bearing Installation Apply plenty of grease to the ball bearing and needle bearings Install the needle bearings so that the manufacturer s marks faces in Install the ball bearing so that the manufacturer s marks faces out Special Tool Bearing Driver Set 57001 1129 A 6 06060551 6 06060351 6 06060451 C SUSPENSION 12 19 Swingarm Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Remove may damage them Check the ball bearing OSince the ball bearing is made to extremely close toler ances the wear must be judged by feel rather than mea surement e Turn A the bearing in the swingarm back and forth while checking for plays roughness or binding xIf bearing play roughness or binding is found replace the bearing 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 x If there is any doubt as to the condition of any of the nee bearings or sleeve replace the sleeve and needle bearings as a set Swingarm Lubrication e Apply gre
40. Pull the tension side exhaust side A of the chain taut to install the chain e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown OThe timing marks of 1 4 must be aligned with the lower surface of crankcase of rear side E OThe timing marks must be aligned with the cylinder head upper surface B C EX mark D IN mark Install the camshaft cap and chain guide OFirst tighten the camshaft cap and all chain guide bolts evenly to seat the camshaft in place then tighten all bolts following the specified tightening sequence Torque Camshaft Cap Bolts 12 N m 1 2 104 in Ib Camshaft Chain Guide Bolts 12 N m 1 2 kgf m 104 in Ib Tighten the camshaft chain tensioner see Camshaft Chain Tensioner Installation Install the cylinder head cover see Cylinder Head Cover Installation 8 11060852 C BOG Oe Koo SUAS gar H wn 598 ale lim Q 3 60 RST 03 0 Ba 5 Bes Jal as WY X9 6 1 1060951 C 4 14 ENGINE TOP END Camshaft Camshaft Chain Camshaft Camshaft Cap Wear Inspection e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft installed in the correct position Measure each clearance between the camshaft journal and the camshaft cap using plastigage press gauge A Tighten Torque Camshaft Cap Bolts 12 N m 1 2 kgf
41. Silicone Sealant 56019 120 Tighten the fan switch and water temperature sensor Torque Radiator Fan Switch 18 N m 1 8 kgf m 13 ft Ib Water Temperature Sensor 7 8 0 80 kgf m 69 in Ib e Fill the coolant and bleed the air from cooling system see Coolant Filling in the Cooling System chapter Radiator Fan Switch Water Temperature Sensor Inspection e Refer to the Electrical System chapter for these inspec tions ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded Specifications Clean Air System Air Suction Valve Remowval Air Suction Valve Installation Air Suction Valve Inspection Vacuum Switch Valve Removal Vacuum Switch Valve Installation Vacuum Switch Valve Test Clean Air System Hose Inspechon 1 2 4 Cylinder Head Cylinder Head Cover Removal Cylinder Head Cover Installation Camshaft Chain Camshaft Chain Tensioner Camshaft Chain Tensioner Installation Camshaft Camshaft Chain Camshaft Removal Camshaft Installation Camshaft Camshaft Cap Wear 2 2 1 2 Camshaft Runout Inspectio
42. Swingarm Pivot Shaft Nut 108 11 80 Uni Trak Rocker Arm Nut 34 Tie Rod Nuts 59 Steering Steering Stem Head Nut 49 36 Steering Stem Locknut 4 9 43 Steering Stem Nut 15 11 Handlebar Bolts 34 25 L Handlebar Holder Bolts 25 18 Handlebar Holder Position Bolts 9 8 87 in lb L Handlebar Weight Screws L Handlebar Switch Housing Screws 3 5 30 in Ib Frame Footpeg Mounting Bolts 34 3 5 25 L Side Stand Mounting Bolt 44 4 5 33 Grab Rail Bolts 25 2 5 18 Footpeg Bracket Mounting Bolts 25 2 5 18 Side Stand Bracket Bolts 49 5 0 36 Rear Frame Bolts and Nuts 44 4 5 33 Rear Shock Absorber Upper Bracket Nut 59 6 0 43 Electrical System Spark Plugs 13 1 3 113 in Ib Alternator Rotor Bolt 120 12 87 Stator Coil Bolts 12 1 2 104 in Ib L Alternator Lead Holding Plate Bolts 6 9 0 70 61 in Ib L Engine Ground Lead Terminal Bolt 9 8 1 0 87 in lb Alternator Cover Bolts 12 1 2 104 in Ib Crankshaft Sensor Coil Cover Bolts 12 1 2 104 in Ib L 1 Crankshaft Sensor Coil Bolts 5 9 0 60 52 Timing Rotor Bolt 44 4 5 33 Starter Motor Mounting Bolts 12 1 2 104 in Ib Handlebar Switch Housing Screws 3 4 0 35 30 in Ib Radiator Fan Switch 18 1 8 13 Water Temperature Sensor 7 8 0 80 69 in Ib SS Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in Ib Neutral Switch 15 1 5 11 Starter Lockout Switch Screws 1 0 0 10 9 Front Brake Light Switch Screws 1 0 0 10 9 GENERAL INFORMATION 1 29 Torque
43. Valves ENGINE TOP END 4 27 Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x If the outside diameter of the seating surface is too large make the 32 grind described below x If the outside diameter A of the seating surface is within the specified range measure the seat width as described below e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above To measure the seat width use a vernier caliper to mea sure the width of the
44. and then check the pilot screw settings Special Tool Pilot Screw Adjuster A 57001 1239 e Check the carburetor synchronization again NOTE not turn the pilot screws carelessly during carburetor synchronization You may cause poor running at low engine speed e For the other than the California model remove the car buretor vacuum hose plugs and carburetor vacuum hose fitting e Check the idle speed Service Fuel Level Inspection Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 e Situate the motorcycle so that it is perpendicular to the ground e Remove the fuel tank see Fuel Tank Removal e Prepare an auxiliary fuel tank and connect the fuel hose to the carburetors e Prepare a fuel hose e Connect the fuel level gauge A to the carburetor float bowl with the fuel hose Special Tool Fuel Level Gauge 57001 1017 e Hold the gauge vertically against the side of the carburetor body so that the middle line B is several millimeters higher than the mark C on the carburetor body e Feed fuel to the carburetor then turn the carburetor drain plug D out a few turns 6006060652 C 2 10 FUEL SYSTEM Carburetors e Wait until the fuel level in the gauge settles Keeping
45. e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 Replace the filter with a new one e Apply engine oil to the gasket A before installation Tighten the filter with the oil filter wrench Torque Oil Filter 31 3 2 kgf m 23 ft lb NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque Pour in the specified type and amount of oil see Engine Oil Change SAE 20W 50 SAE 20W 40 SAE 10W 50 20 10 0 10 20 40 0 L 1 1 1 1 4 14 32 50 68 86 104 F 0509010851 6005040251 ENGINE LUBRICATION SYSTEM 6 7 Oil Pan Oil Pan Removal e Remove Engine Oil drain see Engine Oil Change Muffler see Engine Top End chapter Oil Pan Bolts A Oil Pan B 6606000851 C O Pan Installation Clean the oil screen A e Install the oil screen so that the crankcase rib B fits the slot C of the oil screen e Apply grease to the O rings on the oil pipes A x If the relief valve was removed install it OApply a non permanent locking agent to the threads of the relief valve B and tighten it Torque Oil Pressure Relief Valve 15 1 5 11 ft Ib CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Replace the oil pan gasket wit
46. lt Tail Brake Light 12 V 5 21 W x 2 Alternator Type Three phase AC Rated Output 22 A 14 V 5 000 r min rpm lt Specifications are subject to change without notice and may not apply to every country H WVTA Approval Model with Honeycomb Catalytic Converter PN WVTA Approval Model with Pipe Catalytic Converter Norway Model PR WVTA Approval Model with Pipe Catalytic Converter Restricted Power Model AU Australia CAL California US United States GENERAL INFORMATION 1 9 Periodic Maintenance Chart United States and Canada Models 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 FREQUENCY Whichever ODOMETER READING x 1 000 km x 1 000 mile 24 30 36 OPERATION 15 20 24 Spark plug clean and gap T e e e e e Valve clearance Inspect T Air suction valve Inspect T e e e e Air cleaner element and air vent filter clean T x x Throttle grip play Inspect T e o e o Idle speed Inspect e e e Carburetor synchronization Inspect 1 Fuel hoses Connections Inspect T e e e Engine oil change 6 months e e e e e e e Oil filter replace e e e e Evaporative emission control system CAL Inspect t lice m Drive chain wear I
47. ternator operates properly x If the output voltage shows a much higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective Check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 ONote the readings total 3 measurement Table 2 Stator Coil Resistance Reading Range Tester to Tester to One Black lead Another Black lead 0 3 0 4 Q x there is more resistance than shown in the table or no hand tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Regulator Rectifier Inspection e Remove Seat Cover see Frame chapter Fuel Tank see fuel System chapter Connectors A disconnect Clamp B Bolts A Regulator Rectifier B Charging System EL
48. 0 0051 0 0130 in Service Limit 0 5 mm 0 020 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Insert Crankpin Wear Inspection Measure the bearing insert crankpin B clearance with plastigage A Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance Standard Service Limit 0 031 0 059 mm 0 0012 0 0023 in 0 10 mm 0 004 in x If clearance is within the standard no bearing replace ment is required x lf clearance is between 0 060 mm 0 0024 in and the service limit 0 10 mm 0 004 in replace the bear ing inserts A with inserts painted black B Check insert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x If the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 29 984 30 000 mm 1 1805 1 1811 in Service Limit 29 97 mm 1 180 in 6105040781 6105041881 C 6105041781 8 14 CRANKSHAFT TRANSMISS
49. 0012 0 0023 in 0 004 in Crankpin Diameter 29 984 30 000 mm 29 97 mm 1 1805 1 1811 in 1 180 in Marking None 29 984 29 994 mm 1 1805 1 1809 29 995 30 000 1 1809 1 1811 in Connecting Rod Big End Bore Diameter 33 000 33 016 mm 1 2992 1 2998 Marking None 33 000 33 008 mm 1 2992 1 2995 in 33 009 33 016 mm 1 2996 1 2998 Connecting Rod Big End Bearing Insert Thickness Pink 1 475 1 480 mm 0 0581 0 0583 in Brown 1 480 1 485 mm 0 0583 0 0585 Black 1 485 1 490 mm 0 0585 0 0587 Connecting rod big end bearing insert selection Con rod Big End Crankpin Diameter Bearing Insert Bore Diameter Markin Marking g Size Color Part Number None Pink 92028 1880 None None Brown 92028 1879 Black 92028 1878 Crankshaft Side Clearance 0 05 0 20 mm 0 002 0 008 in 0 40 mm 0 016 in Crankshaft Runout TIR 0 02 0 0008 in mm or less TIR 0 05 mm 0 002 in Crankshaft Main Bearing Insert journal 0 014 0 038 mm 0 07 mm Clearance 0 0006 0 0015 in 0 0028 in Crankshaft Main Journal Diameter 29 984 30 000 mm 29 96 mm 1 1805 1 1811 in 1 1795 in CRANKSHAFT TRANSMISSION 8 5 Specifications Standard Service Limit Marking None 29 984 29 994 mm 1 1805 1 1809 in 29 995 30 000 mm 1 1809 1 1811 in Crankcase Main Bearing Bore Diameter 33 000 3
50. 1 25 57001 1289 A 6 04021251 C 12 10 SUSPENSION Front Fork Hold the fork tube upright press the inner tube and the piston rod all the way down e Pour in the type and amount of fork oil specified Fork Oil Viscosity KHL34 KAYABA G10 or equivalent Amount per side When changing oil approx 455 mL 15 4 US oz ZX600 J1 J3 approx 459 mL 15 5 US oz ZX600 J4 US ZX600J6F CA After disassembly and 537 4 mL 18 2 0 1 US oz completely dry ZX600 J1 J3 541 4 mL 18 3 0 1 US ZX600 J4 US ZX600J6F CA If necessary measure the oil level as follows OHold the outer tube vertically in a vise the inner tube several times to expel air bubbles OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the inner tube to the oil Oil Level fully compressed without spring Standard 116 2 mm 4 57 0 08 in from the top of the inner tube ZX600 J1 J3 113 2 mm 4 45 0 08 in from the top of the inner tube ZX600 J4 US ZX600J6F CA NOTE OFork oil level may also be measured using
51. 13 in Ib e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 0 80 kgf m 69 in Ib e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage 6109060252 C Brake Fluid BRAKES 11 21 3 A WARNING When working with the disc brake observe the pre cautions listed below 1 2 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 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 handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid
52. 3 35 3 5 3 3 30 3 15 3 20 3 26 3 30 3 35 3 40 3 45 0 77 0 81 0 82 0 86 0 92 0 96 0 97 1 01 1 02 1 06 1 27 1 31 INSTALL THE SHIM OF THIS THICKNESS mm Measure the clearance when engine is cold Check present shim size Match clearance in vertical column with present shim size in horizontal column Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 3 10 mm 0 122 in Measured clearance is 0 40 mm 0 016 in Replace 3 10 mm 0 122 in shim with 3 2 mm 0 126 in shim Remeasure the valve clearance and readjust if neces sary Valves ENGINE TOP END 4 23 Valve Removal Remove the cylinder head see Cylinder Head Removal Remove the valve lifter and shim OMark and record the valve lifter and shim locations so they can be installed in their original positions Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 22 57001 1202 B Valve Spring Compressor Adapter 020 57001 1154 Valve Installation e Replace the oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards B
53. 45 angle portion of the seat at sev eral places around the seat xIf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above lf the seat width is too wide make the 60 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B GE15012181 GE15012281 GE15012381 4 28 ENGINE TOP END Valves e Lap the valve to the seat once the seat width and outside diameter are within the ranges specified above 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 A Lapper B Valve Seat C Valve e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the v
54. Button 4 City Light 11 Dimmer Switch 18 Diodes 5 Headlight Relay Hi 12 Alternator 6 Headlight Relay Lo 13 Headlight Fuse 20 A Turn Signal Relay Inspection e Remove Seats see Frame chapter Turn Signal Relay A e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay 8 12040251 Load The Number of Wattage W Turn Signal Lights 21 or 23 140 250 42 or 46 Cycle s per minute Correspond to one light burned out Flashing times c m Lighting System ELECTRICAL SYSTEM 15 55 Turn Signal Light Circuit D BK Y Gy 0 BR 787 0 78 W 3 BK Y BK Y BK Y BK Y US United States model CA Canada model ML Malaysia model 6Y US 4 US CA ML BR Other than US ML GPi20806N3 1 Turn Signal Indicator Lights Right amp Left 2 Front Right Turn Signal Light 3 Front Left Turn Signal Light 4 Hazard Button 5 Turn Signal Switch 6 Turn Signal Relay 7 Junction Box 8 Turn Signal Relay Fuse 10 A 9 Ignition Switch 10 Rear Right Turn
55. C 15 50 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit BK Y 6 110802 3 C Ignition Switch Engine Stop Switch Starter Button Junction Box Starter Circuit Relay Ignition Fuse 10 A Starter Lockout Switch Neutral Switch Starter Motor Starter Relay Main Fuse 30 A Battery United States Canada Australia and Malaysia Models ELECTRICAL SYSTEM 15 51 Lighting System The US Canada Australia and Malaysia models adopt the daylight system and have a headlight relay in the junc tion box In these models the headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is re leased Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster A on the headlight in or out until the beam points straight ahead Headlight Beam Vertical Adjustment e Turn the vertical adjusters B on the headlight in or out to adjust the headlight vertically NOTE high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight s to the proper angle according to
56. Groove Width Standard 6 05 6 15 mm 0 2382 0 2421 in Service Limit 6 25 mm 0 246 in Shift Fork Guide Pin Drum Groove Wear Inspection e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove x If the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 2323 0 2362 in Service Limit 5 8 mm 0 228 in x If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 2382 0 2441 in Service Limit 6 30 mm 0 248 in Gear Dog and Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113011551 C 6113010451 6113010551 8 24 CRANKSHAFT TRANSMISSION Transmission 909090 066000 OOOWOD 47 1 ir zl Drive Shaft Wi L E Ge E WEE ry Output 2 13 re ute DISS y 6113060284 1 1st Gear 11 Toothed Washer 2 2nd Gear 12 Thrust Washer 3 3rd Gear 13 Circlip 4 4th Gear 14 Needle Bearing 5 5th Gear 15 Bearing Outer Race 6 6th Top Gear 16 Bushing 7 Toothed Washer 17 Ball Bearing 8 Thrust Washer Thin 18
57. Hall element magnet and de tector gear gt 6806016151 C Able to cancel the DC off set because of scattering of differential output Comparator amp Output Transistor Able to output the square wave in accordance with the magnetic induction alternation with the transistor turning on or off The magnetic induction passing through the Hall element 7 will be changed in accordance with the relative position EE CN of the sensor and the rotor nut A installed on the engine inns H sprocket will be rotated AN g s Nae amount of magnetic induction when large B a V LAND when small 6806016251 GENERAL INFORMATION 1 23 Technical Information Non Contact Hall IC Type Speed Sensor In the internal system of the Hall IC the switch is operated in accordance with the magnetic induction alternator This makes the square wave equal to the pulse of the rotor nut output Amount of magnetic induction when large A Amount of magnetic induction when small B Operating point C Returning point D When high voltage E When low voltage F e The vehicle speed is indicated in the speedometer alter ing the pulse of this square wave Speed Sensor Inspection e Refer to the Electrical System chapter 15 eae 6806016351 C 1 24 GENERAL INFORMATION Technical Information Alternator Made from Rare Magnet
58. High Beam Indicator Light 12V1 19 Meter Assembly Left Turn Signal Indicator Light 12 1 18 M Right Turn Signal Indicator R BK Light 12V1 1W er Neutral Indicator 6 Light 12V1 1W BI Medien Z So Light 12 1 1 R BL ee ae nee Tachometer Sall S 8L LED Light Emitting Biode Speedometer Light 12V0 7W BK Y R R Water Temperature BK Y BK Y Warning Light LED M i W R wy er Right Headlight 12V60 55W E 55 l SSeone 55 cl Left Handlebar Left Headlight 1 Horn Button 12V60 55W 2 Hazard Button PER zx 3 Turn Signal 5 rne zz 4 Dimmer Switch CE 5 Starter Locko 64 City Light er Ae Headlight Headlight teo TE Low HI Front Right Turn Signal 12 2 5 Light 12V23W Front Left Turn Signal Light 12V23W BK Y BK Y t Headlight Fuse 20 Dimmer Switch R W121968AW5 6 ELECTRICAL SYSTEM 15 7 Wiring Diagram United States and Canada ZX600 J1 J2 5 k R i Turn ch Plugs Fue Junction Box Signal ump Light Relay Switch unction Starter Gircuit Relay Horn Fuse 10 Ignition Fuse Taillight Fuse Turn Signal Relay Fuse 104A Headlight Relay Headlight Fuse Fan Fuse ACC Fuse 10 Ignition Coils TTT Fuel Pump Engine Ground Throttle
59. Hole Removal Installation 8 17 Damage Inspection 8 23 8 2 CRANKSHAFT TRANSMISSION Exploded View 68102191844 C T1 4 9 0 5 kgf m 43 in Ib T11 See the text T2 9 8 1 0 kgf m 87 in Ib D Do not apply any grease or oil 12 N m 1 2 kgf m 104 in Ib EO Apply engine oil T4 15 N m 1 5 11 ft lb G Apply grease 5 20 N m 2 0 14 5 16 L Apply a non permanent locking agent 6 44 N m 4 5 kgf m 33 ft lb LG Apply silicone sealant 92104 1063 T7 30 N m 3 0 22 ft lb M Apply molybdenum disulfide grease T8 18 N m 1 8 kgf m 13 ft Ib S Tighten the fasteners following the speci T9 6 9 0 70 61 in Ib fied sequence T10 34 3 5 25 ft lb SS Apply silicone sealant 56019 120 CRANKSHAFT TRANSMISSION 8 3 Exploded View 99 68102192844 T1 12 N m 1 2 kgfm 104 in Ib T2 15 N m 1 5 kgf m 11 ft lb 28 N m 2 9 kgf m 21 ft lb EO Apply engine oil L Apply a non permanent locking agent R Replacement Parts 8 4 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Big End Side Clearance 0 13 0 33 mm 0 0051 0 0130 in 0 5 mm 0 020 in Connecting Rod Big End Bearing 0 031 0 059 mm 0 10 mm Insert Crankpin Clearance 0
60. Oil Seal 9 Circlip 19 Steel Ball 10 Circlip WHEELS TIRES 9 1 Wheels Tires Table of Contents Exploded ts 9 2 Specifications reip E 9 3 FRIIS EE 9 4 Front Wheel 9 4 Front Wheel Installation 9 4 Rear Wheel 9 5 Rear Wheel Installation 9 6 Wheel EET 9 7 Axle 9 7 9 7 Balance Adjustment reprehe SH ERE RO 9 8 Balance Weight Removal ER LI M Dd ei 9 8 Balance Weight Installauon idi e RE dut hoped 9 8 9 11 Air Pressure 9 11 BRIDELER 9 11 ue LEE 9 12 Tire EE 9 12 TING PRepal Shen as Cer a les ah a 9 14 H b BEAMING EE 9 15 elle Bearing ne LEE EEN 9 15 Hub Bearng pede 9 15 Hub Bearing t feto utto dtt tee 9 16 Hub Bearing Lubrication tette ECKE EN 9 16 9 2 WHEELS TIRES Exploded View T1 20 N m 2 0 kgf m 14 5 16 T2 127 N m 13 kgf m 94 ft lb G Apply grease R Replacement Parts WL Apply soap and water solution or rubber lubri
61. Service Limit 4 5 mm 0 177 in Rear Disc Thickness Standard 4 8 5 2 mm 0 189 0 205 in Service Limit 4 5 mm 0 177 in Brake Disc Warp Inspection Jack up the motorcycle so that the wheel is off the ground see Wheels Tires chapter Special Tool Jack 57001 1238 OFor front disc inspection turn the handlebar fully to one side Set up a dial gauge against the disc A as shown and measure disc runout while turning B the wheel by hand x If runout exceeds the service limit replace the disc Disc Runout Standard 0 15 mm 0 006 in or less Service Limit 0 3 mm 0 012 in 080302 5 11 18 BRAKES Brake Fluid Level Inspection Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the 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 C Check that the brake fluid level in the rear brake reservoir A is above the lower level B x If the fluid level is lower than the lower level line remove the fuel tank and fill the reservoir to the upper level line A WARNING 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 reser voir are unidentified After changing the fluid use
62. Torque Rear Sprocket Nut 59 N m 6 0 kgf m 43 ft Ib Install the rear wheel see Wheels Tires chapter Coupling Installation Grease the following and install the coupling Coupling Grease Seal A Coupling Internal Surface B Coupling Bearing Removal Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers 57001 143 B Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set 57001 1129 B 8 05010951 C 6 05011051 C GK05010781 C 10 12 FINAL DRIVE Sprocket Coupling Coupling Bearing Installation Replace the bearing with a new e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 B Pack the bearing with high temperature grease Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 Replace the grease seal with a new e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in t
63. View 80021565844 C 1 California Model 2 Front Fender Mounting Bolts 3 Footpeg Mounting Bolts 4 Footpeg Bracket Mounting Bolts 5 Sidestand Mounting Bolt T1 25 N m 2 5 kgf m 18 ft lb T2 34 N m 3 5 kgf m 25 ft lb T3 49 N m 5 0 kgf m 36 ft lb T4 44 N m 4 5 kgf m 33 ft lb T5 59 N m 6 0 kgf m 43 ft lb G Apply grease L Apply a non permanent locking agent FRAME 14 3 Exploded View 6002157BW5 C 14 4 FRAME Exploded View 1 PN Model 2 Unitted States Canada Models PN WVTA Approval Model with Pipe Catalytic Converter Norway FRAME 14 5 Seats Rear Seat Removal Insert the ignition switch key into the seat lock A turning the key counterclockwise pulling up the rear of the seat B and pulling the seat backward Rear Seat Installation Slip the rear seat hooks A into the hollow cubic bracket B on the frame Insert the seat pin C into the latch hole D e Push down the rear part of the seat until the lock clicks Front Seat Removal e Remove Rear Seat see Rear Seat Removal Mounting Bolt A Set Bracket rear B e Remove the front seat C by pulling up the rear of it and to the rear Front Seat Installation Slip the front seat hook A under the brace B on the seat bracket front 14 6 FRAME Fairings Lower Fairing Removal e Remove Screws A B Allen Bolts C Pull the lower front
64. and two air suction valves Without using an air pump the air suction valve can draw fresh air into the exhaust passage near the exhaust valves by vacuum that exhaust pulses generate Air Suction Valves The air suction valves is a check valve which allows fresh air to flow only from the air cleaner via air hoses into the exhaust port and prevents return flow Remove and inspect the air suction valves periodically see Engine Top End chapter in this Service Manual Also remove and inspect the air suction valves whenever the idle speed is unstable engine power is greatly reduced or there are abnormal engine noises Vacuum Switch Valve Although the vacuum switch valve usually permits secondary air flow it closes when a high vacuum low pressure is developed at the inlet pipe during engine braking This is to shut off secondary air flow and prevent explosions in the exhaust ports which might be caused by extra unburned fuel in the exhaust during deceleration These explosions or backfiring in the exhaust system could damage the air suction valves Regular inspection of the vacuum switch valve is not needed If backfiring occurs frequently in the exhaust system during engine braking or if there are abnormal engine noises check the vacuum switch valve as described in the text see Engine Top End chapter in this Service Manual 1 20 GENERAL INFORMATION Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION Secondary Air Injection Syste
65. bore in each carburetor x If there is a difference between any two carburetors turn the balance adjusting screw B to obtain the same clear ance e Install the carburetors see Carburetor Installation Adjust the synchronization see Synchronization Adjust ment fk Sar p D lt lt o o 8 8006013981 C Carburetors FUEL SYSTEM 2 15 Carburetor Cleaning A WARNING Clean the carburetors in a well ventilated area and take care that there is no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetors CAUTION Do not use compressed air on an assembled carbu retor or the floats may be crushed by the pressure and the vacuum piston diaphragms may be dam aged Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age to or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be dama
66. click of the fully clockwise position ZX600 J4 US ZX600J6F CA To adjust the compression damping force turn the up per damping adjuster A to the desired position up to the specified turns OThe standard adjuster setting for an average build rider of 68 kg 150 Ib and with no passenger and no accessories is 2 1 2 turns out from fully clockwise position Clockwise Harder Counterclockwise Softer STD 1817161514131211109 8765432 peat 14 Seated position adjuster turned fully clockwise 6 05060451 6 05060551 Counterclockwise Clockwise Sof ter Harder STD 2019181716151413121110 9 a o a Tx N Seated position adjuster turned fully clockwise 6 05060351 12 16 SUSPENSION Rear Shock Absorber Compression Damping Force Adjustment d Setting Load Road Speed A Weak Soft Light Good 1 1 1 1 1 1 i Strong Hard Heavy Bad High A 20 clicks ZX600 J1 J3 5 turns out ZX600 J4 US ZX600J6F CA B 1 click ZX600 J1 J3 Fully clockwise position ZX600 J4 US ZX600J6F CA Spring Preload Adjustment e Remove the rear shock absorber from the frame see Rear Shock Absorber Removal Loosen the locknut and turn out the adjusting nut to free the spring Special Tool Hook Wrench 57001 1101 To adjust the spring preload
67. connected 18 6 19 1 mm 0 73 0 75 in 18 6 19 1mm GP14007B S GP14008B 5 15 60 ELECTRICAL SYSTEM Fuel Cut Valve Fuel Cut Valve Circuit California Model e fark seme 95 95 een BATTERY Q D D i LD Park remrrioN CT 3 BR eatery CEJ CESI Ex I GPi40802W3 lgnition Switch Junction Box Horn Fuse 10 A Starter Relay Main Fuse 30 A Battery Gray Connector Brown Connector Fuel Cut Valve IC Igniter ELECTRICAL SYSTEM 15 61 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 TOUGH 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 Disconnect the leads from the radiator fan switch A e Using an auxiliary wire B connect the radiator fan switch leads xIf the fan rotates inspect the fan switch If the fan does not rotate inspect the following Leads and Connectors Main Fuse and Fan Fuse Fan Motor Fan Motor Inspection e Remove the left lower fairing see Frame chapter e Disconnect the 2 pin connector A in the fan motor leads e Using two auxiliary wires
68. diame ter Crankcase Main Bearing Bore Diameter Marks O mark or no mark NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Bore Diameter Marks 33 000 33 008 1 2992 1 2995 in None 33 009 33 016 mm 1 2996 1 2998 in Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105011451 6105016851 C 6105041781 Crankcase Crankshaft Main Bearing Insert Bearing Bore Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92028 1883 3 5 1 92028 1886 1 2 4 1 92028 1882 3 5 Black O None 92028 1885 1 2 4 92028 1881 3 5 92028 1884 1 2 4 bearing inserts for Nos 1 2 and 4 journals have an oil groove respectively e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 8 17 Starter Motor Clutch Starter Motor Clutch Removal Installation Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter Starter Motor Clutch Inspection e Remove Alternator Cover see Electrical System chapter Starter Idle Gear
69. 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 Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover Modifications to the muffler s or air intake 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 mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic kno
70. filter see Fuel System chapter e Prepare a container filled with kerosene Prepare the rubber hoses and connect them to the pump fittings Connect a suitable pressure gauge to the outlet hose as shown Fuel Pump A Pressure Gauge B Outlet Hose C Inlet Hose D Fuel Filter E Kerosene F 2 Pin Connector G Battery H Auxiliary Leads I Connect the pump leads to the battery using auxiliary wires as shown x If the pump operates check the pump relay the pump does not operate the pump is defective x If the pump operates and the pump relay is normal close the outlet hose while operating the fuel pump e When the pump stops read the pressure gauge x If the pressure gauge reading is out of the specified pres sure the pump is defective Fuel Pump Pressure Standard 11 16 kPa 0 11 0 16 kgf cm 1 6 2 3 psi GP13060481 15 58 ELECTRICAL SYSTEM Fuel Pump Fuel Pump Circuit e o Y R R 5 lt Junction Box Ignition Fuse 10 A Engine Stop Switch Starter Button Fuel Pump Relay Fuel Pump Stick Coil Ignition Switch Main Fuse 30 A Battery IC Igniter OOANDARWDND gt United States Canada Australia and Malaysia Models 6 130802 3 Fuel Cut Valve ELECTRICAL SYSTEM 15 59 The fuel cut valves A are adopted for protection of the catalyt
71. hold the specified pressure or if it holds too much pressure replace it with a new one 6007010451 C 6007010751 COOLING SYSTEM 3 13 Thermostat Thermostat Removal Remove Coolant see Coolant Draining Seats see Frame chapter Fuel Tank see Fuel System chapter Thermostat Housing Cover Bolts A Thermostat Housing Cover B Thermostat Thermostat Installation Be sure to install the O ring A on the housing cover Tighten the housing cover bolts Torque Thermostat Housing Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib Fill the radiator with coolant 8009010451 C Thermostat Inspection e Remove the thermostat and inspect the thermostat valve A at room temperature x lf the valve is open replace the thermostat with a new one XY 6009000851 C To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 58 62 C 136 144 F 6009020252 C 3 14
72. in the connecting rod and check insert crankpin clearance with the plastigage 6105011351 C 6105060151 6105041751 CRANKSHAFT TRANSMISSION 8 15 Crankshaft and Connecting Rods Crankshaft Side Clearance Inspection Insert a thickness gauge A between the crankcase main bearing and the crank web at the No 2 journal B to determine clearance x If the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Crankshaft Side Clearance Standard 0 05 0 20 mm 0 002 0 008 in Service Limit 0 40 mm 0 016 in Crankshaft Runout Inspection Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008in or less Service Limit TIR 0 05 mm 0 002 in Crankshaft Main Bearing Insert Journal Wear Inspection e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 001 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearin
73. lb 34 N m 3 5 kgf m 25 16 G Apply or add grease 1 Nut ZX600 J1 Model Washer ZX600 J2 Model 2 Grease Nipple ZX600 J1 J3 Models 6102060314 C 12 4 SUSPENSION Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Compression Damper Setting Fork Spring Preload Setting Fork Oil Viscosity Fork Oil Capacity Fork Oil Level Fork Spring Free Length 46 1 81 in Atmospheric pressure Non adjustable 7th click from the first click of the fully clockwise position ZX600 J1 J3 Usable Range 1 lt 12 clicks 1 1 2 turns out from fully clockwise position ZX600 J4 US ZX600J6F CA Usable Range fully clockwise position 3 turns out 9th click from the first click of the fully clockwise position ZX600 J1 J3 Usable Range 1 lt 12 clicks 2 turns out from fully clockwise position ZX600 J4 US ZX600J6F CA Usable Range fully clockwise position 3 turns out Adjuster protrusion is 14 mm 0 55 in Usable Range 5 20 0 20 0 79 in KHL34 KAYABA G10 or equivalent 537 4 mL 18 2 0 1 US oz completely dry ZX600 J1 J3 541 4 mL 18 3 0 1 US oz completely dry ZX600 J4 US ZX600J6F CA approx 455 mL 15 4 US oz when changing oil ZX600 J1 J3 approx 459 mL 15 5 US oz when changing oil ZX600 J4 US ZX600J6F CA Fully compressed
74. leads and chassis ground x Any tester reading less than infinity indicates a short itis necessary to replace the crankshaft sensor assembly 8 10061051 C 15 38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Measurement e Remove Fuel Tank see Fuel System chapter Crankshaft Sensor Lead Connector Set the Hand Tester B to the x 25 V DC range and connect it to the peak voltage adapter E as shown in the diagram e Using two auxiliary wires connect the black lead of the adapter to black yellow lead D and red lead to black lead C in the crankshaft sensor connection A e Turn the ignition switch and engine stop switch on e Grasp the clutch lever and pushing the starter button turn the engine 4 5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 3 8 V or more Special Tool Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Stick Coil Ignition Coil together with Spark Plug Cap Removal e Remove the air cleaner housing see Fuel System chap ter e Disconnect the stick coil connectors A e Pull the stick coils B off the spark plugs CAUTION Do not pry the connector part of the coil while re moving the coil Stick Coil Ignition Coil together with Spark Plug Cap Installation e
75. line is not properly main tained Bend and twist the rubber hose while examining it Replace it if any cracks or bulges are noticed SUSPENSION 12 1 Suspension Table of Contents oM REM 12 2 eiser Me le TEE 12 4 aetna 12 6 Rebound Damping Force sse 12 6 Compression Damping Force Adjustment 12 6 Spring Preload Adjustment e coe eb d ERR RU vnda Ne exe t PARE E bep UE 12 7 Front Fork Removal each fork 12 8 Front Fork Installation p eee s 12 8 gongelEe m 12 8 Front Fork DISASSEMBLY ee EET 12 11 Front Fork A a 12 12 Inner Tube Outer Tube Inspection 44000 12 13 D st Seal Inspection r ep ete rr teta rrr 12 14 Spring Tension eet dote te emite 12 14 Rear Shock Absorber erbe rego i ia 12 15 Rebound Damping Force Adjustment usce etos og ce utat d e Pat 12 15 Compression Damping Force Adjustment eeeeeeeseeriiieretreeeeirinttrssstnirrnnsssssrrrrernnnt 12 15 Spring Preload Ad Ustrigpit sx oral gies eut E he dt aA Sour Rear Shock Absorber Removal cccccccceccsesseseceeeceeceeseeesececeeeesseeeeseecseeeeeesesaeaeaseeee
76. local regulations OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 in drop at 7 6 m 25 ft measured from the center of the headlights with the mo torcycle on its wheels and the rider seated 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Height of Headlight Center D Headlight Bulb Replacement e Remove Headlight Connector Headlight Bulb Dust Cover Hook A Headlight Bulb B CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use clean cloth Oil contamination from hands dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution EESK SS GP12060381 C 15 52 ELECTRICAL SYSTEM Lighting System e Replace the headlight bulb e Fit the dust cover A with the Top mark B upward onto the bulb C firmly as shown e After installation adjust the headlight aim see this chap ter Headlight Relay Unit Inspection Remove the windshield Take off the headlight relay units A Set the hand tester to the x 1 Q range and make the measurements shown in the figure Special Tool Hand Tester 57001 1394 B x If the tester readings not as specified replace the headlight relay unit CAUTION Use only Hand Tester 57001 1394
77. only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 NOTE OFollow the procedure shown below to install the front rear brake fluid reservoir cap correctly OFirst tighten the front rear brake fluid reservoir cap B clockwise C by hand until slight resistance is felt indi cating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 D while holding the brake fluid reservoir body A Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake Lt X9 1 y OT j pee GS13024B Brake Fluid BRAKES 11 19 Level the brake fluid reservoir Remove the reservoir cap e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 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 durin
78. pushed down oo When brake pedal is released Side Stand Switch Connections ae When side stand is up When side stand is down Neutral Switch Connections When transmission is in neutral o When transmission is not in neutral Oil Pressure Switch Connections Engine lubrication system is in good condition Switches and Sensors ELECTRICAL SYSTEM 15 69 Radiator Fan Switch Inspection Remove the fan switch see Cooling System chapter e Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged Suspend an accurate thermometer B in the coolant so that the sensitive portions C are 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 gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table Special Tool Hand Tester 57001 1394 x If the hand tester does not show the specified values re place the switch Fan Switch Resistance ORising temperature From OFF to ON at 96 100 C 205 212 F OFalling temperature From ON to OFF at 91 C 196 F or less ON Less than 0 5
79. secondary cup D cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Front Master Cylinder J 6107011151 C 11 16 BRAKES Master Cylinder Check the dust covers for damage x If they are damaged replace them Check the piston return spring for any damage x If the springs are damaged replace them e Check that relief port G and supply port are not plugged xIf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Rear Maser Cylinder K 6107011252 C Brake Disc BRAKES 11 17 Brake Disc Removal Remove the wheel see Wheels Tires chapter e Unscrew the mounting bolts and take off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side A faces out Apply a non permanent locking agent to the threads of the rear brake disc mounting bolts B Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft lb Brake Disc Wear Inspection Measure the thickness of each disc A at the point where it has worn the most x If the disc has worn past the service limit replace it B Measuring Area Front Disc Thickness Standard 4 8 5 1 mm 0 189 0 201 in
80. shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Troubleshooting Guide Abnormal Engine Noise Knocking IC igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure da
81. supply battery B power to the fan motor xIf the fan does not rotate the fan motor is defective and must be replaced 15 62 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit BK BL 1 Radiator Fan BK Y BL W 2 Radiator Fan Switch 3 Junction Box 4 Fan Fuse 10 5 Main Fuse 30 A 6 Battery GP150602W2 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 15 63 Meter Unit Removal Remove Windshield see Handlebar Removal in the Steering chapter Remove the meter unit by taking off the mounting nuts A with the washers Slide the dust cover B and remove the wiring connector CAUTION Place the meter unit so that the face is up If ameter unit is left upside down or sideways for any length of time it will malfunction Meter Gauge Disassembly e Remove Meter Unit see Meters Gauge Removal Screws A Lower Meter Cover B Separate the meter assembly A and upper meter cover Bulb Replacement e Remove Meter Unit e Turn out the socket A counterclockwise Pull the bulb out of the socket 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 15 64 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Electronic Combination Meter Unit Inspection Remove the meter unit CA
82. the engine sprocket Pull the engine sprocket the output shaft Engine Sprocket Installation Replace the sprocket washer and axle cotter pin Install the engine sprocket onto the shaft so that the mark side A faces outwards Apply oil to the threads of the output shaft and the seating surface of the engine sprocket nut e After torquing the engine sprocket nut bend the one side of the washer over the nut NOTE OTighten the nut while applying the rear brake Torque Engine Sprocket Nut 127 N m 13 kgf m 94 ft lb e Adjust the drive chain slack after installing the sprocket see Slack Adjustment Install the engine sprocket cover and tighten the bolts Torque Engine Sprocket Cover Bolts 12 N m 1 2 kgf m 104 in Ib Apply a non permanent locking agent to the threads of the speed sensor bolt and tighten it Torque Speed Sensor Bolt 6 9 N m 0 70 kgf m 61 in Ib FINAL DRIVE 10 11 Sprocket Coupling Rear Sprocket Removal Remove the rear wheel see Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Remove the rear sprocket nuts A Remove the rear sprocket B Rear Sprocket Installation Install the sprocket facing the tooth number marking A outward Tighten the rear sprocket nuts
83. the fork oil level gauge Special Tool Fork Oil Level Gauge 57001 1290 A OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end of the inner tube OSet the gauge stopper C so that its lower side shows the oil level distance specified D OPull the handle slowly to pump out the excess oil until the oil no longer comes out x If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above 6404021381 C 8 04012752 C Front Fork SUSPENSION 12 11 Pull the piston rod A up above the inner tube top Screw the rod nut B on to the piston rod with the cham fered side down OCheck that the visible thread length is at least 11 mm 0 43 in D e Insert the rebound damping adjuster rod into the piston rod e Screw the fork piston rod puller onto the end of the rod Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 Install the fork spring with the smaller end facing down ward e Install Washer Spacer Washer e Check the O ring A on the top plug and replace it with a new one if damaged e Screw in the damper adjuster B of the top plug so that the distance between the adjuster bottom and the spring adjuster C end is 25 mm 0 98 in D e Holding the top plug A with a wrench tighten the pi
84. there is any damage to the wheel replace the wheel Measure the rim runout radial B and axial A with a dial gauge with tire installed x If the rim runout exceeds the service limit check the hub bearings x lf the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 mm 0 04 in Radial TIR 1 mm 0 04 in A WARNING 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 axle for damages x If the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout x If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard 0 05 mm 0 002 in or less Service Limit 0 2 mm 0 08 in Balance Inspection e Remove the wheel 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 va
85. to remove sharp edges or raised areas which cause seal damage xIf 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 CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation e f you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fall in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it 8 04015551 C 7 EE I t 6 04062351 C 12 14 SUSPENSION Front Fork Dust Seal Inspection Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary Spring Tension e Since a spring becomes shorter as it weakens check its free length A to determine its condition x If the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stabil
86. turn in the adjusting nut A to the desired position and tighten the locknut B C Spring Length Spring Preload Setting Standard Spring length 180 mm 7 09 in Usable Range Spring length 182 mm 7 17 in to 170 mm 6 69 in OThe standard adjusting nut setting for an average build rider of 68 kg 150 Ib with no passenger and no acces sories is 180 mm 7 09 in spring length Spring Adjustment Adjuster Damping Setting m Position Force 182 mm 7 17 in Weak Light Good 170 mm 6 69 in Stong Hard Heavy Bad High Rear Shock Absorber Removal Remove the lower fairings see Frame chapter Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 Squeeze the brake lever slowly and it with a band 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 GH04011081 C SUSPENSION 12 17 Rear Shock Absorber e Remove Lower Shock Absorber Bolt A Upper Tie Rod Bolt B e Remove Upper Shock Absorber Nut A Upper Shock Absorber Bolt B Remove the shock absorber forward the ground GMO5039BS1 C Rear Shock Absorber Installation Pack the rocker arm needle bearings with grease Tighten Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nuts 59 N m 6 0 kg
87. until the clearance Y between the adjusting bolt and cylinder come to zero mm Insert the bolt into engine mounting hole and tighten the bolt and locknut K with specified torque Torque Engine Mounting Bolts 44 N m 4 5 kgf m 33 ft lb Engine Mounting Locknuts 49 N m 5 0 kgf m 36 ft lb Special Tool Engine Mount Nut Wrench 57001 1450 e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the General Information chapter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Fuel System chapter Choke Cable see Fuel System chapter Clutch Cable see Clutch chapter Drive Chain see Final drive chapter e Fill the engine with engine oil see Engine Lubrication System chapter e Fill the engine with coolant and bleed the air from the cooling system see Cooling System chapter CRANKSHAFT TRANSMISSION 8 1 Crankshaft Transmission Table of Contents Exploded 8 2 Starter Motor Clutch Inspection 8 17 Specifications ies nni etn nea 8 4 Starter Motor Clutch Disassembly 8 17 Crankcase Splitting 8 6 Starter Motor Clutch Assembly 8 17 Crankcase Splitting 8 6 Transmission 8 18 Crankcase Assembly 8 7 Shift Pedal 8 18 Crankshaft and Connecting Rods 8 9 Shift Pedal Installation
88. z Se 7 Headlight Fuse 10A Ga 8 Fan Fuse 10 9 ACG Fuse 10 gt Throttle Sensor BK BL Rear Right Turn Signal Light i2V21W Euren Tail Brake Light 12V5 21WX2 Rear Left Turn Signal Light 12V21W Water Temp Sensor Pickup Coil pet BE Oil Pressure Switch R Neutral Switch cell BK Y EI HCH 5 Ee HE BK BK Y BL R C kent tee A sie Frame Ground BK BL Pu G h Starter Relay ge 2 ge 3 238500 SS sil EH itty Side Stand Alternator s ie denies Color Code Black BL Blue Brown Chocolate DG Park Green Creen LB right Blue IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS 0 Orange Pink Purple Red White 98081 19714 WIRI971AWS C 15 16 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Capacity Voltage Sealed Battery 12 V 8 Ah 12 8 V or more Charging System Type Three phase AC Alternator Output Voltage 53 5 72 5 Stator Coil Resistance 0 3 040 Charging Voltage Regulator Rectifier 14 7 0 5 V Output Voltage Ignition System Crankshaft Sensor Resistance 452 462 O Crankshaft Sensor Peak Voltage Stick Coil Primary Winding Resistance Secondary Winding
89. 0 8 mm 0 031 in 4 6 ENGINE TOP END Specifications Special Tools Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 Piston Pin Puller Assembly 57001 910 Valve Seat Cutter 45 527 5 57001 1114 Valve Seat Cutter 45 532 57001 1115 Valve Seat Cutter 32 028 57001 1119 Valve Seat Cutter 32 630 57001 1120 Valve Seat Cutter 60 630 57001 1123 Valve Seat Cutter Holder Bar 57001 1128 Valve Spring Compressor Adapter 20 57001 1154 Valve Spring Compressor Adapter 22 57001 1202 Spark Plug Wrench Hex 16 57001 1262 Valve Guide Arbor 4 57001 1273 Valve Guide Reamer 4 57001 1274 Valve Seat Cutter Holder 54 57001 1275 Fork Oil Level Gauge 57001 1290 Compression Gauge Adapter M10 x 1 0 57001 1317 Valve Seat Cutter 60 533 57001 1334 Sealant Kawasaki Bond Silicone Sealant 56019 120 Clean Air System ENGINE TOP END 4 7 Air Suction Valve Removal e Remove Seats see Frame chapter Fuel Tank Air Cleaner Housing see Fuel System chap ter e Separate the intake silencer A from the vacuum switch valve B e Remove Vacuum Switch Valve with the Hoses Air Suction Valve Cover Bolts C Air Suction Valve Cover D Air Suction Valve Air Suction Valve Installation e Install the air suction valve so that its wider side A of the reed faces the rear e Apply a non permanent locking agent to the threads of the air suction valve cover bolts and tighten t
90. 0 94 mm 0 037 in Second 0 92 mm 0 036 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 Inspection e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top 0 77 0 79 mm 0 0303 0 0311 in Second 0 77 0 79 mm 0 0303 0 0311 in Service Limit Top 0 70 mm 0 028 in Second 0 70 mm 0 028 in xIf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Inspection 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 15 0 3 mm 0 0059 0 0118 in Second 0 30 0 45 mm 0 0118 0 0177 in Service Limit Top 0 6 mm 0 024 in Second 0 8 mm 0 031 in xIf the end gap of either ring is greater than the service limit replace all the rings NS Cn sre ASS 3 GE16060381 C 4 34 ENGINE TOP END Carburetor Holder Carburetor Holder
91. 0W 50 SAE10W 40 Capacity 3 4 L 3 6 US qt when filter is not removed 3 6 L 3 8 US qt when filter is removed 4 0 L 4 2 US qt when engine is completely dry Level Between upper and lower level lines Oil Pressure Measurement Oil pressure 4 000 r min 120 180 kPa 1 2 1 8 kgf cm 17 26 psi rpm oil temperature 90 C 194 F Special Tools Outside Circlip Pliers 57001 144 Oil Pressure Gauge 10 kgf cm 57001 164 Oil Filter Wrench 57001 1249 Oil Pressure Gauge Adapter M18 x 1 5 57001 1278 Sealant Kawasaki Bond Silicone Sealant 56019 120 ENGINE LUBRICATION SYSTEM 6 5 Engine Oil and Oil Filter 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 Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and 6005010881 run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seiz
92. 1 25 kgf m 14 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf m 14 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator COOLING SYSTEM 3 5 Coolant Flow Chart 6004060104 C 1 Radiator 5 Drain Plug 2 Radiator Cap 6 Water Pump 3 Radiator Fan 7 Water Temperature Sensor 4 Fan Switch 8 Oil Cooler 9 Thermostat When the engine is cold the thermostat is closed so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly 10 By pass Fitting The fitting is installed to bleed the air 11 Reserver Tank When the engine is very hot the pressure valve in the radiator cap allows air and vapor to escape into the reserve tank When the engine cools down the pressure drop draws the vacuum valve another small valve open admitting coolant from the reserve tank into the radiator 3 6 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Visually inspect the coolant in the reserve 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 ru
93. 10 of tread life 90 worn So it is false economy and unsafe to use the tires until they are bald e Visually inspect the tire for cracks A and cuts B re placing the tire in case of damage Swelling or high spots indicate internal damage requiring tire replacement e Remove any imbedded stones D nail C or other foreign particles from the tread Wear Indicator E e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places x If any measurement is less than the service limit replace the tire Tread Depth Standard Front 4 0 mm 0 16 in DUNLOP 3 8 mm 0 15 in MICHELIN Rear 5 4 mm 0 21 in DUNLOP 5 6 mm 0 22 in MICHELIN Service Limit Front 1 mm 0 04 in DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure 0 05072851 9 12 WHEELS TIRES Tires NOTE OMost countries have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Tire Removal e Remove Wheel see Front Rear Wheels Removal Disc s Valve Core let out the air To maintain wheel balance mark the air valve p
94. 11080851 GE11012281 ENGINE TOP END 4 15 Camshaft Camshaft Chain Camshaft Chain Removal Split the crankcase see Crankshaft Transmission chap ter Remove the camshaft chain A from the crankshaft sprocket 4 16 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Seats see Frame chapter Fuel Tank see Fuel System chapter Air Cleaner Housing see Fuel System chapter Stick Coils Spark Plugs Special Tool Spark Plug Wrench Hex 16 57001 1262 e Attach the compression gauge A and adapter B firmly into the spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tool Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 950 1450 kPa 9 7 14 8 kgf cm 138 210 psi 0350 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs and tighten them Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib GE14012081 C 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 rang
95. 2 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Connect the variable rheostat A to the terminal 7 as shown Check that the number of segments matches the resis tance value of the variable rheostat Resistance Value Temperature METER A S Light 690 HI Flash e f any display function does not work replace the meter unit GP17060881 GP17042081 C 8 17061051 C Meter Gauge Indicator Unit ELECTRICAL SYSTEM 15 67 Tachometer Check Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display Seg ments Check The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 6 Olndicates approximately 6000 rpm in case the input fre quency would be approximately 200 Hz e If the oscillator is not available the tachometer can be checked as follows OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check OUsing an auxiliary wire open and connect the terminal 1 to the terminal 6 repeatedly OThen the tachometer hand A should flick B x If the hand does not flick replace the meter unit Meter Circu
96. 2V21W Tail Brake Light 12V5 21WX2 Rear Left Turn Signal Light 12V21W Water Temp Sensor Pickup Coil Oil Pressure Switch Neutral Switch w RSD Y A Se BK 8L 6 0 Regurator Rectifier IF H GY LG BK 0 6 W BL BR W W R W G BK Y OFF ON siae stang 00107 Code ide an Switch BK Black ENS Bie BR Brown Chocolate Dark Green Alternator S BK Y h Starter Relay California Model Only a Green LB Light Blue 9 Grange CONNECTIONS roti Ta RIGHT HANDLEBAR SWITCH CONNECTIONS Color Brake Lever Pulled In 98052 1097A 1098A Yellow W2R1097AW5 C 15 10 ELECTRICAL SYSTEM Wiring Diagram Australia Right Handlebar Switches 1 Front Brake Light Switch 2 Engne Stop Switch 3 Starter Button o ERA TAIR Radiator Fan Switch BL TD K BK Y Radiator Fan DE EIS Am BATTERY H Ignition Switch ay TAIL ke R BL Saz z TAIL2 R R ena 5 High Beam Indicator Meter Assembly Light 12V1 1 Left Turn Signal Indicator Light 12V1 1W D Right Turn Signal Indicator z R BK Light 12V1 1W Neutral Indicator 6 Light 12Vi 1 BL R Oil Pressure
97. 3 57001 1269 Flywheel Holder 57001 1313 Hand Tester 57001 1394 Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 Peak Voltage Adapter 57001 1415 Lead Wire Peak Voltage Adapter 57001 1449 Needle Adapter Set 57001 1457 Throttle Sensor Setting Adapter 57001 1521 Sealant Kawasaki Bond Silicone Sealant 56019 120 15 18 ELECTRICAL SYSTEM Parts Location 1 Starter Lockout Switch Water Temperature Sen sor Stick Coils Battery Junction Box Igniter Fuel Pump Relay Radiator Fan Switch Alternator Starter Motor Side Stand Switch Speed Sensor Starter Relay and Main Fuse Turn Signal Relay Fuel Pump Front Brake Light Switch Rear Brake Light Switch Regulator Rectifier Crankshaft Sensor CAL WVTA Approval Oil Pressure Switch Throttle Sensor Fuel Cut Valves CAL H Models Headlight Relay California Model with Honeycomb Cat alytic Converter Precautions ELECTRICAL SYSTEM 15 19 There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical s
98. 3 016 1 2992 1 2998 in Marking 33 000 33 008 1 2992 1 2995 in 33 009 33 016 1 2996 1 2998 in Crankshaft Main Bearing Insert Thickness Brown 1 491 1 495 mm 0 0587 0 0589 in Black 1 495 1 499 mm 0 0589 0 0590 in Blue 1 499 1 503 mm 0 0590 0 0592 in Crankshaft main bearing insert selection Crankcase Crankshaft Main Bearing Insert Main Bearing Journal Diameter Bore Diameter Size Color Part Number Journal Nos Marking Marking 92028 1883 3 5 Brown 92028 1886 92028 1882 92028 1885 92028 1881 92028 1884 bearing inserts for Nos 1 2 and 4 journals have an oil groove respectively Item Standard Service Limit Transmission Shift Fork Ear Thickness 5 9 6 0 mm 0 2323 0 2362 in 5 8 mm 0 228 in Gear Groove Width 6 05 6 15 mm 0 2382 0 2421 in 6 25 mm 0 246 in Shift Fork Guide Pin Diameter 5 9 6 0 mm 0 2323 0 2362 in 5 8 mm 0 228 in Shift Drum Groove Width 6 05 6 20 mm 0 2382 0 2441 in 6 3 mm 0 248 in Special Tool Bearing Puller 57001 135 Outside Circlip Pliers 57001 144 Bearing Puller Adapter 57001 317 Flywheel amp Pulley Holder 57001 1605 Sealant Kawasaki Bond Silicone Sealant 56019 120 Kawasaki Bond Silicone Sealant 92104 1063 8 6 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal Installa
99. 52 1054 MARK 50 55 65 70 75 85 90 95 00 10 15 20 25 36 40 45 2 76 3 30 3 36 3 40 3 45 3 50 THICKNESS mm 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 95 2 90 2 95 3 00 3 05 3 10 3 16 3 20 3 25 0 17 0 21 0 22 0 31 0 62 0 66 0 67 0 71 0 72 0 76 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 16 3 20 3 26 2 50 2 65 2 60 2 66 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 2 70 2 76 2 80 2 86 2 90 2 95 3 001 3 05 3 10 3 15 3 20 3 25 3 30 3 36 2 70 2 75 2 80 2 86 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 26 3 30 3 35 3 40 2 85 2 90 2 95 3 00 3 05 3 10 3 15 SPECIFIED CLE 12 55 2 60 2 66 2 70 2 75 2 80 2 86 2 90 2 95 3 00 3 06 3 10 3 15 3 20 3 25 3 30 2 80 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 16 3 20 3 25 3 30 3 35 3 40 3 45 ass 27258 aso lane 290 215150 10 3 15 3 20 3 25 3 30 3 35 3 40 3 46 3 50 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 2 76 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 36 3 40 3 46 3 50 2 80 2 85 2 90 2 95 3 25 3 30 2 90 2 95 3 00 3 05 3 20 3 25
100. 8 in 6606060782 C 6606016651 C Carburetors FUEL SYSTEM 2 11 NOTE ODo not push the needle rod A in during the float height measurement e Assemble the carburetor and recheck the fuel level x lf the fuel level cannot be adjusted by this method the float or the float valve C is damaged Fuel System Cleanliness Inspection Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 Remove the fuel tank see Fuel Tank Removal Connect a suitable hose A to the fitting at the bottom of each carburetor float bowl e Run the lower ends of the hoses into a suitable container Turn out each drain plug B a few turns and drain the float bowls Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 Check to see if water or dirt comes out Tighten the drain plugs any water or dirt appears during the above inspection clean the fuel system see Carburetor Cleaning and Fuel Tank Cleaning Carburetor Removal Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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
101. AJ1LIIAO03001 or 2001 29002 JKAZX600JJA030001 2002 ZX600 J3 JKAZX4J102A048001 2005 ZX600 J4 JKAZX4J105A055001 2006 ZX600J6F JKAZX4J1006A059001 2007 ZX600J7F JKAZX4J107A065001 2008 7 600 8 JKAZX4J108A072001 O This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1254 07 Printed in Japan
102. ATION 7 3 Specifications Special Tool Jack 57001 1238 Engine Mount Nut Wrench 57001 1450 7 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal 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 GH04011081 C 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 Engine Oil see Engine Lubrication System chapter Coolant see Cooling System chapter e Remove Lower Fairings see Frame chapter Fuel Tank see Fuel System chapter Air Cleaner Housing see Fuel System chapter Carburetors see Fuel System chapter Baffle Plate on the Cylinder Head Cover Radiator A Clutch Cable Lower End B Muffler C Shift Lever A Reserve Tank B Speed Sensor C Engine Sprocket see Final Drive chapter ENGINE REMOVAL INSTALLATION 7 5 Engine Removal Installation e Pull off the connectors from the engine and free the wiring from the clamps Crankshaft Sensor Lead Connector A Battery Ground Cable B Starter Motor Cable C Alternator Lead Connector D Side Stand Switch Lead Connector E Speed Sensor Connector F Stick Coil Harness Connector A e Support the rear part of the frame on the jack Sp
103. Air cleaner O ring damaged Air cleaner clogged Fuel pump trouble Fuel pump relay trouble Fuel filter clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect Oil cooler clogged Gauge incorrect Water temperature meter broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated 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 Gauge incorrect Water temperature meter broken Water temperature sensor broken 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 Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive
104. B G Gauge H Drive Chain Specifications Type EX525UVXL2 Endless Link 108 Links e Remove Chain Cover see Drive Chain Removal Engine Sprocket Cover see Engine Sprocket Removal e Grind A the pin head to make it flat e Set the cutting and rivetting pin B as shown e Screw the pin holder until it touches the link pin e Be sure that the cutting pin hits center of the link pin GK04018BS1 C 10 8 FINAL DRIVE Drive Chain Screw the handlebar A into the body e Turn the pin holder with the wrench B clockwise to ex tract the link pin Replace the link pin link plate and grease seals e Apply grease to the link pins A and grease the seals B C Engage the drive chain on the engine and rear sprockets Insert the link pins in the drive chain ends Install the grease seals C e Install the link plate D so that the mark faces out e Push the link plate by hand or plier to fix it e Be sure to set the grease seals correctly e Set the plate holder A A and plate holder B B on the body Fit the plate holder A to the link plate Turn the pin holder by hand until the plate holder B touches the other link plate Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder A e Take off the plate holder GKO4019BS1 GK04020BS1 C GK04021BS1 C GK04023BS1 C
105. Battery Voltage No Good Fuel Cut Valve Operation Replace IC Igniter Starter Button Operation No Good No Good Inspect Side Stand Switch Operation Side Stand Switch Starter Lockout Switch No Good Gear Position Sensor Replace Faulty Parts Starter Circuit Relay No Good GPI0304B 15 36 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent IC igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and IC igniter Crankshaft Sensor Removal Remove Fuel Tank see Fuel System chapter Right Lower Fairing see Frame chapter Water Temperature Sensor Connector A Crankshaft Sensor Lead Connector B Side Stand Switch Lead Connector C Neutral Switch Lead Connector A Crankshaft Sensor Cover Oil Pressure Switch Terminal A Remove the crankshaft sensor B by taking off the crank shaft sensor bolts C Ignition System ELECTRICAL SYSTEM 15 37 Crankshaft Sensor Installation Route the crankshaft sensor lead correctly see Cable Wire
106. Bearing WHEELS TIRES 9 15 Hub Bearing Removal Remove the wheel and take out the following Collars Coupling out of rear hub Grease Seals Circlips A Special Tool Inside Circlip Pliers 57001 143 B e Use the bearing remover to remove the hub bearing A CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Shaft 613 57001 1377 B Bearing Remover Head 25 x 28 57001 1346 C Hub Bearing 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 by using the bearing driver set which does not contact the bearing inner race e Press in each right the bearing A until they are bottomed Special Tool Bearing Driver Set 57001 1129 B e Replace 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 57001 1129 C 6J06060881
107. COOLING SYSTEM Hose and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend ing direction or diameter Avoid sharp bending kinking flattening or twisting Install the clamps A as near as possible to the hose end to clear the raised rib or the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting anything Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib Hose Inspection e Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft to swollen e Replace any damaged hoses GD10010181 C COOLING SYSTEM 3 15 Radiator Fan Switch Water Temperature Sensor Radiator Fan Switch Water Temperature Sensor Removal CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface Such a shock to their parts can damage them e Drain the coolant see Coolant Draining e Remove Radiator Fan Switch Lead Connector A Radiator Fan Switch B Seats see Frame chapter Fuel Tank see Fuel System chapter Water Temperature Sensor Lead Connector A Water Temperature Sensor B Radiator Fan Switch Water Temperature Sensor Installation e Apply silicone sealant to the threads of the water temper ature sensor Sealant Kawasaki Bond
108. CTRICAL SYSTEM Electric Starter System Align the groove A in the right hand end cover and the mark B on the yoke Align the tongue A on the left hand end cover and the terminal B on the right hand end cover Brush Inspection Measure the length A of each brush xlf any is worn down to the service limit replace brushes Starter Motor Brush Length Standard 7 mm 0 28 in Service Limit 3 5 mm 0 14 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator B If the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 24 mm 0 94 in Service Limit 23 mm 0 91 in 8 11061051 C GP11060781 C Electric Starter System ELECTRICAL SYSTEM 15 49 Armature Inspection Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between 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 x If there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if th
109. ECTRICAL SYSTEM 15 31 Rectifier Circuit Check Check the rectifier resistance as follows e Disconnect the regulator rectifier connector Connect the hand tester special tool to the regulator rec tifier as shown in the table and check the resistance in both directions of each diode in the rectifier following the table The resistance should be low in one direction and more than ten times as much in the other direction If any two leads are low or high in both directions the rectifier is defective and the regulator rectifier must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half the scale Connections Tester Tester K K2 BK BL K z e Reading Tester Range A MN 4 5 6 x 100 7 1 2 scale or or 8 less x 1000 9 Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light BK R BK W BK BL BK BK 1 BK2 BK3 GP10060581 15 32 ELECTRICAL SYSTEM Charging System Do the 1st step regulator circuit test OConnect the t
110. INE LUBRICATION SYSTEM 6 11 Oil Cooler Oil Cooler Removal Remove Lower Fairing see Frame chapter Drain Engine Oil see Engine Oil Change Coolant see Cooling System chapter Remove the oil filter Remove the oil cooler hoses A from the oil cooler e Unscrew the oil cooler bolt B from the crankcase and remove the oil cooler C Oil Cooler Installation e Apply grease to the O ring A before installation Apply engine oil to the oil cooler bolt and install the oil cooler with the bolt Install the oil cooler so that the crankcase rib A fits the slot B of the oil cooler Tighten Torque Oil Cooler Mounting Bolt 78 N m 8 0 kgf m 58 ft Ib e Pour Engine Oil see Engine Oil Change Coolant see Cooling System chapter 6 12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement Remove the lower fairing see Frame chapter e Remove the oil passage plug and attach the gauge A and adapter B to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter M18 x 1 5 57001 1278 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 pump relief valve and or crankshaft bear ing insert wear immediately x If the reading is much higher than the standard che
111. ION Crankshaft and Connecting Rods If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 29 984 29 994 mm 1 1805 1 1809 in 29 995 30 000 1 1809 1 1811 in A Crankpin Diameter Marks mark mark Measure the connecting rod big end bore diameter and mark each connecting rod big end in accordance with the bore diameter Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement because of little wear Connecting Rod Big End Bore Diameter Marks None 33 000 mm 33 008 mm 1 2992 1 2995 in O 33 009 33 016 mm 1 2996 1 2998 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark e Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Con rod Big End Bore Diameter Marking Crankpin Diameter Marking Bearing Insert Size Color Part Number None Pink 92028 1880 None Brown 92028 1879 None Black 92028 1878 e Install the new inserts
112. Inspection e Whenever the cables are removed or in accordance with the Periodic Maintenance Chart lubricate the throttle ca bles see General Lubrication in the Appedix chapter OApply a thin coating of grease to the cable upper ends OUse a commercially available pressure cable lubricator to lubricate the cables OWith the cable disconnected at both ends the cable should move freely in the cable housing 6604011251 C 6604011451 C Choke Cable FUEL SYSTEM 2 7 Choke Cable Free Play Inspection e Push the choke lever A all the way to the front Check choke cable free play B ODetermine the amount of choke cable play at the choke lever Pull the choke lever until the starter plunger lever C at the carburetor touches the starter plunger D the amount of choke lever lower end travel is the amount of choke cable play x If the free play is incorrect adjust the choke cable Choke Cable Free Play Standard 2 3 mm 0 08 0 12 in Choke Cable Free Play Adjustment Loosen the locknut A and turn the adjuster B until the cable has the proper amount of free play e Tighten the locknut securely Choke Cable Installation e Install the choke cable in accordance with the Cable Wire and Hose Routing section in the General Informa tion chapter e After installation adjust the cable properly A WARNING Operation with an incorrectly routed or improperly adjusted cable coul
113. Inspection 15 37 Crankshaft Sensor Peak Voltage 15 38 Stick Coil Ignition Coil together with Spark Plug Cap 15 38 Stick Coil Ignition Coil together with Spark Plug Cap Installation 15 38 Stick Coil Ignition Coil together with Spark Plug Cap Inspection 15 39 Stick Coil Primary Peak Voltage 15 39 Spark Plug REMOVAL decertare eee adt ee eed P cadet oai diens apte 15 40 jecit Lm 15 40 Spark Plug Cleaning and 22 1 000 nnne 15 40 Spark Plug Gap 4 15 41 IG eine Ce WEE 15 41 Electric Starter Syste mts 15 46 Starter Motor Removal deg deett 15 46 Starter Motor 8 0 15 46 15 2 ELECTRICAL SYSTEM Starter Motor DISasserDly o hetero 15 46 Starter Motor Assembly deuten eed e 15 47 Br sh INSDECtION EE 15 48 Commutator Cleaning and 15 48 Armature InsSpectlOr 15 49 Brush Lead 15 49 Right hand End Cover Assembly Inspection 15 49 Starter Relay InspectiOr eene o
114. Install the coil using the following steps Olnsert the coil as shown being careful of the coil head A direction OConnect the connectors B OStick coil connectors angle C about 45 CAUTION Do not tap the coil head while installing the coil GP10061181 C GP10061281 C Ignition System ELECTRICAL SYSTEM 15 39 Stick Coil Ignition Coil together with Spark Plug Cap Inspection Remove the stick coils see this chapter e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 range and read the tester Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 range and read the tester Ignition Coil Winding Resistance Primary Windings 1 2 1 6 Secondary Windings 8 5 11 5 x the tester does not read as specified replace the coil Stick Coil Primary Peak Voltage Measurement NOTE OBe sure the battery is fully charged e Remove the stick coils see this chapter but do not re move the spark plugs e Measure the primary peak voltage as follows Olnstall the new spark plug E into each stick coil D and ground them onto the engine OConnect the peak voltage adapter B into the hand tester A which is set to the x 250 V DC range OConnect the adapter to the lea
115. Installation e Be sure to install the O rings A Tighten the carburetor holder bolts B Tighten the 1 3 right carburetor holder bolts with clamp C use of clamps for California Model only Torque Carburetor Holder Bolts 12 N m 1 2 kgf m 104 in Ib GE17060181 Muffler ENGINE TOP END 4 35 A WARNING To avoid a serious burn do not remove the mufflers when the engine is still hot Wait until the mufflers cool down Muffler and Exhaust Pipe Removal e Remove Lower Fairings see Frame chapter Exhaust Pipe Mounting Bolt A Remove the muffler mounting nut A Remove the radiator mount bolt A Loosen the radiator bolts B Move the bottom of the radiator toward the front and then tighten the radiator bolts B e Remove Exhaust Pipe Holder Nuts D Pull the muffler mounting bolt and remove the muffler as sembly OWhen removing the exhaust pipe holder don t hit the ra diator Muffler and Exhaust Pipe Installation Replace the exhaust pipe holder gaskets with new ones Thoroughly warm up the engine wait until the engine cools down and retighten all the bolts and nuts Tighten the exhaust pipe holder nuts Tighten Torque Exhaust Pipe Mounting Bolt 34 N m 3 5 kgf m 25 ft lb 4 36 ENGINE TOP END Muffler Muffler Body Removal Remove Exhaust Pipe Connecting Nuts A Muffler Mounting Bolt Nut B and Washer Pull the muff
116. Mounting Bolt 78 8 0 58 Oil Pan Bolts 9 8 1 0 87 Oil Pipe Holder Bolts 12 1 2 104 in Ib L Oil Pressure Relief Valve 15 1 5 11 L Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in Ib Impeller Bolt 9 8 1 0 87 in lb Oil Passage Plug Right 15 1 5 11 Oil Hose Banjo Bolts 25 2 5 18 Engine Removal Installation Engine Mounting Bolts and Nuts 44 Engine Mounting Locknuts 49 Engine Mounting Bracket Bolts 25 Crankshaft Transmission Breather Plate Bolts 9 8 1 0 87 in lb L Breather Tube Bracket Bolts 12 1 2 104 in Ib Crankcase Bolts 8 30 3 0 22 S 7 20 2 0 14 5 5 6 L38 Front 6 18 1 8 13 5 6 12 1 2 104 in Ib S Oil Passage Plug Left 20 2 0 14 5 L Oil Passage Plug Right 15 1 5 11 Connecting Rod Big End Nuts in the text Engine Ground Lead Terminal Bolt 9 8 1 0 87 Timing Rotor Bolt 44 4 5 33 Oil Pressure Switch 15 1 5 11 55 Gear Positioning Lever Bolt 12 1 2 104 in Ib Shift Shaft Return Spring Pin Bolt 28 2 9 21 L GENERAL INFORMATION 1 27 Torque and Locking Agent Torque Doo ee fep Neutral Switch 15 1 5 11 Shift Drum Bearing Holder Bolt 12 1 2 104 in Ib L Shift Drum Bearing Holder Screw 4 9 0 5 43 in Ib L Shift Drum Cam Bolt 12 1 2 104 in Ib L Oil Pipe Holder Bolts 12 1 2 104 in Ib L Crankshaft Sensor Cover Bolts 12 1 2 104 L 1 Oil Nozzles 6 9 0 70 61 in Ib L Starter Motor Clutch Bolt 34 3 5 25 L Wheels Tires Front A
117. OFF More than 1 MO 8 18020252 C 15 70 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection e Remove the water temperature sensor see Cooling Sys tem chapter e Suspend the sensor A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant so that the sensitive portions C are located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor across the terminal and the body at the tem peratures shown in the table Special Tool Hand Tester 57001 1394 x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance 50 C 122 F 9 18 9 94 80 C 176 F 2 50 3 06 120 C 248 F 0 65 0 73 Throttle Sensor Remova l Installation e Remove the carburetors see Fuel System chapter e Remove the throttle sensor A by unscrewing the mount ing screws e Be sure to adjust the throttle sensor when installing see Throttle Sensor Adjustment Throttle Sensor Inspection e Remove the fuel tank see Fuel System chapter e Prepare an auxiliary fuel t
118. OTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following sees Cutter angle B SDD Outer diameter of cutter Operating Procedures Clean the seat area carefully Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth 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 it will be impossible to adjust the clearance and the cylin der head must be replaced Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F 8 15011851 C 8 15011951 C
119. Remove the caliper with the hose installed Remove Clip A Pad Pin B Brake Pads C 11 12 BRAKES Brake Pads Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the anti rattle spring in place e Install the brake pads Install the pad pin and clip The clip must be outside of the pads Install the caliper see Caliper Installation A WARNING Do not attempt to drive 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 Brake Pad Wear Inspection Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard Front 4 mm 0 16 in Rear 5 mm 0 20 in Service Limit 1 mm 0 04 in 6106007 1 C BRAKES 11 13 Master Cylinder Front Master Cylinder Removal Loosen the reservoir bracket bolts A Disconnect the front brake light switch connectors Remove the banjo bolt A to disconnect the brake hose from the master cylinder see Brake Hose Removal In stallation e Unscrew the clamp bolts B and take off the master cylin der C as an assembly with the reservoir brake lever and brake switch installed
120. Resistance Primary Peak Voltage Spark Plug Spark Plug Gap IC Igniter Inspection Electric Starter System Starter Motor Brush Length Commutator Diameter Fuel Pump Fuel Pump Relay Internal Resistance Fuel Pump Pressure Fuel Cut Valve Fuel Cut Valve Protrusion 3 8 V or more 12 160 8 5 11 5 92 V or more 0 7 0 8 mm 0 028 0 031 in in the text 7 mm 0 28 in Service limit 3 5 0 14 in 24 mm 0 94 in Service limit 23 mm 0 91 in in the text 11 16 kPa 0 11 0 16 kgf cm 1 6 2 3 psi When battery is disconnected 16 6 mm 0 65 in When battery is connected 18 6 19 1 mm 0 73 0 75 in Switch And Sensor Speedometer Sensor Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Fan Switch Connections Rising Temperature Falling Temperature Water Temperature Sensor Resistance in the text ON after about 10 mm 3 94 in pedal travel When engine is stopped ON When engine is running OFF From OFF to ON 96 100 C 205 212 F From ON to OFF below 91 C 196 F or less ON Less than 0 5 O OFF More than 1 MQ 50 C 122 F 9 18 9 94 kO 80 C 176 F 2 50 3 06 120 C 248 F 0 65 0 73 ELECTRICAL SYSTEM 15 17 Specifications Item Standard Throttle Sensor Output Voltage When engine is idling 0 95 1 05 V When engine is fully opened 3 95 4 15 V Special Tools Carburetor Drain Plug Wrench Hex
121. Sensor Soothe ect te a Rear Right Turn Soe Hif nu ad m Tail Brake Light 12V5 218X2 BL EES HIE t x c2 a 88 BK BL BK R R W R BK Y BK BL R BL BL R c Rear Left Turn Signal Light 12V23W Water Temp Sensor Pickup Coil Oil Pressure Switch Neutral Switch BL R SEN H3 TERI SEI 9 e Bi ril z Frame z Switches zzzezzz Ground on Switch LC Regurator kout Switch Rectifier Ska 4 6 BK Y 4 Se Color Code Sige Stand Bk Bleck eu Blue Brom cw Chocolate ni DG Dark Green h Starter Relay California Model Only Alternator 5 IG Igniter run Blue Orange Pink s w 08 color v a amp toler Jere PU Purple RN ERR Rea RIGHT HANDLEBAR SWITCH CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button IGNITION SWITCH CONNECTIONS Starter Lockout Switch Battery lgnition Taill Tail2 Battery Tail3 Bras Lever puted tn Run Push como w white 98051 19684 19694
122. Signal Light A WN A Rear Left Turn Signal Light Main Fuse 30 A Battery 15 56 ELECTRICAL SYSTEM Fuel Pump The fuel pump A operates when the starter button is pushed on or the engine is running When the fuel level in the float chamber is low the fuel pump operates to supply the fuel into the float chamber When the fuel reaches a certain level the fuel pressure rises and the fuel pump stops Fuel Pump Removal Installation e Refer to the Fuel System chapter Fuel Pump Relay Internal Resistance Inspection e Remove the seats see Frame chapter e Take off the fuel pump relay A e Set the hand tester to the x 1 kO range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 x If the tester readings are not as specified replace the fuel pump relay the tester readings are normal check the fuel pump operation CAUTION Use only Hand Tester 57001 1394 for this test An ohmmeter other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the pump relay will be damaged Fuel Pump Relay Internal Resistance Range x Tester Lead Connection 1 1 2 2 OTS 10 100 4 20 200 1 5 GI Tester Lead Connection Fuel Pump ELECTRICAL SYSTEM 15 57 Fuel Pump Operational Inspection Remove the fuel pump with the fuel
123. System chapter Set the Hand Tester A to the x 25 V DC range and nect it to the each fuel cut valve connector B as follows Hand Tester Terminal BR BK Lead Hand Tester Terminal D or O G or or LG BK Lead Special Tool Hand Tester 57001 1394 Remove the each ignition coil at each valve test e Turn the ignition switch on and push the starter button Read the voltage at the moment x If the tester reading is approximately battery voltage it is correct If the voltage is not read replace the IC igniter Starter Button Operation Check Remove the seats see Frame chapter Set the Hand Tester A to the x 10 V DC range connect it to the junction box B lead as follows Hand Tester Terminal BK R Lead Hand Tester Terminal D Frame Ground Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn the ignition switch on and push the starter button e Read the voltage Starter Button Voltage 8 V or more x If the tester reading is not specified one replace the igniter ELECTRICAL SYSTEM 15 43 Ignition System Side Stand Switch Operation Check Remove the seats see Frame chapter Change the transmission gear to the first position and set the side stand to ON position Set the Hand Tester A to the x 25 V DC range and connect it to the junction box B lead as follows Hand Tester Te
124. TION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components GP20000181 APPENDIX 16 1 Appendix Table of Contents Troubleshooting Guide EE 16 2 General PUDCAUOM estes cece ir tse eo tle oo dirette tatc 16 7 ete eee else oeste e e oven avete 16 7 Nut Bolt and Fastener 16 8 Belge E ee BEEN 16 8 Unit CONVEFSION Table iret te dE eu 16 9 16 2 APPENDIX 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 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 Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Cams
125. Turn the starter motor clutch gear a by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C If the starter motor clutch does not operate as it should or if it makes noise go to the next step e Disassemble the starter motor clutch and visually inspect the clutch parts x If there is any worn or damaged part replace it NOTE OExamine the starter motor clutch gear as well Replace it if is worn or damage Starter Motor Clutch Disassembly e Remove Alternator Rotor see Electrical System chapter Starter Motor Clutch Bolts A and Starter Motor Clutch B Starter Motor Clutch Assembly e Apply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 34 3 5 kgf m 25 ft Ib 8 18 CRANKSHAFT TRANSMISSION Transmission Shift Pedal Removal e Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position Remove the shift lever and shift pedal Shift Pedal Installation e Install the shift pedal A so that the distance between the center of the shift pedal and the center line of the shift rod B is about 3 mm by loosening the front and rear locknuts C and turning the rod NOTE OThe locknut next to the groove D of the rod has left hand threads If necessary adjust the pedal position from the standard posit
126. UMP 3 10 Water Pump Installation e e nne nne 3 10 Water Pump Inspection 3 10 Radiator Radiator ESnm i e e e inc a a ene rere e 3 11 Radiator and Radiator Fan 3 11 Radiator Inspection icti e Ere nee tr c e 3 12 Radiator Cap Inspection a c epe n cec ete o EXER E rb re egre tus 3 12 Thermostat sc eu 3 13 Thermostat Removal tint 3 13 Thermostat 3 13 Thermostat INSpecti N c hte e ito e Do 3 13 E 3 14 Hose Installation o Rer re be ee re dede eae a EY 3 14 EE 3 14 Radiator Fan Switch Water Temperature Sensor 3 15 Radiator Fan Switch Water Temperature Sensor 3 15 Radiator Fan Switch Water Temperature Sensor Installation 3 15 Radiator Fan Switch Water Temperature Sensor Inspection 3 15 3 2 COOLING SYSTEM Exploded View 6002060214 C 1 Radiator Fan Switch 12 1 2 kgf m 104 in Ib 2 Water Temperature Sensor T4 7 8 N m 0 80 69 in Ib 3 Coolant By pass Fitting 5 9 8 1 0 kgf m 87 in Ib 4 Drain Plug 6 11 N m 1 1 kgf m 95 in Ib 5 Ther
127. UTION Do not drop the meter unit Place the meter unit so that it faces upward If the meter unit is left upside down or sideways for a long time or dropped it will malfunction e Using the auxiliary wires connect the 12 V battery A to the meter unit connector B as follows OConnect the battery positive terminal to the terminal 1 OConnect the battery negative terminal to the terminal 2 1 Battery Positive 2 Battery Negative 3 Ignition 4 Speed Sensor Electric Source 5 Speed Sensor Pulse 6 Tachometer Pulse 7 Water Temperature CAUTION Do not short the terminals 2 4 and 4 5 Liquid Crystal Display Segments Check Connect the battery positive terminal to the terminal 1 Connect the battery negative terminal to the terminal 2 Connect the terminal 1 to the terminal 3 OWhen the terminals are connected all the LCD segments A and LED warning light B appear for three seconds OWhen the terminals are disconnected within three sec onds all the LCD segments and LED warning light disap pear xIf the LCD segments LED warning light will not ap pear replace the meter unit 8 17060152 C GP17060281 C GP17060381 C Meter Gauge Indicator Unit ELECTRICAL SYSTEM 15 65 ODO TRIP or CLOCK TEMP BUTTON Operate Confir mation Connect the 12 V battery and terminals in the same m
128. Valve Stem C Oil Seal D Spring Seat E Closed Coil End F Exhaust Valve Springs G Retainer H Split Keepers ODual springs A are used for the inlet valve Valve Guide Removal Remove Valve see Valve Removal Oil Seal Spring Seat 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 CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 57001 1273 150303 5 GE15005BS1 C 1 2 EN ty GE150305 5 4 24 ENGINE TOP END Valves Valve Guide Installation Apply oil to the valve guide outer surface before installa tion e Heat the area around the valve guide hole to about 120 150 C 248 302 F Drive the valve guide in from the top of the head using the valve guide arbor The flange stops the guide from going in too far Special Tool Valve Guide Arbor 4 57001 1273 e Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer A even if the old guide is reused 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 S
129. Warning Light 12V1 1 Tachometer Light 1210 79 11 MM Tachometer o Spee et Ligh 2v Speedometer peed Sensor immi dometer amp Tachometer 12V1 1W Ran gt E LH TT BK BL Water Temperature Warning BK Y Light LED wt M GY GY 2 E 5 Frame Right Headlight Ground 12V60 55W 229958555 53 5 ao rata Sevesen ss Left Headlight 12V60 55W EWEN xxx art aot rene GE D I i BR R City Light 12V5W esp E Headlight Headlight Relay Relay Horn eft Handlebar Switches 12 2 5 Horn Button Front Right Turn Signal Light 12V21W ict LES Front Left Turn Signal Light 12V21W Bh Es L i 2 Turn Signal Switch 3 Dinner Switch 4 Starter Lockout Switch 5 Passing Button p LED Light Emitting Diode E HL LEFT HANDLEBAR SWITCH CONNECTIONS Horn Button Turn Signa auch Dimmer Switch Starter Lockout Switch Passing Button Color Color W BK pase Eos pente LL Push Released R 109 Pulled 111970 5 C ELECTRICAL SYSTEM 15 11 Wiring Diagram Australia 5 k d Turn Plugs pues Junction Box Signa Light elay 4 Relay i Junction Box penis 02000 1 Starter Circuit Relay Fuel 2 Horn Fuse 10A Wy Pump 3 Ignition Fuse 10A E 4 Taill
130. X600 J4 US ZX600J6F CA Spring Preload Adjustment e Turn the spring preload adjuster A to change spring preload setting OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 14 mm B from top as shown Adjuster Protrusion from top Standard 14 mm 0 55 in Usable Range 5 20 mm 0 20 0 79 in A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe spring preload can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Adjuster Position Damping Force Setting 5mm Strong Hard Heavy Bad High Clockwise Harder Counterclockwise Softer STD 121110 9 Seated position adjuster turned fully clockwise 6 04060451 C 8 04015251 C 12 8 SUSPENSION Front Fork Front Fork Removal each fork leg e Remove Lower and Upper Fairings see Frame chapter Front Wheel see Wheels Tires chapter Front Fender see Frame chapter Loosen the handlebar holder bolt A upper fork clamp bolt B and fork top plug C beforehand if the fork leg is to be disassembled NOTE OLoosen the top pl
131. a pilot light Connect the hoses to the separator and install the sepa rator on the motorcycle e Disconnect the breather hose from the separator and in ject about 20 mL of gasoline A into the separator B through the hose fitting e Disconnect the fuel return hose C from the fuel tank D e Place the open end of the return hose into the container and hold it with the same level of the tank top E Start the engine and let it idle 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 Canister Inspection Remove the seats and seat cover see Frame chapter Remove the canister and disconnect the hoses from the canister e Visually inspect the canister for cracks and other damage If 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 6613010152 C 2 26 FUEL SYSTEM Evaporative Emission Control System California Model Only Vacuum Valve Inspection e Remove Air Cleaner Housing see Air Cleaner Housing Removal Bracket A and Vacuum Valve B Vacuum Valve Hoses C e Remove the drain screw A from the bottom of the cham ber x If any liquid accumulates in the chamber drain it A WARNING The liquid may contain gasoline
132. able from Kawasaki dealers 10 20 and 30 gram sizes An imbalance of less than 10 grams will not usually affect running stability ODo not use four or more balance weight more than 90 gram If the wheel requires an excess balance weight disassemble the wheel to find the cause e Install the balance weight on the rim OSlip the weight on the rim flange by pushing or lightly ham mering the weight in the direction shown in the figure Push or Hammer A Rim Flange B Tire Bead C Blade D 6J04010781 9 10 WHEELS TIRES Wheels Rims OCheck 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 6J04010881 Tires WHEELS TIRES 9 11 Air Pressure Inspection Adjustment Measure the tire air pressure with an air pressure gauge A when the tires are cold that is when the motorcycle has not been ridden more than a mile during the past 3 hours x Adjust the tire air pressure according to the specifications if necessary Air Pressure when cold Front Up to 182 kg 401 Ib 250 kPa 2 5 kgf cm 36 psi 6J05007BS1 C Rear Up to 182 kg 401 Ib 290 kPa 2 9 kgf cm 41 psi Tire 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
133. alve is the correct part If itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment GE15012081 C ENGINE TOP END 4 29 Valves Valve Seat Repair START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper 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 Caliper Purpose check seat width against spec Too narrow Too wide 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase width of seat area beyond spec to increase O D 60 Grind Tool 60 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve and seat area check valve head for damage 4 30 ENGINE TOP END Cylinder Pistons Cylinder Removal e Remove Engine see Engine Removal Installation chapter Cylinder Head see Cylinder Head Removal Water Hoses A Rear Camshaft Chain Guide and Bolt Remove the cylinder Cylinder Installation NOTE Olf a new cylinder is
134. an ner as specified in the Liquid Crystal Display LCD Seg ments Check Check that when the button A or B is pushed and held continuously the display C or D turns an other mode within two seconds A ODO TRIP B CLOCK TEMP C ODO METER TRIP METER ODO METER D CLOCK TEMPERATURE CLOCK xIf the display function does not work replace the meter unit Indicate the clock mode Check that when the button in CLOCK mode is pushed for more than two seconds the meter display turns to the clock set mode e Check that it is possible to adjust hours and minutes x If the display function does not work and adjust replace the meter unit Indicate the temp mode Check that when the button in TEMP mode is pushed for more than two seconds the figure display turns to Celsius degree or Fahrenheit degree of water temperature Speedometer Check Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check The speed equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the terminal 5 Olndicates approximately 60 mph in case the input fre quency would be approximately 146 Hz Olndicates approximately 60 km h in case the input fre quency would be approximately 91 Hz e f the oscillator is not available the speedometer can be checked as follows
135. an or torque if necessary CAL California GENERAL INFORMATION 1 11 Periodic Maintenance Chart Other than United States and Canada Models 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 FREQUENCY Whichever ODOMETER READING x 1 000 km x 1 000 mile 24 30 36 OPERATION 15 20 24 Spark plug clean and gap T e e e e e Valve clearance Inspect T Air suction valve Inspect T e e e e e Air cleaner element and air vent filter clean T x Throttle grip play Inspect T e o o o Idle speed Inspect e e Carburetor synchronization Inspect T Fuel hoses Connections Inspect T e e e e e e Engine oil change 6 months e e e e Oil filter replace e Drive chain wear Inspect e Brake pad wear Inspect e e e e e e Steering Inspect T Rear shock absorber oil leak Inspect T e e Tire wear Inspect T e e e e Swingarm pivot Unit trak linkage lubricate T General lubrication perform e e e Nut bolts and fasteners tightness Inspect x x Drive chain lubricate 600 km e Drive chain slack Inspect 1000 e e e e e Brake hoses connections Inspect T
136. and Hose Routing in General Information chapter Tighten Torque Crankshaft Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib e Apply silicone sealant A to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount Sealant Kawasaki Bond Silicone Sealant 56019 120 e Apply a non permanent locking agent to the threads of the crankshaft sensor cover bolt A e Install the clamps B and tighten the crankshaft sensor cover bolts Torque Crankshaft Sensor Cover Bolts 11 N m 1 1 kgf m 95 in Ib e Install the oil pressure switch terminal and tighten the ter minal bolt Torque Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in Ib Apply grease to the terminal e Install the other remove parts Crankshaft Sensor Inspection e Remove Fuel Tank see Fuel System chapter Crankshaft Sensor Lead Connector A e Set the hand tester B to the x 100 O range and us ing auxiliary wire connect it to the black lead C and black yellow lead D in the connector A Special Tool Hand Tester 57001 1394 xIf there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance 452 462 e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor
137. and Locking Agent a eee 3 4 Throttle Sensor Mounting Screws 0 35 30 in Ib Side Stand Switch Bolt 8 8 0 90 78 1 1 1 30 GENERAL INFORMATION 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 ft Ib 5 3 4 4 9 0 35 0 50 30 43 in Ib 6 5 9 7 8 0 60 0 80 52 69 in Ib 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 38 165 240 Special Tools and Sealant Bearing Puller 57001 135 Inside Circlip Pliers 57001 143 2 875701355 C 7570143ST C Outside Circlip Pliers 57001 144 7570144ST C Oil Pressure Gauge 10 kgf cm 57001 164 Compression Gauge 20 kgf cm 57001 221 7570164ST C 5157022151 C GENERAL INFORMATION 1 31 Valve Spring Compressor Assembly 57001 241 7570241ST C Bearing Puller Adapter 57001 317 875703175 C Piston Pin Puller Assembly 57001 910 7570910ST C Fuel Level Gauge 57001 1017
138. ank and connect the fuel hose to the carburetors e Start the engine and warm it up thoroughly e Check Idle Speed see Fuel System chapter Battery Charging Condition see this chapter e Turn off the ignition switch e Remove the throttle sensor lead connector A 8 18020352 C Switches and Sensors ELECTRICAL SYSTEM 15 71 Connect the adapter B between the connectors A Special Tool Throttle Sensor Setting Adapter 57001 1521 Connect the hand tester to the adapter Hand Tester gt Y W Lead C Hand Tester BK BL Lead D Starter the engine Check the sensor output voltage with the engine idling Throttle Sensor Output Voltage Standard 0 95 1 05 V When engine is idling x lf it is not within the specified voltage adjust the throt tle sensor position see Throttle Sensor Position Adjust ment x If it is specified voltage go to next test Stop the engine Turn on the ignition switch Check the sensor output voltage with the throttle fully open Throttle Sensor Output Voltage Standard 3 95 4 15 V When throttle is fully opened x If it is not within the specified voltage replace the sensor Throttle Sensor Position Adjustment Start the engine e Check idle speed see Fuel System chapter e Stop the engine and remove the carburetor CAUTION Do not turn the idle adjusting screw when removing the carburetor e Con
139. ard Service Limit Inlet Valve Seat Cutting Angle Valve Seat Surface Width Exhaust Inlet Outside Diameter Exhaust Inlet Valve Spring Free Length Exhaust Inner Inlet Inner Inlet Outer Cylinder Piston Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second Piston Ring Groove Width Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second 0 03 0 12 mm 0 0012 0 0047 in 45 32 60 0 5 1 0 mm 0 02 0 04 in 0 5 1 0 mm 0 02 0 04 in 22 1 22 3 mm 0 870 0 878 in 26 4 26 6 mm 1 039 1 047 in 49 0 mm 1 93 in 44 1 mm 1 44 in 48 2 mm 1 90 in 65 960 65 972 mm 2 5968 2 5973 in 65 935 65 950 mm 2 5957 2 5965 in 0 010 0 037 mm 0 0004 0 0015 in 0 05 0 09 mm 0 0020 0 0035 in 0 03 0 07 mm 0 0012 0 0028 in 0 84 0 86 mm 0 0331 0 0339 in 0 82 0 84 mm 0 0323 0 0331 in 0 77 0 79 mm 0 0303 0 0311 in 0 77 0 79 mm 0 0303 0 0311 in 0 15 0 30 mm 0 0059 0 0118 in 0 30 0 45 mm 0 0118 0 0177 in 0 29 mm 0 011 in 47 6 mm 1 87 in 42 6 mm 1 68 in 46 6 mm 1 83 in 66 06 mm 2 601 in 65 78 mm 2 590 in 0 19 mm 0 0075 in 0 17 mm 0 0067 in 0 94 mm 0 037 in 0 92 mm 0 036 in 0 70 mm 0 028 in 0 70 mm 0 028 in 0 6 mm 0 024 in
140. aring Remover 57001 1058 Bearing Driver Set 57001 1129 Inside Circlip Pliers 57001 143 Jack 57001 1238 12 6 SUSPENSION Front Fork Rebound Damping Force Adjustment ZX600 J1 J3 To adjust the rebound damping force turn the rebound damping adjuster A until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 7th click from the 1st click of the fully clockwise position ZX600 J4 US ZX600J6F CA To adjust the rebound damping force turn the rebound damping adjuster A up to the specified turns OThe standard adjuster setting for the average build rider of 68 kg 150 Ib and with no passenger and accessories is 1 1 2 turns out from fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Rebound Damping Force Adjustment Adjuster Damping Position Force A Weak Ji B Strong A 12 clicks ZX600 J1 J3 3 turns out ZX600 J4 US ZX600J6F CA B 1 click ZX600 J1 J3 Fully clockwise position ZX600 J4 US ZX600J6F CA Compression Damping Force Adjustment
141. ase to the inner surfaces of the needle bearings in accordance with the Periodic Maintenance Chart e Apply a thin coat of grease to the lips of the grease seals 6114010151 12 20 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal e Remove Upper and Lower Fairings see Frame chapter Radiator see Cooling System chapter Muffler see Engine Top End chapter Squeeze the brake lever slowly and hold it with a band A GH04011081 C e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Remove Upper Tie Rod Bolt and Nut A Lower Tie Rod Bolt and Nut B Tie Rods C Tie Rod Installation e Apply grease to the inside of the needle bearings and grease seals e Install the tie rods so that the chamfered side faces the bolts and nuts e Tighten Torque Tie Rod Nuts 59 N m 6 0 kgf m 43 ft Ib Rocker Arm Removal e Remove Upper and Lower Fairings see Frame chapter Radiator see Cooling System chapter Muffler see Engine Top End chapter e Squeeze the brake lever slowly and hold it with a band e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Remove Lower Rear Shock Absorber Bolt and Nut A Lower Tie Rod Bolt and Nut B Rocker Arm Bolt and Nut C Rocker Arm D Rocker Arm Installation e Apply grease to the inside of the needle bearings grease seals e Add grease to the grease nipple ZX600 J1 J3 e Tigh
142. ashers that are on each side of hose fitting with new ones Tighten Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 416 Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line see Bleeding the Brake Line Check the brake for good braking power no brake drag and no fluid leakage Front Master Cylinder Disassembly Remove the front master cylinder see Front Master Cylin der Removal Remove the reservoir cap and diaphragm and pour the brake fluid into a container Unscrew the locknut and pivot bolt and remove the brake lever Pull the dust cover out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 Pull out the piston A secondary cup primary cup and return spring D CAUTION Do not remove the secondary cup from the piston since removal will damage it Rear Master Cylinder Disassembly NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi tion adjustment Remove the rear master cylinder see Rear Master Cylin der Removal e Slide the dust cover on the push rod out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 Pull out the push rod with the piston stop Take off the piston A secondary primary cup and return spring D CAUTION Do not remove the secondary cup from th
143. atalog e Follow the procedures in this manual care fully Don t take shortcuts Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table 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 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 co
144. atalysts and 270 280 C for used catalysts after 10 000 20 000 km ride Energy of Activation bonds Catalyst lowers the energy Calorific Value Energy of Energy of Reactant Compound Time The catalyst itself undergoes no permanent chemical change or can be recovered when the chem ical reaction is completed So the muffler with built in catalyst has the same durability as the conven tional muffler The mechanism of catalytic action is supposed to be a surface phenomenon in which reactants are absorbed onto a small portion of the surface of the catalyst The catalytic converter is made of stainless steel and the surface is applied by alumina aluminum oxide AlzO3 The alumina adheres to the stainless steel wall and the catalyst adheres to the alumina very well The alumina surface is not uniform and there are corners edges dislocations and grain boundaries Catalyst is applied on the alumina and this makes the catalyst surface rough The rougher the surface is the more actively the catalyst absorbs the reactants If various impurities like lead are absorbed they block the small portion of the catalyst surface preventing absorption of CO HC and NOx This is the reason why leaded fuel poisons the catalyst without any break on the surface or generation of heat Catalysts are generally efficient in small quantities A catalyst can catalyze the reaction of several thousand to a million times its w
145. atalytic converter raises the exhaust gas temperature by the catalyst reaction which helps the main catalytic converter operate more efficiently The precatalytic converter purifies CO HC and NOx to a certain extent Main Catalytic Converters D The converter is a three way catalytic converter upon which platinum and rhodium are applied and has a cylindrical metallic honeycomb structure E made by bending a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter The main catalytic converter is installed in the first expansion chamber of the silencer When the exhaust gas passes through the upper portion of the secondary air injection system the precatalytic converter and the inside of the honeycomb the main catalytic converter works efficiently to reduce CO HC and NOx So we can keep it within regulation The honeycomb structure is convenient for the catalytic converter because it has a large surface area but small size to react effectively and has low exhaust resistance In addition its inherent strength helps resist vibration and has simple structure welded directly on the silencer GENERAL INFORMATION 1 15 Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION Catalytic Converters OOOOOOOO Alumina support Stainless honeycomb support 6B060127W3 2 Catalyst Protection System When excessive unburned gasoline flows more than the allowable amount into t
146. aysia Models only 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 Connection Connection Reading Headlight Relay 9 13 Starter Circuit Relay 11 12 United States Canada Australia and Malaysia Mod els only The actual reading varies with the hand tester used Apply tester positive lead Apply tester negative lead Diode Circuit Inspection Remove the junction box Check conductivity of the following pairs of terminals Diode Circuit Inspection Tester Connection 13 8 13 9 12 11 12 14 15 14 16 14 United States Canada Australia and Malaysia Mod els only 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 used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale ELECTRICAL SYSTEM 15 75 Junction Box Junction Box Internal Circuit United States Canada Australia and Malaysia Junction Box Internal Circuit Other than United States Canada Australia and Malaysia
147. ble first e Measure the battery terminal voltage 608010851 Battery ELECTRICAL SYSTEM 15 25 NOTE OMeasure with a digital voltmeter A which can be read to one decimal place voltage x the reading is below the specified refreshing charge is required Battery Terminal Voltage Standard 12 8 V or more Refreshing Charge Remove the battery A Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Never remove seal caps B even at charging Never add water Charge with current and time as stated below Terminal Voltage 11 5 less than 12 8 V Standard Charge 0 9 A x 5 10 h see following chart Quick Charge 4 0 1 0 h If possible do not quick charge If the quick charge is done due to unavoidable circumstances do stan dard charge later on Terminal Voltage less than 11 5 V Charging Method 0 9 A x 20h NOTE the current does not flow when charging raise the voltage initially 25 V as maximum and let down the voltage to charge when the current starts to flow as a yardstick If ammeter shows no change in current after 5 minutes you need a new battery The current if it can flow into the battery tends to become excessive Adjust the voltage as often as possible to keep the current at standard value 0 9 A Battery A Battery Charger B Standard Value C Cur
148. bolts 1 10 Torque Crankcase 8 mm Bolts 30 N m 3 0 kgf m 22 ft Ib Olnstall the brackets A and tighten the 6 mm bolts B Torque Crankcase L38 mm 6 mm Bolts 18 N m 1 8 kgf m 13 ft Ib OTighten the 6 mm bolts C Torque Crankcase 6 mm Bolts 12 N m 1 2 kgf m 104 in Ib e Tighten the upper crankcase bolts in the order listed Torque Crankcase 7 mm Bolts A 20 N m 2 0 kgf m 14 5 ft Ib Crankcase 6 mm Bolts B 12 N m 1 2 kgf m 104 After tightening all crankcase bolts check the following items OCrankshaft and transmission shafts turn freely OWhile spinning the output shaft gears shift smoothly from the 1st to 6th gear and 6th to 1st OWhen the output shaft stays still the gear can not be shifted to 2nd gear or other higher gear positions 6104011251 6104025851 C CRANKSHAFT TRANSMISSION 8 9 Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see Crankcase Splitting e Remove the crankshaft Crankshaft Installation CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply engine oil to the crankshaft main bearing inserts Install the crankshaft with the camshaft chain A hanging on it Connecti
149. cant WHEELS TIRES 9 3 Specifications Item Standard Service Limit Wheels Rims Rim Size Front J17M C x MT3 50 Rear J17 x MT5 50 Rim runout Axial TIR 0 5 mm 0 020 in or less TIR 1 mm 0 040 in Radial TIR 0 8 mm 0 031 in or less TIR 1 mm 0 040 in Axle runout 100 mm 3 9 0 05 mm 0 002 in or less 0 2 mm 0 008 in Wheel balance 10 g 0 35 oz or less Balance weights 2 Tires Air pressure when cold Front Up to 182 kg 401 Ib load 250 kPa 2 5 kgf cm 36 psi Rear Up to 182 kg 401 Ib load 290 kPa 2 9 kgf cm 41 psi Tread depth Front DUNLOP 4 0 mm 0 16 in 1 0 04 in MICHELIN 3 8 mm 0 15 in DE 1 6 mm 0 06 in Rear DUNLOP 5 4 mm 0 21 in Up to 130 km h MICHELIN 5 6 mm 0 22 in 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard tires Make Type Front DUNLOP D207F 120 65 ZR17 56 W MICHELIN Pilot SPORT M ZX600 J1 J2 120 65 ZR17 M C 56 BRIDGESTONE BATTLAX BTO10F W ZX600 J3 RADIAL PIRELLI MTR21 Corsa METZELER MEZ3 Front Racing Rear DUNLOP D207T 180 55 ZR17 73 W MICHELIN Pilot SPORT M ZX600 J1 J2 BRIDGESTONE BATTLAx BTO10R 180 85 ZR17 73 RADIAL G W ZX600 J3 PIRELLI MTR22 Corsa METZELER MEZ3 Racing DE Germany Special Tools Jack 57001 1238 Inside Circlip Pliers 57001 143 Bearing Driver Set 57001 1129 Bearing Remover Shaft 613 57001 1377 Bear
150. case halves must be replaced as a set e With a high flash point solvent clean off the mating sur faces of the crankcases halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves Apply silicone sealant to the breather plate mating surface A 1 to 1 5 mm 0 04 0 06 in thick wait until sealant dries and then install the breather plate Sealant Kawasaki Bond Silicone Sealant 92104 1063 Apply a non permanent locking agent to the threads and tighten the bolts C Torque Breather Plate Bolts 9 8 1 0 kgf m 87 in Ib Install Crankshaft and Connecting Rods Camshaft Chain A Transmission Shaft and Gears Dowel Pins B Shift Drum Shift Forks and Shift Rods e Before fitting the lower case on the upper case check the following sure to hang the camshaft chain on the crankshaft OCheck to see that the shift drum and transmission gears are in the neutral position Apply silicon sealant A to the mating surface of the lower crankcase half Sealant Kawasaki Bond Silicone Sealant 92104 1063 CAUTION Do not apply silicone sealant around the crankshaft main bearing inserts and oil passage holes 8 8 CRANKSHAFT TRANSMISSION Crankcase Splitting Tighten the lower crankcase bolts using the following steps OFollowing the sequence numbers on the lower crankcase half tighten the 8 mm
151. ck the oil passaged for clogging Oil Pressure Standard 120 180 kPa 1 2 1 8 kgf cm 17 26 psi 24 000 r min rpm oil temp 90 C 194 F Stop the engine Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed Install the oil passage plug and tighten it Torque Oil Passage Plug Right 15 N m 1 5 kgf m 11 ft lb ENGINE LUBRICATION SYSTEM 6 13 Oil Pressure Switch Oil Pressure Switch Removal e Remove Right Lower Fairing see Frame chapter Engine Oil drain see Engine Oil Change Switch Cover A Switch Terminal B Oil Pressure Switch C Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb Tighten Torque Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in Ib Apply grease to the terminal ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents Exploded EE 7 2 eelere TEE 7 3 Engine Rernoval InstallatiOri 7 4 Gene a El E 7 4 Giel 7 5 7 2 ENGINE REMOVAL INSTALLATION Exploded View T1 44 N m 4 5 kgf m 33 16 T2 25 N m 2 5 18 16 49 N m 5 0 36 16 ENGINE REMOVAL INSTALL
152. d result in an unsafe riding con dition Choke Cable Lubrication and Inspection e Whenever the cable is removed or in accordance with the Periodic Maintenance Chart lubricate the choke cable see General Lubrication in the Appendix chapter OApply a thin coating of grease to the cable upper end OUse a commercially available pressure cable lubricator to lubricate the cable OWith the cable disconnected at both ends the cable should move freely in the cable housing 6004011481 2 8 FUEL SYSTEM Carburetors Idle Speed Inspection Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides 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 General Information chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an un safe riding condition e Check idle speed the idle speed is out of the specified range adjust it Idle Speed Standard 1 300 50 r min rpm Idle Speed Adjustment Start the engine and warm it up thoroughly e Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified ra
153. d wire peak voltage adapter C which is connected between the stick coil connector and stick coil F IC igniter G Battery Special Tools Hand Tester 57001 1394 Lead Wire Peak Voltage Adapter 57001 1449 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Primary Lead Connection Adapter R to lead wire peak voltage adapter W Adapter BK to lead wire peak voltage adapter R GP10060181 C 15 40 ELECTRICAL SYSTEM Ignition System A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections Turn the ignition switch and the engine stop switch ON Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one stick coil Stick Coil Primary Peak Voltage Standard 92 V or more e Repeat the test for the other stick coil x If the reading is less than the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection IC Igniter see IC Igniter Inspection Spark Plug Removal e Remove Air Cleaner Housing see Fuel System chapter Stick Coils e Remove the spark plugs using the 16 mm plug wrench Owner s Tool Spark Plug Wrench 16 mm 92110 1146 Spark Plug Installation e Insert the spark plug vertically into the plug hole with the plug A installed in th
154. de Stand Switch Lead Neutral Switch Lead Alternator Lead GENERAL INFORMATION 1 41 Cable Wire and Hose Routing dorch 68809869844 C 1 Radiator 11 Face the white mark outward 2 Radiator Fan Switch 12 Face the white mark forward 3 Coolant Reserve Tank 13 Align the marks 4 Reserve Tank Overflow Hose 14 Drain Hose California model only 5 Reserve Tank Cap 15 Install the clamps as shown 6 Rubber Seal 16 The oil hose shall be installed to the lower 7 Oil Cooler crankcase so that the hose fitting contact 8 Water Pump to the case 9 Coolant By pass Hose 17 View from A A 10 Reserve Tank Hose 18 View from B B 1 42 GENERAL INFORMATION Cable Wire and Hose Routing e 1 Coolant By pass Hose 2 Align the mark on the hose with the pro jection on the thermostat cover 3 Cylinder Fitting 4 Align the mark on the hose with the pro jection on the fitting 5 Align the mark on the hose with the pro jection on the water pump cover 6 Drain Plug 7 Water Pump 8 Oil Cooler Hose Face the white mark for wards oro gt om 00 WAG RING d CA CO NS Other than US CA Models To Z4 Carburetor To 1 Carburetor Coolant Valve Coolant Filter Thin Side Thick Side United States Canada Jap 6809061884 C Cable Wire and Hose Routing GENERAL INFORMATION 1 43
155. diodes can not be removed Junction Box Fuse Circuit Inspection Remove the seats see Frame chapter Remove the junction box Pull off the connectors from the junction box 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 xIf the tester does not read as specified replace the junc tion box Special Tool Hand Tester 57001 1394 Fuse Circuit Inspection Tester Connection Tester Reading Tester Connection Tester Reading 1 1A 14 8 1 2 2 8 4 8 6 5 2 63A 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 x If the tester does not read as specified replace the junc tion box Special Tool Hand Tester 57001 1394 5 17 3A 6 17 Relay Circuit Inspection with the battery disconnected Tester Tester Reading Tester Tester Reading ELEM E Q 15 74 ELECTRICAL SYSTEM Junction Box 7 13 Geer 12 13 arter Headlight Relay C Relay 13 9 13 11 eo 12 11 Not United States Canada Australia and Mal
156. e Cylinder compression is lower than usable range Diagnosis Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Gas leakage around cylinder head Bad condition of valve seating Incorrect valve clearance Incorrect piston cylinder clearance Piston seizure Bad condition of piston ring and or piston ring grooves Remedy Action Remove the carbon deposits and replace damaged parts if necessary Replace the gasket with a standard part Replace damaged gasket and check cylinder head warp Repair if necessary Adjust the valve clearance Replace the piston and or cylinder Inspect the cylinder and replace repair the cylinder and or piston as necessary Replace the piston and or the piston rings Cylinder Head ENGINE TOP END 4 17 Cylinder Head Removal Drain the coolant see Cooling System chapter e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshafts see Camshaft Removal Water Temperature Sensor Lead Connector A Oil Hose Banjo Bolt B Remove the 6 mm cylinder head bolts A and then the 10 mm cylinder head bolts B Take off the cylinder head Cylinder Head Installation NOTE OThe camshaft cap is machined with t
157. e BK BK Y Sensor Ox Radiator Fan Bess 22244 __ Tear Tani TON C3 er BR E BATTERY IOIO D lenitiom Switeh en en 921 R BL TAIL CO R High Beam In Light 12 1 1 i 1 Left Turn 51 Meter Assembly gnal Indicator Light 12Vi iW _ BR W Right Turn Signal Indicator in Di F a Neutral Indicator Light 12V1 1H EE Oil Pressure Warning Light 12V1 1W Tachometer Light 12V0 78 11 BL R E LB R BL BK Y L6 wi BL Y Speed Sensor CE EDS i CERES Tachometer Speedom Tachometer 1 eter amp Light 12V1 1 Speedometer Speedometer Y Light 12V0 7W E S D BK Y Water Temperature Warning W R Light LED wey wy er ay 4 Frame Ground Right Headlight 12V60 55W BK W BK Y 0 Di R BK BL R Y BL Y tr Y G R BK e e TH City Light 12750 er D Low HI Horn Left Handlebar Switches Front Right Turn Signal 12V2 5A 1 Horn Button 4 Starter Lockout Light 12V21W Sep uA 2 Turn Signal Switch Switch 1 3 Dimmer Switch 5 Passing Button Headlight Headlight Relay Relay Front Left Turn Signal 6 Light 12V21W Light Emitting Diode Fuse 20A LEFT HANDLEBAR SWITCH CONNECTIONS Horn Button Turn Dimm
158. e St EE Speedometer amp Tachometer Y Light 12Vi 1W 1 Speedometer KL peed Sensor Speedomter Light 12V0 7W 81 E 8K Y Pi R R 2 Water Temperature Warning any ME TAY P 9 i 7 546 G d Right Headlight roun 12V60 55W Yo m Enc Sees Se gt EW Left Headlight 12 60 554 EUN RR PER zem E City Light 12V5W Headlight Headlight 00 000 Relay Relay Low HI eft Handlebar Switches Horn Horn Button 12 2 5 L 1 2 Hazard Button 3 Turn Signal Switch 4 5 Front Right Turn Signal Light 12V21W 26 Front Left Turn Signal Light 12V21W Bh Dinner Switch Starter Lockout Switch g Button 6 Passin Headlight LED Light Emitting Diode ER LEFT HANDLEBAR SWITCH CONNECTIONS Horn Button Hazard Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button Color Clutch Lever W BK Released T Io esp I I l8 i W1L1971AWS C ELECTRICAL SYSTEM 15 15 Wiring Diagram Malaysia Spark Rear Turn Plugs iu Brake Junction Box Signal Light io 3 Relay Junction Box e S I teh 1 Starter Circuit Relay Fuel 2 Horn Fuse 10A TS Pump 3 Ignition Fuse E 4 Taillight Fuse 10A Gesund 5 Turn Signal Relay Fuse 10A roun 6 Headlight Relay N
159. e adapter or hand tester Beginning Inspect IC igniter and crankshaft sensor Do above inspections prove that IC igniter and crankshaft sensor are good Replace damaged part Does engine still operate poorly Replace IC igniter Replace part which was not replaced above Does engine still operate poorly Does engine still operate poorly Replace crankshaft sensor Does engine still operate poorly Trouble may be caused by other ignition system parts or engine itself GPI0305B Ignition System ELECTRICAL SYSTEM 15 45 Ignition System Circuit LG Y G G W G BK BR W dell BR L BR 1 2 3 4 e zn gt miu miu R W R R W B R W G R W Y BK BL Y W BL R W R W BL W G W Y BK BL BK R Y W BL BK W G BK W BL W Y BR W W R BK Y 9 GPi0061484 C A Junction Ignition Switch Engine Stop Switch Starter Button Throttle Sensor Spark Plugs lgnition Coils Stick Coils Ignition Fuse 10 A Main Fuse 30 A 10 11 12 Side Stand Switch 14 15 United States Starter Lockout Switch Battery Neutral Switch Crankshaft Sensor IC Igniter Canada Australia and Malaysia Models 15 46 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal Remove the fuel tank s
160. e foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection Using the x 1 hand tester range measure the resis tance as shown A Terminal Bolt and Positive Brush B Right hand End Cover and Negative Brush Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has an open Replace the positive brush assembly and or the negative brush subassembly Right hand End Cover Assembly Inspection e Using the highest hand tester range measure the resis tance as shown A Terminal and Right hand End Cover Special Tool Hand Tester 57001 1394 x If there is any reading the right hand end cover assembly have a short Replace the right hand end cover assembly Starter Relay Inspection e Remove the seats e Remove the starter relay e Connect the hand tester A and 12 V battery B to the starter relay C as shown Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range 1 range Criteria When battery is connected 0 When battery is disconnected e 6 11060851 C GP11010781
161. e must be checked and adjusted when the engine is cold at room temperature Remove Lower Fairings see Frame chapter Crankshaft Sensor Cover Cylinder Head Cover see Cylinder Head Cover Re moval e Position the crankshaft at 1 4 piston TDC TDC Mark A for 1 4 Pistons Timing Mark B GE11060781 e Using a thickness gauge A measure the valve clearance between the cam and the valve lifter Valve Clearance Standard IN 0 11 0 19 mm 0 0043 0 0075 in EX 0 22 0 31 mm 0 0087 0 0122 in OWhen positioning 4 piston TDC at the end of the compression stroke Inlet valve clearance of 2 and 4 cylinders Exhaust valve clearance of 3 and 4 cylinders Measuring Valve A EX 68 1 2 3 4 GE15020181 OWhen positioning 1 piston TDC at the end of the compression stroke Inlet valve clearance of 1 and 3 cylinders Exhaust valve clearance of 1 and 2 cylinders Measuring Valve A EX 69 60 1 2 3 4 GE15020281 xIf the valve clearance is not within the specified range first record the clearance and then adjust it 4 20 ENGINE TOP END Valves Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the valve lifter and shim locations so they can be reinstalled in their o
162. e piston since removal will damage it 6107061851 C 6107060852 C Master Cylinder BRAKES 11 15 Master Cylinder Assembly 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 Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Rear Dust Covers Tighten Torque Brake Lever Pivot Bolt 1 0 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders 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 x If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and
163. e plug wrench B Owner s Tool Spark Plug Wrench 16 mm 92110 1146 e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib e Fit the stick coils securely Spark Plug Cleaning and Inspection e Remove the spark plug and visually inspect e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Ignition System ELECTRICAL SYSTEM 15 41 Spark Plug Gap Inspection Measure the gap A with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in CAUTION Use only the recommended spark plugs special marks 2 These spark plugs have special marks C on the insulator as shown Other spark plugs will wear prematurely IC Igniter Inspection CAUTION When inspecting the IC igniter A observe the fol lowing to avoid damage to the IC Igniter Do not disconnect the IC igniter with the ignition switch on This may damage the IC igniter Do not disconnect the battery leads while the en gine is running This may damage the IC igniter IC Igniter Operation C
164. e use Be sure to use the dedicated electrolyte container for correct electrolyte volume Check to see that there is no peeling tears or holes in the seal sheet on the top of the battery e Place the battery on a level surface Remove the seal sheet NOTE OA battery whose seal sheet has any peeling tears or holes requires a refreshing charge initial charge Take the electrolyte container out of the vinyl bag e Detach the seal caps A from the container NOTE ODo not discard the seal caps because it is used as the battery plugs later ODo not peel back or pierce the seals B on the container Place the electrolyte container upside down aligning six seals with the six battery filler ports Push the container down strongly enough to break the seals Now the electrolyte should start to flow into the battery NOTE ODo not tilt the container as the electrolyte flow may be interrupted 24 51 C 8 08010451 C SITS 8 08010551 C ELECTRICAL SYSTEM 15 23 Battery Make sure air bubbles A are coming up from all six filler ports OLeave the container this way for 5 minutes or longer NOTE Olf no air bubbles are coming up from a filler port tap B the bottom of the container two or three times Never remove the container from the battery CAUTION 8 08010851 C Fill the electrolyte into battery unti
165. e with compressed air CAUTION Do not apply compressed air to the air vent holes A in the tank cap This could cause damage and clogging of the labyrinth in the cap Fuel Tank Cleaning A 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 solvents to clean the tank Remove the fuel tank and drain it e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits Pour high flash point solvent through the tap in all lever positions e Pour the solvent out of the tank e Remove the fuel tap from the tank see Fuel Tap Re moval Clean the fuel tap filter screens in a high flash point sol vent e Dry the tank and screens with compressed air Install the tank filters in the tank Install the fuel tank see Fuel Tank Installation Fuel Tap Removal e Remove the Fuel Tap Position Lever see Fuel Tank Re moval e Remove the fuel tank and drain it e Remove Bolts A Flat Washers B Fuel Tap C 6609060151 C 2 22 FUEL SYSTEM Fuel Tank Fuel Tap Installation e Be sure the O rings A is in good condition to prevent leaks Be sure the flat washers B are in good condition to vent leaks ODo not use steel washers in place of the flat washers beca
166. eaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Battery discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte insufficient 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 Regulator rectifier trouble Battery faulty General Lubrication APPENDIX 16 7 Lubrication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Motor Oil Rear Brake Rod Joint Points Lubricate with Grease Clutch Cable Upper and Lower Ends Throttle Cable Upper Ends Choke Cable Upper End Cables Lubricate with Rust Inhibiter Choke Cable Throttle Cables Clutch Cable 6604011451 C
167. ecial Tool Jack 57001 1238 e Support the engine with a suitable stand A e Remove the engine mounting bolts and nuts B Loosen the locknuts and adjusting bolts C Special Tool Engine Mount Nut Wrench 57001 1450 e Remove the drive chain from the output shaft e Using the stand take out the engine Engine Installation e Before engine installation loosen the engine bracket bolts A e Support the engine with a suitable stand e Hang the drive chain over the output shaft just before moving the engine into its final position in the frame e Screw the adjusting bolts H J into the frame e Insert the lower mounting bolt B e Insert the upper mounting bolts C G e Set the collar D and insert the middle mounting bolts E 8 04060352 C 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation Left Right 6H04060482 e Turn the adjusting bolt H until the clearance X between the crankcase and frame come to zero mm e Tighten the bracket bolts A Torque Engine Bracket Bolts 25 2 5 kgf m 18 ft Ib e Tighten the engine mounting bolts C B E and locknut L with specified torque Torque Engine Mounting Bolts 44 N m 4 5 kgf m 33 ft Ib Engine Mounting Locknuts 49 N m 5 0 kgf m 36 ft Ib Special Tool Engine Mount Nut Wrench 57001 1450 Pull out the engine mounting bolt G temporarily and turn the adjusting bolt J
168. ed or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Fuel cut valve won t fully open check fuel cut valve Bleed holes of needle jet holder or needle jet clogged Brake dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Drive train trouble 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 trouble 16 4 APPENDIX Troubleshooting Guide Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric starter For KLEEN do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine IC igniter or fuel cut valve trouble IC igniter trouble Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner duct loose Air cleaner poorly sealed or missing
169. ee Fuel System chapter Slide back the rubber cap Remove the starter motor terminal nut A and the mount ing bolts B Pull out the starter motor Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded Replace the O ring A with a new one Apply grease to the O ring Tighten Torque Starter Motor Mounting Bolts 12 N m 1 2 kgf m 104 in Ib Starter Motor Disassembly e Take off the starter motor through bolts A and remove both end covers B and pull the armature out of the yoke C e Remove Brush Springs Brush Holder Plate Screw A Negative Brushes B Brush Holder Plate C Electric Starter System ELECTRICAL SYSTEM 15 47 Unsolder the terminal A on the positive brush plate and remove it Starter Motor Assembly e Apply a thin coat of grease to the oil seal A e Fit the toothed washer B into the left hand end cover e Install the positive brush plate A in the right hand end cover B and solder the terminals C e Press the springs and holding the brush leads with suit able clips A as shown e Put the armature B among the brushes Install the O rings A as shown 8 11041151 C 15 48 ELE
170. ees Rear Shock Absorber Installation Rear Shock Absorber Inspection Rear Shock Absorber Scrapping Ma c a Ius SWingarm REMOVAL m Swingarm Lu nte ead dea tibus Swingarm Bearing Removal eu cates on e See dee EXER EARN E ERR ER Ra ER TERRE Swingarm Bearing Installation x tb onte ceres pd b Swingarm Bearing Sleeve 12 19 Swingarm Bolo ue iojo Pet dS 12 19 BI ee Wee EE 12 20 TlesRod Rerioval e tete om PRI on p te i 12 20 Tie Rod Installation nennen nenne nnn 12 20 Rocker Arm Removal bie 12 20 Rocker eerta ice vate uh aden 12 20 Rocker Arm Tie Rod Bearing Sleeve Inspection 12 21 Rocker Arm Tie Rod Lubriceaton m meer 12 21 12 2 SUSPENSION Exploded View 0 c li __ WO lt lt 0000 Ap 4 Gm Qu Tal 6GM020601N4 T1 20 N m 2 0 kgf m 14 5 ft lb T2 23 N m 2 3 kgf m 16 5 ft lb 28 N m 2 9 kgf m 21 ft lb T4 39 N m 4 0 kgf m 29 ft lb L Apply a non permanent locking agent R Replacement Parts SUSPENSION 12 3 Exploded View T1 59 N m 6 0 43 10 T2 108 N m 11 kgf m 80 ft
171. efore tightening use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch Connecting Rod A Dent here with a punch B Nuts C Fit micrometer pins into dents D Tighten the big end nuts until the bolt elongation reaches the length specified in the table Check the length of the connecting rod bolts x If the stretch is more than the usable range the bolt has stretched too much An overlongated bolt may break in use Bolt Length after Bolt Length tightening before tightening SES Usable Range of Connecting Rod Bolt Stretch Usable Range of Connecting Rod Bolt Stretch 0 30 0 40 mm 0 012 0 016 in ZX600 J1 J3 0 18 0 28 mm 0 007 0 011 in ZX600 J4 2 Tightening Torque Method f you don t have a point micrometer you may tighten the nuts using the Tightening Torque Method e Be sure to clean the bolts nuts and connecting rods thoroughly with high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry
172. eight in reactants The three way catalyst is a blend of platinum Pt and rhodium Rh which are expensive But a converter uses only about 0 05 gram of Pt and 0 01 gram of Rh and a main catalytic converter uses only about 0 4 gram of Pt and 0 1 gram of Rh Catalyst Pt Rh N Alumina support Stainless Steel support 1 22 GENERAL INFORMATION Technical Information Non Contact Hall IC Type Speed Sensor Details The electronic combination meter unit superior to the conventional type in weight and durability is installed on the ZX600 J The hall IC type speed sensor is installed on the ZX600 J together with it which needs no cable and speedometer gears Its construction and operation are de scribed as follows Construction and Operation e The speed sensor A consists of a magnet B and the Hall IC C 6806016051 C e The Hall IC consists of Hall element A the differential amplifier B the high pass filter C the comparator D and the output transistor E ATA Hall Element The semi conductors e g CaAs InAs InSb are called a as mentioned above The magnetic induction applied on A the two 2 Hall elements will be converted into the voltage and outputted Differential Amplifier This can output the difference between output powers of the two 2 Hall elements High Pass Filter Sensitivity of the two 2 Hall elements Surface magnetic induction of a magnet Relative positions of the
173. el Hose Regulator Rectifier Lead 11 Carburetor Vent Hose Yellow Purge Hose green 12 Breather Hose Blue To Fuel Tank Vacuum Hose To 1 Carburetor Holder 13 Return Hose Red To Fuel Tank To Drain Plug 14 Run the red return hose under the regu Run all the evaporative hoses over the lator lead and other hoses over the reg main harness ulator lead To Carburetor 15 Run the red return hose under the fuel To Vacuum Switch Valve hose and other hoses over the fuel 1 Carburetor Holder hoses FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded View 2 2 Coolant Valve Inspection Other Specifications 2 5 than United States and Canada Throttle Grip and Cables 2 6 Models eene ntc 2 17 Throttle Grip Play Inspection 2 6 Air Cleaner 2 18 Throttle Cable Installation 2 6 Element 2 18 Throttle Cable Lubrication and Element Installation 2 18 Inspechon snssenoseeeeeeeeeeeeeeeeeeeeeen 2 6 Element Cleaning and Inspection 2 18 Choke 2 7 Air Cleaner Housing Remowval 2 19 Choke Cable Free Play Air Cleaner Housing Installation 2 19 eost 2 7 Air Vent Filter Cleaning 2 19 Choke Cable Free Play Fuel Tank 2 20 Adjustment ues 2 7 Fuel Tank Removal
174. ement of a muffler assy is necessary to secure the purification efficiency of exhaust gas e case catalytic converters melt down by overheating Especially in the case that a lot of unburned gasoline flows into the catalytic converters under the extreme running condition far beyond common sense there is a possibility that the catalysts overreact and that catalytic converters overheat severely If they melt down it causes poor engine performance deterioration of emission noise level and purification efficiency So the muffler assy must be replaced 2 Durability It has the same durability as a conventional muffler 3 Disposal to Waste As any harmful toxic substance is not used especially it can be disposed as usual industrial wastes The body of the muffler is made of aluminum steel The catalytic converter is also made of stain less steel which has alumina on its surface and the main ingredients of catalysts are platinum and rhodium 4 Handling Precautions Catalyst protection system against mishandling is applied to a vehicle with catalysts But we prohibit depending on the system too much when running 1 Use only unleaded gasoline Usage of leaded gasoline is prohibited completely Only fuel and additives which are specified in the Owner s Manual can be used 2 Use specified engine oil which is described in the Owner s Manual In case of some ingredients which give bad effects to the catalysts such as phosphorus P lead Pb
175. en Bolt Gasket Install the following parts onto the inner tube Dust Seal Retaining Ring Oil Seal Washer Outer Tube Guide Bushing Inner Tube Guide Bushing 6 04062251 C Front Fork SUSPENSION 12 13 Insert the cylinder unit A into the inner tube B Install the cylinder base C on the cylinder unit Insert the inner tube cylinder unit cylinder base as set into the outer tube D Replace the bottom Allen bolt gasket with a new one Stop the cylinder from turning by using the fork cylinder holder Special Tool Fork Cylinder Holder Hex 24 x 119 5 57001 1406 Apply a non permanent locking agent to the Allen bolt and tighten it Torque Front Fork Bottom Allen Bolt 39 N m 4 0 kgf m 29 ft lb e Fit the new outer guide bushing A into the outer tube NOTE OWhen assembling the new outer tube guide bushing hold the used guide bushing B against the new bush ing and tap the used guide bushing with the fork oil seal driver C until it stops Special Tool Front Fork Oil Seal Driver 57001 1219 e After installing the washer install the oil seal by using the fork oil seal driver e Install the retaining ring and dust seal by hand Pour in the specified type of oil see Fork Oil Change Inner Tube Outer Tube Inspection e Visually inspect the inner tube and repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone
176. er Fairing see Frame chapter Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with thrust bearing and pusher C spring and washer Friction Plates Steel Plates Spring Spring Seat Clutch Hub Nut A OHolding the clutch hub B remove the nut Special Tool Clutch Holder 57001 1243 C Remove Clutch Hub e Using the two 4 mm screws A pull out the sleeve B needle bearing C and clutch housing D Remove the spacer Clutch Installation e Inspect the clutch plate assembly length see Clutch Plate Assembly Inspection Install the following parts on the drive shaft A Spacer B Sleeve C Needle Bearing D Clutch Housing E Spacer F Clutch Hub G Washer H Nut GF06100BS2 C 5 8 CLUTCH Clutch Olnstall the spacer A so that the stepped side B faces inward Olnstall the washer so that the OUT SIDE mark faces outward OReplace the clutch hub nut with a new one OHolding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 137 N m 14 kgf m 101 ft Ib e Install the spring seat A and spring B as shown C Clutch Hub e Install the friction plates and steel plates starting with a friction plate and alternating them CAUTION If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate t
177. er Switch Starter Lockout Switch Passing Buttor Color BK WIBK Y Seler GY tetar R Y BL Y R BK Color BK R Color BR Clutch Lever Push wes Released Push Pulled in W121898BN5 C W BK ELECTRICAL SYSTEM 15 13 Wiring Diagram Other than United States Canada Australia and Malaysia 5 Fuel B ae d Turn park Plugs Pump Light Junction Box Signal Relay Switch Relay Ignition CRRA Fuel O00 Coils KEE Pump Junction Box Engine O0 1 Starter Circuit Relay Ground 2 Horn Fuse 10 Baad gt 3 Ignition Fuse A xa 4 Taillight Fuse 10A nni m ee a 5 Turn Signal Relay Fuse 10 EE ria 6 Headlight Fuse 10A Ge 7 Fan Fuse 10 hrottle 8 Fuse 10A ensor BK BL BK R W R BK Y BK BL R W BL BK Y R W R W BL W 6 6 4 L6 BK R Y R BR BK BR W BR Y BR RW LI Ri E Tail Br py eG 12V5 21 HT HEU Rear Left Turn Signal Light 12V21W d Water Temp Sensor Pickup Coil f 011 Pressure Switch g Neutral Switch BK Y zx 253 A ims Frame Ground BK Y gt gt 2555 2 2 2 EE nr Color Code ckout Al 30A Side Stand ternator BK Black tton a e 16 Igniter BL
178. erte ec ter puse ean 15 49 Lighting SV Sots cee 15 51 Headlight Beam Horizontal 15 51 Headlight Beam Vertical 15 51 Headlight Bulb TEE LEE 15 51 Headlight Relay Unit Inspection 15 52 Turn Signal Relay Inspection EE 15 54 EIN O EE 15 56 Fuel Pump Removal lnstallaton 15 56 Fuel Pump Relay Internal Resistance Inspection 15 56 Fuel Pump Operational ene 15 57 Fuel Cut Valve iets PEE 15 59 Fuel Cut Valve Removal 15 59 Fuel Cut Valve Installation 15 59 Fuel Cut Valve Inspection 15 59 le Ee EEN 15 61 Fan System Circuit Inspection eei cari Ap 15 61 Fan Motor Inspection 15 61 Meter Gauge Indicator 15 63 Meter Unit Rermovalz i eee UE e d e e OR ad rea 15 63 Meter Gauge Disassembly ier et Ren eris Eck aues eames 15 63 te ere ken rer E 15 63 Electronic Combination Meter Unit Inspection 15 64 Switches ANG SensOotrs uod ee t e re eerte 15 68 Brake Light Timing Inspection inre
179. es not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit Charging Voltage Inspection e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions e Remove the seats see Frame chapter e Check that the ignition switch is turned off and connect the hand tester A as shown in the table Special Tool Hand Tester 57001 1394 8 10080851 Charging System ELECTRICAL SYSTEM 15 33 Start the engine and note the voltage readings at vari ous engine speeds with the headlight turned on and then turned off To turn off the headlight of US Canada Aus tralia and Malaysia models disconnect the headlight con nector in the upper fairing The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging Voltage Connections Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 2 152 V 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 xIf the charging voltage is much higher than the values speci
180. est light and the 12 V battery to the regula tor rectifier as shown OCheck BK1 BK2 and BK3 terminal respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test 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 12 V to the BK R terminal OCheck BK1 BK2 and BK3 terminal respectively x If the test light turns on the regulator rectifier is defective Replace it x If 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 xIf the test light did not light when the 24 V was applied momentarily to the BK R terminal the regulator rectifier is defective Replace it x If the regulator rectifier passes all of the tests described it may still be defective If the charging system still do
181. ever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem GNO5060281 GNO5006BS1 C 13 8 STEERING Handlebar Handlebar Removal e Remove Screws A and Windshield B Remove Clutch Lever Assembly Left Handlebar Switch Housing Front Brake Master Cylinder Right Handlebar Switch Housing Throttle Case and Grip e Remove the handlebar bolts A and then pull out the handlebars B Handlebar Installation e Fit the pin A of the handlebar in the handlebar holder recess B Apply a non permanent locking agent to the threads of handlebar bolts and tighten the bolts Torque Handlebar Bolts 34 N m 3 5 kgf m 25 ft lb Install the removed parts see appropriate chapters Handlebar Holder Removal Raise the front wheel off the ground Loosen the handlebar holder bolts A and upper fork clamp bolts B Remove stem head nut C and steering stem head D Remove handlebar holder position bolts A and handle bar holders B Handlebar STEERING 13 9 Handlebar Holder Installation Apply a non permanent locking agent to the thread of handlebar position bolts and tighten them Torque Handlebar Holder Position Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the remove parts see appropriate chapters T
182. f 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 ina 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 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
183. f m 104 in Ib A B 6 09060151 Camshaft Chain Tensioner ENGINE TOP END 4 11 Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Seats see Frame chapter Fuel Tank see Fuel System chapter Cap Bolt A Washer B Spring C Rod D Remove the mounting bolts and take off the camshaft chain tensioner Camshaft Chain Tensioner Installation e Release the stopper A and push the push rod B into the tensioner body C Olnsert the push rod so that the push rod teeth are leaved five notches Install the tensioner body so that the stopper faces ward Tighten Torque Camshaft Chain Tensioner Mounting Bolts B 12 N m 1 2 kgf m 104 in Ib Install the spring and washer Tighten the cap bolt A e Turn the crankshaft 2 turns clockwise to allow
184. f m 43 ft Ib Rear Shock Absorber Inspection Remove the rear shock absorber Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it Visually inspect the rubber bushing x If it show any signs of damage replace it Rear Shock Absorber Scrapping A WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas do not incinerate the reser voir tank without first releasing the gas or it may explode Remove the valve cap A and release the nitrogen gas completely from the gas reservoir Remove the valve Since the high pressure gas is dangerous do not point the valve toward your face or body 12 18 SUSPENSION Swingarm Swingarm Removal e Remove Rear Wheel see Wheels Tires chapter Chain Cover see Final Drive chapter Brake Hose Clamp A Lower Shock Absorber Nut and Bolt B Upper Tie Rod Nut and Bolt C Swingarm Pivot Nut D Pull off the pivot shaft and remove the swingarm Swingarm Installation e Apply plenty of grease to the ball bearing needle bearings and grease seals and add plenty grease to the grease nipple Install the collars A and cap B Insert the pivot shaft into the frame from the right side Tighten Torque Swingarm Pivot Nut 108 N m 11 80 ft Ib Swingarm Bearing Removal Remove Swingarm Collars A Cap B
185. f the car buretor body C and apply a small amount of a bonding agent D to the circumference of the plug to fix the plug CAUTION Do not apply too much bonding agent to the plug or the pilot screw itself may be fixed OSet the float height as specified see Service Fuel Level Adjustment e After installing the upper chamber cover check that the vacuum piston slides up and down smoothly without bind ing in the carburetor bore Carburetor Separation Remove the carburetor see Carburetor Removal Read the WARNING in the carburetor disassembly e Mark carburetor locations so that the carburetors can be installed in their original positions Carburetor Joining e The center lines of the carburetor bores must be parallel both horizontally and vertically If they are not loosen the mounting screws and align the carburetors on a flat surface Retighten the mounting screws e After installing the choke mechanism check to see that the starter plunger lever slides right to left smoothly with out abnormal friction CAUTION Fuel mixture trouble could result if the starter plunger does not seat properly in its rest position after the choke lever is returned e Visually synchronize the throttle butterfly valves OCheck to see that all throttle valves open and close smoothly without binding when turning the pulley OVisually check the clearance A between the throttle valve and the carburetor
186. f the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pushing and pulling the forks If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Adjustment e Remove Upper fairing see Frame chapter Fuel Tank see Fuel System chapter Rear View Mirror Bracket e Loosen Lower Fork Clamp Bolts both sides Stem Head Nut A e Adjust the steering Special Tool Steering Stem Nut Wrench 57001 1100 B x If the steering is too tight loosen the stem nut a fraction of a turn x If the steering is too loose tighten the stem nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at a time maximum e Tighten Torque Steering Stem Head Nut 49 N m 5 0 kgf m 36 ft Ib Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 14 5 ft Ib e Check the steering again x If the steering is still too tight or too loose repeat the ad justment STEERING 13 5 Steering Stem Steering Stem Stem Bearing Removal e Remove Fairings see Frame chapter Fuel Tank see Fuel System chapte
187. fects of the pickup coil Inspect and replace the pickup coil Defects of the IC igniter e Inspect and replace the IC igniter Defects of the carburetor Inspect and adjust the carburetor 5 Abnormal no spark ON OFF ON CLOSE Inspect and repair the engine stop switch e Turn the engine stop switch ON and run GENERAL INFORMATION 1 17 Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION Ignition Engine Protection Fuel No Running Condition a Stop Remedy Action Switch Switch System Cutvalve Abnormal no spark OFF ON OFF Short of the ignition or e Inspect and replace switch the ignition switch e Turn the ignition switch and the engine stop switch ON and run e While coasting the motorcycle do not turn the ignition switch OFF 3 Maintenance Special maintenance is not necessary except for the inspection of the air suction valve which has been described in this manual 1 Replacement of Muffler Assy It is impossible to replace only catalytic converters because they are welded in the muffler So in the following case the replacement of the muffler assy is also necessary e In case of using not appointed fuel leaded gasoline etc Purification efficiency decreases in a very short period because lead poisons the catalytic con verters Although the appearance of the converter and engine performance are not effected the replac
188. fference between the highest and lowest dial gauge readings is the amount of runout warp xIf the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 020 in GK05017BS1 C GK05011181 C BRAKES 11 1 Brakes Table of Contents Exploded View 11 2 Rear Brake Pad Installation 11 12 Specifications 11 4 Brake Pad Wear Inspection 11 12 Brake Pedal eee 11 5 Master Cylinder 11 13 Brake Lever Position Adjustment 11 5 Front Master Cylinder Removal 11 13 Brake Pedal Position Inspection 11 5 Front Master Cylinder Installation 11 13 Brake Pedal Position Adjustment 11 5 Rear Master Cylinder Removal 11 13 EM 11 6 Rear Master Cylinder Installation 11 14 Front Caliper Remowval 11 6 Front Master Cylinder Rear Caliper Removal 11 6 Disasserbly dito 11 14 Caliper Installation 11 6 Rear Master Cylinder Front Caliper Disassembly 11 7 5 5 11 14 Front Caliper Assembly 11 8 Master Cylinder Assembly 11 15 Rear Caliper Disassembly 11 8 Master Cylinder Inspection Visual Rear Caliper Assembly 11 9 ee Cali
189. fied in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective 15 34 ELECTRICAL SYSTEM Charging System Charging System Circuit n co 2 GPi00800N3 C 1 Ignition Switch 2 Alternator 3 Regulator Rectifier 4 Battery 5 Main Fuse 30 A 6 Load ELECTRICAL SYSTEM 15 35 Ignition System Ignition System Troubleshooting Faulty Ignition Malfunctioned engine Ignition System Wiring Connector and No Good Battery Voltage Inspection Repair Replace or Charge Good No Good Spark Plug Inspection Replace Good No Good Stick Coil Inspection Replace Good No Good Inspect No Good Stick Coil Peak Voltage Measurement Battery Voltage Charge or Peak Voltage Adapter Replace Stick Coil Connector Faulty Parts No Good Crankshaft Sensor Inspection Good Inspect Crankshaft Sensor Peak Voltage No Good e No Good Replace Measurement Connector Faulty Parts Battery Voltage IC Igniter Inspection Inspect No Good i Battery Voltage IC Igniter Operation 5 Ignition Fuse Inspect Throttle Sensor Operation
190. fitting marked INLET B Be sure to route the hoses so that they will not be kinked or stretched 6510001852 C Fuel Pump Inspection Refer to the Electrical System chapter Fuel Filter Inspection Remove Seats see Frame chapter Fuel Tank see Fuel Tank Removal Band e Visually inspect the fuel filter x lf the filter is clear with no signs of dirt or other contami nation it is not necessary to replace it x If the filter is dark or looks dirty replace it Also check the rest of the fuel system for contamination 2 24 FUEL SYSTEM Evaporative Emission Control System California Model Only The Evaporative Emission Control System routes fuel va pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped AL though no adjustments are required a thorough visual in spection must be made at the intervals specified by the Pe riodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 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
191. for this test An ohmmeter other the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the headlight relay unit will be damaged Testing Relay Criteria When battery is connected 00 When battery is disconnected gt OQ Headlight Relay A 12 V Battery C GP12060781 ELECTRICAL SYSTEM 15 53 Lighting System Headlight Circuit United States and Canada Model gery w Y w vY G alie E G alie Headlight Circuit other than United States Canada Australia and Malaysia Model 5 te R BK gt _ R BK ajin 1 Ignition Switch 10 Headlight Fuse 10 A 2 High Beam Indicator Light 11 Dimmer Switch 3 Headlight 12 Alternator 4 City Light 13 Headlight Fuse 20 A 5 Headlight Relay Hi 14 Main Fuse 30 A 6 Headlight Relay Lo 15 Battery 7 Junction Box 16 Headlight Switch 8 Tail Light Fuse 10 A 17 Passing Button 9 Headlight Circuit Relay 18 Diodes 15 54 ELECTRICAL SYSTEM Lighting System Headlight Circuit Australia and Malaysia Model BK Y BR W GPi2060582 1 Ignition Switch 7 Junction Box 14 Fuse 30 A 2 High Beam Indicator 8 Tail Light Fuse 10 A 15 Battery Light 9 Headlight Circuit Relay 16 Headlight Switch 3 Headlight 10 Headlight Fuse 10 A 17 Passing
192. ft drum bearing holder screw and tighten it and bolt Torque Shift Drum Bearing Holder Bolt 12 N m 1 2 kgf m 104 in Ib Shift Drum Bearing Holder Screw 4 9 N m 0 5 kgf m 43 in Ib Shift Drum Disassembly e Remove the shift drum see Shift Drum and Fork Re moval e While holding the shift drum with a vise remove the shift drum cam holder bolt A Shift Drum Cam Holder Bolt B Dowel Pin Shift Drum Assembly e Be sure to install the dowel pin e Apply a non permanent locking agent to the threads of the shift drum cam holder bolt and tighten it Torque Shift Drum Cam Holder Bolt 12 N m 1 2 kgf m 104 in Ib Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A 6113013051 6113013451 D 6113014551 CRANKSHAFT TRANSMISSION 8 23 Transmission Shift Fork Gear Groove Wear Inspection 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 2323 0 2362 in Service Limit 5 8 mm 0 228 in x If the gear groove is worn over the service limit the gear must be replaced Gear
193. g Insert Journal Clearance Standard 0 014 0 038 mm 0 0006 0 0015 in Service Limit 0 07 mm 0 0028 in x If clearance is within the standard no bearing replace ment is required x lf clearance is between 0 039 mm 0 0015 in and the service limit 0 07 mm 0 003 in replace the bearing in serts with inserts A painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure If clearance exceeds the service limit measure the diam eter of the crankshaft main journal 6105042081 61050304 6105041781 8 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter Standard 29 984 30 000 mm 1 1805 1 1811 in Service Limit 29 96 mm 1 1795 in x If any journal has worn past the service limit replace the crankshaft with a new one x If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 29 984 29 994 mm 1 1805 1 1809 in 1 29 995 30 000 mm 1 1809 1 1811 in Crankshaft Main Journal Diameter Marks 1 mark or no mark Measure the main bearing bore diameter and mark the upper crankcase half in accordance with the bore
194. g the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose e Install the reservoir cap Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 5 N m 0 15 kgf m 13 in Ib Tighten the bleed valve and install the rubber cap e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib x If necessary bleed the air from the lines Bleeding the Brake Line 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 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 6109009851 C 6109060352 C 11 20 BRAKES Brake Fluid NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake Remove t
195. ged e Disassemble the carburetor Immerse all the metal parts in a carburetor cleaning solu tion Rinse the parts in water When the parts are clean dry them with compressed air Blow through the air and fuel passages with compressed air e Assemble the carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 Remove the carburetors e Before disassembling the carburetors check the fuel level see Fuel Level Inspection x If the fuel level is incorrect inspect the rest of the carbu retor before correcting it 2 16 FUEL SYSTEM Carburetors Slide the starter plunger lever to the left and release it to check that the starter plungers move smoothly and return by spring tension the starter plungers do not work properly replace the carburetors Turn the throttle cable pulley to check that the throttle but terfly valves A move smoothly and return by spring ten sion If the throttle valves do not move smoothly replace the carburetors e Disassemble the carburetors e Clean the carburetors Check that the O rings on the float bowl and pilot screw and the diaphragm on the vacuum piston are in good con dition x If an
196. gf m 104 in Ib Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolts A and Plate Alternator Lead Grommet B Stator Coil Bolts C e Remove the stator coil D from the alternator cover Stator Coil Installation Apply a non permanent locking agent to the threads of the stator coil bolts and tighten them Torque Stator Coil Bolts 12 N m 1 2 kgf m 104 in Ib e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 56019 120 e Secure the alternator lead with a holding plate and apply a non permanent locking agent to the threads of the plate bolts and tighten them Torque Alternator Lead Holding Plate Bolts 6 9 N m 0 70 kgf m 62 in Ib e Install the alternator cover see Alternator Cover Installa tion 15 28 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Starter Idle Gear and Shaft Wipe oil off the outer circumference of the rotor Hold the alternator rotor steady with the flywheel holder A and remove the rotor bolt B Special Tool Flywheel Holder 57001 1313 e Using the flywheel puller A remove the alternator rotor from the crankshaft Special Tools Flywheel Puller Assembly M38 1 5 M35 x 1 5 57001 1405 CAUTION Do not a
197. h a new one Tighten Torque Oil Pan Bolts 9 8 N m 1 0 kgf m 87 in Ib 6 8 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal See the Oil Pan Removal Oil Pressure Relief Valve Installation See the Oil Pan Installation Oil Pressure Relief Valve Inspection Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes 8 back to its seat by spring B pressure NOTE A Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance 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 6008060251 A WARNING Clean the 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 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 ENGINE LUBRICATION SYSTEM 6 9 Oil Pump Oil Pump Removal Drain Coolant see Cooling System chapter Engine Oil see Engine Oil Change e Remove Water Hoses A Bolts B and Water Pump Cover C
198. haft seizure Starter idle gear seizure No fuel flow No fuel in tank Battery voltage low Fuel pump trouble Fuel pump relay trouble Fuel tank air vent obstructed Fuel filter clogged Fuel tap clogged Fuel line clogged Float valve clogged Fuel cut valve left close check fuel cut valve and IC igniter Engine flooded Fuel level in carburetor float bowl too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine No spark 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 trouble Cam sensor trouble Neutral starter lockout or sidestand switch trouble Crankshaft sensor trouble Stick coil trouble Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve no
199. haust 22 1 22 3 mm 0 870 0 878 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Inlet Exhaust 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 Tool Valve Seat Cutter Holder 4 57001 1275 B iive Seat Cutter Holder Bar 57001 1128 C For Inlet Valve Seat Valve Seat Cutter 45 527 5 57001 1114 Valve Seat Cutter 32 628 57001 1119 Valve Seat Cutter 60 530 57001 1123 For Exhaust Valve Seat Valve Seat Cutter 45 532 57001 1115 Valve Seat Cutter 32 530 57001 1120 Valve Seat Cutter 60 533 57001 1334 If the manufacturer s instructions are not available use the following procedure 8 15011752 C 6 150307 5 4 26 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil N
200. he coupling back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Coupling Bearing Lubrication e Pack the bearing with good quality bearing grease Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated 6J06006BS1 C 6J06002BS1 C Sprocket Coupling FINAL DRIVE 10 13 Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection A Worn Tooth Engine Sprocket B Worn Tooth Rear Sprocket C Direction of Rotation NOTE Olfa sprocket requires replacement the chain is probably worn also OWhen replacing a sprocket inspect the chain Rear Sprocket Warp Inspection e Raise the rear wheel off the ground see Wheels Tires chapter so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The di
201. he cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head Install a new cylinder head gasket and knock pins e Apply engine oil to both sides A of the cylinder head bolt washers B Tighten the 10 mm cylinder head bolts following the tight ening sequence 1 10 Torque Cylinder Head Bolts 10mm First 20 N m 2 0 kgf m 14 5 ft Ib Final Used Bolts 49 N m 5 0 kgf m 36 16 Tighten the 6 mm cylinder head bolts 11 Torque Cylinder Head Bolts 6 12 1 2 kgf m 104 in Ib Tighten the oil hose banjo bolt Torque Oil Hose Banjo Bolt 25 N m 2 5 kgf m 18 0 ft lb GE14005BS1 GE14020181 C GE14006BS1 C 4 18 ENGINE TOP END Cylinder Head Cylinder Head Warp Inspection Lay a straightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 8 14011951 C ENGINE TOP END 4 19 Valves Valve Clearance Inspection NOTE OValve clearanc
202. he exhaust gas dur ing running the temperature of the catalysts rises abnormally because the unburned gasoline reacts with heated catalysts at the activation temperature or higher In an excessive case the problem such as melting down occurs Moreover there is a possibility that the purification performance be comes poorer when it is cool below the activation temperature So the fuel cut valve A as a catalyst protection system is installed on each carburetor float bowl B It runs by the IC Igniter and opens and closes the fuel passage toward a main jet C A catalyst protection system works in the following cases 1 2 3 2 Prevention of unburned gasoline from flowing when overspeed limiter works The limiter has fuel cut off and ignition cut off operations Prevention of unburned gasoline from flowing when the engine stop switch is turned off during running When the engine stop switch is turned off while coasting the motorcycle fuel is cut off For ex ample fuel is cut off under the abnormal running condition that you go down the slope with the engine stop switch OFF Prevention of unburned gasoline from flowing when misfire occurs by a cutoff of a primary coil in a stick coil Fuel is cut off when an electric current of a primary coil becomes abnormal because of a cutoff of the primary coil when the engine is running Prevention of solenoid valve lock If a driver always runs the engine under the red zone in the tac
203. he reservoir cap and fill the reservoir with fresh 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 at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation Install the reservoir cap Remove the rubber cap from the bleed valve on the caliper e Attach a clear plastic hose to the bleed valve and run the other end of the hose into a container 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 and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 5 N m 0 15 kgf m
204. he steel balls to hold them in place This will cause the positive neutral finder mechanism to malfunction OCheck the ball locking effect that the 5th gear does not come out of the output shaft when moving it up and down by hand e Replace any circlip that were removed with new ones e Install the circlips A so that opening B is aligned with a spline groove C e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 6113042351 Shift Drum and Fork Removal Remove Clutch see Clutch chapter Oil Pan see Engine Lubrication System chapter External Shift Mechanism see External Shift Mecha nism Removal Gear Positioning Lever Bolt A and Screw B Shift Drum Bearing Holder Pull out the shift rods D and take off the shift forks Pull out the shift drum 8 22 CRANKSHAFT TRANSMISSION Transmission Shift Drum and Fork Installation Set the transmission gears in the neutral position e Install the shift drum so that the punch mark A on it faces oil pan side e Install the forks as shown e Position the one with shortest ears A on the drive shaft and place the pin in the center groove in the shift drum OThe two forks on the output shaft are identical Install the shift rods 0 noting the groove position The rods are identical Apply a non permanent locking agent to the threads of the shi
205. heck e Remove the seats see Frame chapter e Disconnect the IC igniter left side connector A e Set the Hand Tester B to the x 25 V DC range and using two auxiliary wires connect it to the connector come from harness side as follows Tester terminal C BR W lead Tester terminal D BK Y lead Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn the ignition switch on and read the voltage IC Igniter Operation Voltage Battery Voltage If the tester reading is not specified one check the battery voltage ignition switch and ignition fuse 15 42 ELECTRICAL SYSTEM Ignition System Throttle Sensor Operation Check Remove the fuel tank see fuel System chapter e Disconnect the throttle sensor lead connector Connect the adapter A between the connectors B Special Tool Throttle Sensor Setting Adapter 57001 1521 Set the Hand Tester E to the x 10 V DC range and connect it to the adapter as follows Hand Tester Terminal BL Lead C Hand Tester Terminal BK BL Lead D Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn the ignition switch on and read the voltage Throttle Sensor Voltage approx 5 V x If the voltage is out of specified one extremely check the Battery Voltage If the Battery Voltage is correct replace the IC igniter Fuel Cut Valve Operation Check Remove the fuel tank see Fuel
206. hem with the specified torque Torque Air Suction Valve Cover Bolts 12 N m 1 2 kgf m 104 in Ib Air Suction Valve Inspection e Visually inspect the reeds A for cracks folds warps heat damage or other damage If there is any doubt as to the condition of the reed replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly 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 Vacuum Switch Valve Removal e Remove the vacuum switch valve see Air Suction Valve Removal GE04060181 C 6 04070251 4 8 ENGINE TOP END Clean Air System Vacuum Switch Valve Installation Install the vacuum switch valve so that the air hole A faces downwards Route the hoses correctly see General Information chap ter Vacuum Switch Valve Test Remove Fuel Tank Air Cleaner Housing see Fuel System chap ter Vacuum Switch Valve Connect a vacuum gauge A and syringe B or fork oil level gauge to the vacuum hoses a
207. hometer the IC igniter doesn t operate overspeed limiter and the catalyst protection system doesn t have a chance to work The 1 16 GENERAL INFORMATION Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION old fuel may gum up the fuel cut valves which remain seated in the float bowls To cope with the IC igniter test operates the fuel cut valves when starting the engine and prevents lock of the valves 5 Usage of leaded gasoline is prohibited completely Leaded gasoline harms the purification efficiency of the catalysts The performance of the catalyst protection system is summed up as follows Fuel Cut Valve Performance of Catalyst Protection System 680601111 Running Condition Switch Ignition Engine Stop Switch Protection System Fuel Cutvalve Remedy Action Not necessary Short of the engine stop switch e While coasting the motorcycle do not turn the engine stop switch OFF 1 Normal ON ON OFF OPEN Normal condition 2 Overspeed performance ON ON ON CLOSE Not necessary 3 Abnormal misfire ON ON ON CLOSE e Defects at the stick coil e Inspect the primary side connection at the primary side of the stick coil 4 Abnormal misfire ON ON OFF OPEN e Defects at the stick coil Inspect the stick coil secondary side Battery is dead Charge the battery Spark plug fouling Clean the spark plug and adjust the gap De
208. ic converter Fuel Cut Valve Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 Remove the fuel tank see Fuel System chapter Connect a suitable hose to the fitting at the bottom of each carburetor float bowl e Run the lower ends of the hoses into a suitable container Turn out each drain plug a few turns and drain the float bowls Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 Disconnect the connectors B of the fuel cut valves Loosen the fuel cut valves and remove them Fuel Cut Valve Installation Install the fuel cut valves with a gray connector A on the 1 4 carburetors e Install the fuel cut valves with a brown connector A on the 2 3 carburetors Do not install the fuel cut valves on the wrong carburetors The fuel cut valves will not work well Fuel Cut Valve Inspection Remove the fuel cut valve A Connect and disconnect one 12 V battery B to the fuel cut valve connector as shown The valve rod moves x lf the protrusion exceeds the standard too long or too short the valve is defective and must be replaced Testing Fuel Cut Valve Standard Protrusion When battery is disconnected 16 6 mm 0 65 in When battery is
209. idize CO and HC by the catalysts the proper amount of oxygen is necessary As original combustion gas has little remaining oxygen air is injected in the exhaust ports by the sec ondary air injection system in order to supply enough oxygen to the combustion gas to purify CO and HC to a certain extent as well as prepare for activation of the catalysts Since the carburetor is set at richer level A and air fuel mixture A F is about 11 14 NOx is at lower level from the beginning as shown in the figure And A F becomes lean about 13 5 15 after the combustion chambers owing to secondary air injection and combustion Exhaust Gas before Purification gt Concentration 96 a A 11 12 13 14 15 16 47 18 19 AIF 2 Precatalytic Converters A 3 A small size three way catalytic converter precatalytic converter is installed in the pipe ahead at the joint B of the silencer A precatalytic converter is made of a punched metal pipe C of stain less steel and its surface is covered with alumina upon which platinum and rhodium as catalysts are applied Generally the temperature of the exhaust gas must be higher than the activation tem perature so we set this precatalytic converter at the upper portion of the main catalytic converter where the temperature of exhaust gas is high Accordingly the precatalytic converter will be acti vated even under low load conditions Activation of the prec
210. ight Fuse 5 Turn Signal Relay Fuse 10A roe 6 Headlight Relay Ce 5 5 7 Headlight Fuse 10 mo a 8 Fan Fuse 10A 9 Fuse Throttle Sensor E 2 R W R R W BL R 78 R wy BK BL BK R R W R BK Y BK BL R BL BL R BK Y R ee 1 Rear Right Turn Signal Light 12V218 Tail Brake Light 12V5 21WX2 Rear Left Turn Signal Light 12V21W Water Temp Sensor Pickup Coil Oil Pressure Switch Neutral Switch Lr mS DEI Ze SC S sak o c s Ec Ground r gt ER BK Y BK Y Xo h Starter Rel Star aif gees 52222202 mm SM T OFF m Side Stand Alternator Switch an IG Igniter Color Code BK Black Bt Blus BR Brown Park Green Green RIGHT HANDLEBAR SWITCH CONNECTIONS LE x White Y Yellow EEN WIRI970AWS C 15 12 ELECTRICAL SYSTEM Wiring Diagram Other than United States Canada Australia and Malaysia Right Handlebar Switches 1 Headlight Switch 2 Front Brake Light Switch 3 Engine Stop Switch 4 Starter Button Radiator Fan Switch Igni Coil on PE Ires BL BK Er r Throttl
211. ight 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 slips off the rim flange e Discard the used balance weight Balance Weight Installation e Check if the weight portion has any play on the blade and clip x If it does discard it A WARNING 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 6J04041481 Ox 6J04010581 6J04010881 WHEELS TIRES 9 9 Wheels Rims 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 Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e When required total weight exceeds 20 g install balance weight at both sides of rim flange as shown Weight Selection Required Total Weight Other Side 209 109 109 50 g 30 g 204 39g 95 70 9 20 9 209 30 g 90 g 20 9 309 209 209 Balance Weight Part Number Weight grams 41075 1014 10 0 35 41075 1015 20 0 70 oz 41075 1016 30 1 05 oz OBalance weights are avail
212. ighten Torque Steering Stem Head Nut 49 N m 5 0 kgf m 36 ft lb Handlebar Holder Bolts 25 2 5 kgf m 18 ft lb Upper Fork Clamp Bolts 20 N m 2 0 kgf m 14 5 ft lb FRAME 14 1 Frame Table of Contents te SE a 14 2 I m 14 5 Rear Seat RemOyal EE 14 5 Rear Seat Installation a re eel ads AEN eoe eei eve eda lobes 14 5 Front Seat Rerrioval iiu ali c Adan nS 14 5 Front Seat Installation eere Ee ete ect nll tee sions AE 14 5 een rM T T ORE 14 6 Lower Fairing E EE 14 6 Inner Upper Fairing Removal 14 6 Inner Lower Fairing 14 6 Upper Faining Removal ee tbe a ERES 14 6 eg e 14 8 Seat Cover REMOVAals 14 8 Seat Cover Installation Cee a le ie 14 8 e EET 14 9 Front Fender Removal nnne enne rin ese rss eres dear sana aad s nga 14 9 Rear Fender RermioVal a net ceto c eee eel De dee dE 14 9 e aes erra EE E doe eA PA dd den 14 10 Rear Frame Removal 3 Rhet ele rei 14 10 Rear Frame Iristallatonm 2 ete 14 10 Frame Inspection ciet NR EXER RE EYE AE EA 14 10 14 2 FRAME Exploded
213. il Pump Removal in the Engine Lubrication Sys tem chapter Water Pump Installation Refer to Oil Pump Installation in the Engine Lubrication System chapter Water Pump Inspection e Check the drainage outlet passage A at the bottom of the water pump body for coolant leaks the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Re place the water pump unit e Visually inspect the impeller A x If the surface is corroded or if the blades are damaged replace the water pump unit 6006011651 C Radiator Radiator Fan COOLING SYSTEM 3 11 Radiator and Radiator Fan Removal 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 DIS CONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES e Remove Lower Fairings see Frame chapter Coolant see Coolant Draining Water Hoses A Radiator Mounting Bolt B Fan Switch Lead Connector A Water Hose B Radiator Mounting Bolts C Radiator Fan Lead Connector D Radiator Radiator Fan Mounting Bolts A Radiator Fan B CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency 3 12 COOLING SYSTEM Radiator Radiat
214. in Service Limit 66 06 mm 2 601 in Piston Wear Inspection Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard 65 935 65 950 mm 2 5957 2 5965 in Service Limit 65 78 mm 2 590 in Piston Ring Piston Ring Groove Wear Inspection e Check for uneven groove wear by inspecting the ring seat ing rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 05 0 09 mm 0 0020 0 0035 in Second 0 03 0 07 mm 0 0012 0 0028 in Service Limit Top 0 19 mm 0 0075 in Second 0 17 mm 0 0067 in 55 Sw KS aren GE16060481 GE16060281 GE16004BS1 ENGINE TOP END 4 33 Cylinder Pistons Piston Ring Groove Width Inspection Measure the piston ring groove width OUse vernier caliper at several points around the piston Piston Ring Groove Width Standard Top 0 84 0 86 mm 0 0331 0 0339 in Second 0 82 0 84 mm 0 0323 0 0331 in Service Limit Top
215. in Plug Wrench Hex 3 57001 1269 5157126951 1 34 GENERAL INFORMATION Special Tools and Sealant Valve Guide Arbor 4 57001 1273 5157127351 C Valve Guide Reamer 4 57001 1274 875712745 Valve Seat Cutter Holder 4 57001 1275 875712755 C Pressure Gauge Adapter M18 1 5 57001 1278 5157127851 Fork Piston Rod Puller M12 x 1 25 57001 1289 N 7571289ST C Fork Oil Level Gauge 57001 1290 5157129051 C Flywheel Holder 57001 1313 7571313ST C Compression Gauge Adapter M10 x 1 0 57001 1317 7571317ST C Valve Seat Cutter 60 033 57001 1334 Steering Stem Bearing Driver 542 5 57001 1344 875713345 6 7571344ST C GENERAL INFORMATION 1 35 Special Tools and Sealant Steering Stem Bearing Driver Adapter 41 5 Fork Cylinder Holder Hex 24 x 119 5 57001 1345 2 57001 1406 ST571345ST C ST571406ST C Bearing Remover Head 25 x 28 Peak Voltage Adapter 57001 1346 57001 1415 T5713468T C ST571415ST C Bearing Remover Shaft 13 Head Pipe Outer Race Driver 55 57001 1377 57001 1446 5157137751 C 875714465 C Hand Tester Head Pipe Outer Race Driver 47 57001 1394 57001 1447 7571394ST C 5157144751 C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 Lead Wire Peak Voltage Adapter 57001 1405 57001 1449
216. ing Remover Head 25 x 28 57001 1346 A WARNING Use the same manufacturer s tires on both front and rear wheels 9 4 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Lower Fairing see Frame chapter Brake Caliper Mounting Bolts A Loosen Right Side Axle Clamp Bolts A Axle B Raise the front wheel off the ground Special Tool Jack 57001 1238 Pull out the axle to the right and drop the front wheel out of the forks CAUTION Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown by an arrow B on the wheel spoke Check the wheel rotation mark on the front wheel and install it e Fit the collars on the both sides of the hub Tighten the axle nut Torque Front Axle Nut 127 N m 13 kg m 94 16 e Before tightening the clamp bolts on the right front fork leg pump the front fork up and down 4 or 5 times to all on the right front fork leg to seat on the front axle NOTE OPut a block in front of the front wheel to stop moving 6J04060181 C Wheels Rims WHEELS TIRES 9 5 Tighten the axle clamp bolts A on the right fork leg first Torque Front Axle Clamp Bolts 20 N m 2 0 kg m 14 5 ft lb Check the clearance B between the right fork leg D a
217. inks Sprockets Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 020 in US United States Model CA Canada Model Special Tools Inside Circlip Pliers 57001 143 Bearing Driver Set 57001 1129 Jack 57001 1238 10 4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OClean the chain if it is dirty and lubricate it if it appears dry Check the wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain is tightest Measure the vertical movement chain slack A midway between the sprockets the chain slack exceeds the standard adjust it Chain Slack Standard 30 35 mm 1 18 1 38 in Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the axle nut B Loosen the both chain adjuster locknuts x If the chain is too loose turn out the left and right chain adjuster D evenly xIf the chain is too tight turn in the left and right chain adjusters evenly and kick the wheel forward e Turn both chain adjusters evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the left wheel alignment indicator F should align with the same swingarm mark or position G that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear a
218. ion to suit you as follows Loosen the front and rear rod locknuts e Turn the rod to adjust the pedal position Tighten the locknuts securely External Shift Mechanism Removal e Remove Engine Oil drain see Engine Lubrication System chap ter Shift Pedal see Shift Pedal Removal Clutch see Clutch chapter Bolts A Oil Pipe Holders B Oil Pipe C and O ring e Remove Shift Shaft A Bolt B Gear Positioning Lever C and Spring External Shift Mechanism Installation Apply a locking agent to the thread of the gear positioning lever mounting bolt Install the gear positioning lever A as shown and tighten the bolt Springs B Collar C Bolt D Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 104 in Ib Apply a locking agent to the thread of oil pipe holder bolt Tighten the oil pipe holder bolts Torque Oil Pipe Holder Bolts 12 N m 1 2 kgf m 104 in Ib 6113036851 6113042151 CRANKSHAFT TRANSMISSION 8 19 Transmission External Shift Mechanism Inspection Examine the shift shaft A for any damage the shaft is bent straighten or replace it x If the serration are damaged replace the shaft x lf the springs C are damaged in any way replace them x If the shift mechanism arm D is damaged any way replace the arm e Check the return spring pin A is not loose xIf it is loose unscrew it apply a non permanent
219. it GP17061281 C GPi70614W2 C Ignition Switch Junction Box Tachometer Speedometer Speed Sensor Water Temperature Sensor Battery Main Fuse 30 A IC Igniter 15 68 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection e Turn on the ignition switch Check the operation of the rear brake light switch by de pressing the brake pedal does not as specified adjust the brake light timing Brake Light Timing Standard On after about 10 mm 3 94 in of pedal travel A Brake Light Timing Adjustment Brake light timing is adjusted by changing the position of the rear brake light switch Adjust the position of the switch so that the brake light goes on after the specified pedal travel by turning the ad justing nut A CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the handlebar switches and the ignition switch refer to the tables in the Wiring Diagram 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 When brake is
220. ity Fork Spring Free Length Standard 234 6 mm 9 24 in Service Limit 230 mm 9 06 in 6 04062551 C 8 04011851 C SUSPENSION 12 15 Rear Shock Absorber Rebound Damping Force Adjustment ZX600 J1 J3 adjust the rebound damping force turn the lower damping adjuster A to the desired position until you feel a click OThe standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position ZX600 J4 US ZX600J6F CA e To adjust the rebound damping force turn the lower damping adjuster A to the desired position up to the specified turns OThe standard adjuster setting for an average build rider of 68 kg 150 Ib and with no passenger and no accessories is 2 1 2 turns out from fully clockwise position Rebound Damping Force Adjustment Speed Weak Low T High A 18 clicks ZX600 J1 J3 4 1 2 turns out ZX600 J4 US ZX600J6F CA B 1 click ZX600 J1 J3 Fully clockwise position ZX600 J4 US ZX600J6F CA Compression Damping Force Adjustment ZX600 J1 J3 To adjust the compression damping force turn the upper damping adjuster A to the desired position until you feel a Click OThe standard adjuster setting for the average build rider of 68 150 with no passenger and no accessories is the 10th click from the 1st
221. kK R Y BK Y Wt W BK R BK BK Y W R BR BK BK W Y H City Light er R 12V5W Headlight ight Headl Relay TE Left Handlebar Switches LOW H Butt Front Right Turn Signal orn Button Light 12V21W m BK Y Hazard Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Front Left Turn Signal 6 Light 12V21W EXES TES Headlight LED Light Emitting Diode Fuse 20 LEFT HANDLEBAR SWITCH CONNECTIONS Color BK WBK Y Color Released OFF Push R Lo Pulled in W2L1097AW5 C ELECTRICAL SYSTEM 15 9 Wiring Diagram United States and Canada ZX600 J3 Spark Rear 5 Turn Plugs Fuel Broke Junction Box Signal ump Light 2002000 Relay Switch QOO Ignition Coils wy Fuel Junction Box Pump 1 Starter Circuit Relay Engine 2 Horn Fuse 10A Ground 3 Ignition Fuse 553 4 Taillight Fuse 10A RENE Xe xd ig 5 Turn Signal Relay Fuse 10 gt ENS 6 Headlight Relay 7 Headlight Fuse 10 Throttle gt 8 Fan Fuse 10A Sensor ACC Fuse 10 BK BL BK R R W R BK Y BK BL R BL BL R 76 ZE BK Y R BK BL Y W 0 6 R 8L 4 BL Y4 BR 4 BL BK4 H T3 gt aro rer m 2 97 gt Boa JL Buet 0 409 ee ve 1 zzz a Rear Right Turn Signal Light 1
222. l the container is completely emptied Be certain that all the electrolyte has flowed out the bottom the same way as above if there is any electrolyte left in the container Now pull the container gently out of the battery Let the battery sit for 20 minutes During this time the electrolyte permeates the special separators and the gas generated by chemical reaction is released e Fit the seal caps A tightly into the filler ports until the seal cap is at the same level as the top of the battery NOTE ODo not hammer Press down evenly with both hands CAUTION 8 08010751 C Once you install the seal caps after filling the bat tery never remove it nor add any water or elec trolyte Initial Charge While a sealed battery can be used after only filling with electrolyte a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below where an initial charge is required before use However if a battery shows a terminal voltage of higher than 12 8 V after 10 minutes of filling Note 1 no initial charge is necessary Condition requiring initial charge Charging method At low temperatures lower than 0 C 0 9A x 2 3 hours Battery has been stored in high temperature and humidity Seal has been removed or broken peeling tear or hole Battery as old as 2 years or more after manufacture 0 9 A x 15 20 hours Battery manufact
223. lace the following steel plate s 13089 1126 1 4 mm 0 055 in 13089 013 1 6 mm 0 063 in STD 13089 1073 2 0 mm 0 08 in NOTE ODo not use the steel plate of 1 4 mm and 2 0 mm thick ness at the same time e Install the removed parts and inspect the clutch plate as sembly length Tighten Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points x If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 2 mm 0 087 in Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 2 mm 0 008 in or less Service Limit 0 3 mm 0 012 in GF06060281 GF13010781 CLUTCH 5 11 Clutch Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A any spring is sho
224. le Speed Carburetor Synchronization Throttle Cables Choke Cable Claw Claw 6606061151 C Carburetors FUEL SYSTEM 2 13 Carburetor Disassembly Remove the carburetors Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 NOTE OCarburetor can be disassembled in the joined state For the US model remove the pilot screw plug as follows punch a hole in the plug and pry there with an awl or other suitable tool e Turn in the pilot screw and count the number of turns until it seats fully but not tightly and then remove the screw This is to set the screw to its original position when as sembling CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm e When removing the jet needle pull straight out the holder A from the vacuum piston B ORemove Holder A Spring B Washer C Jet Needle D 2 14 FUEL SYSTEM Carburetors Carburetor Assembly e Turn in the pilot screw A fully but not tightly and then back it out the same number of turns counted during dis assembly e For the US model install the pilot screw plug as follows install a new plug B in the pilot screw hole o
225. ler body C backward Muffler Body Installation Replacing the muffler body gasket with new one Tighten Torque Muffler Body and Exhaust Pipe Connecting Nuts 45 N m 4 5 kgf m 33 ft lb Thoroughly warm up the engine wait until the engine cools down and retighten all the bolts and nuts CLUTCH 5 1 Clutch Table of Contents Exploded VIGW 5 2 eelere cm O0 0 5 3 Clutch lever and Gables oe a cie de Cas La es 5 4 Clutch Lever Free Play Inspection eeclesie 5 4 Clutch Lever Free Play Adjustment 22 5 4 ole E e E EE 5 5 Clutch Cable Installation nnns 5 5 Clutch Cable nannaa Eas Kanini iaeia ieia kiia 5 5 Clutch Lever Installation e 5 5 Cl tcE COVE TEN A AED Toe dete et iac e AS 5 6 Gl tch Gover Removal tae wheat es 5 6 Clutch Cover Installations 5 6 Clutch Release Shaft 5 6 Clutch Release Shaft Installation 5 6 eic M 5 7 GluteliRerioval meer EE EE 5 7 Cl tchilnstallatiOni 75
226. life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A 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 medical attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage Remove the seats see Frame chapter e Disconnect the battery cables CAUTION Be sure to disconnect the negative ca
227. locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 28 N m 2 9 kgf m 21 16 e Check the gear positioning lever B and it s spring for breaks or distortion x lf the lever or spring are damaged in any way replace them e Visually inspect the shift drum cam C x If they are badly worn or if they show any damage replace it Transmission Shaft Removal Split the crankcase see Crankcase Splitting Remove the drive shaft A and output shaft B Transmission Shaft Installation Check to see that the set pins A and set rings B are in place 8 20 CRANKSHAFT TRANSMISSION Transmission e Install the drive shaft and output shaft into the upper crankcase half e Apply engine oil to the sliding surfaces of the gears and bearings OThe bearing set pins and rings must match properly with the holes or grooves in the bearing outer races When they are properly matched there is no clearance between the crankcase and the bearing outer races A Transmission Shaft Disassembly Remove the transmission shafts see Transmission Shaft Removal Remove the circlips shafts Special Tool Outside Circlip Pliers 57001 144 The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear q
228. locking agent T7 8 8 N m 0 90 kgf m 78 in Ib ZX600J1 Replacement Parts J4 J6F Follow the specific tightening sequence 11 N m 1 1 kgf m 97 in Ib ZX600J7F Apply silicone grease ex PBC grease Zr 0 BRAKES 11 3 Exploded View 11 4 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position Brake Fluid Grade Brake Pads Lining Thickness Front Rear Brake Discs Thickness Front Rear Runout 5 way adjustable to suit rider Non adjustable Non adjustable About 57 mm 2 24 in below footpeg top DOT4 4 mm 0 16 in 5 mm 0 20 in 4 8 5 1 mm 0 189 0 201 in 4 8 5 2 mm 0 189 0 205 in 0 15 mm 0 006 in or less Special Tools Inside Circlip Pliers 57001 143 Jack 57001 1238 1 mm 0 04 in 1 mm 0 04 in 4 5 mm 0 177 in 4 5 mm 0 177 in 0 3 mm 0 012 in BRAKES 11 5 Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 Brake Pedal Position Inspection Check that the brake pedal A is in the cor
229. ly Clutch Lever and Cable CLUTCH 5 5 Clutch Cable Removal Remove the right lower fairing see frame chapter Slide the dust cover at the clutch cable lower end out of place Loosen the nuts and slide the lower end of the clutch cable to give the cable plenty of play Screw in the adjuster Line up the slots A in the clutch lever and adjuster B and then free the cable from the lever e Free the clutch inner cable tip from the clutch release lever Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent the release shaft from falling out e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see General Information chapter e Adjust the clutch cable see Lever Free Play Adjustment Clutch Cable Lubrication Whenever the clutch cable is removed lubricate the clutch cable as follows Apply a thin coating of grease to the cable upper and lower ends Lubricate the cable with a penetrating rust inhibitor Clutch Lever Installation Install the clutch lever so that the mating surface A of the switch housing is aligned with the mating surface B of the clutch lever clamp 6604011451 C 5 6 CLUTCH Clutch Cover Clutch Cover Removal e Remove Engine Oil drain see Engine Lubrication System chap ter Right Lower Fairing see Fra
230. m 6806060482 1 Cleaner Housing 6 Exhaust Valve 2 Air Hose 7 Carburetors 3 Inlet Silencer 8 Inlet Pipe 4 Vacuum Switch Valve 9 Inlet Valve 5 Air Suction Valve 2 Operation of Three way Catalytic Converter The three way catalysts are used for the catalytic converters and the main catalytic converter These converters can clean up carbon monoxide CO hydrocarbons HC and nitrogen oxides NOx at the same time CO and HC are oxidized O is added by platinum Pt and converted to harmless carbon dioxide gas CO2 and water and then the exhaust gas is cleaned up 1 2 O2 gt gt NOx is reduced is removed by rhodium Rh and converted to harmless nitrogen and oxygen Oz and the exhaust gas is cleaned up NOx Oo Main Catalytic Converter c ie 27 Os NOx GENERAL INFORMATION 1 21 Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION 3 Property of Catalyst Most catalysts are powders of metal or of metallic compounds and they increase the rate of a chemical reaction Catalysts are supposed to act in some way to loosen the bonds of the reacting substances In other words they lower the energy of activation thus allowing the reaction to proceed more rapidly To activate catalysts the temperature of the exhaust gas must be higher than the activation temperature that is 220 230 C for new c
231. m age Engine oil viscosity too high Drive train trouble Brake dragging Air suction valve trouble Vacuum switch valve trouble Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Air cleaner O ring damaged Water or foreign matter in fuel Carburetor holder loose Fuel to carburetor insufficient Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Fuel pump trouble Fuel pump relay trouble Fuel filter clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter trouble Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide Poor Running or No Power at High smoothly Speed Carburetor vacuum piston diaphragm dam Firing incorrect aged Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter trouble Crankshaft sensor trouble Stick coil trouble Fuel air mixture incorrect Choke plunger stuck open Main jet clogg
232. m 104 in Ib Camshaft Chain Guide Bolts 12 N m 1 2 kgf m 104 in Ib NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 038 0 081 mm 0 0015 0 0032 in Service Limit 0 17 mm 0 0067in If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 940 23 962 mm 0 9425 0 9434 in Service Limit 23 91 mm 0 941 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 unit Camshaft Runout Inspection e Remove the camshaft e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown x If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 1 mm 0 004 in Cam Wear Inspection e Remove the camshaft e Measure the height A of each cam with a micrometer If the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 34 345 34 453 mm 1 352 1 356 in Inlet 35 146 35 254 mm 1 384 1 388 in Service Limit Exhaust 34 24 mm 1 348 in Inlet 35 04 mm 1 380 in GE11070781 pb 8
233. mage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine 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 Abnormal Drive Train Noise Clutch noise Clutch rubber damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient APPENDIX 16 5 Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearings worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil
234. me chapter Oil Hose Clutch Cable Lower End A Clutch Cover Mounting Bolts B e Turn the release lever A toward the rear as shown and remove the clutch cover B C about 90 Clutch Cover Installation e Apply silicone sealant to the area A where the mating surface of the crankcase touches the clutch cover gasket Sealant Kawasaki Bond Silicone Sealant 56019 120 Replace the cover gasket with a new one Apply a non permanent locking agent to the threads of the two clutch cover bolts B Tighten the cover bolts Torque Clutch Cover Bolts 12 N m 1 2 kgf m 104 in Ib Clutch Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required Remove the clutch cover see Clutch Cover Removal Pull the lever and shaft assembly out of the clutch cover Clutch Release Shaft Installation Apply high temperature grease to the oil seal lips on the upper ridge of the clutch cover Apply molybdenum disulfide grease to the clutch release shaft e Insert the clutch release shaft straight into the upper hole of the clutch cover CAUTION When inserting the clutch release shaft be careful not to remove the spring of the oil seal Clutch CLUTCH 5 7 Clutch Removal Remove Engine Oil drain see Engine Lubrication System chap ter Right Low
235. mostat T7 18 1 8 kgf m 13 ft lb 6 Cooling Hose Assy other than US CA 8 20 N m 2 0 kgf m 14 5 10 Models EO Apply engine oil T1 5 9 N m 0 60 kgf m 52 in Ib L Apply a non permanent locking agent T2 2 0 0 20 17 in Ib SS Apply silicone sealant CA Canada US United States Specifications COOLING SYSTEM 3 3 Item Standard Coolant provided when shipping Type Color Mixed ratio Freezing point Total amount Radiator cap Relief pressure Thermostat Valve opening temperature Valve full opening lift Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 2 3 L 2 43 US qt reserve tank full level including radiator and engine 93 123 kPa 0 95 1 25 kgf cm 14 18 psi 58 62 C 136 144 F 8 mm 0 32 in or more 75 C 167 F Sealant Kawasaki Bond Silicone Sealant 56019 120 3 4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperatu
236. n Cam Wear Inspection Camshaft Chain Removal Cylinder Head Cylinder Compression Measurement eneeenee eneee Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp Inspection MEI 4 2 4 4 4 7 4 7 4 7 4 7 4 7 4 8 4 8 4 8 4 9 4 9 4 10 4 11 Valve Clearance Inspection Valve Clearance Adjustment Valve Remowal Valve Installation Valve Guide Removal Valve Guide Installation Valve to Guide Clearance Measurement Wobble Cylinder Cylinder Removal Cylinder Installation Piston Remowval Piston Installation Cylinder Wear Inspection Piston Wear Inspection Piston Ring Piston Ring Groove Wear Inspection Piston Ring Groove Width Piston Ring Thickness Inspection Piston Ring End Gap Inspection Carburetor Muffler and Exhaust Pipe Removal Muffler and Exhaust Pipe Installation Muffler Body Remowval Muffler Body Installation 4 19 4 20 4 23 4 23
237. n venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Belore ches hates 1 2 Model EE 1 EEN EE Re e e Lee EE 1 6 Periodic Maintenance Chart United States and Canada 1 9 Periodic Maintenance Chart Other than United States and Canada Models 1 11 Technical Information KLEEN KAWASAKI LOW EXHAUST 5 1 13 Technical Information Non Contact Hall IC Type Speed 1 22 Technical Information Alternator Made from Rare 1 24 Torque and le Re er decd 1 25 Special Tools and
238. n LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow OElectrical Connectors Connectors A 8 06010151 C 15 20 ELECTRICAL SYSTEM Precautions Connectors B 6206010251 C Electrical Wiring ELECTRICAL SYSTEM 15 21 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc xIf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary 8 07010551 15 22 ELECTRICAL SYSTEM Battery Battery Removal e Remove Seats see Frame Chapter Front Seat Bracket A Battery Holder Disconnect the negative cable B and then positive cable C CAUTION Be sure to disconnect the negative cable first Remove the battery Electrolyte Filling CAUTION Do not remove the aluminum seal sheet A sealing the filler ports B until just befor
239. nd collar C with the thickness gauge Standard 1 5 mm 0 06 in Usable range 0 5 2 8 mm 0 02 0 11 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 Tighten the axle clamp bolts on the left fork leg Torque Front Axle Clamp Bolts 20 N m 2 0 kg m 14 5 ft Ib Install the front brake calipers see Brakes chapter e Check the front brake effectiveness see Brakes chapter A WARNING Do not attempt to 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 Wheel Removal Remove the lower fairings see Frame chapter Using the jack A raise the rear wheel off the ground OAdjust the length of the jack legs B situate the motorcy cle so that it is perpendicular to the ground Special Tool Jack 57001 1238 e Remove Cotter Pin A Axle Nut B Axle C View from rear sun 9 6 WHEELS TIRES Wheels Rims Remove the rear caliper Remove the chain cover Remove the drive chain A from the rear sprocket toward the left Move the rear wheel back and remove it CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the di
240. nd dust cover B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes D PBC is a special high temperature water resistance grease Install the anti rattle spring A in the caliper as shown Install the pads see Rear Brake Pad Installation e Wipe up any spilled brake fluid on the caliper with wet cloth 6105040251 6105060751 11 10 BRAKES Calipers Caliper Fluid Seal Damage Inspection The fluid seals A around the piston maintain the proper pad disc clearance If the seals are not satisfactory pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature Replace the fluid seals under any of the following condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in inner and outer pad wear d the seal is stuck to the piston x If the fluid seal is replace replace the dust seal as well Also replace all seals every other time the pads are changed Caliper Dust Seal Rubber Boot Damage Inspection Check that the dust seals B and rubber boot C are not cracked worn swollen or otherwise damaged If they show any damage remove the caliper bracket and replace them Caliper Piston and Cylinder Damage Insepction e Visually inspect the piston D and cylinder surfaces Replace the caliper if the cylinder and pi
241. nd if compressed air is not available disassemble the caliper before the brake hose is removed see Front Caliper Disassembly Rear Caliper Removal Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Rear Caliper Disassembly Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones e Tighten Torque Front Caliper Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Rear Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Check the fluid level in the brake reservoirs Bleed the brake line see Bleeding the Brake Line Check the brake for good braking power no brake drag and no fluid leakage 6105060151 C Calipers BRAKES 11 7 A WARNING Do not attempt to drive 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
242. nd may result in an unsafe riding condition Tighten both chain adjuster locknuts securely Tighten the axle nut Torque Rear Axle Nut 108 N m 11 kgf m 80 ft Ib Turn the wheel measure the chain slack again at the tight est position and readjust if necessary e Insert a new cotter pin and spread its ends Wheel Alignment Inspection Adjustment Check that the notch A on the left alignment indicator B aligns with the same swingarm mark or position C that the right alignment indicator notch aligns with x If they do not adjust the chain slack and align the wheel alignment see Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition 6512020851 Drive Chain FINAL DRIVE 10 5 Drive Chain Wear Inspection e Remove Chain Cover e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry Stretch the chain taut by hanging 98 N 10 kg 20 Ib weight A on the chain Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at se
243. ndicate internal leakage Check the cylinder head gasket and the water pump e Remove the pressure tester replenish the coolant and install the radiator cap 6005010951 C 6005011151 C Coolant COOLING SYSTEM 3 9 Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system Drain the cooling system see Coolant Draining 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 Stop the engine and drain the cooling system Fill the system with fresh water Warm up the engine and drain the system 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 Filling Coolant Filter Cleaning Refer to the chapter of carburetor in Fuel System for the cleaning procedures 3 10 COOLING SYSTEM Water Pump Water Pump Removal e Refer to O
244. nect the throttle sensor setting adapter to the sensor lead connectors see Throttle Sensor Inspection Special Tool Throttle Sensor Setting Adapter 57001 1521 e Loosen the throttle sensor mounting screws A e Turn on the ignition switch e When installing the sensor tighten the screws gradually and alternately Torque Throttle Sensor mounting Screw 3 4 N m 0 35 kgf m 30 in Ib e Adjust the position of the throttle sensor until the output voltage is within the specified voltage Throttle Sensor Output Voltage Standard 0 95 1 05 V x If it is not within the specified voltage replace the sensor When installing the sensor tighten the screws gradually and alternately Torque Throttle Sensor Mounting Screw 3 4 N m 0 35 kgf m 30 in Ib 15 72 ELECTRICAL SYSTEM Switches and Sensors Speed Sensor Inspection e Remove Speed Sensor see Final Drive chapter Connect the speed sensor connector A with the battery B 10 resistor C and hand tester D as shown Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 Trace A each side of the speed sensor surface with the screw driver OThen the tester indicator should flick B x If the tester indicator does not flick replace the speed sensor DC25V GP18070181 C Junction Box ELECTRICAL SYSTEM 15 73 The junction box A has fuses B relays and diodes The relays and
245. ng surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives therefore make sure to wipe it off and apply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To rotate the crankshaft manually make sure to do so in the direction of positive rotation Pos itive rotation is counterclockwise as viewed from the left side of the engine To carry out proper adjustment it is furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their original function once they are removed There fore always replace these parts with new ones every time they are removed Although the pre viously mentioned gasket O ring ball bearing needle bearing grease seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Leads All the electrical leads are either one color or two color A two color lead is identified first by the primary color and then the stripe color For example a yellow lead with thin red stripes is referred to as a
246. ng Rod Removal Split the crankcase see Crankcase Splitting Remove the connecting rod nuts Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions Remove the connecting rods from the crankshaft CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no 8105060151 8 10 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse them Replace the connecting rod big end bolts and nuts with new ones Apply engine oil to the inner surface of upper and lower bearing inserts A Apply a small amount of the engine oil to the threads B and seating surface C of the connec
247. nge Readjust if necessary Synchronization Inspection Start the engine and warm it up thoroughly Check the idle speed see Idle Speed Inspection Remove the fuel tank and air cleaner housing see Fuel Tank Removal and Air Cleaner Housing Removal Supply fuel to the carburetors with an auxiliary fuel tank For the models other than the California model remove the 1 4 carburetor vacuum hose plugs and 2 3 carbu retor vacuum hose fitting Connect the suitable pipe joints A to the carburetor vac uum hoses B and vacuum gauge hoses C Install the air cleaner housing Connect the vacuum gauge hoses to a vacuum gauge A Start the engine and let it idle to measure the carburetor intake vacuum x If the vacuum is incorrect adjust the synchronization Carburetor Synchronization Vacuum Standard Less than 2 7 kPa 2 cmHg difference between any two carburetors Carburetors FUEL SYSTEM 2 9 Synchronization Adjustment Turn the adjusting screw to synchronize the carburetors OApply grease to the tip of the adjusting screw threads OFirst synchronize the left two and then the right two car buretors by means of the left and right adjusting screws A C Then synchronize the left two carburetors and the right two carburetors using the center adjusting screw B xIf the carburetor synchronization cannot be obtained by using the adjusting screws check for dirt or blockage
248. nspect Brake pad wear Inspect e e e e Steering Inspect 1 Rear shock absorber oil leak Inspect T e e e Front fork oil leak Inspect T e e e Tire wear Inspect T e e e e e e Swingarm pivot Unit trak linkage lubricate General lubrication perform Nut bolts and fasteners tightness Inspect y S Drive chain lubricate 600 km Drive chain slack Inspect 1000 e e e e e e e Brake hoses connections Inspect T Brake fluid level Inspect T month e e e e e e Clutch adjust Inspect 1 month e e e Radiator hoses connections Inspect T Brake master cylinder cup and dust cover replace edie Coolant change 2 years Caliper fluid seal and dust seal replace 4 years Steering stem bearing lubricate 2 years 1 10 GENERAL INFORMATION Periodic Maintenance Chart United States and Canada Models FREQUENCY Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile Sg 4 726 42 48 24 30 AS OPERATION Every 0 6 4 7 5 12 15 20 24 Coolant filter clean year Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here Replace add adjust cle
249. o avoid clutch plate seizure Olnstall the last friction plate A fitting the tangs in the grooves in the housing as shown GF06040181 C CLUTCH 5 9 Clutch e Apply molybdenum disulfide grease to the pusher end A and install the bearing B pusher C spring D and washer E in the clutch spring plate F GFOG005BS1 C e Install the clutch spring plate and spring and tighten the clutch spring bolts Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the clutch cover see Clutch Cover Installation Clutch Plate Assembly Inspection Inspect the friction plate thickness see Clutch Plate Wear Damage Inspection e Measure the length A of the clutch plate assembly as shown OAssemble Clutch Hub B Spring Seat C Spring D Friction Plate E Steel Plte F Spring Plate G Springs H Spring Holders I Spring Bolts J OTighten Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib Clutch Plate Assembly Standard 37 7 38 3 mm 1 48 1 51 in xIf the length is not within the specified range adjust the length see Clutch Plate Assembly Adjustment GF06137BS2 C 5 10 CLUTCH Clutch Clutch Plate Assembly Adjustment Inspect the clutch plate assembly length and then place the steel plate s which brings the length within the specified range ORemove Spring Bolts Spring Holders Springs Spring Plate Rep
250. o by referring to the coolant manufacturer s directions Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine Check the coolant level in the reserve tank after the en gine cools down x If the coolant level is lower than the low level line add coolant to the full level line CAUTION Do not add more coolant above the full level line Pressure Testing Remove Lower Fairing see Frame chapter e Remove the radiator cap and install a cooling system pressure tester A on the filler neck NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 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 18 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is all right If the pressure drops and no external source is found check for internal leaks Droplets in the engine oil i
251. of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end On a surface plate set the big end arbor on V block 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 connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in 6105040451 6105011651 6105040651 CRANKSHAFT TRANSMISSION 8 13 Crankshaft and Connecting Rods Connecting Rod Twist Inspection e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance Inspeciton Measure connecting rod big end side clearance A Olnsert a thickness gauge B between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 33 mm
252. om full open to close and the throttle closes quickly and completely in all steering positions by the return spring If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e 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 does not change x If the idle speed increase check the throttle cable free play and the cable routing Throttle Grip Free Play Adjustment Loosen the locknuts A and screw both throttle cable ad justers in completely so as to give the throttle grip plenty of play Turn out the decelerator cable adjuster B until there is no play when the throttle grip is completely closed Tighten the locknut Turn the accelerator cable adjuster C until 2 mm 0 08 0 12 in of throttle grip play is obtained Tighten the locknut Throttle Cable Installation Install the throttle cables in accordance with Cable Wire and Hose Routing section in the General Information chapter Install the lower ends of the throttle cables in the cable bracket on the carburetor after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Throttle Cable Lubrication and
253. on 2 25 Carburetor Joining 2 14 Canister Inspection 2 25 Carburetor Cleaning 2 15 Vacuum Valve Inspection 2 26 Carburetor Inspection 2 15 Coolant Filter Cleaning Other than United States and Canada Models eret 2 17 2 2 FUEL SYSTEM Exploded View 1 Air Cleaner Housing 2 Air Cleaner Element 3 Air Vent Filter 4 Vacuum Switch Valve 5 Silencer Assy CAL Model 6 Vacuum Hose Assy CAL Model 7 Carburetor Vent Hose CAL Model AO Apply high quality form air filter oil CAL California 6602060484 FUEL SYSTEM 2 3 Exploded View 6602060584 1 Throttle Cable accelerator 11 Throttle Sensor 2 Throttle Cable decelerator 12 Fuel Cut Valve CAL H Models 3 Choke Cable 13 Cooling Hose Assy other than US CA 4 Pilot Screw Models 5 Pilot Slow Jet 14 Vent Hose Assy CAL Model 6 Pilot Slow Air Jet CL Apply cable lubricant 7 Needle Jet Holder G Apply grease 8 Main Jet H WVTA Approval Model with Honeycomb 9 Plug US CA Models Catalytic Converter 10 Jet Needle CA Canada CAL California United States c Wa 2 4 FUEL SYSTEM Exploded View 1 2 3 4 5 6 7 1 4 CAL Fuel Pump Fuel Filter Seal CAL Model Evaporative Emission Control System CAL Model Vacuum Valve Separator Canister 2 5
254. on wet sump with cooler lt Engine Oil Grade API SE SF or SG c API SH SJ with JASO MA ZX600J1 J4 J6F API SH SJ or SL with JASO MA ZX600J7F Viscosity SAE10W 40 10W 50 20W 40 or 20W 50 SAE10W 40 Capacity 4 0 L 4 23 US qt Drive Train Primary Reduction System Type Gear Reduction Ratio 2 022 89 44 Clutch Type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear Ratios 1st 2 923 38 13 lt 2 2 062 33 16 lt 1 631 31 19 lt 4th 1 380 29 21 5th 1 217 28 23 1 083 26 24 Final Drive System Type Chain drive lt Reduction Ratio 2 666 40 15 lt Overall Drive Ratio 5 843 Top gear Tubular diamond Caster Rake Angle 23 5 Trail 95 mm 3 7 in Front Wheel Tire Type Tubeless Tire Size 120 65 ZR17 56 W 120 65 ZR17 M C 56 W Rim Size J 17M C x MT3 50 Rear Wheel Tire Type Tubeless Tire Size 180 55 ZR17 73 W 180 55 ZR17 M C 73 W Rim Size J 17M C x 5 50 1 8 GENERAL INFORMATION General Specifications Items ZX600 J1 J2 ZX600 J3 Front Suspension Type Telescopic fork Wheel Travel 120 mm 4 7 in Rear Suspension Type Swingarm uni trak Wheel Travel 135 mm 5 3 in Brake Type Front Dual discs Single disc Electrical Equipment Battery 12 V 8 Ah Headlight Type Semi sealed beam Bulb 12 V 60 55 W quartz halogen 2
255. one To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground Connect the hoses according to the diagram of the sys tem Make sure they do not get pinched or kinked Route hoses with a minimum of bending so that the air or vapor will not be obstructed 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 gasoline flows into the breather hose remove the hose and blow it clean with compressed air Hose Inspection Check that the hoses are securely connected Replace any kinked deteriorated or damaged hoses Separator Inspection Remove the seats see Frame chapter e Disconnect the hoses from the liquid vapor separator and remove the separator from the motorcycle e Visually inspect the separator for cracks and other dam age x If the separator has any cracks or is badly damaged re place it with a new one FUEL SYSTEM 2 25 Evaporative Emission Control System California Model Only Separator Operation Test A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with
256. ont Fender Mounting Bolts Prefixes for Units Prefix 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 Mass kg x 2 205 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 kg N x 0 2248 Ib kg x 9 807 N kg x 2 205 Ib Units of Temperature F 40 C 40 20 68 60 20 i 267 104 176 212 80 100 120 140 160 1180 200 1220 240 260 280 300 APPENDIX 16 9 Unit Conversion Table Units of Length 48 9 km x 0 6214 mile m x 3 281 ft mm x 0 03937 in Units of Torque N m x 0 1020 kom N m x 0 7376 ft Ib N m x 8 851 in Ib kg m x 9 807 N m kom x 7 233 16 kom x 86 80 in Ib Units of Pressure kPa x 0 01020 kg cm kPa x 0 1450 psi kPa x 0 7501 cm Hg kg cm x 98 07 kPa kg cm x 14 22 psi cm Hg x 1 333 kPa Units of Speed km h x 0 6214 mph Units of Power kW x 1 360 PS kW x 1 341 HP PS x 0 7355 kW PS x 0 9863 HP 5 F 40 i 100 93 3 116 LEE 248 1120 284 1140 138 F 320 160 C MODEL APPLICATION Year Model Beginning Frame No JKAZX4J10YA000001 or 2000 ZX600 J1 JKAZX600JJA000001 JKAZX
257. or Fan Radiator Inspection Check the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x If the air passages of the radiator core are blocked more than 2096 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 64 ft B from the radiator core Hold the steam gun perpendicular to the core sur face Run the steam gun following the core fin direction Radiator Cap Inspection e Check the condition of the top A and bottom B valve seals and valve spring C If any one of them shows visible damage replace the cap with a new one e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge hand flicks downward Stop pumping and measure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure 2 Standard 93 123 kPa 0 95 1 25 kgf cm 14 18 psi x If the cap cannot
258. 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 wiped up imme diately 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 11 22 BRAKES Brake Hose Brake Hose Removal Installation CAUTION Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wiped up immediately with wet cloth 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 temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e There are washers on each side of the brake hose fitting Replace them with new ones when installing e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in General Infor mation chapter e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line after installing the brake hose see Bleeding the Brake Line Brake Hose Inspection The high pressure inside the brake line can cause fluid to leak or the hose to burst if the
259. osition on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C 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 Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Use the same manufacture s on both front and rear wheels Inspect the rim and tire and replace them if necessary Clean the sealing surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve 6J05006BS1 C Tires WHEELS TIRES 9 13 Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the air valve A through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubbe
260. oth A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper 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 Remove the dust seal and fluid seal e Remove the bleed valve and rubber cap 6105040251 6105012851 Calipers BRAKES 11 9 NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pads and spring see Rear Brake Pad Re moval OPump the brake pedal to remove the caliper piston Rear Caliper Assembly Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Tighten Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Replace the fluid seal A with a new OApply brake fluid to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one if it is damaged OApply brake fluid to the dust seal and install it into the cylinder by hand Apply brake fluid to the outside of the piston and push it into the cylinder by hand Replace the shaft rubber boot A a
261. part of the lower fairing outward to clear the stoppers D Remove the lower fairing Remove the other side lower fairing in the same manner NOTE OWhen removing the left and right lower fairings at the same time do not remove the screws B both sides and stoppers D Inner Upper Fairing Removal e Remove Screws A Inner Upper Fairing B Inner Lower Fairing Removal Remove Lower Fairing Left or Right Other Side Inner Fairing Screw B Inner Lower Fairing A Upper Fairing Removal Remove Inner Upper Fairings Spring Bands A Left and Right Screws B Left and Right Fairings FRAME 14 7 e Remove Rear View Mirrors A Bolts B e Remove Air Vent Filter Hose A Headlight Turn Signal Light Lead Connector B Upper Fairing 14 8 FRAME Seat Covers Seat Cover Removal Remove Seats Bolts and Grab Rails A Screws and Seat Lock B Screws C Left and Right Pull the seat cover backward Seat Cover Installation Set the seat cover A and insert the rivet B into the holes in the seat cover and rear fender e Push in the screw C into the rivet Install the grab rails and tighten the bolts Torque Grab Rail Bolts 25 N m 2 5 kgf m 18 16 e Install the remove parts FRAME 14 9 Fenders Front Fender Removal Remove Brake Hose Clamps A Left and Right Bolts B and Screws C Left and Right Remo
262. passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low 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 Steering stem locknut too tight 16 6 APPENDIX Troubleshooting Guide 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 pivot bearings worn Rim warped or not balanced Wheel bearing worn Handlebar clamp bolts loose Steering stem head nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or l
263. pecial Tool Valve Guide Reamer 4 57001 1274 Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Inlet 0 03 0 12 mm 0 0012 0 0047 in Exhaust 0 10 0 18 mm 0 004 0 007 in Service Limit Inlet 0 29 mm 0 011 in Exhaust 0 35 mm 0 014 in GE150306 5 GE15010481 ENGINE TOP END 4 25 Valves Valve Seat Inspection Remove the valve see Valve Removal Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Inlet 26 4 26 6 mm 1 039 1 047 in Ex
264. per Fluid Seal Damage Brake Inspechon nssensseeeeeeeeeeeeeeeeeeeea 11 10 Brake Disc Caliper Dust Seal Rubber Boot Brake Disc Installation Damage Inspection 11 10 Brake Disc Wear Inspection Caliper Piston and Cylinder Brake Disc Warp Inspection Damage Insepction 11 10 Brake Caliper Holder Shaft Wear Level Inspection e e BETEN 11 10 Brake Fluid Change Brake Pads eet es 11 11 Bleeding the Brake Line Front Brake Pad Remowval 11 11 Brake b Es Front Brake Pad Installation 11 11 Brake Hose Removal Installation 11 22 Rear Brake Pad Removal 11 11 Brake Hose 11 22 11 2 BRAKES Exploded View 6L02060384 1 Brake Rod Joint Cotter Pin T8 18 N m 1 8 kgf m 13 ft lb 2 Brake Pedal Bolt T9 21 2 1 kgf m 15 16 T1 1 0 0 10 kgf m 9 in Ib T10 27 N m 2 8 20 16 T2 1 5 0 15 kgf m 13 in Ib T11 25 N m 2 5 kgf m 18 ft lb 2 9 0 30 26 in Ib T12 34 3 5 25 ft lb T4 5 9 0 60 52 in Ib Apply brake fluid 6 9 N m 0 70 kgf m 61 Apply grease 6 7 8 0 80 69 in Ib Apply a non permanent
265. perform the work above it ORemove the spring and pads see Front Brake Pad Re moval OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper GLO5011BS1 11 8 BRAKES Calipers Front Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Tighten Torque Bleed Valve 7 8 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply brake fluid to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply brake fluid to the dust seals and install them into the cylinders by hand e Replace the O rings A if they are damaged e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the O rings e Tighten the caliper assembly bolts Torque Front Caliper Assembly Bolts 21 N m 2 1 kgf m 15 ft Ib e Install the pads see Front Brake Pad Installation e Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly e Remove the rear caliper e Remove the pads and anti rattle spring see Rear Brake Pad Removal e Using compressed air remove the piston OCover the caliper opening with a clean heavy cl
266. pilot light Drain the coolant For the other than US amp CA models see Cooling System chapter Remove Seats see Frame chapter Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal Vent Hose Fuel Hose Coolant Hoses For the other than US amp CA Models Throttle Sensor Connector Fuel Cut Valve Connectors CAL and H Model 6606016751 2 12 FUEL SYSTEM Carburetors Loosen the carburetor clamp screws A and remove the carburetors Remove the throttle cable ends and choke cable Stuff pieces of lint free clean cloth into the carburetor holders to keep dirt out of the engine If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Carburetor Installation Route the cables harness and hoses correctly see Gen eral Information chapter Tighten the clamps for the carburetor holders at the posi tion in the figure Be sure to install the holder clamp screws in the di rection shown Or the screws could come in con tact with the throttle linkage resulting in unsafe rid ing condition Check fuel leakage from the carburetors A WARNING Fuel spilled from the carburetors is hazardous e Adjust the following items if necessary Id
267. r OThe air valve is shown in the figure A Valve Cap B Valve Core C Stem Seal D Valve Stem E Valve Seat F Valve Opened e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads Check the tire rotation mark the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B e Position the tire on the rim so that the air valve A is at the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire 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 57 psi Overinflation can explode the tire with possibility of injury and loss of life 6J05005BS1 C 9 14 WHEELS TIRES Tires Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core
268. r Rear View Mirror Bracket Brake Hose Joint Bolt A and Bracket Bolt A Front Wheel see Wheels Tires chapter Front Fork see Suspension chapter Steering Stem Head Nut and Washer Steering Stem Head and Handlebars e Pushing up the stem base and remove the steering stem lock nut A steering stem nut B stem cap C then re move the steering stem D Special Tool Steering Stem Nut Wrench 57001 1100 e Remove the upper ball bearing inner race e To remove the bearing outer races A pressed into the head pipe B insert a bar C into the recesses D of head pipe and applying it to both recess alternately hammer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones e Remove the lower bearing inner race with its grease seal which is pressed onto the steering stem with a suitable commercially available bearing puller Steering Stem 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 57001 1075 A Head Pipe Outer Race Driver 55 57001 1446 B Head Pipe Outer Race Driver 47 57001 1447 C GN05040281 C 13 6 STEERING Steering Stem Replace the bearing inner races wi
269. r Rectifier Lead Clamp Band Main Harness Battery Cable Coolant Reserve Overflow Hose Cable Wire and Hose Routing GENERAL INFORMATION 1 39 H cs In Li T M 4 5 6809061513 NETS Rear Brake Switch Lead Battery Alternator Lead Connector Battery Cable Starter Relay Junction Box IC Igniter Fuel Pump Relay Headlight Fuse Lead Turn Signal Relay Tail Brake Light Lead Left Turn Signal Light Lead Right Turn Signal Light Lead Clamp 1 40 GENERAL INFORMATION Cable Wire and Hose Routing gt es P d 9 1 Headlight Turn Signal 12 Fuel Pump Relay Light Lead 13 Regulator Rectifier 2 Headlight Relay Lead 14 Rear Brake Light Switch 3 Horn 15 Starter Relay 4 Radiator Fan Switch 16 Run the speed sensor lead 5 Alternator under the clamp 6 Neutral Switch 17 Clamp Speed Sensor Lead 7 Speed Sensor Side Stand Switch Lead 8 Side Stand Switch Lead Neutral Switch Lead Alter 9 Speed Sensor Lead nator Lead 10 Junction Box 18 Clamp Main Harness Reg 11 IC Igniter ulator Lead Oil Pressure Switch Lead 68809061644 C Engine Battery Ground Cable Clamp Oil Pressure Switch Lead Main Harness Regulator Rectifier Lead Speed Sensor Lead Si
270. r element A see this chapter Clean the element in bath of high flash point solvent and then dry it with compressed air or by shaking it e After cleaning saturate a clean lint free towel with SE SF or SG class SAE 30 oil and apply the oil to the element by tapping the element outside with the towel Visually check the element for tears or breaks x If the element has any tears or breaks replace the ele ment FUEL SYSTEM 2 19 Air Cleaner Air Cleaner Housing Removal e Remove Seats see Frame chapter Fuel Tank see Fuel Tank Removal Engine Breather Hose A Rubber Plugs B Fuel Cut Valve Connectors C California and H Models Remove Air Cleaner Housing Mounting Bolts A Free the main harness from the clamp B OPull up the rear of the housing and then remove it from the air ducts Air Cleaner Housing Installation Insert the housing into the air ducts A securely and fit the projection B of the housing in the recess of the air ducts Tighten Housing Mounting Bolts e Be sure to fit the engine breather hose Install the rubber plugs in place Air Vent Filter Cleaning Slide the clamps of air vent filter and remove the filter Clean the filter by directing a stream of compressed air from clean side A to dirty side B 2 20 FUEL SYSTEM Fuel Tank Fuel Tank Removal Gasoline is extremely flammable and can be ex plosi
271. re is below 55 C 131 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is 58 62 C 136 144 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 96 100 C 205 212 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 91 C 196 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 excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95
272. rect position B Footpeg Pedal Position Standard About 57 mm 2 24 in C below top of footpeg x If it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when push rod locknut has been loosened e Remove the rear master cylinder cover B and then tighten the master cylinder bolts A only e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x If the length C shown is 65 1 mm 2 56 0 04 ml 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 e Checkthe brake light switch operation see Electrical Sys tem chapter 11 6 BRAKES Calipers Front Caliper Removal Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc CAUTION Do not loosen the caliper assembly bolts D Take out only the caliper mounting bolts for caliper re moval Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hose E from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal a
273. ree play A Measure the gap between the lever and the lever holder x If the gap is too wide the clutch not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in Clutch Lever Free Play Adjustment A WARNING To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible Slide the dust cover A at the clutch cable lower end out of place Loosen both adjusting nuts B at the clutch cover as far as they will go Pull the clutch outer cable C tight and tighten the adjust ing nuts against the bracket D Slip the rubber dust cover back onto place Turn the adjuster at the clutch lever until the free play is correct e Push the release lever A toward the front of the motor cycle until it becomes hard to turn OAt this time the release lever should have the proper an gle shown x If the angle is wrong check the clutch and release parts for wear WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement After the adjustment start the engine and check that the clutch does not slip and that it releases proper
274. rent Starts to flow D 0 25 50 75 100 Battery Charge 4 le Terminal Voltage V Refreshing Charge t B Good is required 8 08010951 C 8 08011051 C Charge Time h 9 1 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V 4208021851 8 08011451 C 15 26 ELECTRICAL SYSTEM Battery Determine battery condition after refreshing charge ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below 12 0 12 8 V or lower Charge insufficient gt Recharge 12 0 V or lower Unserviceable Replace Charging System ELECTRICAL SYSTEM 15 27 Alternator Cover Removal Remove Left Lower Fairing see Frame chapter Coolant Reserve Tank A Fuel Tank see Fuel System chapter Alternator Lead Connector B e Place a suitable container under the alternator cover C and remove the cover Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Kawasaki Bond Silicone Sealant 56019 120 Check that knock pins B are in place on the crankcase Install a new gasket and the alternator cover Tighten Torque Alternator Cover Bolts 12 1 2 k
275. riginal positions Olf there is no clearance select a shim which is several sizes smaller and then measure the clearance To select a new shim which brings the valve clearance within the specified range refer to the Valve Clearance Adjustment Charts e Apply a thin coat of molybdenum disulfide grease to the valve lifters e Install the camshafts Be sure to time the camshafts prop erly see Camshaft Installation any valve clearance that was adjusted Readjust if necessary CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage ENGINE TOP END 4 21 Valves VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE PRESENT SHIM Example PART No 92180 10141016 1018 1020 1022 1024 1026 1028 11030110321 1034 1036 1038 1040 1042 1044 1046 1048 1050 1052 1054 5 56 es 70 75 80 86 90 95 05 10 15 20 25 30 as 4o 45 50 THICKNESS mm 2 50 2 56 2 60 2 85 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 26 3 30 3 35 3 40 3 46 3 50 _ 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 2 89 2 55 2 60 2 66 2 70 2 75 2 80 2 85 2 90 2 5 3 00 3 05
276. rious positions it is well balanced x If the wheel always stops in one position adjust the wheel balance GJ04130BS1 6J04018BS1 C 6J04041381 C 9 8 WHEELS TIRES Wheels Rims Balance Adjustment elt the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape 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 x If 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 Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced Repeat the entire procedure as many times as necessary to achieve correct wheel balance Permanently install the balance weight Balance Weight Removal 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 When the tire is on the rim 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 we
277. rminal G BK Lead Hand Tester Terminal D Frame Ground Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn the ignition switch on and push the starter button e Read the voltage Side Stand Switch Operation Voltage 6 13 4 V x If the tester reading is not specified one check the side stand switch starter lock out switch gear position sensor and starter circuit relay x If the tester reading is correct check the following e Grasp the clutch lever and start the engine OSide stand ON position transmission gear first position e Release the clutch lever slowly x If the engine does not stop after releasing the clutch lever fully the IC igniter is defective NOTE OSome inspections as to the IC igniter are operated but the cause of troubles may be not able to clear enoughly If the cause of troubles are not cleared in described inspections replace the IC igniter with a new one CAUTION Use only Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the IC igniter will be damaged 15 44 ELECTRICAL SYSTEM Ignition System CDI Unit Troubleshooting m 1 IC igniter or crankshaft sensor is damaged 2 Even if the preceding checks show good it may be defective in some manner not readily detectable with igniter checker peak voltag
278. rs B in addition to the secondary air injection system Moreover a BDSR 36 type carburetor has been adopted because of its good balance between cost and performance As a result we can reduce the exhaust gas emission below the current standards without hurting the output performance and the actual riding feeling at all The harmful ingredients in the exhaust gas are reduced considerably under running performance of emission regulation like LA4 or EC mode As actual examples carbon monoxide CO is reduced about 70 hydrocarbons HC about 60 nitrogen oxides NOx about 10 Moreover in order to improve the reliability of the system we install fuel cut valves C as a catalyst protection system Exhaust Gas after Purification Exhaust Gas after Muffler e e ae Purification Efficiency 12 13 14 15 16 17 Air Fuel Ratio after Main Catalytic Converter C Kawasaki Low Exhaust Emission System bs ee 1 6806060582 1 14 GENERAL INFORMATION Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION 1 Exhaust Purification System The burned gas which goes out from the combustion chamber is injected with secondary air adding necessary oxygen and is cleaned up while passing through the small precatalytic converters in the joint pipe and the main catalytic converter in the silencer and then goes out to the atmosphere Secondary Air Injection System 1 In order to ox
279. rter than the service limit it must be replaced Clutch Spring Free Length Standard 82 1 mm 3 23 in Service Limit 78 0 mm 3 07 in 6206060351 ENGINE LUBRICATION SYSTEM 6 1 Engine Lubrication System Table of Contents Exploded 6 2 Engine Qil Fow d nm 6 3 Specifications wiv LE 6 4 Engine Oil ane e Ni M p 6 5 EUREN ee In EE 6 5 neet REEL 6 5 Oil Filter Change oar egt eR eec de Ro EUR UAR Ue 6 6 PAM Tum 6 7 Oll Pan REMOVAL E E E eda 6 7 OiliParn gl EC UE e 6 7 Oil Pressure Relief iur eee eh er Eed 6 8 Oil Pressure Relief Valve Removal eene nennen nennen nis 6 8 Oil Pressure Relief Valve 2 nnne 6 8 Oil Pressure Relief Valve Inspechon 6 8 UE TA 6 9 Oil PUMP Rermoval x eee ge ee Pere e tet he ee Da c 6 9 Oil Pump E UE e 6 9 Oil Pump Drive Gear Removal nennen nennen 6 10 Oil Pump Drive Gear Installatton 1 000000000000000000000 6 10 EU Lee rm 6 11 Oil GOGIEFIREMOVAl dads 6 11 Oil Cooler Iristall tiorniz oe See eege ett e i e e Een 6 11 Oil Pressure Measurement ret tution 6 12 Oil Pressure Measurement 6 12 Oil Pressure d cette
280. ry tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads Edges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent Gasket O Ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious dam age GENERAL INFORMATION 1 3 Before Servicing 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unle
281. s 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 should stop air flow Spring A Diaphragm B Valve C Low Vacuum D Secondary Air Flow E 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 Vacuum Switch Valve Closing Pressure Open Close Standard 57 65 kPa 430 490 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 air cleaner housing vacuum switch valve 1 and 4 carbu retor holders and air suction valve covers xIf they are not correct them Replace them if they are damaged 04070451 8 04010451 8 04010551 8 04010851 ENGINE TOP END 4 9 Cylinder Head Cover Cylinder Head Cover Removal e Remove Lower Fairing see Frame chapter Coolant drain see Cooling System chapter Other than US CAL Models Seats see Frame chapter Fuel Tank Air Cleaner Housing and Carburetor see Fuel System chapter Vacu
282. s will not function on the first appli cation of the lever or pedal if this is not done Front Caliper Disassembly e Loosen the front caliper assembly bolt A and banjo bolt B and tighten them loosely Remove Front Caliper C see Caliper Removal Brake Pads Front Caliper Assembly Bolts O rings e Using compressed air remove the pistons One way to remove the pistons is as follows Olnstall a rubber gasket A and a wooden board B more than 10 mm thick on the caliper half and fasten them together with a suitable bolt and nut as shown Leave one of the oil passages C open OLightly apply compressed air D to the oil passage until the pistons hit the rubber gasket Block the hose joint opening E during this operation if the caliper half has the opening F Bolt and Nut G Oil Passage sealed by Rubber Gasket H Push down A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the pistons by hand Remove the dust seals A and fluid seals B Remove the bleed valve C and rubber cap D Repeat the previous step to remove the pistons from the other side of the caliper body NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and
283. sc does not touch the ground Rear Wheel Installation e Engage the drive chain with the rear sprocket Install the caliper bracket A onto the swingarm stop B Olnsert the axle from the right side of the wheel and tighten the axle nut Torque Rear Axle Nut 127 N m 13 kg m 94 ft Ib Install a new cotter pin NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut e Adjust the drive chain slack after installation see Final Drive chapter e Install the rear caliper and the chain cover e Check the rear brake effectiveness 6J04071BS1 C 6J04072BS1 C A WARNING Do not attempt to drive 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 Wheels Rims WHEELS TIRES 9 7 Wheel Inspection Raise the front rear wheel off the ground Special Tool Jack 57001 1238 Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings Inspect the wheel for small cracks dents bending warp x If
284. se until it just be comes hard to turn Do not overtighten or the steering will be too tight Special Tool Steering Stem Nut Wrench 57001 1100 A Torque Steering Stem Nut 15 1 5 kgf m 11 ft Ib Steering Stem Lock Nut 4 9 N m 0 5 kgf m 43 in Ib e Install the front fork see Suspension chapter GNO5060581 C STEERING 13 7 Steering Stem NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolts Torque Steering Stem Head Nut 49 N m 5 0 kgf m 36 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 5 ft Ib Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 14 5 ft lb A WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Gen eral Information chapter Steering Stem Bearing Lubrication Remove the steering stem e Using a high flash point solvent wash the upper and lower ball bearings in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage Pack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races Install the steering stem and adjust the steering Steering Stem Warp Inspection When
285. ss 171 kg 377 Ib CAL 173 kg 382 Ib 172 kg 379 Ib Curb Mass Front 100 kg 221 Ib 96 kg 212 Ib CAL 98 kg 216 Ib 97 kg lt 214 Ib Fuel Tank Capacity 18 L 4 76 US gal Minimum Turning Radius 3 2 m 10 5 ft Engine Type 4 stroke DOHC 4 cylinder lt Cooling System Liquid cooled lt Bore And Stroke 66 x 43 8 mm 2 60 1 72 in Displacement 599 cm 36 6 cu in lt 12 8 lt 81 6 kW 111 PS 12 500 r min rpm lt AU 80 6 kW 109 6 PS 12 500 r min rpm PR 78 2 kW 106 3 PS 12 500 r min rpm US Maximum Torque 65 6 6 7 kgf m 48 ft lb 10 000 r min rpm AU 64 6 N m 6 6 kgf m 48 10 10 000 r min rpm US Carburetion System Carburetors Mikuni BDSR 36R 4 Starting System Electric starter Ignition System Battery and coil transistorized Timing Advance Electronically advanced digital igniter Ignition Timing From 12 5 BTDC 1 300 r min rpm to 42 5 BTDC 5 000 r min rpm Spark Plug lt Cylinder Numbering Method Left to right 1 2 3 4 Firing Order 1 2 4 3 Valve Timing Inlet Open 56 BTDC 80 ABDC Duration 316 GENERAL INFORMATION 1 7 General Specifications Exhaust Open 61 BBDC 33 ATDC Duration 274 Lubrication System Forced lubricati
286. ss it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while the motorcycle is driven leading to a major problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any slidi
287. ssembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation or assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assem bled in the same way It is preferable to mark and record the locations and routing whenever possible Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a part first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessa
288. sting In either case flush the cooling system x lf the coolant gives off an abnormal smell check for cooling system leak It may be caused by exhaust gas leaking into the 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 mo torcycle held perpendicular If the coolant level is lower than the low level line A add coolant to the full level line B 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 en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant Draining 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 Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking
289. ston rod nut B against the top plug Torque Piston Rod Nut 28 N m 2 9 kgf m 21 ft Ib e Raise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation Front Fork Disassembly e Remove the front fork see Front Fork Removal e Drain the fork oil see Fork Oil Change e Hold the front fork in a vise A e Stop the cylinder B from turning by using the fork cylinder holder C Special Tool Fork Cylinder Holder Hex 24 x 119 5 57001 1406 e Unscrew the Allen bolt D then take the bolt and gasket out of the bottom of the inner tube 6 04021151 C 12 12 SUSPENSION Front Fork Take the cylinder unit A ODo not disassemble the cylinder unit e Separate the inner tube from the outer tube as follows OSlide up the dust seal A ORemove the retaining ring B from the outer tube OGrasp the inner tube and stroke the outer tube up and down several times The shock to the fork seal separates the inner tube from the outer tube x If the tubes are tight use a fork outer tube weight Special Tool Fork Outer Tube Weight 57001 1218 Remove the inner tube guide bushing A outer tube guide bushing washer oil seal from the inner tube Remove the cylinder base from the bottom of the outer tube Front Fork Assembly Replace the following parts with new Oil Seal Guide Bushings Bottom All
290. ston are badly scores or rusty Front Caliper F Rear Caliper G Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts E If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber boots are not dam aged If the rubber boot is damaged replace the rubber boot To replace the rubber boot remove the pads and the caliper bracket x If the caliper holder shaft is damage replace the caliper bracket 6105060351 C Brake Pads BRAKES 11 11 Front Brake Pad Removal e Remove Pad Spring Bolts A Pad Spring B Clip A Pad Pin B Brake Pads C Front Brake Pad Installation Push the caliper pistons in by hand as far as they will go e Install the brake pads Install the pad pin and clip The clip must be outside of the pads Install the pad spring and tighten the pad spring bolts Torque Front Brake Pad Spring Bolts 2 9 N m 0 30 kgf m 26 in Ib A WARNING Do not attempt to 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
291. sulfur S are included the purification efficiency decreases 3 Coasting such as cranking while going down a slope is prohibited with the ignition system OFF The engine running without igniting causes a great flow of unburned gasoline and the decreasing of purification efficiency and melting down of catalysts at the activation temperature or higher 1 18 GENERAL INFORMATION Technical Information KLEEN KAWASAKI LOW EXHAUST EMISSION When the ignition switch A is turned off the fuel cut valves B do not work So avoid coasting with the ignition switch OFF e Do not run the engine nor coast the motorcycle under the misfire which occurs by defects such as a bad connection with the spark plug at the secondary wiring of the stick coil C Do not coast too much with the engine stop switch D OFF Under the condition that the engine stop switch is turned off during running the IC igniter E closes the fuel cut valves to shut off fuel Do not run the engine nor coast the motorcycle too much under the condition that the primary wiring of the stick coil does not connect completely misfire Incomplete connection or cut off of the pri mary coil makes the fuel cut valves start to cut fuel In this case from the standpoint to protect the catalysts the fuel for all cylinders is cut off even if one cylinder has been affected Kawasaki Low Exhaust Emission System Silencer 680608603 3
292. t seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter trouble Crankshaft sensor trouble Stick coil trouble Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Choke plunger stuck open Fuel level in carburetor float bowl too high or too low Fuel tank air vent obstructed APPENDIX 16 3 Troubleshooting Guide Fuel cut valve won t fully open check fuel cut valve and IC igniter Carburetor holder loose Air cleaner duct loose Air cleaner O ring damaged Fuel pump trouble Fuel pump relay trouble Fuel filter clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other IC igniter trouble Carburetor not synchronizing Carburetor vacuum piston doesn t slide smoothly Carburetor vacuum piston diaphragm da
293. ten Torque Rocker Arm Nut 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nut 59 N m 6 0 kgf m 43 ft Ib Rear Shock Absorber Nut 34 N m 3 5 kgf m 25 ft Ib Tie Rod Rocker Arm SUSPENSION 12 21 Rocker Arm Tie Rod Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Remove may damage them Visually inspect the swingarm sleeves and needle bear ings e The 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 If there is any doubt as to the condition of any of the nee dle bearings or sleeve replace the sleeve and needle bearings as a set Rocker Arm Tie Rod Lubrication e Apply grease to the inner surfaces of the needle bearings in accordance with the Periodic Maintenance Chart e Apply a thin coat of grease to the lips of the grease seals STEERING 13 1 Steering Table of Contents Exploded VieW osese 13 2 eelere IT 13 3 US STIG tates dh 13 4 Steering o 13 4 lte Be E d LEE 13 4 String Sterti EE 13 5 Steering Stem Stem Bearing 13 5 Steering Stem Stem Bearing 13 5 Steering Stem Bearing Lubrication
294. th new ones e Install the oil seal D on the steering stem and drive the lower ball bearing inner race A applied the grease onto the stem Special Tools Steering Stem Bearing Driver 642 5 57001 1344 B Steering Stem Bearing Driver Adapter 641 5 57001 1345 C Install the lower ball bearing A onto the stem e Apply grease to the upper ball bearing B and inner race C Install the stem through the head pipe and install the ball bearing and inner race on it Install stem cap A and steering stem nut B and hand tighten it and steering stem lock nut C Install the stem head Install the washer D and tighten the stem head nut lightly Settle the bearings in place as follows OTighten the steering stem nut with 15 N m 1 5 kgf m 11 ft lb of torque first and loosen it a fraction of a turn until it turns lightly To tighten the stem nut to the specified torque hook the wrench on the stem nut and pull the wrench at the hole by 84 N 8 3 kg B force in the di rection shown Afterward tighten it again with specified torque using a special tool A OTighten the steering stem lock nut with specified torque using a special tool A OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearing may be damaged OAgain back out the stem lock nut a fraction of turn until it turns lightly e Turn the stem lock nut lightly clockwi
295. that the ring opening A does not coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall 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 NOTE OThe oil ring rails have no top or bottom GE16003BS1 GE16040281 GE16002BS1 C GE16013081 C 4 32 ENGINE TOP END Cylinder Pistons Do not mix up the top and second ring Install the top ring A so that the R mark B faces up Olnstall the second ring C so that the RN mark D faces up Cylinder Wear Inspection Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown in the figure xIf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder A 10 mm 0 39 in B 60 mm 2 36 in Cylinder Inside Diameter Standard 65 960 65 972 mm 2 5968 2 5973
296. the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 6105040351 8 12 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Apply a small amount of engine oil to the threads A and seating surface B of the connecting rod nuts e First tighten the nuts to the specified torque Next tighten the nuts 160 more OMark A the connecting rod big end caps and nuts so that nuts can be turned 160 B properly Torque Angle 15 N m 1 5 kgf m 11 16 160 ZX600 J1 J3 Torque Angle 15 N m 1 5 kgf m 11 ft Ib 120 ZX600 J4 CAUTION Since the friction force of the mating surface and thread portion of new nuts is different from that of used ones the nut tightening torque should be changed as specified in the above table Be careful not to overtighten the nuts Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Inspection e Remove the connecting rod big end bearing insets and reinstall the connecting rod big end cap 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 Select an arbor
297. the gauge vertical align the middle line with the mark NOTE ODo not lower the middle line below the mark of the carburetor body If the gauge is lowered and then raised again the fuel level measured shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel into a suitable container and start the procedure over again Read the fuel level E in the gauge and compare to the specification Screw in the carburetor drain plug Stop feeding and remove the fuel level gauge x If the fuel level is incorrect adjust it see Service Fuel Level Adjustment Service Fuel Level below the mark on the carburetor body Standard 20 2 1 mm 0 80 0 04 in Service Fuel Level Adjustment A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 Remove the carburetor and drain the fuel into a suitable container e Remove the float bowl Slide out the pivot pin A with a suitable tool B and remove the float C and float valve needle D e Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard 7 2 mm 0 28 0 0
298. the ten sioner to expand and recheck the camshaft chain timing 4 12 ENGINE TOP END Camshaft Camshaft Chain Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Pickup Coil Cover Position the crankshaft at 1 4 piston TDC A TDC mark for 1 4 Pistons B Timing Mark crankcase halves mating surface e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Rubber Gaskets and Cylinder Head Cover Gasket Camshaft Cap Bolts Chain Guide A Camshaft Cap B Camshafts C 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 the chain and the sprocket Camshaft Installation Be sure to install the following parts A O rings B Pins e Apply engine oil to all cam parts and journals e If anew camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE OThe exhaust camshaft has a 117 EX mark A and the inlet camshaft has 117 IN mark Be careful not to mix up these shafts GE11060781 GE11011BS1 C ENGINE TOP END 4 13 Camshaft Camshaft Chain Position the crankshaft at 1 4 piston TDC
299. ting rod nuts OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a tight ening torque method Observe one of the following two but the bolt length measurement method is preferable be cause this is a more reliable way to tighten the big end nuts 1 Bolt Length Measurement Method Be sure to clean the bolts nuts and connecting rods thoroughly with high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 6105030151 CRANKSHAFT TRANSMISSION 8 11 Crankshaft and Connecting Rods Install new bolts in reused connecting rods Dent both bolt head and bolt tip with a punch as shown B
300. tion chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Crankshaft Sensor see Electrical System chapter Oil Hose Cylinder Head Lower Crankcase Clutch see Clutch chapter External Shift Mechanism see External Shift Mecha nism Removal Starter Motor see Electrical System chapter Oil Pump see Engine Lubrication System chapter Alternator Rotor see Electrical System chapter Oil Filter see Engine Lubrication System chapter Oil Cooler see Engine Lubrication System chapter xlIf the crankshaft is to be removed remove the pistons see Engine Top End chapter e Hold the timing rotor A steady with the holder B and remove the timing rotor bolt C and the rotor Special Tool Flywheel amp Pulley Holder 57001 1605 e Remove the upper crankcase bolts OFirst loosen the 6 mm bolts 7 mm Bolts A 6 mm Bolts B e Remove the oil pan oil screen and oil pipes see Engine Lubrication System chapter e Remove the lower crankcase bolts and brackets OFirst loosen the 6 mm bolts 6 mm Bolts A 8 mm Bolts B e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase 6104011151 CRANKSHAFT TRANSMISSION 8 7 Crankcase Splitting Crankcase Assembly NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crank
301. tive 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 intake 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 carburetion 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 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 what 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 o
302. 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 1999 Kawasaki Heavy Industries Ltd 7th Edition 1 Jun 26 2007 K 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 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 watt s h hour s 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 and California Air Resources Board Addi tionally Kawasaki has incorporated an evapora
303. ttempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth A Crankshaft Tapered Portion B Alternator Rotor Tapered Portion Apply a thin coat of molybdenum disulfide grease to the crankshaft C Install the starter gear A and washer B e Again clean the crankshaft tapered portion C and dry there Install the alternator rotor A while turning B it counter clockwise Charging System ELECTRICAL SYSTEM 15 29 Install the washer A so that the chamfer side B faces outward NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque Olnstall the rotor and tighten it with 70 N m 7 kgfm 52 ft lb of torque ORemove the washer and rotor bolt OCheck the tightening torque with rotor puller If the rotor is not pulled out with 20 N m 2 kgf m 15 16 of drawing torque it is installed correctly If the rotor is pulled out with under 20 N m 2 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque Tighten the alternator rotor bolt while holding the alterna tor rotor steady
304. ug after loosening the handlebar holder bolt and upper fork clamp bolt e Loosen the handlebar holder bolt A upper fork clamp bolt B and lower fork clamp bolts C e With a twisting motion work the fork leg down and out 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 Tighten Torque Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 14 5 ft Ib Front Fork Top Plugs 23 2 3 kgf m 16 5 ft Ib NOTE OTighten the top plug before tightening the handlebar holder bolt and upper fork clamp bolt e Tighten Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 5 ft lb e Adjust the spring preload and the damping force Fork Oil Change Remove the front fork see Front Fork Removal OTurn the spring preload adjuster A counterclockwise until the fully position Unscrew the top plug B out of the inner tube Front Fork SUSPENSION 12 9 Holding the piston rod nut A with a wrench B remove the fork top plug from the piston rod Remove Rebound Damping Adjuster Rod A Washer B Spacer C Washer A Fork Spring B Drain the fork oil into a suitable container OPump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M12 x
305. uickly C and pull it off upward disassemble the transmission Remove the ball bearing A from each shafts Special Tools Bearing Puller 57001 135 B Bearing Puller Adapter 57001 317 C Discard the bearing Transmission Shaft Assembly Install the ball bearing on the drive shaft with the groove toward the clutch side Install the gear bushing A on the shafts with their oil holes B aligned A BU Sr 61130302 S 6113040651 6113040851 CRANKSHAFT TRANSMISSION 8 21 Transmission The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place Install the 3rd 4th gear onto the drive shaft with their holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 5th and 6th gears onto the output shaft with their holes aligned e Fitthe steel balls into the 5th gear holes in the output shaft as shown View A A see CRANKSHAFT TRANSMISSION 8 24 A Gear 5th B Shaft C Steel Balls CAUTION Do not apply grease to t
306. um Valve California Model only Vacuum Switch Valve and Hoses Stick Coil see Electrical System Engine Side Cover A and Bolts B e Turn the handlebar to left side Remove Radiator Mount Bolts A Radiator Bracket Bolts B Radiator Bracket C Move the radiator toward the down and put the suit able support E under the radiator CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency Remove Baffle Plate Bolts A Baffle Plate B NOTE Olf the baffle plate cannot easily be removed remove the air suction valve covers Remove the cylinder head cover bolts A 4 10 ENGINE TOP END Cylinder Head Cover Remove the cylinder head cover A Cylinder Head Cover Installation e Replace the head cover gasket with a new one if dam aged Apply silicone sealant to the cylinder head as shown A Sealant Kawasaki Bond Silicone Sealant 56019 120 e Be sure to install the pins A and rubber gaskets B C e Install the washer with the metal side A faces upward Tighten Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 B Baffle Plate Bolts 9 8 N m 1 0 kgf m 87 in Ib 8 09010851 C Apply a non permanent locking agent to the threads of the engine side cover bolt A Tighten Torque Engine Side Cover Bolts 12 N m 1 2 kg
307. ure 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 Engine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine e Remove the engine drain plug A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Change Replace the drain plug gasket B with a new one if it is damaged e Tighten the drain plug Torque Engine Drain Plug 20 N m 2 0 kgf m 14 5 ft Ib e Pour in the specified type and amount of oil GG05005BS1 C Engine Oil ZX600 J1 J2 ZX600 J3 Grade API SE SF or SG API SH SJ or SL with JASO MA SAE 10W40 10W50 20W40 or 20W50 3 4 L 3 6 US qt when filter is not removed 3 6 L 3 8 US qt when filter is removed 4 0 L 4 2 US qt when engine is completely dry Viscosity SAE 10W40 Amount 6 6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter 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 Change Drain the engine oil see Engine Oil Change e Remove Left Lower Fairing see Frame chapter
308. uring date is printed on battery top Example 12 10 93 T1 Day Month Year Mfg location Note 1 Terminal voltage To measure battery terminal voltage use a digital voltmeter 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 the this chapter 15 24 ELECTRICAL SYSTEM Battery 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 safety valve operates to keep the battery safe 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
309. use they will not seal the bolts properly and fuel will leak e Be sure to clamp the fuel hoses to the tap to prevent leaks Torque Fuel Tap Bolts with white washer 2 5 N m 0 25 kg m 22 Fuel Tap Bolts with black washer 4 9 N m 0 50 kom 43 in Ib Fuel Tap Inspection Remove the fuel tap Check the fuel tap filter screens A for any breaks or de terioration x If the fuel tap screens have any breaks or are deterio rated they may allow dirt to reach the carburetor causing poor running Replace the fuel tap x If the fuel tap leaks or allows fuel to flow when it is at OFF position replace the damaged gasket B or O ring C 6609011151 C 6609011351 C FUEL SYSTEM 2 23 Fuel Pump Fuel Filter Fuel Pump Fuel Filter Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 e Remove Seats see Frame chapter Fuel Tank see Fuel Tank Removal Fuel Hose A Fuel Pump Lead Connector B Remove the fuel pump C and fuel filter D Fuel Pump Fuel Filter Installation e Install the fuel filter so that the arrow A on it shows the fuel flow from the fuel tank to the fuel pump Connect the fuel hose C from the fuel filter to the pump
310. used use new piston ring Install the pins A and new cylinder gasket Apply engine oil to the cylinder bore Prepare two auxiliary head bolts with their head cut Install the two bolts B diagonally in the crankcase The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring A Top Ring B Second Ring C Oil Ring Steel Rails D Oil Ring Expander E Hollow e Position the crankshaft so that all the piston heads are almost level Install the cylinder block A Auxiliary Head Bolts B Pistons C Insert the piston rings with your thumbs Piston Removal Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston 30 40 GE16012081 C Cylinder Pistons ENGINE TOP END 4 31 Remove the piston pins Special Tool Piston Pin Puller Assembly 57001 910 A e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation NOTE Olf a new piston is used use new piston ring Install the piston with its marking hollow facing forward e Fit a new piston pin snap ring into the side of the piston so
311. ve the front fender D Rear Fender Removal e Remove Seats Fuel Tank Seat Cover Junction Box Starter Relay Assy Turn Signal Relay Battery Rear Brake Reservoir Mounting Bolt Tail Brake Light Lead Connectors A Clamp B Tail Brake Light C Remove Turn Signal Light Lead Connectors A Bolts B e Remove the rear fender rearward 14 10 FRAME Frame Rear Frame Removal e Remove Rear Fender see Rear Fender Removal Bolts A and IC Igniter Bracket B Clamps for Main Harness Frame Bolts and Nuts C Rear Frame Installation Tighten Torque Rear Frame Bolts and Nuts 44 N m 4 5 kgf m 33 ft Ib Frame Inspection e Visually inspect the frame 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 6009010451 ELECTRICAL SYSTEM 15 1 Electrical System Table of Contents Exploded E 15 3 Wiring Diagram United States and Canada ZX600 J1 2 15 6 Wiring Diagram United States and Canada 7 600 73 3 15 8 Wiring Diagram Australia WEE 15 10 Wiring Diagram Other than United States Canada Australia and Malaysia 15 12 Wiring Diagram Malaysia EE 15 14 Specifications EE 15 16 Parts Poeallopic sie chet itd
312. ve under certain conditions Turn the ignition switch OFF 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 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 Turn the fuel tap position lever A to the OFF position Remove Seats see Frame chapter Evaporative Emission Hoses California model Fuel Filter Hose B Fuel Tap Position Lever Screws C e Remove Mounting Bolts A Bracket B Pull the rear part of the fuel tank right side to clear the fuel tap and then remove the fuel tank Fuel Tank Installation Read the WARNING mentioned in Fuel Tank removal e Route the hoses correctly see General Information chap ter e Be sure the hoses are clamped securely to prevent leaks Check the rubber dampers If any damper is damaged or deteriorated replace it Fuel Tank FUEL SYSTEM 2 21 Fuel Tank Inspection Remove the hose s from the fuel tank and open the tank cap e Check to see if the water drain pipe B also the breather pipe C for the California model in the tank is not clogged Check the tank cap breather also x If they are clogged remove the tank and drain it and then blow the pipes fre
313. veral places If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 72 in A WARNING If the drive chain wear exceeds the service limit place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safety use only the standard chain Standard Chain Make ENUMA Type EX525MVXL Endless ZX600 J1 J3 EX525UVXL2 ZX600 J4 US ZX600J6F CA Link 108 Links Drive Chain Lubrication special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning an O ring drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O ring Immediately blow the chain dry
314. with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes 6 04060651 C 10 6 FINAL DRIVE Drive Chain Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil Wipe off any excess oil Oil Applied Areas A O ring B GK04060781 Drive Chain Removal Remove Chain Cover Screws A Chain Cover B Rear Wheel see Wheels Tires chapter Swingarm see Suspension chapter Engine Sprocket Cover see this chapter e Disengage the drive chain A from the engine sprocket B and take it off the chassis Drive Chain Installation Engage the drive chain to the engine sprocket e Install Swingarm see Suspension chapter Rear Wheel see Wheels Tires chapter Engine Sprocket Cover Chain Cover OFit the flap A into the slot B in the swingarm e Adjust the chain slack after installing the chain see Slack Adjustment FINAL DRIVE 10 7 Drive Chain Drive Chain Replacement ZX600 J4 US ZX600J6F CAUTION For safety if the drive chain shall be replaced re place it using a recommended tool Recommended Tool Type EK JOINT Tool 50 Brand ENUMA CHAIN GKO4016BS1 Body A Handlebar B Cutting and Rivetting Pin C For Cutting D For Rivetting E Plate Holder A F Plate Holder
315. with the flywheel holder Special Tool Flywheel Holder 57001 1313 Torque Alternator Rotor Bolt 120 12 kgf m 87 ft lb Apply a thin coat of molybdenum disulfide grease to the shaft A and install it and starter idle gear B Install the alternator cover see Alternator Cover Installa tion Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output To check the alternator output voltage do the following procedures OTurn off the ignition switch ORemove the fuel tank see Fuel System chapter OSupply fuel to the carburetors with an auxiliary fuel tank ODisconnect the alternator lead connector A OConnect the hand tester as shown in the table 1 OStart the engine and run it 6 000 rpm 5 minutes ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage Teste e Range Tester to Tester to 4 000 rpm 250 V One Black lead Another Black lead 53 5 72 5 V 15 30 ELECTRICAL SYSTEM Charging System x If the output voltage shows the value in the table the al
316. without fork spring below from inner tube top 116 2 mm 4 57 0 08 in ZX600 J1 J3 Fully compressed without fork spring below from inner tube top 113 2 mm 4 45 0 08 in ZX600 J4 US ZX600J6F CA 234 6 mm 9 24 in Service limit 230 mm 9 06 in Rear Shock Absorber Rebound Damper Set Compression Damper Set 10th click from the fist click of the fully clockwise position ZX600 J1 J3 Usable Range 1 18 clicks 2 1 2 turns out from fully clockwise position ZX600 J4 US ZX600J6F CA Usable Range fully clockwise position 5 turns out 10th click from the first click of the fully clockwise position ZX600 J1 J3 Usable Range 1 20 clicks 2 1 2 turns out from fully clockwise position ZX600 J4 US ZX600J6F CA Usable Range fully clockwise position 4 1 2 turns out SUSPENSION 12 5 Specifications Item Standard Spring Preload Setting Position Standard Spring length 180 mm 7 09 in Usable Range Spring length 182 mm 7 17 in to 170 mm 6 69 in weaker to stronger Gas Pressure 980 kPa 10 kg cm 142 psi Non adjustable CA Canada Model US United States Model Special Tools Fork Piston Rod Puller M12 1 25 57001 1289 Fork Oil Level Gauge 57001 1290 Fork Outer Tube Weight 57001 1218 Fork Cylinder Holder Hex 24 x 1119 5 57001 1406 Front Fork Oil Seal Driver 57001 1219 Hook Wrench 57001 1101 Oil Seal amp Be
317. wledge 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 Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts C
318. xle Clamp Bolts 20 2 0 14 5 Front Axle Nut 127 13 94 Rear Axle Nut 127 13 94 Final Drive Engine Sprocket Nut 127 13 94 Engine Sprocket Cover Bolts 12 1 2 104 in Ib Speed Sensor Mounting Bolt 6 9 0 70 61 in lb E Rear Sprocket Nuts 59 6 0 43 Rear Sprocket Studs L Brakes Bleed Valves 7 8 0 80 69 in Ib Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 1 0 0 10 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 0 60 52 mb Front Brake Reservoir Cap Stopper Screw 1 5 0 15 13 in lb Front Brake Reservoir Bracket Bolt 6 9 0 70 61 in Ib Front Brake Light Switch Screws 1 0 0 10 9 in Ib Front Master Cylinder Clamp Bolts ZX600J1 J4 8 8 0 90 78 S ZX600J7F 11 1 1 97 mb S Front Brake Pad Spring Bolts 2 9 0 30 26 in lb Front Caliper Mounting Bolts 34 3 5 25 Front Caliper Assembly Bolts 21 2 1 15 Brake Disc Mounting Bolts 27 2 8 20 L Rear Caliper Mounting Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Master Cylinder Push Rod Locknut 18 1 8 13 Suspension Front Fork Clamp Bolts Upper 20 2 0 14 5 Front Fork Clamp Bolts Lower 20 2 0 14 5 Front Fork Top Plugs 23 2 3 16 5 Piston Rod Nut 28 2 9 21 Front Fork Bottom Allen Bolt 39 4 0 29 L Front Axle Clamp Bolts 20 2 0 14 5 1 28 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Nm kgf m ftlb Remarks Rear Shock Absorber Nuts Upper and Lower 34 3 5 25 Rear Shock Absorber Upper Bracket Nut 59 6 0 43
319. y of the O rings or diaphragms not in good con dition replace them e Check the plastic tip A of the float valve needle B It should be smooth without any grooves scratches or tears x If the plastic tip is damaged C replace the needle e Push the rod D in the other end of the float valve needle and then release it E x If the rod does not spring out replace the needle Check the tapered portion A of the pilot screw B for wear or damage If the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it Check that the vacuum piston A moves smoothly in the carburetor body The surface of the piston must not be excessively worn x lf the vacuum piston does not move smoothly or if it is very loose in carburetor body replace the carburetor 6606014351 6606017251 Carburetors FUEL SYSTEM 2 17 Coolant Filter Cleaning Other than United States and Canada Models Before winter season starts clean the filter of carburetor system Remove the fuel tank see Fuel Tank Removal e Drain the coolant see Cooling System chapter Remove the filter A from the cooling hoses B of carbu retor system e Blow off dirt and sediment on the filter with compressed air Coolant Valve Inspection Other than United States and Canada Models Drain the coolant see Cooling System chapter
320. ystem 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 cables 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 ODo not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb 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 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 leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brow

Download Pdf Manuals

Related Search

ZX600 J x600 jupiter zx600 hp zx600 kawasaki zx600 ninja zx600g zx600 trainers zx600 adidas z600 galvanised x600 getac zx600lc-3 zx600f z600 gaming z600 galvanised roof sheeting z600 hp z600 kawasaki

Related Contents

user manual - Extrasensory Software  ER3™ - Paintball Solutions  GALAXY® GX2 Automated Test System  Samsung SF-40T36 User Manual  

Copyright © All rights reserved. Failed to retrieve file