Z1000
Z1000 ABS
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 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Clutch 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Crankshaft/Transmission 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
Appendix 17 j
Z1000
Z1000 ABS
Motorcycle
Service Manual
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.
LIST OF ABBREVIATIONS
A
ampere(s) IC
integrated circuit
ABDC after bottom dead cente
r
in.
inch(es)
ABS antilock brake system km/h kilometers per hour
AC alternating current L liter(s)
Ah ampere hour LCD liquid crystal display
ATDC after top dead center LED light emitting diode
BBDC before bottom dead center lb pound(s)
BDC bottom dead center m meter(s)
BTDC before top dead center min minute(s)
°C degree(s) Celsius mmHg millimeters of mercury
cmHg centimeters of mercury mph miles per hour
CU
central prcessing unit N
newton(s)
cu in.
cubic inch(es)
oz
ounce(s)
DC
direct current Pa
pascal(s)
DFI digital fuel injection PS horsepower
DOHC double overhead camshaft psi pound(s) per square inch
DOT department of transportation qt quart(s)
ECU electronic control unit r revolution
F farad(s) rpm revolution(s) per minute
°F degree(s) Fahrenheit s second(s)
ft foot, feet TDC top dead center
g gram(s) TIR total indicator reading
gal gallon(s) V volt(s)
h
hour(s)
W
watt(s)
HP
horsepower(s) ohm(s)
C
OUNTRY AND AREA CODES
AT Austria MY Malaysia
AU Australia PH Philippines
BR Brazil
SEA-B1 Southeast Asia B1 (with Evaporative
Emission Control System)
CA Canada SEA-B2 Southeast Asia B2
CAL California SEA-B3 Southeast Asia B3
CH Switzerland TH Thailand
DE Germany US United States
EUR Europe WVTA
(FULL H)
WVTA Model with Honeycomb
Catalytic Converter (Full Power)
GB
United Kingdom
GB WVTA
(FULL H)
WVTA Model with Honeycomb Catalytic
Converter (Left Side Traffic, Full Power)
ID Indonesia WVTA
(78.2 H)
WVTA Model with Honeycomb
Catalytic Converter (78.2 Kw Power)
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 evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the 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 fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped.
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 of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser...”
NOTE
○
The 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 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 knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle.
•
Follow the Periodic Maintenance Chart in the
Service Manual.
•
Be alert for problems and non-scheduled
maintenance.
•
Use proper tools and genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
•
Follow the procedures in this manual care-
fully. Don’t take shortcuts.
•
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Ta-
ble of Contents.
For example, if you want stick coil information,
use the Quick Reference Guide to locate the
Electrical System chapter. Then, use the Table
of Contents on the first page of the chapter to
find the Stick Coil section.
Whenever you see symbols, heed their in-
structions! Always follow safe operating and
maintenance practices.
DANGER
DANGER indicates a hazardous situa-
tion which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situa-
tion which, if not avoided, could result
in death or serious injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.
NOTE
○
NOTE indicates information that may help
or guide you in the operation or service of
the vehicle.
•
Indicates a procedural step or work to be
done.
Indicates 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
1
General Information
Table of Contents
Before Servicing . ＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮ 1-2
Model Identification. ＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮ 1-7
General Specifications. ＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮ 1-9
Unit Conversion Table . ＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮＮ 1-12
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca-
ble to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High
flash-point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
All of the tightening torque values are for use with dry,
solvent - cleaned threads unless otherwise indicated. If a
fastener which should have dry, clean threads gets contami-
nated with lubricant, etc., applying even the specified torque
could damage it.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thor-
oughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
ZR1000FE Left Side View
ZR1000FE Right Side View
Frame Number Engine Number
1-8 GENERAL INFORMATION
Model Identification
ZR1000GE Left Side View
ZR1000GE Right Side View
GENERAL INFORMATION 1-9
General Specifications
Items ZR1000FE ∼ FF/GE ∼ GF
Dimensions
Overall Length 2 045 mm (80.51 in.)
Overall Width 790 mm (31.10 in.)
Overall Height 1 055 mm (41.54 in.)
Wheelbase 1 435 mm (56.50 in.)
Road Clearance 125 mm (4.92 in.)
Seat Height 815 mm (32.09 in.)
Curb Mass:
ZR1000F
220 kg (485 lb)
ZR1000G 221 kg (487 lb)
Front:
ZR1000F 111kg(245lb)
ZR1000G 111kg(245lb)
Rear:
ZR1000F 109 kg (240 lb)
ZR1000G 110 kg (243 lb)
Fuel Tank Capacity 17 L (4.5 US gal.)
Performance
Minimum Turning Radius 3.2 m (10.5 ft)
Engine
Type 4-stroke, DOHC, 4-cylinder
Cooling System Liquid-cooled
Bore and Stroke 77.0 × 56.0 mm (3.03 × 2.20 in.)
Displacement 1 043 cm³ (63.64 cu in.)
Compression Ratio 11.8:1
Maximum Horsepower
104.5 kW (142 PS) @10 000 r/min (rpm)
(SEA-B1/B2, TH) 100.9 kW (137 PS) @9 800 r/min (rpm)
(WVTA (78.2 H)) 78.2 kW (106 PS) @9 000 r/min (rpm)
(CA),(CAL),(US)–––
Maximum Torque
111 N·m (11.3 kgf·m, 82 ft·lb) @7 300 r/min (rpm)
(SEA-B1/B2, TH) 109 N·m (11.1 kgf·m, 80 ft·lb) @7 300 r/min (rpm)
(WVTA (78.2 H)) 95 N·m (9.7 kgf·m, 70 ft·lb) @6 000 r/min (rpm)
(CA),(CAL),(US)–––
Fuel System FI (Fuel Injection) KEIHIN TTK38 × 4
Fuel Type:
Minimum Octane Rating:
Research Octane
Number (RON)
95
Antiknock Index
(RON + MON)/2
90
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (IC igniter in ECU)
Ignition Timing From 10° BTDC @1 100 r/min (rpm) to 40.2° BTDC
@5 200 r/min (rpm)
Spark Plug NGK CR9EIA-9
1-10 GENERAL INFORMATION
General Specifications
Items ZR1000FE ∼ FF/GE ∼ GF
Cylinder Numbering Method Left to right, 1-2-3-4
Firing Order 1-2-4-3
Valve Timing:
Intake:
Open 25° BTDC
Close 65° ABDC
Duration 270°
Exhaust:
Open 58° BBDC
Close 18° ATDC
Duration 256°
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Type
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity
SAE 10W-40
Capacity 4.0L(4.2USqt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 1.627 (83/51)
Clutch Type
Wet multi disc
Transmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.600 (39/15)
2nd 1.950 (39/20)
3rd
1.600 (24/15)
4th
1.389 (25/18)
5th
1.238 (26/21)
6th 1.107 (31/28)
Final Drive System:
Type Chain drive
Reduction Ratio 2.867 (43/15)
Overall Drive Ratio 5.165 at Top gear
Frame
Type Tubular, diamond
Caster (Rake Angle) 24.5°
Trail 101 mm (3.97 in.)
Front Tire:
Type Tubeless
Size 120/70 ZR17 M
/C (58W)
Rim Size J17M/C × MT3.50
GENERAL INFORMATION 1-11
General Specifications
Items ZR1000FE ∼ FF/GE ∼ GF
Rear Tire:
Type Tubeless
Size 190/50 ZR17 M/C (73W)
Rim Size J17M/C × MT6.00
Front Suspension:
Type Telescopic fork (upside-down)
Wheel Travel 120 mm (4.72 in.)
Rear Suspension:
Type Swingarm
Wheel Travel 122 mm (4.80 in.)
Brake Type:
Front Dual discs
Rear Single disc
Electrical Equipment
Battery 12V10Ah(10HR)
Headlight:
High Beam LED × 2
Low Beam LED × 2
Brake/Tail Light LED
Alternator:
Type
Three-phase AC
Specifications are subject to change without notice, and may not apply to every country.
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix Symbol Power
mega M × 1 000 000
kilo k × 1 000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Units of Mass:
kg × 2.205 = lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US)
L × 0.2200 = gal (IMP)
L×1.057=
qt (US)
L × 0.8799 =
qt (IMP)
L × 2.113 = pint (US)
L × 1.816 = pint (IMP)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (IMP)
mL × 0.06102 = cu in.
Units of Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg × 9.807 = N
kg × 2.205 = lb
Units of Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in.
Units of Torque:
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Units of Pressure:
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg × 1.333 = kPa
Units of Speed:
km/h
× 0.6214 = mph
Units of Power:
kW × 1.360 = PS
kW × 1.341 = HP
PS
× 0.7355 = kW
PS × 0.9863 = HP
Units of Temperature:
PERIODIC MAINTENANCE 2-1
2
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-3
Torque and Locking Agent...................................................................................................... 2-5
Specifications ......................................................................................................................... 2-11
Special Tools .......................................................................................................................... 2-13
Periodic Maintenance Procedures.......................................................................................... 2-14
Fuel System (DFI)................................................................................................................ 2-14
Air Cleaner Element Replacement.................................................................................... 2-14
Idle Speed Inspection ....................................................................................................... 2-15
Idle Speed Adjustment...................................................................................................... 2-15
Throttle Control System Inspection................................................................................... 2-15
Engine Vacuum Synchronization Inspection..................................................................... 2-16
Fuel System ...................................................................................................................... 2-19
Fuel Hose Replacement ................................................................................................... 2-20
Evaporative Emission Control System Inspection (CAL, SEA-B1 and TH Models).......... 2-22
Cooling System.................................................................................................................... 2-22
Coolant Level Inspection................................................................................................... 2-22
Cooling System................................................................................................................. 2-23
Coolant Change................................................................................................................ 2-23
Water Hose and O-ring Replacement ............................................................................... 2-26
Engine Top End ................................................................................................................... 2-27
Valve Clearance Inspection .............................................................................................. 2-27
Valve Clearance Adjustment............................................................................................. 2-28
Air Suction System Damage Inspection............................................................................ 2-32
Clutch................................................................................................................................... 2-33
Clutch Operation Inspection ............................................................................................. 2-33
Engine Lubrication System .................................................................................................. 2-34
Engine Oil Change............................................................................................................ 2-34
Oil Filter Replacement ...................................................................................................... 2-35
Wheels/Tires........................................................................................................................ 2-35
Air Pressure Inspection..................................................................................................... 2-35
Wheels and Tires .............................................................................................................. 2-35
Wheel Bearing Damage Inspection .................................................................................. 2-36
Final Drive............................................................................................................................ 2-37
Drive Chain Lubrication Condition Inspection ................................................................... 2-37
Drive Chain Slack Inspection ............................................................................................ 2-38
Drive Chain Slack Adjustment .......................................................................................... 2-38
Wheel Alignment Inspection ............................................................................................. 2-38
Wheel Alignment Adjustment............................................................................................ 2-39
Drive Chain Wear Inspection ............................................................................................ 2-39
Chain Guide Wear Inspection ........................................................................................... 2-40
Brakes.................................................................................................................................. 2-40
Brake System.................................................................................................................... 2-40
Brake Operation Inspection .............................................................................................. 2-41
Brake Fluid Level Inspection............................................................................................. 2-41
Brake Fluid Change .......................................................................................................... 2-42
Brake Hose and Pipe Replacement.................................................................................. 2-44
Master Cylinder Rubber Parts Replacement .................................................................... 2-48
Caliper Rubber Parts Replacement .................................................................................. 2-49
Brake Pad Wear Inspection .............................................................................................. 2-52
Brake Light Switch Operation Inspection.......................................................................... 2-53
2-2 PERIODIC MAINTENANCE
Suspension.......................................................................................................................... 2-54
Suspension System .......................................................................................................... 2-54
Steering ............................................................................................................................... 2-55
Steering Play Inspection ................................................................................................... 2-55
Steering Play Adjustment.................................................................................................. 2-55
Steering Stem Bearing Lubrication ................................................................................... 2-57
Electrical System ................................................................................................................. 2-58
Lights and Switches Operation Inspection........................................................................ 2-58
Headlight Aiming Inspection ............................................................................................. 2-60
Side Stand Switch Operation Inspection........................................................................... 2-61
Engine Stop Switch Operation Inspection......................................................................... 2-62
Spark Plug Replacement .................................................................................................. 2-63
Others.................................................................................................................................. 2-63
Chassis Parts Lubrication ................................................................................................ 2-63
Condition of Bolts, Nuts and Fasteners Tightness Inspection .......................................... 2-64
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
*A: Service at number of years shown or indicated odometer reading intervals, whichever comes
first.
*B: For higher odometer readings, repeat at the frequency interval established here.
*C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed,
or frequent starting/stopping.
: Emission Related Item
: Inspection
: Change or Replace
: Lubrication
Odometer Reading (*B)
× 1 000 km (× 1 000 mile)
Items
year
(*A)
1
(0.6)
6
(3.8)
12
(7.6)
18
(11.4)
24
(15.2)
See
Page
Fuel System
Air cleaner element (*C) 2-14
Idle speed 2-15
Throttle control system (play, smooth return,
no drag)
:1
2-15
Engine vacuum synchronization 2-16
Fuel system
:1
2-19
Fuel hose
:5
2-20
Evaporative emission control system (CAL,
SEA-B1 and TH Models)
2-22
Cooling System
Coolant level 2-22
Cooling system
:1
2-23
Coolant, water hoses and O-rings
:3
: every 36 000 km
(22 500 mile)
2-23,
2-26
Engine Top End
Valve clearance (US and CA Models) 2-27
Valve clearance (Other than US and CA
Models)
: every 42 000 km
(26 250 mile)
2-27
Air suction system 2-32
Clutch
Clutch operation (play, engagement,
disengagement)
2-33
Engine Lubrication System
Engine oil and oil filter (*C)
:1
2-34,
2-35
Wheels and Tires
Tire air pressure
:1
2-35
Wheels and tires
:1
2-35
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
Odometer Reading (*B)
× 1 000 km (× 1 000 mile)
Items
year
(*A)
1
(0.6)
6
(3.8)
12
(7.6)
18
(11.4)
24
(15.2)
See
Page
Wheel bearing damage
:1
2-36
Final Drive
Drive chain lubrication condition (*C)
: every 600 km (400 mile)
2-37
Drivechainslack(*C)
: every 1 000 km (600 mile)
2-38
Drive chain wear (*C)
2-39
Drive chain guide wear 2-40
Brakes
Brake system
:1
2-40
Brake operation (effectiveness, play, no
drag)
:1
2-41
Brake fluid level
:0.5
2-41
Brake fluid (front and rear)
:2
2-42
Brake hose/rubber parts of brake master
cylinder and caliper
:4
: every 48 000 km
(30 000 mile)
2-44,
2-48,
2-49
Brake pad wear (*C) 2-52
Brake light switch operation 2-53
Suspension
Suspension system
:1
2-54
Steering
Steering play
:1
2-55
Steering stem bearing
s
:2
2-57
Electrical System
Electrical system
:1
2-58
Spark plugs
2-63
Others
Chassis parts
:1
2-63
Condition of bolts, nuts and fasteners 2-64
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or silicone sealant etc. All of the values are for use with dry solvent -
cleaned threads unless otherwise indicated.
Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease.
SS: Apply silicone sealant.
2T: Apply 2-stroke oil.
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Fuel System (DFI)
Throttle Body Assy Holder Clamp Bolts 2.9 0.30 26 in·lb
Delivery Pipe Assy Mounting Screws 3.43 0.35 30 in·lb
Air Cleaner Housing Assembly Screws
1.1 0.11 10 in·lb
Air Cleaner Housing Plate Screws
1.1 0.11 10 in·lb
Throttle Case Bolts 3.5 0.36 31 in·lb
Air Cleaner Housing Clamp Bolts 2.0 0.20 18 in·lb
Oxygen Sensor (Equipped Models) 44 4.5 32
Water Temperature Sensor 12 1.2 106 in·lb
Exhaust Butterfly Valve Actuator Pulley Bolt
5.0 0.51 44 in·lb
Exhaust Butterfly Valve Actuator Mounting Screws
1.2 0.12 11 in·lb
Vehicle-down Sensor Mounting Bolts 5.9 0.60 52 in·lb
Crankshaft Sensor Bolts 5.9 0.60 52 in·lb
Intake Air Temperature Sensor Screw 1.2 0.12 11 in·lb
Fuel Pump Bolts 9.8 1.0 87 in·lb L, S
Cooling System
Water Hose Clamp Screws
3.0 0.31 27 in·lb
Fitting Bolt 8.8 0.90 78 in·lb L
Thermostat Housing Bolts 5.9 0.60 52 in·lb L
Water Pipe Bolts 12 1.2 106 in·lb L
Water Pump Impeller Bolt 9.8 1.0 87 in·lb
Water Pump Cover Bolts
11 1.1 97 in·lb
Coolant Drain Bolt
11 1.1 97 in·lb
Engine Top End
Air Suction Valve Cover Bolts
9.8 1.0 87 in·lb L
Spark Plugs
13 1.3 115 in·lb
Cylinder Head Cover Bolts 10 1.0 89 in·lb S
Camshaft Cap Bolts 12 1.2 106 in·lb S
Upper Camshaft Chain Guide Bolts 12 1.2 106 in·lb S
Cylinder Head Bolts (M10) (First) 30 3.1 22 S, MO
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Cylinder Head Bolts (M10) (Final) 54 5.5 40 S, MO
Cylinder Head Jacket Plugs 19.6 2.00 14.5 L
Cylinder Head Bolts (M6)
12 1.2 106 in·lb
S
Throttle Body Assy Holder Bolts 12 1.2 106 in·lb L
Throttle Body Assy Holder Clamp Bolts 2.9 0.30 26 in·lb
Camshaft Chain Tensioner Cap Bolt
20 2.0 15
Camshaft Chain Tensioner Mounting Bolts 11 1.1 97 in·lb
Camshaft Sprocket Bolts 15 1.5 11 L
Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18
Rear Camshaft Chain Guide Bolt 25 2.5 18
Front Camshaft Chain Guide Bolt (Lower) 12 1.2 106 in·lb
Exhaust Pipe Cover Bracket Bolts
10 1.0 89 in·lb
Exhaust Buttery Valve Actuator Pulley Bolt 5.0 0.51 44 in·lb
Exhaust Battery Valve Actuator Mounting Screws 1.2 0.12 11 in·lb
Muffler Body Mounting Bolts
34 3.5 25
Premuffler Chamber Mounting Bolt 34 3.5 25
Muffler Body Clamp Bolts 21 2.1 15
Clutch
Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S
Clutch Spring Bolts 8.8 0.90 78 in·lb
Clutch Hub Nut
135 13.8 100 R
Clutch Cover Bolts 9.8 1.0 87 in·lb
Oil Filler Plug 2.0 0.20 18 in·lb
Engine Lubrication System
Oil Cooler Bolts 12 1.2 106 in·lb L
Oil Filler Plug 2.0 0.20 18 in·lb
Oil Passage Plugs
20 2.0 15 L
Oil Passage Plug 9.8 1.0 87 in·lb
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 2.0 0.20 18 in·lb G
Oil Pressure Relief Valve 15 1.5 11 L
Oil Filter 17 1.7 13 G, R
Oil Filter Pipe
25 2.5 18 L
Engine Oil Drain Bolt 29 3.0 21
Lower Fairing Bracket Bolts 12 1.2 106 in·lb
Oil Pan Bolts
12 1.2 106 in·lb
S
Exhaust Pipe Cover Bracket Bolts 10 1.0 89 in·lb
Engine Removal/Installation
Upper Engine Bracket Bolts 44 4.5 32 S
Lower Engine Bracket Bolts 59 6.0 44 S
Upper Adjusting Collar 5.0 0.51 44 in·lb 2T, S
Upper Adjusting Collar Locknut
49 5.0 36
S
Upper Engine Mounting Bolt (L = 65 mm) 44 4.5 32 S
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Torque
Fastener
N·m
kgf·m ft·lb
Remarks
Lower Engine Mounting Nut 44 4.5 32
S
Lower Adjusting Collar Locknut 49 5.0 36 S
Middle Engine Mounting Nut 44 4.5 32 S
Middle Engine Bracket Bolts 25 2.5 18 L, S
Lower Adjusting Collar 9.8 1.0 87 in·lb S
Upper Engine Mounting Bolt (L = 40 mm)
44 4.5 32
S
Crankshaft/Transmission
Balancer Shaft Clamp Bolt 9.8 1.0 87 in·lb
Balancer Shaft Clamp Lever Bolt 25 2.5 18 L
Connecting Rod Big End Nuts
see the
text
MO
Breather Side Plate Bolt
5.9 0.60 52 in·lb L
Breather Plate Bolts 9.8 1.0 87 in·lb L
Starter Motor Clutch Bolts 12 1.2 106 in·lb L
Oil Passage Plugs
20 2.0 15 L
Oil Passage Plug
9.8 1.0 87 in·lb
Crankcase Bolts (M6) 12 1.2 106 in·lb S
Crankcase Bolts (M7) 20 2.0 15 S
Crankcase Bolts (M8) 27 2.8 20 S
Crankcase Bolts (M9) 40 4.1 30 S, MO
Gear Positioning Lever Bolt
12 1.2 106 in·lb
Shift Drum Bearing Holder Bolts
12 1.2 106 in·lb L
Shift Drum Cam Holder Bolt 12 1.2 106 in·lb L
Shift Shaft Return Spring Pin 39 4.0 29 L
Shift Pedal Mounting Bolt 25 2.5 18
Neutral Switch 15 1.5 11
Wheels/Tires
Front Axle Clamp Bolts
20 2.0 15 AL
Front Axle 108 11.0 79.7
Rear Axle Nut 98 10.0 72
Final Drive
Chain Guide Bolts 9.8 1.0 87 in·lb L
Engine Sprocket Outer Cover Screws 0.70 0.07 6.2 in·lb
Engine Sprocket Nut 125 12.7 92.2 MO
Rear Sprocket Nuts 59 6.0 44 R, S
Chain Adjuster Clamp Bolts
64 6.5 47
Brakes
Front Brake Reservoir Cap Bolts 1.5 0.15 13 in·lb
Front Brake Reservoir Inner Bolt 1.2 0.12 11 in·lb L
Front Brake Reservoir Bolt 7.8 0.80 69 in·lb L
Brake Lever Pivot Bolt 1.0 0.10 8.9 in·lb Si
Front Master Cylinder Bleed Valve 5.4 0.55 48 in·lb
Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Front Brake Light Switch Screw 1.2 0.12 11 in·lb
Front Master Cylinder Clamp Bolts 11 1.1 97 in·lb S
Brake Hose Banjo Bolts 25 2.5 18
Bleed Valves 7.8 0.80 69 in·lb
Front Brake Pad Pins 15 1.5 11
Front Caliper Mounting Bolts
34 3.5 25
Front Brake Disc Mount
ing Bolts
27 2.8 20 L, S
Rear Master Cylinder Mounting Bolts 25 2.5 18
Rear Wheel Rotation Sensor Bolt 25 2.5 18
Brake Pedal Bolt 8.8 0.90 78 in·lb L
Rear Master Cylinder Push Rod Locknut 17 1.7 13
Rear Brake Disc Mounting Bolts 27 2.8 20 L, S
Rear Caliper Mounting Bolts 25 2.5 18
Brake Pipe Joint Nuts (ABS Equipped Models) 18 1.8 13
Front Wheel Rotation Sensor Bolt (ABS Equipped
Models)
25 2.5 18
Suspension
Upper Front Fork Clamp Bolts
20 2.0 15
Lower Front Fork Clamp Bolts 23 2.3 17 AL
Front Fork Top Plugs 35 3.6 26
Piston Rod Guide Case
90 9.2 66
Front Axle Clamp Bolts 20 2.0 15 AL
Upper Rear Shock Absorber Bolt 34 3.5 25
Swingarm Pivot Shaft Nut 108 11.0 79.7
Swingarm Pivot Shaft 20 2.0 15
Swingarm Pivot Adjusting Collar Locknut 98 10.0 72
Tie-Rod Nuts 34 3.5 25 R
Lower Rear Shock Absorber Nut 34 3.5 25 R
Rocker Arm Nut 34 3.5 25 R
Torque Link Nuts 34 3.5 25
Steering
Handlebar Holder Bolts 25 2.5 18 S
Right Switch Housing Bolts 3.5 0.36 31 in·lb
Throttle Case Bolts 3.5 0.36 31 in·lb
Left Switch Housing Bolts 3.5 0.36 31 in·lb
Steering Stem Head Bolt
108 11.0 79.7
Upper Front Fork Clamp Bolts 20 2.0 15
Steering Stem Nut 30 3.1 22
Lower Front Fork Clamp Bolts 23 2.3 17 AL
Frame
Rear View Mirror Locknut (Upper) 18 1.8 13 Lh
Rear View Mirror Nut (Lower) 30 3.1 22
Middle Fairing Screws 1.2 0.12 11 in·lb
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Torque
Fastener
N·m
kgf·m ft·lb
Remarks
Upper Fairing Screws
1.2 0.12 11 in·lb
Front Fender Mounting Bolts 3.9 0.40 35 in·lb
Rear Frame Bracket Bolts 44 4.5 32
Front Footpeg Bracket Bolts 25 2.5 18
Side Stand Switch Bolt 8.8 0.90 78 in·lb L
Side Stand Bracket Bolts 49 5.0 36 L
Side Stand Bolt 29 3.0 21 S
Side Stand Nut 44 4.5 32 R, S
Rear Footpeg Bracket Bolts 25 2.5 18
Rear Frame Bolts 25 2.5 18 L
Rear Frame End Cover Screws 1.2 0.12 11 in·lb
Flap Screws 1.2 0.12 11 in·lb
Electrical System
Meter Cover Bolts 0.40 0.04 3.5 in·lb
City Light Mounting Screws
1.2 0.12 11 in·lb
Headlight (LED) Assembly Mounting Screws
1.2 0.12 11 in·lb
Headlight Control Unit Bracket Screws 1.2 0.12 11 in·lb
Turn Signal Light Screws 1.2 0.12 11 in·lb
Licence Plate Light Screws 1.2 0.12 11 in·lb
Left Switch Housing Bolts 3.5 0.36 31 in·ib
Right Switch Housing Bolts
3.5 0.36 31 in·lb
Front Brake Light Switch Screw
1.2 0.12 11 in·lb
Side Stand Switch Bolt 8.8 0.90 78 in·lb L
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 2.0 0.20 18 in·ib G
Neutral Switch 15 1.5 11
Timing Rotor Bolt 39 4.0 29
Alternator Cover Bolts 12 1.2 106 in·lb
Alternator Lead Holding Plate Bolt 12 1.2 106 in·ib L
Stator Coil Bolts 12 1.2 106 in·ib L
Alternator Rotor Bolt 155 15.8 114
Starter Motor Clutch Bolts 12 1.2 106 in·lb L
Starter Motor Cable Terminal Bolt 2.9 0.30 26 in·lb
Starter Motor Mounting Bolts 9.8 1.0 87 in·lb S
Crankshaft Sensor Bolts 5.9 0.60 52 in·lb
Crankshaft Sensor Cover Bolts
12 1.2 106 in·lb
Spark Plugs
13 1.3 115 in·lb
Water Temperature Sensor 12 1.2 106 in·lb
Fuel Pump Bolts 9.8 1.0 87 in·lb L, S
Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb
Oxygen Sensor (Equipped Models) 44 4.5 32
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Torque
Threads Diameter
(mm)
N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240
PERIODIC MAINTENANCE 2-11
Specifications
Item Standard Service Limit
Fuel System (DFI)
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––
Idle Speed 1 100 ±50 r/min (rpm) –––
Throttle Body Vacuum
40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed
–––
Bypass Screws (Turn Out) 2 1/2 (for reference)
–––
Air Cleaner Element Viscous paper element –––
Cooling System
Coolant:
Type (Recommended) Permanent type of antifreeze –––
Color Green
–––
Mixed Ratio
Soft water 50%, coolant 50%
–––
Freezing Point –35°C (–31°F) –––
Total Amount 2.9 L (3.1 US qt) –––
Engine Top End
Valve Clearance:
Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) –––
Intake 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) –––
Clutch
Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
–––
Engine Lubrication System
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1
or MA2
–––
Viscosity SAE 10W-40 –––
Capacity 3.2 L (3.4 US qt) (when filter is not removed) –––
3.8 L (4.0 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 (Wait
several minutes after idling or running)
–––
Wheels/Tires
Tread Depth:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
(AT, CH, DE) 1.6
mm (0.06 in.)
Rear 6.5 mm (0.26 in.) Up to 130 km/h
(80 mph): 2 mm
(0.08 in.)
Over 130 km/h
(80 mph): 3 mm
(0.12 in.)
Air Pressure (when Cold):
Front Up to 180 kg (397 lb) load:
250kPa(2.50kgf/cm²,36psi)
–––
Rear Up to 180 kg (397 lb) load:
290kPa(2.90kgf/cm²,42psi)
–––
2-12 PERIODIC MAINTENANCE
Specifications
Item Standard Service Limit
Final Drive
DriveChainSlack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) –––
Drive Chain Wear (20-link
Length)
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.)
Standard Chain:
Make ENUMA –––
Type EK525ZX –––
Link 112 links –––
Brakes
Brake Fluid:
Grade DOT4 –––
Brake Pad Lining
Thickness:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 5.0 mm (0.20 in.) 1 mm (0.04 in.)
Brake Light Timing:
Front Pulled ON –––
Rear ON after about 10 mm (0.39 in.) of pedal travel –––
Electrical System
Spark Plug:
Type NGK CR9EIA-9 –––
Gap 0.8 ∼ 0.9 mm (0.032 ∼ 0.036 in.) –––
PERIODIC MAINTENANCE 2-13
Special Tools
Inside Circlip Pliers:
57001-143
Steering Stem Nut Wrench:
57001-1100
Jack:
57001-1238
Pilot Screw Adjuster, A:
57001-1239
Oil Filter Wrench:
57001-1249
Attachment Jack:
57001-1252
Vacuum Gauge:
57001-1369
Throttle Sensor Setting Adapter:
57001-1538
Extension Tube:
57001-1578
Jack Attachment:
57001-1608
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System (DFI)
Air Cleaner Element Replacement
NOTE
○
In dusty areas, the element should be replaced more
frequently than the recommended interval.
WARNING
If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident. Replace the air cleaner
element according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Connector Bracket [A]
Air Cleaner Housing Assembly Screws [B]
Upper Air Cleaner Housing [C]
•
Discard the air cleaner element [A].
•
Install a new element [A] so that the screen side [B] faces
upward.
•
Install:
Upper Air Cleaner Housing
•
Tighten:
Torque - Air Cleaner Housing Assembly Screws: 1.1 N·m
(0.11 kgf·m, 10 in·lb)
•
Install:
Fuel Tank (see Fuel Tank Installation in the Fuel System
(DFI) chapter)
PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
Idle Speed Inspection
•
Start the engine and warm it up thoroughly.
•
With the engine idling, turn the handlebars to both sides
[A].
If handlebars movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed, or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.
•
Check the idle speed.
If the idle speed is out of specified range, adjust it.
Idle Speed
Standard: 1 100 ±50 r/min (rpm)
Idle Speed Adjustment
•
Start the engine and warm it up thoroughly.
•
Turn the adjusting screw [A] until the idle speed is correct.
Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Throttle Control System Inspection
•
Check that the throttle grip [A] moves smoothly from full
open to close, and the throttle closes quickly and com-
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
•
Check the throttle grip free play [B].
Throttle Grip Free Play
Standard: 2
∼ 3 mm (0.08 ∼ 0.12 in.)
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If the free play is incorrect, adjust the throttle cable as
follows.
•
Slide the dust covers.
•
Loosen the locknuts [A] [B].
•
Screw both throttle cable adjusters [C] [D] to give the
throttle grip plenty of play.
•
Turn the decelerator cable adjuster [C] until there is no
play when the throttle grip play completely closed.
•
Tighten the locknut [A].
•
Turn the accelerator cable adjuster [D] until 2 ∼ 3mm
(0.08 ∼ 0.12 in.) of throttle grip play is obtained.
•
Tighten the locknut [B].
If the free play can not be adjusted with the adjusters,
replace the cable.
Engine Vacuum Synchronization Inspection
NOTE
○
These procedures are explained on the assumption that
the intake and exhaust systems of the engine are in
good condition.
•
Situate the motorcycle so that it is vertical.
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Fuel Hose (see Fuel Hose Replacement)
•
Pull off the rubber caps [A] from the fittings of each throttle
body.
•
For the CAL, SEA-B1 and TH Models, pull off the vacuum
hoses.
•
Connect a vacuum gauge and hoses [A] (Special Tool:
57001-1369) to the fittings on the throttle body.
Special Tool - Vacuum Gauge: 57001-1369
•
Connect a highly accurate tachometer lead [B] to one of
the stick coil primary leads.
PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
•
Plug the air switching valve hose end [A] and air cleaner
housing fitting [B].
•
Install the air cleaner housing (see Air Cleaner Housing
Installation in the Fuel System (DFI) chapter).
•
Connect the following parts temporarily.
Fuel Pump Lead Connector [A]
Extension Tube [B]
Special Tool - Extension Tube: 57001-1578
•
Start the engine and warm it up thoroughly.
•
Check the idle speed, using a highly accurate tachometer
[A].
Idle Speed
Standard: 1 100 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it with
the adjusting screw (see Idle Speed Adjustment).
NOTICE
Do not measure the idle speed by the tachometer of
the meter unit.
•
While idling the engine, inspect the throttle body vacuum,
using the vacuum gauge [B].
Throttle Body Vacuum
Standard: 40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If any vacuum is not within specifications, adjust the by-
pass screws [A].
View from Rear [B]
Special Tool - Pilot Screw Adjuster, A [C]: 57001-1239
•
Adjust the each vacuum (#1 ∼ #4) to the standard value.
•
Open and close the throttle valves after each measure-
ment.
NOTE
○
Do not turn the center adjusting screw [D].
•
Check the vacuums as before.
If all vacuums are within the specification range, finish the
engine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
replace the bypass screws #1 ∼ #4 with new ones, refer
to the following procedure.
•
Remove the throttle body assy (see Throttle Body Assy
Removal in the Fuel System (DFI) chapter).
•
Turn in the bypass screw [A] with counting the number of
turns until it seals fully but not tightly. Record the number
of turns.
•
Remove:
Bypass Screw
Spring [B]
Washer [C]
O-ring [D]
•
Check the bypass screw hole in the throttle body for car-
bon deposits.
If any carbons accumulate, wipe the carbons off from the
hole, using a cotton pad penetrated with a high flash-point
solvent.
•
Replace the bypass screw, spring, washer and O-ring as
aset.
•
Turn in the bypass screw until it seats fully but not tightly.
NOTICE
Do not over-tighten the bypass screw. The tapered
portion [E] of the bypass screw could be damaged.
PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
•
Back out the same number of turns counted when first
turned in. This is to set the screw to its original position.
NOTE
○
A throttle body has different “turns out” of the bypass
screw for each individual unit. On setting the bypass
screw, use the “turns out” determined during disassem-
bly.
•
Repeat the same procedure for other bypass screws.
•
Repeat the synchronization.
If the vacuums are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
Main Throttle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor Y/W) lead
Digital Meter (–) → BK (sensor G) lead
Standard: DC 1.02
∼ 1.06 V at idle throttle opening
If the output voltage is out of the standard, check the in-
put voltage of the main throttle sensor (see Main Throttle
Sensor Input Voltage Inspection in the Fuel System (DFI)
chapter).
•
Remove the vacuum gauge hoses and install the rubber
caps on the original position.
•
For CAL, SEA-B1 and TH Models, install the vacuum
hoses.
Run the vacuum hoses according to Cable, Wire, and
Hose Routing section in the Appendix chapter.
•
Install the removed parts (see appropriate chapters).
Fuel System
Fuel Hose Inspection (fuel leak, damage, installation
condition)
If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re-
moval in the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Check that the fuel hose is routed according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Hose Joints [A]
Fuel Hose [B]
•
Check that the fuel hose joints are securely connected.
Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked.
WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe by sliding the
joint.
If it does not locked, reinstall the hose joint.
Fuel Hose Replacement
•
Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
•
Remove the connector bracket from the air cleaner hous-
ing.
•
Disconnect the intake air temperature sensor lead con-
nector.
•
Be sure to place a piece of cloth around the fuel hose joint.
•
Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.
When removing with standard tip screwdriver
•
Insert the standard tip screwdriver [A] into slit on the joint
lock [B].
•
Turn the driver to disconnect the joint lock.
When removing with fingers
•
Open and push up [C] the joint lock with your fingers.
NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.
PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
•
Pull the fuel hose joint [A] out of the delivery pipe [B].
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
•
Clean the delivery pipe.
•
Cover the delivery pipe with the vinyl bag to keep it clean.
•
Remove the vinyl bag on the pipe.
•
Check that there are no flaws, burrs, and adhesion of
foreign materials on the delivery pipe [A].
•
Replace the fuel hose with a new one.
•
Run the fuel hose correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
•
Insert [A] the fuel hose joint [B] straight onto the delivery
pipe until the hose joint clicks.
•
Push [C] the joint lock [D].
•
Push and pull [A] the fuel hose joint [B] back and forth
more than two times and make sure it is locked and does
not come off.
WARNING
Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.
If it comes off, reinstall the hose joint.
•
Install the removed parts (see appropriate chapters).
•
Start the engine and check the fuel hose for leaks.
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Evaporative Emission Control System Inspection
(CAL, SEA-B1 and TH Models)
•
Inspect the canister as follows.
Remove the front seat (see Front Seat Removal in the
Frame chapter).
Pull the canister [A] out of the rear fender.
Slide the clamps [B].
Disconnect the hoses [C].
Remove the canister.
Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.
NOTE
○
The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under
normal conditions.
•
Inspect the purge valve (see Purge Valve Inspection in
the Fuel System (DFI) chapter).
Check that the hoses are securely connected and clips
are in position.
Replace any kinked, deteriorated or damaged hoses.
Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.
When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and run the hoses with a minimum of
bending so that the emission flow will not be obstructed.
Cooling System
Coolant Level Inspection
NOTE
○
Check the level when the engine is cold (room or ambi-
ent temperature).
•
Check the coolant level in the reserve tank [A] with
the motorcycle held perpendicular (Do not use the side
stand).
If the coolant level is lower than the “L” level line [B], un-
screw the reserve tank cap and add coolant to the “F”
level line [C].
“L”: Low
“F”: Full
NOTICE
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 ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.
PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
Cooling System
Water Hose and Pipe Inspection (coolant leak, damage,
installation condition)
The high pressure inside the water hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.
•
Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
•
Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
Coolant Change
WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.
•
Remove:
Right Middle Fairing (see Middle Fairing Removal in the
Frame chapter)
Radiator Cap [A]
Remove the radiator cap in two steps. First turn the cap
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.
•
Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
•
Place a container under the drain bolt [A] of the water
pump cover.
•
Drain the coolant from the radiator by removing the drain
bolt.
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Remove:
Lower Rear Shock Absorber Nut and Bolt [A] (see Rear
Shock Absorber Removal in the Suspension chapter)
•
Remove:
Coolant Reserve Tank Bolts [A]
Collars
•
Pull up the coolant reserve tank [A].
•
Disconnect the radiator overflow hose [B].
•
Remove the cap [C].
•
Pour the coolant into a container.
•
Install:
Radiator Overflow Hose
Coolant Reserve Tank
Collars
•
Apply a non-permanent locking agent to the threads of
the coolant reserve tank bolts and tighten them.
•
Replace the lower rear shock absorber nut with a new
one.
•
Tighten:
Torque - Lower Rear Shock Absorber Nut: 34 N·m (3.5
kgf·m, 25 ft·lb)
•
Tighten the drain bolt with new gasket.
Torque - Coolant Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
•
When filling the coolant, choose a suitable mixture ratio
by referring to the coolant manufacturer’s directions.
NOTICE
Soft or distilled water must be used with the an-
tifreeze in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and consider-
ably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water: 50%
Coolant: 50%
Freezing Point:
–35°C (–31°F)
Total Amount:
2.9 L (3.1 US qt)
PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
•
Fill the radiator up to the filler neck [A] with coolant.
NOTE
○
Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
•
Check the cooling system for leaks.
•
Tap the water hoses to force any air bubbles caught in-
side.
•
Fill the radiator up to the filler neck with coolant.
•
Fill the reserve tank up to the “F” (full) level line [A] with
coolant and install the cap [B].
•
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.
If the coolant level is lower than the “L” (low) level line [C],
add coolant to the “F” level line.
NOTICE
Do not add more coolant above the “F” level line.
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Water Hose and O-ring Replacement
•
Drain the coolant (see Coolant Change).
•
Remove:
Middle Fairing (see Middle Fairing Removal in the Frame
chapter)
Oil Cooler [A] (see Oil Cooler Removal in the Engine
Lubrication System chapter)
Thermostat Housing Cover [B] (see Thermostat Re-
moval in the Cooling System chapter)
Water Pump Housing [C] (see Water Pump Removal in
the Cooling System chapter)
•
Replace the hoses [D] and O-rings [E] with new ones.
•
Apply grease or soap and water solution to the new O
-rings.
•
Run the new hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
•
Tighten:
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
•
Install the removed parts (see appropriate chapters).
•
Fill the coolant (see Coolant Change).
•
Check the cooling system for leaks.
PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
Engine Top End
Valve Clearance Inspection
NOTE
○
Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
•
Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Crankshaft Sensor Cover (see Crankshaft Sensor Re-
moval in the Electrical System chapter)
•
Using a wrench on the timing rotor bolt [A], turn the crank-
shaft clockwise until the line [B] (TDC mark for #1,4 pis-
tons) on the timing rotor is aligned with the mating surface
[C] of the crankcase.
•
Using a thickness gauge [A], measure the valve clearance
between the cam and the valve lifter.
Valve Clearance
Standard:
Exhaust
0.22
∼ 0.31 mm (0.0087 ∼ 0.0122 in.)
Intake
0.15
∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
NOTE
○
Thickness gauge is horizontally inserted on the valve
lifter.
Appropriateness [A]
Inadequacy [B]
Thickness Gauge [C]
Horizontally Inserts [D]
Cam [E]
Valve Lifter [F]
Hits the Valve Lifter Ahead [G]
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
When positioning #1 piston TDC at the end of the
compression stroke:
Intake Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [A]
When positioning #4 piston TDC at the end of the
compression stroke:
Intake Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [A]
If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.
Valve Clearance Adjustment
•
To change the valve clearance, remove the camshaft
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.
NOTE
○
Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.
PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
Besides the standard shims in the valve clearance adjust-
ment charts, the following shims may be installed at the
factory. Although they are not available as spare parts,
they can be used to adjust valve clearance.
Adjustment Shims
Thickness
2.675 mm
2.725 mm
2.775 mm
2.825 mm
2.875 mm
2.925 mm
2.975 mm
3.025 mm
3.075 mm
3.125 mm
3.175 mm
3.225 mm
3.275 mm
3.325 mm
•
Clean the shim to remove any dust or oil.
•
Measure the thickness of the removed shim [A].
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE
1. Measure the clearance (when engine is cold).
2. Check present shim size.
3. Match clearance in vertical column with present shim size in horizontal column.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example: Present shim is 2.95 mm
Measured clearance is 0.45 mm
Replace 2.95 mm shim with 3.20 mm shim.
5. Remeasure the valve clearance and readjust if necessary.
PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE
1. Measure the clearance (when engine is cold).
2. Check present shim size.
3. Match clearance in vertical column with present shim size in horizontal column.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example: Present shim is 2.95 mm.
Measured clearance is 0.47 mm.
Replace 2.95 mm shim with 3.15 mm shim.
5. Remeasure the valve clearance and readjust if necessary.
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTICE
Be sure to remeasure the clearance after selecting
a shim according to the table. If the clearance is out
of the specified range, use the additional shim.
If there is no valve clearance, use a shim that is a few
sizes smaller, and remeasure the valve clearance.
•
When installing the shim, face the marked side toward the
valve lifter. At this time, apply engine oil to the shim or
the valve lifter to keep the shim in place during camshaft
installation.
NOTICE
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex-
tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.
•
Apply engine oil to the valve lifter surface and install the
lifter.
•
Install the camshafts (see Camshaft Installation in the En-
gine Top End chapter).
•
Recheck the valve clearance and readjust if necessary.
•
Install the removed parts (see appropriate chapters).
Air Suction System Damage Inspection
•
Disconnect:
Subthrottle Sensor Connector [A]
Air Switching Valve Hose [B]
•
Connect the subthrottle sensor connector.
•
Start the engine and run it at idle speed.
•
Plug the air switching valve hose end [A] with your finger
and feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical Sys-
tem chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).
PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
Clutch
Clutch Operation Inspection
•
Pull the clutch lever just enough to take up the free play
[A].
•
Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2
∼ 3 mm (0.08 ∼ 0.12 in.)
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
•
Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B]
of threads is 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 clutch cover [D].
•
Slip the dust cover back onto place.
•
Turn the adjuster at the clutch lever until the free play is
correct.
•
Push the release lever [A] toward the front of the motor-
cycle until it becomes hard to turn.
At this time, the release lever should have the proper an-
gle shown.
60° [B]
If the angle is wrong, check the clutch and release parts
for wear.
WARNING
Too much cable play can prevent clutch disengage-
ment and cause an accident resulting in serious in-
jury or death. When adjusting the clutch or replac-
ing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.
•
After the adjustment, start the engine and check that the
clutch does not slip and that it releases properly.
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Engine Lubrication System
Engine Oil Change
•
Situate the motorcycle so that it is vertical after warming
up the engine.
•
Remove the engine oil drain bolt [A] to drain the oil.
The oil in the oil filter can be drained by removing the filter
(see Oil Filter Replacement).
•
Replace the drain bolt gasket [B] with a new one.
•
Tighten the drain bolt.
Torque - Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)
•
Remove the oil filler plug [A].
•
Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity:
SAE 10W-40
Capacity: 3.2 L (3.4 US qt) (when filter is not removed)
3.8 L (4.0 US qt) (when filter is removed)
4.0 L (4.2 US qt) (when engine is completely
dry)
NOTE
○
Do not add any chemical additive to the oil.Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
○
Although 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.
•
Replace the O-ring of the oil filler plug with a new one.
•
Apply grease to the new O-ring.
•
Install the oil filler plug.
Torque - Oil Filler Plug: 2.0 N·m (0.20 kgf·m, 18 in·lb)
•
Check the oil level (see Oil Level Inspection in the Engine
Lubrication System chapter).
PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
Oil Filter Replacement
•
Drain the engine oil (see Engine Oil Change).
•
Remove the oil filter with the oil filter wrench [A].
Special Tool - Oil Filter Wrench: 57001-1249
•
Replace the filter with a new one.
•
Apply grease to the gasket [A] before installation.
•
Tighten the filter with the oil filter wrench.
Special Tool - Oil Filter Wrench: 57001-1249
Torque - Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb)
NOTE
○
Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.
•
Pour in the specified type and capacity of oil (see Engine
Oil Change).
Wheels/Tires
Air Pressure Inspection
•
Remove the air valve cap.
•
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).
•
Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front:
Up to 180 kg (397 lb) load:
250kPa(2.50kgf/cm²,36psi)
Rear:
Up to 180 kg (397 lb) load:
290kPa(2.90kgf/cm²,42psi)
Wheels and Tires
Wheel/Tire Damage Inspection
•
Remove any imbedded stones [A] or other foreign parti-
cles [B] from tread.
•
Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate inter-
nal damage, requiring tire replacement.
•
Visually inspect the wheel for cracks, cuts and dents dam-
age.
If any damage is found, replace the wheel if necessary.
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tire Tread Wear Inspection
As the tire tread wears down, the tire becomes more sus-
ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
•
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.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).
Tread Depth
Standard:
Front
4.0 mm (0.16 in.)
Rear
6.5 mm (0.26 in.)
Service Limit:
Front
1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)
Rear
2 mm (0.08 in.) (Up to 130 km/h (80 mph))
3 mm (0.12 in.) (Over 130 km/h (80 mph))
WARNING
Some replacement tires may adversely affect han-
dling and cause an accident resulting in serious in-
jury or death. To ensure proper handling and sta-
bility, use only the recommended standard tires for
replacement, inflated to the standard pressure.
NOTE
○
Most countries may have their own regulations a mini-
mum tire tread depth: be sure to follow them.
○
Check and balance the wheel when a tire is replaced
with a new one.
Wheel Bearing Damage Inspection
•
Raise the front wheel off the ground with the jack (see
Front Wheel Removal in the Wheels/Tires chapter).
Special Tools - Jack: 57001-1238
Attachment Jack: 57001-1252
Jack Attachment: 57001-1608
•
Turn the handlebars all the way to the right or left.
•
Inspect the roughness of the front wheel bearing by push-
ing and pulling [A] the wheel.
•
Spin [B] the front wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
•
Raise the rear wheel off the ground with the stand (see
Rear Wheel Removal in the Wheels/Tires chapter).
•
Inspect the roughness of the rear wheel bearing by push-
ing and pulling [A] the wheel.
•
Spin [B] the rear wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Re-
moval, Hub Bearing Inspection in the Wheels/Tires chap-
ter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).
Final Drive
Drive Chain Lubrication Condition Inspection
Lubrication is necessary after riding through rain or on wet
roads, or any time that the chain appears dry.
Use a lubricant for sealed chains to prevent deterioration
of chain seals. If the chain is especially dirty, clean it using a
cleaner for sealed chains following the instructions supplied
by the chain cleaner manufacturer.
NOTICE
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 chain cleaner for cleaning of the O-ring of
the drive chain. Any other cleaning solution such
as gasoline will cause deterioration and swelling
of the O-ring. Immediately blow the chain dry with
compressed air after cleaning. Complete cleaning
and drying the chain within 10 minutes.
•
Apply chain 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-rings [B]
•
Wipe off lubricant that gets on the tire surface.
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Chain Slack Inspection
NOTE
○
Check the slack with the motorcycle setting on its side
stand.
○
Clean the chain if it is dirty, and lubricate it if it appears
dry.
•
Check the wheel alignment (see Wheel Alignment Inspec-
tion).
•
Rotate the rear wheel to find the position where the chain
is tightest.
•
Measure the vertical movement (chain slack) [A] midway
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard: 20
∼ 30 mm (0.8 ∼ 1.2 in.)
Drive Chain Slack Adjustment
•
Loosen the left and right chain adjuster clamp bolts [A].
•
Using an Allen wrench [B], turn the adjusters [C] forward
or rearward until the drive chain has the correct amount
of chain slack.
•
Tighten:
Torque - Chain Adjuster Clamp Bolts: 64 N·m (6.5 kgf·m, 47
ft·lb)
Wheel Alignment Inspection
•
Check that the left and right notches [A] on the swingarm
should point to the same marks or positions [B] on the left
and right adjuster.
If they do not, adjust the chain slack (see Drive Chain
Slack Adjustment) and align the wheel alignment.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
Wheel Alignment Adjustment
•
Remove the right retaining ring [A].
•
Loosen the axle nut [B].
•
Loosen the right chain adjuster clamp bolt [C], and turn
the right chain adjuster [D] so that the left and right
notches on the swingarm may point to the same marks
or positions on the left and right adjusters.
•
Tighten:
Torque - Chain Adjuster Clamp Bolt: 64 N·m (6.5 kgf·m, 47
ft·lb)
Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
•
Replace the right retaining ring with a new one and install
it.
Drive Chain Wear Inspection
•
Remove the chain cover (see Drive Chain Replacement
in the Final Drive chapter).
•
Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
•
Stretch the chain taut by hanging a 10 kg (22 lb) 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 several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard: 317.5
∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit: 319 mm (12.6 in.)
WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain.
Standard Chain
Make: ENUMA
Type: EK525ZX
Link: 112 links
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Chain Guide Wear Inspection
•
Remove the swingarm (see Swingarm Removal in the
Suspension chapter).
•
Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.
Brakes
Brake System
Brake Fluid Leak (Brake Hose and Pipe) Inspection
•
For ABS equipped models, remove the air cleaner hous-
ing (see Air Cleaner Housing Removal in the Fuel System
(DFI) chapter).
•
Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A], pipe [B] (ABS equipped
models) and fittings [C].
If the brake fluid leaked from any position, inspect or re-
place the problem part.
PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
Brake Hose and Pipe Damage and Installation Condi-
tion Inspection
•
For ABS equipped models, remove the air cleaner hous-
ing (see Air Cleaner Housing Removal in the Fuel System
(DFI) chapter).
•
Inspect the brake hoses, pipe and fittings for deteriora-
tion, cracks and signs of leakage.
The high pressure inside the brake line can cause fluid to
leak [A] or the hose, pipe (ABS equipped models) to burst
if the line is not properly maintained. Bend and twist the
rubber hose while examining it.
Replace the hose and pipe (ABS equipped models) if any
crack [B], bulge [C] or leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts (ABS Equipped Models): 18
N·m (1.8 kgf·m, 13 ft·lb)
•
Inspect the brake hose and pipe routing.
If any brake hose and pipe routing is incorrect, run the
brake hose and pipe according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
Brake Operation Inspection
•
Inspect the operation of the front and rear brake by run-
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
WARNING
When test riding the vehicle, be aware of surround-
ing traffic for your safety.
Brake Fluid Level Inspection
•
Check that the brake fluid level in the front brake reservoir
[A] is above the lower level line [B].
NOTE
○
Hold the reservoir horizontal by turning the handlebars
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
•
Tighten:
Torque - Front Brake Reservoir Cap Bolts: 1.5 N·m (0.15
kgf·m, 13 in·lb)
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Check that the brake fluid level in the rear brake reservoir
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
Remove the stopper [D].
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
Recommended Disc Brake Fluid
Grade: DOT4
•
Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
First, tighten the brake fluid reservoir cap [B] clockwise
[C] by hand until slight resistance is felt indicating that
the cap is seated on the reservoir body, then tighten the
cap an additional 1/6 turn [D] while holding the brake fluid
reservoir body [A].
•
Install the stopper and tighten the screw.
Brake Fluid Change
NOTE
○
The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for
the front brake.
•
Level the brake fluid reservoir.
•
Remove the reservoir cap, diaphragm plate and di-
aphragm.
•
Remove the rubber cap [A] from the bleed valve on the
caliper.
•
Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.
•
Fill the reservoir with fresh specified brake fluid.
PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
•
Change the brake fluid.
Repeat 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
○
The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
○
Front Brake: Repeat the above steps for the other
caliper.
•
Remove the clear plastic hose.
•
Install the diaphragm, diaphragm plate and reservoir cap.
•
Tighten:
Torque - Front Brake Reservoir Cap Bolts: 1.5 N·m (0.15
kgf·m, 13 in·lb)
•
Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].
•
Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
•
After changing the fluid, check the brake for good braking
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose and Pipe Replacement
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
•
Remove:
Upper Fairing Cover (see Upper Fairing Removal in the
Frame chapter)
Brake Hose Fitting Bolt [A]
Brake Hose Banjo Bolts [B]
Bolts [C]
•
When removing the brake hoses [D], note the following.
Take care not to spill the brake fluid on the painted or
plastic parts.
Temporarily secure the end of the brake hose to some
high place to keep fluid loss to a minimum.
Immediately wash away any brake fluid that spills.
•
When installing the brake hoses, note the following.
Avoid sharp bending, kinking, flatting or twisting, and run
the hoses according to Cable, Wire, and Hose Routing
section in the Appendix chapter.
There are washers on each side of the brake hose fitting.
Replace them with new ones.
Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
•
Fill the brake line after installing the brake hose (see
Brake Fluid Change).
PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
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2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
For ABS equipped models; note the following.
NOTE
○
When removing the brake pipes and hoses on the hy-
draulic unit, remove them with the flare nut wrench ac-
cording to each assembly of the exploded view in the
Brakes chapter.
•
Remove:
Upper Fairing Cover (see Upper Fairing Removal in the
Frame chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Battery Case (see Battery Case Removal in the Frame
chapter)
Brake Pipe Joint Nuts [A]
Brake Hose Banjo Bolts [B]
Bolts [C]
Clamps
•
There are washers on each side of the brake hose and
pipe fitting. Replace them with new ones when installing.
•
Before installing the brake pipe, check to see that there is
no damage on the threads of the brake pipe joint nut.
If there is any damage, replace the damaged parts with
new ones.
NOTE
○
Tighten the brake pipe joint nut at both ends of the brake
pipe temporarily and then tighten them to the specified
torque.
•
Install the brake pipes and brake hoses to the specified
angle (see Cable, Wire, and Hose Routing section in the
Appendix chapter).
•
Tighten the brake pipe joint nuts with the flare nut wrench.
•
Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)
•
Fill the brake line after installing the brake hose and pipe
(see Brake Fluid Change).
PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
•
Remove the front master cylinder (see Front Master Cylin-
der Removal in the Brakes chapter).
•
Remove:
Front Brake Reservoir Cap Bolts [A]
Reservoir Cap [B]
Diaphragm Plate [C]
Diaphragm [D]
Float [E]
Front Brake Reservoir Inner Bolt [F]
Front Brake Reservoir Bolt [G]
•
Pull out the fluid reservoir [H] and O-rings [I].
•
Unscrew the locknut [J] and pivot bolt [K], and remove the
brake lever.
•
Remove the circlip [L].
Special Tool - Inside Circlip Pliers: 57001-143
•
Pull out the piston assembly [M].
•
Replace:
Diaphragm [D]
O-rings [I]
Circlip [L]
Piston Assembly [M]
Rear Master Cylinder Disassembly
•
Remove the rear master cylinder (see Rear Master Cylin-
der Removal in the Brakes chapter).
•
Remove the circlip [A], connector [B] and O-ring [C].
Special Tool - Inside Circlip Pliers: 57001-143
•
Slide the dust cover [D] out of place, and remove the cir-
clip [E].
•
Pull out the push rod assembly [F].
•
Remove the piston assembly [G] and return spring [H].
NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.
•
Replace:
Circlip [A]
O-ring [C]
Circlip [E]
Push Rod Assembly [F]
Piston Assembly [G]
Diaphragm [I]
PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures
Master Cylinder Assembly
•
Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
NOTICE
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.
•
Apply brake fluid to the new parts and to the inner wall of
the cylinder.
•
Take care not to scratch the piston or the inner wall of the
cylinder.
•
Apply silicone grease to the followings.
Front: Brake Lever Pivot Bolt
Rear:
Dust Cover of Push Rod Assembly
•
For the front master cylinder, tighten the brake lever pivot
bolt and the locknut.
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9
in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
•
For the front master cylinder, apply a non-permanent lock-
ing agent to the threads of the front master cylinder reser-
voir inner bolt and front master cylinder reservoir bolt.
•
Tighten:
Torque - Front Brake Reservoir Bolt: 7.8 N·m (0.80 kgf·m,
69 in·lb)
Front Brake Reservoir Inner Bolt: 1.2 N·m (0.12
kgf·m, 11 in·lb)
•
For the front master cylinder, install the bleed valve and
rubber cap.
Torque - Front Master Cylinder Bleed Valve: 5.4 N·m (0.55
kgf·m, 48 in·lb)
Caliper Rubber Parts Replacement
Front Caliper Disassembly
•
Loosen the front caliper pad pins [A] and banjo bolt [B]
and tighten them loosely.
•
Remove:
Front Caliper [C] (see Front Caliper Removal in the
Brakes chapter)
Brake Pads (see Front Brake Pad Removal in the Brakes
chapter)
2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Hold the pistons nearest the oil passage [A] with the
bands [B].
•
Using compressed air, remove the pistons.
Cover the caliper opening with a clean heavy cloth [A].
Lightly apply compressed air [B] to the oil passage.
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
Pull out the pistons by hand.
•
Remove the dust seals [A] and fluid seals [B].
•
Cut the bands.
•
Repeat the previous step to remove the pistons from the
other side of the caliper body.
•
Remove the bleed valve and rubber cap.
Front Caliper Assembly
•
Clean the caliper parts except for the pads.
NOTICE
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
•
Install the bleed valve and rubber cap.
•
Tighten:
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
•
Replace the fluid seals [A] with new ones.
Apply silicone grease to the fluid seals, and install them
into the cylinders by hand.
•
Replace the dust seals [B] with new ones if they are dam-
aged.
Apply silicone grease to the dust seals, and install them
into the cylinders by hand.
PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures
•
Apply brake fluid to the outside of the pistons, and push
them into each cylinder by hand.
•
Install the removed parts (see appropriate chapters).
•
Wipe up any spilled brake fluid on the caliper with wet
cloth.
Rear Caliper Disassembly
•
Remove:
Rear Caliper (see Rear Caliper Removal in the Brakes
chapter)
Brake Pads (see Rear Brake Pad Removal in the Brakes
chapter)
Caliper Holder [A]
•
Remove:
Dust Boot [A]
Friction Boot [B]
•
Using compressed air, remove the piston.
Cover the caliper opening with a clean heavy cloth [A].
Remove the piston by lightly applying compressed air [B]
to where the brake line fits into the caliper.
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
•
Remove the pad spring.
•
Remove the dust seal and fluid seal.
•
Remove the bleed valve and rubber cap.
Rear Caliper Assembly
•
Clean the caliper parts except for the pads.
NOTICE
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
•
Install the bleed valve and rubber cap.
•
Tighten:
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Replace the fluid seal [A] with a new one.
Apply silicone grease to the fluid seal, and install it into
the cylinder by hand.
•
Replace the dust seal [B] with a new one.
Apply silicone grease to the dust seal, and install it into
the cylinder by hand.
•
Install the pad spring [A] in the caliper as shown.
•
Apply brake fluid to the outside of the piston [B], and push
it into the cylinder by hand.
•
Replace the friction boot [C] and dust boot [D].
•
Apply a silicone grease to the caliper holder shafts [A].
•
Check that the guide [B] is in place on the caliper holder.
•
Assemble the caliper and the caliper holder.
•
Install the pads (see Rear Brake Pad Installation in the
Brakes chapter).
•
Wipe up any spilled brake fluid on the caliper with wet
cloth.
Brake Pad Wear Inspection
•
Remove the brake pads (see Front/Rear Brake Pad Re-
moval in the Brakes chapter).
•
Check the lining thickness [A] of the pads in each caliper.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Front Brake Pad [C]
Rear Brake Pad [D]
Pad Lining Thickness
Standard:
Front
4.0 mm (0.16 in.)
Rear
5.0 mm (0.20 in.)
Service Limit: 1 mm (0.04 in.)
PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
Brake Light Switch Operation Inspection
•
Turn the ignition switch on.
•
The brake light (LED) [A] should go on when the brake
lever is applied or after the brake pedal is depressed
about 10 mm (0.39 in.).
If it does not, adjust the brake light switch.
•
Remove the front footpeg bracket bolts [A].
•
Pull the right footpeg bracket [B] outward.
•
While holding the switch body, turn the adjusting nut to
adjust the switch.
Switch Body [A]
Adjusting Nut [B]
Light sooner as the body rises [C]
Light later as the body lowers [D]
NOTICE
To avoid damaging the electrical connections in-
side the switch, be sure that the switch body does
not turn during adjustment.
•
Tighten:
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
If it does not go on, inspect or replace the following parts.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Brake Light (LED) (see Tail/Brake Light (LED) Re-
moval/Installation in the Electrical System chapter)
Main Fuse 30 A and Brake Light/Horn Fuse 7.5 A (see
Fuse Inspection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Suspension
Suspension System
Front Forks/Rear Shock Absorber Operation Inspec-
tion
•
Pump the forks down and up [A] 4 or 5 times, and inspect
the smooth stroke.
If the forks do not smoothly or noise is found, inspect the
fork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).
•
Pump the rear seat down and up [A] 4 or 5 times, and
inspect the smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection).
Front Fork Oil Leak Inspection
•
Visually inspect the front forks [A] for oil leakage.
Replace any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
•
Visually inspect the rear shock absorber [A] for oil leak-
age.
If the oil leakage is found on it, replace the rear shock
absorber with a new one.
Rocker Arm Operation Inspection
•
Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the rocker arms [A] do not smoothly stroke or noise is
found, inspect the fasteners and bearings (see Rocker
Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen-
sion chapter).
PERIODIC MAINTENANCE 2-55
Periodic Maintenance Procedures
Tie-Rod Operation Inspection
•
Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the tie-rod [A] do not smoothly stroke or noise is found,
inspect the fasteners and tie-rod bearings (see Rocker
Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen-
sion chapter).
Steering
Steering Play Inspection
•
Raise the front wheel off the ground with the jack (see
Front Wheel Removal in the Wheels/Tires chapter).
Special Tools - Jack: 57001-1238
Attachment Jack: 57001-1252
Jack Attachment: 57001-1608
•
With the front wheel pointing straight ahead, alternately
tap each end of the handlebars. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
•
Feel for steering looseness by pushing and pulling [A] the
forks.
If you feel looseness, the steering is too loose.
NOTE
○
The cables and wiring will have some effect on the mo-
tion of the fork which must be taken into account.
○
Be sure the leads and cables are properly routed.
○
The bearings must be in good condition and properly
lubricated in order for any test to be valid.
Steering Play Adjustment
•
Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Ignition Switch Cover (see Ignition Switch Cover Re-
moval in the Frame chapter)
Handlebars (see Handlebar Removal in the Steering
chapter)
Steering Stem Head Bolt Plug [A]
Steering Stem Head Bolt [B] and Washer
•
Loosen the upper front fork clamp bolts [C].
•
Remove the stem head [D].
2-56 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Bend the claws [A] of the claw washer straighten.
•
Remove:
Steering Stem Locknut [B]
Claw Washer
•
Adjust the steering using the steering stem nut wrench
[A].
Special Tool - Steering Stem Nut Wrench: 57001-1100
If the steering is too tight, loosen the stem nut [B] a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
○
Turn the stem nut 1/8 turn at time maximum.
•
Install the claw washer [A] so that its bent side [B] faces
upward, and engage the bent claws with the grooves of
stem locknut [C].
•
Hand tighten the stem locknut until it touches the claw
washer.
•
Hand tighten the stem locknut clockwise until the claws
are aligned with the second groove of stem nut [D], and
bend the 2 claws downward [E].
•
Install the stem head.
•
Install the washer, and temporary tighten the stem head
bolt.
NOTE
○
Tighten the upper front fork clamp bolts first, next the
stem head bolt.
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Steering Stem Head Bolt: 108 N·m (11.0 kgf·m,
79.7 ft·lb)
WARNING
If the handlebars do not turn to the steering stop,
they may cause an accident resulting in injury or
death. Be sure the cables, harnesses and hoses are
routed properly and do not interfere with handlebar
movement (see Cable, Wire, and Hose Routing sec-
tion in the Appendix chapter).
•
Check the steering again.
If the steering is still too tight or too loose, repeat the ad-
justment.
•
Install the removed parts (see appropriate chapters).
PERIODIC MAINTENANCE 2-57
Periodic Maintenance Procedures
Steering Stem Bearing Lubrication
•
Remove the steering stem (see Stem, Stem Bearing Re-
moval in the Steering chapter).
•
Using a high flash-point solvent, wash the upper and
lower ball bearings [A] 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.
•
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 in the cages with
grease, and apply a light coat of grease to the upper and
lower outer races.
•
Install the steering stem (see Stem, Stem Bearing Instal-
lation in the Steering chapter).
•
Adjust the steering (see Steering Play Adjustment).
2-58 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Electrical System
Lights and Switches Operation Inspection
First Step
•
Set the gear position in the neutral position.
•
Turn the ignition switch on.
•
The following lights should go on according to below table.
City Light (LED) [A] Goes on
Taillight (LED) [B] Goes on
License Plate Light [C] Goes on
Meter Panel Illumination (LED) [D] Goes on
Meter Panel LCD [E] Goes on
Green Neutral Indicator (LED) [F] Goes on
Oil Pressure Warning Indicator [G] and Red
Warning Indicator (LED) [H]
Goes on
Yellow ABS Indicator (LED) [I] (ABS
Equipped Models)
Goes on
If the light does not go on, inspect or replace the following
parts.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
City Light (LED) (see City Light (LED) Removal/Installa-
tion in the Electrical System chapter)
License Plate Light Bulb (see License Plate Light Bulb
Replacement in the Electrical System chapter)
Meter Panel LCD (see Meter Unit Inspection in the Elec-
trical System chapter)
Green Neutral Indicator (LED) (see Meter Unit Inspec-
tion in the Electrical System chapter)
Red Warning Indicator (LED) (Oil Pressure Warning)
(see Meter Unit Inspection in the Electrical System
chapter)
Meter Panel Illumination (LED) (see Meter Unit Inspec-
tion in the Electrical System chapter)
ECU (see ECU Power Supply Inspection in the Fuel Sys-
tem (DFI) chapter)
Main Fuse 30 A, Meter Fuse 7.5 A and Brake Light/Horn
Fuse 7.5 A (see Fuse Inspection in the Electrical System
chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
OilPressureSwitch(seeSwitchInspectionintheElec-
trical System chapter)
Neutral Switch (see Neutral Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Yellow ABS Indicator (LED) (ABS Equipped Models)
(see Yellow ABS Indicator (LED) Inspection in the
Brakes chapter)
PERIODIC MAINTENANCE 2-59
Periodic Maintenance Procedures
•
Turn the ignition switch off.
•
The all lights should go off.
For models equipped with an immobilizer system, red
warning indicator (LED) will blinks. Refer to the Immobi-
lizer System (Equipped Models) section in the Electrical
System chapter).
If the light does not go off, replace the ignition switch.
Second Step (Other than US, CA and CAL Models)
•
Turn the ignition switch to hazard position.
•
The all lights should go off.
If the light goes on, inspect or replace the following item.
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Third Step
•
Turn the ignition switch on.
•
Turn on the turn signal switch [A] (left or right position).
•
The left or right turn signal lights [B] (front and rear) ac-
cording to the switch position should blink.
•
The green turn signal indicators (LED) [C] in the meter
unit should blink.
If the each light does not blink, inspect or replace the fol-
lowing parts.
Turn Signal Light Bulb (see Turn Signal Light Bulb Re-
placement in the Electrical System chapter)
Green Turn Signal Indicator (LED) (see Meter Unit In-
spection in the Electrical System chapter)
Turn Signal Relay Fuse 7.5 A (see Fuse Inspection in
the Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
•
Push the turn signal switch.
•
The turn signal lights and green turn signal indicator (LED)
should go off.
If the light does not go off, inspect or replace the following
parts.
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
2-60 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fourth Step
•
Set the dimmer switch [A] to low beam position.
•
Start the engine.
•
The low beam headlights should go on.
If the low beam headlights do not go on, inspect or replace
the following parts.
Headlight (LED) Assembly (see Headlight (LED) Assem-
bly Removal/Installation in the Electrical System chap-
ter)
Headlight Fuses (Low) 7.5 A (see Fuse Inspection in the
Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
•
Set the dimmer switch to high beam position.
•
The low beam [A] and high beam [B] headlights should
go on.
•
The blue high beam indicator (LED) [C] should goes on.
If the high beam headlight and/or blue high beam indicator
(LED) does not go on, inspect or replace the following
parts.
Headlight (LED) Assembly (see Headlight (LED) Assem-
bly Removal/Installation in the Electrical System chap-
ter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
•
Turn the engine stop switch to stop position.
•
The low beam and high beam headlights should stay go-
ing on.
If the headlights and blue high beam indicator (LED) go
off, inspect or replace the headlight relay (see Relay Cir-
cuit Inspection in the Electrical System chapter).
•
Turn the ignition switch off.
•
The headlights and blue high beam indicator (LED)
should go off.
Headlight Aiming Inspection
•
Inspect the headlight beam for aiming.
If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.
WARNING
The cooling fins [A] at the rear of headlight become
hot during normal operation and can cause serious
burns. To prevent burns, never touch the cooling
fins at the rear of headlight while the engine is run-
ning or shortly after it has been stopped.
PERIODIC MAINTENANCE 2-61
Periodic Maintenance Procedures
Headlight Beam Horizontal Adjustment
•
Turn the horizontal adjuster [A] in both headlights in or out
until the beam points straight ahead.
If the headlight beam points too low or high, adjust the
vertical beam.
Headlight Beam Vertical Adjustment
•
Turn the vertical adjuster [B] in both headlights in or out
to adjust the headlight vertically.
NOTE
○
ON high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an-
gle according to local regulations.
○
For the US model, the proper angle is 0.4 degrees be-
low horizontal. This is 50 mm (2.0 in.) drop at 7.6 m (25
ft) measured from the center of the headlight with the
motorcycle on its wheels and the rider seated.
50 mm (2.0 in.) [A]
Center of Brightest Spot [B]
7.6 m (25 ft) [C]
Height of Headlight Center [D]
Side Stand Switch Operation Inspection
•
Raise the rear wheel off the ground with the stand (see
Rear Wheel Removal in the Wheels/Tires chapter).
•
Inspect the side stand switch [A] operation accordance to
below table.
Side Stand Switch Operation
Side Stand
Gear
Position
Clutch
Lever
Engine
Start
Engine
Run
Up Neutral Released Starts
Continue
running
Up Neutral Pulled in Starts
Continue
running
Up In Gear Released
Does not
start
Continue
running
Up In Gear Pulled in Starts
Continue
running
Down Neutral Released Starts
Continue
running
Down Neutral Pulled in Starts
Continue
running
Down
In Gear
Released
Does not
start
Stops
Down
In Gear
Pulled in
Does not
start
Stops
2-62 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If the side stand switch operation does not work, inspect
or replace the following parts.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Side Stand Switch (see Switch Inspection in the Electri-
cal System chapter)
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Lockout Switch (see Switch Inspection in the
Electrical System chapter)
Starter Relay (see Starter Relay Inspection in the Elec-
trical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
If the all parts are good condition, replace the ECU (see
ECU Removal/Installation in the Fuel System (DFI) chap-
ter).
Engine Stop Switch Operation Inspection
First Step
•
Turn the ignition switch on.
•
Set the gear position in the neutral position.
•
Turn the engine stop switch to stop position [A].
•
Push the starter button.
•
The engine does not start.
If the engine starts, inspect or replace the engine stop
switch (see Switch Inspection in the Electrical System
chapter).
Second Step
•
Turn the ignition switch on.
•
Set the gear position in the neutral position.
•
Turn the engine stop switch to run position [A].
•
Push the starter button and start the engine.
•
Turn the engine stop switch to stop position.
•
Immediately the engine should be stop.
If the engine does not stop, inspect or replace the engine
stop switch (see Switch Inspection in the Electrical Sys-
tem chapter).
If the engine stop switch is good condition, replace the
ECU (see ECU Removal/Installation in the Fuel System
(DFI) chapter).
PERIODIC MAINTENANCE 2-63
Periodic Maintenance Procedures
Spark Plug Replacement
•
Remove the stick coils (see Stick Coil Removal in the
Electrical System chapter).
•
Remove the spark plugs using the 16 mm (0.63 in.) plug
wrench [A] vertically.
•
Replace the spark plugs with new ones.
Standard Spark Plug
Type:
NGK CR9EIA-9
•
Insert the spark plug vertically into the spark plug hole
with the spark plug installed in the plug wrench [A], and
finger-tighten it first.
NOTICE
If tightening the spark plug with the wrench in-
clined, the insulator of the spark plug may break.
•
Tighten:
Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)
•
Install the stick coils (see Stick Coil Installation in the Elec-
trical System chapter).
•
After installation, be sure the stick coils are installed se-
curely by pulling up them lightly.
Others
Chassis Parts Lubrication
•
Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
•
Lubricate the points listed below with indicated lubricant.
NOTE
○
Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri-
cation.
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Master Cylinder Push Rod Joint Pin
Side Stand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
2-64 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cables
•
Lubricate the cables by seeping the oil between the cable
and housing.
The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
•
With the cable disconnected at both ends, the inner cable
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Condition of Bolts, Nuts and Fasteners 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
○
For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the spec-
ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
PERIODIC MAINTENANCE 2-65
Periodic Maintenance Procedures
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Bolt Locknut
Engine Mounting Bolts and Nuts
Exhaust Pipe Holder Nuts
Muffler Body Clamp Bolts
Muffler Body Mounting Bolts and Nuts
Premuffler Chamber Mounting Bolt
Radiator Bolts
Wheels:
Front Axle Clamp Bolts
Front Axle
Rear Axle Nut
Brakes:
Brake Lever Pivot Bolt Locknut
Brake Pedal Bolt
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolts and Nuts
Swingarm Pivot Shaft Nut
Tie-rod Nuts
Rocker Arm Nut
Steering:
Handlebar Holder Bolts
Steering Stem Head Bolt
Others:
Footpeg Bracket Bolts
Front Fender Mounting Bolts
Rear Frame Bolts
Side Stand Bolt
Side Stand Bracket Bolts
FUEL SYSTEM (DFI) 3-1
3
Fuel System (DFI)
Table of Contents
Exploded View........................................................................................................................ 3-4
DFI System............................................................................................................................. 3-10
DFI Parts Location.................................................................................................................. 3-20
Specifications ......................................................................................................................... 3-23
Special Tools and Sealant ...................................................................................................... 3-25
DFI Servicing Precautions ...................................................................................................... 3-27
DFI Servicing Precautions ................................................................................................... 3-27
Troubleshooting the DFI System ............................................................................................ 3-29
Outline ................................................................................................................................. 3-29
Inquiries to Rider.................................................................................................................. 3-33
DFI System Troubleshooting Guide ....................................................................................... 3-36
Self-Diagnosis ........................................................................................................................ 3-41
Self-Diagnosis Outline ...................................................................................................... 3-41
Self-Diagnosis Procedures ............................................................................................... 3-42
Service Code Reading ...................................................................................................... 3-44
Service Code Erasing ....................................................................................................... 3-44
Backups ............................................................................................................................ 3-45
Main Throttle Sensor (Service Code 11) ................................................................................ 3-48
Main Throttle Sensor Removal/Adjustment ...................................................................... 3-48
Main Throttle Sensor Input Voltage Inspection ................................................................. 3-48
Main Throttle Sensor Resistance Inspection .................................................................... 3-49
Main Throttle Sensor Output Voltage Inspection .............................................................. 3-49
Intake Air Pressure Sensor #1 (Service Code 12).................................................................. 3-52
Intake Air Pressure Sensor #1 Removal........................................................................... 3-52
Intake Air Pressure Sensor #1 Installation........................................................................ 3-52
Intake Air Pressure Sensor #1 Input Voltage Inspection................................................... 3-53
Intake Air Pressure Sensor #1 Output Voltage Inspection................................................ 3-54
Intake Air Temperature Sensor (Service Code 13)................................................................. 3-58
Intake Air Temperature Sensor Removal/Installation........................................................ 3-58
Intake Air Temperature Sensor Output Voltage Inspection ............................................... 3-58
Intake Air Temperature Sensor Resistance Inspection ..................................................... 3-59
Water Temperature Sensor (Service Code 14) ...................................................................... 3-61
Water Temperature Sensor Removal/Installation ............................................................. 3-61
Water Temperature Sensor Output Voltage Inspection..................................................... 3-61
Water Temperature Sensor Resistance Inspection........................................................... 3-62
Intake Air Pressure Sensor #2 (Service Code 16).................................................................. 3-63
Intake Air Pressure Sensor #2 Removal........................................................................... 3-63
Intake Air Pressure Sensor #2 Installation........................................................................ 3-63
Intake Air Pressure Sensor #2 Input Voltage Inspection................................................... 3-64
Intake Air Pressure Sensor #2 Output Voltage Inspection................................................ 3-65
Crankshaft Sensor (Service Code 21).................................................................................... 3-67
Crankshaft Sensor Removal/Installation........................................................................... 3-67
Crankshaft Sensor Resistance Inspection ........................................................................ 3-67
Crankshaft Sensor Peak Voltage Inspection..................................................................... 3-67
Rear Wheel Rotation Sensor Signal (Service Code 24, 25)................................................... 3-68
Rear Wheel Rotation Sensor Signal Inspection................................................................ 3-68
Front Wheel Rotation Sensor Signal (Service Code 27, ABS Equipped Models) .................. 3-71
Front Wheel Rotation Sensor Signal Inspection ............................................................... 3-71
Vehicle-down Sensor (Service Code 31)................................................................................ 3-73
Vehicle-down Sensor Removal ......................................................................................... 3-73
3-2 FUEL SYSTEM (DFI)
Vehicle-down Sensor Installation ...................................................................................... 3-74
Vehicle-down Sensor Input Voltage Inspection................................................................. 3-74
Vehicle-down Sensor Output Voltage Inspection .............................................................. 3-75
Subthrottle Sensor (Service Code 32).................................................................................... 3-78
Subthrottle Sensor Removal/Adjustment.......................................................................... 3-78
Subthrottle Sensor Input Voltage Inspection..................................................................... 3-78
Subthrottle Sensor Output Voltage Inspection .................................................................. 3-79
Subthrottle Sensor Resistance Inspection ........................................................................ 3-81
Oxygen Sensor - not activated (Service Code 33, Equipped Models) ................................... 3-82
Oxygen Sensor Removal/Installation................................................................................ 3-82
Oxygen Sensor Inspection................................................................................................ 3-82
Exhaust Butterfly Valve Actuator Sensor (Service Code 34).................................................. 3-85
Exhaust Butterfly Valve Actuator Sensor Removal/Installation......................................... 3-85
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection................................... 3-85
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection ................................ 3-86
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection ...................................... 3-87
Immobilizer Amplifier (Service Code 35, Equipped Models) .................................................. 3-88
Antenna Resistance Inspection ........................................................................................ 3-88
Amplifier Input Voltage Inspection..................................................................................... 3-88
Blank Key Detection (Service Code 36, Equipped Models) ................................................... 3-89
Ignition Key Inspection...................................................................................................... 3-89
ECU Communication Error (Service Code 39) ....................................................................... 3-90
ECU Communication Line Inspection ............................................................................... 3-90
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)........................................................ 3-91
Stick Coil Removal/Installation.......................................................................................... 3-91
Stick Coil Primary Winding Resistance Inspection ........................................................... 3-91
Stick Coil Input Voltage Inspection.................................................................................... 3-91
Radiator Fan Relay (Service Code 56)................................................................................... 3-93
Radiator Fan Relay Removal/Installation.......................................................................... 3-93
Radiator Fan Relay Inspection.......................................................................................... 3-93
Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-94
Subthrottle Valve Actuator Removal ................................................................................. 3-94
Subthrottle Valve Actuator Inspection ............................................................................... 3-94
Subthrottle Valve Actuator Resistance Inspection ............................................................ 3-94
Subthrottle Valve Actuator Input Voltage Inspection ......................................................... 3-95
Exhaust Butterfly Valve Actuator (Service Code 63) .............................................................. 3-97
Exhaust Butterfly Valve Actuator Removal ....................................................................... 3-97
Exhaust Butterfly Valve Actuator Installation .................................................................... 3-97
Exhaust Butterfly Valve Actuator Inspection ..................................................................... 3-97
Exhaust Butterfly Valve Actuator Resistance Inspection .................................................. 3-97
Air Switching Valve (Service Code 64) ................................................................................... 3-99
Air Switching Valve Removal/Installation .......................................................................... 3-99
Air Switching Valve Inspection .......................................................................................... 3-99
Oxygen Sensor Heater (Service Code 67, Equipped Models) ............................................... 3-100
Oxygen Sensor Heater Removal/Installation .................................................................... 3-100
Oxygen Sensor Heater Resistance Inspection ................................................................. 3-100
Oxygen Sensor Heater Power Source Voltage Inspection ............................................... 3-101
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) ................. 3-103
Oxygen Sensor Removal/Installation................................................................................ 3-103
Oxygen Sensor Inspection................................................................................................ 3-103
Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models) ........................................... 3-106
Purge Valve Removal/Installation ..................................................................................... 3-106
Purge Valve Inspection ..................................................................................................... 3-106
Warning Indicator Light (LED) ................................................................................................ 3-108
Yellow Engine Warning/Red Warning Indicator (LED) Inspection..................................... 3-108
ECU........................................................................................................................................ 3-109
ECU Identification ............................................................................................................. 3-109
FUEL SYSTEM (DFI) 3-3
ECU Removal ................................................................................................................... 3-109
ECU Installation ................................................................................................................ 3-110
ECU Power Supply Inspection.......................................................................................... 3-110
DFI Power Source ..................................................................................................................3-113
ECU Fuse Removal .......................................................................................................... 3-113
ECU Fuse Installation ....................................................................................................... 3-113
ECU Fuse Inspection ........................................................................................................ 3-113
ECU Main Relay Removal/Installation .............................................................................. 3-113
ECU Main Relay Inspection .............................................................................................. 3-113
Fuel Line................................................................................................................................. 3-114
Fuel Pressure Inspection .................................................................................................. 3-114
Fuel Flow Rate Inspection ................................................................................................ 3-115
Fuel Pump .............................................................................................................................. 3-117
Fuel Pump Removal ......................................................................................................... 3-117
Fuel Pump Installation ...................................................................................................... 3-118
Fuel Pump Operation Inspection ...................................................................................... 3-118
Fuel Pump Operating Voltage Inspection ......................................................................... 3-119
Pressure Regulator Removal............................................................................................ 3-120
Pump Screen, Fuel Filter Cleaning ................................................................................... 3-120
Fuel Pump Relay Removal/Installation............................................................................. 3-120
Fuel Pump Relay Inspection............................................................................................. 3-120
Fuel Injectors.......................................................................................................................... 3-122
Fuel Injector Removal/Installation..................................................................................... 3-122
Fuel Injector Audible Inspection........................................................................................ 3-122
Fuel Injector Resistance Inspection.................................................................................. 3-122
Fuel Injector Power Source Voltage Inspection ................................................................ 3-123
Fuel Injector Output Voltage Inspection ............................................................................ 3-124
Fuel Injector Fuel Line Inspection ..................................................................................... 3-125
Throttle Grip and Cables ........................................................................................................ 3-128
Free Play Inspection ......................................................................................................... 3-128
Free Play Adjustment........................................................................................................ 3-128
Cable Installation .............................................................................................................. 3-128
Cable Lubrication.............................................................................................................. 3-128
Throttle Body Assy ................................................................................................................. 3-129
Idle Speed Inspection/Adjustment .................................................................................... 3-129
Synchronization Inspection/Adjustment ............................................................................ 3-129
Throttle Body Assy Removal............................................................................................. 3-129
Throttle Body Assy Installation.......................................................................................... 3-131
Throttle Body Assy Disassembly ...................................................................................... 3-132
Throttle Body Assy Assembly ........................................................................................... 3-133
Air Cleaner.............................................................................................................................. 3-134
Air Cleaner Element Removal/Installation ........................................................................ 3-134
Air Cleaner Element Inspection ........................................................................................ 3-134
Air Cleaner Oil Draining .................................................................................................... 3-134
Air Cleaner Housing Removal........................................................................................... 3-134
Air Cleaner Housing Installation........................................................................................ 3-135
Fuel Tank ................................................................................................................................ 3-136
Fuel Tank Removal ........................................................................................................... 3-136
Fuel Tank Installation ........................................................................................................ 3-138
Fuel Tank and Cap Inspection .......................................................................................... 3-139
Fuel Tank Cleaning ........................................................................................................... 3-140
Evaporative Emission Control System (CAL, SEA-B1 and TH Models)................................. 3-141
Parts Removal/Installation ................................................................................................ 3-141
Hose Inspection ................................................................................................................ 3-141
Purge Valve Inspection ..................................................................................................... 3-141
Canister Inspection .......................................................................................................... 3-141
3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Throttle Body Assy Holder Clamp Bolts
2.9 0.30 26 in·lb
2 Delivery Pipe Assy Mounting Screws 3.43 0.35 30 in·lb
3 Air Cleaner Housing Assembly Screws 1.1 0.11 10 in·lb
4 Air Cleaner Housing Plate Screws 1.1 0.11 10 in·lb
5 Throttle Case Bolts 3.5 0.36 31 in·lb
6
Air Cleaner Housing Clamp Bolts
2.0 0.20 18 in·lb
7. Immobilizer System Equipped Models
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
R: Replacement Parts
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Oxygen Sensor (Equipped Models)
44 4.5 32
2 Water Temperature Sensor 12 1.2 106 in·lb
3 Exhaust Butterfly Valve Actuator Pulley Bolt 5.0 0.51 44 in·lb
4
Exhaust Butterfly Valve Actuator Mounting
Screws
1.2 0.12 11 in·lb
5 Vehicle-down Sensor Mounting Bolts 5.9 0.60 52 in·lb
6 Crankshaft Sensor Bolts 5.9 0.60 52 in·lb
7 Intake Air Temperature Sensor Screw 1.2 0.12 11 in·lb
R: Replacement Parts
3-8 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-9
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Fuel Pump Bolts 9.8 1.0 87 in·lb
L, S
2. Purge Valve
3. Canister
4. Other than CAL, SEA-B1 and TH Models
5. CAL, SEA-B1 and TH Models
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
3-10 FUEL SYSTEM (DFI)
DFI System
DFI System
FUEL SYSTEM (DFI) 3-11
DFI System
1. ECU
2. Battery 12 V 10 Ah
3. Vehicle-down Sensor
4. Pressure Regulator
5. Fuel Pump
6. Fuel Filter
7. Intake Air Temperature Sensor
8. Delivery Pipe Assy
9. Fuel Injectors
10. Wheel Rotation Sensors
11. Exhaust Butterfly Valve Actuator
12. Oxygen Sensor (Equipped Models)
13. Water Temperature Sensor
14. Crankshaft Sensor
15. Main Throttle Sensor
16. Intake Air Pressure Sensor #2
17. Intake Air Pressure Sensor #1
18. Air Switching Valve
19. Subthrottle Valve Actuator
20. Subthrottle Sensor
21. Air Flow
22. Fuel Flow
3-12 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram
FUEL SYSTEM (DFI) 3-13
DFI System
Part Names
1. ECU
2. Rear Wheel Rotation Sensor
3. Joint Connector E
4. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
5. Exhaust Butterfly Valve Actuator
6. Fuel Pump
7. Frame Ground 4
8. Frame Ground 2
9. Frame Ground 1
10. Engine Ground
11. Battery 12 V 10 Ah
12. Starter Relay
13. Main Fuse 30 A
14. ECU Fuse 15 A
15. Relay Box
16. Fuel Pump Relay
17. ECU Main Relay
18. Radiator Fan Relay
19. Meter Unit
20. Ignition Switch
21. Fuse Box 1
22. Fan Fuse 15 A
23. Ignition Fuse 15 A
24. Joint Connector D
25. Joint Connector C
26. Immobilizer Antenna (Equipped Models)
27. Immobilizer Amplifier (Equipped Models)
28. Fan Motor
29. Air Switching Valve
30. Engine Stop Switch
31. Starter Button
32. Spark Plugs
33. Stick Coil #1, #2, #3, #4
34. Vehicle-down Sensor
35. Intake Air Temperature Sensor
36. Crankshaft Sensor
37. Fuel Injector #1
38. Fuel Injector #2
39. Fuel Injector #3
40. Fuel Injector #4
41. Subthrottle Valve Actuator
42. Main Throttle Sensor
43. Subthrottle Sensor
44. Intake Air Pressure Sensor #2
45. Intake Air Pressure Sensor #1
46. Water Temperature Sensor
47. Oxygen Sensor (Equipped Models)
3-14 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram (ABS Equipped Models)
FUEL SYSTEM (DFI) 3-15
DFI System
Part Names
1. ECU
2. Rear Wheel Rotation Sensor
3. Joint Connector E
4. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
5. Exhaust Butterfly Valve Actuator
6. Fuel Pump
7. ABS Hydraulic Unit
8. Frame Ground 5
9. Frame Ground 2
10. Frame Ground 1
11. Engine Ground
12. Battery 12 V 10 Ah
13. Starter Relay
14. Main Fuse 30 A
15. ECU Fuse 15 A
16. Relay Box
17. Fuel Pump Relay
18. ECU Main Relay
19. Radiator Fan Relay
20. Meter Unit
21. Front Wheel Rotation Sensor
22. Ignition Switch
23. Fuse Box 1
24. Fan Fuse 15 A
25. Ignition Fuse 15 A
26. Joint Connector D
27. Joint Connector C
28. Immobilizer Antenna (Equipped Models)
29. Immobilizer Amplifier (Equipped Models)
30. Fan Motor
31. Air Switching Valve
32. Engine Stop Switch
33. Starter Button
34. Spark Plugs
35. Stick Coil #1, #2, #3, #4
36. Vehicle-down Sensor
37. Intake Air Temperature Sensor
38. Crankshaft Sensor
39. Fuel Injector #1
40. Fuel Injector #2
41. Fuel Injector #3
42. Fuel Injector #4
43. Subthrottle Valve Actuator
44. Main Throttle Sensor
45. Subthrottle Sensor
46. Intake Air Pressure Sensor #2
47. Intake Air Pressure Sensor #1
48. Water Temperature Sensor
49. Oxygen Sensor (Equipped Models)
3-16 FUEL SYSTEM (DFI)
DFI System
Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green
G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
FUEL SYSTEM (DFI) 3-17
DFI System
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3-18 FUEL SYSTEM (DFI)
DFI System
Terminal Numbers of ECU Connectors
Terminal Names
1. Subthrottle Valve Actuator: P/BL
2. Exhaust Butterfly Valve Actuator (–): W/R
3. Unused
4. Power Supply to Sensors: BL
5. Fuel Pump Relay: BR/Y
6. Power Supply to ECU (from Battery): BR/W
7. Power Supply to ECU (from Battery): W/BK
8. Oxygen Sensor (Equipped Models): BL/Y
9. Unused
10. Front Wheel Rotation Sensor Signal (ZR1000G): G/Y
Unused (ZR1000F)
11. Immobilizer Amplifier (Equipped Models): V
12. Subthrottle Valve Actuator: Y/BK
13. Exhaust Butterfly Valve Actuator (+): W/BL
14. Unused
15. Unused
16. Intake Air Temperature Sensor: R/BK
17. Intake Air Pressure Sensor #2: G/W
18. Intake Air Pressure Sensor #1: Y/BL
19. Vehicle-down Sensor: Y/G
20. Rear Wheel Rotation Sensor Signal (ZR1000F): BK/O
Unused (ZR1000G)
21. Rear Wheel Rotation Sensor Signal (ZR1000G): R/Y
Unused (ZR1000F)
22. Immobilizer Amplifier (Equipped Models): P/BK
23. Subthrottle Valve Actuator: BK/O
24. Subthrottle Valve Actuator: G
25. Unused
26. Warning Indicator (LED): BL/O
27. Main Throttle Sensor: Y/W
28. Subthrottle Sensor: BL/W
29. Exhaust Butterfly Valve Actuator Sensor: GY
30. Water Temperature Sensor: W/G
31. Unused
FUEL SYSTEM (DFI) 3-19
DFI System
32. Power Supply to Rear Wheel Rotation Sensor (ZR1000F): W/G
Unused (ZR1000G)
33. Side Stand Switch: G/BK
34. Unused
35. Starter Button: R/BK
36. Neutral Switch: LG
37. Crankshaft Sensor (–): Y/BK
38. Ground for Control System: BK/BL
39. Ground for Fuel System: BK/Y
40. Fuel Injector #3: BL/O
41. Fuel Injector #2: BL/R
42. Fuel Injector #1: BL/BK
43. Stick Coil #4: BK/G
44. Stick Coil #1: BK
45. Unused
46. Starter Lockout Switch: R/G
47. External Communication Line (Immobilizer System (Equipped Models)/*KDS): LG/BK
48. Crankshaft Sensor (+): Y
49. Ground for Sensors: G
50. Purge Valve (CAL, SEA-B1 and TH Models): R/Y
51. Unused
52. Fuel Injector #4: BL/G
53. Unused
54. Unused
55. Stick Coil #2: BK/R
56. Unused
57. Engine Stop Switch: R
58. Ground: P
59. Rear Wheel Rotation Sensor Output: P
60. External Communication Line (Immobilizer System (Equipped Models)/*KDS): GY/BL
61. Meter Unit (Tachometer): LB
62. Radiator Fan Relay: Y/BL
63. Air Switching Valve: R/BL
64. Oxygen Sensor Heater (Equipped Models): P/BK
65. Ground for Ignition System: BK/Y
66. Stick Coil #3: BK/O
*: KDS (Kawasaki Diagnostic System)
3-20 FUEL SYSTEM (DFI)
DFI Parts Location
Main Throttle Sensor [A]
Subthrottle Sensor [B]
Subthrottle Valve Actuator [C]
Intake Air Pressure Sensor #2 [D]
Stick Coils #1, #2, #3, #4 [E]
Intake Air Pressure Sensor #1 [F]
Fuel Injectors #1, #2, #3, #4 [G]
Air Switching Valve [A]
Water Temperature Sensor [A]
Intake Air Temperature Sensor [A]
Crankshaft Sensor [A]
Oxygen Sensor [B] (Equipped Models)
FUEL SYSTEM (DFI) 3-21
DFI Parts Location
Vehicle-down Sensor [A]
Battery 12 V 10 Ah [B]
Fuse Box 1 [C]
Exhaust Butterfly Valve Actuator [D]
MainFuse30A[A]
ECUFuse15A[B]
ECU [A]
Relay Box [B] (ECU Main Relay, Fuel Pump Relay, Ra-
diator Fan Relay)
Immobilizer (Equipped Models)/Kawasaki Diagnostic
System Connector [C]
Fuel Pump [A]
Ignition Key [A] (Transponder, Immobilizer System
Equipped Models)
Immobilizer Antenna [B] (Equipped Models)
Ignition Switch [C]
Yellow Engine Warning Indicator (LED) [D]
3-22 FUEL SYSTEM (DFI)
DFI Parts Location
Immobilizer Amplifier [A] (Equipped Models)
Front Wheel Rotation Sensor [A] (ABS Equipped Mod-
els)
Rear Wheel Rotation Sensor [A]
Purge Valve [A] (CAL, SEA-B1 and TH Models)
FUEL SYSTEM (DFI) 3-23
Specifications
Item Standard
Digital Fuel Injection System
Idle Speed 1 100 ±50 r/min (rpm)
Throttle Body Assy:
Throttle Valve Dual throttle valve
Bore
38 mm (1.42 in.)
Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg)
Bypass Screws (Turn Out) 2 1/2 (for reference)
ECU:
Make DENSO
Type
Digital memory type, with built in IC igniter, sealed
with resin
Fuel Pressure (High Pressure Line) 294 kPa (3.0 kgf/cm², 43 psi) with engine idling
Fuel Pump:
Type In-tank friction pump
Discharge 50 mL (1.7 US oz.) or more for 3 seconds
Fuel Injectors:
Type EAT289
Nozzle Type Fine atomizing type with 8 holes
Resistance
About 11.7 ∼ 12.3 at 20°C (68°F)
Main Throttle Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 1.02 ∼ 1.06 V at idle throttle opening
DC 4.22 ∼ 4.42 V at full throttle opening (for reference)
Resistance 4 ∼ 6k
Intake Air Pressure Sensor #1/#2:
Input Voltage
DC 4.75 ∼ 5.25 V
Output Voltage DC 3.80 ∼ 4.20 V at standard atmospheric pressure
(see this text for details)
Intake Air Temperature Sensor:
Output Voltage About DC 2.25 ∼ 2.50 V at 20°C (68°F)
Resistance 5.4 ∼ 6.6 k at 0°C (32°F)
0.29 ∼ 0.39 k at 80°C (176°F)
Water Temperature Sensor:
Output Voltage About DC 2.80 ∼ 2.97 V at 20°C (68°F)
Vehicle-down Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage with sensor tilted 60 ∼ 70° or more right or left: DC
0.65 ∼ 1.35 V
with sensor arrow mark pointed up: DC 3.55 ∼ 4.45 V
3-24 FUEL SYSTEM (DFI)
Specifications
Item Standard
Subthrottle Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 1.08 ∼ 1.12 V at subthrottle valve full close
position
DC 4.2 ∼ 4.4 V at subthrottle valve full open position
(for reference)
Resistance
4 ∼ 6k
Exhaust Butterfly Valve Actuator Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 3.46 ∼ 3.76 V at pulley original position
Resistance 4 ∼ 6k
Immobilizer Antenna (Equipped Models):
Resistance
About 3.0 ∼ 4.6
Exhaust Butterfly Valve Actuator:
Resistance 5 ∼ 200 (for reference)
Subthrottle Valve Actuator:
Resistance About 5.2 ∼ 7.8
Input Voltage About DC 8.5 ∼ 10.5 V and then 0 V or About DC
8.5 ∼ 10.5 V
Oxygen Sensor (Equipped Models):
Output Voltage (Rich) DC 0.7 V or more
Output Voltage (Lean) DC 0.2 V or less
Heater Resis
tance
11.7 ∼ 14.5 at 20°C (68°F)
Purg Valve (CAL, SEA-B1 and TH
Models):
Resistance 30 ∼ 34 at 20°C (68°F)
Throttle Grip and Cables
ThrottleGripFreePlay 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Air Cleaner
Element Viscous paper element
FUEL SYSTEM (DFI) 3-25
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²:
57001-125
Carburetor Drain Plug Wrench, Hex 3:
57001-1269
Fork Oil Level Gauge:
57001-1290
Vacuum Gauge:
57001-1369
Throttle Sensor Setting Adapter #1:
57001-1400
Peak Voltage Adapter:
57001-1415
Needle Adapter Set:
57001-1457
Throttle Sensor Setting Adapter:
57001-1538
Extension Tube:
57001-1578
Fuel Pressure Gauge Adapter:
57001-1593
3-26 FUEL SYSTEM (DFI)
Special Tools and Sealant
Fuel Hose:
57001-1607
Measuring Adapter:
57001-1700
Liquid Gasket, TB1211:
56019-120
FUEL SYSTEM (DFI) 3-27
DFI Servicing Precautions
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.
This DFI system is designed to be used with a 12 V sealed
battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
Do not reverse the battery cable connections. This will
damage the ECU.
To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is on, or while the engine is running.
Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.
Whenever the DFI electrical connections are to be dis-
connected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the con-
nector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the en-
gine.
Connect these connectors until they click [A].
Do not turn the ignition switch on while any of the DFI
electrical connectors are disconnected. The ECU memo-
rizes service codes.
Do not spray water on the electrical parts, DFI parts, con-
nectors, leads and wiring.
If a transceiver is installed on the motorcycle, make sure
that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.
When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
Before removing the fuel system parts, blow the outer sur-
faces of these parts clean with compressed air.
When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
When installing the fuel hoses, avoid sharp bending, kink-
ing, flattening or twisting, and run the fuel hoses with a
minimum of bending so that the fuel flow will not be ob-
structed.
Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.
To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.
3-28 FUEL SYSTEM (DFI)
DFI Servicing Precautions
If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak or the hose
to burst. Remove the fuel tank (see Fuel Tank Removal)
and check the fuel hose [A].
Replace the fuel hose if any fraying, cracks or bulges are
noticed.
To maintain the correct fuel/air mixture (F/A), there must
be no intake air leaks in the DFI system. Be sure to install
the oil filler plug [A] after filling the engine oil.
Torque - Oil Filler Plug: 2.0 N·m (0.20 kgf·m, 18 in·lb)
FUEL SYSTEM (DFI) 3-29
Troubleshooting the DFI System
Outline
When a problem occurs with DFI system, the yellow en-
gine warning indicator (LED) [A] goes on to alert the rider.
For models equipped with an immobilizer system, the red
warning indicator (LED) [A] and immobilizer warning indica-
tor [B] blink, when a problem occurs in the system.
With the engine stopped and turned in the self-diagnosis
mode, the service code [A] is displayed on the LCD (Liquid
Crystal Display) by the number of two digits.
If the problem is with the following parts, the ECU can
not recognize these problem. Therefore, the yellow engine
warning indicator (LED) does not go on, and service code
is not displayed.
Fuel Pump
Fuel Pump Relay
Fuel Injectors
Stick Coil Secondary Wiring and Ground Wiring
ECU Main Relay
3-30 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
When the service code [A] is displayed, for first ask the
rider about the conditions [B] of trouble, and then start to
determine the cause [C] of problem.
As a pre-diagnosis inspection, check the ECU for ground
and power supply, the fuel line for no fuel leaks, and for
correct pressure. The pre-diagnosis items are not indicated
by the yellow engine warning indicator (LED).
Don’t rely solely on the DFI self-diagnosis function, use
common sense.
Even when the DFI system is operating normally, the yel-
low engine warning indicator (LED) goes on may be dis-
played under strong electrical interference. Additional mea-
sures are not required. Turn the ignition switch off to stop
the indicator.
If the yellow engine warning indicator (LED) of the motor-
cycle brought in for repair still goes on, check the service
code.
When the repair has been done, the yellow engine warn-
ing indicator (LED) goes off. But the service codes stored
in memory of the ECU are not erased to preserve the prob-
lem history. The problem history can be referred using the
KDS (Kawasaki Diagnostic System) when solving unstable
problems.
When the motorcycle is down, the vehicle-down sensor
operates and the ECU shuts off the fuel pump relay, fuel
injectors and ignition system. The ignition switch is left on. If
the starter button is pushed, the electric starter turns but the
engine does not start. When the starter button is pushed,
the yellow engine warning indicator (LED) blinks but the
service code is not displayed. To start the engine again,
raise the motorcycle, turn the ignition switch off, and then
on.
Much of the DFI system troubleshooting work consists
of confirming continuity of the wiring. The DFI parts are
assembled and adjusted with precision, and it is impossible
to disassemble or repair them.
FUEL SYSTEM (DFI) 3-31
Troubleshooting the DFI System
•
When checking the DFI parts, use a digital meter which
can be read two decimal place voltage or resistance.
The DFI part connectors [A] have seals [B], including the
ECU. When measuring the input or output voltage with the
connector joined, use the needle adapter set [C]. Insert
the needle adapter inside the seal until the needle adapter
reaches the terminal.
Special Tool - Needle Adapter Set: 57001-1457
NOTICE
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
•
Make sure that measuring points are correct in the con-
nector, noting the position of the lock [D] and the lead
color before measurement. Do not reverse connections
of a digital meter.
•
Be careful not to short-circuit the leads of the DFI or elec-
trical system parts by contact between adapters.
•
Turn the ignition switch on and measure the voltage with
the connector joined.
NOTICE
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.
After measurement, remove the needle adapters and ap-
ply silicone sealant to the seals [A] of the connector [B]
for waterproofing.
Sealant - Liquid Gasket, TB1211: 56019-120
•
Always check battery condition before replacing the DFI
parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.
•
Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
•
Measure coil winding resistance when the DFI part is cold
(at room temperature).
•
Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, short,
etc. Deteriorated leads and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.
3-32 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
•
Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect the connectors securely.
•
Check the wiring for continuity.
Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
Connect a tester between the ends of the leads.
If the tester does not read about 0 , the lead is defective.
Replace the lead or the main harness or the subharness.
If both ends of a harness [A] are far apart, ground [B] the
one end [C], using a jumper lead [D] and check the con-
tinuity between the end [E] and the ground [F]. This en-
ables to check a long harness for continuity. If the harness
is open, repair or replace the harness.
When checking a harness [A] for short circuit, open one
end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or re-
placed.
•
Narrow down suspicious locations by repeating the con-
tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.
FUEL SYSTEM (DFI) 3-33
Troubleshooting the DFI System
DFI Diagnosis Flow Chart
Inquiries to Rider
Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.
Try to find out exactly what problem occurred under exactly what conditions by asking the rider;
knowing this information may help you reproduce the problem.
The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.
3-34 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.): Year of initial registration:
Model: Engine No.: Frame No.:
Date problem occurred: Mileage:
Environment when problem occurred.
Weather fine, cloudy, rain, snow, always, other:
Temperature hot, warm, cold, very cold, always, other:
Problem
frequency
chronic, often, once
Road
street, highway, mountain road ( uphill, downhill), bumpy, pebble
Altitude normal, high (about 1 000 m or more)
Motorcycle conditions when problem occurred.
goes on immediately after turning the ignition switch on, and goes off after about
1 second (normal)
goes on immediately after turning the ignition switch on, goes off after about 1
second, and goes on again after about 10 seconds (ECU communication error)
goes on immediately after turning the ignition switch on, goes off after about 1
second, and goes on again and stays on [DFI problem]
Yellow engine
warning
indicator
(LED)
does not go on after turning the ignition switch on [indicator (LED), meter unit
fault]
Starts blinking about 1 second after ignition switch on, and the immobilizer
warning indicator on the LCD starts blinking (immobilizer system problem).
Does not go on about 1 second after ignition switch on (ECU or meter unit fault).
Red warning
indicator
(LED)
light up (battery, oil pressure, water temperature, immobilizer or meter unit
problem)
starter motor not rotating.
starter motor rotating but engine do not turn over.
starter motor and engine do not turn over.
no fuel flow ( no fuel in tank, no fuel pump sound).
no spark.
Starting
difficulty
other:
right after starting.
when opening throttle grip.
when closing throttle grip.
when moving off.
when stopping the motorcycle.
when cruising.
Engine stalls
other:
FUEL SYSTEM (DFI) 3-35
Troubleshooting the DFI System
very low idle speed, very high idle speed, rough idle speed.
battery voltage is low (charge the battery).
spark plug loose (tighten it).
spark plug dirty, broken, or gap maladjusted (remedy it).
backfiring.
afterfiring.
hesitation when acceleration.
engine oil viscosity too high.
brake dragging.
engine overheating.
clutch slipping.
Poor running
at low speed
other:
spark plug loose (tighten it).
spark plug dirty, broken, or gap maladjusted (remedy it).
spark plug incorrect (replace it).
knocking (fuel poor quality or incorrect, use high-octane gasoline).
brake dragging.
clutch slipping.
engine overheating.
engine oil level too high.
engine oil viscosity too high.
Poor running
or no power at
high speed
other:
3-36 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
NOTE
○
This is not an exhaustive list, giving every possible cause for each problem listed. It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties in
DFI system.
○
The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits are checked out good, be sure to check the ECU for ground and power supply. If the
ground and power supply are checked good, replace the ECU.
Engine Won’t Turn Over
Symptoms or Possible Causes Actions (chapter)
Neutral, starter lockout or side stand switch
trouble
Inspect each switch (see chapter 16).
Immobilizer system trouble Inspect (see chapter 3).
Vehicle-down sensor operated Turn ignition switch off (see chapter 3).
Vehicle-down sensor trouble Inspect (see chapter 3).
Crankshaft sensor trouble Inspect (see chapter 16).
Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
ECU ground and power supply trouble Inspect (see chapter 3).
ECU trouble Inspect (see chapter 3).
No or little fuel in tank Supply fuel (see Owner’s Manual).
Fuel injector trouble Inspect and replace (see chapter 3).
Fuel pump not operating Inspect (see chapter 3).
Fuel pump relay trouble Inspect and replace (see chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator trouble
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Poor Running at Low Speed
Symptoms or Possible Causes Actions (chapter)
Spark weak:
Stick coil shorted or not in good contact Inspect or reinstall (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
ECU trouble Inspect (see chapter 3).
Fuel/air mixture incorrect:
Little fuel in tank Supply fuel (see Owner’s Manual).
Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 2).
Air duct loose
Reinstall (see chapter 3).
Throttle body assy holder loose
Reinstall (see chapter 3).
Throttle body assy dust seal damage Replace (see chapter 3).
Fuel injector O-ring damage Replace (see chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
FUEL SYSTEM (DFI) 3-37
DFI System Troubleshooting Guide
Symptoms or Possible Causes Actions (chapter)
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble
Inspect (see chapter 3).
Main throttle sensor trouble
Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Unstable (rough) idling:
Fuel pressure too low or too high Inspect (see chapter 3).
Fuel injector trouble
Inspect (see chapter 3).
Main throttle sensor trouble
Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Engine vacuum not synchronizing Inspect and adjust (see chapter 2).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).
Intake air temperature sensor trouble Inspect (see chapter 3).
Engine stalls easily:
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble Inspect (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Fuel pressure too low or too high
Inspect (see chapter 3).
Fuel pressure regulator trouble
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged
Inspect and repair (see chapter 3).
Poor acceleration:
Fuel pressure too low Inspect (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
Fuel pump trouble
Inspect (see chapter 3).
Fuel injector trouble
Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
3-38 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes Actions (chapter)
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble Inspect (see chapter 3).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Stumble:
Fuel pressure too low Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble Inspect (see chapter 3).
Surge:
Unstable fuel pressure Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and replace fuel pump) (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Backfiring when deceleration:
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16).
Fuel pressure too low Inspect (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble Inspect (see chapter 3).
Air switching valve trouble Inspect and replace (see chapter 16).
Air suction valve trouble
Inspect and replace (see chapter 5).
After fire:
Spark plug burned or gap maladjusted Replace (see chapter 2).
Fuel injector trouble Inspect (see chapter 3).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).
Inta
ke air temperature sensor trouble
Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-39
DFI System Troubleshooting Guide
Symptoms or Possible Causes Actions (chapter)
Other:
Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight,
and examine leads for signs of burning or fraying
(see chapter 3).
Poor Running or No Power at High Speed
Symptoms or Possible Causes Actions (chapter)
Firing incorrect:
Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
ECU trouble Inspect (see chapter 3).
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Clean element or inspect sealing (see chapter 2).
Air duct loose Reinstall (see chapter 3).
Throttle body assy holder loose Reinstall (see chapter 3).
Throttle body assy dust seal damage Replace (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel injector O-ring damage Replace (see chapter 3).
Fuel injector clogged
Inspect and repair (see chapter 3).
Fuel line clogged
Inspect and repair (see chapter 3).
Fuel pump operates intermittently and often DFI
fuse blows.
Fuel pump bearings may wear. Replace the fuel
pump (see chapter 3).
Fuel pump trouble
Inspect (see chapter 3).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Cracked or obstructed intake air pressure sensor
#1 and #2 vacuum hoses
Inspect and repair or replace (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Knocking:
Fuel poor quality or incorrect Fuel change (Use the gasoline recommended in
the Owner’s Manual).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
Stick coil trouble Inspect (see chapter 16).
ECU trouble Inspect (see chapter 3).
Engine vacuum not synchronizing Inspect and adjust (see chapter 2).
Intake air pressure sensor #1 trouble Inspect (see chapter 3).
Intake air pressure sensor #2 trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
3-40 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes Actions (chapter)
Intake air temperature sensor trouble
Inspect (see chapter 3).
Miscellaneous:
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Throttle valves will not fully open Inspect throttle cables and lever linkage (see
chapter 3).
Engine overheating - Water temperature sensor
or crankshaft sensor trouble
(see Overheating of Troubleshooting Guide in
chapter 17)
Air switching valve trouble Inspect and replace (see chapter 16).
Air suction valve trouble
Inspect and replace (see chapter 5).
Exhaust Smokes Excessively:
(Black smoke)
Air cleaner element clogged Clean element (see chapter 2).
Fuel pressure too high Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).
Intake air tempe
rature sensor trouble
Inspect (see chapter 3).
(Brown smoke)
Air duct loose Reinstall (see chapter 3).
Fuel pressure too low Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble
Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-41
Self-Diagnosis
Self-Diagnosis Outline
The self-diagnosis system is monitoring the following
mechanisms.
DFI System and Ignition System
Immobilizer System (Equipped Models)
The following indicators (LED) are used for warning indi-
cators of below table.
LED Color
Warning Indicators
Red [A]
Oil Pressure
Battery
Water Temperature
Immobilizer (Equipped Models)
Yellow [B] FI
The self-diagnosis system has two modes and can be
switched to another mode by operating the meter unit.
User Mode
The ECU notifies the rider of troubles in DFI system, ig-
nition system and immobilizer system (equipped models)
by lighting or blinking the yellow engine warning indicator
(LED) [A], red warning indicator (LED) [B] and warning in-
dicator [C] when DFI, ignition and immobilizer system parts
are faulty, and initiates fail-safe function. In case of serious
troubles, ECU stops the injection and ignition operations.
Dealer Mode
The LCD (Liquid Crystal Display) displays the service
code(s) [A] to show the problem(s) which the above system
has at the moment of diagnosis.
3-42 FUEL SYSTEM (DFI)
Self-Diagnosis
Self-Diagnosis Procedures
NOTE
○
Use a fully charged battery when conducting
self-diagnosis. Otherwise, the warning indicator (LED)
and indicator do not light or blink.
•
Turn the ignition switch on.
When a problem occurs with DFI system and ignition sys-
tem, the yellow engine warning indicator (LED) [A] goes
on to alert the rider.
When a problem occurs with immobilizer system
(equipped models), the red warning indicator (LED)
[A] and immobilizer warning indicator [B] blink.
Push the upper button [A] to display the odometer.
•
Push the upper button [A] the for more than two seconds.
•
The service code [B] is displayed on the LCD by the num-
ber of two digits.
FUEL SYSTEM (DFI) 3-43
Self-Diagnosis
•
Any of the following procedures ends self-diagnosis.
When the service code is displayed on the LCD, push the
upper button for more than two seconds. The display will
return to the previous display.
When the ignition switch is turned off.
Self-Diagnosis Flow Chart
3-44 FUEL SYSTEM (DFI)
Self-Diagnosis
Service Code Reading
The service code(s) is displayed on the LCD by the num-
ber of two digits.
When there are a number of problems, all the service
codes can be stored and the display will begin starting
from the lowest number service code in the numerical or-
der.
Then after completing all codes, the display is repeated
until the ignition switch is turned off or upper button is
pushed for more than two seconds.
For example, if three problems occurred in the order of
56, 16, 33, the service codes are displayed (each two sec-
onds) from the lowest number in the order listed as shown
below. (163356)(163356)· · ·(repeated)
If there is no problem or when the repair has been done,
yellow engine warning indicator (LED) or red warning indi-
cator (LED) and immobilizer warning indicator go off and
service code is not displayed.
ServiceCodeErasing
When repair has been done, yellow engine warning indicator (LED) or red warning indicator (LED)
and immobilizer warning indicator go off and service code is not displayed.
The service codes stored in memory of the ECU can be erased using Kawasaki Diagnostic System
(KDS Ver.3).
Service Code Table
The service codes of the immobilizer system appear to system equipped models.
Service
Code
System Problems
11 FI Main throttle sensor malfunction, wiring open or short
12 FI Intake air pressure sensor #1 malfunction, wiring open or short
13 FI Intake air temperature sensor malfunction, wiring open or short
14 FI Water temperature sensor malfunction, wiring open or short
16 FI Intake air pressure sensor #2 malfunction, wiring open or short
21 FI
Crankshaft sensor malfunction, wiring open or short
24 and 25 FI
Rear wheel rotation sensor signal abnormal (sensor or rotor missing,
too large clearance, rotor tooth worn or missing, wiring open)
First 24 is displayed and then 25
27 FI
Front wheel rotation sensor signal abnormal (sensor or rotor missing,
too large clearance, rotor tooth worn or missing, wiring open) [ABS
Equipped Models]
3
1
F
I
Vehicle-down sensor malfunction, wiring open or short
32 FI Subthrottle sensor malfunction, wiring open or short
33 FI Oxygen sensor inactivation, wiring open or short (Equipped Models)
34 FI
Exhaust butterfly valve actuator sensor malfunction, wiring open or
short
FUEL SYSTEM (DFI) 3-45
Self-Diagnosis
Service
Code
System Problems
35 Immobilizer
Immobilizer amplifier malfunction (Equipped Models)
36 Immobilizer Blank key detection (Equipped Models)
39 FI ECU communication error
51 FI Stick coil #1 malfunction, wiring open or short
52 FI Stick coil #2 malfunction, wiring open or short
53 FI
Stick coil #3 malfunction, wiring open or short
54 FI
Stick coil #4 malfunction, wiring open or short
56 FI Radiator fan relay malfunction, wiring open or short
62 FI Subthrottle valve actuator malfunction, wiring open or short
63 FI Exhaust butterfly valve actuator malfunction, wiring open or short
64 FI Air switching valve malfunction, wiring open or short
67 FI
Oxygen sensor heater malfunction, wiring open or short (Equipped
Models)
94 FI Oxygen sensor malfunction, wiring open or short (Equipped Models)
3A FI
Purge valve malfunction, wiring open or short (CAL, SEA-B1 and TH
Models)
Notes:
The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to check the ECU for ground and power supply. If the ground and power supply are checked good,
replace the ECU.
When no service code is displayed, the electrical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.
Backups
The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo-
bilizer system parts have troubles.
Service
Codes
Parts or
Function
Output Signal Usable
Range or Criteria
Backups by ECU
11
Main Throttle
Sensor
Output Voltage
0.2 ∼ 4.8 V
If the main throttle sensor system fails (the
output voltage is out of the usable range,
wiring short or open), the ECU locks ignition
timing into the ignition timing at closed throttle
position and sets the DFI in the D-J method (1).
12
Intake Air
Pressure
Sensor #1
Intake Air Pressure
(Absolute)
Pv = 100 ∼ 900 mmHg
If the intake air pressure sensor #1 system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets the DFI
in the -N method (2).
13
Intake Air
Temperature
Sensor
Intake Air Temperature
Ta = –30 ∼ +120°C
If the intake air temperature sensor system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets Ta at 40°C.
14
Water
Temperature
Sensor
Water Temperature
Tw = –30 ∼ +120°C
If the water temperature sensor system fails
(the signal is out of the usable range, wiring
short or open), the ECU sets Tw at 80°C and
the radiator fan operates.
16
Intake Air
Pressure
Sensor #2
Atmospheric Pressure
(Absolute)
Pa = 100 ∼ 900 mmHg
If the intake air pressure sensor #2 system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets Pa at 760
mmHg (the standard atmospheric pressure).
3-46 FUEL SYSTEM (DFI)
Self-Diagnosis
Service
Codes
Parts or
Function
Output Signal Usable
Range or Criteria
Backups by ECU
21
Crankshaft
Sensor
Crankshaft sensor must
send 22 signals to the ECU
at the 1 cranking.
If the crankshaft sensor fails, the engine stops
by itself.
24
Rear Wheel
Rotation
Sensor
Rear wheel rotation sensor
must send 45 signals to
theECUatthe1rotationof
the wheel.
If the rear wheel rotation sensor system
fails (the signal is m
issing, wiring open) the
speedometer shows 0.
25
Gear
Position
The gear position is
decided by the signal of
the ECU and rear wheel
rotation sensor.
If the rear wheel rot
ation sensor system fails
(no signal, wiring short or open), the ECU set
the top (6th) gear position.
27
Front Wheel
Rotation
Sensor (ABS
Equipped
Models)
Front wheel rotation sensor
must send 48 signals to
theECUatthe1rotationof
the wheel.
–
31
Vehicle
-down
Sensor
Output Voltage
0.10 ∼ 4.84 V
If the vehicle-down sensor system has failures
(the output voltage is out of the usable range,
wiring short or open), the ECU shuts off the
fuel pump relay, the fuel injectors and the
ignition system.
32
Subthrottle
Sensor
Output Voltage
0.15 ∼ 4.85 V
If the subthrottle sensor system fails (the
output voltage is out of the usable range, wiring
short or open), the ECU drive the subthrottle
valve to the full closed position, and it stops
the current to the subthrottle valve actuator.
33
Oxygen
Sensor
(Equipped
Models)
The oxygen sensor is
active and sensor must
send signals (output
voltage) continuously to
the ECU.
If the oxygen sensor is not activated, the ECU
stops the fee
dback mode of the oxygen sensor.
34
Exhaust
Butterfly
Valve
Actuator
Sensor
Output Voltage 0.1 ∼ 4.8 V
If the exhaust butterfly valve sensor system
fails (the output voltage is out of the usable
range, wiring short or open), the ECU locks
the exhaust butterfly valve at full open position
near, and it stops the current to the exhaust
butterfly valve actuator.
35
Immobilizer
Amplifier
(Equipped
Models)
–
If the immobilizer system fails (no signal, wiring
short or open), the vehicle is no start and run.
36 Ignition Key
The ignition key must use
register key.
If the blank key or broken key is used, the
vehicle is no start and run.
39 ECU
The communication error
between the ECU and
meter unit
–
51 Stick Coil #1*
The ECU sends
signals (output voltage)
continuously to the stick
coil.
If the stick coil #1 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #1 to stop fuel to the
cylinder #1, though the engine keeps running.
FUEL SYSTEM (DFI) 3-47
Self-Diagnosis
Service
Codes
Parts or
Function
Output Signal Usable
Range or Criteria
Backups by ECU
52
Stick Coil #2*
The ECU sends
signals (output voltage)
continuously to the stick
coil.
If the stick coil #2 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #2 to stop fuel to the
cylinder #2, though the engine keeps running.
53 Stick Coil #3*
The ECU sends
signals (output voltage)
continuously to the stick
coil.
If the stick coil #3 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #3 to stop fuel to the
cylinder #3, though the engine keeps running.
54 Stick Coil #4*
The ECU sends
signals (output voltage)
continuously to the stick
coil.
If the stick coil #4 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #4 to stop fuel to the
cylinder #4, though the engine keeps running.
56
Radiator Fan
Relay
When the radiator fan relay
is OFF, the relay is opened.
–
62
Subthrottle
Valve
Actuator
The actuator operates
open and close of the
subthrottle valve by the
pulse signal from the ECU.
If the subthrottle valve actuator fails (the
signal is out to the usable range, wiring short
or open), the ECU stops the current to the
actuator.
63
Exhaust
Butterfly
Valve
Actuator
The actuator operates
open and close of the
exhaust butterfly valve by
the pulse signal from the
ECU.
If the exhaust butterfly valve actuator fails (the
signal is out to the usable range, wiring short
or open), the ECU stops the current to the
actuator.
64
Air Switching
Valve
The air switching valve
controls the flow of the
secondary air by opening
and shutting the solenoid
valve.
–
67
Oxygen
Sensor
Heater
(Equipped
Models)
The oxygen sensor heater
raises temperature of
the sensor for its earlier
activation.
If the oxygen sensor heater fails (wiring short
or open), the ECU stops the current to the
heater, and it stops the feedback mode of the
oxygen sensor.
94
Oxygen
Sensor
(Equipped
Models)
The oxygen sensor must
send signals (output
voltage) continuously to
the ECU
If the oxygen sensor output voltage is incorrect,
the ECU stops oxygen sensor feed back mode.
3A
Purge Valve
(CAL, SEA
-B1 and TH
Models)
The purge valve controls
the flow of the secondary
air by opening and shutting
the solenoid valve.
–
Note:
(1): D-J Method: When the engine load is light like at idling or low speed, the ECU determines the
injection quantity by calculating from the throttle vacuum (vacuum sensor output voltage) and
engine speed (crankshaft sensor output voltage). This method is called D-J method.
(2): -N Method: As the engine speed increases, and the engine load turns middle to heavy, the
ECU determines the injection quantity by calculating from the throttle opening (throttle sensor
output voltage) and the engine speed. This method is called -N method.
*: This depends on the number of stopped cylinders.
3-48 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11)
The main throttle sensor is a rotating variable resistor that
change output voltage according to throttle operating. The
ECU senses this voltage change and determines fuel injec-
tion quantity, and ignition timing according to engine rpm,
and throttle opening.
Input Terminal [A]: BL
Output Terminal [B]: Y/W
Ground Terminal [C]: G
Main Throttle Sensor Removal/Adjustment
NOTICE
Do not remove or adjust the main throttle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the main throttle sen-
sor can damage it.
Main Throttle Sensor Input Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Disconnect the main throttle sensor connector and con-
nect the setting adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
•
Connect a digital meter to the setting adapter leads.
Main Throttle Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the input voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Input Voltage
Standard: DC 4.75
∼ 5.25 V
•
Turn the ignition switch off.
If the reading is within the standard, check the main throt-
tle sensor resistance (see Main Throttle Sensor Resis-
tance Inspection).
FUEL SYSTEM (DFI) 3-49
Main Throttle Sensor (Service Code 11)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
BL lead (ECU terminal 4) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Main Throttle Sensor Resistance Inspection
•
Turn the ignition switch off.
•
Disconnect the main throttle sensor connector.
•
Connect the setting adapter [A] to the sensor connector
only.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
•
Measure the main throttle sensor resistance.
Main Throttle Sensor Resistance
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
Standard: 4
∼ 6kΩ
If the reading is out of the standard, replace the throttle
body assy.
If the reading is within the standard, check the output volt-
age (see Main Throttle Sensor Output Voltage Inspec-
tion).
Main Throttle Sensor Output Voltage Inspection
•
Measure the output voltage at the main throttle sensor in
the same way as input voltage inspection, note the follow-
ing.
Disconnect the main throttle sensor connector and con-
nect the setting adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
Main Throttle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor Y/W) lead
Digital Meter (–) → BK (sensor G) lead
•
Start the engine and warm it up thoroughly.
•
Check idle speed to ensure the throttle opening is correct
(see Idle Speed Inspection in the Periodic Maintenance
chapter).
Idle Speed
Standard: 1 100 ±50 r/min (rpm)
3-50 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11)
•
Turn the ignition switch off.
•
Measure the output voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Output Voltage
Standard: DC 1.02
∼ 1.06 V at idle throttle opening
DC 4.22
∼ 4.42 V at full throttle opening (for
reference)
NOTE
○
Open the throttle, confirm the output voltage will be
raise.
○
The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.
○
When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.02 × 4.75 ÷ 5.00 = 0.969 V
1.06 × 4.75 ÷ 5.00 = 1.007 V
Thus, the valid range is 0.969
∼
1.007 V
•
Turn the ignition switch off.
If the reading is out of the standard, replace the throttle
body assy.
If the reading is within the standard, replace the ECU and
check the wiring for continuity between main harness con-
nectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
Y/W lead (ECU terminal 27) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-51
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Circuit
1. Main Throttle Sensor
2. Subthrottle Sensor
3. ECU
3-52 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Removal
NOTICE
Never drop the intake air pressure sensor #1 espe-
cially on a hard surface. Such a shock to the sensor
can damage it.
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
•
Disconnect:
Intake Air Pressure Sensor #1 Connector [A]
•
Disconnect the intake air pressure sensor #1 [B] from the
bracket [C].
•
Disconnect the vacuum hose [A].
•
Remove the rubber damper [B] from the intake air pres-
sure sensor #1 [C].
Intake Air Pressure Sensor #1 Installation
NOTE
○
The intake air pressure sensor #1 is the same part as
the intake air pressure sensor #2.
•
Installation is the reverse of removal.
•
Position the intake air pressure sensor #1 [A] between the
projections [B] on the rubber damper.
•
Install the rubber damper [A] on the bracket [B].
FUEL SYSTEM (DFI) 3-53
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Input Voltage
Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
•
Disconnect the intake air pressure sensor #1 connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #1 [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Intake Air Pressure Sensor #1 Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the input voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Input Voltage
Standard: DC 4.75
∼ 5.25 V
•
Turn the ignition switch off.
If the reading is within the standard, check the output volt-
age (see Intake Air Pressure Sensor #1 Output Voltage
Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #1 Connector [B]
BL lead (ECU terminal 4) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-54 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Output Voltage
Inspection
•
Measure the output voltage at the intake air pressure sen-
sor #1 in the same way as input voltage inspection, note
the following.
Disconnect the intake air pressure sensor #1 connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #1 [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #1 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor Y/BL) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the output voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Output Voltage
Usable Range:
DC 3.80
∼ 4.20 V at standard
atmospheric pressure (101.32 kPa,
76 cmHg)
NOTE
○
The output voltage changes according to local atmo-
spheric pressure.
•
Turn the ignition switch off.
If the reading is out of the usable range, replace the sen-
sor.
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #1 Connector [B]
Y/BL lead (ECU terminal 18) [C]
G lead (ECU terminal 49) [D]
FUEL SYSTEM (DFI) 3-55
Intake Air Pressure Sensor #1 (Service Code 12)
If the wiring is good, check the sensor for various vacuum.
•
Remove the intake air pressure sensor #1 [A] and discon-
nect the vacuum hose from the sensor.
•
Connect an auxiliary hose [B] to the intake air pressure
sensor #1.
•
Temporarily install the intake air pressure sensor #1.
Connect a digital meter [C], vacuum gauge [D], the fork oil
level gauge [E] and the measuring adapter to the intake
air pressure sensor #1.
Special Tools - Fork Oil Level Gauge: 57001-1290
Vacuum Gauge: 57001-1369
Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #1 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor Y/BL) lead
Digital Meter (–) → BK (sensor G) lead
Turn the ignition switch on.
Measure the intake air pressure sensor #1 output voltage
from various vacuum readings, while pulling the handle of
the fork oil level gauge.
Check the intake air pressure sensor #1 output voltage,
using the following formula and chart.
Suppose:
Pg: Vacuum Pressure (Gauge) of Throttle Body
Pl: Local Atmospheric Pressure (Absolute) measured by
a barometer
Pv: Vacuum Pressure (Absolute) of Throttle Body
Vv: Sensor Output Voltage (V)
then
Pv = Pl – Pg
For example, suppose the following data is obtained:
Pg = 8 cmHg (Vacuum Gauge Reading)
Pl = 70 cmHg (Barometer Reading)
Vv = 3.2 V (Digital Meter Reading)
then
Pv = 70 – 8 = 62 cmHg (Absolute)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.
Usable range = 3.08 ∼ 3.48 V
Plot Vv (3.2 V) on the vertical line. Point [3].
Results: In the chart, Vv is within the usable range and
the sensor is normal.
If the reading is out of the usable range, replace the sen-
sor.
If the reading is within the usable range, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-56 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12)
ID: Idling
Ps: Standard Atmospheric Pressure (Absolute)
Pv: Throttle Vacuum Pressure (Absolute)
ST: Standard of Sensor Output Voltage (V)
TO: Throttle Full Open
UR: Usable Range of Sensor Output Voltage (V)
Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
FUEL SYSTEM (DFI) 3-57
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Circuit
1. Intake Air Pressure Sensor #2
2. Intake Air Pressure Sensor #1
3. ECU
3-58 FUEL SYSTEM (DFI)
Intake Air Temperature Sensor (Service Code 13)
Intake Air Temperature Sensor Removal/Instal-
lation
NOTICE
Never drop the intake air temperature sensor espe-
cially on a hard surface. Such a shock to the sensor
can damage it.
•
Remove the fuel tank (see Fuel Tank Removal).
•
Disconnect the connector [A] from the intake air temper-
ature sensor [B].
•
Remove:
Intake Air Temperature Sensor Screw [C]
Intake Air Temperature Sensor
•
Be sure to install the O-ring [A].
•
Install the intake air temperature sensor.
•
Tighten:
Torque - Intake Air Temperature Sensor Screw: 1.2 N·m
(0.12 kgf·m, 11 in·lb)
•
Connect the intake air temperature sensor lead connec-
tor.
•
Install the fuel tank (see Fuel Tank Installation).
Intake Air Temperature Sensor Output Voltage
Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the fuel tank (see Fuel Tank Removal).
•
Disconnect the intake air temperature sensor connector
and connect the measuring adapter [A] between these
connectors as shown.
Main Harness [B]
Intake Air Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Intake Air Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor R/BK) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the output voltage with the engine stopped and
the connector joined.
•
Turn the ignition switch on.
Output Voltage
Standard: About DC 2.25
∼ 2.50 V at 20°C (68°F)
NOTE
○
The output voltage changes according to the intake air
temperature.
FUEL SYSTEM (DFI) 3-59
Intake Air Temperature Sensor (Service Code 13)
•
Turn the ignition switch off.
If the reading is within the standard, check the ECU for
its ground, and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Temperature Sensor Connector [B]
R/BK lead (ECU terminal 16) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the intake air temperature sen-
sor resistance (see Intake Air Temperature Sensor Resis-
tance Inspection).
Intake Air Temper
ature Sensor Resistance
Inspection
•
Remove the intake air temperature sensor (see Intake Air
Temperature Sensor Removal/Ins
tallation).
•
Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion is submerged.
•
Suspend a thermometer [B] with the heat-sen
sitive por-
tion [C] located in almost the same depth with the sensor.
NOTE
○
The sensor and thermometer must not touch the con-
tainer side or bottom.
•
Place the container over a source of heat and gradually
raise the temperature of the oil while stirring the oil gently
for even temperature.
•
Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the following.
Intake Air Temperature Sensor Resistance
Standard: 5.4
∼ 6.6 kΩ at 0°C (32°F)
0.29
∼ 0.39 kΩ at 80°C (176°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
3-60 FUEL SYSTEM (DFI)
Intake Air Temperature Sensor (Service Code 13)
Intake Air Temperature Sensor Circuit
1. Intake Air Temperature Sensor
2. ECU
FUEL SYSTEM (DFI) 3-61
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
NOTICE
Never drop the water temperature sensor especially
on a hard surface. Such a shock to the sensor can
damage it.
•
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
•
Disconnect:
Water Temperature Sensor Connector [A]
•
Remove:
Water Temperature Sensor [B] with O-ring
•
Replace the O-ring with a new one.
•
Tighten:
Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106
in·lb)
•
Fill the engine with coolant and bleed the air from the cool-
ing system (see Coolant Change in the Periodic Mainte-
nance chapter).
Water Temperature Sensor Output Voltage
Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Disconnect the water temperature sensor connector and
connect the measuring adapter [A] between these con-
nectors as shown.
Sub Harness [B]
Water Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Water Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor W/BL) lead
Digital Meter (–) → BK (sensor W/R) lead
•
Measure the output voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Output Voltage
Standard: About DC 2.80
∼ 2.97 V at 20°C (68°F)
NOTE
○
The output voltage changes according to the coolant
temperature in the engine.
•
Turn the ignition switch off.
If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-62 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main and sub
harness connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Sub Harness Connector [B]
W/G lead (ECU terminal 30) [C]
G lead (ECU terminal 49) [D]
Sub Harness Connector [A] ←→
Water Temperature Sensor Connector [B]
W/R lead [C]
W/BL lead [D]
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).
Water Temperature Sensor Resistance Inspection
•
Refer to the Water Temperature Sensor Inspection in the
Electrical System chapter.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Water Temperature Sensor Circuit
1. Water Temperature Sensor
2. ECU
FUEL SYSTEM (DFI) 3-63
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Removal
NOTICE
Never drop the intake air pressure sensor #2 espe-
cially on a hard surface. Such a shock to the sensor
can damage it.
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
•
Disconnect:
Intake Air Pressure Sensor #2 Connector [A]
•
Disconnect the intake air pressure sensor #2 [B] from the
bracket [C].
•
Disconnect the vacuum hose [A].
•
Remove the rubber damper [B] from the intake air pres-
sure sensor #2 [C].
Intake Air Pressure Sensor #2 Installation
NOTE
○
The intake air pressure sensor #2 is the same part as
the intake air pressure sensor #1.
•
Installation is the reverse of removal.
•
Position the intake air pressure sensor #2 [A] between the
projections [B] on the rubber damper.
•
Install the rubber damper [A] on the bracket [B].
3-64 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Input Voltage
Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
•
Disconnect the intake air pressure sensor #2 connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #2 [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Intake Air Pressure Sensor #2 Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the input voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Input Voltage
Standard: DC 4.75
∼ 5.25 V
•
Turn the ignition switch off.
If the reading is within the standard, check the output volt-
age (see Intake Air Pressure Sensor #2 Output Voltage
Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #2 Connector [B]
BL lead (ECU terminal 4) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-65
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Output Voltage
Inspection
•
Measure the output voltage at the intake air pressure sen-
sor #2 in the same way as input voltage inspection, note
the following.
Disconnect the intake air pressure sensor #2 connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #2 [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #2 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor G/W) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the output voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Output Voltage
Usable Range:
DC 3.80
∼ 4.20 V at standard
atmospheric pressure (101.32 kPa, 76
cmHg absolute)
NOTE
○
The output voltage changes according to the local at-
mospheric pressure.
•
Turn the ignition switch off.
If the reading is out of the usable range, replace the sen-
sor.
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #2 Connector [B]
G/W lead (ECU terminal 17) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the sensor for various vac-
uum (see Intake Air Pressure Sensor #1 Output Voltage
Inspection).
3-66 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Circuit
1. Intake Air Pressure Sensor #2
2. Intake Air Pressure Sensor #1
3. ECU
FUEL SYSTEM (DFI) 3-67
Crankshaft Sensor (Service Code 21)
The crankshaft sensor has no power source, and when
the engine stops, the crankshaft sensor generates no sig-
nals.
Crankshaft Sensor Removal/Installation
•
Refer to the Crankshaft Sensor Removal/Installation in
the Electrical System chapter.
Crankshaft Sensor Resistance Inspection
•
Refer to the Crankshaft Sensor Inspection in the Electrical
System chapter.
If the reading is within the standard, check the peak volt-
age (see Crankshaft Sensor Peak Voltage Inspection).
Crankshaft Sensor Peak Voltage Inspection
•
Refer to the Crankshaft Sensor Peak Voltage Inspection
in the Electrical System chapter.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Crankshaft Sensor Connector [B]
Y/BK lead (ECU terminal 37) [C]
Y lead (ECU terminal 48) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Crankshaft Sensor Circuit
1. Crankshaft Sensor
2. ECU
3-68 FUEL SYSTEM (DFI)
Rear Wheel Rotation Sensor Signal (Service Code 24, 25)
Rear Wheel Rotation Sensor Signal Inspection
The rear wheel rotation sensor sends the signal to the
ECU through the ABS hydraulic unit (ABS equipped mod-
els). For other than ABS equipped models, the signal is
sent directly to the ECU.
The ECU uses the rear wheel rotation sensor signal for
motorcycle speed.
The service code 24 and 25 are detected with the ECU.
•
Inspect the wheel rotation sensor air gap (see Wheel Ro-
tation Sensor Air Gap Inspection in the Brakes chapter).
•
Inspect the wheel rotation sensor rotor (see Wheel Rota-
tion Sensor Rotor Inspection in the Brakes chapter).
•
When service code 24 and 25 are displayed, do the fol-
lowing inspection procedures.
•
Disconnect:
ECU Connectors (see ECU Removal in the Fuel System
(DFI) chapter)
Rear Wheel Rotation Sensor Lead Connector
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal in the Brakes chapter)
•
For ABS equipped models, check the wiring for continuity
between harness connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
ABS Hydraulic Unit Connector [B]
R/Y lead (ECU terminal 21, ABS Hydraulic Unit
terminal 16) [C]
Wiring Continuity Inspection
ABS Hydraulic Unit Connector [A] ←→
Rear Wheel Rotation Sensor Connector [B]
BK/O lead (ABS Hydraulic Unit Connector terminal
14) [C]
W/G lead (ABS Hydraulic Unit Connector terminal
13) [D]
•
For other than ABS equipped models, check the wiring
for continuity between harness connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Rear Wheel Rotation Sensor Connector [B]
W/G lead (ECU terminal 32) [C]
BK/O lead (ECU terminal 20) [D]
FUEL SYSTEM (DFI) 3-69
Rear Wheel Rotation Sensor Signal (Service Code 24, 25)
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection in the
Fuel System (DFI) chapter).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).
Wheel Rotation Sensor Circuit (ABS Equipped Models)
1. Front Wheel Rotation Sensor
2. Rear Wheel Rotation Sensor
3. ECU
4. ABS Hydraulic Unit
3-70 FUEL SYSTEM (DFI)
Rear Wheel Rotation Sensor Signal (Service Code 24, 25)
Wheel Rotation Sensor Circuit (other than ABS Equipped Models)
1. ECU
2. Rear Wheel Rotation Sensor
FUEL SYSTEM (DFI) 3-71
Front Wheel Rotation Sensor Signal (Service Code 27, ABS Equipped Models)
Front Wheel Rotation Sensor Signal Inspection
The front wheel rotation sensor sends the signal to the
ECU through the ABS hydraulic unit.
The service code 27 is detected with the ECU.
•
Inspect the wheel rotation sensor air gap (see Wheel Ro-
tation Sensor Air Gap Inspection in the Brakes chapter).
•
Inspect the wheel rotation sensor rotor (see Wheel Rota-
tion Sensor Rotor Inspection in the Brakes chapter).
•
When service code 27 is displayed, do the following in-
spection procedures.
•
Disconnect:
ECU Connectors (see ECU Removal in the Fuel System
(DFI) chapter)
Front Wheel Rotation Sensor Lead Connector
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal in the Brakes chapter)
•
Check the wiring for continuity between harness connec-
tors.
Wiring Continuity Inspection
ECU Connector [A] ←→
ABS Hydraulic Unit Connector [B]
G/Y lead (ECU terminal 10, ABS Hydraulic Unit
terminal 8) [C]
Wiring Continuity Inspection
ABS Hydraulic Unit Connector [A] ←→
Front Wheel Rotation Sensor Connector [B]
W/BK lead (ABS Hydraulic Unit Connector terminal
12) [C]
BK/W lead (ABS Hydraulic Unit Connector terminal
3) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection in the
Fuel System (DFI) chapter).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).
3-72 FUEL SYSTEM (DFI)
Front Wheel Rotation Sensor Signal (Service Code 27, ABS Equipped Models)
Wheel Rotation Sensor Circuit
1. Front Wheel Rotation Sensor
2. Rear Wheel Rotation Sensor
3. ECU
4. ABS Hydraulic Unit
FUEL SYSTEM (DFI) 3-73
Vehicle-down Sensor (Service Code 31)
This sensor has a weight [A] with two magnets inside,
and sends a signal to the ECU. But when the motorcycle
banks 60 ∼ 70° or more to either side (in fact falls down),
the weight turns and the signal changes. The ECU senses
this change, and stops the fuel pump relay, the fuel injectors
and the ignition system.
Hall IC [B]
When the motorcycle is down, the ignition switch is left on.
If the starter button is pushed, the electric starter turns but
the engine does not start. To start the engine again, raise
the motorcycle, turn the ignition switch off, and then turn it
on.
Vehicle-down Sensor [A]
Ground Terminal [B]: G
Output Terminal [C]: Y/G
Power Source Terminal [D]: BL
Vehicle-down Sensor Removal
NOTICE
Never drop the vehicle-down sensor especially on
a hard surface. Such a shock to the sensor can
damage it.
•
Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Tank Bracket Bolts [A]
Fuel Tank Bracket [B]
Rivet [C]
•
Turn up the heat insulation rubber plate.
•
Disconnect:
Vehicle-down Sensor Connector [A]
•
Remove:
Vehicle-down Sensor Bolts [B] and Bracket [C]
Vehicle-down Sensor
3-74 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Installation
•
Be sure to install the rubber dampers [A] and collars [B]
on the battery case.
•
The UP mark [A] of the sensor should face upward.
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situ-
ations for an accident resulting in injury or death.
Ensure that the vehicle-down sensor is held in
place by the battery case.
•
Install the bracket.
•
Tighten:
Torque - Vehicle-down Sensor Mounting Bolts: 5.9 N·m
(0.60 kgf·m, 52 in·lb)
•
Install the removed parts (see appropriate chapters).
Vehicle-down Sensor Input Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Disconnect the vehicle-down sensor connector and con-
nect the measuring adapter [A] between these connectors
as shown.
Main Harness [B]
Vehicle-down Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Vehicle-down Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the input voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Input Voltage
Standard: DC 4.75
∼ 5.25 V
•
Turn the ignition switch off.
If the reading is within the standard, check the output volt-
age (see Vehicle-down Sensor Output Voltage Inspec-
tion).
FUEL SYSTEM (DFI) 3-75
Vehicle-down Sensor (Service Code 31)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
BL lead (ECU terminal 4) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Vehicle-down Sensor Output Voltage Inspection
•
Remove the vehicle-down sensor (see Vehicle-down
Sensor Removal).
•
Connect the measuring adapter [A] to the vehicle-down
sensor connectors as shown.
Special Tool - Measuring Adapter: 57001-1700
Main Harness [B]
Vehicle-down Sensor [C]
•
Connect a digital meter [D] to the measuring adapter
leads.
Vehicle-down Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor Y/G) lead
Digital Meter (–) → BK (sensor G) lead
3-76 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
•
Hold the sensor vertically.
•
Measure the output voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
•
Tilt the sensor 60 ∼ 70° or more [A] right or left, then hold
the sensor almost vertical with the arrow mark pointed up
[B], and measure the output voltage.
Output Voltage
Standard: Withsensortilted60
∼ 70° or more right or
left: DC 0.65 ∼ 1.35 V
With sensor arrow mark pointed up: DC
3.55
∼ 4.45 V
•
Turn the ignition switch off.
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
Y/G lead (ECU terminal 19) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-77
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Circuit
1. Vehicle-down Sensor
2. ECU
3-78 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32)
The subthrottle sensor is a rotating variable resistor that
change output voltage according to throttle operating. The
ECU senses this voltage change and determines fuel injec-
tion quantity, and ignition timing according to engine rpm,
and throttle opening.
Input Terminal [A]: BL
Output Terminal [B]: BL/W
Ground Terminal [C]: G
Subthrottle Sensor Removal/Adjustment
NOTICE
Do not remove or adjust the subthrottle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the subthrottle sen-
sor can damage it.
Subthrottle Sensor Input Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Disconnect the subthrottle sensor connector and connect
the setting adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
•
Connect a digital meter to the setting adapter leads.
Subthrottle Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
•
Measure the input voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Input Voltage
Standard: DC 4.75
∼ 5.25 V
•
Turn the ignition switch off.
If the reading is within the standard, check the output volt-
age (see Subthrottle Sensor Output Voltage Inspection).
FUEL SYSTEM (DFI) 3-79
Subthrottle Sensor (Service Code 32)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subthrottle Sensor Connector [B]
BL lead (ECU terminal 4) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Subthrottle Sensor Output Voltage Inspection
•
Measure the output voltage at the subthrottle sensor in
the same way as input voltage inspection, note the fol-
lowing.
Disconnect the subthrottle sensor connector and connect
the setting adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
Subthrottle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL/W) lead
Digital Meter (–) → BK (sensor G) lead
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
•
Disconnect the subthrottle valve actuator connector [A].
3-80 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32)
•
Measure the output voltage with the engine stopped with
the connector joined.
•
Turn the ignition switch on.
•
Measure the output voltage when the subthrottle valves
[A] are fully opened by hand.
Output Voltage
Standard: DC 1.08
∼ 1.12 V at subthrottle valve full
close position
DC 4.2
∼ 4.4 V at subthrottle valve full open
position (for reference)
NOTE
○
Open the subthrottle valves, confirm the output voltage
will be raise.
○
The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.
○
When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.08 × 4.75 ÷ 5.00 = 1.03 V
1.12 × 4.75 ÷ 5.00 = 1.06 V
Thus, the valid range is 1.03
∼
1.06 V
•
Turn the ignition switch off.
If the reading is out of the standard, check the subthrot-
tle sensor resistance (see Subthrottle Sensor Resistance
Inspection).
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subthrottle Sensor Connector [B]
BL/W lead (ECU terminal 28) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-81
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Resistance Inspection
•
Turn the ignition switch off.
•
Disconnect the subthrottle sensor connector.
•
Connect the setting adapter [A] to the sensor connector
only.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
•
Measure the subthrottle sensor resistance.
Subthrottle Sensor Resistance
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
Standard: 4
∼ 6kΩ
If the reading is out of the standard, replace the throttle
body assy.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Subthrottle Sensor Circuit
1. Main Throttle Sensor
2. Subthrottle Sensor
3. ECU
3-82 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
Oxygen Sensor Removal/Installation
•
Refer to the Oxygen Sensor Removal/Installation
(Equipped Models) in the Electrical System chapter.
Oxygen Sensor Inspection
•
Turn the ignition switch off.
•
Open the clamp [A], and pull out the oxygen sensor lead
connector [B].
•
Disconnect the oxygen sensor lead connector and con-
nect the measuring adapter [A] between these connec-
tors.
Main Harness [B]
Oxygen Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (−) → BK (sensor W) lead
•
Remove the air switching valve [A] (see Air Switching
Valve Removal in the Engine Top End chapter).
Do not disconnect the air switching valve connector [B].
FUEL SYSTEM (DFI) 3-83
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
•
Install the suitable plugs [A] on the fitting of the air suction
valve covers, and shut off the secondary air.
•
Remove the fuel hose (see Fuel Hose Replacement in the
Periodic Maintenance chapter).
•
Connect the following parts temporary.
Fuel Pump Lead Connector [A]
Extension Tube [B]
Air Cleaner Housing (see Air Cleaner Housing Installa-
tion)
Special Tool - Extension Tube: 57001-1578
•
Warm up the engine thoroughly until the radiator fan
starts.
•
Measure the output voltage with the connector joined.
Output Voltage (with Plugs, Rich)
Standard: DC 0.7 V or more
•
Turn the ignition switch off.
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
•
Remove the plugs from the fittings [A].
WARNING
The engine gets extremely hot during normal oper-
ation and can cause serious burns. Never touch a
hot engine.
•
Install the air cleaner housing temporary (see Air Cleaner
Housing Installation).
•
Start the engine, and let it idle.
•
Measure the output voltage with the connector joined.
Output Voltage (without Plugs, Lean)
Standard: DC 0.2 V or less
•
Turn the ignition switch off.
3-84 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
If the reading is out of the standard (with plugs: DC 0.7
V or more, without plugs: DC 0.2 V or less), remove the
ECU and check the wiring for continuity between main
harness connectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connectors [A] ←→
Oxygen Sensor Connector [B]
BL/Y lead (ECU terminal 8) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, replace the sensor.
If the reading is within the standard (with plugs: DC 0.7 V
or more, without plugs: DC 0.2 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Oxygen Sensor Circuit
1. Ignition Switch
2. Fuse Box 1
3. Ignition Fuse 15 A
4. Oxygen Sensor
5. ECU
6. Joint Connector E
7. Frame Ground 5
8. Engine Ground
9. Battery 12 V 10 Ah
10. Starter Relay
11.MainFuse30A
12. ECU Fuse 15 A
13. Relay Box
14. ECU Main Relay
FUEL SYSTEM (DFI) 3-85
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor
Removal/Installation
The exhaust butterfly valve actuator sensor is built in the
exhaust butterfly valve actuator. So, the sensor itself can
not be removed. Remove the exhaust butterfly valve actu-
ator (see Exhaust Butterfly Valve Actuator Removal in the
Engine Top End chapter).
Exhaust Butterfly Valve Actuator Sensor Input
Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the front seat (see Front Seat Removal in the
Frame chapter).
•
Remove the fuse boxes from the battery case.
•
Disconnect the exhaust butterfly valve actuator sensor
lead connector (3 pins connector) and connect the har-
ness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
•
Connect a digital meter to the harness adapter leads.
Exhaust Butterfly Valve Actuator Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → Y/W (actuator W) lead
Digital Meter (−) → BK/BL (actuator BK) lead
•
Measure the input voltage with the engine stopped and
with the connector joined.
•
Turn the igniti
on switch on.
Input Voltage
Standard: DC 4.75
∼ 5.25 V
•
Turn the ignition switch off.
If the reading is within the standard, check the output volt-
age (see Exhaust Butterfly Valve Actuator Sensor Output
Voltage Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Exhaust Butterfly Valve Actuator Sensor Connector [B]
BL lead (ECU terminal 4) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-86 FUEL SYSTEM (DFI)
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor Output
Voltage Inspection
NOTE
○
Before this inspection, confirm the pulley is original po-
sition (see Exhaust Butterfly Valve Cable Installation in
the Engine Top End chapter).
•
Disconnect:
3 Pins Connector [A]
2 Pins Connector [B]
•
Connect the harness adapter [A] between the 3 pins con-
nectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
•
Connect a digital meter to the harness adapter leads.
Exhaust Butterfly Valve Actuator Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → BL (actuator Y) lead
Digital Meter (−) → BK/BL (actuator BK) lead
•
Measure the output voltage at the 3 pins connector of the
exhaust butterfly valve actuator when the pulley is original
position.
•
Turn the ignition switch on.
Output Voltage
Standard: DC 3.46
∼ 3.76 V at pulley original position
•
Turn the ignition switch off.
If the reading is out of the standard, check the exhaust
butterfly valve actuator sensor resistance (see Exhaust
Butterfly Valve Actuator Sensor Resistance Inspection).
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Exhaust Butterfly Valve Actuator Sensor Connector [B]
GY lead (ECU terminal 29) [C]
G lead (ECU terminal 49) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-87
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor
Resistance Inspection
•
Turn the ignition switch off.
•
Disconnect the exhaust butterfly valve actuator sensor
connector (3 pins connector) [A] (see Exhaust Butterfly
Valve Actuator Sensor Input Voltage Inspection).
•
Connect a digital meter [B] to the exhaust butterfly valve
actuator sensor connector.
•
Measure the exhaust butterfly valve actuator sensor re-
sistance.
Exhaust Butterfly Valve Actuator Sensor Resistance
Connections: W lead [C] ←→ BK lead [D]
Standard: 4
∼ 6kΩ
If the reading is out of the standard, replace the exhaust
butterfly valve actuator.
If the reading within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Exhaust Butterfly Valve Actuator Sensor Circuit
1. ECU
2. Exhaust Butterfly Valve Actuator
3-88 FUEL SYSTEM (DFI)
Immobilizer Amplifier (Service Code 35, Equipped Models)
Antenna Resistance Inspection
•
Turn the ignition switch off.
•
Remove the left middle fairing (see Middle Fairing Re-
moval in the Frame chapter).
•
Slide the dust cover [A].
•
Disconnect the antenna lead connector [B].
•
Measure the antenna resistance.
Antenna Resistance
Connections: BK lead ←→ BK/W lead
Standard: About 3.0
∼ 4.6 Ω
If the reading is out of the standard, replace the ignition
switch (see Immobilizer System Parts Replacement in the
Electrical System chapter).
If the reading is within the standard, check the wiring to
the amplifier (see Immobilizer System Circuit).
If the wiring is good, check the input voltage of the ampli-
fier (see Amplifier Input Voltage Inspection).
Amplifier Input Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the fuel tank (see Fuel Tank Removal).
•
Turn up the heat insulation rubber plate.
•
Pull out the immobilizer amplifier [A] from the bracket.
•
Open the clamp [B].
•
Connect a digital meter to the amplifier connector [C] with
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Amplifier Input Voltage
Connections to Amplifier Connector:
Digital Meter (+) → BR/W lead
Digital Meter (–) → BK/Y lead
•
Measure the input voltage with the engine stopped and
with the connector joined.
•
Turn the ignition switch on.
Input Voltage
Standard: Battery Voltage
•
Turn the ignition switch off.
If the reading is out of the standard, check the wiring (see
Immobilizer System Circuit).
If the reading is within the standard, check the wiring to
ECU (see Immobilizer System Circuit).
If the wiring is good, replace the amplifier (see Immobi-
lizer System Parts Replacement in the Electrical System
chapter).
FUEL SYSTEM (DFI) 3-89
Blank Key Detection (Service Code 36, Equipped Models)
•
This code appears in the following conditions.
The transponder [A] in the ignition key is malfunction.
When the spare key of unregistration is used.
When the ignition key is registered in the registered ECU.
•
Therefore, the service code 36 will disappear when the
above issue is solved.
Ignition Key Inspection
•
Register the ignition key correctly (see Key Registration
in the Electrical System chapter).
If the service code 36 appears again, the transponder in
the key is malfunction, replace it.
Immobilizer System Circuit
1. Ignition Switch
2. ECU
3. Immobilizer/Kawasaki
Diagnostic System
Connector
4. Frame Ground 2
5. Frame Ground 1
6. Engine Ground
7. Battery 12 V 10 Ah
8. Starter Relay
9. Main Fuse 30 A
10. Meter Unit
11. Fuse Box 1
12. Ignition Fuse 15 A
13. Joint Connector C
14. Immobilizer Antenna
15. Immobilizer Amplifier
3-90 FUEL SYSTEM (DFI)
ECU Communication Error (Service Code 39)
ECU Communication Line Inspection
When the data is not sent from the ECU to the meter unit
for more than about 10 seconds, the service code 39 is
displayed.
The service code 39 is detected with meter unit.
•
Remove the ECU and meter unit, check the wiring for
continuity between main harness connectors.
Disconnect the ECU and meter unit connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→ Meter Unit Connector [B]
BL/O lead (ECU terminal 26) [C]
If the wiring is good, check the meter unit (see Meter Unit
Inspection in the Electrical System chapter).
If the meter unit is normal, replace the ECU (see ECU
Removal/Installation).
ECU Communication Line Circuit
1. Meter Unit
2. ECU
3. Frame Ground 1
FUEL SYSTEM (DFI) 3-91
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
Stick Coil #1: Service Code 51
Stick Coil #2: Service Code 52
Stick Coil #3: Service Code 53
Stick Coil #4: Service Code 54
Stick Coil Removal/Installation
•
Refer to the Stick Coil Removal/Installation in the Electri-
cal System chapter.
Stick Coil Primary Winding Resistance Inspection
•
Refer to the Stick Coil Inspection in the Electrical System
chapter.
If the reading is within the standard, check the input volt-
age (see Stick Coil Input Voltage Inspection).
Stick Coil Input Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the ECU (see ECU Removal).
Do not disconnect the ECU connectors.
•
Connect a digital meter [A] to the connector [B] with the
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Stick Coil Input Voltage
Connections to ECU Connector:
For Stick Coil #1
Digital Meter (+) → BK lead (terminal 44)
Digital Meter (–) → Frame Ground Terminal
For Stick Coil #2
Digital Meter (+) → BK/R lead (terminal 55)
Digital Meter (–) → Frame Ground Terminal
For Stick Coil #3
Digital Meter (+) → BK/O lead (terminal 66)
Digital Meter (–) → Frame Ground Terminal
For Stick Coil #4
Digital Meter (+) → BK/G lead (terminal 43)
Digital Meter (–) → Frame Ground Terminal
•
Measure the input voltage to each primary winding of the
stick coils with the engine stopped and with the connec-
tors joined.
•
Turn the engine stop switch to run position.
•
Turn the ignition switch on.
Input Voltage
Standard:
Battery Voltage
3-92 FUEL SYSTEM (DFI)
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
•
Turn the ignition switch off.
If the input voltage is out of the standard, check the wiring
for continuity (see Stick Coil Circuit).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the input voltage is within the standard, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Stick Coil Circuit
1. Engine Stop Switch
2. Stick Coil #1
3. Stick Coil #2
4. Stick Coil #3
5. Stick Coil #4
6. ECU
7. Frame Ground 2
8. Joint Connector D
9. Engine Ground
10. Battery 12 V 10 Ah
11. Starter Relay
12. Main Fuse 30 A
13. Ignition Switch
14. Fuse Box 1
15. Ignition Fuse 15 A
FUEL SYSTEM (DFI) 3-93
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation
The radiator fan relay is built in the relay box [A].
•
Refer to the Relay Box Removal in the Electrical System
chapter.
Radiator Fan Relay Inspection
•
Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.
If the radiator fan relay is normal, check the wiring for
continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Radiator Fan Relay Circuit
1. Ignition Switch
2. Fan Motor
3. Fuse Box 1
4. Ignition Fuse 15 A
5. Fan Fuse 15 A
6. Joint Connect
or C
7. Water Temperature Sensor
8. ECU
9. Frame Ground 5
10. Frame Ground 2
11. Engine Ground
12. Battery 12 V 10 Ah
13. Starter Relay
14. Main Fuse 30 A
15. Relay Box
16. Radiator Fan Relay
3-94 FUEL SYSTEM (DFI)
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Removal
NOTICE
Do not remove the subthrottle valve actuator [A]
since it has been adjusted and set with precision
at the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the subthrottle valve
actuator can damage it.
Subthrottle Valve Actuator Inspection
NOTE
○
Be sure the battery is fully charged.
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
•
Turn the ignition switch on.
•
Check to see that all the subthrottle valves [A] open and
close smoothly.
•
Turn the ignition switch off.
If the subthrottle valves do not operate, check the sub-
throttle valve actuator resistance (see Subthrottle Valve
Actuator Resistance Inspection).
Subthrottle Valve Actuator Resistance Inspection
•
Turn the ignition switch off.
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
•
Disconnect the subthrottle valve actuator connector [A].
•
Connect a digital meter to the subthrottle valve actuator
connector [A].
•
Measure the subthrottle valve actuator resistance.
Subthrottle Valve Actuator Resistance
Connections: Y/BK lead [1] ←→ P/BL lead [2]
G lead [3] ←→ BK/O lead [4]
Standard: About 5.2
∼ 7.8 Ω
If the reading is out of the standard, replace the throttle
body assy.
If the reading is within the standard, check the input volt-
age (see Subthrottle Valve Actuator Input Voltage Inspec-
tion).
FUEL SYSTEM (DFI) 3-95
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Input Voltage
Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Disconnect the subthrottle valve actuator connector and
connect the measuring adapter [A] between these con-
nectors as shown.
Main Harness [B]
Subthrottle Valve Actuator [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect the peak voltage adapter [D] and a digital meter
[E] to the measuring adapter leads.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Subthrottle Valve Actuator Input Voltage
Connections to Adapter:
(I) Digital Meter (+) → R (actuator BK/O) lead
Digital Meter (–) → Battery (–) terminal
(II) Digital Meter (+) → BK (actuator G) lead
Digital Meter (–) → Battery (–) terminal
(III) Digital Meter (+) → W (actuator P/BL) lead
Digital Meter (–) → Battery (–) terminal
(IV) Digital Meter (+) → Y (actuator Y/BK) lead
Digital Meter (–) → Battery (–) terminal
•
Measure the actuator input voltage with the engine
stopped and with the connector joined.
•
Turn the ignition switch on.
Input Voltage
Standard: About DC 8.5
∼ 10.5 V and then 0 V or
About DC 8.5
∼ 10.5 V
•
Turn the ignition switch off.
If the reading is in specification, but the actuator does not
operate, replace the throttle body assy.
If the reading is out of the specification, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and actuator connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subthrottle Valve Actuator Connector [B]
P/BL lead (ECU terminal 1) [C]
Y/BK lead (ECU terminal 12) [D]
BK/O lead (ECU terminal 23) [E]
G lead (ECU terminal 24) [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-96 FUEL SYSTEM (DFI)
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Circuit
1. Subthrottle Valve Actuator
2. ECU
FUEL SYSTEM (DFI) 3-97
Exhaust Butterfly Valve Actuator (Service Code 63)
Exhaust Butterfly Valve Actuator Removal
•
Refer to the Exhaust Butterfly Valve Actuator Removal in
the Engine Top End chapter.
Exhaust Butterfly Valve Actuator Installation
•
Refer to the Exhaust Butterfly Valve Actuator Installation
in the Engine Top End chapter.
Exhaust Butterfly Valve Actuator Inspection
NOTE
○
Be sure the battery is fully charged
•
Remove the front seat (see Front Seat Removal in the
Frame chapter).
•
Turn the ignition switch on.
•
Make sure that the pulley turns clockwise, then coun-
terclockwise and then returns slightly clockwise [A] as
shown.
NOTE
○
The stop position [B] of the pulley is changed by the
cables tension and the closed position of the exhaust
butterfly valve.
•
Turn the ignition switch off.
If the pulley does not operate, check the exhaust butter-
fly valve actuator resistance (see Exhaust Butterfly Valve
Actuator Inspection Resistance Inspection).
Exhaust Butterfly Valve Actuator Resistance
Inspection
•
Remove the front seat (see Front Seat Removal in the
Frame chapter).
•
Remove the fuse boxes from the battery case.
•
Turn the ignition switch off.
•
Disconnect the exhaust butterfly valve actuator lead con-
nector (2 pins connector) [A].
•
Connect a tester to the exhaust butterfly valve actuator
connector.
•
Measure the exhaust butterfly valve actuator resistance.
Exhaust Butterfly Valve Actuator Resistance
Connections: P lead ←→ GY lead
Standard: 5
∼ 200 Ω (for reference)
If the reading is 0 or infinity () , replace the exhaust
butterfly valve actuator.
3-98 FUEL SYSTEM (DFI)
Exhaust Butterfly Valve Actuator (Service Code 63)
If the reading is in specification, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Disconnect the ECU and actuator connectors.
Wiring Inspection
ECU Connector [A] ←→
Exhaust Butterfly Valve Actuator Connector [B]
W/Rlead(ECUterminal2)[C]
W/BL lead (ECU terminal 13) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Exhaust Butterfly Valve Actuator Circuit
1. ECU
2. Exhaust Butterfly Valve Actuator
FUEL SYSTEM (DFI) 3-99
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation
•
Refer to the Air Switching Valve Removal/Installation in
the Engine Top End chapter.
Air Switching Valve Inspection
•
Refer to the Air Switching Valve Unit Test in the Electrical
System chapter.
If the air switching valve is normal, check the wiring for
continuity (see Air Switching Valve Circuit).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Air Switching Valve Circuit
1. Ignition Switch
2. Fuse Box 1
3. Ignition Fuse 15 A
4. Air Switching Valve
5. ECU
6. Joint Connector E
7. Frame Ground 5
8. Frame Ground 2
9. Engine Ground
10. Battery 12 V 10 Ah
11. Starter Relay
12. Main Fuse 30 A
13. ECU Fuse 15 A
14. Joint Connector C
15. Relay Box
16. ECU Main Relay
3-100 FUEL SYSTEM (DFI)
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Removal/Installation
The oxygen sensor heater is built in the oxygen sensor.
So, the heater itself can not be removed. Remove the oxy-
gen sensor (see Oxygen Sensor Removal (Equipped Mod-
els) in the Electrical System chapter).
Oxygen Sensor Heater Resistance Inspection
•
Turn the ignition switch off.
•
Open the clamp [A], and pull out the oxygen sensor lead
connector [B].
•
Disconnect the oxygen sensor lead connector.
•
Connect a digital meter [A] to the oxygen sensor lead con-
nector [B].
•
Measure the oxygen sensor heater resistance.
Oxygen Sensor Heaters Resistance
Connections: BK lead [C] ←→ BK lead [D]
Standard: 11.7
∼ 14.5 Ω at 20° C (68°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, check the power
source voltage (see Oxygen Sensor Heater Power
Source Voltage Inspection).
FUEL SYSTEM (DFI) 3-101
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Power Source Voltage
Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Disconnect the oxygen sensor lead connector and con-
nect the measuring adapter [A] between these connec-
tors.
Main Harness [B]
Oxygen Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter lead.
Oxygen Sensor Power Source Voltage
Connections to Adapter:
Digital Meter (+) → R (main harness BR/W) lead
Digital Meter (–) → Frame Ground Terminal
•
Measure the power source voltage with the engine
stopped and with the connector joined.
•
Turn the ignition switch on.
Power Source Voltage
Standard: Battery Voltage
•
Turn the ignition switch off.
If the reading is in specification, but the problem still ex-
ists, replace the ECU (see ECU Removal/Installation).
If the reading is out of the standard, check the following.
ECU Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
Power Source Wiring (see Oxygen Sensor Circuit)
If the fuse and wiring are good, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Oxygen Sensor Connector [B]
P/BK lead (ECU terminal 64) [C]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-102 FUEL SYSTEM (DFI)
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Circuit
1. Ignition Switch
2. Fuse Box 1
3. Ignition Fuse 15 A
4. Oxygen Sensor
5. ECU
6. Joint Connector E
7. Frame Ground 5
8. Engine Ground
9. Battery 12 V 10 Ah
10. Starter Relay
11.MainFuse30A
12. ECU Fuse 15 A
13. Relay Box
14. ECU Main Relay
FUEL SYSTEM (DFI) 3-103
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
Oxygen Sensor Removal/Installation
•
Refer to the Oxygen Sensor Removal/Installation
(Equipped Models) in the Electrical System chapter.
Oxygen Sensor Inspection
•
Turn the ignition switch off.
•
Open the clamp [A], and pull out the oxygen sensor lead
connector [B].
•
Disconnect the oxygen sensor lead connector and con-
nect the measuring adapter [A] between these connec-
tors.
Main Harness [B]
Oxygen Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (−) → BK (sensor W) lead
•
Remove the air switching valve [A] (see Air Switching
Valve Removal in the Engine Top End chapter).
Do not disconnect the air switching valve connector [B].
3-104 FUEL SYSTEM (DFI)
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
•
Install the suitable plugs [A] on the fitting of the air suction
valve covers, and shut off the secondary air.
•
Remove the fuel hose (see Fuel Hose Replacement in the
Periodic Maintenance chapter).
•
Connect the following parts temporary.
Fuel Pump Lead Connector [A]
Extension Tube [B]
Air Cleaner Housing (see Air Cleaner Housing Installa-
tion)
Special Tool - Extension Tube: 57001-1578
•
Warm up the engine thoroughly until the radiator fan
starts.
•
Measure the output voltage with the connector joined.
Output Voltage (with Plugs, Rich)
Standard: DC 0.7 V or more
•
Turn the ignition switch off.
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
•
Remove the plugs from the fittings [A].
WARNING
The engine gets extremely hot during normal oper-
ation and can cause serious burns. Never touch a
hot engine.
•
Install the air cleaner housing temporary (see Air Cleaner
Housing Installation).
•
Start the engine, and let it idle.
•
Measure the output voltage with the connector joined.
Output Voltage (without Plugs, Lean)
Standard: DC 0.2 V or less
•
Turn the ignition switch off.
FUEL SYSTEM (DFI) 3-105
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
If the reading is out of the standard (with plugs: DC 0.7
V or more, without plugs: DC 0.2 V or less), check the
following.
Fuel Pressure (see Fuel Pressure Inspection)
Fuel Injector (see Fuel Injectors section)
If the fuel pressure and fuel injectors are good, replace
the sensor.
If the reading is within the standard (with plugs: DC 0.7 V
or more, without plugs: DC 0.2 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Oxygen Sensor Circuit
1. Ignition Switch
2. Fuse Box 1
3. Ignition Fuse 15 A
4. Oxygen Sensor
5. ECU
6. Joint Connector E
7. Frame Ground 5
8. Engine Ground
9. Battery 12 V 10 Ah
10. Starter Relay
11. Main Fuse 30 A
12. ECU Fuse 15 A
13. Relay Box
14. ECU Main Relay
3-106 FUEL SYSTEM (DFI)
Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models)
Purge Valve Removal/Installation
•
Remove:
Battery Case (see Battery Case Removal in the Frame
chapter)
•
Disconnect the purge valve lead connector [A].
•
Remove the nut [B].
•
Remove the purge valve [C] from the bracket.
•
Slide the clamps [D].
•
Disconnect the hoses [E].
•
Installation is the reverse of removal.
•
Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
Purge Valve Inspection
•
Remove the purge valve (see Purge Valve Removal/In-
stallation).
•
Connect a digital meter [A] to the purge valve terminals
as shown.
Purge Valve Resistance
Standard: 30
∼ 34 Ω at 20°C (68°F)
If the resistance reading is out of the specified value, re-
place it with a new one.
•
Connect the 12 V battery [A] to the purge valve terminals
as shown.
•
Blow the air to the intake air duct [A], and make sure that
the air flows from the outlet air duct [B].
FUEL SYSTEM (DFI) 3-107
Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models)
•
Disconnect the 12 V battery.
•
Blow the air to the intake air duct [A] again, and make sure
that the air does not flow from the outlet air duct [B].
If the purge valve dose not operate as described, replace
it with a new one.
Purge Valve Circuit
1. Ignition Switch
2. Fuse Box 1
3. Ignition Fuse 15 A
4. Purge Valve
5. ECU
6. Joint Connector E
7. Frame Ground 5
8. Engine Ground
9. Battery 12 V 10 Ah
10. Starter Relay
11. Main Fuse 30 A
12. ECU Fuse 15 A
13. Relay Box
14. ECU Main Relay
3-108 FUEL SYSTEM (DFI)
Warning Indicator Light (LED)
Yellow Engine Warning/Red Warning Indicator
(LED) Inspection
Yellow Engine Warning Indicator (LED) [A]
Red Warning Indicator (LED) [B]
In this model, the above mentioned warning indicators
(LED) go on or blink by the data sent from the ECU.
•
Refer to the Meter Unit Inspection in the Electrical System
chapter.
Warning Indicator (LED) Circuit
1. Meter Unit
2. Joint Connector C
3. ECU
4. Frame Ground 2
5. Frame Ground 1
FUEL SYSTEM (DFI) 3-109
ECU
ECU Identification
Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with
each other and use only the ECU for your model. Other-
wise, the motorcycle cannot clear the regulation.
ECU Identification
Part Number [A] Specification
AU, with Immobilizer
ID, with Immobilizer
PH, with Immobilizer
MY, with Immobilizer
SEA-B3, with Immobilizer
WVTA (FULL H), with Immobilizer
21175-0861
GB WVTA (FULL H), with Immobilizer
21175-0862
WVTA (78.2 H), with Immobilizer
US, without Immobilizer
21175-0863
CA, without Immobilizer
21175-0864
CAL, without Immobilizer
SEA-B1, with Immobilizer
21175-0865
TH, with Immobilizer
21175-0866 BR, with Immobilizer
21175-0895 SEA-B2, with Immobilizer
ECU Removal
NOTICE
Never drop the ECU especially on a hard surface.
Such a shock to the ECU can damage it.
NOTE
○
Refer to the Immobilizer System Parts Replacement
in the Electrical System chapter for the models with
guards.
•
Remove:
Seat Cover (see Seat Cover Removal in the Frame
chapter)
Bolts [A]
Rear Frame Cover [B]
3-110 FUEL SYSTEM (DFI)
ECU
•
Lift up the ECU [A] with rubber protector [B] to clear the
projections.
•
Remove the relay box [C] from the rubber protector.
•
Disconnect the ECU connectors [D].
•
Remove:
ECU (with Rubber Protector)
ECU Installation
•
Connect the ECU connectors [A].
•
Install:
ECU [B] (in Rubber Protector [C])
Insert the slits of the rubber protector to the projections
[D] of the rear fender.
•
Install the removed parts (see appropriate chapters).
ECU Power Supply Inspection
•
Visually inspect the ECU connectors.
If the connector is clogged with mud or dust, blow it off
with compressed air.
•
Remove the ECU (see ECU Removal).
•
Visually inspect the terminals [A] of the ECU and main
harness connectors.
If the terminals of the main harness connectors are dam-
aged, replace the main harness.
If the terminals of the ECU connectors are damaged, re-
place the ECU.
•
Turn the ignition switch off.
•
Disconnect the ECU connectors.
Gray Connector [A]
•
Set a tester [B] and check the following wiring for conti-
nuity.
ECU Grounding Inspection
Connections:
(I) BK/Y leads (ECU
terminal 39 or 65)
←→
Battery (–) Terminal
BK/BL lead (ECU
terminal 38)
(II) Engine Ground
←→
Battery (–) Terminal
Criteria:
Both: 0 Ω
If no continuity, check the connectors, the engine ground
lead, or main harness, and repair or replace them if nec-
essary.
FUEL SYSTEM (DFI) 3-111
ECU
If the wiring is good, check the power source voltage of
the ECU.
NOTE
○
Be sure the battery is fully charged.
•
Connect the ECU connectors.
•
Connect a digital meter [A] to the connector (black) [B]
with the needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
ECU Power Supply Inspection
Connections:
(I) Digital Meter (+) → Terminal 6 (BR/W)
Digital Meter (–) → Battery (–) terminal
(II) Digital Meter (+) → Terminal 7 (W/BK)
Digital Meter (–) → Battery (–) terminal
Ignition Switch off:
Terminal 6 (BR/W): 0 V
Terminal 7 (W/BK): Battery Voltage
Ignition Switch on:
Both: Battery Voltage
If the reading is out of the specification, check the follow-
ing.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
ECU Fuse 15 A (see Fuse Inspection Electrical System
chapter)
ECU Main Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Power Source Wiring (see wiring diagram in this section)
If the fuse, wiring and relay are good, replace the ECU
(see ECU Removal/Installation).
3-112 FUEL SYSTEM (DFI)
ECU
ECU Power Source Circuit
1. Ignition Switch
2. Fuse Box 1
3. Ignition Fuse 15 A
4. Joint Connector C
5. Joint Connector D
6. ECU
7. Joint Connector E
8. Frame Ground 5
9. Frame Ground 2
10. Engine Ground
11. Battery 12 V 10 Ah
12. Starter Relay
13. Main Fuse 30 A
14. ECU Fuse 15 A
15. Relay Box
16. ECU Main Relay
FUEL SYSTEM (DFI) 3-113
DFI Power Source
ECU Fuse Removal
•
Refer to the 30 A Main/15 A ECU Fuse Removal in the
Electrical System chapter.
ECU Fuse Installation
If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.
•
Refer to the Fuse Installation in the Electrical System
chapter.
ECU Fuse Inspection
•
Refer to the Fuse Inspection in the Electrical System
chapter.
ECU Main Relay Removal/Installation
The ECU main relay is built in the relay box [A].
•
Refer to the Relay Box Removal in the Electrical System
chapter.
ECU Main Relay Inspection
•
Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.
3-114 FUEL SYSTEM (DFI)
Fuel Line
Fuel Pressure Inspection
NOTE
○
Be sure the battery is fully charged.
•
Remove:
Seat Cover (see Seat Cover Removal in the Frame
chapter)
Fuel Tank Bolts [A]
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
•
Install the fuel pressure gauge adapter [A] and fuel hoses
(Special Tool: 57001-1607) [B] between the fuel outlet
pipe and delivery pipe.
•
Secure the fuel hoses with the clamps.
•
Connect the pressure gauge [C] to the fuel pressure
gauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607
WARNING
Fuel is extremely flammable and can be explosive
under certain conditions resulting in serious injury
or death. Do not try to start the engine with the fuel
hoses disconnected.
•
Turn the engine stop switch run position.
•
Turn the ignition switch on.
The fuel pump should operate for 3 seconds, and then
should stop.
NOTE
○
After turning on the engine stop switch and ignition
switch, inspect the fuel leakage from the connected
portion of the special tools.
NOTICE
Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
FUEL SYSTEM (DFI) 3-115
Fuel Line
•
Start the engine, and let it idle.
•
Measure the fuel pressure with the engine idling.
Fuel Pressure (with Engine Idling)
Standard: 294kPa(3.0kgf/cm²,43psi)
NOTE
○
The gauge needle will fluctuate. Read the pressure at
the average of the maximum and minimum indications.
•
Turn the ignition switch off.
If the fuel pressure is much higher than specified, replace
the fuel pump because the fuel pressure regulator in the
fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check
the following.
Fuel Line Leakage (see Fuel Injector Fuel Line Inspec-
tion)
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
•
After above checks, measure the fuel pressure again.
•
Remove the fuel pressure gauge, hoses and adapter.
•
Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)
•
Start the engine and check for fuel leakage.
Fuel Fl
ow Rate Inspection
WARNING
Gasolin
e is extremely flammable and can be explo-
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any s
ource of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Wait until the engine cools down.
•
Prepare a fuel hose (Special Tool: 57001-1607) and a
measuring cylinder.
Special Tool - Fuel Hose: 57001-1607
•
Remove:
Seat Cover (see Seat Cover Removal in the Frame
chapter)
Fuel Tank Bolts [A]
3-116 FUEL SYSTEM (DFI)
Fuel Line
•
Open the fuel tank cap [A] to lower the pressure in the
tank.
•
Remove the fuel hose from the fuel pump (see Fuel Tank
Removal).
Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
•
Connect the prepared fuel hose [A] to the fuel outlet pipe.
•
Secure the fuel hose with a clamp.
•
Insert the fuel hose into the measuring cylinder [B].
WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
•
Close the fuel tank cap.
•
Turn the engine stop switch to run position.
•
Turn the ignition switch on.
The fuel pump should operate for 3 seconds, and then
should stop.
NOTICE
Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
•
Measure the discharge for 3 seconds.
Repeat this operation several times.
Amount of Fuel Flow
Standard: 50 mL (1.7 US oz.) or more for 3 seconds
•
Turn the ignition switch off.
If the fuel flow is much less than the specified, replace the
fuel pump (see Fuel Pump Removal/Installation).
•
Install the fuel tank (see Fuel Tank Installation).
•
Start the engine and check for fuel leakage.
FUEL SYSTEM (DFI) 3-117
Fuel Pump
Fuel Pump Removal
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
NOTICE
Never drop the fuel pump especially on a hard sur-
face. Such a shock to the pump can damage it.
•
Draw the fuel out from the fuel tank with a commercially
available electric pump.
•
Remove the fuel tank (see Fuel Tank Removal).
Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
•
Turn the fuel tank upside down.
•
Remove the fuel pump bolts [A], and take out the fuel
pump [B].
NOTICE
Do not pull the leads of the fuel pump. If they are
pulled, the lead terminals may be damaged.
•
Discard the fuel pump gasket [A].
3-118 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Installation
•
Remove dirt or dust from the fuel pump [A] by lightly ap-
plying compressed air.
•
Replace the fuel pump gasket with a new one.
NOTE
○
Be careful not to bend the fuel level sensor arm.
•
Check that the fuel pump terminal [A] and band [B] are in
place.
•
Apply a non-permanent locking agent to the threads of
the fuel pump bolts.
•
Tighten the fuel pump bolts [C] to a snug fit.
•
Tighten the fuel pump bolts alternating diagonally.
Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
•
Tighten the pump bolts again to check the tightness.
Fuel Pump Operation Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the engine stop switch to run position.
•
Turn the ignition switch on and make sure that the fuel
pump operates (make light sounds) for 3 seconds, and
then stops.
•
Turn the ignition switch off.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).
FUEL SYSTEM (DFI) 3-119
Fuel Pump
Fuel Pump Operating Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the front seat (see Front Seat Removal in the
Frame chapter).
•
Disconnect the fuel pump lead connector and connect
the measuring adapter [A] between these connectors as
shown.
Main Harness [B]
Fuel Pump [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter
leads.
Fuel Pump Operating Voltage
Connections to Adapter:
Digital Meter (+) → R (pump BK/Y) lead
Digital Meter (–) → BK (pump BK/W) lead
•
Measure the operating voltage with engine stopped and
with the connector joined.
•
Turn the engine stop switch run position.
•
Turn the ignition switch on.
Operating Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
•
Turn the ignition switch off.
If the reading stays on battery voltage and never shows 0
V, check the fuel pump relay (see Relay Circuit Inspection
in the Electrical System chapter).
If the fuel pump relay is normal, check the ECU for its
ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If there is still no battery voltage, check the fuel pump re-
lay (see Relay Circuit Inspection in the Electrical System
chapter).
If the fuel pump relay is normal, check the wiring for con-
tinuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is in specification, but the pump does not op-
erate, replace the fuel pump (see Fuel Pump Removal/In-
stallation).
3-120 FUEL SYSTEM (DFI)
Fuel Pump
Pressure Regulator Removal
The pressure regulator [A] is built into the fuel pump [B]
and can not be removed.
Pump Screen, Fuel Filter Cleaning
The pump screen [A] and fuel filter [B] are built into the
fuel pump and can not be cleaned or checked.
If the pump screen or fuel filter is suspected of clogging
or being damaged, replace it with the fuel pump as a set.
Fuel Pump Relay Removal/Installation
The fuel pump relay is built in the relay box [A].
•
Refer to the Relay Box Removal in the Electrical System
chapter.
Fuel Pump Relay Inspection
•
Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.
FUEL SYSTEM (DFI) 3-121
Fuel Pump
Fuel Pump Circuit
1. Ignition Switch
2. Engine Stop Switch
3. Fuse Box 1
4. Ignition Fuse 15 A
5. Joint Connector D
6. ECU
7. Fuel Pump
8. Frame Ground 2
9. Engine Ground
10. Battery 12 V 10 Ah
11. Starter Relay
12. Main Fuse 30 A
13. ECU Fuse 15 A
14. Relay Box
15. Fuel Pump Relay
3-122 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Removal/Installation
•
Refer to the Throttle Body Assy Disassembly/Assembly.
Fuel Injector Audible Inspection
NOTE
○
Be sure the battery is fully charged.
•
Start the engine, and let it idle.
•
Apply the standard tip screwdriver [A] to the fuel injector
[B]. Put the grip end onto your ear, and listen whether the
fuel injector is clicking or not.
A sound scope can also be used.
The click interval becomes shorter as the engine speed
rises.
•
Do the same for the other fuel injectors.
If all the fuel injectors click at a regular intervals, the fuel
injectors are normal.
•
Turn the ignition switch off.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).
Fuel Injector Resistance Inspection
•
Remove the throttle body assy with the connectors in-
stalled (see Throttle Body Assy Removal).
•
Disconnect the fuel injector connector.
•
Connect a digital meter to the terminals [A] of the fuel
injector.
•
Measure the fuel injector resistance.
Fuel Injector Resistance
Connections:
Standard: About 11.7
∼ 12.3 Ω at 20°C (68°F)
If the reading is out of the standard, replace the fuel in-
jector.
If the reading is within the standard, check the power
source voltage (see Fuel Injector Power Source Voltage
Inspection).
FUEL SYSTEM (DFI) 3-123
Fuel Injectors
Fuel Injector Power Source Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the throttle body assy with the connectors in-
stalled (see Throttle Body Assy Removal).
•
Disconnect the injector connector and connect the mea-
suring adapter [A] between these connectors as shown.
Main Harness [B]
Fuel Injector #1 [C]
Special Tool - Measuring Adapter: 57001-1700
•
Connect a digital meter [D] to the measuring adapter lead.
Fuel Injector Power Source Voltage
Connections to Adapter:
For Fuel Injector #1, #2, #3, #4
Digital Meter (+) → R (injector R or W/R) lead
Digital Meter (–) → Battery (–) terminal
•
Measure the power source voltage with the engine
stopped.
•
Turn the engine stop switch to run position.
•
Turn the ignition switch on.
Power Source Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
•
Turn the ignition switch off.
If the reading stays on battery voltage and never shows 0
V, check the fuel pump relay (see Relay Circuit Inspection
in the Electrical System chapter).
If the fuel pump relay is normal, check the ECU for its
ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If there is still no battery voltage, check the fuel pump re-
lay (see Relay Circuit Inspection in the Electrical System
chapter).
If the fuel pump relay is normal, check the power source
wiring (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is in specification, check the output voltage
(see Fuel Injector Output Voltage Inspection).
3-124 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Output Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
•
Turn the ignition switch off.
•
Remove the ECU (see ECU Removal).
Do not disconnect the ECU connector.
•
Connect a digital meter [A] to the connector [B] with the
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Fuel Injector Output Voltage
Connections to ECU Connector:
For Fuel Injector #1
Digital Meter (+) → BL/BKlead(ECUterminal42)
Digital Meter (–) → Battery (–) terminal
For Fuel Injector #2
Digital Meter (+) → BL/R lead (ECU terminal 41)
Digital Meter (–) → Battery (–) terminal
For Fuel Injector #3
Digital Meter (+) → BL/O lead (ECU terminal 40)
Digital Meter (–) → Battery (–) terminal
For Fuel Injector #4
Digital Meter (+) → BL/G lead (ECU terminal 52)
Digital Meter (–) → Battery (–) terminal
•
Measure the output voltage with the engine stopped and
with the connector joined.
•
Turn the engine stop switch to run position.
•
Turn the ignition switch on.
Output Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
•
Turn the ignition switch off.
If the reading is in specification, check the ECU for its
ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-125
Fuel Injectors
If the reading is out of the specification, remove the ECU
and check the wiring for continuity between main harness
connectors.
Disconnect the ECU and injector connector.
Wiring Continuity Inspection
ECU Connector (Gray)
[A]
←→
Fuel Injector Connector
[B]
For Fuel Injector #1 [C]
BL/BK lead (ECU terminal 42) [D]
For Fuel Injector #2
BL/R lead (ECU terminal 41)
For Fuel Injector #3
BL/O lead (ECU terminal 40)
For Fuel Injector #4
BL/G lead (ECU terminal 52)
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Fuel Injector Fuel Line Inspection
•
Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
3-126 FUEL SYSTEM (DFI)
Fuel Injectors
•
Check the fuel injector fuel line for leakage as follows.
Connect a commercially available vacuum/pressure
pump [A] to the nipple of the delivery pipe [B] with the
fuel hose [C] (both ends with the clamps [D]) as shown.
Rear Side View [E]
Apply soap and water solution to the areas [F] as shown.
Watching the pressure gauge, squeeze the pump lever
[G], and build up the pressure until the pressure reaches
the maximum pressure.
Injector Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm², 43 psi)
NOTICE
During pressure testing, do not exceed the maxi-
mum pressure for which the system is designed.
Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once or if bubbles are found in the
area, the fuel line is leaking. Replace the delivery pipe
assy, injectors and related parts.
Repeat the leak test, and check the fuel line for no leak-
age.
•
Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)
•
Start the engine and check for fuel leakage.
FUEL SYSTEM (DFI) 3-127
Fuel Injectors
Fuel Injector Circuit
1. Ignition Switch
2. Engine Stop Switch
3. Fuse Box 1
4. Ignition Fuse 15 A
5. Joint Connector D
6. Fuel Injector #1
7. Fuel Injector #2
8. Fuel Injector #3
9. Fuel Injector #4
10. ECU
11. Frame Ground 2
12. Engine Ground
13. Battery 12 V 10 Ah
14. Starter Relay
15. Main Fuse 30 A
16. ECU Fuse 15 A
17. Relay Box
18. Fuel Pump Relay
3-128 FUEL SYSTEM (DFI)
Throttle Grip and Cables
Free Play Inspection
•
Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.
Free Play Adjustment
•
Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.
Cable Installation
•
Install the throttle cables in accordance with the Cable,
Wire, and Hose Routing section in the Appendix chapter.
•
Install the lower ends of the throttle cables in the throttle
pulley on the throttle body assy after installing the upper
ends of the throttle cables in the grip.
•
After installation, adjust each cable properly (see Throttle
Control System Inspection in the Periodic Maintenance
chapter).
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition. Be sure the cables are routed correctly and
properly adjusted.
Cable Lubrication
•
Refer to the Chassis Parts Lubrication in the Periodic
Maintenance chapter.
FUEL SYSTEM (DFI) 3-129
Throttle Body Assy
Idle Speed Inspection/Adjustment
•
Refer to the Idle Speed Inspection/Adjustment in the Pe-
riodic Maintenance chapter.
Synchronization Inspection/Adjustment
•
Refer to the Engine Vacuum Synchronization Inspection
in the Periodic Maintenance chapter.
Throttle Body Assy Removal
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
NOTICE
Never drop the throttle body assy especially on a
hard surface. Such a shock to the body assy can
damage it.
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
•
Disconnect:
Intake Air Pressure Sensor #1 Connector [A]
Intake Air Pressure Sensor #2 Connector [B]
Subthrottle Valve Actuator Connector [C]
Main Throttle Sensor Connector [D]
Subthrottle Sensor Connector [E]
•
Open the clamp [F].
•
For CAL, SEA-B1 and TH Models, disconnect the vacuum
hose.
•
Slide the dust covers [A].
•
Loosen the locknuts [B].
•
Turn the adjusters [C] to give the more free play.
3-130 FUEL SYSTEM (DFI)
Throttle Body Assy
•
Remove:
Bolts [A]
Throttle Pulley Cover [B]
•
Remove:
Throttle Cable Holder Clamp [A]
Throttle Cable Lower Ends [B]
•
Loosen the throttle body assy holder clamp bolts [A].
Special Tool - Carburetor Drain Plug Wrench, Hex 3:
57001-1269
•
Remove the throttle body assy [A] from the throttle body
assy holders.
•
Disconnect the fuel injector connectors [B].
•
Remove the clamps [C].
•
After removing the throttle body assy, stuff pieces of lint
-free, clean cloth into the throttle body assy holders.
NOTICE
If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.
FUEL SYSTEM (DFI) 3-131
Throttle Body Assy
Throttle Body Assy Installation
•
Be sure to position the throttle body assy holder clamp in
original position (see Throttle Body Assy Holder Installa-
tion in the Engine Top End chapter).
•
Connect the fuel injector connectors [A].
•
Install the throttle body assy to the throttle body assy hold-
ers.
•
Tighten:
Torque - Throttle Body Assy Holder Clamp Bolts: 2.9 N·m
(0.30 kgf·m, 26 in·lb)
Special Tool - Carburetor Drain Plug Wrench, Hex 3:
57001-1269
•
Apply a thin coat of grease to the throttle cable lower ends.
•
Fit the accelerator cable end [A] and the decelerator cable
end [B] into the throttle pulley.
The accelerator cable has a clamp [C].
•
Install the clamp securely.
•
Turn the throttle grip and make sure that the throttle pulley
moves smoothly and return by spring force.
•
Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
•
Adjust:
Throttle Grip Free Play (see Throttle Control System In-
spection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
3-132 FUEL SYSTEM (DFI)
Throttle Body Assy
Throttle Body Assy Disassembly
1. Throttle Body Assy
2. Subthrottle Valve Actuator
3. Main Throttle Sensor
4. Subthrottle Sensor
5. Fuel Injectors
6. Delivery Pipe Assy
7. Intake Air Pressure Sensor #1
8. Intake Air Pressure Sensor #2
NOTICE
Do not remove, disassemble or adjust the main
throttle sensor, subthrottle sensor, subthrottle
valve actuator, throttle link mechanism and throttle
body assy, because they are adjust or set surely at
the manufacturer. Adjustment of these parts could
result in poor performance, requiring replacement
of the throttle body assy.
•
Remove the throttle body assy (see Throttle Body Assy
Removal).
•
Remove the delivery pipe assy mounting screws [A] to
pull out the fuel injectors [B] from the throttle body assy
together with the delivery pipe assy [C].
NOTE
○
Do not damage the insertion portions of the injectors
when they are pulled out from the throttle body.
FUEL SYSTEM (DFI) 3-133
Throttle Body Assy
•
Remove the fuel injectors [A] from the delivery pipe assy
[B].
NOTE
○
Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.
NOTICE
Never drop the fuel injector especially on a hard
surface. Such a shock to the injector can damage
it.
Throttle Body Assy Assembly
•
Before assembling, blow away dirt or dust from the throttle
body and delivery pipe assy by applying compressed air.
•
Replace the O-rings [A] of the joint pipe [B] with new ones.
•
Apply engine oil to the new O-rings, and insert it to the
delivery pipes [C].
Insert the joint pipe so that the short side [D] faces right
side.
Left and right delivery pipes are identical.
•
Replace the O-rings [A] of each fuel injector [B] with new
ones.
•
Apply engine oil to the new O-rings, insert them to the
delivery pipe assy [C] and confirm whether the injectors
turn smoothly or not.
•
Replace the dust seals [A] with new ones.
•
Apply engine oil to the new dust seals.
•
Install the fuel injectors along with the delivery pipe assy
to the throttle body.
•
Tighten:
Torque - Delivery Pipe Assy Mounting Screws: 3.43 N·m
(0.35 kgf·m, 30 in·lb)
•
Install the throttle body assy (see Throttle Body Assy In-
stallation).
3-134 FUEL SYSTEM (DFI)
Air Cleaner
Air Cleaner Element Removal/Installation
•
Refer to the Air Cleaner Element Replacement in the Pe-
riodic Maintenance chapter.
Air Cleaner Element Inspection
•
Remove the air cleaner element (see Air Cleaner Element
Replacement in the Periodic Maintenance chapter).
•
Visually check the element [A] for tears or breaks.
If the element has any tears or breaks, replace the ele-
ment.
Air Cleaner Oil Draining
A drain hose is connected to the bottom of the air cleaner
to drain water or oil accumulated in the cleaner part.
•
Visually check the catch tank [A] of the drain hose, if the
water or oil accumulates in the tank.
If any water or oil accumulates in the catch tank, remove
the catch tank from the drain hose and drain it.
WARNING
Oil on tires will make them slippery and can cause
an accident and injury. Be sure to reinstall the catch
tank after draining.
Air Cleaner Housing Removal
•
Remove:
Fuel Tank (see Fuel Tank Removal)
Connector Bracket [A]
•
Slide the clamp [B].
•
Disconnect:
Breather Hose [C]
Intake Air Temperature Sensor Connector [D]
•
Remove:
Bolt [A]
FUEL SYSTEM (DFI) 3-135
Air Cleaner
•
Loosen the air cleaner housing clamp bolt [A] on both
sides.
•
Lift up the air cleaner housing, and disconnect the air
switching valve hose [A].
•
After removing the air cleaner housing, cover the clean
cloth on the throttle body assy.
Air Cleaner Housing Installation
•
Install the clamp bolt heads [A] outside as shown.
•
Install the air switching valve hose [B] to the air cleaner
housing.
•
Install the air cleaner housing on the throttle body assy.
Push in the ducts touch the stopper of the throttle body
assy.
•
Tighten the air cleaner housing clamp bolt (left) first, and
then air cleaner housing bolt (right).
Torque - Air Cleaner Housing Clamp Bolts: 2.0 N·m (0.20
kgf·m, 18 in·lb)
•
Tighten the bolt [C] securely.
•
Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
3-136 FUEL SYSTEM (DFI)
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
•
Turn the ignition switch off.
•
Wait until the engine cools down.
•
Disconnect the battery (–) terminal (see Battery Removal
in the Electrical System chapter).
•
Remove:
Seat Cover (see Seat Cover Removal in the Frame
chapter)
Fuel Tank Bolts [A]
•
Disconnect the fuel pump lead connector [A].
•
Clear the fuel pump lead from the clamp [B].
•
Open the fuel tank cap [A] to lower the pressure in the
tank.
During tank removal, keep the tank cap open to release
pressure in the tank. This makes fuel spillage less.
FUEL SYSTEM (DFI) 3-137
Fuel Tank
•
Draw the fuel out from the fuel tank with a commercially
available pump [A].
Use a soft plastic hose [B] as a pump intake hose in order
to insert the hose smoothly.
Put the hose through the fill opening [C] into the tank and
draw the fuel out.
WARNING
Spilled fuel is flammable and can be explosive un-
der certain conditions. The fuel can not be removed
completely from the fuel tank. Be careful for re-
mained fuel spillage.
•
Slide the clamp [A].
•
Disconnect the drain hose [B], and free the drain hose
from the clamps [C].
•
Be sure to place a piece of cloth around the fuel hose joint.
•
Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.
When removing with standard tip screwdriver
•
Insert the standard tip screwdriver [A] into slit on the joint
lock [B].
•
Turn the driver to disconnect the joint lock.
When removing with fingers
•
Open and push up [C] the joint lock with your fingers.
NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.
3-138 FUEL SYSTEM (DFI)
Fuel Tank
•
Pull [A] the fuel hose joint [B] out of the outlet pipe.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
•
Slide the clamp [A].
•
Disconnect:
Fuel Tank Breather Hose [B]
•
Remove:
Fuel Tank Bolt [C]
•
Close the fuel tank cap.
•
Remove the fuel tank, and place it on a flat surface.
Do not apply the load to the fuel pipe of the fuel pump.
•
Cleanthepipe[A].
•
Cover the pipe and the hose joint [B] with the vinyl bags
[C] to keep it clean.
Fuel Tank Installation
•
Note the above WARNING (see Fuel Tank Removal).
•
Check that the dampers [A] and trim [B] are in place on
the frame and the fuel tank.
If the dampers and trim are damaged or deteriorated, re-
place them.
•
Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
FUEL SYSTEM (DFI) 3-139
Fuel Tank
•
Remove the vinyl bag on the pipe and fuel hose joint.
•
Check the joint lock for deformation and wear.
If the joint lock is deformed, replace the fuel hose with a
new one.
•
Check that there are no flaws, burrs, and adhesion of
foreign materials on the pipe [A].
•
Apply engine oil to the pipe.
•
Insert the fuel hose joint [A] straight onto the fuel outlet
pipe until the hose joint clicks.
•
Push [B] the joint lock [C] until the hose joint clicks.
•
Push and pull [A] the hose joint [B] back and forth more
than two times, and make sure it is locked and does not
come off.
WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe.
If it comes off, reinstall the hose joint.
•
Connect the fuel pump lead connector and the battery (–)
terminal (see Battery Installation in the Electrical System
chapter).
•
Install the removed parts (see appropriate chapters).
Fuel Tank and Cap Inspection
•
Open the tank cap.
•
Visually inspect the gasket [A] on the tank cap for any
damage.
Replace the tank cap if gasket is damaged.
•
Check to see if the water drain pipe [B] and fuel breather
pipe [C] in the tank are not clogged. Check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.
NOTICE
Do not apply compressed air to the air vent holes
[D] in the
tank cap. This could cause damage and
clogging of the labyrinth in the cap.
3-140 FUEL SYSTEM (DFI)
Fuel Tank
Fuel Tank Cleaning
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area. Do not use gasoline
or low flash-point solvents to clean the tank.
•
Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Pump (see Fuel Pump Removal)
•
Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
•
Draw the solvent out of the fuel tank.
•
Dry the tank with compressed air.
•
Install:
Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)
FUEL SYSTEM (DFI) 3-141
Evaporative Emission Control System (CAL, SEA-B1 and TH Models)
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
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.
NOTICE
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capac-
ity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
•
Connect the hoses according to the diagram of the sys-
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.
Hose Inspection
•
Refer to the Evaporative Emission Control System In-
spection (CAL, SEA-B1 and TH Models) in the Periodic
Maintenance chapter.
Purge Valve Inspection
•
Refer to the Purge Valve Inspection.
Canister Inspection
•
Refer to the Evaporative Emission Control System In-
spection (CAL, SEA-B1 and TH Models) in the Periodic
Maintenance chapter.
COOLING SYSTEM 4-1
4
Cooling System
Table of Contents
Exploded View........................................................................................................................ 4-2
Coolant Flow Chart................................................................................................................. 4-4
Specifications ......................................................................................................................... 4-6
Special Tools ......................................................................................................................... 4-7
Coolant ................................................................................................................................... 4-8
Coolant Deterioration Inspection....................................................................................... 4-8
Coolant Level Inspection................................................................................................... 4-8
Coolant Draining ............................................................................................................... 4-8
Coolant Filling ................................................................................................................... 4-8
Pressure Testing ............................................................................................................... 4-8
Cooling System Flushing .................................................................................................. 4-9
Coolant Reserve Tank Removal/Installation ..................................................................... 4-9
Water Pump............................................................................................................................ 4-10
Water Pump Removal....................................................................................................... 4-10
Water Pump Installation .................................................................................................... 4-10
Water Pump Inspection..................................................................................................... 4-12
Water Pump Impeller Disassembly/Assembly .................................................................. 4-12
Water Pump Impeller Inspection ....................................................................................... 4-12
Water Pump Housing Disassembly .................................................................................. 4-12
Water Pump Housing Assembly ....................................................................................... 4-13
Mechanical Seal Inspection .............................................................................................. 4-13
Radiator.................................................................................................................................. 4-14
Radiator and Radiator Fan Removal ................................................................................ 4-14
Radiator and Radiator Fan Installation ............................................................................. 4-15
Radiator Inspection ........................................................................................................... 4-16
Radiator Cap Inspection ................................................................................................... 4-16
Radiator Filler Neck Inspection ......................................................................................... 4-17
Thermostat ............................................................................................................................. 4-18
Thermostat Removal......................................................................................................... 4-18
Thermostat Installation...................................................................................................... 4-18
Thermostat Inspection ...................................................................................................... 4-19
Hose and Pipes ...................................................................................................................... 4-21
Hose Installation ............................................................................................................... 4-21
Hose Inspection ................................................................................................................ 4-21
Water Temperature Sensor .................................................................................................... 4-22
Water Temperature Sensor Removal/Installation ............................................................. 4-22
Water Temperature Sensor Inspection ............................................................................. 4-22
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Water Hose Clamp Screws
3.0 0.31 27 in·lb
2 Fitting Bolt 8.8 0.90 78 in·lb L
3 Thermostat Housing Bolts 5.9 0.60 52 in·lb L
4 Water Pipe Bolts 12 1.2 106 in·lb L
5 Water Pump Impeller Bolt 9.8 1.0 87 in·lb
6
Water Pump Cover Bolts
11 1.1 97 in·lb
7
Coolant Drain Bolt
11 1.1 97 in·lb
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
W: Apply water.
WL: Apply soap and water solution or rubber lubricant.
4-4 COOLING SYSTEM
Coolant Flow Chart
1. Radiator
2. Radiator Fan
3. Water Temperature Sensor
4. Air Bleeder Hose
5. Radiator Overflow Hose
6. Radiator Cap
7. Thermostat Housing
8. Outlet Pipe
9. Reserve Tank Overflow Hose
10. Reserve Tank
11. Water Pump
12. Intake Pipe
13. Cylinder Jacket
14. Oil Cooler
15. Cylinder Head Jacket
16. Hot Coolant
17. Cold Coolant
COOLING SYSTEM 4-5
Coolant Flow Chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro-
sion. When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The
thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is less than 55°C (131°F), the thermostat closes so that the coolant flow
is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant
temperature is more than 58 ∼ 62°C (136 ∼ 144°F), the thermostat opens and the coolant flows.
When the coolant temperature goes up beyond 100°C (212°F), the radiator fan relay conducts to
operate the radiator fan. The radiator fan draws air through the radiator core when there is not suffi-
cient air flow such as at low speeds. This increases up the cooling action of the radiator. When the
coolant temperature is below 97.5°C (208°F), the fan relay opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine op-
erates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure
escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 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.
4-6 COOLING SYSTEM
Specifications
Item Standard
Coolant Provided when Shipping
Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol
plus corrosion and rust inhibitor chemicals for aluminum
engines and radiators)
Color Green
Mixed Ratio Soft water 50%, coolant 50%
Freezing Point 35°C (31°F)
Total Amount 2.9 L (3.1 US qt) (reserve tank full level, including radiator
and engine)
Radiator Cap
Relief Pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
Thermostat
Valve Opening Temperature 58 ∼ 62°C (136 ∼ 144°F)
Valve Full Opening Lift 8 mm (0.31 in.) or more at 75°C (167°F)
COOLING SYSTEM 4-7
Special Tools
Bearing Driver Set:
57001-1129
OilSealDriver 37.5:
57001-1660
4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection
•
Visually inspect the coolant in the reserve tank [A].
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
•
Refer to the Coolant Level Inspection in the Periodic Main-
tenance chapter.
Coolant Draining
•
Refer to the Coolant Change in the Periodic Maintenance
chapter.
Coolant Filling
•
Refer to the Coolant Change in the Periodic Maintenance
chapter.
Pressure Testing
•
Remove the right middle fairing (see Middle Fairing Re-
moval in the Frame chapter).
•
Remove the radiator cap, and install a cooling system
pressure tester [A] on the filler neck.
NOTE
○
Wet 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/cm², 18 psi).
NOTICE
During pressure testing, do not exceed the pres-
sure for which the system is designed. The maxi-
mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
•
Watch the gauge for at least 6 seconds.
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 indicate
internal leakage. Check the cylinder head gasket and the
water pump.
•
Remove the pressure tester, replenish the coolant, and
install the radiator cap.
•
Install the right middle fairing (see Middle Fairing Installa-
tion in the Frame chapter).
COOLING SYSTEM 4-9
Coolant
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. 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 Change in the Pe-
riodic Maintenance chapter).
•
Fill the cooling system with fresh water mixed with a flush-
ing compound.
NOTICE
Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.
•
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.
•
Fill the system with a permanent type coolant and bleed
the air from the system (see Coolant Change in the Peri-
odic Maintenance chapter).
Coolant Reserve Tank Removal/Installation
•
The coolant reserve tank is removed and installed dur-
ing coolant change (see Coolant Change in the Periodic
Maintenance chapter).
4-10 COOLING SYSTEM
Water Pump
Water Pump Removal
•
Drain:
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
•
Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
•
Remove the water pipe bolts [A], and disconnect the water
pipes [B].
•
Loosen the water hose clamp screw [C].
•
Disconnect:
Water Hose [D]
•
Remove:
Water Pump Cover Bolts [A]
Clamp [B]
Water Pump Cover [C]
•
Remove:
Water Pump Impeller Bolt [A] and Washer
WaterPumpImpeller[B]
Water Pump Housing [C]
Water Pump Installation
•
Replace the O-ring [A] with a new one, and install it.
COOLING SYSTEM 4-11
Water Pump
•
Be sure to install the dowel pins [A].
•
Install:
Water Pump Housing [A]
Water Pump Impeller [B]
•
Replace the washer with a new one, and install it.
•
Tighten:
Torque - Water Pump Impeller Bolt [C]: 9.8 N·m (1.0 kgf·m,
87 in·lb)
•
Be sure to install the dowel pins [D].
•
Replace the O-ring [A] with a new one, and install it.
•
Install:
Water Pump Cover [A]
Clamp [B]
•
Tighten:
Torque - Water Pump Cover Bolts [C]: 11 N·m (1.1 kgf·m, 97
in·lb)
•
Replace the O-rings [D] with new ones.
•
Apply soap and water solution to the O-rings.
•
Install the water pipes [A] to the water pump cover.
•
Apply a non-permanent locking agent to the threads of
the water pipe bolts [B], and tighten them.
Torque - Water Pipe Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
•
Install the water hose [C] and clamp (see Cable, Wire,
and Hose Routing section in the Appendix chapter).
•
Tighten:
Torque - Water Hose Clamp Screw [D]: 3.0 N·m (0.31 kgf·m,
27 in·lb)
•
Install the removed parts (see appropriate chapters).
4-12 COOLING SYSTEM
Water Pump
Water Pump Inspection
•
Check the drainage outlet passage [A] at the bottom of
the water pump housing for coolant leaks.
•
If a coolant leak or ooze is found, start the engine and
check if the coolant leaks continuously.
When coolant does not continuously leak, it is normal.
If the mechanical seal is damaged, the coolant continu-
ously leaks through the drainage outlet passage. Replace
the mechanical seal unit.
If the oil seal is damaged, engine oil leaks through the
drainage outlet passage. Replace the oil seal.
Water Pump Impeller Disassembly/Assembly
•
Remove the water pump impeller (see Water Pump Re-
moval).
•
The sealing seat [A] and rubber seal [B] may be removed
easily by hand.
•
Apply water or coolant around the surfaces of the rubber
seal and sealing seat.
•
Install the rubber seal and sealing seat into the impeller by
pressing them by hand until the seat stops at the bottom
of the hole.
•
Install the water pump impeller (see Water Pump Instal-
lation).
Water Pump Impeller Inspection
•
Remove the water pump cover (see Water Pump Re-
moval).
•
Visually inspect the water pump impeller [A].
If the surface is corroded or if the blades are damaged,
replace the water pump impeller.
Water Pump Housing Disassembly
NOTICE
Do not damage the hole wall of the water pump
housing.
•
Insert a bar [A] into the pump housing [B], and hammer
evenly around the circumference of the mechanical seal
bottom [C].
COOLING SYSTEM 4-13
Water Pump
•
Take the oil seal [A] out of the housing [B] with a hook [C].
WaterPumpHousingAssembly
NOTICE
Do not reuse the mechanical seal and oil seal.
•
Apply high-temperature grease to the oil seal lips [A].
•
Press the new oil seal into the housing with a bearing
driver [B] until it stops at the bottom surface [C] of the
housing.
Special Tool - Bearing Driver Set: 57001-1129
NOTICE
Be careful not to damage the sealing surface of the
mechanical seal.
•
Press the new mechanical seal into the housing with the
oil seal driver [A] until its flange [B] touches the surface
[C] of the housing.
Special Tool - Oil Seal Driver
37.5: 57001-1660
Mechanical Seal Inspection
•
Remove the water pump impeller (see Water Pump Re-
moval).
•
Visually inspect the mechanical seal.
If any one of the parts is damaged, replace the mechani-
cal seal as a unit.
Impeller Sealing Seat Surface [A]
Rubber Seal [B]
Mechanical Seal [C]
4-14 COOLING SYSTEM
Radiator
Radiator and Radiator Fan Removal
•
Drain:
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Bolts [A]
•
Disconnect the connectors [B], and remove the horn [C].
•
Slide the dust cover [A].
•
Disconnect the radiator fan motor lead connector [B].
•
Remove the bolt [A] and collar.
•
Loosen the water hose clamp screw [B].
•
Disconnect the water hose [C].
•
Loosen the water hose clamp screw [A].
•
Disconnect the water hose [B].
•
Remove the radiator lower bolt [C].
•
Remove:
Radiator Upper Bolt [A]
COOLING SYSTEM 4-15
Radiator
•
Move the radiator rightward [A] to clear the frame projec-
tion [B].
•
Remove:
Radiator [C]
NOTICE
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.
•
Remove:
Radiator Fan Mounting Bolts [A]
Radiator Fan [B]
Radiator and Radiator Fan Installation
•
Installation is the reverse of removal.
•
Install the rubber dampers [A] and radiator bracket collars
[B] as shown.
Larger [C]
Smaller [D]
Frame Projection [E]
4-16 COOLING SYSTEM
Radiator
•
Fit the slits [A] of the heat insulation rubber plate to the up-
per mounting brackets [B] and fan bracket [C] as shown.
•
Run the radiator fan motor lead [D] into the slit.
•
Insert the upper right mounting bracket [A] to the frame
projection [B].
•
Run the radiator fan motor lead correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
•
Install the water hoses and clamps (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
•
Tighten:
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
•
Install the removed parts (see appropriate chapters).
Radiator Inspection
•
Remove the radiator (see Radiator and Radiator Fan Re-
moval).
•
Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably de-
formed fins, replace the radiator with a new one.
NOTICE
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 (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular [C] (not oblique
[D]) to the core surface.
Run the steam gun, following the core fin direction.
Radiator Cap Inspection
•
Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Radiator Cap
•
Check the condition of the bottom [A] and top [B] valve
seals and valve spring [C].
If any one of them shows visible damage, replace the cap
with a new one.
COOLING SYSTEM 4-17
Radiator
•
Install the cap [A] on a cooling system pressure tester [B].
NOTE
○
Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
•
Watching the pressure gauge, pump the pressure tester
to build up the pressure until the relief valve opens: the
gauge needle flicks downward. Stop pumping and mea-
sure leak time at once. The relief valve must open within
the specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard: 93
∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi)
If the cap can not hold the specified pressure or if it holds
too much pressure, replace it with a new one.
Radiator Filler Neck Inspection
•
Remove:
Right Middle Fairing (see Middle Fairing Removal in the
Frame chapter)
Radiator Cap
•
Check the radiator filler neck for signs of damage.
•
Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
4-18 COOLING SYSTEM
Thermostat
Thermostat Removal
•
Drain:
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
•
Remove:
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
Harness Holder Clamp [A]
•
Loosen the water hose clamp screw [B].
•
Disconnect the water hose [C].
•
Remove the water pipe bolt [D], and disconnect the water
pipe [E].
•
Loosen the water hose clamp screw [A].
•
Remove the water hose [B] together with the water pipe.
•
Remove:
Thermostat Housing Bolts [A]
Thermostat Housing Cover [B]
Thermostat
Thermostat Installation
•
Install the thermostat [A] in the housing so that the air
bleeder hole [B] is on top.
COOLING SYSTEM 4-19
Thermostat
•
Replace the O-ring [A] with a new one.
•
Apply grease to the O-ring, and install it.
•
Install the thermostat housing cover.
NOTE
○
Note that the thermostat does not move at the place
when installing the thermostat housing cover.
•
Apply a non-permanent locking agent to the threads of
the thermostat housing bolts.
•
Tighten:
Torque - Thermostat Housing Bolts: 5.9 N·m (0.60 kgf·m,
52 in·lb)
•
Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
•
Replace the water pipe O-ring with a new one.
•
Apply soap and water solution to the water pipe O-ring.
•
Apply a non-permanent locking agent to the threads of
the water pipe bolt.
•
Tighten:
Torque - Water Pipe Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
•
Fill the radiator with coolant (see Coolant Change in the
Periodic Maintenance chapter).
•
Install the removed parts (see appropriate chapters).
Thermostat Inspection
•
Remove the thermostat (see Thermostat Removal).
•
Inspect the thermostat valve [A] at room temperature.
If the valve is open, replace the thermostat with a new
one.
4-20 COOLING SYSTEM
Thermostat
•
To check valve opening temperature, suspend the ther-
mostat [A] in a container of water and raise the tempera-
ture of the water.
The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an ac-
curate thermometer [B] in the water so that the heat sen-
sitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
Standard: 58
∼ 62°C (136 ∼ 144°F)
COOLING SYSTEM 4-21
Hose and Pipes
Hose Installation
•
Install the hoses and pipes, being careful to follow bend-
ing direction. Avoid sharp bending, kinking, flattening or
twisting.
•
Run the hoses (see Cable, Wire, and Hose Routing sec-
tion in the Appendix chapter).
•
Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
The clamp screws should be positioned correctly to pre-
vent the clamps from contacting the other parts.
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
Hose Inspection
•
Refer to the Water Hose and Pipe Inspection in the Peri-
odic Maintenance chapter.
4-22 COOLING SYSTEM
Water Temperature Sensor
NOTICE
The water temperature sensor should never be al-
lowed to fall on a hard surface. Such a shock to the
water temperature sensor can damage it.
Water Temperature Sensor Removal/Installation
•
Refer to the Water Temperature Sensor Removal/Instal-
lation in the Fuel System (DFI) chapter.
Water Temperature Sensor Inspection
•
Refer to the Water Temperature Sensor Inspection in the
Electrical System chapter.
ENGINE TOP END 5-1
5
Engine Top End
Table of Contents
Exploded View................................... 5-2
Exhaust System Identification ........... 5-6
Specifications .................................... 5-8
Special Tools and Sealants ............... 5-10
Clean Air System............................... 5-13
Air Suction Valve Removal........... 5-13
Air Suction Valve Installation........ 5-14
Air Suction Valve Inspection ........ 5-15
Air Switching Valve Removal ....... 5-15
Air Switching Valve Installation .... 5-15
Air Switching Valve Operation
Test............................................ 5-15
Air Switching Valve Unit Test ....... 5-15
Clean Air System Hose
Inspection.................................. 5-16
Cylinder Head Cover ......................... 5-17
Cylinder Head Cover Removal .... 5-17
Cylinder Head Cover Installation . 5-17
Camshaft Chain Tensioner ................ 5-19
Camshaft Chain Tensioner
Removal .................................... 5-19
Camshaft Chain Tensioner
Installation ................................. 5-19
Camshaft, Camshaft Chain ............... 5-20
Camshaft Removal ...................... 5-20
Camshaft Installation ................... 5-21
Camshaft, Camshaft Cap Wear
Inspection.................................. 5-24
Camshaft Runout Inspection........ 5-24
Cam Wear Inspection .................. 5-25
Camshaft Chain Removal ............ 5-25
Cylinder Head.................................... 5-26
Cylinder Compression
Measurement ............................ 5-26
Cylinder Head Removal ............... 5-27
Cylinder Head Installation ............ 5-28
Cylinder Head Warp Inspection ... 5-29
Valves ................................................ 5-30
Valve Clearance Inspection ......... 5-30
Valve Clearance Adjustment........ 5-30
Valve Removal ............................. 5-30
Valve Installation .......................... 5-30
Valve Guide Removal .................. 5-30
Valve Guide Installation ............... 5-31
Valve-to-Guide Clearance
Measurement (Wobble
Method) ..................................... 5-32
Valve Seat Inspection .................. 5-32
Valve Seat Repair ........................ 5-33
Cylinder, Pistons................................ 5-38
Cylinder Removal......................... 5-38
Cylinder Installation...................... 5-38
Piston Removal............................ 5-39
Piston Installation......................... 5-40
Cylinder Wear Inspection............. 5-41
Piston Wear Inspection ................ 5-41
Piston Ring, Piston Ring Groove
Wear Inspection ........................ 5-41
Piston Ring Groove Width
Inspection.................................. 5-41
Piston Ring Thickness Inspection 5-42
Piston Ring End Gap Inspection .. 5-42
Throttle Body Assy Holder................. 5-43
Throttle Body Assy Holder
Removal .................................... 5-43
Throttle Body Assy Holder
Installation................................. 5-43
Muffler................................................ 5-44
Muffler Body Removal.................. 5-44
Muffler Body Installation............... 5-46
Exhaust Pipe Removal................. 5-49
Exhaust Pipe Installation.............. 5-49
Exhaust Butterfly Valve Cable
Removal .................................... 5-49
Exhaust Butterfly Valve Cable
Installation................................. 5-51
Exhaust Butterfly Valve Actuator
Removal .................................... 5-52
Exhaust Butterfly Valve Actuator
Installation................................. 5-53
Exhaust Butterfly Valve Actuator
Adjustment ................................ 5-54
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Air Suction Valve Cover Bolts
9.8 1.0 87 in·lb L
2 Spark Plugs 13 1.3 115 in·lb
3 Cylinder Head Cover Bolts 10 1.0 89 in·lb S
4 Camshaft Cap Bolts 12 1.2 106 in·lb S
5 Upper Camshaft Chain Guide Bolts 12 1.2 106 in·lb S
Cylinder Head Bolts (M10) (First)
30 3.1 22
S, MO
6
Cylinder Head Bolts (M10) (Final)
54 5.5 40
S, MO
7 Cylinder Head Jacket Plugs 19.6 2.00 14.5 L
8 Cylinder Head Bolts (M6) 12 1.2 106 in·lb S
9 Throttle Body Assy Holder Bolts 12 1.2 106 in·lb L
10 Throttle Body Assy Holder Clamp Bolts 2.9 0.30 26 in·lb
11 Camshaft Chain Tensioner Cap Bolt 20 2.0 15
12 Camshaft Chain Tensioner Mounting Bolts 11 1.1 97 in·lb
13 Camshaft Sprocket Bolts 15 1.5 11 L
14
Front Camshaft Chain Guide Bolt (Upper)
25 2.5 18
15
Rear Camshaft Chain Guide Bolt
25 2.5 18
16 Front Camshaft Chain Guide Bolt (Lower) 12 1.2 106 in·lb
17. Face the round end outward.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
5-4 ENGINE TOP END
Exploded View
ENGINE TOP END 5-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Exhaust Pipe Cover Bracket Bolts
10 1.0 89 in·lb
2 Exhaust Buttery Valve Actuator Pulley Bolt 5.0 0.51 44 in·lb
3
Exhaust Battery Valve Actuator Mounting
Screws
1.2 0.12 11 in·lb
4 Muffler Body Mounting Bolts 34 3.5 25
5 Premuffler Chamber Mounting Bolt 34 3.5 25
6 Muffler Body Clamp Bolts 21 2.1 15
G: Apply grease.
R: Replacement Parts
5-6 ENGINE TOP END
Exhaust System Identification
Exhaust Pipe Mark Position [A]
Left Muffler Body Mark Position [A]
ENGINE TOP END 5-7
Exhaust System Identification
Right Muffler Body Mark Position [A]
Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C]
(Equipped Models)
Honeycomb Type Catalyst Positions [A]
5-8 ENGINE TOP END
Specifications
Item Standard Service Limit
Camshafts
Cam Height:
Exhaust 33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.) 33.64 mm (1.324 in.)
Intake 34.443 ∼ 34.557 mm (1.3560 ∼ 1.3605 in.) 34.34 mm (1.352 in.)
Camshaft Journal, Camshaft
Cap Clearance
0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) 0.17 mm (0.0067 in.)
Camshaft Journal Diameter 23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.) 23.91 mm (0.9413 in.)
Camshaft Bearing In
side
Diameter
24.000 ∼ 24.021 mm (0
.9449 ∼ 0.9457 in.)
24.08 mm (0.9480 in.
)
Camshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.004 in.)
Cylinder Head
Cylinder Compression (Usable Range)
966 ∼ 1 478 kPa (9.9 ∼ 15.1 kgf/cm², 140 ∼
214 psi) at 280 r/min (rpm)
–––
Cylinder Head Warp ––– 0.05 mm (0.002 in.)
Valves
Valve Clearance:
Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) –––
Intake 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) –––
Valve Head Thickness:
Exhaust
0.8 mm (0.031 in.) 0.6 mm (0.024 in.)
Intake
0.5 mm (0.020 in.) 0.3 mm (0.012 in.)
Valve Stem Bend TIR 0.01 mm (0.0
004 in.) or less
TIR 0.05 mm (0.0
02 in.)
Valve Stem Diameter:
Exhaust 4.455 ∼ 4.470 mm (0.1754 ∼ 0.1760 in.) 4.44 mm (0.175 in.)
Intake 4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.) 4.46 mm (0.176 in.)
Valve Guide Inside Diameter:
Exhaust 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.) 4.58 mm (0.180 in.)
Intake 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.) 4.58 mm (0.180 in.)
Valve/Valve Guide
Clearance (Wobble Method):
Exhaust
0.08 ∼ 0.16 m
m (0.0031 ∼ 0.0063 in.)
0.35 mm (0.0
13 in.)
Intake 0.03 ∼ 0.10 mm (0.0012 ∼ 0.0039 in.) 0.30 mm (0.012 in.)
Valve Seat Cutting Angle 32°, 45°, 60° –––
Valve Seating Surface:
Width:
Exhaust
0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)
–––
Intake
0.5 ∼ 1.0 mm
(0.020 ∼ 0.039 in.)
–––
Outside Diameter:
Exhaust 24.7 ∼ 24.9 mm (0.972 ∼ 0.980 in.) –––
Intake 28.9 ∼ 29.1 mm (1.138 ∼ 1.146 in.) –––
Valve Spring Free Length:
Exhaust 36.62 mm (1.442 in.) 35.2 mm (1.39 in.)
Intake 36.62 mm (1.442 in.) 35.2 mm (1.39 in.)
ENGINE TOP END 5-9
Specifications
Item Standard Service Limit
Cylinder, Pistons
Cylinder Inside Diameter 76.994 ∼ 77.006 mm (3.0313 ∼ 3.0317 in.) 77.09 mm (3.035 in.)
Piston Diameter
76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.) 76.82 mm (3.024 in.)
Piston/Cylinder Clearance 0.010 ∼ 0.032 mm (0.0004 ∼ 0.0013 in.)
–––
Piston Ring/Groove
Clearance:
Top 0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.) 0.17 mm (0.0067 in.)
Second 0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.) 0.16 mm (0.0063 in.)
Piston Ring Groove Width:
Top 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) 0.92 mm (0.0362 in.)
Second 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.) 0.91 mm (0.0358 in.)
Piston Ring Thickness:
Top 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.028 in.)
Second 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.028 in.)
Piston Ring End Gap:
Top 0.20 ∼ 0.30 mm (0.0079 ∼ 0.0118 in.) 0.6 mm (0.024 in.)
Second 0.38 ∼ 0.48 mm (0.0150 ∼ 0.0189 in.) 0.8 mm (0.031 in.)
5-10 ENGINE TOP END
Special Tools and Sealants
Compression Gauge, 20 kgf/cm²:
57001-221
Valve Spring Compressor Assembly:
57001-241
Piston Pin Puller Assembly:
57001-910
Valve Seat Cutter, 45° - 27.5:
57001-1114
Valve Seat Cutter, 45° - 32:
57001-1115
Valve Seat Cutter, 32° - 28:
57001-1119
Valve Seat Cutter Holder Bar:
57001-1128
Valve Seat Cutter, 32° - 33:
57001-1199
Valve Seat Cutter Holder, 4.5:
57001-1330
Valve Guide Arbor, 4.5:
57001-1331
ENGINE TOP END 5-11
Special Tools and Sealants
Valve Guide Reamer, 4.5:
57001-1333
Valve Seat Cutter, 60° - 33:
57001-1334
Valve Seat Cutter, 60° - 27:
57001-1409
Engine Mount Nut Wrench:
57001-1450
Valve Guide Driver:
57001-1564
Valve Spring Compressor Adapter, 24:
57001-1586
Compression Gauge Adapter, M10 × 1.0:
57001-1601
L-Shape Hose:
57001-1606
Washer:
57001-1612
Liquid Gasket, TB1211F:
92104-0004
5-12 ENGINE TOP END
Special Tools and Sealants
Liquid Gasket, TB1216B:
92104-1064
ENGINE TOP END 5-13
Clean Air System
Air Suction Valve Removal
•
Remove:
Air Switching Valve (see Air Switching Valve Removal)
Bolts [A]
•
Disconnect the connectors [B], and remove the horn [C].
•
Slide the dust cover [A].
•
Disconnect the radiator fan motor lead connector [B].
•
Remove:
Radiator Lower Bolt [A]
•
Remove:
Radiator Upper Bolt [A]
•
Remove:
Radiator Cap Mounting Bolt [A]
Collar
5-14 ENGINE TOP END
Clean Air System
•
Move the radiator rightward [A] to clear the frame projec-
tion [B], and remove it.
•
Disconnect the stick coil connectors.
•
Turn up the heat insulation rubber plate.
•
Install the radiator temporarily to prevent damage the ra-
diator core.
•
Remove the connector [A] from the bracket.
•
Remove:
Air Suction Valve Cover Bolts [B] (Both Sides)
Connector Bracket
Air Suction Valve Covers [C]
•
Remove the air suction valve [A] on both sides.
Air Suction Valve Installation
•
Install the air suction valve so that opening [A] of the reed
faces the front and downward.
•
Install the connector bracket [A] as shown.
•
Install the air suction valve cover.
•
Apply a non-permanent locking agent to the threads of
the air suction valve cover bolts [B], and tighten them.
Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
•
Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-15
Clean Air System
Air Suction Valve Inspection
•
Remove the air suction valve (see Air Suction Valve Re-
moval).
•
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 reeds, re-
place the air suction valve as an assembly.
•
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high flash-point solvent.
NOTICE
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
Air Switching Valve Removal
NOTICE
Never drop the air switching valve especially on a
hard surface. Such a shock to the air switching
valve can damaged it.
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).
•
Disconnect the connector [A].
•
Disconnect the hoses [B] from the air suction valve cov-
ers, and remove the air switching valve [C].
Air Switching Valve Installation
•
Install the air switching valve [A] with hoses as shown.
Left Side View [B]
About 40° [C]
•
Install the removed parts (see appropriate chapters).
Air Switching Valve Operation Test
•
Refer to the Air Suction System Damage Inspection in the
Periodic Maintenance chapter.
Air Switching Valve Unit Test
•
Refer to the Air Switching Valve Unit Test in the Electrical
System chapter.
5-16 ENGINE TOP END
Clean Air System
Clean Air System Hose Inspection
•
Be certain that all the hoses are routed without being flat-
tened or kinked, and are connected correctly to the air
cleaner housing, air switching valve and air suction valve
covers.
If they are not, correct them. Replace them if they are
damaged.
ENGINE TOP END 5-17
Cylinder Head Cover
Cylinder Head Cover Removal
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Stick Coils (see Stick Coil Removal in the Electrical Sys-
tem chapter)
Air Suction Valves (see Air Suction Valve Removal)
Bracket Bolt [A]
Bracket [B]
•
Remove:
Cylinder Head Cover Bolts [A] with Washers
Cylinder Head Cover
Cylinder Head Cover Installation
•
Replace the plug hole gaskets with new ones.
•
Install:
Dowel Pins [A]
Plug Hole Gaskets [B]
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket [A] to the cylinder head as shown.
Sealant - Liquid Gasket, TB1216B: 92104-1064
NOTE
○
Make the application finish within 20 minutes with the
liquid gasket (TB1216B) to the mating surface of the
cylinder head cover is applied.
5-18 ENGINE TOP END
Cylinder Head Cover
•
Replace the head cover gasket with a new one.
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket [A] to the cylinder head cover [B] as
shown.
Sealant - Liquid Gasket, TB1211F: 92104-0004
•
Install the gasket to the cylinder head cover.
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket [A] to the cylinder head cover [B] as
shown.
Sealant - Liquid Gasket, TB1211F: 92104-0004
•
Replace the washers with new ones.
•
Install the washers with the metal side [A] faces upward.
•
Tighten the cylinder head cover bolts following the speci-
fied tightening sequence [1 ∼ 6].
Torque - Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89
in·lb)
•
Install:
Bracket
•
Tighten the bracket bolt.
•
Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-19
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
NOTICE
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below.
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in “Camshaft Chain Ten-
sioner Installation.”
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing, and damage the valves.
•
Remove:
Cap Bolt [A]
Washer [B]
Spring [C]
Rod [D]
Camshaft Chain Tensioner Mounting Bolts [E]
Camshaft Chain Tensioner Body [F]
Camshaft Chain Tensioner Installation
•
Replace the O-ring [A] with a new one.
•
Apply grease to the new O-ring.
•
Release the stopper [B] and push the push rod [C] into
the interior of the tensioner body [D].
•
Install the tensioner body so that the stopper faces up-
ward.
•
Tighten:
Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 11
N·m (1.1 kgf·m, 97 in·lb)
•
Install the rod, spring and washer.
•
Tighten:
Torque - Camshaft Chain Tensioner Cap Bolt [B]: 20 N·m
(2.0 kgf·m, 15 ft·lb)
•
Turn the crankshaft 2 turns clockwise to allow the ten-
sioner to expand and recheck the camshaft chain timing.
5-20 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Removal
•
Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Crankshaft Sensor Cover (see Crankshaft Sensor Re-
moval in the Electrical System chapter)
•
Using a wrench on the timing rotor bolt [A], turn the crank-
shaft clockwise until the line [B] (TDC mark for #1, 4 pis-
tons) on the timing rotor is aligned with the mating surface
[C] of the crankcase.
•
Remove the camshaft chain tensioner (see Camshaft
Chain Tensioner Removal).
•
Loosen the upper camshaft chain guide bolts and
camshaft cap bolts gradually and evenly as shown se-
quence [1 ∼ 20], and remove them.
•
Remove:
Upper Camshaft Chain Guide [A]
Camshaft Caps [B]
Camshafts [C]
•
Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.
•
Remove:
Camshaft Sprocket Mounting Bolts [A]
Camshaft Sprockets [B]
NOTICE
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.
ENGINE TOP END 5-21
Camshaft, Camshaft Chain
Camshaft Installation
•
Be sure to install the following parts.
Plug Hole Gaskets [A]
Dowel Pins [B]
NOTE
○
The exhaust camshaft has a 8943 EX mark [A] and the
intake camshaft has a 8943 IN mark [B]. Be careful not
to mix up these shafts.
•
Install the camshaft sprockets so that position the timing
marks [A] outside.
The intake camshaft sprocket and exhaust camshaft
sprocket are identical.
•
Apply a non-permanent locking agent to the threads of
the camshaft sprocket bolts and tighten them.
Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11
ft·lb)
•
Apply molybdenum disulfide oil solution to all cam parts
and journals.
•
Using a wrench on the timing rotor bolt [A], turn the crank-
shaft clockwise until the line [B] (TDC mark for #1,4 pis-
tons) on the timing rotor is aligned with the mating surface
[C] of the crankcase.
NOTICE
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.
5-22 ENGINE TOP END
Camshaft, Camshaft Chain
•
Pull the tension side (exhaust side) [A] of the chain taut
to install the chain.
•
Engage the camshaft chain with the sprockets so that tim-
ing marks on the sprockets are positioned as shown.
The timing marks must be aligned with the cylinder head
upper surface [B].
EX mark [C]
IN mark [D]
#1 pin [E]
#2 pin [F]
#30 pin [G]
#31 pin [H]
ENGINE TOP END 5-23
Camshaft, Camshaft Chain
•
Before installing the camshaft caps and upper chain
guide, install the camshaft chain tensioner body tem-
porarily (see Camshaft Chain Tensioner Installation).
•
Install the camshaft caps and upper camshaft chain guide
[A] as shown.
Identification No. 1 ∼ 4 (Camshaft Cap) [B]
•
First tighten the all camshaft cap bolts and upper
camshaft chain guide bolts evenly to seat the camshaft
in place, then tighten all bolts following the specified
tightening sequence.
Torque - Camshaft Cap Bolts [1
∼ 18]: 12 N·m (1.2 kgf·m,
106 in·lb)
Upper Camshaft Chain Guide Bolts [19, 20]: 12
N·m (1.2 kgf·m, 106 in·lb)
•
Install the camshaft chain tensioner (see Camshaft Chain
Tensioner Installation).
•
Turn the crankshaft 2 turns clockwise to allow the ten-
sioner to expand and recheck the camshaft chain timing.
•
Install the removed parts (see appropriate chapters).
5-24 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft, Camshaft Cap Wear Inspection
•
Remove:
Camshaft Caps (see Camshaft Removal)
•
Cut the strips of plastigage (press gauge) to journal width.
Place a strip on each journal parallel to the camshaft in-
stalled in the correct position.
•
Tighten the camshaft cap bolts and upper camshaft chain
guide bolts to the specified torque (see Camshaft Instal-
lation).
NOTE
○
Do not turn the camshaft when the plastigage is be-
tween the journal and camshaft cap.
•
Remove the camshaft cap again, measure each clear-
ance between the camshaft journal and the camshaft cap
using plastigage [A].
Camshaft Journal, Camshaft Cap Clearance
Standard: 0.038
∼ 0.081 mm (0.0015 ∼ 0.0032 in.)
Service Limit: 0.17 mm (0.0067 in.)
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 (0.9413 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the service limit, re-
place the cylinder head unit.
Camshaft Runout Inspection
•
Remove the camshafts (see Camshaft Removal).
•
Set the camshaft in a camshaft alignment jig or on V
blocks.
•
Measure the runout with a dial gauge [A] at the specified
place as shown.
If the runout exceeds the service limit, replace the
camshaft.
Camshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.1 mm (0.004 in.)
ENGINE TOP END 5-25
Camshaft, Camshaft Chain
Cam Wear Inspection
•
Remove the camshafts (see Camshaft Removal).
•
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
33.743
∼ 33.857 mm (1.3285 ∼ 1.3330 in.)
Intake
34.443
∼ 34.557 mm (1.3560 ∼ 1.3605 in.)
Service Limit:
Exhaust
33.64 mm (1.324 in.)
Intake
34.34 mm (1.352 in.)
Camshaft Chain Removal
•
Split the crankcase (see Crankcase Splitting in the Crank-
shaft/Transmission chapter).
•
Remove the camshaft chain [A] from the crankshaft
sprocket.
5-26 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
NOTE
○
Use the battery which is fully charged.
•
Warm up the engine thoroughly.
•
Stop the engine.
•
Remove:
Spark Plugs (see Spark Plug Replacement in the Peri-
odic Maintenance chapter)
•
Attach the compression gauge [A] and adapter [B] firmly
into the spark plug hole.
•
Using the starter motor, turn the engine over with the throt-
tle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1601
L-Shape Hose: 57001-1606
Cylinder Compression
Usable Range:
966
∼ 1 478 kPa (9.9 ∼ 15.1 kgf/cm²,
140 ∼ 214 psi) at 280 r/min (rpm)
•
Repeat the measurement for the other cylinders.
•
Install the spark plugs (see Spark Plug Replacement in
the Periodic Maintenance chapter).
The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem Diagnosis Remedy (Action)
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).
Remove the carbon deposits
and replace damaged parts if
necessary.
Cylinder compression
is higher than usable
range.
Incorrect cylinder head gasket
thickness
Replace the gasket with a standard
part.
Gas leakage around cylinder head
Replace damaged gasket and
check cylinder head warp.
Bad condition of valve seating Repair if necessary.
Incorrect valve clearance Adjust the valve clearance.
Incorrect piston/cylinder clearance Replace the piston and/or cylinder.
Piston seizure Inspect the cylinder and
replace/repair the cylinder and/or
piston as necessary.
Cylinder compression
is lower than usable
range.
Bad condition of piston ring and/or
piston ring grooves
Replace the piston and/or the
piston rings.
ENGINE TOP END 5-27
Cylinder Head
Cylinder Head Removal
•
Drain:
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
•
Remove:
Camshafts (see Camshaft Removal)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Exhaust Pipe (see Exhaust Pipe Removal)
Radiator (Radiator and Radiator Fan Removal in the
Cooling System)
Timing Rotor (see Timing Rotor Removal in the Electrical
System chapter)
•
Slide the clamp [A].
•
Disconnect:
Air Bleeder Hose [B]
•
Turn up the heat insulation rubber plates [C].
•
Loosen the water hose clamp screw [A].
•
Disconnect:
Water Hose [B]
Water Temperature Sensor Connector [C]
•
Remove:
Front Camshaft Chain Guide Bolts [A]
Collar
Front Camshaft Chain Guide [B]
Rear Camshaft Chain Guide Bolt [C]
Rear Camshaft Chain Guide [D]
•
Loosen:
Lower Engine Bracket Bolts (Both Sides) [A]
Upper Engine Mounting Bolts (Left)
•
Remove:
Upper Engine Mounting Bolts (Right) [B]
•
Loosen:
Upper Adjusting Collar Locknut [C]
Special Tool - Engine Mount Nut Wrench: 57001-1450
•
Loosen:
Upper Adjusting Collar [D]
5-28 ENGINE TOP END
Cylinder Head
•
Remove the M6 cylinder head bolts [A].
•
Loosen the M10 cylinder head bolts as shown sequence
[1 ∼ 10], and remove them with washers and spring wash-
ers.
•
Remove the cylinder head.
Cylinder Head Installation
NOTE
○
The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.
•
Replace the cylinder head gasket [A] with a new one.
•
Install the dowel pins [B] and cylinder head gasket.
•
Replace the cylinder head bolt washers [A] and spring
washers [B] with new ones.
•
Apply molybdenum disulfide oil solution to the followings.
Both Side of Cylinder Head Bolt Washers
Both Side of Spring Washers
Threads of Cylinder Head Bolts
•
Install the cylinder head bolt washers and spring washers
to the cylinder head bolts as shown.
•
Tighten the M10 cylinder head bolts following the tighten-
ing sequence [1 ∼ 10].
Torque - Cylinder Head Bolts (M10):
First
30N·m(3.1kgf·m,22ft·lb)
Final
54N·m(5.5kgf·m,40ft·lb)
•
Tighten the M6 cylinder head bolts [A].
Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106
in·lb)
•
Tighten the following parts (see Engine Removal/Installa-
tion in the Engine Removal/Installation chapter).
Upper Adjusting Collar
Upper Adjusting Collar Locknut
Upper Engine Mounting Bolts
Lower Engine Bracket Bolts
ENGINE TOP END 5-29
Cylinder Head
•
Install:
Front Camshaft Chain Guide [A]
Rear Camshaft Chain Guide [B]
New O-rings [C]
Collar [D]
•
Tighten:
Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25
N·m (2.5 kgf·m, 18 ft·lb)
Front Camshaft Chain Guide Bolt (Lower) [F]: 12
N·m (1.2 kgf·m, 106 in·lb)
Rear Camshaft Chain Guide Bolt [G]: 25 N·m (2.5
kgf·m, 18 ft·lb)
•
Install the removed parts (see appropriate chapters).
Cylinder Head Warp Inspection
•
Clean the cylinder head.
•
Lay a straightedge across the lower surface of the cylinder
head at several positions.
•
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.)
If the cylinder head is warped more than the service limit,
replace it.
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).
5-30 ENGINE TOP END
Valves
Valve Clearance Inspection
•
Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.
Valve Clearance Adjustment
•
Refer to the Valve Clearance Adjustment in the Periodic
Maintenance chapter.
Valve Removal
•
Remove:
Cylinder Head (see Cylinder Head Removal)
Valve Lifter and Shim
NOTE
○
Mark 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 [A]:
57001-241
Valve Spring Compressor Adapter,
24 [B]:
57001-1586
Valve Installation
•
Replace the oil seal with a new one.
•
Apply a thin coat of molybdenum disulfide grease to the
valve stem before valve installation.
•
Install the springs so that the closed coil end faces down-
wards.
Valve Stem [A]
Oil Seal [B]
Spring Seat [C]
Closed Coil End [D]
ValveSpring[E]
Retainer [F]
Split Keepers [G]
Valve Guide Removal
•
Remove:
Valve(seeValveRemoval)
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.
NOTICE
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Special Tool - Valve Guide Arbor, 4.5: 57001-1331
ENGINE TOP END 5-31
Valves
Valve Guide Installation
•
Apply oil to the valve guide outer surface before installa-
tion.
•
Heat the area around the valve guide hole to about 120 ∼
150°C (248 ∼ 302°F).
NOTICE
Do not heat the cylinder head with a torch. This Will
warp the cylinder head. Soak the cylinder head and
heat the oil.
•
Using the valve guide driver [A] and two washers [B],
press and insert the valve guide in until the valve guide
driver surface touches the head surface [C].
12.8 ∼ 13.0 mm (0.504 ∼ 0.512 in.) [D]
Special Tools - Valve Guide Driver: 57001-1564
Washer: 57001-1612
•
Ream the valve guide with valve guide reamer [A], even
if the old guide is reused.
Special Tool - Valve Guide Reamer,
4.5: 57001-1333
5-32 ENGINE TOP END
Valves
Valve-to-Guide Clearance Measurement (Wobble
Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
•
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.
•
Move the stem back and forth [C] to measure valve/valve
guide clearance.
•
Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
NOTE
○
The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
Exhaust
0.08
∼ 0.16 mm (0.0031 ∼ 0.0063 in.)
Intake
0.03
∼ 0.10 mm (0.0012 ∼ 0.0039 in.)
Service Limit:
Exhaust
0.35 mm (0.013 in.)
Intake
0.30 mm (0.012 in.)
Valve Seat Inspection
•
Remove the valve (see Valve Removal).
•
Check the valve seating surface [A] between the valve [B]
and valve seat [C].
Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust
24.7
∼ 24.9 mm (0.972 ∼ 0.980 in.)
Intake
28.9
∼ 29.1 mm (1.138 ∼ 1.146 in.)
Measure 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]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust
0.8
∼ 1.2 mm (0.031 ∼ 0.047 in.)
Intake
0.5
∼ 1.0 mm (0.020 ∼ 0.039 in.)
ENGINE TOP END 5-33
Valves
Valve Seat Repair
•
Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder Bar [B]: 57001
-1128
Valve Seat Cutter Holder,
4.5 [C]: 57001
-1330
[For Exhaust Valve Seat]
Valve Seat Cutter, 45° -
27.5: 57001-1114
Valve Seat Cutter, 32° -
28: 57001-1119
Valve Seat Cutter, 60° -
27: 57001-1409
[For Intake Valve Seat]
Valve Seat Cutter, 45° -
32: 57001-1115
Valve Seat Cutter, 32° -
33: 57001-1199
Valve Seat Cutter, 60° -
33: 57001-1334
If the manufacturer’s instructions are not available, use
the following procedure.
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTICE
Do not use a wire brush to remove the metal par-
ticles 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
○
Prior 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.
60° ........................... Cutter angle [B]
37.5
....................... Outer diameter of cutter [C]
5-34 ENGINE TOP END
Valves
Operating Procedures
•
Clean the seat area carefully.
•
Coat the seat with machinist’s dye.
•
Fit a 45° cutter into the holder and slide it into the valve
guide.
•
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
NOTICE
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.
•
Measure the outside diameter of the seating surface with
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the spec-
ified range.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
•
Measure the outside diameter of the seating surface with
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° [A] grind until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○
Remove all pittings of flaws from 45° ground surface.
○
After 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.
○
When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
ENGINE TOP END 5-35
Valves
If the outside diameter [A] of the seating surface is too
large, make the 32° [B] grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described be-
low.
•
Grind the seat at a 32° angle until the seat outside diam-
eter is within the specified range.
To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
NOTICE
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
After making the 32° grind, return to the seat outside di-
ameter measurement step above.
•
To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.
If the seat width is too wide, make the 60° [A] grind de-
scribed below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
•
Grind the seat at a 60° angle until the seat width is within
the specified range.
To make the 60° grind, fit 60° cutter into the holder, and
slide it into the valve guide.
Turn the holder, while pressing down lightly.
After making the 60° grind, return to the seat width mea-
surement step above.
Correct Width [B]
5-36 ENGINE TOP END
Valves
•
Lap the valve to the valve seat, once the seat width and
outside diameter are within the ranges specified above.
Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
Repeat the process with a fine grinding compound.
Lapper [A]
Valve Seat [B]
Valve [C]
•
The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
•
Be sure to remove all grinding compound before assem-
bly.
•
When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Inspection in the Periodic
Maintenance chapter).
ENGINE TOP END 5-37
Valves
5-38 ENGINE TOP END
Cylinder, Pistons
Cylinder Removal
•
Remove:
Cylinder Head (see Cylinder Head Removal)
Engine Bracket (see Engine Removal in the Engine Re-
moval/Installation chapter)
Radiator Bracket Bolt [A]
Radiator Bracket [B]
•
Loosen the water hose clamp screw [A].
•
Disconnect the water hose [B].
•
Remove:
Upper Engine Mounting Bolts (Left) [A]
•
Remove:
Cylinder [A]
NOTE
○
If it is hard to remove it, tap lightly using a plastic-faced
mallet [B].
Cylinder Installation
NOTE
○
If a new cylinder is used, use new piston ring.
•
Replace the cylinder gasket [A] with a new one.
•
Install the dowel pins [B] and new cylinder gasket.
•
Apply molybdenum disulfide oil solution to the cylinder
bore.
ENGINE TOP END 5-39
Cylinder, Pistons
•
The piston ring openings must be positioned as shown.
The openings of the oil ring steel rails must be about 30
∼ 40° of angle from the opening of the top ring.
Top Ring [ A ]
Second Ring [B]
Upper Oil Ring Steel Rail [C]
Oil Ring Expander [D]
Lower Oil Ring Steel Rail [E]
Dent [F]
30 ∼ 40° [G]
•
Position the crankshaft at #2, 3 piston TDC.
•
Prepare two auxiliary head bolts with their head cut.
Install the two cylinder head bolts [A] diagonally in the
crankcase.
•
Install the cylinder block [B].
Pistons [C]
First insert the #2, 3 pistons, and then rotate the crank-
shaft at 90° angle, and insert the #1, 4 pistons.
Insert the piston rings with your thumbs or the standard
tip screwdriver.
•
Install the removed parts (see appropriate chapters).
Piston Removal
•
Remove the cylinder (see Cylinder Removal).
•
Place a clean cloth under the pistons and remove the pis-
ton pin snap ring [A] from the outside of each piston.
•
Using the piston pin puller assembly [A], remove the pis-
ton pins.
Special Tool - Piston Pin Puller Assembly: 57001-910
•
Remove the pistons.
5-40 ENGINE TOP END
Cylinder, Pistons
•
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
○
If a new piston is used, use new piston ring.
•
Apply molybdenum disulfide oil solution to the oil ring ex-
pander, and install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] not butt together.
•
Apply molybdenum disulfide oil solution to the oil ring steel
rails, and install the oil ring steel rails, one above the ex-
pander and one below it.
Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
Release the rail into the bottom piston ring groove.
NOTE
○
The oil ring rails have no “top” or “bottom”.
•
Apply molybdenum disulfide oil solution to the piston
rings.
NOTE
○
Do not mix up the top and second ring.
•
Install the top ring [A] so that the “1T” mark [B] faces up.
•
Install the second ring [C] so that the “2T” mark [D] faces
up.
•
Install the piston with its dent mark facing forward.
•
Apply molybdenum disulfide oil solution to the piston pins
and piston journals.
•
Fit a new piston pin snap ring into the side of the piston
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
When installing the piston pin snap ring, compress it only
enough to install it and no more.
NOTICE
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
•
Install the cylinder (see Cylinder Installation).
ENGINE TOP END 5-41
Cylinder, Pistons
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) as shown.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the cylinder.
10 mm (0.39 in.) [A]
60 mm (2.36 in.) [B]
Cylinder Inside Diameter
Standard: 76.994
∼ 77.006 mm (3.0313 ∼ 3.0317 in.)
Service Limit: 77.09 mm (3.035 in.)
Piston Wear Inspection
•
Measure the outside diameter [A] of each piston 11 mm
(0.43 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: 76.974
∼ 76.984 mm (3.0305 ∼ 3.0309 in.)
Service Limit: 76.82 mm (3.024 in.)
Piston Ring, Piston Ring Groove Wear Inspection
•
Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
•
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
0.03
∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
Second 0.02
∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
Service Limit:
Top
0.17 mm (0.0067 in.)
Second 0.16 mm (0.0063 in.)
Piston Ring Groove Width Inspection
•
Measure the piston ring groove width.
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard:
Top [A]
0.82
∼ 0.84 mm (0.0323 ∼ 0.0331 in.)
Second [B] 0.81
∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
Service Limit:
Top
0.92 mm (0.0362 in.)
Second 0.91 mm (0.0358 in.)
If the width of any of the two grooves are wider than the
service limit at any point, replace the piston.
5-42 ENGINE TOP END
Cylinder, Pistons
Piston Ring Thickness Inspection
•
Measure the piston ring thickness.
Use the micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top [A]
0.77
∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Second [B] 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.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
○
When 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
•
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.
•
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top 0.20
∼ 0.30 mm (0.0079 ∼ 0.0118 in.)
Second 0.38
∼ 0.48 mm (0.0150 ∼ 0.0189 in.)
Service Limit:
Top 0.6 mm (0.024 in.)
Second 0.8 mm (0.031 in.)
If the end gap of either ring is greater than the service
limit, replace all the rings.
ENGINE TOP END 5-43
Throttle Body Assy Holder
Throttle Body Assy Holder Removal
•
Remove:
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Clamps [A]
Throttle Body Assy Holder Bolts [B]
Throttle Body Assy Holders [C]
Throttle Body Assy Holder Installation
•
Replace the O-rings [A] with new ones.
•
Apply grease to the O-rings, and install them.
•
Apply a non-permanent locking agent to the threads of
the throttle body assy holder bolts.
•
Tighten:
Torque - Throttle Body Assy Holder Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
•
Fit the hole of all clamps [A] to the projection [B] of all
holders [C].
Be sure that the clamp bolt heads [D] face as shown.
•
Install:
Throttle Body Assy (see Throttle Body Assy Installation
in the Fuel System (DFI) chapter)
5-44 ENGINE TOP END
Muffler
WARNING
The exhaust pipe or muffler body can become ex-
tremely hot during normal operation and cause se-
vere burns. Do not remove the exhaust pipe or muf-
fler body while it is hot.
Muffler Body Removal
Left Muffler Body
•
Loosen the muffler body clamp bolt [A].
•
Remove:
Left Muffler Body Mounting Bolt [B], Washer and Nut
Left Muffler Body [C]
Right Muffler Body
•
Clear the exhaust butterfly valve cables [A] from the clamp
[B].
•
Slide the dust covers [A].
•
Loosen the locknuts [B], and turn the adjuster [C] to give
the cable plenty of play.
•
Remove:
Bolts [A]
Exhaust Butterfly Valve Pulley Cover [B]
ENGINE TOP END 5-45
Muffler
•
Loosen the locknuts [A].
•
Remove the cable lower ends [B].
•
Remove the bolts [A] and collars.
•
Clear the hook [B], and remove the exhaust pipe cover
[C].
•
Loosen the muffler body clamp bolt [A].
•
Remove:
Right Muffler Body Mounting Bolt [B], Washer and Nut
Right Muffler Body [C]
5-46 ENGINE TOP END
Muffler
Muffler Body Installation
•
Replace the muffler body gaskets [A] with new ones.
•
Install the muffler body gaskets until it is bottomed so that
the inside chamfer side faces rear [B].
•
Install the muffler body clamps [C] so that the projection
[D] fits into the clamp slit [E].
Downside [F]
Inside [G]
Viewed from Rear [H]
•
Install the exhaust butterfly valve cables (see Exhaust
Butterfly Valve Cable Installation).
•
Install the muffler bodies until it stops at the bottom sur-
face of the exhaust pipe.
•
Install the muffler body mounting bolts and nuts.
•
Tighten:
Torque - Muffler Body Mounting Bolts [I]: 34 N·m (3.5 kgf·m,
25 ft·lb)
•
Turn the muffler body clamps outward until it stops at the
slit ends.
•
Tighten the muffler body clamp bolt while pulling the muf-
fler body outward (both sides).
Torque - Muffler Body Clamp Bolts [J]: 21 N·m (2.1 kgf·m,
15 ft·lb)
ENGINE TOP END 5-47
Muffler
•
After installation, make sure that the clearance [A] of both
side mufflers are 12 mm (0.47 in.) or more.
Muffler Body [B]
Swingarm [C]
•
Install the exhaust pipe cover, and tighten its bolts to-
gether with the collars.
Insert the hook [A] into the grommet [B].
•
Thoroughly warm up the engine, wait until the engine
cools down, retighten all the bolts and nuts.
5-48 ENGINE TOP END
Muffler
•
When installing the muffler covers, note the following.
•
Install the pads [A] to the muffler covers as shown.
•
Install the dampers [B], collars [C] and pads [D] as shown.
Align the center line of the pad aligns with the edge [E] of
the bracket.
Align the side [F] of the pad with the edge of the bracket.
•
Tighten the muffler cover bolts temporarily.
•
Tighten the two muffler cover bolts [G].
•
Pull the muffler body cover outward.
•
Tighten the two muffler cover bolts [H].
•
Make sure the gap between the muffler body and muffler
cover.
•
Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-49
Muffler
Exhaust Pipe Removal
•
Remove:
Muffler Bodies (see Muffler Body Removal)
Oxygen Sensor (Equipped Models) (see Oxygen Sen-
sor Removal (Equipped Models) in the Electrical System
chapter)
•
Support the premuffler chamber with the suitable stand
[A].
•
Remove the premuffler chamber mounting bolt [B].
•
Remove:
Exhaust Pipe Holder Nuts [A]
Exhaust Pipe (Premuffler Chamber) [B]
In this photo, the radiator and the middle fairings have
been removed for clarity.
Exhaust Pipe Installation
•
Replace the exhaust pipe gaskets [A] with new ones.
•
Apply grease to the exhaust pipe gaskets and install them.
•
Install the exhaust pipe.
•
Tighten the exhaust pipe holder nuts [B] and premuffler
chamber mounting bolt [C].
Torque - Premuffler Chamber Mounting Bolt: 34 N·m (3.5
kgf·m, 25 ft·lb)
•
Install the removed parts (see appropriate chapters).
•
Thoroughly warm up the engine, wait until the engine
cools down, retighten all the bolts and nuts.
Exhaust Butterfly Valve Cable Removal
WARNING
The exhaust pipe or muffler body can become ex-
tremely hot during normal operation and cause se-
vere burns. Do not remove the exhaust butterfly
valve cable while the exhaust pipe or muffler body
is hot.
•
Remove the front seat (see Front Seat Removal in the
Frame chapter).
•
Clear the exhaust butterfly valve cables [A] from the clamp
[B].
5-50 ENGINE TOP END
Muffler
•
Slide the dust covers [A] off the adjusters [B].
•
Loosen the locknuts [C], and turn the adjusters to give the
cable plenty of play.
•
Remove:
Bolts [A]
Exhaust Butterfly Valve Pulley Cover [B]
•
Loosen the locknuts [A].
•
Remove the cable lower ends [B].
•
Remove:
Bolt [A]
Bracket [B] with Fuel Pump Lead Connector.
•
Remove:
Clamp [A]
Exhaust Butterfly Valve Cable Upper Ends [B]
Exhaust Butterfly Valve Cables [C]
ENGINE TOP END 5-51
Muffler
Exhaust Butterfly Valve Cable Installation
•
Before installing the exhaust butterfly valve cables, con-
firm that the exhaust valve actuator pulley [A] is in the
original position as shown.
The pulley edge [B] and housing screw [C] are on the
same line. This position is original position of the pulley.
If the pulley is not in the original position, adjust it (see
Exhaust Butterfly Valve Actuator Adjustment).
NOTICE
Do not attempt to move the pulley by hand or using
a tool as internal actuator damage will occur.
•
Install the close cable (black) [A], and then install the open
cable (silver) [B] to the exhaust valve actuator pulley.
•
Install the clamp [C].
•
Install the exhaust butterfly valve cables to the muffler
body as shown (see Cable, Wire, and Hose Routing sec-
tion in the Appendix chapter).
[A] Close Cable (Black)
[B] Open Cable (Silver)
[C] Top
•
Tighten the exhaust butterfly valve cable locknuts.
•
Install the pulley cover.
•
Adjust the open cable (Silver) first. Loosen the locknut [A]
and turn the adjuster [B] until there is no play in the cable.
•
Tighten the open cable locknut.
•
Adjust the close cable (Black). Loosen the locknut [C] and
turn the adjuster [D] until there is no play in the cable.
•
Turn the adjuster of the close cable clockwise by 1/2 to 1
rotation.
•
Tighten the close cable locknut.
NOTICE
To keep the correct exhaust butterfly valve position,
adjust the open cable first. Adjust the cables only
until there is no play. If the cables are adjus
ted any
further, the exhaust butterfly valve actuator will not
operate correctly.
5-52 ENGINE TOP END
Muffler
•
After adjusting the cables, turn the ignition switch on and
make sure that the pulley turns clockwise, then counter-
clockwise and then returns slightly clockwise as shown.
NOTE
○
The stop position [A] of the pulley is changed by the
cables tension and the closed position of the exhaust
butterfly valve.
If the pulley does not move smoothly, adjust the cables
again.
Exhaust Butterfly Valve Actuator Removal
NOTICE
Never drop the exhaust butterfly valve actuator es-
pecially on a hard surface. Such a shock to the ac-
tuator can damage it.
•
Remove:
Exhaust Butterfly Valve Cables (see Exhaust Butterfly
Valve Cable Removal)
Fuse Boxes
•
Disconnect the exhaust butterfly valve actuator lead con-
nectors [A].
•
Remove:
Exhaust Butterfly Valve Actuator Mounting Screws [A]
and Collars
Exhaust Butterfly Valve Actuator [B]
ENGINE TOP END 5-53
Muffler
•
When replacing the pulley, note the following.
•
Remove the pulley bolt while holding the pulley [A] with
the suitable tool [B].
NOTICE
If the pulley bolt is removed without holding, the
actuator damage will occur.
•
Remove the pulley from the actuator.
Exhaust Butterfly Valve Actuator Installation
•
When replacing the pulley, note the following.
•
Install the pulley [A] on the actuator so that the holes side
[B] aligns with the groove [C].
•
Tighten the pulley bolt [A] while holding the pulley [B] with
the suitable tool [C].
Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 5.0
N·m (0.51 kgf·m, 44 in·lb)
NOTICE
If the pulley bolt is tightened without holding, the
actuator damage will occur.
•
Install:
Exhaust Butterfly Valve Actuator
Exhaust Butterfly Valve Actuator Mounting Screws and
Collars
Torque - Exhaust Butterfly Valve Actuator Mounting
Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb)
•
Install the exhaust butterfly valve cables (see Exhaust
Butterfly Valve Cable Installation).
5-54 ENGINE TOP END
Muffler
Exhaust Butterfly Valve Actuator Adjustment
Pulley Position Electrically Adjustment
•
Turn the ignition switch off.
•
Disconnect the exhaust butterfly valve actuator connec-
tors.
•
Connect the exhaust butterfly valve actuator connector (2
pins) to the battery to turn the pulley as follows.
Connection for counterclockwise [A]
Connection for clockwise [B]
•
Adjust the pulley position until it returns to the original
position.
•
Confirm that the exhaust valve actuator pulley [A] is in the
original position as shown.
The pulley edge [B] and housing screw [C] are on the
same line. This position is original position of the pulley.
CLUTCH 6-1
6
Clutch
Table of Contents
Exploded View........................................................................................................................ 6-2
Specifications ......................................................................................................................... 6-4
Special Tool and Sealant ........................................................................................................ 6-5
Clutch Lever and Cable.......................................................................................................... 6-6
Clutch Lever Free Play Inspection .................................................................................... 6-6
Clutch Lever Free Play Adjustment .................................................................................. 6-6
Clutch Cable Removal ...................................................................................................... 6-6
Clutch Cable Installation ................................................................................................... 6-6
Clutch Cable Lubrication................................................................................................... 6-6
Clutch Lever Assembly Installation ................................................................................... 6-6
Clutch Lever Installation.................................................................................................... 6-7
Clutch Cover........................................................................................................................... 6-8
Clutch Cover Removal ...................................................................................................... 6-8
Clutch Cover Installation ................................................................................................... 6-8
Release Shaft Removal .................................................................................................... 6-8
Release Shaft Installation ................................................................................................. 6-9
Clutch Cover Disassembly................................................................................................ 6-9
Clutch Cover Assembly..................................................................................................... 6-10
Clutch ..................................................................................................................................... 6-11
Clutch Removal................................................................................................................. 6-11
Clutch Installation.............................................................................................................. 6-11
Clutch Plate Assembly Inspection..................................................................................... 6-14
Clutch Plate Assembly Adjustment ................................................................................... 6-14
Clutch Plate, Wear, Damage Inspection ........................................................................... 6-15
Clutch Plate Warp Inspection............................................................................................ 6-15
Clutch Spring Free Length Measurement ......................................................................... 6-15
Clutch Housing Finger Inspection ..................................................................................... 6-15
Clutch Housing Spline Inspection ..................................................................................... 6-15
6-2 CLUTCH
Exploded View
CLUTCH 6-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Clutch Lever Clamp Bolts
7.8 0.80 69 in·lb
S
2 Clutch Spring Bolts 8.8 0.90 78 in·lb
3 Clutch Hub Nut 135 13.8 100 R
4 Clutch Cover Bolts 9.8 1.0 87 in·lb
5 Oil Filler Plug 2.0 0.20 18 in·lb
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
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
6-4 CLUTCH
Specifications
Item Standard Service Limit
Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
–––
Clutch
Clutch Plate Assembly Length 51.1 ∼ 51.7 mm (2.01 ∼ 2.04 in.) –––
Friction Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.)
Friction and Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
Clutch Spring Free Length 64.8 mm (2.55 in.) 61.8 mm (2.43 in.)
CLUTCH 6-5
SpecialToolandSealant
Clutch Holder:
57001-1243
Liquid Gasket, TB1211F:
92104-0004
6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection
•
Refer to the Clutch Operation Inspection in the Periodic
Maintenance chapter.
Clutch Lever Free Play Adjustment
•
Refer to the Clutch Operation Inspection in the Periodic
Maintenance chapter.
Clutch Cable Removal
•
Remove:
Upper Fairing Cover (see Upper Fairing Removal in the
Frame chapter)
Right Middle Fairing (see Middle Fairing Removal in the
Frame chapter)
•
Slide the dust cover [A] at the clutch cable lower end out
of place.
•
Loosen the nuts [B], and slide the lower end of the clutch
cable to give the cable plenty of play.
•
Screw in the adjuster [A].
•
Line up the slots [B] in the clutch lever and adjuster, and
then free the cable from the lever.
•
Free the clutch inner cable tip from the clutch release
lever.
•
Remove the clutch cable out of the frame.
Clutch Cable Installation
•
Run the clutch cable correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
•
Adjust the clutch cable (see Clutch Operation Inspection
in the Periodic Maintenance chapter).
•
Install the removed parts (see appropriate chapters).
Clutch Cable Lubrication
•
Refer to the Chassis Parts Lubrication in the Periodic
Maintenance chapter.
Clutch Lever Assembly Installation
•
Install the clutch lever so that the mating surface [A] of the
clutch lever clamp is aligned with the punch mark [B].
•
Tighten the upper clamp bolt first, and then the lower
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
Torque - Clutch Lever Clamp Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
CLUTCH 6-7
Clutch Lever and Cable
Clutch Lever Installation
WARNING
If the starter lockout switch pin has been damaged
the starter lockout system will not work properly.
This allows the motorcycle to be started in gear with
the clutch lever released (clutch engaged), creat-
ing sudden forward movement that can result in an
accident or injury. Check that the starter lockout
switch operates properly when installing the clutch
lever.
•
Replace the locknut with a new one.
•
Apply grease to the clutch lever collar.
•
Install the clutch lever [A] from frame left side [B] so that
it may not damage a pin [C] of the starter lockout switch.
•
Tighten the locknut [A].
•
Install the upper end of the clutch cable (see Clutch Cable
Installation).
•
Adjust the clutch cable (see Clutch Operation Inspection
in the Periodic Maintenance chapter).
•
Check that the pin [B] of the starter lockout switch moves
smoothly.
WARNING
Too much cable play can prevent clutch disengage-
ment and cause an accident resulting in serious in-
jury or death. When adjusting the clutch or replac-
ing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.
6-8 CLUTCH
Clutch Cover
Clutch Cover Removal
•
Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
•
Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Clutch Cable Lower End (see Clutch Cable Removal)
Clutch Cover Bolts [A]
Bracket [B]
•
Turn the release lever [A] counterclockwise as shown,
and remove the clutch cover [B].
About 90° [C]
Clutch Cover Installation
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket to the area [A] where the mating sur-
face of the crankcase touches the clutch cover gasket.
Sealant - Liquid Gasket, TB1211F: 92104-0004
•
Be sure to dowel pins [B] are in position.
•
Replace the clutch cover gasket with a new one and install
it.
•
Install:
Clutch Cover [A]
Bracket [B]
•
Tighten:
Torque - Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
•
Install the removed parts (see appropriate chapters).
Release Shaft Removal
NOTICE
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If re-
moved, the oil seal replacement may be required.
•
Remove the clutch cover (see Clutch Cover Removal).
•
Pull the release lever and shaft assembly [A] straight out
of the clutch cover.
CLUTCH 6-9
Clutch Cover
Release Shaft Installation
•
Apply grease to the oil seal lips on the upper ridge of the
clutch cover.
•
Apply engine oil to the needle bearings in the hole of the
clutch cover.
•
Apply molybdenum disulfide grease to the pusher-holding
portion [A] on the release shaft.
•
Install the washer [B] and spring [C].
•
Insert the release shaft straight into the upper hole of the
clutch cover.
NOTICE
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
•
Fit the spring [A] as shown.
Viewed from Rear [B]
Release Shaft [C]
Clutch Cover [D]
Clutch Cover Disassembly
•
Remove:
Clutch Cover (see Clutch Cover Removal)
Release Lever and Shaft Assembly (see Release Shaft
Removal)
Oil Filler Plug [A]
Oil Seal [B]
Needle Bearing [C]
•
Remove:
Needle Bearing [A]
Oil Level Inspection Window [B]
6-10 CLUTCH
Clutch Cover
Clutch Cover Assembly
•
Replace the needle bearings and oil seal with new ones.
NOTE
○
Install the needle bearings so that the manufacture’s
mark face out.
•
Apply soap and water solution to the oil seal.
•
Install the needle bearings [A] and oil seal [B] position as
shown.
Press the needle bearing until the bottom [C].
Press the needle bearing so that the bearing surface [D]
is flush with the housing end of clutch cover [E].
Press the oil seal until the bottom.
•
Apply grease to the oil seal lips.
•
Apply soap and water solution to the rubber portion [A] of
the oil level inspection window.
•
Press the oil level inspection window until the bottom so
that its projection [B] faces inside of the clutch cover [C].
•
Replace the O-ring [A] of the oil filler plug [B] with a new
one.
•
Apply grease to the new O-ring.
•
Tighten:
Torque - Oil Filler Plug: 2.0 N·m (0.20 kgf·m, 18 in·lb)
CLUTCH 6-11
Clutch
Clutch Removal
•
Remove:
Clutch Cover (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs
Clutch Spring Plate [B] (with Washer, Needle Bearing
and Pusher [C])
Friction Plates and Steel Plates
Spring and Spring Seat
NOTE
○
The two plates at both ends are different from the plate
installed between these plates.
However, it is impossible to identify it on externals.
○
Mark and record the locations of the friction plates so
that they can be reinstalled in their original positions.
•
Holding the clutch hub [A], remove the nut [B] and wash-
ers.
Special Tool - Clutch Holder [C]: 57001-1243
•
Remove:
Clutch Hub
Spacer (
47 × 25.5)
•
Using the two 4 mm (0.16 in.) bolts or screws [A], pull out
the sleeve [B], needle bearing [C] and clutch housing.
•
Remove the spacer (
56 × 25).
Clutch Installation
•
Install the spacer (
56 × 25) [A] so that the tapered side
[B] faces inward.
6-12 CLUTCH
Clutch
•
Install the clutch housing [A] to the drive shaft.
•
While holding the clutch housing, install the needle bear-
ing [B] and sleeve [C].
The holes [D] of the sleeve face outward.
•
Install the following parts to the drive shaft.
Spacer (
47 × 25.5) [A]
Clutch Hub
Washer
•
Install the washer [A] so that the “OUTSIDE” mark [B]
faces outward.
•
Replace the clutch hub nut with a new one.
•
Holding the clutch hub, tighten the clutch hub nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 135 N·m (13.8 kgf·m, 100 ft·lb)
•
Install the spring seat [A] and spring [B] as shown.
Clutch Hub [C]
CLUTCH 6-13
Clutch
•
Install the friction plates and steel plates, starting with a
friction plate and alternating them.
NOTE
○
Install the both ends marked two friction plates at dis-
assembled to the their original position.
○
When replace the friction plates with new ones, mark
the both ends two friction plates so that the two kinds of
friction plates do not mix up at opening the package.
NOTICE
If new dry friction plates and steel plates are in-
stalled, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
Install the last friction plate [A] fitting the tangs in the
grooves in the housing as shown.
•
Apply molybdenum disulfide grease to the pusher shaft
[A].
•
Apply engine oil to the needle bearing [B].
•
Install the pusher [C], needle bearing and washer [D] in
the clutch spring plate [E].
•
Install the clutch spring plate so that there are no gap [A].
If it has gap [B], turn the clutch spring plate to install it
again.
Correct [C]
Wrong [D]
•
Install:
Clutch Springs
•
Tighten:
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
•
Install the clutch cover (see Clutch Cover Installation).
6-14 CLUTCH
Clutch
Clutch Plate Assembly Inspection
•
Inspect the friction plate thickness (see Clutch Plate,
Wear, Damage Inspection).
•
Measure the length [A] of the clutch plate assembly as
shown.
Assemble:
Clutch Hub [B]
Spring Seat [C]
Spring [D]
Friction Plates [E]
Steel Plates [F]
Clutch Spring Plate [G]
Clutch Springs [H]
Clutch Spring Bolts [I]
NOTE
○
Install the both ends marked two friction plates at dis-
assembled to the their original position.
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Clutch Plate Assembly Length
Standard: 51.1
∼ 51.7 mm (2.01 ∼ 2.04 in.)
If the length is not within the specified range, adjust the
length (see Clutch Plate Assembly Adjustment).
Clutch Plate Assembly Adjustment
•
Inspect the clutch plate assembly length, and then re-
place the steel plate(s) which brings the length within the
specified range.
•
Remove:
Clutch Spring Bolts
Clutch Springs
Clutch Spring Plate
•
Replace the following steel plate(s).
Thickness Part Number
2.3 mm (0.091 in.)
13089-0008
2.6 mm (0.102 in.) (STD)
13089-0009
2.9 mm (0.114 in.)
13089-1093
NOTE
○
Do not use the steel plates of 2.3 mm (0.091 in.) and
2.9 mm (0.114 in.) thickness at the same time.
•
Install the removed parts, and inspect the clutch plate as-
sembly length.
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
CLUTCH 6-15
Clutch
Clutch Plate, Wear, Damage Inspection
•
Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.
•
Measure the thickness of each friction plate [A] at several
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard: 2.72
∼ 2.88 mm (0.107 ∼ 0.113 in.)
Service Limit: 2.4 mm (0.094 in.)
Clutch Plate Warp Inspection
•
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.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
Standard: 0.15 mm (0.0059 in.) or less
Service Limit: 0.3 mm (0.012 in.)
Clutch Spring Free Length Measurement
•
Measure the free length of the clutch springs [A].
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard: 64.8 mm (2.55 in.)
Service Limit: 61.8 mm (2.43 in.)
Clutch Housing Finger Inspection
•
Visually inspect the clutch housing fingers [A] where the
friction plate tangs [B] hit.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.
Clutch Housing Spline Inspection
•
Visually inspect the teeth [A] on the steel plates and the
clutch hub splines [B] for wear.
If there are notches worn into the splines, replace the
clutch hub. Also, replace the steel plates if their teeth are
damaged.
ENGINE LUBRICATION SYSTEM 7-1
7
Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................ 7-2
Engine Oil Flow Chart............................................................................................................. 7-4
Specifications ......................................................................................................................... 7-5
Special Tools and Sealants .................................................................................................... 7-6
Engine Oil and Oil Filter.......................................................................................................... 7-7
Oil Level Inspection........................................................................................................... 7-7
Engine Oil Change............................................................................................................ 7-7
Oil Filter Replacement ...................................................................................................... 7-7
Oil Pan.................................................................................................................................... 7-8
Oil Pan Removal ............................................................................................................... 7-8
Oil Pan Installation ............................................................................................................ 7-8
Oil Screen............................................................................................................................... 7-10
Oil Screen Removal .......................................................................................................... 7-10
Oil Screen Installation ....................................................................................................... 7-10
Oil Screen Cleaning .......................................................................................................... 7-10
Oil Pressure Relief Valve........................................................................................................ 7-11
Oil Pressure Relief Valve Removal ................................................................................... 7-11
Oil Pressure Relief Valve Installation ................................................................................ 7-11
Oil Pressure Relief Valve Inspection................................................................................. 7-11
Oil Pump................................................................................................................................. 7-12
Oil Pump Removal ............................................................................................................ 7-12
Oil Pump Installation ......................................................................................................... 7-12
Oil Pump Drive Gear Removal.......................................................................................... 7-13
Oil Pump Drive Gear Installation....................................................................................... 7-13
Oil Cooler................................................................................................................................ 7-14
Oil Cooler Removal........................................................................................................... 7-14
Oil Cooler Installation........................................................................................................ 7-14
Oil Pressure Measurement..................................................................................................... 7-15
Oil Pressure Measurement ............................................................................................... 7-15
Oil Pressure Switch ................................................................................................................ 7-16
Oil Pressure Switch Removal ........................................................................................... 7-16
Oil Pressure Switch Installation ........................................................................................ 7-16
Oil Pipe................................................................................................................................... 7-17
Oil Pipe Removal .............................................................................................................. 7-17
Oil Pipe Installation ........................................................................................................... 7-17
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
ENGINE LUBRICATION SYSTEM 7-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Oil Cooler Bolts
12 1.2 106 in·lb L
2 Oil Filler Plug 2.0 0.20 18 in·lb
3 Oil Passage Plugs 20 2.0 15 L
4 Oil Passage Plug 9.8 1.0 87 in·lb
5 Oil Pressure Switch 15 1.5 11 SS
6
Oil Pressure Switch Terminal Bolt
2.0 0.20 18 in·lb
G
7
Oil Pressure Relief Valve
15 1.5 11 L
8 Oil Filter 17 1.7 13 G, R
9 Oil Filter Pipe 25 2.5 18 L
10 Engine Oil Drain Bolt 29 3.0 21
11 Lower Fairing Bracket Bolts 12 1.2 106 in·lb
12 Oil Pan Bolts 12 1.2 106 in·lb S
13 Exhaust Pipe Cover Bracket Bolts 10 1.0 89 in·lb
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
1. Balancer Oil Passage
2. Camshaft Oil Passage
3. Crankshaft Oil Passage
4. Drive Shaft Oil Passage
5. Output Shaft Oil Passage
6. Oil Pump
7. Oil Pipe
8. Oil Screen
9. Oil Pressure Relief Valve
10. Oil Cooler
11. Oil Filter
12. Main Oil Passage
13. Oil Pressure Switch
14. Engine Oil
15. Blowby Gas
ENGINE LUBRICATION SYSTEM 7-5
Specifications
Item Standard
Engine Oil
Type
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity
SAE 10W-40
Capacity: 3.2 L (3.4 US qt) (when filter is not removed)
3.8 L (4.0 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 (Wait several minutes after
idling or running)
Oil Pressure Measurement
Oil Pressure 255 ∼ 304 kPa (2.6 ∼ 3.1 kgf/cm², 37 ∼ 44 psi) at 4 000 r/min (rpm),
Oil Temperature 50°C (122°F)
7-6 ENGINE LUBRICATION SYSTEM
Special Tools and Sealants
Outside Circlip Pliers:
57001-144
Oil Pressure Gauge, 10 kgf/cm²:
57001-164
Oil Pressure Gauge Adapter, PT3/8:
57001-1233
Liquid Gasket, TB1211:
56019-120
Liquid Gasket, TB1207B:
92104-2068
ENGINE LUBRICATION SYSTEM 7-7
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
Oil Level Inspection
•
Check that the engine oil level is between the upper [A]
and lower [B] levels in the oil level inspection window.
NOTE
○
Situate the motorcycle so that it is perpendicular to the
ground.
○
If the motorcycle has just been used, wait several min-
utes for all the oil to drain down.
○
If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not func-
tion properly, the red warning indicator (LED) and
oil pressure warning indicator will light. If it stays
on when the engine is running above idle speed,
stop the engine immediately and find the cause.
If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.
NOTE
○
If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Engine Oil Change
•
Refer to the Engine Oil Change in the Periodic Mainte-
nance chapter.
Oil Filter Replacement
•
Refer to the Oil Filter Replacement in the Periodic Main-
tenance chapter.
7-8 ENGINE LUBRICATION SYSTEM
Oil Pan
Oil Pan Removal
•
Remove:
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)
Oil Pan Bolts [A]
Oil Pan [B]
•
Remove the following parts if necessary.
Oil Screen (see Oil Screen Removal)
OilPipe(seeOilPipeRemoval)
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
Removal)
Oil Pan Installation
•
Install the following parts if removed.
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
Installation)
Oil Pipe (see Oil Pipe Installation)
Oil Screen (see Oil Screen Installation)
•
Replace the O-rings [A] with new ones.
•
Apply grease to the O-rings, and install them.
•
Install the dowel pins [B].
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket [A] to the mating surface of the oil pan.
Sealant - Liquid Gasket, TB1207B: 92104-2068
NOTE
○
Especially, apply liquid gasket so that it shall be filled up
on the grooves [B].
ENGINE LUBRICATION SYSTEM 7-9
Oil Pan
NOTE
○
Make the application finish within 7 minutes when the
liquid gasket to the mating surface of the oil pan is ap-
plied.
○
Moreover fit the oil pan and tighten the bolts just after
application of the liquid gasket.
•
Tighten the oil pan bolts following sequence [1 ∼ 22].
Torque - Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
•
Install the removed parts (see appropriate chapters).
7-10 ENGINE LUBRICATION SYSTEM
Oil Screen
Oil Screen Removal
•
Remove:
Oil Pan (see Oil Pan Removal)
Oil Screen [A]
Oil Screen Installation
•
Clean the oil screen (see Oil Screen Cleaning).
•
Replace the O-ring [A] with a new one, and install it.
•
Apply grease to the O-ring.
•
Install the rubber damper [B] to the oil pressure relief
valve.
•
Install:
Oil Screen
Oil Pan (see Oil Pan Installation)
Oil Screen Cleaning
•
Remove the oil screen (see Oil Screen Removal).
•
Clean the oil screen with a high flash-point solvent and
remove the particles stuck.
•
Blow away the particles by applying compressed air [A]
from the inside to the outside (from the clean side to the
dirty side).
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the screen.
NOTE
○
While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
•
Check the screens carefully for any damage.
If the screen is damaged, replace the oil screen.
ENGINE LUBRICATION SYSTEM 7-11
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
•
Remove:
Oil Screen (see Oil Screen Removal)
Oil Pressure Relief Valve [A]
Oil Pressure Relief Valve Installation
•
Apply a non-permanent locking agent to the threads of
the oil pressure relief valve, and tighten it.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11
ft·lb)
•
Install the oil screen (see Oil Screen 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
back to its seat by spring [B] pressure.
NOTE
○
Inspect the valve in its assembled state. Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high flash-point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the oil pressure relief valve in a
well-ventilated area, and take care that there are no
sparks or flame anywhere near the working area;
this includes any appliance with a pilot light. Do
not use gasoline or a low flash-point solvent to
clean the oil pressure relief valve.
If cleaning does not solve the problem, replace the oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for re-
placement of individual parts.
7-12 ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
•
Remove:
Water Pump (see Water Pump Removal in the Cooling
System chapter)
Oil Pump Cover [A]
•
Remove:
Oil (Water) Pump Shaft [A] with Inner Rotor [B]
Outer Rotor [C]
Oil Pump Installation
•
Install the outer rotor [A] into the crankcase.
•
Apply grease to the pin [A].
•
Assemble the pin, inner rotor [B] and oil (water) pump
shaft [C].
•
Turn the pump shaft so that the slot [A] in its shaft fits onto
the projection [B] of the pump drive gear shaft.
ENGINE LUBRICATION SYSTEM 7-13
Oil Pump
•
Pack grease into the cavity [A] between the inner rotor
and outer rotor for improve the oil pump initial priming.
•
Install the dowel pin [B].
•
Install the oil pump cover [C] so that the dowel pin fits into
the hole [D] of the oil pump cover.
•
Install the water pump (see Water Pump Installation in the
Cooling System chapter).
Oil Pump Drive Gear Removal
•
Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Oil Pan (see Oil Pan Removal)
Circlip [A] and Washer [B]
Special Tool - Outside Circlip Pliers: 57001-144
•
Remove:
Oil Pump Drive Gear [A]
Washer [B]
Oil Pump Drive Gear Installation
•
Apply molybdenum disulfide oil solution to the hole of the
oil pump drive gear shaft in the crankcase.
•
Apply molybdenum disulfide grease to the journal portion
[A] on the oil pump drive gear shaft [B].
•
Install the washer [C] to the shaft.
•
Replace the circlip [A] with a new one.
•
Insert the oil pump drive gear to the lower crankcase.
•
Install the washer [B] and circlip.
Special Tool - Outside Circlip Pliers: 57001-144
•
Fit the projection on the shaft and oil (water) pump shaft
slot.
•
Set the circlip to the original position.
7-14 ENGINE LUBRICATION SYSTEM
Oil Cooler
Oil Cooler Removal
•
Drain:
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
•
Loosen the water hose clamp screws [A].
•
Disconnect the water hoses [B].
•
Remove:
Oil Cooler Bolts [C]
Oil Cooler [D]
Oil Cooler Installation
•
Replace the O-ring [A] with a new one.
•
Apply grease to the O-ring and install it.
•
Install the oil cooler.
•
Apply a non-permanent locking agent to the threads of
the oil cooler bolts.
•
Tighten:
Torque - Oil Cooler Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
•
Install the water hoses [A] and clamps as shown.
•
Tighten:
Torque - Water Hose Clamp Screws [B]: 3.0 N·m (0.31
kgf·m, 27 in·lb)
•
Pour:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
ENGINE LUBRICATION SYSTEM 7-15
Oil Pressure Measurement
Oil Pressure Measurement
•
Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Oil Passage Plug [A]
•
Attach the adapter [A] and gauge [B] to the plug hole.
Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164
Oil Pressure Gauge Adapter, PT3/8: 57001
-1233
•
Start the engine and warm up the engine.
•
Run the engine at the specified speed, and read the oil
pressure gauge.
Oil Pressure
Standard: 255
∼ 304 kPa (2.6 ∼ 3.1 kgf/cm², 37 ∼ 44
psi) at 4 000 r/min (rpm), oil temperature
50°C (122°F)
If the oil pressure is much lower than the standard, check
the oil pump, relief valve, and/or crankshaft bearing insert
wear immediately.
If the reading is much higher than the standard, check the
oil passages for clogging.
•
Stop the engine.
•
Remove the oil pressure gauge and adapter.
WARNING
Hot oil can cause severe burns. Beware of hot en-
gine oil that will drain through the oil passage when
the gauge adapter is removed.
•
Apply a non-permanent locking agent to the oil passage
plug, and tighten it.
Torque - Oil Passage Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)
7-16 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
•
Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
•
Remove the left lower fairing (see Lower Fairing Removal
in the Frame chapter).
•
Slide the switch cover.
•
Remove:
Switch Terminal Bolt [A]
OilPressureSwitch[B]
Oil Pressure Switch Installation
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket to the threads of the oil pressure
switch and tighten it.
Sealant - Liquid Gasket, TB1211: 56019-120
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
•
Install the switch lead (see Cable, Wire, and Hose Routing
section in the Appendix chapter).
•
Tighten:
Torque - Oil Pressure Switch Terminal Bolt: 2.0 N·m (0.20
kgf·m, 18 in·lb)
•
Apply grease to the terminal.
NOTE
○
Apply a small amount grease to the terminal so that
grease should not close two breather holes [A] for
switch diaphragm.
•
Install the switch cover.
•
Install the removed parts (see appropriate chapters).
ENGINE LUBRICATION SYSTEM 7-17
Oil Pipe
Oil Pipe Removal
•
Remove:
Oil Pan (see Oil Pan Removal)
Oil Pipe [A]
Oil Pipe Installation
•
Replace the O-rings [A] with new ones.
•
Apply grease to the O-rings, and install them.
•
Install:
Oil Pipe
Oil Pan (see Oil Pan Installation)
ENGINE REMOVAL/INSTALLATION 8-1
8
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................ 8-2
Special Tool ............................................................................................................................ 8-4
Engine Removal/Installation................................................................................................... 8-5
Engine Removal................................................................................................................ 8-5
Engine Installation............................................................................................................. 8-8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Upper Engine Bracket Bolts 44 4.5 32
S
2 Lower Engine Bracket Bolts 59 6.0 44 S
3 Upper Adjusting Collar 5.0 0.51 44 in·lb 2T, S
4 Upper Adjusting Collar Locknut 49 5.0 36 S
5 Upper Engine Mounting Bolt (L = 65 mm) 44 4.5 32 S
6 Lower Engine Mounting Nut 44 4.5 32
S
7
Lower Adjusting Collar Locknut
49 5.0 36
S
8 Middle Engine Mounting Nut 44 4.5 32 S
9 Middle Engine Bracket Bolts 25 2.5 18 L, S
10 Lower Adjusting Collar 9.8 1.0 87 in·lb S
11 Upper Engine Mounting Bolt (L = 40 mm) 44 4.5 32 S
12. Immobilizer System Equipped Models
L: Apply a non-permanent locking agent.
S: Follow the specified tightening sequence.
2T: Apply 2-stroke oil.
8-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Engine Mount Nut Wrench:
57001-1450
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
Engine Removal
•
Support the rear part of the swingarm with a stand.
•
Squeeze the brake lever slowly and hold it with a band
[A].
WARNING
Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the engine.
NOTICE
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
•
Drain:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
•
Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Clutch Cable Lower End (see Clutch Cable Removal in
the Clutch chapter)
Regulator/Rectifier (see Regulator/Rectifier Removal in
the Electrical System chapter)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Air Switching Valve (see Air Switching Valve Removal in
the Engine Top End chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Shift Lever (see Shift Pedal Removal in the Crank-
shaft/Transmission chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
•
Remove:
Bolt [A]
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
•
Slide the clamp [A].
•
Disconnect the air bleeder hose [B].
•
Remove the heat insulation rubber plate.
•
Loosen the water hose clamp screw [A].
•
Disconnect:
Water Hose [B]
Water Temperature Sensor Connector [C]
•
Disconnect:
Stick Coil Connector (see Stick Coil Removal in the Elec-
trical System chapter)
Alternator Lead Connector (see Alternator Cover Re-
moval in the Electrical System chapter)
Crankshaft Sensor Lead Connector (see Crankshaft
Senor Removal in the Electrical System chapter)
Starter Motor Cable (see Starter Motor Removal in the
Electrical System chapter)
•
Disconnect the connector [A] from the bracket.
•
Open the clamp [A].
•
Remove the clamps [B].
•
Disconnect the oil pressure switch lead [C] and neutral
switch lead connector [D].
•
Remove:
Engine Ground Cable Terminal Bolt [A]
ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
•
Remove the drive chain [A] from the output shaft [B].
•
Remove:
Clamp [A]
Upper Engine Bracket Bolts [B]
Middle Fairing Bracket [C]
Lower Engine Bracket Bolt [D] and Washer
Engine Bracket [E]
•
Free the clutch cable [A] from the guide and clamp.
•
Remove:
Upper Engine Bracket Bolts [B]
Middle Fairing Bracket [C]
Lower Engine Bracket Bolt [D] and Washer
Engine Bracket [E]
•
Remove:
Exhaust Pipe Cover Bracket Bolts [A]
Exhaust Pipe Cover Bracket [B]
•
Support the engine with a suitable stand [A].
Put a plank [B] onto the suitable stand for engine balance.
8-8 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
•
Remove:
Upper Engine Mounting Bolt [A] (Both Sides)
Middle Engine Mounting Nut [B] and Bolt
Lower Engine Mounting Nut [C]
•
Using the nut wrench [A], loosen the upper adjusting collar
locknut [B].
Special Tool - Engine Mount Nut Wrench: 57001-1450
•
Using the Hexagon Wrench, turn the adjusting collar [C]
counterclockwise to make the gap between the engine
and adjusting collar.
•
Using the nut wrench [A], loosen the lower adjusting collar
locknut [B].
Special Tool - Engine Mount Nut Wrench: 57001-1450
•
Remove the lower engine mounting bolt [C].
•
Using the Hexagon Wrench, turn the adjusting collar [D]
counterclockwise to make the gap between the engine
and adjusting collar.
•
Using the suitable stand, take out the engine.
Engine Installation
•
Support the engine with a suitable stand.
Put a plank onto the suitable stand for engine balance.
•
Apply 2-stroke oil to the upper adjusting collar [A].
•
Screw the upper adjusting collar and lower adjusting col-
lar [B] to the frame.
ENGINE REMOVAL/INSTALLATION 8-9
Engine Removal/Installation
This page intentionally left blank.
8-10 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
•
Install the engine mounting bolts and nuts, following the specified installing sequence.
First, hang the drive chain over the output shaft just before moving the engine into its final position
in the frame.
Second, apply a non-permanent locking agent to the threads of the middle engine bracket bolts [A].
Install the middle engine bracket [B] and bracket [C], tighten the middle engine bracket bolts.
Torque - Middle Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Third, insert the lower engine mounting bolt [D].
Forth, install the collar [E], and insert the middle engine mounting bolt [F].
Fifth, tighten the left upper engine mounting bolt [G].
Torque - Upper Engine Mounting Bolt (L = 40 mm): 44 N·m (4.5 kgf·m, 32 ft·lb)
Sixth, tighten the upper adjusting collar locknut [H] and right upper engine mounting bolt [I] tem-
porarily.
Seventh, tighten the lower adjusting collar [J].
Torque - Lower Adjusting Collar: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Eighth, tighten the lower adjusting collar locknut [K] and lower engine mounting nut [L].
Torque - Lower Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb)
Lower Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb)
Special Tool - Engine Mount Nut Wrench: 57001-1450
Ninth, tighten the middle engine mounting nut [M].
Torque - Middle Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb)
Tenth, install the left engine bracket [N], washer and left middle fairing bracket, and tighten the
mounting bolts evenly.
Torque - Upper Engine Bracket Bolts [O]: 44 N·m (4.5 kgf·m, 32 ft·lb)
Lower Engine Bracket Bolt [P]: 59 N·m (6.0 kgf·m, 44 ft·lb)
Eleventh, install the right engine bracket [Q] just like the left engine bracket.
Twelfth, remove the right upper engine mounting bolt [I].
Thirteenth, tighten the upper adjusting collar [R].
Torque - Upper Adjusting Collar: 5.0 N·m (0.51 kgf·m, 44 in·lb)
Fourteenth, tighten the upper adjusting collar locknut [H].
Torque - Upper Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb)
Special Tool - Engine Mount Nut Wrench: 57001-1450
Lastly, tighten the right upper engine mounting bolt [I].
Torque - Upper Engine Mounting Bolt (L = 65 mm): 44 N·m (4.5 kgf·m, 32 ft·lb)
ENGINE REMOVAL/INSTALLATION 8-11
Engine Removal/Installation
•
Run the leads, cables and hoses correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
•
Adjust:
Throttle Cables (see Throttle Control System Inspection
in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Operation Inspection in the Pe-
riodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Inspection in the
Periodic Maintenance chapter)
•
Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).
•
Fill the engine with coolant (see Coolant Change in the
Periodic Maintenance chapter).
CRANKSHAFT/TRANSMISSION 9-1
9
Crankshaft/Transmission
Table of Contents
Exploded View................................... 9-2
Specifications .................................... 9-6
Special Tools and Sealants ............... 9-8
Crankcase Splitting............................ 9-9
Crankcase Splitting ...................... 9-9
Crankcase Assembly ................... 9-10
Crankshaft and Connecting Rods...... 9-15
Crankshaft Removal .................... 9-15
Crankshaft Installation ................. 9-15
Connecting Rod Removal ............ 9-15
Connecting Rod Installation ......... 9-16
Crankshaft/Connecting Rod
Cleaning .................................... 9-19
Connecting Rod Bend Inspection 9-20
Connecting Rod Twist Inspection. 9-20
Connecting Rod Big End Side
Clearance Inspection ................ 9-20
Connecting Rod Big End
Bearing Insert/Crankpin Wear
Inspection.................................. 9-21
Crankshaft Side Clearance
Inspection.................................. 9-22
Crankshaft Runout Inspection...... 9-23
Crankshaft Main Bearing
Insert/Journal Wear Inspection . 9-23
Balancer ............................................ 9-26
Balancer Removal........................ 9-26
Balancer Installation..................... 9-26
Balancer Adjustment.................... 9-27
Balancer Damper Inspection........ 9-27
Starter Motor Clutch .......................... 9-28
Starter Motor Clutch
Removal/Installation.................. 9-28
Starter Motor Clutch Inspection ... 9-28
Starter Motor Clutch Disassembly 9-28
Starter Motor Clutch Assembly .... 9-28
External Shift Mechanism.................. 9-29
Shift Pedal Removal .................... 9-29
Shift Pedal Installation ................. 9-29
External Shift Mechanism
Removal .................................... 9-30
External Shift Mechanism
Installation................................. 9-30
External Shift Mechanism
Inspection.................................. 9-31
Transmission ..................................... 9-33
Transmission Shaft Removal ....... 9-33
Transmission Shaft Installation .... 9-33
Transmission Shaft Disassembly. 9-33
Transmission Shaft Assembly...... 9-34
Shift Drum and Fork Removal...... 9-38
Shift Drum and Fork Installation... 9-38
Shift Drum Disassembly............... 9-38
Shift Drum Assembly ................... 9-38
Shift Fork Bending Inspection...... 9-39
Shift Fork/Gear Groove Wear
Inspection.................................. 9-39
Shift Fork Guide Pin/Drum
Groove Wear Inspection ........... 9-39
Gear Dog and Gear Dog Hole
Damage Inspection ................... 9-39
Ball Bearing, Needle Bearing, and Oil
Seal................................................. 9-40
Ball and Needle Bearing
Replacement............................. 9-40
Ball and Needle Bearing Wear
Inspection.................................. 9-40
Oil Seal Inspection ....................... 9-40
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Balancer Shaft Clamp Bolt
9.8 1.0 87 in·lb
2 Balancer Shaft Clamp Lever Bolt 25 2.5 18 L
3 Connecting Rod Big End Nuts see the text MO
4 Breather Side Plate Bolt 5.9 0.60 52 in·lb L
5 Breather Plate Bolts 9.8 1.0 87 in·lb L
6 Starter Motor Clutch Bolts 12 1.2 106 in·lb L
7 Oil Passage Plugs 20 2.0 15 L
8 Oil Passage Plug 9.8 1.0 87 in·lb
9
Crankcase Bolts (M6)
12 1.2 106 in·lb
S
10
Crankcase Bolts (M7)
20 2.0 15
S
11 Crankcase Bolts (M8) 27 2.8 20 S
12 Crankcase Bolts (M9) 40 4.1 30 S, MO
13. Do not apply any grease or oil.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Gear Positioning Lever Bolt
12 1.2 106 in·lb
2 Shift Drum Bearing Holder Bolts 12 1.2 106 in·lb L
3 Shift Drum Cam Holder Bolt 12 1.2 106 in·lb L
4 Shift Shaft Return Spring Pin 39 4.0 29 L
5 Shift Pedal Mounting Bolt 25 2.5 18
6
Neutral Switch
15 1.5 11
EO: Apply engine oil.
G: Apply grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
R: Replacement Parts
9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item Standard Service Limit
Crankcase, Crankshaft, Connecting
Rods
Connecting Rod Bend ––– TIR 0.2/100 mm
(0.008/3.94 in.)
Connecting Rod Twist ––– TIR 0.2/100 mm
(0.008/3.94 in.)
Connecting Rod Big End Side
Clearance
0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm
(0.023 in.)
Connecting Rod Big End Bearing
Insert/Crankpin Clearance
0.030 ∼ 0.060 mm (0.0012 ∼ 0.0024 in.)
0.10 mm
(0.0039 in.)
Crankpin Diameter: 34.484 ∼ 34.500 mm (1.3576 ∼ 1.3583 in.)
34.47 mm
(1.357 in.)
Marking:
None
34.484 ∼ 34.492 mm (1.3576 ∼ 1.3579 in.)
–––
34.493 ∼ 34.500 mm (1.3580 ∼ 1.3583 in.)
–––
Connecting Rod Big End Inside
Diameter:
37.500 ∼ 37.516 mm (1.4764 ∼ 1.4770 in.)
–––
Marking:
None 37.500 ∼ 37.508 mm (1.4764 ∼ 1.4766 in.) –––
37.509 ∼ 37.516 mm (1.4767 ∼ 1.4770 in.)
–––
Connecting Rod Big End Bearing
Insert Thickness:
Brown 1.478 ∼ 1.483 mm (0.05819 ∼ 0.05839 in.) –––
Black
1.483 ∼ 1.488 mm (0.05839 ∼ 0.05858 in.)
–––
Blue
1.488 ∼ 1.493 mm (0.05858 ∼ 0.05878 in.)
–––
Connecting Rod Bolt Stretch (Usable Range)
0.20 ∼ 0.32 mm (0.0079 ∼ 0.0126 in.) –––
Crankshaft Side Clearance 0.09 ∼ 0.19 mm (0.0035 ∼ 0.0075 in.) 0.39 mm
(0.0154 in.)
Crankshaft #3 Main Journal Width 23.49 ∼ 23.54 mm (0.9248 ∼ 0.9267 in.)
–––
Crankshaft Runout TIR 0.02 mm (0.0008 in.) or less
TIR 0.05 mm
(0.0020 in.)
Crankshaft Main Bearing
Insert/Journal Clearance
0.010 ∼ 0.034 mm (0.0004 ∼ 0.0013 in.) 0.06 mm
(0.0024 in.)
Crankshaft Main Journal Diameter: 34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.)
34.96 mm
(1.376 in.)
Marking:
None
34.984 ∼ 34.992 mm (1.3773 ∼ 1.3776 in.)
–––
1 34.993 ∼ 35.000 mm (1.3777 ∼ 1.3780 in.) –––
Crankcase Main Bearing Inside
Diameter:
38.000 ∼ 38.016 mm (1.4961 ∼ 1.4967 in.) –––
Marking
None
38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.)
–––
38.000 ∼ 38.008 mm (1.4961 ∼ 1.4963 in.)
–––
CRANKSHAFT/TRANSMISSION 9-7
Specifications
Item Standard Service Limit
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.) –––
Transmission
Shift Fork Ear Thickness 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.) 5.8 mm
(0.228 in.)
Gear Groove Width 6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.) 6.25 mm
(0.246 in.)
Shift Fork Guide Pin Diameter 6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)
6.8 mm
(0.268 in.)
Shift Drum Groove Width 7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.) 7.3 mm
(0.287 in.)
Connecting Rod Big End Bearing Insert Selection
Bearing Insert
Con-rod Big End
Inside Diameter
Marking
Crankpin Diameter
Marking
Size Color Part Number
None
Brown 92139-0124
None None
Black 92139-0123
None Blue 92139-0122
Crankshaft Main Bearing Insert Selecti
on
Bearing Insert*Crankcase Main
Bearing Inside
Diameter Marking
Crankshaft Main
Journal Diameter
Marking
Size Color Part Number Journal Nos.
92139-0034 2, 4
1 Brown
92139-0219 1, 3, 5
None 1 92139-0033 2, 4
None
Black
92139-0218 1, 3, 5
92139-0032 2, 4
None None Blue
92139-0217 1, 3, 5
*: The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.
9-8 CRANKSHAFT/TRANSMISSION
Special Tools and Sealants
Bearing Puller:
57001-135
Outside Circlip Pliers:
57001-144
Bearing Puller Adapter:
57001-317
Bearing Driver, 32:
57001-382
Bearing Driver Set:
57001-1129
Flywheel Holder:
57001-1313
Liquid Gasket, TB1216B:
92104-1064
Liquid Gasket, TB1207B:
92104-2068
CRANKSHAFT/TRANSMISSION 9-9
Crankcase Splitting
Crankcase Splitting
•
Remove the engine (see Engine Removal in the Engine
Removal/Installation chapter).
•
Set the engine on a clean surface and hold the engine
steady while parts are being removed.
•
Remove:
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Clutch (see Clutch Removal in the Clutch chapter)
External Shift Mechanism (see External Shift Mecha-
nism Removal)
Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubri-
cation System chapter)
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)
Oil Cooler (see Oil Cooler Removal in the Engine Lubri-
cation System chapter)
Oil Pipe (see Oil Pipe Removal in the Engine Lubrication
System chapter)
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
Removal in the Engine Lubrication System chapter)
If the crankshaft is to be removed, remove the pistons
(see Piston Removal in the Engine Top End chapter).
•
Loosen the balancer shaft clamp bolt [A].
•
Remove:
Balancer Shaft Clamp Lever Bolt [B]
Balancer Shaft Clamp Lever [C]
•
Remove the upper crankcase bolts, following the speci-
fied sequence.
Firstly, loosen the M6 bolts [A].
Secondly, loosen the M7 bolts [B].
Lastly, loosen the M8 bolts [C].
9-10 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
•
Remove the lower crankcase bolts, following the specified
sequence.
Firstly, loosen the M7 bolts [A].
Lastly, loosen the M9 bolts as shown sequence [1 ∼ 10].
•
Tap lightly around the crankcase mating surface with a
plastic mallet, and split the crankcase.
Take care not to damage the crankcase.
Crankcase Assembly
NOTICE
The upper and lower crankcase halves are ma-
chined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
•
With a high flash-point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.
•
Using compressed air, blow out the oil passages in the
crankcase halves.
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket to the breather plate mating surface
[A] 1 mm (0.04 in.) or more thick, and then install the
breather plate.
Sealant - Liquid Gasket, TB1207B: 92104-2068
NOTE
○
Make the application finish within 7 minutes when the
liquid gasket to the mating surface of the breather plate
is applied.
○
Moreover fit the plate and tighten the bolts just after
application of the liquid gasket.
CRANKSHAFT/TRANSMISSION 9-11
Crankcase Splitting
•
Apply a non-permanent locking agent to the threads of
the breather plate bolts [A] and tighten them.
Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
•
Install the breather side plate [A] so that the plate hole [B]
fit the projection [C] of the upper crankcase.
•
Apply a non-permanent locking agent to the threads of
the breather side plate bolt [D] and tighten it.
Torque - Breather Side Plate Bolt: 5.9 N·m (0.60 kgf·m, 52
in·lb)
•
Press the fitting [A] in the upper crankcase [B] until it is
bottomed.
Special Tool - Bearing Driver Set: 57001-1129
•
Press the plug [C] in the upper crankcase so that the plug
is deeper than crankcase surface.
•
Press the new needle bearing [A] for the shift shaft so that
its marked side faces outside and its surface [B] is flush
with the end of the hole.
•
Install the new oil seal [C] so that its surface [D] is flush
with the end of the hole.
•
Apply grease to the oil seal lips.
•
Apply a non-permanent locking agent to the oil passage
plugs [A], and tighten them.
Torque - Oil Passage Plugs: 20 N·m (2.0 kgf·m, 15 ft·lb)
•
Install the oil passage plug [B] in the lower crankcase, and
tighten it.
Torque - Oil Passage Plug: 9.8 N·m (1.0 kgf·m, 87 in·lb)
9-12 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
•
Install:
Crankshaft (see Crankshaft Installation)
Connecting Rods (see Connecting Rod Installation)
Balancer (see Balancer Installation)
Transmission Shafts (see Transmission Shaft Installa-
tion)
Dowel Pins [A]
Shift Drum (see Shift Drum and Fork Installation)
Shift Forks and Shift Rods (see Shift Drum and Fork In-
stallation)
•
Before fitting the lower case on the upper case, check the
following.
Be sure to hang the camshaft chain on the crankshaft.
Check to see that the shift drum and transmission gears
are in the neutral position.
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket [A] to the mating surface of the lower
crankcase half.
Sealant - Liquid Gasket, TB1216B: 92104-1064
NOTE
○
Especially, apply a liquid gasket so that it shall be filled
up on the grooves [B].
○
Do not apply liquid gasket to the inside of the groove
[C].
NOTICE
Do not apply liquid gasket around the crankshaft
main bearing inserts and oil passage holes.
CRANKSHAFT/TRANSMISSION 9-13
Crankcase Splitting
•
Fit the lower crankcase to the upper crankcase.
NOTE
○
Make the application finish within 20 minutes when
the liquid gasket to the mating surface of the lower
crankcase half is applied.
○
Moreover fit the case and tighten the bolts just after
application of the liquid gasket.
•
The M9 bolts [A] have copper plated washers [B], replace
them with new ones.
•
Apply molybdenum disulfide oil solution to both sides [C]
of the copper plated washer and threads [D] of the M9
bolts.
•
Tighten the lower crankcase bolts using the following
steps.
Following the sequence numbers on the lower crankcase
half, tighten the M9 bolts [1 ∼ 10] with copper plated wash-
ers.
Torque - Crankcase Bolts (M9): 40 N·m (4.1 kgf·m, 30 ft·lb)
Replace the washer [A] with a new one.
Tighten the M7 bolts.
Torque - Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
L=60mm(2.36in.) [B]
L=50mm(1.97in.) [C]
L=45mm(1.77in.) [D]
9-14 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
•
Tighten the upper crankcase bolts using the following
steps.
Tighten the M8 bolts [A].
Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb)
Replace the washer [B] with a new one.
Tighten the M7 bolts.
L=85mm(3.35in.) [C]
L=50mm(1.97in.) [D]
Torque - Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
Tighten the M6 bolts.
L=68mm(2.69in.) [E]
L = 40 mm (1.57 in.) [F]
Torque - Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)
•
After tightening all crankcase bolts, check the following
items.
Wipe up the liquid gasket that seeps out around the
crankcase mating surface.
Crankshaft and transmission shafts turn freely.
While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.
•
Install the removed parts (see appropriate chapters).
CRANKSHAFT/TRANSMISSION 9-15
Crankshaft and Connecting Rods
Crankshaft Removal
•
Split the crankcase (see Crankcase Splitting).
•
Remove:
Connecting Rods (see Connecting Rod Removal)
Balancer (see Balancer Removal)
Crankshaft [A]
Crankshaft Installation
NOTICE
If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with a plastigage
(press gauge) before assembling engine to be sure
the correct bearing inserts are installed.
•
Apply molybdenum disulfide oil solution to the crankshaft
main bearing inserts.
•
Install the crankshaft with the camshaft chain [A] hanging
on it.
•
Install the removed parts (see appropriate chapters).
Connecting Rod Removal
•
Split the crankcase (see Crankcase Splitting).
•
Remove:
Connecting Rod Big End Nuts [A]
Connecting Rod Big End Caps [B]
NOTE
○
Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.
•
Remove the connecting rods from the crankshaft.
NOTICE
Discard the connecting rod bolts. To prevent dam-
age to the crankpin surfaces, do not allow the con-
necting rod bolts to bump against the crankpins.
9-16 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Installation
NOTICE
To minimize vibration, the connecting rods should
have the same weight mark.
BigEndCap[A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark [D]: “
”ornomark
NOTICE
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.
•
Apply molybdenum disulfide oil solution [A] to the inner
surfaces of upper and lower bearing inserts.
•
Apply molybdenum disulfide grease to the connecting rod
big end inside surface [B].
•
Do not apply any grease or oil to the cap inside and cap
insert outside [C].
•
Install the inserts so that their nails [D] are on the same
side and fit them into the recess of the connecting rod and
cap.
NOTICE
Wrong application of oil and grease could cause
bearing damage.
When installing the inserts [A], be careful not to damage
the insert surface with the edge of the connecting rod [B]
or the cap [C]. One way to install inserts is as follows.
Installation [D] to Cap
Installation [E] to Connecting Rod
Push [F]
Spare Dowel Pin [G]
Connecting Rod Bolts [H]
•
Remove debris and clean the surface of inserts.
•
Install the cap on the connecting rod, aligning the weight
and diameter marks.
•
Apply molybdenum disulfide oil solution [MO] to the
threads and seating surfaces of the big end nuts and
bolts.
CRANKSHAFT/TRANSMISSION 9-17
Crankshaft and Connecting Rods
•
Install each connecting rod on its original crankpin.
The connecting rod big end is bolted using the “plastic
region fastening method.”
This method precisely achieves the needed clamping
force without exceeding it unnecessarily, allowing the
use of thinner, lighter bolts further decreasing connecting
rod weight.
There are two types of the plastic region fastening. One is
a bolt length measurement method and other is a rotation
angle method. Observe one of the following two, but the
bolt length measurement method is preferable because
this is a more reliable way to tighten the big end nuts.
NOTICE
The connecting rod bolts are designed to stretch
when tightened. Never reuse the connecting rod
bolts. See the table below for correct bolt and nut
usage.
NOTICE
Be careful not to overtighten the nuts.
The bolts must be positioned on the seating surface
correctly to prevent the bolt heads from hitting the
crankcase.
(1) Bolt Length Measurement Method
•
Be sure to clean the bolts, nuts, and connecting rods
thoroughly with a high flash-point solvent, because the
new connecting rods, bolts, and nuts are treated with an
anti-rust solution.
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the bolts, nuts, and connecting rods
in a well-ventilated area, and take care that there
are no sparks or flame anywhere near the working
area; this includes any appliance with a pilot light.
Do not use gasoline or a low flash-point solvent to
clean them.
NOTICE
Immediately dry the bolts and nuts with com-
pressed air after cleaning.
Clean and dry the bolts and nuts completely.
9-18 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
•
Install new bolts and nuts in reused connecting rod.
If the connecting rod assy was replaced, use the bolts and
nuts attached to the new connecting rod assy.
•
Apply a small amount of molybdenum disulfide oil solution
to the following portions.
Threads [A] of Bolts and Nuts
Seating Surfaces [B] of Nuts and Connecting Rod Caps
•
Dent both bolt head and bolt tip with a punch as shown.
•
Before tightening, use a point micrometer to measure the
length of new connecting rod 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 as follows.
Bolt Length after
tightening
–
Bolt Length before
tightening
=
Bolt Stretch
Connecting Rod Bolt Stretch
Usable Range:
0.20
∼ 0.32 mm (0.0079 ∼ 0.0126 in.)
•
Check the length of the connecting rod bolts.
If the stretch is more than the usable range, the bolt has
stretched too much. An overelongated bolt may break in
use.
(2) Rotation Angle Method
If you do not have a point micrometer, you may tighten
the nuts using the “Rotation Angle Method.”
•
Be sure to clean the bolts, nuts and connecting rods thor-
oughly with a high flash-point solvent, because the new
connecting rods, bolts and nuts are treated with an anti
-rust solution.
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the bolts, nuts, and connecting rods
in a well-ventilated area, and take care that there
are no sparks or flame anywhere near the working
area; this includes any appliance with a pilot light.
Do not use gasoline or a low flash-point solvent to
clean them.
NOTICE
Immediately dry the bolts and nuts with com-
pressed air after cleaning.
Clean and dry the bolts and nuts completely.
CRANKSHAFT/TRANSMISSION 9-19
Crankshaft and Connecting Rods
•
Install new bolts and nuts in reused connecting rods.
If the connecting rod assy was replaced, use the bolts and
nuts attached to the new connecting rod assy.
•
Apply a small amount of molybdenum disulfide oil solution
to the following portions.
Threads [A] of Bolts and Nuts
Seating Surfaces [B] of Nuts and Connecting Rod Caps
•
First, tighten the nuts to the specified torque. See the
table below.
•
Next, tighten the nuts 120° ±5° .
Mark [A] the connecting rod big end caps and nuts so that
nuts can be turned 120° [B] properly.
Tighten the hexagon nut by 2 corners.
Torque + Angle
Connecting
Rod Assy
Bolt Nut
N·m (kgf·m, ft·lb)
Attached to
22 (2.2, 16)
new con-rod
+120°
20 (2.0, 15)
New
Use the bolts
attached to
new con-rod.
New
+120°
26 (2.7, 19)
Used
+120°
26 (2.7, 19)
Used
Replace the
bolts with new
ones.
New
+120°
The nuts can be tightened by using a torque angle gauge
[A].
Crankshaft/Connecting Rod Cleaning
•
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
.
9-20 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Bend Inspection
•
Remove the connecting rod big end bearing inserts, 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 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 [C].
•
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.
If the connecting rod bend exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Bend
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist Inspection
•
With the big-end arbor [A] still on V block [C], hold the
connecting rod horizontally and measure the amount that
the arbor [B] varies from being paralleled with the surface
plate over a 100 mm (3.94 in.) length of the arbor to de-
termine the amount of connecting rod twist.
If the connecting rod twist exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Big End Side Clearance
Inspection
•
Measure connecting rod big end side clearance.
Insert a thickness gauge [A] between the big end and ei-
ther crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard: 0.13
∼ 0.38 mm (0.0051 ∼ 0.0150 in.)
Service Limit: 0.58 mm (0.023 in.)
If the clearance exceeds the service limit, replace the con-
necting rod with new one and then check clearance again.
If the clearance is too large after connecting rod replace-
ment, the crankshaft also must be replaced.
CRANKSHAFT/TRANSMISSION 9-21
Crankshaft and Connecting Rods
Connecting Rod Big End Bearing Insert/Crankpin
Wear Inspection
•
Remove the connecting rod big end (see Connecting Rod
Removal).
•
Cut strips of plastigage (press gauge) to crankpin width.
Place a strip on the crankpin parallel to the crankshaft
installed in the correct position.
•
Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).
NOTE
○
Do not move the connecting rod and crankshaft during
clearance measurement.
•
Remove the connecting rod big end again, measure each
clearance between the bearing insert and crankpin [A] us-
ing plastigage (press gauge) [B].
NOTICE
After measurement, replace the connecting rod
bolts.
Connecting Rod Big End Bearing Insert/Crankpin Clearance
Standard: 0.030
∼ 0.060 mm (0.0012 ∼ 0.0024 in.)
Service Limit: 0.10 mm (0.0039 in.)
If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.061 mm (0.0024 in.) and
the service limit (0.10 mm, 0.0039 in.), replace the bear-
ing inserts [A] with inserts painted blue [B]. Check in-
sert/crankpin clearance with the plastigage. The clear-
ance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard: 34.484
∼ 34.500 mm (1.3576 ∼ 1.3583 in.)
Service Limit: 34.47 mm (1.357 in.)
If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameters [A] are not less than
the service limit, but do not coincide with the original di-
ameter markings [B] on the crankshaft, make new marks
on it.
Crankpin Diameter Marks
None
34.484
∼ 34.492 mm (1.3576 ∼ 1.3579 in.)
34.493
∼ 34.500 mm (1.3580 ∼ 1.3583 in.)
: Crankpin Diameter Marks, “
”ornomark.
9-22 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
•
Measure the connecting rod big end inside diameter, and
mark each connecting rod big end in accordance with the
inside diameter.
•
Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).
NOTE
○
The mark already on the big end should almost coincide
with the measurement.
Connecting Rod Big End Inside Diameter Marks
None
37.500
∼ 37.508 mm (1.4764 ∼ 1.4766 in.)
37.509
∼ 37.516 mm (1.4767 ∼ 1.4770 in.)
BigEndCap[A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: “
”orno
mark
•
Select the proper bearing insert [A] in accordance with the
combination of the connecting rod and crankshaft coding.
Size Color [B]
Bearing Insert
Con-rod Big End
Inside Diameter
Marking
Crankpin
Diameter
Marking
Size Color
Part Number
None
Brown 92139-0124
None None
Black 92139-0123
None Blue 92139-0122
•
Install the new inserts in the connecting rod and check
insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance Inspection
•
Insert a thickness gauge [A] between the crankcase main
bearing and the crank web at the #3 journal to determine
clearance.
If the clearance exceeds the service limit, replace the
crankcase halves as a set.
NOTE
○
The 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: 0.09
∼ 0.19 mm (0.0035 ∼ 0.0075 in.)
Service Limit: 0.39 mm (0.0154 in.)
CRANKSHAFT/TRANSMISSION 9-23
Crankshaft and Connecting Rods
Crankshaft Runout Inspection
•
Measure the crankshaft runout.
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.05 mm (0.0020 in.)
Crankshaft Main Bearing Insert/Journal Wear
Inspection
•
Split the crankcase (see Crankcase Splitting).
•
Cut strips of plastigage (press gauge) to journal width.
•
Place a strip on each journal parallel to the crankshaft
installed in the correct position.
•
Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
NOTE
○
Do not turn the crankshaft during clearance measure-
ment.
○
Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage [A], however, using gen-
uine parts maintains the minimum standard clearance.
•
Split the crankcase again, measure each clearance be-
tween the bearing insert and journal [B] using plastigage
(press gauge).
Crankshaft Main Bearing Insert/Journal Clearance
Standard: 0.010
∼ 0.034 mm (0.0004 ∼ 0.0013 in.)
Service Limit: 0.06 mm (0.0024 in.)
If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.035 mm (0.0014 in.) and the
service limit (0.06 mm, 0.0024 in.), replace the bearing in-
serts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.
9-24 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Main Journal Diameter
Standard: 34.984
∼ 35.000 mm (1.3773 ∼ 1.3780 in.)
Service Limit: 34.96 mm (1.376 in.)
If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters [A] are not less than the
service limit, but do not coincide with the original diameter
markings [B] on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None
34.984
∼ 34.992 mm (1.3773 ∼ 1.3776 in.)
1
34.993
∼ 35.000 mm (1.3777 ∼ 1.3780 in.)
: Crankshaft Main Journal Diameter Marks, “1” or no
mark.
•
Measure the main bearing inside diameter, and mark the
upper crankcase half in accordance with the inside diam-
eter.
Crankcase Main Bearing Inside Diameter Marks: “
”or
no mark.
•
Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
NOTE
○
The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks
38.000
∼ 38.008 mm (1.4961 ∼ 1.4963 in.)
None
38.009
∼ 38.016 mm (1.4964 ∼ 1.4967 in.)
•
Select the proper bearing insert [A] in accordance with the
combination of the crankcase and crankshaft coding.
Size Color [B]
CRANKSHAFT/TRANSMISSION 9-25
Crankshaft and Connecting Rods
Bearing Insert*
Crankcase Main
Bearing Inside
Diameter Marking
Crankshaft Main
Journal Diameter
Marking
Size Color Part Number Journal Nos.
92139-0034 2, 4
1 Brown
92139-0219 1, 3, 5
None 1 92139-0033 2, 4
None
Black
92139-0218 1, 3, 5
92139-0032 2, 4
None None Blue
92139-0217 1, 3, 5
* The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.
•
Install the new inserts in the crankcase halves and check
insert/journal clearance with the plastigage.
9-26 CRANKSHAFT/TRANSMISSION
Balancer
Balancer Removal
•
Split the crankcase (see Crankcase Splitting).
•
Remove:
Oil Seal [A]
Balancer [B]
Balancer Installation
•
Check that the rubber dampers [A] are in place as shown.
•
Apply molybdenum disulfide oil solution to the damper
contact portions of the balancer weight [A].
•
Install the balancer weight into the gear [B].
Align the punch mark [C] of the balancer weight with the
groove [D] of the gear.
•
Apply molybdenum disulfide oil solution to the needle
bearings. Insert the needle bearings.
•
Fit the washers [A] on both ends of the weight and gear
assembly. The projected sides [B] face inward.
•
Insert the pin [A] as shown.
•
Set the balancer on the upper crankcase half.
Align the punch mark [B] on the balancer gear [C] with the
mark [D] on the balancer drive gear [E] of crankshaft.
CRANKSHAFT/TRANSMISSION 9-27
Balancer
•
Assemble the crankcase (see Crankcase Assembly).
•
Fill the oil seal lips with grease.
•
Install the new oil seal [A] so that its surface is flush with
the surface of the crankcase.
•
Install the balancer shaft clamp lever [B].
•
Apply a non-permanent locking agent to the threads of
the balancer shaft clamp lever bolt [C].
•
Tighten:
Torque - Balancer Shaft Clamp Lever Bolt: 25 N·m (2.5
kgf·m, 18 ft·lb)
•
Turn the balancer shaft so that its mark [D] faces down-
ward.
•
Check that the balancer shaft clamp lever is in contact
with the oil seal.
•
Tighten:
Torque - Balancer Shaft Clamp Bolt [E]: 9.8 N·m (1.0 kgf·m,
87 in·lb)
Balancer Adjustment
•
Start the engine and warm it up thoroughly.
•
Adjust the balancer gear backlash with the engine idling.
The amount of backlash can be changed by turning the
balancer shaft which has eccentric journals.
Start the engine and let it idle.
Loosen the clamp bolt [A] and turn the balancer shaft [B]
clockwise [C] until the balancer gear makes a whining
sound.
Turn the shaft counterclockwise [D] until the balancer gear
whining sound disappears and tighten the clamp bolt.
Torque - Balancer Shaft Clamp Bolt: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Balancer Damper Inspection
•
Remove the balancer and disassemble the weight and
gear assembly.
•
Visually inspect the rubber dampers [A].
If they appear damaged or deteriorated, replace them.
9-28 CRANKSHAFT/TRANSMISSION
Starter Motor Clutch
Starter Motor Clutch Removal/Installation
•
Refer to the Starter Motor Clutch Disassembly/Assembly.
Starter Motor Clutch Inspection
•
Remove:
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Starter Idle Gear and Shaft
•
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.
•
Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.
NOTE
○
Examine the starter motor clutch gear as well. Replace
it if it worn or damaged.
Starter Motor Clutch Disassembly
•
Remove:
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
•
Hold the alternator rotor with the flywheel holder [A].
Special Tool - Flywheel Holder: 57001-1313
•
Remove the starter motor clutch bolts [B].
•
Remove:
Starter Motor Clutch Housing [A]
Starter Motor Clutch [B]
Starter Motor Clutch Assembly
•
Install the starter motor clutch to the housing so that the
flange [A] fit to the housing groove [B].
•
Hold the alternator rotor with the flywheel holder.
Special Tool - Flywheel Holder: 57001-1313
•
Apply a non-permanent locking agent to the threads of
the starter motor clutch bolts and tighten them.
Torque - Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)
CRANKSHAFT/TRANSMISSION 9-29
External Shift Mechanism
Shift Pedal Removal
•
Remove:
Shift Lever Bolt [A]
Shift Lever [B]
If the tie-rod is removed from the shift pedal and shift lever,
note the following.
The following portions have left-hand threads.
Locknut [C] of Shift Lever Side
Ball Joint [D] of Shift Lever
•
Remove:
Shift Pedal Mounting Bolt [E]
Shift Pedal [F] with Tie-Rod [G]
Shift Pedal Installation
•
Apply grease to the sliding surface [A] on the shift pedal
mounting bolt [B].
•
Install:
Washer [C]
Tie-Rod [D] and Shift Pedal [E]
•
Tighten:
Torque - Shift Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)
•
Align the punch mark [A] on the shift shaft with the slit [B]
of the shift lever.
•
Tighten the shift lever bolt [C].
•
After installation, confirm that the shift pedal [A] is posi-
tioned as shown.
About 90° [B]
If the pedal position is different, adjust it as follows.
To adjust the pedal position, loosen the front locknut [C]
(left-hand threads) and rear locknut [D], and then turn the
tie-rod [E].
Tighten the locknuts securely.
9-30 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
External Shift Mechanism Removal
•
Remove:
Shift Lever (see Shift Pedal Removal)
Clutch (see Clutch Removal in the Clutch chapter)
Circlip [A]
Washer [B]
Special Tool - Outside Circlip Pliers: 57001-144
•
Remove:
ShiftShaftAssembly[A]
•
Remove:
Gear Positioning Lever Bolt [A]
Gear Positioning Lever [B]
Collar and Spring [C]
External Shift Mechanism Installation
•
Assemble the following parts as shown.
Gear Positioning Lever [A]
Spring [B]
Collar [C]
Gear Positioning Lever Bolt [D]
Hang the spring end [E] to the gear positioning lever.
•
While prying the gear positioning lever [A], tighten the
gear positioning lever bolt [B].
Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m,
106 in·lb)
CRANKSHAFT/TRANSMISSION 9-31
External Shift Mechanism
•
Apply grease to the lips of the oil seal [A].
•
Install the shift shaft [A] so that the return spring pin [B]
fits between the spring [C].
•
Install the washer [A].
•
Replace the circlip [B] with a new one, and install it.
Special Tool - Outside Circlip Pliers: 57001-144
Fit the circlip into the groove of the shift shaft securely.
•
Install the removed parts (see appropriate chapters).
External Shift Mechanism Inspection
•
Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the serration [B] are damaged, replace the shaft.
If the springs [C] are damaged in any way, replace them.
If the shift mechanism arm [D] is damaged in any way,
replace the shift shaft.
•
Check the return spring pin [A] is not loose.
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 39 N·m (4.0 kgf·m,
29 ft·lb)
9-32 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
•
Check the gear positioning lever [A] and its spring for
breaks or distortion.
If the lever or spring are damaged in any way, replace
them.
•
Visually inspect the shift drum cam [B].
If it is badly worn or shows any damage, replace it.
CRANKSHAFT/TRANSMISSION 9-33
Transmission
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.
•
Apply molybdenum disulfide oil solution to the transmis-
sion gears.
•
Install the drive shaft and output shaft into the upper
crankcase half.
•
Apply engine oil to the bearings.
The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races or bear-
ings. When they are properly matched, there is no clear-
ance [A] between the crankcase and the bearing outer
races or bearings.
•
Assemble the crankcase (see Crankcase Assembly).
•
Replace the oil seal [A] with a new one.
•
Apply grease to the oil seal lips.
•
Apply soap and water solution to the outer circumference
of the oil seal so that it will go into place smoothly.
•
Press in the oil seal into the crankcase so that the surface
of the oil seal is flush with the surface [B] of the crankcase.
•
Install the collar [C].
Transmission Shaft Disassembly
•
Remove the transmission shafts (see Transmission Shaft
Removal).
•
Remove the circlips, and disassemble the transmission
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.
Set the output shaft in a vertical position holding the 3rd
gear [B].
Spin the 5th gear quickly [C] and pull it off upward.
9-34 CRANKSHAFT/TRANSMISSION
Transmission
•
Remove the ball bearing [A] from each shafts.
Special Tools - Bearing Puller [B]: 57001-135
Bearing Puller Adapter [C]: 57001-317
•
Discard the bearing.
Transmission Shaft Assembly
•
Install the new ball bearing [A] on the each shaft, using
the bearing driver.
Spacial Tool - Bearing Driver,
32: 57001-382
•
Apply engine oil to the bushings, ball bearings and shafts.
•
Install the gear bushings [A] on the shaft with their holes
[B] aligned.
•
Replace any circlips removed with new ones.
•
Install the circlips [A] so that the opening [B] is aligned
withasplinegroove[C].
CRANKSHAFT/TRANSMISSION 9-35
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 oil
holes aligned.
•
Install the 5th and 6th gear bushings onto the drive shaft
with their oil holes aligned.
•
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.
•
Install the 6th gear onto the output shaft with their oil holes
aligned.
•
Install the 2nd and 3rd/4th gear bushings onto the output
shaft with their oil holes aligned.
NOTE
○
When the toothed washers are assembled onto the
each shaft, note the following.
○
Align the punch marks [A] of the toothed washers (only
on drive shaft).
○
When the tangs [B] of the toothed washer shall be as-
sembled, they should be installed into the notch [C] of
the toothed washer (see Page 9-36).
•
Fit the steel balls into the 5th gear holes in the output
shaft, aligning the holes as shown.
5th Gear [A]
Output Shaft [B]
Steel Balls [C]
NOTICE
Do not apply grease to the balls to hold them in
place. This will cause the positive neutral finder
mechanism to malfunction.
After assembling the 5th gear with steel balls in place on
the output shaft, check the ball-locking effect that the 5th
gear doesn’t come out of the output shaft when moving it
up and down by hand.
•
Check that each gear spins or slides freely on the trans-
mission shafts without binding after assembly.
9-36 CRANKSHAFT/TRANSMISSION
Transmission
CRANKSHAFT/TRANSMISSION 9-37
Transmission
1. Output Shaft
2. Collar
3. Ball Bearings
4. Bushing
5. 2nd Gear (39 T)
6. Washer (
34 × 28.1)
7. Circlips (
33 × 25.9)
8. Top Gear (31 T)
9. Toothed Washer (
34)
10. 4th Gear (25 T)
11. Bushings
12. Toothed Washer (
40.5)
13. Toothed Washer (
37)
14. 3rd Gear (24 T)
15. Steel Balls
16. 5th Gear (26 T)
17. Low Gear (39 T)
18. Washers (
31 × 20.5)
19. Races
20. Needle Bearings
21. Circlips (
22.2 × 18.7)
22. Needle Bearing
23. Low Gear (15 T) (Drive Shaft)
24. Bushing
25. 5th Gear (21 T)
26. Toothed Washers (
31)
27. Circlips (
29 × 22.6)
28. 3rd/4th Gear (15 T/18 T)
29. Bushing
30. Top Gear (28 T)
31. Toothed Washer (
34.2)
32. Toothed Washer (
32)
33. 2nd Gear (20 T)
34. Washer (
30 × 20.5)
9-38 CRANKSHAFT/TRANSMISSION
Transmission
Shift Drum and Fork Removal
•
Remove:
Lower Crankcase Half (see Crankcase Splitting)
Transmission Shafts (see Transmission Shaft Removal)
Gear Positioning Lever (see External Shift Mechanism
Removal)
Shift Drum Bearing Holder Bolts [A]
Shift Drum Bearing Holder [B]
•
Pull out the shift rods [C], and remove the shift forks.
•
Pull out the shift drum [D].
Shift Drum and Fork Installation
•
Apply engine oil to the shift drum, forks and rods.
•
Install the shift drum [A].
•
Install the shift rods [B] and shift forks, note the following.
The rods are identical.
Position the one with shortest ears [C] on the drive shaft
and place the pin in the center groove in the shift drum.
The two forks [D] on the output shaft are identical.
Install the forks so that its “0061” and “0062” side faces
engine left side.
•
Apply a non-permanent locking agent to the threads of
the shift drum bearing holder bolts, and tighten them.
Torque - Shift Drum Bearing Holder Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
•
Install the removed parts (see appropriate chapters).
Shift Drum Disassembly
•
Remove the shift drum (see Shift Drum and Fork Re-
moval).
•
While holding the shift drum with a vise, remove the shift
drum cam holder bolt [A].
•
Remove:
Shift Drum Cam [B]
Dowel Pin [C]
Ball Bearing [D]
Shift Drum Assembly
•
Install:
Ball Bearing [A]
Dowel Pin [B] and Shift Drum Cam [C]
Align the pin with the groove in the shift drum cam.
•
Apply a non-permanent locking agent to the threads of
the shift drum cam holder bolt [D] and tighten it.
Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m,
106 in·lb)
CRANKSHAFT/TRANSMISSION 9-39
Transmission
Shift Fork Bending Inspection
•
Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
Shift Fork/Gear Groove Wear Inspection
•
Measure the thickness of the shift fork ears [A], and mea-
sure the width of the gear grooves [B].
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 5.9
∼ 6.0 mm (0.232 ∼ 0.236 in.)
Service Limit: 5.8 mm (0.228 in.)
If the gear groove is worn over the service limit, the gear
mu
st be replaced.
Gear Groove Width
Standard: 6.05
∼ 6.15 mm (0.238 ∼ 0.242 in.)
Service Limit: 6.25 mm (0.246 in.)
Shift Fork Guide Pin/Drum Groove Wear
Inspection
•
Measure the diameter of each shift fork guide pin [A], and
measure the width of each shift drum groove [B].
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: 6.9
∼ 7.0 mm (0.272 ∼ 0.276 in.)
Service Limit: 6.8 mm (0.268 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard: 7.05
∼ 7.20 mm (0.278 ∼ 0.283 in.)
Service Limit: 7.3 mm (0.287 in.)
Gear Dog and Gear Dog Hole Damage Inspection
•
Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
9-40 CRANKSHAFT/TRANSMISSION
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
NOTICE
Do not remove the ball or needle bearings unless it
is necessary. Removal may damage them.
•
Using a press or puller, remove the ball bearing and/or
needle bearings.
NOTE
○
In the absence of the above mentioned tools, satisfac-
tory results may be obtained by heating the case to ap-
proximately 93°C (200°F) max., and tapping the bearing
in or out.
NOTICE
Do not heat the case with a torch. This will warp the
case. Soak the case in oil and heat the oil.
•
Using a press and the bearing driver set [A], install the
new ball bearing until it stops at the bottom of its housing.
The new needle bearings must be pressed into the
crankcase so that the end is flush with the end of the
hole.
Special Tool - Bearing Driver Set: 57001-1129
Ball and Needle Bearing Wear Inspection
NOTICE
Do not remove the bearings for inspection. Re-
moval may damage them.
•
Check the ball bearings.
Since the ball bearings are made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement. Clean each bearing in a high flash-point sol-
vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
•
Check the needle bearings.
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.
If there is any doubt as to the condition of a needle bear-
ing, replace it.
Oil Seal Inspection
•
Inspect the oil seals.
Replace it if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.
WHEELS/TIRES 10-1
10
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 10-2
Specifications ......................................................................................................................... 10-4
Special Tools .......................................................................................................................... 10-5
Wheels (Rims) ........................................................................................................................ 10-6
Front Wheel Removal ....................................................................................................... 10-6
Front Wheel Installation .................................................................................................... 10-6
Rear Wheel Removal........................................................................................................ 10-7
Rear Wheel Installation..................................................................................................... 10-9
Wheel Inspection .............................................................................................................. 10-10
Axle Inspection.................................................................................................................. 10-10
Balance Inspection............................................................................................................ 10-11
Balance Adjustment .......................................................................................................... 10-11
Balance Weight Removal.................................................................................................. 10-11
Balance Weight Installation............................................................................................... 10-11
Tires........................................................................................................................................ 10-13
Air Pressure Inspection/Adjustment.................................................................................. 10-13
Tire Inspection .................................................................................................................. 10-13
Tire Removal..................................................................................................................... 10-13
Tire Installation.................................................................................................................. 10-13
Tire Repair ........................................................................................................................ 10-15
Hub Bearing............................................................................................................................ 10-16
Hub Bearing Removal....................................................................................................... 10-16
Hub Bearing Installation.................................................................................................... 10-16
Hub Bearing Inspection..................................................................................................... 10-17
Hub Bearing Lubrication ................................................................................................... 10-17
10-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 10-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Front Axle Clamp Bolts
20 2.0 15 AL
2 Front Axle 108 11.0 79.7
3 Rear Axle Nut 98 10.0 72
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
HG: Apply high-temperature grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES
Specifications
Item Standard Service Limit
Wheels (Rims)
Rim Runout:
Axial
TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.)
Radial
TIR 0.3 mm (0.01 in.) or less TIR 1.0 mm (0.04 in.)
Axle Runout/100 mm (3.
94 in.):
Front TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.)
Rear TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.)
Wheel Balance 10 g (0.35 oz.) or less –––
Balance Weights 10 g (0.35 oz.), 20 g (0.71 oz.),
30 g (1.06 oz.)
–––
Rim Size:
Front
J17M/C × MT3.50
–––
Rear
J17M/C × MT6.00
–––
Tires
Air Pressure (when Cold):
Front
Up to 180 kg (397 lb) load: 250 kPa
(2.50 kgf/cm², 36
psi)
–––
Rear Up to 180 kg (397 lb) load: 290 kPa
(2.90 kgf/cm², 42 psi)
–––
Tread Depth:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm
(0.06 in.)
Rear
6.5 mm (0.26 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.)
Over 130 km/h (8
0 mph):
3 mm (0.12 in.)
Standard Tires: Make, Type Size
Front DUNLOP, SPORTMAX D214F T 120/70 ZR17 M/C (58 W)
Rear
DUNLOP, SPORTMAX D214 T 190/50 ZR17 M/C (73 W)
WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in
serious injury or death. To ensure proper handling and stability, use only the recommended
s
tandard tires for replacement, inflated to the standard pressure.
WHEELS/TIRES 10-5
Special Tools
Bearing Driver Set:
57001-1129
Jack:
57001-1238
Attachment Jack:
57001-1252
Bearing Remover Head, 20 × 22:
57001-1293
Bearing Remover Shaft, 13:
57001-1377
Jack Attachment:
57001-1608
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
•
For the ABS equipped models, remove the bolt [A] and
front wheel rotation sensor [B].
•
Remove:
Front Caliper Mounting Bolts [C] (Both Sides)
Front Caliper [D] (Both Sides)
•
Loosen:
Front Axle Clamp Bolts [A]
Front Axle [B]
•
Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Oxygen Sensor [Equipped Models] (see Oxygen Sen-
sor Removal (Equipped Models) in the Electrical System
chapter)
•
Raise the front wheel off the ground.
Special Tools - Jack [A]: 57001-1238
Attachment Jack [B]: 57001-1252
Jack Attachment [C]: 57001-1608
•
Pull out the front axle to the right and drop the front wheel
out of the front forks.
NOTICE
Do not lay the wheel down on one of the discs. This
can damage or warp the disc. Place blocks un-
der the wheel so that the disc does not touch the
ground.
Front Wheel Installation
NOTE
○
The 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.
WHEELS/TIRES 10-7
Wheels (Rims)
•
Apply high-temperature grease to the grease seal lips.
•
Fit the collar [A] on the both sides of the hub.
The collars are identical.
•
Insert the front axle from the right side.
•
Tighten:
Torque - Front Axle: 108 N·m (11.0 kgf·m, 79.7 ft·lb)
•
Before tightening the front axle clamp bolts [A] on the right
front fork leg, pump the front fork up and down 4 or 5 times
to allow the right front fork leg to seat on the front axle.
NOTE
○
Put a block in front of the front wheel to stop moving.
•
Tighten:
Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
NOTE
○
Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
•
Install the removed parts (see appropriate chapters).
•
Check the front brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
Rear Wheel Removal
•
Raise the rear wheel off the ground with the stand [A].
10-8 WHEELS/TIRES
Wheels (Rims)
•
Loosen the torque link nuts [A] lightly to turn the chain
adjuster easily.
•
Remove:
Bolt [A]
Clamp [B]
Rear Wheel Rotation Sensor [C]
Rear Caliper Mounting Bolts [D]
Rear Caliper [E]
•
Loosen the chain adjuster clamp bolt [A] on both sides.
•
Turn the chain adjuster [B] to make the chain slack.
•
Remove:
Retaining Ring [C] (Both Sides)
Rear Axle Nut [D]
Washer
•
Remove:
Rear Axle [A] (from Left Side)
•
Remove the drive chain [A] from the rear sprocket toward
the left.
•
Move the rear wheel back and remove it.
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
WHEELS/TIRES 10-9
Wheels (Rims)
Rear Wheel Installation
•
Apply high-temperature grease to the grease seal lips.
•
Fit the collars on the both sides of the hub.
Left Side Collar [A] (
40 × 35)
Right Side Collar [B] (
41 × 28)
•
Engage the drive chain with the rear sprocket.
•
Insert the rear axle from the left side of the wheel.
•
Align the hole of the brake holder with hole of the rear
wheel.
•
Install:
Washer
Rear Axle Nut [A]
•
Before tightening the rear axle nut, check that the scale
on the left and right adjusters set the same position.
•
Tighten:
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
•
Replace the retaining rings [B] with new ones, and install
them.
•
Adjust the drive chain slack after installation (see Drive
Chain Slack Inspection in the Periodic Maintenance chap-
ter).
•
Tighten:
Torque - Torque Link Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
•
Install the removed parts (see appropriate chapters).
•
Check the rear brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
10-10 WHEELS/TIRES
Wheels (Rims)
Wheel Inspection
•
Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238
Attachment Jack: 57001-1252
Jack Attachment: 57001-1608
•
Spin the wheel lightly, and check for roughness or binding.
If roughness or binding is found, replace the hub bearings
(see Hub Bearing Removal/Installation).
•
Inspect the wheel for small cracks, dents, bending, or
warp.
If there is any damage to the wheel, replace the wheel.
•
Remove the wheel, and support it with the tire by the axle.
•
Measure the rim runout, axial [A] and radial [B], with a dial
gauge.
If rim runout exceeds the service limit, check the hub bear-
ings (see Hub Bearing Inspection).
If the problem is not due to the bearings, replace the
wheel.
Rim Runout (with tire installed)
Standard:
Axial TIR 0.5 mm (0.02 in.) or less
Radial TIR 0.3 mm (0.01 in.) or less
Service Limit:
Axial TIR 1.0 mm (0.04 in.)
Radial TIR 1.0 mm (0.04 in.)
WARNING
Damaged wheel parts may fail and cause an acci-
dent resulting in serious injury or death. Never at-
tempt to repair a damaged wheel part. If the wheel
part is damaged, it must be replaced with a new one.
Axle Inspection
•
Remove the front and rear axles (see Front/Rear Wheel
Removal).
•
Visually inspect the front and rear axle for damages.
If the axle is damaged or bent, replace it.
•
Place the axle in V blocks that are 100 mm (3.94 in.) [A]
apart, and set a dial gauge [B] on the axle at a point
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.
If axle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)
Standard:
Front
TIR 0.03 mm (0.0012 in.) or less
Rear
TIR 0.1 mm (0.004 in.) or less
Service Limit: TIR 0.2 mm (0.008 in.)
WHEELS/TIRES 10-11
Wheels (Rims)
Balance Inspection
•
Remove the front and rear wheels (see Front/Rear Wheel
Removal).
•
Support the wheel so that it can be spun freely.
•
Spin the wheel lightly, and mark [A] the wheel at the top
when the wheel stops.
Repeat this procedure several times. If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance (see Balance Adjustment).
Balance Adjustment
•
If 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.
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
•
Insert a standard tip screwdrivers [A] [B] between the rib
[C] and weight [D] as shown.
•
Pry the balance weight with two screwdrivers and remove
the balance weight.
•
Discard the used balance weight.
NOTICE
Do not tap the screwdrivers. The rim could be dam-
aged.
Balance Weight Installation
•
Check if the weight portion has any play on the blade [A]
and clip [B].
If it does, discard it.
WARNING
Unbalanced wheels can create an unsafe riding
condition. If the balance weight has any play on
the rib of the rim,
the blade and/or clip have been
stretched. Replace the loose balance weight. Do
not reuse used balance weight.
10-12 WHEELS/TIRES
Wheels (Rims)
Balance Weight
Part Number Weight
41075-0007
10 g (0.35 oz.)
41075-0008
20 g (0.71 oz.)
41075-0009
30 g (1.06 oz.)
NOTE
○
Balance weights are available from Kawasaki dealers
in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes.
An imbalance of less than 10 grams (0.35 oz.) will not
usually affect running stability.
○
Do not use four or more balance weight (more than 90
grams, 3.2 oz.). If the wheel requires an excess balance
weight, disassemble the wheel to find the cause.
•
Slip the balance weight [A] onto the rib [B] by pushing or
lightly hammering [C] the clip [D].
Left Side [E]
Right Side [F]
•
Be sure to install the balance weight.
Check that the blade [A] and clip [B] are fully seated on
the rim [C] and that the clip is hooked over the rib [D].
Left Side [E]
Right Side [F]
WHEELS/TIRES 10-13
Tires
Air Pressure Inspection/Adjustment
•
Refer to the Air Pressure Inspection in the Periodic Main-
tenance chapter.
Tire Inspection
•
Refer to the Wheel/Tire Damage Inspection in the Peri-
odic Maintenance chapter.
Tire Removal
•
Remove:
Wheels (see Front/Rear Wheel Removal)
Valve Core (Let out the air)
•
To maintain wheel balance, mark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Yellow Mark [A]
Valve Stem [B]
Align [C]
•
Lubricate the tire beads and rim flanges on both sides with
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
NOTICE
Never lubricate with engine oil or petroleum distil-
lates because they will deteriorate the tire.
•
Removethetirefromtherimusingasuitablecommer-
cially available tire changer.
NOTE
○
The tires cannot be removed with hand tools because
they fit the rims too tightly.
Tire Installation
WARNING
Some replacement tires may adversely affect han-
dling and cause an accident resulting in serious in-
jury or death. To ensure proper handling and sta-
bility, use only the recommended standard tires for
replacement, inflated to the standard pressure.
•
Inspect the rim and tire, and replace them if necessary.
•
Clean the sealing surfaces of the rim and tire, and smooth
thesealingsurfacesoftherimwithafineemeryclothif
necessary.
•
Remove the air valve and discard it.
NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
10-14 WHEELS/TIRES
Tires
•
Install a new valve in the rim.
Remove the valve cap, lubricate the stem seal [A] with a
soap and water solution or rubber lubricant, and pull [B]
the valve stem through the rim from the inside out until it
snaps into place.
NOTICE
Do not use engine oil or petroleum distillates to lu-
bricate the stem because they will deteriorate the
rubber.
The air valve is as shown.
Valve Cap [A]
ValveCore[B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
•
Check the tire rotation mark on the front and rear tires and
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotating Direction [B]
•
Position the tire on the rim so that the valve [A] align with
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.
•
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.
WARNING
Overinflating a tire can cause it to explode, causing
serious injury or death. Be sure to install the valve
core whenever inflating the tire, and do not inflate
the tire to more than 400 kPa (4.0 kgf/cm², 57 psi).
WHEELS/TIRES 10-15
Tires
•
Check to see that the rim lines [A] on both sides of the tire
sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall rim lines are not parallel,
remove the valve core.
•
Lubricate the rim flanges and tire beads.
•
Install the valve core and inflate the tire again.
•
After the tire beads seat in the rim flanges, check for air
leakage.
Inflate the tire slightly above standard inflation.
Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
•
Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chap-
ter).
•
Install the air valve cap.
•
Adjust the wheel balance (see Balance Adjustment).
Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) re-
pair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally under-
stood that higher running durability is obtained by perma-
nent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for 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.
10-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Removal
•
Remove the wheels (see Front/Rear Wheel Removal),
and take out the following.
Collars [A]
Coupling [B] (Out of rear hub)
Grease Seals [C]
•
Use the bearing remover to remove the hub bearings [A].
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Special Tools - Bearing Remover Head, 20 × 22 [B]:
57001-1293
Bearing Remover Shaft,
13 [C]: 57001
-1377
Hub Bearing Installation
•
Before installing the hub bearings, blow any dirt or foreign
particles out of the hub with compressed air to prevent
contamination of the bearings.
•
Replace the bearings with new ones.
•
Install the bearings by using the bearing driver set which
does not contact the bearing inner race.
NOTE
○
Install the bearings so that the marked side faces out.
•
Press in each right the bearing [A] until they are bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129
WHEELS/TIRES 10-17
Hub Bearing
•
Replace the grease seals with new ones.
•
Press in the grease seals [A] so that the seal surface is
flush [B] with the end of the hole.
Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set [C]: 57001-1129
•
Install the removed parts (see appropriate chapters).
Hub Bearing Inspection
Since the hub bearings are made to extremely close tol-
erances, the clearance can not normally be measured.
NOTE
○
Do 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.
If bearing play, roughness, or binding is found, replace
the bearing.
•
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication
NOTE
○
Since the hub bearings are packed with grease and
sealed, lubrication is not required.
FINAL DRIVE 11-1
11
Final Drive
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Special Tools .......................................................................................................................... 11-5
Drive Chain............................................................................................................................. 11-6
Drive Chain Slack Inspection ............................................................................................ 11-6
Drive Chain Slack Adjustment .......................................................................................... 11-6
Wheel Alignment Inspection/Adjustment .......................................................................... 11-6
Drive Chain Wear Inspection ............................................................................................ 11-6
Drive Chain Lubrication..................................................................................................... 11-6
Drive Chain Removal ........................................................................................................ 11-6
Drive Chain Installation ..................................................................................................... 11-6
Drive Chain Replacement ................................................................................................. 11-6
Sprocket, Coupling ................................................................................................................. 11-10
Engine Sprocket Removal ................................................................................................ 11-10
Engine Sprocket Installation ............................................................................................. 11-10
Engine Sprocket Cover Disassembly................................................................................ 11-11
Engine Sprocket Cover Assembly .................................................................................... 11-11
Rear Sprocket Removal.................................................................................................... 11-12
Rear Sprocket Installation................................................................................................. 11-12
Coupling Installation.......................................................................................................... 11-12
Coupling Bearing Removal ............................................................................................... 11-13
Coupling Bearing Installation ............................................................................................ 11-13
Coupling Bearing Inspection ............................................................................................. 11-14
Coupling Bearing Lubrication............................................................................................ 11-14
Coupling Damper Inspection............................................................................................. 11-14
Sprocket Wear Inspection................................................................................................. 11-14
Rear Sprocket Warp Inspection ........................................................................................ 11-15
11-2 FINAL DRIVE
Exploded View
FINAL DRIVE 11-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Chain Guide Bolts
9.8 1.0 87 in·lb L
2 Engine Sprocket Outer Cover Screws 0.70 0.07 6.2 in·lb
3 Engine Sprocket Nut 125 12.7 92.2 MO
4 Rear Sprocket Nuts 59 6.0 44 R, S
5 Chain Adjuster Clamp Bolts 64 6.5 47
HG: Apply high-temperature grease.
HO: Apply heavy oil.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
11-4 FINAL DRIVE
Specifications
Item Standard Service Limit
Drive Chain
Drive Chain Slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.)
–––
Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.)
Standard Chain:
Make ENUMA –––
Type EK525ZX –––
Link 112 links –––
Link Pin Outside Diameter
(When drive chain replacing)
5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) –––
Link Plates Outside Width
(When drive chain replacing)
20.35 ∼ 20.55 mm (0.8012 ∼ 0.8091 in.) –––
Sprockets
Rear Sprocket Warp TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm (0.020
in.)
FINAL DRIVE 11-5
Special Tools
Inside Circlip Pliers:
57001-143
Bearing Driver Set:
57001-1129
11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
•
Refer to the Drive Chain Slack Inspection in the Periodic
Maintenance chapter.
Drive Chain Slack Adjustment
•
Refer to the Drive Chain Slack Adjustment in the Periodic
Maintenance chapter.
Wheel Alignment Inspection/Adjustment
•
Refer to the Wheel Alignment Inspection in the Periodic
Maintenance chapter.
Drive Chain Wear Inspection
•
Refer to the Drive Chain Wear Inspection in the Periodic
Maintenance chapter.
Drive Chain Lubrication
•
Refer to the Drive Chain Lubrication Condition Inspection
in the Periodic Maintenance chapter.
Drive Chain Removal
•
Refer to the Drive Chain Replacement.
Drive Chain Installation
•
Refer to the Drive Chain Replacement.
Drive Chain Replacement
•
Remove:
Engine Sprocket Cover (see Engine Sprocket Removal)
Mud Guard (see Mud Guard Removal in the Frame
chapter)
Chain Cover Bolt [A]
•
Remove:
Clamp [A]
Chain Cover [B]
NOTICE
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
FINAL DRIVE 11-7
Drive Chain
Body [A]
Handlebar [B]
Cutting and Riveting Pin [C]
For Cutting [D]
For Riveting [E]
Plate Holder (A) [F]
Plate Holder (B) [G]
Gauge [H]
•
Grind [A] the pin head to make it flat.
•
Set the cutting and riveting pin [B] as shown.
•
Screw the pin holder until it touches the chain pin.
•
Be sure that the cutting pin hits center of the chain pin.
•
Screw the handlebar [A] into the body.
•
Turn the pin holder with the wrench [B] clockwise to ex-
tract the chain pin.
•
Replace the link pin, link plate and grease seals.
•
Apply grease to the link pins [A] and grease 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.
•
Install the link plate [D] so that the mark faces out.
•
Push the link plate by hand or plier to fix it.
•
Be sure to set the grease seals correctly.
11-8 FINAL DRIVE
Drive Chain
•
Set the plate holder (A) [A] and plate holder (B) [B] on the
body.
•
Fit the plate holder (A) [A] to the link plate.
•
Turn the pin holder by hand until the plate holder (B) [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).
•
Take off the plate holder.
•
Set the plate holder (B) [A] and cutting and riveting pin [B]
as shown.
•
Turn the pin holder until the riveting pin touches the link
pin.
FINAL DRIVE 11-9
Drive Chain
•
Turn the wrench clockwise until the tip of riveting pin hits
to the link pin.
•
Rivet it.
•
Same work for the other link pin.
•
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: 20.35
∼ 20.55 mm (0.8012 ∼ 0.8091 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 (see
Drive Chain Slack Adjustment in the Periodic Mainte-
nance chapter).
•
Insert the projection [A] on the chain cover into the
swingarm hole [B].
•
Install the clamp [A] as shown.
•
Apply a non-permanent locking agent to the threads of
the chain cover bolt and tighten it.
•
Install the removed parts (see appropriate chapters).
11-10 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Removal
•
Remove:
Engine Sprocket Cover Bolts [A]
Engine Sprocket Cover [B]
•
Flatten out the bended washer [A].
•
Remove the engine sprocket nut [B] and washer.
NOTE
○
When loosening the engine sprocket nut, hold the rear
brake on.
•
Raise the rear wheel off the ground with the stand.
•
Loosen the drive chain (see Drive Chain Slack Adjust-
ment in the Periodic Maintenance chapter).
•
Remove the drive chain from the rear sprocket toward the
right.
•
Disengage the drive chain [A] from the engine sprocket
[B].
•
Pull the engine sprocket off the output shaft [C].
Engine Sprocket Installation
•
Replace the sprocket washer.
•
Install the engine sprocket so that “OUT SIDE” letters [A]
face outward.
•
Apply molybdenum disulfide oil solution to the threads
and the seating surface of the engine sprocket nut.
•
Tighten:
Torque - Engine Sprocket Nut: 125 N·m (12.7 kgf·m, 92.2
ft·lb)
NOTE
○
Tighten the engine sprocket nut while applying the rear
brake.
•
After torquing the engine sprocket nut, bend the one side
of the washer over the nut.
•
Adjust the drive chain slack after installing the engine
sprocket (see Drive Chain Slack Adjustment in the Pe-
riodic Maintenance chapter).
FINAL DRIVE 11-11
Sprocket, Coupling
•
Install:
Dowel Pins [A]
•
Install:
Engine Sprocket Cover [A]
•
Tighten the engine sprocket cover bolts.
First tighten the two bolts [B] at the dowel pin positions.
Engine Sprocket Cover Disassembly
•
Remove:
Engine Sprocket Cover (see Engine Sprocket Removal)
Chain Guide Bolts [A]
Chain Guide [B]
Engine Sprocket Outer Cover Screws [C]
•
Separate the engine sprocket outer cover and inner cover.
Engine Sprocket Cover Assembly
•
Install the engine sprocket outer cover [A] to the inner
cover [B].
•
Tighten:
Torque - Engine Sprocket Outer Cover Screws [C]: 0.70
N·m (0.07 kgf·m, 6.2 in·lb)
•
Install the chain guide [D].
•
Apply a non-permanent locking agent to the threads of
the chain guide bolts [E], and tighten them.
Torque - Chain Guide Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
•
Install:
Engine Sprocket Cover (see Engine Sprocket Installa-
tion)
11-12 FINAL DRIVE
Sprocket, Coupling
Rear Sprocket Removal
•
Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
•
Remove:
Rear Sprocket Nuts [A]
Rear Sprocket [B]
Rear Sprocket Installation
•
Install the sprocket facing the tooth number marking [A]
outward.
•
Replace the rear sprocket nuts with new ones.
•
Tighten the rear sprocket nuts following the specified
tightening sequence.
Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
•
Install the rear wheel (see Rear Wheel Installation in the
Wheels/Tires chapter).
Coupling Installation
•
Apply high-temperature grease to the following.
Coupling Grease Seal Lips [A]
Coupling Internal Surface [B]
FINAL DRIVE 11-13
Sprocket, Coupling
•
Install:
Collar [A]
Coupling [B]
Coupling Bearing Removal
•
Remove:
Coupling
Grease Seal
Circlip [A]
Special Tool - Inside Circlip Pliers: 57001-143
•
Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set [B]: 57001-1129
Coupling Bearing Installation
•
Replace the bearing with a new one.
•
Press in the bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129
•
Replace the circlip with a new one.
Special Tool - Inside Circlip Pliers: 57001-143
•
Replace the grease seal with a new one.
•
Press in the grease seal so that the seal surface is flush
with the end of the hole.
Apply high-temperature grease to the grease seal lip.
Special Tool - Bearing Driver Set: 57001-1129
11-14 FINAL DRIVE
Sprocket, Coupling
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
○
It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
•
Turn the bearing in the coupling back and forth [A] while
checking for plays, roughness or binding.
If the bearing play, roughness or binding is found, replace
the bearing.
•
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Coupling Bearing Lubrication
NOTE
○
Since the coupling bearing is packed with grease and
sealed, lubrication is not required.
Coupling Damper Inspection
•
Remove the rear wheel coupling, and inspect the rubber
dampers [A].
•
Replace the damper if it appears damaged or deterio-
rated.
Sprocket Wear Inspection
•
Visually inspect the engine and rear sprocket teeth for
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
NOTE
○
If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.
FINAL DRIVE 11-15
Sprocket, Coupling
Rear Sprocket Warp Inspection
•
Raise the rear wheel off the ground with the stand so that
it will turn freely.
•
Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard: TIR 0.4 mm (0.016 in.) or less
Service Limit: TIR 0.5 mm (0.020 in.)
BRAKES 12-1
12
Brakes
Table of Contents
Exploded View........................................................................................................................ 12-3
Specifications ......................................................................................................................... 12-10
Special Tools .......................................................................................................................... 12-11
Brake Lever, Brake Pedal....................................................................................................... 12-12
Brake Lever Position Adjustment...................................................................................... 12-12
Brake Pedal Position Inspection ....................................................................................... 12-12
Brake Pedal Position Adjustment...................................................................................... 12-12
Brake Pedal Removal ....................................................................................................... 12-12
Brake Pedal Installation .................................................................................................... 12-13
Calipers .................................................................................................................................. 12-14
Front Caliper Removal ...................................................................................................... 12-14
Rear Caliper Removal....................................................................................................... 12-14
Caliper Installation ............................................................................................................ 12-14
Front Caliper Disassembly................................................................................................ 12-14
Front Caliper Assembly..................................................................................................... 12-15
Rear Caliper Disassembly ................................................................................................ 12-15
Rear Caliper Assembly ..................................................................................................... 12-15
Caliper Fluid Seal Damage Inspection.............................................................................. 12-15
Caliper Dust Seal Damage Inspection .............................................................................. 12-15
Rear Caliper Dust Boot and Friction Boot Damage Inspection......................................... 12-16
Caliper Piston and Cylinder Damage Inspection .............................................................. 12-16
Rear Caliper Holder Shaft Wear Inspection...................................................................... 12-16
Brake Pads ............................................................................................................................. 12-17
Front Brake Pad Removal................................................................................................. 12-17
Front Brake Pad Installation.............................................................................................. 12-17
Rear Brake Pad Removal ................................................................................................ 12-17
Rear Brake Pad Installation .............................................................................................. 12-18
Brake Pad Wear Inspection .............................................................................................. 12-18
Master Cylinder ...................................................................................................................... 12-19
Front Master Cylinder Removal ........................................................................................ 12-19
Front Master Cylinder Installation ..................................................................................... 12-19
Rear Master Cylinder Removal......................................................................................... 12-19
Rear Master Cylinder Installation...................................................................................... 12-20
Front Master Cylinder Disassembly .................................................................................. 12-20
Rear Master Cylinder Disassembly................................................................................... 12-20
Master Cylinder Assembly ................................................................................................ 12-20
Master Cylinder Inspection (Visual Inspection)................................................................. 12-21
Brake Disc .............................................................................................................................. 12-22
Brake Disc Removal ......................................................................................................... 12-22
Brake Disc Installation ...................................................................................................... 12-22
Brake Disc Wear Inspection.............................................................................................. 12-22
Brake Disc Warp Inspection.............................................................................................. 12-23
Brake Fluid ............................................................................................................................. 12-24
Brake Fluid Level Inspection............................................................................................. 12-24
Brake Fluid Change .......................................................................................................... 12-24
Brake Line Bleeding.......................................................................................................... 12-24
Brake Hose............................................................................................................................. 12-28
Brake Hose Removal/Installation...................................................................................... 12-28
Brake Hose and Pipe Inspection....................................................................................... 12-28
Anti-Lock Brake System (Equipped Models) .......................................................................... 12-29
12-2 BRAKES
Parts Location ................................................................................................................... 12-29
ABS Servicing Precautions............................................................................................... 12-33
ABS Troubleshooting Outline............................................................................................ 12-35
Inquiries to Rider............................................................................................................... 12-38
Self-diagnosis Outline ....................................................................................................... 12-40
Self-diagnosis Procedures ................................................................................................ 12-40
Service Code Clearing Procedures................................................................................... 12-41
How to Read Service Codes............................................................................................. 12-44
How to Erase Service Codes ............................................................................................ 12-44
Yellow ABS Indicator (LED) Inspection............................................................................. 12-47
Solenoid Valve Inspection (Service Code 13, 14, 17, 18)................................................. 12-47
ABS Solenoid Valve Relay Inspection (Service Code 19) ................................................ 12-47
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) .............................. 12-48
ABS Motor Relay Inspection (Service Code 35) ............................................................... 12-49
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) .................................. 12-49
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) ................................ 12-50
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)................................... 12-50
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45).................................. 12-51
Power Supply Voltage Abnormal [Low-Voltage] (Service Code 52).................................. 12-51
Power Supply Voltage Abnormal [Over-Voltage] (Service Code 53) ................................ 12-52
ABS Solenoid Valve Relay Supply Voltage Inspection (Low-Voltage) (Service Code 54) 12-52
ECU Inspection (Service Code 55) ................................................................................... 12-52
Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83).......... 12-53
Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code 84) ........... 12-53
Fluid Pressure Sensor Supply Voltage Inspection (Service Code 89) .............................. 12-53
ABS Hydraulic Unit Removal ............................................................................................ 12-53
ABS Hydraulic Unit Installation ......................................................................................... 12-55
ABS Hydraulic Unit Inspection .......................................................................................... 12-55
Front Wheel Rotation Sensor Removal ............................................................................ 12-56
Front Wheel Rotation Sensor Installation ......................................................................... 12-56
Rear Wheel Rotation Sensor Removal ............................................................................. 12-57
Rear Wheel Rotation Sensor Installation .......................................................................... 12-57
Wheel Rotation Sensor Inspection.................................................................................... 12-58
Wheel Rotation Sensor Air Gap Inspection ...................................................................... 12-58
Wheel Rotation Sensor Rotor Inspection.......................................................................... 12-59
ABS Solenoid Valve Relay Fuse (15 A) Removal............................................................. 12-59
ABS Motor Relay Fuse (25 A) Removal ........................................................................... 12-59
Fuse Installation................................................................................................................ 12-59
Fuse Inspection................................................................................................................. 12-60
BRAKES 12-3
Exploded View
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12-4 BRAKES
Exploded View
BRAKES 12-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Front Brake Reservoir Cap Bolts
1.5 0.15 13 in·lb
2 Front Brake Reservoir Inner Bolt 1.2 0.12 11 in·lb L
3 Front Brake Reservoir Bolt 7.8 0.80 69 in·lb L
4 Brake Lever Pivot Bolt 1.0 0.10 8.9 in·lb Si
5 Front Master Cylinder Bleed Valve 5.4 0.55 48 in·lb
6 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
7 Front Brake Light Switch Screw 1.2 0.12 11 in·lb
8 Front Master Cylinder Clamp Bolts 11 1.1 97 in·lb S
9 Brake Hose Banjo Bolts 25 2.5 18
10 Bleed Valves 7.8 0.80 69 in·lb
11 Front Brake Pad Pins 15 1.5 11
12
Front Caliper Mounting Bolts
34 3.5 25
13 Front Brake Disc Mounting Bolts 27 2.8 20
L, S
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease.
12-6 BRAKES
Exploded View
BRAKES 12-7
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Brake Hose Banjo Bolts 25 2.5 18
2 Rear Master Cylinder Mounting Bolts 25 2.5 18
3 Brake Pedal Bolt 8.8 0.90 78 in·lb L
4 Rear Master Cylinder Push Rod Locknut 17 1.7 13
5 Rear Wheel Rotation Sensor Bolt 25 2.5 18
6 Bleed Valve 7.8 0.80 69 in·lb
7 Rear Brake Disc Mounting Bolts 27 2.8 20 L, S
8 Rear Caliper Mounting Bolts 25 2.5 18
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease.
12-8 BRAKES
Exploded View
ABS Equipped Models
BRAKES 12-9
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Brake Hose Banjo Bolts 25 2.5 18
2 Brake Pipe Joint Nuts 18 1.8 13
3 Front Wheel Rotation Sensor Bolt 25 2.5 18
4. ABS Hydraulic Unit
R: Replacement Parts
NOTE
○
When disassembling the brake hose and pipe, disassemble them by the unit as shown in the
exploded view.
12-10 BRAKES
Specifications
Item Standard Service Limit
Brake Lever, Brake Pedal
Brake Lever Position 6-way adjustable (to suit rider) –––
Brake Lever Free Play Non-adjustable –––
Pedal Free Play Non-adjustable –––
Pedal Position
About 62 mm (2.4 in.) bel
ow footpeg top
–––
Brake Pads
Lining Thickness:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 5.0 mm (0.20 in.) 1 mm (0.04 in.)
Brake Discs
Thickness:
Front 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.) 4.5 mm (0.18 in.)
Rear 5.8 ∼ 6.2 mm (0.23 ∼ 0.24 in.) 5.5 mm (0.22 in.)
Runout:
Front TIR 0.15 mm (0.006 in.) or less TIR 0.3 mm (0.01 in.)
Rear TIR 0.15 mm (0.006 in.) or less TIR 0.3 mm (0.01 in.)
Brake Fluid
Grade DOT4 –––
ABS (Equipped Models)
ABS Hydraulic Unit:
Make BOSCH –––
Wheel Rotation Sensor
Air Gap:
Front
0.1 ∼ 2.1 mm (0.004 ∼ 0.083 in.)
–––
Rear
0.1 ∼ 1.7 mm (0.004 ∼ 0.067 in.)
–––
BRAKES 12-11
Special Tools
Jack:
57001-1238
Attachment Jack:
57001-1252
Needle Adapter Set:
57001-1457
Jack Attachment:
57001-1608
12-12 BRAKES
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever adjuster has 6 positions so that the brake
lever position can be adjusted to suit the operator’s hand.
•
Push the lever forward and turn the adjuster [A] to align
the number with the arrow mark [B] on the lever.
The distance from the grip to the lever is minimum at num-
ber 6 and maximum at number 1.
Brake Pedal Position Inspection
•
Check that the brake pedal [A] is in the correct position.
Footpeg [B]
Pedal Position
Standard: About 62 mm (2.4 in.) [C] below top of
footpeg
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
NOTE
○
Usually it is not necessary to adjust the pedal position,
but always adjust it when the push rod locknut has been
loosened.
•
Loosen the locknut [A] and turn the push rod with the hex
head [B] to achieve the correct pedal position.
If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.),the
pedal position will be within the standard range.
•
Tighten:
Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m
(1.7 kgf·m, 13 ft·lb)
•
Check the brake light switch operation (see Brake Light
Switch Operation Inspection in the Periodic Maintenance
chapter).
Brake Pedal Removal
•
Remove:
Right Front Footpeg Bracket Bolts [A]
BRAKES 12-13
Brake Lever, Brake Pedal
•
Remove:
Cotter Pin [A]
Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D]
Brake Pedal Bolt [E] and Washer
Brake Pedal [F]
Brake Pedal Installation
•
Apply grease to the footpeg pivot shaft [A].
•
Install:
Washer [B]
Brake Pedal [C]
Washer [D]
•
Apply a non-permanent locking agent to the threads of
the brake pedal bolt [E], and tighten it.
Torque - Brake Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
•
Hook the shorter end of the rear brake light switch spring
[A] on the brake light switch.
•
Hook the upper end of the return spring [B] on the footpeg
bracket hook.
Face the both lower spring ends forward.
•
Replace the cotter pin [A] with a new one.
•
Insert the cotter pin and bend the pin ends [B].
•
Install the front footpeg bracket.
•
Tighten:
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
•
Check the brake pedal position (see Brake Pedal Position
Inspection).
12-14 BRAKES
Calipers
Front Caliper Removal
•
Remove (ABS Equipped Models):
Bolt [A]
Front Wheel Rotation Sensor [B]
•
Loosen the banjo bolt [C] at the brake hose lower end,
and tighten it loosely.
•
Remove the caliper mounting bolts [D], and detach the
caliper [E] from the disc.
•
Remove the banjo bolt and disconnect the brake hose
from the caliper (see Brake Hose and Pipe Replacement
in the Periodic Maintenance chapter).
NOTICE
Immediately wash away any brake fluid that spills.
Rear Caliper Removal
•
Loosen the banjo bolt [A] at the brake hose lower end,
and tighten it loosely.
•
Remove the caliper mounting bolts [B], and detach the
caliper [C] from the disc.
•
Remove the banjo bolt and disconnect the brake hose [D]
from the caliper.
NOTICE
Immediately wash away any brake fluid that spills.
Caliper Installation
•
Install the caliper and brake hose lower end.
For the front caliper, be sure to install the collars [A] on the
fork leg and fit the holes of the front caliper to the collars.
Replace the washers on each side of hose fitting with new
ones.
Touch the brake hoses to the stopper of the caliper.
•
Tighten:
Torque - Caliper Mounting Bolts
Front: 34 N·m (3.5 kgf·m, 25 ft·lb)
Rear: 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 Brake Line Bleeding).
•
Check the brake for good braking power, no brake drag,
and no fluid leakage.
WARNING
After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.
Front Caliper Disassembly
•
Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
BRAKES 12-15
Calipers
Front Caliper Assembly
•
Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
Rear Caliper Disassembly
•
Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
Rear Caliper Assembly
•
Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
Caliper Fluid Seal Damage Inspection
The fluid seal (piston seal) [A] is placed around the pis-
ton to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the tem-
perature of the discs or the brake fluid to increase.
•
Replace the fluid seal if it exhibits any of the conditions
listed below.
Brake fluid leakage around the pad.
Brakes overheat.
Considerable difference in inner and outer pad wear.
Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.
Caliper Dust Seal Damage Inspection
•
Check that the dust seals [A] are not cracked, worn,
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.
Pistons [B]
Fluid Seals [C]
12-16 BRAKES
Calipers
Rear Caliper Dust Boot and Friction Boot Damage
Inspection
•
Check that the dust boot [A] and friction boot [B] are not
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
Caliper Piston and Cylinder Damage Inspection
•
Visually inspect the pistons [A] and cylinder surfaces [B].
Replace the caliper if the cylinder and piston are badly
scores or rusty.
Rear Caliper Holder Shaft Wear Inspection
The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
perature.
•
Check to see that the caliper holder shafts are not badly
worn or stepped, and that the rubber friction boots are not
damaged.
If the rubber friction boot is damaged, replace the rubber
friction boot. To replace the friction boot, remove the pads
and the caliper bracket.
If the caliper holder shaft is damaged, replace the caliper
holder.
BRAKES 12-17
Brake Pads
Front Brake Pad Removal
•
Loosen the pad pins [A].
•
Remove the front caliper with the hose installed (see Front
Caliper Removal).
•
Remove:
Pad Pins
Brake Pads
Front Brake Pad Installation
•
Check that the pad spring [A] is in place on the caliper.
•
Push the caliper pistons in by hand as far as they will go.
•
Install the brake pads [A] on the pad spring correctly.
Fit the pad into the groove of the caliper as shown.
•
Install the pad pins while pushing the brake pads lightly.
•
Tighten the pad pins temporarily.
•
Install the front caliper (see Caliper Installation).
•
Tighten:
Torque - Front Brake Pad Pins: 15 N·m (1.5 kgf·m, 11 ft·lb)
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
Rear Brake Pad Removal
•
Remove the rear caliper with the hose installed (see Rear
Caliper Removal).
•
Remove:
Clip [A]
Pad Pin [B]
•
Remove the brake pad [C] of the jaw side from the holder
shaft [D], then remove the other pad [E].
12-18 BRAKES
Brake Pads
Rear Brake Pad Installation
•
Check that the pad spring [A], guide [B] and insulator [C]
are in place on the caliper and holder.
•
Push the caliper piston in by hand as far as it will go.
•
Install the brake pad [A] on the piston side first, then install
the other pad on the holder shaft.
Fit the projections [B] of the piston side pad into the re-
cesses [C] of the caliper holder.
•
Install the pad pin while pushing the brake pad of the jaw
side lightly.
•
Replace the clip with a new one.
•
Install a new clip.
•
Install the rear caliper (see Caliper Installation).
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
Brake Pad Wear Inspection
•
Refer to the Brake Pad Wear Inspection in the Periodic
Maintenance chapter.
BRAKES 12-19
Master Cylinder
Front Master Cylinder Removal
•
Remove the rear view mirror (see Rear View Mirror Re-
moval in the Frame chapter).
•
Remove the banjo bolt [A] to disconnect the brake hose
from the master cylinder.
•
Unscrew the clamp bolts [B], and take off the master cylin-
der [C] as an assembly with the reservoir, brake lever, and
brake light switch installed.
•
Disconnect the front brake light switch connector [D].
NOTICE
Immediately wash away any brake fluid that spills.
Front Master Cylinder Installation
•
Install the master cylinder clamp so that the arrow mark
[A] faces upward.
•
Set the front master cylinder to match its mating surface
[B] to the punch mark [C] of the handlebar.
•
Tighten the upper clamp bolt first, and then the lower
clamp bolt.
Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1
kgf·m, 97 in·lb)
•
Connect the front brake light switch connector.
•
Replace the washers that are on each side of the hose
fitting with new ones.
•
Install the brake hose.
Touch the brake hose to the stopper of the front master
cylinder.
•
Tighten:
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
•
Bleed the brake line (see Brake Line Bleeding).
•
Check the brake for good braking power, no brake drag,
and no fluid leakage.
Rear Master Cylinder Removal
•
Remove the brake hose banjo bolt [A] and disconnect the
brake hose.
NOTICE
Immediately wash away any brake fluid that spills.
•
Remove:
Rear Master Cylinder Mounting Bolts [B]
Front Footpeg Bracket Bolts [C]
12-20 BRAKES
Master Cylinder
•
Remove:
Cotter Pin [A]
Joint Pin [B]
•
Slide the clamp [C].
•
Disconnect the reservoir hose lower end, and drain the
brake fluid into a container.
Rear Master Cylinder Installation
•
Replace the cotter pin [A] with a new one.
•
Insert the cotter pin and bend the pin ends [B].
•
Tighten:
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
NOTE
○
Depress the brake pedal [A] and then align the holes of
the master cylinder [B].
○
After installation, check that the rear brake light switch
spring is hooked on the return spring.
•
Replace the washers that are on each side of hose fitting
with new ones.
•
Install the brake hose.
Touch the brake hose to the stopper of the rear master
cylinder.
•
Tighten:
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
•
Bleed the brake line (see Brake Line Bleeding).
•
Check the brake for good braking power, no brake drag,
and no fluid leakage.
Front Master Cylinder Disassembly
•
Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
•
Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.
Master Cylinder Assembly
•
Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.
BRAKES 12-21
Master Cylinder
Master Cylinder Inspection (Visual Inspection)
•
Remove the master cylinders (see Front/Rear Master
Cylinder Removal).
•
Disassemble the front and rear master cylinders (see
Master Cylinder Rubber Parts Replacement in the Peri-
odic Maintenance chapter).
•
Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
•
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cups.
•
Check the dust covers [E] for damage.
If they are damaged, replace them.
•
Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
•
Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Front Master Cylinder [I]
Rear Master Cylinder [J]
12-22 BRAKES
Brake Disc
Brake Disc Removal
•
Remove the wheels (see Front/Rear Wheel Removal in
the Wheels/Tires chapter).
•
Remove the brake disc mounting bolts [A], and take off
the disc [B].
•
Remove the wheel rotation sensor rotor [C] (Front, ABS
equipped models).
Brake Disc Installation
•
Replace the gaskets with new ones.
•
Install the brake disc on the wheel so that the marked side
[A] faces out.
•
Install the wheel rotation sensor rotor on the brake disc
so that the marked side faces out.
•
Apply a non-permanent locking agent to the threads of
the front and rear brake disc mounting bolts.
•
Tighten the front and rear brake disc mounting bolts fol-
lowing the specified tightening sequence.
Front Brake Discs [B]
Rear Brake Disc [C]
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.
If the disc has worn past the service limit, replace it.
MeasuringArea[B]
Brake Discs Thickness
Standard:
Front
4.8
∼ 5.2 mm (0.19 ∼ 0.20 in.)
Rear
5.8
∼ 6.2 mm (0.23 ∼ 0.24 in.)
Service Limit:
Front
4.5 mm (0.18 in.)
Rear
5.5 mm (0.22 in.)
BRAKES 12-23
Brake Disc
Brake Disc Warp Inspection
•
Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238
Attachment Jack: 57001-1252
Jack Attachment: 57001-1608
For front disc inspection, turn the handlebars 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.
If runout exceeds the service limit, replace the disc.
Disc Runout
Standard:
Front
TIR 0.15 mm (0.006 in.) or less
Rear
TIR 0.15 mm (0.006 in.) or less
Service Limit:
Front
TIR 0.3 mm (0.01 in.)
Rear
TIR 0.3 mm (0.01 in.)
12-24 BRAKES
Brake Fluid
Brake Fluid Level Inspection
•
Refer to the Brake Fluid Level Inspection in the Periodic
Maintenance chapter.
Brake Fluid Change
•
Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.
Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake lever or pedal has a soft or
"spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.
NOTE
○
The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
•
Remove:
Front Brake Reservoir Cap Bolts
Front Brake Reservoir Cap
Diaphragm Plate
Diaphragm
Float
•
Fill the reservoir with fresh brake fluid to the upper level
line [A] in the reservoir.
•
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 reservoir.
•
Remove the rubber cap from the bleed valve on the front
master cylinder.
•
Attach a clear plastic hose [A] to the bleed valve, and run
the other end of the hose into a container.
BRAKES 12-25
Brake Fluid
•
Bleed the brake line and the master cylinder.
Repeat 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].
NOTICE
After pumping the brake lever several times, re-
leasing it without opening and closing of the bleed
valve may cause brake fluid to be blown back from
the master cylinder reservoir. Brake fluid spilt
on painted surfaces and plastic parts will quickly
damage them. Be sure to open and close the bleed
valve.
NOTE
○
The 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.
•
Remove the clear plastic hose.
•
Tighten the bleed valve, and install the rubber cap.
Torque - Front Master Cylinder Bleed Valve: 5.4 N·m (0.55
kgf·m, 48 in·lb)
•
Remove the rubber cap from the bleed valve on the
caliper.
•
Attach a clear plastic hose [A] to the bleed valve, and run
the other end of the hose into a container.
12-26 BRAKES
Brake Fluid
•
Bleed the brake line and the caliper.
Repeat 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
○
The 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.
○
Tap the brake hose lightly from the caliper to the reser-
voir for more complete bleeding.
○
Front Brake: First bleeding the right caliper then repeat
the above steps for the left caliper.
•
Remove the clear plastic hose.
•
Install:
Float
Diaphragm
Diaphragm Plate
Front Brake Reservoir Cap
•
Tighten:
Torque - Front Brake Reservoir Cap Bolts: 1.5 N·m (0.15
kgf·m, 13 in·lb)
•
Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
First, tighten the brake fluid reservoir cap [B] clockwise
[C] by hand until slight resistance is felt indicating that
the cap is seated on the reservoir body, then tighten the
cap an additional 1/6 turn [D] while holding the brake fluid
reservoir body [A].
•
Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
•
Check the fluid level (see Brake Fluid Level Inspection in
the Periodic Maintenance chapter).
•
After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.
BRAKES 12-27
Brake Fluid
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
•
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 dete-
riorate.
•
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 of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine
oil, or any other petroleum distillate will cause de-
terioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will
eventually deteriorate the rubber used in the disc
brake.
•
When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets on
the pads or disc with a high flash-point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be
cleaned satisfactorily.
•
Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up im-
mediately.
•
If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THEBRAKELINE.
12-28 BRAKES
Brake Hose
Brake Hose Removal/Installation
•
Refer to the Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter.
Brake Hose and Pipe Inspection
•
Refer to the Brake Hose and Pipe Damage and Instal-
lation Condition Inspection in the Periodic Maintenance
chapter.
BRAKES 12-29
Anti-Lock Brake System (Equipped Models)
Parts Location
Front Wheel Rotation Sensor [A]
Front Wheel Rotation Sensor Rotor [B]
NOTE
○
The rear wheel rotation sensor and rotor are standard
parts of this motorcycle.
Rear Wheel Rotation Sensor [A]
Rear Wheel Rotation Sensor Rotor [B]
Yellow ABS Indicator (LED) [A]
ABS Hydraulic Unit [A]
Fuse Box 2 [A]
12-30 BRAKES
Anti-Lock Brake System (Equipped Models)
ABS Kawasaki Diagnosis System Connector [A]
ABS Self-diagnosis Terminal [B]
BRAKES 12-31
Anti-Lock Brake System (Equipped Models)
ABS System Wiring Diagram
1. ECU
2. Rear Wheel Rotation Sensor
3. Rear Brake Light Switch
4. ABS Hydraulic Unit
5. ABS Self-diagnosis Terminal
6. ABS Kawasaki Diagnosis System Connector
7. Frame Ground 4
8. Frame Ground 1
9. Engine Ground
10. Battery 12 V 10 Ah
11.MainFuse30A
12. Starter Relay
13. Meter Unit
14. Front Wheel Rotation Sensor
15. Ignition Switch
16. Front Brake Light Switch
17. Fuse Box 1
18. Ignition Fuse 15 A
19. Brake Light/Horn Fuse 7.5 A
20. Fuse Box 2
21. ABS Motor Relay Fuse 25 A
22. ABS Solenoid Valve Relay Fuse 15 A
Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green
G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
12-32 BRAKES
Anti-Lock Brake System (Equipped Models)
ABS Hydraulic Unit Terminal Names
1. Ground: BK/BL
2. Unused
3. Front Wheel Rotation Sensor Signal Input: BK/W
4. Power Supply: BR/W
5. ABS Kawasaki Diagnosis System Terminal: P
6. Front and Rear Brake Light Switch Signal: BL/R
7. ABS Self-diagnosis Terminal: GY
8. Front Wheel Rotation Sensor Signal Output: G/Y
9. Power Supply to ABS Solenoid Valve Relay: R/BK
10. Ground to Motor: BK
11. Unused
12. Power Supply to Front Wheel Rotation Sensor: W/BK
13. Power Supply to Rear Wheel Rotation Sensor: W/G
14. Rear Wheel Rotation Sensor Signal Input: BK/O
15. Unused
16. Rear Wheel Rotation Sensor Signal Output: R/Y
17. Yellow ABS Indicator (LED): Y
18. Power Supply to ABS Motor Relay: R/W
BRAKES 12-33
Anti-Lock Brake System (Equipped Models)
ABS Servicing Precautions
There are a number of important precautions that should
be followed servicing the ABS system.
This ABS system is designed to be used with a 12 V
sealed battery as its power source. Do not use any
other battery except for a 12 V sealed battery as a power
source.
Do not reverse the battery cable connections. This will
damage the ABS hydraulic unit.
To prevent damage to the ABS parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is on or while the engine is
running.
Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
Do not turn the ignition switch on while any of the ABS
electrical connectors are disconnected. The ABS hy-
draulic unit memorizes service codes.
Do not spray water on the electrical parts, ABS parts, con-
nectors, leads and wiring.
If a transceiver is installed on the motorcycle, make sure
that the operation of the ABS system is not influenced
by electric wave radiated from the antenna. Locate the
antenna as far as possible away from the ABS hydraulic
unit.
Whenever the ABS electrical connections are to be dis-
connected, first turn off the ignition switch.
The ABS parts should never be struck sharply, as with
a hammer, or allowed to fall on a hard surface. Such a
shock to the parts can damage them.
The ABS parts cannot be disassembled. Even if a fault is
found, do not try to disassemble and repair the ABS parts,
replace it.
The ABS has many brake lines, pipes, and leads. And
the ABS cannot detect problems with the conventional
braking system (brake disc wear, unevenly worn brake
pad, and other mechanical faults). To prevent trouble,
check the brake lines and pipes for correct routing and
connection, the wiring for correct routing, and the brakes
for proper braking power. Be sure to check for fluid leak-
age, and bleed the brake line thoroughly.
12-34 BRAKES
Anti-Lock Brake System (Equipped Models)
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If any of the brake line fittings, including the
ABS hydraulic unit joint nuts, or the bleed valve is
opened at any time, the air must be bled completely
from the brake line. If the brake lever has a soft
or "spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.
NOTICE
Do not ride the motorcycle with air in the brake line,
or the ABS could malfunction.
The yellow ABS indicator (LED) [A] may light if the
tire pressure is incorrect, a non-recommended tire is
installed, or the wheel is deformed. If the indicator light
lights, remedy the problem and clear the service code.
WARNING
Use of non-recommended tires may cause malfunc-
tioning of ABS and can lead to extended braking
distance resulting in an accident causing serious
injury or death. Always use recommended stan-
dard tires for this motorcycle.
BRAKES 12-35
Anti-Lock Brake System (Equipped Models)
The yellow ABS indicator (LED) may come on if the en-
gine is run with the motorcycle on its stand and the trans-
mission in gear. If the indicator comes on, just turn the
ignition switch off, then clear service code 42, which indi-
cates a “Faulty front wheel rotation sensor.”
When the ABS operates, the ABS makes noise and the
rider feels the reaction force on the brake lever and brake
pedal. This is a normal condition. It informs the rider that
the ABS is operating normally.
Service codes detected once by the ABS hydraulic unit
will be memorized in the ABS hydraulic unit. Therefore,
after maintenance work is finished, be sure to erase the
service codes. Do not erase the service codes during
troubleshooting. Wait until all the checks and repair work
are finished to prevent duplication of previous service
codes and unnecessary maintenance work.
Before delivering the motorcycle to the customer, be
sure to erase any service codes which might be stored in
the ABS hydraulic unit. Using the self-diagnosis feature,
make sure that the yellow ABS indicator (LED) lights.
A fully charged battery is a must for conducting reliable
self-diagnosis. Test run the motorcycle at a speed of
more than 20 km/h (12 mph) to see that the yellow ABS
indicator (LED) does not come on. Finally, test run the
motorcycle at a speed of more than 30 km/h (20 mph)
and brake suddenly to see that the motorcycle stops
without loss of steering control and the ABS operates
normally (The reaction force generated is felt in the brake
lever and pedal.). This completes the final inspection.
ABS Troubleshooting Outline
When an abnormality in the system occurs, the yellow
ABS indicator (LED) lights up to alert the rider. In addition,
the nature of the fault is stored in the memory of the ABS
hydraulic unit and when in the self-diagnosis mode, the ser-
vice code [A] is indicated by the number of times the yellow
ABS indicator (LED) blinks. The service codes stored in
memory are not erased until the mode has been changed
to the fault erase mode after the fault has been corrected.
Therefore, after correcting the problem, always erase the
service codes and then run the self-diagnosis program to
confirm normal signal output. When, due to a malfunction,
the yellow ABS indicator (LED) remains lit, get a thorough
understanding of the background before starting the repair
work. Ask the rider about the conditions [B] under which
the problem occurred and try to determine the cause [C].
Do not rely solely on the ABS self-diagnosis function, use
common sense; check the brakes for proper braking power,
and brake fluid level, search for leaks, etc.
12-36 BRAKES
Anti-Lock Brake System (Equipped Models)
Even when the ABS is operating normally, the yellow ABS
indicator (LED) may light up under the conditions listed be-
low. Turn the ignition switch off to stop the indicator light.
If the motorcycle runs without erasing the service code, the
indicator may light up again.
After continuous riding on a rough road.
When the engine is started with the stand raised and the
transmission engaged, and the rear wheel turns.
When accelerating so abruptly that the front wheel leaves
the ground.
When the ABS has been subjected to strong electrical
interference.
When tire pressure is abnormal. Adjust tire pressure.
When a tire different in size from the standard size is being
used. Replace with standard size.
When the wheel is deformed. Replace the wheel.
Much of the ABS troubleshooting work consists of con-
firming continuity of the wiring. The ABS parts are assem-
bled and adjusted by the manufacturer, so there is no need
to disassemble or repair them. Replace the ABS hydraulic
unit.
The basic troubleshooting procedures are listed below.
•
Carry out pre-diagnosis inspections as a preliminary in-
spection.
•
Determine the fault using the self-diagnosis function.
•
Check wiring and connections from the ABS hydraulic unit
connector to the suspected faulty ABS part, using a tester.
•
Visually inspect the wiring for signs of burning or fraying.
If any wiring is poor, replace the damaged wiring.
•
Pull each connector apart and inspect it for corrosion, dirt
and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
•
Check the wiring for continuity.
Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
Connect a tester between the ends of the leads.
If the tester does not read about 0 , the lead is defective.
Replace the main harness [A] if necessary.
•
Narrow down suspicious parts and close in on the faulty
ABS part by repeating the continuity tests.
If no abnormality is found in the wiring or connectors, the
ABS parts are the next likely suspects. Check each part
one by one.
If an abnormality is found, replace the affected ABS part.
BRAKES 12-37
Anti-Lock Brake System (Equipped Models)
ABS Diagnosis Flow Chart
12-38 BRAKES
Anti-Lock Brake System (Equipped Models)
Inquiries to Rider
Each rider reacts to problems in different ways, so it is important to confirm what kind of condition
the rider is dissatisfied with.
Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know-
ing this information may help you reproduce the problem in the shop.
The diagnosis sheet will help prevent you from overlooking any keys, so always use it.
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.):
Year of initial registration: Model:
Engine No.: Frame No.:
Date problem occurred: Frequency:
Weather: Mileage:
Phenomenon Brake lever vibration or noise
Pedal vibration or noise
Yellow ABS indicator (LED) blinks
Yellow ABS indicator (LED) remains lit up
Braking distance too long
Abnormal brake lever movement
Abnormal pedal movement
ABS not working
ABS works but yellow ABS indicator (LED) doesn’t light up
ABS operating too frequently
Engine conditions at
problem
At start-up
After starting
At 5 000 r/min (rpm) or more
Road conditions
Slippery road ( snow, gravel, other )
Rough surface
Other
Driving conditions High-speed cornering
Driving10km/h(6mph)orabove
Driving below 10 km/h (6 mph)
When stopping
When turning
Brake application
Gradual
Abrupt
Other conditions
Large brake lever stroke
Large pedal stroke
BRAKES 12-39
Anti-Lock Brake System (Equipped Models)
Pre-Diagnosis Inspection 1
12-40 BRAKES
Anti-Lock Brake System (Equipped Models)
Pre-Diagnosis Inspection 2
Self-diagnosis Outline
When the yellow ABS indicator light (LED) has blinked or goes on, the ABS hydraulic unit memorizes
and stores the service code (19 codes including “Normal Code”) for the service person to troubleshoot
easily. The service code memory is powered directly by the battery and cannot be canceled by the
ignition switch.
The ABS hydraulic unit can memorize up to 6 service codes. Further service codes are memorized
after erasing the preceding 6 service codes. If there is no fault, only the start code 12 is shown,
indicating that “The ABS is normal”.
Self-diagnosis Procedures
When a problem occurs with the ABS system, the yellow
ABS indicator (LED) [A] lights.
NOTE
○
Use a fully charged battery when conducting
self-diagnosis. Otherwise, the indicator blinks very
slowly or doesn’t blink.
○
The motorcycle is stopped.
○
Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.
BRAKES 12-41
Anti-Lock Brake System (Equipped Models)
•
Remove the front seat (see Front Seat Removal in the
Frame chapter).
•
Ground the self-diagnosis terminal [A] (Gray) to the bat-
tery (–) terminal, using a suitable lead.
•
Turn the ignition switch on.
Count the blinks of the indicator to read the service code.
Keep the auxiliary lead ground until you finish reading the
service code.
Service Code Clearing Procedures
•
Start the service code erase mode with the following pro-
cedure.
The erase mode starts when the ABS self-diagnosis ter-
minal is disconnected from the battery (–) terminal after
starting the self-diagnosis mode.
The service code can be erased by grounding and un-
grounding (each time for at least one second) the ABS
self-diagnosis terminal three times within about 12.5 sec-
onds after starting the erase mode.
The yellow ABS indicator (LED) remains lit during the
erase mode.
After erasing, the yellow ABS indicator (LED) blinks and
lights.
Once erasing is finished, enter the self-diagnosis mode
again to confirm that the service codes have been
erased. If the ABS has been reset and all codes have
been erased, only start code 12 will be shown.
12-42 BRAKES
Anti-Lock Brake System (Equipped Models)
BRAKES 12-43
Anti-Lock Brake System (Equipped Models)
Self-diagnosis Flow Chart
12-44 BRAKES
Anti-Lock Brake System (Equipped Models)
How to Read Service Codes
Service codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED)
as shown below.
Read 10th digit and unit digit as the yellow ABS indicator light (LED) blinks.
When there are a number of faults, a maximum of 6 service codes can be stored and the display
will begin starting from the last service code entered.
For the display pattern, first, start code 12 is shown, next up to 6 service codes starting with the last
one stored, then the display is repeated from the start code once again.
If there is no fault, the yellow ABS indicator (LED) lights as shown.
How to Erase Service Codes
Even if the ignition switch is turned off, the battery or the ABS hydraulic unit are disconnected, all
service codes remain in the ABS hydraulic unit.
Refer to the Service Code Clearing Procedure for the service code erasure.
BRAKES 12-45
Anti-Lock Brake System (Equipped Models)
Service Code Table
Service
Code
Yellow ABS Indicator Light (LED) Problems
Light
State
12 Start code (not fault)
After
starts,
turn off
13
Rear inlet solenoid valve trouble (shorted
or open, stuck valve)
ON
14
Rear outlet solenoid valve trouble (shorted
or open, stuck valve)
ON
17
Front inlet solenoid valve trouble (shorted
or open, stuck valve)
ON
18
Front outlet solenoid valve trouble (shorted
or open, stuck valve)
ON
19
ABS solenoid valve relay trouble (wiring
shorted or open, stuck relay)
ON
25
Front, rear tire abnormal (substandard
tire, deformation wheel, sensor rotor teeth
number wrong)
ON
35
ABS motor relay trouble (wiring shorted,
open or lock, stuck relay)
ON
42
Front wheel rotation sensor signal
abnormal (sensor or rotor missing, too
large clearance, rotor tooth worn or
missing)
ON
43
Front wheel rotation sensor wiring
abnormal (wiring shorted or open)
ON
44
Rear wheel rotation sensor signal
abnormal (sensor or rotor missing, too
large clearance, rotor tooth worn or
missing)
ON
45
Rear wheel rotation sensor wiring
abnormal (wiring shorted or open)
ON
52
Power supply voltage abnormal
(low-voltage)
ON
53
Power supply voltage abnormal
(low-voltage)
ON
54
ABS solenoid valve relay supply voltage
(low voltage)
ON
55
ECU trouble (ECU operation abnormal) ON
83
Output fluid pressure sensor (front brake)
trouble (voltage abnormal, wiring shorted
or open)
ON
12-46 BRAKES
Anti-Lock Brake System (Equipped Models)
Service
Code
Yellow ABS Indicator Light (LED) Problems
Light
State
84
Output fluid pressure sensor (front brake)
trouble (offset abnormal)
ON
89
Power supply voltage for fluid pressure
sensor abnormal (voltage abnormal,
wiring shorted or open)
ON
BRAKES 12-47
Anti-Lock Brake System (Equipped Models)
Yellow ABS Indicator (LED) Inspection
In this model, the yellow ABS indicator (LED) [A] goes on
or blinks by the control of the ABS hydraulic unit.
•
Turn the ignition switch on.
If the yellow ABS indicator (LED) lights, it is normal.
If the yellow ABS indicator (LED) does not light, refer to
the Meter Unit Inspection in the Electrical System chapter.
If the meter is good, check the wiring continuity of the Y
lead in the main harness.
Special Tool - Needle Adapter Set: 57001-1457
Wiring Continuity Inspection
Meter Connector [A]
←→
ABS Hydraulic Unit
Connector [B]
Y Lead [C]
If there is not the continuity in the lead, replace or repair
the main harness.
If there is the continuity in the lead, replace the ABS hy-
drauli
c unit.
Solenoid Valve Inspection (Service Code
13, 14,
17, 18)
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2
, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] light, the solenoid
valve in the ABS hydraulic unit has trouble. Replace the
ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
ABS Solenoid Valve Relay Inspection (Service
Code 19)
•
Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
•
Check the ABS solenoid valve relay fuse (15 A) [A] (see
Fuse Inspection in the Electrical System chapter).
12-48 BRAKES
Anti-Lock Brake System (Equipped Models)
If the fuse is good, check the wiring continuity between
the positive (+) terminal [A] of the battery and R/BK lead
terminal [B] in the ABS hydraulic unit lead connector [C].
If there is not the continuity in the lead, replace or repair
the main harness.
If there is the continuity in the lead, go to next step.
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Front, Rear Wheel Rotation Difference Abnormal
(Service Code 25)
•
Check the following and correct the faulty part.
Incorrect Tire Pressure
Tires not recommended for the motorcycle were installed
(incorrect tire size).
Deformation of Wheel or Tire
Missing Teeth and Clogging with Foreign Matter of Sen-
sor Rotor (see Wheel Rotation Sensor Inspection)
If the all parts correct, recheck the service code indica-
tion; erase the service code, perform the pre-diagnosis
inspection 1 and 2, and retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
BRAKES 12-49
Anti-Lock Brake System (Equipped Models)
ABS Motor Relay Inspection (Service Code 35)
•
Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
•
Check the ABS motor relay fuse (25 A) [A] (see Fuse
Inspection in the Electrical System chapter).
If the fuse is good, check the wiring continuity between
the positive (+) terminal [A] of the battery and R/W lead
terminal [B] in the ABS hydraulic unit lead connector [C].
If there is not the continuity in the lead, replace or repair
the main harness.
If there is the continuity in the lead, go to next step.
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Front Wheel Rotation Sensor Signal Abnormal
(Service Code 42)
•
Measure the air gap between the front wheel rotation sen-
sor and sensor rotor (see Wheel Rotation Sensor Air Gap
Inspection).
•
Check the front wheel rotation sensor (see Wheel Rota-
tion Sensor Inspection).
If both inspections are good, go to next step.
•
Check that there is iron or other magnetic deposits be-
tween the sensor [A] and sensor rotor [B], and the sensor
rotor slots for obstructions.
•
Check the installation condition of the sensor for loose-
ness.
•
Check the sensor rotor tip for deformation or damage
(e.g., chipped sensor rotor teeth).
If the sensor rotor in bad condition, remove the any de-
posits. Install the proper part or replace faulty part.
If the all items are good, go to next step.
12-50 BRAKES
Anti-Lock Brake System (Equipped Models)
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Front Wheel Rotation Sensor Wiring Inspection
(Service Code 43)
•
Disconnect:
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal)
Front Wheel Rotation Sensor Connector (see Front
Wheel Rotation Sensor Removal)
•
Check the wiring continuity of the BK/W lead and W/BK
lead.
Wiring Continuity Inspection
ABS Hydraulic Unit
Connector [A]
←→
Front Wheel Rotation
Sensor Connector [B]
BK/W Lead Terminal [C]
W/BK Lead Terminal [D]
If there is not the continuity in the lead, replace or repair
the main harness.
If the wiring is good, go to next step.
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, replace the
front wheel rotation sensor (see Front Wheel Rotation
Sensor Removal).
Still, when it is not good, replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Rear Wheel Rotation Sensor Signal Abnormal
(Service Code 44)
•
Measure the air gap between the rear wheel rotation sen-
sor and sensor rotor (see Wheel Rotation Sensor Air Gap
Inspection).
•
Check the rear wheel rotation sensor (see Rear Wheel
Rotation Sensor Inspection).
If both inspections are good, go to next step.
BRAKES 12-51
Anti-Lock Brake System (Equipped Models)
•
Check that there is iron or other magnetic deposits be-
tween the sensor [A] and sensor rotor [B], and the sensor
rotor slots for obstructions.
•
Check the installation condition of the sensor for loose-
ness.
•
Check the sensor rotor tip for deformation or damage
(e.g., chipped sensor rotor teeth).
If the sensor rotor in bad condition, remove the any de-
posits. Install the proper part or replace faulty part.
If the all items are good, go to next step.
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Rear Wheel Rotation Sensor Wiring Inspection
(Service Code 45)
•
Disconnect:
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal)
Rear Wheel Rotation Sensor Connector (see Rear
Wheel Rotation Sensor Removal)
•
Check the wiring continuity of the BK/O lead and W/G
lead.
Wiring Continuity Inspection
ABS Hydraulic Unit
Connector [A]
←→
Rear Wheel Rotation
Sensor Connector [B]
BK/O Lead Terminal [C]
W/G Lead Terminal [D]
If there is not the continuity in the lead, replace or repair
the main harness.
If the wiring is good, go to next step.
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, replace the
rear wheel rotation sensor (see Rear Wheel Rotation Sen-
sor Removal).
Still, when it is not good, replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Power Supply Voltage Abnormal [Low-Voltage]
(Service Code 52)
•
Check the battery condition (see Charging Condition In-
spection in the Electrical System chapter).
If the battery is good condition, go to next step.
12-52 BRAKES
Anti-Lock Brake System (Equipped Models)
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Power Supply Voltage Abnormal [Over-Voltage]
(Service Code 53)
•
Check the charging voltage (see Charging Voltage In-
spection in the Electrical System chapter).
If the charging voltage is good, go to next step.
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
ABS Solenoid Valve Relay Supply Voltage
Inspection (Low-Voltage) (Service Code 54)
•
Check the charging voltage (see Charging Voltage In-
spection in the Electrical System chapter).
If the charging voltage is good, go to next step.
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
ECU Inspection (Service Code 55)
•
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not light, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
BRAKES 12-53
Anti-Lock Brake System (Equipped Models)
Output Fluid Pressure Sensor (Front Brake)
Wiring Inspection (Service Code 83)
•
Perform the Pre-Diagnosis Inspection 1 and 2 (see In-
quiries to Rider).
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not lgiht, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Output Fluid Pressure Sensor (Front Brake) Offset
Abnormal (Service Code 84)
•
Perform the Pre-Diagnosis Inspection 1 and 2 (see In-
quiries to Rider).
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not lgiht, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
Fluid Pressure Sensor Supply Voltage Inspection
(Service Code 89)
•
Perform the Pre-Diagnosis Inspection 1 and 2 (see In-
quiries to Rider).
If the yellow ABS indicator (LED) [A] lights, the ABS hy-
draulic unit has trouble. Replace the ABS hydraulic unit.
If the yellow ABS indicator (LED) does not lgiht, ABS sys-
tem is normal (service code is not stored; temporary fail-
ure.).
ABS Hydraulic Unit Removal
NOTICE
The ABS hydraulic unit [A] has been adjusted
and set with precision at the factory. Therefore, it
should be handled carefully, never struck sharply,
as with a hammer, or allowed to fall on a hard
surface.
Be careful not to get water or mud on the ABS hy-
draulic unit.
•
Drain the brake fluid from the front and rear brake lines.
Drain the brake fluid through the bleed valve by pumping
the brake lever and pedal.
12-54 BRAKES
Anti-Lock Brake System (Equipped Models)
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Battery Case (see Battery Case Removal in the Frame
chapter)
•
Clean the ABS hydraulic unit.
NOTICE
Clean all fittings on the ABS hydraulic unit and the
rear master cylinder because dirt around the banjo
bolts could contaminate the brake fluid in the line
during removal/installation.
Spread over a shop towel around the ABS hydraulic
unit before removing the brake line so that brake
fluid does not leak on the parts.
•
Pull the lever [A] backward to disconnect the ABS hy-
draulic unit connector [B].
•
Loosen the brake pipe joint nuts [A] with the flare nut
wrench.
•
Disconnect the brake pipe from the ABS hydraulic unit.
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
•
Clear the radiator overflow hose [A] from the clamp [B].
•
Remove:
Bolts [C]
BRAKES 12-55
Anti-Lock Brake System (Equipped Models)
•
Remove:
Bolts [A]
Bracket [B]
•
Pull up the ABS hydraulic unit [A].
•
Remove:
Bolts [B]
ABS Hydraulic Unit
NOTICE
The ABS hydraulic unit has been adjusted and set
with precision at the factory. Do not try to disas-
semble and repair the ABS hydraulic unit.
ABS Hydraulic Unit Installation
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
•
Installation is the reverse of removal.
•
Be sure to install the dampers [A] and collars [B] on the
bracket [C].
•
Install the brake pipes (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
•
Tighten the brake pipe joint nuts with the flare nut wrench.
Torque - Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)
•
Pull the lever forward to connect the ABS hydraulic unit
connector [A].
•
Bleed the brake line (see Brake Line Bleeding).
•
Check the brake for good braking power, no brake drag,
and no fluid leakage.
ABS Hydraulic Unit Inspection
•
Remove the ABS hydraulic unit (see ABS Hydraulic Unit
Removal).
•
Visually inspect the ABS hydraulic unit.
Replace the ABS hydraulic unit if any of them are cracked,
or otherwise damaged.
12-56 BRAKES
Anti-Lock Brake System (Equipped Models)
•
Visually inspect the connector terminals [A].
Replace the ABS hydraulic unit or main harness if either
of the terminals are cracked, bent, or otherwise damaged.
If the ABS hydraulic unit connector is clogged with mud
or dust, blow it off with compressed air.
Front Wheel Rotation Sensor Removal
NOTICE
The wheel rotation sensor should be handled care-
fully, never struck sharply, as with a hammer, or al-
lowed to fall on a hard surface since the wheel rota-
tion sensor is precision made. Be careful not to get
water or mud on the wheel rotation sensor.
Do not try to disassemble or repair the wheel rota-
tion sensor.
•
Remove the headlight assy (see Headlight Cover Re-
moval in the Frame chapter).
•
Disconnect the front wheel rotation sensor lead connector
[A].
•
Remove the front wheel rotation sensor from the lower
headlight bracket [B].
•
Clear the sensor lead from the clamps [C].
•
Clear the sensor lead from the clamps [A].
•
Remove:
Bolt [B]
Front Wheel Rotation Sensor [C]
Front Wheel Rotation Sensor Installation
•
Installation is the reverse of removal.
•
Tighten:
Torque - Front Wheel Rotation Sensor Bolt: 25 N·m (2.5
kgf·m, 18 ft·lb)
Run the lead correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
BRAKES 12-57
Anti-Lock Brake System (Equipped Models)
Rear Wheel Rotation Sensor Removal
NOTICE
The wheel rotation sensor should be handled care-
fully, never struck sharply, as with a hammer, or al-
lowed to fall on a hard surface since the wheel rota-
tion sensor is precision made. Be careful not to get
water or mud on the wheel rotation sensor.
Do not try to disassemble or repair the wheel rota-
tion sensor.
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
•
Disconnect the rear wheel rotation sensor lead connector
[A].
•
Remove the rear wheel rotation sensor from the connec-
tor bracket [B].
•
Clear the sensor lead from the clamp [C].
•
Clear the sensor lead from the clamps [A].
•
Clear the sensor lead from the clamps [A].
•
Remove:
Bolt [B]
Clamp [C]
Rear Wheel Rotation Sensor [D]
Rear Wheel Rotation Sensor Installation
•
Installation is the reverse of removal.
•
Tighten:
Torque - Rear Wheel Rotation Sensor Bolt: 25 N·m (2.5
kgf·m, 18 ft·lb)
Run the lead correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
12-58 BRAKES
Anti-Lock Brake System (Equipped Models)
Wheel Rotation Sensor Inspection
•
Remove the front wheel rotation sensor [A] from the front
fork.
•
Remove the rear wheel rotation sensor [B] from the
caliper bracket.
•
Visually inspect the wheel rotation sensors.
Replace the wheel rotation sensor if it is cracked, bent, or
otherwise damaged.
Wheel Rotation Sensor Air Gap Inspection
•
Raise the front/rear wheel off the ground (see Front/Rear
Wheel Removal in the Wheels/Tires chapter).
•
Measure the air gap between the sensor and sensor rotor
at several points by turning the wheel slowly.
Thickness Gauge [A]
Air Gap
Standard:
Front
0.1
∼ 2.1 mm (0.004 ∼ 0.083 in.)
Rear
0.1
∼ 1.7 mm (0.004 ∼ 0.067 in.)
NOTE
○
The sensor air gap cannot be adjusted.
If the air gap is not within the specification, inspect the hub
bearing (see Hub Bearing Inspection in the Wheels/Tires
chapter), sensor installation condition and sensor (see
Wheel Rotation Sensor Inspection).
BRAKES 12-59
Anti-Lock Brake System (Equipped Models)
Wheel Rotation Sensor Rotor Inspection
•
Remove:
Wheels (see Front/Rear Wheel Removal in the
Wheels/Tires chapter)
Brake Disc Mounting Bolts [A]
Sensor Rotor [B]
Front Wheel [C]
Rear Wheel [D]
•
Visually inspect the wheel rotation sensor rotor.
If the rotor is deformed or damaged (chipped teeth [A]),
replace the sensor rotor with a new one.
If there is iron or other magnetic deposits [B], remove the
deposits.
ABS Solenoid Valve Relay Fuse (15 A) Removal
•
Refer to the Fuse Box Fuse Removal in the Electrical Sys-
tem chapter.
ABS Motor Relay Fuse (25 A) Removal
•
Refer to the Fuse Box Fuse Removal in the Electrical Sys-
tem chapter.
Fuse Installation
•
If a fuse fails during operation, inspect the electrical sys-
tem to determine the cause, and then replace it with a
new fuse of proper amperage (see Fuse Installation in the
Electrical System chapter).
12-60 BRAKES
Anti-Lock Brake System (Equipped Models)
Fuse Inspection
•
Remove the fuses (see ABS Solenoid Valve Relay Fuse
(15 A)/ABS Motor Relay Fuse (25 A) Removal).
•
Refer to the Fuse Inspection in the Electrical System
chapter.
SUSPENSION 13-1
13
Suspension
Table of Contents
Exploded View........................................................................................................................ 13-2
Specifications ......................................................................................................................... 13-6
Special Tools .......................................................................................................................... 13-7
Front Fork ............................................................................................................................... 13-9
Rebound Damping Force Adjustment............................................................................... 13-9
Compression Damping Force Adjustment ........................................................................ 13-9
Spring Preload Adjustment ............................................................................................... 13-10
Front Fork Removal (Each Fork Leg) ............................................................................... 13-10
Front Fork Installation (Each Fork Leg) ............................................................................ 13-10
Front Fork Oil Change ...................................................................................................... 13-12
Front Fork Disassembly .................................................................................................... 13-20
Front Fork Assembly......................................................................................................... 13-20
Inner Tube Inspection ....................................................................................................... 13-21
Dust Seal Inspection ......................................................................................................... 13-21
Spring Tension Inspection................................................................................................. 13-22
Rear Shock Absorber ............................................................................................................. 13-23
Rebound Damping Force Adjustment............................................................................... 13-23
Spring Preload Adjustment ............................................................................................... 13-23
Rear Shock Absorber Removal ........................................................................................ 13-24
Rear Shock Absorber Installation ..................................................................................... 13-25
Rear Shock Absorber Inspection ...................................................................................... 13-25
Rear Shock Absorber Scrapping ...................................................................................... 13-25
Rear Shock Absorber Bearing Removal ........................................................................... 13-26
Rear Shock Absorber Bearing Installation ........................................................................ 13-26
Swingarm................................................................................................................................ 13-27
Swingarm Removal........................................................................................................... 13-27
Swingarm Installation........................................................................................................ 13-28
Swingarm Bearing Removal ............................................................................................. 13-29
Swingarm Bearing Installation .......................................................................................... 13-29
Swingarm Bearing, Sleeve Inspection .............................................................................. 13-30
Swingarm Bearing Lubrication .......................................................................................... 13-30
Chain Guide Inspection..................................................................................................... 13-30
Tie-Rod, Rocker Arm.............................................................................................................. 13-31
Tie-Rod Removal .............................................................................................................. 13-31
Tie-Rod Installation ........................................................................................................... 13-31
Rocker Arm Removal........................................................................................................ 13-31
Rocker Arm Installation..................................................................................................... 13-32
Tie-Rod and Rocker Arm Bearing Removal...................................................................... 13-33
Tie-Rod and Rocker Arm Bearing Installation................................................................... 13-33
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection ............................................................. 13-34
Rocker Arm/Tie-Rod Bearing Lubrication ......................................................................... 13-34
13-2 SUSPENSION
Exploded View
SUSPENSION 13-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Upper Front Fork Clamp Bolts
20 2.0 15
2 Lower Front Fork Clamp Bolts 23 2.3 17 AL
3 Front Fork Top Plugs 35 3.6 26
4
Piston Rod Guide Case
90 9.2 66
5 Front Axle Clamp Bolts 20 2.0 15 AL
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
R: Replacement Parts
13-4 SUSPENSION
Exploded View
SUSPENSION 13-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Upper Rear Shock Absorber Bolt
34 3.5 25
2 Swingarm Pivot Shaft Nut 108 11.0 79.7
3 Swingarm Pivot Shaft 20 2.0 15
4 Swingarm Pivot Adjusting Collar Locknut 98 10.0 72
5 Tie-Rod Nuts 34 3.5 25 R
6 Lower Rear Shock Absorber Nut 34 3.5 25 R
7 Rocker Arm Nut 34 3.5 25 R
8 Torque Link Nuts 34 3.5 25
G: Apply grease.
R: Replacement Parts
13-6 SUSPENSION
Specifications
Item Standard
Front Fork (Per One Unit)
Fork Inner Tube Diamete
r
41 mm (1.6 in.)
Air Pressure Atmospheric pressure (Non-adjustable)
Rebound Damper Setting 2 1/2 turns out from the fully clockwise position
(Usable Range: 0 5 1/2 turns out)
Compression Damper Setting 4 1/2 turns out from the fully clockwise position
(Usable Range: 0 7 turns out)
Fork Spring Preload Setting 6 1/4 turns in from the fully counterclockwise position
(Usable Range: 0 20 turns in)
Suspension Oil Kawasaki SS-47 or equivalent
Amount:
Right Front Fork
Approx. 430 mL (14.5 US oz.) (when changing oil)
503 ±2.5 mL (17.0 ±0.085 US oz.) (after disassembly and
completely dry)
Left Front Fork Approx. 440 mL (14.9 US oz.) (when changing oil)
518 ±2.5 mL (17.5 ±0.085 US oz.) (after disassembly and
completely dry)
Oil Level:
Right Front Fork 77 ±2 mm (3.03 ±0.08 in.) (fully compressed, below from
the top of outer tube)
Left Front Fork 73 ±2 mm (2.87 ±0.08 in.) (fully compressed, below from
the top of outer tube)
Fork Spring Free Length 267.7 mm (10.54 in.) (Service Limit: 262 mm (10.3 in.))
Rear Shock Absorber
Rebound Damper Setting 3/4 turns out from the fully clockwise position
(Usable Range: 0 2 1/2 turns out)
Spring Preload Setting Position:
Standard Spring length: 185.3 mm (7.295 in.)
Usable Range
Spring length: 180.3 ∼ 188.3 mm (7.098 ∼ 7.413 in.)
(stronger to weaker)
Gas Pressure 980 kPa (10.0 kgf/cm², 142 psi, Non-adjustable)
SUSPENSION 13-7
Special Tools
Inside Circlip Pliers:
57001-143
Oil Seal & Bearing Remover:
57001-1058
Bearing Driver Set:
57001-1129
Jack:
57001-1238
Fork Oil Seal Driver, 41:
57001-1288
Fork Oil Level Gauge:
57001-1290
Hook Wrench T=3.2 R37:
57001-1539
Swingarm Pivot Nut Wrench:
57001-1597
Jack Attachment:
57001-1608
Needle Bearing Driver, 17/ 18:
57001-1609
13-8 SUSPENSION
Special Tools
Needle Bearing Driver, 28:
57001-1610
TopPlugWrench(45mm):
57001-1741
Rod Guide Case Wrench, 33 mm:
57001-1744
Fork Oil Seal Driver Weight, 26 ∼ 46:
57001-1795
Fork Oil Seal Driver Attachment, 36 ∼ 46:
57001-1798
SUSPENSION 13-9
Front Fork
Rebound Damping Force Adjustment
•
To adjust the rebound damping force, turn the rebound
damping force adjuster [A].
The standard adjuster setting is the 21/2turnsoutfrom
the fully clockwise position.
The 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
Position
Damping
Force
Setting
Load Road
Speed
51/2
turns out
Weak Soft Light Good Low
0 Strong Hard Heavy Bad High
Compression Damping Force Adjustment
•
To adjust the compression damping force, turn the com-
pression damping force adjuster [A].
The standard adjuster setting is the 41/2turnsoutfrom
the fully clockwise position.
The 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
Adjuster
Position
Damping
Force
Setting
Load Road
Speed
7 turns out
Weak Soft Light Good Low
0 Strong Hard Heavy Bad High
13-10 SUSPENSION
Front Fork
Spring Preload Adjustment
•
To adjust the spring preload, turn the spring preload ad-
juster [A].
The standard adjuster setting is the 61/4turnsinfrom
the fully counterclockwise position.
The 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
Load Road
Speed
0 Weak
Soft
Light
Good
Low
20 turns in
Strong
Hard Heavy Bad High
Front Fork Removal (Each Fork Leg)
•
Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
If fork leg is to be disassembled, loosen the upper and
lower front fork clamp bolts to lower the fork leg [A] as
shown. And retighten the lower front fork clamp bolts.
Then, loosen the top plug [B] beforehand.
Special Tool - Top Plug Wrench (45 mm) [C]: 57001-1741
Loosen the lower front fork clamp bolts.
•
Loosen:
Upper Front Fork Clamp Bolt [A]
Lower Front Fork Clamp Bolts [B]
•
With a twisting motion, work the fork leg down and out.
Front Fork Installation (Each Fork Leg)
Tighten the front fork top plug to the specified torque if the
front fork top plug is removed.
Torque - Front Fork Top Plugs: 35 N·m (3.6 kgf·m, 26 ft·lb)
SUSPENSION 13-11
Front Fork
NOTE
○
Tighten the front fork top plug before tightening the han-
dlebar clamp bolt and upper front fork clamp bolt.
○
The torque of front fork top plug is specified to 35 N·m
(3.6 kgf·m, 26 ft·lb) however, when you use the top
plug wrench (special tool: 57001-1741) [A], reduce the
torque to 90% of the specified value [31 N·m (3.2 kgf·m,
23 ft·lb)] due to the distance [B] between the center of
the square hole, where the torque wrench is fitted, and
that of the octagonal hole of the wrench.
○
This torque value [31 N·m (3.2 kgf·m, 23 ft·lb)] is ap-
plicable when you use a torque wrench whose length
[C] gives leverage of approximately 310 mm (12.2 in.)
between the grip point [D] to the center of the coupling
square.
○
To obtain the correct tightening torque with your torque
wrench, you need to calculate as follows.
Formula:
a×b÷(b+c)=d
[a] Specified torque
[b] Length from center of square hole to grip point
[c]Offset=44mm
[d] Tightening torque
For an example:
35 N·m × 310 ÷ (310 + 44) = 31 N·m
•
Install the fork so that the top end [A] of the outer tube as
shown.
9 mm (0.35 in.) [B]
Steering Stem Head [C]
•
Tighten:
Torque - Lower Front Fork Clamp Bolts: 23 N·m (2.3 kgf·m,
17 ft·lb)
NOTE
○
Tighten the two lower front fork clamp bolts alternately
two times to ensure even tightening torque.
•
Tighten:
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
•
Install the removed parts (see appropriate chapters).
•
Adjust:
Spring Preload (see Spring Preload Adjustment)
Rebound Damping Force (see Rebound Damping Force
Adjustment)
Compression Damping Force (see Compression Damp-
ing Force Adjustment)
13-12 SUSPENSION
Front Fork
Front Fork Oil Change
Right Front Fork
•
Remove the front fork (see Front Fork Removal (Each
Fork Leg)).
•
Hold the inner tube lower end in a vise.
•
Using the wrench [A], unscrew the top plug [B] out of the
outer tube.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Holding the piston rod nut with a wrench [A], remove the
top plug [B] from the piston rod.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Remove:
Rebound Damping Adjuster Rod (Inside) [A]
Compression Damping Adjuster Rod (Outside) [B]
Piston Rod Nut [C]
•
Using the rod guide case wrench [A], remove the piston
rod guide case from the inner tube.
Special Tool - Rod Guide Case Wrench, 33 mm: 57001
-1744
NOTICE
A socket of piston rod guide case is shallow (4 mm)
and therefore be sure to check that the wrench
(Special Tool: 57001-1744) is securely seated on
the piston rod guide case.
When loosening the piston rod guide case. If the
wrench is not securely seated on it, the piston rod
guide case may break.
SUSPENSION 13-13
Front Fork
•
Remove:
Piston Rod Assy [A]
Collar [B]
Fork Spring [C]
•
Drain the fork oil into a suitable container [A].
Pump the inner tube up and down at least 10 times to
expel the oil from the fork.
•
Install:
Fork Spring [A]
•
Install the collar [B] so that the large diameter side faces
downward.
•
Hold the fork tube upright, press the outer tube.
•
Pour in the type and amount of fork oil specified.
Pour the fork oil until the upper of the inner tube hole [A].
Suspension Oil - SS-47 (1 L): 44091-0010
Amount:
When changing oil:
Approx. 430 mL (14.5 US oz.)
After disassembly and completely dry:
503 ±2.5 mL (17.0 ±0.085 US oz.)
•
Move the inner tube up and down more than 10 times in
order to expel the air from the fork oil.
•
Install the piston rod assy and piston rod guide case into
the inner tube.
NOTE
○
Lifting the outer tube, and install the piston rod guide
case.
NOTICE
When inserting, be careful not to damage the piston
ring [A].
13-14 SUSPENSION
Front Fork
•
Hold the inner tube bottom by a vise.
•
Using the rod guide case wrench [A], tighten the piston
rod guide case to the inner tube.
Special Tool - Rod Guide Case Wrench, 33 mm: 57001
-1744
Torque - Piston Rod Guide Case: 90 N·m (9.2 kgf·m, 66 ft·lb)
NOTE
○
The tightening torque of the piston rod guide case is
specified to 90 N·m (9.2 kgf·m, 66 ft·lb), however in use
of the rod guide case wrench (special tool: 57001-1744)
[A] you reduce the torque to about 90% of the specified
value [81 N·m (8.3 kgf·m, 60 ft·lb)] due to the offset [B]
of the wrench square hole.
○
This torque value [81 N·m (8.3 kgf·m, 60 ft·lb)] is appli-
cable when you use a wrench whose length [C] gives
leverage of approximately 450 mm (17.7 in.) between
the grip point [D] to the center of the coupling square.
○
To obtain the correct tightening torque with your torque
wrench, you need to calculate as follows.
Formula:
a×b÷(b+c)=d
[a] Specified torque
[b] Length from center of square hole to grip point
[c]Offset=50mm
[d] Tightening torque
For an example:
90 N·m × 450 ÷ (450 + 50) = 81 N·m
NOTICE
A socket of piston rod guide case is shallow (4 mm)
and therefore be sure to check that the wrench
(Special Tool: 57001-1744) is securely seated on
the piston rod guide case.
When tightening the piston rod guide case. If the
wrench is not securely seated on it, the piston rod
guide case may break.
•
Install the piston rod nut [A] until it is bottomed.
•
Install:
Compression Damping Adjuster Rod (Outside) [B]
Rebound Damping Adjuster Rod (Inside) [C]
SUSPENSION 13-15
Front Fork
•
Replace the O-ring [A] with a new one.
•
Apply grease to the new O-ring.
•
Install the top plug [B] to the piston rod.
•
Holdingthetopplugwithawrench[C],tightenthepiston
rod nut against the top plug.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Pour the fork oil of the remainder until the upper [A] of the
piston rod guide case [B].
•
Move the piston rod assy up and down more than 10 times
in order to expel all the air from the fork oil.
•
Move the outer tube up and down more than 10 times in
order to expel all the air from the fork oil.
•
Measure the oil level as follows.
Hold the inner tube vertically in a vise.
Wait until the oil level settles.
With the fork fully compressed, insert a tape measure or
rod into the piston rod guide case [A], and measure the
distance [B] from the top [C] of the outer tube [D] to the
oil.
Oil Level (fully compressed)
Standard: 77 ±2 mm (3.03 ±0.08 in.)
NOTE
○
Fork oil level may also be measured using the fork oil
level gauge [E].
Special Tool - Fork Oil Level Gauge: 57001-1290
Pull the handle slowly to pump out the excess oil until the
oil no longer comes out.
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.
•
Lift the outer tube.
•
Using the wrench, tighten the top plug temporary.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Install the front fork (see Front Fork Installation (Each Fork
Leg)).
NOTE
○
After installing the front fork, adjust the damping force
correctly.
13-16 SUSPENSION
Front Fork
Left Front Fork
•
Remove the front fork (see Front Fork Removal (Each
Fork Leg)).
•
Turn the spring preload adjuster fully counterclockwise for
removing the piston rod assy easily.
•
Hold the inner tube lower end in a vise.
•
Using the wrench [A], unscrew the top plug [B] out of the
outer tube.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Holding the piston rod nut with a wrench [A], remove the
top plug [B] from the piston rod.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Remove:
Spring Preload Adjuster Rod [A]
Piston Rod Nut [B]
•
Using the rod guide case wrench [A], remove the piston
rod guide case from the inner tube.
Special Tool - Rod Guide Case Wrench, 33 mm: 57001
-1744
NOTICE
A socket of piston rod guide case is shallow (4 mm)
and therefore be sure to check that the wrench
(Special Tool: 57001-1744) is securely seated on
the piston rod guide case.
When loosening the piston rod guide case. If the
wrench is not securely seated on it, the piston rod
guide case may break.
SUSPENSION 13-17
Front Fork
•
Remove:
Piston Rod [A]
Collar [B]
Fork Spring [C]
•
Drain the fork oil into a suitable container [A].
Pump the inner tube up and down at least 10 times to
expel the oil from the fork.
•
Install:
Fork Spring [A]
•
Install the collar [B] so that the large diameter side faces
downward.
•
Hold the fork tube upright, press the outer tube.
•
Pour in the type and amount of fork oil specified.
Pour the fork oil until the upper of the inner tube hole [A].
Suspension Oil - SS-47 (1 L): 44091-0010
Amount:
When changing oil:
Approx. 440 mL (14.9 US oz.)
After disassembly and completely dry (Total):
518 ±2.5 mL (17.5 ±0.085 US oz.)
•
Move the inner tube up and down more than 10 times in
order to expel the air from the fork oil.
13-18 SUSPENSION
Front Fork
•
Insert the piston rod into the inner tube.
•
Hold the inner tube bottom by a vise.
•
Using rod guide case wrench [A], tighten the piston rod
guide case to the inner tube.
Special Tool - Rod Guide Case Wrench, 33 mm: 57001
-1744
Torque - Piston Rod Guide Case: 90 N·m (9.2 kgf·m, 66 ft·lb)
NOTE
○
The tightening torque of the piston rod guide case is
specified to 90 N·m (9.2 kgf·m, 66 ft·lb), however in use
of the rod guide case wrench (special tool: 57001-1744)
[A] you reduce the torque to about 90% of the specified
value [81 N·m (8.3 kgf·m, 60 ft·lb)] due to the offset [B]
of the wrench square hole.
○
This torque value [81 N·m (8.3 kgf·m, 60 ft·lb)] is appli-
cable when you use a wrench whose length [C] gives
leverage of approximately 450 mm (17.7 in.) between
the grip point [D] to the center of the coupling square.
○
To obtain the correct tightening torque with your torque
wrench, you need to calculate as follows.
Formula:
a×b÷(b+c)=d
[a] Specified torque
[b] Length from center of square hole to grip point
[c]Offset=50mm
[d] Tightening torque
For an example:
90 N·m × 450 ÷ (450 + 50) = 81 N·m
NOTICE
A socket of piston rod guide case is shallow (4 mm)
and therefore be sure to check that the wrench
(Special Tool: 57001-1744) is securely seated on
the piston rod guide case.
When tightening the piston rod guide case. If the
wrench is not securely seated on it, the piston rod
guide case may break.
•
Install the piston rod nut [A] until it is bottomed.
•
Install:
Spring Preload Adjuster Rod [B]
SUSPENSION 13-19
Front Fork
•
Replace the O-ring [A] with a new one.
•
Apply grease to the new O-ring.
•
Install the top plug [B] to the piston rod.
•
Holding the top plug with the wrench [C], tighten the piston
rod nut against the top plug.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Pour the fork oil of the remainder until the upper [A] of the
piston rod guide case [B].
•
Move the piston rod assembly up and down more than 10
times in order to expel all the air from the fork oil.
•
Move the outer tube up and down more than 10 times in
order to expel all the air from the fork oil.
•
Measure the oil level as follows.
Hold the inner tube vertically in a vise.
Wait until the oil level settles.
With the fork fully compressed, insert a tape measure or
rod into the piston rod guide case [A], and measure the
distance [B] from the top [C] of the outer tube [D] to the
oil.
Fork Oil Level (fully compressed)
Standard: 73 ±2 mm (2.87 ±0.08 in.)
NOTE
○
Fork oil level may also be measured using the fork oil
level gauge [E].
Special Tool - Fork Oil Level Gauge: 57001-1290
Pull the handle slowly to pump out the excess oil until the
oil no longer comes out.
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.
•
Lift the outer tube.
•
Using the wrench, tighten the top plug temporary.
Special Tool - Top Plug Wrench (45 mm): 57001-1741
•
Install the front fork (see Front Fork Installation (Each Fork
Leg)).
NOTE
○
After installing the front fork, adjust the spring preload
correctly.
13-20 SUSPENSION
Front Fork
Front Fork Disassembly
•
Remove the front fork (see Front Fork Removal (Each
Fork Leg)).
•
Drain the fork oil (see Front Fork Oil Change).
•
Remove the dust seal [A] from the outer tube.
•
Remove the circlip [B].
Special Tool - Inside Circlip Pliers: 57001-143
•
Separate the outer tube from the inner tube.
•
Remove the following parts from the inner tube.
Slide Bushing [A]
Guide Bushing [B]
Washer [C]
Oil Seal [D]
Circlip [E]
Dust Seal [F]
Front Fork Assembly
•
Replace the following parts with new ones.
Slide Bushing
Guide Bushing
Oil Seal
Circlip
•
Install the following parts to the inner tube [A].
Dust Seal [B]
Circlip [C]
Special Tool - Inside Circlip Pliers: 57001-143
•
Apply grease to the oil seal lips.
•
Install the oil seal [A] so that the stamp side faces lower
side.
•
Install the washer [B].
•
Install the guide bushing [C] so that the slit of it is posi-
tioned perpendicular to the traveling direction.
•
Install the slide bushing [D] so that the slit of it is positioned
perpendicular to the traveling direction.
•
Apply grease to the slide and guide bushings and oil seal.
SUSPENSION 13-21
Front Fork
•
Insert the inner tube to the outer tube.
•
After installing the washer, install the oil seal [A] by using
the fork oil seal driver [B].
Special Tools - Fork Oil Seal Driver,
41: 57001-1288
or Fork Oil Seal Driver Weight,
26 ∼ 46:
57001-1795
Fork Oil Seal Driver Attachment,
36 ∼ 46:
57001-1798
•
Install the circlip and dust seal.
Special Tool - Inside Circlip Pliers: 57001-143
•
Pour in the specified type of oil (see Front Fork Oil
Change).
Inner Tube Inspection
•
Visually inspect the inner tube [A].
If there is any damage, replace the inner tube. Since
damage to the inner tube damages the oil seal and dust
seal, replace the oil seal and dust seal whenever the inner
tube is replaced.
NOTICE
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
•
Temporarily assemble the inner tube [A] and outer tube
[B], and pump [C] them back and forth manually to check
for smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident resulting in seri-
ous injury or death. Replace a badly bent or dam-
aged inner or outer tube and inspect the other tube
carefully before reusing it.
Dust Seal Inspection
•
Inspect the dust seals [A] for any signs of deterioration or
damage.
Replace it if necessary.
13-22 SUSPENSION
Front Fork
Spring Tension Inspection
•
Since a spring becomes shorter as it weakens, check its
free length [A] to determine its condition.
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 stability.
Spring Free Length
Standard: 267.7 mm (10.54 in.)
Service Limit: 262 mm (10.3 in.)
SUSPENSION 13-23
Rear Shock Absorber
Rebound Damping Force Adjustment
•
To adjust the rebound damping force, turn the rebound
damping force adjuster [A] to the desired position.
The standard adjuster setting is the 3/4 turns out from
the fully clockwise position.
Rebound Damping Force Adjustment
Adjuster
Position
Damping
Force
Setting
Load Road
Speed
21/2turns
out
Weak
Soft
Light
Good
Low
0
Strong
Hard Heavy Bad High
Spring Preload Adjustment
When rear shock absorber is removed:
•
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 T=3.2 R37: 57001-1539
•
To adjust the spring preload, turn in the adjusting nut [A]
to the desired position and tighten the locknut [B].
Spring Length [C]
Spring Preload Setting
Standard: Spring length 185.3 mm (7.295 in.)
Usable Range:
Spring length 180.3
∼ 188.3 mm (7.098
∼ 7.413 in.)
When rear shock absorber is installed:
•
Remove:
Muffler Body Mounting Bolt [A] and Nut (Both Sides)
Front Footpeg Bracket Bolts [B] (Both Sides)
Front Footpeg Bracket [C] (Both Sides)
13-24 SUSPENSION
Rear Shock Absorber
•
To adjust the spring preload, turn in the adjusting nut to
the desired position and tighten the locknut by using hook
wrenches [A] with the rear shock absorber attached the
frame.
Special Tool - Hook Wrench T=3.2 R37: 57001-1539
If the spring action feels too soft or too stiff, adjust it.
Spring Adjustment
Adjuster
Position
Damping
Force
Setting
Load Road
Speed
188.3 mm
(7.413 in.)
Weak
Soft
Light
Good
Low
180.3 mm
(7.098 in.)
Strong Hard Heavy Bad High
Rear Shock Absorber Removal
•
Support the motorcycle with the stand.
•
Remove:
Side Stand Bracket Bolts [A]
Side Stand Bracket [B] with Side Stand
•
Squeeze the brake lever slowly and hold it with a band
[A].
•
Remove the exhaust pipe cover (see Muffler Body Re-
moval in the Engine Top End chapter).
•
Raise the rear wheel off the ground with the jack.
Special Tools - Jack [A]: 57001-1238
Jack Attachment [B]: 57001-1608
WARNING
When raising the rear wheel off the ground with the
jack and removing part(s) from the motorcycle, be
sure to hold the front brake, or the motorcycle may
fall over. It could cause an accident and injury.
SUSPENSION 13-25
Rear Shock Absorber
•
Remove:
Lower Rear Shock Absorber Nut and Bolt [A]
Upper Rear Shock Absorber Bolt [B]
•
Remove the rear shock absorber [C] rearward.
Rear Shock Absorber Installation
•
Replace the rear shock absorber nuts with new ones.
•
Install the rear shock absorber so that the rebound damp-
ing force adjuster faces rightward.
•
Tighten:
Torque - Upper Rear Shock Absorber Bolt: 34 N·m (3.5
kgf·m, 25 ft·lb)
Lower Rear Shock Absorber Nut: 34 N·m (3.5
kgf·m, 25 ft·lb)
•
Install the removed parts (see appropriate chapters).
Rear Shock Absorber Inspection
•
Remove the rear shock absorber (see Rear Shock Ab-
sorber Removal).
•
Visually inspect the following items.
Oil Leakage
Crack or Dent
If there is any damage to the rear shock absorber, replace
it.
•
Visually inspect the rubber bushing.
If it show any signs of damage, replace it.
Rear Shock Absorber Scrapping
WARNING
Since the rear shock absorber contains nitrogen
gas, do not incinerate the rear shock absorber with-
out first releasing the gas or it may explode. Before
a rear shock absorber is scrapped, drill a hole at the
point [A] shown to release the nitrogen gas com-
pletely. Wear safety glasses when drilling the hole,
as the gas may blow out bits of drilled metal when
the hole opens.
13-26 SUSPENSION
Rear Shock Absorber
Rear Shock Absorber Bearing Removal
•
Remove:
Rear Shock Absorber (see Rear Shock Absorber Re-
moval)
Sleeve [A]
Grease Seals [B]
•
Remove the needle bearing, using a suitable tool.
Rear Shock Absorber Bearing Installation
•
Replace the needle bearing [A] and grease seals [B] with
new ones.
•
Install the needle bearing position as shown.
7.5 mm (0.30 in.) [C]
•
Apply plenty of grease to the lips of the grease seals.
•
Install the grease seals and sleeve [D].
SUSPENSION 13-27
Swingarm
Swingarm Removal
•
Remove:
Rear Brake Hose Lower End (see Rear Caliper Removal
in the Brakes chapter)
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Mud Guard (see Mud Guard Removal in the Frame
chapter)
Chain Cover (see Drive Chain Replacement in the Final
Drive chapter)
Rocker Arm (see Rocker Arm Removal)
•
Remove:
Cotter Pin [A]
Torque Link Bolt and Nut [B]
Torque Link [C]
•
Remove:
Brake Hose Clamp Bolt [A]
•
Clear the brake hose [B] from the guide [C] on the
swingarm.
•
Remove the swingarm pivot shaft nut [A].
•
Using the swingarm pivot nut wrench [A], loosen the
swingarm pivot adjusting collar locknut [B].
Special Tool - Swingarm Pivot Nut Wrench: 57001-1597
13-28 SUSPENSION
Swingarm
•
Turn the swingarm pivot shaft [A] counterclockwise to free
the adjusting collar from the swingarm.
Make the gap between the adjusting collar and swingarm.
•
Pull out the pivot shaft to the right side and remove the
swingarm.
Swingarm Installation
•
Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.
•
Apply grease to the lips of the grease seals [A].
•
Be sure to install the grease seals and sleeve [B] to the
swingarm.
•
Fit the collar [C] on the grease seal of the left side.
•
Screw the adjusting collar [A] into the frame [B] so that the
collar does not project the swingarm mating surface [C].
•
Install the swingarm and insert the swingarm pivot shaft
[A] into the adjusting collar [B] from the right side, and
tighten the pivot shaft.
NOTE
○
Tighten the swingarm pivot shaft until the clearance [C]
between the ball bearing [D] and collar comes to 0 mm
(0 in.).
Torque - Swingarm Pivot Shaft: 20 N·m (2.0 kgf·m, 15 ft·lb)
•
Using the swingarm pivot nut wrench, tighten the
swingarm pivot adjusting collar locknut [E].
Special Tool - Swingarm Pivot Nut Wrench: 57001-1597
Torque - Swingarm Pivot Adjusting Collar Locknut: 98 N·m
(10.0 kgf·m, 72 ft·lb)
SUSPENSION 13-29
Swingarm
•
Tighten the swingarm pivot shaft nut.
Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m,
79.7 ft·lb)
•
Move the swingarm up and down to check for abnormal
friction.
•
Install the removed parts (see appropriate chapters).
Swingarm Bearing Removal
•
Remove:
Swingarm (see Swingarm Removal)
Collar [A]
Grease Seals [B]
Sleeve [C]
Circlip (Right Side) [D]
Special Tool - Inside Circlip Pliers: 57001-143
•
Remove the ball bearing and needle bearings.
Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058
Swingarm Bearing Installation
•
Replace the needle bearings [A], ball bearing [B], grease
seals [C] and circlip [D] with new ones.
•
Install the needle bearings, ball bearing, grease seals and
circlip as shown.
Left Side [E]
Right Side [F]
9.5 mm (0.37 in.) [G]
29.5 mm (1.16 in.) [H]
NOTE
○
Install the needle and ball bearings so that the marked
side faces out.
Special Tool - Needle Bearing Driver,
28: 57001-1610
Press in the ball bearing until it bottomed.
Special Tool - Bearing Driver Set: 57001-1129
Install the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
Press in the grease seals so that seal surface is flushed
with the end of housing.
Special Tool - Bearing Driver Set: 57001-1129
13-30 SUSPENSION
Swingarm
Swingarm Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection. Re-
moval may damage them.
•
Inspect the needle bearings [A] and ball bearing [B] in-
stalled in the swingarm.
The rollers and ball in a bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
visually inspect the bearing for abrasion, discoloration, or
other damage.
If the needle bearing and sleeve [C] show any sings of
abnormal wear, discoloration, or damage, replace them
as a set.
•
Turn the bearing in the swingarm back and forth [A] while
checking for plays, roughness, or binding.
If bearing play, roughness, or binding is found, replace
the bearing.
•
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Swingarm Bearing Lubrication
NOTE
○
Since the bearings are packed with grease and sealed,
lubrication is not required.
Chain Guide Inspection
•
Refer to the Chain Guide Wear Inspection in the Periodic
Maintenance chapter.
SUSPENSION 13-31
Tie-Rod, Rocker Arm
Tie-Rod Removal
•
Remove:
Mud Guard (see Mud Guard Removal in the Frame
chapter)
•
Squeeze the brake lever slowly and hold it with a band
[A].
•
Raise the rear wheel off the ground with the jack (see
Rear Shock Absorber Removal).
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
WARNING
When raising the rear wheel off the ground with the
jack and removing part(s) from the motorcycle, be
sure to hold the front brake, or the motorcycle may
fall over. It could cause an accident and injury.
•
Remove:
Upper Tie-Rod Bolt and Nut [A]
Lower Tie-Rod Bolt and Nut [B]
Tie-Rod [C]
Tie-Rod Installation
•
Apply grease to the inside of the grease seals.
•
Install the tie-rod.
•
Replace the tie-rod nuts with new ones.
•
Tighten:
Torque - Tie-Rod Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
•
Install the removed parts (see appropriate chapters).
Rocker Arm Removal
•
Remove:
Mud Guard (see Mud Guard Removal in the Frame
chapter)
•
Squeeze the brake lever slowly and hold it with a band
[A].
13-32 SUSPENSION
Tie-Rod, Rocker Arm
•
Raise the rear wheel off the ground with the jack (see
Rear Shock Absorber Removal).
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
WARNING
When raising the rear wheel off the ground with the
jack and removing part(s) from the motorcycle, be
sure to hold the front brake, or the motorcycle may
fall over. It could cause an accident and injury.
•
Remove:
Lower Rear Shock Absorber Bolt and Nut [A]
Upper Tie-Rod Bolt and Nut [B]
Rocker Arm Bolt and Nut [C]
Rocker Arms [D]
Rocker Arm Installation
•
Apply grease to the inside of the oil seals.
•
Replace the following nuts with new ones.
Rocker Arm Nut
Upper Tie-Rod Nut
Lower Rear Shock Absorber Nut
•
Install the rocker arms so that the marked side faces left
side.
•
Tighten:
Torque - Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb)
Tie-Rod Nut: 34 N·m (3.5 kgf·m, 25 ft·lb)
Lower Rear Shock Absorber Nut: 34 N·m (3.5
kgf·m, 25 ft·lb)
•
Install the removed parts (see appropriate chapters).
SUSPENSION 13-33
Tie-Rod, Rocker Arm
Tie-Rod and Rocker Arm Bearing Removal
•
Remove:
Tie-Rod(seeTie-RodRemoval)
Rocker Arms (see Rocker Arm Removal)
Swingarm [A] (see Swingarm Removal)
Sleeves [B]
Grease Seals [C]
•
Remove the needle bearings [D], using a suitable tool.
Tie-Rod and Rocker Arm Bearing Installation
•
Replace the needle bearing [A] and grease seals with new
ones.
•
Install the needle bearings position as shown.
Screw the needle bearing driver into the driver holder.
Insert the needle bearing driver into the needle bearing
and press the needle bearing.
7.5 mm (0.30 in.) [B]
NOTE
○
For a bearing of inner diameter
17, select the pressing
side of the needle bearing driver according to its press-
ing depth.
Special Tools - Bearing Driver Set: 57001-1129
Needle Bearing Driver,
17/ 18: 57001
-1609
•
Apply plenty of grease to the lips of the grease seals.
•
Install the grease seals.
13-34 SUSPENSION
Tie-Rod, Rocker Arm
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection. Re-
moval may damage them.
•
Visually inspect the rocker arm, or tie-rod sleeves [A] and
needle bearings [B].
•
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.
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 Bearing Lubrication
NOTE
○
Since the bearings are packed with grease, lubrication
is not required.
STEERING 14-1
14
Steering
Table of Contents
Exploded View........................................................................................................................ 14-2
Special Tools .......................................................................................................................... 14-4
Steering .................................................................................................................................. 14-5
Steering Inspection ........................................................................................................... 14-5
Steering Adjustment.......................................................................................................... 14-5
Steering Stem......................................................................................................................... 14-6
Stem, Stem Bearing Removal........................................................................................... 14-6
Stem, Stem Bearing Installation........................................................................................ 14-7
Steering Stem Bearing Lubrication ................................................................................... 14-9
Steering Stem Warp Inspection ........................................................................................ 14-9
Stem Cap Deterioration, Damage Inspection ................................................................... 14-9
Handlebar............................................................................................................................... 14-10
Handlebar Removal .......................................................................................................... 14-10
Handlebar Installation ....................................................................................................... 14-10
14-2 STEERING
Exploded View
STEERING 14-3
Exploded View
Torque
No. Fastener
N·m kgf·m ft·lb
Remarks
1 Handlebar Holder Bolts 25 2.5 18 S
2 Right Switch Housing Bolts 3.5 0.36 31 in·lb
3
Throttle Case Bolts
3.5 0.36 31 in·lb
4 Left Switch Housing Bolts 3.5 0.36 31 in·lb
5 Steering Stem Head Bolt 108 11.0 79.7
6 Upper Front Fork Clamp Bolts 20 2.0 15
7 Steering Stem Nut 30 3.1 22
8 Lower Front Fork Clamp Bolts 23 2.3 17 AL
AD: Apply adhesive.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
S: Follow the specified tightening sequence.
14-4 STEERING
Special Tools
Head Pipe Outer Race Press Shaft:
57001-1075
Head Pipe Outer Race Driver, 54.5:
57001-1077
Steering Stem Nut Wrench:
57001-1100
Steering Stem Bearing Driver, 42.5:
57001-1344
Steering Stem Bearing Driver Adapter, 41.5:
57001-1345
Head Pipe Outer Race Driver, 55:
57001-1446
STEERING 14-5
Steering
Steering Inspection
•
Refer to the Steering Play Inspection in the Periodic Main-
tenance chapter.
Steering Adjustment
•
Refer to the Steering Play Adjustment in the Periodic
Maintenance chapter.
14-6 STEERING
Steering Stem
Stem, Stem Bearing Removal
•
Remove:
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Handlebars (see Handlebar Removal)
Clamp [A]
Bolts [B]
Upper Fairing Bracket (Upper) [C]
•
Disconnect the horn connectors [A].
•
Remove:
Horn Mounting Bolts [B]
Horn [C]
Brake Hose Fitting Bolt [D]
Bolts [E]
Clamp [F] (ABS Equipped Models)
Upper Fairing Bracket (Lower) [G]
•
Remove:
Steering Stem Head Bolt Plug [A]
Steering Stem Head Bolt [B] and Washer
•
Remove the front forks (see Front Fork Removal in the
Suspension chapter).
•
Bend the claws [A] of claw washer straighten.
•
Remove the steering stem locknut [B].
Special Tool - Steering Stem Nut Wrench: 57001-1100
•
Remove the claw washer.
STEERING 14-7
Steering Stem
•
Pushing up the stem base, and remove the steering stem
nut [A].
Special Tool - Steering Stem Nut Wrench [B]: 57001-1100
•
Remove:
Steering Stem
Stem Cap [C]
Upper Ball Bearing Inner Race and Ball Bearing
•
To remove the ball bearing outer races [A] pressed into
the head pipe [B], insert a bar [C] into the recesses of
head pipe, and applying it to both recesses alternately
hammer it to drive the race out.
NOTE
○
If 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.
•
Remove the lower ball bearing from the steering stem.
•
Remove the lower ball bearing inner race (with its oil seal)
[A] which is pressed onto the steering stem with a suitable
commercially available chisel [B].
Stem, Stem Bearing Installation
•
Replace the bearing outer races with new ones.
•
Drivethemintotheheadpipeatthesametime.
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver,
54.5 [B]:
57001-1077
Head Pipe Outer Race Driver,
55: 57001
-1446
•
Apply grease to the outer races.
•
Replace the bearing inner races and oil seal with new
ones.
•
Apply grease to the oil seal.
•
Install the oil seal [A] on the steering stem.
•
Apply grease to the stem and hammer the lower ball bear-
ing inner race [B].
Special Tools - Steering Stem Bearing Driver,
42.5 [C]:
57001-1344
Steering Stem Bearing Driver Adapter,
41.5 [D]: 57001-1345
14-8 STEERING
Steering Stem
•
Apply grease to the lower ball bearing [A], and install it
onto the steering stem.
The lower and upper ball bearings are identical.
•
Apply grease to the upper ball bearing [B] and inner race
[C].
•
Install the lower ball bearing to the steering stem.
•
Install the stem [A] through the head pipe and install the
ball bearing [B] and inner race [C] on it.
•
Install:
Stem Cap [D]
Steering Stem Nut [E]
•
Settle the bearings in place as follows.
Tighten the steering stem nut with 65 N·m (6.6 kgf·m, 48
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a steering stem nut wrench [A].
Special Tool - Steering Stem Nut Wrench: 57001-1100
Torque - Steering Stem Nut: 30 N·m (3.1 kgf·m, 22 ft·lb)
•
Install the claw washer [A] so that its bent side [B] faces
upward, and engage the bent claws with the grooves of
stem locknut [C].
•
Hand tighten the stem locknut until it touches the claw
washer.
•
Hand tighten the stem locknut clockwise until the claws
are aligned with the second groove of stem nut [D], and
bend the 2 claws downward [E].
•
Install the stem head.
•
Install the washer, and temporary tighten the steering
stem head bolt.
•
Install the front forks (see Front Fork Installation in the
Suspension chapter).
STEERING 14-9
Steering Stem
NOTE
○
Tighten the upper front fork clamp bolts first, next the
stem head bolt, last the lower front fork clamp bolts.
○
Tighten the two lower front fork clamp bolts alternately
two times to ensure even tightening torque.
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Steering Stem Head Bolt: 108 N·m (11.0 kgf·m,
79.7 ft·lb)
Lower Front Fork Clamp Bolts: 23 N·m (2.3 kgf·m,
17 ft·lb)
WARNING
If the handlebars do not turn to the steering stop,
they may cause an accident resulting in injury or
death. Be sure the cables, harnesses and hoses are
routed properly and do not interfere with handlebar
movement (see Cable, Wire, and Hose Routing sec-
tion in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
Steering Stem Bearing Lubrication
•
Refer to the Steering Stem Bearing Lubrication in the Pe-
riodic Maintenance chapter.
Steering Stem Warp Inspection
•
Whenever the steering stem is removed, or if the steering
can not be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
Stem Cap Deterioration, Damage Inspection
Replace the stem cap if its oil seal [A] shows damage.
14-10 STEERING
Handlebar
Handlebar Removal
•
Remove:
Rear View Mirror [A] (see Rear View Mirror Removal in
the Frame chapter)
Clutch Lever Clamp Bolts [B]
Clutch Lever Assembly [C]
Left Switch Housing [D]
Handlebar Weight [E]
Left Handlebar Grip [F]
•
Remove:
Rear View Mirror [A] (see Rear View Mirror Removal in
the Frame chapter)
Front Master Cylinder [B] (see Front Master Cylinder Re-
moval in the Brakes chapter)
Right Switch Housing [C]
Throttle Case [D]
Handlebar Weight [E]
Throttle Grip [F]
•
Remove:
Meter Unit (see Meter Unit Removal in the Electrical Sys-
tem chapter)
Handlebar Holder Bolts [A]
Handlebar Holder [B]
Handlebars [C]
Handlebar Installation
•
Check that the pads [A] are in place on the handlebar
holder [B].
Align the pad parallel [C] to the edge of the handlebar
holder.
Do not place the pad on the edge [D].
•
Align the punch mark [A] on the handlebars and the corner
edge [B] on the stem head.
STEERING 14-11
Handlebar
•
Install the handlebar holder [A].
•
Tighten the front holder bolts [B] first, and then tighten the
rear holder bolts [C]. There will be a gap [D] at the rear
part of the holder after tightening.
Torque - Handlebar Holder Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the adhesive coating area. Dry them with
a clean cloth.
•
Apply adhesive cement to the inside of the left handlebar
grip.
•
Install the left handlebar grip.
Install the left handlebar grip [A] so that the edge of the
left handlebar grip aligns the punch mark [B] on the han-
dlebars (Engine No. ZRT00DE063072 ∼).
•
Install the throttle grip and left/right handlebar weight.
Wipe off any protruding adhesive cement.
•
Apply a non-permanent locking agent to the threads of
the handlebar weight screws, and tighten them.
•
Install the throttle cable tips [A].
•
Install the throttle case.
Fit the projection [B] into a hole in the handlebars.
•
Tighten:
Torque - Throttle Case Bolts: 3.5 N·m (0.36 kgf·m, 31 in·lb)
•
Install the left and right switch housings.
Fit the projection [A] into a hole [B] in the handlebars.
•
Tighten:
Torque - Switch Housing Bolts: 3.5 N·m (0.36 kgf·m, 31
in·lb)
•
Install:
Clutch Lever Assembly (see Clutch Lever Assembly In-
stallation in the Clutch chapter)
Front Master Cylinder (see Front Master Cylinder Instal-
lation in the Brakes chapter)
•
Run the leads, cables and hoses correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
FRAME 15-1
15
Frame
Table of Contents
Exploded View................................... 15-2
Seats ................................................. 15-8
Front Seat Removal ..................... 15-8
Front Seat Installation .................. 15-8
Rear Seat Removal...................... 15-8
Rear Seat Installation................... 15-8
Fairings.............................................. 15-9
Upper Fairing Removal ................ 15-9
Upper Fairing Installation ............. 15-10
Upper Fairing Disassembly.......... 15-10
Upper Fairing Assembly............... 15-11
Fuel Tank Cover Removal............ 15-11
Fuel Tank Cover Installation......... 15-11
Middle Fairing Removal ............... 15-12
Middle Fairing Installation ............ 15-12
Middle Fairing Disassembly ......... 15-13
Middle Fairing Assembly.............. 15-13
Lower Fairing Removal ................ 15-13
Lower Fairing Installation ............. 15-13
Ignition Switch Cover Removal .... 15-14
Ignition Switch Cover Installation . 15-14
Side Covers ....................................... 15-15
Side Cover Removal .................... 15-15
Side Cover Installation ................. 15-15
Seat Covers....................................... 15-16
Seat Cover Removal.................... 15-16
Seat Cover Installation................. 15-16
Fenders ............................................. 15-18
Front Fender Removal ................. 15-18
Front Fender Installation .............. 15-18
Flap and Rear Fender Removal... 15-18
Flap and Rear Fender Installation 15-19
Frame ................................................ 15-20
Frame Inspection ......................... 15-20
Rear Frame Removal................... 15-20
Rear Frame Installation................ 15-20
Rear Frame Bracket Removal ..... 15-20
Rear Frame Bracket Installation .. 15-21
Battery Case...................................... 15-22
Battery Case Removal................. 15-22
Battery Case Installation.............. 15-22
Guard................................................. 15-23
Mud Guard Removal.................... 15-23
Mud Guard Installation................. 15-23
Side Stand......................................... 15-24
Side Stand Removal .................... 15-24
Side Stand Installation ................. 15-24
Rear View Mirrors.............................. 15-25
Rear View Mirror Removal........... 15-25
Rear View Mirror Installation........ 15-25
15-2 FRAME
Exploded View
FRAME 15-3
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Rear View Mirror Locknut (Upper)
18 1.8 13 Lh
2 Rear View Mirror Nut (Lower) 30 3.1 22
3 Middle Fairing Screws 1.2 0.12 11 in·lb
4 Upper Fairing Screws 1.2 0.12 11 in·lb
5 Front Fender Mounting Bolts 3.9 0.40 35 in·lb
6. US, CA, CAL, AU and MY Models
Lh: Left-hand Threads
S: Follow the specified tightening sequence.
15-4 FRAME
Exploded View
FRAME 15-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Rear Frame Bracket Bolts 44 4.5 32
2 Front Footpeg Bracket Bolts 25 2.5 18
3 Side Stand Switch Bolt 8.8 0.90 78 in·lb L
4 Side Stand Bracket Bolts 49 5.0 36 L
5 Side Stand Bolt 29 3.0 21 S
6
Side Stand Nut
44 4.5 32
R, S
7 Rear Footpeg Bracket Bolts 25 2.5 18
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
15-6 FRAME
Exploded View
FRAME 15-7
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1 Rear Frame Bolts 25 2.5 18 L
2 Rear Frame End Cover Screws 1.2 0.12 11 in·lb
3
Flap Screws
1.2 0.12 11 in·lb
4. AU Model
5. US, CA, and CAL Models
L: Apply a non-permanent locking agent.
15-8 FRAME
Seats
Front Seat Removal
•
Insert the ignition switch key [A] into the seat lock.
•
Pull up the rear part of the front seat [B] while turning the
key clockwise, and remove it backward.
Front Seat Installation
•
Insert the front seat tabs [A] under the fuel tank bracket
[B].
•
Insert the seat hook [C] into the latch hole [D].
•
Push down the rear part of the front seat until the lock
clicks.
Rear Seat Removal
•
Remove:
Front Seat (see Front Seat Removal)
•
Remove the rear seat [A] backward.
Rear Seat Installation
•
Insert the rear seat tabs [A] under the frame bracket [B].
FRAME 15-9
Fairings
Upper Fairing Removal
WARNING
The cooling fins [A] at the rear of headlight become
hot during normal operation and can cause serious
burns. To prevent burns, never touch the cooling
fins at the rear of headlight while the engine is run-
ning or shortly after it has been stopped.
•
Remove the bolts [A] and washers.
•
Clear the projection [B], and then pull the upper fairing
cover [C] backward to clear the hooks [D].
•
Remove the bolts [A].
NOTICE
Do not disconnect the headlight connectors [B].
If the headlight connectors are disconnected, the
headlight (LED) may be broken by static electricity.
•
Pull the upper fairing [A] upward to clear the projections
[B].
•
Disconnect:
Turn Signal Light Lead Connectors [A]
Headlight Control Unit Connector [B]
•
Remove the upper fairing [C].
15-10 FRAME
Fairings
Upper Fairing Installation
•
Installation is the reverse of removal.
•
Insert the projections [A] into the holes [B].
•
Hold the turn signal light leads with the clamps [C].
•
Insert the hooks [A] into the slots [B].
•
Insert the projection [C] into the hole [D].
Upper Fairing Disassembly
•
Remove the headlight control unit bracket screws [A] and
washers.
•
Remove the bracket [B] with the headlight control unit [C]
installed.
NOTICE
Do not disconnect the headlight connectors [D].
If the headlight connectors are disconnected, the
headlight (LED) may be broken by static electricity.
•
Remove:
Headlight (LED) Assembly Mounting Screws [A]
Headlight (LED) Assembly [B]
•
Remove the upper fairing screws [A], and separate the
upper fairings [B] and the turn signal lights [C].
FRAME 15-11
Fairings
Upper Fairing Assembly
•
Assembly is the reverse of disassembly.
Torque - Upper Fairing Screws: 1.2 N·m (0.12 kgf·m, 11
in·lb)
Headlight (LED) Assembly Mounting Screws: 1.2
N·m (0.12 kgf·m, 11 in·lb)
Headlight Control Unit Bracket Screws: 1.2 N·m
(0.12 kgf·m, 11 in·lb)
Fuel Tank Cover Removal
•
Remove:
Front Seat (see Front Seat Removal)
Bolts [A] and Washers
Bolt [B]
•
Pull the rear part of the fuel tank cover [C] upward to clear
the hook fasteners [D] and projections [E], and then re-
move the fuel tank cover backward to clear the hooks [F].
Fuel Tank Cover Installation
•
Check that the hook fasteners [A] are in place on the fuel
tank cover [B] and the fuel tank [C].
Fit the hook fastener to the concave shape on the fuel
tank and the fuel tank cover.
•
Install the fuel tank cover in the following order.
Insert the hooks [A] into the slots [B].
Insert the projections [C] into the holes [D].
Fit the hook fasteners [E].
Tigh
ten the two front side bolts together with the washers.
Tighten the rear side bolt.
15-12 FRAME
Fairings
Middle Fairing Removal
•
Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal)
Bolt [A] (L = 16 mm) and Washer
Bolt [B] (L = 10 mm) and Washer
Bolt [C] (L = 20 mm) and Washer
•
Remove the bolts [A].
•
Pull the middle fairing [B] outward to clear the projection
[C] and the hook fastener [D], and remove the middle fair-
ing.
Middle Fairing Installation
•
Installation is the reverse of removal.
•
Check that the hook fasteners [A] are in place on the fuel
tank [B] and the middle fairing [C].
Fit the hook fastener to the concave shape on the fuel
tank and the middle fairing.
•
For the right side fairing, check that the pad [A] is in place
on the fairing [B].
Fit the pad to the line on the middle fairing.
•
Insert the projection [A] into the hole [B], and fit the hook
fasteners [C].
FRAME 15-13
Fairings
Middle Fairing Disassembly
•
Remove:
Middle Fairing (see Middle Fairing Removal)
Quick Rivet [A]
Middle Fairing Screws [B]
•
Clear the projections [C], and remove the cover [D].
•
Remove:
Middle Fairing Screws [A]
Middle Fairing Screws [B] and Washers
Cover [C]
Brackets [D]
•
Separate the middle fairings [E].
Middle Fairing Assembly
•
Assembly is the reverse of disassembly.
•
Insert the projections [A] into the holes [B].
Torque - Middle Fairing Screws: 1.2 N·m (0.12 kgf·m, 11
in·lb)
Lower Fairing Removal
•
Remove the quick rivets [A].
•
Remove:
Bolt [A]
Bolt [B] and Washer
Lower Fairing [C]
Lower Fairing Installation
•
Installation is the reverse of removal.
15-14 FRAME
Fairings
Ignition Switch Cover Removal
•
Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal)
Bolts [A] and Washers
•
Remove the bolts [A] while pulling the middle fairing [B]
outward.
•
Remove the ignition switch cover [C].
Ignition Switch Cover Installation
•
Installation is the reverse of removal.
FRAME 15-15
Side Covers
Side Cover Removal
•
Remove:
Middle Fairing (see Middle Fairing Removal)
Bolts [A] and Washers
Bolt [B] and Collar (Only on Left Side Cover)
•
Pull the side cover [C] outward to clear the projection [D]
and the hooks [E], and remove the side cover.
Side Cover Installation
•
Installation is the reverse of removal.
•
Check that the pads [A] are in place on the side cover [B].
Align the pad with the upper end [C] of the tab.
Place the pad [D] between the tabs evenly.
Fit the pad [E] to the tab.
•
Insert the projections [A] and the hooks [B] into the holes
[C] and the slots [D].
•
Hang the hooks [E] on the frame.
15-16 FRAME
Seat Covers
Seat Cover Removal
•
Remove:
Seats (see Front/Rear Seat Removal)
Side Covers (see Side Cover Removal)
Bolt [A] and Washer
•
Pull the seat cover [B] outward to clear the projection [C].
•
Clear the hook [A] with the standard tip screwdriver [B].
Push the sear cover from its lower side [C] to remove it
easily.
•
Pull the seat cover [A] forward to clear the hooks [B], and
remove the seat cover.
Seat Cover Installation
•
Installation is the reverse of removal.
•
Check that the pad [A] is in place on the seat cover [B].
Align the pad with the mark [C] on the seat cover.
FRAME 15-17
Seat Covers
•
Insert the hooks [A] into the slots [B].
•
Insert the projection [A] into the hole [B].
•
Be sure to insert the hooks [A].
15-18 FRAME
Fenders
Front Fender Removal
•
Clear the brake hose from the clamps [A].
•
For ABS equipped models, clear the front wheel rotation
sensor lead from the clamp [B].
•
Remove:
Bolts [C] and Washers
Front Fender [D]
Front Fender Installation
•
Install the front fender.
•
Tighten:
Torque - Front Fender Mounting Bolts: 3.9 N·m (0.40 kgf·m,
35 in·lb)
•
Run the brake hoses and front wheel rotation sensor lead
correctly (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
Flap and Rear Fender Removal
•
Remove:
Seat Covers (see Seat Cover Removal)
Owner’s Tool
Bolts [A]
Rear Frame Cover [B]
•
Remove:
ECU [A] and Relay Box [B]
Turn Signal Relay [C]
Diagnostic Connectors [D]
Bolts [E]
•
Disconnect:
Rear Turn Signal Light Lead Connectors [F]
License Plate Light Lead Connector [G]
•
Remove:
Rear Fender End Cover Screws [A]
Rear Fender End Cover Bolts [B] and Washers
Rear Fender End Covers [C]
FRAME 15-19
Fenders
•
Open the clamp [A].
•
Remove:
Bolts [B]
Guide [C]
•
Remove:
Connector Bracket Screws [A]
Connector Bracket [B]
Flap Screws [C]
Flap [D]
Rear Fender [E]
Flap and Rear Fender Installation
•
Installation is the reverse of removal.
Torque - Rear Frame End Cover Screws: 1.2 N·m (0.12
kgf·m, 11 in·lb)
Flap Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb)
•
Check that the pads [A] are in place on the rear fender
[B].
Align the pad with the line [C] on the rear fender.
Attach the ends of the pad in the upper side [D].
Align the pad with the edge [E] of the rear fender.
SectionA–A[F]
•
Check that the pads [A] are in place on the connector
bracket [B].
15-20 FRAME
Frame
Frame Inspection
•
Visually inspect the frame for cracks, dents, bending, or
warp.
If there is any damage to the frame, replace it.
WARNING
A repaired frame may fail in use, possibly causing
an accident resulting in injury or death. If the frame
is bent, dented, cracked, or warped, replace it.
Rear Frame Removal
•
Remove:
Rear Fender (see Flap and Rear Fender Removal)
Tail/Brake Light (see Tail/Brake Light Removal in the
Electrical System chapter)
Rear Frame Bolts [A] (Both Sides)
Rear Frame [B]
Rear Frame Installation
•
Check that the pads [A] are in place on the rear frame [B].
•
Apply a non-permanent locking agent to the threads of
the rear frame bolts.
•
Tighten:
Torque - Rear Frame Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
•
Install the removed parts (see appropriate chapters).
Rear Frame Bracket Removal
•
Remove:
Rear Frame (see Rear Frame Removal)
Battery Case (see Battery Case Removal)
Clamps [A]
•
Remove the bolts [A].
FRAME 15-21
Frame
•
Remove:
Rear Footpeg Bracket Bolts [A] (Both Sides)
Rear Frame Bracket Bolts [B] (Both Sides)
Rear Frame Brackets [C]
Rear Frame Bracket Installation
•
Tighten:
Torque - Rear Frame Bracket Bolts: 44 N·m (4.5 kgf·m, 32
ft·lb)
Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
•
Install the removed parts (see appropriate chapters).
15-22 FRAME
Battery Case
Battery Case Removal
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Battery (see Battery Removal in the Electrical System
chapter)
Bolts [A]
Fuel Tank Bracket [B]
•
Remove:
Rivet [A]
Clamp [B]
•
Disconnect:
Vehicle-down Sensor Lead Connector [A]
•
Remove:
Fuse Box 1 [B]
Fuse Box 2 [C]
Starter Relay [D]
Bolts [E]
Bracket [F]
Exhaust Butterfly Valve Actuator [G]
Clamp [H]
Battery Case [I]
Battery Case Installation
•
Check that the trims [A] are in place on the battery case
[B].
•
Installation is the reverse of removal.
•
Run the cables, leads, harness and hose correctly (see
Cable, Wire, and Hose Routing section in the Appendix
chapter).
FRAME 15-23
Guard
Mud Guard Removal
•
Remove:
Mud Guard Mounting Bolts [A]
•
Remove:
Right Front Footpeg Bracket Bolts [A]
•
Remove:
QuickRivets[A]
Mud Guard Mounting Bolt [B]
Bracket [C]
Mud Guard [D]
Mud Guard Installation
•
Installation is the reverse of removal.
•
Apply a non-permanent locking agent to the threads of the
mud guard mounting bolts, and tighten them securely.
•
Tighten:
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
15-24 FRAME
Side Stand
Side Stand Removal
•
Raise the rear wheel off the ground with a stand.
•
Remove:
Side Stand Switch Bolt [A]
Side Stand Switch [B]
•
Remove:
Spring [A]
Side Stand Nut [B]
Side Stand Bolt [C]
Collar
Side Stand [D]
Side Stand Installation
•
Applygreasetotheslidingarea[A]ofthesidestand[B].
•
Replace the side stand nut [C] with a new one.
•
Install:
Side Stand
Collar [D]
•
Tighten the side stand bolt [E] first, and then the side
stand nut.
Torque - Side Stand Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)
Side Stand Nut: 44 N·m (4.5 kgf·m, 32 ft·lb)
•
Hook the spring [F] so that the long spring end faces up-
ward.
Install the spring hook direction as shown.
•
Install the side stand switch.
•
Apply a non-permanent locking agent to the threads of
the side stand switch bolt, and tighten it.
Torque - Side Stand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78
in·lb)
FRAME 15-25
Rear View Mirrors
Rear View Mirror Removal
•
Remove:
Bolt [A]
Cover [B]
•
Loosen the rear view mirror locknut (upper) [A], and re-
move the rear view mirror stay [B] from the rear view mir-
ror nut (lower) [C].
The rear view mirror locknut (upper) and rear view mirror
stay are left-hand thread.
•
Loosen the rear view mirror nut (lower), and remove it.
Rear View Mirror Installation
•
Check that the pad [A] is in place on the cover [B].
Install the pad to the inside of the cover.
•
Tighten the rear view mirror nut (lower) [A].
Torque - Rear View Mirror Nut (Lower): 30 N·m (3.1 kgf·m,
22 ft·lb)
•
Tighten the rear view mirror stay [B] until the fully position.
•
Adjust the rear view mirror stay to assure the safe condi-
tions of the rear with the rider sitting on the motorcycle.
The rear view mirror locknut (upper) [C] and rear view
mirror stay are left-hand thread.
Align the center [A] of the grip with the lower end [B] of
the mirror.
•
Tighten the rear view mirror locknut (upper).
Torque - Rear View Mirror Locknut (Upper): 18 N·m (1.8
kgf·m, 13 ft·lb)
•
Install the cover and tighten its bolt.
•
Adjust the rear view mirror by slightly moving only the
mirror portion of the assembly.
Installation and adjustment of the right side are common
with those of the left side. Follow the procedure specified
at the left side.
ELECTRICAL SYSTEM 16-1
16
Electrical System
Table of Contents
Exploded View........................................................................................................................ 16-4
Specifications ......................................................................................................................... 16-10
Special Tools and Sealant ...................................................................................................... 16-11
Parts Location......................................................................................................................... 16-13
Wiring Diagram (SEA-B1 Model)............................................................................................ 16-16
Wiring Diagram (Other than SEA-B1 Model).......................................................................... 16-18
Wiring Diagram (ABS Equipped Models: US, CA and CAL Models) ..................................... 16-20
Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)....................................... 16-22
Wiring Diagram (ABS Equipped Models: Other than US, CA, CAL, SEA-B1 and TH
Models)................................................................................................................................ 16-24
Precautions............................................................................................................................. 16-26
Electrical Wiring...................................................................................................................... 16-27
Wiring Inspection .............................................................................................................. 16-27
Battery .................................................................................................................................... 16-28
Battery Removal ............................................................................................................... 16-28
Battery Installation ............................................................................................................ 16-28
Battery Activation .............................................................................................................. 16-28
Precautions ....................................................................................................................... 16-31
Interchange ....................................................................................................................... 16-32
Charging Condition Inspection.......................................................................................... 16-32
Refreshing Charge............................................................................................................ 16-32
Charging System.................................................................................................................... 16-34
Alternator Cover Removal................................................................................................. 16-34
Alternator Cover Installation.............................................................................................. 16-34
Stator Coil Removal .......................................................................................................... 16-34
Stator Coil Installation ....................................................................................................... 16-35
Alternator Rotor Removal ................................................................................................. 16-35
Alternator Rotor Installation .............................................................................................. 16-36
Charging Voltage Inspection ............................................................................................. 16-38
Alternator Inspection ......................................................................................................... 16-38
Regulator/Rectifier Removal ............................................................................................. 16-40
Regulator/Rectifier Installation .......................................................................................... 16-40
Regulator/Rectifier Inspection........................................................................................... 16-40
Ignition System ....................................................................................................................... 16-43
Crankshaft Sensor Removal ............................................................................................. 16-43
Crankshaft Sensor Installation .......................................................................................... 16-44
Crankshaft Sensor Inspection........................................................................................... 16-45
Crankshaft Sensor Peak Voltage Inspection..................................................................... 16-46
Timing Rotor Removal ...................................................................................................... 16-46
Timing Rotor Installation ................................................................................................... 16-46
Stick Coil Removal............................................................................................................ 16-47
Stick Coil Installation......................................................................................................... 16-47
Stick Coil Inspection.......................................................................................................... 16-47
Stick Coil Primary Peak Voltage Inspection ...................................................................... 16-47
Spark Plug Removal ......................................................................................................... 16-48
Spark Plug Installation ...................................................................................................... 16-48
Spark Plug Condition Inspection....................................................................................... 16-49
Interlock Operation Inspection .......................................................................................... 16-49
IC Igniter Inspection .......................................................................................................... 16-50
Electric Starter System ........................................................................................................... 16-53
16-2 ELECTRICAL SYSTEM
Starter Motor Removal...................................................................................................... 16-53
Starter Motor Installation................................................................................................... 16-53
Starter Motor Disassembly................................................................................................ 16-53
Starter Motor Assembly .................................................................................................... 16-54
Brush Inspection ............................................................................................................... 16-55
Commutator Cleaning and Inspection............................................................................... 16-55
Armature Inspection.......................................................................................................... 16-55
Brush Lead Inspection ...................................................................................................... 16-56
Right-hand End Cover Assembly Inspection .................................................................... 16-56
Starter Relay Inspection.................................................................................................... 16-56
Lighting System ...................................................................................................................... 16-58
Headlight Beam Horizontal Adjustment ............................................................................ 16-58
Headlight Beam Vertical Adjustment................................................................................. 16-58
Headlight (LED) Assembly Removal/Installation .............................................................. 16-58
Headlight Harness Circuit Inspection................................................................................ 16-58
City Light (LED) Removal ................................................................................................. 16-59
City Light (LED) Installation .............................................................................................. 16-60
Tail/Brake Light (LED) Removal........................................................................................ 16-60
Tail/Brake Light (LED) Installation..................................................................................... 16-61
License Plate Light Bulb Replacement ............................................................................. 16-61
Turn Signal Light Bulb Replacement ................................................................................ 16-63
Turn Signal Relay Inspection ............................................................................................ 16-63
Air Switching Valve ................................................................................................................. 16-66
Air Switching Valve Operation Test ................................................................................... 16-66
Air Switching Valve Unit Test ............................................................................................ 16-66
Radiator Fan System.............................................................................................................. 16-68
Fan Motor Inspection ........................................................................................................ 16-68
Meter, Gauge, Indicator Unit................................................................................................... 16-69
Meter Unit Removal .......................................................................................................... 16-69
Meter Unit Installation ....................................................................................................... 16-69
Meter Unit Disassembly .................................................................................................... 16-70
Meter Operation Inspection............................................................................................... 16-70
Meter System Inspection .................................................................................................. 16-72
Meter Unit Inspection ........................................................................................................ 16-73
Fuel Level Sensor Line Self-Diagnosis Mode Inspection.................................................. 16-81
Immobilizer System (Equipped Models) ................................................................................. 16-84
Operational Cautions ........................................................................................................ 16-84
Key Registration................................................................................................................ 16-84
Immobilizer System Parts Replacement ........................................................................... 16-102
Immobilizer System Inspection ......................................................................................... 16-105
Immobilizer System (Equipped Models) ................................................................................. 16-106
Switches and Sensors............................................................................................................ 16-107
Brake Light Timing Inspection........................................................................................... 16-107
Brake Light Timing Adjustment ......................................................................................... 16-107
Switch Inspection.............................................................................................................. 16-107
Water Temperature Sensor Inspection ............................................................................. 16-108
Oxygen Sensor Removal (Equipped Models)................................................................... 16-108
Oxygen Sensor Installation (Equipped Models)................................................................ 16-109
Oxygen Sensor Inspection (Equipped Models)................................................................. 16-109
Fuel Level Sensor Inspection............................................................................................ 16-109
Relay Box ............................................................................................................................... 16-110
Relay Box Removal .......................................................................................................... 16-110
Relay Circuit Inspection .................................................................................................... 16-110
Diode Circuit Inspection .................................................................................................... 16-111
Fuse........................................................................................................................................ 16-113
30 A Main/15 A ECU Fuse Removal................................................................................. 16-113
Fuse Box Fuse Removal................................................................................................... 16-113
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Meter Cover Bolts
0.40 0.04 3.5 in·lb
2 City Light Mounting Screws 1.2 0.12 11 in·lb
3 Headlight (LED) Assembly Mounting Screws 1.2 0.12 11 in·lb
4 Headlight Control Unit Bracket Screws 1.2 0.12 11 in·lb
5 Turn Signal Light Screws 1.2 0.12 11 in·lb
6
Licence Plate Light Screws
1.2 0.12 11 in·lb
L: Apply a non-permanent locking agent.
16-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-7
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Left Switch Housing Bolts
3.5 0.36 31 in·ib
2 Right Switch Housing Bolts 3.5 0.36 31 in·lb
3 Front Brake Light Switch Screw 1.2 0.12 11 in·lb
4 Side Stand Switch Bolt 8.8 0.90 78 in·lb L
5 Oil Pressure Switch 15 1.5 11 SS
6
Oil Pressure Switch Terminal Bolt
2.0 0.20 18 in·ib
G
7
Neutral Switch
15 1.5 11
8 Timing Rotor Bolt 39 4.0 29
9
Alternator Cover Bolts
12 1.2 106 in·lb
10 Alternator Lead Holding Plate Bolt 12 1.2 106 in·ib L
11 Stator Coil Bolts 12 1.2 106 in·ib L
12 Alternator Rotor Bolt 155 15.8 114
13 Starter Motor Clutch Bolts 12 1.2 106 in·lb L
14 Starter Motor Cable Terminal Bolt 2.9 0.30 26 in·lb
15
Starter Motor Mounting Bolts
9.8 1.0 87 in·lb
S
16
Crankshaft Sensor Bolts
5.9 0.60 52 in·lb
17 Crankshaft Sensor Cover Bolts 12 1.2 106 in·lb
18. Immobilizer System Equipped Models
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
WL: Apply soap and water solution or rubber lubricant.
16-8 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-9
Exploded View
Torque
No. Fastener
N·m
kgf·m ft·lb
Remarks
1
Spark Plugs
13 1.3 115 in·lb
2 Water Temperature Sensor 12 1.2 106 in·lb
3 Fuel Pump Bolts 9.8 1.0 87 in·lb L, S
4 Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb
5 Oxygen Sensor (Equipped Models) 44 4.5 32
6. WVTA (78.2 H) and GB WVTA (FULL H) Models
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
16-10 ELECTRICAL SYSTEM
Specifications
Item Standard
Battery
Type Sealed Battery
Model Name
YT12A-BS
Capacity 12V10Ah(10HR)
Voltage 12.8 V or more
Gross Weight 3.5kg(7.7lb)
Electrolyte Volume 0.47 L (29 cu in.)
Charging System
Type
Three-phase AC
Alternator Output Voltage 51 V or more at 4 000 r/min (rpm)
Stator Coil Resista
nce
0.18 ∼ 0.28 at 20°C (
68°F)
Charging Voltage 14.2 ∼ 14.8 V
(Regulator/Rectifier Output Voltage)
Ignition System
Crankshaft Sensor Resistance 376 ∼ 564
Crankshaft Sensor Peak Voltage 2.0 V or more
Stick Coil:
Primary Winding Resistance 1.1 ∼ 1.5
Secondary Winding Resistance 6.4 ∼ 9.6 k
Primary Peak Voltage 100 V or more
Spark Plug:
Type NGK CR9EIA-9
Gap 0.8 ∼ 0.9 mm (0.032 ∼ 0.036 in.)
Electric Starter System
Starter Motor:
Brush Length 7 mm (0.28 in.) [Service Limit: 5 mm (0.20 in.)]
Commutator Diameter 24 mm (0.94 in.) [Service Limit: 23 mm (0.91 in.)]
Air Switching Valve
Resistance
20 ∼ 24 at 20°
C (68°F)
Switches and Sensors
Rear Brake Light Switch Timing ON after about 10 mm (0.39 in.) pedal travel
Engine Oil Pressure Switch Connections When engine is stopped: ON
When engine is running: OFF
Water Temperature Sensor Resistance in the text
Fuel Level Sensor Resistance:
Full Position 9.6 ∼ 12.4
Empty Position 222 ∼ 228
ELECTRICAL SYSTEM 16-11
Special Tools and Sealant
Peak Voltage Adapter:
57001-1415
Lead Wire - Peak Voltage Adapter:
57001-1449
Needle Adapter Set:
57001-1457
Key Registration Unit:
57001-1582
Grip:
57001-1591
Flywheel & Pulley Holder:
57001-1605
Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:
57001-1615
Stopper:
57001-1679
Rotor Holder:
57001-1690
Measuring Adapter:
57001-1700
16-12 ELECTRICAL SYSTEM
Special Tools and Sealant
Key Registration Adapter:
57001-1746
Rotor Holder:
57001-1757
Liquid Gasket, TB1211F:
92104-0004
ELECTRICAL SYSTEM 16-13
Parts Location
Timing Rotor [A]
Crankshaft Sensor [B]
Oxygen Sensor (Equipped Models) [C]
Horn [A]
Regulator/Rectifier [B]
Relay Box [A]
ECU [B]
Turn Signal Relay [C]
Rear Brake Light Switch [A]
Immobilizer Amplifier (Immobilizer Equipped Models) [A]
16-14 ELECTRICAL SYSTEM
Parts Location
Water Temperature Sensor [A]
Alternator [B]
Radiator Fan Motor [C]
Stater Motor [D]
Neutral Switch [A]
OilPressureSwitch[B]
Side Stand Switch [C]
Battery 12 V 10 Ah [A]
Starter Relay [B]
Fuse Box 1 [C]
Fuse Box 2 [D]
Air Switching Valve [A]
Stick Coils [B]
Spark Plugs [C]
Starter Lockout Switch [A]
Ignition Switch [B] (Immobilizer Equipped Models: In-
cluding Immobilizer Antenna)
Meter Unit [C]
Front Brake Light Switch [D]
ELECTRICAL SYSTEM 16-15
Parts Location
This page intentionally left blank.
16-16 ELECTRICAL SYSTEM
Wiring Diagram (SEA-B1 Model)
ELECTRICAL SYSTEM 16-17
Wiring Diagram (SEA-B1 Model)
16-18 ELECTRICAL SYSTEM
Wiring Diagram (Other than SEA-B1 Model)
ELECTRICAL SYSTEM 16-19
Wiring Diagram (Other than SEA-B1 Model)
16-20 ELECTRICAL SYSTEM
Wiring Diagram (ABS Equipped Models: US, CA and CAL Models)
ELECTRICAL SYSTEM 16-21
Wiring Diagram (ABS Equipped Models: US, CA and CAL Models)
16-22 ELECTRICAL SYSTEM
Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)
ELECTRICAL SYSTEM 16-23
Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)
16-24 ELECTRICAL SYSTEM
Wiring Diagram (ABS Equipped Models: Other than US, CA, CAL, SEA-B1 and
TH Models)
ELECTRICAL SYSTEM 16-25
Wiring Diagram (ABS Equipped Models: Other than US, CA, CAL, SEA-B1 and
TH Models)
16-26 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
The 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.
To 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.
Because 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.
Take care not to short the cables that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
Troubles 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.
Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system op-
eration.
Measure coil and winding resistance when the part is cold
(at room temperature).
ELECTRICAL SYSTEM 16-27
Electrical Wiring
Wiring Inspection
•
Visually inspect the wiring for signs of burning, fraying,
etc.
If any wiring is poor, replace the damaged wiring.
•
Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
•
Check the wiring for continuity.
Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
Connect a tester between the ends of the leads.
If the tester does not read about 0 , the lead is defective.
Replace the lead or the wiring harness [B] if necessary.
16-28 ELECTRICAL SYSTEM
Battery
Battery Removal
•
Turn the ignition switch off.
•
Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
•
Disconnect the negative (–) cable [A].
NOTICE
Be sure to disconnect the negative (–) cable first.
•
Slide out the positive (+) terminal cap [B] and disconnect
the positive (+) cable [C].
•
Remove the battery.
Battery Installation
•
Turn the ignition switch off.
•
Put the battery into the battery case.
•
Install the positive (+) cable [A] first.
•
Install the negative (–) cable [B].
•
Apply a light coat of grease on the terminals to prevent
corrosion.
•
Cover the positive (+) terminal with the cap [C].
•
Install the front seat (see Front Seat Installation in the
Frame chapter).
Battery Activation
Electrolyte Filling
•
Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name
ZR1000F/G: YT12A-BS
NOTICE
Each battery comes with its own specific elec-
trolyte container; using the wrong container may
overfill the battery with incorrect electrolyte, which
can shorten battery life and deteriorate battery per-
formance. Be sure to use the electrolyte container
with the same model name as the battery since the
electrolyte volume and specific gravity vary with
the battery type.
ELECTRICAL SYSTEM 16-29
Battery
NOTICE
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
DANGER
Sulfuric acid in battery electrolyte can cause severe
burns. To prevent burns, wear protective clothing
and safety glasses when handling electrolyte. If
the electrolyte comes in contact with your skin or
eyes, wash the area with liberal amounts of water
and seek medical attention for more severe burns.
•
Place the battery on a level surface.
•
Check to see that the sealing sheet has no peeling, tears,
or holes in it.
•
Remove the sealing sheet.
NOTE
○
The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
•
Remove the electrolyte container from the vinyl bag.
•
Detach the strip of caps [A] from the container and set
aside, these will be used later to seal the battery.
NOTE
○
Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
•
Place the electrolyte container upside down with the six
sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○
Do not tilt the electrolyte container.
16-30 ELECTRICAL SYSTEM
Battery
•
Check the electrolyte flow.
If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.
NOTE
○
Be careful not to have the battery fall down.
•
Keep the container in place. Don’t remove the container
from the battery, the battery requires all the electrolyte
from the container for proper operation.
NOTICE
Removal of the container before it is completely
empty can shorten the service life of the battery.
Do not remove the container until it is completely
empty.
•
After filling, let the battery sit for 20 ∼ 60 minutes with the
electrolyte container kept in place, which is required for
the electrolyte to fully permeate into the plates.
•
Make sure that the container cells have emptied com-
pletely, and remove the container from the battery.
•
Place the strip of caps [A] loosely over the filler ports,
press down firmly with both hands to seat the strip of caps
into the battery (don’t pound or hammer). When properly
installed, the strip of caps will be level with the top of the
battery.
NOTICE
Once the strip of caps is installed onto the battery,
never remove the caps, nor add water or electrolyte
to the battery.
NOTE
○
Charging the battery immediately after filling can
shorten service life.
ELECTRICAL SYSTEM 16-31
Battery
Initial Charge
•
Newly activated sealed batteries require an initial charge.
Standard Charge:
1.2 A × 5
∼ 10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO2
Yuasa MB-2040/2060
Christie C10122S
If the above chargers are not available, use equivalent
one.
•
Let battery sit 30 minutes after initial charge, then check
voltage using a voltmeter. (Voltage immediately after
charging becomes temporarily high. For accurate mea-
suring, let the battery sit for given time.)
NOTE
○
Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. If voltage is not at least 12.8 V, repeat
charging cycle.
○
To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V the
battery is defective.
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. F
orcibly 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 Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. H
owever, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable re-
moved. Give a refresh charge once a month during storage.
4) Battery life.
If the battery will not 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).
16-32 ELECTRICAL SYSTEM
Battery
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri-
ous injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite
any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medial at-
tention for more severe burns.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
Battery charging condition can be checked by measuring
battery terminal voltage with a digital meter [A].
•
Remove:
Battery (see Battery Removal)
•
Measure the battery terminal voltage.
NOTE
○
Measure with a digital voltmeter which can be read one
decimal place voltage.
If the reading is 12.8 V or more, no refresh charge is re-
quired, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
Standard:
12.8 V or more
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]
Refreshing Charge
•
Remove the battery [A] (see Battery Removal).
•
Do refresh charge by following method according to the
battery terminal voltage.
WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.
ELECTRICAL SYSTEM 16-33
Battery
Terminal Voltage: 11.5 ∼ less than 12.8 V
Standard Charge: 1.2 A × 5
∼ 10 h (see following chart)
Quick Charge:
5A×1h
NOTICE
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
Charging Method:
1.2A×20h
NOTE
○
Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
•
Determine the battery condition after refresh charge.
Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria
Judgement
12.8 V or higher
Good
12.0 ∼ lower than 12.8 V
Charge insufficient Recharge
lowerthan12.0V Unserviceable Replace
16-34 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal
•
Drain:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
•
Disconnect the alternator lead connector [A].
•
Clear the alternator lead from the clamp [B].
•
Place a suitable container under the alternator cover [A].
•
Open the clamp [B].
•
Remove:
Alternator Cover Bolts [C]
Alternator Cover
Alternator Cover Installation
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket to the alternator lead grommet and
crankcase halves mating surface [A] on the front and rear
sides of the cover mount.
Sealant - Liquid Gasket, TB1211F: 92104-0004
•
Check that dowel pins [B] are in place on the crankcase.
•
Replace the alternator cover gasket with a new one.
•
Tighten:
Torque - Alternator Cover Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)
•
Run the alternator lead correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
Stator Coil Removal
•
Remove:
Alternator Cover (see Alternator Cover Removal)
Alternator Lead Holding Plate Bolt [A] and Plate
Alternator Lead Grommet [B]
Stator Coil Bolts [C]
•
Remove the stator coil [D] from the alternator cover.
ELECTRICAL SYSTEM 16-35
Charging System
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, 106 in·lb)
•
Secure the alternator lead with a holding plate.
•
Apply a non-permanent locking agent to the threads of
the plate bolt and tighten it.
Torque - Alternator Lead Holding Plate Bolt: 12 N·m (1.2
kgf·m, 106 in·lb)
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket to the circumference of the alternator
lead grommet [A], and fit the grommet into the notch of
the cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004
•
Install the alternator cover (see Alternator Cover Installa-
tion).
Alternator Rotor Removal
•
Remove:
Alternator Cover (see Alternator Cover Removal)
Starter Idle Gear [A] and Shaft [B]
•
Hold the alternator rotor steady with the rotor holder [A]
and stopper [B].
•
Remove the rotor bolt [C] and washer.
Special Tools - Grip [D]: 57001-1591
Stopper: 57001-1679
Rotor Holder: 57001-1690
If using the rotor holder (57001-1757).
•
Hold the alternator rotor steady with the rotor holder [A].
•
Remove the rotor bolt [B] and washer.
Special Tool - Rotor Holder: 57001-1757
16-36 ELECTRICAL SYSTEM
Charging System
•
Using the flywheel puller [A], remove the alternator rotor
[B] from the crankshaft.
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1615
NOTICE
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.
Alternator Rotor Installation
•
Apply a thin coat of molybdenum disulfide grease to the
crankshaft [A] and the outer surface [B] of the starter
clutch gear [C].
•
Install the starter clutch gear [A].
•
Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions and dry them with a clean cloth.
Crankshaft Tapered Portion [B]
Alternator Rotor Tapered Portion [C]
•
Fit the woodruff key [D] securely in the slot in the crank-
shaft before installing the alternator rotor.
•
Install the alternator rotor [A] while turning [B] the starter
clutch gear [C] clockwise.
•
Using a cleaning fluid, clean off any oil or dirt on the
washer [A] and dry it with a clean cloth.
•
Install the washer.
NOTE
○
Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.
•
Install the rotor bolt [B] and tighten it with 70 N·m (7.0
kgf·m, 52 ft·lb) of torque.
ELECTRICAL SYSTEM 16-37
Charging System
•
Remove the rotor bolt and washer.
•
Check the tightening torque with flywheel puller [A].
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1615
If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 N·m (2.0 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.
•
Install the washer and rotor bolt.
•
Tighten the alternator rotor bolt [A] while holding the alter-
nator rotor steadily with the holder [B].
Special Tools - Grip [C]: 57001-1591
Stopper [D]: 57001-1679
Rotor Holder: 57001-1690
Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114
ft·lb)
If using rotor holder (57001-1757).
•
Install the washer and rotor bolt.
•
Tighten the alternator rotor bolt [A] while holding the alter-
nator rotor steadily with the holder [B].
Special Tool - Rotor Holder: 57001-1757
Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114
ft·lb)
•
Using a thickness gauge, make sure the clearance [A]
between the starter clutch gear [B] and the starter clutch
race [C] is 0.4 mm (0.02 in.) or more.
If the clearance is less than 0.4 mm (0.02 in.), remove the
rotor and starter clutch race, and then clean them thor-
oughly and reinstall them.
16-38 ELECTRICAL SYSTEM
Charging System
•
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).
Charging Voltage Inspection
•
Check the battery condition (see Charging Condition In-
spection).
•
Warm up the engine to obtain actual alternator operating
conditions.
•
Check that the ignition switch is turned off, and connect a
tester [A] to the battery terminals [B].
•
Start the engine, and note the voltage readings at var-
ious engine speeds with the headlight turned on and
then turned off (To turn off the headlight, disconnect
the headlight connector on the headlight unit.). The
readings should show nearly battery voltage when the
engine speed is low, and, as the engine speed rises, the
readings should also rise. But they must be kept under
the specified voltage.
Charging Voltage
Connections
Tes te r ( +) to Te st er ( –) to
Reading
Battery (+) Battery (–) DC 14.2 ∼ 14.8 V
•
Turn off the ignition switch to stop the engine, and discon-
nect the tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
ELECTRICAL SYSTEM 16-39
Charging System
•
To check the alternator output voltage, do the following
procedures.
Turn the ignition switch off.
Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
Disconnect the alternator lead connector [A].
Connect a tester as shown in the table 1.
Install the fuel tank temporary (see Fuel Tank Installation
in the Fuel System (DFI) chapter).
Start the engine.
Run it at the rpm given in the table 1.
Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage at 4 000 r/min (rpm)
Connections
Tes te r ( +) to Tes ter ( –) to
Reading
One Black lead
Another Black lead
AC 51 V or more
If the output voltage shows the value in the table, the al-
ternator operates properly.
If the output voltage shows a much lower reading than
that given in the table, stop the engine and inspect the
stator coil resistance.
•
Check the stator coil resistance as follows.
Stop the engine.
Connect the tester as shown in the table 2.
Note the readings (total 3 measurement).
Table 2 Stator Coil Resistance at 20°C (68°F)
Connections
Tes te r ( +) to Te st er (– ) to
Reading
One Black lead Another Black lead 0.18 ∼ 0.28
If there is more resistance than shown in the table, or
no 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.
•
Measure the resistance between each of the black leads
and chassis ground.
Any tester reading less than infinity () indicates a short,
necessitating stator replacement.
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.
16-40 ELECTRICAL SYSTEM
Charging System
Regulator/Rectifier Removal
•
Remove:
Left Middle Fairing (see Middle Fairing Removal in the
Frame chapter)
•
Disconnect the connector [A].
•
Remove:
Bolts [B]
Regulator/Rectifier [C] with Bracket
•
Remove:
Bolts and Nuts [A]
Regulator/Rectifier [B]
Regulator/Rectifier Installation
•
Installation is the reverse of removal.
•
Install the regulator/rectifier [A] on the left side of the
bracket [B].
Regulator/Rectifier Inspection
•
Refer to the Charging System Troubleshooting for the
Regulator/Rectifier Inspection.
Charging System Troubleshooting
•
Before inspection, remove all accessories that consume
electrical power.
NOTE
○
Even when the charging system is working properly, the
battery may discharge if the motorcycle is equipped with
too many accessories.
•
Pay attention to riding conditions and the customer’s rid-
ing habits which could affect the charging system such
as:
Frequent use at low engine
speed
Frequent and unnecessary brake
pedal dragging
Battery Discharged
•
Recharge the battery if it is discharged.
ELECTRICAL SYSTEM 16-41
Charging System
16-42 ELECTRICAL SYSTEM
Charging System
Charging System Circuit
1. Ignition Switch
2. Load
3. Frame Ground 1
4. Engine Ground
5. Battery 12 V 10 Ah
6. Starter Relay
7. Main Fuse 30 A
8. Regulator/Rectifier
9. Alternator
ELECTRICAL SYSTEM 16-43
Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plug, stick coil or stick
coil lead while the engine is running, or you could
receive a severe electrical shock.
NOTICE
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
ECU damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
ECU.
Crankshaft Sensor Removal
NOTICE
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
•
Disconnect the crankshaft sensor lead connector [A].
•
Remove the clamp [B], and turn up the heat insulation
rubber plate [C].
•
Remove the immobilizer amplifier [A] from the bracket.
•
Clear the crankshaft sensor lead from the clamps [B].
•
Clear the crankshaft sensor lead from the clamps [A].
16-44 ELECTRICAL SYSTEM
Ignition System
•
Remove:
Crankshaft Sensor Cover Bolts [A]
Crankshaft Sensor Cover [B]
•
Remove:
Crankshaft Sensor Bolts [A]
Crankshaft Sensor [B]
Crankshaft Sensor Installation
•
Tighten:
Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52
in·lb)
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
•
Apply liquid gasket [A] to the crankshaft sensor lead grom-
met and crankcase halves mating surface on the front and
rear sides of the crankshaft sensor cover mount.
Sealant - Liquid Gasket, TB1211F: 92104-0004
•
Replace the O-ring [A] with a new one.
ELECTRICAL SYSTEM 16-45
Ignition System
•
Install:
Crankshaft Sensor Cover [A]
•
Tighten the crankshaft sensor cover bolts [B] while push-
ing the crankshaft sensor cover rearward.
Torque - Crankshaft Sensor Cover Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
•
Run the crankshaft sensor lead and clutch cable correctly
(see Cable, Wire, and Hose Routing section in the Appen-
dix chapter).
•
Install the removed parts (see appropriate chapters).
Crankshaft Sensor Inspection
•
Disconnect the crankshaft sensor lead connector (see
Crankshaft Sensor Removal).
•
Set a tester [A], and connect it to the crankshaft sensor
lead connector [B].
Special Tool - Needle Adapter Set [C]: 57001-1457
Crankshaft Sensor Resistance
Connections:
Tester (+) → Ylead
Tester (–) → BK lead
Standard: 376
∼ 564 Ω
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
th
an this resistance means the coil is shorted, and must
be replaced.
•
Measure the resistance between the crankshaft sensor
leads and chassis g
round.
Any tester reading less than infinity () indicates a short,
necessitating replacement of the crankshaft sensor.
16-46 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Peak Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
○
Using the peak voltage adapter [A] is more reliable way
to determine the condition of the crankshaft sensor than
crankshaft sensor internal resistance measurements.
•
Disconnect the crankshaft sensor lead connector [B] (see
Alternator Cover Removal).
•
Set a tester [C], and connect it peak voltage adapter.
Special Tools - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Needle Adapter Set [D]: 57001-1457
•
Connect the adapter to the terminals of the crankshaft
sensor lead connector.
Connections:
Crankshaft
Sensor Lead
Peak Voltage
Adapter
Tester
Ylead
←
R lead
→
(+)
BK lead
←
BK lead
→
(–)
•
Turn the engine stop switch to run position.
•
Turn the ignition switch on.
•
Pushing the starter button, turn the engine 4 ∼ 5sec-
onds with the transmission gear in neutral to measure the
crankshaft sensor peak voltage.
•
Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
Standard:
2.0 V or more
If the reading is less than the standard, inspect the crank-
shaft sensor (see Crankshaft Sensor Inspection).
Timing Rotor Removal
•
Remove the crankshaft sensor (see Crankshaft Sensor
Removal).
•
Holding the timing rotor with the flywheel & pulley holder
[A] and remove the timing rotor bolt [B].
Special Tool - Flywheel & Pulley Holder: 57001-1605
•
Remove the timing rotor [C].
Timing Rotor Installation
•
Install the timing rotor [A] on the crankshaft [B] with their
teeth [C] aligned.
•
Holding the timing rotor with the flywheel & pulley holder
and tighten the timing rotor bolt.
Torque - Timing Rotor Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
Special Tool - Flywheel & Pulley Holder: 57001-1605
•
Install the crankshaft sensor (see Crankshaft Sensor In-
stallation).
ELECTRICAL SYSTEM 16-47
Ignition System
Stick Coil Removal
NOTICE
Never drop the stick coils, especially on a hard sur-
face.
Such a shock to the stick coils can damage it.
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
•
Disconnect the stick coil connectors [A].
•
Remove the stick coils [B].
NOTICE
Do not pry the connector part of the coil while re-
moving the coil.
Stick Coil Installation
•
Insert the stick coils [A] so that the coil heads align with
the lines [B] on the cylinder head cover.
NOTICE
Do not tap the coil head while installing the coil.
•
After installation, be sure the stick coils are installed se-
curely by pulling up them lightly.
•
Run the leads correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
Stick Coil Inspection
•
Remove the stick coils (see Stick Coil Removal).
•
Measure the primary winding resistance [A] as follows.
Connect a tester between the coil terminals.
•
Measure the secondary winding resistance [B] as follows.
Connect the tester between the plug terminal and (–) coil
terminal.
Stick Coil Winding Resistance
Primary Windings:
1.1
∼ 1.5 Ω
Secondary Windings: 6.4
∼ 9.6 kΩ
If the tester does not read as specified, replace the coil.
Stick Coil Primary Peak Voltage Inspection
NOTE
○
Be sure the battery is fully charged.
16-48 ELECTRICAL SYSTEM
Ignition System
•
Remove the stick coils (see Stick Coil Removal), but do
not remove the spark plugs.
•
Measure the primary peak voltage as follows.
Install the new spark plug [A] into each stick coil [B], and
ground them onto the engine.
Connect the peak voltage adapter [C] into a tester [D].
Connect the adapter to the lead wire-peak voltage
adapter [E] which is connected between the stick coil
connector and stick coil.
ECU [F]
Battery [G]
Special Tools - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Lead Wire - Peak Voltage Adapter: 57001
-1449
Primary Lead Connection
Adapter (R, +) to lead wire-peak voltage adapter (W)
Adapter (BK, –) to lead wire-peak voltage adapter (R)
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
•
Turn the engine stop switch to run position.
•
Turn the ignition switch on.
•
Pushing the starter button, turn the engine 4 ∼ 5 seconds
with the transmission in neutral to measure the primary
peak voltage.
•
Repeat the measurements 5 times for one stick coil.
Stick Coil Primary Peak Voltage
Standard:
100 V or more
•
Repeat the test for the other stick coil.
If the reading is less than the specified value, check the
following.
Stick Coils (see Stick Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
ECU (see ECU Power Supply Inspection in the Fuel Sys-
tem (DFI) chapter)
Spark Plug Removal
•
Refer to the Spark Plug Replacement in the Periodic
Maintenance chapter.
Spark Plug Installation
•
Refer to the Spark Plug Replacement in the Periodic
Maintenance chapter.
ELECTRICAL SYSTEM 16-49
Ignition System
Spark Plug Condition Inspection
•
Remove the spark plugs (see Spark Plug Replacement in
the Periodic Maintenance chapter).
•
Visually inspect the spark plugs.
If the spark plug center electrode [A] and/or side elec-
trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.
•
Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap: 0.8
∼ 0.9 mm (0.032 ∼ 0.036 in.)
•
Use the standard spark plug or its equivalent.
Spark Plug: NGK CR9EIA-9
Interlock Operation Inspection
•
Raise the rear wheel off the ground with the stand.
•
Turn the engine stop switch on (run position).
1st Check
•
Start the engine to the following conditions.
Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Side Stand → Down or Up
Turn the ignition switch on and push the starter button.
Then the starter motor should not turn when the starter
system circuit is normality.
If the engine is start, inspect the starter lockout switch,
neutral switch and relay box.
2nd Check
•
Start the engine to the following conditions.
Condition:
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Side Stand → Up
Turn the ignition switch on and push the starter button.
Then the starter motor should turn when the starter sys-
tem circuit is normality.
If the starter motor is not turn, inspect the starter lockout
switch, side stand switch, relay box, and starter relay.
16-50 ELECTRICAL SYSTEM
Ignition System
3rd Check
•
Inspect the engine for its secure stop after the following
operations are completed.
•
Run the engine to the following conditions.
Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Side Stand → Up
•
Set the side stand on the ground, then the engine will
stop.
If the engine does not stop, inspect the neutral switch,
side stand switch and relay box.
If their parts are normality, replace the ECU.
IC Igniter Inspection
The IC igniter is built in the ECU [A].
•
Refer to the following items.
Interlock Operation Inspection (see Interlock Operation
Inspection)
Ignition System Troubleshooting (see Ignition System
section)
ECU Power Supply Inspection (see ECU Power Supply
Inspection in the Fuel System (DFI) chapter)
ELECTRICAL SYSTEM 16-51
Ignition System
16-52 ELECTRICAL SYSTEM
Ignition System
Ignition System Circuit
1. Engine Stop Switch
2. Spark Plugs
3. Stick Coils
4. Vehicle-down Sensor
5. Crankshaft Sensor
6. Main Throttle Sensor
7. Subthrottle Sensor
8. Water Temperature Sensor
9. Neutral Switch
10. Side Stand Switch
11. ECU
12. Joint Connector E
13. Frame Ground 5
14. Relay Box
15. ECU Main Relay
16. Starter Lockout Switch
17. Engine Ground
18. Battery 12 V 10 Ah
19. Starter Relay
20. Main Fuse 30 A
21. ECU Fuse 15 A
22. Ignition Switch
23. Fuse Box 1
24. Ignition Fuse 15 A
25. Joint Connector B
26. Joint Connector C
27. Joint Connector D
28. Frame Ground 2
ELECTRICAL SYSTEM 16-53
Electric Starter System
Starter Motor Removal
•
Remove the throttle body assy (see Throttle Body Assy
Removal in the Fuel System (DFI) chapter)
•
Slide out the rubber cap [A].
•
Remove:
Starter Motor Cable Terminal Bolt [B]
Starter Motor Mounting Bolts [C]
Starter Motor [D]
Starter Motor Installation
NOTICE
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
•
Clean the starter motor legs [A] and crankcase [B] where
the starter motor is ground.
•
Replace the O-ring [A] with a new one.
•
Apply soap and water solution to the new O-ring.
•
Tighten the starter motor mounting bolt (rear) [A] first, and
then starter motor mounting bolt (front) [B].
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
•
Install the starter motor cable [C] as shown.
•
Tighten:
Torque - Starter Motor Cable Terminal Bolt [D]: 2.9 N·m
(0.30 kgf·m, 26 in·lb)
•
Slide back the rubber cap to the original position.
•
Install the removed parts (see appropriate chapters).
Starter Motor Disassembly
•
Remove:
Starter Motor (see Starter Motor Removal)
Starter Motor Through Bolts [A]
16-54 ELECTRICAL SYSTEM
Electric Starter System
•
Remove:
Left-hand End Cover [A]
Right-hand End Cover [B]
Armature [C]
Yoke [D]
Starter Motor Assembly
•
Apply a thin coat of grease to the oil seal [A].
•
Install:
Toothed Washer [B]
Washer [C]
•
Press the springs holding the brush leads with suitable
clips [A] as shown.
•
Put the armature [B] among the brushes.
•
Install the new O-rings [A] as shown.
•
Align the groove [A] in the right-hand end cover and the
hollow mark [B] on the yoke.
ELECTRICAL SYSTEM 16-55
Electric Starter System
•
Align the hollow mark [A] on the left-hand end cover and
the hollow mark [B] on the yoke.
Brush Inspection
•
Measure the length [A] of each brush.
If any is worn down to the service limit, replace the right
-hand end cover assembly.
Starter Motor Brush Length
Standard: 7 mm (0.28 in.)
Service Limit: 5 mm (0.20 in.)
Commutator Cleaning and Inspection
•
Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
•
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.)
Armature Inspection
•
Measure the resistance between any two commutator
segments [A].
If there is a high resistance or no reading () between any
two segments, a winding is open and the starter motor
must be replaced.
•
Measure the resistance between the segments and the
shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
16-56 ELECTRICAL SYSTEM
Electric Starter System
NOTE
○
Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with a 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
•
Measure the resistance as shown.
Terminal and Positive Brush [A]
Right-hand End Cover and Negative Brush [B]
If there is not close to zero ohms, the brush lead has an
open. Replace the right-hand end cover assembly.
Right-hand End Cover Assembly Inspection
•
Measure the resistance as shown.
Terminal and Right-hand End Cover [A]
If there is any reading, the right-hand end cover assembly
have a short. Replace the right-hand end cover assembly.
Starter Relay Inspection
•
Remove:
Battery Negative (–) Cable (see Battery Removal)
Starter Relay Cover [A]
•
Disconnect:
Connector [A]
Cable Terminals [B]
•
Remove:
Starter Relay [C]
ELECTRICAL SYSTEM 16-57
Electric Starter System
•
Connect a tester [A] and 12 V battery [B] to the starter
relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Criteria: When battery is connected → 0 Ω
When battery is disconnected →∞Ω
Electric Starter Circuit
1. Engine Stop Switch
2. Starter Button
3. Neutral Switch
4. Joint Connector B
5. Side Stand Switch
6. Joint Connector C
7. Joint Connector E
8. Frame Ground 5
9. Frame Ground 2
10. Engine Ground
11. Battery 12 V 10 Ah
12. Main Fuse 30 A
13. Starter Relay
14. Starter Motor
15. Relay Box
16. Starter Circuit Relay
17. Starter Lockout Switch
18. Ignition Switch
19. Fuse Box 1
20. Ignition Fuse 15 A
16-58 ELECTRICAL SYSTEM
Lighting System
This motorcycle adopt the daylight system and have a
headlight relay in the relay box. The headlight does not
go on when the ignition switch and the 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 released.
Headlight Beam Horizontal Adjustment
•
Refer to the Headlight Aiming Inspection in the Periodic
Maintenance chapter.
Headlight Beam Vertical Adjustment
•
Refer to the Headlight Aiming Inspection in the Periodic
Maintenance chapter.
Headlight (LED) Assembly Removal/Installation
•
Refer to the Upper Fairing Disassembly/Assembly in the
Frame chapter.
Headlight Harness Circuit Inspection
NOTE
○
Be sure the battery is fully charged.
•
Inspect the headlight fuses (see Fuse Inspection).
•
Remove the upper fairing (see Upper Fairing Removal in
the Frame chapter).
NOTICE
Do not disconnect the headlight connectors [A]. If
the headlight connectors are disconnect, the head-
light (LED) may be broken by static electricity.
•
Connect the measuring adapter [A] to the headlight con-
trol unit lead connector [B].
Special Tool - Measuring Adapter: 57001-1700
•
Inspect the ground wiring continuity as shown.
Wiring Continuity Inspection
BK/O Lead [C] ←→BK/O Lead [D]
If the wiring is not good, replace the main harness.
If the wiring is good, check the input voltage.
ELECTRICAL SYSTEM 16-59
Lighting System
Input Voltage Inspection
•
Connect the measuring adapter [A] to the headlight con-
trol unit lead connector [B].
Special Tool - Measuring Adapter: 57001-1700
•
Inspect the input voltage as shown.
Input Voltage
(1) Connection to Adapter (Left Headlight):
Digital Meter (+) → R (main harness R) lead
Digital Meter (–) → BK (main harness BK/O) lead
(2) Connection to Adapter (Right Headlight):
Digital Meter (+) → Y (main harness R/W) lead
Digital Meter (–) → BK (main harness BK/O) lead
(3) Connection to Adapter (High Beam Control):
Digital Meter (+) → W (main harness R/BK) lead
Digital Meter (–) → BK (main harness BK/O) lead
•
Turn the ignition switch on.
•
Set the dimmer switch to high beam position.
•
Start the engine, and then stop the engine using the en-
gine stop switch immediately.
Left/Right Headlight Input Voltage (1, 2)
Standard: Battery Voltage
High Beam Control Voltage (3)
Standard: 4.1
∼ 5.1 V
•
Turn the ignition switch off.
If the left/right headlight input voltage is out of the stan-
dard, check the headlight relay (see Relay Circuit Inspec-
tion).
If the high beam control voltage is out of the standard,
check the meter unit (see Meter Unit Inspection [Blue High
Beam Indicator (LED) Inspection]).
If the headlight relay and the meter unit are good, check
the headlight wiring for continuity (see Headlight/Tail Light
Circuit).
If the left/right headlight input voltage and the high beam
control voltage are within the standard, replace the head-
light (LED) assembly (see Headlight (LED) Assembly Re-
moval/Installation).
City Light (LED) Removal
•
Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Meter Cover (see Meter Unit Removal)
•
Clear the city light lead from the clamps [A].
•
Disconnect the city light lead connector [B].
•
Remove:
Bolts [C]
City Light (LED) [D] with Bracket
16-60 ELECTRICAL SYSTEM
Lighting System
•
Remove:
City Light Mounting Screws [A]
Bracket [B]
City Light (LED) [C]
City Light (LED) Installation
•
Installation is the reverse of removal.
•
Check that the pad [A] is in place on the city light (LED)
[B].
Do not install the pad on the mark [C].
Fit the pad to the corner line [D].
•
Tighten:
Torque - City Light Mounting Screws: 1.2 N·m (0.12 kgf·m,
11 in·lb)
•
Run the lead correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
Tail/Brake Light (LED) Removal
•
Remove:
Seat Covers (see Seat Cover Removal in the Frame
chapter)
Bolts [A]
Rear Frame Cover [B]
•
Disconnect the tail/brake light lead connector [A].
ELECTRICAL SYSTEM 16-61
Lighting System
•
Remove:
Bolts [A]
Clamp [B]
•
Remove the tail/brake light (LED) [C] rearward.
Tail/Brake Light (LED) Installation
•
Installation is the reverse of removal.
•
Check that the pads [A] are in place on the tail/brake light
(LED) [B]
Fit the pad to the corner line [C].
[D] 15 ∼ 20 mm (0.59 ∼ 0.78 in.)
•
Insert the projection [A] into the slit [B].
•
Run the lead correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
License Plate Light Bulb Replacement
•
Remove:
License Plate Light Cover Screws [A]
License Plate Light Cover [B] and Lens
•
Pull out the bulb [A] straight from the socket.
NOTICE
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage then the specified valve.
•
Replace the bulb with a new one.
•
Insert the new bulb into the socket.
•
Install the license plate light cover.
•
Tighten the license plate light cover screws.
16-62 ELECTRICAL SYSTEM
Lighting System
Headlight/Tail Light Circuit
1. Ignition Switch
2. Fuse Box 1
3. Headlight Relay Fuse 15 A
4. Brake Light/Horn Fuse 7.5 A
5. Fuse Box 2
6. Headlight Fuse (Low Left) 7.5 A
7. Headlight Fuse (Low Right) 7.5 A
8. Joint Connector E
9. Tail/Brake Light (LED)
10. License Plate Light 12 V 5 W
11. Frame Ground 3
12. Frame Ground 1
13. Frame Ground 5
14. Engine Ground
15. Battery 12 V 10 Ah
16. Main Fuse 30 A
17. Starter Relay
18. Relay Box
19. Headlight Circuit Relay
20. Alternator
21. Dimmer Switch
22. Passing Button
23. Headlight Control Unit
24. Headlight (LED)
25. City Light (LED)
26. Joint Connector A
27. Meter Unit
ELECTRICAL SYSTEM 16-63
Lighting System
Turn Signal Light Bulb Replacement
•
Remove:
Turn Signal Light Lens Screw [A]
Turn Signal Light Lens [B]
•
Push and turn the bulb [A] counterclockwise and remove
it.
•
Insert the new bulb [A] by aligning its pins [B] with the
grooves [C] in the socket, and turn the bulb clockwise.
Turn the bulb about 15°.
•
Fit the projection [A] of the lens into the groove [B] of the
turn signal light.
•
Tighten the turn signal light lens screw.
Turn Signal Relay Inspection
•
Remove:
Rear Frame Cover (see Tail/Brake Light (LED) Removal
in the Frame chapter)
•
Remove the turn signal relay [A].
•
Disconnect the turn signal relay connector [B].
16-64 ELECTRICAL SYSTEM
Lighting System
•
Connect one 12 V battery and turn signal lights as indi-
cated, and count how many times the lights blink for one
minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not blink as specified, replace the turn sig-
nal relay.
Testing Turn Signal Relay
Load
The Number of Turn
Signal Lights
Wattage (W)
Blinking Times
(c/m*)
1**
10 140 ∼ 250
2 20 75 ∼ 95
(*): Cycle(s) per minute
(**): Correspond to “one light burned out.”
ELECTRICAL SYSTEM 16-65
Lighting System
Turn Signal Light Circuit
1. Ignition Switch (Other than US, CA and
CAL Models)
2. Ignition Switch (US, CA and CAL Models)
3. Fuse Box 2
4. Turn Signal Relay Fuse 7.5 A
5. Joint Connector E
6. Rear Right Turn Signal Light 12 V 10 W
7. Rear Left Turn Signal Light 12 V 10 W
8. Frame Ground 5
9. Engine Ground
10. Battery 12 V 10 Ah
11. Main Fuse 30 A
12. Starter Relay
13. Frame Ground 3
14. Frame Ground 1
15. Turn Signal Switch
16. Hazard Switch
17. Turn Signal Relay
18. Front Left Turn Signal Light 12 V 10 W
19. Front Right Turn Signal Light 12 V 10 W
20. Joint Connector A
21. Meter Unit
16-66 ELECTRICAL SYSTEM
Air Switching Valve
Air Switching Valve Operation Test
•
Refer to the Air Suction System Damage Inspection in the
Periodic Maintenance chapter.
Air Switching Valve Unit Test
•
Remove the air switching valve (see Air Switching Valve
Removal in the Engine Top End chapter).
•
Connect a tester [A] to the air switching valve terminals
as shown.
Air Switching Valve Resistance
Standard: 20
∼ 24 Ω at 20°C (68°F)
If the resistance reading is out of the specified value, re-
place it with a new one.
•
Connect the 12 V battery [A] to the air switching valve
terminals as shown.
•
Blow the air to the intake air duct [A], and make sure does
not flow the blown air from the outlet air ducts [B].
•
Disconnect the 12 V battery.
•
Blow the air to the intake air duct [A] again, and make sure
flow the blown air from the outlet air duct [B].
If the air switching valve does not operate as described,
replace it with a new one.
NOTE
○
To check air flow through the air switching valve, just
blow through the air switching valve hose (intake side)
[C].
ELECTRICAL SYSTEM 16-67
Air Switching Valve
Air Switching Valve Circuit
1. Ignition Switch
2. Fuse Box 1
3. Ignition Fuse 15 A
4. Air Switching Valve
5. ECU
6. Joint Connector E
7. Frame Ground 5
8. Frame Ground 2
9. Engine Ground
10. Battery 12 V 10 Ah
11. Starter Relay
12. Main Fuse 30 A
13. ECU Fuse 15 A
14. Joint Connector C
15. Relay Box
16. ECU Main Relay
16-68 ELECTRICAL SYSTEM
Radiator Fan System
Fan Motor Inspection
•
Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).
•
Slide the dust cover [A].
•
Disconnect the connector [B].
•
Using an auxiliary leads, supply battery power to the fan
motor.
If the fan does not rotate, the fan motor is defective and
must be replaced.
Radiator Fan Circuit
1. Ignition Switch
2. Fan Motor
3. Fuse Box 1
4. Ignition Fuse 15 A
5. Fan Fuse 15 A
6. Joint Connector C
7. Water Temperature Sensor
8. ECU
9. Frame Ground 5
10. Frame Ground 2
11. Engine Ground
12. Battery 12 V 10 Ah
13. Starter Relay
14. Main Fuse 30 A
15. Relay Box
16. Radiator Fan Relay
ELECTRICAL SYSTEM 16-69
Meter, Gauge, Indicator Unit
Meter Unit Removal
•
Remove:
Meter Cover Bolts [A] and Washers
Meter Cover [B]
•
Remove:
Bolts [A] and Washers
Collars
City Light (LED) [B]
•
Slide the dust cover [A], and disconnect the meter con-
nector.
•
Remove:
Meter Mounting Bolts [B] and Washers
Collars
•
Clear the projection [C] and remove the meter unit [D]
rearward.
Meter Unit Installation
•
Insert the projection [A] of the meter unit into the hole [B].
•
Install the collars.
•
Apply a non-permanent locking agent to the meter mount-
ing bolts, and tighten them together with the washers.
•
Connect the meter connector, and install the dust cover.
•
Install the city light (LED), and tighten its bolts together
with the collars and washers.
•
Check that the pads [A] are in place on the meter cove
[B].
Fit the pad to the line [C] on the cover.
Fit the pad to the corner line [D].
•
Install the meter cover, and tighten its bolts together with
the washers.
Torque - Meter Cover Bolts: 0.40 N·m (0.04 kgf·m, 3.5 in·lb)
16-70 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Unit Disassembly
•
Remove:
Meter Unit (see Meter Unit Removal)
Pads [A]
Screws [B]
Lower Meter Cover [C]
•
Separate the meter assembly [A] and upper meter cover
[B].
Meter Operation Inspection
Check 1: Meter Unit Switching Inspection
Display Mode Setting
•
Turn the ignition switch on and check the following.
•
By pushing the upper button [A] each time, check that the
display [B] changes as shown.
Unit Setting
•
Set the ODO mode by pushing the upper button.
•
By pushing the lower button each time while the upper
button pushed in, check that the display changes as
shown.
NOTE
○
Mile/Km Display can alternate between English and
metric modes (mile and km) in the digital meter. Make
sure that km or mile according to local regulations is
correctly displayed before riding.
If the display function does not work, replace the meter
unit.
ELECTRICAL SYSTEM 16-71
Meter, Gauge, Indicator Unit
Clock Setting
•
Set the CLOCK mode [A] by pushing the upper button [B].
•
Push the lower button [C] for more than two seconds.
The clock setting menu (hour and minute) should blink.
•
Push the lower button.
The hour display [A] starts blinking.
•
By pushing the upper button each time, check that the
hour display changes.
•
By pushing the lower button, check that the hour display
decides and minute display [A] starts blinking.
•
By pushing the upper button each time, check that the
minute display changes.
•
By pushing the lower button, check that the hour and
minute display start blinking.
•
By pushing the upper button, check that the hour and
minute display decide.
•
When both hour and minute display is blinking, by pushing
the lower button, check that the hour display start blinking.
This blinking returns the hour setting display.
If the display function does not work, replace the meter
unit.
Tachometer Brightness Setting
•
Push the upper and lower buttons, and hold them in until
the all tachometer segments go on.
•
By pushing the upper button each time, check that the
tachometer brightness changes as shown.
[A] Brightest Setting (Standard)
[B] Medium Setting
[C] Darkest Setting
•
Push the upper and lower buttons, and hold them to finish
the setting mode.
If the meter does not work, replace the meter unit.
16-72 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter System Inspection
Check 2-1: Tachometer Brightness Sensor Inspection
NOTE
○
This meter unit has the automatically tachometer bright-
ness function by the sensor in addition to the manual
brightness setting.
•
Push the upper and lower buttons, and hold them in until
the all tachometer segments go on.
•
Check if the tachometer brightness [A] is changed by shin-
ing a light on the sensor [B] with the penlight.
•
Push the upper and lower buttons, and hold them to finish
the setting mode.
If the meter does not work, replace the meter unit.
Check 2-2: Water Temperature Inspection
•
Disconnect the water temperature sensor connector [A]
(see Water Temperature Sensor Removal/Installation in
the Fuel System (DFI) chapter).
•
Connect the variable rheostat [B] to the W/BL lead [C] and
W/R lead [D] terminals.
LCD Display Resistance (kΩ)
–––
1.231 or more
40°C (104°F)
1.136 ±0.095
100°C (212°F)
0.1553 ±0.0070
HI 0.1483 or less
•
Turn the ignition switch on.
•
Read the temperature in the display.
The display range is 40 ∼ 119°C (104 ∼ 247°F).
If the temperature is out of the range, check the wiring
(see Meter Circuit).
If the wiring is good, replace the meter unit.
Check 2-3: Battery Warning Indicator Inspection
•
When the battery condition is low voltage (10.8 ∼ 11.2 V or
less) or high voltage (15.5 ∼ 16.5 V or more), the battery
warning indicator [A] and red warning indicator (LED) [B]
go on.
If the battery warning indicator and red warning indicator
(LED) go on, inspect the charging voltage (see Charging
Voltage Inspection).
If the charging voltage is good, replace the meter unit.
ELECTRICAL SYSTEM 16-73
Meter, Gauge, Indicator Unit
Meter Unit Inspection
•
Remove the meter unit [A] (see Meter Unit Removal).
[1] ECU Communication Line
[2] Fuel Level Sensor
[3] Green Left Turn Signal Indicator (LED) (+)
[4] Yellow ABS Indicator (LED) (–) [Equipped Models]
[5] Unused
[6] Ignition
[7] Red Warning Indicator (LED) (–)
[8] Battery (+)
[9] Blue High Beam Indicator (LED) (–)
[10] Rear Wheel Rotation Sensor Pulse
[11] Tachometer Pulse
[12] Green Neutral Indicator (LED) (–)
[13] Green Right Turn Signal Indicator (LED) (+)
[14] Unused
[15] Blue High Beam Indicator (LED) (+)
[16] Ground (–)
Check 3-1: Meter Unit Primary Operation Check
•
Using the auxiliary leads, connect the 12 V battery to the
meter unit connector as follows.
Connect the battery positive (+) terminal to the terminal
[8].
Connect the battery negative (–) terminal to the terminal
[16].
•
Connect the terminal [6] to the battery (+) terminal.
•
Check the following items.
All the LCD segments [A] appear for about 1 second.
The red warning indicator (LED) [B], yellow engine warn-
ing indicator (LED) [C] and tachometer (LED) [D] go on
for about 1 second.
The yellow ABS indicator (LED) [E] goes on (equipped
models).
If the meter unit does not work, replace the meter unit.
16-74 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
About 5 seconds after, the all fuel level gauge segments
and fuel level warning indicator start blinking [A].
If the fuel level gauge does not blink, replace the meter
unit.
NOTE
○
This meter unit has a failure detection function (for open
or short) of the fuel level gauge. When the fuel level
gauge is open or short, the meter unit alerts the rider by
the all fuel level gauge segments blink in the display.
About 10 seconds after, the yellow engine warning indi-
cator (LED) [A] goes on.
If the yellow engine warning indicator (LED) does not go
on, replace the meter unit.
NOTE
○
This meter unit has a failure detection function of the
communication. When the communication error was
detected, the meter unit alerts the rider by the yellow
engine warning indicator (LED) goes on.
•
Disconnect the terminal [6].
All the LCD segments disappear.
The red warning indicator (LED) [A] starts blinking (see
Abstract section in the Immobilizer System).
If the segments do not disappear, replace the meter unit.
Check 3-2: Meter Communication Line (Service Code
39) Check
•
Connect the leads in the same circuit as Check 3-1.
•
After 10 seconds, the yellow engine warning indicator
(LED) goes on.
•
Set the ODO mode [A] by pushing the upper button [B].
•
Push the upper button for more than 2 seconds.
ELECTRICAL SYSTEM 16-75
Meter, Gauge, Indicator Unit
•
Check the following items.
The number 39 [A] in the display appears and yellow en-
gine warning indicator (LED) [B] goes on.
•
Push the upper button for more than 2 seconds.
•
Check the following items.
The display returns ODO mode from number 39.
The yellow engine warning indicator (LED) goes on.
If the meter unit does not work, replace the meter unit.
NOTE
○
The number 39 is service code of Self-Diagnosis (see
Fuel System (DFI) chapter). It is the service code of the
meter communication line error.
○
The number 39 in the display and yellow engine warning
indicator (LED) disappear when the meter unit is con-
nected to main harness of the normal motorcycle.
Check 3-3: Immobilizer Blinking Mode Inspection
•
Connect the leads in the same circuit as Check 3-1.
•
Disconnect the terminal [6].
•
Check that the red warning indicator (LED) [A] starts blink-
ing (Immobilizer Warning Indicator Blinking Mode).
•
Push the upper [B] and lower [C] buttons more than 2
seconds, within 20 seconds after the terminal [6] discon-
nected.
•
Check that the red warning indicator (LED) goes on 1 sec-
ond, and then the indicator goes off (Immobilizer No Blink-
ing Mode).
NOTE
○
For this inspection, be sure the battery is 12.2 V or
more. Immobilizer Blinking Mode does not work, when
the battery voltage is less than 12 ±0.2 V.
•
Connect the terminal [6] to the battery (+) terminal.
•
And then, disconnect the terminal [6].
16-76 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
•
Push the upper [A] and lower [B] buttons more than 2
seconds, within 20 seconds after the terminal [6] discon-
nected.
•
Check that the red warning indicator (LED) [C] goes on 1
second, and then the indicator starts blinking (Immobilizer
Warning Indicator Blinking Mode).
If the meter function does not work, replace the meter unit.
Check 3-4: Blue High Beam Indicator (LED) Inspection
•
Connect the leads in the same circuit as Check 3-1.
•
Connect the terminal [15] to the battery (+) terminal.
•
Check that the blue high beam indicator (LED) [A] goes
on.
If the indicator (LED) does not go on, replace the meter
unit.
Check 3-5: Green Left Turn Signal Indicator (LED) In-
spection
•
Connect the leads in the same circuit as Check 3-1.
•
Connect the terminal [3] to the battery (+) terminal.
•
Check that the green left turn signal indicator (LED) [A]
goes on.
If the indicator (LED) does not go on, replace the meter
unit.
ELECTRICAL SYSTEM 16-77
Meter, Gauge, Indicator Unit
Check 3-6: Green Right Turn Signal Indicator (LED) In-
spection
•
Connect the leads in the same circuit as Check 3-1.
•
Connect the terminal [13] to the battery (+) terminal.
•
Check that the green right turn signal indicator (LED) [A]
goes on.
If the indicator (LED) does not go on, replace the meter
unit.
Check 3-7: Green Neutral Indicator (LED) Inspection
•
Connect the leads in the same circuit as Check 3-1.
•
Connect the terminal [12] to the battery (–) terminal.
•
Check that the green neutral indicator (LED) [A] goes on.
If the indicator (LED) does not go on, replace the meter
unit.
Check 3-8: Yellow ABS Indicator (LED) Inspection
(Equipped Models)
•
Connect the leads in the same circuit as Check 3-1.
The yellow ABS indicator (LED) goes on.
•
Connect the terminal [4] to the battery (–) terminal.
16-78 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
•
Check that the yellow ABS indicator (LED) [A] goes off.
If the indicator (LED) does not go off, replace the meter
unit.
Check 3-9: Red Warning Indicator (LED) Inspection (Oil
Pressure Warning)
•
Connect the leads in the same circuit as Check 3-1.
•
Connect the terminal [7] to the battery (–) terminal.
•
Check that the oil pressure warning indicator [A] and red
warning indicator (LED) [B] go on.
If the oil pressure warning indicator and indicator (LED)
do not go on, replace the meter unit.
Check 3-10: Fuel Gauge Inspection
•
Connect the leads in the same circuit as Check 3-1.
The all segments of the fuel gauge in the display will blink.
•
Connect the variable rheostat [A] to the terminal [2] and
the battery (–) terminal.
ELECTRICAL SYSTEM 16-79
Meter, Gauge, Indicator Unit
•
Check that the number of segments on the fuel level
gauge [A] matches the resistance value of the variable
rheostat.
When the terminal [2] is connected, 1 segment in the fuel
level gauge should appear about every 15 seconds.
Variable Rheostat Resistance () Display Segments
20 6 segments go on
40
5 segments go on
60 4 segments go on
80 3 segments go on
110 2 segments go on
170 1 segment goes on
210 1 segment blinks
If the display function does not work, replace the meter
assembly.
Check 3-11: Speedometer Inspection
•
Connect the leads in the same circuit as Check 3-1.
•
The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave is input into terminal
[10].
Indicates approximately 60 km/h if the input frequency is
approximately 370 Hz.
Indicates approximately 60 mph if the input frequency is
approximately 600 Hz.
If the meter function does not work, replace the meter unit.
NOTE
○
The input frequency of the oscillator adds the integrated
value of the odometer.
○
The integrated value of the odometer cannot be reset.
Check 3-12: Odometer Check
•
Check the odometer with the speedometer check in the
same way.
If value indicated in the odometer is not added, replace
the meter unit.
NOTE
○
The data is maintained even if the battery is discon-
nected.
○
When the figures come to 999999, they are stopped and
locked.
○
The integrated value of the odometer cannot be reset.
16-80 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 3-13: Trip A/B Meter Check
•
Check the trip meter with the speedometer in the same
way.
If value indicated in the trip meter is not added, replace
the meter unit.
NOTE
○
The integrated value of the odometer cannot be reset.
•
Check that when the lower button is pushed for more than
two seconds, the figure display turns to 0.0.
If the figure display does not indicate 0.0, replace the me-
ter unit.
Check 3-14: Tachometer Inspection
•
Connect the leads in the same circuit as Check 3-1.
•
The engine speed (rpm) equivalent to the input frequency
is indicated in the oscillator [A], if the square wave is input
into terminal [11].
Indicates approximately 4 000 rpm if the input frequency
is approximately 133 Hz.
If the meter function does not work, replace the meter unit.
Check 3-15: Other Inspection
The following items are displayed while running.
AVERAGE
CURRENT
RANGE
ECO Mark
•
When the above item is faulty indication check the follow-
ing items.
Wiring (see Wiring Inspection)
ECU Communication Line (see ECU Communication
Line Inspection in the Fuel System (DFI) chapter)
Fuel Injectors (see Fuel Injectors section in the Fuel Sys-
tem (DFI) chapter)
Rear Wheel Rotation Sensor (see Rear Wheel Rotation
Sensor Signal (Service Code 24, 25) section in the Fuel
System (DFI) chapter)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
If the above items are good, replace the meter unit and/or
ECU.
ELECTRICAL SYSTEM 16-81
Meter, Gauge, Indicator Unit
Fuel Level Sensor Line Self-Diagnosis Mode
Inspection
NOTE
○
Usually when the open or short of the fuel level sensor
circuit is detected, it becomes the Fuel Level Sensor
Line Self-Diagnosis Mode.
The all segments of the fuel level gauge and fuel level
warning indicator [A] in the display will blink. (This func-
tion is Fuel Level Sensor Line Self-Diagnosis Mode.)
If the meter enters the self-diagnosis mode when the me-
ter is installed in the motorcycle, check the fuel level sen-
sor (see Fuel Level Sensor Inspection) and wiring.
If the fuel level sensor and wiring are good, replace the
meter unit.
16-82 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Circuit (ZR1000F)
1. Ignition Switch
2. Water Temperature Sensor
3. Neutral Switch
4. Oil Pressure Switch
5. ECU
6. Rear Wheel Rotation Sensor
7. Fuel Level Sensor
8. Frame Ground 2
9. Frame Ground 1
10. Engine Ground
11. Battery 12 V 10 Ah
12. Main Fuse 30 A
13. Starter Relay
14. to Dimmer Switch and Passing Button
15. to Turn Signal Switch (Right)
16. to Headlight Control Unit
17. to Turn Signal Switch (Left)
18. Meter Unit
19. Joint Connector B
20. Fuse Box 1
21. Ignition Fuse 15 A
22. Meter Fuse 7.5 A
23. Joint Connector D
ELECTRICAL SYSTEM 16-83
Meter, Gauge, Indicator Unit
Meter Circuit (ZR1000G)
1. Ignition Switch
2. Water Temperature Sensor
3. Neutral Switch
4. Oil Pressure Switch
5. ECU
6. Rear Wheel Rotation Sensor
7. Fuel Level Sensor
8. ABS Hydraulic Unit
9. Frame Ground 2
10. Frame Ground 1
11. Engine Ground
12. Battery 12 V 10 Ah
13. Main Fuse 30 A
14. Starter Relay
15. to Dimmer Switch and Passing Button
16. to Turn Signal Switch (Right)
17. to Headlight Control Unit
18. to Turn Signal Switch (Left)
19. Meter Unit
20. Fuse Box 1
21. Ignition Fuse 15 A
22. Meter Fuse 7.5 A
23. Joint Connector B
24. Joint Connector D
16-84 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This
system provides a theft proof device by means of matching a code between the inbuilt key transponder
and ECU. If the code does not match, ignition system, injectors, subthrottle valve actuator and exhaust
butterfly valve actuator will not operate and the engine will not start.
Abstract
•
Do not keep more than one immobilizer key of any system on a key ring. Jamming of the key code
signal may occur and the operation of the system may be affected.
•
The red warning indicator (LED) will blink for a period of 24 hours once the ignition switch has been
switched off and the key removed. This blinking can be set to on or off as desired by holding the
upper and lower buttons down for 2 seconds within 20 seconds of switching the ignition off.
•
If all coded keys are lost the ECU and ignition switch will have to be replaced.
•
The immobilizer system can not function until the ignition key code is registered in the ECU.
•
A total of five keys can be registered in the ECU at any one time.
Operational Cautions
1. Do not put two keys of any immobilizer system on the same key ring.
2. Do not submerge any key in water.
3. Do not expose any key to excessively high temperature.
4. Do not place any key close to magnet.
5. Do not place a heavy item on any key.
6. Do not grind any key or alter its shape.
7. Do not disassemble the plastic part of any key.
8. Do not drop the key and/or apply any shocks to the key.
9. When a ignition key is lost, the user should go to his dealer to invalidate the lost key registration
in the ECU.
10.When the all ignition keys are lost, the user should go to his dealer and have a new ECU installed
and register the ignition keys.
NOTE
○
No.9 and 10 are strongly recommended to the customer to ensure security of the motorcycle.
Key Registration
Case 1: When additional spare ignition key is required.
•
Prepare a new spare ignition key.
•
Cut the key in accordance with the shape of the current
ignition key.
•
Remove the front seat (see Front Seat Removal in the
Frame chapter).
•
Remove the immobilizer/Kawasaki diagnostic system
connector cap [A].
•
Connect the key registration unit [A] and key registration
adapter [B] as shown.
Special Tools - Key Registration Unit: 57001-1582
Key Registration Adapter: 57001-1746
ELECTRICAL SYSTEM 16-85
Immobilizer System (Equipped Models)
•
Insert the registered ignition key to the ignition switch and
turn it to “ON.”
Verified
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the registration mode (go to
the next step).
Not Verified
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the collation error (refer to the
following failure illustrations).
Immobilizer Amplifier Failure
Registered Ignition Key Collation Error
•
Turn the registered ignition key to “OFF” and remove the
registered ignition key.
If there are other registered ignition keys, they should all
do the procedure above.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink continuously to display that the ECU is
in the registration mode for 15 seconds.
NOTE
○
Insert next key and turn it to “ON” within 15 seconds af-
ter previous key is turned to “OFF” and removed other-
wise registration mode will be ended and the red warn-
ing indicator (LED) and immobilizer warning indicator
stops blinking.
○
To return to the registration mode start the registered
ignition key(s) verification procedure. This applies to all
ignition key registration.
•
Insert the ignition key 1 to the ignition switch and turn it to
“ON.”
NOTE
○
Keep the other ignition key away from the immobilizer
antenna.
16-86 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
•
The ignition key 1 is successfully registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 3 times and stops for 1 second and then
repeats this cycle.
ELECTRICAL SYSTEM 16-87
Immobilizer System (Equipped Models)
•
Turn the ignition key 1 to “OFF” and remove the ignition
key 1.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the registration mode.
NOTE
○
Turn to “OFF” the ignition switch and wait for the period
of 15 seconds or more. The registration mode automat-
ically finishes and the red warning indicator (LED) and
immobilizer warning indicator will switch off.
○
This procedure registered the registered ignition key
and one ignition key.
○
Continue with the procedure to register the second and
later keys before the 15 seconds period has elapsed.
•
Insert the ignition key 2 to the ignition switch and turn it to
“ON.”
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
16-88 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
•
The ignition key 2 is registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 4 times and stops for 1 second and then
repeats this cycle.
This procedure has registered the 2 ignition keys.
•
Continue with the procedure to register an additional one
ignition key.
NOTE
○
The ECU can store up the five key codes.
Red Warning Indicator (LED) and Immobilizer Warning
Indicator Blink
Indicators
Blinks
Indicators
Stop
Remarks
Ignition Key 3 5times 1 second Repeat
•
Turn to “OFF” the ignition switch and wait for period of
more than 15 seconds.
•
The registration mode automatically ends.
•
The red warning indicator (LED) goes off [A].
•
Remove the key registration unit, key registration adapter
and install the immobilizer/Kawasaki diagnostic system
connector cap.
NOTE
○
Turn the ignition switch to “ON” with the registered igni-
tion key.
○
Check that the engine can be started using all regis-
tered ignition keys.
ELECTRICAL SYSTEM 16-89
Immobilizer System (Equipped Models)
Spare Ignition Key Registration Flow Chart
16-90 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
Case 2: When the ignition switch is faulty and to be
replaced.
•
Prepare a new ignition switch [A] and two new ignition
keys [B].
These parts are available as a set. Prepare the current
registered ignition key [C].
•
Remove:
Ignition Switch (see Immobilizer System Parts Replace-
ment)
Front Seat (see Front Seat Removal in the Frame chap-
ter)
•
Remove the immobilizer/Kawasaki diagnostic system
connector cap [A].
•
Connect the key registration unit [A] and key registration
adapter [B] as shown.
Special Tools - Key Registration Unit: 57001-1582
Key Registration Adapter: 57001-1746
•
Connect:
New Ignition Switch Lead Connector [A]
Current Immobilizer Antenna Lead Connector [B]
NOTE
○
Keep the ignition switches more than 15 cm (5.9 in.).
New Ignition Switch [C]
Current Ignition Switch [D]
•
Insert the current registered ignition key [A] at the current
ignition switch [B].
•
Insert the new ignition key 1 [C] to the new ignition switch
[D] and turn it to “ON.”
ELECTRICAL SYSTEM 16-91
Immobilizer System (Equipped Models)
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 1 time and stops for 1 second and re-
peats this cycle.
Not Verified
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the collation error.
Immobilizer Amplifier Failure
Registered Ignition Key Collation Error
•
Turn to “OFF” and remove the new ignition key 1.
NOTE
○
Insert the next key and turn it to “ON” within 15 sec-
onds after previous key is turned to “OFF” and removed
otherwise registration mode will be ended and the red
warning indicator (LED) and immobilizer warning indi-
cator stops blinking.
Verified
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the ECU is in the registration
mode (go to the next step).
16-92 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
•
Disconnect the immobilizer antenna lead connector, then
connect the antenna lead connector of the new ignition
switch.
•
Insert the ignition key 1 [A] again into the new ignition
switch and turn it to “ON.”
NOTE
○
Insert the next key and turn it to “ON” within 15 sec-
onds after previous key is turned to “OFF” and removed
otherwise registration mode will be ended and the red
warning indicator (LED) and immobilizer warning indi-
cator stops blinking.
○
To return to the registration mode start the registered
ignition key verification procedure. This applies to all
ignition key registration.
○
Keep other ignition keys away from the ignition switch.
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
ELECTRICAL SYSTEM 16-93
Immobilizer System (Equipped Models)
•
The ignition key 1 is successfully registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 2 times and stops for 1 second and
then repeats this cycle to indicate successful registering
of ignition key 1.
•
Turn to “OFF” and remove ignition key 1.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the registration mode.
NOTE
○
Turn to “OFF” the ignition switch and wait for the period
more than 15 seconds. The registration mode automat-
ically ends and red warning indicator (LED) and immo-
bilizer warning indicator go off.
○
This procedure has , registered the registered ignition
key and one ignition key.
○
Continue the procedure to program the second and
later keys.
•
Insert the ignition key 2 to the ignition switch and turn it to
“ON.”
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
16-94 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
Ignition Key Collation Error
•
The ignition key 2 is successfully registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 3 times and stops for 1 second and then
repeat this cycle to indicate successful programming of
ignition key 2.
•
Turn to “OFF” the ignition switch and wait for period more
than 15 seconds.
•
The registration mode automatically ends.
•
The red warning indicator (LED) goes off [A].
•
Remove the key registration unit, key registration adapter
and install the immobilizer/Kawasaki diagnostic system
connector cap.
NOTE
○
Turn the ignition switch to “ON” with the registered igni-
tion key.
○
Check that the engine can be started using all regis-
tered ignition keys.
•
Install the new ignition switch (see Immobilizer System
Parts Replacement).
Case 3: When the ECU is faulty and has to be replaced.
•
Prepare a new ECU [A] and current registered ignition
key(s) [B].
NOTE
○
The key registration unit is not required.
○
After replacing the ECU, be sure to register the 2 ignition
keys. If the 2 keys are not registered, the engine can
not be started.
ELECTRICAL SYSTEM 16-95
Immobilizer System (Equipped Models)
•
Replace the ECU [A] (see ECU Removal/Installation in
the Fuel System (DFI) chapter).
•
Insert the current registered ignition key into the ignition
switch and turn it to “ON.”
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
Registered Ignition Key Collation Error
•
The registered ignition key is registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 1 time and stops for 1 second and the
repeats this cycle to indicate successful registration of the
registered ignition key.
16-96 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
•
Turn to “OFF” the registered ignition key and remove it.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the registration mode.
NOTE
○
Insert next key and turn it to “ON” within 15 seconds af-
ter previous key is turned to “OFF” and removed other-
wise registration mode will be ended and the red warn-
ing indicator (LED) and immobilizer warning indicator
go off.
○
To return to the registration mode start the registered
ignition key verification procedure. This applies to all
ignition key registration.
•
Insert the other remaining registered ignition key to the
ignition switch and turn it to “ON.”
NOTE
○
Keep the other ignition keys away from the immobilizer
antenna.
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
ELECTRICAL SYSTEM 16-97
Immobilizer System (Equipped Models)
•
The other remaining ignition key is registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 2 times and stops for 1 second and
then repeats this cycle to indicate successful registration
of ignition key.
•
Turn to “OFF” the ignition switch and wait for period more
than 15 seconds.
•
The registration mode automatically ends.
•
The red warning indicator (LED) goes off [A].
NOTE
○
Turn the ignition switch to “ON” with the registered igni-
tion key.
○
Check that the engine can be started using all regis-
tered ignition keys.
Case 4: When all registered ignition keys are faulty or
lost.
The all registered ignition keys replacement is considered
very rare case. However if it is required, the following is
necessary.
NOTE
○
The ECU must be replaced with a new one because
the registered ignition key code that is registered in the
current ECU can not be rewritten.
•
Prepare a new ECU [A] and 2 new ignition keys [B].
NOTE
○
The key registration unit is not required.
○
After replacing the ECU, be sure to register the 2 ignition
keys. If the 2 keys are not registered, the engine can
not be started.
•
Insert the first ignition key into the ignition switch and turn
it to “ON.”
16-98 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
Ignition Key Collation Error
•
The first ignition key is registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 1 time and stops for 1 second and the
repeats this cycle to indicate successful registration of the
first ignition key.
•
Turn to “OFF” the first ignition key and remove it.
•
The red warning indicator (LED) and immobilizer warning
indicator [A] blink to display the registration mode.
NOTE
○
Insert next key and turn it to “ON” within 15 seconds af-
ter previous key is turned to “OFF” and removed other-
wise registration mode will be ended and the red warn-
ing indicator (LED) and immobilizer warning indicator
go off.
○
To return to the registration mode start the registered
ignition key verification procedure. This applies to all
ignition key registration.
•
Insert the second ignition key to the ignition switch and
turn it to “ON.”
NOTE
○
Keep the other ignition keys away from the immobilizer
antenna.
ELECTRICAL SYSTEM 16-99
Immobilizer System (Equipped Models)
If there is any problem in the registration, the red warning
indicator (LED) and immobilizer warning indicator [A] blink
to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted
Ignition Key Collation Error
•
The second ignition key is registered in the ECU.
The red warning indicator (LED) and immobilizer warning
indicator [A] blink 2 times and stops for 1 second and
then repeats this cycle to indicate successful registration
of second ignition key.
•
Turn to “OFF” the ignition switch and wait for period more
than 15 seconds.
•
The registration mode automatically ends.
•
The red warning indicator (LED) [A] goes off.
16-100 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
NOTE
○
Turn the ignition switch to “ON” with the registered igni-
tion key.
○
Check that the engine can be started using all regis-
tered ignition keys.
ELECTRICAL SYSTEM 16-101
Immobilizer System (Equipped Models)
All Keys Initial Registration Flow Chart
16-102 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
Immobilizer System Parts Replacement
Ignition Switch Replacement
•
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Ignition Switch Cover (see Ignition Switch Cover Re-
moval in the Frame chapter)
•
Slide the dust cover [A].
•
Disconnect the lead connectors [B].
•
Using a punch [A], mark the punch mark at the center of
broken Torx bolt head.
NOTE
○
Make the punch mark at center of the bolt head surely.
•
Extend the punch mark with the
2 mm drill [A].
•
In addition, extend the punch mark with the
3.5 mm drill.
•
Lastly, shave off the Torx bolt head with the
6.5 mm drill.
NOTE
○
Be sure to do not damage the lead wires and compo-
nent parts with a drill.
•
Remove the clamp.
•
Remove the bracket [A] together with the pad [B].
•
Remove:
Ignition Switch Bolts [A], Washers and Dampers
Bracket [B]
ELECTRICAL SYSTEM 16-103
Immobilizer System (Equipped Models)
•
Replace the ignition switch [A] with a new one.
•
Install:
Pad [B]
Brackets [C]
Trim [D]
Dampers [E]
Washers [F]
Bolts [G]
•
Hold the ignition switch leads with the clamp [H], and in-
stall the clamp to the bracket.
•
Check that the pad [A] is in place on the frame.
•
Tighten a new Torx bolt [A] until the bolt head [B] is broken
[C].
•
Run the leads correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
•
Register the more than two ignition keys (see Key Regis-
tration).
Immobilizer Amplifier Replacement
•
Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
•
Remove the clamp [A], and turn up the heat insulation
rubber plate [B].
16-104 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
•
Remove the immobilizer amplifier [A] from the bracket.
•
Disconnect the connector [B].
•
Installation is the reverse of removal.
ECU Replacement
NOTICE
Never drop the ECU especially on a hard surface.
Such a shock to the ECU can damage it.
NOTE
○
Replace the ECU according to the following procedure
for the models with guards.
○
Refer to the ECU section in the Fuel System (DFI) chap-
ter for the models without guards.
•
Remove the ECU with installed its connectors (see ECU
Removal in the Fuel System (DFI) chapter).
•
Using a small chisel or other suitable tool, remove the
screws [A].
•
Remove the upper guard [B] and lower guard [C].
•
Remove the connector guard [D].
•
Disconnect the connectors.
•
Remove the ECU [E].
ELECTRICAL SYSTEM 16-105
Immobilizer System (Equipped Models)
•
Check that the pads [A] and trims [B] are in place on the
upper [C] and lower [D] guards.
•
Connect the connectors to the ECU.
•
Install the connector guard to the ECU connector.
•
Install the lower and upper guards to the ECU.
NOTICE
Do not pinch the leads.
•
Tighten the new screws using the Kawasaki genuine
screws of which threads are coated with locking agent.
Registered Immobilizer Relational Parts Replacement
Chart
Failed or Lost Part
Ignition
Keys
Ignition
Switch
Amplifier ECU
Ignition
Key
•
Ignition
Switch
•
Amplifier
•
*
ECU
•
*
Replacement Part
•
Main Replacement Part
Additional Replacement Part
Immobilizer System Inspection
•
Refer to the Immobilizer Amplifier and Blank Key Detec-
tion section in the Fuel System (DFI) chapter.
16-106 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
Immobilizer System Circuit
1. Ignition Switch
2. ECU
3. Immobilizer/Kawasaki Diagnostic System Connector
4. Frame Ground 2
5. Frame Ground 1
6. Engine Ground
7. Battery 12 V 10 Ah
8. Starter Relay
9. Main Fuse 30 A
10. Meter Unit
11. Fuse Box 1
12. Ignition Fuse 15 A
13. Joint Connector C
14. Immobilizer Antenna
15. Immobilizer Amplifier
ELECTRICAL SYSTEM 16-107
Switches and Sensors
Brake Light Timing Inspection
•
Refer to the Brake Light Switch Operation Inspection in
the Periodic Maintenance chapter.
Brake Light Timing Adjustment
•
Refer to the Brake Light Switch Operation Inspection in
the Periodic Maintenance chapter.
Switch Inspection
•
Using a tester, check to see that only the connections
shown in the table have continuity (about zero ohms).
For the switch housings and the ignition switch, refer to
the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Rear Brake Light Switch Connections
Side Stand Switch Connections
Neutral Switch Connections
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.
16-108 ELECTRICAL SYSTEM
Switches and Sensors
Water Temperature Sensor Inspection
•
Remove the water temperature sensor (see Water Tem-
perature Sensor Removal/Installation in the Fuel System
(DFI) chapter).
•
Suspend the sensor [A] in a container of coolant so that
the threaded portion is submerged.
•
Suspend an accurate thermometer [B] with temperature
sensing portions [C] located in almost the same depth.
NOTE
○
The sensor and thermometer must not touch the con-
tainer side or bottom.
•
Place the container over a source of heat and gradu-
ally raise the temperature of the coolant while stirring the
coolant gently.
•
Using a digital meter, measure the internal resistance of
the sensor.
If the digital meter does not show the specified values,
replace the sensor.
Water Temperature Sensor Resistance
Temperature
Resistance (k)
–20°C (–4°F) *18.80 ±2.37
0°C (32°F) *(about 6.544)
40°C (104°F)
1.136 ±0.095
100°C (212°F)
0.1553 ±0.0070
*: Reference Information
Oxygen Sensor Removal (Equipped Models)
NOTICE
Never drop the sensor especially on a hard surface.
Such a shock to the sensor can damage it.
NOTICE
Do not pull strongly, twist, or bend the oxygen sen-
sor lead. This may cause the wiring open.
•
Clear the oxygen sensor lead from the clamp [A].
•
Disconnect the oxygen sensor lead connector [B].
•
Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Exhaust Pipe Cover (see Muffler Body Removal in the
Engine Top chapter)
•
Clear the oxygen sensor lead from the clamp [A].
•
Remove the oxygen sensor [B].
ELECTRICAL SYSTEM 16-109
Switches and Sensors
Oxygen Sensor Installation (Equipped Models)
NOTICE
Never drop the oxygen sensor [A] especially on a
hard surface. Such a shock to the unit can damage
it. Do not touch the sensing part [B] and filter holes
[C] of the sensor to prevent oil contact. Oil contami-
nation from hands can reduce sensor performance.
•
Tighten:
Torque - Oxygen Sensor: 44 N·m (4.5 kgf·m, 32 ft·lb)
•
Run the oxygen sensor lead correctly (see Cable, Wire,
and Hose Routing section in the Appendix chapter).
•
Install the removed (see appropriate chapters).
Oxygen Sensor Inspection (Equipped Models)
•
Refer to the Oxygen Sensor Inspection in the Fuel System
(DFI) chapter.
Fuel Level Sensor Inspection
•
Remove:
Fuel Pump (see Fuel Pump Removal in the Fuel System
(DFI) chapter)
•
Check that the float moves up and down smoothly without
binding. It should go down under its own weight.
If the float does not move smoothly, replace the fuel pump.
Float in Full Position [A]
Float in Empty Position [B]
•
Using a tester [A], measure the resistance across the ter-
minals in the fuel level sensor lead connector [B].
Special Tool - Needle Adapter Set: 57001-1457
If the tester readings are not as specified, or do not
change smoothly according as the float moves up and
down, replace the fuel pump.
Fuel Level Sensor Resistance
Standard: Full position: 9.6
∼ 12.4 Ω
Empty position: 222
∼ 228 Ω
16-110 ELECTRICAL SYSTEM
Relay Box
The relay box [A] has relays and diodes. The relays and
diodes can not be removed.
Relay Box Removal
NOTICE
Never drop the relay box especially on a hard sur-
face.
Such a shock to the relay box can damage it.
•
Remove the rear frame cover (see Tail/Brake Light (LED)
Removal).
•
Disconnect:
Connectors [A]
•
Remove:
Relay Box [B]
Relay Circuit Inspection
•
Remove the relay box (see Relay Box Removal).
•
Check conductivity of the following numbered terminals
by connecting a tester and one 12 V battery to the relay
box as shown (see Relay Box Internal Circuit in this sec-
tion).
If the tester does not read as specified, replace the relay
box.
Relay Circuit Inspection (with the battery disconnected)
Tester Connection Tester Reading ()
Headlight Circuit
Relay
1-3
7-6
ECU Main Relay
4-5
Not *
7-8
Fuel Pump Relay
9-10
Not *
11-16
Starter Circuit Relay
11-12
17-20
Fan Relay
18-19
Not *
*: The actual reading varies with the tester used.
ELECTRICAL SYSTEM 16-111
Relay Box
Relay Circuit Inspection (with the battery connected)
Battery
Connection
(+) (–)
Tes te r
Connection
Tes te r
Reading ()
Headlight Relay 2-11 1-3 0
ECU Main Relay
4-5 7-6 0
Fuel Pump Relay 9-10 7-8 0
Fan Relay 18-19 17-20 0
Battery
Connection
(+) (–)
Tes te r
Connection
(+) (–)
Tester Reading
(V)
Starter
Circuit Relay
16-12 11-12 Battery Voltage
(+): Apply positive lead.
(–): Apply negative lead.
Diode Circuit Inspection
•
Remove the relay box (see Relay Box Removal).
•
Check conductivity of the following pairs of terminals (see
Relay Box Internal Circuit in this section).
Diode Circuit Inspection
Tester Connection
1-11, 2-11, 12-13, 12-15, 12-16, 13-14,
13-15
The resistance should be low in one direction and more
than 10 times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the relay box must be replaced.
NOTE
○
The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking,
the lower reading should be from zero to one half the
scale.
16-112 ELECTRICAL SYSTEM
Relay Box
Relay Box Internal Circuit
A: Headlight Circuit Relay
B: ECU Main Relay
C: Fuel Pump Relay
D: Starter Circuit Relay
E: Fan Relay
ELECTRICAL SYSTEM 16-113
Fuse
30 A Main/15 A ECU Fuse Removal
•
Remove:
Starter Relay Cover (see Starter Relay Inspection)
•
Pull out the fuses [A] from the starter relay with needle
nose pliers.
Fuse Box Fuse Removal
•
Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
•
Unlock the hook [A] to lift up the lid.
Fuse Box 1 [B]
Fuse Box 2 [C]
•
Pull the fuses [A] straight out of the fuse box with needle
nose pliers.
Fuse Installation
If a fuse fails during operation, inspect the electrical sys-
tem to determine the cause, and then replace it with a
new fuse of proper amperage.
•
Install the fuse box fuses on the original position as spec-
ified on the lid.
Fuse Inspection
•
Removethefuse(see30AMain/15AECU/FuseBox
Fuse Removal).
•
Inspect the fuse element.
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]
NOTICE
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
APPENDIX 17-1
17
Appendix
Table of Contents
Cable, Wire, and Hose Routing .............................................................................................. 17-2
Troubleshooting Guide ........................................................................................................... 17-57
17-2 APPENDIX
Cable, Wire, and Hose Routing
1. Right Switch Housing Lead
2. Throttle Cables
3. Front Brake Hose
4. Clamp (Hold the meter lead and city light lead.)
5. Left Switch Housing Lead
6. Clutch Cable
7. Clamps (Hold the headlight leads.)
8. Headlight Lead Connectors
9. Headlight Control Unit Lead Connector
10. Hold the front turn signal light leads with the hooks of the headlight assembly.
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Run the right switch housing lead in back of the front brake hose and throttle cables. Run the
throttle cables in front of the front brake hose.
2. Harness Cover (Hold the right switch housing lead, throttle cables and front brake hose.)
3. Run the right switch housing lead and throttle cables in back of the guide on the headlight
bracket.
4. Clamp (Hold the throttle cables and front brake hose.)
5. Harness Cover (Hold the clutch cable and left switch housing lead.)
6. Clamp (Hold the meter lead and city light lead as shown.)
7. Run the throttle cables in front of the front brake hose, main harness, left switch housing lead
and city light lead.
8. Run the clutch cable in front of the throttle cables, front brake hose, main harness, left switch
housing lead and city light lead.
9. Meter Lead
10. Clamp (Hold the meter lead and city light lead as shown.)
11. City Light Lead
12. Front
13. Clamp (Hold the meter lead.)
14. Place the city light lead connector to the left side of the main harness.
15. Run the front brake light switch lead downward.
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Clamp (Hold the horn lead.)
2. Clamp (Hold the clutch cable and right switch housing lead. Run the right switch housing lead
to inside of the clutch cable.)
3. Run the headlight control unit lead to the left side of the connector.
4. Run the main harness in back of the throttle cables, front brake hose and clutch cable. Run the
throttle cables in front of the front brake hose, main harness, left switch housing lead and city
light lead. Run the clutch cable in front of the throttle cables.
5. Main Harness
6. Right Switch Housing Lead
7. Front Brake Hoses (ABS Equipped Models)
8. Throttle Cables
9. Clutch Cable
10. Headlight Control Unit Lead Connector
11. Install the front wheel rotation sensor lead connector (ABS equipped models) to the headlight
bracket.
12. Run the front turn signal light leads above the headlight bracket.
13. Run the clutch cable in back of the front brake hose.
14. Install the front turn signal light lead connectors to the headlight bracket.
15. Run the left front turn signal light lead in front of the front wheel rotation sensor lead (ABS
equipped models).
17-6 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Headlight Control Unit
2. Left Switch Housing Lead
3. Throttle Cables
4. Main Harness
5. Regulator/Rectifier
6. Run the throttle cables to the inside of the immobilizer antenna lead (equipped models), left
switch housing lead and ignition switch lead.
7. Clamp (Hold the regulator/rectifier lead.)
8. Run the throttle cables, left switch housing lead and the main harness into the clamp. Place the
blue tape of the main harness to the clamp.
9. Run the regulator/rectifier lead above the throttle cables.
10. Run the main harness, left switch housing lead and throttle cables to the inside of the engine
bracket.
11. Run the regulator/rectifier lead above the immobilizer antenna lead (equipped models), left
switch housing lead and ignition switch lead.
12. Engine Subharness Connector
13. Run the engine subharness to the outside of the left switch housing lead, throttle cables and
main harness.
14. Immobilizer Antenna Lead Connector (Equipped Models)
15. Left Switch Housing Lead Connector
16. Ignition Switch Lead Connector
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Run the clutch cable in back of the front brake hose.
2. Clamp (Hold the clutch cable and right switch housing lead. Run the right switch housing lead
to inside of the clutch cable.)
3. Clamp (Hold the horn lead.)
4. Run the right switch housing lead to inside of the main frame and engine bracket.
5. Radiator Fan Motor Leads
6. Radiator Fan Motor Lead Connector
7. Right Switch Housing Lead Connector
8. Ignition Coil Connector
9. Right Switch Housing Leads
10. Run the clutch cable between the engine bracket and radiator.
11. Clamp (Hold the clutch cable.)
12. Run the clutch cable into the clamp of engine bracket.
17-10 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Run the main harness under the air switching valve.
2. Run the radiator fan motor lead under the frame.
3. Clamp (Hold the main harness (for throttle sensors) at the white tape.)
4. Viewed from A
5. Run the right switch housing lead under the frame. Run it to the outside of the radiator.
6. Run the main throttle sensor lead and subthrottle sensor lead under the air switching valve hose.
7. Clamps (Hold the fuel injector lead at the white tape position.)
8. Intake Air Temperature Sensor Lead Connector
9. Run the intake air temperature sensor lead under the crankshaft sensor lead and rear wheel
rotation sensor lead, and run it above the alternator lead.
10. Rear Wheel Rotation Sensor Lead
11. Crankshaft Sensor Lead
12. Alternator Lead
13. Frame Ground Terminal (The angle of ground lead is as shown.)
14. Fuel Hose
15. Breather Hose
16. Run the side stand switch lead in front of the frame. Run it under the fuel injector lead.
17. Run the fuel injector lead in front of the breather hose.
18. Take care not to pinch the engine subharness by the throttle body assy holder clamps.
19. Run the immobilizer antenna lead (equipped models) and ignition switch lead above the frame.
20. Run the main harness and throttle cables under the frame. Run them to the outside of the
radiator.
21. Run the immobilizer antenna lead (equipped models) and ignition switch lead around the ignition
switch.
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Frame Ground Terminal (The angle of ground lead is as shown.)
2. Alternator Lead
3. Rear Wheel Rotation Sensor Lead
4. Crankshaft Sensor Lead
5. Run the alternator lead under the rear wheel rotation sensor lead and crankshaft sensor lead.
6. Clamp (Hold the rubber portion of the rear wheel rotation sensor lead.)
7. Fuel Pump Lead
8. Run the fuel pump lead above the main harness.
9. Clamp (Hold the main harness. Install it to the battery case.)
10. Clamp (Hold the fuel pump lead.)
11. Exhaust Butterfly Valve Actuator Lead Connector (Place it between the fuse box and battery
case.)
12. Install the fuel pump lead connector to the bracket.
13. Install the clamp to the frame as shown.
14. Starter Motor Cable
15. Fuse Boxes
16. Run the main harness and starter motor cable between the rear frame bracket and battery case.
17. Battery Negative (–) Cable
18. Vehicle-down Sensor
19. Fuel Tank Breather Hose (Other than CAL, SEA-B1 and TH Models)
20. Main Harness
21. Run the battery negative (–) cable above the main harness and run it under the fuel tank breather
hose (other than CAL, SEA-B1 and TH models).
17-14 APPENDIX
Cable, Wire, and Hose Routing
1. Clamp (Hold the immobilizer antenna lead (equipped models) and ignition switch lead.)
2. Radiator Fan Motor Lead
3. Run the right switch housing lead and clutch cable under the frame, and run them to the outside
of the radiator mounting portion.
Run the right switch housing lead above the clutch cable.
4. Run the clutch cable to the outside of the engine bracket.
5. Radiator Fan Motor Lead Connector
6. Right Switch Housing Lead Connector
7. Clamp (Hold the right switch housing lead.)
8. Run the main harness (for right switch housing lead) under the air switching valve.
9. Main Harness (for Right Switch Housing Lead)
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Alternator Lead Connector (Install it to the connector bracket.)
2. Crankshaft Sensor Lead Connector (Install it to the connector bracket.)
3. Connector Bracket (Install it to the air cleaner housing.)
4. Rear Wheel Rotation Sensor Lead Connector (Install it to the connector bracket.)
5. Run the alternator lead under the rear wheel rotation sensor lead and crankshaft sensor lead.
6. Rear Brake Light Switch Lead
7. Run the main harness above the brake hoses (ABS equipped models).
8. Clamp (Hold the rubber portion of the rear wheel rotation sensor lead.)
9. Install the clamp to the frame as shown.
10. Clamp (Hold the immobilizer amplifier lead (equipped models), oxygen sensor lead (equipped
models), rear brake light switch lead and crankshaft sensor lead.)
11. Run the intake air temperature sensor lead under the crankshaft sensor lead, rear wheel rotation
sensor lead and alternator lead.
12. Run the alternator lead, rear wheel rotation sensor lead and crankshaft sensor lead in front of
the breather hose.
17-16 APPENDIX
Cable, Wire, and Hose Routing
1. Fuel Pump Lead
2. Main Harness
3. Install the clamp to the battery case as shown.
4. Clamp (Hold the main harness. Install it to the rear frame bracket as shown.)
5. Front
6. Install the fuel pump lead connector to the bracket.
7. Install the clamps to the frame as shown.
8. ECU Lead
9. Starter Relay
10. Run the main harness and starter motor cable between the rear frame bracket and battery case.
11. Clamp (Hold the fuel pump lead.)
12. Vehicle-down Sensor
13. Run the fuel pump lead above the main harness.
14. Immobilizer Amplifier (Equipped Models)
APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Install the clamp to the left side of the projection as shown.
2. Projection of Frame
3. Install the clamp to the frame as shown.
4. Run the immobilizer antenna lead (equipped models) and ignition switch lead above the frame.
5. Run the main harness, left switch housing lead and throttle cables under the frame. Run them
to the inside of the engine bracket.
6. Run the immobilizer antenna lead (equipped models) and ignition switch lead under the main
harness and air switching valve lead.
7. Run the throttle cables above the immobilizer antenna lead (equipped models) and ignition
switch lead. Run them under the main harness (for right switch housing lead).
8. Run the main harness (for main throttle sensor) to the inside of the throttle cables.
17-18 APPENDIX
Cable, Wire, and Hose Routing
1. Battery Negative (–) Cable
2. Fuel Tank Breather Hose (Other than CAL, SEA-B1 and TH Models)
3. Run the battery negative (–) cable between the fuel tank breather hose (other than CAL, SEA-B1
and TH models) and main harness.
4. Fuel Tank Drain Hose
5. Run the side stand switch lead under the fuel injector lead.
6. Install the clamp to the frame as shown.
7. Run the intake air temperature sensor lead under the crankshaft sensor lead, rear wheel rotation
sensor lead and alternator lead.
8. Brake Hoses (ABS Equipped Models)
APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Install the clamp to the frame as shown.
2. Battery Positive (+) Cable
3. Starter Motor Cable
4. Battery Positive (+) Lead Connector
5. Run the battery positive (+) lead under the starter motor cable.
6. Fuel Tank Breather Hose (Other than CAL, SEA-B1 and TH Models)
7. Run the battery negative (–) cable to the outside of the fuel tank breather hose (other than CAL,
SEA-B1 and TH models).
8. Run the battery negative (–) cable under the fuel tank breather hose (other than CAL, SEA-B1
and TH models). Run it above the main harness.
17-20 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-21
Cable, Wire, and Hose Routing
1. Clamp (Hold the alternator lead, side stand switch lead, engine subharness and fuel tank drain
hose. Face the open side of the clamp to the inside.)
2. Clamp (Hold the alternator lead and side stand switch lead. Install it to the frame as shown.)
3. Run the side stand switch lead under the fuel injector lead.
4. Alternator Lead
5. Starter Motor Cable
6. Main Harness
7. Install the clamp to the rear frame bracket as shown.
8. Run the fuel tank breather hose (other than CAL, SEA-B1 and TH models), fuel tank drain hose
and side stand switch lead to the inside of the engine sprocket cover.
9. Run the side stand switch lead to the outside of the lower fairing.
10. Side Stand Switch Lead Connector
11. Fuel Hose
12. ABS Hydraulic Unit (ABS Equipped Models)
13. Run the starter motor cable to inside of the brake hoses (ABS equipped models), fuel tank
breather hose (other than CAL, SEA-B1 and TH models), fuel tank drain hose, side stand switch
lead, alternator lead, engine subharness and air cleaner drain hose.
14. Engine Ground Terminal
15. Fuel Tank Breather Hose (Other than CAL, SEA-B1 and TH Models)
16. Fuel Tank Drain Hose
17. Air Cleaner Drain Hose
18. Run the engine subharness to the inside of the air cleaner drain hose.
19. Engine Subharness
17-22 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-23
Cable, Wire, and Hose Routing
1. Immobilizer Amplifier (Equipped Models)
2. Clamp (Equipped Models: Hold the immobilizer amplifier lead (equipped models), oxygen sen-
sor lead (equipped models), crankshaft sensor lead, rear wheel rotation sensor lead and rear
brake light switch lead. Install it to the immobilizer amplifier bracket.)
3. Run the rear wheel rotation sensor lead and rear brake light switch lead between the frame and
the brake pipes (ABS equipped models).
4. Brake Hoses (ABS Equipped Models)
5. Clamp (Hold the oxygen sensor lead (equipped models) and crankshaft sensor lead. Face the
open side of the clamp rearward.)
6. Oxygen Sensor Lead Connector (Equipped Models)
7. Clamp (Equipped Models: Hold the oxygen sensor lead (equipped models) and crankshaft sen-
sor lead. Install it to the immobilizer amplifier bracket.)
8. Clamp (Hold the rear wheel rotation sensor lead and rear brake hose.)
9. Reserve Tank Overflow Hose
10. Clamp (Hold the oxygen sensor lead (equipped models) and crankshaft sensor lead.)
11. Oxygen Sensor Lead
12. Crankshaft Sensor Lead
17-24 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-25
Cable, Wire, and Hose Routing
1. Breather Hose (CAL, SEA-B1 and TH Models)
2. Fuel Pump Lead
3. Main Harness
4. Run the exhaust butterfly valve cables to the outside of the purge hose and breather hose (CAL,
SEA-B1 and TH models).
5. Run the exhaust butterfly valve cables under the main harness and fuel pump lead.
6. Exhaust Butterfly Valve Cables
7. Purge Hose (CAL, SEA-B1 and TH Models)
8. Canister (CAL, SEA-B1 and TH Models)
9. Exhaust Butterfly Valve Actuator
10. Run the exhaust butterfly valve cables between the rear frame bracket and battery case.
11. Battery Case
12. Run the exhaust butterfly valve cables to the inside of the rear wheel rotation sensor lead and
rear brake light switch lead.
13. Clamp (Hold the rear wheel rotation sensor lead and rear brake light switch lead.)
14. Rear Wheel Rotation Sensor Lead
15. Brake Hoses (ABS Equipped Models)
16. Rear Brake Light Switch Lead
17. Clamp (Hold the exhaust butterfly valve cables.)
18. Rubber Boots
19. Run the exhaust butterfly valve cables into the guide.
17-26 APPENDIX
Cable, Wire, and Hose Routing
1. Clamp (Hold the rear wheel rotation sensor lead.)
2. Clamp (Hold the grommet of the rear wheel rotation sensor lead.)
3. Clamps (Hold the rear wheel rotation sensor lead and rear brake hose.)
4. Run the rear wheel rotation sensor lead to the inside of the rear brake reservoir hose.
5. Fuel Tank Drain Hose
6. Clamp (Hold the side stand switch lead and alternator lead.)
7. Side Stand Switch Lead
8. Alternator Lead
9. Engine Subharness
10. Fuel Hose
11. Starter Motor Cable
12. ABS Hydraulic Unit Lead (ABS Equipped Models)
APPENDIX 17-27
Cable, Wire, and Hose Routing
1. Relay Box
2. ECU
3. Turn Signal Relay
4. Install the clamp to the rear frame bracket as shown.
5. ABS Self-diagnosis Terminal (ABS Equipped Models)
6. ABS Kawasaki Diagnosis System Connector (ABS Equipped Models)
7. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
8. Rear Right Turn Signal Light Lead Connector (Hold it to the bracket.)
9. Rear Left Turn Signal Light Lead Connector (Hold it to the bracket.)
10. License Plate Light Lead Connector (Hold it to the bracket.)
11. Tail/Brake Light Lead Connector (Hold it to the bracket.)
17-28 APPENDIX
Cable, Wire, and Hose Routing
1. Install the clamp to the rear frame bracket as shown.
2. Fuel Pump Lead
3. Rear Right Turn Signal Light Lead Connector (Install it to the bracket.)
4. Rear Left Turn Signal Light Lead Connector (Install it to the bracket.)
5. License Plate Light Lead Connector (Install it to the bracket.)
6. Tail/Brake Light Lead Connector (Install it to the bracket.)
7. Run the license plate light lead and tail/brake light lead to the outside of the rear turn signal light
lead connectors.
8. Pad (Hold the tail/brake light lead connector.)
9. Take care not to pinch the leads by the tool kit.
10. Clamp (Hold the rear turn signal light leads, license plate light lead and tail/brake light lead.)
11. Run the rear turn signal light leads and license plate light lead into this hole.
12. Tail/Brake Light Lead
APPENDIX 17-29
Cable, Wire, and Hose Routing
1. Run the rear turn signal light leads, license plate light lead and tail/brake light lead into this hole.
2. Take care not to pinch the leads by the tool kit.
3. Clamp (Hold the rear turn signal light leads, license plate light lead and tail/brake light lead.)
4. Tail/Brake Light Lead
5. Run the rear turn signal light leads and license plate light lead into this hole.
6. Run the rear turn signal light leads and license plate light lead in the flap. Take care not to pinch
the leads by the flap.
17-30 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-31
Cable, Wire, and Hose Routing
1. Rivet
2. Run the fuel tank breather hose (other than CAL, SEA-B1 and TH models) and battery negative
(–) cable into the hole of the heat insulation rubber plate.
3. Run the fuel tank drain hose into the hole of the heat insulation rubber plate.
4. Run the fuel hose into the hole of the heat insulation rubber plate.
5. Run the alternator lead in front of the heat insulation rubber plate.
6. Run the fuel pump lead above the heat insulation rubber plate.
7. Clamp (Hold the main harness and heat insulation rubber plate, and face the open side of the
clamp to the right side.)
17-32 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-33
Cable, Wire, and Hose Routing
1. Front Heat Insulation Rubber Plate
2. Stick Coil Connectors
3. Throttle Body Assy Holder #3 and #4
4. Breather Hose
5. Fuel Hose
6. Rear Heart Insulation Rubber Plate (Install the rear heat insulation rubber plate to the throttle
body assy holder #2 and #3.)
7. Insert this tab into the slit [A].
17-34 APPENDIX
Cable, Wire, and Hose Routing
1. Water Temperature Sensor Lead
2. Subharness
3. Clamp (Hold the neutral switch/oil pressure switch lead. Attach the clamp to the upside of the
water pipe branch.
4. Run the neutral switch/oil pressure switch lead to the rear side of the water pipe branch.
5. Connect the neutral switch lead to the neutral switch. Do not stretch the lead after connected.
6. Run the oil pressure switch lead to the inside of the water hose.
7. Cover the oil pressure switch with the switch cover.
8. Water Pipe
9. Run the alternator lead between the crankcase and water pipe.
10. Viewed from A
APPENDIX 17-35
Cable, Wire, and Hose Routing
1. Install the clamps as shown.
2. Water Hoses
3. Air Bleeder Hose
4. Radiator Overflow Hose
5. Reserve Tank Overflow Hose
6. Coolant Reserve Tank
17-36 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-37
Cable, Wire, and Hose Routing
1. Water Hoses
2. Install the clamps as shown.
3. Install the water hose so that the white paint mark faces upward.
4. Install the water hose so that the white paint mark faces outward.
5. Align the white paint mark of the water hose with the projection on the water pipe.
6. Install the water hose until the rised portion of the water pipe.
7. Curve Side
8. Air Bleeder Hose
9. Install the air bleeder hose above the thermostat cover bolt.
10. Viewed from A
11. Viewed from B
12. Install the clamp so that the tab of the clamp faces rearward.
13. Breather Hose
14. Install the clamp so that the tab of the clamp faces rightward.
15. Install the breather hose so that the white paint mark faces rearward.
17-38 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-39
Cable, Wire, and Hose Routing
1. Run the fuel tank drain hose to the outside of the fuel hose, side stand switch lead and alternator
lead. Run it to the inside of the engine subharness and fuel tank breather hose (other than CAL,
SEA-B1 and TH models).
2. Run the fuel tank breather hose (other than CAL, SEA-B1 and TH models) to the outside of
the starter motor cable, engine subharness, side stand switch lead, fuel tank drain hose and
alternator lead.
3. Clamp (Hold the fuel tank breather hose (other than CAL, SEA-B1 and TH models), engine
subharness, side stand switch lead, fuel tank drain hose and alternator lead.)
4. Run the fuel tank breather hose (other than CAL, SEA-B1 and TH models), fuel tank drain hose
and side stand switch lead to the inside of the engine sprocket cover.
5. Place the fuel tank drain hose end in this position.
6. Air Cleaner Drain Hose
7. Alternator Lead
8. Fuel Hose
9. Side Stand Switch Lead
10. Starter Motor Cable
11. ABS Hydraulic Unit (ABS Equipped Models)
12. Fuel Tank Breather Hose (Other than CAL, SEA-B1 and TH Models)
13. Fuel Tank Drain Hose
14. Breather Hose
15. Engine Subharness
17-40 APPENDIX
Cable, Wire, and Hose Routing
1. Take care not to pinch the fuel tank drain hose between the fuel tank and air cleaner housing.
2. Run the fuel tank drain hose along the shape of the upper air cleaner housing.
3. Run the fuel tank drain hose between the brake hoses (ABS equipped models) and main har-
ness.
4. Brake Hoses (ABS Equipped Models)
APPENDIX 17-41
Cable, Wire, and Hose Routing
1. Starter Motor Cable
2. Battery Negative (–) Cable
3. Fuel Tank Breather Hose (Other than CAL, SEA-B1 and TH Models)
4. Run the fuel tank breather hose (other than CAL, SEA-B1 and TH models) above the starter
motor cable, battery negative (–) cable and main harness.
5. Run the fuel tank breather hose (other than CAL, SEA-B1 and TH models) and fuel tank drain
hose to the inside of the brake hose (ABS equipped models).
6. Fuel Tank Drain Hose
7. Brake Hoses (ABS Equipped Models)
8. Clamp (Hold the reserve tank overflow hose.)
9. Run the radiator overflow hose and reserve tank overflow hose under the frame.
10. Radiator Overflow Hose
17-42 APPENDIX
Cable, Wire, and Hose Routing
1. Radiator Overflow Hose
2. Run the reserve tank overflow hose in front of the middle engine bracket.
3. Run the reserve tank overflow hose to the inside of the oxygen sensor lead (equipped models)
and crankshaft sensor lead.
4. Reserve Tank Overflow Hose
5. Oxygen Sensor Lead (Equipped Models)
6. Crankshaft Sensor Lead
APPENDIX 17-43
Cable, Wire, and Hose Routing
1. Fuel Tank Breather Hose (Other than CAL, SEA-B1 and TH Models)
2. Starter Motor Cable
3. Fuel Hose
4. Fuel Tank Drain Hose
5. Clamp (Hold the engine subharness, side stand switch lead, fuel tank drain hose and alternator
lead.)
6. Battery Negative (–) Cable
7. Clamp (Hold the reserve tank overflow hose. Install it to the bracket.)
8. Radiator Overflow Hose
9. Clamp (Hold the radiator overflow hose and reserve tank overflow hose.)
10. Run the reserve tank overflow hose above the radiator overflow hose.
11. Clamp (Hold the radiator overflow hose.)
17-44 APPENDIX
Cable, Wire, and Hose Routing
1. Front Brake Hose
2. Clamp (Hold the front brake hose.)
3. Clamps (Hold the front brake hose.)
4. Viewed from A
APPENDIX 17-45
Cable, Wire, and Hose Routing
1. Rear Wheel Rotation Sensor
2. Run the rear wheel rotation sensor lead through the clamp.
3. Clamp (Hold the rear wheel rotation sensor lead.)
4. Rear Wheel Rotation Sensor Lead
5. Clamp (Hold the rear brake hose.)
6. Clamps (Hold the rear brake hose and rear wheel rotation sensor lead.)
7. Clamp (Hold the rear wheel rotation sensor lead.)
8. Clamp (Hold the rear wheel rotation sensor lead.)
9. Rear Brake Hose
17-46 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-47
Cable, Wire, and Hose Routing
1. About 90°
2. About 50°
3. Clamps (Hold the brake pipes.)
4. Clamp (Hold the front brake hose.)
5. Front Wheel Rotation Sensor Lead Connector
6. Clamp (Hold the front wheel rotation sensor lead.)
7. Clamps (Hold the front brake hose and front wheel rotation sensor lead.)
8. Viewed from A
9. Clamps (Hold the front brake hose.)
10. Run the front wheel rotation sensor lead in front of the brake hose.
11. Front Wheel Rotation Sensor
17-48 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-49
Cable, Wire, and Hose Routing
1. Rear Wheel Rotation Sensor
2. Run the rear wheel rotation sensor lead through the clamp.
3. Rear Brake Hose
4. Clamp (Hold the rear wheel rotation sensor lead.)
5. Clamp (Hold the rear brake hose.)
6. Clamp (Hold the rear brake hose.)
7. Clamps (Hold the rear brake hose and rear wheel rotation sensor lead.)
8. Clamp (Hold the rear wheel rotation sensor lead.)
9. Clamp (Hold the rear wheel rotation sensor lead.)
10. About 9°
11. About 3°
17-50 APPENDIX
Cable, Wire, and Hose Routing
CAL, SEA-B1 and TH Models
APPENDIX 17-51
Cable, Wire, and Hose Routing
1. Run the purge hose above the engine subharness.
2. Run the purge hose above the stick coil #3 lead.
3. Run the purge hose between the air switching valve hose and stick coil #4 lead.
4. Run the purge hose above the radiator overflow hose.
5. Run the purge hose between the main throttle sensor and subthrottle sensor.
6. Run the purge hose under the rear wheel rotation sensor lead, crankshaft sensor lead, rear
brake light switch lead and alternator lead.
7. Run the purge hose above the brake hoses (ABS equipped models) and main harness.
8. Clamp (Hold the purge hose. Install it to the frame.)
9. Run the purge hose to the outside of the starter motor lead and battery negative (–) cable.
10. Run the purge hose to the inside of the fuel tank drain hose.
17-52 APPENDIX
Cable, Wire, and Hose Routing
CAL, SEA-B1 and TH Models
APPENDIX 17-53
Cable, Wire, and Hose Routing
1. Run the purge hose between the brake hoses (ABS equipped models) and frame ground lead.
2. Clamp (Hold the breather hose and purge hose. Place it to the hose joint of the breather hose.)
3. Run the purge hose above the fuel pump lead and main harness. Run the breather hose under
the fuel pump lead and main harness.
4. Clamp (Hold the breather hose. Install it to the battery case.)
5. Run the purge hose and breather hose between the battery case and rear frame bracket.
6. Run the breather hose above the battery negative (–) cable, purge hose and main harness.
7. Purge Valve
8. Run the purge hose under the battery negative (–) cable. Run it above the main harness. Run
it to the outside of the starter motor cable.
9. Run the purge hose (from throttle body assy) under the brake hoses (ABS equipped models)
and purge hose (to canister).
17-54 APPENDIX
Cable, Wire, and Hose Routing
CAL, SEA-B1 and TH Models
1. Run the purge hose to the inside of the brake hoses (ABS equipped models).
2. Run the purge hose above the radiator overflow hose.
3. Run the purge hose above the radiator overflow hose. Run it to the outside of the main harness.
4. Run the breather hose above the battery negative (–) cable, purge hose, starter motor cable
and main harness.
5. Run the purge hose to the inside of the fuel tank drain hose.
6. Clamp (Hold the purge hose. Install it to the frame.)
7. Run the purge hose under the rear wheel rotation sensor lead, crankshaft sensor lead and rear
brake light switch lead.
8. Run the purge hose above the brake hoses (ABS equipped models) and main harness.
9. Run the purge hose under the brake hoses (ABS equipped models). Run it to the inside of the
ABS hydraulic unit lead (ABS equipped models).
APPENDIX 17-55
Cable, Wire, and Hose Routing
CAL, SEA-B1 and TH Models
1. Run the purge hose and breather hose between the battery case and rear frame bracket.
2. Purge Hose
3. Breather Hose
4. Canister
5. Run the breather hose under the fuel pump lead and main harness. Run the purge hose above
the fuel pump lead and main harness.
6. Clamp (Hold the breather hose and purge hose. Place it to the hose joint of the breather hose.)
7. Clamp (Hold the purge hose. Install it to the battery case.)
8. Run the breather hose above the battery negative (–) cable and main harness.
9. Run the purge hose and breather hose to the inside of the exhaust butterfly valve cables.
17-56 APPENDIX
Cable, Wire, and Hose Routing
CAL, SEA-B1 and TH Models
1. Canister
2. Breather Hose
3. Clamp (Hold the breather hose and purge hose. Place it to the hose joint of the breather hose.)
4. Run the purge hose and breather hose to the inside of the exhaust butterfly valve cables.
5. Purge Hose (to Canister)
6. Purge Valve
7. Brake Hoses (ABS Equipped Models)
8. Run the purge hose (from throttle body assy) to the outside of the battery negative (–) cable,
starter motor cable and fuel hose.
9. ABS Hydraulic Unit (ABS Equipped Models)
10. Run the purge hose (from throttle body assy) under the brake hoses (ABS equipped models)
and purge hose (to canister).
11. Purge Hose (from Throttle Body Assy)
APPENDIX 17-57
Troubleshooting Guide
NOTE
○
Refer to the Fuel System chapter for most
of DFI trouble shooting guide.
○
This 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:
Ignition and engine stop switch not on
Starter lockout switch or neutral switch trou-
ble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Starter system wiring shorted or open
Ignition switch trouble
Engine stop switch trouble
Main 30 A or ignition fuse blown
Starter motor rotating but engine doesn’t
turn over:
Vehicle-down sensor (DFI) coming off
Immobilizer system trouble (Equipped Mod-
els)
Starter clutch trouble
Starter idle gear trouble
Engine won’t turn over:
Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure
Balancer bearing seizure
No fuel flow:
No fuel in tank
Fuel pump trouble
Fuel tank air vent obstructed
Fuel filter clogged
Fuel line clogged
No spark; spark weak:
Vehicle-down sensor (DFI) coming off
Ignition switch not on
Engine stop switch turned to stop position
Clutch lever not pulled in or gear not in neu-
tral
Battery voltage low
Immobilizer system trouble (Equipped Mod-
els)
Spark plug dirty, broken, or gap malad-
justed
Spark plug incorrect
Stick coil shorted or not in good contact
Stick coil trouble
ECU trouble
Neutral, starter lockout, or side stand switch
trouble
Crankshaft sensor trouble
Ignition switch or engine stop switch
shorted
Starter system wiring shorted or open
Main 30 A or ignition fuse blown
Fuel/air mixture incorrect:
Bypass screw maladjusted
Air passage clogged
Air cleaner clogged, poorly sealed, or miss-
ing
Leak from oil filler cap, crankcase breather
hose or air cleaner drain hose.
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valvespringbrokenorweak
No valve clearance
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Immobilizer system trouble (Equipped Mod-
els)
Stick coil trouble
Stick coil shorted or not in good contact
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
ECU trouble
Crankshaft sensor trouble
Fuel/air mixture incorrect:
Bypass screw maladjusted
Air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or miss-
ing
Fuel tank air vent obstructed
Fuel pump trouble
Fuel to injector insufficient
17-58 APPENDIX
Troubleshooting Guide
Fuel line clogged
Throttle body assy holder loose
Air cleaner housing holder loose
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)
Camshaft cam worm
Run-on (dieseling):
Ignition switch trouble
Engine stop switch trouble
Fuel injector trouble
Carbon accumulating on valve seating sur-
face
Engine overheating
Other:
ECU trouble
Throttle body assy not synchronizing
Engine oil viscosity too high
Drive train trouble
Brake dragging
Clutch slipping
Engine overheating
Air suction valve trouble
Air switching valve trouble
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
Stick coil shorted or not in good contact
trouble
Stick coil trouble
ECU trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or miss-
ing
Air cleaner housing holder loose
Water or foreign matter in fuel
Throttle body assy holder loose
Fuel to injector insufficient
Fuel tank air vent obstructed
Fuel line clogged
Fuel pump trouble
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
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
Valvespringbrokenorweak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface.)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
ECU trouble
Miscellaneous:
Throttle valve won’t fully open
Brake dragging
Clutch slipping
Engine overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Camshaft cam worm
Air suction valve trouble
Air switching valve trouble
Catalytic converter melt down due to muffler
overheating (KLEEN)
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
ECU trouble
Muffler overheating:
For KLEEN, do not run the engine even if
with only one cylinder misfiring or poor
running (Request the nearest service fa-
cility to correct it)
For KLEEN, do not push-start with a dead
battery (Connect another full-charged
battery with jumper cables, and start the
engine using the electric starter)
For KLEEN, do not start the engine under
misfire due to spark plug fouling or poor
connection of the stick coil
For KLEEN, do not coast the motorcycle
with the ignition switch off (Turn the igni-
tion switch on and run the engine)
ECU trouble
Fuel/air mixture incorrect:
Throttle body assy holder loose
APPENDIX 17-59
Troubleshooting Guide
Air cleaner housing holder loose
Air cleaner poorly sealed, or missing
Air cleaner 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
Wrong coolant mixed ratio
Cooling system component incorrect:
Radiator fin damaged
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan relay 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:
Thermostat trouble
Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch hub or housing unevenly worn
No clutch lever play
Clutch inner cable trouble
Clutch release mechanism trouble
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
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
Abnormal Engine Noise:
Knocking:
ECU trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valvespringbrokenorweak
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
17-60 APPENDIX
Troubleshooting Guide
Piston ring groove worn
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaft runout excessive
Engine mount loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Air switching valve damaged
Alternator rotor loose
Catalytic converter melt down due to muffler
overheating (KLEEN)
Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Balancer rubber damper damaged
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
Clutch housing/friction plate clearance ex-
cessive
Clutch housing gear worn
Wrong installation of outside friction plate
Transmission noise:
Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc. not properly
mounted or tightened
Warning Indicator (LED) (Oil
Pressure Warning) Doesn’t Go OFF:
Engine oil pump damaged
Engine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearing worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
damaged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Brown smoke:
Air cleaner housing holder loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebars hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade-
quate
Steering stem bent
Tire air pressure too low
Handlebars shakes or excessively
vibrates:
Tire worn
Swingarm pivot bearing worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar holder bolt loose
Steering stem nut loose
Front, rear axle runout excessive
Engine mounting bolt loose
Handlebars pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering maladjusted
Front fork bent
APPENDIX 17-61
Troubleshooting Guide
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 leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
cylinder
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery cable making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty
Part No.99924-1478-02
MODEL APPLICATION
Year Model Beginning Frame No.
2014 ZR1000FE
JKAZRCF1EA000001
JKAZRT00FFA000001
2014 ZR1000GE
JKAZRCG1EA000001
JKAZRT00FGA000001
2015 ZR1000FF
JKAZRCF1FA010001
JKAZRT00FFA010001
2015
ZR1000GF
JKAZRCG1FA005001
JKAZRT00FGA010001
:This digit in the frame number changes from one machine to another.
