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Kawasaki 2015 Z1000 User Manual
Page 684
Kawasaki 2015 Z1000 Kwasaki
User Manual - Page 684
For 2015 Z1000.
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General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table
Periodic Maintenance
Periodic Maintenance Chart
Torque and Locking Agent
Specifications
Special Tools
Periodic Maintenance Procedures
Fuel System (DFI)
Air Cleaner Element Replacement
Idle Speed Inspection
Idle Speed Adjustment
Throttle Control System Inspection
Engine Vacuum Synchronization Inspection
Fuel System
Fuel Hose Replacement
Evaporative Emission Control System Inspection (CAL, SEA-B1 and TH Models)
Cooling System
Coolant Level Inspection
Cooling System
Coolant Change
Water Hose and O-ring Replacement
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Air Suction System Damage Inspection
Clutch
Clutch Operation Inspection
Engine Lubrication System
Engine Oil Change
Oil Filter Replacement
Wheels/Tires
Air Pressure Inspection
Wheels and Tires
Wheel Bearing Damage Inspection
Final Drive
Drive Chain Lubrication Condition Inspection
Drive Chain Slack Inspection
Drive Chain Slack Adjustment
Wheel Alignment Inspection
Wheel Alignment Adjustment
Drive Chain Wear Inspection
Chain Guide Wear Inspection
Brakes
Brake System
Brake Operation Inspection
Brake Fluid Level Inspection
Brake Fluid Change
Brake Hose and Pipe Replacement
Master Cylinder Rubber Parts Replacement
Caliper Rubber Parts Replacement
Brake Pad Wear Inspection
Brake Light Switch Operation Inspection
Suspension
Suspension System
Steering
Steering Play Inspection
Steering Play Adjustment
Steering Stem Bearing Lubrication
Electrical System
Lights and Switches Operation Inspection
Headlight Aiming Inspection
Side Stand Switch Operation Inspection
Engine Stop Switch Operation Inspection
Spark Plug Replacement
Others
Chassis Parts Lubrication
Condition of Bolts, Nuts and Fasteners Tightness Inspection
Fuel System (DFI)
Exploded View
DFI System
DFI Parts Location
Specifications
Special Tools and Sealant
DFI Servicing Precautions
DFI Servicing Precautions
Troubleshooting the DFI System
Outline
Inquiries to Rider
DFI System Troubleshooting Guide
Self-Diagnosis
Self-Diagnosis Outline
Self-Diagnosis Procedures
Service Code Reading
Service Code Erasing
Backups
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Removal/Adjustment
Main Throttle Sensor Input Voltage Inspection
Main Throttle Sensor Resistance Inspection
Main Throttle Sensor Output Voltage Inspection
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Removal
Intake Air Pressure Sensor #1 Installation
Intake Air Pressure Sensor #1 Input Voltage Inspection
Intake Air Pressure Sensor #1 Output Voltage Inspection
Intake Air Temperature Sensor (Service Code 13)
Intake Air Temperature Sensor Removal/Installation
Intake Air Temperature Sensor Output Voltage Inspection
Intake Air Temperature Sensor Resistance Inspection
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
Water Temperature Sensor Output Voltage Inspection
Water Temperature Sensor Resistance Inspection
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Removal
Intake Air Pressure Sensor #2 Installation
Intake Air Pressure Sensor #2 Input Voltage Inspection
Intake Air Pressure Sensor #2 Output Voltage Inspection
Crankshaft Sensor (Service Code 21)
Crankshaft Sensor Removal/Installation
Crankshaft Sensor Resistance Inspection
Crankshaft Sensor Peak Voltage Inspection
Rear Wheel Rotation Sensor Signal (Service Code 24, 25)
Rear Wheel Rotation Sensor Signal Inspection
Front Wheel Rotation Sensor Signal (Service Code 27, ABS Equipped Models)
Front Wheel Rotation Sensor Signal Inspection
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Removal
Vehicle-down Sensor Installation
Vehicle-down Sensor Input Voltage Inspection
Vehicle-down Sensor Output Voltage Inspection
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Removal/Adjustment
Subthrottle Sensor Input Voltage Inspection
Subthrottle Sensor Output Voltage Inspection
Subthrottle Sensor Resistance Inspection
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
Oxygen Sensor Removal/Installation
Oxygen Sensor Inspection
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor Removal/Installation
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection
Immobilizer Amplifier (Service Code 35, Equipped Models)
Antenna Resistance Inspection
Amplifier Input Voltage Inspection
Blank Key Detection (Service Code 36, Equipped Models)
Ignition Key Inspection
ECU Communication Error (Service Code 39)
ECU Communication Line Inspection
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
Stick Coil Removal/Installation
Stick Coil Primary Winding Resistance Inspection
Stick Coil Input Voltage Inspection
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation
Radiator Fan Relay Inspection
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Removal
Subthrottle Valve Actuator Inspection
Subthrottle Valve Actuator Resistance Inspection
Subthrottle Valve Actuator Input Voltage Inspection
Exhaust Butterfly Valve Actuator (Service Code 63)
Exhaust Butterfly Valve Actuator Removal
Exhaust Butterfly Valve Actuator Installation
Exhaust Butterfly Valve Actuator Inspection
Exhaust Butterfly Valve Actuator Resistance Inspection
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation
Air Switching Valve Inspection
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Removal/Installation
Oxygen Sensor Heater Resistance Inspection
Oxygen Sensor Heater Power Source Voltage Inspection
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
Oxygen Sensor Removal/Installation
Oxygen Sensor Inspection
Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models)
Purge Valve Removal/Installation
Purge Valve Inspection
Warning Indicator Light (LED)
Yellow Engine Warning/Red Warning Indicator (LED) Inspection
ECU
ECU Identification
ECU Removal
ECU Installation
ECU Power Supply Inspection
DFI Power Source
ECU Fuse Removal
ECU Fuse Installation
ECU Fuse Inspection
ECU Main Relay Removal/Installation
ECU Main Relay Inspection
Fuel Line
Fuel Pressure Inspection
Fuel Flow Rate Inspection
Fuel Pump
Fuel Pump Removal
Fuel Pump Installation
Fuel Pump Operation Inspection
Fuel Pump Operating Voltage Inspection
Pressure Regulator Removal
Pump Screen, Fuel Filter Cleaning
Fuel Pump Relay Removal/Installation
Fuel Pump Relay Inspection
Fuel Injectors
Fuel Injector Removal/Installation
Fuel Injector Audible Inspection
Fuel Injector Resistance Inspection
Fuel Injector Power Source Voltage Inspection
Fuel Injector Output Voltage Inspection
Fuel Injector Fuel Line Inspection
Throttle Grip and Cables
Free Play Inspection
Free Play Adjustment
Cable Installation
Cable Lubrication
Throttle Body Assy
Idle Speed Inspection/Adjustment
Synchronization Inspection/Adjustment
Throttle Body Assy Removal
Throttle Body Assy Installation
Throttle Body Assy Disassembly
Throttle Body Assy Assembly
Air Cleaner
Air Cleaner Element Removal/Installation
Air Cleaner Element Inspection
Air Cleaner Oil Draining
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank and Cap Inspection
Fuel Tank Cleaning
Evaporative Emission Control System (CAL, SEA-B1 and TH Models)
Parts Removal/Installation
Hose Inspection
Purge Valve Inspection
Canister Inspection
Cooling System
Exploded View
Coolant Flow Chart
Specifications
Special Tools
Coolant
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Cooling System Flushing
Coolant Reserve Tank Removal/Installation
Water Pump
Water Pump Removal
Water Pump Installation
Water Pump Inspection
Water Pump Impeller Disassembly/Assembly
Water Pump Impeller Inspection
Water Pump Housing Disassembly
Water Pump Housing Assembly
Mechanical Seal Inspection
Radiator
Radiator and Radiator Fan Removal
Radiator and Radiator Fan Installation
Radiator Inspection
Radiator Cap Inspection
Radiator Filler Neck Inspection
Thermostat
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Hose and Pipes
Hose Installation
Hose Inspection
Water Temperature Sensor
Water Temperature Sensor Removal/Installation
Water Temperature Sensor Inspection
Engine Top End
Exploded View
Exhaust System Identification
Specifications
Special Tools and Sealants
Clean Air System
Air Suction Valve Removal
Air Suction Valve Installation
Air Suction Valve Inspection
Air Switching Valve Removal
Air Switching Valve Installation
Air Switching Valve Operation Test
Air Switching Valve Unit Test
Clean Air System Hose Inspection
Cylinder Head Cover
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Camshaft, Camshaft Chain
Camshaft Removal
Camshaft Installation
Camshaft, Camshaft Cap Wear Inspection
Camshaft Runout Inspection
Cam Wear Inspection
Camshaft Chain Removal
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Warp Inspection
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve-to-Guide Clearance Measurement (Wobble Method)
Valve Seat Inspection
Valve Seat Repair
Cylinder, Pistons
Cylinder Removal
Cylinder Installation
Piston Removal
Piston Installation
Cylinder Wear Inspection
Piston Wear Inspection
Piston Ring, Piston Ring Groove Wear Inspection
Piston Ring Groove Width Inspection
Piston Ring Thickness Inspection
Piston Ring End Gap Inspection
Throttle Body Assy Holder
Throttle Body Assy Holder Removal
Throttle Body Assy Holder Installation
Muffler
Muffler Body Removal
Muffler Body Installation
Exhaust Pipe Removal
Exhaust Pipe Installation
Exhaust Butterfly Valve Cable Removal
Exhaust Butterfly Valve Cable Installation
Exhaust Butterfly Valve Actuator Removal
Exhaust Butterfly Valve Actuator Installation
Exhaust Butterfly Valve Actuator Adjustment
Clutch
Exploded View
Specifications
Special Tool and Sealant
Clutch Lever and Cable
Clutch Lever Free Play Inspection
Clutch Lever Free Play Adjustment
Clutch Cable Removal
Clutch Cable Installation
Clutch Cable Lubrication
Clutch Lever Assembly Installation
Clutch Lever Installation
Clutch Cover
Clutch Cover Removal
Clutch Cover Installation
Release Shaft Removal
Release Shaft Installation
Clutch Cover Disassembly
Clutch Cover Assembly
Clutch
Clutch Removal
Clutch Installation
Clutch Plate Assembly Inspection
Clutch Plate Assembly Adjustment
Clutch Plate, Wear, Damage Inspection
Clutch Plate Warp Inspection
Clutch Spring Free Length Measurement
Clutch Housing Finger Inspection
Clutch Housing Spline Inspection
Engine Lubrication System
Exploded View
Engine Oil Flow Chart
Specifications
Special Tools and Sealants
Engine Oil and Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Replacement
Oil Pan
Oil Pan Removal
Oil Pan Installation
Oil Screen
Oil Screen Removal
Oil Screen Installation
Oil Screen Cleaning
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Oil Pressure Relief Valve Inspection
Oil Pump
Oil Pump Removal
Oil Pump Installation
Oil Pump Drive Gear Removal
Oil Pump Drive Gear Installation
Oil Cooler
Oil Cooler Removal
Oil Cooler Installation
Oil Pressure Measurement
Oil Pressure Measurement
Oil Pressure Switch
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Oil Pipe
Oil Pipe Removal
Oil Pipe Installation
Engine Removal/Installation
Exploded View
Special Tool
Engine Removal/Installation
Engine Removal
Engine Installation
Crankshaft/Transmission
Exploded View
Specifications
Special Tools and Sealants
Crankcase Splitting
Crankcase Splitting
Crankcase Assembly
Crankshaft and Connecting Rods
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend Inspection
Connecting Rod Twist Inspection
Connecting Rod Big End Side Clearance Inspection
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
Crankshaft Side Clearance Inspection
Crankshaft Runout Inspection
Crankshaft Main Bearing Insert/Journal Wear Inspection
Balancer
Balancer Removal
Balancer Installation
Balancer Adjustment
Balancer Damper Inspection
Starter Motor Clutch
Starter Motor Clutch Removal/Installation
Starter Motor Clutch Inspection
Starter Motor Clutch Disassembly
Starter Motor Clutch Assembly
External Shift Mechanism
Shift Pedal Removal
Shift Pedal Installation
External Shift Mechanism Removal
External Shift Mechanism Installation
External Shift Mechanism Inspection
Transmission
Transmission Shaft Removal
Transmission Shaft Installation
Transmission Shaft Disassembly
Transmission Shaft Assembly
Shift Drum and Fork Removal
Shift Drum and Fork Installation
Shift Drum Disassembly
Shift Drum Assembly
Shift Fork Bending Inspection
Shift Fork/Gear Groove Wear Inspection
Shift Fork Guide Pin/Drum Groove Wear Inspection
Gear Dog and Gear Dog Hole Damage Inspection
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
Ball and Needle Bearing Wear Inspection
Oil Seal Inspection
Wheels/Tires
Exploded View
Specifications
Special Tools
Wheels (Rims)
Front Wheel Removal
Front Wheel Installation
Rear Wheel Removal
Rear Wheel Installation
Wheel Inspection
Axle Inspection
Balance Inspection
Balance Adjustment
Balance Weight Removal
Balance Weight Installation
Tires
Air Pressure Inspection/Adjustment
Tire Inspection
Tire Removal
Tire Installation
Tire Repair
Hub Bearing
Hub Bearing Removal
Hub Bearing Installation
Hub Bearing Inspection
Hub Bearing Lubrication
Final Drive
Exploded View
Specifications
Special Tools
Drive Chain
Drive Chain Slack Inspection
Drive Chain Slack Adjustment
Wheel Alignment Inspection/Adjustment
Drive Chain Wear Inspection
Drive Chain Lubrication
Drive Chain Removal
Drive Chain Installation
Drive Chain Replacement
Sprocket, Coupling
Engine Sprocket Removal
Engine Sprocket Installation
Engine Sprocket Cover Disassembly
Engine Sprocket Cover Assembly
Rear Sprocket Removal
Rear Sprocket Installation
Coupling Installation
Coupling Bearing Removal
Coupling Bearing Installation
Coupling Bearing Inspection
Coupling Bearing Lubrication
Coupling Damper Inspection
Sprocket Wear Inspection
Rear Sprocket Warp Inspection
Brakes
Exploded View
Specifications
Special Tools
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Brake Pedal Removal
Brake Pedal Installation
Calipers
Front Caliper Removal
Rear Caliper Removal
Caliper Installation
Front Caliper Disassembly
Front Caliper Assembly
Rear Caliper Disassembly
Rear Caliper Assembly
Caliper Fluid Seal Damage Inspection
Caliper Dust Seal Damage Inspection
Rear Caliper Dust Boot and Friction Boot Damage Inspection
Caliper Piston and Cylinder Damage Inspection
Rear Caliper Holder Shaft Wear Inspection
Brake Pads
Front Brake Pad Removal
Front Brake Pad Installation
Rear Brake Pad Removal
Rear Brake Pad Installation
Brake Pad Wear Inspection
Master Cylinder
Front Master Cylinder Removal
Front Master Cylinder Installation
Rear Master Cylinder Removal
Rear Master Cylinder Installation
Front Master Cylinder Disassembly
Rear Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection (Visual Inspection)
Brake Disc
Brake Disc Removal
Brake Disc Installation
Brake Disc Wear Inspection
Brake Disc Warp Inspection
Brake Fluid
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Bleeding
Brake Hose
Brake Hose Removal/Installation
Brake Hose and Pipe Inspection
Anti-Lock Brake System (Equipped Models)
Parts Location
ABS Servicing Precautions
ABS Troubleshooting Outline
Inquiries to Rider
Self-diagnosis Outline
Self-diagnosis Procedures
Service Code Clearing Procedures
How to Read Service Codes
How to Erase Service Codes
Yellow ABS Indicator (LED) Inspection
Solenoid Valve Inspection (Service Code 13, 14, 17, 18)
ABS Solenoid Valve Relay Inspection (Service Code 19)
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)
ABS Motor Relay Inspection (Service Code 35)
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)
Power Supply Voltage Abnormal [Low-Voltage] (Service Code 52)
Power Supply Voltage Abnormal [Over-Voltage] (Service Code 53)
ABS Solenoid Valve Relay Supply Voltage Inspection (Low-Voltage) (Service Code 54)
ECU Inspection (Service Code 55)
Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83)
Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code 84)
Fluid Pressure Sensor Supply Voltage Inspection (Service Code 89)
ABS Hydraulic Unit Removal
ABS Hydraulic Unit Installation
ABS Hydraulic Unit Inspection
Front Wheel Rotation Sensor Removal
Front Wheel Rotation Sensor Installation
Rear Wheel Rotation Sensor Removal
Rear Wheel Rotation Sensor Installation
Wheel Rotation Sensor Inspection
Wheel Rotation Sensor Air Gap Inspection
Wheel Rotation Sensor Rotor Inspection
ABS Solenoid Valve Relay Fuse (15 A) Removal
ABS Motor Relay Fuse (25 A) Removal
Fuse Installation
Fuse Inspection
Suspension
Exploded View
Specifications
Special Tools
Front Fork
Rebound Damping Force Adjustment
Compression Damping Force Adjustment
Spring Preload Adjustment
Front Fork Removal (Each Fork Leg)
Front Fork Installation (Each Fork Leg)
Front Fork Oil Change
Front Fork Disassembly
Front Fork Assembly
Inner Tube Inspection
Dust Seal Inspection
Spring Tension Inspection
Rear Shock Absorber
Rebound Damping Force Adjustment
Spring Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Inspection
Rear Shock Absorber Scrapping
Rear Shock Absorber Bearing Removal
Rear Shock Absorber Bearing Installation
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Bearing Removal
Swingarm Bearing Installation
Swingarm Bearing, Sleeve Inspection
Swingarm Bearing Lubrication
Chain Guide Inspection
Tie-Rod, Rocker Arm
Tie-Rod Removal
Tie-Rod Installation
Rocker Arm Removal
Rocker Arm Installation
Tie-Rod and Rocker Arm Bearing Removal
Tie-Rod and Rocker Arm Bearing Installation
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
Rocker Arm/Tie-Rod Bearing Lubrication
Steering
Exploded View
Special Tools
Steering
Steering Inspection
Steering Adjustment
Steering Stem
Stem, Stem Bearing Removal
Stem, Stem Bearing Installation
Steering Stem Bearing Lubrication
Steering Stem Warp Inspection
Stem Cap Deterioration, Damage Inspection
Handlebar
Handlebar Removal
Handlebar Installation
Frame
Exploded View
Seats
Front Seat Removal
Front Seat Installation
Rear Seat Removal
Rear Seat Installation
Fairings
Upper Fairing Removal
Upper Fairing Installation
Upper Fairing Disassembly
Upper Fairing Assembly
Fuel Tank Cover Removal
Fuel Tank Cover Installation
Middle Fairing Removal
Middle Fairing Installation
Middle Fairing Disassembly
Middle Fairing Assembly
Lower Fairing Removal
Lower Fairing Installation
Ignition Switch Cover Removal
Ignition Switch Cover Installation
Side Covers
Side Cover Removal
Side Cover Installation
Seat Covers
Seat Cover Removal
Seat Cover Installation
Fenders
Front Fender Removal
Front Fender Installation
Flap and Rear Fender Removal
Flap and Rear Fender Installation
Frame
Frame Inspection
Rear Frame Removal
Rear Frame Installation
Rear Frame Bracket Removal
Rear Frame Bracket Installation
Battery Case
Battery Case Removal
Battery Case Installation
Guard
Mud Guard Removal
Mud Guard Installation
Side Stand
Side Stand Removal
Side Stand Installation
Rear View Mirrors
Rear View Mirror Removal
Rear View Mirror Installation
Electrical System
Exploded View
Specifications
Special Tools and Sealant
Parts Location
Wiring Diagram (SEA-B1 Model)
Wiring Diagram (Other than SEA-B1 Model)
Wiring Diagram (ABS Equipped Models: US, CA and CAL Models)
Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)
Wiring Diagram (ABS Equipped Models: Other than US, CA, CAL, SEA-B1 and TH Models)
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Battery Activation
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Charging System
Alternator Cover Removal
Alternator Cover Installation
Stator Coil Removal
Stator Coil Installation
Alternator Rotor Removal
Alternator Rotor Installation
Charging Voltage Inspection
Alternator Inspection
Regulator/Rectifier Removal
Regulator/Rectifier Installation
Regulator/Rectifier Inspection
Ignition System
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Crankshaft Sensor Inspection
Crankshaft Sensor Peak Voltage Inspection
Timing Rotor Removal
Timing Rotor Installation
Stick Coil Removal
Stick Coil Installation
Stick Coil Inspection
Stick Coil Primary Peak Voltage Inspection
Spark Plug Removal
Spark Plug Installation
Spark Plug Condition Inspection
Interlock Operation Inspection
IC Igniter Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Brush Lead Inspection
Right-hand End Cover Assembly Inspection
Starter Relay Inspection
Lighting System
Headlight Beam Horizontal Adjustment
Headlight Beam Vertical Adjustment
Headlight (LED) Assembly Removal/Installation
Headlight Harness Circuit Inspection
City Light (LED) Removal
City Light (LED) Installation
Tail/Brake Light (LED) Removal
Tail/Brake Light (LED) Installation
License Plate Light Bulb Replacement
Turn Signal Light Bulb Replacement
Turn Signal Relay Inspection
Air Switching Valve
Air Switching Valve Operation Test
Air Switching Valve Unit Test
Radiator Fan System
Fan Motor Inspection
Meter, Gauge, Indicator Unit
Meter Unit Removal
Meter Unit Installation
Meter Unit Disassembly
Meter Operation Inspection
Meter System Inspection
Meter Unit Inspection
Fuel Level Sensor Line Self-Diagnosis Mode Inspection
Immobilizer System (Equipped Models)
Operational Cautions
Key Registration
Immobilizer System Parts Replacement
Immobilizer System Inspection
Immobilizer System (Equipped Models)
Switches and Sensors
Brake Light Timing Inspection
Brake Light Timing Adjustment
Switch Inspection
Water Temperature Sensor Inspection
Oxygen Sensor Removal (Equipped Models)
Oxygen Sensor Installation (Equipped Models)
Oxygen Sensor Inspection (Equipped Models)
Fuel Level Sensor Inspection
Relay Box
Relay Box Removal
Relay Circuit Inspection
Diode Circuit Inspection
Fuse
30 A Main/15 A ECU Fuse Removal
Fuse Box Fuse Removal
Fuse Installation
Fuse Inspection
Appendix & Troubleshooting
Cable, Wire, and Hose Routing
Troubleshooting Guide
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Contents
Table of Contents
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17-12
APPENDIX
Cable,
Wire,
a
nd
Hose
Routing
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File type: PDF
File name: 21516064_2015-z1000.pdf
File size: 21.32 MB
File Language: English
Pages: 734
Author: Kawasaki
File created: 2022-01-18
Published: 2022-01-19
Updated: 2023-05-15
Download File
Table of Contents
×
General Information
11
Before Servicing
12
Model Identification
17
General Specifications
19
Unit Conversion Table
22
Periodic Maintenance
23
Periodic Maintenance Chart
25
Torque and Locking Agent
27
Specifications
33
Special Tools
35
Periodic Maintenance Procedures
36
Fuel System (DFI)
36
Air Cleaner Element Replacement
36
Idle Speed Inspection
37
Idle Speed Adjustment
37
Throttle Control System Inspection
37
Engine Vacuum Synchronization Inspection
38
Fuel System
41
Fuel Hose Replacement
42
Evaporative Emission Control System Inspection (CAL, SEA-B1 and TH Models)
44
Cooling System
44
Coolant Level Inspection
44
Cooling System
45
Coolant Change
45
Water Hose and O-ring Replacement
48
Engine Top End
49
Valve Clearance Inspection
49
Valve Clearance Adjustment
50
Air Suction System Damage Inspection
54
Clutch
55
Clutch Operation Inspection
55
Engine Lubrication System
56
Engine Oil Change
56
Oil Filter Replacement
57
Wheels/Tires
57
Air Pressure Inspection
57
Wheels and Tires
57
Wheel Bearing Damage Inspection
58
Final Drive
59
Drive Chain Lubrication Condition Inspection
59
Drive Chain Slack Inspection
60
Drive Chain Slack Adjustment
60
Wheel Alignment Inspection
60
Wheel Alignment Adjustment
61
Drive Chain Wear Inspection
61
Chain Guide Wear Inspection
62
Brakes
62
Brake System
62
Brake Operation Inspection
63
Brake Fluid Level Inspection
63
Brake Fluid Change
64
Brake Hose and Pipe Replacement
66
Master Cylinder Rubber Parts Replacement
70
Caliper Rubber Parts Replacement
71
Brake Pad Wear Inspection
74
Brake Light Switch Operation Inspection
75
Suspension
76
Suspension System
76
Steering
77
Steering Play Inspection
77
Steering Play Adjustment
77
Steering Stem Bearing Lubrication
79
Electrical System
80
Lights and Switches Operation Inspection
80
Headlight Aiming Inspection
82
Side Stand Switch Operation Inspection
83
Engine Stop Switch Operation Inspection
84
Spark Plug Replacement
85
Others
85
Chassis Parts Lubrication
85
Condition of Bolts, Nuts and Fasteners Tightness Inspection
86
Fuel System (DFI)
89
Exploded View
92
DFI System
98
DFI Parts Location
108
Specifications
111
Special Tools and Sealant
113
DFI Servicing Precautions
115
DFI Servicing Precautions
115
Troubleshooting the DFI System
117
Outline
117
Inquiries to Rider
121
DFI System Troubleshooting Guide
124
Self-Diagnosis
129
Self-Diagnosis Outline
129
Self-Diagnosis Procedures
130
Service Code Reading
132
Service Code Erasing
132
Backups
133
Main Throttle Sensor (Service Code 11)
136
Main Throttle Sensor Removal/Adjustment
136
Main Throttle Sensor Input Voltage Inspection
136
Main Throttle Sensor Resistance Inspection
137
Main Throttle Sensor Output Voltage Inspection
137
Intake Air Pressure Sensor #1 (Service Code 12)
140
Intake Air Pressure Sensor #1 Removal
140
Intake Air Pressure Sensor #1 Installation
140
Intake Air Pressure Sensor #1 Input Voltage Inspection
141
Intake Air Pressure Sensor #1 Output Voltage Inspection
142
Intake Air Temperature Sensor (Service Code 13)
146
Intake Air Temperature Sensor Removal/Installation
146
Intake Air Temperature Sensor Output Voltage Inspection
146
Intake Air Temperature Sensor Resistance Inspection
147
Water Temperature Sensor (Service Code 14)
149
Water Temperature Sensor Removal/Installation
149
Water Temperature Sensor Output Voltage Inspection
149
Water Temperature Sensor Resistance Inspection
150
Intake Air Pressure Sensor #2 (Service Code 16)
151
Intake Air Pressure Sensor #2 Removal
151
Intake Air Pressure Sensor #2 Installation
151
Intake Air Pressure Sensor #2 Input Voltage Inspection
152
Intake Air Pressure Sensor #2 Output Voltage Inspection
153
Crankshaft Sensor (Service Code 21)
155
Crankshaft Sensor Removal/Installation
155
Crankshaft Sensor Resistance Inspection
155
Crankshaft Sensor Peak Voltage Inspection
155
Rear Wheel Rotation Sensor Signal (Service Code 24, 25)
156
Rear Wheel Rotation Sensor Signal Inspection
156
Front Wheel Rotation Sensor Signal (Service Code 27, ABS Equipped Models)
159
Front Wheel Rotation Sensor Signal Inspection
159
Vehicle-down Sensor (Service Code 31)
161
Vehicle-down Sensor Removal
161
Vehicle-down Sensor Installation
162
Vehicle-down Sensor Input Voltage Inspection
162
Vehicle-down Sensor Output Voltage Inspection
163
Subthrottle Sensor (Service Code 32)
166
Subthrottle Sensor Removal/Adjustment
166
Subthrottle Sensor Input Voltage Inspection
166
Subthrottle Sensor Output Voltage Inspection
167
Subthrottle Sensor Resistance Inspection
169
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
170
Oxygen Sensor Removal/Installation
170
Oxygen Sensor Inspection
170
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
173
Exhaust Butterfly Valve Actuator Sensor Removal/Installation
173
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection
173
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection
174
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection
175
Immobilizer Amplifier (Service Code 35, Equipped Models)
176
Antenna Resistance Inspection
176
Amplifier Input Voltage Inspection
176
Blank Key Detection (Service Code 36, Equipped Models)
177
Ignition Key Inspection
177
ECU Communication Error (Service Code 39)
178
ECU Communication Line Inspection
178
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
179
Stick Coil Removal/Installation
179
Stick Coil Primary Winding Resistance Inspection
179
Stick Coil Input Voltage Inspection
179
Radiator Fan Relay (Service Code 56)
181
Radiator Fan Relay Removal/Installation
181
Radiator Fan Relay Inspection
181
Subthrottle Valve Actuator (Service Code 62)
182
Subthrottle Valve Actuator Removal
182
Subthrottle Valve Actuator Inspection
182
Subthrottle Valve Actuator Resistance Inspection
182
Subthrottle Valve Actuator Input Voltage Inspection
183
Exhaust Butterfly Valve Actuator (Service Code 63)
185
Exhaust Butterfly Valve Actuator Removal
185
Exhaust Butterfly Valve Actuator Installation
185
Exhaust Butterfly Valve Actuator Inspection
185
Exhaust Butterfly Valve Actuator Resistance Inspection
185
Air Switching Valve (Service Code 64)
187
Air Switching Valve Removal/Installation
187
Air Switching Valve Inspection
187
Oxygen Sensor Heater (Service Code 67, Equipped Models)
188
Oxygen Sensor Heater Removal/Installation
188
Oxygen Sensor Heater Resistance Inspection
188
Oxygen Sensor Heater Power Source Voltage Inspection
189
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
191
Oxygen Sensor Removal/Installation
191
Oxygen Sensor Inspection
191
Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models)
194
Purge Valve Removal/Installation
194
Purge Valve Inspection
194
Warning Indicator Light (LED)
196
Yellow Engine Warning/Red Warning Indicator (LED) Inspection
196
ECU
197
ECU Identification
197
ECU Removal
197
ECU Installation
198
ECU Power Supply Inspection
198
DFI Power Source
201
ECU Fuse Removal
201
ECU Fuse Installation
201
ECU Fuse Inspection
201
ECU Main Relay Removal/Installation
201
ECU Main Relay Inspection
201
Fuel Line
202
Fuel Pressure Inspection
202
Fuel Flow Rate Inspection
203
Fuel Pump
205
Fuel Pump Removal
205
Fuel Pump Installation
206
Fuel Pump Operation Inspection
206
Fuel Pump Operating Voltage Inspection
207
Pressure Regulator Removal
208
Pump Screen, Fuel Filter Cleaning
208
Fuel Pump Relay Removal/Installation
208
Fuel Pump Relay Inspection
208
Fuel Injectors
210
Fuel Injector Removal/Installation
210
Fuel Injector Audible Inspection
210
Fuel Injector Resistance Inspection
210
Fuel Injector Power Source Voltage Inspection
211
Fuel Injector Output Voltage Inspection
212
Fuel Injector Fuel Line Inspection
213
Throttle Grip and Cables
216
Free Play Inspection
216
Free Play Adjustment
216
Cable Installation
216
Cable Lubrication
216
Throttle Body Assy
217
Idle Speed Inspection/Adjustment
217
Synchronization Inspection/Adjustment
217
Throttle Body Assy Removal
217
Throttle Body Assy Installation
219
Throttle Body Assy Disassembly
220
Throttle Body Assy Assembly
221
Air Cleaner
222
Air Cleaner Element Removal/Installation
222
Air Cleaner Element Inspection
222
Air Cleaner Oil Draining
222
Air Cleaner Housing Removal
222
Air Cleaner Housing Installation
223
Fuel Tank
224
Fuel Tank Removal
224
Fuel Tank Installation
226
Fuel Tank and Cap Inspection
227
Fuel Tank Cleaning
228
Evaporative Emission Control System (CAL, SEA-B1 and TH Models)
229
Parts Removal/Installation
229
Hose Inspection
229
Purge Valve Inspection
229
Canister Inspection
229
Cooling System
231
Exploded View
232
Coolant Flow Chart
234
Specifications
236
Special Tools
237
Coolant
238
Coolant Deterioration Inspection
238
Coolant Level Inspection
238
Coolant Draining
238
Coolant Filling
238
Pressure Testing
238
Cooling System Flushing
239
Coolant Reserve Tank Removal/Installation
239
Water Pump
240
Water Pump Removal
240
Water Pump Installation
240
Water Pump Inspection
242
Water Pump Impeller Disassembly/Assembly
242
Water Pump Impeller Inspection
242
Water Pump Housing Disassembly
242
Water Pump Housing Assembly
243
Mechanical Seal Inspection
243
Radiator
244
Radiator and Radiator Fan Removal
244
Radiator and Radiator Fan Installation
245
Radiator Inspection
246
Radiator Cap Inspection
246
Radiator Filler Neck Inspection
247
Thermostat
248
Thermostat Removal
248
Thermostat Installation
248
Thermostat Inspection
249
Hose and Pipes
251
Hose Installation
251
Hose Inspection
251
Water Temperature Sensor
252
Water Temperature Sensor Removal/Installation
252
Water Temperature Sensor Inspection
252
Engine Top End
253
Exploded View
254
Exhaust System Identification
258
Specifications
260
Special Tools and Sealants
262
Clean Air System
265
Air Suction Valve Removal
265
Air Suction Valve Installation
266
Air Suction Valve Inspection
267
Air Switching Valve Removal
267
Air Switching Valve Installation
267
Air Switching Valve Operation Test
267
Air Switching Valve Unit Test
267
Clean Air System Hose Inspection
268
Cylinder Head Cover
269
Cylinder Head Cover Removal
269
Cylinder Head Cover Installation
269
Camshaft Chain Tensioner
271
Camshaft Chain Tensioner Removal
271
Camshaft Chain Tensioner Installation
271
Camshaft, Camshaft Chain
272
Camshaft Removal
272
Camshaft Installation
273
Camshaft, Camshaft Cap Wear Inspection
276
Camshaft Runout Inspection
276
Cam Wear Inspection
277
Camshaft Chain Removal
277
Cylinder Head
278
Cylinder Compression Measurement
278
Cylinder Head Removal
279
Cylinder Head Installation
280
Cylinder Head Warp Inspection
281
Valves
282
Valve Clearance Inspection
282
Valve Clearance Adjustment
282
Valve Removal
282
Valve Installation
282
Valve Guide Removal
282
Valve Guide Installation
283
Valve-to-Guide Clearance Measurement (Wobble Method)
284
Valve Seat Inspection
284
Valve Seat Repair
285
Cylinder, Pistons
290
Cylinder Removal
290
Cylinder Installation
290
Piston Removal
291
Piston Installation
292
Cylinder Wear Inspection
293
Piston Wear Inspection
293
Piston Ring, Piston Ring Groove Wear Inspection
293
Piston Ring Groove Width Inspection
293
Piston Ring Thickness Inspection
294
Piston Ring End Gap Inspection
294
Throttle Body Assy Holder
295
Throttle Body Assy Holder Removal
295
Throttle Body Assy Holder Installation
295
Muffler
296
Muffler Body Removal
296
Muffler Body Installation
298
Exhaust Pipe Removal
301
Exhaust Pipe Installation
301
Exhaust Butterfly Valve Cable Removal
301
Exhaust Butterfly Valve Cable Installation
303
Exhaust Butterfly Valve Actuator Removal
304
Exhaust Butterfly Valve Actuator Installation
305
Exhaust Butterfly Valve Actuator Adjustment
306
Clutch
307
Exploded View
308
Specifications
310
Special Tool and Sealant
311
Clutch Lever and Cable
312
Clutch Lever Free Play Inspection
312
Clutch Lever Free Play Adjustment
312
Clutch Cable Removal
312
Clutch Cable Installation
312
Clutch Cable Lubrication
312
Clutch Lever Assembly Installation
312
Clutch Lever Installation
313
Clutch Cover
314
Clutch Cover Removal
314
Clutch Cover Installation
314
Release Shaft Removal
314
Release Shaft Installation
315
Clutch Cover Disassembly
315
Clutch Cover Assembly
316
Clutch
317
Clutch Removal
317
Clutch Installation
317
Clutch Plate Assembly Inspection
320
Clutch Plate Assembly Adjustment
320
Clutch Plate, Wear, Damage Inspection
321
Clutch Plate Warp Inspection
321
Clutch Spring Free Length Measurement
321
Clutch Housing Finger Inspection
321
Clutch Housing Spline Inspection
321
Engine Lubrication System
323
Exploded View
324
Engine Oil Flow Chart
326
Specifications
327
Special Tools and Sealants
328
Engine Oil and Oil Filter
329
Oil Level Inspection
329
Engine Oil Change
329
Oil Filter Replacement
329
Oil Pan
330
Oil Pan Removal
330
Oil Pan Installation
330
Oil Screen
332
Oil Screen Removal
332
Oil Screen Installation
332
Oil Screen Cleaning
332
Oil Pressure Relief Valve
333
Oil Pressure Relief Valve Removal
333
Oil Pressure Relief Valve Installation
333
Oil Pressure Relief Valve Inspection
333
Oil Pump
334
Oil Pump Removal
334
Oil Pump Installation
334
Oil Pump Drive Gear Removal
335
Oil Pump Drive Gear Installation
335
Oil Cooler
336
Oil Cooler Removal
336
Oil Cooler Installation
336
Oil Pressure Measurement
337
Oil Pressure Measurement
337
Oil Pressure Switch
338
Oil Pressure Switch Removal
338
Oil Pressure Switch Installation
338
Oil Pipe
339
Oil Pipe Removal
339
Oil Pipe Installation
339
Engine Removal/Installation
341
Exploded View
342
Special Tool
344
Engine Removal/Installation
345
Engine Removal
345
Engine Installation
348
Crankshaft/Transmission
353
Exploded View
354
Specifications
358
Special Tools and Sealants
360
Crankcase Splitting
361
Crankcase Splitting
361
Crankcase Assembly
362
Crankshaft and Connecting Rods
367
Crankshaft Removal
367
Crankshaft Installation
367
Connecting Rod Removal
367
Connecting Rod Installation
368
Crankshaft/Connecting Rod Cleaning
371
Connecting Rod Bend Inspection
372
Connecting Rod Twist Inspection
372
Connecting Rod Big End Side Clearance Inspection
372
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
373
Crankshaft Side Clearance Inspection
374
Crankshaft Runout Inspection
375
Crankshaft Main Bearing Insert/Journal Wear Inspection
375
Balancer
378
Balancer Removal
378
Balancer Installation
378
Balancer Adjustment
379
Balancer Damper Inspection
379
Starter Motor Clutch
380
Starter Motor Clutch Removal/Installation
380
Starter Motor Clutch Inspection
380
Starter Motor Clutch Disassembly
380
Starter Motor Clutch Assembly
380
External Shift Mechanism
381
Shift Pedal Removal
381
Shift Pedal Installation
381
External Shift Mechanism Removal
382
External Shift Mechanism Installation
382
External Shift Mechanism Inspection
383
Transmission
385
Transmission Shaft Removal
385
Transmission Shaft Installation
385
Transmission Shaft Disassembly
385
Transmission Shaft Assembly
386
Shift Drum and Fork Removal
390
Shift Drum and Fork Installation
390
Shift Drum Disassembly
390
Shift Drum Assembly
390
Shift Fork Bending Inspection
391
Shift Fork/Gear Groove Wear Inspection
391
Shift Fork Guide Pin/Drum Groove Wear Inspection
391
Gear Dog and Gear Dog Hole Damage Inspection
391
Ball Bearing, Needle Bearing, and Oil Seal
392
Ball and Needle Bearing Replacement
392
Ball and Needle Bearing Wear Inspection
392
Oil Seal Inspection
392
Wheels/Tires
393
Exploded View
394
Specifications
396
Special Tools
397
Wheels (Rims)
398
Front Wheel Removal
398
Front Wheel Installation
398
Rear Wheel Removal
399
Rear Wheel Installation
401
Wheel Inspection
402
Axle Inspection
402
Balance Inspection
403
Balance Adjustment
403
Balance Weight Removal
403
Balance Weight Installation
403
Tires
405
Air Pressure Inspection/Adjustment
405
Tire Inspection
405
Tire Removal
405
Tire Installation
405
Tire Repair
407
Hub Bearing
408
Hub Bearing Removal
408
Hub Bearing Installation
408
Hub Bearing Inspection
409
Hub Bearing Lubrication
409
Final Drive
411
Exploded View
412
Specifications
414
Special Tools
415
Drive Chain
416
Drive Chain Slack Inspection
416
Drive Chain Slack Adjustment
416
Wheel Alignment Inspection/Adjustment
416
Drive Chain Wear Inspection
416
Drive Chain Lubrication
416
Drive Chain Removal
416
Drive Chain Installation
416
Drive Chain Replacement
416
Sprocket, Coupling
420
Engine Sprocket Removal
420
Engine Sprocket Installation
420
Engine Sprocket Cover Disassembly
421
Engine Sprocket Cover Assembly
421
Rear Sprocket Removal
422
Rear Sprocket Installation
422
Coupling Installation
422
Coupling Bearing Removal
423
Coupling Bearing Installation
423
Coupling Bearing Inspection
424
Coupling Bearing Lubrication
424
Coupling Damper Inspection
424
Sprocket Wear Inspection
424
Rear Sprocket Warp Inspection
425
Brakes
427
Exploded View
429
Specifications
436
Special Tools
437
Brake Lever, Brake Pedal
438
Brake Lever Position Adjustment
438
Brake Pedal Position Inspection
438
Brake Pedal Position Adjustment
438
Brake Pedal Removal
438
Brake Pedal Installation
439
Calipers
440
Front Caliper Removal
440
Rear Caliper Removal
440
Caliper Installation
440
Front Caliper Disassembly
440
Front Caliper Assembly
441
Rear Caliper Disassembly
441
Rear Caliper Assembly
441
Caliper Fluid Seal Damage Inspection
441
Caliper Dust Seal Damage Inspection
441
Rear Caliper Dust Boot and Friction Boot Damage Inspection
442
Caliper Piston and Cylinder Damage Inspection
442
Rear Caliper Holder Shaft Wear Inspection
442
Brake Pads
443
Front Brake Pad Removal
443
Front Brake Pad Installation
443
Rear Brake Pad Removal
443
Rear Brake Pad Installation
444
Brake Pad Wear Inspection
444
Master Cylinder
445
Front Master Cylinder Removal
445
Front Master Cylinder Installation
445
Rear Master Cylinder Removal
445
Rear Master Cylinder Installation
446
Front Master Cylinder Disassembly
446
Rear Master Cylinder Disassembly
446
Master Cylinder Assembly
446
Master Cylinder Inspection (Visual Inspection)
447
Brake Disc
448
Brake Disc Removal
448
Brake Disc Installation
448
Brake Disc Wear Inspection
448
Brake Disc Warp Inspection
449
Brake Fluid
450
Brake Fluid Level Inspection
450
Brake Fluid Change
450
Brake Line Bleeding
450
Brake Hose
454
Brake Hose Removal/Installation
454
Brake Hose and Pipe Inspection
454
Anti-Lock Brake System (Equipped Models)
455
Parts Location
455
ABS Servicing Precautions
459
ABS Troubleshooting Outline
461
Inquiries to Rider
464
Self-diagnosis Outline
466
Self-diagnosis Procedures
466
Service Code Clearing Procedures
467
How to Read Service Codes
470
How to Erase Service Codes
470
Yellow ABS Indicator (LED) Inspection
473
Solenoid Valve Inspection (Service Code 13, 14, 17, 18)
473
ABS Solenoid Valve Relay Inspection (Service Code 19)
473
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)
474
ABS Motor Relay Inspection (Service Code 35)
475
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)
475
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)
476
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)
476
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)
477
Power Supply Voltage Abnormal [Low-Voltage] (Service Code 52)
477
Power Supply Voltage Abnormal [Over-Voltage] (Service Code 53)
478
ABS Solenoid Valve Relay Supply Voltage Inspection (Low-Voltage) (Service Code 54)
478
ECU Inspection (Service Code 55)
478
Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83)
479
Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code 84)
479
Fluid Pressure Sensor Supply Voltage Inspection (Service Code 89)
479
ABS Hydraulic Unit Removal
479
ABS Hydraulic Unit Installation
481
ABS Hydraulic Unit Inspection
481
Front Wheel Rotation Sensor Removal
482
Front Wheel Rotation Sensor Installation
482
Rear Wheel Rotation Sensor Removal
483
Rear Wheel Rotation Sensor Installation
483
Wheel Rotation Sensor Inspection
484
Wheel Rotation Sensor Air Gap Inspection
484
Wheel Rotation Sensor Rotor Inspection
485
ABS Solenoid Valve Relay Fuse (15 A) Removal
485
ABS Motor Relay Fuse (25 A) Removal
485
Fuse Installation
485
Fuse Inspection
486
Suspension
487
Exploded View
488
Specifications
492
Special Tools
493
Front Fork
495
Rebound Damping Force Adjustment
495
Compression Damping Force Adjustment
495
Spring Preload Adjustment
496
Front Fork Removal (Each Fork Leg)
496
Front Fork Installation (Each Fork Leg)
496
Front Fork Oil Change
498
Front Fork Disassembly
506
Front Fork Assembly
506
Inner Tube Inspection
507
Dust Seal Inspection
507
Spring Tension Inspection
508
Rear Shock Absorber
509
Rebound Damping Force Adjustment
509
Spring Preload Adjustment
509
Rear Shock Absorber Removal
510
Rear Shock Absorber Installation
511
Rear Shock Absorber Inspection
511
Rear Shock Absorber Scrapping
511
Rear Shock Absorber Bearing Removal
512
Rear Shock Absorber Bearing Installation
512
Swingarm
513
Swingarm Removal
513
Swingarm Installation
514
Swingarm Bearing Removal
515
Swingarm Bearing Installation
515
Swingarm Bearing, Sleeve Inspection
516
Swingarm Bearing Lubrication
516
Chain Guide Inspection
516
Tie-Rod, Rocker Arm
517
Tie-Rod Removal
517
Tie-Rod Installation
517
Rocker Arm Removal
517
Rocker Arm Installation
518
Tie-Rod and Rocker Arm Bearing Removal
519
Tie-Rod and Rocker Arm Bearing Installation
519
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
520
Rocker Arm/Tie-Rod Bearing Lubrication
520
Steering
521
Exploded View
522
Special Tools
524
Steering
525
Steering Inspection
525
Steering Adjustment
525
Steering Stem
526
Stem, Stem Bearing Removal
526
Stem, Stem Bearing Installation
527
Steering Stem Bearing Lubrication
529
Steering Stem Warp Inspection
529
Stem Cap Deterioration, Damage Inspection
529
Handlebar
530
Handlebar Removal
530
Handlebar Installation
530
Frame
533
Exploded View
534
Seats
540
Front Seat Removal
540
Front Seat Installation
540
Rear Seat Removal
540
Rear Seat Installation
540
Fairings
541
Upper Fairing Removal
541
Upper Fairing Installation
542
Upper Fairing Disassembly
542
Upper Fairing Assembly
543
Fuel Tank Cover Removal
543
Fuel Tank Cover Installation
543
Middle Fairing Removal
544
Middle Fairing Installation
544
Middle Fairing Disassembly
545
Middle Fairing Assembly
545
Lower Fairing Removal
545
Lower Fairing Installation
545
Ignition Switch Cover Removal
546
Ignition Switch Cover Installation
546
Side Covers
547
Side Cover Removal
547
Side Cover Installation
547
Seat Covers
548
Seat Cover Removal
548
Seat Cover Installation
548
Fenders
550
Front Fender Removal
550
Front Fender Installation
550
Flap and Rear Fender Removal
550
Flap and Rear Fender Installation
551
Frame
552
Frame Inspection
552
Rear Frame Removal
552
Rear Frame Installation
552
Rear Frame Bracket Removal
552
Rear Frame Bracket Installation
553
Battery Case
554
Battery Case Removal
554
Battery Case Installation
554
Guard
555
Mud Guard Removal
555
Mud Guard Installation
555
Side Stand
556
Side Stand Removal
556
Side Stand Installation
556
Rear View Mirrors
557
Rear View Mirror Removal
557
Rear View Mirror Installation
557
Electrical System
559
Exploded View
562
Specifications
568
Special Tools and Sealant
569
Parts Location
571
Wiring Diagram (SEA-B1 Model)
574
Wiring Diagram (Other than SEA-B1 Model)
576
Wiring Diagram (ABS Equipped Models: US, CA and CAL Models)
578
Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)
580
Wiring Diagram (ABS Equipped Models: Other than US, CA, CAL, SEA-B1 and TH Models)
582
Precautions
584
Electrical Wiring
585
Wiring Inspection
585
Battery
586
Battery Removal
586
Battery Installation
586
Battery Activation
586
Precautions
589
Interchange
590
Charging Condition Inspection
590
Refreshing Charge
590
Charging System
592
Alternator Cover Removal
592
Alternator Cover Installation
592
Stator Coil Removal
592
Stator Coil Installation
593
Alternator Rotor Removal
593
Alternator Rotor Installation
594
Charging Voltage Inspection
596
Alternator Inspection
596
Regulator/Rectifier Removal
598
Regulator/Rectifier Installation
598
Regulator/Rectifier Inspection
598
Ignition System
601
Crankshaft Sensor Removal
601
Crankshaft Sensor Installation
602
Crankshaft Sensor Inspection
603
Crankshaft Sensor Peak Voltage Inspection
604
Timing Rotor Removal
604
Timing Rotor Installation
604
Stick Coil Removal
605
Stick Coil Installation
605
Stick Coil Inspection
605
Stick Coil Primary Peak Voltage Inspection
605
Spark Plug Removal
606
Spark Plug Installation
606
Spark Plug Condition Inspection
607
Interlock Operation Inspection
607
IC Igniter Inspection
608
Electric Starter System
611
Starter Motor Removal
611
Starter Motor Installation
611
Starter Motor Disassembly
611
Starter Motor Assembly
612
Brush Inspection
613
Commutator Cleaning and Inspection
613
Armature Inspection
613
Brush Lead Inspection
614
Right-hand End Cover Assembly Inspection
614
Starter Relay Inspection
614
Lighting System
616
Headlight Beam Horizontal Adjustment
616
Headlight Beam Vertical Adjustment
616
Headlight (LED) Assembly Removal/Installation
616
Headlight Harness Circuit Inspection
616
City Light (LED) Removal
617
City Light (LED) Installation
618
Tail/Brake Light (LED) Removal
618
Tail/Brake Light (LED) Installation
619
License Plate Light Bulb Replacement
619
Turn Signal Light Bulb Replacement
621
Turn Signal Relay Inspection
621
Air Switching Valve
624
Air Switching Valve Operation Test
624
Air Switching Valve Unit Test
624
Radiator Fan System
626
Fan Motor Inspection
626
Meter, Gauge, Indicator Unit
627
Meter Unit Removal
627
Meter Unit Installation
627
Meter Unit Disassembly
628
Meter Operation Inspection
628
Meter System Inspection
630
Meter Unit Inspection
631
Fuel Level Sensor Line Self-Diagnosis Mode Inspection
639
Immobilizer System (Equipped Models)
642
Operational Cautions
642
Key Registration
642
Immobilizer System Parts Replacement
660
Immobilizer System Inspection
663
Immobilizer System (Equipped Models)
664
Switches and Sensors
665
Brake Light Timing Inspection
665
Brake Light Timing Adjustment
665
Switch Inspection
665
Water Temperature Sensor Inspection
666
Oxygen Sensor Removal (Equipped Models)
666
Oxygen Sensor Installation (Equipped Models)
667
Oxygen Sensor Inspection (Equipped Models)
667
Fuel Level Sensor Inspection
667
Relay Box
668
Relay Box Removal
668
Relay Circuit Inspection
668
Diode Circuit Inspection
669
Fuse
671
30 A Main/15 A ECU Fuse Removal
671
Fuse Box Fuse Removal
671
Fuse Installation
671
Fuse Inspection
671
Appendix & Troubleshooting
673
Cable, Wire, and Hose Routing
674
Troubleshooting Guide
729
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