ER-6n (2006) - Motorcycle KAWASAKI - Free user manual and instructions

Brand	Kawasaki
Model	ER-6n
Year	2006
Category	Naked motorcycle
Engine type	Liquid-cooled, 4-stroke, parallel twin
Displacement	649 cc
Bore x stroke	83.0 x 60.0 mm
Compression ratio	11.3:1
Fuel system	Fuel injection (DFI)
Transmission	6-speed, chain drive
Front suspension	41 mm telescopic fork, 125 mm travel
Rear suspension	Bottom-link Uni-Trak with adjustable preload, 130 mm travel
Front brakes	Dual 300 mm petal discs, 2-piston calipers
Rear brakes	Single 220 mm petal disc, 1-piston caliper
Overall length	2,105 mm (82.9 in)
Overall width	770 mm (30.3 in)
Overall height	1,315 mm (51.8 in)
Seat height	785 mm (30.9 in)
Wheelbase	1,415 mm (55.7 in)
Curb weight	206 kg (454 lb)
Fuel capacity	16 L (4.2 US gal)
Maintenance interval	Every 6,000 km (3,700 mi)
Repair manual	Available from Kawasaki or online

Frequently Asked Questions - ER-6n (2006) KAWASAKI

What type of oil should I use for the ER-6n?

Use 10W-40 with API SG or higher, capacity 2.2 L with filter change.

How often should I change the oil?

Every 6,000 km (3,700 mi) or 12 months, whichever comes first.

What is the recommended tire pressure?

Front: 36 psi (250 kPa), Rear: 42 psi (290 kPa) for solo riding.

How can I adjust the chain slack?

Chain slack should be 25-35 mm (1.0-1.4 in). Loosen axle nut, adjust chain adjusters evenly, then retorque axle nut to 108 N·m.

What spark plugs are recommended?

NGK CR9EIA-9 or equivalent, gap 0.8-0.9 mm (0.031-0.035 in).

How do I check the coolant level?

Check the reservoir when cold; level should be between LOW and FULL marks. Use a 50/50 mix of distilled water and ethylene glycol coolant.

Why won't my ER-6n start?

Check kill switch, sidestand switch, neutral indicator, battery voltage (≥12.6V), and fuses.

What is the valve clearance interval?

Check every 24,000 km (15,000 mi). Intake: 0.15-0.21 mm, Exhaust: 0.23-0.30 mm.

Can I use ethanol-blended fuel?

Yes, up to 10% ethanol (E10). Higher blends may damage fuel system components.

How do I clean the air filter?

The foam filter can be washed with mild soap, dried, and re-oiled with foam filter oil. Replace if damaged.

USER MANUAL ER-6n (2006) KAWASAKI

Black and white exterior view of a Kawasaki motorcycle with visible engine, wheels, and front wheel (no text or symbols)

Motorcycle ServiceManual

QuickReferenceGuide

GeneralInformation1
PeriodicMaintenance2
FuelSystem(DFI)3
CoolingSystem4
EngineTopEnd5
Clutch	6
EngineLubricationSystem	7
EngineRemoval/Installation	8
Crankshaft/Transmission	9
Wheels/Tires	10
FinalDrive	11
Brakes	12
Suspension	13
Steering	14
Frame	15
ElectricalSystem	16
Appendix	17

This quick reference guidewill assist you in locating adesired topic or procedure.

• Bendthepagesbacktomatchthe blacktabofthedesiredchapternumberwiththeblacktabontheedgeateachtableofcontentspage.
• Refertothesectionaltableofcontents fortheexactpagestolocatethespecifictopicrequired.

Motorcycle ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,or transmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise, withoutthepriorwrittenpermissionofQualityDivision/ConsumerProducts&MachineryCompany/Kawasaki HeavyIndustries,Ltd.,Japan.

Noliability can be accepted for any inaccuracies or missions in this publication, although he very possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changestoproducts manufactured previously. See your Motorcycle dealer forthelatest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

LISTOFABBREVIATIONS

Aampere($)	lbpound(s)
ABDCafter	bottomdeadcenter	m	meter(s)
AC	alternatingcurrentmin		minute(s)
ATDCafter	topdeadcenter	N	newton(s)
BBDCbefore	bottomdeadcenterPapascal(s)
BDCbottom	deadcenterPShorsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
DC	direct current	rpm	revolution(s) per minute
F	farad(s)	TDC	top dead center
°F	degree(s) Fahrenheit	TIR	total indicator reading
ft	foot, feet	V	volt(s)
g	gram(s)	W	watt(s)
h	hour(s)	Ω	ohm(s)
L	liter(s)

Read OWNER'S MANUAL before operating.

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However, it contains enough detail and basic information to make useful to the owner who desire to perform his own basic maintenance and repair work. Abasicknowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repairs satisfactorily. Whenever the owner has insufficient experience or doubt this ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

Inordertoperformtheworkefficiently and toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.Wheneverspecialtoolsorequipmentarespecified,donotuse makeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,and the use of substitute tools may adverselyaffectsafeoperation.

Forthedurationofthewarrantyperiod, we recommend that all repairs and scheduled maintenancebeperformedinaccordancewith thisservicemanual. Anyownermaintenanceor repair procedure not performed in accordance withthismanualmayvoidthewarranty. Togetthelongestlifeoutofyourvehicle:

• FollowthePeriodicMaintenanceChartintheServiceManual.
• Be alert for problems and non-scheduled maintenance.
• UsepropertoolsandgenuineKawasakiMotorcycleparts. Specialtools, gauges, and testersthatarenecessary whenservicing Kawasakimotorcyclesareintroduced by the Service Manual. Genuine parts provided as sparepartsarelistedinthePartsCatalog.
• Follow the procedures in this manual carefully. Don't take shortcuts.
• Remembertokeepcompleterecordsofmaintenanceand repairwithdatesand anynew partsinstalled.

HowtoUseThisManual

Inpreparing this manual, wedivided the product into its major systems. Thesesystems became the manual's chapters. All information for particular system from adjustment through disassembly and inspection is located in single chapter.

TheQuickReferenceGuideshowsyouall oftheproduct'ssystem andassistsinlocating theirchapters.Eachchapterinturnhasitsown comprehensiveTableofContents.

The Periodic Maintenance Chartis located in the Periodic Maintenance chapter. The chart gives atimescheduleforrequiredmaintenance operations.

If you want spark plugin information, fore example, goto the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guidetolocate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follows safe operating and maintenance practices.

WARNING

This warningsymbolidentifiesspecial instructionsorprocedureswhich,ifnot correctlyfollowed,couldresultinpersonalinjury,orlossoflife.

CAUTION

Thiscautionsymbolidentifiesspecial instructionsorprocedureswhich,ifnot strictlyobserved,couldresultindam- agetoordestructionofequipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

○ Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.
- Indicatesaproceduralsteporworktobe done.
○Indicatesaproceduralsub-steporhowtodo theworkoftheproceduralstepitfollows.It alsoprecedesthetextofaNOTE.
★Indicates a conditional stepor what action to take based on the result of the test or inspection in the procedural steporsub-stepit follows.

Inmostchaptersanexplodedviewillustration of the system components follow the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease oralocking agent during assembly.

GeneralInformation

TableofContents

Before Servicing 1-2

Model Identification.... 1-7

General Specifications.... 1-8

TechnicalInformation-CassetteTypeTransmission....1-11

TechnicalInformation-InletAirPressureSensor....1-12

Unit Conversion Table 1-13

1-2GENERALINFORMATION

BeforeServicing

Beforestartingtopermaninspectionserviceorcarryoutadisassemblyandreassemblyoperation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the item that require particular attention during the removal and reinstallationordisassemblyandreassembly of general parts.

Especiallynotethefollowing:

BatteryGround

Beforecompletinganyserviceonthemotorcycle, disconnectthebatterywiresfromthebatterytopreventtheengine fromaccidentallyturningover.Disconnectthegroundwire (-) firstandthenthepositive (+) .Whencompletedwith the service,firstconnectthepositive (+) wiretothepositive (+) terminalofthebatterythenthenegative (-) wiretothenegativeterminal.

EdgesofParts

Liftlargeorheavypartswearingglovestopreventinjury frompossiblesharpedgesontheparts.

Solvent

Useahigh-flushpointsolventwhencleaningparts.High -flushpointsolventshouldbeusedaccordingtodirections ofthesolventmanufacturer.

Cleaning Vehicle before Disassembly

Cleanthevehiclethoroughlybeforedisassembly.Dirtor otherforeignmaterialsenteringintosealedareasduringveh-cledisassemblycancauseexcessivewearanddecrease performanceofthevehicle.

Illustration of hands holding a cylindrical engine block with a no-handled hand symbol nearby (no text or labels)

Line drawing of a motorcyclist with hands adjusting the wheel (no text or symbols)

BeforeServicing

ArrangementandCleaningofRemovedParts

Disassembledpartsareeasytoconfuse.Arrangethe partsaccordingtotheorderthepartsweredisassembled andcleanthepartsinorderpriortoassembly.

StorageofRemovedParts

After all the parts including subassembly part have been cleaned, store the parts in a clean area. Put a clean cloth or plastics sheet over the part stop protect from any foreign material that may collect before assembly.

Inspection

Reuseofwornordamagedpartsmayleadtoseriousaccident. Visuallyinspectremovedpartsforcorrosion, discoloration, orotherdamage. Refertotheappropriatesections of this manualforservicelimitsonindividualparts. Replace thepartsifanydamagehasbeenfoundorifthepartisbeyonditsservicelimit.

ReplacementParts

ReplacementpartsmustbeKAWASAKIgenuineor recommendedbyKAWASAKI.Gaskets,O-rings,oilseals, greaseseals,circlipsorcotterpinsmustbereplacedwith newoneswheneverdisassembled.

AssemblyOrder

Inmostcasesassemblyorderisthereverseofdisassembly,however,ifassemblyorderisprovidedinthisService Manual,followtheproceduresgiven.

Technical line drawing of a mechanical assembly with gears, gears, and components (no text or symbols)

Isometric line drawing of a tray with various mechanical components and fixtures (no text or symbols)

Hand holding a small cylindrical object with a small dark mark, next to a small abstract shape (no text or symbols)

Line drawing of hands using a tool to adjust mechanical parts on a workbench (no text or symbols)

BeforeServicing

TighteningSequence

Generally, when installing apart with several bolts, nuts, or screws, start them all in their holes and tight them to as nugfit. Thentightenthem according to the specified sequence to prevent casewar page or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen allof them by about a quarter turn and then removethem. If these specified tightening sequence is not indicated, tight the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fastener stothespecified torque using a good quality torque wrench. Often, the tightening sequence is followed twice - initial tightening and final tightening with torque wrench.

Force

Usecommonsenseduringdisassemblyandassembly, excessiveforcecancauseexpensiveorhardtorepairdamage. Whennecessary, removescrewsthathaveanon-permanentlockingagentappliedusinganimpactdriver. Useaplastic-facedmalletwhenevertappingisnecessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-ringsafterdisassembly can reduce sealing performance. Remove old gaskets and clean these sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

LiquidGasket, Non-permanentLockingAgent

For application 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. Donot apply them excessively. Excessive application can log oil passages and causes serious damage.

Line drawing of hands using a tool to lift a mechanical component (no text or symbols)

Line drawing of a hand using a tool to cut or adjust a mechanical component (no text or symbols)

Line drawing of two hands adjusting a flange with a magnified inset showing the circular opening (no text or symbols)

Hand holding a tool applying material to a mechanical component, with a circular symbol indicating no chemical symbols (no text or labels present)

BeforeServicing

Press

Foritemssuchasbearingsoroilsealsthatmustbe pressedintoplace,applysmallamountofoiltothecontactarea.Besuretomaintainproperalignmentanduse smoothmovementswheninstalling.

BallBearingandNeedleBearing

Donotremovepressedballorneedleunlessremovalis absolutelynecessary.Replacewithnewoneswhenever removed.Pressbearingswiththemanufacturerandsize marksfacingout.Pressthebearingintoplacebyputting pressureonthecorrectbearingraceasshown.

Pressingtheincorrectracecancausepressurebetween theinnerandouterraceandresultinbearingdamage.

OilSeal, GreaseSeal

Donotremovepressedoilorgreasesealsunlessremoval isnecessary.Replacewithnewoneswheneverremoved. Pressnewoilsealswithmanufactureandsizemarksfacing out.Makesurethesealisalignedproperlywheninstalling.

Applyspecifiedgreasetothelipofsealbeforeinstalling theseal.

Circlips, CotterPins

Replacecirclipsorcotterpinsthatwereremovedwithnew ones. Takecarenottoopentheclipexcessivelywheninstallingtopreventdeformation.

Technical line drawing of a mechanical assembly with hands and a small component (no text or symbols)

Technical drawing of a mechanical assembly with two views showing a bearing and a circular component (no text or symbols)

Line drawing of a hand holding a tool with a pen, next to a cylindrical object (no text or symbols)

1-6GENERALINFORMATION

BeforeServicing

Lubrication

Itisimportanttolubricaterotatingorslidingpartsduring assemblytominimizewearduringinitialoperation.Lubricationpointsarecalledoutthroughoutthismanual,apply thespecificoilorgreaseasspecified.

DirectionofEngineRotation

Whenrotatingthecrankshaftbyhand, thefreeplay amountofrotatingdirectionwillaffecttheadjustment. Rotatethecrankshafttopositivedirection(clockwiseviewed fromoutputside).

ElectricalWires

Atwo-colorwireisidentifiedfirstbytheprimarycolorand thenthestripecolor.Unlessinstructedotherwise,electrical wiresmustbeconnectedtothoseofthesamecolor.

Instrument

Useameterthathasenoughaccuracyforanaccurate measurement.Readthemanufacture'sinstructionsthor- oughlybeforeusingthemeter.Incorrectvaluesmaylead toimproperadjustments.

Line drawing of hands using a tool to lift a tire (no text or symbols)

Line drawing of a mechanical component with a lever and adjustment arrow (no text or symbols)

Line drawing of a hand using a multimeter to test electrical components (no text or symbols present)

ModelIdentification

ER650A6F/ER650A6SLeftSideView

Side profile of a black motorcycle with visible engine and front wheel (no text or symbols)

ER650A6F/ER650A6SRightSideView

Side profile of a black motorcycle with visible engine and wheel (no text or symbols)

ER650A6F:Australia,Malaysia
ER650A6S:Europe

GeneralSpecifications

ItemsER650A6F/ER650A6S
Dimensions
OverallLength2100mm(82.7in.)
OverallWidth760mm(29.9in.)
OverallHeight1095mm(43.1in.)
Wheelbase1405mm(55.3in.)
RoadClearance140mm(5.5in.)
SeatHeight785mm(30.9in.)
DryMass174kg(383.7lb)
CurbMass:
Front	98kg(216.1lb)
Rear98kg(216.1lb)
FuelTankCapacity15.5L(4.1USgal.)
Performance
MinimumTurningRadius	2.7m(8.9ft)
Engine
Type	4-stroke, DOHC, 2-cylinder
CoolingSystem	Liquid-cooled
BoreandStroke	83×60mm(3.3×2.4in.)
Displacement	649cm3(39.60cuin.)
Compression Ratio	11.3 : 1
Maximum Horsepower	53 kW (72 PS) @8 500 r/min (rpm),
Maximum Torque	66 N·m (6.7 kgf·m, 49 ft·lb) @7 000 r/min (rpm),
Carburetion System	FI (Fuel Injection) KEIHIN TTK38 × 2
StartingSystem	Electricstarter
Ignition System	Battery and coil (transistorized)
Timing Advance	Electronically advanced(digitaligniter)
IgnitionTiming	From 10° BTDC @1 300 r/min (rpm) to 35° BTDC @4 800 r/min(rpm)
SparkPlug	NGKCR9EIA-9
Cylinder Numbering Method	Left to right, 1-2
FiringOrder	1-2
ValveTiming:
Inlet:
Open	31°BTDC
Close	61°ABDC
Duration	272°
Exhaust:
Open	50°BBDC
Close	30°ATDC
Duration	260°
Lubrication System	Forced lubrication (semi-dry sump)
EngineOil:
Type	APISE,SForSG
	APISH,SJor SLwithJASOMA

GeneralSpecifications

ItemsER650A6F/ER650A6S
ViscositySAE10W-40Capacity2.4L(2.5USqt)
DriveTrainPrimaryReductionSystem:TypeGearReductionRatio2.095(88/42)ClutchTypeTransmission:Type6-speed,constantmesh,returnshiftGearRatios:1st2nd1.714(36/21)3rd1.333(32/24)4th1.111(30/27)5th0.966(28/29)6thFinalDriveSystem:TypeChaindriveReductionRatio3.067(46/15)OverallDriveRatio 5.473@Topgear
FrameTypeCaster(RakeAngle)TrailFrontTire:TypeTubelessSizeRimSizeRearTire:TypeTubelessSizeRimSizeFrontSuspension:TypeWheelTravelRearSuspension:TypeSwingarmWheelTravelBrakeType:FrontRear	Tubular,diamond24.5°102 mm (4.0 in.)120/70ZR17M/C(58W)17×3.50160/60ZR17M/C(69W)17×4.50Telescopicfork120mm(4.7in.)125mm(4.9in.)Dual discsSingledisc
ElectricalEquipmentBattery	12V10Ah

1-10GENERALINFORMATION

GeneralSpecifications

ItemsER650A6F/ER650A6S
Headlight:TypeSemi-sealedbeamBulb1 2 V 5 5 W × 2 / 5 5 W ( Hi / Lo )Tail/BrakeLight12V5/21WAlternator:TypeThree-phaseACRatedOutput24A/14V@5000r/min(rpm)

Specificationsaresubjecttochangewithoutnotice, and may not apply to every country.

TechnicalInformation-CassetteTypeTransmission

CassetteTypeTransmission

The transmission of the current model is unable to be removed without disassembling upper and lower crank case halves.

TheER650Aenablestransmissiontoberemovedfromtherightsideofengineasanassy, without disassemblingcrankcasehalves(seeTransmissionAssyRemovalintheCrankshaft/Transmission chapter).

TransmissionAssy: DriveShaft[A] OutputShaft[B] ShiftRods[C] ShiftDram[D] ShiftForks[E] TransmissionCase[F]

Detailed cutaway view of a mechanical transmission assembly (no visible text or labels)

1-12GENERALINFORMATION

TechnicalInformation-InletAirPressureSensor

AtmosphericpressuresensorandcamshaftpositionsensorarenotequippedwiththeER650A.As asubstituteofthesesensorsabove,theER650Arecognizesatmosphericpressureandintakestroke of#1bythesignalofinletairpressuresensor.

The ECU detects atmospheric pressure when the ignition is switched ON. While the engine is running, the ECU also presumes atmospheric pressure by analyzing the waveform of boost pressure over fixed period. The intake stroke is recognized by waveform of boost pressure, therefore the system can recognize difference of each stroke.

UnitConversionTable

PrefixesforUnits:

PrefixSymbolPower
megaM×1 kilok×1000 centic×0 millim×0.001 microμ×0.000001	0 0 0 0 0 0 . 0 1 0 1 000001

UnitsofMass:

kg	×	2.205	=	lb
g	×	0.03527	=	oz

UnitsofVolume:

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

UnitsofForce:

N	×	0.1020	=	kg
N	×	0.2248	=	lb
kg	×	9.807	=	N
kg	×	2.205	=	lb

UnitsofLength:

km	×	0.6214	=	mile
m	×	3.281	=	ft
mm	×	0.03937	=	in

UnitsofTorque:

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

UnitsofPressure:

kPax	0.01020	=		kgf/cm2
kPax	0.1450	=	psi
kPax	0.7501	=	cmHg
kgf/cm2	×	98.07	=	kPa
kgf/cm2	×	14.22	=	psi
cmHg	×	1.333	=	kPa

UnitsofSpeed:

km/h

×

0.6214

=

mph

UnitsofPower:

kW	×	1.360	=	PS
kW	×	1.341	=	HP
PS	×	0.7355	=	kW
PS	×	0.9863	=	HP

UnitsofTemperature:

PeriodicMaintenance

TableofContents

Periodic Maintenance Chart 2-3

Torque and Locking Agent.... 2-6

Specifications 2-11

Special Tools 2-13

Periodic Maintenance Procedures.... 2-14

Fuel System (DFI) 2-14

FuelHoseInspection(fuelleak,damage,installationcondition)....2-14

Throttle Control System Inspection.... 2-14

Idle Speed Inspection 2-15

Idle Speed Adjustment.... 2-15

Air Cleaner Element Cleaning.... 2-16

EngineVacuumSynchronizationInspection....2-17

Cooling System.... 2-19

Coolant Level Inspection.... 2-19

RadiatorHoseandPipeInspection(coolantleak,damage,installationcondition)......2-20

Air Suction System 2-20

AirSuctionSystemDamageInspection....2-20

Engine Top End 2-20

Valve Clearance Inspection 2-20

Valve Clearance Adjustment.... 2-22

Clutch 2-25

Clutch Operation Inspection.... 2-25

Wheels/Tires 2-25

Air Pressure Inspection.... 2-25

Wheel/Tire Damage Inspection 2-26

Tire Tread Wear, Abnormal Wear Inspection 2-26

WheelBearingDamageInspection 2-27

Drive Train 2-27

Drive Chain Lubrication Condition Inspection 2-27

Drive Chain Slack Inspection 2-28

Drive Chain Slack Adjustment 2-28

Wheel Alignment Inspection 2-29

Drive Chain Wear Inspection 2-30

Chain Guide Inspection.... 2-30

Brake System 2-31

BrakeFluidLeak(BrakeHoseandPipe)Inspection....2-31

Brake Hose Damage and Installation Condition Inspection 2-31

Brake Operation Inspection 2-31

Brake Fluid Level Inspection 2-32

Brake Pad Wear Inspection 2-33

BrakeLightSwitchOperationInspection....2-33

Suspensions 2-34

FrontForks/RearShockAbsorberOperationInspection....2-34

Front Fork Oil Leak Inspection 2-34

Rear Shock Absorber Oil Leak Inspection 2-34

Steering System 2-35

Steering Play Inspection 2-35

Steering Play Adjustment.... 2-35

Steering Stem Bearing Lubrication 2-36

Electrical System 2-37

Spark Plug Condition Inspection 2-37

LightsandSwitchesOperationInspection......2-38

Headlight Aiming Inspection 2-40

SidestandSwitchOperationInspection 2-41

EngineStopSwitchOperationInspection......2-42

Others 2-43

Chassis Parts Lubrication 2-43

Bolts,NutsandFastenersTightnessInspection......2-44

Replacement Parts 2-45

AirCleanerElementReplacement....2-45

Engine Oil Change 2-45

Oil Filter Replacement 2-46

Fuel Hose Replacement 2-46

Coolant Change 2-47

RadiatorHoseandO-ringReplacement....2-50

BrakeHoseandPipeReplacement....2-51

Brake Fluid Change 2-51

MasterCylinderRubberPartsReplacement....2-53

CaliperRubberPartsReplacement....2-54

Spark Plug Replacement 2-56

PeriodicMaintenanceChart

Thescheduledmaintenancemustbedoneinaccordancewiththischarttokeepthemotorcyclein goodrunningcondition. Theinitialmaintenanceisvitallyimportantandmustnotbeneglected.

PeriodicInspection

FREQUENCY	Whichever comes first ↓ Every	*ODOMETERREADING ×1000km (×1000mile)							See Page
		161(0.6)	2182(4)	4303(7.5)	6(12)	(15)	(20)	(24)
INSPECTION
Fuel System
Aircleanerelement -clean				●		●		●	2-16
Throttle control system (play, smooth return,no drag)- inspect	year	●		●		●		●	2-14
Enginevacuumsynchronization-inspect				●		●		●	2-17
Idlespeed - inspect		●		●		●		●	2-15
Fuelleak(fuelhoseandpipe)-inspect year		●		●		●		●	2-14
Fuelhoseandpipedamage-inspect year		●		●		●		●	2-14
Fuelhose andpipe installationcondition - inspect	year	●		●		●		●	2-14
CoolingSystem
Coolantlevel -inspect		●		●		●		●	2-19
Coolant leak (radiator hose and pipe) - inspect	year	●		●		●		●	2-20
Radiatorhosedamage-inspect	year	●		●		●		●	2-20
Radiator hose installation condition - inspect	year	●		●		●		●	2-20
AirSuction System
Airsuctionsystemdamage-inspect				●		●		●	2-20
EngineTop End
Valve clearance - inspect	Every 42 000 km (26 000 mile)								2-20
Clutch
Clutch operation( play, disengagement, engagement)- inspect		●		●		●		●	2-25
Wheels andTires
Tire air pressure - inspect	year			●		●		●	2-25
Wheel/tiredamage-inspect				●		●		●	2-26
Tiretreadwear,abnormalwear-inspect				●		●		●	2-26
Wheelbearingdamage-inspect	year			●		●		●	2-27
Drive Train
Drive chain lubrication condition - inspect #	Every 600 km (400 mile)								2-27
Drive chain slack - inspect #	Every 1 000 km (600 mile)								2-28
Drivechainwear -inspect#				●		●		●	2-30
Chainguidewear -inspect				●		●		●	2-30
Brake System
Brake fluid leak (brake hose and pipe) - inspect	year	●	●	●	●	●	●	●	2-31

2-4 PERIODIC MAINTENANCE

PeriodicMaintenanceChart

FREQUENCY	Whichever comes first ↓ Every	*ODOMETERREADING × 1000k (×1000mile)							m See Page
		161(0.6)	2182(4)	4303(7.5)	6(12)	(15)	(20)	(24)
INSPECTION
Brakehoseandpipedamage-inspectyear		●●	●●●●	●					2-31
Brakehoseinstallationcondition-inspect	year	●●	●●●●	●					2-31
Brakeoperation(effectiveness,play,no drag)-inspect	year	●●	●●●●	●					2-31
Brakefluidlevel-inspect	6 months	●●	●●●●	●					2-32
Brakepadwear-inspect#			●●●●●	●					2-33
Brakelightswitchoperation-inspect		●●	●●●●	●					2-33
Suspensions
Frontforks/rearshockabsorberoperation (dampingandsmoothstroke)-inspect				●		●		●	2-34
Frontforks/rearshockabsorberoilleak-inspect	year			●		●		●	2-34
SteeringSystem
Steeringplay-inspect	year	●		●		●		●	2-35
Steering stem bearings - lubricate	2 years					●			2-36
ElectricalSystem
Sparkplugcondition-inspect				●		●		●	2-37
Lightsandswitchesoperation-inspect	year			●		●		●	2-38
Headlightaiming-inspect	year			●		●		●	2-40
Sidestandswitchoperation-inspect	year			●		●		●	2-41
Enginestopswitchoperation-inspect	year			●		●		●	2-42
Others
Chassisparts-lubricate	year			●		●		●	2-43
Boltsandnutstightness-inspect		●		●		●		●	2-44

: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: Forhigherodometerreadings,repeatatthefrequencyintervalestablishedhere.

PeriodicMaintenanceChart

PeriodicReplacementParts

CHANGE/REPLACE ITEM	FREQUENCY Whichever comes first ↓ Every	*ODOMETERREADING ×1000km (×1000mile)					See Page
		112(0.6)	243648(7.5)	(15)	(24)	(30)
Aircleanerelement#2years2-45
Engineoil#	year	●	●	●	●	●	2-45
Oilfilter	year	●	●	●	●	●	2-46
Fuelhose	4years					●	2-46
Coolant	3years				●		2-47
RadiatorhoseandO-ring	3years				●		2-50
Brakehoseandpipe	4years					●	2-51
Brakefluid	2years			●		●	2-51
Rubber parts of master cylinder and caliper	4 years					●	2-53
Sparkplug			●	●	●	●	2-56

: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

TorqueandLockingAgent

The following tables list the tightening torque for them major fasteners requiring use of a non-permanent locking agentor liquid gasket.

Lettersusedinthe"Remarks"columnmean:

AL: Tightenthewoclampboltsalternatelytwotimestoensureeventighteningtorque.

EO:Applyengineoil.

L: Applyanon-permanentlockingagenttothethreads.

Lh:Left-handthreads

MO:Applymolybdenumdisulfideoilsolution.

R:ReplacementParts

S: Tightenthefastenersfollowingthespecifiedsequence.

Si:Applysiliconegrease(ex.PBCgrease).

SS:Applysiliconesealant.

Fastener	Torque			Remarks
	N·mkgf	mft·lb
FuelSystem
WaterTemperatureSensor121.2106in·lb
SpeedSensorBolt7.8 0.8069in·lb	L
Fuel Pump Bolts	9.8	1.0	87 in·lb	L, S
OxygenSensor	44.1	4.50	32.5
CoolingSystem
Radiator Hose Clamp Screws	2.0	0.20	17 in·lb
Water Pump Impeller Bolt	9.8	1.0	87 in·lb
Water Pump Cover Bolts	9.8	1.0	87 in·lb
Water Pump Drain Bolt	7.0	0.70	62 in·lb
Thermostat Housing Bolts	9.8	1.0	87 in·lb
WaterTemperatureSensor121.2106in·lb
EngineTopEnd
Air Suction Valve Cover Bolts	9.8	1.0	87 in·lb
Cylinder Head Cover Bolts	9.8	1.0	87 in·lb
Camshaft Cap Bolts	12	1.2	106 in·lb	S
CylinderHeadBolts(M10NewBolts)	545.5	40		MO,S
Cylinder Head Bolts (M10 Used Bolts)	49	5.0	36	MO, S
Cylinder Bolt (M8)	27.5	2.8	20	MO, S
Cylinder Nut (M10)	49	5.0	36	MO, S
Cylinder Head Bolts (M6)	12	1.2	106 in·lb	S
Cylinder Bolts (M6)	12	1.2	106 in·lb	S
Throttle Body Holder Bolts	12	1.2	106 in·lb
Rear Camshaft Chain Guide Bolt	20	2.0	15	L
Camshaft Chain Tensioner Mounting Bolts	9.8	1.0	87 in·lb
CamshaftChainTensionerCapBolt	202.0	15
Camshaft Sprocket Bolts	15	1.5	11	L
Spark Plugs	15	1.5	11
Exhaust Pipe Manifold Holder Nuts	17	1.7	12
Muffler Body Mounting Bolt (Front)	20	2.0	15
Muffler Body Mounting Bolt (Rear)	20	2.0	15
BafflePlateBolts	5.9	0.6052in·lb

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf	mft·lb
Clutch
UpperCaponClutchCover3.90.4035in·lb				Hand-tighten
LowerCaponClutchCover	—
OilFillerPlug—Hand-tighten
ClutchCoverMountingBolts9.81.087in·lb
ClutchSpringBolts	9.81.087	in·lb
ClutchHubNut	132	13.5	98	R
Clutch Lever Clamp Bolts	7.8	0.80	69 in·lb	S
Oil Pump Chain Guide Bolts	12	1.2	106 in·lb	L
Clutch Cable Holder Bolts	9.8	1.0	87 in·lb	L
ClutchCableClampBolt	9.81.087	in·lb
EngineLubrication
Engine Oil Drain Bolt	20	2.0	15
Filter Plate Bolt	9.8	1.0	87 in·lb	L
Oil Filter	17.2	1.75	13	EO, R
Holder Mounting Bolt	25	2.5	18	L
Oil Pan Bolts	12	1.2	106 in·lb
OilPipeBolts	9.81.087	in·lb
Oil Pipe Plate Bolt	9.8	1.0	87 in·lb	L
Oil Pressure Relief Valve	15	1.5	11	L
Oil Pressure Switch	15	1.5	11	SS
OilPumpCoverBolts	9.81.087	in·lb	L
Oil Pump Sprocket Bolt	12	1.2	106 in·lb	L, Lh
Oil Passage Plug	20	2.0	15	L
Oil Plate Bolts	9.8	1.0	89 in·lb	L
EngineRemoval/Installation
Engine Mounting Bracket Bolts	25	2.5	18
Front Engine Mounting Bolts	44	4.5	32
Rear Engine Mounting Nuts	44	4.5	32
Crankshaft/Transmission
OilPlateBolts	9.81.087	in·lb	L
BreatherPlateBolts	9.81.087	in·lb	L
Crankcase Bolts (M9, L = 113 mm)	44	4.5	32	MO, S
CrankcaseBolts(M9,L=83 mm)	44	4.5	32	MO,S
Crankcase Bolts (M8, L = 73 mm)	35	3.6	26	MO, S
Crankcase Bolts (M8, L = 60 mm)	35	3.6	26	MO, S
Crankcase Bolts (M8, L = 110 mm)	27.5	2.8	20	S
Crankcase Bolts (M8, L = 50 mm)	27.5	2.8	20	S
Crankcase Bolts (M6)	19.6	2.0	15	S
UpperCrankcaseBolts	27.52.8	20		S
Shift Drum Bearing Holder Screw	4.9	0.50	43 in·lb	L
Connecting Rod Big End Nuts	see Text	←	←	←
Timing Rotor Bolt	40	4.1	30

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf	mft·lb
OilPressureSwitch	151.511			SS
OilPassagePlug202.015L
Gear Positioning Lever Bolt	12	1.2	106 in·lb	L
ShiftShaftReturnSpringpin292.922L
Shift Drum Cam Bolt	12	1.2	106 in·lb	L
NeutralSwitch	151.511
TransmissionCaseBolts	202.015
Shift Rod Plate Bolt	9.8	1.0	87 in·lb
Neutral Switch Holder Screw	4.9	0.50	43 in·lb	L
Shift Shaft Cover Bolts	9.8	1.0	87 in·lb	L (see Text)
Shift Shaft Cover Screw	4.9	0.50	43 in·lb	L
Wheels/Tires
Front Axle	108	11.0	80
FrontAxleClampBolt	343.525
Rear Axle Nut	108	11.0	80
FinalDrive
Engine Sprocket Nut	125	12.7	92	MO
Rear Axle Nut	108	11.0	80
RearSprocketNuts	596.044
Speed Sensor Bolt	7.8	0.80	69 in·lb	L
Speed Sensor Bracket Bolts	9.8	1.0	87 in·lb
Brakes
Bleed Valve	7.8	0.80	69 in·lb
Brake Hose Banjo Bolts	25	2.5	18
Brake Lever Pivot Bolt	1.0	0.10	9 in·lb	Si
Brake Lever Pivot Bolt Locknut	5.9	0.60	52 in·lb
Brake Pedal Bolt	8.8	0.90	78 in·lb
Front Brake Disc Mounting Bolts	27	2.8	20	L
Front Brake Light Switch Screw	1.0	0.10	9 in·lb
Front Brake Reservoir Cap Screws	1.0	0.10	9 in·lb
Front CaliperMountingBolts	343.525
Front Master Cylinder Clamp Bolts	8.8	0.90	78 in·lb	S
Rear Brake Disc Mounting Bolts	27	2.8	20	L
Rear CaliperMountingBolts	252.518
Rear Master Cylinder Mounting Bolts	25	2.5	18
Rear Master Cylinder Push Rod Locknut	18	1.8	13
Suspension
FrontAxleClampBolt	343.525
Front Fork Bottom Allen Bolts	30	3.1	22	L
Front Fork Clamp Bolts (Lower)	20	2.0	15	AL
Front Fork Clamp Bolts (Upper)	20	2.0	15
Front Fork Top Plugs	25	2.5	18
RearShock AbsorberBolt	596.044

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf	mft·lb
RearShockAbsorberNut	596.044
SwingarmPivotShaftNut10811.080
Steering
FrontForkClampBolts(Lower)202.015AL
FrontForkClampBolts(Upper)202.015
Handlebar Holder Bolts	25	2.5	18	S
LeftSwitchHousingScrews	3.5	0.36	31in·lb
Right Switch Housing Screws	3.5	0.36	31 in·lb
SteeringStemHeadBolt	10811.080
Steering Stem Nut	20	2.0	15
Frame
FootpegStayBolts	343.525
Front Fender Bolts	3.9	0.40	35 in·lb
Front Fender Bracket Bolts	8.8	0.90	78 in·lb	L
GrabRailMountingBolts	252.518
Lower Fairing Mounting Bolts	8.8	0.90	78 in·lb
SidestandBolt	444.532
Sidestand Switch Bolt	8.8	0.90	78 in·lb	L
ElectricalSystem
Alternator Cover Bolts	9.8	1.0	87 in·lb
Alternator Lead Holding Plate Bolt	9.8	1.0	87 in·lb	L
Alternator Rotor Bolt	155	15.8	114	MO
Crankshaft Sensor Bolts	6.0	0.60	53 in·lb
Front Brake Light Switch Screw	1.2	0.12	11 in·lb
Left Switch Housing Screws	3.5	0.36	31 in·lb
License Plate Light Cover Screws	0.90	0.090	8 in·lb
License Plate Light Mounting Screws	1.2	0.12	11 in·lb
MeterScrews	1.2	0.12	11in·lb
Neutral Switch	15	1.5	11
Oil Pressure Switch	15	1.5	11	SS
OxygenSensor	44.1	4.5032.5
Regulator/Rectifier Bolts	8.8	0.90	78 in·lb
Right Switch Housing Screws	3.5	0.36	31 in·lb
SidestandSwitchBolt	8.8	0.90	78 in·lb	L
Spark Plugs	15	1.5	11
Speed Sensor Bolt	7.8	0.80	69 in·lb	L
Starter Motor Cable Terminal Nut	6.0	0.60	53 in·lb
Starter Motor Clutch Bolts	34	3.5	25	L
Starter Motor Mounting Bolts	9.8	1.0	87 in·lb	L
StarterMotorTerminalLocknut	11	1.1	97in·lb
Starter Motor Through Bolts	4.9	0.50	43 in·lb
Stator Coil Bolts	12	1.2	106 in·lb	L

2-10 PERIODIC MAINTENANCE

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf	mft·lb
TimingRotorBolt404.130WaterTemperatureSensor121.2106in·lb

Thetablebelow, relatingtighteningtorquetothreaddiameter, liststhebasictorquefortheboltsand nuts. Use histable for only the bolts and nuts which donot require as specific torque value. Allof the values are for use with dry solvent-cleaned threads.

BasicTorqueforGeneralFasteners

ThreadsDiameter(mm)	Torque
	N·mkgf·m	ft·lb
5	3.4 ~ 4.9	0.35 ~ 0.50	30 ~ 43 in·lb
6	5.9 ~ 7.8	0.60 ~ 0.80	52 ~ 69 in·lb
8	14 ~ 19	1.4 ~ 1.9	10.0 ~ 13.5
10	25 ~ 34	2.6 ~ 3.5	19.0 ~ 25
12	44 ~ 61	4.5 ~ 6.2	33 ~ 45
14	73 ~ 98	7.4 ~ 10.0	54 ~ 72
16	115 ~ 155	11.5 ~ 16.0	83 ~ 115
18	165 ~ 225	17.0 ~ 23.0	125 ~ 165
20	225 ~ 325	23.0 ~ 33.0	165 ~ 240

Specifications

ItemStandardServiceLimit
FuelSystemThrottle Grip Free PlayIdleSpeed1 300±50r/mBypass Screws (Turn Out)EngineVacuum35.3±1.3kPaAirCleanerElementPolyurethaneFoam- - -		- - -
		- - -
CoolingSystemCoolant:Type(recommended)ColorMixed RatioFreezingPointTotal Amount	Permanenttypeofantifreeze- - -GreenSoft water 50%, Coolant 50%-35°C(-31°F)1.2 L (1.3 US qt)	- - -
		- - -
EngineTopEndValveClearance:ExhaustInlet	0.22 ~ 0.31 mm (0.0087 ~ 0.0122 in.)0.15 ~ 0.21 mm (0.0059 ~ 0.0083 in.)	- - -
		- - -
ClutchClutch Lever Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)	- - -
EngineLubricationSystemEngineOil:TypeViscosityCapacityLevel	API SE, SF or SGAPISH,SJorSLwithJASOMASAE 10W-401.7 L (1.8 US qt) (when filter is not removed)1.9 L (2.0 US qt) (when filter is removed)2.4 L (2.5 US qt) (when engine is completelydry)Between upper and lower level lines(afteridlingorrunning)	- - -
		- - -
		- - -
		- - -
		- - -
		- - -
Wheels/TiresTreadDepth:FrontRearAirPressure(whenCold):FrontRear	6.5 mm (0.26 in.)9.0 mm (0.35 in.)Upto180kg(397lb)load:225kPa(2.25kgf/cm2,32psi)Upto180kg(397lb)load:250kPa(2.50kgf/cm2,36psi)	1 mm (0.04 in.), (AT, CH,DE)1.6 mm (0.06 in.)Up to 130 km/h (80 mph):2 mm (0.08 in.),Over130km/h(80mph):3 mm (0.12in.)
		- - -
		- - -

Specifications

ItemStandardServiceLimit
FinalDrive
Drive Chain Slack	30 ~ 40 mm (1.2 ~ 1.6 in.)	- - -
DriveChainWear(20-link Length)	317.5 ~ 318.2 mm (12.50 ~ 12.53 in.)	323 mm (12.7 in.)
StandardChain:MakeENUMA--TypeEK520MVXL1--Link114links	- - -
Brakes
BrakeFluid:Grade	DOT4	- - -
Brake Pad LiningThickness:Front	4.5mm(0.18in.)	1mm(0.04in.)
Rear	5.0 mm (0.20 in.)	1 mm (0.04 in.)
BrakeLightTiming:Front	PulledON	- - -
Rear	ONafterabout10mm(0.39in.) of pedaltravel	- - -
ElectricalSystem
Spark Plug Gap	0.8 ~ 0.9 mm (0.03 ~ 0.04 in.)	- - -

AT:Austria
CH: Switzerland
DE: Germany

SpecialTools

InsideCirclipPliers: 57001-143

Line drawing of a pair of pliers (no text or symbols)

SteeringStemNutWrench: 57001-1100

Line drawing of a mechanical wrench tool (no text or symbols on the tool itself)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

OilFilterWrench: 57001-1249

Technical line drawing of a mechanical knob or dial (no text or symbols)

ExtensionTube: 57001-1578

Technical line drawing of a U-shaped pipe fitting with two flanged ends (no text or symbols)

PilotScrewAdjuster,E: 57001-1603

Technical line drawing of a pipe fitting with a bent end (no text or symbols)

JackAttachment: 57001-1608

Technical line drawing of two mechanical fasteners with cylindrical base (no text or symbols)

2-14 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

FuelSystem(DFI)

FuelHoseInspection(fuelleak,damage,installation condition)

The fuelhose is designed to be used throughout the motorcycle's lifewithout anymaintenance. However, if the motorcycle is not properly handled, the high pressure in-sidetheuelline can cause fuel to leak [A] or the hose to burst. Removetheueltank (see Fuel Tank Removal Fuel System (DFI) chapter) and check the fuel hose.
★Replacethefuelhoseifanyfraying, cracks[B]orbulges [C]arenotic.
- Check that the hosesarerouted according to Cable, Wire, and HoseRoutingsection in the Appendix chapter.
★Replacethehoseifithasbeensharplybentorkinked. HoseJoints[A] FuelHose[B]

• Check that the hose joints are securely connected.
  ○Pushandpull[A]thehosejoint[B]backandforthmore thantwotimes,andmakesureitislocked.
  ★ Ifitdoesnotlocked, reinstallthehosejoint.

WARNING

Makesurethehosejointisinstalledcorrectlyonthe deliverypipebyslidingthejoint,orthefuelcould leak.

ThrottleControlSystemInspection

• Check that the throttle grip movess smoothly from full open to close [A], and the throttle closes quickly and completely by thereturnspring in all steering positions.
  ★ Ifthethrottlegripdoesn'treturnproperly, checkthethrottlecablerouting, gripfreeplay, andcabledamage. Then lubricatethrottlecable.

• Checkthethrottlegripfreeplay[A].
  ★Ifthefreeplayisincorrect,adjustthethrottlecable.

ThrottleGripFreePlay

Standard: 2 \~ 3 mm (0.08 \~ 0.12 in.)

Close-up of a motorcycle handle and lever with a labeled component (A) and directional arrow, no readable text or symbols beyond the label.

Close-up of a motorcycle handle and lever with a labeled component (A) and no visible text or symbols on the device itself.

PeriodicMaintenanceProcedures

★ If necessary, adjust the throttleable as follows.
- Loosenthelocknut[A]attheupperendoftheaccelerator cable.
- Turntheadjuster[B]incompletelysoastogivethethrottle griplentyofplay.

• Loosenthelocknut[A]atthemiddleofthedecelerator cable.
• Turntheadjuster[B]untilthereisnoplaywhenthethrottle gripiscompletelyclosed.
• Tightenthelocknut.
• Turntheacceleratorcableadjusteruntiltheproper amountofthrottlegripfreeplayisobtained.
• Tightenthelocknut.

IdleSpeedInspection

• Starttheengineandwarmitupthoroughly.
• Withtheengineidling,turnthehandlebartobothsides [A].
  ★ Ifhandlebarmovementchangestheidlespeed, the throttlecablesmaybeimproperlyadjustedorincorrectly routedordamaged. Besuretocorrectanyofthese conditionsbeforeriding(seeThrottleControlSystem InspectionorCable,Wire,andHoseRoutingsectionin theAppendixchapter).

WARNING

Operationwithimproperlyadjusted, incorrectly routedordamagedcablescouldresultinanunsafe ridingcondition.

• Checkidlespeed.
  ★If the idle speed is out of the specified range, adjust it.

IdleSpeed

Standard: 1300±50r/min(rpm)

IdleSpeedAdjustment

• Starttheengineandwarmitupthoroughly.
• Turntheadjustingscrew[A]untiltheidlespeediscorrect.
  Open and close the throttle a few times to make sure that theidlespeediswithinthespecifiedrange.Readjustif necessary.

Close-up of a car's roof structure with two labeled points A and B (no text or symbols beyond labels)

Close-up of a motorcycle's front wheel and side-mounted steering wheel (no visible text or symbols)

Close-up of mechanical components with no visible text or symbols

2-16PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

AirCleanerElementCleaning

NOTE

○ Industryareas, theelementshouldbecleanedmore frequentlythantherecommendedinterval.
○ Afterridingthroughrainoronmuddilyroads, the elements should be cleaned immediately.

WARNING

Ifdirtordustisallowedtopassthroughintothe throttleassy,thethrottlemaybecomestuck,possiblycausingaccident.

CAUTION

Ifdirtgetsthroughintotheengine,excessiveenginewearandpossiblyenginedamagewillooccur.

• Removethefueltank(seeFuelTankRemovalintheFuel System(DFI)chapter).
• Remove: AirSwitchingValveHoseA AirCleanerElementScrew[B] AirCleanerElement[C]

- Remove: UpperPlasticHolder[A] Element[B]

NOTE

○ Thewirescreen[A]isfastenedwithanadhesiveforthe shadedportion[B].Donotremovethewirescreen.

PeriodicMaintenanceProcedures

WARNING

Cleantheelementinawell-ventilatedarea,and makesurethattherearenosparksorflameany-whereneartheworkingarea. Becauseofthedangerofhighlyflammableliquids, donotusegasolineoralowflash-pointsolventto cleantheelement.

• Cleantheelement[A]inabathofhighflash-pointsolvent, andthendryitwithcompressedairorbyshakingit.
• Aftercleaning, saturateaclean, lint-freetowel with SE, SF, or SGclassSAE30oil and apply the oil to the element by tapping the element outsidewith the towel.
• Visuallychecktheelementfortearsorbreaks.
• Iftheelementhasanytearsorbreaks,replacetheelement.
• Installtheelementunit[A]withthefoamelementside(gray)[B]facingdown.

Close-up of a plastic mechanical part with a labeled section A (no text or symbols beyond label)

EngineVacuumSynchronizationInspection

NOTE

These procedures are explained on the assumption that the inlet and exhaust system sof the engine are good condition.

• Situatethemotorcyclesothatitisvertical.
• Removethecenterfairing(seeCenterFairingRemoval intheFramechapter).
• Pullofftherubbercaps[A]fromthefittingofeachthrottle body(Inthephoto, thethrottlebodyhasbeenremoved forclarity).

CAUTION

Donotremovetheinletairpressuresensorhose [B]ontheleftfittingofthethrottlebody.

• Connectacommerciallyavailablevacuumgaugeand hoses[A]tothefittingsofthethrottlebodyasshown.
• Connectahighlyaccuratetachometertooneofthestick coilprimaryleads.

Technical line drawing of a mechanical assembly with gears and pipes (no text or symbols)

2-18 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

• Starttheengineandwarmitupthoroughly.
• Checktheidlespeed.
  Tachometer[A]
• Openandclosethethrottle.
  ★Iftheidlespeedisoutofthespecifiedrange,adjustit.

CAUTION

Donotmeasuretheidlespeedbythetachometerof themeterunit.

- Whileidlingtheengine, inspect the engine vacuum, using the vacuum gauge[B].

EngineVacuum

Standard:35.3±1.3kPa(265±10mmHg)atIdle

Speed1300±50r/min(rpm)

★Ifanyonevacuumisnotwithinthespecification,turnin thebypassscrewsuntilitseatsfullybutnottightly.

SpecialTool-PilotScrewAdjuster, E[A]:57001-1603

CAUTION

Donotovertightenthem. They could bedamaged, requiring replacement.

• Turnoutthebypassscrewofthehighervacuumbetween #1[A]and#2[B]tothelowervacuum.
• Openandclosethethrottlevalvesaftereachmeasurementandadjusttheidlespeedasnecessary.
• Inspectthevacuumsasbefore.
  ★Ifbothvacuumsarewithinthespecification,finishtheenginevacuumsynchronization.
  ★Ifanyvacuumcannotbeadjustedwithinthespecification, removethebypassscrews#1,#2andcleanthem.

- Removethebypassscrew[A], spring[B], washer[C] and O-ring[D].

○Checkthebypassscrewanditsholeforcarbondeposits.

★Ifanycarbonaccumulates,wipethecarbonoffthebypass screwandthehole,usingacottonpadpenetratedwith a high-flashpointsolvent.

○ReplacetheO-ringwithanewone.

○Checkthetaperedportion[E]ofthebypassscrewfor wearordamage.

★Ifthebypassscrewiswornordamaged,replaceit.

- Turninthebypassscrewuntilitseatsfullybutnottightly.

Close-up of mechanical components with no visible text or symbols

PeriodicMaintenanceProcedures

• Repeatthesameprocedureforotherbypassscrews.
• Repeatthesynchronization.
  ★ If the vacuums are correct, check the output voltage of themainthrottlesensor (see Main Throttle Sensor Output Voltage Inspection in the Fuel System (DFI) chapter).

MainThrottleSensorOutputVoltage ConnectionstoECU

Meter(+)→ Y/Wlead(terminal7)

Meter(-)→ BR/BKlead(terminal28)

Standard:

1.055\~ 1.095VDC(atidlethrottleopening)

★ If the output voltage is out of the range, check the throttle input voltage (see Main Throttle Sensor Input Voltage Inspection in the Fuel System (DFI) chapter).
- Removethevacuumgaugehosesandinstallthevacuum hosesandrubbercaps.

CoolingSystem

CoolantLevelInspection

NOTE

○Checkthelevelwhentheengineiscold(roomorambienttemperature).

• Checkthecoolantlevelinthereservetank[A]withthe motorcycleheldperpendicular(Donotusethesidestand).
  ★ If the coolant level is slower than the "L" levelline[B], remove the right center fairing (see Center Fairing Removal in the Frame chapter) and unscrew the reservoir tank cap, and add coolant to the "F" levelline[C].

"L":low

"F":full

CAUTION

Forrefilling, addthespecifiedmixture of coolant and softwater. Adding water alonedilutesthe coolant and degrades its anticorrosion properties. Thediluted coolant can attack the aluminum engine parts. Inan emergency, softwater alone can be added. But the diluted coolant must be returned to the correct mixturerati within a few days. If coolant must be added often or thereservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Cool an truinspainted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts.

2-20PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

RadiatorHoseandPipeInspection(coolantleak, damage, installationcondition)

○Thehighpressureinsidetheradiatorhoseandpipecan causecoolanttoleak[A]orthehosetoburstifthelineis notproperlymaintained.
- Visuallyinspectthehosesforsignsofdeterioration. Squeezethehos. Ahoseshouldnotbehardand brittle, nor shouldditbesoftorswollen.
★Replacethehoseifanyfraying,cracks[B]orbulges[C]arenoticed.
- Check that the hoses are securely connected and clamps are tightened correctly.

Torque-RadiatorHoseClampScrews:2.0N·m(0.20kgf·m, 17in·lb)

AirSuctionSystem

AirSuctionSystemDamageInspection

• Removethefueltank(seeFuelTankRemovalintheFuel System(DFI)chapter).
• Removethefuelhose(seeFuelHoseReplacement).
• Connect:

FuelPumpLeadConnector[A] ExtensionTube[B]

Special Tool - Extension Tube: 57001-1578

• Pull the air switching valve hose [C] out of the air cleaner housing.
• Starttheengineandrunitatidlespeed.
• Plug[A]theairswitchingvalve hoseendwith yourfinger andfeelvacuumpulsinginthehose.
  ★Ifthereisnovacuumpulsation,checkthehoselinefor leak. If there is no leak, check the air switching valve (seeAirSwitchingValveUnitTestintheElectricalSystemchapter)orairsuctionvalve(seeAirSuctionValveInspectionintheEngineTopEndchapter).

EngineTopEnd

ValveClearanceInspection

NOTE

○ Valveclearancemustbecheckedandadjustedwhen theengineiscold(roomtemperature).

• Remove the cylinder head cover (see Cylinder Head CoverRemovalintheEngineTopEndchapter).
• Unscrewtheupper[A]andlower[B]capsontheclutch cover.

Close-up of a gloved hand holding a component with a labeled section 'A' (no readable text or symbols beyond the label)

PeriodicMaintenanceProcedures

• CheckthevalveclearancewhenthepistonsareatTDC.
• Thepistonsarenumberedbeginningwiththeengineleft side.
• Usingawrench[A]onthecrankshaftrotationbolt,turn thecrankshaftclockwiseuntilthe"1|T"markonthetiming rotorisalignedwiththenotch[B]intheedgeoftheupper holeintheclutchcoverfor#1pistonand"2|T"markfor #2piston.

1|TMark[A]

2|TMark[B]

Hole[C]ofUpperCap

Notch[D]inEdgeofUpperHole

○Measurethevalveclearanceofthevalvesforwhichthe camareturnedawayfromeachother.

- Usingthethicknessgauge[A],measurethevalveclearancebetweencamandvalvelifter.

ValveClearance

Standard:

Exhaust 0.22 \~ 0.31 mm (0.0087 \~ 0.0122 in.)

Inlet 0.15 \~ 0.21 mm (0.0059 \~ 0.0083 in.)

Close-up mechanical assembly with labeled component A (no readable text or symbols)

○Eachpistonhastwoinletandtwoexhaustvalves.Measurethesetwoinletorexhaustvalvesatthesamecrankshaftposition.

ValveClearanceMeasuringPosition

1PistonTDCatEndofCompressionStroke→

Inletvalveclearancesof#1piston,and

Exhaustvalveclearancesof#1piston

NOTE

○Checkthevalveclearanceusingthismethodonly. Checkingtheclearanceatanyothercampositionmay resultinimpropervalveclearance.

ValveClearanceMeasuringPosition

2PistonTDCatEndofCompressionStroke→

Inletvalveclearancesof#2piston,and Exhaustvalveclearancesof#2piston

★ If the valve clearance is not within the specified range, first record the clearance, and adjust it.

ValveClearanceAdjustment

- Tochangethevalveclearance,removethecamshaft chaintensioner,camshaftsandvalvelifters.Replacethe shimwithoneofadifferentthickness.

NOTE

○ Markandrecordthevalvelifterandshimlocationsso theycanbereinstalledintheiroriginalpositions.
○ Ifthereisnoclearance,selectashimwhichisseveral sizesmallerandthenmeasuretheclearance.

Donotputshimstockundertheshim. This may cause the topopoutathighrpm, causing extensiveenginedamage. Donotgrindtheshim. This may cause it to fracture, causing extensiveenginedamage.

PeriodicMaintenanceProcedures

VALVECLEARANCEADJUSTMENTCHARTINLETVALVE

INLET

	PRESENT SHIM
Part No. (92180)	1014	1016	1018	1020	1022	1024	1026	1028	1030	1032	1034	1036	1038	1040	1042	1044	1046	1048	1050	1052	1054
MARK	50	55	60	65	70	75	80	85	90	95	00	S	10	15	20	25	30	35	40	45	50
THICKNESS (mm)	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20	3.25	3.30	3.35	3.40	3.45	3.50

1. Measure the clearance (when engine is cold).
2. Checkpresentshimsize.
3. Matchclearanceinverticalcolumnwithpresentshimsizeinhorizontalcolumn.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Presentshimis2.95mm

Measuredclearanceis0.45mm

Replace 2.95 mm shim with 3.20 mm shim.

1. Remeasure the valve clearance and readjust if necessary.

VALVECLEARANCEADJUSTMENTCHARTEXHAUSTVALVE

EXHAUST

	PRESENT SHIM									Example
Part No. (92180)	1014	1016	1018	1029	1022	1024	1026	1028	1030	1032	1034	1036	1038	1040	1042	1044	1046	1048	1050	1052	1054
MARK	50	55	60	65	70	75	80	85	90	95	00	5	10	15	20	25	30	35	40	45	50
THICKNESS (mm)	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20	3.25	3.30	3.35	3.40	3.45	3.50

1. Measure the clearance (when engine is cold).
2. Checkpresentshimsize.
3. Matchclearanceinverticalcolumnwithpresentshimsizeinhorizontalcolumn.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Presentshimis2.95mm.

Measuredclearanceis0.47mm.

Replace 2.95 mm shim with 3.15 mm shim.

1. Remeasure the valve clearance and readjust if necessary.

PeriodicMaintenanceProcedures

Clutch

ClutchOperationInspection

• Pulltheclutchleverjustenoughtotakeupthefreeplay [A].
• Measurethegapbetweentheleverandtheleverholder.
  ★Ifthegapistoowide,theclutchmaynotreleasefully.If thegapistoonarrow,theclutchmaynotengagefully.In eithercase,adjustit.

ClutchLeverFreePlay

Standard: 2 \~ 3 mm (0.08 \~ 0.12 in.)

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols beyond the label.

WARNING

To avoid a serious burn, nevertouch the engine or exhaust pipe during clutch adjustment.

- Turn the adjuster [A] so that 5 \~ 6 mm (0.20 \~ 0.24 in.) [B] of threads are visible.

• Slidethedustcover[A]atthemiddleoftheclutchcable outofplace.
• Loosenthelocknut[B]atthemiddleofclutchcable.
• Turntheadjustingnut[C]untilthefreeplayiscorrect.

WARNING

Besurethattheoutercableendatheclutchlever isfullyseatedintheadjusterattheclutchlever,or itcouldslipintoplacelater,creatingenoughcable playtopreventclutchdisengagement.

- Aftertheadjustment, tightenthelocknutandstarttheengineandcheckthattheclutchdoesnotslipandthatit releasesproperly.

Wheels/Tires

AirPressureInspection

• Removetheairvalvecap.
• Measure the air pressure with an air pressure gauge [A] when the tires are cold (thatis, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Installtheairvalvecap.
  ★Adjustthetireairpressureaccordingtothespecifications ifnecessary.

AirPressure(whenCold)

Front: Upto180kg(397lb) 225kPa(2.25kgf/cm²,32psi)

Rear: Upto180kg(397lb) 250kPa(2.50kgf/cm²,36psi)

PeriodicMaintenanceProcedures

Wheel/TireDamageInspection

• Removeanyimbeddedstones[A]orotherforeignparticles[B]fromtread.
• Visually inspect the tire for cracks and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tirereplacement.
• Visually inspect the wheelfor cracks, cuts and dents damage.
  ★Ifanydamageisfound, replacethewheelifnecessary.

TireTreadWear, AbnormalWearInspection

Asthetiretreadwearsdown, the tirebecomesmoresusceptibletopuncture 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 unsafetouse the tires until they are bald.

- Measurethetreaddepthatthecenterofthetreadwitha depthgauge[A].Sincethetiremaywearunevenly,take measurementatseveralplaces.

★Ifanymeasurementislessthantheservicelimit,replace thetire(seeTireRemoval/InstallationintheWheels/Tires chapter).

TreadDepth

Standard:

Front6.5mm(0.26in.)

Rear9.0mm(0.35in.)

ServiceLimit:

Front	1mm(0.04in.) (AT,CH,DE)1.6mm(0.06in.)
Rear	2mm(0.08in.) (Upto130km/h(80mph)) 3mm(0.12in.) (Over130km/h(80mph))

WARNING

Toensuresafehandlingandstability,useonlythe recommended standard tires for replacement, inflatedtothestandardpressure.

NOTE

○ Mostcountriesmayhavetheirownregulationsamini-mumtiretreaddepth:besuretofollowthem.
○ Checkandbalancethewheelwhenatireisreplaced withanewone.

PeriodicMaintenanceProcedures

WheelBearingDamageInspection

• Raisethefrontwheeloffthegroundwithjack(seeFront WheelRemovalintheWheels/Tireschapter).
• Turnthehandlebarallthewaytotherightorleft.
• Inspecttheroughnessofthefrontwheelbearingbypushingandpulling[A]thewheel.
• Spin[B]thefrontwheellightly,andcheckforsmoothly turn,roughness,bindingornoise.
  ★ Ifroughness, bindingornoiseisfound, removethefront wheelandinspectthewheelbearing(seeFrontWheel Removal, HubBearingInspectionintheWheels/Tires chapter).
• Raisetherearwheeloffthegroundwithstand(seeRear WheelRemovalintheWheels/Tireschapter).
• Inspecttheroughnessoftherearwheelbearingbypushingandpulling[A]thewheel.
• Spin[B]therearwheellightly,andcheckforsmoothly turn,roughness,bindingornoise.
  ★ Ifroughness, binding or noise is found, removetherear wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter).

DriveTrain

DriveChainLubricationConditionInspection

• Ifaspeciallubricantisnotavailable, aheavyoilsuchas SAE90 is preferred to alighteroil because it will stay on the chain longer and provide better lubrication.
• If the chain appears especially dirty, clean it before lubrication.

CAUTION

TheO-ringsbetweenthesideplatessealinthelubricantbetweenthepinandthebushing.Toavoid damagingtheO-ringsandresultantlossoflubricant,observethefollowingrules.

UseonlykeroseneordieseloilforcleaninganO-ringdrivechain.Anyothercleaningsolutionsuch asgasolineortrichloroethylenewillcausedeteriorationandswellingoftheO-ring.Immediatelyblow thechaindrywithcompressedairaftercleaning. Completecleaninganddryingthechainwithin10 minutes.

2-28PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

• Applyoiltothesidesoftherollerssothatoilwillpenetrate totherollersandbushings.ApplytheoiltotheO-ringsso thattheO-ringswillbecoatedwithoil.
• Wipeoffanyexcessoil. OilAppliedAreas[A] O-rings[B]

DriveChainSlackInspection

NOTE

○ Checktheslackwiththemotorcyclesettingonitssidestand.
○ Cleanthechainifitisdirty, and lubricateitifitappears dry.

• Checkthewheelalignment(seeWheelAlignmentInspection).
• Rotatetherearwheeltofindthepositionwherethechain istightest.
• Measure the vertical movement (chainslack) [A] midway between the prospects.
  ★Ifthechainslackexceedsthestandard,adjustit.

ChainSlack

Standard: 30 \~ 40 mm (1.2 \~ 1.6 in.)

DriveChainSlackAdjustment

• Removethecotterpin[A], and loosentheaxlenut[B].
• Loosenthebothchainadjusterlocknuts[C].
  ★Ifthechainistooloose,turnintheleftandrightchain adjusternuts[D]evenly.
  ★Ifthechainistootight,turnouttheleftandrightchain adjusternutsevenly,andkickthewheelforward.
• Turnbothchainadjusternutsevenlyuntilthedrivechain hasthecorrectamountofslack.Tokeepthechainand wheelproperlyaligned,thevalue[E]ontheleftwheel alignmentadjuster[F]shouldalignwiththesame(leftor right)edge[G]ofinspectionwindowontheswingarmthat therightwheelalignmentadjustervaluealignswith.

WARNING

Misalignmentofthewheelwillresultinabnormal wearandmayresultinanunsaferidingcondition.

• Tightenbothchainadjusterlocknutssecurely.
• Tightentheaxlenut.
• Turnthewheel, measure the chainslack again at the tightest position, and read just if necessary.

Torque-RearAxleNut:108N·m(11.0kgf·m,80ft·lb)

PeriodicMaintenanceProcedures

- Insertanewcotterpin[A].

NOTE

When inserting the cotterpin, if the slots in thenut do not align with the cotterpinhole in the axle, tighten the nut clockwise [B] uptonextalignment.
○Itshouldbewithin30°.
○Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

- Bendthecotterpin[A]overthenut[B].

WARNING

Iftherearaxlenutisnotsecurelytightenedorthe cotterpinisnotinstalled,anunsaferidingconditionmayresult.

WheelAlignmentInspection

• Checkthatthevalue[A]ontheleftwheelalignmentadjuster[B]alignswiththesame(leftorright)edge[C]of inspectionwindowontheswingarmthattherightwheel alignmentadjustervaluealignswith.
  ★ Iftheydonot, adjust the chainslack and align the wheel alignment (seeDriveChainSlack Adjustment).

NOTE

○ Wheelalignmentcanbealsocheckedusingthe straightedgeorstringmethod.

WARNING

Misalignmentofthewheelwillresultinabnormal wear, and may result in an unsaferiding condition.

2-30 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

DriveChainWearInspection

• Remove:
  ChainCover(seeSwingarmRemovalintheSuspension chapter)
• Rotatetherearwheeltoinspectthedrivechainfordamagedrollers, and loosepinsandlinks.
  ★Ifthereisanyirregularity, replacethedrivechain.
  ★Lubricatethedrivechainifitappearsdry.
• Stretchthechaintautbyhanginga98N(10kg,20lb) weight[A]onthechain.
• Measurethelengthof20links[B]onthestraightpart[C]of thechainfromthepincenterofthe1stpintothepincenter ofthe21stpin.Sincethechainmaywearunevenly,take measurementsatseveralplaces.
  ★Ifanymeasurementsexceedtheservicelimit,replace the chain.Also,replacethefrontandrearsprocketswhenthe drivechainisreplaced.

DriveChain20-linkLength

Standard: 317.5 \~ 318.2 mm (12.50 \~ 12.53 in.)

ServiceLimit:323mm(12.7in.)

WARNING

Ifthedrivechainwearexceedstheservicelimit,re- placethechainoranunsaferidingconditionmay result.Achainthatbreaksorjumpsoffthesprock- etscouldsnagontheenginesprocketorlockthe rearwheel,severelydamagingthemotorcycleand causingittogooutofcontrol. Forsafely,useonlythestandardchain.Itisanend- lesstypeandshouldnotbecutforinstallation.

StandardChain

Make:ENUMA

Type: EK520MVXL1

Link: 114links

ChainGuideInspection

• Remove:
  Swingarm(seeSwingarmRemovalintheSuspension chapter)
• Visuallyinspectthechainguide[A].
  ★Replacethechainguideifitshowsanysignsofabnormal wearordamage.

Close-up of a mechanical component with labeled section A (no readable text or symbols beyond label)

PeriodicMaintenanceProcedures

BrakeSystem

BrakeFluidLeak(BrakeHoseandPipe)Inspection

• Applythebrakeleverorpedalandinspectthebrakefluid leakfromthebrakehoses[A]andfittings[B].
  ★ Ifthebrakefluidleakedfromanyposition,inspectorre-placetheproblempart.

BrakeHoseDamageandInstallationCondition Inspection

• Inspectthebrakehosesandfittingsfordeterioration, cracksandsignsofleakage.
  ○Thehighpressureinsidethebrakelinecancausefluidto leak[A]orthehosetoburstifthelineisnotproperlymaintained.Bendandtwisttherubberhosewhileexamining it.
  ★Replacethehoseifanycrack[B],bulge[C]orleakageis noticed.
  ★Tightenanybrakehosebanjobolts.

Torque-BrakeHoseBanjoBolts:25N·m(2.5kgf·m,18 ft·lb)

• Inspectthebrakehoserouting.
  ★Ifanybrakehoseroutingisincorrect, routethebrakehose accordingtoCable, Wire, and HoseRoutingsectioninthe Appendixchapter.

BrakeOperationInspection

• Inspecttheoperationofthefrontandrearbrakebyrunningthevehicleonthedryroad.
  ★ Ifthebrakeoperationisinsufficiency, inspectthebrake system.

WARNING

When inspecting by running the vehicle, notea surrounding traffic situation enough in the place of safety.

2-32PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

BrakeFluidLevelInspection

- Check that the brake fluid level in the front braker reservoir [A] is abovethelower levelline [B].

NOTE

○ Holdthereservoirhorizontalbyturningthehandlebar whencheckingbrakefluidlevel.

★Ifthefluidlevelislowerthanthelowerlevelline,fillthe reservoirtotheupperlevelline[C]inthereservoir.

- Removetheseat(seeSeatRemovalintheFramechapter).

- Check that the brake fluid level in therear braker reservoir [A] is abovethelower levelline[B].

★Ifthefluidlevelislowerthanthelowerlevelline,fillthe reservoirtotheupperlevelline[C].

WARNING

Changethebrakefluidinthebrakelinecompletely ifthebrakefluidmustberefilledbutthetypeand brandofthebrakefluidthatisalreadyinthereservoirareunidentified. Afterchangingthefluid, use onlythesametypeandbrandoffluidthereafter.

RecommendedDiscBrakeFluid Grade:DOT4

- Follow the procedure below to install therear brake fluid reservoir cap correctly.

○First,tightentherearbrakefluidreservoircap[B]clockwise[C]byhanduntilslightresistanceisfeltindicating thatthecapisseatedonthereservoirbody,thentighten thecapanadditional1/6turn[D]whileholdingthebrake fluidreservoirbody[A].

PeriodicMaintenanceProcedures

BrakePadWearInspection

• Checktheliningthickness[A]ofthepadsineachcaliper.
  ★ Iftheliningthicknessofeitherpadislessthantheservice limit[B],replacebothpadsinthecaliperasaset.

PadLiningThickness

Standard:

Front 4.5mm(0.18in.)

Rear 5.0mm(0.20in.)

ServiceLimit:1mm(0.04in.)

BrakeLightSwitchOperationInspection

• Turnontheignitionswitch.
• Thebrakelight[A]shouldgoonwhenthebrakeleveris appliedorafterthebrakepedalisdepressedabout10 mm(0.39in.).

★ Ifitdoesnot,adjustthebrakelightswitch.
- Whileholdingtheswitchbody,turntheadjustingnut[A] toadjusttheswitch.

CAUTION

To avoid damaging the electrical connections in sidetheswitch, besure that the switch body does not turn during adjustment.

★ Ifitdoesnotgoon, inspectorreplacethefollowingitems.
Battery(seeChargingConditionInspectionintheElectricalSystemchapter)
BrakeLight(seeTail/BrakeLightRemovalintheElectricalSystemchapter)
MainFuse30AandTaillightFuse10A(seeFuseInspectionintheElectricalSystemchapter)
FrontBrakeLightSwitchA
RearBrakeLightSwitch(seeSwitchInspectioninthe ElectricalSystemchapter)
Harness(see Wiring Inspection in the Electrical System chapter)

Close-up of a motorcycle's front wheel and dashboard (no visible text or symbols)

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

Close-up mechanical assembly with labeled component A (no readable text or symbols)

2-34PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

Suspensions

FrontForks/RearShockAbsorberOperation Inspection

• Pumptheforksdownandup[A]4or5times,andinspect thesmoothstroke.
  ★Iftheforksdonotsmoothlyornoiseisfound,inspectthe forkoillevelorforkclamps(seeFrontForkOilChangein theSuspensionchapter).

- Pumptheseatdownandup[A]4or5times,andinspect thesmoothstroke.

★Iftheshockabsorberdoesnotsmoothlystrokeornoise isfound, inspecttheoilleak(seeRearShockAbsorber OilLeakInspection).

FrontForkOilLeakInspection

• Visuallyinspectthefrontforks[A]foroilleakage.
  ★Replaceorrepairanydefectiveparts,ifnecessary.

RearShockAbsorberOilLeakInspection

• Visuallyinspecttheshockabsorber[A]foroilleakage.
  ★Iftheoilleakageisfoundonit,replacetheshockabsorber withanewone.

Close-up of a motorcycle's side panel with a hand adjusting the seat area, showing no visible text or symbols.

Close-up mechanical assembly showing a spring and bearing component (no visible text or symbols)

PeriodicMaintenanceProcedures

SteeringSystem

SteeringPlayInspection

- Raisethefrontwheeloffthegroundwithjack.

SpecialTools-Jack:57001-1238

JackAttachment:57001-1608

- With the front wheelpointing straight ahead, alternately tapeach end of the handle bar. The front wheel should swing fully left and right from the force of gravity until the fork hit the stop.

★ If the wheel binds or catches before the stop, the steering istootight.

- Feelforsteeringloosenessbypushingandpullingthe forks.

★ Ifyoufeellooseness, thesteeringistooloose.

NOTE

○ Thecablesandwiringwillhavesomeeffectonthemotionoftheforkwhichmustbetakenintoaccount.

○Besurethewiresandcablesareproperlyrouted.

○ Thebearingsmustbeingoodconditionandproperly lubricatedinorderforanytesttobevalid.

SteeringPlayAdjustment

- Remove:

HeadlightAssy(seeHeadlightRemoval/Installationin theElectricalSystemchapter)

Handlebar(seeHandlebarRemovalintheSteering chapter)

UpperForkClampBolts[A]

SteeringStemHeadBoltPlug[B]

StemHeadBolt[C]

- Removethesteeringstemhead[D].

- Straightentheclaws[A]oftheclawwasher.

- Removethesteeringstemlocknut[B]andclawwasher [C].

Close-up of a car wheel assembly with a hand adjusting the brake caliper (no visible text or symbols)

2-36PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

- Adjustthesteering.

SpecialTool-SteeringStemNutWrench[A]:57001-1100

★Ifthesteeringistootight,loosenthestemnut[B]afraction ofaturn.

★Ifthesteeringistooloose,tightenthestemnutafraction ofaturn.

NOTE

○ Turnthestemnut1/8turnattimemaximum.

• Installtheclawwasher[A]sothatitsbentside[B]faces upward, and engage the bent claw with the grooves of stemlocknut[C].
• Handtightenthestemlocknutuntilittouchestheclaw washer.
• Tightenthestemlocknutclockwiseuntiltheclawsare alignedwiththegrooves(rangingfrom2ndto4th)ofstem nut[D],andbendthe2clawsdownward[E].
  • Installthesteeringstemhead.
  • Installthewasher, and tightenthestemheadbolt.
• Tighten:

Torque-SteeringStemHeadBolt:108N·m(11.0kgf·m,80ft·lb)

FrontForkClampBolts(Upper):20N·m(2.0 kgf·m,15ft·lb)

• Checkthesteeringagain.
  ★Ifthesteeringisstilltootightortooloose,repeathead-justment.
• Installtheremovedparts(seeappropriatechapters).

SteeringStemBearingLubrication

• Removethesteeringstem(seeStem,StemBearingRemovalintheSteeringchapter).
• Using a high flash-point solvent, wash the upper and lowerballbearingsinthecages,andwipetheupperand lowerouterraces,whicharepress-fittedintotheframe headpipe,cleanoffgreaseanddirt.
• Visuallychecktheouterracesandtheballbearings.
  ★Replace the bearing assemblies if they show wear or damage.
• Packtheupperandlowerballbearings[A]inthecages withgrease,andapplylightcoatofgreasetotheupper andlowerouterraces.
• Installthesteeringstem(seeStem,StemBearingInstallationintheSteeringchapter).
• Adjustthesteering(seeSteeringPlayAdjustment).

Technical line drawing of a mechanical assembly with labeled component A (no text or symbols beyond label)

PeriodicMaintenanceProcedures

ElectricalSystem

SparkPlugConditionInspection

• Removethesparkplugs(seeSparkPlugReplacement).
• Visuallyinspectthesparkplugs.
  ★Ifthesparkplugcenterelectrode[A]and/orsideelectrode[B]arecorrodedordamaged,oriftheinsulator[C]iscracked,replacetheplug.
  ★ Ifthesparkplugisdirtiedorthecarbonisaccumulated, replacethesparkplug.
• Measurethegap[D]withawire-typethicknessgauge.
  ★ Ifthegapisincorrect, replacethesparkplug.

Spark Plug Gap: 0.8 \~ 0.9 mm (0.03 \~ 0.04 in.)

- Usethestandardsparkplugoritsequivalent.

SparkPlug:CR9EIA-9

2-38PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

LightsandSwitchesOperationInspection

FirstStep

• Turnontheignitionswitch.
• The following light should go on according to below table.

CityLight[A]	goeson
Taillight[B]	goeson
LicensePlateLight[C]	goeson
MeterPanelLCD[D]	goeson
NeutralIndicatorLight(LED)[E]	goeson
OilPressure/WaterTemperatureWarning IndicatorLight(LED)[F]	goeson
FllndicatorLight(LED)[G]	goeson (about2seconds)

★Ifthelightdoesnotgoon,inspectorreplacethefollowing item.
Battery(seeChargingConditionInspectionintheElectricalSystemchapter)
ApplicableBulb(seeWiringDiagramintheElectrical Systemchapter)
MeterUnitforMeterPanelLCD(seeElectronicCombinationMeterUnitInspectionintheElectricalSystem chapter)
MeterUnitforNeutralIndicatorLight(LED)(seeElectronicCombinationMeterUnitInspectionintheElectricalSystemchapter)
MeterUnitforOilPressure/WaterTemperatureWarning IndicatorLight(LED)(seeElectronicCombinationMeter UnitInspectionintheElectricalSystemchapter)
MeterUnitforFllndicatorLight(LED)(seeElectronic CombinationMeterUnitInspectionintheElectricalSystemchapter)
ECU(seeECUPowerSupplyInspectionintheFuelSystem(DFI)chapter)
MainFuse30AandTaillightFuse10A(seeFuseInspectionintheElectricalSystemchapter)
IgnitionSwitch(seeSwitchInspectionintheElectrical Systemchapter)
NeutralSwitch(seeSwitchInspectionintheElectrical Systemchapter)
Harness(see Wiring Inspection in the Electrical System chapter)

• Turnofftheignitionswitch.
  • Thealllightsshouldgooff.
  ★Ifthelightdoesnotgooff,replaceignitionswitch.

SecondStep

• TurntheignitionswitchtoP(Park)position.
• Thecitylight,taillightandlicenseplatelightshouldgoon.
  ★Ifthelightdoesnotgoon,inspectorreplacethefollowing item.

IgnitionSwitch(seeSwitchInspectionintheElectrical Systemchapter)

Close-up of a motorcycle's head and neck showing internal gear structure (no text or symbols visible)

PeriodicMaintenanceProcedures

ThirdStep

• TurnontheturnsignalswitchA.
• TheleftorrightturnsignallightsBaccordingtotheswitchpositionsshouldflash.
• Theturnsignalindicatorlight(LED)[C]inthemeterunit shouldflash.
  ★ If the each light does not flash, inspector replace the following item.

TurnSignalLightBulb(seeTurnSignalLightBulbReplacementintheElectricalSystemchapter)

MeterUnitforTurnSignalLightIndicatorLight(LED) (seeElectronicCombinationMeterUnitInspectioninthe ElectricalSystemchapter)

TurnSignalRelayFuse10A(seeFuseInspectioninthe ElectricalSystemchapter)

TurnSignalSwitch(seeSwitchInspectionintheElectricalSystemchapter)

TurnSignalRelay(seeTurnSignalRelayInspectionin theElectricalSystemchapter)

Harness(see Wiring Inspection in the Electrical System chapter)

• Pushtheturnsignalswitch.
• Theturnsignallightsandindicatorlight(LED)shouldgo off.
  ★ Ifthelightdoesnotgooff, inspectorreplacethefollowing item.

TurnSignalSwitch(seeSwitchInspectionintheElectricalSystemchapter)

TurnSignalRelay(see TurnSignalRelayInspection in the Electrical Systemchapter)

Close-up of a camera lens and adjustment knobs mechanism (no visible text or symbols)

Close-up of a mechanical device with labeled component B, no visible text or symbols

Close-up of a scooter's front wheel with speedometer and control buttons (no visible text or symbols)

FourthStep

• Setthedimmerswitch[A]tolowbeamposition.
• Starttheengine.
• Thelowbeamheadlightshouldgoon.
  ★ Ifthelowbeamheadlightdoesnotgoon, inspectorre-placethefollowingitem.

HeadlightLowBeamBulb(seeHeadlightBulbReplacementintheElectricalSystemchapter)

HeadlightFuse10A(seeFuseInspectionintheElectricalSystemchapter)

DimmerSwitch(seeSwitchInspectionintheElectrical Systemchapter)

HeadlightRelayinRelayBox(seeRelayCircuitInspectionintheElectricalSystemchapter)

Harness(see Wiring Inspection in the Electrical System chapter)

Close-up of a mechanical device's control panel with labeled component A (no readable text or symbols beyond label)

2-40PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

• Setthedimmerswitchtohighbeamposition.
• Thelowbeam[A]andhighbeam[B]headlightsshould goon.
• Thehighbeamindicatorlight(LED)[C]shouldgoon.
  ★Ifthehighbeamheadlightand/orhighbeamindicatorlight(LED)doesnotgoon,inspectorreplacethefollowing item.
  HeadlightHighBeamBulb(seeHeadlightBulbReplacementintheElectricalSystemchapter)
  DimmerSwitch(seeSwitchInspectionintheElectrical Systemchapter)
• Turnofftheenginestopswitch.
• Thelowbeamandhighbeamheadlightsshouldstaygoingon.
  ★Iftheheadlightsandhighbeamindicatorlight(LED)does gooff,inspectorreplacethefollowingitem.
  HeadlightRelayinRelayBox(seeRelayCircuitInspectionintheElectricalSystemchapter)
• Turnofftheignitionswitch.
• Theheadlightsandhighbeamindicatorlight(LED)should gooff.

HeadlightAimingInspection

• Inspecttheheadlightbeamforaiming.
  ★Iftheheadlightbeampointstoonesideratherthan straightahead,adjustthehorizontalbeam.

HeadlightBeamHorizontalAdjustment

- Turnthehorizontaladjuster[A]ontheheadlightwiththe screwdriverinoroutuntilthebeampointsstraightahead.

★Iftheheadlightbeampointstooloworhigh,adjustthe verticalbeam.

HeadlightBeamVerticalAdjustment

- Turntheverticaladjuster[A]ontheheadlightwiththe screwdriverinorouttoadjusttheheadlightvertically.

Front view of a scooter's head and dashboard with visible controls and a speedometer (no text or symbols)

Close-up of a mechanical component with a labeled part 'A' and a circular arrow, showing internal structure without any readable text or symbols.

Close-up of mechanical components with visible wiring and a labeled component 'A' (no readable text or symbols beyond the label)

PeriodicMaintenanceProcedures

NOTE

○ONhighbeam, the brightestpointsshouldbeslightly below horizontal with themotorcycleonitswheels and theriderseated. Adjust the headlight to the proper angle according to local regulations.

LowBeam[A]

HeightofHeadlightCenter[B]

HighBeam[C]

Line drawing of a motorcycle with gear and wheel, showing motion direction (no text or symbols)

SidestandSwitchOperationInspection

- Inspectthesidestandswitch[A]operationaccordanceto belowtable.

SidestandSwitchOperation

Sidestand	Gear Position	Clutch Lever	Engine Start	Engine Run
UpNeutralReleased			Starts	Continue running
UpNeutralPulledin			Starts	Continue running
Up	InGear	Released	Doesn't start	Stops
UpInGearPulledinStarts				Continue running
DownNeutralReleasedStarts				Continue running
DownNeutralPulledinStarts				Continue running
Down	InGear	Released	Doesn't start	Stops
Down	InGear	Pulledin	Doesn't start	Stops

Close-up of mechanical components with no visible text or symbols

2-42PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

★Ifthesidestandswitchoperationdoesnotwork,inspect orreplacethefollowingitem.
Battery(seeChargingConditionInspectionintheElectricalSystemchapter)
MainFuse30A(seeFuseInspectionintheElectrical Systemchapter)
IgnitionFuse10A(seeFuseInspectionintheElectrical Systemchapter)
IgnitionSwitch(seeSwitchInspectionintheElectrical Systemchapter)
SidestandSwitch(seeSwitchInspectionintheElectrical Systemchapter)
EngineStopSwitch(seeSwitchInspectionintheElectricalSystemchapter)
StarterButton(seeSwitchInspectionintheElectrical Systemchapter)
NeutralSwitch(seeSwitchInspectionintheElectrical Systemchapter)
StarterControlRelay(seeStarterRelayInspectionin the ElectricalSystemchapter)
RelayBox(seeRelayCircuitInspectionintheElectrical Systemchapter)
StarterCircuitRelay(seeRelayCircuitInspectioninthe ElectricalSystemchapter)
Harness(see Wiring Inspection in the Electrical System chapter)

★Iftheallpartsaregoodcondition,replaceECU(see ECURemoval/InstallationintheFuelSystem(DFI)chapter).

EngineStopSwitchOperationInspection

FirstStep

• Turnontheignitionswitch.
• Settheneutralposition.
• Turntheenginestopswitchtostopposition[A].
• Pushthestarterbutton.
  • Theenginedoesnotstart.
  ★Iftheenginestarts,inspectorreplacethefollowingitem. EngineStopSwitch(seeSwitchInspectionintheElectricalSystemchapter)

SecondStep

• Turnontheignitionswitch.
• Settheneutralposition.
• Turntheenginestopswitchtorunposition[A].
• Pushthestarterbuttonandruntheengine.
• Turntheenginestopswitchtostopposition.
• Immediatelytheengine shouldbestop.

★Iftheengine does not stop, inspector replace the following item.

EngineStopSwitch(seeSwitchInspectionintheElectricalSystemchapter)

★Iftheenginestopswitchisgoodcondition,replace the ECU(seeECURemoval/InstallationintheFuelSystem (DFI)chapter).

Close-up of a mechanical device with labeled component A (no readable text or symbols beyond label)

PeriodicMaintenanceProcedures

Others

ChassisPartsLubrication

• Beforelubricatingeachpart,cleanoffanyrustyspotswith rustremoverandwipeoffanygrease,oil,dirt,orgrime.
• Lubricatethepointslistedbelowwithindicatedlubricant.

NOTE

○ Wheneverthevehiclehasbeenoperatedunder wetorrainyconditions,orespeciallyafterusing a high-pressurewaterspray,performthegenerallubrication.

Pivots:LubricatewithGrease.

BrakeLever BrakePedal ClutchLever RearBrakeJointPin Sidestand

Points:LubricatewithGrease.

ClutchInnerCableUpperandLowerEnds[A] ThrottleInnerCableUpperandLowerEnds

Cables:LubricatewithRustInhibitor.

ClutchCable ThrottleCables

• Lubricatethecablesbyseepingtheoilbetweenthecable andhousing.
  ○Thecablemaybelubricatedbyusingacommercially availablepressurecablelubricatorwithanaerosolcable lubricant.

Line drawing of two hands holding a syringe and a bottle, no text or symbols present

- With the cable disconnected at both ends, the inner cable should move freely [A] within the cable housing.

★Ifcablemovementisnotfreeafterlubricating,ifthecable isfrayed[B],orifthecablehousingiskinked[C],replace thecable.

Bolts, Nuts and Fasteners Tightness Inspection

- Checkthetightnessoftheboltsandnutslistedhere. Also, checktoseethateachcotterpinisinplaceandingood condition.

NOTE

○ Fortheenginefasteners, check the tightness of them when the engine is cold (at room temperature).

★Ifthereareloosefasteners,retightenthemtothespecifiedtorquefollowingthespecifiedtighteningsequence. Refertotheappropriatechapterfortorquespecifications. Iftorquespecificationsarenotintheappropriatechapter, seetheStandardTorqueTable.Foreachfastener,first loosenitby1/2turn,thentightenit.

★Ifcotterpinsaredamaged, replacethemwithnewones.

Bolt, Nutand Fastenertobechecked

Engine:

ClutchLeverPivotNut

EngineMountingBoltsandNuts

ExhaustPipeManifoldHolderNuts

MufflerBodyMountingBolts

Wheels:

FrontAxle

FrontAxleClampBolt

RearAxleNut

RearAxleNutCotterPin

Brakes:

BrakeLeverPivotNut

BrakePedalBolt

BrakeRodJointCotterPin

CaliperMountingBolts

FrontMasterCylinderClampBolts

RearMasterCylinderMountingBolts

Suspension:

FrontForkClampBolts

RearShockAbsorberBoltandNut

SwingarmPivotShaftNut

Steering:

SteeringStemHeadBolt

HandlebarHolderBolts

Others:

FootpegStayBolts

FrontFenderBolts

SidestandBolt

PeriodicMaintenanceProcedures

ReplacementParts

AirCleanerElementReplacement

- RefertotheAirCleanerElementCleaning.

EngineOilChange

• Situatethemotorcyclesothatis vertical after warming up the engine.
• Unscrewtheoilfillerplug[A].

• Placeonoilpanbeneaththeengine.

• Removetheengineoidrainbolt[A]todraintheoil.
  ○Theoilintheoilfiltercanbedrainedbyremovingthefilter (seeOilFilterReplacement).
  ★Replacethedrainboltgasket[B]withanewone.

• Tightenthedrainbolt.

Torque-EngineOilDrainBolt:20N·m(2.0kgf·m,15ft·lb)

- Pourinthespecifiedtypeandamountofoil.

RecommendedEngineOil

Type:

APISE,SForSG

APISH,SJorSLwithJASOMA

Viscosity:

SAE10W-40

Capacity:1.7L(1.8USqt)(whenfilterisnot removed)

1.9L(2.0USqt)(whenfilterisremoved)

2.4L(2.5USqt)(whenengineis completelydry)

NOTE

Although 10W-40engineoilistherecommendedoil formostconditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

- Checktheoillevel(seeOilLevelInspectionintheEngine LubricationSystemchapter).

2-46PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

OilFilterReplacement

• Draintheengineoil(seeEngineOilChange).

• Removetheoilfilter[A]withtheoilfilterwrench[B].
  SpecialTool-OilFilterWrench:57001-1249

• Replacethefilterwithanewone.

• Applyengineoiltothegasket[A]beforeinstallation.
• Tightenthefilterwiththeoilfilterwrench.

Torque-OilFilter:17.2N·m(1.75kgf·m,13ft·lb)

NOTE

○ Handtighteningoftheoilfiltercannotbeallowedsince itdoesnotreachtothistighteningtorque.

- Pourinthespecifiedtypeandamountofoil(seeEngine OilChange).

FuelHoseReplacement

CAUTION

Whenremovingandinstallingthefuelhosejoint,do notapplystrongforcetotheoutletpipeonthefuel pumpanddeliverypipeonthethrottlebodyassy. Thepipesmadefromresincouldbedamaged.

• Removethefueltank(seeFuelTankRemovalintheFuel System(DFI)chapter).
• Besuretoplaceapieceofcloth[A]aroundthefuelhose joint.
• Insertaminusscrewdriver[B]intotheslit[C]onthejoint lock.
• Turn[A]thedrivertodisconnectthejointlock[B].
• Pull[C]thefuelhosejoint[D]outofthedeliverypipe.

WARNING

Bepreparedforfuelspillage;anyspilledfuelmust becompletelywipedupimmediately. Whenthefuelhoseisdisconnected,fuelspillsout fromthehoseandthepipe.Coverthehoseconnectionwithacleanshoptoweltopreventfuelspillage.

Technical line drawing of a mechanical component with labeled point A (no text or symbols beyond label)

PeriodicMaintenanceProcedures

• Installthenewfuelhose.
- Insert[A]thefuelhosejoint[B]straightontothedelivery pipeuntilthehosejointclicks.
- Push[C]thejointlock[D].

- Pushandpull[A]thefuelhosejoint[B]backandforth morethantwotimesandmakesureitislockedand doesn'tcomeoff.

WARNING

Makesurethefuelhosejointisinstalledcorrectly onthedeliverypipeorthefuelcouldleak.

★ Ifitcomesoff, reinstallthehosejoint.
- Runthefuelhosecorrectly(seeCable, Wire, and Hose RoutingsectionintheAppendixchapter).
• Installtheremovedparts(seeappropriatechapters).
- Starttheengineandcheckthefuelhoseforleaks.

CoolantChange

WARNING

Toavoidburns, donotremovetheradiatorcapor trytochangethecoolantwhentheengineisstill hot. Wait until cools down. Coolantontires will makethemslippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine, or other painted parts. Since coolantisharmful to the human body, donot use for drinking.

• Remove:
  RightCenterFairing(seeCenterFairingRemovalinthe Framechapter)
  LowerFairing(seeLowerFairingRemovalintheFrame chapter)
• Remove:
  ReserveTankBolts[A] ReserveTank[B]

Close-up of a mechanical assembly with labeled parts A and B, showing no readable text or symbols beyond labels

2-48PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

- Put[A]theprojection[B]onthereservetankintothehole [C]ontheframebracket,andplacethereservetankon therightsideofframe.

- Placeacontainerunderthewaterpumpdrainbolt[A], thenremovethedrainbolt.

- Removetheradiatorcap[A]intwosteps.Firstturnthe capcounterclockwisetothefirststop.Thenpushandturn itfurtherinthesamedirectionandremovethecap. ○Thecoolantwilldrainfromtheradiatorandengine.

- Turnover[A]thereservetank,removethecap,andpour thecoolantintoasuitablecontainer. - Placethereservetankontherightsideofframe. - Tightenthedrainboltwiththegasket. - Replacethedrainboltgasketwithanewone. Torque-WaterPumpDrainBolt:7.0N·m(0.70kgf·m,92 in·lb)

Close-up of a mechanical component with labeled section A, showing internal structure and mounting brackets (no readable text or symbols beyond label)

Close-up mechanical component with labeled section A, showing no readable text or symbols beyond the label

PeriodicMaintenanceProcedures

- Whenfillingthecoolant,chooseasuitablemixtureratio byreferringtothecoolantmanufacturer'sdirections.

CAUTION

Softordistilledwatermustbeusedwiththeantifreezeinthecoolingsystem. Ifhardwaterisusedinthesystem, itcausesscales accumulationinthewaterpassages, and considerablyreducetheefficiencyofthecoolingsystem.

WaterandCoolantMixtureRatio(Recommended)

SoftWater:50%

Coolant:50%

FreezingPoint: -35^(-31^)

TotalAmount: 1.2L(1.3USqt)

- Filltheradiatoruptothefillerneck[A]withcoolant.

NOTE

○Pourinthecoolantslowlysothatitcanexpeltheair fromtheengineandradiator.

• Checkthecoolingsystemforleaks.
• Taptheradiatorhosestoforceanyairbubblescaught inside.
• Filltheradiatoruptothefillerneckwithcoolant.
• Temporarily installthereservetanktotheframewithtwo mountingbolts.
• Fillthereservetankuptothe“F”(full)levelline[A]with coolantandinstallthecap[B].
• Starttheengine, warmitupthoroughly untiltheradiator fanturnson and thenstoptheengine.
• Checkthecoolantlevelinthereservetankaftertheenginecoolsdown.
  ★ If the coolant level is slower than the "L" levelline, add coolant to the "F" levelline.

CAUTION

Donotaddmorecoolantabovethe“F”levelline.

Close-up of a mechanical component with labeled point A pointing to a cylindrical opening (no readable text or symbols)

2-50PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

RadiatorHoseandO-ringReplacement

• Drainthecoolant(seeCoolantChangeinthePeriodic Maintenancechapter).
• Remove: ThermostatHousingA WaterPumpCoverB Hoses[C] O-rings[D]
• ApplygreasetothenewO-ringsandinstallthem.
• Instalthenewhosesandtightentheclampssecurely.
• Fillthecoolant(seeCoolantChangeinthePeriodicMaintenancechapter).
• Checkthecoolingsystemforleaks.

PeriodicMaintenanceProcedures

BrakeHoseandPipeReplacement

CAUTION

Brakefluidquicklyruinspaintedplasticsurfaces; anyspilledfluidshouldbecompletelywashedaway immediately.

• Removethebanjobolts[A].
• Whenremovingthebrakehose, takecarenottospillthe brakefluidonthepaintedorplasticparts.
• When removing the brake hoses [B], temporarily secure the end of the brake hosetosome high placeto keep fluid lossto a minimum.
• Immediatelywashawayanybrakefluidthatspills.
• Therearewashersoneachsideofthebrakehosefitting. Replacethemwithnewoneswheninstalling.
• Tighten:

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Wheninstallingthehoses,avoidsharpbending,kinking,flattingortwisting,androutethehosesaccordingto Cable,Wire,andHoseRoutingsectionintheAppendix chapter.
• Fillthebrakelineafterinstallingthebrakehose(see BrakeFluidChange).

BrakeFluidChange

NOTE

○ Theproceduretochangethefrontbrakefluidisasfollows. Changingtherearbrakefluidisthesameasfor thefrontbrake.

2-52PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

• Levelthebrakefluidreservoir.
• Removethereservoircapanddiaphragm.
• Removetherubbercapfromthebleedvalve[A]onthe caliper.
• Attachaclearplastichose[B]tothebleedvalve,andrun theotherendofthehoseintoacontainer.
• Fillthereservoirwithfreshspecifiedbrakefluid.

- Changethebrakefluid. ○Repeatthisoperationuntilfreshbrakefluidcomesout fromtheplasticchoseorthecolorofthefluidchanges.

1. Openthebleedvalve[A].
2. Applythebrakeandholdit[B].
   3.Closethebleedvalve[C].
3. Releasethebrake[D].

NOTE

○ Thefluidlevelmustbecheckedoftenduringthechangingoperationandreplenishedwithfreshbrakefluid. If thefluidinthereservoirrunsoutanytimeduringthe changingoperation,thebrakeswillneedtobebled sinceairwillhaveenteredthebrakeline.
○ FrontBrake: Repeat the abovesteps for the other caliper.

• Removetheclearplastichose.
  • Installthediaphragmandreservoircap.
• Tighten:

Torque-FrontBrakeReservoirCapScrews:1.0N·m(0.10 kgf·m,9in·lb)

• Follow the procedure below to install therear brake fluid reservoir cap correctly.
  ○First,tightentherearbrakefluidreservoircap[B]clockwise[C]byhanduntilslightresistanceisfeltindicating thatthecapisseatedonthereservoirbody,thentighten thecapanadditional1/6turn[D]whileholdingthebrake fluidreservoirbody[A].

• Tightenthebleedvalve, and installtherubbercap.

• Afterchangingthefluid, checkthebrakeforgoodbraking power, nobrakedrag, andnofluidleakage.
  ★Ifnecessary,bleedtheairfromthelines.

Torque-BleedValve:7.8N·m(0.80kgf·m,69in·lb)

Close-up of a mechanical assembly with labeled parts A and B (no readable text or symbols beyond labels)

PeriodicMaintenanceProcedures

MasterCylinderRubberPartsReplacement

FrontMasterCylinderDisassembly

• Removethefrontmastercylinder(seeFrontMasterCylinderRemovalintheBrakeschapter).
• Removethereservoircapanddiaphragm, and pour the brakefluid into a container.
• Unscrewthelocknutandpivotbolt, andremovethebrake lever.
• Pullthedustcover[A]outofplace,andremovethecirclip [B].

SpecialTool-InsideCirclipPliers:57001-143

- Pulloutthepiston[C], secondarycup[D], primarycup[E], andreturnspring[F].

CAUTION

Donotremovethesecondarycupfromthepiston sinceremovalwilldamageit.

RearMasterCylinderDisassembly

NOTE

○ Donotremovethepushrodclevisformastercylinder disassemblysinceremovalreguiresbrakepositionadjustment.

• Removetherearmastercylinder(seeRearMasterCylinderRemovalintheBrakeschapter).
• Slidethedustcoveronthepushrodoutofplace,and removethecirclip.

SpecialTool-InsideCirclipPliers:57001-143

• Pulloutthepushrodwiththepistonstop.
• Takeoffthepiston[A], secondarycup[B], primarycup[C] and returnspring[D].

CAUTION

Donotremovethesecondarycupfromthepiston sinceremovalwilldamageit.

MasterCylinderAssembly

- Beforeassembly, cleanallpartsincludingthemaster cylinderwithbrakefluidoralcohol.

CAUTION

Exceptforthediscpadsanddisc,useonlydisc brakefluid,isopropylalcohol,orethylalcoholfor cleaningbrakeparts.Donotuseanyotherfluidfor cleaningtheseparts.Gasoline,engineoil,orany otherpetroleumdistillatewillcausedeteriorationof therubberparts.Oilspilledonanypartwillbedifficulttowashoffcompletely,andwilleventuallydeterioratetherubberusedinthediscbrake.

2-54PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

• Applybrakefluidtothenewpartsandtotheinnerwallof thecylinder.
• Takecarenottoscratchthepistonortheinnerwallofthe cylinder.
• Tightenthebrakeleverpivotboltandlocknut.
• Applysiliconegrease. BrakeLeverPivotBolt
• Tighten:

Torque-BrakeLeverPivotBolt:1.0N·m(0.10kgf·m,9 in·lb) BrakeLeverPivotBoltLocknut:5.9N·m(0.60 kgf·m,52in·lb)

CaliperRubberPartsReplacement FrontCaliperDisassembly

• Remove:
  FrontCaliper(seeFrontCaliperRemovalintheBrakes chapter) BrakePads(seeFrontBrakePadRemovalintheBrakes chapter)
  • Usingcompressedair, removethepistons.
  ○Coverthepistonareawithaclean,thickcloth[A].
  ○Blowcompressedair[B]intotheholeforthebanjoboltto removethepiston.

WARNING

Toavoidseriousinjury,neverplaceyourfingersor palminfrontofthepiston.Ifyouapplycompressed airintothecaliper,thepistonmaycrushyourhand orfingers.

○Pulloutthepistonsbyhand.

• Removethedustseals[A]andfluidseals[B].
• Removethebleedvalve[C]andrubbercap[D].

NOTE

○ Ifcompressedairisnotavailable, withthebrakehose stillattached, applythebrakelevertoremovethepiston. Theremainingprocessisasdescribedabove.

FrontCaliperAssembly

- Cleanthecaliperpartsexceptforthepads.

CAUTION

Forcleaningtheparts, useonlydiscbrakefluid, isopropylalcohol, orethylalcohol.

• Installthebleedvalveandrubbercap.

Torque-BleedValve:7.8N·m(0.80kgf·m,69in·lb)

PeriodicMaintenanceProcedures

• Replacethefluidseals[A]withnewones.
  ○Applybrakefluidtothefluidseals, and install them into the cylinders by hand.

• Replacethedustseals[B]withnewonesiftheyaredamaged.
  ○Applybrakefluidtothedustseals, and install them into the cylinders by hand.

• Applybrakefluidtotheoutsideofthepistons, and push themintoeachcylinderbyhand.

• Checktheshaftrubberfrictionboot[A]andthedustcover [B]replacethemwithnewonesiftheyaredamaged.
• ApplyathincoatofPBC(PolyButylCuprysil)greaseto thecaliperholdershafts[C]andholderholesD.

• Installtheanti-rattlespring[A].
- Installthepads(seeFrontBrakePadInstallationinthe Brakeschapter).
- Wipeupanyspilledbrakefluidonthecaliperwithwet cloth.

Mechanical component diagram showing internal parts and a labeled section (A), no readable text or symbols present.

RearCaliperDisassembly

• Removetherearcaliper(seeRearCaliperRemovalin theBrakeschapter).
• Removethepadsandanti-rattlespring(seeRearBrake PadRemovalintheBrakeschapter).
• Usingcompressedair,removethepiston.
  ○Coverthepistonareawithaclean,thickcloth[B].
  ○Blowcompressedair[A]intotheholeforthebanjoboltto removethepiston.

WARNING

To avoid serious injury, never place your fingers or palminidethecaliper opening. If you apply compressed air into the caliper, the piston may crush your handorfingers.

• Removethedustsealandfluidseal.
• Removethebleedvalveandrubbercap.

NOTE

○ Ifcompressedairisnotavailable, withthebrakehose stillattached, applythebrakepedaltoremovethepiston. Theremainingprocessisasdescribedabove.

2-56PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

RearCaliperAssembly

- Cleanthecaliperpartsexceptforthepads.

CAUTION

Forcleaningoftheparts,useonlydiscbrakefluid, isopropylalcohol,orethylalcohol.

• Installthebleedvalveandrubbercap.

Torque-BleedValve:7.8N·m(0.80kgf·m,69in·lb)

- Replacethefluidseal[A]withanewone.

○Applybrakefluidtothefluidseal, and installitintothe cylinderbyhand.

- Replacethedustseal[B]withanewoneifitisdamaged.

○Applybrakefluidtothedustseal, and installitintothe cylinderbyhand.

- Applybrakefluidtotheoutsideofthepiston,andpushit intothecylinderbyhand.

- Replacetheshaftrubberfrictionboot[A]anddustcover [B]iftheyaredamaged.

- ApplyathincoatofPBC(PolyButylCuprysil)greaseto thecaliperholdershafts[C]andholderholesD.

• Installtheanti-rattlespring[A]inthecaliperasshown.

- Installthepads(seeRearBrakePadInstallationinthe Brakeschapter).

- Wipeupanyspilledbrakefluidonthecaliperwithwet cloth.

SparkPlugReplacement

- Remove:

StickCoils(seeStickCoil(IgnitionCoiltogetherwith SparkPlugCap)RemovalintheElectricalSystemchapter)

- Removethesparkplugsusingthe16mmplugwrench [A].

Owner's Tool-SparkPlugWrench, 16mm:92110-1132

Mechanical component with labeled section A, showing internal parts and mounting features (no readable text or symbols)

Close-up of mechanical components with a labeled section A (no readable text or symbols)

PeriodicMaintenanceProcedures

- Insertthesparkplugverticallyintotheplugholewiththe sparkpluginstalledintheplugwrench[A].

Owner's Tool-Spark Plug Wrench, 16mm:92110-1132

- Tighten:

Torque-SparkPlugs:15N·m(1.5kgf·m,11ft·lb)

- Install:

StickCoils(seeStickCoil(IgnitionCoiltogetherwith SparkPlugCap)InstallationintheElectricalSystem chapter)

Close-up of an engine cylinder assembly with visible components and no text or symbols

FuelSystem(DFI)

TableofContents

Exploded View.... 3-4

DFI System.... 3-8

DFI System.... 3-10

DFI Parts Location.... 3-13

Specifications 3-14

Special Tools and Sealant 3-16

DFI Servicing Precautions 3-18

DFI Servicing Precautions 3-18

Troubleshooting the DFI System 3-20

Outline 3-20

Outline.... 3-20

Inquiries to Rider.... 3-24

Inquiries to Rider 3-24

DFI System Troubleshooting Guide 3-27

Self-Diagnosis 3-35

Self-diagnosis Outline 3-35

Self-diagnosis Outline 3-35

Self-diagnosis Procedures.... 3-35

Self-diagnosis Procedures 3-35

Service Code Clearing Procedures 3-36

ServiceCodeClearingProcedures....3-36

How to Read Service Codes.... 3-38

How to Read Service Codes.... 3-38

How to Erase Service Codes.... 3-38

How to Erase Service Codes 3-38

Service Code Table 3-39

Service Code Table 3-39

Backups 3-40

Backups 3-40

Main Throttle Sensor (Service Code 11) 3-42

MainThrottleSensorRemoval/Adjustment....3-42

Input Voltage Inspection.... 3-42

Output Voltage Inspection.... 3-43

Resistance Inspection.... 3-44

Inlet Air Pressure Sensor (Service Code 12).... 3-45

Removal.... 3-45

Installation.... 3-45

Input Voltage Inspection.... 3-45

Output Voltage Inspection 3-46

InletAirTemperatureSensor(ServiceCode13)....3-50

Removal/Installation.... 3-50

Output Voltage Inspection 3-50

Sensor Resistance Inspection 3-51

Water Temperature Sensor (Service Code 14) 3-52

WaterTemperatureSensorRemoval/Installation....3-52

Water Temperature Sensor Output Voltage Inspection.... 3-52

Sensor Resistance Inspection 3-53

Crankshaft Sensor (Service Code 21).... 3-54

CrankshaftSensorRemoval/Installation....3-54

Crankshaft Sensor Inspection 3-54

Speed Sensor (Service Code 24, 25) 3-55

SpeedSensorRemoval/Installation....3-55

Speed Sensor Inspection 3-55

SpeedSensorInputVoltageInspection....3-55

SpeedSensorOutputVoltageInspection....3-55

Vehicle-down Sensor (Service Code 31) 3-57

Vehicle-down Sensor Removal 3-57

Vehicle-down Sensor Installation 3-57

Vehicle-down Sensor Inspection.... 3-57

Subthrottle Sensor (Service Code 32).... 3-60

SubthrottleSensorRemoval/Adjustment....3-60

SubthrottleSensorInputVoltageInspection....3-60

SubthrottleSensorOutputVoltageInspection....3-61

SubthrottleSensorResistanceInspection....3-62

OxygenSensor-notactivated(ServiceCode33)-EuropeModel....3-63

OxygenSensorRemoval/Installation....3-63

Oxygen Sensor Inspection.... 3-63

Stick Coils (#1, #2: Service Code 51, 52) 3-65

Stick Coil Removal/Installation.... 3-65

Stick Coil Input Voltage Inspection.... 3-65

Radiator Fan Relay (Service Code 56).... 3-67

RadiatorFanRelayRemoval/Installation....3-67

Radiator Fan Relay Inspection.... 3-67

Subthrottle Valve Actuator (Service Code 62) 3-68

Subthrottle Valve Actuator Removal 3-68

SubthrottleValveActuatorAudibleInspection....3-68

SubthrottleValveActuatorVisualInspection....3-68

Subthrottle Valve Actuator Resistance Inspection....3-68

SubthrottleValveActuatorInputVoltageInspection....3-69

Air Switching Valve (Service Code 64) 3-70

AirSwitchingValveRemoval/Installation....3-70

Air Switching Valve Inspection 3-70

OxygenSensorHeater(ServiceCode67)-EuropeModel....3-71

OxygenSensorHeaterRemoval/Installation....3-71

OxygenSensorHeaterInspection....3-71

OxygenSensor-IncorrectOutputVoltage(ServiceCode94)-EuropeModel....3-73

OxygenSensorRemoval/Installation....3-73

Oxygen Sensor Inspection 3-73

FI Indicator Light (LED) 3-75

FI Indicator Light (LED) Inspection 3-76

ECU 3-77

ECU Removal 3-77

ECU Installation 3-77

ECU Power Supply Inspection 3-78

Fuel Line 3-80

Fuel Pressure Inspection 3-80

Fuel Flow Rate Inspection 3-82

Fuel Pump 3-84

Fuel Pump Removal 3-84

Fuel Pump Installation 3-84

Fuel Pump Operation Inspection 3-85

FuelPumpOperatingVoltageInspection....3-85

Pressure Regulator Removal.... 3-86

Pump Screen, Fuel Filter Cleaning 3-86

Fuel Injectors 3-88

Removal/Installation.... 3-88

Audible Inspection.... 3-88

FuelInjectorPowerSourceVoltageInspection....3-88

FuelInjectorOutputVoltageInspection....3-89

Injector Signal Test.... 3-89

Injector Resistance Inspection 3-90

Injector Unit Test 3-91

Injector Fuel Line Inspection 3-91

Throttle Grip and Cables 3-93

Throttle Grip Free Play Inspection 3-93

Throttle Grip Free Play Adjustment.... 3-93

Throttle Cable Installation 3-93

Throttle Cable Lubrication 3-93

Throttle Body Assy 3-94

Idle Speed Inspection 3-94

EngineVacuumSynchronizationInspection/Adjustment....3-94

HighAltitudePerformanceAdjustment....3-94

Throttle Body Assy Removal 3-94

Throttle Body Assy Installation.... 3-95

Throttle Body Assy Disassembly 3-96

Throttle Body Assy Assembly 3-97

Air Cleaner.... 3-98

AirCleanerElementRemoval/Installation....3-98

Air Cleaner Element Inspection 3-98

Air Cleaner Oil Draining 3-98

Air Cleaner Housing Removal 3-98

Air Cleaner Housing Installation 3-99

Fuel Tank 3-100

Fuel Tank Removal 3-100

Fuel Tank Installation 3-101

Fuel Tank and Cap Inspection 3-102

Fuel Tank Cleaning 3-103

ExplodedView

No.Fastener	Torque			Remarks
	N·mkgf·	mft·lb
1 FuelPumpBolts9.81.087in·lb				L, S

2.FIIndicatorLEDLight

1. Throttle Cable (Accelerator)

2. ThrottleCable(Decelerator)

3. ThrottleBodyAssy

4. Injectors

CL:Applycablelubricant.

EO:Applyengineoil.

G:Applygrease.

L: Applyanon-permanentlockingagent.

R:ReplacementParts

S: Follow the specified tightening sequence.

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1	WaterTemperatureSensor	121.2106in·lb
2SpeedSensorBolt7.80.8066in·lbL
3	Oxygen Sensor (Europe Model)	44.1	4.50	32.5

1. InletAirPressureSensor
2. AirSwitchingValve
3. InletAirTemperatureSensor
4. CrankshaftSensor
5. SealedBattery
6. RelayBox
7. StickCoil
8. Vehicle-downSensor
9. ECU(ElectronicControlUnit)
   L: Applyanon-permanentlockingagent.
   R: ReplacementParts
   SS: Applysiliconesealant.

DFISystem

6017022CH5

DFISystem

1. IgnitionSwitch
   2.StarterLockoutSwitch
2. StarterRelay
3. Tachometer
   5.FIIndicatorLight(LED)
   6.InletAirPressureSensor
   7.SparkPlug
   8.CrankshaftSensor
4. Injector
   10.MainThrottleSensor
   11.DeliveryPipe
   12.SubthrottleSensor
   13.SubthrottleValve
   14.MainThrottleValve
   15.SubthrottleValveActuator
   16.FuelPump
5. PressureRegulator
   18.FuelTank
   19.AirCleanerElement
   20.AirSwitchingValve
   21.InletAirTemperatureSensor
   22.AirCleanerHousing
   23.NeutralSwitch
   24.SpeedSensor
6. Vehicle-downSensor
   26.OxygenSensor(EuropeModel)
7. ECU(ElectronicControlUnit)
   28.SealedBattery
8. AirFlow
   30.FuelFlow
   31.WaterTemperatureSensor

DFISystemWiringDiagram

DFISystem

PartName

1. OxygenSensor(EuropeModel)
   2.CrankshaftSensor
2. InletAirTemperatureSensor
3. WaterTemperatureSensor
4. Water-proofJointE
5. Injectors
6. Vehicle-downSensor
7. Water-proof JointD
   9.InletAirPressureSensor
   10.MainThrottleSensor
   11.SubthrottleSensor
   12.SubthrottleValveActuator
   13.SpeedSensor
8. AirSwitchingValve
   15.Water-proofJointC
   16.StickCoil
   17.FanMotor
9. EngineStopSwitch
   19.IgnitionSwitch
   20.FIIndicatorLight(LED)
   21.WaterTemperatureGauge
   22.Tachometer
   23.Speedometer
   24.Water-proofJointA
   25.Water-proofJointB
   26.OxygenSensorHeaterFuse10A
   27.RadiatorFanFuse15A
   28.ECUFuse15A
   29.IgnitionFuse10A
   30.RadiatorFanRelay
   31.ECUMainRelay
   32.FuelPumpRelay
   33.RelayBox
   34.MainFuse30A
   35.Battery
   36.FrameGround
   37.FuelPump
   38.DiagnosisConnector
   39.Self-diagnosisTerminal
   40.JointConnector
   41.ECU

GC17969BH2 C

TerminalNames

1. Subthrottle Valve Actuator Drive Signal 2

2.SubthrottleValveActuatorDriveSignal1

1. Water Temperature Warning Light Signal

2. Unused

5.OxygenSensorSignal

6.SpeedSensorSignal

7.MainThrottleSensorSignal

1. InletAirPressureSensorSignal

9.Unused

10.PowerSupplytoSensors

1. Vehicle-downSensorSignal

2. NeutralSwitchSignal

13.CrankshaftSensor(+)Signal

14.Unused

15.Unused

1. PowerSupplytoECU(fromECUMainRelay)

2. PowerSupplytoECU(fromBattery)

18.SubthrottleValveActuatorDriveSignal4

19.SubthrottleValveActuatorDriveSignal3

20.WaterTemperatureSensorSignal

21.Unused

22.Self-diagnosisTerminal

23.Unused

24.SubthrottleSensorSignal

25.Unused

26.InletAirTemperatureSensorSignal

27.Unused

28.GroundtoSensors

29.OxygenSensorHeaterSignal

30.CrankshaftSensor(−)Signal

31.Unused

32.ExternalDiagnosisSystemSignal

33.Unused

34.GroundtoECU

1. EngineStopSwitchSignal

36.StarterLockoutSwitchSignal

37.StarterButtonSignal

38.Unused

39.FuelPumpRelaySignal

40.AirSwitchingValveSignal

41.FuellInjector#2Signal

42.FuellInjector#1Signal

43.StickCoil#1Signal

44.SidestandSwitchSignal

45.RadiatorFanRelaySignal

1. ExternalCommunicationLine(Mode Switch)

47.TachometerSignal

48.FIIndicatorLEDLight

49.-

50.GroundforFuelSystem

51.GroundforignitionSystem

52.StickCoil#2Signal

DFIPartsLocation

DFI:DigitalFuelInjectionParts

1.FIIndicatorLightLED(DFI)
2.IgnitionSwitch
3. ThrottleBodyAssy
4.InletAirTemperatureSensor
5. Injectors
6.FuelPump
7. RelayBox(ECUMainRelay, FuelPump Relay, RadiatorFanRelay)
8. FuseBox(ECUFuse15A, OxygenSensorHeaterFuse10A)
9.ECU
10.SealedBattery
11.OxygenSensor

12.SpeedSensor
13.NeutralSwitch
14.WaterTemperatureSensor
15.SubthrottleSensor
16.MainThrottleSensor
17.SubthrottleValveActuator
18.StickCoils
19.InletAirPressureSensor
20.DiagnosisConnector
21.Self-diagnosisTerminal
22.AirSwitchingValve
23.CrankshaftSensor
24. Vehicle-downSensor

Specifications

ItemStandard
DigitalFuelInjectionSystem
IdleSpeed1300±50r/min(rpm)
ThrottleAssy:
TypeTwobarreltype	38mm(1.50in.)
Bore
ECU(ElectronicControlUnit):
MakeDenso
Type	Digitalmemorytype,withbuiltinICigniter,sealed withresin
UsableEngineSpeed100~12000r/min(rpm)
FuelPressure(HighPressureLine):
RightafterIgnitionSwitchON323kPa(3.3kgf/cm2,47psi)withfuelpumprunning
After3SecondsfromIgnitionSwitchON265kPa(2.7kgf/cm2,38psi)withfuelpumpstopped
WithEngineIdling333kPa(3.4kgf/cm2,48psi)withfuelpumprunning
FuelPump:
Typeln-tankfrictionpump
Discharge60mLormorefor3seconds
FuelInjectors:
TypeINP-287
NozzleType	Onespraytypewith12holes
Resistance	about 11.7 ~ 12.3 Ω at 20°C (68°F)
MainThrottleSensor:	Non-adjustableandnon-removable
Input Voltage	4.75 ~ 5.25 V DC between BL and BR/BK leads
Output Voltage at Idle Throttle Opening	1.073 ~ 1.077 V DC between Y/W and BR/BK leads
Output Voltage at Full Throttle Opening	4.29 ~ 4.49 V DC between Y/W and BR/BK leads
Resistance	4~ 6 kΩ
InletAirPressureSensor:
Input Voltage	4.75 ~ 5.25 V DC between BL and BR/BK leads
Output Voltage	3.80 ~ 4.20 V DC at standard atmospheric pressure (seethistextfordetails)
InletAirTemperatureSensor:
Resistance	5.4 ~ 6.6 kΩ at 0°C (32°F)
Output Voltage at ECU	0.29~ 0.39kΩ at80°C(176°F)
WaterTemperatureSensor:	about 2.25 ~ 2.50 V @20°C (68°F)
ResistanceseeElectricalSystemchapter
Output Voltage at ECU	about 2.80 ~ 2.97 V @20°C (68°F)
SpeedSensor:
Input Voltage at Sensor	about 9 ~ 11 V DC at Ignition Switch ON
Output Voltage at Sensor	about 0.05 ~ 0.07 V DC at Ignition Switch ON and 0 km/h
Vehicle-downSensor:
DetectionMethod	Magneticfluxdetectionmethod
DetectionAngle	morethan60~ 70°foreachbank

Specifications

ItemStandard
Output Voltage	with the sensor tilted 60 ~ 70° or more: 0.65 ~ 1.35 V withsensorarrowmarkpointedup:3.55~ 4.45V
SubthrottleSensor:Non-adjustableandnon-removal
Input Voltage	4.75 ~ 5.25 V DC between BL and BR/BK leads
Output Voltage at Idle Throttle Opening	0.4 ~ 0.6 V DC between BL/W and BR/BK leads
Output Voltage at Full Throttle Opening	3.625 ~ 3.775 V DC between BL/W and BR/BK leads
Resistance	4 ~ 6 kΩ
SubthrottleValveActuator:Resistance	about 5.5 ~ 7.5 Ω
InputVoltageabout8.5~ 10.5VDCOxygenSensor(EuropeModel):OutputVoltage(Rich)0.7VormoreOutputVoltage(Lean)0.2VorlessHeater Resistance	11.7 ~ 14.5 Ω at 20°C (68°F)
ThrottleGripandCables
Throttle Grip Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)

3-16FUELSYSTEM(DFI)

SpecialToolsandSealant

OilPressureGauge,5kgf/cm²: 57001-125

Technical line drawing of a pressure gauge with attached tubing (no text or symbols)

ForkOilLevelGauge: 57001-1290

Technical line drawing of three mechanical components (no text or symbols)

HandTester: 57001-1394

Technical line drawing of a mechanical housing or enclosure with internal components and mounting holes (no text or symbols)

ThrottleSensorSettingAdapter#1: 57001-1400

Technical line drawing of a mechanical tool or connector assembly (no text or symbols)

PeakVoltageAdapter: 57001-1415

Pure electrical circuit lines without any symbols

NeedleAdapterSet: 57001-1457

Technical line drawing of two screwdriver tips (no text or symbols)

ThrottleSensorSettingAdapter: 57001-1538

Pure electrical connector diagram without any text, numbers, or symbols

SensorHarnessAdapter: 57001-1561

Technical line drawing of a Y-shaped connector with multiple leads (no text or symbols)

FuelPressureGaugeAdapter: 57001-1593

Technical line drawing of a mechanical connector or fitting (no text or symbols)

FuelHose: 57001-1607

Two U-shaped metal pipe fittings with flanges, shown from different angles (no text or symbols)

SpecialToolsandSealant

KawasakiBond(SiliconeSealant): 56019-120

DFIServicingPrecautions

Thereareanumberofimportantprecautionsthatshould befollowedservicingtheDFIsystem.

○ThisDFIsystemisdesignedtobeusedwitha12Vsealed batteryasitspowersource.Donotuseanyotherbattery exceptfora12Vsealedbatteryasapowersource.

- Donotreversethebatterycableconnections. This will damagetheECU.

- TopreventdamagetotheDFIparts, donotdisconnectthe batterycablesoranyotherelectricalconnectionswhen theignitionswitchisonorwhiletheengineisrunning.

○Takecarenottoshorttheleadsthataredirectlyconnectedtothebatterypositive(+)terminaltothechassis ground.

○Whencharging,removethebatteryfromthemotorcycle. ThisistopreventECUdamagebyexcessivevoltage.

○DonotturntheignitionswitchONwhileanyoftheDFI electricalconnectorsaredisconnected.TheECUmemorizesservicecodes.

○Donotspraywaterontheelectricalparts,DFIparts,connectors,leads,andwiring.

○WhenevertheDFIelectricalconnectionsaretobedis-connected,firstturnofftheignitionswitch,anddisconnect thebattery(−)terminal.Donotpullthelead,onlytheconnector.Conversely,makesurethatalltheDFIelectrical connectionsarefirmlyreconnectedbeforestartingtheengine.

○Connecttheseconnectorsuntiltheyclick[A]

○Ifatransceiverisinstalledonthemotorcycle,makesure thattheoperationoftheDFIsystemisnotinfluencedby electricwaveradiatedfromtheantenna.Checkoperation ofthesystemwiththeengineatidle.Locatetheantenna asfaraspossibleawayfromtheECU.

Whenanyfuelhoseisdisconnected,fuelmayspoutout byresidualpressureinthefuelline.Coverthehosejoint withapieceofcleanclothopreventfuelspillage.

○Whenanyfuelhoseisdisconnected,donotturnonthe ignitionswitch.Otherwise,thefuelpumpwilloperateand fuelwillspoutfromthefuelhose.

○Donotoperatethefuelpumpifthepumpiscompletely dry. Thisistopreventpumpseizure.

○Beforeeremovingthefuelsystemparts, blowtheoutersurfacesofthesepartscleanwithcompressedair.

- Topreventcorrosionanddepositsinthefuelsystem,do notaddtofuelanyfuelantifreezechemicals.

DFIServicingPrecautions

- Tomaintainthecorrectfuel/airmixture(F/A),theremust benoinletairleaksintheDFIsystem.Besuretoinstall theoilfillerplug[A]afterfillingtheengineoil. ClutchCover[B]

Torque-OilFillerPlug:Hand-tighten

Outline

Outline

Whenanabnormalityinthesystemoccurs, theFlindicatorLED(LightEmittingDiode)lightgoesontoalerttherider onthemeterpanel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit). With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by then number of times the FlindicatorLED lightblinks.

Whenduetoamalfunction, the FlindicatorLEDlightremainslit, asktheriderabouttheconditions[B]underwhich theproblemoccurredandtrytodeterminethecause[C].

- First, conduct as self-diagnosis inspection and then an non-self-diagnosis inspection. Then on self-diagnosis items are not indicated by the Fl indicator LED light. Don't rely solely on the DFI self-diagnosis function, use common sense.

EvenwhentheDFIsystemisoperatingnormally,theFI indicatorLEDlight[A]maylightupunderstrongelectrical interference.Norepairneeded.Turntheignitionswitch OFFtostoptheindicatorlight.

WhentheFlindicatorLEDlightgoesonandthemotorcycleisbroughtinforrepair,checktheservicecodes.

Whentherepairhasbeendone,theLEDlightdoesn'tgo on.Buttheservicecodesstoredinmemoryarenoterased topreservetheproblemhistory,andtheLEDlightcandis-playthecodesintheself-diagnosismode.Theproblem historyisreferredwhensolvingunstableproblems.

Whenthemotorcycleisdown,thevehicle-downsensoristurnedOFFandtheECUshutsoffthefuelinjectorsandignitionsystem.TheFlindicatorLEDlightblinksbuttheservicecodecannotbedisplayed.TheignitionswitchisleftON.Ifthestarterbuttonispushed,theelectricstarterturnsbuttheengineedsen'tstart.Tostarttheengineagain,raisethemotorcycle,turntheignitionswitchOFF,andthenON.Thevehicle-downsensoristurnedONandtheLEDlightgoesOFF.

TroubleshootingtheDFISystem

○TheDFIpartconnectors[A]haveseals[B],includingthe ECU.

- Jointheconnectorandinserttheneedleadapters[C] insidetheseals[B]frombehindtheconnectoruntilthe adapterreachestheterminal.

SpecialTool-NeedleAdapterSet:57001-1457

CAUTION

Inserttheneedleaderstraightalongtheterminal intheconnectortopreventshort-circuitbetween terminals.

• Makesurethatmeasuringpointsarecorrectintheconnector, noting the position of the lock[D] and the lead color before measurement. Donot reverse connections of the hand tester or a digital meter.
• Becarefulnottoshort-circuittheleadsoftheDFlorelectricalsystempartsbycontactbetweenadapters.
• TurntheignitionswitchONandmeasurethevoltagewith theconnectorjoined.

CAUTION

Incorrect, reverseconnectionorshortcircuitby needleadapterscoulddamagetheDFlorelectrical systemparts.

○Aftermeasurement,removetheneedleadaptersandap- plysiliconesealanttotheseals[A]oftheconnector[B] forwaterproofing.

SiliconeSealant(KawasakiBond:56019-120)-Seals of Connector

- AlwayscheckbatteryconditionbeforereplacingtheDFI parts.Afullychargedbatteryisamustforconducting accuratetestsoftheDFIsystem.

• Troublemayinvolveoneorinsomecasesallitems. Neverreplaceadefectivepartwithoutdeterminingwhat CAUSEDtheproblem.Iftheproblemwascausedby someotheritemoritems,theytoomustberepairedor replaced,orthenewreplacementpartwillsoonfailagain.
• MeasurecoilwindingresistancewhentheDFIpartiscold (atroomtemperature).
• Makesureallconnectorsinthecircuitarecleanandtight, andexaminewiresforsignsofburning,fraying,short, etc.Deterioratedwiresandbadconnectionscancause reappearanceofproblemsandunstableoperationofthe DFIsystem.
  ★Ifanywiringisdeteriorated,replacethewiring.

TroubleshootingtheDFISystem

• Pulleachconnector[A]apartandinspectitforcorrosion, dirt, and damage.
  ★Iftheconnectoriscorrodedordirty,cleanitcarefully.Ifit isdamaged,replaceit.Connecttheconnectorssecurely.
• Checkthewiringforcontinuity.
  ○Usethewiringdiagramtofindtheendsoftheleadwhich issuspectedofbeingaproblem.
  ○Connectthehandtesterbetweentheendsoftheleads.
  ○Setthetestertothe×1Ω range,andreadthetester.
  ★Ifthetesterdoesnotread0Ω, theleadisdefective. Re-placetheleadorthemainharnessorthesubharness.
  Olfbothendsofaharness[A]arefarapart,ground[B]the oneend[C],usingajumperlead[D]andcheckthecontinuitybetweentheend[E]andtheground[F].Thisenablestocheckalongharnessforcontinuity.Iftheharness isopen,repairorreplacetheharness.

Whencheckingaharness[A]forshortcircuit, openone end[B]andcheckthecontinuitybetweentheotherend [C]andground[D]. If thereiscontinuity, theharnesshas ashortcircuttoground, anditmustberepairedorreplaced.

• NarrowdownsuspiciouslocationsbyrepeatingthecontinuitytestsfromtheECUconnectors.
  ★Ifnoabnormalityisfoundinthewiringorconnectors,the DFIpartsarethenextlikelysuspects.Checkthepart, startingwithinputandoutputvoltages.However,thereis nowaytochecktheECUitself.
  ★Ifanabnormalityisfound,replaceaffectedDFIpart.
  ★Ifnoabnormalityisfoundinthewiring,connectors,and DFIparts,replaceECU.

○LeadColorCodes:

BK:Black

BL:Blue

BR:Brown

CH:Chocolate

DG:Darkgreen

G:Green

GY:Gray

LB:Lightblue

LG:Lightgreen

O:Orange

P:Pink

PU:Purple

R:Red

W:White

Y:Yellow

graph TD
    A["A"] --> B["B"]
    B --> C["C"]
    C --> D["D"]
    D --> E["E"]
    E --> F["F"]
    F --> G["Ground Symbol"]
    style A fill:#f9f,stroke:#333
    style B fill:#f9f,stroke:#333
    style C fill:#f9f,stroke:#333
    style D fill:#f9f,stroke:#333
    style E fill:#f9f,stroke:#333
    style F fill:#f9f,stroke:#333
    style G fill:#f9f,stroke:#333

TroubleshootingtheDFISystem

- TherearetwowaystoinspecttheDFIsystem.Oneis voltageCheckMethodandtheotherisResistanceCheck Method.

(VoltageCheckMethod)

- This method is conducted by measuring the input voltage [B] to as sensor [A] first, and then the output voltage [C] from the sensor.

○SometimesthismethodcandetectafaultoftheECU.

• Refertoeachsensorinspectionsectionfordetailinthis chapter.
• Useafullychargedbatteryandadigitalmeter[D]which canbereadtwodecimalplacesvoltageorresistance.

(ResistanceCheckMethod)

○Thismethodissimple.Noneedforafullychargedbattery andtheneedleadapter.Justdothefollowingsespecially whenasensor[A]issuspect.

• TurntheignitionswitchOFFanddisconnecttheconnectors.
• Inspectthesensorresistance, usingadigitalmeter(see eachsensorinspectioninthischapter).
• Inspectthewiringandconnectors[B]forcontinuity, using thehandtesterC rather thanadigital meter.

SpecialTool-HandTester:57001-1394

★ Ifthesensor, the wiring and connections are good, inspect the ECU for its ground and powers supply (seethis chapter). If the ground and powers supply are good, the ECU is suspect. Replace the ECU.

DFIDiagnosisFlowChart

graph TD
    A["Problem occurs."] --> B["Confirm problems."]
    B --> C["Gather information from rider."]
    C --> D["The ignition switch is turned on, and the state of the FI indicator light (LED) is seen."]
    D --> E["unlit"]
    D --> F["lit"]
    E --> G["Conduct non-self-diagnosis inspection."]
    F --> H["Conduct self-diagnosis inspection."]
    G --> I["Conduct general fuel system inspection."]
    H --> J["End."]
    I --> J
    style A fill:#f9f,stroke:#333
    style J fill:#f9f,stroke:#333

InquiriestoRider

InquiriestoRider

○Eachriderreactstoproblemsindifferentways,soitisimportanttoconfirmwhatkindofsymptomstheriderhasencountered.
O Trytofindoutexactlywhatproblemoccurrendreunderexactlywhatconditionsbyaskingtherider; knowingthisinformationmayhelpyoureproducetheproblem.
○Thefollowingsamplediagnosisssheetwillhelppreventyoufromoverlookinganyareas,andwill helpyoudecideifitisaDFIsystemproblem,orageneralengineproblem.

TroubleshootingtheDFISystem

SampleDiagnosisSheet

Ridername:RegistrationNo.(licenseplateNo.):
Yearofinitialregistration:Model:
EngineNo.:FrameNo.:
Dateproblemoccurred:Mileage:
Environmentwhenproblemoccurred.
Weather	□fine, □cloudy,□rain, □snow, □always, □other:
Temperature	□hot, □warm, □cold, □very cold, □always
Problem frequency	□chronic, □often, □once
Road	□street, □highway, □mountain road (□uphill, □downhill), □bumpy, □pebble
Altitude	□normal, □high (about 1 000 m or more)
Motorcycleconditionswhenproblemoccurred.
Flindicator light(LED)	□light up immediately after ignition switch ON, and goes off after 1 ~ 2 seconds (normal)
	□lights blinks immediately after ignition switch ON, and stays on (DFI problem)
	□lights up immediately after ignition switch ON, but goes off after about 10 seconds (DFIproblem)
	□unlights(light(LED),ECUoritswiringfault)
	□sometimeslightsup(probablywiringfault)
Starting difficulty	□startermotornotrotating
	□startermotorrotatingbutenginedoesn’tturnover
	□startermotorandengine don’tturnover
	□no fuel flow (□no fuel in tank, □no fuel pump sound)
	□engine flooded (do not crank engine with throttle opened, which promotes engine flooding)
	□nospark
	□choke lever is not pulled fully when using the lever (pull it fully when using)
	□other
Enginestops	□rightafterstarting
	□whenopeningthrottlegrip
	□whenclosingthrottlegrip
	□whenmovingoff
	□whenstoppingthemotorcycle
	□whencruising
	□other
Poor running atlowspeed	□very low idle speed, □very high idle speed, □rough idle speed
	□batteryvoltageislow(chargethebattery)
	□sparkplugloose(tightenit)
	□sparkplugdirty, broken,orgapmaladjusted(remedyit)
	□backfiring
	□afterfiring
	□hesitationwhenacceleration
	□engineoilviscositytoohigh□brakedragging
	□engineoverheating

TroubleshootingtheDFISystem

	□clutchslipping
	□other
Poorrunning ornopowerat highspeed	□sparkplugloose(tightenit)
	□sparkplugdirty,broken,orgapmaladjusted(remedyit)
	□sparkplugincorrect(replaceit)
	□knocking (fuel poor quality or incorrect, → use high-octane gasoline)
	□brakedragging
	□clutchslipping
	□engineoverheating
	□engineoilleveltoohigh
	□engineoilviscositytoohigh
	□other

DFISystemTroubleshootingGuide

NOTE

○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simplyasaroughguidetoassistthetroubleshootingforsomeofthemorecommandifficulties.
TheECUmaybeinvolvedintheDFIelectricalandignitionsystemtroubles.Ifthesepartsandcircuitsarecheckedoutgood,besuretochecktheECUforgroundandpowersupply.Ifthegroundandpowersupplyarecheckedgood,replacetheECU.

EngineDoesn'tStart, StartingDifficulty

SymptomsorpossibleCausesActions(chapter)
Startermotornotrotating:
IgnitionandenginestopswitchesnotONTurnbothswitchesON.
StarterlockoutswitchorneutralswitchtroubleInspect(seechapter16)
StartermotortroubleInspect(seechapter16).
Batteryvoltagelow	Inspectandcharge(seechapter16).
StarterrelaysnotcontactingoroperatingInspectthestarterrelay(seechapter16).
StarterbuttonnotcontactingInspectandreplace(seechapter16).
StartersystemwiringopenorshortedInspectthewiring(seechapter16).
Ignitionswitchtrouble	Inspectandreplace(seechapter16).
Engine stop switch trouble	Inspect and repair or replace (see chapter 16).
Main 30A or ignition fuse blown	Inspect and replace (see chapter 16).
Startermotorrotatingbutengineedsn'tturnover:
Starterclutchtrouble	Inspect(seechapter16).
Starteridlegeartrouble	Inspect(seechapter16).
Enginewon'tturnover:
Valve seizure	Inspectandreplace(seechapter5).
Cylinder,pistonseizure	Inspectandreplace(seechapter5).
Camshaftseizure	Inspectandreplace(seechapter5).
Connectingrodsmallendseizure	Inspectandreplace(seechapter9).
Connectingrodbigendseizure	Inspectandreplace(seechapter9).
Crankshaftseizure	Inspectandreplace(seechapter9).
Transmissiongearorbearingseizure	Inspectandreplace(seechapter9).
Balancerbearingseizure	Inspectandreplace(seechapter9).
Nofuelflow:
No or little fuel in tank	Supply fuel (see Owner's Manual).
Fuelpumpnotrotating	Inspect(seechapter3).
Fuelinjectortrouble	Inspectandreplace(seechapter3).
Fueitankairventobstructed	Inspectandrepair(seechapter3).
Fuel filter or pump screen clogged	Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator clogged	Inspect and replace fuel pump (see chapter 3).
Fuellineclogged	Inspectandrepair(seechapter3).
Engineflooded:
Spark plug dirty, broken or gap maladjusted	Replace (see chapter 2).
Starting technique faulty	When flooded, don't crank engine with throttle fullyopened.
Nosparkorsparkweak:
IgnitionandenginestopswitchesnotONTurnbothswitchesON.

DFISystemTroubleshootingGuide

SymptomsorpossibleCausesActions(chapter)
Clutchlevernotpulledinandgearnotinneutralwhethersidestandupornot	Pulltheleverinandshiftthegearinneutral.
Thoughclutchleverpulledin,sidestandupand gearnotinneutral	Sidestanddownandclutchleverpulledin whethergearinneutralornot
Vehicle-down-sensorcomingoffReinstall(seechapter3).
Vehicle-down-sensortroubleInspect(seechapter3).
ECUgroundorpowersupplytroubleInspect(seechapter3).
BatteryvoltagelowInspectandcharge(seechapter16).
Sparkplugdirty,brokenorgapmaladjustedReplace(seechapter2).
StickcoiltroubleInspectstickcoil(seechapter16).
StickcoilshortedornotingoodcontactReinstallorinspectstickcoil(seechapter16).
SparkplugincorrectReplaceitwiththecorrectplug(seechapter16).
ICigniterinECUtrouble Inspect(seechapter16).
Neutral,starterlockoutorsidestandswitch trouble	Inspecteachswitch(seechapter16).
Crankshaftsensortrouble Inspect(seechapter16).
StickcoiltroubleInspect(seechapter16).
Ignitionswitchshorted Inspectandreplace(seechapter16).
Engine stop switch shorted	Inspect and repair or replace (see chapter 2) .
Starter system wiring shorted or open	Inspect and repair or replace (see chapter 16).
Main30Aorignitionfuseblown Inspectandreplace(seechapter16).
Fuel/airmixtureincorrect:
Aircleanerclogged,poorlysealedormissing	Cleanorreinstall(seechapter3).
Leakfromoilfillercap,crankcasebreatherhose oraircleanerdrainhose	Inspectandrepairorreplace(seechapter3).
Water or foreign matter in fuel	Change fuel. Inspect and clean fuel system (see chapter3).
Fuelpressureregulatortrouble Inspectfuelpressureandreplacefuelpump(see chapter3).
Mainthrottlesensortrouble Inspect(seechapter3).
FuelpressuremaybelowInspect(seechapter3).
Fuelpumptrouble Inspect(seechapter3).
Fuelinjectortrouble Inspect(seechapter3).
Inletairpressuresensortrouble Inspect(seechapter3).
Inletairtemperaturesensortrouble Inspect(seechapter3).
Water temperature sensor trouble Inspect (see chapter 3).
Crankshaftsensortrouble Inspect(seechapter3).
Compressionlow:
Sparkplugloose Reinstall(seechapter16).
Cylinder head not sufficiently tightened down Tighten (see chapter 5).
Cylinder,pistonworn Inspectandreplace(seechapter5).
Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).
Piston ring/groove clearance excessive Inspect and replace (see chapter 5).
Cylinderheadgasketdamaged Replace(seechapter5).
Cylinder head warped Inspect and replace (see chapter 5).

DFISystemTroubleshootingGuide

SymptomsorpossibleCausesActions(chapter)
NovalveclearanceAdjust(seechapter2).
Valveguideworn	Inspectandreplace(seechapter5).
ValvespringbrokenorweakInspectandreplace(seechapter5).
Valvenotseatingproperly(valvebent,wornor carbonaccumulatingonseatingsurface)	Inspectandrepairorreplace(seechapter5).

PoorRunningatLowSpeed

SymptomsorPossibleCausesActions(chapter)
Sparkweak:
BatteryvoltagelowInspectandcharge(seechapter16).
Sparkplugdirty,brokenorgapmaladjustedReplace(seechapter2).
StickcoiltroubleInspectthestickcoil(seechapter16).
StickcoilshortedornotingoodcontactReinstallerinspectstickcoil(seechapter16).
SparkplugincorrectReplaceitwiththecorrectplug(seechapter16).
IC igniter in ECU trouble	Inspect (see chapter 16).
Crankshaftssensortrouble	Inspect(seechapter16).
StickcoiltroubleInspect(seechapter16).
Fuel/airmixtureincorrect:
Little fuel in tank	Supply fuel (see Owner's Manual).
Air cleaner clogged, poorly sealed, or missing	Clean element or inspect sealing (see chapter 2,3).
Aircleanerductloose	Reinstall(seechapter3).
Air cleaner O-ring damaged	Replace (see chapter 3).
FueItankairventobstructed	Inspectandrepair(seechapter3).
Throttlebo dyassyloose	Reinstall(seechapter3).
ThrottlebodyassyO-ringdamage	Replace(seechapter3).
Fuel filter or pump screen clogged	Inspect and replace fuel pump (see chapter 3).
Fuelpressureregulatorclogged	Inspectfuelpressureandreplacefuelpump(seechapter3).
Fuellineclogged	Inspectandrepair(seechapter3).
Inletairpressuresensortrouble	Inspect(seechapter3).
Inletairtemperaturesensortrouble	Inspect(seechapter3).
Thermostattrouble	Inspectandreplace(seechapter4).
Unstable(rough)idling:
Fuelinjectortrouble	Inspect(seechapter3).
Mainthrottlesensortrouble	Inspect(seechapter3).
Crankshaftssensortrouble	Inspect(seechapter3).
Throttlevalvesnotsynchronizing	Inspect(seechapter2).
Inletairtemperaturesensortrouble	Inspect(seechapter3).
Watertemperaturesensortrouble	Inspect(seechapter3).
Fuelpressuretoolowortoohigh	Inspect(seechapter3).
BatteryvoltagelowInspectandcharge(seechapter16).
Incorrectidespeed:
Water temperature sensor trouble	Inspect (see chapter 3).
Mainthrottlesensortrouble	Inspect(seechapter3).

DFISystemTroubleshootingGuide

SymptomsorPossibleCausesActions(chapter)
Enginestallseasily:
Fuelpumptrouble	Inspect(seechapter3).
FuelinjectortroubleInspect(seechapter3).
MainthrottlesensortroubleInspect(seechapter3).
FuelpressuretoolowortoohighInspect(seechapter3).
InletairpressuresensortroubleInspect(seechapter3).
WatertemperaturesensortroubleInspect(seechapter3).
Inletairtemperaturesensortrouble	Inspect(seechapter3).
FuellinecloggedInspectandrepair(seechapter3).
FuelpressuretoolowortoohighInspect(seechapter3).
Fuel pressure regulator trouble	Inspect fuel pressure and replace fuel pump (see chapter3).
Crankshaftsensortrouble	Inspect(seechapter16).
Stickcoiltrouble	Inspect(seechapter16).
CompressionLow:
Sparkplugloose	Reinstall(seechapter16).
Cylinder head not sufficiently tightened down	Tighten (see chapter 5).
Novalveclearance	Adjust(seechapter2).
Cylinder,pistonworn	Inspectandreplace(seechapter5).
Piston ring bad (worn, weak, broken or sticking )	Inspect and replace (see chapter 5).
Piston ring/groove clearance excessive	Inspect and replace (see chapter 5).
Cylinderheadgasketdamaged	Replace(seechapter5).
Cylinderheadwarped	Inspectandreplace(seechapter5).
Valve guide worn or stem seal damaged	Inspect and replace (see chapter 5).
Valve spring broken or weak	Inspect and replace (see chapter 5).
Valvenotseatingproperly(valvebent,wornor carbon accumulatingonseatingsurface)	Inspect and repair or replace (see chapter 5).
Camshaftcamworn	Inspectandreplace(seechapter5).
Hesitation:
Too low fuel pressure	Inspect (see chapter 3).
Cloggedfuelline	Inspectandrepair(seechapter3).
Crackedorobstructedinletairpressuresensor hose	Inspect and repair or replace (see chapter 3).
Fuelpumptrouble	Inspect(seechapter3).
FuelinjectortroubleInspect(seechapter3).
Inletairtemperaturesensortrouble	Inspect(seechapter3).
MainthrottlesensortroubleInspect(seechapter3).
Subthrottlesensortrouble	Inspect(seechapter3).
Subthrottlevalveactuatortrouble	Inspect(seechapter3).
WatertemperaturesensortroubleInspect(seechapter3).
InletairpressuresensortroubleInspect(seechapter3).
Looseinjectorconnectors	Remedy(seechapter3).
Crankshaft sensor trouble	Inspect and repair or replace (see chapter 16).
Stick coil trouble	Inspect and repair or replace (see chapter 16).

DFISystemTroubleshootingGuide

SymptomsorPossibleCausesActions(chapter)
Looseterminalofbattery(−)leadorengine groundlead	Inspectandrepair(seechapter16).
DelayofignitiontimingInspectcrankshaftsensorand	CigniterinECU (seechapter16).
Pooracceleration:
ToolowfuelpressureInspect(seechapter3).
WaterorforeignmatterinfuelChangefuel.Inspectandcleanfuelsystem(see chapter3).
CloggedfuelfilterorpumpscreenInspectandreplacefuelpump(seechapter3).
FuelpumptroubleInspect(seechapter3).
FuelinjectortroubleInspect(seechapter3).
Inletairtemperaturesensortrouble	Inspect(seechapter3).
Watertemperaturesensortrouble	Inspect(seechapter3).
Subthrottlesensortrouble	Inspect(seechapter3).
Subthrottlevalveactuatortrouble	Inspect(seechapter3).
Stickcoiltrouble	Inspectandreplace(seechapter16).
EngineoilleveltohighRepair(seechapter7).
Spark plug dirty, broken or gap maladjusted	Replace (see chapter 2).
Stumble:
ToolowfuelpressureInspect(seechapter3).
FuelinjectortroubleInspect(seechapter3).
Mainthrottlesensormalfunction	Inspect(seechapter3).
Subthrottlesensortrouble	Inspect(seechapter3).
Subthrottlevalveactuatortrouble	Inspect(seechapter3).
Watertemperaturesensortrouble	Inspect(seechapter3).
Inletairpressuresensortrouble	Inspect(seechapter3).
Surge:
Unstablefuelpressure	Fuelpressureregulatorortrouble(Inspectand replacefuelpump)orkinkedfuelline(Inspect andrepairfuelline)(seechapter3).
FuelinjectortroubleInspect(seechapter3).
Watertemperaturesensortrouble	Inspect(seechapter3).
Backfiringwhendeceleration:
Spark plug dirty, broken or gap maladjusted	Replace (see chapter 2).
ToolowfuelpressureInspect(seechapter3).
FuelpumptroubleInspect(seechapter3).
Mainthrottlesensortrouble	Inspect(seechapter3).
Inletairtemperaturesensortrouble	Inspect(seechapter3).
Watertemperaturesensortrouble	Inspect(seechapter3).
Inletairpressuresensortrouble	Inspect(seechapter3).
Airswitchingvalvebroken	Inspectandreplace(seechapter5).
Airsuctionvalvetrouble	Inspectandreplace(seechapter5).
Afterfire:
Crankshaftsensortrouble	Inspect(seechapter16).
Spark plug burned or gap maladjusted	Replace (see chapter 2).

DFISystemTroubleshootingGuide

SymptomsorPossibleCausesActions(chapter)
InletairtemperaturesensortroubleInspect(seechapter3).
WatertemperaturesensortroubleInspect(seechapter3).
InletairpressuresensortroubleInspect(seechapter3).
FuelinjectortroubleInspect(seechapter3).
Run-on(dieseling):
IgnitionswitchtroubleInspectandreplace(seechapter16).
EnginestopswitchtroubleInspectandrepairorreplace(seechapter2).
FuelinjectortroubleInspect(seechapter3).
Looseterminalofbattery(-)cableorECU groundlead	Inspectandrepair(seechapter16).
CarbonaccumulatingonvalveseatingsurfaceRepair(seechapter5).
Engineoverheating	(seeOverheatingofTroubleshootingGuide,see chapter17)
Other:
Engineoilviscositytoohigh Change(seechapter2).
Drivetraintrouble	Inspectdrivechain(seechapter2)andsprocket (seechapter11).
Brakedragging	Inspectcaliperfluidsealdamageorclogging ofmastercylinderreliefandsupplyports(see chapter12).
Clutchslipping	Inspectfrictionplatesforwear(seechapter6).
Engineoverheating	(seeOverheatingofTroubleshootingGuide,see chapter17)
Airswitchingvalvetrouble	Inspectandreplace(seechapter5).
Airsuctionvalvetrouble	Inspectandreplace(seechapter5).
Intermittent any DFI fault and its recovery	Check that DFI connectors are clean and tight, andexaminewiresforsignsofburningorfraying (seechapter3).

PoorRunningorNoPoweratHighSpeed:

SymptomsorPossibleCausesActions(chapter)
Firingincorrect:
Sparkplugdirty,brokenormaladjusted	Replace(seechapter2).
Stickcoiltrouble	Inspectstickcoil(seechapter16).
Stick coil shorted or not in good contact	Reinstall or inspect stick coil (see chapter 16).
Spark plug incorrect	Replace it with the correct plug (see chapter 16).
ICigniterinECUtrouble	Inspect(seechapter16).
Crankshaftsensortrouble	Inspect(seechapter16).
Stickcoiltrouble	Inspect(seechapter16).
Fuel/airmixtureincorrect:
Air cleaner clogged, poorly sealed, or missing	Clean element or inspect sealing (see chapter 3).
Aircleanerductloose	Reinstall(seechapter3).
AircleanerO-ringdamaged	Replace(seechapter3).
Water or foreign matter in fuel	Change fuel. Inspect and clean fuel system (see chapter3).
Throttlebodyassyloose	Reinstall(seechapter3).

DFISystemTroubleshootingGuide

SymptomsorPossibleCausesActions(chapter)
ThrottlebodyassyO-ringdamagedReplace(seechapter3).
Fueltankairventobstructed	Inspectandrepair(seechapter3).
FuellinecloggedInspectandrepair(seechapter3).
FuelpumpoperatesintermittentlyandoftenDFI fuseblows.	Pumpbearingsmaywear.Replacehepump(seechapter3).
FuelpumptroubleInspect(seechapter3).
InletairtemperaturesensortroubleInspect(seechapter3).
MainthrottlesensortroubleInspect(seechapter3).
InletairpressuresensortroubleInspect(seechapter3).
Crackedorobstructedinletairpressuresensor hose	Inspectandrepairorreplace(seechapter3).
Injectorclogged	Visuallyinspectandreplace(seechapter3).
Compressionlow:
Sparkplugloose	Reinstall(seechapter16).
Cylinderheadnotsufficientlytighteneddown	Tighten(seechapter5).
Novalveclearance	Adjust(seechapter2).
Cylinder,pistonworn	Inspectandreplace(seechapter5).
Piston ring bad (worn, weak, broken or sticking)	Inspect and replace (see chapter 5).
Piston ring/groove clearance excessive	Inspect and replace (see chapter 5).
Cylinder head gasket damaged	Replace (see chapter 5).
Cylinderheadwarped	Inspectandreplace(seechapter5).
Valvespringbrokenorweak	Inspectandreplace(seechapter5).
Valvenotseatingproperly(valvebent,wornor carbonaccumulatingontheseatingsurface)	Inspectandrepairorreplace(seechapter5).
Knocking:
Carbonbuiltupincombustionchamber	Repair(seechapter5).
Fuelpoorqualityorincorrect(Usethegasoline recommendedintheOwner'sManual)	Changefuel(seechapter3).
Sparkplugincorrect	Replaceitwiththecorrectplug(seechapter16).
Stickcoiltrouble	Inspect(seechapter16).
ICigniterinECUtrouble	Inspect(seechapter16).
InletairtemperaturesensortroubleInspect(seechapter3).
Miscellaneous:
Subthrottlesensortrouble	Inspect(seechapter3).
Subthrottlevalveactuatortrouble	Inspect(seechapter3).
Speedsensortrouble	Inspect(seechapter3).
Throttlevalveswon'tfullyopen	Inspectthrottlecableandleverlinkage(see chapter3).
Brakedragging	Inspectcaliperfluidsealdamageorclogging ofmastercylinderreliefandsupplyports(see chapter12).
Clutchslipping	Inspectfrictionplatesforwear(seechapter6).
Engineoverheating-Watertemperaturesensor, crankshaftsensororspeedsensortrouble	(seeOverheatingofTroubleshootingGuidein chapter17).
Engineoilleveltoohigh	Repair(seechapter7).
Engineoilviscositytoohigh	Change(seechapter2).

DFISystemTroubleshootingGuide

SymptomsorPossibleCausesActions(chapter)
Drivetraintrouble	Inspectdrivechain(seechapter2)andsprockets (seechapter11).
CamshaftcamwornInspectandreplace(seechapter5).
AirswitchingvalvetroubleInspectandreplace(seechapter5).
AirsuctionvalvetroubleInspectandreplace(seechapter5).
Catalyticconvertersmeltdownduetomuffler overheating	Replacemuffler(seechapter5).
ExhaustSmokesExcessively:
(Whitesmokes)
PistonoilringwornInspectandreplace(seechapter5).
CylinderwornInspectandreplace(seechapter5).
ValveoilsealdamagedReplace(seechapter5).
Valveguidewom	Replacetheguide(seechapter5).
Engineoilleveltoohigh	Repair(seechapter7).
(Blacksmoke)
Aircleanerclogged	Clean(seechapter3).
Too high fuel pressure	Inspect (see chapter 3).
Injectorstuckopen	Inspect(seechapter3).
Water temperature sensor trouble	Inspect and replace (see chapter 3).
Inlet air temperature sensor trouble	Inspect and replace (see chapter 3).
(Brownsmoke)
Aircleanerductloose	Reinstall(seechapter3).
AircleanerO-ringdamaged	Replace(seechapter3).
Too low fuel pressure	Inspect fuel line and fuel pump (see chapter 3).
Water temperature sensor trouble	Inspect and replace (see chapter 3).
Inlet air temperature sensor trouble	Inspect and replace (see chapter 3)

Self-Diagnosis

Self-diagnosisOutline

Self-diagnosisOutline

Theself-diagnosisssystemhasthreemodesandcanbe switchedtoanothermodebygroundingtheself-diagnosis terminal.

UserMode

TheECUnotifiestherideroftroublesinDFIsystemandignitionsystembylightingtheFlindicatorwhenDFIsystemandignitionsystempartsarefaulty,andinitiatesfail-safe function.Incaseofseriousoustroubles,theECUstopsthe injection/ignition/startermotoroperation.

DealerMode1

TheFlindicatorlight(LED)emitsservicecode(s)toshow theproblem(s)whichtheDFIsystem,andignitionsystem hasatthemomentofdiagnosis.

DealerMode2

TheFlindicatorlight(LED)emitsservicecode(s)toshow theproblem(s)whichtheDFIsystem,andignitionsystem hadinthepast.

Self-diagnosis Procedures

Self-diagnosis Procedures

When a problem occurs with the DFIsystem and ignition system, the DFI indicator light(LED)[A] goes on.

NOTE

○Useafullychargedbatterywhenconducting self-diagnosis. Otherwise, thelight(LED)blinks veryslowlyordoesn'tblink.
○Keeptheself-diagnosisterminalgroundedduringself-diagnosis, withanauxiliarylead.

- Removetheseat(seeSeatRemovalintheFramechapter).

- Ground[A]theself-diagnosisterminalBtothebattery(−)terminal[C]orbattery(−)leadconnector,usingawire.

• Turnontheignitionswitch.
• Connectanauxiliarylead[E]totheself-diagnosisterminal [G]forgrounding.
• Toentertheself-diagnosisdealermode1,ground[A]the self-diagnosisindicatorterminaltothebattery(−)terminal formorethan2seconds[C],andthenkeepitgrounded continuously[D].

○Count the blinks of the light (LED) to read the service code. Keep the auxiliary leadground until you finish reading the service code.

Self-Diagnosis

- Toentertheself-diagnosisdealermode2, open[B] and ground[A] theleadmorethanfivetimes[F] within2seconds[C] aftertheleadisfirstgrounded, and then keepit grounded continuously[D] formorethan2seconds.

○Counttheblinksofthelight(LED)toreadtheservice code.Keeptheauxiliaryleadgrounduntilyoufinishreadingtheservicecode.

AuxiliaryLead[E]

Self-diagnosisTerminal[G]

NOTE

○ Toenterthedealermode2fromthedealermode1,turn offtheignitionswitchonce.

ServiceCodeClearingProcedures

ServiceCodeClearingProcedures

- Entertheself-diagnosisdealermode2(seeSelf-diagnosisProceduresinthischapter).

NOTE

○ Makesuretokeepthegroundinguntilthefollowing openingandgroundingstarts.

- Pulltheclutchleverinmorethan5seconds, and then releaseit.

- Repeatopening[B]andgrounding[A]thelead (self-diagnosisterminal)morethanfivetimes[F]within2 seconds[C]aftertheleadisgrounded,andthenkeepit groundedcontinuously[D]formorethan2seconds.

AuxiliaryLead[E]

Self-diagnosisTerminal[G]

Self-Diagnosis

graph TD
    A["Turn the ignition switch OFF"] --> B["Turn the ignition switch ON, and self-diagnosis mode starts, using an auxiliary lead."]
    B --> C["Dealer Mode 1.<br>Ground the self-diagnosis terminal for more than 2 seconds and then keep it grounded."] --> D["FI indicator light (LED) blinks to display the service code for more than 2 seconds."]
    B --> E["Dealer Mode 2.<br>Ground and open the self-diagnosis terminal more than five times within 2 seconds and then keep it grounded."] --> D
    D --> F["Locate the problem with the service code table and check and repair DFI or ignition system according to inspection procedure on all service codes."]
    F --> G["Remove the auxiliary lead, ending the self-diagnosis mode."]
    G --> H["Make sure the FI indicator light (LED) doesn't go ON."]
    H -->|NG| I["End"]
    H -->|NG| J["Run the engine for several minutes at idling and run the motorcycle at 30 km/h (18 mph) or above in order to confirm no problem."]
    J --> K["OK"]
    K --> L["END"]

HowtoReadServiceCodes

HowtoReadServiceCodes

○ServicecodesareshownbyaseriesoflongandshortblinksoftheFlindicatorlight(LED)asshown below.
○Read10thdigitandunitdigitastheFlindicatorlight(LED)blinks.
○Whenthereareanumberofproblems,alltheservicecodescanbestoredandthedisplaywill beginstartingfromthelowestnumberservicecodeinthenumericalorder. Thenaftercompleting allcodes,thedisplayisrepeateduntiltheself-diagnosisindicatorterminalisopen.
○Ifthereisnoproblem,nocodeandunlight.
○Forexample,iftwoproblemsoccurredintheorderof21,12,theservicecodesaredisplayedfrom the lowestnumberintheorderlisted.

$$ (1 2 \rightarrow 2 1) \rightarrow (1 2 \rightarrow 2 1) \rightarrow \dots (\text { repeated }) $$

Of the problem is with the following parts, the ECU cannot memorize these problems, the Fl indicator light(LED) doesn't goon, and noservice codes can be displayed.

FllIndicatorLight(LED)

FuelPump

FuelPumpRelay

DFIMainRelay

ECUPowerSourceWiringandGroundWiring(seeECUInspection)

FuelInjectors

HowtoEraseServiceCodes

HowtoEraseServiceCodes

○EveniftheignitionswitchisturnedOFF,thebatteryortheECUaredisconnectedortheproblemis solved,allservicecodesremainintheECU.

○RefertotheServiceCodeClearingProcedurefortheservicecodeerasure.

Self-Diagnosis

ServiceCodeTable

ServiceCodeTable

Service Code	FllndicatorLEDLightProblems
11		Mainthrottlesensormalfunction,wiringopenorshort
12	[22AB]	Inletairpressuresensormalfunction,wiringopenorshort
13	[30TT]	Inletairtemperaturesensormalfunction,wiringopenorshort
14		Watertemperaturesensormalfunction,wiringopenorshort
21		Crankshaftsensormalfunction,wiringopenorshort
24 and 25	+[ZZDH]	Speedsensormalfunction,wiringopenorshortFirst24isdisplayedandthen25,repeatedly
31	[5HZK]	Vehicle-downsensor,malfunction,wiringopenorshort
32	[4003]	Subthrottlesensormalfunction,wiringopenorshort
33	[8KB4]	Oxygensensorinactivation,wiringopenorshort(EuropeModel)
51		Stick(Ignition)coil#1malfunction,wiringopenorshort
52	[0ZA3]	Stick(Ignition)coil#2malfunction,wiringopenorshort
56	[ZZD3]	Radiatorfanrelaymalfunction,wiringopenorshort
62		Subthrottlevalveactuatormalfunction,wiringopenorshort
64	[KS43]	Airswitchingvalvemalfunction,wiringopenorshort
67	[KA05]	Oxygensensorheatermalfunction,wiringopenorshort(EuropeModel)
94		Oxygensensormalfunction,wiringopenorshort(EuropeModel)

Notes:

The ECU maybe involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and powers supply. If the ground and powers supply are checked good, replace the ECU.

○Whennoservicecodeisdisplayed, the electrical part of the DFIsystem has no fault, and the mechanical part of the DFIsystem and the enginearesuspect.

Backups

Backups

○TheECUtakesthefollowingmeasurestopreventenginedamagewhentheDFIortheignition systempartshavetroubles.

Service Codes	Parts	OutputSignalUsable RangeorCriteria	BackupsbyECU
11	MainThrottle Sensor	MainThrottleSensor OutputVoltage 0.20~4.8V	Ifthemainthrottlesensorsystemfails(the signalisoutoftheusablerange,wiringshort oropen),theECUlocksignitiontimingintothe ignitiontimingatclosedthrottlepositionand setstheDFlintheD-Jmethod.Also,themainthrottlesensorsystemmand inletairpressurefails,theECUlocksignition timingintotheignitiontimingatclosedthrottle positionandsetstheDFlintheα-Nmethod.
12	InletAir Pressure Sensor	InletAirPressure (absolute)Pv=150mmHg~800 mmHg	Iftheinletairpressuresensorsystemfails(the signalPvisoutoftheusablerange,wiring shortoropen),theECUsetstheDFlintheα-Nmethod.
13	InletAir Temperature Sensor	InletAirTemperature Ta=-30°C~+120°C	Iftheinletairtemperaturesensorfails(the signalisoutoftheusablerange,wiringshort oropen),theECUsetsTaat40°C.
14	Water Temperature Sensor	WaterTemperature Tw=-30C°~+120°C	Ifthewatertemperaturesensorsystemfails (thesignalisoutoftheusablerange,wiring shortoropen),theECUsetsTwat80°C.
21	Crankshaft Sensor	Crankshaftsensormust send22signals(output signal)totheECUat theonecranking.	Ifcrankshaftsensorgeneratesotherthan22 signals,theenginestopsbyitself.
24 and 25	SpeedSensor	Speedsensormust send4signals(output signal)totheECUat theonerotationofthe enginesprocket.Thegearpositionis decidedbythesignalof thespeedsensor.	Ifthespeedsensorsystemfails(nosignal, wiringshortoropen),thespeedometershows 0,andtheECUsetsthetop(6)gearposition.
31	Vehicle-down Sensor	Vehicle-downSensor OutputVoltage(signal)Vd=0.65V~4.45V	Ifthevehicle-downsensorsystemhasfailures (theoutputvoltageVdismorethanusable range,wiringopen),theECUshutsoffthe fuelpump,thefuelinjectorsandtheignition system.
32	Subthrottle Sensor	SubthrottleSensor OutputVoltage 0.15~4.85V	Ifthesubthrottlesensorsystemfails(the signalisoutoftheusablerange,wiringshort oropen),theactuatorlockssubthrottlevalve atfullopenposition.
33	OxygenSensor (EuropeModel)	Theoxygenensoris activeandsensormust sendsignals(output voltage)continuously to theECU.	Iftheoxygensensorisnotactivated,theECU stopsoygensensorfeedbackmode.

Self-Diagnosis

Service Codes	Parts	OutputSignalUsable RangeorCriteria	BackupsbyECU
51	StickCoil#1 (IgnitionCoil)*	Thestickcoilprimary windingmustsend signals(outputvoltage) continuouslytothe ECU.	Iftheignitionprimarywinding#1hasfailures (nosignal,wiringshortoropen),theECU shutsofftheinjector#1tostopfueltothe cylinder#1,thoughtheenginekeepsrunning.
52	StickCoil#2 (IgnitionCoil)*	Thestickcoilprimary windingmustsend signals(outputvoltage) continuouslytothe ECU.	Iftheignitionprimarywinding#2hasfailures (nosignal,wiringshortoropen),theECU shutsofftheinjector#2tostopfueltothe cylinder#2,thoughtheenginekeepsrunning.
62	Subthrottle ValveActuator	Theactuatoroperates openandcloseofthe subthrottlevalvebythe pulsesignalfromthe ECU.	Ifthesubthrottlevalveactuatorfails(the signalisoutoftheusablerange,wiringshort oropen),theECUstopsthecurrenttothe actuator.
67	OxygenSensor (EuropeModel)	Theoxygenensor heaterraise temperatureofthe sensorforitsearlier activation.12V-6.6W, 0.55A	Iftheoxygenensorheaterfails(wiringshort oropen),theECUstopsthecurrenttothe heater.
94	OxygenSensor (EuropeModel)	Theoxygensensor mustsendsignals (outputvoltage) continuouslytothe EUC	Iftheoxygenensoroutputvoltageisincorrect, theECUstopsoygensensorfeedbackmode.

Note:

(1) D-J Method and -N Method: When the engine load is light like at idling or low speed, the ECU determinestheinjectionquantitybycalculatingfromthethrottlevacuum(inletairpressuresensor outputvoltage)andenginespeed(crankshaftsensoroutputvoltage).ThismethodiscalledD-J method(low-speedmode).Astheenginespeedincreases,andtheengineloadturnsmiddleto heavy,theECUdeterminestheinjectionquantitybycalculatingfromthethrottleopening(throttle sensor output voltage) and the engine speed. This method is called -N method (high-speed mode).

(*) This depends on the number of stopped cylinders.

MainThrottleSensorRemoval/Adjustment

CAUTION

Donotremoveoradjustthemainthrottlesensor[A] sinceithasbeenadjustedandsetwithprecisionat thefactory.

Neverdropthesensor,especiallyonahardsurface.

Suchashocktothesensorcandamageit.

Input Voltage Inspection

NOTE

○ Besurethebatteryisfullycharged.

• TurntheignitionswitchOFF.
• Disconnectthemainthrottlesensorconnectorandconnecttheharnessadapter[A]betweentheseconnectors.
• Connectadigitalmetertotheharnessadapterlead.

SpecialTool-ThrottleSensorHarnessAdapter:57001-1538

- Measurethesensorinputvoltagewiththeenginestopped andwiththeconnectorjoined.

- TurntheignitionswitchON.

MainThrottleSensorInputVoltage ConnectionstoAdapter

Meter(+)→ R(sensorBL)lead

Meter(-)→ BK(sensorBR/BK)lead

Standard:4.75\~5.25VDC

• TurntheignitionswitchOFF.
  ★Iftheinputvoltageisnormal,checkthesensoroutput voltage.
  ★Iftheinputvoltageislessthanthestandard,removethe ECUandcheckthewiringbetweentheseconnectors.
  ○DisconnecttheECUandsensorconnectors.

WiringConnection

ECUConnector[A]←→ ThrottleSensorConnector[B]

BLlead(ECUterminal10)

BR/BKlead(ECUterminal28)

★Ifthewiringisgood,checktheECUforitsgroundand powersupply(seeECUPowerSupplyInspection).

Close-up mechanical assembly showing a component labeled 'A' and part identifier 'GC178673 P' (no readable text or symbols beyond labels)

Close-up mechanical assembly showing hoses and components (no visible text or symbols)

MainThrottleSensor(ServiceCode11)

OutputVoltageInspection

• Measure the output voltage at the main throttlesensor in the same way as input voltage inspection, Not the following.
• Disconnectthemainthrottlesensorconnectorandconnecttheharnessadapter[A]betweentheseconnectors.

SpecialTool-ThrottleSensorHarnessAdapter:57001-1538

• Starttheengineandwarmitupthoroughly.
• Checkidlespeedtoensurethethrottleopeningiscorrect.

IdleSpeed

Standard:1300±50r/min(rpm)

★ If the idlespeedis out of the specified range, adjust it (see Idle Speed Inspection in the Periodic Maintenance chapter).
- Turnofftheignitionswitch.
- Measure the output voltage of the sensor with the engine stopped, and with the connector joined.
- TurntheignitionswitchON.

MainThrottleSensorOutputVoltage ConnectionstoAdapter

Meter(+)→ R(sensorY/W)lead

Meter(-)→ W(sensorBR/BK)lead

Standard:

1.073\~ 1.077VDC(atidlethrottleopening)

4.29\~ 4.49VDC(atfullthrottleopening)

★ If the output voltage is out of the standard, inspect the main throttles sensor resistance.
★ If the output voltage is normal, check the wiring for continuity.
WiringConnection
ECUConnector[A]←→ ThrottleSensorConnector[B]
Y/Wlead(ECUterminal7)
BR/BKlead(ECUterminal28)
★ Ifthewiringisgood, checktheECUforitsgroundand powersupply(seeECUPowerSupplyInspection).

Close-up mechanical assembly with labeled component A, showing gears and wiring (no readable text or symbols)

MainThrottleSensor(ServiceCode11)

ResistanceInspection

• TurntheignitionswitchOFF.
• Disconnectthemainthrottlesensorconnector.
• Connectadigitalmeter[A]tothemainthrottlesensor connector[B].
• Measurethemainthrottlesensorresistance.

MainThrottleSensorResistance

Connections:BLlead[C]←→ BR/BKlead[D]

Standard:4\~6 k Ω

★Ifthereadingisoutoftherange,replacethethrottlebody assy.
★ If thereading is within the range, but the problem still exists, replace the ECU (see ECURemoval).

MainThrottleSensorCircuit

GC17972BH2 C

1. ECU
2. Water-proof JointE
3. Water-proof JointD
   4.MainThrottleSensor

InletAirPressureSensor(ServiceCode12)

CAUTION

Neverdropthesensor,especiallyonahardsurface. Suchashocktothepartcandamageit.

Removal

• Remove:
  LeftCenterFairing(seeCenterFairingRemovalinthe Framechapter)
• Disconnecttheinletairpressuresensorconnector[A]and thevacuumhose[B].
• Pulluptheinletairpressuresensor[C].

Installation

• Install:
  VacuumHose
  InletAirPressureSensor

Input Voltage Inspection

NOTE

○Besurethebatteryisfullycharged.
○ Theinspectionisthesameas "Input Voltage Inspection" of themainthrottlesensor.

• TurntheignitionswitchOFF.
• RemovetheECU(seeECURemoval).Donotdisconnect theECUconnectors.
• Connectadigitalvoltmeter[A]totheconnector[B]with theneedleadapterset.

SpecialTool-NeedleAdapterSet:57001-1457

• Measure the input voltage with the engine stopped, and with the connectors joined.
• TurntheignitionswitchON.

InletAirPressureSensorInputVoltage ConnectionstoECU

Meter(+)→ BLlead(terminal10) Meter(-)→ BR/BKlead(terminal28)

Standard:4.75\~5.25VDC

★ Ifthereadingiswithinthestandardrange,checkthesensoroutputvoltage.
★ Ifthereadingislessthanthestandardrange,removethe ECUandcheckthewiringbetweentheseconnectors.
★ Ifthewiringisgood, checktheECUforitsgroundand powersupply(seeECUPowerSupplyInspection).

Output Voltage Inspection

NOTE

○ Theoutputvoltagechangesaccordingtothelocalatmosphericpressure.

- Measure the output voltage at the ECU in the same way as input voltage inspection. Not the following.

InletAirPressureSensorOutputVoltage ConnectionstoECU

Meter(+)→ Y/BLlead(terminal17)

Meter(-)→ BR/BKlead(terminal14)

UsableRange: 3.74\~4.26VDCatthestandard atmosphericpressure(101.32kPa, 76cmHgabs.)

• TurntheignitionswitchOFF.
  ★Iftheoutputvoltageiswithintheusablerange,checkthe ECUforitsground,andpowersupply(seeECUPower SupplyInspection).
  ★Iftheoutputvoltageisoutoftheusablerange,remove thefueltankandcheckthewiring.Iftheoutputvoltageis 4.8V,theECUisnormal.

★Ifthewiringisgood,checkthesensorforvariousvacuum.

★Iftheoutputvoltageforvariousvacuumisnormal,check theECUforitsground,andpowersupply(seeECU PowerSupplyInspection).

- Removetheinletairpressuresensor[A]anddisconnect thevacuumhosefromthesensor.

○Donotdisconnectthesensorconnector.

- Connectanauxiliaryhose[B]totheinletairpressuresensor.

- Temporarily install the inletair pressuresensor.

○Connectacommerciallyavailabledigitalmeter[C], vacuumgauge[D], theforkoillevelgauge[E] and theharnessadapter to the inlet air pressures sensor.

SpecialTools-ForkOilLevelGauge:57001-1290

SensorHarnessAdapter:57001-1561

InletAirPressureSensorOutputVoltage

ConnectiontoAdapter

Meter(+)→ G(sensorY/BL)lead

Meter(-)→ BK(sensorBR/BK)lead

○TurntheignitionswitchON.
○Measuretheinletairpressuresensoroutputvoltagefromvariousvacuumreadings,whilepulling thehandleoftheforkoillevelgauge.
○Checktheinletairpressuresensoroutputvoltage,usingthefollowingformulaandchart.

Suppose:

Pg:VacuumPressure(gauge)toSensor
PI:LocalAtmosphericPressure(absolute)measuredbyabarometer
Pv:VacuumPressure(absolute)toSensor
Vv:SensorOutputVoltage(v)

InletAirPressureSensor(ServiceCode12)

then

$$ P v = P I - P g $$

Forexample, supposethe following data is obtained:

Pg=8cmHg(Vacuumgaugereading)

PI=70cmHg(Varometerreading)

Vv=3.2V(Digitalvoltmeterreading)

then

$$ \mathrm{Pv} = 7 0 - 8 = 6 2 \mathrm{cmHg(Abs)} $$

PlotthisPv(62cmHg)atapoint[1]onthechartanddrawaverticallinethroughthepoint. Then, you cangettheusablerange[2]ofthesensoroutputvoltage.

Usablerange=3.04\~3.49V

PlotVv(3.2V)ontheverticalline.→ Point[3].

Results: Inthechart, Vviswithintheusablerangeandthesensorisnormal.

Pv=24\~55cmHg

Pv=55\~86cmHg

Vv:InletAirPressureSensorOutputVoltage(V)(DigitalMeterReading)
Pv:ThrottleVacuumPressure(Absolute)
Ps:StandardAtmosphericPressure(Absolute)
ID:Idling
TO:ThrottleFullOpen
ST:StandardofSensorOutputVoltage(v)
UR:UsableRangeofSensorOutputVoltage(v)

InletAirPressureSensor(ServiceCode12)

InletAirPressureSensorCircuit

graph TD
    A["①"] --> B["3"]
    A --> C["2"]
    A --> D["4"]
    B --> E["T/BL"]
    B --> F["BR/BL"]
    B --> G["BL"]
    C --> H["BR/BL"]
    C --> I["BR/BL"]
    D --> J["T/BL"]
    D --> K["BR/BL"]
    D --> L["BL"]

GC17973BH2 C

1.ECU
2. Water-proof JointE
3. Water-proof JointD
4. InletAirPressureSensor

Removal/Installation

CAUTION

Neverdropthesensor,especiallyonahardsurface. Suchashocktothesensorcandamageit.

• Removethefueltank(seeFuelTankRemoval).
• Disconnecttheconnector[A]fromtheinletairtemperaturesensor.
• Removethescrew[B].
• Pullouttheinletairtemperaturesensor[C].
• Puttheinletairtemperaturesensorintotheaircleaner housing.
• Tightenthescrewsecurely.

Output Voltage Inspection

NOTE

○ Besurethebatteryisfullycharged.
○ Theoutputvoltagechangesaccordingtotheinletair temperature.

- RemovetheECU(seeECURemoval).Donotdisconnect theECUconnectors.

- ConnectadigitalvoltmetertotheECUconnector, using needleadapterset.

SpecialTool-NeedleAdapterSet:57001-1457

- Measurethesensoroutputvoltagewiththeengine stoppedandtheconnectorjoined.

- TurntheignitionswitchON.

InletAirTemperatureSensorOutputVoltage ConnectionstoECUConnector

Meter(+)→ Ylead(terminal26)

Meter(-)→ BR/BKlead(terminal28)

Standard: about2.25\~2.50Vatinletairtemperature 20°C(68°F)

• TurntheignitionswitchOFF.
  ★Iftheoutputvoltageisoutofthestandard,removethe fueltankandcheckthewiring.Andiftheoutputvoltage is4.8V,theECUisnormal.
  ★Iftheoutputvoltageiswithinthestandard,checktheECU foritsground,andpowersupply(seeECUPowerSupply Inspection).
  ★Ifthewiringisgood,checkthesensorresistance.
• Removetheneedleadapterset, and applysilicone sealanttothesealsoftheconnectorforwaterproofing.

SiliconeSealant(KawasakiBond:56019-120)-Seals of ECUConnectors

InletAirTemperatureSensor(ServiceCode13)

SensorResistanceInspection

• Removetheinletairtemperaturesensor.
• Suspendthesensor[A]inacontainerofmachineoilso thattheheat-sensitiveportionissubmerged.
• Suspendathermometer[B]withtheheat-sensitiveportion[C]locatedinalmostthesamedepthwiththesensor.

NOTE

○ Thesensorandthermometermustnottouchthecontainersideorbottom.

• Placethecontaineroverasourceofheatandgradually raisethetemperatureoftheoilwhilestirringtheoilgently foreventemperature.
• Usingadigitalmeter,measuretheinternalresistance ofthesensoracrosstheterminalsatthetemperatures showninthetable.

InletAirTemperatureSensorResistance

Standard:

5.4 \~ 6.6 kΩ at 0°C (68°F)

0.29 \~ 0.39 kΩ at 80°C (176°F)

★ Ifthemeasurementisoutoftherange, replacethesensor.
★ Ifthemeasurementiswithinthespecified,replace the ECU.

InletAirTemperatureSensorCircuit

GC17974BW2 C

1.ECU
2. InletAirTemperatureSensor
3. Water-proof JointE

WaterTemperatureSensorRemoval/Installation

CAUTION

Neverdropthesensor,especiallyonahardsurface. Suchashocktothesensorcandamageit.

• Drainthecoolant(seeCoolantChangeinthePeriodic Maintenancechapter).
• Disconnectthesensorconnector[A], and unscrew the watertemperaturesensor[B].

Torque-WaterTemperatureSensor:12N·m(1.2kgf·m,106 in·lb)

• ApplygreasetonewO-ringonthewatertemperaturesensor.
• Filltheenginewithcoolantandbleedtheairfromthecoolingsystem(seeCoolantChangeinthePeriodicMaintenancechapter).

WaterTemperatureSensorOutputVoltageInspection

NOTE

○ Besurethebatteryisfullycharged.

• RemovetheECU(seeECURemoval).Donotdisconnect theconnectors.
• Connectadigitalvoltmeter[A]totheECUconnector[B] withtheneedleadapterset.

SpecialTool-NeedleAdapterSet:57001-1457

• Measurethesensoroutputvoltagewiththeengine stoppedandtheconnectorjoined.
• TurntheignitionswitchON.

WaterTemperatureSensorOutputVoltage ConnectionstoECU

Meter(+)→ Olead(terminal20)

Meter(-)→ BR/BKlead(terminal28)

Standard:about2.80\~ 2.97Vat20°C(68°F)

NOTE

○ Theoutputvoltagechangesaccordingtothecoolant temperatureintheengine.

• TurntheignitionswitchOFF.
  ★Iftheoutputvoltageiswithinthestandard,checktheECU foritsground,andpowersupply(seeECUPowerSupply Inspection).
  ★Iftheoutputvoltageisoutofthestandard,checkthe wiring.Andiftheoutputvoltageis4.8V,theECUisnormal.
  ★Ifthewiringisgood, checkthewatertemperaturesensor resistance.
• Removetheneedleadapterset, andapplysilicone sealanttothesealsoftheconnectorforwaterproofing.

SiliconeSealant(KawasakiBond:56019-120)-Seals of ECUConnectors

Close-up of a mechanical assembly with labeled parts A and B, showing hoses and components (no readable text or symbols beyond labels)

WaterTemperatureSensor(ServiceCode14)

WaterTemperatureSensorCircuit

GC17975BH2 C

1.ECU
2. WaterTemperatureSensor
3. Water-proof JointE
4.MeterUnit

SensorResistanceInspection

• Removethewatertemperaturesensor(seeWaterTemperatureSensorRemoval/Installation).
• RefertoWaterTemperatureSensorInspectioninthe ElectricalSystemchapter.

CrankshaftSensor(ServiceCode21)

StarttheengineandswitchthediagnosismodetoDealer 1modetoknowalltheproblemthattheDFIsystemhasat thetimeofself-diagnosis. Iftheenginecannotbestarted, theself-diagnosisissystemdoesnotdetectdynamicconditionofthecrankshaftsensor. Inthiscase, turnofftheignitionswitchandturnitonagaintoentertheDealer2mode. Inthismode, thesystemtellsallthetroubleswhichtheDFIsystemhadinbothstaticanddynamicconditions.

CrankshaftSensorRemoval/Installation

- SeethelIgnitionSystemsectionintheElectricalSystem chapter.

CrankshaftSensorInspection

○Thecrankshaftsensorhasnopowersource, and when theenginestops, thecrankshaftsensorgeneratesnosignals.

- Cranktheengineandmeasurethepeakvoltageofthecrankshaftsensor(seeCrankshaftSensorInspectionintheElectricalSystem)inordertocheckthesensor.

- Checkthewiringforcontinuity, using the following diagram.

CrankshaftSensorCircuit

GC17976BH2 C

1. ECU

2.CrankshaftSensor

SpeedSensor(ServiceCode24,25)

SpeedSensorRemoval/Installation

- SeetheSwitchesandSensorssectionintheElectrical Systemchapter.

SpeedSensorInspection

- SeeSpeedSensorInspectionsectionintheElectrical Systemchapter.

SpeedSensorInputVoltageInspection

NOTE

○Besurethebatteryisfullycharged.

• TurntheignitionswitchOFF.
• Disconnectthespeedsensorconnectorandconnectthe harnessadapter[A]betweentheharnessconnectorand speedsensorconnector.
• Connectadigitalmetertotheharnessadapterleads.

SpecialTool-ThrottleSensorSettingAdapter#1:57001-1400

• Measurethesensorinputvoltagewiththeengine stopped, and with the connector joined.
• TurntheignitionswitchON.

SpeedSensorInputVoltage

ConnectiontoAdapter

Meter(+)→ BL(sensorP)lead[C] Meter(-)→ BK(sensorBK/Y)lead[D]

Standard: About9\~ 11VDCatlgnitionSwitchON

★ Ifthereadingisoutoftherange, checkthewiring(see wiringdiagraminthissection), andmeter(seeElectronic CombinationMeterUnitInspectionintheElectricalSystemchapter).
★ If thereading is good, check the output voltage.
- TurntheignitionswitchOFF.

SpeedSensorOutputVoltageInspection

- Beforethisinspection, inspecttheinputvoltage(see SpeedSensorInputVoltageInspection).

NOTE

○Besurethebatteryisfullycharged.

- TurntheignitionswitchOFF.

Close-up mechanical assembly with labeled component A (no readable text or symbols beyond label)

3-56FUELSYSTEM(DFI)

SpeedSensor(ServiceCode24,25)

• Disconnectthespeedsensorconnectorandconnectthe harnessadapter[A]betweentheharnessconnectorand speedsensorconnector.
• Connectadigitalmetertotheharnessadapterleads.
  SpecialTool-ThrottleSensorSettingAdapter#1:57001 -1400
• Measurethesensoroutputvoltagewiththeengine stopped, and with the connector joined.
• TurntheignitionswitchON.

SpeedSensorOutputVoltageatSensor ConnectionstoAdapter

Meter(+)→ Y/W(sensorLG/R)lead[C]

Meter(-)→ BK(sensorBK/Y)lead[D]

Standard: About0.05\~ 0.07VDC

NOTE

○ Ifyourotatetheenginesprocket, the output voltage will be increased.

★Ifthereadingisoutoftherange,checkthespeedsensor operation(seeSpeedSensorInspectionintheElectrical Systemchapter)andthewiringtoECU(seewiringdiagraminthissection).
★Ifthereading,speedsensoroperationandwiringare good,checktheECUforitsground,andpowersupply (seeECUPowerSupplyInspection).

Close-up mechanical assembly showing gears and shafts with no visible text or symbols

SpeedSensorCircuit

graph TD
    A["①"] --> B["②"]
    B --> C["③"]
    C --> D["④"]
    D --> E["⑤"]
    E --> F["⑥"]
    C --> G["①"]
    G --> H["②"]
    H --> I["③"]
    I --> J["④"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#ffc,stroke:#333
    style F fill:#cff,stroke:#333
    style G fill:#ffc,stroke:#333
    style H fill:#cfc,stroke:#333
    style I fill:#cfc,stroke:#333

GC17977BW2 C

1.ECU
2.SpeedSensor
3.MeterUnit
4. Water-proof JointB
5.FrameGround
6.JointConnector

Vehicle-downSensor(ServiceCode31)

Vehicle-downSensorRemoval

CAUTION

Neverdropthedown-sensor,especiallyonahard surface.Suchashocktothesensorcandamageit.

- Remove:

Bolts[A]

ConnectionandVehicle-downSensor[B]

Vehicle-downSensorInstallation

- TheUPmark[A]ofthesensorshouldfaceupward.

WARNING

Incorrect installation of the vehicle-downsensor could cause sudden loss of engine power. The rider could lose balanced during certain ridings situations like leaning over in aturn with the potential for an accident resulting in injury or death. Ensure that the downsensor is held in place by the sensor brackets.

Vehicle-down Sensor Inspection

NOTE

○Besurethebatteryisfullycharged.

- Connectadigitalvoltmeter[C]totheconnector[B]ofthe vehicle-downsensor[A]withtheneedleadapterset[D].

Vehicle-downSensorPowerSourceVoltage ConnectionstoSensor

Meter(+)→ BLlead[D]

Meter(-)→ BR/BKlead[E]

- TurntheignitionswitchON, and measure the power source voltage with the connector joined.

Vehicle-downSensorInputVoltage Standard:4.75\~5.25VDC

- TurntheignitionswitchOFF.

★ Ifthereadingofinputvoltageislessthanthestandard, checktheECUforitsground,powersupplyandwiring shorted.

★ Ifthepowersourceisnormal, checktheoutputvoltage.

0C17004CS1 C

0C17312BS2 C

Vehicle-downSensor(ServiceCode31)

• Removethesensor.
• Connectadigitalvoltmeter[A]totheconnectorwithneedleadapterset[B].

SpecialTool-NeedleAdapterSet:57001-1457

Vehicle-downSensorOutputVoltage ConnectionstoSensor

Meter(+)→ Y/Glead[E]

Meter(-)→ BR/BKlead[F]

• Holdthesensorvertically.
• TurntheignitionswitchON, and measure the output voltage with the connector joined.
  ○Tilt the sensor 60 \~ 70° or more [C] right or left, then hold the sensor almost vertical with the arrow mark pointed up [D], and measure the output voltage.

OutputVoltageatSensor

Standard:withsensortilted60\~70°ormoreright orleft:0.65\~1.35V

withsensorarrowmarkpointedup: 3.55\~4.45V

NOTE

○ Ifyouneedtotestagain,turntheignitionswitchOFF, andthenON.

• TurntheignitionswitchOFF.
• Removetheneedleadapterset, and applysilicone sealanttothesealsoftheconnectorforwaterproofing.
  SiliconeSealant(KawasakiBond:56019-120)-Seals of Vehicle-down Sensor Connector

★Iftheoutputvoltageisnormal,thewiringissuspect. Checkthewiring.

★Ifthewiringisgood,checktheECUforitsgroundand powersupply(seeECUPowerSupplyInspection).

★ If the output voltage is out of the specified, replace the vehicle-downsensor.

Vehicle-downSensor(ServiceCode31)

Vehicle-downSensorCircuit

GC17978BH2 C

1.ECU
2. Water-proofJointE
3. Vehicle-downSensor
4. Water-proof JointD

SubthrottleSensorRemoval/Adjustment

CAUTION

Donotremoveoradjustthesubthrottlesensor[A] sinceithasbeenadjustedandsetwithprecisionat thefactory.

Neverdropthesensor,especiallyonahardsurface.

Suchashocktothesensorcandamageit.

SubthrottleSensorInputVoltageInspection

NOTE

○ Besurethebatteryisfullycharged.

• Removethefueltank(seeFuelTankRemoval).
• TurntheignitionswitchOFF.
• Disconnect the subthrottlesensorconnector and connect the harness adapter[A] between these connectors.
• Connectadigitalmetertotheharnessadapterlead.

SpecialTool-ThrottleSensorHarnessAdapter:57001

-1400

• Measurethesensorinputvoltagewiththeenginestopped andwiththeconnectorjoined.
• TurntheignitionswitchON.

SubthrottleSensorInputVoltage

ConnectionstoAdapter

Meter(+)→ BL(sensorBL)lead

Meter(-)→ BK(sensorBR/BK)lead

Standard:4.75\~5.25VDC

• TurntheignitionswitchOFF.
  ★Iftheinputvoltageisnormal,checkthesensoroutput voltage.
  ★ If the input voltage is less than the standard, removes the ECU and check the wiring between these connectors.
  ○DisconnecttheECUandsensorconnectors.

WiringConnection

ECUConnector[A]←→

SubthrottleSensorConnector[B]

BLlead(terminal10)

Close-up of a mechanical component with visible wiring and a labeled section (A), no readable text or symbols present.

Close-up of an automotive engine bay with hoses and components (no visible text or symbols)

SubthrottleSensor(ServiceCode32)

SubthrottleSensorOutputVoltageInspection

• Removethefueltank(seeFuelTankRemoval).
• Measure the output voltage at the subthrottlesensor in the same way as input voltage inspection. Not the following.
• Disconnectthesubthrottlesensorconnectorand(black)connecttheharnessadapter[A]betweentheseconnectors.

SpecialTool-ThrottleSensorHarnessAdapter:57001-1400

• Measure the output voltage of the sensor with the engine stopped, and with the connector joined.
• TurntheignitionswitchON.
• Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand.

SubthrottleSensorOutputVoltage ConnectionstoAdapter

Meter(+)→ Y(sensorBL/W)lead Meter(-)→ BK(sensorBR/BK)lead

Standard:

0.4\~ 0.6VDC(atidlethrottleopening) 3.625\~ 3.775VDC(atfullthrottleopening)

★ If the output voltage is out of the standard, inspect the subthrottles sensor resistance.
★ Iftheoutputvoltageisnormal, checkthewiringforcontinuity.

WiringConnection

ECUConnector[A]←→ SubthrottleSensorConnector[B] BL/Wlead(terminal7) BR/BKlead(terminal28)

★ Ifthewiringisgood, checktheECUforitsgroundand powersupply(seeECUPowerSupplyInspection).

Close-up of a mechanical assembly with hoses and components, no visible text or symbols

3-62FUELSYSTEM(DFI)

SubthrottleSensor(ServiceCode32)

SubthrottleSensorResistanceInspection

• TurntheignitionswitchOFF.
• Disconnectthesubthrottlesensorconnector.
• Connectadigitalmeter[A]tothesubthrottlesensorconnector[B].
• Measurethesubthrottlesensorresistance.

ThrottleSensorResistance

Connections:BLlead[C]←→ BKlead[D]

Standard:4\~6 k Ω

★Ifthereadingisoutoftherange,replacethethrottlebody assy.
★Ifthereadingiswithintherange,buttheproblemstill exists,replaceECU(seeECUsection).

SubthrottleSensorCircuit

GC17979BH2 C

1. ECU
2. Water-proof JointE
3. Water-proof JointD
   4.SubthrottleSensor

OxygenSensor-notactivated(ServiceCode33)-EuropeModel

OxygenSensorRemoval/Installation

- RefertoSwitchesandSensorssectionintheElectrical Systemchapter.

OxygenSensorInspection

• Warmuptheenginethoroughlyuntiltheradiatorfan starts.
• TurntheignitionswitchOFF.
• Remove: LeftCenterFairing(seeCenterFairingRemovalinthe Framechapter) SprocketCover(seeEngineSprocketRemovalinthe FinalDrivechapter)
• Connectadigitalvoltmeter[A]totheoxygenensorconnectorB,usingtheneedleadapter set[C].

SpecialTool-NeedleAdapterSet:57001-1457

OxygenSensorOutputVoltage ConnectionstoOxygenSensorConnector

Meter(+)→ BL/YIlead

Meter(-)→ BR/BKlead

• Removetheairswitchingvalvehosesfromthefitting.
• Installthesuitableplugs[A]onthefitting[B]andshutoff thesecondaryair.

• TurntheignitionswitchON.
• Starttheengine, andletitidle.
• Measure the output voltage of the sensor with the connector joined.

OxygenSensorOutputVoltage(withPlugs)

Standard: 0.7Vormore

- Next,removetheplugsfromthefitting[A]withidling.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols beyond label)

OxygenSensor-notactivated(ServiceCode33)-EuropeModel

- Measure the output voltage of the sensor with the connector joined.

OxygenSensorOutputVoltage(withoutPlugs)

Standard: 0.2Vorless

★Ifthereadingiswithinrange(withplugs:0.7Vormore,
withoutplugs:0.2Vorless),theoxygenensorisgood.
★Ifthereadingiswithoutrange,replaceoxygenensor.

OxygenSensorCircuit

graph TD
    A["①"] --> B["②"]
    B --> C["③"]
    C --> D["④"]
    D --> E["⑤"]
    E --> F["⑥"]
    F --> G["⑦"]
    G --> H["⑧"]
    H --> I["⑨"]

    subgraph Component 1
        J["BL/Y"] --> K["BR/BR/FBR"]
        L["BL/Y"] --> M["BR/BR"]
        N["BL/Y"] --> O["BR/BR"]
        P["X/Y"] --> Q["P/BR"]
        R["GL/Y"] --> S["BL/BR"]
        T["X/Y"] --> U["X/Y"]
    end

    subgraph Component 2
        V["OK"] --> W["OK"]
        X["OK"] --> Y["OK"]
        Z["X"] --> AA["X"]
    end

    subgraph Component 3
        AB["UR/BR"]
        AC["DR/BR"]
    end

    subgraph Component 4
        AD[" "] --> AE[" "]
    end

    subgraph Component 5
        AF["X/Y"] --> AG["X/Y"]
    end

    subgraph Component 6
        AH[" "] --> AI[" "]
        AJ["X/Y"] --> AK["X/Y"]
    end

    subgraph Component 7
        AL[" "] --> AM[" "]
        AN["X/Y"] --> AO["X/Y"]
    end

    subgraph Component 8
        AP["X/Y"] --> AQ["X/Y"]
    end

    style Component 1 fill:#f9f,stroke:#333
    style Component 2 fill:#ccf,stroke:#333
    style Component 3 fill:#cfc,stroke:#333
    style Component 4 fill:#fcc,stroke:#333
    style Component 5 fill:#cff,stroke:#333
    style Component 6 fill:#ffc,stroke:#333
    style Component 7 fill:#cfc,stroke:#333
    style Component 8 fill:#fcc,stroke:#333

1. ECU
   2.OxygenSensor
2. Water-proof JointE
3. Water-proof JointD
   5.OxygenSensorHeaterFuse10A
   6.MainFuse30A
   7.Battery
   8.FrameGround
   9.JointConnector

StickCoils(#1,#2:ServiceCode51,52)

StickCoil#1:IgnitionCoil(ServiceCode51)

StickCoil#2:IgnitionCoil(ServiceCode52)

StickCoilRemoval/Installation

CAUTION

Neverdropthestickcoils,especiallyonahardsurface.Suchashocktothestickcoilcandamageit.

- RefertotheIgnitionSystemsectionintheElectricalSystemchapter.

StickCoilInputVoltageInspection

NOTE

○Besurethebatteryisfullycharged.

• TurntheignitionswitchOFF.
• RemovetheECU(seeECURemoval).Donotdisconnect theECUconnector.
• Connectadigitalvoltmeter[A]asshown,withtheneedle adapterset[B].
  ○Measure the input voltage to each primary winding of the ignition coil with the engine stopped, and with the connectors joined.
• TurntheignitionswitchON.

Stick Coil Input Voltage at ECU Connections for Stick Coil #1

Meter(+)→ BKlead(terminal43)

Meter(-)→ BK/Ylead(terminal51)

ConnectionsforStickCoil#2

Meter(+)→ BK/Glead(terminal52)

Meter(-)→ BK/Ylead(terminal51)

InputVoltageatECU

Standard: Battery Voltage(12.8Vormore)

★ If thereading is out of the standard, check the wiring (see next wiring diagram).
★ Ifthereadingisgood, theinputvoltageisnormal. Crank theengine, and check the peak voltage of the stick coils (see Stick Coil Primary Peak Voltage in the Electrical System chapter) in order to check the primary coils.

StickCoilCircuit

GC17980BH2 C

1. ECU
2. Water-proof JointC
   3.StickCoils
3. EngineStopSwitch
4. IgnitionSwitch
   6.IgnitionFuse10A
   7.MainFuse30A
   8.Battery
   9.FrameGround
   10.JointConnector

RadiatorFanRelay(ServiceCode56)

RadiatorFanRelayRemoval/Installation

• Radiatorfanrelayisbultintherelaybox.
• Removetherelaybox(seeRelayBoxRemovalinthe ElectricalSystemchapter).

RadiatorFanRelayInspection

• SeeRelayCircuitInspectionintheElectricalSystem chapter.
• RemovetherelayboxandECU(seeECUREmoval).Do not disconnecttherelayboxandECUconnectors.Check the wiring for continuity, using the following diagram.
  ★Ifwiringandradiatorfanrelayaregood,checktheECU foritsground,andpowersupply(seeECUPowerSupply Inspection).Ifthegroundandpowersupplyaregood, replacetheECU.

RadiatorFanRelayCircuit

1.ECU
2. Water-proof JointC
3. Water-proof JointB
4. RadiatorFanFuse15A
5.RelayBox
6.RadiatorFanRelay
7.MainFuse30A
8.Battery
9.FrameGround
10.JointConnector

Subthrottle ValveActuatorRemoval

CAUTION

Donotremovethesubthrottlevalveactuator[A] sinceithasbeenadjustedandsetwithprecision atthefactory.

Neverdroptheactuator,especiallyonahardsurface.Suchashocktotheactuatorcandamageit.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols beyond label)

Subthrottle Valve Actuator Audible Inspection

NOTE

○ Besurethebatteryisfullycharged.

• TurntheignitionswitchONandensurethattheactuator valvesopenandclose(makelightsounds)severaltimes withinseconds, and then close at the idle throttle opening position.
• TurntheignitionswitchOFF.
  ★Iftheactuatordoesnotworkasdescribedabove,dothe visualinspection.

Subthrottle Valve Actuator Visual Inspection

• Removethethrottlebodyassy(seeThrottleBodyAssyRemoval).
• TurntheignitionswitchON.
• Checktoseethatallthesubthrottlevalves[A]openand closesmoothly.
  ★If the subthrottle valves donot operate, check the actuator internal resistance (see Subthrottle Valve Actuator Resistance Inspection).

Subthrottle Valve Actuator Resistance Inspection

• TurntheignitionswitchOFF.
• Removethethrottlebodyassy(see ThrottleBodyAssy Removal).

• Disconnectthesubthrottlevalveactuatorconnector[A].

• Connectadigitalmetertothesubthrottlevalveactuator connector[A].

• Measure the subthrottle valve actuator resistance.

SubthrottleValveActuatorResistance

Connections:BKlead[1]←→ Plead[2]

Glead[3]←→ W/BLlead[4]

Standard: About5.5\~7.5kΩ

SpecialTool-HandTester:57001-1394

★Ifthereadingisoutoftherange,replacetheactuator alongwiththethrottlebodyassy.
★Ifthereadingiswithintherange,checktheinputvoltage (seeSubthrottleValveActuatorInputVoltageInspection).

Close-up of a mechanical component with two circular cavities and a labeled section A, being handled by a hand (no readable text or symbols)

0C171598S1 C

SubthrottleValveActuator(ServiceCode62)

Subthrottle Valve Actuator Input Voltage Inspection

NOTE

○Besurethebatteryisfullycharged.

• TurntheignitionswitchOFF.
• Connectthepeakvoltageadapter[A]andadigitalmeter[B]totheconnector[C],usingtheneedleadapterset[D].

SpecialTools-PeakVoltageAdapter:57001-1415

Type:KEK-54-9-B

Brand:KOWASEIKI

NeedleAdapterSet:57001-1457

SubthrottleValveActuatorInputVoltage ConnectionstoHarnessConnector

(I)Meter(+)→ B K / B L I e a d [1]

Meter(-)→ Plead[2]

(II)Meter (+) W/BLlead[3]

Meter(-)→ G/Ylead[4]

• Measure the actuator input voltage with the engine stopped, and with the connector joined.

- TurntheignitionswitchON.

InputVoltageatActuator

Standard: about8.5\~10.5VDC

★If the reading is within the standard but the actuator doesn't operate, replace it.
★ If thereading is out of the range, check the wiring to ECU (seewiring diagram in this section).
★ If the wiring is good, check the ECU for its ground and powersupply (see ECUPowerSupplyInspection).

SubthrottleValveActuatorCircuit

GC17981BH2

1.ECU

2.SubthrottleValveActuator

AirSwitching ValveRemoval/Installation

- RefertoCleanAirSystemsectionintheEngineTopEnd chapter.

AirSwitchingValveInspection

• RefertoAirSwitchingValvesectionintheElectricalSystemchapter.
• Removethefueltankandcheckthewiringcontinuity,usingthefollowingdiagram.

AirSwitchValveCircuit

graph TD
    A["Component 1"] -->|R/RL| B["Relays"]
    C["Component 2"] -->|R/R| D["Switch"]
    E["Component 3"] -->|R/R| F["Switch"]
    G["Component 4"] --> H["Reactor with Battery"]
    I["Component 5"] --> J["Switch"]
    K["Component 6"] --> L["Switch"]
    M["Component 7"] --> N["Switch"]
    O["Component 8"] --> P["Switch"]
    Q["Component 9"] --> R["Switch"]
    S["Component 10"] --> T["Switch"]
    U["Component 11"] --> V["Switch"]
    W["Component 12"] --> X["Switch"]
    Y["Ground"] --> Z["Ground"]

1. ECU
2. AirSwitchingValve
   3.Water-proofJointC
3. IgnitionSwitch
4. Water-proof JointA
   6.ECUFuse15A

7.ECUMainRelay
8.RelayBox
9.MainFuse30A

10.Battery
11.FrameGround
12.JointConnector

OxygenSensorHeater(ServiceCode67)-EuropeModel

OxygenSensorHeaterRemoval/Installation

Theoxygen sensor heater is built in the oxygen sensor. So, the heater itself cannot be removed. Removethe oxygen sensor (see Oxygen Sensor Removal in the Electrical System chapter).

OxygenSensorHeaterInspection

• Removetheenginesprocketcover(seeEngineSprocketRemovalintheFinalDrivechapter).
• Disconnecttheoxygen sensorleadconnector[A].

- Setthehandtester[A]tothe×1Ω rangeandconnectit totheterminalsintheoxygenensorleadconnector[B]. Black[C] Black[D]

SpecialTool-HandTester:57001-1394

OxygenSensorResistance

Standard: 11.7 \~ 14.5 Ω at 20°C (68°F)

★ Ifthetesterreadingisnotasspecified, replacetheoxygen sensorwithanewone.
★ If the tester reading is specified, check the powers source voltage inspection.

NOTE

○Besurethebatteryisfullycharged.

- Connectadigitalvoltmeter[A]totheoxygenensorconnector[B],usingtheneedleadapter[C].

SpecialTool-NeedleAdapterSet:57001-1457

- Measure the powersource voltage with the engine stopped, and with the oxygensensor connector joined.

OxygenSensorPowerSourceVoltage

ConnectionstoOxygenSensorConnector

Tester(+)→ W/Ylead[D]

Tester (-) Battery (-) Terminal [E]

Standard: BatteryVoltage

OxygenSensor[F]

★ If thereading is incorrect, check the following. Battery

MainFuse30A

OxygenSensorHeaterFuse10A

★ Ifthereadingisgood, thepowersourcevoltageisnormal, InspecttheRed/Blackleadbetweentheoxygenensor connectorandtheECUforcontinuity, usingthefollowing diagram.

★ Ifthewiringisgood, inspecttheECUforitsground, and powersupply(seeECUPowerSupplyInspection). If the groundandpowersupplyaregood, replacetheECU.

Close-up of a hand using a tool to adjust mechanical components, no visible text or symbols

OxygenSensorCircuit

graph TD
    A["①"] -->|5 V/7| B["②"]
    A -->|28V/8K P/8K BL/8K BL/7| C["③"]
    A -->|6V/7| D["④"]
    A -->|BL/7| E["⑤"]
    A -->|BL/7| F["⑥"]
    A -->|BL/7| G["⑦"]
    A -->|BL/7| H["⑧"]
    A -->|BL/7| I["⑨"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#fcc,stroke:#333
    style H fill:#ffc,stroke:#333
    style I fill:#fcc,stroke:#333

1.ECU
2.OxygenSensor
3. Water-proof JointE
4. Water-proof JointD
5.OxygenSensorHeaterFuse10A

6.MainFuse30A
7.Battery
8.FrameGround
9.JointConnector

OxygenSensor-IncorrectOutputVoltage(ServiceCode94)-EuropeModel

OxygenSensorRemoval/Installation

- RefertoOxygenSensorRemoval/InstallationintheElectricalSystemchapter.

OxygenSensorInspection

• Warmuptheenginethoroughlyuntiltheradiatorfan starts.
• TurntheignitionswitchOFF.
• Remove: LeftCenterFairing(seeCenterFairingRemovalinthe Framechapter) SprocketCover(seeEngineSprocketRemovalinthe FinalDrivechapter)
• Connectadigitalvoltmeter[A]totheoxygenensorconnectorB,usingtheneedleadapter set[C].

SpecialTool-NeedleAdapterSet:57001-1457

OxygenSensorOutputVoltage ConnectionstoOxygenSensorConnector

Meter(+)→ BL/YIlead

Meter(-)→ BR/BKlead

• Removetheairswitchingvalvehosesfromthefitting.
• Installthesuitableplugs[A]onthefitting[B]andshutoff thesecondaryair.

• TurntheignitionswitchON.
• Starttheengine, and let it idle.
• Measure the output voltage of the sensor with the connector joined.

OxygenSensorOutputVoltage(withPlugs)

Standard: 0.7Vormore

- Next,removetheplugsfromthefitting[A]withidling.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols beyond label)

OxygenSensor-IncorrectOutputVoltage(ServiceCode94)-EuropeModel

- Measure the output voltage of the sensor with the connector joined.

OxygenSensorOutputVoltage(withoutPlugs)

Standard: 0.2Vorless

★Ifthereadingiswithinrange(withplugs:0.7Vormore, withoutplugs:0.2Vorless),theoxygenensorisgood.
★Ifthereadingiswithoutrange,inspecttheengineandfuel supplysystem.
★Iftheengineandfuelsupplysystemgood,replacethe oxygensensor.

OxygenSensorCircuit

graph TD
    A["①"] -->|BL/Y| B["②"]
    A -->|P/BR| C["③"]
    A -->|BL/T| D["④"]
    A -->|BL/T| E["⑤"]
    A -->|BL/T| F["⑥"]
    A -->|BL/T| G["⑦"]
    A -->|BL/T| H["⑧"]
    A -->|BL/T| I["⑨"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#fcc,stroke:#333
    style H fill:#ffc,stroke:#333
    style I fill:#fcc,stroke:#333

1.ECU
2.OxygenSensor
3. Water-proof JointE
4. Water-proof JointD
5.OxygenSensorHeaterFuse10A

6.MainFuse30A
7.Battery
8.FrameGround
9.JointConnector

FllIndicatorLight(LED)

InspectionFlowChart

graph TD
    A["Turn the ignition SW ON."] --> B["Does the light (LED) goes on?"]
    B -->|Yes (goes on)| C["Does the light (LED) go off after 1~2 seconds?"]
    B -->|No (Flashes once then goes off or unfit)| D["Check the light (LED) and the wiring."]
    D -->|Good| E["DFI and ignition systems are considered to be normal."]
    E --> F["DFI and ignition systems are abnormal."]
    F --> G["Turn the ignition SW OFF."]
    G --> H["Turn the ignition SW OFF."]
    H --> I["Run the engine with idling."]
    I --> J["Does the light (LED) go off after 10~20 seconds?"]
    J --> K["Turn the ignition SW OFF."]
    K --> L["Ask the rider if the problem occurs again."]
    L -->|No| M["DFI and ignition systems are normal."]
    L -->|Yes (occurs)| N["Replace the ECU."]
    N --> A
    A --> O["Repair or replace the meter or wiring"]
    O --> P["NG"]

GC17852B F

FllIndicatorLight(LED)

FllndicatorLight(LED)Inspection

• Removethemeterunit(seeMeterUnitRemovalinthe ElectricalSystemchapter).
• Usingtwoauxiliaryleads, supplybatterypowertotheFI indicatorlight(LED)[A]. 12VBattery[B]

FllIndicatorLight(LED)Check

Connector:MeterConnectorC

Connection: W/BKLeadTerminal[1] of the Meter → Battery(+)Terminal

BR/RLeadTerminal[16]oftheMeter → Battery(−)Terminal

Criterion: Thelight(LED) shouldlight.

★Ifthelight(LED)doesnotgoon,replacemetheterunit.

FllIndicatorLight(LED)Circuit

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    G --> H["8"]
    H --> I["9"]
    I --> J["10"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#cfc,stroke:#333
    style H fill:#fcc,stroke:#333
    style I fill:#ffc,stroke:#333

1.ECU
2. Water-proof JointC
3. IgnitionSwitch
4.MeterUnit
5. IgnitionFuse10A

6.MainFuse30A
7.Battery
8.FrameGround
9.JointConnector

ECU

CAUTION

NeverdroptheECU,especiallyonahardsurface.

SuchashocktotheECUcandamageit.

ECURemoval

- Remove:

Seat(seeSeatRemovalintheFramechapter) GrabRailsA CenterSeatCoverB SeatCoversC RearFenderRearBolts[D]

- Pulldowntherearfenderrear[A].

Close-up of a motorcycle's front wheel and side gear assembly (no visible text or symbols)

• RemovetheECUbracketbolts[A].
  • TaketheECU[B]outalongwiththeharness.
• DisconnecttheECUleadconnectors.

ECUInstallation

- Fit[A]thebracketontheECUasshown.

ECU

ECUPowerSupplyInspection

- Visuallyinspecttheterminals[A]oftheECUconnectors.

★Iftheconnectoriscloggedwithmudordust,blowitoff withcompressedair.

★Replacethemainharnessiftheterminalsofthemain harnessconnectorsarecracked,bent,orotherwisedamaged.

★ReplacetheECUiftheterminalsoftheECUconnectors arecracked,bent,orotherwisedamaged.

- WiththeECUconnectors[A]connected,checkthefollowinggroundleadforcontinuitywiththeignitionswitch OFF,usingatesterandneedleadapterset.

Battery[B] Tester[C]

SpecialTool-NeedleAdapterSet:57001-1457

ECUGroundingInspection

34,50,or51(BK/Y) Terminal

Battery(-)Terminal:0Ω

EngineGround

←→ Battery(−)Terminal:0Ω

★Ifnocontinuity,checktheconnector,theengineground lead,ormainharness,andrepairorreplacethemifnecessary.

- ChecktheECUpowersourcevoltagewithadigitalmeter [A].

○Positiontheterminalinaccordancewithterminalnumbers ofECUconnectors[B]inthischapterfigure. Battery[C]

ECUPowerSourceInspection

MeterConnections:

BetweenTerminal16(BR/W)andBattery(−)Terminal

BetweenTerminal17(W/BK)andBattery(−)Terminal

IgnitionSwitchOFF:

Terminal16(BR/W):0V

Terminal17(W/BK):BatteryVoltage(12.6Vormore)

IgnitionSwitchON:

Both:BatteryVoltage(12.6Vormore)

★Ifthemeterdoesnotreadasspecified,checkthefollowing:

MainFuse30A(seeFusesectionintheElectricalSystemchapter)

ECUFuse15A(seeFuseInspectionintheElectrical Systemchapter)

ECUMainRelay(seeRelayCircuitInspectioninthe ElectricalSystemchapter)

PowerSourceWiring(seewiringdiagrambelow)

★Iftheinspectionchecksgood,theECUisdamaged.ReplaceetheECU.TheECUitselfcannotbecheckedorserviced.

Close-up of hands holding electronic components with labeled parts (A), no readable text or symbols present.

ECU

ECUPowerSourceCircuit

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    G --> H["8"]
    H --> I["9"]
    I --> J["10"]
    J --> K["11"]
    K --> L["12"]
    L --> M["13"]
    M --> N["14"]
    N --> O["15"]
    O --> P["16"]
    P --> Q["17"]
    Q --> R["18"]
    R --> S["19"]
    S --> T["20"]
    T --> U["21"]
    U --> V["22"]
    V --> W["23"]
    W --> X["24"]
    X --> Y["25"]
    Y --> Z["26"]
    Z --> AA["27"]
    AA --> AB["28"]
    AB --> AC["29"]
    AC --> AD["30"]
    AD --> AE["31"]
    AE --> AF["32"]
    AF --> AG["33"]
    AG --> AH["34"]
    AH --> AI["35"]
    AI --> AJ["36"]
    AJ --> AK["37"]
    AK --> AL["38"]
    AL --> AM["39"]
    AM --> AN["40"]

1. ECU
2. Water-proofJointC
3. IgnitionSwitch

4. Water-proofJointA
   5.ECUMainFuse15A
   6.ECUMainRelay

5. RelayBox
   8.MainFuse30A
   9.Battery
   10.FrameGround
   11.JointConnector

FuelLine

FuelPressureInspection

NOTE

○ ThisinspectioncandeterminewhichtroubletheDFI systemhas,mechanicalorelectricaltrouble.
○ Itispreferabletomeasurethefuelpressurewhilerunningthemotorcyclejustwhentroubleoccurredinorder toknowsymptomwell.
○ Besurethebatteryisfullycharged.

• Removethefueltank(seeFuelTankRemoval).
• Besuretoplaceapieceofclotharoundthefuelhosejoint andthedeliverypipe.
• Insertaminusscrewdriver[A]intotheslitonthejointlock [B].
• Turnthedrivertodisconnectthejointlock.
• Removethefuelhose[C].

WARNING

Bepreparedforfuelspillage;anyspilledfuelmust becompletelywipedupimmediately. Whenthefuelhoseisdisconnected,fuelspillsout fromthehoseandthepipebecauseofresidual pressure.Coverthehoseconnectionwithapiece ofcleanclothopreventfuelspillage.

• Installthefuelpressuregaugeadapter[A]andfuelhoses betweenthefuelpumpoutletpipe[B]andthedelivery pipe[C].
• Connectthepressuregauge[D]tothefuelpressure gaugeadapter.
  SpecialTools-OilPressureGauge,5kgf/cm²:57001-125 FuelPressureGaugeAdapter:57001-1593 FuelHose:57001-1607

WARNING

Donottrytostarttheenginewiththefuelhoses disconnected.

- Temporarily, install the fuel tank [E]. Clamps [F]

FuelLine

- TurntheignitionswitchON. The fuel pump will turn for 3 seconds, and then stop.

CAUTION

Donotdrivethefuelpumpwithoutthefuelinthe fueltank.

- Measure the fuel pressure with the engine stopped.

FuelPressure

RightafterIgnitionSwitchON,withpumprunning:

Standard:323kPa(3.3kgf/cm²,47psi)

After3secondsfromIgnitionSwitchON,withpump stopped:

Standard:265kPa(2.7kgf/cm²,38psi)(residual fuelpressure)

Thesystemshouldholdtheresidual pressureabout30seconds.

- Starttheengine, andletitidle.

- Measurethefuelpressurewiththeengineidling.

FuelPressure(Idling)

Standard: 333 kPa (3.4 kgf/cm², 48 psi)

NOTE

○ Thegaugeneedlewillfluctuate. Read the pressure at the average of the maximum and minimum indications.

★ If the fuel pressure is normal, the fuel circulation system (fuelpump, pressureregulator, and fuelpassage) is no faults. Check the DF I electronic control system (injectors, sensors, crankshaft sensor, and ECU).

★ If the fuel pressure is much lower than specified, check the following:

FuelLineLeakage

FuelPumpOperation(checkthesoundofthepump)

AmountofFuelFlow(seeFuelFlowRateInspection)

★ If the fuel pressure is much higher than specified, check the following:

DeliveryPipeClogging

InjectorClogging

- Removethefuelpressuregaugeandadapter.

- Installthefueltank(seeFuelTankInstallation).

FuelLine

FuelFlowRateInspection

NOTE

○ Besurethebatteryisfullycharged.

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Makesurethearea iswell-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.Donotsmoke.TurntheignitionswitchOFF. Bepreparedforfuelspillage;anyspilledfuelmust becompletelywipedupimmediately.

• Turntheignitionswitch, and enginestopswitchOFF.
• Waituntiltheenginecoolsdown.
  ● Prepareaplastichoseoftheinsidediameter7.5mm (0.30in.) andameasuringcylinder.
• Removethefueltankbolt(seeFuelTankRemoval).
• Openthefueltankcap[A]tolowerthepressureinthe tank.

Close-up of a mechanical component with labeled section A, showing a circular opening and central bore (no text or symbols beyond label)

WARNING

Bepreparedforfuelspillage;anyspilledfuelmust becompletelywipedupimmediately. Whenthefuelhoseisdisconnected,fuelspillsout fromthehoseandthepipebecauseofresidual pressure.Coverthehoseconnectionwithapiece ofcleanclothtopreventfuelspillage.

• Connecttheplastichose[A]tothefuelpumpoutletpipe.
• Securetheplastichosewithaclamp[B].
• Runtheothersideoftheplastichoseintothemeasuring cylinder[C].

WARNING

Wipeoffspilledoutfuelimmediately. Besuretoholdthemeasuringcylinderververtical.

• Temporarily install the fueltank and closet the fueltank cap.
• With the engine stopped, turn the ignitions switch ON. The fuel pump should operate for 3 seconds, and then should stop. Repeat this several times until the plastic chose is filled with fuel.

FuelLine

CAUTION

Donotdrivethefuelpumpwithoutthefuelinthe fueltank.

• Measurethedischargefor3secondswiththeplastichose filledwithfuel.
  ○Repeatthisoperationseveraltimes.

AmountofFuelFlow

Standard:60mLormorefor3seconds

★Ifthefuelflowismuchlessthanthespecified, check thebatterycondition(seeBatterysectionintheElectricalSystemchapter).Ifthebatteryisgood,replace fuelpump.
- Afterinspection, install the fuel tank. (see Fuel Tank Installation).
- Starttheengineandcheckforfuelleakage.

FuelPump

FuelPumpRemoval

CAUTION

Neverdropthefuelpump,especiallyonahardsurface.Suchashocktothepumpcandamageit.

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Makesurethearea iswell-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.Donotsmoke.TurntheignitionswitchOFF. Disconnectthebattery(−)terminal. Tomakefuelspillageminimum,drawthefuelout fromthefueltankwhentheengineiscold.Be preparedforfuelspillage;anyspilledfuelmustbe completelywipedupimmediately.

• Drawthefueloutfromthefueltankwithacommercially availableelectricpump.
• Removethefueltank(seeFuelTankRemoval).
  ○Becarefuloffuelspillagefromthefueltankssincefuelstill remainsinthefueltankandfuelpump.Plugthefuelpipe ofthefueltank.
• Turnthefueltankupsidedown.
• Remove: FuelPumpBolts[A] FuelPump[B]andgasket
• Discardthefuelpumpgasket.

CAUTION

Donotpulltheleadofthefuelpump.Iftheyare pulled,theleadterminalsmaybedamaged.

FuelPumpInstallation

- Removedirtordustfromthefuelpump[A]bylightlyapplyingcompressedair.

Mechanical component with labeled section A and cable, no readable text or symbols beyond label

FuelPump

- Replacethefuelpumpgasket[A]withanewone.

Technical line drawing of a mechanical device with labeled component A and reference number 0C10045BS1 (no text or symbols on the diagram itself)

• Applyanon-permanentlockingagenttothethreadsof thefuelpumpbolts.
• Tightenthefuelpumpboltstoasnugfit,tightenthem alternatingdiagonally.

Torque-FuelPumpBolts:9.8N·m(1.0kgf·m,87in·lb)

- Tightenthepumpboltsagainalternatingdiagonallyto checkthetightness.

FuelPumpOperationInspection

NOTE

○Besurethebatteryisfullycharged.

○Justlistentothepumpsoundinthefueltanktoconfirm pumpoperation.

• TurntheignitionswitchONandmakesurethatthefuel pumpoperates(makelightsounds)for3seconds,and thenstops.
• TurntheignitionswitchOFF.
  ★ If the pump does not work as described above, inspect the operating voltage.

FuelPumpOperatingVoltageInspection

NOTE

○Besurethebatteryisfullycharged.

• TurntheignitionswitchOFF.
• Removetheleftsidecover(seeSideCoverRemovalin theFramechapter).

FuelPump

- Connectthehandtester(25VDC)tothefuelpumpconnector[A]withneedleadapterset.

SpecialTools-HandTester:57001-1394

NeedleAdapterSet:57001-1457

○Measuretheoperatingvoltagewiththeenginestopped, andwiththeconnectorjoined.

- TurntheignitionswitchON.

○Thetesterneedleshouldindicatebatteryvoltagefor3 seconds,andthen0V.

PumpOperatingVoltageatPump

ConnectionstoPumpConnectors

Tester(+)→ W/RLead

Tester(-)→ BK/YLead

Operating Voltage at Pump Connector

Standard:BatteryVoltage(12.8Vormore)for3 seconds,andthen0V.

★Ifthereadingstaysonbatteryvoltage,andnevershows 0V.ChecktheECUandfuelpumprelay.
★Ifthevoltageisinspecification,butthepumpdoesn't work,replacethepump.
★Ifthereisstillnobatteryvoltage,checkthepumprelay (seeRelayBoxsectionintheElectricalSystemchapter).

PressureRegulatorRemoval

○Thepressureregulator[A]isbuiltintothefuelpump[B] and cannot be removed.

Close-up of mechanical components with labeled parts (A and C) showing no readable text or symbols beyond labels

PumpScreen, FuelFilterCleaning

○Thefuelfilter[A]isbuiltintothepumpandcannotbe cleanedorchecked.

★ If the fuelfilterissuspected of cloggingor being damaged, replace it with the fuelpumpasaset.

Mechanical component with labeled section A and cable, no visible text or symbols

FuelPump

FuelPumpCircuit

graph TD
    A["1"] --> B["2"]
    A --> C["3"]
    A --> D["4"]
    B --> E["5"]
    C --> F["6"]
    D --> G["7"]
    E --> H["8"]
    F --> I["9"]
    G --> J["10"]
    H --> K["11"]
    I --> L["12"]
    J --> M["13"]
    K --> N["14"]
    L --> O["15"]
    M --> P["16"]
    N --> Q["17"]
    O --> R["18"]
    P --> S["19"]
    Q --> T["20"]
    R --> U["21"]
    S --> V["22"]
    T --> W["23"]
    U --> X["24"]
    V --> Y["25"]
    W --> Z["26"]

1. ECU
2. Water-proofJointC
3. EngineStopSwitch
4. IgnitionSwitch
5. IgnitionFuse10A

6.FuelPumpRelay
7. RelayBox
8.MainFuse30A
9.Battery
10.FrameGround
11.FuelPump

FuellInjectors

Removal/Installation

- RefertotheThrottleBodyAssyDisassembly/Assembly.

AudibleInspection

• Starttheengine.
• Applythetipofascrewdriver[A]totheinjector[C].Put thegripendontoyourear, andlistenwhethertheinjector isclickingornot.
  ○Asoundscope[B]canalsobeused.
• Dothesamefortheotherinjectors.
  ★Ifalltheinjectorsclickataregularintervals,theinjectors aregood. Thetroublemayberelatedtothefuelline, requiringfuelpressureinspection(seeFuelLinesection).
  ○Theclickintervalbecomesshorterastheenginespeed rises.
  ★Ifanyinjector(s)doesn'tclick,theDFIcircuitortheinjector issuspect.Perform "FuelInjectorPowerSourceVoltage Inspection",first.

FuelInjectorPowerSourceVoltageInspection

• RemovetheECU(seeECUPowerSupplyInspection).
  ○DonotdisconnecttheECUconnector.
• Connectadigitalmeter[A]totheECUconnector[B],usingtheneedleadapter[C].

SpecialTool-NeedleAdapterSet:57001-1457

○Measure the powersource voltage with the engine stopped, and with the connector joined.
- TurntheignitionswitchON.

InjectorPowerSourceVoltageatECU

Connections:Meter(+)→ W/Y(terminal16)

Meter(-)→ Battery(-)Terminal

ServiceLimit: Voltage(12.6Vormore)

★Ifthemeterdoesn'treadasspecified,checkthefollowing.

MainFuse30A(seeFusesectionintheElectricalSystemchapter)

FuelPumpRelay(seeRelayCircuitInspectioninthe ElectricalSystemchapter)

PowerSourceWiring(see Wiring Diagram below)

TochecktheW/Rleadsbetweentheinjectorconnector andthefuelpumprelay,removethefueltank(seeFuel TankRemoval)andtheleftsidecover(seeSide Cover RemovalintheFramechapter).

★If the power source voltage is normal, check the output voltageoftheinjectors.

FuellInjectors

FuelInjectorOutputVoltageInspection

• TurntheignitionswitchOFF.
• RemovetheECU(seeECUPowerSupplyInspection).
• Connectadigitalvoltmeter[A]totheECUconnector[B] withtheneedleadapterset[C].

SpecialTool-NeedleAdapterSet:57001-1457

InjectorOutputVoltage

Connectionstolnjector#1

Meter(+)→ BL/Rlead(terminal42)

Meter (-) Battery (-) Terminal

Connectionstoljector#2

Meter(+)→ BL/Glead(terminal41)

Meter (-) Battery (-) Terminal

- TurntheignitionswitchON.

OutputVoltageatInjectorConnector

Standard:BatteryVoltage(12.8Vormore)

★ If the output voltage is normal, perform "InjectorSignal Test".

★ Iftheoutputvoltageisoutofthestandard,turntheignition switchOFF,removethefueltank,andchecktheinjector wiringforcontinuity.

InjectorWiringInspection

ECUConnectorInjectorConnectors

Terminal36 → Injector#1Terminal(BL/R)

Terminal35 → Injector#2Terminal(BL/G)

★ If the wiring is good, inspect the resistance of the injectors (see Injector Resistance Inspection).
- Removetheneedleader.
- ApplysiliconesealanttothesealsoftheECUconnector forwaterproofing.

SiliconeSealant(KawasakiBond:56019-120)-Seals of ECUConnectors

InjectorSignalTest

• Preparetwotestlightsetswithmaleterminalsasshown. RatingofBulb[A]:12V×3\~3.4W
  TerminalWidth[B]:1.8mm(0.071in.)
  TerminalThickness[C]:0.8mm(0.031in.)

CAUTION

Donotuselargerterminalsthanspecifiedabove.A largerterminalcoulddamagetheinjectormainharnessconnector(female),leadingtoharnessrepair orreplacement.

Besuretoconnectbulbsinseries.Thebulbworks as a current limiter to protect the solenoid in the injectorfromexcessivecurrent.

FuellInjectors

• Removethefueltank(seeFuelTankRemoval).
• Removetheaircleanerhousing(seeAirCleanerHousingRemoval)
• Removeconnectorsforinjector[A].
• Connecteachtestlightset[B]totheinjectorsubharness connector[C].
• TurntheignitionswitchON.
• Whilecrankingtheenginewiththestartermotor,watch thetestlights.
  ★Ifthetestlightsflickeratregularintervals, theinjector circuitintheECU, andthewiringaregood. Perform the "InjectorResistanceInspection".

○Injectorsignalscanbealsoconfirmedbyconnectingthe handtester(×10VAC)insteadofthetestlightsetto theirinjectormainharness(female)connector.Crankthe enginewiththestartermotor,andchecktoseeifthehand oscillatesatregularintervals.

SpecialTool-HandTester:57001-1394

★Ifthetestlightdoesn'tflicker(orthetesterneedledoesn't oscillates),checkthewiringandconnectorsagain.Ifthe wiringisgood,checktheinjectorvoltage.Ifthewiringis good,inspecttheECUforitsgroundandpowersupply (seeECUPowerSupplyInspection).

InjectorResistanceInspection

• Removethefueltank(seeFuelTankRemoval).
• Removetheaircleanerhousing(seeAirCleanerHousingRemoval).
• Disconnecttheconnectorfromtheinjector[A].
• Measure the injector resistance with the hand tester [B].

SpecialTool-HandTester:57001-1394

InjectorResistance

Connectionstoljector

Meter(+)Meter(-)

1:W/R←→ BL/RTerminal

2: W/R ←→ BL/G Terminal

Standard: about 11.7 \~ 12.3 Ω @20°C (68°F)

★If the reading is out of the range, perform the "Injector Unit Test".
★ If thereading is normal, perform the "InjectorUnitTest" for confirmation.

FuellInjectors

InjectorUnitTest

• Usetwoleads[A]andthesametestlightset[B]asin "InjectorSignalTest".
  RatingofBulb[C]:12V×(3\~3.4)W
  12VBattery[D]

CAUTION

Besuretoconnectthebulbinseries.Thebulb worksasacurrentlimitertoprotectthesolenoid intheinjectorfromexcessivecurrent.

• Connectthetestlightsettotheinjector[E]asshown.
• Openandconnect[F]theendoftheleadtothebattery (-)terminalrepeatedly.Theinjectorshouldclick.
  ★ If the injectordoes not click, replace the injector.
  ★ Iftheinjectorclicks, checkthewiringagain. Ifthewiring isgood, replacetheinjector(maybeclogged) or ECU.

InjectorFuelLineInspection

• Remove:
  FuelTank(seeFuelRemoval)
• Besuretoplaceapieceofclotharoundthefuelhosejoint andthedeliverypipe.
• Insertaminusscrewdriver[A]intotheslitonthejointlock [B].
• Turnthedrivertodisconnectthejointlock.
• Pullthefuelhosejoint[C]outofthedeliverypipe.

- Checktheinjectorfuellineforleakageasfollows: ○Connectacommerciallyavailablevacuum/pressure pump[A]tothenippleofthedeliverypipe[B]with a high-pressurefuelhoseCasshown.

Torque-FuelHoseClampScrews:1.5N·m(0.15kgf·m,13in·lb)

○Applysoapandwatersolutiontotheareas[E]asshown.
- Watching the pressure gauge, squeezethepumplever [F], and build up the pressure until the pressurereaches themaximum pressure.

InjectorFuelLineMaximumPressure

Standard: 333 kPa (3.4 kgf/cm², 48 psi)

CAUTION

Duringpressuretesting, donotexceedthemaxi-mumpressureforwhichthesystemisdesigned.

• Watchthegaugeforatleast6seconds.
  ★ If the pressure holds steady, the system is good.
  ★ If the pressuredropsatonceorifbubblesarefound in the area, the line is leaking. Replacethedeliverypipe, injectors and related parts.
  ○Repeat the leak test, and check the fluelline for no leakage.
• Installthepumpoutlethose(seeFuelTankInstallation).
• Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

FuelInjectorCircuit

graph TD
    A["①"] --> B["②"]
    B --> C["③"]
    C --> D["④"]
    D --> E["⑤"]
    E --> F["⑥"]
    F --> G["⑦"]
    G --> H["⑧"]
    H --> I["⑨"]
    I --> J["⑩"]
    J --> K["⑪"]
    K --> L["⑫"]
    L --> M["⑬"]
    M --> N["⑭"]
    N --> O["⑮"]
    O --> P["⑯"]
    P --> Q["⑰"]
    Q --> R["⑱"]
    R --> S["⑲"]
    S --> T["⑳"]
    T --> U["⑪"]
    U --> V["⑫"]
    V --> W["⑬"]
    W --> X["⑭"]
    X --> Y["⑮"]
    Y --> Z["⑯"]
    Z --> AA["⑰"]
    AA --> AB["⑱"]
    AB --> AC["⑲"]
    AC --> AD["⑳"]
    AD --> AE["⑪"]
    AE --> AF["⑫"]
    AF --> AG["⑬"]
    AG --> AH["⑭"]
    AH --> AI["⑮"]
    AI --> AJ["⑯"]
    AJ --> AK["⑰"]
    AK --> AL["⑱"]
    AL --> AM["⑲"]

1.ECU
2.FuellInjectors
3. Water-proof JointC
4. EngineStopSwitch
5. IgnitionSwitch
6. IgnitionFuse10A

1. Fuel Pump Relay (for fuel pump and injectors)
   8.RelayBox
   9.MainFuse30A
   10.Battery
   11.FrameGround
   12.JointConnector

ThrottleGripandCables

ThrottleGripFreePlayInspection

- RefertoThrottleControlSystemInspectioninthePeriodicMaintenancechapter.

ThrottleGripFreePlayAdjustment

- RefertoThrottleControlSystemInspectioninthePeriodicMaintenancechapter.

Throttle Cable Installation

• InstallthethrottlecablesinaccordancewithCable, Wire, and HoseRoutingsectionintheAppendixchapter.
• Installthelowerendsofthethrottlecablesinthecable bracketonthethrottleassyafterinstallingtheupperends ofthethrottlecablesinthegrip.
• Afterinstallation,adjusteachcableproperly.

WARNING

Operationwithincorrectlyroutedorimproperlyadjustedcablescouldresultinanunsaferidingcondition.

ThrottleCableLubrication

- RefertoChassisPartsLubricationinthePeriodicMaintenancechapter.

ThrottleBodyAssy

IdleSpeedInspection

- RefertoIdleSpeedInspectioninthePeriodicMaintenancechapter.

EngineVacuumSynchronizationInspection/Adjustment

- RefertoEngineVacuumSynchronizationInspectionin thePeriodicMaintenancechapter.

HighAltitudePerformanceAdjustment

- Anymodificationisnotnecessaryinthismodelsince theinletairpressuresensorsensesinletairpressure changeduetohighaltitudeandtheECUcompensates thechange.

ThrottleBodyAssyRemoval

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Disconnectthebattery(−)cableterminal.Donotsmoke.Makesuretheareas well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light. Bepreparedforfuelspillage:anyspilledfuelmust becompletelywipedupimmediately.

- Remove: FuelTank(seeFuelTankRemoval)

- Disconnect: MainThrottleSensorConnector[A] FuelHoseLowerEnd[B] VacuumHose[C] SubthrottleSensorActuator[D]Connector

- Disconnect: #1.#2InjectorConnector[A] SubthrottleSensorConnector[B] - Loosen: HolderandDuctClampBolts[C]

ThrottleBodyAssy

• Loosenthelocknutandscrewinthethrottledcableadjuster fullytogivethecablesplentyofplay.
• Removetherightswitchhousingandtakeouttheacceleratorcableupperend[A]anthedeceleratorcableupper end[B].
• Removethethrottledcablelowerends[A]fromthethrottle pulley.
• Afterremovingthethrottlebodyassy, stuffpiecesoflint-free, cleanclothintothethrottlebodyholders.

CAUTION

Ifdirtgetsintotheengine,excessiveenginewear andpossibleenginedamagewilloccur.

ThrottleBodyAssyInstallation

- Installtheholderclampbolts[A]inthedirections shown with each boltheads[B], facing outwards.

• Installtheaircleanerductclampscrew[A]sothattheir screwheads[B]facetheright.
• Runthevacuumhose(seeCable, Wire, and HoseRoutingsectionintheAppendixchapter).

Close-up mechanical assembly showing a car wheel and gear mechanism (no visible text or symbols)

ThrottleBodyAssy

• Fittheacceleratorcableend[A]andthedeceleratorcable end[B]intothethrottlepulley.
• Checkfuelleakagefromthethrottlebodyassy.

WARNING

Fuelspilledfromthecarburetorsishazardous.

• Applyathincoatingofgreasetothethrottlecableupper ends.
  • Installtheupperendsofthethrottlecablesinthegrip.
• Fittheprojection[A]oftherightswitchhousingintothe hole[B]ofthehandlebar.
• Turnthethrottlegripandmakesurethatthethrottlevalves movesmoothlyandreturnbyspringforce.
• Checkthethrottlegripfreeplay(seeThrottleControlSystemInspectioninthePeriodicMaintenancechapter).

WARNING

Operationwithanincorrectlyroutedcablecouldresultinanunsaferidingcondition.

- Adjust:

Throttle Grip Free Play IdleSpeed

ThrottleBodyAssyDisassembly

CAUTION

Donotremove, disassembleor adjust themain throttlesensor[A], subthrottlesensor[B], sub-throttle valve actuator[C], throttle link mechanism [D] and throttle body assy[E], because they are adjusted or set at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.

- Removethethrottlebodyassy(see ThrottleBodyAssy Removal).

CAUTION

Neverdropethethrottlebodyassy,especiallyona hardsurface.Suchashocktothebodyassycan damageit.

0017018CS1 C

ThrottleBodyAssy

- Remove:

Screws[A]

DeliveryPipe[B]

FuellInjectors[C]

ThrottleBodyAssyAssembly

○ReplacetheO-rings[A]andseals[B]withthenewones.

- Beforeassembling, blowawaydirtordustfromthethrottle bodyanddeliverypipebyapplyingcompressedair.

- ApplyengineoiltothenewO-ringsofeachinjector[C], insertthemintothedeliverypipeandconfirmwhetherthe injectorsturnsmoothlyornot.

- Installtheinjectorsalongwiththedeliverypipeassyinto thethrottlebodies.

- Install the throttle body assy (see Throttle Body Assy Installation).

graph TD
    A["Component A"] --> B["Component B"]
    B --> C["Component C"]
    C --> A
    C --> B
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333

AirCleaner

AirCleanerElementRemoval/Installation

- RefertoAirCleanerElementReplacementinthePeriodic Maintenancechapter.

AirCleanerElementInspection

• Removetheaircleanerelement(seeAirCleanerElement ReplacementinthePeriodicMaintenancechapter).
• Visuallychecktheelement[A]fortearsorbreaks.
  ★Iftheelementhasanytearsorbreaks,replacetheelement.

AirCleanerOilDraining

Adrainhoseisconnectedtothebottomoftheaircleaner todrainwateroroilaccumulatedinthecleanerpart.

• Visuallycheckthedrainhose[A]ifthewateroroilaccumulates.
  ★Ifanywateroroilaccumulatesinthehose,removethe plug[B]fromthedrainhoseanddrainit.

WARNING

Besuretoreinstallthepluginthedrainhoseafterdraining.Oilontireswillmakethemslipperyandcancauseanaccidentandinjury.

AirCleanerHousingRemoval

• Removedisconnect. Hose(Disconnect)[A] InletAirTemperatureSensorConnector[B] Screws[C] Cover[D]
• Disconnectthebreatherhose[A]ontheuppercrankcase.

Technical diagram of a mechanical part with labeled point A (no text or symbols beyond label)

Close-up of mechanical components with no visible text or symbols

AirCleaner

- Unscrewthebolts[A]andremovetheaircleanerhousing [B].

AirCleanerHousingInstallation

• Installtheclamponthehose[A]sothatitspinchheads [B]facetheright.
• Installtheclamponthebreatherhose[C]sothatitspinch heads[D]facethefront.

FuelTank

FuelTankRemoval

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Makesurethearea iswell-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.Donotsmoke.TurntheignitionswitchOFF. Bepreparedforfuelspillage;anyspilledfuelmust becompletelywipedupimmediately.

- Remove:

Seat(seeSeatRemovalintheFramechapter) SideCovers(seeSideCoversRemovalintheFrame chapter) FuelTankBolts[A]

• Turntheignitionswitch,andenginestopswitchOFF.
• Waituntiltheenginecoolsdown.

• Openthefueltankcap[A]tolowerthepressureinthe tank.
  ○Duringtankremoval, keep the tank cap open to release pressure in the tank. This makes fuel spillage less.

• Drawthefueloutfromthefueltankwithacommercially availablepump[A].
  ○Useasoftplastichose[B]asapumpinlethoseinorder toinsertthehosesmoothly.

• Putthehosethroughthefillopening[C]intothetankand drawthefuelout. Front[D]

WARNING

The fuel could not be removed completely from the fuel tank. Becareful for remained fuel spillage.

• Remove:
  LeftSideCover(seeSideCoverRemovalintheFrame chapter)
• Disconnectthefuelpumpleadconnector[A]andthetube[B].

Close-up of mechanical components with labeled point A (no readable text or symbols beyond label)

Close-up of a mechanical component with labeled section A, showing a circular opening and central bore (no text or symbols beyond label)

FuelTank

• Besuretoplaceapieceofcloth[A]aroundthefuelhose joint.

• Insertaminusscrewdriver[B]intotheslit[C]onthejoint lock.

• Turn[A]thedrivertodisconnectthejointlock[B].

• Pull[C]thefuelhosejointout[D]oftheoutletpipe.

CAUTION

When removing the fuel hose joint, donot apply strong forceto the outlet pipe on the fuel pump. The pipemade from resincould bed damaged.

• Closethefueltankcap.
• Removethefueltank, and placeitonaflatsurface.
  ○Donotapplytheloadtothefuelpumpoutletportion[A] especiallytheoutletpipemadefromresin.

FuelTankInstallation

• NotetheaboveWARNING(seeFuelTankRemoval).
• Routethehosescorrectly(seeCable, Wire, and Hose RoutingintheAppendixchapter).

• Check that the rubber dampers[A] are on the frame and the fuel tank.

• Checkthatthedampers[A]areinplaceonthefueltank aswell.
  ★ If the dampers are damaged, deteriorated, replace them.

Close-up of a mechanical component with a magnified circular detail labeled 'A', no visible text or symbols beyond the label.

FuelTank

• Besurethatthetrimseal[A]isonthefueltank.
  ReverseSideofFuelTank[B]
  SideCover[C]
  Approx.17mm(0.67in.)[D]
  Front[E]

- Insert[A]thefuelhosejoint[B]straightontothedelivery pipeuntilthehosejointclicks.

CAUTION

Wheninstallingthefuelhosejoint, donotapply strongforcetotheoutletpipeonthefuelpump. The pipemadefromresincouldbedamaged.

- Push[C]thejointlock[D].

- Pushandpull[A]thehosejoint[B]backandforthmore thantwotimesandmakesureitislockedanddoesn't comeoff.

WARNING

Makesurethehosejointisinstalledcorrectlyonthe deliverypipebyslidingthejoint,orthefuelcould leak.

★ Ifitcomesoff, reinstallthehosejoint.
- Connectthefuelpumpandthefuellevelsensorconnectorsandthebattery(−)cableterminal.

FuelTankandCapInspection

• Visuallyinspectthegasket[A]onthetankcapforany damage.
  ★Replacethegasketifitisdamaged.
• Checktoseeifthewaterdrainpipe[B]inthetankisnot clogged.checkthetankcapbreatheralso.
  ★Iftheyareclogged,removethetankanddrainit,andthen blowthebreatherfreewithcompressedair.

CAUTION

Donotapplycompressedairtotheairventholes [C]inthetankcap. This could cause damage and clogging of the labyrinth in the cap.

FuelTank

FuelTankCleaning

WARNING

Cleanthetankinawell-ventilatedarea, and take care that there are no sparks or flame any where near the working area. Because of the danger or highly flammable liquids, donot use gasoline or low-flash points solvent st o cleanthetank.

• Removethefueltank(seeFuelTankRemoval).
• Removethefuelpumpinlethoseandthefuelpump(see FuelPumpsection).
• Poursomehigh-flashpointsolventintothefueltankand shakethetanktoremovedirtandfueldeposits.
• Drawthesolventoutofthefueltank.
• Drythetankwithcompressedair.
• Installthefuelpump(seeFuelPumpInstallation).
• Installthefueltank(seeFuelTankInstallation).

CoolingSystem

TableofContents

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

CoolantReserveTankRemoval/Installation....4-9

Water Pump 4-10

Water Pump Removal 4-10

Water Pump Installation 4-10

Mechanical Seal Inspection 4-11

Water Pump Housing Disassembly 4-11

Water Pump Housing Assembly 4-11

Impeller Assembly 4-12

Pump Impeller Inspection 4-12

Radiator 4-13

RadiatorandRadiatorFanRemoval....4-13

Radiator and Radiator Fan Installation 4-14

Radiator Inspection 4-14

Radiator Cap Inspection 4-14

Radiator Filler Neck Inspection 4-15

Thermostat 4-16

Thermostat Removal 4-16

Thermostat Installation.... 4-16

Thermostat Inspection 4-16

Hose and Pipes 4-18

Hose Installation 4-18

Hose Inspection 4-18

Water Temperature Sensor 4-19

WaterTemperatureSensorRemoval/Installation....4-19

WaterTemperatureSensorInspection 4-19

6002056875

ExplodedView

No.	Fastener	Torque			Remarks
		N·mkgf·mft·lb
1	RadiatorHoseClampScrews	2.00.20	17in·lb
2	WaterPumpImpellerBolt9.81.087in·lb
3	WaterPumpCoverBolts9.81.087in·lb
4	Water Pump Drain Bolt	7.0	0.70	62 in·lb
5	ThermostatHousingBolts	9.81.087in·lb
6	Water Temperature Sensor	12	1.2	106 in·lb
7	Baffle Plate Bolts	5.9	0.60	52 in·lb	L

1. ReserveTank

2. BafflePlate

3. CylinderHeadCover

4. Thermostat

5. WaterPumpImpeller

6. MechanicalSeal

G: Applygrease.

HG: Applyhigh-temperaturegrease.

R: ReplacementParts

CoolantFlowChart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. Whentheenginestarts,thewaterpumpturnsandthecoolantcirculates.

Thethermostatisawaxpellettypewhichopensorcloseswithcoolanttemperaturechanges. The thermostatcontinuouslychangesitsvalveopeningtokeepthecoolanttemperatureattheproperlevel. When coolant temperature is below 80.5 \~ 83.5°C (177 \~ 182°F), the thermostat closes so that the coolantflowisrestrictedthroughtheairbleederhole,causingtheenginetowarmupmorequickly. When coolant temperature is more than 80.5 \~ 83.5°C, the thermostat opens and the coolant flows.

When the coolant temperature goes up beyond 93 \~ 103°C (199 \~ 217°F), the radiator fan relay conductstoooperatetheradiatorfan. Theradiatorfandrawsairthroughtheradiatorcorewhenthere isnotsufficientairflowsuchasatlowspeeds. Thisincreasesupthecoolingactionoftheradiator. When the temperature is below 91°C (196°F) \~ temperature less than ON temperature, the fan relay opensandtheradiatorfanstops.

In this way, this system control the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies.

Thesystemispressurizedbytheradiatorcaptosuppressboilingandtheresultantairbubbles whichcancauseengineoverheating.Astheenginewarmsup,thecoolantintheradiatorandthe waterjacketexpands.Theexcesscoolantflowsthroughtheradiatorcapandhosetothereservetank tobestoredtheretemporarily.Conversely,astheenginecoolsdown,thecoolantintheradiatorand thewaterjacketcontracts,andthestoredcoolantflowsbacktotheradiatorfromthereservetank.

Theradiatorcaphastwovalves.Oneisapressurevalvewhichholdsthepressureinthesystem when the engine is running. When the pressure exceeds 112.3 \~ 141.7 kPa (1.15 \~ 1.45 kgf/cm², 16.3 \~ 20.5 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 112.3 \~ 141.7 kPa (1.15 \~ 1.45 kgf/cm², 16.3 \~ 20.5 psi). When the engine cools down, another small valve (vacuum valve) in the capopens.Asthecoolantcools,thecoolantcontractstoformavacuuminthesystem.Thevacuum valveopensandallowsthecoolantfromthereservetanktoentertheradiator.

Specifications

ItemStandard
CoolantProvidedwhenShippingType(Recommended)Permanenttype	ofantifreeze(softwaterandethyleneglycolpluscorrosionandrustinhibitorchemicalsforaluminumenginesandradiators)
ColorGreenMixedRatioSoftwater50%,coolant50%FreezingPointTotalAmount	-35°C(-31°F)1.2L(1.3USqt)(reservetankfulllevel,includingradiatorandengine)
RadiatorCapRelief Pressure	112.3 ~ 141.7 kPa (1.15 ~ 1.45 kgf/cm2, 16.3 ~ 20.5 psi)
ThermostatValve Opening TemperatureValveFullOpeningLift8mm(0.31in.)or	80.5 ~ 83.5°C (177 ~ 182°F)more@95°C(203°F)

SpecialTools

BearingDriverSet: 57001-1129

Isometric line drawing of a mechanical device with multiple circular components and a rectangular opening (no text or symbols)

ST571129ST C

OilSealDriver: 57001-1660

Simple line drawing of a cylindrical mechanical part (no text or symbols)

\$1571660ST C

Coolant

CoolantDeteriorationInspection

• Removetherightcenterfairingcover(seeCenterFairing RemovalintheFramechapter).
• Visuallyinspectthecoolant[A]inthereservetank.
  ★Ifwhitishcotton-likewaftsareobserved,aluminumparts inthecoolingsystemarecorroded.Ifthecoolantis brown,ironorsteelpartsarerusting.Ineithercase,flush thecoolingsystem.
  ★Ifthecoolantgivesoffanabnormalsmell,checkfora coolingsystemleak.Itmaybecausedbyexhaustgas leakingintothecoolingsystem.

CoolantLevelInspection

- RefertoCoolantLevelinthePeriodicMaintenancechapter.

CoolantDraining

- RefertoCoolantChangeinthePeriodicMaintenance chapter.

CoolantFilling

- RefertoCoolantChangeinthePeriodicMaintenance chapter.

Pressure Testing

• Removethereservetank(seeCoolantChangeinthePeriodicMaintenancechapter).
• Removetheradiatorcap, and installacoolingsystem pressuretester[A]onthefillerneck[B].

NOTE

○ Wetthecapsealingsurfaceswithwaterorcoolantto preventpressureleaks.

- Build up pressure in the system carefully until the pressurereaches141.7kPa(1.45kgf/cm²,20.5psi).

CAUTION

Duringpressuretesting, donotexceedthepressureforwhichthesystemisdesigned. Themaximumpressureis141.7kPa(1.45kgf/cm²,20.5psi).

• Watchthegaugeforatleast6seconds.
  ★Ifthepressureholdssteady,thesystemisallright.
  ★If the pressuredrops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder headgasket and the waterpump.
• Removethepressuretester,replenishthecoolant,and installtheradiatorcap.

Close-up of a white plastic container with labeled component A, mounted on a mechanical vehicle (no visible text or symbols beyond label)

Coolant

CoolingSystemFlushing

Overaperiodoftime, thecoolingsystem accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the coolingsystem. If this accumulation is not removed, it will clog up the water passage and consider ablereducetheefficiency of the coolingsystem.

• Drainthecoolingsystem(seeCoolantChangeinthePeriodicMaintenancechapter).
• Fillthecoolingsystemwithfreshwatermixedwithaflushingcompound.

CAUTION

Donotuseaflushingcompoundwhichisharmfulto thealuminumengineandradiator.Carefullyfollow theinstructionssuppliedbythemanufacturerofthe cleaningproduct.

• Warmuptheengine, and runitatnormaloperatingtemperatureforabouttenminutes.
• Stoptheengine, anddrainthecoolingsystem.
• Fillthesystemwithfreshwater.
• Warmuptheengineanddrainthesystem.
• Repeat the previous wostepsoncemore.
• Fillthesystemwithapermanenttypecoolantandbleed theairfromthesystem(seeCoolantChangeinthePeriodicMaintenancechapter).

CoolantReserveTankRemoval/Installation

- Thecoolantreservetankisremovedandinstalledduringcoolantchange(seeCoolantChangeinthePeriodicMaintenancechapter).

WaterPump

WaterPumpRemoval

• Drainthecoolant(seeCoolantChangeinthePeriodic Maintenancechapter).
• Loosentheclampandremovetheradiatorhose[A]from thewaterpumpcover[B].

• Removethewaterpumpcoverbolts[C].

• Shiftthetransmissioninto1stgear.

• Whileapplyingtherearbrake,removethewaterpump impellerbolt[A].
• Remove: Impeller[B] WaterPumpHousing[C]

WaterPumpInstallation

• Wheninstallingthewaterpumpimpellerbolt,shiftthe transmissioninto1stgearandapplytherearbrake.
• ReplacetheO-rings[A]onthewaterpumphousingwith newonesandapplygreasethem.
• Applyhightemperaturegreasetothelipsofthewaterpumphousingoilseal[B].

- Besurethatthedowelpin[A]isinposition.

• Installthewaterpumphousing.

- Tighten: Torque-WaterPumpImpellerBolt:9.8N·m(1.0kgf·m,87 in·lb)

- ReplacetheO-ring[A]onthewaterpumpcoverwitha newoneandgreaseit.

Technical line drawing of a mechanical assembly with no visible text or symbols

Cross-sectional view of a mechanical component with labeled point A (no text or symbols beyond label)

WaterPump

• Installthewaterpumpcover, being careful of the two dowelpins[A].
  Torque-WaterPumpCoverBolts:9.8N·m(1.0kgf·m,87in·lb)

Mechanical assembly diagram showing a gear and pump component with labeled parts (no readable text or symbols)

MechanicalSealInspection

• Visuallyinspectthemechanicalseal.
  ★Ifanyoneofthepartsisdamaged, replacethemechanicalsealasaunit.
  ○Thesealingseatandrubbersealmayberemovedeasily byhand.
  [A]ImpellerSealingSeatSurface
  [B]RubberSeal
  [C]MechanicalSealDiaphragm

WaterPumpHousingDisassembly

CAUTION

Becarefulnottodamagethesealingsurfaceofthe mechanicalseal.

- Taketheoilseal[A]outofthehousing[B]withahook[C].

- Pressthemechanicalseal[A]outofthehousingwitha bearingdriver[B].

SpecialTool-BearingDriverSet:57001-1129

WaterPumpHousingAssembly

• Applyahighttemperaturegrease[A]tothenewoilseal [B].
• Presstheoilsealintothehousingwithabearingdriverso thatthesealsurfaceisflush[C]withtheendofthehole.
• Pressthenewmechanicalsealintothehousingwiththe oilsealdriver[D]untilitsflange[E]touchesthesurface [F]ofthehousing.

SpecialTool-OilSealDriver:57001-1660

WaterPump

ImpellerAssembly

- Cleantheslidingsurfaceofthemechanicalsealwitha highflash-pointsolvent, and applyalittlecoolanttothe slidingsurfacetogivethemechanicalsealinitiallubrication.

- Applycoolanttothesurfacesoftherubberseal[A]and sealingseat[B], and installtherubbersealandsealing seatintotheimpellerbypassingthembyhanduntilthe seatstopsatthebottomofthehole.

PumpImpellerInspection

- Visuallychecktheimpeller[A].

★Ifthesurfaceiscorroded,orifthebladesaredamaged, replacetheimpeller.

Mechanical component with labeled parts (A and P), no readable text or symbols beyond labels

Radiator

RadiatorandRadiatorFanRemoval

- Drainthecoolant(seeCoolantChangeinthePeriodic Maintenancechapter).

- Remove: Left/RightCenterFairing(seeCenterFairinginthe Framechapter) ReserveTank(seeCoolantChangeinthePeriodicMaintenancechapter) RadiatorFanMotorConnectorA RadiatorHoseClampScrewB

- Loosen: RadiatorHoseClampScrew[A] - Remove: CotterPin[B]

- Pull[A]theradiator[B]towardtheleft,notingthebaffle plate[C]onthecylinderheadcover.

CAUTION

Donottouchtheradiatorcore. This could damage theradiatorfins, resulting in loss of cooling efficiency.

- Ifnecessary, remove: RadiatorFanMountingBolts[A] RadiatorFan[B]

Radiator

RadiatorandRadiatorFanInstallation

• Installthegrommet[A]sothatitslargesidefacesthe front.
  • Installtheradiator[B]totheframe.
  ○Align[C]theprojectionontheradiatorwiththeholeon theframe.
  ○Align[D] the projection on the framework with radiator.
  ○Notethebaffleplateonthecylinderheadcoverwhen intallingtheradiator.
  ○Positiontheradiatorhoseclampscrews[E]asshown.

RadiatorInspection

• Checktheradiatorcore.
  ★Ifthereareobstructionstoairflow,removethem.
  ★Ifthecorrugatedfins[A]aredeformed,carefully straightenthem.
  ★Iftheairpassagesoftheradiatorcoreareblockedmore than20%byunremovableobstructionsorirreparablydeformedfins,replacetheradiatorwithanewone.

CAUTION

Whencleaningtheradiatorwithsteamcleaner, be carefulofthefollowingtopreventradiatorordamage: Keepthesteamgun[A]awaymorethan0.5m(1.6 ft)[B]fromtheradiatorcore.

HoldthesteamgunperpendicularCtothecoresurface.

Runthesteamgun, following the core find direction.

RadiatorCapInspection

• Remove:
  ReserveTank(seeCoolantChangein thePeriodicMaintenancechapter) RadiatorCap
• Checktheconditionofthebottom[A]andtop[B]valve sealsandvalvespring[C].
  ★Ifany oneofthemshowsvisibledamage, replacethecap withanewone.

Radiator

- Installthecap[A]onacoolingsystempressuretester[B].

NOTE

○Wetthecapsealingsurfaceswithwaterorcoolantto preventpressureleaks.

- Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gaugeneedleflicks downward. Stoppumping and measureleak time at once. There lief valvemustopen within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds.

RadiatorCapReliefPressure

Standard: 112.3 \~ 141.7 kPa (1.15 \~ 1.45 kgf/cm², 16.3 \~ 20.5psi)

★ Ifthecapcannotholdthespecifiedpressureorifitholds toomuchpressure,replaceitwithanewone.

RadiatorFillerNeckInspection

• Removethereservetank(seeCoolantChangeinthePeriodicMaintenancechapter).
• Removetheradiatorcap.
• Checktheradiatorfillerneckforsignsofdamage.
• Checktheconditionofthetopandbottomsealingseats [A]inthefillerneck. They must besmoothandcleanfor theradiatorcaptofunctionproperly.

Thermostat

ThermostatRemoval

• Drainthecoolant(seeCoolantChangeinthePeriodic Maintenancechapter).
• Remove: LeftCenterFairing(seeCenterFairingRemovalinthe Framechapter) ThermostatHosingBolts[A] ThermostatHosing[B]

- Pullthethermostat[A]outofthecylinderhead.

Close-up mechanical assembly showing a rotating component with labeled point A (no readable text or symbols)

ThermostatInstallation

• Installthethermostat[A]inthecylinderheadsothatthe airbleederhole[B]isontop.
• InstallanewO-ringintothehousingandapplygreaseit.
• Tighten:

Torque-ThermostatHosingBolts:9.8N·m(1.0kgf·m,87in·lb)

- Filltheradiatorwithcoolant(seeCoolantChangeinthe PeriodicMaintenancechapter).

ThermostatInspection

• Removethethermostat, and inspect the thermostat valve [A] at room temperature.
  ★Ifthevalveisopen, replacethethermostatwithanew one.

Close-up of a metallic mechanical component with a labeled section (A) and reference number 60098049 P (no text or symbols on the object itself)

Thermostat

• Tocheckvalveopeningtemperature, suspendthethermostat[A]inacontainerofwaterandraisethetemperatureofthewater.
  ○Thethermostatmustbecompletelysubmergedandmust nottouchthecontainersidesorbottom.Suspendanaccuratethermometer[B]inthewatersothattheheatsensitiveportions[C]arelocatedinalmostthesamedepth. Itmustnottouchthecontainer,either.
  ★ If themeasurement is out of the specified range, replace the thermostat with anewone.

ThermostatValveOpeningTemperature

80.5 \~ 83.5°C (177 \~ 182°F)

HoseandPipes

HoseInstallation

• Install the hoses and pipes, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting.
• Runthehoses(seeCable, Wire, and HoseRoutingsectionintheAppendixchapter).
• Installtheclamp[A]asnearaspossibletothehoseend tocleartheraisedribofthefitting. This will prevent the hoses from working loose.
  ○Theclampscrewsshouldbepositionedcorrectlytopreventtheclampsfromcontactingtheotherparts.

Torque-RadiatorHoseClampScrews:2.0N·m(0.20kgf·m, 17in·lb)

HoseInspection

- RefertoCoolingHoseandConnectionInspectioninthe PeriodicMaintenancechapter.

WaterTemperatureSensor

CAUTION

Thewatertemperaturesensorshouldneverbeallowedtofallonahardsurface.Suchashocktothe watertemperaturesensorcandamageit.

WaterTemperatureSensorRemoval/Installation

- RefertoWaterTemperatureSensorRemoval/Installation intheFuelSystem(DFI)chapter. WaterTemperatureSensor[A]

Close-up mechanical assembly showing gears and shafts with a labeled component 'A' (no readable text or symbols beyond label)

WaterTemperatureSensorInspection

- RefertoWaterTemperatureSensorInspectioninthe ElectricalSystemchapter.

EngineTopEnd

TableofContents

ExplodedView....5-2

Specifications....5-7

SpecialToolsandSealant......5-9

CleanAirSystem....5-11

AirSuctionValveRemoval......5-11

AirSuctionValveInstallation......5-11

AirSuctionValveInspection......5-11

AirSwitchingValveRemoval......5-11

AirSwitchingValveInstallation....5-12

Air Switching Valve Operation Test....5-12

AirSwitchingValveUnitTest......5-12

CleanAir System Hose Inspection....5-12

CylinderHeadCover....5-13

CylinderHeadCoverRemoval....5-13

CylinderHeadCoverInstallation .5-13

CamshaftChainTensioner....5-14

Camshaft Chain Tensioner Removal....5-14

Camshaft Chain Tensioner Installation....5-14

Camshaft,CamshaftChain....5-15

CamshaftRemoval....5-15

CamshaftInstallation....5-15

Camshaft and Sprocket Assembly....5-18

Camshaft,CamshaftCapWear...5-18

CamshaftRunout 5-19

CamWear....5-19

CamshaftChainRemoval......5-19

CylinderHead....5-20

CylinderCompression Measurement....5-20

CylinderHeadRemoval....5-21

CylinderHeadInstallation....5-22

CylinderHeadWarp....5-24

Valves....5-25

ValveClearanceInspection .....5-25

ValveClearanceAdjustment......5-25

ValveRemoval 5-25

ValveInstallation 5-25

ValveGuideRemoval 5-25

ValveGuideInstallation .....5-26

Valve-to-Guide Clearance Measurement (Wobble Method)....5-26

ValveSeatInspection 5-27

ValveSeatRepair....5-27

Cylinder, Pistons....5-32

CylinderRemoval....5-32

CylinderInstallation....5-32

PistonRemoval....5-32

PistonInstallation....5-33

CylinderWear....5-34

PistonWear....5-34

PistonRing, PistonRing Groove Wear....5-35

PistonRingGrooveWidth......5-35

PistonRingThickness....5-35

PistonRingEndGap....5-36

ThrottleBodyHolder 5-37

ThrottleBodyHolderInstallation..5-37

Muffler....5-38

Muffler BodyRemoval......5-38

ExhaustPipeRemoval......5-38

Muffler Body and Exhaust Pipe Installation....5-39

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1	AirSuctionValveCoverBolts	9.81.087in·lb
2CylinderHeadCoverBolts9.81.087in·lb
3	Camshaft Cap Bolts	12	1.2	106 in·lb	S
4	Cylinder Head Bolts (M10 New Bolts)	54	5.5	40	MO, S
	Cylinder Head Bolts (M10 Used Bolts)	49	5.0	36	MO, S
5	Cylinder Head Bolts (M6)	12	1.2	106 in·lb	S
6	Throttle Body Holder Bolts	12	1.2	106 in·lb
7	Rear Camshaft Chain Guide Bolts	20	2.0	15	L
8	Camshaft Chain Tensioner Mounting Bolts	9.8	1.0	87 in·lb
9	CamshaftChainTensionerCapBolt	202.0	15
10	Spark Plugs	15	1.5	11
11	Camshaft Sprocket Bolts	15	1.5	11	L
12	Baffle Plate Bolts	5.9	0.60	52 in·lb	L

L: Applyanon-permanentlockingagent.
M:Applymolybdenumdisulfidegrease.
MO:Applymolybdenumdisulfideoilsolution.
(mixtureoftheengineoilandmolybdenumdisulfidegreaseinaweightratio10: 1)
R:ReplacementParts
S: Followthespecifictighteningsequence.
SS:Applysiliconesealant.

GE02200B75 C

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1	CylinderBolt(M8)	27.52.820			MO,S
2	Cylinder Nut (M10)	49	5.0	36	MO,S
3	Cylinder Bolts (M6)	12	1.2	106 in·lb	S
4ExhaustPipeManifoldHolderNuts171.712
5	Muffler Body Mounting Bolt (Front)	20	2.0	15
6	Muffler Body Mounting Bolt (Rear)	20	2.0	15

1. "R"marked sidefaces up.
2. "RN"marked sidefacesup.
3. Hollowmark facesforward.
   MO: Applymolybdenumdisulfideoilsolution.
   (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
   R: ReplacementParts

Exhaust System ER650A6F

graph TD
    A["MANIFOLD"] --> B["Non-Catalyst"]
    A --> C["SILENCER"]
    C --> D["Honeycomb Type Catalyst with Oxygen Sensor"]
    D --> E["P/No. 18091-0284\nMark : KHI K 492"]
    C --> F["Honeycomb Type Catalyst without Oxygen Sensor"]
    F --> G["P/No. 18091-0285\nMark : KHI K 492"]
    C --> H["Honeycomb Type Catalyst without Oxygen Sensor"]
    H --> I["P/No. 18091-0270\nMark : KHI K 499"]
    D --> J["ITEM NAME: WVTA (FULL H), GB WVTA (FULL H)"]
    F --> K["Australia"]
    H --> L["Malaysia"]
    J --> M["ORG PRODUCT: ER650A6S, ER650A6S"]
    L --> N["ORG PRODUCT: ER650A6F"]

Full: Full Power
H: HoneycombTypeCatalyst
GB: UnitedKingdom Model

ExplodedView

Silencer[C]withHole[A]forOxygenSensor[B]

Specifications

ItemStandardServiceLimit
Camshafts
CamHeight:
Exhaust	35.843 ~ 35.957 mm (1.4111 ~ 1.4156 in.)	35.74 mm (1.4071 in.)
Inlet	36.543 ~ 36.657 mm (1.4387 ~ 1.4432 in.)	36.44mm(1.4346in.)
CamshaftJournal,Camshaft CapClearance	0.028 ~ 0.071 mm (0.0011 ~ 0.0028 in.)	0.16 mm (0.0063 in.)
CamshaftJournalDiameter	23.950~ 23.972mm(0.9429~ 0.9438 in.)	23.92mm(0.942in.)
CamshaftBearingInside Diameter	24.000 ~ 24.021 mm (0.9449 ~ 0.9457 in.)	24.08mm(0.948in.)
Camshaft Runout	TIR 0.02 mm (0.0008 in.) or less	TIR 0.1 mm (0.004 in.)
CylinderHead
CylinderCompression	(UsableRange)961~ 1471kPa(9.8~ 15.0kgf/cm2, 139~ 213psi)@400r/min(rpm)	-- --
Cylinder Head Warp	-- --	0.05 mm (0.002 in.)
Valves
Exhaust	0.22 ~ 0.31 mm (0.0087 ~ 0.0122 in.)	-- --
Inlet	0.15 ~ 0.21 mm (0.0059 ~ 0.0083 in.)	-- --
ValveHeadThickness:
Exhaust	0.8mm(0.031in.)	0.5mm(0.020in.)
Inlet	0.5 mm (0.020 in.)	0.25 mm (0.0098 in.)
ValveStemBend	TIR0.01mm(0.0004in.)orless	TIR0.05mm (0.002in.)
ValveStemDiameter:
Exhaust	4.455 ~ 4.470 mm (0.1754 ~ 0.1760 in.)	4.44 mm (0.175 in.)
Inlet	4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in.)	4.46 mm (0.176 in.)
ValveGuideInsideDiameter:
Exhaust	4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in.)	4.58 mm (0.180 in.)
Inlet	4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in.)	4.58 mm (0.180 in.)
Valve/ValveGuideClearance (WobbleMethod):
Exhaust	0.07 ~ 0.14 mm (0.0028 ~ 0.0055 in.)	0.27 mm (0.0106 in.)
Inlet	0.02 ~ 0.08 mm (0.0008 ~ 0.0032 in.)	0.22 mm (0.0087 in.)
Valve Seat Cutting Angle	45°, 32°, 55°, 60°	-- --
ValveSeatingSurface:
Width:
Exhaust	0.5 ~ 1.0 mm (0.020 ~ 0.039 in.)	-- --
Inlet	0.5~ 1.0mm(0.020~ 0.039in.)	-- --
OutsideDiameter:
Exhaust	27.6 ~ 27.8 mm (1.087 ~ 1.094 in.)	-- --
Inlet	32.6 ~ 32.8 mm (1.283 ~ 1.291 in.)	-- --

Specifications

ItemStandardServiceLimit
ValveSpringFreeLength:Exhaust41.91mm(1.650in.)40.3mm(1.587in.)Inlet41.91mm(1.650in.)40.3mm(1.587in.)
Cylinder,Pistons
CylinderInsideDiameter	82.994 ~ 83.006 mm (3.2675 ~ 3.2679 in.)	83.10mm(3.2716in.)
PistonDiameter	82.969 ~ 82.984 mm (3.2665 ~ 3.2671 in.)	82.82mm(3.2606in.)
Piston/Cylinder Clearance	0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in.)	-- --
PistonRing/GrooveClearance: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.)
PistonRingGrooveWidth:Top	0.92 ~ 0.94 mm (0.0362 ~ 0.0370 in.)	1.02 mm (0.040 in.)
Second	1.01 ~ 1.03 mm (0.0398 ~ 0.0406 in.)	1.11 mm (0.044 in.)
PistonRingThickness:Top	0.87 ~ 0.89 mm (0.0342 ~ 0.0350 in.)	0.80 mm (0.031 in.)
Second	0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.)	0.90 mm (0.035 in.)
PistonRingEndGap:Top	0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in.)	0.7 mm (0.028 in.)
Second	0.40 ~ 0.55 mm (0.0157 ~ 0.0217 in.)	0.8 mm (0.031 in.)

SpecialToolsandSealant

CompressionGauge,20kgf/cm²: 57001-221

Technical line drawing of a pressure gauge with a valve, shown without any text or symbols

ValveSpringCompressorAssembly: 57001-241

Line drawing of a mechanical clamp or spring-loaded component (no text or symbols)

ValveSeatCutter,45°-35: φ 57001-1116

Isometric line drawing of a cylindrical mechanical part with concentric rings (no text or symbols)

ValveSeatCutter,32°-30: 57001-1120

Simple line drawing of a cylindrical mechanical part with concentric rings (no text or symbols)

ValveSeatCutter,32°-35: φ 57001-1121

Isometric line drawing of a cylindrical mechanical part with concentric rings and textured surface (no text or symbols)

ValveSeatCutter,60°-30:φ 57001-1123

Simple line drawing of a conical object with a circular top and textured base (no text or symbols)

ValveSeatCutterHolderBar: 57001-1128

Simple line drawing of a cylindrical object with no text or symbols

ValveSeatCutter,45°-30:φ 57001-1187

Simple line drawing of a cylindrical mechanical part with concentric rings and a central hole (no text or symbols)

ValveSeatCutter,55°-35:φ 57001-1247

Simple line drawing of a conical object with a circular top and textured base (no text or symbols)

ValveSpringCompressorAdapter,21φ 57001-1272

Technical line drawing of a mechanical component (no text or symbols)

5-10ENGINETOPEND

SpecialToolsandSealant

CompressionGaugeAdapter, M10×1.0: 57001-1317

Line drawing of a U-shaped connector with two connectors and a central hub (no text or symbols)

ValveSeatCutterHolder,4.5 57001-1330

Line drawing of a cylindrical mechanical component with a pointed tip and a base (no text or symbols)

ValveGuideArbor,4.5: 57001-1331

Technical line drawing of a mechanical component with a cylindrical shaft and flanged end (no text or symbols)

ValveGuideReamer,4.5: 57001-1333

Line drawing of a mechanical tool or rod with a flanged end (no text or symbols)

PistonPinPuller: 57001-1568

Technical line drawing of a mechanical device with cutaway view and two small components (no text or symbols)

PistonPinPullerAdapterC: 57001-1657

Technical line drawing of a mechanical connector (no text or symbols)

KawasakiBond(SiliconeSealant): 92104-0004

CleanAirSystem

AirSuctionValveRemoval

- Remove:

FuelTank(seeFuelTankRemovalintheFuelSystem (DFI)chapter)

AirCleanerHousing(seeAirCleanerHousingRemoval intheFuelSystem(DFI)chapter)

AirSwitchingValvewithHoses(seeAirSwitchingValve Removal)

AirSuctionValveCoverBolts[A]andClamp

AirSuctionValveCover[B]

AirSuctionValve[C]

AirSuctionValveInstallation

• Installtheairsuctionvalve[A]sothatitssidewherestopperisfixedwiththescrews[B]facesthefront[C].
• Tighten:

Torque-AirSuctionValveCoverBolts:9.8N·m(1.0kgf·m, 87in·lb)

AirSuctionValveInspection

• Removetheairsuctionvalve(seeAirSuctionValveRemoval).
• Visually inspect thereeds for cracks, folds, warps, heat damage or other damage.
  ★ If thereisanydoubtastotheconditionofthereeds[A], replacetheairsuctionvalveasanassembly.
• Checkthereedcontactareas[B]ofthevalveholderfor grooves,scratches,anysignsofseparationfromthe holderorheatdamage.
• Ifthereisanydoubtastotheconditionofthereedcontact areas,replaceheairsuctionvalveasanassembly.
• Ifanycarbonorotherforeignparticles have accumulated between thereed and thereed contact area, wash the valve assembly clean with a high-flash pointsolvent.

CAUTION

Donotscrapeoffthedepositswithascpraperasthis coulddamagetherubber,requiringreplacementof thesuctionvalveassembly.

AirSwitchingValveRemoval

- Remove:

FuelTank(seeFuelTankRemovalintheFuelSystem (DFI)chapter)

AirSwitchingValveConnectorA VacuumSwitchValve[B]

CleanAirSystem

AirSwitching Valve Installation

• Installthevacuumswitchvalvesothatthevacuumfitting [A]facesleftside.
• Routethehosescorrectly(seeCable, Wire, and Hose RoutingsectionintheAppendixchapter).

AirSwitching ValveOperationTest

- RefertoAirSwitchingValveOperationTestintheElectricalSystemchapter.

AirSwitchingValveUnitTest

- RefertoAirSwitchingValveUnitTestintheElectricalSystemchapter.

CleanAirSystemHoseInspection

- Becertainthatallthehosesareroutedwithoutbeingflattenedorkinked,andareconnectedcorrectlytotheair cleanerhousing,airswitchingvalve,#1and#2throttle bodyholdersandairsuctionvalvecovers.

★Iftheyarenot,correctthem.Replaceethemiftheyare damaged.

CylinderHeadCover

CylinderHeadCoverRemoval

- Remove:

FuelTank(seeFuelTankRemovalintheFuelSystem (DFI)chapter)

AirCleanerHousing(seeAirCleanerHousingRemoval intheFuelSystem(DFI)chapter)

AirSuctionValveCover[A]withHose[B] StickCoils[C]

BafflePlate

CylinderHeadCoverBolts[D]

CylinderHeadCover[E]

CylinderHeadCoverInstallation

• Replacetheheadcovergasket[A]withanewone.
• Applysiliconesealant[B]tothecylinderheadasshown.

Sealant-KawasakiBond(SiliconeSealant):92104-0004

• Install:

DowelPins[C]

PlugHoleGaskets[D]

- Install:

Washers[A]

CylinderHeadCoverBolts[B]

○Installthewasherswithmetalside[C]facesupward.

- Tighten:

Torque-CylinderHeadCoverBolts:9.8N·m(1.0kgf·m,87in·lb)

• Installthebaffleplate[A].
• Puttheinsulators[B]underthebaffleplateandthewashers[C]onthebaffleplate.
  ○Applyanon-permanentlockingagenttothebaffleplate boltsandtorquethem.

Torque-BafflePlateBolts:5.9N·m(0.60kgf·m,52in·lb)

CamshaftChainTensionerRemoval

CAUTION

Thisisanon-returntypecamshaftchaintensioner. Thepushroddoesnotreturntoitsoriginalposition onceitmovesouttotakeupcamshaftchainslack. Observealltheruleslistedbelow:

Whenremovingthetensioner, donottakeoutthe mountingboltsonlyhalfway. Retighteningthe mountingboltsfromthispositioncoulddamage thetensionerandthecamshaftchain. Oncethe boltsareloosened, thetensionermustberemoved andresetasdescribedin "CamshaftChainTensionerInstallation."

Donotturnoverthecrankshaftwhilethetensioner isremoved. Thiscouldupsetthecamshaftchain timing, anddamagethevalves.

- Remove:

CapBolt[A]

Washer [B]

Spring[C]

- Removethemountingbolts[D]andtakeoffthecamshaft chaintensioner.

CamshaftChainTensionerInstallation

- Releasethestopper[A]andpushthepushrod[B]into thetensioner[C].

- Installthetensionersothatthestopperfacesupward.

- Tightenthetensionermountingbolts[A].

Torque-CamshaftChainTensionerMountingBolts: 9.8 N·m(1.0kgf·m,87in·lb)

• Installthespringandwasher.

- Tightenthecapbolt[B].

Torque-CamshaftChainTensionerCapBolt:20N·m(2.0 kgf·m,15ft·lb)

- Turnthecrankshaft2turnsclockwisetoallowthetensionertoexpandandrecheckthecamshaftchaintiming.

Camshaft,CamshaftChain

CamshaftRemoval

• Remove:
  CylinderHeadCover(see CylinderHeadCoverRemoval)
• Positionthecrankshaftasfollows.
  ○Removetheupper[A]andlower[B]capsontheclutch cover.

○Usingawrenchonthecrankshaftrotationbolt,turnthe crankshaftclockwiseuntilthe2|Tmarkline[A]onthetimingrotorisalignedwiththenotch[B]intheedgeofthe upperhole[C]intheclutchcover.

- Remove:

CamshaftChainTensioner(seeCamshaftChainTensionerRemoval)

CamshaftCapBolts[A]

CamshaftCaps[B]

Camshafts[C]

CAUTION

Thecrankshaftmaybeturnedwhilethecamshafts areremoved.Alwayspullthechaintautwhileturningthecrankshaft.Thisavoidskinkingthechain onthelower(crankshaft)sprocket.Akinkedchain coulddamageboththechainandthesprocket.

CamshaftInstallation

- Besuretoinstallthefollowingparts.

PlugHoleGaskets[A]

DowelPins[B]

Camshaft, CamshaftChain

• Applymolybdenumdisulfideoilsolutiontoallcams[A] journals[B]andthrustblocks[C]with×marks.
• Ifanewcamshaftistobeused, applyathincoatofmolybdenumdisulfidegreasetothecamsurfaces.

NOTE

○ Theexhaustcamshafthasa2412EXmark[D]andthe inletcamshafthasa2412INmark[E].Becarefulnot tomixuptheseshafts.

GE11153BH2 C

• Positionthecrankshaftasfollows.
• Pullthetensionside(exhaustside)ofthechaintauto installthechain.
• Engagethecamshaftchainwiththecamshaftsprockets sothatthetimingmarksonthesprocketsarepositioned asshown.
  ○Usingawrenchonthecrankshaftrotationbolt,turnthe crankshaftclockwiseuntilthe2|Tmarkline[A]onthetimingrotorisalignedwiththenotch[B]intheedgeofthe upperhole[C]intheclutchcover.

- If the clutch covers removed, perform then next procedure.

○Usingawrenchonthecrankshaftrotationbolt,turnthe crankshaftclockwiseuntilthe1|Tmarkline[A]onthe timingrotorisalignedwiththewatingsurface[B]ofthe crankcasehalves.

Camshaft,CamshaftChain

OThetimingmarksmustbealignedwiththecylinderhead uppersurface[C]. EXmarkD INmarkE

1Pin[F]

2Pin[G]

31Pin[H]

32Pin[J]

- Installthecamshaftcap, whilepushingthecamshaft chain, tightenallcamshaftboltsandchainguidebolts.

NOTE

○Theexhaustcaphasa“EX”mark[A]andtheinletcaphasa“IN”mark[B].Becarefulnottomixupthesecaps.

○Firsttightenallthecamshaftcapboltsevenlytoseatthe camshaftinplace, thentightenallboltsfollowingthespecifiedtighteningsequence.

Torque-CamshaftCapBolts(1\~12):12N·m(1.2kgf·m, 106in·lb)

- Install: CamshaftChainTensioner(seeCamshaftChainTensionerInstallation) CylinderHeadCover(seeCylinderHeadCoverInstallation)

Camshaft, CamshaftChain

CamshaftandSprocketAssembly

○Theinletandexhaustsprocketsareidentical.

- Installthesprocketssothatthemarked("IN"and"EX") sidefacestotherightside.

CAUTION

Inletsprocketmustuse“IN”markedboltsholes[A]. Exhaustsprocketmustuse“EX”markedbolts holes[B].

- Applyanon-permanentlockingagenttothecamshaft sprocketsboltsandtightenthem.

Torque-CamshaftSprocketsBolts:15N·m(1.5kgf·m,11ft·lb)

★Ifanewcamshaftistobeused,applyathincoatofa molybdenumdisulfidegreasetothecamsurfaces.

Camshaft, Camshaft Cap Wear

- Remove:

CamshaftCaps(seeCamshaftRemoval)

- Cutstripsofplastigagetojournalwidth.Placeastrip oneachjournalparalleltothecamshaftinstalledinthe correctposition.

- Measureeachclearancebetweenthecamshaftjournal andthecamshaftcapusingplastigage(pressgauge)[A].

- Tighten:

Torque-CamshaftCapBolts:12N·m(1.2kgf·m,106in·lb)

NOTE

○ Donotturnthecamshaftwhentheplastigageisbetweenthejournalandcamshaftcap.

CamshaftJournal, CamshaftCapClearance

Standard: 0.028 \~ 0.071 mm (0.0011 \~ 0.0028 in.) ServiceLimit:0.16mm(0.0063in.)

★Ifanyclearanceexceedstheservicelimit,measurethe diameterofeachcamshaftjournalwithamicrometer.

CamshaftJournalDiameter

Standard: 23.950 \~ 23.972 mm (0.9429 \~ 0.9438 in.) ServiceLimit: 23.92mm(0.942in.)

★Ifthecamshaftjournaldiameterislessthantheservice limit, replacethecamshaftwithanewoneandmeasure theclearanceagain.

★Iftheclearancestillremainsoutofthelimit,replace the cylinderheadunit.

Camshaft,CamshaftChain

CamshaftRunout

• Removethecamshaft(seeCamshaftRemoval).
• SetthecamshaftinacamshaftalignmentjigoronV blocks.
• Measurerunoutwithadialgaugeatthespecifiedplace asshown.
  ★ Iftherunoutexceedstheservicelimit, replacetheshaft.

CamshaftRunout

Standard: TIR0.02mm(0.0008in.) or less

ServiceLimit:TIR0.1mm(0.004in.)

Technical line drawing of a mechanical assembly with pressure gauge and mounting base (no text or symbols)

CamWear

• Removethecamshaft(seeCamshaftRemoval).
• Measuretheheight[A]ofeachcamwithamicrometer.
  ★ Ifthecamsareworndownpasttheservicelimit,replace thecamshaft.

CamHeight

Standard:

Exhaust 35.843 \~ 35.957 mm (1.4111 \~ 1.4156 in.)

Inlet 36.543 \~ 36.657 mm (1.4387 \~ 1.4432 in.)

ServiceLimit:

Exhaust 35.74mm(1.4071in.)

Inlet 36.44mm(1.4346in.)

CamshaftChainRemoval

• Splitthecrankcase(seeCrankcaseSplittingintheCrankshaft/Transmissionchapter).
• Removethecamshaftchain[A]fromthecrankshaft sprocket.

Mechanical assembly diagram showing gears and shafts in a vehicle (no text or symbols visible)

CylinderCompressionMeasurement

NOTE

○ Usethebatterywhichisfullycharged.

● Warmuptheenginethoroughly.
- Stoptheengine.
- Remove:

Seat(seeSeatRemovalintheFramechapter)

FuelTank(seeFuelTankRemovalintheFuelSystem (DFI)chapter)

AirCleanerHousing(seeAirCleanerHousingRemoval intheFuelSystem(DFI)chapter)

StickCoils(seeStickCoil(IgnitionCoiltogetherwith SparkPlugCap)RemovalintheElectricalSystemchapter)

SparkPlugs(seeSparkPlugReplacementinthePeriodicMaintenancechapter)

Owner's Tool-SparkPlugWrench, 16mm:92110-1132

NOTE

○ Reconnecttheconnectorsoftheairswitchingvalve leadandtheinletairtemperaturesensorlead. When theignitionswitchisturnedONwiththeaboveconnec-torsdisconnected,theservicecodes(13,64)arestores intheECU.

• Attachthecompressiongauge[A]andadapter[B]firmly intothesparkplughole.
  ○Usingthestartermotor,turntheengineoverwiththethrottlefullyopenuntilthecompressiongaugestopsrising;the compressionisthehighestreadingobtainable.

SpecialTools-Compression Gauge,20 kgf/cm²:57001-221

CompressionGaugeAdapter, M10×1.0:

57001-1317

CylinderCompression

UsableRange: 961 \~ 1 471 kPa (9.8 \~ 15.0 kgf/cm², 139

\~ 213psi)@400r/min(rpm)

• Repeatthemeasurementfortheothercylinders.
  • Installthesparkplugs.

Torque-SparkPlugs:15N·m(1.5kgf·m,11ft·lb)

CylinderHead

The following tables should be consulted if the obtainable compression reading is not within the usability range.

ProblemDiagnosis	sisRemedy(Action)
Cylindercompression ishigherthanusable range	Carbonaccumulationonpistonandin combustionchamberpossiblydueto damagedvalvestemoilsealand/or damagedpistonoilrings(Thismaybe indicatedbywhiteexhaustsmoke).	Removethecarbondeposits andreplacedamagedpartsif necessary.
	Incorrectcylinderheadgasket thickness	Replacethegasketwithastandard part.
Cylindercompression islowerthanusable range	Gasleakagearoundcylinderhead	Replacedamagedgasketand checkcylinderheadwarp.
	BadconditionofvalveseatingRepairifnecessary.
	IncorrectvalveclearanceAdjustthevalveclearance.
	Incorrectpiston/cylinderclearanceReplace thepistonand/orcylinder.
	Pistonseizure	Inspectthecylinderand replace/repairthecylinderand/or pistonasnecessary.
	Badconditionofpistonringand/or pistonringgrooves	Replacethepistonand/orthe pistonrings.

CylinderHeadRemoval

- Remove:

ExhaustPipes(seeExhaustPipeRemoval)

CylinderHeadCover(see CylinderHead Cover Removal)

Camshafts(seeCamshaftRemoval)

ThrottleBodyAssy(see ThrottleBodyAssyRemovalin theFuelSystem(DFI)chapter)

ThrottleBodyHolder

Water Hose

WaterTemperatureSensorConnector[A]

FrontCamshaftChainGuide

Close-up of mechanical components with labeled parts (A) and no visible text or symbols

5-22ENGINETOPEND

CylinderHead

• FirstlyremovetheM6cylinderheadboltsandM6cylinder bolts[A].
• Secondly,removetheM8bolts[B].
• Thirdly,removetheM10nut[C].
• Fourthly,removetheM10bolts[D].

CylinderHeadInstallation

NOTE

○ Thecamshaftcapismachinedwiththecylinderhead, soifanewcylinderheadisinstalled,usethecapthat issuppliedwiththenewhead.

- Installanewcylinderheadgasket[A]anddowelpins[B].

CylinderHead

- Applymolybdenumdisulfideoilsolution[A]tobothsides ofwashersandthethreadsofboltsandnut.

M10CylinderHeadBolts[B]

M10CylinderNut[C]

M8CylinderBolt[D]

- Torquethealltheboltsandnutfollowingthetightening sequence[1\~8].

Torque-CylinderHeadBolts(M10):

First:25N·m(2.5kgf·m,18ft·lb)

Final:

UsedBolts49N·m(5.0kgf·m,36ft·lb)

NewBolts54N·m(5.5 k g f · m, 40 ft · lb)

CylinderNut(M10):49N·m(5.0kgf·m,36ft·lb)

CylinderBolt(M8):27.5N·m(2.8kgf·m,20ft·lb)

NOTE

○ThetighteningsequenceNo.1 \~ No.5arethecylinder headboltsthataretightenedbetweenthecylinderhead withthecrankcase.
○TheNo.6isthecylinderheadboltthatistightenedbetweenthecylinderheadwiththecylinder.
○TheNo.7andNo.8arethecylindernutandcylinder boltthataretightenedbetweenthecylinderandthe crankcase.

5-24ENGINETOPEND

CylinderHead

- TightentheM6cylinderheadboltsandM6cylinderbolts [A].

Torque-CylinderHeadBolts(M6):12N·m(1.2kgf·m,106 in·lb)

CylinderBolts(M6):12N·m(1.2kgf·m,106in·lb)

• Installthefrontcamshaftchainguide[A].
○Inserttheend[B]offrontcamshaftchainguideintothe hollowonthelowercrankcasehalf.
- Installtheremovedparts(seeappropriatechapters).

CylinderHeadWarp

• Cleanthecylinderhead.
• Layastraightedgeacrossthelowersurfaceofthecylinder headatseveralpositions.
• Useathicknessgauge[A]tomeasurethespacebetween thestraightedge[B]andthehead.

CylinderHeadWarp

Standard: ---

ServiceLimit:0.05mm(0.002in.)

★Ifthecylinderheadiswarpedmorethantheservicelimit, replaceit.
★Ifthecylinderheadiswarpedlessthantheservicelimit, repairtheheadbyrubbingthelowersurfaceonemery papersecuredtoasurfaceplate(firstNo.200,thenNo.400).

Valves

ValveClearanceInspection

- RefertoValveClearanceInspectioninthePeriodicMaintenancechapter.

ValveClearanceAdjustment

- RefertoValveClearanceAdjustmentinthePeriodic Maintenancechapter.

ValveRemoval

- Removecylinderhead(seeCylinderHeadRemoval).

- Removethevalvelifterandshim.

○Markandrecordthevalvelifterandshimlocationssothey canbeinstalledintheiroriginalpositions.

- Using the valvespringcompressorassembly, remove the valve.

SpecialTools-ValveSpringCompressorAssembly:57001-241[A]

ValveSpringCompressorAdapter, 21: 57001-1272[B]

ValveInstallation

- Replacetheoilsealwithanewone.

○Applyengineoiltotheoilseallip.

- Applyathincoatofmolybdenumdisulfidegreasetothe valvestembeforevalveinstallation.

- Installthespringssothattheclosedcoilendfacesdownwards(thesidepaintedingreenfacesupwards).

ValveStem[A]

OilSeal[B]

SpringSeat[C]

ClosedCoilEnd[D]

ValveSpring[E]

SidePaintedinGreen[F]

Retainer[G]

SplitKeepers[H]

Valve Guide Removal

- Remove:

Valve(seeValveRemoval)

OilSeal

SpringSeat

- Heattheareaaroundthevalveguideto120\~ 150°C(248

\~ 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.

CAUTION

Donotheatthecylinderheadwithatorch. This will warp the cylinderhead. Soakthecylinderhead in oil and heat the oil.

Special Tool - Valve Guide Arbor, 4.5 : 57001-1331

Valves

ValveGuideInstallation

• Applyoiltothevalveguideoutersurfacebeforeinstallation.
• Heattheareaaroundthevalveguideholetoabout120\~150°C(248\~302°F).
• Drivethevalveguideinfromthetopoftheheadusingthe valveguidearbor. Theflangestopstheguidefromgoing intoofar.

SpecialTool-ValveGuideArbor,4.5:57001-1331

• Waituntilthecylinderheadcoolsdownandthenreamthe valveguidewiththevalveguidereamer[A]eveniftheold guideisreused.
  ○Turnthereamerinaclockwisedirectionuntilthereamer turnsfreelyintheguide.Neverturnthereamercounter-clockwiseoritwillbedulled.
  ○Oncetheguidesarereamedtheymustbecleanedthoroughly.

SpecialTool-ValveGuideReamer,4.5:57001-1333

Valve-to-GuideClearanceMeasurement(Wobble Method)

Ifasmallboregaugeisnotavailable,inspectthevalve guidewearbymeasuringthevalvetovalveguideclearance withthewobblemethodasindicatedbelow.

• Insertanewvalve[A]intotheguide[B]andsetadial gaugeagainstthestemperpendiculartoitascloseas possibletothecylinderheadmatingsurface.
• Movethestembackandforth[C]tomeasurevalve/valve guideclearance.
• Repeatthemeasurementinadirectionatarightangleto thefirst.
  ★ Ifthereadingexceedstheservicelimit, replacetheguide.

NOTE

○ Thereadingisnotactualvalve/valveguideclearance becausethemeasuringpointisabovetheguide.

Valve/ValveGuideClearance(WobbleMethod)

Standard:

Exhaust 0.07 \~ 0.14 mm (0.0028 \~ 0.0055 in.)

Inlet 0.02 \~ 0.08 mm (0.0008 \~ 0.0032 in.)

ServiceLimit:

Exhaust 0.27mm(0.0106in.)

Inlet 0.22mm(0.0087in.)

Valves

ValveSeatInspection

• Removethevalve(seeValveRemoval).
• Checkthevalveseatingsurface[A]betweenthevalve[B] andvalveseat[C].
  ○Measuretheoutsidediameter[D]oftheseatingpattern onthevalveseat.
  ★ Iftheoutsidediameteristoolargeortoosmall, repair the seat(seeValveSeatRepair).

ValveSeatingSurfaceOutsideDiameter

Standard:

Exhaust 27.6 \~ 27.8 mm (1.087 \~ 1.094 in.)

Inlet 32.6 \~ 32.8 mm (1.283 \~ 1.291 in.)

○Measuretheseatwidth[E]oftheportionwherethereis nobuild-upcarbon(whiteportion)ofthevalveseatwitha verniercaliper. Good[F]

★ Ifthewidthistoowide[G], toonarrow[H]oruneven[J], repairtheseat(seeValveSeatRepair).

ValveSeatingSurfaceWidth

Standard:

Exhaust 0.5 \~ 1.0 mm (0.020 \~ 0.039 in.)

Inlet 0.5 \~ 1.0 mm (0.020 \~ 0.039 in.)

ValveSeatRepair

- Repairthevalveseatwiththevalveseatcutters[A]. SpecialTools-ValveSeatCutterHolderBar:57001-1128[C] ValveSeatCutterHolder, 4.5:57001 - 1330[B]

ForExhaustValveSeat

ValveSeatCutter,45°- φ30:57001-1187

ValveSeatCutter,32°- φ30:57001-1120

ValveSeatCutter,60°- φ30:57001-1123

ForInletValveSeat

ValveSeatCutter,45°- φ35:57001-1116

ValveSeatCutter,32°- φ35:57001-1121

ValveSeatCutter,55°- φ35:57001-1247

★ Ifthemanufacturer's instructions are not available, use the following procedure.

Valves

SeatCutterOperationCare

1. This valveseatcutterisdeveloped to grind the valve for repair. Therefore the cutterm must not be used for other purpose sthan seat repair.
2. Donotdroporshockthevalveseatcutter, orthedia-mondparticles may falloff.
3. Donotfailtoapplyengineoiltothevalveseatcutter beforegrindingtheseatsurface. Alsowashoffground particlesstickingtothecutterwithwashingoil.

NOTE

○ Donotuseawirebrushtoremovethemetalparticles fromthecutter.Itwilltakeoffthediamondparticles.

1. Setting the valveseat cutterholderinposition, operate the cutterinonehand. Donot apply to much force to the diamond portion.

NOTE

○ Priorogrinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil.

1. After use, washit with washing oil and apply thin layer of engine oil before storing.

MarksStampedontheCutter

Themarksstampedonthebackofthecutter[A]represent the following.

60°....Cutterangle[B]

37.5 ......Outerdiameterofcutter[C]

OperatingProcedures

• Cleantheseatareacarefully.
• Coattheseatwithmachinist'sdye.
• Fita45°cutterintotheholderandslideitintothevalve guide.
• Pressdownlightlyonthehandleandturnitrightorleft. Grindtheseatingsurfaceonlyuntilissmooth.

CAUTION

Donotgrindtheseattoomuch. Overgrindingwill reducevalveclearancebysinkingthevalveintothe head.Ifthevalvesinkstoofarintothehead,itwill beimpossibletoadjusttheclearance,andthecylinderheadmustbereplaced.

Valves

• Measuretheoutsidediameteroftheseatingsurfacewithaverniercaliper.
  ★ Iftheoutsidediameteroftheseatingsurfaceistoosmall, repeatthe45°grinduntilthediameteriswithinthespecifiedrange.

WidenedWidth[A]ofengagementbymachiningwith 45°cutter

GroundVolume[B]by32°cutter 32°[C]

CorrectWidth[D]

GroundVolume[E]by60°or55°cutter

60°or55°[F]

• Measuretheoutsidediameteroftheseatingsurfacewithaverniercaliper.
  ★ Iftheoutsidediameteroftheseatingsurfaceistoosmall, repeatthe45°grind[A]untilthediameteriswithinthe specifiedrange.

OriginalSeatingSurface[B]

NOTE

○Removeallpittingsofflawsfrom45°groundsurface.
○Aftergrindingwith45°cutter,applythincoatofmachinist'sdyetoseatingsurface. Thismakesseatingsurface distinctand32°and60°(or55°)grindingoperationeasier.
○ Whenthevalveguideisreplaced, besuretogrindwith 45°cutterforcenteringandgoodcontact.

★ Iftheoutsidediameter[A]oftheseatingsurfaceistoo large, makethe32°grinddescribedbelow.
★ If the outsided diameter of these seating surface is within the specified range, measure these seat width as described below.
- Grindtheseatata32°angle[B]untiltheseatoutside diameteriswithinthespecifiedrange.
OTomakethe32°grind, fita32°cutterintotheholder, and slideitintothevalveguide.
○Turntheholderoneturnatatimewhilepressingdown verylightly.Checktheseataftereachturn.

CAUTION

The32°cutterremovesmaterialveryquickly. Checktheseatoutsidediameterfrequentlytoppreventovergrinding.

○Aftermakingthe32°grind, return to theseatoutsidediametermeasurementstepabove.
- Tomeasuretheseatwidth, useaverniercalipertomea- surethewidthofthe45°angleportionoftheseatatseveralplacesaroundtheseat.
★ If theseatwidthistoonarrow, repeat the 45° grind until theseatisslightly toowide, and then return to theseat outsidediameter measurement step above.

Valves

★Iftheseatwidthhistoowide,makethe60°or55°[A]grind describedbelow.
★Iftheseatwidthiswithinthespecifiedrange,lapthevalve totheseatasdescribedbelow.
- Grindtheseatata60°or55°angleuntiltheseatwidthis withinthespecifiedrange.
- Tomakethe60°or55°grind, fit60°or55°cutterintothe holder, and slide it into the valve guide.
○Turntheholder,whilepressingdownlightly.
○Aftermakingthe60°or55°grind,returntotheseatwidth measurementstepabove.
CorrectWidth[B]

• Lapthevalvetotheseat, oncetheseatwidthandoutside diameterarewithintherangesspecifiedabove.
• Putalittlecoarsegrindingcompoundonthefaceofthe valveinanumberofplacesaroundthevalvehead.
  ○Spinthevalveagainsttheseatuntilthegrindingcompoundproducesasmooth, matchedsurfaceonboththe seatandthevalve.
  ○Repeat the process with a fine grinding compound.
  Lapper[A] ValveSeat[B] Valve[C]

- Theseatingareashouldbemarkedaboutinthemiddle ofthevalveface.

★Iftheseatareaisnotintherightplaceonthevalve,check tobesurethevalveisthecorrectpart.Ifitis,itmayhave beenrefacedtoomuch;replaceit.

- Besuretoremoveallgrindingcompoundbeforeassembly.

- Whentheengineisassembled,besuretoadjustthevalve clearance(seeValveClearanceAdjustmentinthePeriodicMaintenancechapter).

Valves

graph TD
    A["START"] --> B["Machinist's dye on seat"]
    B --> C["45° Grind"]
    C --> D["Measure Seating Area O.D."]
    D --> E["Tools: Vernier Caliper\nPurpose: check seat O.D.\ngainst spec."]
    E --> F["Results"]
    F --> G["Too small"]
    G --> H["45° Grind\nTool: 45°Cutter\nPurpose: increase O.D. of\ncat area to spec."]
    F --> I["OK"]
    I --> J["Measure Seat Width\nTool: Vernier Caliper\nPurpose: check seat width\nagainst spec."]
    J --> K["Results"]
    K --> L["Too narrow"]
    L --> M["45° Grind\nTool: 45°Cutter\nPurpose: increase width of seat\nta area beyond spec.\nto increase O.D."]
    K --> N["OK"]
    N --> O["Too wide"]
    O --> P["Machinist's dye on seat"]
    P --> Q["60° or 55° Grind\nTool: 60°Cutter\nPurpose: reduce seat width\nto specification."]
    K --> R["Lap Valve\nTools: Valve Lapper,\nGrinding Compound\nPurpose: perfectly match valve\nand seat area; check\nvalve head for damage."]
    R --> S["FINISHED"]

5-32ENGINETOPEND

Cylinder, Pistons

CylinderRemoval

- Remove:

CylinderHead(see CylinderHeadRemoval) Horn

- Remove:

FrontEngineMountingBolts(BothSide)A FrontEngineBrackets(BothSide)B Cylinder[C]

CylinderInstallation

NOTE

○ Ifanewcylinderisused, usenewpistonring.

- Installthedowelpins[A]andnewcylindergasket[B].

- Thepistonringopeningsmustbepositionedasshownin thefigure. Theopeningsoftheoilringsteelrailsmustbe about30\~40°ofanglefromtheopeningofthetopring.

TopRing[A]

SecondRing[B]

OilRingSteelRails[C]

OilRingExpander[D]

Hollow[E]

30\~40°F

- Applymolybdenumdisulfideoilsolutiontothecylinder bore, pistonringsandpiston.

● Preparetwoauxiliaryheadboltswiththeirheadcut.

○Installthetwobolts[A]diagonallyinthecrankcase.

- Positionthecrankshaftsothatallthepistonheadsare almostlevel.

• Installthecylinderblock.

○Insertthepistonringswithyourthumbs.

PistonRemoval

- Removethecylinder(seeCylinderRemoval).

- Placeacleanclothunderthepistonsandremovethepistonpinsnapring[A]fromtheoutsideofeachpiston.

Close-up mechanical assembly showing hoses and components (no visible text or symbols)

Close-up of a mechanical component with labeled parts (A and B) and no readable text or symbols beyond labels

Cylinder, Pistons

- Removethepistonpins.

SpecialTool-PistonPinPuller:57001-1568[A]

PistonPinPullerAdapterC:57001-1657[D]

CenterBolt[B]

ShallofPiston[C]

- Removethepistons.

• Carefullyspreadtheringopeningwithyourthumbsand thenpushupontheoppositesideofthering[A]toremove it.
• Removethe3-pieceoilringwithyourthumbsinthesame manner.

PistonInstallation

• Installtheoilringexpander[A]inthebottompistonring groovesotheends[B]butttogether.
• Installtheoilringsteelrails,oneabovetheexpanderand onebelowit.
  ○Spreadtherailwithyourthumbs,butonlyenoughtofit therailoverthepiston.
  ○Releasetherailintothebottompistonringgroove.

NOTE

○Theoilringrailshaveno "top" or "bottom".

• Donotmixupthetopandsecondring.
• Installthetopring[A]sothatthe"R"mark[B]facesup.
• Installthesecondring[C]sothatthe"RN"mark[D]faces up.

Cylinder, Pistons

NOTE

○ Ifanewpistonisused, usenewpistonring.

• Install the piston with its marking hollow facing forward.
- Fitanewpistonpinsnapringintothesideofthepiston sothattheringopening[A]doesnotcoincidewiththeslit [B]ofthepistonpinhole.
○Applymolybdenumdisulfideoilsolutiontothepistonpins andpistonjournals.
When installing the piston pinsnapring, compressit only enough to install it and nomore.

CAUTION

Donotreusesnaprings,asremovalweakensand deformsthem.Theycouldfalloutandscorethe cylinderwall.

- Installthecylinder(see Cylinder Installation).

CylinderWear

• Sincethereisadifferenceincylinderwearindifferentdirections, takeaside-to-sideandafront-to-backmeasurementateachofthetwolocations(totaloffourmeasurements)showninthefigure.
  ★Ifanyofthecylinderinsidediametermeasurementsexceedstheservicelimit,replacethecylinder. 10mm(0.39in.)[A] 60mm(2.36in.)[B]

CylinderInsideDiameter

Standard: 82.994 \~ 83.006 mm (3.2675 \~ 3.2679 in.)

ServiceLimit:83.10mm(3.2716in.)

PistonWear

• Measuretheoutsidediameter[A]ofeachpiston18mm (0.7087in.)[B]upfromthebottomofthepistonataright angletothedirectionofthepistonpin.
  ★Ifthemeasurementisunderservicelimit, replacethepiston.

PistonDiameter

Standard: 82.969 \~ 82.984 mm (3.2665 \~ 3.2671 in.)

ServiceLimit:82.82mm(3.2606in.)

GE10144BS1 C

GE10145851 C

GE10146851 C

Cylinder, Pistons

PistonRing, PistonRingGrooveWear

• Checkforunevengroovewearbyinspectingtheringseating.
  ★Theringsshouldfitperfectlyparalleltogroovesurfaces. Ifnot, replacethepistonandallthepistonrings.
• With the piston rings in their grooves, makes several measurements with a thickness gauge [A] to determine piston ring/groove clearance.

PistonRing/GrooveClearance

Top

Standard: 0.03 \~ 0.07 mm (0.0012 \~ 0.0028 in.)

ServiceLimit:0.17mm(0.0067in.)

Second

Standard: 0.02 \~ 0.06 mm (0.0008 \~ 0.0024 in.)

ServiceLimit:0.16mm(0.0063in.)

PistonRingGrooveWidth

• Measurethepistonringgroovewidth.
  ○Useaverniercaliperatseveralpointsaroundthepiston.

PistonRingGrooveWidth

Top[A]

Standard: 0.92 \~ 0.94 mm (0.0362 \~ 0.0370 in.)

ServiceLimit:1.02mm(0.040in.)

Second[B]

Standard: 1.01 \~ 1.03 mm (0.0398 \~ 0.0406 in.)

ServiceLimit:1.11mm(0.044in.)

★ If the width of any of the two grooves is wider than the servicelimitat anypoint, replacethepiston.

PistonRingThickness

● Measure the piston ring thickness.
○Usethemicrometertomeasureatseveralpointsaround thering.

PistonRingThickness

Top[A]

Standard: 0.87 \~ 0.89 mm (0.0342 \~ 0.0350 in.)

ServiceLimit: 0.80mm(0.031in.)

Second[B]

Standard: 0.97 \~ 0.99 mm (0.0382 \~ 0.0390 in.)

ServiceLimit: 0.90mm(0.035in.)

★ Ifanyofthemeasurementsislessthantheservicelimit oneitheroftherings,replacealltherings.

NOTE

○Whenusingnewringsinausedpiston,checkforunevengroovewear. Theringsshouldfitperfectlyparallel tothegroovesides. Ifnot,replacethepiston.

Cylinder, Pistons

PistonRingEndGap

• Placethepistonring[A]insidethecylinder,usingthepistontolocatetheringsquarelyinplace.Setitclosetothe bottomofthecylinder,wherecylinderwearislow.
• Measurethegap[B]betweentheendsoftheringwitha thicknessgauge.

PistonRingEndGap

Top

Standard: 0.25 \~ 0.40 mm (0.0098 \~ 0.0157 in.)

ServiceLimit:0.7mm(0.028in.)

Second

Standard: 0.40 \~ 0.55 mm (0.0157 \~ 0.0217 in.)

ServiceLimit:0.8mm(0.031in.)

★Iftheendgapofeitherringisgreaterthantheservice limit,replacealltherings.

ThrottleBodyHolder

ThrottleBodyHolderInstallation

• BesuretoinstalltheO-rings[A].
• Installtheclamps[B]asshownandsothattheirprojec-tionsfit[C]ontheholesoftheholders.
  ○Besurethattheclampboltheads[D]faceoutwards.

- Tighten:

Torque-ThrottleBodyHolderBolts[E]:12N·m(1.2kgf·m, 106in·lb)

Muffler

A WARNING

Toavoidaseriousburn, donotremovethemuffler whentheengineisstillhot. Waituntilthemuffler cooldown.

MufflerBodyRemoval

- Remove:

RightFrameCover(seeFrameCoverRemovalinthe Framechapter)

- Removetheboltsandliftuptherightfootpegstay[A].

- Removethemufflerbodymountingbolts[A]andnut,and pullthemufflerbody[B]backward.

ExhaustPipeRemoval

- Remove:

LowerFairing(seeLowerFairingRemovalintheFrame chapter)

CenterFairing(seeCenterFairingRemovalinthe Framechapter)

MufflerBodyClampBolt[A]

ExhaustPipeManifoldHolderNuts[B]

ExhaustPipe[C]

Gaskets

Mechanical assembly diagram showing a car chassis with labeled component A (no readable text or symbols)

Muffler

MufflerBodyandExhaustPipeInstallation

- Replacetheexhaustpipegaskets[A]andmufflerbody connectiongasket[B]withnewonesandinstallthem.

○Installthemufflerbodyconnectiongasketuntilitisbot-tomedsothatthechamferside[C]fecesmufflerbody[D].

- Install: MufflerBody ExhaustPipe[E]

- Tighten:

Torque-ExhaustPipeManifoldHolderNut[F]:17N·m(1.7 kgf·m,12ft·lb) MufflerBodyMountingBolts(FrontandRear)[G]: 20N·m(2.0kgf·m,15ft·lb)

- Tightenthemufflerbodyclampbolts[H].

○Installthemufflerbodyclampbolt[H]asshown.

GE18024BH2 C

- Thoroughlywarmuptheengine, waituntiltheengine coolsdown, andretightenalltheboltsandnuts.

Clutch

TableofContents

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

ClutchLeverFreePlayAdjustment....6-6

Clutch Cable Removal 6-6

Clutch Cable Installation 6-6

Clutch Cable Lubrication.... 6-6

Clutch Lever Installation.... 6-7

Clutch Lever Adjustment.... 6-7

Clutch Cover 6-8

Clutch Cover Removal 6-8

Clutch Cover Installation 6-8

Release Shaft Removal 6-9

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

ClutchPlate,Wear,DamageInspection....6-13

Clutch Plate Warp Inspection.... 6-13

Clutch Spring Free Length Measurement 6-14

Clutch Housing Finger Inspection 6-14

Clutch Housing Spline Inspection 6-14

ExplodedView

No.F	Fastener	Torque			Remarks
		N·mkgf	·mft·lb
1	UpperCaponClutchCover3.90.4035in·lb
2	LowerCaponClutchCover—Hard-tighten
3	OilFillerPlug—Hard-tighten
4	ClutchCoverMountingBolts	9.8	1.0	87in·lb
5	Clutch Spring Bolts	9.8	1.0	87 in·lb
6	Clutch Hub Nut	132	13.5	98	R
7	Oil Pump Sprocket Bolt	12	1.2	106 in·lb	L, Lh
8	Clutch Lever Clamp Bolts	7.8	0.80	69 in·lb	S
9	Oil Pump Chain Guide Bolts	12	1.2	106 in·lb	L
10	ClutchCableHolderBolts	9.8	1.0	87 in·lb	L
11	Clutch Cable Clamp Bolt	9.8	1.0	87 in·lb

CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
HG: Applyhigh-temperature grease.
Lh: Left-hard Threads
M: Applymolybdenum disulfidegrease.
R: Replacement Parts
W: Applywater.

Specifications

ItemStandardServiceLimit
Clutch Lever Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)	-- --
Clutch
Friction Plate Thickness	2.92 ~ 3.08 mm (0.115 ~ 0.121 in.)	2.8 mm (0.110 in.)
Friction Plate Warp	0.15 mm (0.16 in.) or less	0.3 mm (0.012 in.)
Steel Plate Warp	0.2 mm (0.008 in.) or less	0.3 mm (0.012 in.)
Clutch Spring Free Length	33.6 mm (1.32 in.)	32.6 mm (1.28 in.)

SpecialToolandSealant

ClutchHolder: 57001-1243

Technical line drawing of a mechanical clamp or bracket assembly (no text or symbols)

KawasakiBond(SiliconeSealant): 92104-0004

ClutchLeverandCable

ClutchLeverFreePlayInspection

- RefertoClutchOperationInspectioninthePeriodicMaintenancechapter.

ClutchLeverFreePlayAdjustment

- RefertoClutchOperationInspectioninthePeriodicMaintenancechapter.

ClutchCableRemoval

- Removetherightframecover(seeFrameCoverRemoval intheFramechapter).

- Slidethedustcover[A]atthemiddleofclutchcableout ofplace.

- Loosenthelocknut[B], and turnthead adjusting nut[C] to givethecable plenty of play.

- Screwintheadjuster.

- Lineuptheslots[A]intheclutchleverandadjuster[B], and thenfreethecablefromthelever.

- Freetheclutchinnercabletipfromtheclutchrelease lever.

- Disconnecttheclutchcableclamp[A]onthecylinder headcover.

- Pulltheclutchcableoutoftheframe.

ClutchCableInstallation

- Runtheclutchcablecorrectly(seeCable, Wire, and Hose RoutingsectionintheAppendixchapter).

- Adjusttheclutchcable(seeClutchOperationInspection inthePeriodicMaintenancechapter).

ClutchCableLubrication

- RefertoChassisPartsLubricationinthePeriodicMaintenancechapter.

Technical line drawing of a mechanical device with labeled component A (no text or symbols beyond label)

ClutchLeverandCable

ClutchLeverInstallation

• Installtheclutchleversothatthematingsurface[B]ofthe clutchleverclampisalignedwiththepunchmark[A].
• Tightentheupperclampboltfirst, andthenthelower clampbolt. Therewillbeagapatthelowerpartofthe clampaftertightening.

Torque-ClutchLeverClampBolts:7.8N·m(0.80kgf·m,69in·lb)

ClutchLeverAdjustment

Theadjusterhas5positionssothattheclutchleverpositioncanbeadjustedtosuittheoperator'shand.

• Pushtheleverforwardandturntheadjuster[A]toalign thenumberwiththearrowmark[B]ontheleverholder.
  ○The distance from the griptotheleveris minimum at number 5 and maximum at number 1.

ClutchCover

ClutchCoverRemoval

- Remove:

EngineOil(drain,seeEngineOilChangeinthePeriodic Maintenancechapter) RightFrameCover(seeFrameCoverRemovalinthe Framechapter) ClutchCableLowerEnd[A] ClutchCoverMountingBolts[B]

• Turnthereleaselever[A]towardtherearasshown,and removetheclutchcover[B]. About90°[C]
• Pushthereleaselevertowardthefrontofthemotorcycle andtapethereleaselevertotheclutchcovertoprevent thereleaseshaftfromfallingout.

Mechanical component diagram showing a central circular component with labeled points A and B, surrounded by mechanical parts (no readable text or symbols)

ClutchCoverInstallation

- Applysiliconesealanttothearea[A]wherethemating surfaceofthecrankcasetouchestheclutchcovergasket andtothecrankshaftsensorleadgrommet[B].

Sealant-KawasakiBond(SiliconeSealant):92104-0004

• Besurethatthedowelpins[C]areinposition.
• Replacetheclutchcovergasket[D]withanewone.
• Tightentheclutchcovermountingbolts.

Torque-ClutchCoverMountingBolts:9.8N·m(1.0kgf·m, 87in·lb)

ClutchCover

ReleaseShaftRemoval

CAUTION

Donotremovetheclutchreleaseleverandshaft assemblyunlessitisabsolutelynecessary.Ifremoved,theoilsealreplacementmayberequired.

• Removetheclutchcover(seeClutchCoverRemoval).
• Pulltheleverandshaftassemblystraightoutoftheclutch cover.

ReleaseShaftInstallation

• Applyhigh-temperaturegreasetotheoilseallipsonthe upperridgeoftheclutchcover.
• Applyengineoiltotheneedlebearingsintheholeofthe clutchcover.
• Applymolybdenumdisulfidegreasetothepusher-holding portion[A]onthereleaseshaft.
  • Installthewasher[B]andspring[C].
• Insertthereleaseshaftstraightintotheupperholeofthe clutchcover.

CAUTION

Wheninsertingthereleaseshaft,becarefulnotto removethespringoftheoilseal.

• Fitthespring[A]asshown.
  ReleaseShaft[B]
  ClutchCover[C]

ClutchCoverDisassembly

• Remove:
  OilSeal[A]
  NeedleBearings[B]

Close-up of a mechanical component with labeled parts A and B, no readable text or symbols beyond labels

ClutchCover

- Removetheoillevelgauge[A].

ClutchCoverAssembly

- Replacetheneedlebearingsandoilsealwithnewones.

NOTE

○ Installtheneedlebearingssothatthemanufacture's markfaceout.

- Installtheneedlebearings[A]andoilseal[B]positionas shown.

Press[C]thebearingsothathebearingsurface[D]is flushwiththehousingendofclutchcover[E].

- Applywatertotherubberoftheoilgauge[A]andpress [C]itsothatthering[B]faceoutside.

Clutch

ClutchRemoval

- Remove:

EngineOil(drain,seeEngineOilChangeinthePeriodic Maintenancechapter)
ClutchCover(seeClutchCoverRemoval)
ClutchSpringBolts[A]
ClutchSprings
ClutchSpringPlateB

- Remove:

FrictionPlates,SteelPlates ClutchHubNut[A]

○Holdingtheclutchhub[B],removethenutandwasher.

SpecialTool-ClutchHolder[C]:57001-1243

- Remove:

ClutchHub Spacer

- Removetheoilpumpsprocketboat[A].

NOTE

○Theoilpumpsprocketbolthasaleft-handthreads.

• Usingthehole[B], pulloutthesleeve[C].

- Removethefollowingasaset.

ClutchHousing[D] OilPumpChain[E] OilPumpSprocket[F]

- Unscrewthebolts[A]andremovetheoilpumpchain guide[B].

ClutchInstallation

- Applyanon-permanentlockingagenttotheoilpump chainguideboltsandtightenthem.

Torque-OilPumpChainGuideBolts:12N·m(1.2kgf·m, 106in·lb)

- Puttheoilpumpchain[A]ontheclutchhousinggear[B] andtheoilpumpsprocket[C].

Mechanical gear assembly diagram showing internal components labeled A and B (no text or symbols beyond labels)

Clutch

- Besurethatthespacer[A]isinposition.

• Insertthefollowingonthedriveshaft. ClutchHousing[A]withChain[B]andSprocket[C] Sleeve[D]
• Align[E]theholeontheoilpumpsprocketwiththeoil pumpshaft.

- Installthefollowingpartsonthedriveshaft. Spacer[A] ClutchHub[B] Washer[C] Nut[D]

○InstallthewashersothattheOUTSIDEmark[A]faces outward.

Close-up mechanical assembly showing gears and a central component (no visible text or symbols)

Close-up of a mechanical component with labeled point A and reference number GF00851 P (no readable text or symbols beyond labels)

- Replacetheclutchhubnutwithanewone. - Holdingtheclutchhub,tightentheclutchhubnut. SpecialTool-ClutchHolder:57001-1243 Torque-ClutchHubNut:132N·m(13.5kgf·m,98ft·lb)

Clutch

- Install the friction plates and steel plates, starting with a friction plate and alternating them.

CAUTION

If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plateto avoid clutch plates seizure.

○Forthefirststeelplate[A],itsthicknessis2.6mm(0.10 in.).Theothersare2.3mm(0.09in.).

○Installthelastfrictionplate[A]fittingthetangsinthe groovesinthehousingasshown.

Technical illustration of a mechanical gear assembly with labeled component A (no text or symbols beyond label)

• Applymolybdenumdisulfidegreasetothepusherends [A]andinstallitintheclutchspringplate[B].
  ○Applyengineoiltothebearing[C].
• Installtheclutchspringplateandsprings[D], andtighten theclutchspringbolts[E].

Torque-ClutchSpringBolts:9.8N·m(1.0kgf·m,87in·lb)

- Installtheclutchcover(seeClutchCoverInstallation).

ClutchPlate, Wear, DamageInspection

• Visually inspect the friction and steel plates for sign of seizure, overheating (discoloration), or uneven wear.
• Measurethethicknessofeachfrictionplate[A]atseveral points.
  ★Ifanyplatesshowsignsofdamage,oriftheyhaveworn pasttheservicelimit,replacethemwithnewones.

FrictionPlateThickness

Standard: 2.92 \~ 3.08 mm (0.115 \~ 0.121 in.)

ServiceLimit:2.8mm(0.110in.)

ClutchPlateWarpInspection

• Placeeachfrictionplateorsteelplateonasurfaceplate andmeasurethegapbetweenthesurfaceplate[A]and eachfrictionplateorsteelplate[B]withathicknessgauge [C].Thegapistheamountoffrictionorsteelplatearp.
  ★ Ifanyplateiswarpedovertheservicelimit, replaceitwith anewone.

FrictionandSteelPlateWarp

Standard:0.15mm(0.006in.)orless

ServiceLimit:0.3mm(0.012in.)

Clutch

ClutchSpringFreeLengthMeasurement

• Measurethefreelengthoftheclutchsprings[A].
  ★Ifanyspringisshorterthantheservicelimit, it must be replaced.

ClutchSpringFreeLength

Standard:33.6mm(1.32in.)

ServiceLimit:32.6mm(1.28in.)

ClutchHousingFingerInspection

• Visuallyinspecttheclutchhousingfingers[A]wherethe frictionplatetangs[B]hitthem.
  ★Iftheyarebadlywornoriftherearegroovecutswherethe tangshit,replacethehousing.Also,replacethefriction platesiftheirtangsaredamaged.

ClutchHousingSplineInspection

• Visuallyinspectwheretheteeth[B]onthesteelplates wearagainsttheclutchhubsplines[A].
  ★Iftherearenotcheswornintothesplines,replace the clutchhub.Also,replacethesteelplatesiftheirteethare damaged.

EngineLubricationSystem

TableofContents

Exploded View 7-2

Engine Oil Flow Chart.... 7-4

Specifications 7-6

Special Tools and Sealant 7-7

Engine Oil and Oil Filter 7-8

Oil Level Inspection.... 7-8

Engine Oil Change 7-8

Oil Filter Replacement 7-8

Oil Pan 7-9

Oil Pan Removal 7-9

Oil Pan Installation 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 7-13

Oil Pressure Measurement.... 7-14

Oil Pressure Measurement 7-14

Oil Pressure Switch 7-15

Oil Pressure Switch Removal 7-15

Oil Pressure Switch Installation 7-15

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1EngineOilDrainBolt202.015
2FilterPlateBolts9.81.087in·lbL
3	Oil Filter	17.2	1.75	13	EO, R
4	Holder Mounting Bolt	25	2.5	18	L
5	Oil Pan Bolts	12	1.2	106 in·lb
6	Oil Pipe Plate Bolt	9.8	1.0	87 in·lb	L
7	Oil Pressure Relief Valve	15	1.5	11	L
8	Oil Pressure Switch	15	1.5	11	SS
9	Oil Pump Cover Bolts	9.8	1.0	87 in·lb	L
10	OilPumpSprocketBolt	12	1.2	106 in·lb	L, Lh
11	Oil Passage Plugs	20	2.0	15	L
12	Lower Fairing Bracket Bolts	12	1.2	106 in·lb	L
13	OilPump ChainGuideBolts	12	1.2	106 in·lb	L
14	Oil Plate Bolts	9.8	1.0	87 in·lb	L

EO: Applyengineoil.
G: Applygrease.
L: Applyanon-permanentlockingagent.
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: ReplacementParts
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

7-4 ENGINE LUBRICATION SYSTEM

EngineOilFlowChart

EngineOilFlowChart

Specifications

ItemStandard
EngineOilTypeViscositySAE10W-40Capacity:1.7L(1.8USgt)(whenfilterisnotremoved)LevelBetweenupperandlower	APISE,SForSGAPISH,SJorSLwithJASOMA1.9L(2.0USgt)(whenfilterisremoved)2.4L(2.5USgt)(whenengineiscompletelydry)evellines
OilPressureMeasurementOil Pressure	216 ~ 294 kPa (2.2 ~ 3.0 kgf/cm2, 31 ~ 43 psi) @4 000 r/min (rpm), OilTemperature90°C(194°F)

SpecialToolsandSealant

OilPressureGauge,10kgf/cm²: 57001-164

Line drawing of a pressure gauge with a handle and connector (no text or symbols)

OilPressureGaugeAdapter,PT3/8×19/in.: 57001-1233

Technical line drawing of a mechanical connector (no text or symbols)

OilFilterWrench: 57001-1249

Technical line drawing of a mechanical component with hexagonal base and central nut (no text or symbols)

KawasakiBond(SiliconeSealant): 56019-120

EngineOilandOilFilter

WARNING

Motorcycleoperationwithinsufficient,deteriorated,orcontaminatedengineoilwillcause acceleratedwearandmayresultinengineortransmissionseizure,accident,andinjury.

OilLevelInspection

- Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.

NOTE

○ Situatethemotorcyclesothatitisperpendiculartothe ground.
○ Ifthemotorcyclehasjustbeenused, waitseveralminutesforalltheoiltodraindown.
○ Iftheoilhasjustbeenchanged,starttheengineand runitforseveralminutesatidlespeed. Thisfillstheoil filterwithoil. Stoptheengine,thenwaitseveralminutes untiltheoilsettles.

CAUTION

Racingtheenginebeforetheoilreacheseverypart cancauseengineseizure. Iftheengineoilgetsextremelyloworiftheoilpump oroilpassagescloguporotherwisedonotfunction properly,theoilpressurewarninglightwilllight.If thislightstaysonwhentheengineisrunningabove idlespeed,stoptheengineimmediatelyandfindthe cause.

★Iftheoillevelistoohigh,removetheexcessoil,usinga syringorsomeothersuitabledevice.
★Iftheoillevelistoolow,addthecorrect amountofoil through the oil filter opening. Use the same type and makeofoilthatisalreadyintheengine.

NOTE

○ Iftheengineoiltypeandmakeareunknown,useany brandofthespecifiedoiltotopoffthelevelinpreference torunningtheenginewiththeoillevellow. Thenatyour earliestconvenience,changetheoilcompletely.

EngineOilChange

- RefertoEngineOilChangeinthePeriodicMaintenance chapter.

OilFilterReplacement

- Refer to Oil Filter Replacement in the Periodic Maintenancechapter.

OilPan

OilPanRemoval

- Remove:

EngineOil(drain,seeEngineOilChangeinthePeriodic Maintenancechapter) ExhaustPipe(seeExhaustPipeRemovalintheEngine TopEndchapter) MufflerBody(seeMufflerBodyRemovalintheEngine TopEndchapter) OilPanBolts[A] OilPan[B] Gasket[C] Damper[D]

- Removethefollowingfromtheoilpanasnecessary. FilterPlateBolts[A] FilterPlate[B] Filter[C]

- Removethefollowingfromthelowercrankcasehalfas necessary. OilScreen[A] OilPipePlateBolt[B] OilPipePlate[C] OilPipes[D] OilPressureReliefValve[E]

7-10ENGINELUBRICATIONSYSTEM

OilPan

OilPanInstallation

• ApplygreasetotheO-ringsontheoilpipes[A].
• Installtheoilpipeplate[B]sothatitsguideportion[C]fits thebreatherpipe[D]asshown.
• Applyanon-permanentlockingagenttotheoilpipeplate bolt.

Torque-OilPipePlateBolt[E]:9.8N·m(1.0kgf·m,87in·lb)

★Iftheoilpressurereliefvalve[F]wasremoved,installit.
○Applyanon-permanentlockingagenttothethreads[G] oftheoilpressurereliefvalve,andtightenit.

CAUTION

Donotapplytoomuchnon-permanentlocking agenttothethreads. This may block the oil passage.

Torque-OilPressureReliefValve:15N·m(1.5kgf·m,11ft·lb)

• ApplygreasetotheO-ring[A]ontheoilscreen[B]and installitonthelowercrankcasehalfasshown.

• Besurethedamper[C]isontheendofthebreatherpipe [D].

• Replacetheoilpangasketwithanewone.

• Wheninstallingtheoilpan, align[A]thedamper[B]on thebreatherpipewiththehollow[C]ontheoilpan.

- Tighten: Torque-OilPanBolts:12N·m(1.2kgf·m,106in·lb)

OilPressureReliefValve

OilPressureReliefValveRemoval

- SeeOilPanRemoval.

OilPressureReliefValveInstallation

- SeeOilPanInstallation.

OilPressureReliefValveInspection

- Checktoseeifthevalve[A]slidessmoothlywhenpushingitinwithawoodenorothersoftrod,andseeifitcomes backtoitsseatbyspring[B]pressure.

NOTE

○Inspectthevalveinitsassembledstate.Disassembly andassemblymaychangethevalveperformance.

★Ifanyroughspotsarefoundduringaboveinspection, washthevalvecleanwithahigh-flashpointsolventand blowoutanyforeignparticlesthatmaybeinthevalvewith compressedair.

WARNING

Cleantheoilpressurereliefvalveinawell -ventilatedarea,andtakecarethatthereisno sparkorflameanywhereneartheworkingarea. Becauseofthedangerofhighlyflammableliquids, donotusegasolineorlow-flashpointsolvent.

★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 replacement of individual parts.

7-12ENGINELUBRICATIONSYSTEM

OilPump

OilPumpRemoval

• Drain:
  EngineOil(seeEngineOilChangeinthePeriodicMaintenancechapter)
• Remove:
  Clutch(seeClutchRemovalintheClutchchapter) OilPumpCoverBolts[A] OilPumpCover[B]

- Remove:

InnerRotor[A]forScavengePump OuterRotor[B]forScavengePump

- Remove:

DowelPin[A]

Pin[B]

OilPumpBody[C]withOilPumpShaft[D]andPin

- Remove:

InnerRotor[A]forFeedPump

OuterRotor[B]forFeedPump

OilPump

OilPumpInstallation

• Applymolybdenumdisulfidegreasetotheportion[A]of theoilpumpshaft,asshown.
• Install: OuterRotor[B]forFeedPump InnerRotor[C]forFeedPump OilPumpShaft[D]andPin[E] DowelPin[F] OilPumpBody[G] Pin[H]andInnerRotor[I]forScavengePump OuterRotor[J]forScavengePump OilPumpCover[K]

NOTE

○ Thescavengepumprotorsarewiderthanthefeed pumprotors.

- Applyanon-permanentlockingagenttotheoilpump coverboltsandtightenthem. Torque-OilPumpCoverBolts:9.8N·m(1.0kgf·m,87in·lb)

7-14ENGINELUBRICATIONSYSTEM

OilPressureMeasurement

OilPressureMeasurement

• Removethelowerfairing(seeLowerFairingRemovalin theFramechapter).
• Removetheoilpassageplug, and attach the adapter[A] and gauge[B] to the plughole.

SpecialTools-OilPressureGauge,10kgf/cm²:57001-164 OilPressureGaugeAdapter,PT3/8×19/in.: 57001-1233

• Starttheengineandwarmuptheengine.
• Runtheengineatthespecifiedspeed,andreadtheoil pressuregauge.
  ★Iftheoilpressureismuchlowerthanthestandard,check theoilpump,reliefvalve,and/orcrankshaftbearinginsert wearimmediately.
  ★Ifthereadingismuchhigherthanthestandard,checkthe oilpassagesforclogging.

OilPressure

Standard: 216 \~ 294 kPa (2.2 \~ 3.0 kgf/cm², 31 \~ 43 psi)@4000r/min(rpm),oiltemperature. 90°C(194°F)

• Stoptheengine.
• Removetheoilpressuregaugeandadapter.

WARNING

Takecareagainstburnsformhotengineoilthat willdrainthroughtheoilpassagewhenthegauge adapterisremoved.

- Applyanon-permanentlockingagenttotheoilpassage plug, and installit.

Torque-OilPassagePlug(Right): 20N·m(2.0kgf·m,15ft·lb)

OilPressureSwitch

OilPressureSwitchRemoval

- Removeordrain:

EngineOil(seeEngineOilChangeinthePeriodicMaintenancechapter)

SwitchCover[A]

SwitchTerminalBolt[B]

OilPressureSwitch[C]

OilPressureSwitchInstallation

- Applysiliconesealanttothethreadsoftheoilpressure switchandtightenit.

Sealant-KawasakiBond(SiliconeSealant):56019-120

Torque-OilPressureSwitch:15N·m(1.5kgf·m,11ft·lb)

- Tightentheterminalboltsecurely.

- Applyasmallamountgreasetotheterminalsothat greaseshouldnotclosetheholes[A]oftheswitchcover.

Pure mechanical part diagram with no text, numbers, or symbols

EngineRemoval/Installation

TableofContents

Exploded View 8-2

Engine Removal/Installation 8-4

Engine Removal 8-4

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1EngineMountingBracketBolts252.518
2FrontEngineMountingBolts444.532
3RearEngineMountingNuts444.532

1. EngineMountingBrackets
   5.Collar

8-4 ENGINEREMOVAL/INSTALLATION

EngineRemoval/Installation

EngineRemoval

• Supporttherearpartoftheswingarmwithastand.
• Squeezethebrakeleverslowlyandholditwithaband [A].

WARNING

Besuretoholdthefrontbrakewhenremovingthe engine,orthemotorcyclemayfallover.Itcould causeanaccidentandinjury.

Close-up of a motorcycle's handle and lever assembly with labeled component A (no text or symbols beyond label)

CAUTION

Besuretoholdthefrontbrakewhenremovingthe engine,orthemotorcyclemayfallover.Theengine orthemotorcyclecouldbedamaged.

• Drain:
  EngineOil(seeEngineOilChangeinthePeriodicMaintenancechapter)
  Coolant(seeCoolantChangeinthePeriodicMaintenancechapter)
• Remove:
  Seat(seeSeatRemovalintheFramechapter)
  LowerFairingandCenterFairing(seeFairingsectionin theFramechapter)
  SideCovers(seeSideCoverRemovalintheFrame chapter)
  FrameCovers(seeFrameCoverRemovalintheFrame chapter)
  RadiatorandHoses(seeRadiatorandRadiatorFanRemovalintheCoolingSystemchapter)
• Unscrewthelowerfairingbracketbolts(bothsides)[A] andremovethebrackets(bothsides)[B].
• Disconnecttheoilpressureswitchterminal[A].

Mechanical assembly diagram showing components with no visible text or symbols

EngineRemoval/Installation

- Disconnectthecrankshaftsensorleadconnector[A].

Close-up mechanical assembly showing a valve labeled 'A' and a circular component (no readable text or symbols)

- Remove:

ExhaustPipe(see Exhaust Pipe Removal in the Engine Top End chapter)

MufflerBody(see MufflerBody Removal in the Engine Top End chapter)

FuelTank(seeFuelTankRemovalintheFuelSystem (DFI)chapter)

AirSwitchingValveandHose(seeAirSwitchingValveRemovalintheEngineTopEndchapter)

AirCleanerHousing(seeAirCleanerHousingRemoval intheFuelSystem(DFI)chapter)

ThrottleBodyAssy(see ThrottleBodyRemovalinthe FuelSystem(DFI)chapter)

ClutchCable(seeClutchCableRemovalintheClutch chapter)

- Remove:

StickCoils[A]

BafflePlate[B]

- Removeordisconnect:

WaterTemperatureSensorLeadConnector[A] StarterMotorCable[B]

EngineGroundCableTerminalBolt[C]

AlternatorLeadConnector[D]

SidestandSwitchLeadConnector[E]

SpeedSensorLeadConnector[F]

8-6ENGINEREMOVAL/INSTALLATION

EngineRemoval/Installation

- Removetheenginesprocketcover(seeEngineSprocketRemovalintheFinalDrivechapter).

- RemovetheshiftpedalA.

- Disconnect: OxygenSensorLeadConnector[B] NeutralSwitchLeadTerminal[C]

- Removethebracket[D]andtheenginesprocketE.

- Remove: HornLeadsA HornBolt[B] Horn[C]

- Supporttheenginewithastandorjack[A].

○Putawoodenboard[B]onthesuitablestand.

- Removetheenginemountingbolts[C].

- Removetheenginemountingbracketbolts(bothsides) [D]andremovethebrackets[E].

- Removetheengine[F].

- Inserttherearenginemountingboltsfromtheleftsideof theengineandtightenthenuts.

- Installtheenginemountingbrackets[A]withthebolts[B].

- Insertthefrontenginemountingbolts[C]andtightenthe bolts.

○Positionthecollar[D]ontherightenginemounting bracket.

EngineRemoval/Installation

- Tighten:

Torque-RearEngineMountingNuts:44N·m(4.5kgf·m,32ft·lb)

FontEngineMountingBolts:44N·m(4.5kgf·m, 32ft·lb)

EngineMountingBracketbolts:25N·m(2.5kgf·m, 18ft·lb)

• Installtheenginesprocket(seeEngineSprocketInstallationintheFinalDrivechapter).
• Runtheleads, cables, and hosescorrectly (see Cable, Wire, and HoseRoutingsection in the Appendix chapter).
• Installtheremovedparts(seeappropriatechapters).
• Adjust:

ThrottleCables(see ThrottleControlSystemInspection inthePeriodicMaintenancechapter)

ClutchCable(seeClutchOperationInspectioninthePeriodicMaintenancechapter)

DriveChain(seeDriveChainSlackAdjustmentinthe PeriodicMaintenancechapter)

- Filltheenginewithengineoil(seeEngineOilChangein thePeriodicMaintenancechapter).

- Filltheenginewithcoolantandbleedtheairfromthecoolingsystem(seeCoolantChangeinthePeriodicMaintenancechapter).

- Adjusttheidling(seeIdleSpeedAdjustmentinthePeriodicMaintenancechapter).

Crankshaft/Transmission

TableofContents

ExplodedView....9-2

Specifications....9-6

SpecialToolsandSealant....9-9

CrankcaseSplitting....9-10

CrankcaseSplitting......9-10

CrankcaseAssembly....9-11

CrankshaftandConnectingRods.....9-17

CrankshaftRemoval....9-17

CrankshaftInstallation......9-17

ConnectingRodRemoval......9-17

ConnectingRodInstallation......9-18

Crankshaft/ConnectingRod Cleaning....9-21

ConnectingRodBend......9-21

ConnectingRodTwist......9-22

ConnectingRodBigEndSide Clearance....9-22

ConnectingRodBigEndBearing Insert/CrankpinWear....9-22

CrankshaftSideClearance......9-24

CrankshaftRunout......9-24

CrankshaftMainBearing Insert/JournalWear....9-24

Balancer....9-27

BalancerRemoval....9-27

BalancerInstallation....9-27

BalancerShaftBearing Insert/JournalClearance......9-27

Transmission.... 9-29

ShiftPedalRemoval....9-29

ShiftPedallInstallation....9-29

ExternalShiftMechanism Removal.... 9-29

ExternalShiftMechanism Installation.... 9-30

ExternalShiftMechanism Inspection.... 9-31

TransmissionAssyRemoval...... 9-32

TransmissionAssyDisassembly. 9-33

TransmissionAssyAssembly.....9-33

TransmissionAssyInstallation..... 9-34

TransmissionShaftRemoval..... 9-35

TransmissionShaftInstallation.... 9-35

TransmissionShaftDisassembly.9-36

TransmissionShaftAssembly.....9-36

ShiftDrumandForkRemoval.....9-39

ShiftDrumandForkInstallation...9-39

ShiftDrumDisassembly......9-39

ShiftDrumAssembly....9-39

ShiftForkBending....9-39

ShiftFork/GearGrooveWear.....9-39

ShiftFork GuidePin/Drum GrooveWear....9-40

GearDogandGearDogHole Damage.... 9-40

BallBearing,NeedleBearing,andOil

Seal.... 9-41

Ball and NeedleBearing Replacement.... 9-41

BallandNeedleBearingWear.....9-41

OilSealInspection....9-41

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1	ConnectingRodBigEndNuts	seeText←	← ←
2TimingRotorBolt404.130
3	Oil Plate Bolts	9.8	1.0	87 in·lb	L
4	Breather Plate Bolts	9.8	1.0	87 in·lb	L
5	Shift Shaft Return Spring Pin	29	2.9	22	L
6	Oil Pipe Bolts	9.8	1.0	87 in·lb	L
7	CrankcaseBolts(M9, L =113mm)	444.532			MO,S
8	Crankcase Bolts (M9, L = 83 mm)	44	4.5	32	MO, S
9	Crankcase Bolts (M8, L = 73 mm)	35	3.6	26	MO, S
10	Crankcase Bolts (M8, L = 60 mm)	35	3.6	26	MO, S
11	Crankcase Bolts (M8, L = 110 mm)	27.5	2.8	20	S
12	Crankcase Bolts (M8, L = 50 mm)	27.5	2.8	20	S
13	CrankcaseBolts(M6)	19.6	2.015		S
14	Upper Crankcase Bolts	27.5	2.8	20	S

1. Donotapplyanygreaseoroil.
   G: Applygrease.
   L: Applyanon-permanentlockingagent.
   LG: Apply liquid gasket (Kawasaki Bond: 92104-1064).
   M: Applymolybdenumdisulfidegrease.
   MO: Applymolybdenumdisulfideoilsolution.
   (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
   R: ReplacementParts
   S: Followthespecifictighteningsequence.
   SS: Applysiliconesealant(ThreeBond1207B).

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1	GearPositioningLeverBolt	121.2106in·lbL
2TransmissionCaseBolts202.015
3	Shift Drum Cam Bolt	12	1.2	106 in·lb	L
4	Shift Drum Bearing Holder Screw	4.9	0.50	43 in·lb	L
5	Shift Rod Plate Bolt	9.8	1.0	87 in·lb
6	Neutral Switch Holder Screw	4.9	0.50	43 in·lb	L
7	NeutralSwitch	151.511
8	Shift Shaft Cover Bolts	9.8	1.0	87 in·lb	(L)
9	Shift Shaft Cover Screw	4.9	0.50	43 in·lb	L

EO:Applyengineoil.

G:Applygrease.

L: Applyanon-permanentlockingagent.

MO:Applymolybdenumdisulfideoilsolution.

(mixtureoftheengineoilandmolybdenumdisulfidegreaseinaweightratio10:1)

R:ReplacementParts

Specifications

ItemStandardServiceLimit
Crankshaft,ConnectingRodsConnectingRodBend-- TIR0.2/100mmConnectingRodTwistConnectingRodBigEndSideClearanceConnectingRodBigEndBearingInsert/Crankpin ClearanceCrankpinDiameter:Marking:None37.984~ 37.992mm○ConnectingRodBigEndInsideDiameter:Marking:None41.000~ 41.008mm○ConnectingRodBigEndBearingInsert Thickness:Brown1.475~ 1.480mmBlack1.480~ 1.485mmBlue1.485~ 1.490mm		0.13~ 0.38mm(0.0051~ 0.0150in.)0.017~ 0.041mm(0.0007~ 0.0016in.)37.984~ 38.000mm(1.4954~ 1.4961in.)		(0.008/3.94in.)TIR0.2/100mm(0.008/3.94in.)0.58mm(0.023in.)0.08mm(0.0031in.)37.97mm(1.4949in.)----
		(1.4954~ 1.4957in.)37.993~ 38.000mm(1.4958~ 1.4961in.)41.000~ 41.016mm(1.6142~ 1.6148in.)		----
		(1.6142~ 1.6145in.)41.009~ 41.016mm(1.6145~ 1.6148in.)		----
		(0.05807~ 0.05827in.)		----
		(0.05827~ 0.05846in.)		----
		(0.05846~ 0.05866in.)		----
ConnectingRodBigEndBearingInsertSelection:
	Con-rodBigEnd BoreDiameter Marking	CrankpinDiameter Marking	BearingInsert
			SizeColorPartNumber
	None	○	Brown92139-0116
	None	None	Black	92139-0115
	○	○
	○	None	Blue	92139-0114
ConnectingRodBoltStretch:(UsableRange)NewConnectingRodUsed Connecting RodCrankshaftSideClearance			0.24~ 0.36mm(0.0094~ 0.0142in.)0.20~ 0.32 mm(0.0079~ 0.0126in.)0.05~ 0.20mm(0.0020~ 0.0079in.)

Specifications

ItemStandardServiceLimit
CrankshaftRunoutTIR0.02mm(0.0008in.)	orless	TIR0.05mm(0.0020in.)
CrankshaftMainBearingInsert/JournalClearance0.012~ 0.036mm(0.0005~ 0.0014in.)	0.07mm(0.0028in.)
CrankshaftMainJournalDiameter:	37.984~ 38.000mm(1.4954~ 1.4961in.)	37.96mm(1.4945in.)
Marking:
None37.984~ 37.992mm	(1.4954~ 1.4957in.)	-- --
137.993~ 38.000mm	(1.4958~ 1.4961in.)	-- --
CrankcaseMainBearingInsideDiameter:	41.000~ 41.016mm(1.6142~ 1.6148in.)	-- --
Marking:
○	41.000~ 41.008mm(1.6142~ 1.6145in.)	-- --
None41.009~ 41.016mm	(1.6145~ 1.6148in.)	-- --
CrankshaftMainBearingInsertThickness:
Brown1.490~ 1.494mm	(0.0587~ 0.0588in.)	-- --
Black1.494~ 1.498mm	(0.0588~ 0.0590in.)	-- --
Blue1.498~ 1.502mm	(0.0590~ 0.0591in.)	-- --

CrankshaftMainBearingInsertSelection:

CrankcaseMain BearingInside DiameterMarking	CrankshaftMain JournalDiameter Marking	BearingInsert*
		SizeColor	PartNumber
○	1	Brown	92028-1905
None	1	Black	92028-1904
○	None
None	None	Blue	92028-1903

*ThebearinginsertsforNos.1,2and3journalshaveoilgrooves.

BalancerShaft
Balancer Shaft Bearing Insert/Journal Clearance	0.011 ~ 0.033 mm(0.0004~ 0.0013in.)	0.08mm(0.0031in.)
BalancerShaftJournalDiameter:	27.987~ 28.000mm(1.1019~ 1.1024in.)	27.96mm(1.1108in.)
Marking:
None	27.987 ~ 27.993 mm(1.1019~ 1.1021in.)	-- --
○	27.994~ 28.000mm(1.1021~ 1.1024in.)	-- --

Specifications

ItemStandardServiceLimit
CrankcaseBearingBoreDiameter:		31.000~31.016mm(1.2205~1.2228in.)		---
Marking:
○		31.000~31.008mm(1.2205~1.2208in.)		---
None31.009~31.016mm		(1.2208~1.2211in.)		---
BalancerShaftBearingInsertThickness:
Brown1.490~1.494mm		(0.0587~0.0588in.)		---
Black1.494~1.498mm		(0.0588~0.0590in.)		---
Blue1.498~1.502mm		(0.0590~0.0591in.)		---
BalancerShaftBearingInsertSelection:
	BalancerShaftJournalDiameterMarking	BearingInsert*CrankcaseBearing
		SizeColorPartNumber
	○	○	Brown92139-0119
	○	None	Black	92139-0118
	None	○
	None	None	Blue	92139-0117
*ThebearinginsertsforNos. 1,2journalshaveoilgrooves.
TransmissionShiftForkEarThickness		5.9~6.0mm(0.232~0.236in.)		5.8mm(0.228 in.)
Gear Groove Width		6.05~6.15 mm(0.238~0.242in.)		6.25 mm(0.246 in.)
ShiftForkGuidePinDiameter		6.9~7.0mm(0.272~0.276in.)		6.8mm(0.268 in.)
ShiftDrumGrooveWidth		7.05~7.20mm(0.278~0.283in.)		7.3mm(0.287 in.)

SpecialToolsandSealant

OutsideCirclipPliers: 57001-144

Line drawing of a pair of pliers (no text or symbols on the tool itself)

KawasakiBond: 92104-1064

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

CrankcaseSplitting

CrankcaseSplitting

- Remove:

Engine(seeEngineRemovalintheEngineRemoval/Installationchapter)

Cylinder(see CylinderRemovalintheEngineTopEnd chapter)

Pistons(seePistonRemovalintheEngineTopEnd chapter)

StaterMotor(seeStarterMotorRemovalintheElectrical Systemchapter)

Clutch(seeClutchRemovalintheClutchchapter)

TransmissionAssy(see TransmissionAssyRemoval)

AlternatorRotor(seeAlternatorRotorRemovalinthe ElectricalSystemchapter)

- Removetheuppercrankcasebolts(M8)[A]andthewashers.

- Removetheoilpan,reliefvalve,oilscreenandoilpipes (seeOilPanRemovalintheEngineLubricationSystem chapter).

- Removethelowercrankcasebolts.

○FirstlyloosentheM6bolts,secondlytheM8boltsand lastlytheM9bolts.

M6Bolts[A]

M8Bolts[B]

M9Bolts[C]andWashers

- Taplightlyaroundthecrankcasematingsurfacewitha plasticmallet,andsplitthecrankcase.Takecarenotto damagethecrankcase.

Technical line drawing of a mechanical assembly (no text or symbols visible)

CrankcaseSplitting

★Iftheoilpieistoberemoved,followthenextprocedure. ○Unscrewthebolts[A]andremovetheoilpipe[B].

- Preparea5mmrod[B], and insertittotheholeofthe uppercrankcasehalf. - Removetheoilpipe[A], tapping[C]therodasshown.

★Ifthebreatherplate[A]istoberemoved,followthenext procedure. ○Removetheoilpipe(seeabove). ○Cutthegasketaroundtheplate[B]. ○Remove: BreatherPlateBolts[C] BreatherPlatewithPipe

CrankcaseAssembly

CAUTION

Theupperandlowercrankcasehalvesaremachinedatthefactoryintheassembledstate,sothe crankcasehalvesmustbereplacedasaset.

• Withahigh-flashpointsolvent,cleanoffthematingsurfacesofthecrankcaseshalvesandwipedry.
• Usingcompressedair, blowout the oil passages in the crankcase halves.
• If the oil plate [A] on the upper crank case half was removed, install it as shown.
• Applyanon-permanentlockingagenttotheoilplatebolts andtorquethem.

Torque-OilPlateBolts[B]:9.8N·m(1.0N·m,87in·lb)

CrankcaseSplitting

- Pressandinsert[A]thenewneedlebearing[B]forthe shiftdrumuntilitisbottomed.

SpecialTool-BearingDriverSet:57001-1129

- Pressandinsert[C]thenewneedlebearing[D]forthe shiftshaftsothatthebearingsurfaceisflushwiththeend ofthehole.

SpecialTool-BearingDriverSet:57001-1129

LowerCrankcaseHalf[E]

- Applysilicones equalant to the breather platematings surface [A] 1 mm (0.04 in.) or more thick, and then install the breather plate.

Sealant-ThreeBond1207B

NOTE

○ Maketheapplicationfinishwithin7minuteswhenthe liquidgaskettothematingsurfaceofthebreatherplate isapplied.

○ Moreoverfittheplateandtightentheboltsjustafter applicationoftheliquidgasket.

- Applyanon-permanentlockingagenttothethreadsandtightenthebolts[A].

Torque-BreatherPlateBolts:9.8N·m(1.0kgf·m,87in·lb)

Mechanical assembly with labeled components A, showing internal components and mounting holes (no readable text or symbols)

• Installthebreatherpipe[A].

○Align thewhitemark [B] on the pipewith [C] on the breatherfittling.

○Installtheclamp[D]sothatthepinchportions[E]facethe whitemarks.

- Installtheoilpipe[A]sothatitsflange[B]touchesto the surface [C] of the upper crankcase half.

- Apply grease to the O-ring [D] on the oil pipe.

CrankcaseSplitting

• Installthecrankshaftassemblyandthebalancershaftassemblyontheuppercrankcasehalf.
  ○Align[A]thetimingmarkonthebalancergear[B]withthe timingmarkonthebalancerdrivegear[C]ofthecrank-shaft.

• Besuretohangthecamshaftchain[A]onthecrankshaft.

• Besurethatthedowelpins[A]areinposition.
• Setthebearinggroove[A]onthepositioningring[B]as shown.

Close-up of a mechanical engine component with gears and shafts (no visible text or symbols)

CrankcaseSplitting

- Applyliquidgasket[A]tothematingsurfaceofthelower crankcasehalf.

Sealant-KawasakiBond:92104-1064

NOTE

○ Especially, applyaliquidgasketcarefullysothatitshall befilleduponthegrooves.

CAUTION

Donotapplyliquidgasketaroundthecrankshaft mainbearinginserts, andoilpassageholes.

○Donotapplyliquidgaskettotheoilpassage[B].

G104217BH2 C

CrankcaseSplitting

- Fitthelowercrankcasehalftotheuppercrankcasehalf.

OInser[A]thebreatherpipe[B]ontheuppercrankcase halfthroughthehole[C]onthelowercrankcasehalf.

NOTE

○ Maketheapplicationfinishwithin20minuteswhen theliquidgaskettothematingsurfaceofthelower crankcasehalfisapplied.
○Moreoverfitthecaseandtightenthecaseboltsjust afterfinishingtheapplicationoftheliquidgasket.

○The M9 bolts [1 \~ 6] (see the next figure) have copper platedwashers. Replacethemwithnewones.
- Applymolybdenumdisulfideoilsolutiontobothsides[A] oftheM9boltswashersandthethreads[B]oftheM9 bolts.
- Applymolybdenumdisulfideoilsolutiontoflange[A]and thethreads[B]oftheM8boltswhichistighteningorderis [7\~10]only(seethenextfigure).

CrankcaseSplitting

• Tightenthelowercrankcaseboltsusingthefollowing steps.
  ○Followingthesequencenumbersonthelowercrankcase half,tightentheM9bolts[1,2]L=113mm(4.45in.)with washers.
  Torque-CrankcaseBolts(M9):44N·m(4.5kgf·m,32ft·lb)

○TightentheM9bolts[3,4]L=83mm(3.27in.)withwashers.

Torque-CrankcaseBolts(M9):44N·m(4.5kgf·m,32ft·lb)

○TightentheM9bolts[5,6]L=113mm(4.45in.)with washers.

Torque-CrankcaseBolts(M9):44N·m(4.5kgf·m,32ft·lb)

○TightentheM8bolts[7\~10].

Torque-CrankcaseBolts(M8):35N·m(3.6kgf·m,26ft·lb)

○TightentheM8boltsA.

Torque-CrankcaseBolts(M8):27.5N·m(2.8kgf·m,20ft·lb)

○TightentheM6bolts[B].

Torque-CrankcaseBolts(M6):19.6N·m(2.0kgf·m,15ft·lb)

- Tightentheuppercrankcasebolts.

- Theuppercrankcaseboltshavecopperplatedwashers.
-Replacethemwithnewones.

Torque-UpperCrankcaseBolts(M8)[A]:27.5N·m(2.8 kgf·m,20ft·lb)

- Aftertighteningallcrankcasebolts, check the following items.

○Crankshaftandbalancershaftsturnfreely.

Technical line drawing of a mechanical assembly with no visible text or symbols

CrankshaftandConnectingRods

CrankshaftRemoval

• Splitthecrankcase(seeCrankcaseSplitting).
• Removethecrankshaft[A].

Mechanical gear assembly with labeled component A (no readable text or symbols)

CrankshaftInstallation

CAUTION

Ifthecrankshaft,bearinginserts,orcrankcase halvesarereplacedwithnewones,selectthebearinginsertsandcheckclearancewithaplastigage (pressgauge)beforeassemblingenginetobesure thecorrectbearinginsertsareinstalled.

• Applymolybdenumdisulfideoilsolutiontothecrankshaft mainbearinginserts.
  ○Align[A]thetimingmarkonthebalancergear[B]withthe timingmarkonthebalancerdrivegear[C]ofthecrankshaft.
• Installthecrankshaftwiththecamshaftchain[A]hanging onit.

Close-up of a mechanical engine component with gears and shafts, no visible text or symbols

ConnectingRodRemoval

• Splitthecrankcase(seeCrankcaseSplitting).
• Removetheconnectingrodnuts[A].
• Removethecrankshaft.

NOTE

○Markandrecordthelocationsoftheconnectingrods andtheirbigendcapssothattheycanbereassembled intheiroriginalpositions.

- Removetheconnectingrodsfromthecrankshaft.

CAUTION

Discardtheconnectingrodbolts. Topreventdamagetothecrankpinsurfaces, donotallowtheconnectingrodboltstobumpagainstthecrankpins.

9-18CRANKSHAFT/TRANSMISSION

CrankshaftandConnectingRods

ConnectingRodInstallation

CAUTION

Tominimize vibration, the connecting rod should havethesameweightmark.

BigEndCap[A]

ConnectingRod[B]

WeightMark,Alphabet[C]

DiameterMark[D]:“ ○” or nomark

CAUTION

If the connecting rods, bigendbearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with laplasti-gage (press gauge) before assembling engineetobe sure the correct bearing inserts are installed.

• Applymolybdenumdisulfidegrease[A]totheoutersurfaceoftheupperinsertandtheinnersurfaceoftheconnectingrodbigend.
• Applymolybdenumdisulfideoilsolution[B]totheinner surfacesofupperandlowerbearinginserts.
  ○Themolybdenumdisulfideoilsolutionisamixtureofengineoilandmolybdenumdisulfidegreasewithaweight ratio(10:1).
  ○Donotapplyanygreaseoroil[C]tothecapinsideand capinsertoutside.
  ○Installtheinsertssothattheirnails[D]areonthesame sideandfitthemintotherecessoftheconnectingrodand cap.

CAUTION

Wrongapplicationofoilandgreasecouldcause bearingdamage.

Wheninstallingtheinserts[A],becarefulnottodamage theinsertsurfacewiththeedgeoftheconnectingrod[B] orthecap[C].Onewaytoinstallinsertsisasfollows: Installation[D]toCap Installation[E]toConnectingRod Push[F] SpareDowelPin[G] ConnectingRodBolts[H]

• Installthecapontheconnectingrod, aligningtheweight anddiametermarks.
• Removedebrisandcleanthesurfaceofinserts.
• Applymolybdenumdisulfideoilsolution[MO]tothe threadsandseatingsurfacesofthebigendnutsand bolts.

CrankshaftandConnectingRods

• Installthecrankshaft(seeCrankshaftInstallation).
• Installeachconnectingrodonitsoriginalcrankpin.

NOTE

○Installeachconnectingrodsothatitsoiljet[A]facesthe exhaustside(thefront[B])(seeEngineOilFlowChart intheEngineLubricationSystemchapter).

○Theconnectingrodbigendisboltedusingthe"plastic regionfasteningmethod".
- Thismethodpreciselyachievestheneededclamping forcewithoutexceedingitunnecessarily,allowingthe useofthinner,lighterboltsfurtherdecreasingconnectingrodweight.
- There are two types of the plastic region fastening. One is abolt 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 more reliable way to light the big end nuts.

CAUTION

Theconnectingrodboltsaredesignedtostretch whentightened.Neverreusetheconnectingrod bolts.Seethetablebelowforcorrectboltandnut usage.

CAUTION

Becarefulnottovertightenthenuts. Theboltsmustbepositionedontheseatingsurface correctlytopreventtheboltheadsfromhittingthe crankcase.

(1) BoltLengthMeasurementMethod

- Besuretocleanthebolts, nuts, and connecting rods thoroughly with a high-flash points solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.

WARNING

Cleanthebolts, nuts, and connectingrodsinawell-ventilated area, and take care that there is nospark or flame any where near the working area. This includes any appliance with a pilot light. Because of the danger of highly flammable liquids, donot use gasoline or low flash points solvent to clean them.

CAUTION

Immediately dry the bolts and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely.

CrankshaftandConnectingRods

• Installnewboltsinreusedconnectingrods.
- Dentbothboltheadandbolttipwithapunchasshown.
- Beforetightening, useapointmicrometer[A]tomeasure thelengthofnewconnectingrodboltsandrecordthevaluestofindtheboltstretch.
ConnectingRod[B]
Markherewithapunch[C].
Nuts[D]
Fitmicrometerpinsintopunchmarks[E].

• Applyasmallamountofmolybdenumdisulfideoilsolution tothefollowing:
  ThreadsofNutsandBolts
  SeatingSurfacesofNutsandCon-rods
• Tightenthebigendnutsuntiltheboltelongationreaches thelengthspecifiedinthetable.
• Checkthelength[F]oftheconnectingrodbolts.
  ★Ifthestretchismorethantheusablerange,thebolthas stretchedtoomuch.Anoverelongatedboltmaybreakin use.

BoltLengthaftertightening

-

BoltLengthbeforetightening

=

BoltStretch

ConnectingRod Assy	BoltNut		UsableRangeof ConnectingRod BoltStretch
New	Usethebolts attachedto newcon-rod.	Attachedto newcon-rod	0.24~0.36mm(0.0094~0.0142in.)
		New
Used	Replacethe boltswithnew ones.	Used	0.20~0.32mm(0.0079~0.0126in.)
		New

(2)RotationAngleMethod

★Ifyoudon'thaveapointmicrometer,youmaytightenthe nutsusingthe"RotationAngleMethod".
- Besuretocleantheboltsandnutsthoroughlywithahigh -flashpointsolvent,becausethenewboltsandnutsare treatedwithananti-rustsolution.

WARNING

Cleantheboltsandnutsinawell-ventilatedarea, andtakecarethatthereisnosparkorflameany-whereneartheworkingarea. Thisincludesanyappliancewithapilotlight.Becauseofthedanger orhighlyflammableliquids,donotusegasolineor low-flashpointsolventstocleanthem.

CAUTION

Immediately dry the bolts and nuts with compressed air after cleaning.

Cleananddrytheboltsandnutscompletely.

CrankshaftandConnectingRods

• Installnewboltsinreusedconnectingrods.
• Applyasmallamountofmolybdenumdisulfideoiltothe following:
  Threads[A]ofNutsandBolts SeatingSurfaces[B]ofNutsandCon-rods

• First, tightenthenutstothespecifiedtorque. Seethe tablebelow.
• Next,tightenthenuts 120^±5^ .
  OMark[A]theconnectingrodbigendcapsandnutssothat nutscanbeturned120°[B]properly.

ConnectingRod Assy	BoltNut		Torque+AngleN·m(kgf·m,ft·lb)
New	Usethebolts attachedto newcon-rod.	Attachedto newcon-rod	18(1.8,13.0)+120°
		New	20(2.0,14.5)+120°
Used	Replacethe boltswith newones.	Used	24(2.4,17.4)+120°
		New	25(2.6,18.8)+120°

Crankshaft/ConnectingRodCleaning

• Afterremovingtheconnectingrodsfromthecrankshaft, cleanthemwithahigh-flashpointsolvent.
• Blowthecrankshaftoilpassageswithcompressedairto removeanyforeignparticlesorresiduethatmayhave accumulatedinthepassages.

ConnectingRodBend

- Removetheconnectingrodbigendbearinginserts, and reinstalltheconnectingrodbigendcap.

- Selectanarbor[A]ofthesamediameterastheconnectingrodbigend, and insert the earborthrough the connectingrodbigend.

- Selectanarborofthesamediameterathestepistonpin andatleast100mm(3.94in.)long,andinsertthearbor [B]throughtheconnectingrodsmallend.

- Onasurfaceplate, setthebig-endarboronVblock[C].

- With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arborabovethesurfaceplate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend.

★ Ifconnectingrodbendexceedstheservicelimit, theconnectingrodmustbereplaced.

ConnectingRodBend

Service Limit: TIR0.2/100mm(0.008/3.94in.)

CrankshaftandConnectingRods

ConnectingRodTwist

• Withthebig-endarbor[A]stillonVblock[C], hold the connectingrodhorizontally and measure the amount that the arbor[B] varies from being paralleled with the surface plateover a 100mm (3.94in.) length of the arbortode-terminethe amount of connecting rodtwist.
  ★Ifconnectingrodtwistexceedstheservicelimit,theconnectingrodmustbereplaced.

ConnectingRodTwist

ServiceLimit:TIR0.2/100mm(0.008/3.94in.)

ConnectingRodBigEndSideClearance

• Measureconnectingrodbigendsideclearance.
  ○Insertathicknessgauge[A]betweenthebigendandeithercrankwebtodetermineclearance.

ConnectingRodBigEndSideClearance

Standard: 0.13 \~ 0.38 mm (0.0051 \~ 0.0150 in.)

ServiceLimit:0.58mm(0.023in.)

★Iftheclearanceexceedstheservicelimit,replacetheconnectingrodwithnewoneandthencheckclearanceagain. Ifclearanceistoolargeafterconnectingrodreplacement, thecrankshaftalsomustbereplaced.

ConnectingRodBigEndBearingInsert/Crankpin Wear

• Measurethebearinginsert/crankpin[B]clearancewith plastigage[A].
• Tightenthebigendnutstothespecifiedtorque(seeConnectingRodInstallation).

NOTE

○ Donotmovetheconnectingrodandcrankshaftduring clearancemeasurement.

CAUTION

Aftermeasurement, replacetheconnectingrod bolts.

Connecting Rod Big End Bearing Insert/Crankpin Clearance

Standard: 0.017 \~ 0.041 mm (0.0001 \~ 0.0016 in.)

ServiceLimit: 0.08mm(0.0031in.)

★Iftheclearanceiswithinthestandard,nobearingreplacementisrequired.
★Iftheclearanceisbetween0.042mm(0.00165in.)and theservicelimit(0.08mm,0.0031in.),replacethebearing inserts [A] with inserts painted blue [B]. Check insert/crankpinclearancewiththeplastigage. Theclear-ancemayexceedthestandardslightly,butitmustnotbe lessthanthemminuminordertoavoidbearingseizure.
★ If the clearance exceed stheservicelimit, measure the diameter of the crankpins.

CrankpinDiameter

Standard: 37.984 \~ 38.000 mm (1.4954 \~ 1.4961 in.)

ServiceLimit:37.97mm(1.4949in.)

Close-up of mechanical gears and shafts with a labeled section A, no readable text or symbols present.

CrankshaftandConnectingRods

★Ifanycrankpinhaswornpasttheservicelimit,replace the crankshaftwithanewone.
★ Ifthemeasuredcrankpindiametersarenotlessthanthe servicelimit, butdonotcoincidewiththeoriginaldiameter markingsonthecrankshaft, makenewmarksonit.

CrankpinDiameterMarks

None 37.984 \~ 37.992 mm (1.4954 \~ 1.4957 in.)

37.993 \~ 38.000 mm (1.4958 \~ 1.4961 in.)

Δ:CrankpinDiameterMarks," ○" or n o m a r k.

• Measure the connecting rodbigend insided diameter, and markeach connecting rodbigend in accordance with the insided diameter.
• Tightentheconnectingrodbigendnutstothespecified torque(seeConnectingRodInstallation).

NOTE

○ Themarkalreadyonthebigendshouldalmostcoincide withthemeasurement.

ConnectingRodBigEndInsideDiameterMarks

None 41.000 \~ 41.008 mm (1.6142 \~ 1.6145 in.)

☐ 41.009 \~ 41.016 mm (1.6145 \~ 1.6148 in.)

Big End Cap [A]

ConnectingRod[B]

WeightMark,Alphabet[C]

DiameterMark(AroundWeightMark)[D]:“ ○” or no mark

- Selecttheproperbearinginsert[A]inaccordancewiththe combinationoftheconnectingrodandcrankshaftcoding. SizeColor[B]

Con-rodBigEndInsideDiameterMarking	CrankpinDiameterMarking	BearingInsert
		SizeColor	PartNumber
None	○	Brown921	39-0116
None	None	Black	92139-0115
○	○
○	None	Blue	92139-0114

- Installthenewinsertsintheconnectingrodandcheck insert/crankpinclearancewiththeplastigage.

CrankshaftandConnectingRods

CrankshaftSideClearance

• Insertathicknessgauge[A]betweenthecrankcasemain bearingandthecrankwebattheNo.2journal[B]to determineclearance.
  ★Iftheclearanceexceedstheservicelimit,replace the crankcasehalvesasaset.

NOTE

○ Theupperandlowercrankcasehalvesaremachined atthefactoryintheassembledstate,sothecrankcase halvesmustbereplacedasaset.

CrankshaftSideClearance

Standard: 0.05 \~ 0.20 mm (0.0020 \~ 0.0079 in.)

ServiceLimit:0.40mm(0.0157in.)

CrankshaftRunout

• Measurethecrankshaftrunout.
  ★Ifthemeasurementexceedstheservicelimit,replace the crankshaft.

CrankshaftRunout

Standard: TIR0.02mm(0.0008in.) or less

ServiceLimit:TIR0.05mm(0.0020in.)

CrankshaftMainBearingInsert/JournalWear

- Usingaplastigage(pressgauge)[A],measurethebearinginsert/journal[B]clearance.

NOTE

○ Tightenthecrankcaseboltstothespecifiedtorque(see CrankcaseAssembly).
○ Donotturnthecrankshaft during clearancemeasurement.
○ Journal clearance less than 0.025 mm (0.00098 in.) can not be measured by plastigage, however, using genuine partsmaintainstheminimumstandardclearance.

CrankshaftMainBearingInsert/JournalClearance

Standard: 0.012 \~ 0.036 mm (0.0005 \~ 0.0014 in.)

ServiceLimit: 0.07mm(0.0028in.)

★If the clearance is within the standard, nobearing replacement is required.
★Iftheclearanceis between0.037mm(0.0015in.)andthe servicelimit(0.07mm,0.0028in.),replacethebearinginserts[A]withinsertspainted blue[B].Checkinsert/journal clearance withtheplastigage.Theclearance mayexceed thestandardslightly,butitmustnotbelessthanthemiminuminordertoavoidbearingseizure.
★Iftheclearanceexceedstheservicelimit,measurethe diameterofthecrankshaftmainjournal.

Technical line drawing of a mechanical assembly with no visible text or symbols

CrankshaftandConnectingRods

CrankshaftMainJournalDiameter

Standard: 37.984 \~ 38.000 mm (1.4954 \~ 1.4961 in.)

ServiceLimit:37.96mm(1.4945in.)

★Ifanyjournalhaswornpasttheservicelimit,replace the crankshaftwithanewone.
★ Ifthemeasuredjournaldiametersarenotlessthanthe servicelimit, butdonotcoincidewiththeoriginaldiameter markingsonthecrankshaft, makenewmarksonit.

CrankshaftMainJournalDiameterMarks

None 37.984 \~ 37.992 mm (1.4954 \~ 1.4957 in.)

1 37.993 \~ 38.000 mm (1.4958 \~ 1.4961 in.)

☐:CrankshaftMainJournalDiameterMarks,"1"orno mark.

- Measurethemainbearinginsidediameter, and mark the uppercrankcasehalfinaccordance with the insidediameter.

CrankcaseMainBearingInsideDiameterMarks: "O" or nomark.

- Tightenthecrankcaseboltstothespecifiedtorque(see CrankcaseAssembly).

NOTE

○ Themarkalreadyontheuppercrankcasehalfshould almostcoincidewiththemeasurement.

CrankcaseMainBearingInsideDiameterMarks

○ 41.000 \~ 41.008 mm (1.6142 \~ 1.6145 in.)

None 41.009 \~ 41.016 mm (1.6145 \~ 1.6148 in.)

□□□:CrankcaseMainBearingInsideDiameterMarks," ○" markornomark

[A]No.1Journal

[B]No.2Journal

[C]No.3Journal

- Selecttheproperbearinginsert[A]inaccordancewiththe combinationofthecrankcaseandcrankshaftcoding. SizeColor[B]

CrankcaseMainBearingInsideDiameterMarking	CrankshaftMainJournalDiameterMarking	BearingInsert*
		SizeColorPartNumber
○	1	Brown	92028-1905
None	1	Black	92028-1904
○	None
None	None	Blue	92028-1903

*ThebearinginsertsforNos.1,2and3journalshaveoilgroove.

9-26CRANKSHAFT/TRANSMISSION

CrankshaftandConnectingRods

- Installthenewinsertsinthecrankcasehalvesandcheck insert/journalclearancewiththeplastigage.

Balancer

BalancerRemoval

• Splitthecrankcase(seeCrankcaseSplitting).
• Pullthebalancershaftwiththebalancergearoutofthe crankcase.

BalancerInstallation

• Applymolybdenumdisulfideoilsolutiontotheinsideof thebalancershaftbearinginsert.
• Align[A]thetimingmarkonthebalancergear[B]withthe timingmarkonthebalancerdrivegear[C]ofthecrankshaft.
• Assemblethecrankcase(seeCrankcaseAssembly).

BalancerShaftBearingInsert/JournalClearance

• Measurethebearinginsert/journalclearanceusinga plastigage.
  ○Splitthecrankcaseandwipeeachbearinginsertandjournalsurfacecleanofoil.
  ○Cutstripsofplastigagetobearinginsertwidth, and place astriponeachjournalparalleltothebalancershaftsothat theplastigagewillbecompressedbetweenthejournal andthebearinginsert.
  ○Installthelowercrankcasehalf, andtightenthecasebolts tothespecifiedtorque(seeCrankcaseAssembly).

NOTE

○Donotturnthebalancershaftduringclearancemeasurement.

- Removethelowercrankcasehalfandmeasuretheplastigagewidth[A]todeterminethebearinginsert/journal[B] clearance.

BalancerShaftBearingInsert/JournalClearance

Standard: 0.011 \~ 0.033 mm (0.0004 \~ 0.0013 in.) ServiceLimit:0.08mm(0.0031in.)

★ If the clearance is within the standard, nobearing insert replacement is required.
★ If the clearance is between 0.050 mmand the service limit (0.09 mm), replace the bearing inserts [A] within- sertspainted blue [B] Check insert/journal clearance with aplastigage. The clearancemay exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.
★ If the clearance exceed stheservicelimit, measure the diameter of the balancershaft journal.

BalancerShaftJournalDiameter

Standard: 27.987 \~ 28.000 mm (1.1019 \~ 1.1024 in.)

ServiceLimit: 27.96mm(1.1008in.)

Balancer

★lfeitherjournalhaswornpasttheservicelimit,replace thebalancershaftwithanewone.
★Ifthemeasuredjournaldiametersarenotlessthanthe servicelimit,butdonotcoincidewiththeoriginaldiameter markingsonthebalancershaft,writenewmarksonit.

BalancerShaftDiameterMarks

None 27.987 \~ 27.993 mm (1.1019 \~ 1.1021 in.)

27.994 \~ 28.000 mm (1.1021 \~ 1.1024 in.)

Δ:BalancerShaftJournalDiameterMarks," "m a r k o r nomark.

• Putthelowercrankcasehalfontheuppercrankcasehalf withoutbearinginserts, andtightenthecaseboltstothe specified torque and sequence (seeCrankcaseAssembly).
• Measurethecrankcasebearingborediameterforthebalancershaft,andmarktheuppercrankcasehalfinaccordancewiththeborediameter.

NOTE

○ Themarkalreadyontheuppercrankcasehalfshould almostcoincidewiththemeasurement.

CrankcaseBearingBoreDiameterMarks

31.000 \~ 31.008 mm (1.2205 \~ 1.2208 in.)

None 31.009 \~ 31.016 mm (1.2208 \~ 1.2211 in.)

□□:CrankcaseBearingBoreDiameterMarks," ○" m a r k ornomark.

[A]No.1Journal

[B]No.2Journal

- Selecttheproperbearinginsertinaccordancewiththe combinationofthecrankcaseandthebalancershaftcoding.

- Installthenewinsertsinthecrankcaseandcheckinsert/journalclearancewithaplastigage.

BalancerShaftBearingInsertSelection

BearingBoreDiameter Mark	CrankshaftMain JournalDiameterMark	BearingInsert*CrankcaseMain
		SizeColor	PartNumber
○	○	Brown	92139-0119
○	None	Black	92139-0118
None	○
None	None	Blue	92139-0117

Transmission

ShiftPedalRemoval

- Remove: ShiftLeverBolt[A] ShiftLever[B]

ShiftPedalInstallation

• Alignthemark[A]ontheshiftshaftwiththeslit[B]onthe shiftlever.
• Tightentheshiftleverboltsecurely.

• Besuretheshiftpedalpositionisasshown. ShiftPedalDamper[A] Bottom[B]ofLeftFootpegStay ShiftLever[C] Bolt[D]ofLeftFootpegStay

ExternalShiftMechanismRemoval

- Remove:

EngineOil(drain,seeEngineOilChangeinthePeriodic Maintenancechapter)
ShiftPedal(seeShiftPedalRemoval) EngineSprocket(seeEngineSprocketRemovalinthe FinalDrive)
NeutralSwitchLeadConnector(Disconnect) ShiftShaftCoverBolts[A] ShiftShaftCoverScrew[B] ShiftShaftCover[C]

- Removetheshiftshaftassembly[A].

9-30CRANKSHAFT/TRANSMISSION

Transmission

- Remove:

Clutch(seeClutchRemovalintheClutchchapter)

GearPositioningLeverBolt[A]

GearPositioningLever[B], Spacer, WasherandSpring

ExternalShiftMechanismInstallation

• Installthegearpositioninglever[A]asshown.

Spring[B]

Washer[C]

Spacer[D]

Bolt[E]

○Fookthespringatgearpositioninglever,pushingup[F] thefookportion,asshown.

- Applyanon-permanentlockingagenttothegearpositioningleverboltandtorqueit.

Torque-GearPositioningLeverBolt:12N·m(1.2kgf·m, 106in·lb)

• Installtheshiftshaftassembly.

○Apply[A]molybdenumdisulfideoilsolutionotherubbingsurfacebetweenthelever[B]andpawl[C]andmove themtwoorthreetimesupanddowntolubricatethem.

○Besurethatthewasher[A]isontheshaft.

○Besurethatthespringhookportions[B]areasshown.

ShiftShaftCoverScrew:4.9N·m(0.50kgf·m,43in·lb)

ExternalShiftMechanismInspection

- Examinetheshiftshaft[A]foranydamage.

★ Iftheshaftisbent, straightenorreplaceit.

★Iftheserration[B]aredamaged,replacetheshaft.

★ Ifthesprings[C]aredamagedinanyway, replacethem.

★ Iftheshiftmechanismarm[D]isdamagedinanyway, replacethearm.

- Checkthereturnspringpin[A]isnotloose.

★ Ifitisloose, unscrewit, applyanon-permanentlocking agenttothethreads, and tightenit.

Torque-ShiftShaftReturnSpringPin:29N·m(2.9kgf·m, 21ft·lb)

Close-up mechanical assembly with labeled component A (no readable text or symbols)

Transmission

• Check the gear positioninglever[A] and it spring for breaksordistortion.
  ★Iftheleverorspringaredamagedinanyway,replace them.
• Visuallyinspecttheshiftdrumcam[B].
  ★Iftheyarebadlywornoriftheyshowanydamage,replace it.

TransmissionAssyRemoval

• Remove:
  ShiftShaftAssembly(seeExternalShiftMechanismRemoval)
  NeutralSwitchHolderBolt[A]
  NeutralSwitchHolder[B]andPin
  ShiftDrumHolder[C]andPin

- Remove:

Collar[A]

O-ring[B]

- Remove:

Clutch(seeClutchRemovalintheClutchchapter)

TransmissionCaseBolts[A]

★Ifthetransmissionassyistobedisassembled, following.

ShiftRodPlateBolt[B]

ShiftRodPlate[C]

GearPositioningLeverBolt[D]

GearPositioningLever[E]withSpring,Washerand

Spacer

- Pullthetransmissionassy[A]outofthecrankcase.

Close-up of a mechanical assembly with gears and a hand holding a component (no visible text or symbols)

Transmission

TransmissionAssyDisassembly

• Removethetransmissionassy(seeTransmissionAssy Removal)
• Removethefollowingfromthetransmissioncase[A]. ShiftRods[B] ShiftForks[C] DriveShaft[D] OutputShaft[E]

- Remove: ShiftDrumCamBolt[A] ShiftDrum[B]andPin ShiftDrum[C]

TransmissionAssyAssembly

- Whenthenewallbearings[A]areinstalledinthetransmissioncase[B],pressandinsertthemuntiltheyarebotomed.

SpecialTool-BearingDriverSet57001-1129

Transmission

- Installthefollowingonthetransmissioncase[A].

ShiftDrum[B]

Pin[C]

ShiftDrumCam[D]

○Alignthepinwiththeholeontheshiftdrumcam.

- Applyanon-permanentlockingagenttotheshiftdrum camboltandtorqueit.

Torque-ShiftDrumCamBolt:12N·m(1.2kgf·m,106in·lb)

• Installthefollowingasaset.

DriveShaft[F]

OutputShaft[G]

- Installtheforksasshown.

○Positiontheone[H]withshortestearsonthedriveshaft andplacethepininthecentergrooveintheshiftdrum.

○Thetwoforks[J]ontheoutputshaftareidentical.

- Installtheshiftrods,notingthegrooveposition.

○Therod[K]lengthoftheoutputshaftsideisshorterthan therod[L]lengthofthedriveshaftside.

- ApplymolybdenumdisulfideoilsolutiontothetransmissiongearsshownwithXmarks[M].

- Besurethatthespacer[P]isontheoutputshaft.

G113244BH2 C

TransmissionAssyInstallation

• Assemblethetransmissionassy(seeTransmissionAssy Assembly).
• Besurethatthedowelpins[A]areinposition.
• ApplygreasetotheO-ring[B]ontheoilpipe.
• Installthetransmissionassyonthecrankcase.
• Tightenthetransmissioncasebolts.

Torque-TransmissionCaseBolts:20N·m(2.0kgf·m,15ft·lb)

Transmission

• Install the gear positioninginglever (see External Shift Mechanism Installation).
  • Installtheshiftrodplate.
  Torque-ShiftRodPlateBolt:9.8N·m(1.0kgf·m,87in·lb)
• Setthegearpositioninglevertotheneutralposition[A].
• Checkthatthedriveandoutputshaftturnfreely.

- Install: Pin[A] ShiftDrumHolder[B] Pin[C] NeutralSwitchHolder[D] NeutralSwitchHolderScrew[E]

○Applyanon-permanentlockingagenttotheneutralswitch holderscrewandtorqueit.

Torque-NeutralSwitchHolderScrew:4.9N·m(0.50kgf·m, 43in·lb)

• ApplygreasetotheO-ring[A]andinstallitsposition[B]ontheoutputshaft.
• Applygreasetothelipoftheoilseal[C].
• Installthecollar[D].

Close-up of mechanical components with a highlighted circular area labeled 'A' (no readable text or symbols)

TransmissionShaftRemoval

• Removethetransmissionassy(seeTransmissionAssyRemoval).
• Remove: ShiftRods[A] ShiftForks[B] DriveShaft[C]andOutputShaft[D]

TransmissionShaftInstallation

- Besurethatthespacer[A]isontheoutputshaft[B].

Transmission

• Installthetransmissionassyonthecrankcase(seeTransmissionAssyInstallation).
• Pressintheoilseal[A]ontocollar[B]sothatthesurface oftheoilsealisflushwiththesurface[C]ofthecrankcase.
  ○Applyoiltotheoutercircumference[D]oftheoilsealso thatitwillgointplacessmoothly.
  ○Applygreasetothelip[E]oftheoilseal.

TransmissionShaftDisassembly

• Removethetransmissionshafts(seeTransmissionShaft Removal).
• Removethecirclips, disassemblethetransmission shafts.

SpecialTool-OutsideCirclipPliers:57001-144

• The5thgear[A]ontheoutputshaftthasthreesteelballs assembledintoitforthepositiveneutralfindermechanism.Removethe5thgear.
  ○Settheoutputshaftinaverticalpositionholdingthe3rd gear[B].
  ○Spinthe5thgearquickly[C]andpullitoffupward.

TransmissionShaftAssembly

• Applyengineoiltothebushings, needlebearings and shafts.

• Installthegearbushings[A]ontheshaftwiththeirholes [B]aligned.

• Replaceanycirclipsremovedwithnewones.

• Installthecirclips[A]sothattheopening[B]isaligned with aspline groove[C].

Transmission

• Thedriveshaftgearscanberecognizedbysize:thegear withthesmallestdiameteris1stgear,andthelargestone is6thgear.Besurethatallpartsareputbackinthecorrectsequenceandallcirclipsandwashersareproperlyin place.
• Installthe3rd/4thgearontothedriveshaftwiththeiroil holesaligned.
• Installthe6thgearbushingontothedriveshaftwiththeir oilholesaligned.
• Theoutputshaftgearscanberecognizedbysize:the gearwiththelargestdiameteris1stgear,andthesmall-estoneis6thgear.Besurethatallpartsareputback inthecorrectsequenceandallcirclipsandwashersare properlyinplace.
• Installthe5thand6thgearsontotheoutputshaftwith theiroilholesaligned.
• Installthe3rd/4thgearbushingsontotheoutputshaftwith theiroilholesaligned.
• Fitthesteelballsintothe5thgearholesintheoutput shaft, aligningthreeoilholes[D].
  5thGear[A]
  OutputShaft[B]
  SteelBalls[C]

CAUTION

Donotapplygreasetotheballstoholdthemin place. This will cause the positiveneutralfinder mechanismtomalfunction.

Afterassembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th geardoesn't come out of the output shaft when moving it up and down by hand.

- Checkthateachgearspinsorslidesfreelyonthetransmissionshaftswithoutbindingafterassembly.

Transmission

1.1stGear

2.2ndGear

3.3rdGear

4.4thGear

5.5thGear

6.6th(Top)Gear

7.BallBearing

8.Bushing

9.ToothedWasher, φ34mm(1.34in.)

10.Circlip

11.Bushing

1. ThrustWasher, 30mm(1.18in.)

13.NeedleBearing

14.Circlip

15.OilSeal

16.Collar

17.Washer

18.Nut

19.O-ring

20.Bearing

21.Spacer, φ39mm(1.54in.)

22.PositioningRing

23.Washer, φ40mm(1.57in.)

24.Bushing

25.ToothedWasher, φ38mm(1.50in.)

26.Shim, φ28mm(1.10in.)

27.SteelBall

28.Circlip, φ32.2mm(1.268in.)

29.ThrustWasher, φ25mm(0.98in.)

Transmission

ShiftDrumandForkRemoval

• Removethetransmissionassy(seeTransmissionAssyRemoval).
• Removetheshiftforks[A]andshiftdrumB.

ShiftDrumandForkInstallation

- RefertoTransmissionAssyAssemblyandInstallation.

ShiftDrumDisassembly

- RefertoTransmissionAssyRemovalandDisassembly.

ShiftDrumAssembly

- RefertoTransmissionAssemblyandInstallation.

ShiftForkBending

- Visuallyinspecttheshiftforks, and replaceanyforkthatis bent. Abentforkcouldcauseddifficultyinshifting, orallow thetransmissiontojumpoutofgearwhenunderpower. 90°[A]

ShiftFork/GearGrooveWear

• Measurethethicknessoftheshiftforkears[A], and measurethewidth[B]ofthegeargrooves.
  ★ Ifthethicknessofashiftforkearislessthantheservice limit, theshiftforkmustbereplaced.

ShiftForkEarThickness

Standard: 5.9 \~ 6.0 mm (0.232 \~ 0.236 in.)

ServiceLimit:5.8mm(0.228in.)

★ If the gear groove is worn over the service limit, the gear must bereplaced.

GearGrooveWidth

Standard: 6.05 \~ 6.15 mm (0.238 \~ 0.242 in.)

ServiceLimit:6.25mm(0.246in.)

Transmission

ShiftForkGuidePin/DrumGrooveWear

• Measurethediameterofeachshiftforkguidepin[A], and measurethewidth[B]ofeachshiftdrumgroove.
  ★ Iftheguidepinonanyshiftforkislessthantheservice limit, theforkmustbereplaced.

ShiftForkGuidePinDiameter

Standard: 6.9 \~ 7.0 mm (0.272 \~ 0.276 in.)

ServiceLimit:6.8mm(0.268in.)

★Ifanyshiftdrumgrooveiswornovertheservicelimit,the drummustbereplaced.

ShiftDrumGrooveWidth

Standard: 7.05 \~ 7.20 mm (0.278 \~ 0.283 in.)

ServiceLimit:7.3mm(0.287in.)

GearDogandGearDogHoleDamage

• Visuallyinspectthegeardogs[A]andgeardogholes[B].
  ★Replaceanydamagedgearsorgearswithexcessively worndogsordogholes.

BallBearing, NeedleBearing, and Oil Seal

BallandNeedleBearingReplacement

CAUTION

Donotremovetheballorneedlebearingsunlessit isnecessary.Removalmaydamagethem.

- Usingapressorpuller,removetheballbearingand/or needlebearings.

NOTE

○Intheabsenceoftheabovementionedtools,satisfactoryresultsmaybeobtainedbyheatingthecasetoapproximately93°C(200°F)max.,andtappingthebearinginorout.

CAUTION

Donotheatthecasewithatorch. This will warp the case. Soakthecaseinoilandheattheoil.

• Usingapressandthebearingdriverset[A],installthe newballbearinguntilitstopsatthebottomofitshousing.
  ○Thenewneedlebearingsmustbepressedintothe crankcasesothattheendisflushwiththeendofthe hole.

SpecialTool-BearingDriverSet:57001-1129

BallandNeedleBearingWear

CAUTION

Donotremovethebearingsforinspection. Removalmaydamagethem.

• Checktheballbearings.
  ○Sincetheballbearingsaremadetoextremelyclosetolerances,thewearmustbejudgedbyfeelratherthanmeasurement.Cleaneachbearinginahigh-flashpointsolvent,dryit(donotspinthebearingwhileitisdry),andoil itwithengineoil.

○Spin[A]thebearingbyhandtocheckitscondition.

★ If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it.
- Checktheneedlebearings.
○Therollersinaneedlebearingnormallywearverylittle, andwearisdifficulttomeasure. Insteadofmeasuring, inspectthebearingforabrasion,colorchange, orother damage.

★ If there is any doubt to the condition of a needle bearing, replace it.

OilSealInspection

• Inspecttheoilseals.
  ★Replaceitifthelipsaremisshapen,discolored(indicating thattherubberhasdeteriorated),hardenedorotherwise damaged.

Wheels/Tires

TableofContents

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.... 10-8

Rear Wheel Installation.... 10-8

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.... 10-16

Hub Bearing Lubrication 10-17

ExplodedView

No.Fastener	Torque			Remarks
	N·mkgf	mft·lb
1FrontAxle10811.080
2FrontAxleClampBolt343.525
3RearAxleNut10811.080

G: Applygrease.
HG: Applyhigh-temperaturegrease.
R: ReplacementParts
WL: Applysoapandwatersolutionorrubberlubricant.

Specifications

ItemStandardServiceLimit
Wheels(Rims)RimRunout:AxialTIR0.5mm(0.02in.)orlessTIR1.0mm(0.04in.)RadialTIR0.8mm(0.03in.)orlessTIR1.0mm(0.04in.)Axle Runout/100 mm (3.94 in.)WheelBalance10g(0.35oz.)orless——BalanceWeightsRimSize:Front17×3.50Rear	TIR 0.03 mm (0.0012 in.) or less——10g(0.35oz.),20g(0.71oz.),30g(1.06oz.)————17 × 4.50	TIR 0.2 mm (0.008 in.)———
TiresAirPressure(whenCold):FrontUpto180kg(397lb)load:225kPaRearTreadDepth:FrontRear	(2.25kgf/cm2,32psi)Upto180kg(397lb)load:250kPa(2.50kgf/cm2,36psi)6.5mm(0.26in.)9.0 mm (0.35 in.)	———1mm(0.04 in.)(AT,CH,DE) 1.6mm(0.06in.)Up to 130 km/h (80 mph):2mm(0.08 in.)Over130km/h(80mph):3mm(0.12 in.)
Standard Tires:FrontDUNLOP,SPORTMAX RADIALRear	Make, Type	Size
	D221FAJDUNLOP, SPORTMAX D221J	120/70ZR17M/C(58W)160/60 ZR17 M/C (69 W)

AT: Austria
CH:Switzerland
DE:Germany

WARNING

Usethesamemanufacturer'stiresonbothfrontandrearwheels.

SpecialTools

BearingDriverSet: 57001-1129

Isometric line drawing of a mechanical housing with multiple circular components and a central opening (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

BearingRemoverHead,20×22: φ 57001-1293

Technical line drawing of a mechanical connector (no text or symbols)

BearingRemoverShaft,13φ 57001-1377

Line drawing of a long, elongated object with a pointed tip and textured end (no text or symbols)

JackAttachment: 57001-1608

Technical line drawing of two mechanical fasteners with cylindrical base (no text or symbols)

Wheels(Rims)

FrontWheelRemoval

- Remove: BrakeCaliperMountingBolts[A] FrontBrakeCalipers[B]

- Loosen: AxleClampBolt[A] - Removethefrontaxle[B].

- Removethelowerfairing(seeLowerFairingRemovalin theFramechapter). - Raisethefrontwheeloffthegroundwithjack. SpecialTools-Jack:57001-1238 JackAttachment:57001-1608

- Pullouttheaxletotherightanddropthefrontwheelout oftheforks.

CAUTION

Donotlaythewheelonthegroundwiththediscs facingdown. This candamageorwarpthedisc. Placewoodenblocksunderthewheelsothatthe discdoesnottouchtheground.

FrontWheelInstallation

NOTE

○ Thedirectionofthewheelrotation[A]isshownbyan arrow[B]onthewheelspoke.

- Checkthewheelrotationmarkonthefrontwheeland installit.

Wheels(Rims)

• Applyhigh-temperaturegreasetothegreaseseallips.
  ● Fitthecollars[A]onthebothsidesofthehub.

Close-up of mechanical components with labeled parts A, showing internal circular features and bolted joints (no readable text or symbols)

• Insertthefrontaxle, andtightentheaxle.
  Torque-FrontAxle:108N·m(11.0kgf·m,80ft·lb)
• Before tightening the axle clamp bolt 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 go on the front axle.

NOTE

○Putablockinfrontofthefrontwheeltostopmoving.

- Tightentheaxleclampbolt[A]. Torque-FrontAxleClampBolt:34N·m(3.5kgf·m,25ft·lb)

Close-up of a car brake system with labeled components (no readable text or symbols)

• Installthelowerfairing(seeLowerFairingInstallationin theFramechapter).
• Installthefrontbrakecalipers(seeCaliperInstallationin theBrakeschapter).
• Checkthefrontbrakeeffectiveness(seeBrakeOperationInspectioninthePeriodicMaintenancechapter).

WARNING

Donotattempttodrivethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc.Thebrakewill notfunctiononthefirstapplicationoftheleverif thisisnotdone.

10-8WHEELS/TIRES

Wheels(Rims)

RearWheelRemoval

- Raisetherearwheeloffthegroundwithstand[A].

- Remove:

BrakeCaliperMountingBolts[A] RearBrakeCaliper[B]

- Remove:

CotterPin[A]

AxleNut[B]

Washer[C]

Axle[D]withWasher

• Removethedrivechain[A]fromtherearsprockettoward theleft.
• Movetherearwheelbackandremoveit.

CAUTION

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageorwarpthedisc. Placewoodenblocksunderthewheelsothatthe discdoesnottouchtheground.

RearWheelInstallation

• Applyhigh-temperaturegreasetothegreaseseallips.
• Fitthecollars[A]onthebothsidesofthehub.

Close-up of a motorcycle's wheel mounted on a metal platform, labeled with point A and GJ048419 P (no text or symbols on the object itself)

Close-up mechanical assembly showing a gear and wheel with labeled component A (no readable text or symbols)

Mechanical gear assembly diagram showing two views of a wheel with labeled components (no text or symbols present)

Wheels(Rims)

• Engagethedrivechainwiththerearsprocket.
• Installthecaliperbracket[A]ontotheswingarmstop[B].
• Inserttheaxlefromtherightsideofthewheel, andtighten the axlenut.

Torque-RearAxleNut:108N·m(11.0kgf·m,80ft·lb)

- Insertanewcotterpin[A].

NOTE

When inserting the cotterpin, if the slots in thenut do not align with the cotterpinhole in the axle, tighten the nut clockwise [B] uptonextalignment.
○Itshouldbewithin30°.
○ Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

- Bendthecotterpin[A]overthenut[B].

WARNING

Iftherearaxlenutisnotsecurelytightenedorthe cotterpinisnotinstalled,anunsaferidingconditionmayresult.

• Adjustthedrivechainslackafterinstallation(seeDriveChainSlackInspectioninthePeriodicMaintenancechapter).
• Installtherearbrakecaliper(seeCaliperInstallationin theBrakeschapter).
• Checktherearbrakeeffectiveness(seeBrakeOperationInspectioninthePeriodicMaintenancechapter).

WARNING

Donotattemptlodrivethemotorcycleuntilafull brakepedalisobtainedbypumpingthebrakepedal untilthepadsareagainstthedisc. Thebrakewill notfunctiononthefirstapplicationofthepedalif thisisnotdone.

Wheels(Rims)

WheelInspection

- Raisethefront/rearwheeloffthegroundwithjack.

SpecialTools-Jack:57001-1238

JackAttachment:57001-1608

• Spinthewheellightly, and check for roughnessor binding.
  ★Ifroughnessorbindingisfound, replacethehubbearings.
• Inspectthewheelforsmallcracks, dents, bending, or warp.
  ★Ifthereisanydamagetothewheel,replacethewheel.
• Removethewheel, and support it without the tire by the axle.
• Measuretherimrunout, axial[A]andradial[B], withadial gauge.
  ★ Ifrimrunoutexceedstheservicelimit, checkthehubbearings.
  ★Iftheproblemisnotduetothebearings,replace the wheel.

RimRunout

Standard:

Axial TIR0.5mm(0.02in.)orless

Radial TIR0.8mm(0.03in.)orless

ServiceLimit:

Axial TIR1.0mm(0.04in.)

Radial TIR1.0mm(0.04in.)

WARNING

Neverattempttorepairadamagedwheel.Ifthere isanydamagebesideswheelbearings,thewheel mustbereplacedtoinsuresafeoperationalcondition.

AxleInspection

• Removethefrontandrearaxles(seeFront/RearWheelRemoval).
• Visuallyinspectthefrontandrearaxlefordamages.
  ★Iftheaxleisdamagedorbent,replaceit.
• PlacetheaxleinVblocksthatare100mm(3.94in.)[A] apart, and set adial gauge[B] on the axle at a point halfway between the blocks. Turn[C] the axlet omea suretherunout. The difference between the highest and lowest dial readings sisthe amount of runout.
  ★Ifaxlerunoutexceedstheservicelimit,replacetheaxle.

AxleRunout/100mm(3.94in.)

Standard: TIR0.03mm(0.0012in.) or less

ServiceLimit: TIR0.2mm(0.008in.)

Wheels(Rims)

BalanceInspection

• Removethefrontandrearwheels(seeFront/RearWheel Removal).
• Supportthewheelsothatitcanbespunfreely.
• Spinthewheellightly, and mark[A]thewheelatthetop whentewheelstops.
  ○Repeatthisprocedureseveraltimes.Ifthewheelstopsofitsownaccordinvariouspositions,itiswellbalanced.
  ★ If the wheel always stops in one position, adjust the wheel balance (see Balance Adjustment).

BalanceAdjustment

• Ifthewheelalwaysstopsinoneposition,provisionally attachabalanceweight[A]ontherimatthemarkingusing adhesivetape.
• Rotatethewheel1/4turn[B], and seewhetherornotthe wheelstopsinthisposition. If it does, the correct balance weight is being used.
  ★ Ifthewheelrotatesandtheweightgoesup,replace the weightwiththenextheaviersize.Ifthewheelrotatesand theweightgoesdown,replace the weightwiththenext lightersize.Repeat these steps until the wheel remains at rest after being rotated 1/4 turn.
• Rotatethewheelanother1/4turnandthenanother1/4turntoseeifthewheeliscorrectlybalanced.
• Repeat the entire procedure as many times necessary to achieve correct wheel balance.
• Permanentlyinstallthebalanceweight.

BalanceWeightRemoval

• Insertaregulartipscrewdrivers[A][B]betweentherib[C] andtheweight[D]asshown.
• Prythebalanceweightwithtwoscrewdriversandremove thebalanceweight.
• Discardtheusedbalanceweight.

CAUTION

Donottapthescrewdrivers.Therimcouldbedamaged.

BalanceWeightInstallation

• Checkiftheweightportionhasanyplayontheblade[A] andclip[B].
  ★ Ifitdoes, discardit.

WARNING

If the balance weight has any play on the rib of the rim, the blade and or clip have been stretched. Re placethelose balance weight. Donot reuse used balance weight. Unbalanced wheels can create an safer iding condition.

BalanceWeight

PartNumberWeight
41075-000710g(0.35oz.)
41075-000820g(0.71oz.)
41075-000930g(1.06oz.)

NOTE

○ BalanceweightsareavailablefromKawasakidealersin 10,20,and30grams(0.35,0.71,and1.06oz.)sizes.Animbalanceoflessthan10grams(0.35oz.)willnot usuallyaffectrunningstability.
○ Donotusefourormorebalanceweight(morethan90 gram,3.17oz.). If the wheel requires an excess balance weight, disassemble the wheel to find the cause.

- Slipthebalanceweight[A]ontotherib[B]bypushingor lightlyhammering[C]theclip[D].

LeftSide[E] RightSide[F]

- Besuretoinstallthebalanceweight.

○Checkthattheblade[A]andclip[B]arefullyseatedontherim[C]andthattheclipishookedovertherib[D].

LeftSide[E] RightSide[F]

Tires

AirPressureInspection/Adjustment

- RefertotheAirPressureInspectioninthePeriodicMaintenancechapter.

TireInspection

- RefertotheWheel/TireDamageInspectioninthePeriodicMaintenancechapter.

TireRemoval

- Remove:

Wheel(seeFront/RearWheelRemoval) ValveCore(Letouttheair)

- Tomaintainwheelbalance, markthevalvestemposition onthetirewithchalksothatthetirecanbereinstalledin thesameposition.

ChalkMarkorYellowMark[A] AirValve[B] Align[C]

- Lubricatethetirebeadsandrimflangesonbothsideswith asoapandwatersolutionorrubberlubricant. This helps the tirebeadsslipofftherimflanges.

CAUTION

Neverlubricatewithengineoilorpetroleumdistillatesbecausetheywilldeterioratethetire.

- Removethetirefromtherimusingasuitablecommerciallyavailabletirechanger.

NOTE

○ Thetires cannot be removed with hand tools because they fit their imstootightly.

TireInstallation

WARNING

Usethesamemanufacturer'stiresonbothfrontand rearwheels.

• Inspecttherimandtire, andreplacethemifnecessary.
• Cleanthesealingsurfacesoftherimandtire, andsmooth the sealing surfaces of the rim with a fine emery cloth if necessary.
• Removetheairvalveanddiscardit.

CAUTION

Replacetheairvalvewheneverthetireisreplaced. Donotreusetheairvalve.

Tires

• Installanewvalveintherim.
- Removethevalvecap, lubricatethestemseal[A]witha soapandwatersolutionorrubberlubricant, andpull[B] thevalvestemthroughtherimfromtheinsideoutuntil snapsintoplace.

CAUTION

Donotuseengineoilorpetroleumdistillatestolubricatethestembecausetheywilldeterioratethe rubber.

○Theairvalveisshowninthefigure.

ValveCap[A]

ValveCore[B]

StemSeal[C]

ValveStem[D]

ValveSeat[E]

ValveOpened[F]

- Checkthetirerotationmarkonthefrontandreartiresand installthemontherimaccordingly.

TireRotationMark[A]

RotatingDirection[B]

• Positionthetireontherimsothatthevalve[A]alignwith thetirebalancemarkB.
• Install the tire bead over therim flange using as suitable commercially available tire changer.
• Lubricatethetirebeadsandrimflangeswithasopand watersolutionorrubberlubricanttohelpseathetire beadsinthesealingsurfacesoftherimwhileinflatingthe tire.
• Centertheriminthetirebeads, andinflatethetirewith compressedairuntilthetirebeadsseatinthesealing surfaces.

WARNING

Besuretoinstallthevalvecorewheneverinflating thetire, anddonotinflatethetiretomorethan400 kPa(4.0kgf/cm², 57psi). Overinflationcanexplode thetirewithpossibilityofinjuryandlossoflife.

Tires

• Checktoseethatherimlines[A]onbothsidesofthetire sidewallsareparallelwiththerimflanges.
  ★ Iftherimflangesandtiresidewallrimlinesarenotparallel, removethevalvecore.
• Lubricatetherimflangesandtirebeads.
• Installthevalvecoreandinflatethetireagain.
• Afterthetirebeadsseatintherimflanges, checkforair leakage.

○Inflatethetireslightlyabovestandardinflation.

OUseasoapandwatersolutionorsubmergethetire, and checkforbubblesthatwouldindicateleakage.

• Adjust the air pressure to the specified pressure (see Air Pressure Inspection in the Periodic Maintenance chapter).
• Installtheairvalvecap.
• Adjustthewheelbalance(seeBalanceAdjustment).

TireRepair

Currentlytwotypesofrepairfortubelesstireshavecome intowideuse.Onetypeiscalledatemporary(external)repairwhichcanbecarriedoutwithoutremovingthetirefrom therim,andtheothertypeiscalledpermanent(internal)repairwhichrequirestireremoval.Itisgenerallyunderstoodthathigherrunningdurabilityisobtainedbypermanent(internal)repairsthanbytemporary(external)ones. Also,permanent(internal)repairshavetheadvantageof permittingathoroughexaminationforsecondarydamage notvisiblefromexternalinspectionofthetire.Forthese reasons,Kawasakidoesnotrecommendtemporary(external)repair.Onlyappropriatepermanent(internal)repairs arerecommended.Repairmethodsmayvaryslightlyfrom maketomake.Followtherepairmethodsindicatedbythe manufactureroftherepairtoolsandmaterialssothatsafe resultscanbeobtained.

HubBearing

HubBearingRemoval

- Removethewheel(seeFront/RearWheelRemoval), and takeoutthefollowing.

Collars

Coupling(Outofrearhub)

GreaseSeals

- Usethebearingremovertoremovethehubbearings[A].

CAUTION

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageorwarpthedisc. Placewoodenblocksunderthewheelsothatthe discdoesnottouchtheground.

SpecialTools-BearingRemoverHead,20×22[B]: 57001-1293

BearingRemoverShaft, 13[C] :57001-1377

HubBearingInstallation

• Beforeinstallingthehubbearings,blowanydirtorforeign particlesoutofthehubwithcompressedairtoprevent contaminationofthebearings.
• Replacethebearingswithnewones.

NOTE

○ Installthebearingssothatthemarkedsidefacesout.

• Installthebearingsbyusingthebearingdriversetwhich doesnotcontactthebearinginnerrace.
• Pressineachbearing[A]rightuntiltheyarebottomed.

SpecialTool-BearingDriverSet[B]:57001-1129

• Replacethegreasesealswithnewones.
• Pressinthegreaseseals[A]sothatthesealsurfaceis flush[B] withtheend ofthe hole.
  ○Applyhigh-temperaturegreasetothegreaseseallips.

SpecialTool-BearingDriverSet[C]:57001-1129

HubBearing Inspection

Since the hub bearings are made to extremely close tolerances, the clearance cannot normally be measured.

NOTE

○ Donotremoveanybearingsforinspection. Ifanybearingsareremoved, they will need to be replaced with new ones.

• Turneach bearinginthehubbackandforth[A]while checkingforplays,roughnessorbinding.
  ★Ifbearingplay,roughnessorbindingisfound,replacethe bearing.
• Examinethebearingseal[B]fortearsorleakage.
  ★Ifthesealistornorisleaking,replacethebearing.

HubBearing

HubBearingLubrication

NOTE

○Sincethehubbearingsarepackedwithgreaseand sealed,lubricationisnotrequired.

FinalDrive

TableofContents

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

WheelAlignmentInspection/Adjustment....11-6

Drive Chain Wear Inspection 11-6

Drive Chain Lubrication.... 11-6

Drive Chain Removal 11-6

Drive Chain Installation 11-7

Sprocket, Coupling 11-10

Engine Sprocket Removal 11-10

Engine Sprocket Installation 11-11

Rear Sprocket Removal.... 11-11

Rear Sprocket Installation.... 11-11

Coupling Installation.... 11-12

Coupling Bearing Removal 11-12

Coupling Bearing Installation 11-12

Coupling Bearing Inspection 11-13

Coupling Bearing Lubrication.... 11-13

Coupling Damper Inspection.... 11-13

Sprocket Wear Inspection.... 11-13

Rear Sprocket Warp Inspection 11-14

GK02088B75 C

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1	Engine Sprocket Nut	125	12.7	92	MO
2RearAxleNut10811.080
3	Rear Sprocket Nuts	59	6.0	44
4	Speed Sensor Bolt	7.8	0.80	69 in·lb	L
5	Speed Sensor Bracket Bolts	9.8	1.0	87 in·lb

G: Applygrease.
HG: Applyhigh-temperature grease.
HO: Apply heavyoil.
L: Applya non-permanentlockingagent.
MO: Applymolybdenumdisulfide oilsolution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts

Specifications

ItemStandardServiceLimit
DriveChain
Drive Chain Slack	30 ~ 40 mm (1.2 ~ 1.6 in.)	-- --
Drive Chain Wear (20-link Length)	317.5 ~ 318.2 mm (12.50 ~ 12.53 in.)	323 mm (12.7 in.)
StandardChain:
MakeENUMA-- --
TypeEK520MVXL1-- --
Link	114 links	-- --
Sprockets
Rear Sprocket Warp	0.4 mm (0.016 in.) or less	0.5 mm (0.020 in.)

SpecialTools

InsideCirclipPliers: 57001-143

Line drawing of a pair of pliers (no text or symbols)

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

DriveChain

DriveChainSlackInspection

- RefertotheDriveChainSlackInspectioninthePeriodic Maintenancechapter.

DriveChainSlackAdjustment

- RefertotheDriveChainSlackAdjustmentinthePeriodic Maintenancechapter.

WheelAlignmentInspection/Adjustment

- RefertotheWheelAlignmentInspectioninthePeriodic Maintenancechapter.

DriveChainWearInspection

- RefertotheDriveChainWearInspectioninthePeriodic Maintenancechapter.

DriveChainLubrication

- RefertotheDriveChainLubricationConditionInspection inthePeriodicMaintenancechapter.

DriveChainRemoval

NOTE

○ Sincethedrivechainisinstalledthroughtheswingarm, thechaincannotberemovedotherthanbycuttingit. Preparethenewlinkpin, linkplate, greaseseals, and toolsforrejoiningthechain.

- Usingasuitabletool, cutthedrivechainbyremovingthe linkpins.

RecommendedTool: EKJointTool#50

CAUTION

ReadtheToolManualbeforeremoving.

Body[A]

Handlebar[B]

CuttingandRivetingPin[C]

ForCutting[D]

ForRiveting[E]

PlateHolder(a)[F]

PlateHolder(b)[G]

Gauge[H]

- Grind[A]thepinheadtomakeitflat.

- Setthecuttingandrivetingpin[B]asshown.

DriveChain

• Screwthepinholderuntilittoucheschainpin.

• Besurethatthecuttingpinhitscenterofchainpin.

• Screwthehandlebar[A]intobody.

• Turnthepinholderwithwrench[B]clockwisetoextract chainpin.

Technical line drawing of a mechanical assembly with rollers and a shaft, showing a curved arrow indicating motion (no text or symbols)

DriveChainInstallation

• Engagethenewdrivechaintotheolddrivechainandpull theendoftheolddrivechainuntiltheyarechangingthe position.
• Removetheolddrivechainfromthenewdrivechain.
• Applygreasetothelinkpins[A]andgreaseseals[B][C].
• Engagethedrivechainontherearsprocketthroughthe swingarm.
• Insertthelinkpinsinthedrivechainends.
  • Installthegreaseseals[C].
  • Installthelinkplatesothatthemark[D]facesout.
• Pushthelinkplatebyhandorpliertofixit.
• Incaseofgreasesealchain,besuretosetthegrease sealscorrectly.
• Settheplateholder(a)[A]andplateholder(b)[B]onthe body.

11-8FINALDRIVE

DriveChain

• Fittheplateholder(a)tolinkplate.

• Turnthepinholderbyhanduntilplateholder(b)touches theotherlinkplate.

• Turnthepinholderbywrenchclockwiseuntiltwopinsof linkcomeintogrooveofplateholder(a).
  • Takeofftheplateholder(a).

- Settheplateholder(b)[A]andcuttingandrivetingpin[B]asshown.

- Turnthepinholderuntilrivetingpintoucheslinkpin.

• Turnthewrenchclockwiseuntiltipofrivetingpinhitsof linkpin.
  • Rivetit.
• Sameworkfortheotherlinkpin.

Mechanical assembly diagram showing a rotating shaft and chain mechanism (no text or symbols)

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical line drawing of a mechanical assembly with rotating shaft and housing (no text or symbols)

Technical line drawing of a mechanical assembly with spring-loaded components and a curved arrow indicating rotation (no text or symbols)

DriveChain

• Afterstaking, checkthestakedareaofthelinkpinfor cracks.
• Measuretheoutsidediameter[A]ofthelinkpinandlink plateswidth[B].

LinkPinOutsideDiameter

Standard: 5.7 \~ 6.0 mm (0.22 \~ 0.24 in.)

LinkPlatesOutsideWidth

Standard: 17.25 \~ 17.45 mm (0.679 \~ 0.687 in.)

★ If thereading exceed sthespecified length, cut andrejoin thechain again.
- Check:
MovementoftheRollers
- Adjustthedrivechainsslackafterinstallingthechain(see DriveChainSlackAdjustmentinthePeriodicMaintenancechapter).

11-10FINALDRIVE

Sprocket, Coupling

EngineSprocketRemoval

- Remove: EngineSprocketCoverBolts[A] EngineSprocketCover[B]

- Remove: SpeedSensorBracketBolts[A] SpeedSensorBracket[B]

- Flattenoutthebendedwasher[A]. - Removetheenginesprocketnut[B]andwasher.

NOTE

○ Whenlooseningtheenginesprocketnut, holdtherear brakeon.

• Raisetherearwheeloffthegroundwithstand.
• Removetheaxlecotterpin, and loosentherearaxlenut.
• Loosenthedrivechain(seeDriveChainSlackAdjustmentinthePeriodicMaintenancechapter).
• Removethedrivechainfromtherearsprockettowardthe right.
• Pulltheenginesprocket[A]withdrivechain[B]offthe outputshaft[C].
• Disengagethedrivechainfromtheenginesprocket.

Mechanical component diagram showing a central circular component with labeled points A and B, surrounded by springs and gears (no readable text or symbols)

Mechanical gear assembly with labeled components A and B (no readable text or symbols beyond labels)

Sprocket, Coupling

EngineSprocketInstallation

• Replacethesprocketwasherandaxlecotterpin.
• Installtheenginesprocket[A]sothat"OUTSIDE"letters faceoutward.
• Applymolybdenumdisulfideoilsolutiontothethreads oftheoutputshaftandseatingsurfaceoftheengine sprocketnut.
• Aftertorquingtheenginesprocketnut,bendtheoneside ofthewasher[B]overthenut.

NOTE

○ Tightentheenginesprocketnutwhileapplyingtherear brake.

- Tighten:

Torque-EngineSprocketNut:125N·m(12.7kgf·m,92ft·lb) SpeedSensorBracketBolts:9.8N·m(1.0kgf·m, 87in·lb)

• Installtheenginesprocketcover, andtightenthebolts.
• Adjustthedrivechainslackafterinstallingthesprocket (seeDriveChainSlackAdjustmentinthePeriodicMaintenancechapter).
• Bendtheendofaxlecotterpinsurelyaftertighteningthe axlenut(seeRearWheelInstallationintheWheels/Tires chapter).

RearSprocketRemoval

- Removetherearwheel(seeRearWheelRemovalinthe Wheels/Tireschapter).

CAUTION

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageorwarpthedisc. Placewoodenblocksunderthewheelsothatthe discdoesnottouchtheground.

• Removetherearsprocketnuts[A].
• Removetherearsprocket[B].

RearSprocketInstallation

• Installthesprocketfacingthetoothnumbermarking[A] outward.
• Tightentherearsprocketnuts. Torque-RearSprocketNuts:59N·m(6.0kgf·m,44ft·lb)
• Installtherearwheel(seeRearWheelInstallationinthe Wheels/Tireschapter).

Close-up of a mechanical gear with visible teeth and central knob (no text or symbols)

11-12FINALDRIVE

Sprocket, Coupling

Coupling Installation

• Applyhigh-temperaturegreasetothecouplinggrease seallips[A].

• Applygreasetothecouplinginternalsurface[B].

• Greasethefollowing. WheelFlangePortion[A] O-ring[B]
  • Installthecollar[C].

CouplingBearingRemoval

• Remove:
  Coupling
  GreaseSeal
  Circlip[A]

SpecialTool-InsideCirclipPliers:57001-143

• Removethebearing[A]bytappingfromthewheelside.
  SpecialTool-BearingDriverSet[B]:57001-1129

CouplingBearingInstallation

• Replacethebearingwithanewone.
• Pressinthebearing[A]untilitisbottomed.
  SpecialTool-BearingDriverSet[B]:57001-1129
• Replacethecirclipwithanewone.
  SpecialTool-InsideCirclipPliers:57001-143

Close-up of a mechanical component with a central circular bore and bolt holes (no visible text or symbols)

Sprocket, Coupling

• Replacethegreasesealwithanewone.
• Pressinthegreasesealsothatthesealsurfaceisflush withtheendofthehole.
  ○Applyhigh-temperaturegreasetothegreaseseallips.

SpecialTool-BearingDriverSet:57001-1129

CouplingBearingInspection

Sincethecouplingbearingismadetoextremelyclose tolerances, the clearance cannot normally be measured.

NOTE

- Itisnotnecessarytoremovethecouplingbearingfor inspection. Ifthebearingisremoved, itwillneedtobe replacedwithanewone.

• Turnthebearinginthecouplingbackandforth[A]while checkingforplays,roughnessorbinding.
  ★ If the bearing play, roughnessor binding is found, replace the bearing.
• Examinethebearingseal[B]fortearsorleakage.
  ★ Ifthesealistornorisleaking, replacethebearing.

CouplingBearingLubrication

NOTE

○Sincethecouplingbearingispackedwithgreaseand sealed,lubricationisnotrequired.

CouplingDamperInspection

• Removetherearwheelcoupling, and inspecttherubber dampers[A].
• Replacethedamperifitappearsdamagedordeteriorated.

SprocketWearInspection

• Visually inspect the engine and rears procketteeth for wear and damage.
  ★ Iftheteetharewornasillustrated, replacethesprocket, and inspect the drivechainwear (seeDriveChainWear Inspection in the Periodic Maintenance chapter). WornTooth (Engine Sprocket) [A] WornTooth (Rear Sprocket) [B] Direction of Rotation [C]

NOTE

○ Ifasprocketrequiresreplacement,thechainisprobablywornalso.Whenreplacingasprocket,inspectthe chain.

Close-up of a mechanical component with central hub and mounting holes (no visible text or symbols)

RearSprocketWarpInspection

• Raisetherearwheeloffthegroundwithstandsothatit willturnfreely.
• Setadialgauge[A]againsttherearsprocket[B]nearthe teethasshown,androtate[C]therearwheeltomeasure thesprocketrunout(warp). Thedifferencebetween the highestandlowestdialgaugereadingsistheamountof runout(warp).
  ★Iftherunoutexceedstheservicelimit,replacetherear sprocket.

RearSprocketWarp

Standard:0.4mm(0.016in.)orless

ServiceLimit:0.5mm(0.020in.)

Brakes

TableofContents

ExplodedView....12-2

Specifications....12-6

SpecialTools....12-7

BrakeLever, BrakePedal....12-8

BrakeLeverPositionAdjustment.12-8

BrakePedalPositionInspection..12-8

BrakePedalPositionAdjustment.12-8

BrakePedalRemoval....12-9

BrakePedallInstallation....12-9

Calipers....12-11

FrontCaliperRemoval....12-11

RearCaliperRemoval......12-11

CaliperInstallation....12-11

FrontCaliperDisassembly......12-12

FrontCaliperAssembly....12-12

RearCaliperDisassembly......12-12

RearCaliperAssembly....12-12

CaliperFluidSealDamage......12-12

RearCaliperDustBootand FrictionBootDamage....12-12

CaliperPistonandCylinder Damage....12-13

RearCaliperHolderShaftWear..12-13

BrakePads.... 12-14

FrontBrakePadRemoval......12-14

FrontBrakePadInstallation......12-14

RearBrakePadRemoval...... 12-14

RearBrakePadInstallation...... 12-14

BrakePadWearInspection......12-14

MasterCylinder.... 12-15

FrontMasterCylinderRemoval...12-15

FrontMasterCylinderInstallation 12-15

RearMasterCylinderRemoval.... 12-16

RearMasterCylinderInstallation.12-16

FrontMasterCylinder Disassembly.....12-16

RearMasterCylinder Disassembly.....12-16

MasterCylinderAssembly...... 12-16

MasterCylinderInspection......12-17

BrakeDisc.... 12-18

BrakeDiscRemoval....12-18

BrakeDisclInstallation....12-18

BrakeDiscWear.... 12-18

Brake Disc Warp 12-18

BrakeFluid.... 12-19

BrakeFluidLevelInspection...... 12-19

BrakeFluidChange.... 12-19

BrakeLineBleeding......12-19

BrakeHose.... 12-22

BrakeHoseRemoval/Installation.12-22

BrakeHoseInspection......12-22

ExplodedView

No.	Fastener	Torque			Remarks
		N·mkgf	f·mft·lb
1	BleedValve7.80.8069in·lb
2	BrakeHoseBanjoBolts252.518
3	Brake Lever Pivot Bolt	1.0	0.10	9 in·lb	Si
4	Brake Lever Pivot Bolt Locknut	5.9	0.60	52 in·lb
5	Front Brake Disc Mounting Bolts	27	2.8	20	L
6	Front Brake Light Switch Screw	1.0	0.10	9 in·lb
7	FrontBrakeReservoirCapScrews	1.0	0.10	9 in·lb
8	Front Caliper Mounting Bolts	34	3.5	25
9	Front Master Cylinder Clamp Bolts	8.8	0.90	78 in·lb	S

B: Applybrakefluid.

L: Applyanon-permanentlockingagent.

R: ReplacementParts

S: Followthespecifiedtighteningsequence.

Si: Applysiliconegrease(ex. PBCgrease).

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	·mft·lb
1BleedValve7.80.8069in·lb
2BrakeHoseBanjoBolts252.518
3BrakePedalBolt8.80.9078in·lb
4	Rear Brake Disc Mounting Bolts	27	2.8	20	L
5	Rear Caliper Mounting Bolts	25	2.5	18
6	Rear Master Cylinder Mounting Bolts	25	2.5	18
7	RearMasterCylinder Push RodLocknut	181.8	3

B: Applybrakefluid.
G: Applygrease.
L: Applyanon-permanent lockingagent.
R: ReplacementParts
Si: Apply silicone grease (ex. PBC grease).

Specifications

ItemStandardServiceLimit
BrakeLever,BrakePedalBrakeLeverPosition5-wayadjustable(tosuitrider)-- --BrakeLeverFreePlayNon-adjustable-- --PedalFreePlayNon-adjustable-- --PedalPositionAbout40mm(1.6in.)belowtopoffootpeg-- --
BrakePadsLiningThickness:FrontRear	4.5mm(0.18in.)1mm(0.04in.)5.0mm(0.20in.)1mm(0.04in.)
BrakeDiscThickness:FrontRearRunout	4.3 ~ 4.7 mm (0.17 ~ 0.19 in.)4.8 ~ 5.2 mm (0.19 ~ 0.20 in.)0.15 mm (0.006 in.) or less	4.0 mm (0.16 in.)4.5 mm (0.18 in.)0.3 mm (0.01 in.)
BrakeFluidGrade	DOT4	-- --

SpecialTools

InsideCirclipPliers: 57001-143

Line drawing of a pair of pliers (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

JackAttachment: 57001-1608

Technical line drawing of two mechanical fasteners with cylindrical base (no text or symbols)

12-8BRAKES

BrakeLever, BrakePedal

BrakeLeverPositionAdjustment

Thebrakeleveradjusterhas5positionssothatthebrake leverpositioncanbeadjustedtosuittheoperator'shand.

• Pushtheleverforwardandturntheadjuster[A]toalign thenumberwiththearrowmark[B]ontheleverholder.
  ○The distance from the griptotheleveris minimum at number 5 and maximum at number 1.

BrakePedalPositionInspection

- Check that the brake pedal [A] is in the correct position. Footpeg [B]

PedalPosition

Standard: About40mm(1.6in.)[C]belowtopof footpeg

★Ifitisincorrect,adjustthebrakepedalposition.

BrakePedalPositionAdjustment

NOTE

○ Usuallyitisnotnecessarytoadjustthepedalposition, butalwaysadjustitwhenthepushrodlocknuthasbeen loosened.

- Remove:

FrameCover(seeFrameCoverRemovalintheFrame chapter) Bolts[A] RightFootpegStay[B]

- Loosenthelocknut[A]andturnthepushrodwiththehex head[B]toachievethecorrectpedalposition.

★Ifthelength[C]shownis70±1mm(2.76±0.04in.), the pedalpositionwillbewithinthestandardrange.

- Tighten:

- Loosenthelocknut[A]andturnthepushrodwiththehex head[B]toachievethecorrectpedalposition. ★Ifthelength[C]shownis70±1mm(2.76±0.04in.), the pedalpositionwillbewithinthestandardrange. ● Tighten:

Torque-RearMasterCylinderPushRodLocknut:18N·m (1.8kgf·m, 13ft·lb)

• Installthefootpegstay, andtightenthebolts.

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

- Checkthebrakelightswitchoperation(seeBrakeLight SwitchOperationInspectioninthePeriodicMaintenance chapter).

Mechanical assembly diagram showing labeled components A and B (no readable text or symbols beyond labels)

BrakeLever, BrakePedal

BrakePedalRemoval

- Remove:

FrameCover(seeFrameCoverRemovalintheFrame chapter) Bolts[A] RightFootpegStay[B]

- Remove:

CotterPin[A] JointPin[B] RearBrakeLightSwitchSpring[C] ReturnSpring[D]

- Removethemountingbolt[E]andtakeoutthebrake pedal.

BrakePedallInstallation

• Applygreasetothepivotshaft[A]andinstallthewasher [B].
• Install:
  BrakePedal[C] Washer[D] BrakePedalBolt[E]

Torque-BrakePedalBolt:8.8N·m(0.90kgf·m,78in·lb)

• Hookthelowerendoftherearbrakelightswitchspring [A]onthepedalhook.

• Hooktheupperendofthereturnspring[B]onthepedal hook.

• Replacethecotterpinwithanewone.

• Insertthecotterpin[A]andbendthepinends[B].

Mechanical assembly diagram showing labeled components A and B (no readable text or symbols beyond labels)

Mechanical assembly diagram showing two labeled components (A and B) with no readable text or symbols

12-10BRAKES

BrakeLever, BrakePedal

• Installtherightfootpegstay, andtightenthebolts.
Torque-FootpegStayBolts:34N·m(3.5kgf·m,25ft·lb)
○Depressthebrakepedal[A]andthenaligntheboltsholes ofthemastercylinder[B].
Torque-RearMasterCylinderMountingBolts:25N·m(2.5 kgf·m,18ft·lb)
- Checkthebrakepedalposition(seeBrakePedalPosition Inspection).

Calipers

FrontCaliperRemoval

• Loosenthebanjobolt[A]atthebrakehoselowerend, andtightenitloosely.
• Unscrewthecalipermountingbolts[B], and detach the caliper[C] fromthedisc.
• Unscrewthebanjoboltandremovethebrakehoses[D] fromthecaliper(seeBrakeHoseRemoval/Installation).

CAUTION

Immediatelywashawayanybrakefluidthatspills.

NOTE

○Ifthecaliperistobedisassembledafterremovalandif compressedairisnotavailable,disassemblethecaliper beforethebrakehoseisremoved(seeFrontCaliper Disassembly).

RearCaliperRemoval

• Loosenthebanjobolt[A]atthebrakehoselowerend, andtightenitloosely.
• Unscrewthecalipermountingbolts[B], and detach the caliper[C] fromthedisc.
• Unscrewthebanjoboltandremovethebrakehose[D] fromthecaliper(seeBrakeHoseRemoval/Installation).

CAUTION

Immediatelywashawayanybrakefluidthatspills.

NOTE

○ Ifthecaliperistobedisassembledafterremovalandif compressedairisnotavailable,disassemblethecaliper beforethebrakehoseisremoved(seeRearCaliper Disassembly).

CaliperInstallation

• Installthecaliperandbrakehoselowerend.
○Replacethewashersoneachsideofhosefittingwithnew ones.
- Tighten:

Torque-CaliperMountingBolts

Front:34N·m(3.5kgf·m,25ft·lb)

Rear:25N·m(2.5kgf·m,18ft·lb)

BrakeHoseBanjoBolts:25N·m(2.5kgf·m,18ft·lb)

• Checkthefluidlevelinthebrakereservoirs.
• Bleedthebrakeline(seeBrakeLineBleeding).
• Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

WARNING

Donotattempttodrivethemotorcycleuntilafull brakeleverorpedalisobtainedbypumpingthe brakeleverorpedaluntilthepadsareagainstthe disc. Thebrakeswillnotfunctiononthefirstapplicationoftheleverorpedalifthisisnotdone.

Calipers

FrontCaliperDisassembly

- RefertotheCaliperRubberPartsReplacementinthePeriodicMaintenancechapter.

FrontCaliperAssembly

- RefertotheCaliperRubberPartsReplacementinthePeriodicMaintenancechapter.

RearCaliperDisassembly

- RefertotheCaliperRubberPartsReplacementinthePeriodicMaintenancechapter.

RearCaliperAssembly

- RefertotheCaliperRubberPartsReplacementinthePeriodicMaintenancechapter.

CaliperFluidSealDamage

Thefluidseal(pistonseal)[A]isplacedaroundthepistontomaintainclearancebetweenthepadandthedisc.If thesealisinapoorcondition,itcouldleadthepadtowear excessivelyorthebraketodrag,whichmaycausethetemperatureofthediscsorthebrakefluidtoincrease.

- Replacethefluidsealifitexhibitsanyoftheconditions listedbelow.

○Brakefluidleakagearoundthepad.

○Brakesoverheat.

○Considerabledifferenceininnerandouterpadwear.

○Sealandpistonarestucktogether.

★Ifthefluidsealisreplaced, replacethedustseal[B]as well. Also, replaceallsealseveryothertimethepadsare changed.

RearCaliperDustBootandFrictionBootDamage

- Check that the dustboot[A] and frictionboot[B] are not cracked, worn, swollen, or other wisedamaged.

★Iftheyshowanydamage,replaceit.

Calipers

CaliperPistonandCylinderDamage

• Visuallyinspectthepistons[A]andcylindersurfaces[B].
  ★Replacethecaliperifthecylinderandpistonarebadly scoresorrusty.

RearCaliperHolderShaftWear

Thecaliperbodymustslidessmoothlyonthecaliperholder shafts[A].Ifthebodydoesnotslidessmoothly,onepadwill wearmorethantheother,padwearwillincrease,andconstantdragonthediscwillraisebrakeandbrakefluidtemperature.

• Checktoseethatthecaliperholdershaftsarenotbadly wornorstepped, and thattherubberfrictionbootsarenot damaged.
  ★ Iftherubberfrictionbootisdamaged, replacetherubber frictionboot. Toreplacethefrictionboot, removethepads and thecaliperbracket.
  ★ Ifthecaliperholdershaftisdamage, replacothecaliper bracket.

BrakePads

FrontBrakePadRemoval

• Removethefrontcaliperwiththehoseinstalled(seeFront CaliperRemoval).
• Drawouttheholdershaftpin[A], andtakeofftheholder shaft[B].
• Removethepad[C]onthepistonside.
• Pushtheholder[D]towardsthepiston,andremovethe padoftheotherside[E]fromtheholdershaft[F].

FrontBrakePadInstallation

• Pushthecaliperpistonsinbyhandasfarastheywillgo.
  • Installtheanti-rattlespringinitscorrectposition.
• Installthepadonthepistonsidefirst, then installtheother padontheholder.
• Installthefrontcaliper(seeCaliperInstallation).

WARNING

Donotattempttodrivethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc.Thebrakewill notfunctiononthefirstapplicationoftheleverif thisisnotdone.

RearBrakePadRemoval

• Removetherearcaliperwiththehoseinstalled(seeRear CaliperRemoval).
• Drawouttheholdershaftpin[A], and takeofftheholder shaft[B].
• Removethepad[C]onthepistonside.
• Pushtheholder[D]towardsthepiston,andremovethe padoftheotherside[E]fromtheholdershaft[F].

RearBrakePadInstallation

• Pushthecaliperpistoninbyhandasfarasitwillgo.
  • Installtheanti-rattlespringinitscorrectposition.
• Installthepadonthepistonsidefirst, theninstalltheother padontheholder.
• Installtherearcaliper(seeCaliperInstallation).

WARNING

Donotattemptlodrivethemotorcycleuntilafull brakepedalisobtainedbypumpingthebrakepedal untilthepadsareagainstthedisc. Thebrakewill notfunctiononthefirstapplicationofthepedalif thisisnotdone.

BrakePadWearInspection

- RefertotheBrakePadWearInspectioninthePeriodic Maintenancechapter.

MasterCylinder

FrontMasterCylinderRemoval

- Removethebanjobolt[A]todisconnectthebrakehose fromthemastercylinderB.

- Disconnectthefrontbrakelightswitchconnectors[A]. - Unscrewtheclampbolts[B], and takeoffthemastercylinderasanassemblywiththereservoir, brakeleverand brakeswitchinstalled.

CAUTION

Immediatelywashawayanybrakefluidthatspills.

- Remove: BrakeLeverPivotBolt[A]andLocknut BrakeLever[B] FrontBrakeLightSwitch[C]

FrontMasterCylinderInstallation

- Installthefrontmastercylindersothatthepunchmark[A] ofthehandlebarisalignedwiththematingsurface[B]of themastercylinderclamptolevelthereservoir.

- Themastercylinderclampmustbeinstalledwiththearrowmark[A]upward.

- Tightentheupperclampbolt[B]first,andthenthelower clampbolt[C].Therewillbeagapatthelowerpartofthe clampaftertightening.

Torque-FrontMasterCylinderClampBolts:8.8N·m(0.90 kgf·m,78in·lb)

- Replacethewashersoneachsideofthehosefittingwith newones.

- Tightenthebrakehosebanjobolt.

Torque-BrakeHoseBanjoBolt:25N·m(2.5kgf·m,18ft·lb)

- Bleedthebrakeline(seeBrakeLineBleeding).

- Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

12-16BRAKES

MasterCylinder

RearMasterCylinderRemoval

- Unscrewthebrakehosebanjobolt[A]onthemastercylinder(seeBrakeHoseRemoval/Installation).

• Unscrewthemastercylindermountingbolts[A].
• Removethecotterpin[B].

NOTE

○ Pulloffthejointpinwhilepressingdownthebrake pedal.

• Pulloffthereservoirhoselowerend[C], anddrainthe brakefluidintoacontainer.
• Removethemastercylinder.

RearMasterCylinderInstallation

• Replacethecotterpin[A]withanewone.
• Replacethewashersoneachsideofhosefittingwithnew ones.
• Tightenthefollowingbolts.

Torque-RearMasterCylinderMountingBolts:25N·m(2.5 kgf·m,18ft·lb)

Brake Hose Banjo Bolt: 25N·m (2.5kgf·m

• Bleedthebrakeline(seeBrakeLineBleeding).
• Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

FrontMasterCylinderDisassembly

- RefertotheMasterCylinderRubberPartsReplacement inthePeriodicMaintenancechapter.

RearMasterCylinderDisassembly

- RefertotheMasterCylinderRubberPartsReplacement inthePeriodicMaintenancechapter.

MasterCylinderAssembly

- RefertotheMasterCylinderRubberPartsReplacement inthePeriodicMaintenancechapter.

Close-up of mechanical components with labeled component A (no readable text or symbols beyond label)

MasterCylinder

MasterCylinderInspection

• Removethemastercylinders(seeFront/RearMaster CylinderRemoval).
• Disassemblethefrontandrearmastercylinders.
• 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].
  ★Ifamastercylinderorpistonshowsanydamage,replace them.
• Inspecttheprimarycup[C]andsecondarycup[D].
  ★Ifacupisworn,damagedsoftened(rotted),orswollen, thepistonassemblyshouldbereplacedtorenewthe cups.
  ★ Iffluidleakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.

FrontMasterCylinder[J]

• Checkthedustcovers[E]fordamage.
  ★ Iftheyaredamaged, replacethem.
• Checkthepistonreturnsprings[F]foranydamage.
  ★ Ifthespringsaredamaged, replacethem.
• Checkthatreliefport[G]andsupplyport[H]arenot plugged.
  ★ Ifthereliefportbecomesplugged, thebrakepadswill dragonthedisc. Blowtheportscleanwithcompressed air.

RearMasterCylinder[K]

BrakeDisc

BrakeDiscRemoval

- Removethewheel(seeFront/RearWheelRemovalinthe Wheels/Tireschapter).

- Unscrewthemountingbolts, and takeoffthedisc.

- Removethegaskets.

BrakeDiscInstallation

• Replacethegasketswithnewones.
• Installthebrakedisconthewheelsothatthemarkedside [A]facesout.
• Applyanon-permanentlockingagenttothethreadsof thefrontandrearbrakediscmountingbolts[B].
• Tighten:

Torque-BrakeDiscMountingBolts:27N·m(2.8kgf·m,20ft·lb)

BrakeDiscWear

• Measurethethicknessofeachdisc[A]atthepointwhere ithaswornthemost.
  ★Ifthedischaswornpasttheservicelimit,replaceit. MeasuringArea[B]

BrakeDiscsThickness

Standard:

Front 4.3 \~ 4.7 mm (0.17 \~ 0.19 in.)

Rear 4.8 \~ 5.2 mm (0.19 \~ 0.20 in.)

ServiceLimit:

Front 4.0mm(0.16in.)

Rear 4.5mm(0.18in.)

BrakeDiscWarp

- Raisethewheeloffthegroundwithjack(seeFront/Rear WheelRemovalintheWheels/Tireschapter).

SpecialTools-Jack:57001-1238

JackAttachment:57001-1608

○Forfrontdiscinspection, turn the handlebarfully to one side.

• Setupadialgaugeagainstthedisc[A]asshownand measurediscrunout,whileturning[B]thewheelbyhand.
  ★ Ifrunoutexceedstheservicelimit,replacethedisc.

DiscRunout

Standard:0.15mm(0.006in.)orless

ServiceLimit:0.3mm(0.01in.)

BrakeFluid

BrakeFluidLevelInspection

- RefertotheBrakeFluidLevelInspectioninthePeriodic Maintenancechapter.

BrakeFluidChange

- RefertotheBrakeFluidChangeinthePeriodicMaintenancechapter.

BrakeLineBleeding

Thebrakefluidhasaverylowcompressioncoefficientso thatalmostallthemovementofthebrakeleverorpedal istransmitteddirectlytothecaliperforbrakingaction.Air, however,iseasilycompressed.Whenairentersthebrake lines,brakeleverorpedalmovementwillbepartiallyused incompressingtheair.Thiswillmaketheleverorpedalfeel spongy,andtherewillbealossinbrakingpower.

WARNING

Besuretobleedtheairfromthebrakelinewhen-everbrakeleverorpedalactionfeelssoftor spongyafterthebrakefluidischanged,orwheneverabrakelinefittinghasbeenloosenedforany reason.

NOTE

○ Theproceduretobleedthefrontbrakelineisasfollows. Bleedingtherearbrakelineisthesameasforthefront brake.

• Removethereservoircap[A]anddiaphragm.
• Fillthereservoirwithfreshbrakefluidtotheupperlevel lineinthereservoir.

• Slowlypumpthebrakeleversealtimesuntilnoair bubblescanbeseenrisingupthroughthefluidfromthe holesatthebottomofthereservoir.
  ○Bleedtheaircompletelyfromthemastercylinderbythis operation.

• Removetherubbercapfromthebleedvalve[A]onthe caliper.

• Attachaclearplastichose[B]tothebleedvalve, and run theotherendofthehoseintoacontainer.

Close-up mechanical assembly diagram showing components labeled A and B (no readable text or symbols)

BrakeFluid

• Bleedthebrakelineandthecaliper.
  ○Repeatthisoperationuntilnomoreaircanbeseencomingoutintotheplastichose.

• Pumpthebrakeleveruntilbecomeshard, and apply thebrakeandholdit[A].

• Quickly open and close [B] the bleed valv while holding the brake applied.
• Releasethebrake[C].

NOTE

○ Thefluidlevelmustbecheckedoftenduringthebleedingoperationandreplenishedwithfreshbrakefluidas necessary. If thefluidinthereservoirrunscompletely outanytimeduringbleeding, thebleedingoperation mustbedoneoveragainfromthebeginningsinceair willhaveenteredtheline.
○ Tapthebrakehoselightlyfromthecalipertothereservoirformorecompletebleeding.
○ FrontBrake: Firstbleedingtherightcaliperthenrepeat theabovestepsfortheleftcaliper.

• Removetheclearplastichose.
• Installthediaphragmandreservoircap.
• Tighten:

Torque-FrontBrakeReservoirCapScrews:1.0N·m(0.10 kgf·m,9in·lb)

• Follow the procedure below to install therear brake fluid reservoir cap correctly.
  ○First,tightentherearbrakefluidreservoircap[B]clockwise[C]byhanduntilslightresistanceisfeltindicating thatthecapisseatedonthereservoirbody,thentighten thecapanadditional1/6turn[D]whileholdingthebrake fluidreservoirbody[A].

- Tightenthebleedvalve, and installtherubbercap.

Torque-BleedValve:7.8N·m(0.80kgf·m,69in·lb)

• Checkthefluidlevel(seeBrakeFluidLevelInspectionin thePeriodicMaintenancechapter).
• Afterbleedingisdone, checkthebrakeforgoodbraking power, nobrakedrag, andnofluidleakage.

WARNING

When working with the disc brake, observ the precautions listed below.

1. Neverreuseoldbrakefluid.
2. Donotusefluidfromacontainerthathasbeenleft unsealedorthathasbeenopenforalongtime.

3. Donotmixtwotypesandbrandsoffluidforusein thebrake. Thislowersthebrakefluidboilingpoint andcouldcausethebraketobeineffective. It may also cause therubberbrakepartstodeteriorate.

4. Don'tleavethereservoircapofforanylengthof timetoavoidmoisturecontaminationofthefluid.

5. Don't changethe fluid in therain or when a strong wind is blowing.

6. Except forthediscpadsanddisc, use only disc brake fluid, isopropylalcohol, orethylalcohol for cleaning of the brake parts. Donot 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 difficult to wash off completely and while eventually deteriorate the rubber used in the disc brake.

7. When handling the discpadsordisc, be careful that nodiscbrakefluidoranyoilgetsonthem. Cleanoff any fluidorolthatinadvertently gets on the pads or disc with a high-flash pointsolvent. Donotuse one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.

8. Brakefluidquicklyruinspaintedsurfaces; any spilledfluidshouldbecompletelywipedupimmediately.

9. If any of the brakeline fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE.

BrakeHose

BrakeHoseRemoval/Installation

- RefertotheBrakeHoseandPipeReplacementinthe PeriodicMaintenancechapter.

BrakeHoseInspection

- RefertotheBrakeHoseDamageandInstallationConditionInspectioninthePeriodicMaintenancechapter.

Suspension

TableofContents

Exploded View.... 13-2

Specifications 13-6

Special Tools 13-7

Front Fork 13-9

Front Fork Removal 13-9

Front Fork Installation 13-9

Front Fork Oil Change 13-9

Front Fork Disassembly 13-11

Front Fork Assembly 13-12

Inner Tube Inspection 13-13

Dust Seal Inspection 13-13

Fork Spring Inspection 13-14

Rear Shock Absorber 13-15

Spring Preload Adjustment 13-15

Rear Shock Absorber Removal 13-15

Rear Shock Absorber Installation 13-16

Rear Shock Absorber Inspection 13-16

Swingarm.... 13-17

Swingarm Removal.... 13-17

Swingarm Installation.... 13-17

Swingarm Bearing Removal 13-18

Swingarm Bearing Installation 13-18

SwingarmBearing,SleeveInspection....13-19

Swingarm Bearing Lubrication 13-20

Chain Guide Inspection.... 13-20

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1	FrontAxleClampBolt	343.525
2	FrontForkBottomAllenBolts303.122L
3	FrontForkClampBolts(Lower)202.015AL
4	FrontForkClampBolts(Upper)	202.015
5	FrontForkTopPlugs252.518

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanentlocking agent.
R: ReplacementParts

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1	RearShockAbsorberBolt	596.044
2RearShockAbsorberNut596.044
3SwingarmPivotShaftNut10811.080

G:Applygrease.
R:ReplacementParts

Specifications

ItemStandard
FrontFork(PerOneUnit)
ForkInnerTubeOutsideDiameter41mm	(1.6in.)
AirPressure	Atmosphericpressure(Non-adjustable)
ForkSpringSettingNon-adjustable
DamperSettingNon-adjustable
ForkOil:
ViscosityKAYABAKHL34-G10orequivalent
Amountapprox.390mL(13.2USoz.)(whenchangingoil)
ForkOilLevel115±2mm(4.5±0.08in.)(belowfrominnertubetopwithfullycompressed,withoutforspring)
Fork Spring Free Length	277.8 mm (10.94 in.) (Service limit 272 mm (10.7 in.))
RearShockAbsorber
Spring Preload	3rd position (Adjustable Range: 1st ~ 7th position)
GasPressure	980kPa( 10kgf/cm^2 ,142psi,Non-adjustable)

SpecialTools

InsideCirclipPliers: 57001-143

Line drawing of a pair of pliers (no text or symbols)

ForkCylinderHolderHandle: 57001-183

Simple line drawing of a long rod or tool with a flanged end and a small circular end (no text or symbols)

ForkCylinderHolderAdapter: 57001-1057

Technical line drawing of a conical mechanical component (no text or symbols)

OilSeal&BearingRemover: 57001-1058

Technical line drawing of a mechanical component assembly (no text or symbols)

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing various circular components, no text or symbols present

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

ForkOilSealDriver,41φ 57001-1288

Technical line drawing of two mechanical bracket components (no text or symbols)

ForkOilLevelGauge: 57001-1290

Technical line drawing of mechanical components including a cylindrical spring and a coiled spring (no text or symbols)

JackAttachment: 57001-1608

Technical line drawing of two mechanical fasteners with cylindrical base (no text or symbols)

StemBearingDriver,28¢ 57001-1610

Technical line drawing of a mechanical component with two views: top and side (no text or symbols)

SpecialTools

Spacer,28: 57001-1663

ST571663ST C

FrontFork

FrontForkRemoval

- Remove:

FrontWheel(seeFrontWheelRemovalinthe Wheels/Tireschapter)

FrontFender(seeFrontFenderRemovalintheFrame chapter)

★Loosentheupperforkclampbolt[A]andforktopplug[B]beforehandiftheforklegistobedisassembled.

NOTE

○Loosenthetopplugafterlooseningtheupperfork clampbolt.

• Loosentheupperforkclampboltandlowerforkclamp bolts[C].
• Withatwistingmotion,worktheforklegdownandout.

FrontForkInstallation

• Installtheforkwiththeupperendoftheinnertubeflush [A]againstthetopsurfaceofthestemhead[B].
• Tighten:

Torque-FrontForkClampBolts(Lower):20N·m(2.0 kgf·m,15ft·lb)

FrontForkTopPlug:25N·m(2.5kgf·m,18ft·lb)

NOTE

○ Tightenthetopplugbeforetighteningtheupperfork clampbolt.
○ Tightenthetwoclampboltsalternatelytwotimestoensureeventighteningtorque.

• Tighten:
  Torque-FrontForkClampBolt(Upper):20N·m(2.0kgf·m, 15ft·lb)
• Installtheremovedparts(seeappropriatechapters).

FrontForkOilChange

• Removethefrontfork(seeFrontForkRemoval).
• Remove:

Top Plug [A] with O-ring Collar[B]

ForkSpringSeat[C]

ForkSpring[D]

FrontFork

• Compress[A]thefork[B]upsidedowntodrawouttheoil intothesuitablecontainer[C].
• Pourinthespecifiedamountofoil.

ForkOil

Viscosity:

KAYABAKHL34-G10or equivalent

Amount(PerSide):

Whenchangingoil: approx.390mL(13.2USoz.)

Afterdisassembly

andcompletelydry:458±4mL(15.5±0.14USoz.)

NOTE

○ Movetheoutertubeupanddownafewtimestoremove theairthatistrappedintheforkoilinordertostabilize theoillevel.

• Holdtheoutertubeverticallyinaviseandcompressthe forkcompletely.
• Waituntiltheoillevelstabilizes.
• Usetheforkoillevelgauge[A]tomeasurethedistance betweenthetopoftheinnertubetotheoillevel.

SpecialTool-ForkOilLevelGauge:57001-1290

○Settheoillevelgaugestopper[B]sothatthedistance[C] fromthebottomofthestoppertothelowerendofthepipe isthestandardoilleveldistance.
○Acorrectmeasurementcannotbeobtainedunlessthe levelgaugepipeisplacedinthecenteroftheinnertube.

OilLevel(fullycompressed, withoutspring)

Standard:115±2mm(4.5±0.08in.)

• Placethestopperofthelevelgaugeatthetop[D]ofthe innertube[E]andpullthehandleslowlytodrawoutthe excessoilfromforkintothegauge,thusattainingthestandardlevel.
  Olfnotoilisdrawnout, there is not enough oil in the fork. Pour insomemore oil and measure again.

• Repeatthesameprocedureforadjustingtheotherfork.

• Installtheforkspring[A],forkspringseat[B]andcollar [C].
• InspectthetopplugO-ringandreplaceitwithanewone.
• Installthefrontfork(seeFrontForkInstallation).

FrontFork

FrontForkDisassembly

• Removethefrontfork(seeFrontForkRemoval).
• Removethetopplug[A]withO-ring,takeoutthecollar [B],forkspringseat[C],andforkspring[D].
• Draintheforkoil(seeFrontForkOilChange).

- RemovetheAllenbolt[A]fromthebottomofthefork. SpecialTools-ForkCylinderHolderHandle[B]:57001-183 ForkCylinderHolderAdapter[C]:57001 -1057

NOTE

○Holdtheoutertubeinavise[D],stopthecylinderunit[E]fromturningbyusingthespecialtools,andunscrew theAllenbolt.

• Removethecylinderunit[A], washer, and the spring[B] from the innertube.
• Removethefollowingfromthetopoftheoutertube. DustSeal[A] RetainingRing[B]
• Separatetheinnertube[A]fromtheoutertube[B].

NOTE

○Fromthecompressedstate, firmlypulldowntheouter tubeafewtimestowardsthedirectionofelongation.

Mechanical component with labeled parts A and B, showing internal structure without any text or symbols beyond labels

13-12 SUSPENSION

FrontFork

- Removethefollowingfromtheinnertube.

InnerGuideBushing[A]

OuterGuideBushing[B]

Washer[C]

OilSeal[D]

- Removethecylinderbase[A]fromthebottomoftheouter tube.

FrontForkAssembly

• CheckthetopplugO-ringandreplaceitwithanewone.
• Replacethefollowingpartswithnewones.

RetainingRing[A]

DustSeal[B]

OilSeal[C]

InnerGuideBushing[D]

OuterGuideBushing[E]

ForkBottomAllenBoltGasket[F]

• Installtheguidebushingontheendoftheinnertube.
- Insertthecylinderunitandthespringintotheinnertube, andinstallthecylinderbase[A]ontothecylinderend[B] thatprotrudesfromthebottom.

○Installthecylinderbasestartingwithitssteppedend.

- Inserttheinnertube, cylinderunit, washer, spring, and cylinderbaseasasetintotheoutertube.

• Installtheguidebushingintotheoutertube.
- Afterinstallingthewasher, installtheoilseal[A]byusing theforkoilsealdriver[B].

SpecialTool-ForkOilSealDriver,41:57001-1288

• Installtheretainingringintotheoutertube.
• Installthedustsealbyhand.

Close-up of a mechanical component with a white connector labeled 'A' and a metallic handle (no text or symbols beyond label)

FrontFork

• Applynon-permanentlockingagenttothethreadsofthe bottomAllenbolt[A].
• Holdthefrontforkhorizontallyinavise[B].
• Holdthecylinderunit[C]withthespecialtoolsandtighten thebottomAllenbolttosecurethecylinderinplace.

Torque-FrontForkBottomAllenBolt:30N·m(3.1kgf·m, 22ft·lb)

SpecialTools-ForkCylinderHolderHandle[D]:57001-183

ForkCylinderHolderAdapter[E]:57001

-1057

- Pourinthespecifiedtypeofoil(seeFrontForkOil Change).

InnerTubeInspection

• Visually inspect the innertube[A], and repair any damage.
• Nicksorrustdamagecansometimesberepairedbyusing awet-stonetoremovesharpedgesorraisedareaswhich causesealdamage.
  ★ Ifthedamageisnotrepairable,replaceiinnertube. Sincedamagetotheinnertubedamagestheoilseal, replacetheoilsealwhenevertheinnertubeisrepaired orreplaced.

CAUTION

Iftheinnertubeisbadlybentorcreased,replace it.Excessivebending,followedbysubsequent straightening,canweakentheinnertube.

• Temporarily assemble the inner and outer tubes, and pumpthemback and forthmanually to check for smooth operation.
• If you feel binding or catching, the inner and outer tubes must bereplaced.

WARNING

Astraightenedinnerorouterforktubemayfallin use, possibly causing an accident. Replace abadly bentordamaged inneroroutertube and inspect the othertubecarefully before reusing it.

DustSealInspection

• Inspectthedustseal[A]foranysignsofdeteriorationor damage.
  ★Replaceitifnecessary.

Technical line drawing of a cylindrical mechanical component with a labeled connection point A (no text or symbols beyond label)

Technical line drawing of a coiled spring with a labeled point A (no text or symbols beyond label)

FrontFork

ForkSpringInspection

• Measurethefreelength[A]oftheforkspring[B].
  ★Ifthemeasuredlengthisshorterthantheservicelimit,the springmustbereplaced.Ifthefreelengthofthereplacementspringandthatoftheremainingspringvarygreatly, theremainingspringshouldalsobereplacedinorderto keeptheforklegsbalancedtoensurestability.

ForkSpringFreeLength

Standard:277.8mm(10.94in.)

ServiceLimit:272mm(10.7in.)

RearShockAbsorber

SpringPreloadAdjustment

- Usingthehookwrench[A],turntheadadjustingnut[B]to adjustthespringpreload.

○Thestandardadjustersettingforaverage-buildriderof68 kg(150lb)withnopassengerandnoaccessoriesis3rd position.

SpringPreloadSetting

StandardPosition: 3rdposition

AdjustableRange:1stto7thposition

- If the compression of the spring is not suited to the operating conditions, adjust to an appropriate position by referring to the table below.

SpringPreloadAdjustment

Adjuster Position	Damping Force	Shock Absorber Hardness	Load	Road Conditions	Driving Speed
1stWeak↑ ↑↓ ↓7th	↑ ↑ ↑↓ ↓ ↓Strong	Soft↑↓Hard	Light	Good	Low
			Heavy	Bad	Highway

RearShockAbsorberRemoval

- Remove:

FrameCovers(seeFrameCoverRemovalintheFrame chapter)

MufflerBody(see Muffler Body Removal in the Engine Top End chapter)

- Raisetherearwheeloffthegroundwithjack.

Special Tools - Jack:57001-1238

JackAttachment:57001-1608

- Squeezethebrakeleverslowlyandholditwithaband [A].

WARNING

Besuretoholdthefrontbrakewhenremovingthe shockabsorber,orthemotorcyclemaytallover. It could cause an accident and injury.

- Remove:

RightStayCover[A]

Close-up of a mechanical component with labeled point A and reference number 00258196 P (no readable text or symbols beyond labels)

13-16 SUSPENSION

RearShockAbsorber

- Remove:

UpperShockAbsorberBolt[A] LowerShockAbsorberNutandWasher LowerShockAbsorberBolt[B]

- Removetheshockabsorber[C]frombackward.

RearShockAbsorberInstallation

- Installationisthereverseofremoval. - Applygreasetothelipofoilsealsandbearingofrear shockabsorber.

○Besuretoinstalltheoilsealstotheshockabsorber.

- Tighten:

Torque-RearShockAbsorberBolt:59N·m(6.0kgf·m,44 ft·lb) RearShockAbsorberNut:59N·m(6.0kgf·m,44 ft·lb)

• Installtheremovedparts(seeappropriatechapters).

RearShockAbsorberInspection

- Removetherearshockabsorber(seeRearShockAbsorberRemoval).

- Visuallyinspectthefollowingitems. SmoothStroke OilLeakage CrackorDent

★Ifthereisanydamagetotherearshockabsorber,replace it.
- Visuallyinspecttherubberbushing.
★Ifitshowanysignsofdamage,replaceit.

Swingarm

SwingarmRemoval

- Remove: ChainCoverBolts[A]andCover[B]

• Remove: RightSideCover(seeSideCoverRemovalintheFrame chapter) FrameCovers(seeFrameCoverRemovalintheFrame chapter)
• Removethebrakehosebanjoboltfromtherearcaliper, freethebrakehose[A]fromtheclamps[B], and remove thefootpegstaywiththerearmastercylinder(seeRear CaliperRemovalintheBrakeschapter).
• Remove: MufflerBody(seeMufflerBodyRemovalintheEngine TopEndchapter) RearWheel(seeRearWheelRemovalinthe Wheels/Tireschapter)

- Raisetherearwheeloffthegroundwithjack.

SpecialTools-Jack:57001-1238 JackAttachment:57001-1608

- Removethelowershockabsorbernutandbolt[A].

• Removethedrivechain(seeDriveChainRemovalinthe FinalDrivechapter).
• Unscrewtheswingarmpivotshaftnut[A].
• Pulloffthepivotshaft[B], andremovetheswingarm.

Close-up of mechanical components with labeled section A (no readable text or symbols)

SwingarmInstallation

• Installationisthereverseofremoval.
  ○Applygreasetothelipoftheoilseals.
  ○Besuretoinstalltheoilsealandcollartotheswingarm.
• Tightenthepivotshaftnut.

Torque-SwingarmPivotShaftNut:108N·m(11.0kgf·m, 80ft·lb)

- Installtheremovedparts(seeappropriatechapters).

Swingarm

SwingarmBearingRemoval

- Remove:

Swingarm(seeSwingarmRemoval)

Collar[A]

OilSeals[B]

Sleeve[C]

Circlip[D]

SpecialTool-InsideCirclipPliers:57001-143

- Removetheballbearingandneedlebearings.

SpecialTool-OilSeal&BearingRemover[A]:57001-1058

SwingarmBearingInstallation

• Replacetheballandneedlebearings[A]withnewones.
• Installtheballandneedlebearingssothatthemanufac-turer'smarksfaceout.

SpecialTools-BearingDriverSet:57001-1129

StemBearingDriver, 28[B] :57001-1610

Spacer, 28:57001 - 1663

Swingarm

- Installtheneedlebearings[A],ballbearing[B]andoil seals[C]positionasshown.

Circlip[D]

25mm(0.98in.)[E]

17mm(0.67in.)[F]

1mm(0.04in.)[G]

0.5mm(0.02in.)[H]

1mm(0.04in.)[l]

23.5mm(0.93in.)[J]

6mm(0.24in.)[K]

SwingarmBearing, SleeveInspection

CAUTION

Donotremovethebearingsforinspection. Removalmaydamagethem.

- Inspecttheneedlebearings[A]andballbearinginstalled intheswingarm.

○Therollersandballinabearingnormallywearverylittle, andwearisdifficulttomeasure.Insteadofmeasuring, visuallyinspectthebearingforabrasion,discoloration,or otherdamage.

★ Iftheneedlebearingandsleeve[B]showanysingsof abnormalwear,discoloration,ordamage,replacethem asaset.

13-20 SUSPENSION

Swingarm

• Turnthebearingintheswingarmbackandforth[A]while checkingforplays,roughness,orbinding.
  ★Ifthebearingplay,roughness,orbindingisfound,replace thebearing.
• Examinethebearingseal[B]fortearsorleakage.
  ★Ifthesealistornorisleaking,replacehebearing.

SwingarmBearingLubrication

NOTE

○ Sincethebearingsarepackedwithgreaseandsealed, lubricationisnotrequired.

ChainGuideInspection

- RefertotheChainGuideWearInspectioninthePeriodic Maintenancechapter.

Steering

TableofContents

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

Stem Bearing Lubrication.... 14-8

Steering Stem Warp 14-9

StemCapDeterioration,Damage....14-9

Handlebar 14-10

Handlebar Removal 14-10

Handlebar Installation 14-10

ExplodedView

No.F	Fastener	Torque			Remarks
		N·mkgf·mft·lb
1	FrontForkClampBolts(Lower)	202.015	AL
2	FrontForkClampBolts(Upper)202.015
3	HandlebarHolderBolts252.518S
4	Left Switch Housing Screws	3.5	0.36	31 in·lb
5	Right Switch Housing Screws	3.5	0.36	31 in·lb
6	Steering Stem Head Bolt	108	11.0	80
7	SteeringStem Nut	202.015

AD: Apply adhesive.
AL: Tighten the two clamp bolts alternately two times to ensure even tighten torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.

SpecialTools

SteeringStemNutWrench: 57001-1100

Line drawing of a mechanical wrench tool (no text or symbols present)

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

SteeringStemBearingDriver,42.5: 57001-1344

Technical line drawing of a cylindrical mechanical component with a textured inner layer (no text or symbols)

SteeringStemBearingDriverAdapter,41.5:57001-1345

Simple line drawing of a cylindrical object with layered top surface (no text or symbols)

Steering

SteeringInspection

- RefertotheSteeringPlayInspectioninthePeriodicMaintenancechapter.

SteeringAdjustment

- RefertotheSteeringPlayAdjustmentinthePeriodic Maintenancechapter.

SteeringStem

Stem, StemBearingRemoval

- Remove:

FrontWheel(seeFrontWheelRemovalinthe

Wheels/Tireschapter)

HeadlightAssy(seeHeadlightRemoval/Installationin theElectricalSystemchapter)

Handlebar(seeHandlebarRemoval)

SteeringStemHeadBoltPlug[A]

SteeringStemHeadBolt[B]andWasher

FrontForkClampBolts(Upper)C

SteeringStemHead[D]

- Remove:

UnderBracketA

FrontForks(seeFrontForkRemovalintheSuspension chapter)

- Straightentheclaws[A]oftheclawwasher.

- Removethesteeringstemlocknut[B]andclawwasher [C].

- Pushingupthestembase, andremovethesteeringstem nut[A]withstemcap[B].

SpecialTool-SteeringStemNutWrench[C]:57001-1100

- Removethesteeringstem[D] underside.

- Removetheupperstembearinginnerraceandbearing.

- Toremovethebearingouterraces[A]pressedintothe headpipe[B],insertabar[C]intotherecessesofhead pipe,andapplyingittobothrecessalternatelyhammerit todrivetheraceout.

NOTE

○ Ifeithersteeringstembearingisdamaged,itisrecommendedthatboththeupperandlowerbearings(includingouterraces)shouldbereplacedwithnewones.

Close-up of a mechanical assembly with visible components and a labeled section (A), no readable text or symbols present.

SteeringStem

- Removethelowerbearinginnerrace[A]whichispressed ontothesteeringstemwithasuitablecommerciallyavailablechisel[B].

Stem, StemBearingInstallation

• Replacethebearingouterraceswithnewones.
• Applygreasetotheouterraces, and drivetheminto the headpipeatthesametime.

SpecialTool-BearingDriverSet[A]:57001-1129

• Replacethebearinginnerracesandoilsealwithnew ones.
• Applygreasetotheoilseal.
• Drivethelowerballbearinginnerraceappliedthegrease ontothestem.

SpecialTools-SteeringStemBearingDriver,42.5[A]: 57001-1344

SteeringStemBearingDriverAdapter, 41.5[B]:57001 - 1345

• Applygreasetothelowerballbearing[A], and install it onto the stem.

• Applygreasetotheupperballbearing[B]andinnerrace [C].

• Installthestem[A]throughtheheadpipeandinstallthe ballbearing[B]andinnerrace[C]onit.

• Installthestemcap[D]andsteeringstemnut[E].

Close-up of a mechanical component with labeled section A (no readable text or symbols)

Three ball bearing rings labeled A, B, and C, shown in grayscale without any text or symbols.

SteeringStem

• Settletheinnerracesinplaceasfollows.
  ○Tightenthesteeringstemnutwith39N·m(4.0kgf·m,29ft·lb)oftorquefirst,andloosenitafractionofaturnuntilitturnslightly.Afterwardtightenitagainwithspecifiedtorqueusingastemnutwrench[A]inthedirectionshown.
  ○Checkthatthereisnoplayandthesteeringstemturns smoothlywithouttrattles.Ifnot,thesteeringstembearings maybedamaged.

SpecialTool-SteeringStemNutWrench:57001-1100

Torque-SteeringStemNut:20N·m(2.0kgf·m,15ft·lb)

• Installtheclawwasher[A]sothatitsbentside[B]faces upward, and engage the bent claw with the grooves of stemlocknut[C].
• Handtightenthestemlocknutuntilittouchestheclaw washer.
• Tightenthestemlocknutclockwiseuntiltheclawsare alignedwiththegrooves(rangingfrom2ndto4th)ofstem nut[D],andbendthe2clawsdownward[E].
• Installthestemhead.
• Installthewasher, and tightenthestemheadbolt with specified torque.
• Installthefrontforks(seeFrontForkInstallationinthe Suspensionchapter).

NOTE

○ Tightentheupperforkclampboltsfirst, nextthestem headbolt, lastthelowerforkclampbolts.
○ Tightenthetwoclampboltsalternatelytwotimestoensureeventighteningtorque.

Torque-FrontForkClampBolts(Upper): 20N·m(2.0 kgf·m,15ft·lb)

SteeringStemHeadBolt:108N·m(11.0kgf·m,80ft·lb)

FrontForkClampBolts(Lower): 20N·m(2.0 kgf·m,15ft·lb)

WARNING

Donotimpedethehandlebarturningbyroutingthe cables,harnessesandhosesimproperly(seeCable, Wire,andHoseRoutingsectionintheAppendixchapter).

• Installthesteeringstemheadboltplug.
- Installtheremovedparts(seeappropriatechapters).

StemBearingLubrication

- RefertotheSteeringStemBearingLubricationinthePeriodicMaintenancechapter.

SteeringStem

SteeringStemWarp

• Whenever thesteering stem is removed, or if thesteering cannot be adjusted for smooth action, check thesteering stem for straightness.
  ★ Ifthesteeringstem[A]isbent,replacesteeringstem.

StemCapDeterioration, Damage

★Replacethestemcapifitsoilseal[A]showsdamage.

Close-up of a hand holding a coiled black hose with a labeled component (A), no visible text or symbols on the object itself.

14-10STEERING

Handlebar

HandlebarRemoval

• Remove:
  ClutchLeverAssembly[A]
  LeftSwitchHousing[B]
  LeftHandlebarWeight[C]

• Remove:
  FrontBrakeMasterCylinderA
  RightSwitchHousing[B]
  RightHandlebarWeight[C]
  ThrottleGrip[D]

• Removethehandlebarholderbolts[A].

• Removethehandlebarholder[B]andthenpulloutthe handlebar.

HandlebarInstallation

- Alignthepunchmark[A]onthehandlebarandthecorner edge[B]onthestemhead.

- Tightenthefrontholderboltsfirst, andthentherearholder bolts. Therewillbeagap[A]attherearpartofthehandlebarholderaftertightening.

Torque-HandlebarHolderBolts:25N·m(2.5kgf·m,18ft·lb)

Close-up of a mechanical component with two labeled points A, showing no visible text or symbols.

Handlebar

• Installtheclutchlever(seeClutchLeverInstallationinthe Clutchchapter).
• Applyadhesivecementtotheinsideofthelefthandlebar grip.

• Applyanon-permanentlockingagenttothelefthandlebar weightbolt.
  • Installtheleftswitchhousing.
  ○Fittheprojection[A]intoasmallhole[B]inthehandlebar.
  Torque-LeftSwitchHousingScrews:3.5N·m(0.36kgf·m, 31in·lb)

• Install:
  ThrottleGrip
  ThrottleCableTips[A]
  RightSwitchHousing

○Fittheprojection[B]intoasmallhole[C]inthehandlebar.

Torque-RightSwitchHousingScrews:3.5N·m(0.36 kgf·m,31in·lb)

• Applyanon-permanentlockingagenttotherighthandlebarweightbolt.
• Installthefrontbrakemastercylinder(seeFrontMaster CylinderInstallationintheBrakeschapter).

Frame

TableofContents

Exploded View 15-2

Seat 15-8

Seat Removal 15-8

Seat Installation 15-8

Fairings.... 15-9

Lower Fairing Removal 15-9

Lower Fairing Installation 15-9

Center Fairing Removal 15-9

Center Fairing Installation 15-9

Upper Fairing Removal 15-10

Upper Fairing Installation 15-10

Upper Fairing Bracket Removal 15-10

Inner Fairing Removal.... 15-11

Inner Fairing Installation.... 15-11

Side Covers 15-12

Side Cover Removal 15-12

Side Cover Installation 15-12

Seat Covers.... 15-13

Seat Cover Removal 15-13

Seat Cover Installation.... 15-13

Fenders 15-14

Front Fender Removal 15-14

Front Fender Installation 15-14

Flap and Rear Fender Rear Removal 15-14

Flap and Rear Fender Rear Installation 15-14

Rear Fender Front Removal 15-15

Rear Fender Front Installation 15-15

Frame 15-16

Frame Inspection 15-16

Sidestand.... 15-17

Sidestand Removal 15-17

Sidestand Installation.... 15-17

Frame Cover.... 15-18

Frame Cover Removal 15-18

Frame Cover Installation.... 15-18

Rear View Mirrors.... 15-19

Rear View Mirrors Removal 15-19

Rear View Mirrors Installation.... 15-19

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1	FootpegStayBolts	343.525
2SidestandBolt444.533
3SidestandSwitchBolt8.80.9078in·lbL

G:Applygrease.
L: Applyanon-permanentlockingagent.
R:ReplacementParts

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·	mft·lb
1	FrontFenderBolts3.90.4035in·lb
2	Front Fender Bracket Bolts	8.8	0.90	78 in·lb	L

L: Applyanon-permanentlockingagent.

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·	mft·lb
1	GrabRailMountingBolts	252.518
2	Lower Fairing Mounting Bolts	8.8	0.90	78 in·lb

15-8FRAME

Seat

SeatRemoval

- Inserttheignitionswitchkey[A]intotheseatlock,turning thekeyclockwise,pullingupontherearoftheseat[B], andpullingtheseatbackward.

SeatInstallation

- Sliptheseathook[A]underthebrace[B]onthefueltank bracket.

- Inserttheseatlatch[A]intothelatchhole[B].

- Pushdowntherearpartoftheseatuntilthelockclicks.

Fairings

LowerFairingRemoval

- Removethemountingbolts[A]andlowerfairing[B].

Mechanical assembly diagram showing components labeled A and B (no readable text or symbols beyond labels)

LowerFairingInstallation

- Installthelowerfairing, andtightenthemountingbolts.

Torque-LowerFairing, Mounting Bolts: 8.8N·m (0.90 kgf·m, 78in·lb)

CenterFairingRemoval

- Removethemountingbolts[A].

- Pullthecenterfairing[B]evenlyoutwardtoclearthestoppers.

- Disconnecttheturnsignalleadconnector[A].

Close-up of mechanical components with visible wiring and a labeled section (A), no readable text or symbols present.

- Removetheinnerfairing(seeInnerFairingRemoval).

- Removethebracketscrews[A]andturnsignallight[B].

CenterFairingInstallation

- Installtheturnsignallighttothecenterfairing.

- Installtheinnerfairing(seeInnerFairingInstallation).

Fairings

• Connecttheturnsignalleadconnector.
• Inserttheprojections[A]intotheholes[B].
  • Installthemountingbolts.

UpperFairingRemoval

• Remove:
  HeadlightAssy(seeHeadlightRemoval/Installationin theElectricalSystemchapter) MountingBolts[A] UpperFairings

Close-up of a mechanical component with labeled parts A, showing internal structure and mounting holes (no readable text or symbols)

UpperFairingInstallation

- Installationisthereverseofremoval.

UpperFairingBracketRemoval

- Remove: HeadlightAssy(seeHeadlightRemoval/Installationin theElectricalSystemchapter) MeterUnit(seeMeterUnitRemovalintheElectricalSystemchapter) Bolts[A]

- Freethefollowingpartsfromthebracket. ClutchCable IgnitionSwitchLead MainHarness BrakeHose ThrottleCables SwitchHousingLeads

- Removetheupperfairingbracket[B].

- Remove: Clamp[A] Bolts[B] UnderBracket[C]

Mechanical assembly diagram showing interconnected components labeled A and B (no readable text or symbols beyond labels)

Fairings

InnerFairingRemoval

- Remove: CenterFairings(seeCenterFairingRemoval) MountingScrews[A] InnerFairing[B]

InnerFairingInstallation

• Tightenthemountingscrews.
• Installthecenterfairings(seeCenterFairingInstallation).

15-12FRAME

SideCovers

SideCoverRemoval

• Removetheseat(seeSeatRemoval).
• Removethebolt[A].
• Pullthesidecover[B]evenlyoutwardtoclearthestoppers.

SideCoverInstallation

• Insertthetabs[A]intotheholes[B].
• Tightenthebolt.
• Installtheseat(seeSeatInstallation).

SeatCovers

SeatCoverRemoval

• Remove:
  Seat(seeSeatRemoval)
  Bolts[A]
  GrabRails[B]
  ScrewRivets[C]

• Pushthecentralpin, and then removethe quickrivets[A].

• Pullthefrontandrearportionsoftheseatcoveroutside, andthenremovetheseatcovers.

SeatCoverInstallation

• Installationisthereverseofremoval.
• Puttheprojection[A]intothegrommet[B]ontherear fenderrear.

- Puttheprojection[A]intothehole[B]oftheseatcover.

• Install: GrabRailsandBolts

Torque-GrabRailMountingBolts:25N·m(2.5kgf·m,18 ft·lb)

- Inserttheprojections[A]ofthecenterseatcoverintothe holes[B]ofthesideseatcover.

- Install: ScrewRivets Seat(seeSeatInstallation)

15-14FRAME

Fenders

FrontFenderRemoval

• Remove: BrakeHoseClamps[A] Bolts[B]withCollar(BothSide)
• Removethefrontfender[C].

FrontFenderInstallation

• Tighten: Torque-FrontFenderBolts:3.9N·m(0.40kgf·m,35in·lb)
• Installthebrakehoseclampstothefrontfenderholes.

FlapandRearFenderRearRemoval

• Remove: Seat(seeSeatRemoval) SeatCovers(seeSeatCoverRemoval) Tail/BrakeLightA

- Remove: Nuts[A]andBolts[B] Flap(withLicensePlateLight)

Close-up of a mechanical component with labeled point A (no readable text or symbols)

• Remove: SeatLockCableLowerEnd[A] QuickRivet[B]
• Freetheclampsfromtherearfenderrear.
• Pullouttherearfenderrearbackwardanddownward.

Close-up mechanical assembly showing internal components with labeled parts A and B (no readable text or symbols beyond labels)

FlapandRearFenderRearInstallation

- Installationisthereverseofremoval.

Fenders

RearFenderFrontRemoval

- Remove:

RearFenderRear(seeFlapandRearFenderRearRemoval) Battery(seeBatteryRemovalintheElectricalSystem chapter) RelayBox(seeRelayBoxRemovalintheElectricalSystemchapter) StarterRelay(seeStarterRelayInspectionintheElectricalSystemchapter)

• Removethefuseboxfromtherearfenderfront.
• Remove: Bolt[A] Clamp[B]
• Freetheclampfromtherearfenderfront.
• Removetherearfenderfront[A]backwardandupward.

Close-up of mechanical components with a labeled component 'A' and an arrow pointing to it (no readable text or symbols)

RearFenderFrontInstallation

• Installationisthereverseofremoval.
• Installtheremovedparts(seeappropriatechapters).

Frame

FrameInspection

- Visually inspect the frame for cracks, dents, bending or warp.

○Ifthereisanydamagetotheframe,replaceit.

WARNING

Arepairedframemayfailinuse, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.

Sidestand

SidestandRemoval

• Raisetherearwheeloffthegroundwithstand.
• Remove:
  FrameCover(seeFrameCoverRemoval) Bolts[A] FootpegStay[B]

- Remove: SidestandSwitchBolt[A]withClamp SidestandSwitch[B]

- Remove: Spring[A] SidestandNut[B] SidestandBolt[C] Sidestand[D]

Mechanical assembly diagram showing two labeled components A and B, no readable text or symbols present.

SidestandInstallation

• Applygreasetotheslidingarea[A]ofthesidestand[B].
• Tightentheboltandlockthemwiththenut.
  Torque-SidestandBolt:44N·m(4.5kgf·m,33ft·lb)
• Hookthespring.
  • Installthesidestandswitch.
  ○Applyanon-permanentlockingagenttothethreadofthe switchbolt.

Torque-SidestandSwitchBolt:8.8N·m(0.90kgf·m,78in·lb)

• Installthefootpegstay.

- Tighten:

Torque-FootpegStayBolts:34N·m(3.5kgf·m,25ft·lb)

15-18FRAME

FrameCover

FrameCoverRemoval

• Removethebolt[A].
• Pulltheframecover[B]outwardtoclearthestoppers.

FrameCoverInstallation

• Inserttheprojections[A]intotheholes[B].
• Tightenthebolt.

Close-up of a motorcycle's front wheel and side-mounted sensors (no visible text or symbols)

RearViewMirrors

RearViewMirrorsRemoval

- Loosenthelowerhexagonalarea[A]fortighteningtoremovetherearviewmirrorfromtheholder.

CAUTION

Donotforcetotightenand/orloosentheupper hexagonalarea(adapter)[B]withapairofspanners.DisassemblyofthisareaisNotAvailable. Non-permanentlockingagent[C]isalreadyapplied tothethreadsofthisinnerarea.Forciblelooseningmaydamagetheadapterand/ortheturning mechanismofthestay[D].

RearViewMirrorsInstallation

- Screwthemountingareaoftherightrearviewmirrorinto theholderalltheway,andtightenthelowerhexagonal areafortighteningsecurely. LowerHexagonalAreaforTightening[A] UpperHexagonalArea(Adapter)[B] RearViewMirror(Right)[C]

- Turnthestay[A]toassurethesafeconditionsoftherear withtheoperatorsatonthemotorcycle. - Adjusttherearviewmirrorslightlywithitsmirror[B]. ○Installationandadjustmentoftheleftsidearecommon withthoseoftherightside.Followtheproceduresspecifiedattherightside.

ElectricalSystem

TableofContents

Exploded View.... 16-3

Specifications 16-10

Special Tools and Sealants 16-11

Parts Location.... 16-12

Wiring Diagram.... 16-14

Precautions.... 16-16

Electrical Wiring.... 16-18

Wiring Inspection 16-18

Battery 16-19

Battery Removal 16-19

Battery Installation 16-19

Battery Activation.... 16-19

Precautions 16-22

Interchange 16-22

Charging Condition Inspection.... 16-23

Refreshing Charge.... 16-23

Charging System 16-25

Alternator Cover Removal.... 16-25

Alternator Cover Installation.... 16-25

Stator Coil Removal 16-25

Stator Coil Installation 16-26

Alternator Rotor Removal 16-26

Alternator Rotor Installation 16-26

Alternator Inspection.... 16-28

Regulator/Rectifier Inspection.... 16-29

Charging Voltage Inspection.... 16-31

Starter Motor Clutch 16-33

StarterMotorClutchRemoval/Installation....16-33

Starter Motor Clutch Inspection 16-33

Starter Motor Clutch Disassembly 16-33

Starter Motor Clutch Assembly 16-33

Ignition System 16-34

Crankshaft Sensor Removal 16-34

Crankshaft Sensor Installation 16-35

Crankshaft Sensor Inspection.... 16-35

CrankshaftSensorPeakVoltageInspection....16-35

Timing Rotor Removal 16-36

Timing Rotor Installation 16-36

Stick Coil (Ignition Coil together with Spark Plug Cap) Removal.... 16-36

Stick Coil (Ignition Coil together with Spark Plug Cap) Installation.... 16-36

Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection.... 16-37

Stick Coil Primary Peak Voltage 16-37

Spark Plug Removal 16-38

Spark Plug Installation 16-38

Spark Plug Condition Inspection.... 16-38

Interlock Operation Inspection 16-39

IC Igniter Inspection 16-40

Electric Starter System 16-43

Starter Motor Removal 16-43

Starter Motor Installation.... 16-43

Starter Motor Disassembly.... 16-43

Starter Motor Assembly 16-44

Brush Inspection 16-45

CommutatorCleaningandInspection....16-45

Armature Inspection.... 16-45

Brush Lead Inspection 16-46

BrushPlateandTerminalBoltInspection....16-46

Starter Relay Inspection.... 16-46

Lighting System 16-49

HeadlightBeamHorizontalAdjustment....16-49

Headlight Beam Vertical Adjustment.... 16-49

Headlight Bulb Replacement 16-49

City Light Bulb Replacement.... 16-50

Headlight Removal/Installation 16-51

Tail/Brake Light Removal 16-51

Tail/Brake Light Installation 16-51

LicensePlateLightBulbReplacement....16-52

Turn Signal Light Bulb Replacement 16-53

Turn Signal Relay Inspection 16-54

Air Switching Valve 16-56

Air Switching Valve Operation Test 16-56

Air Switching Valve Unit Test 16-56

Radiator Fan System.... 16-58

Fan Motor Inspection 16-58

Meter, Gauge, Indicator Unit.... 16-59

Meter Unit Removal 16-59

Meter, Gauge Disassembly 16-59

ElectronicCombinationMeterUnitInspection....16-60

Switches and Sensors 16-67

Brake Light Timing Inspection.... 16-67

Brake Light Timing Adjustment 16-67

Switch Inspection 16-67

WaterTemperatureSensorInspection....16-68

Speed Sensor Removal 16-68

Speed Sensor Installation 16-68

Speed Sensor Inspection.... 16-69

OxygenSensorRemoval(EuropeModels)......16-69

OxygenSensorInstallation(EuropeModels)......16-69

OxygenSensorInspection(EuropeModels)......16-70

Fuel Reserve Switch Inspection.... 16-70

Relay Box 16-71

Relay Box Removal 16-71

Relay Circuit Inspection 16-71

Diode Circuit Inspection 16-72

Fuse.... 16-74

30 A Main Fuse Removal 16-74

Fuse Box Fuse Removal 16-74

15 A ECU Fuse Removal 16-74

Fuse Installation.... 16-75

Fuse Inspection.... 16-75

ExplodedView

DummyPage

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	·mft·lb
1LicensePlateLightCoverScrews0.900.0908 i n · l b
2LicensePlateLightMountingScrews1.20.1211in·lb
3	Meter Screws	1.2	0.12	11 in·lb

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1	FrontBrakeLightSwitchScrew1.20.121in·lb
2	LeftSwitchHousingScrews3.50.3631in·lb
3	Right Switch Housing Screws	3.5	0.36	31 in·lb
4	StarterMotorCableTerminalNut	6.00.60	53in·lb
5	Starter Motor Mounting Bolts	9.8	1.0	87 in·lb	L
6	Starter Motor Terminal Locknut	11	1.1	97 in·lb
7	Starter Motor Through Bolts	4.9	0.50	43 in·lb

G: Applygrease.
L: Applyanon-permanentlockingagent.
R: ReplacementParts

ExplodedView

No.	Fastener	Torque			Remarks
		N·mkgf	·mft·lb
1	AlternatorCoverBolts9.81.087in·lb
2	Alternator Lead Holding Plate Bolt	9.8	1.0	87 in·lb	L
3	Alternator Rotor Bolt	155	15.8	114	MO
4	Crankshaft Sensor Bolts	6.0	0.60	53 in·lb
5	Neutral Switch	15	1.5	11
6	Oil Pressure Switch	15	1.5	11	SS
7	OxygenSensor	44.1	4.50	32.5
8	Regulator/Rectifier Bolts	8.8	0.90	78 in·lb
9	Sidestand Switch Bolt	8.8	0.90	78 in·lb	L
10	Spark Plugs	15	1.5	11
11	Speed Sensor Bolt	7.8	0.80	69 in·lb	L
12	Starter Motor Clutch Bolts	34	3.5	25	L
13	StatorCoilBolts	12	1.2	106 in·lb	L
14	Timing Rotor Bolt	40	4.1	30
15	Water Temperature Sensor	12	1.2	106 in·lb

L: Applyanon-permanentlocking agent.
M:Applymolybdenumdisulfidegrease.
MO:Applymolybdenumdisulfideoil solution.
(Mixtureoftheengineoilandmolybdenumdisulfidegreaseinaweightratio10:1)
R:ReplacementParts
SS:Applysilicone sealant.

Specifications

ItemStandard
BatteryTypeModelNameYTX12-BSCapacity12V10AhVoltage12.8Vormore	SealedBattery
ChargingSystemTypeThree-phaseACAlternatorOutputVoltage42Vormoreat4000r/min(rpm)StatorCoilResistance0.18~ 0.27ΩChargingVoltage14.2~ 15.2V(Regulator/RectifierOutputVoltage)
IgnitionSystemCrankshaft Sensor ResistanceCrankshaftSensorPeakVoltageStickCoil:Primary Winding ResistanceSecondary Winding ResistancePrimaryPeakVoltageSparkPlug:Spark Plug Gap	376 ~ 564 Ω1.9Vormore1.1 ~ 1.5 Ω10.8 ~ 16.2 kΩ88Vormore0.8 ~ 0.9 mm (0.03 ~ 0.04 in.)
ElectricStarterSystemStarterMotor:BrushLengthCommutator Diameter	12mm(0.47in.)(Servicelimit:6.0mm,0.24in.)28 mm (1.10 in.) (Service limit: 27 mm, 1.06 in.)
AirSwitchingValveResistance	18~ 22Ω at20°C(68°F)
SwitchandSensorRear Brake Light Switch TimingEngine Oil Pressure Switch ConnectionsWater Temperature Sensor Resistance	ON after about 10 mm (0.39 in.) pedal travelWhen engine is stopped: ONWhenengineisrunning: OFFin the text

SpecialToolsandSealants

HandTester: 57001-1394

Technical line drawing of a mechanical housing or enclosure with internal components and mounting holes (no text or symbols)

FlywheelPullerAssembly, M38×1.5/M35×1.5: 57001-1405

Technical line drawing of a mechanical component with a cylindrical body and hexagonal top (no text or symbols)

PeakVoltageAdapter: 57001-1415

Simple line drawing of a coiled electrical component with two probes and a rectangular block (no text or symbols)

LeadWire-PeakVoltageAdapter: 57001-1449

Pure electrical connector diagram without any text, numbers, or symbols

NeedleAdapterSet: 57001-1457

Technical line drawing of two screwdriver tips (no text or symbols)

Grip: 57001-1591

Technical line drawing of a metal bracket with two bolts and a hole, no text or symbols present

Flywheel&PulleyHolder: 57001-1605

Technical line drawing of a mechanical bracket assembly with mounting holes and mounting points (no text or symbols)

RotorHolder: 57001-1658

Technical line drawing of two mechanical components: a circular ring with flange and a hexagonal nut (no text or symbols)

KawasakiBond(SiliconeSealant): 56019-120

KawasakiBond(SiliconeSealant): 92104-0004

PartsLocation

1. AirSwitchingValve

2. Alternator

3.Battery12V10Ah

4.CrankshaftSensor

5.ECU(ElectricControlUnit)

6.FanMotor

7.FrontBrakeLightSwitch

8.FuseBoxwithECUMainFuse

9.IgnitionSwitch

10.MeterUnit

1. NeutralSwitch

12.OilPressureSwitch

13.RearBrakeLightSwitch

14.Regulator/Rectifier

15.RelayBox

16.SidestandSwitch

17.SpeedSensor

18.StarterLockoutSwitch

19.StarterMotor

20.StarterRelaywithMainFuse

21.StickCoils

22.TurnSignalRelay

23.WaterTemperatureSensor

24.OxygenSensor(EuropeModels)

PartsLocation

DummyPage

LEFT SWITCH HOUSING CONNECTIONS

Horn Button

Hazard Button

Turn Signal Switch

Dinner Switch

Starter Lockout Switch

Passing Button

Color

BK/W

BK/Y

Color

G

O

GY

Color

G

O

GY

Color

R/BK

BL/Y

R/Y

Color

BK

BK/R

Color

R/BK

BL/Y

L

HI

Clutch tear

Push

Push

OFF (Push)

Released

Push

OFF (Push)

R

LO

Pulled in

T2L0221AH5 C

WiringDiagram

Precautions

Thereareanumberofimportantprecautionsthatare mustswhenservicingelectricalsystems.Learnandobservealltherulesbelow.

• Donotreversethebatterycableconnections. This will burnoutthediodesontheelectricalparts.
  ○Alwayscheckbatteryconditionbeforecondemningother partsofanelectricalsystem.Afullychargedbatteryisa mustforconductingaccurateelectricalsystemtests.
  ○Theelectricalpartsshouldneverbestrucksharply,as withahammer,orallowedtofallonahardsurface.Such ashocktothepartscandamagethem.
• Toppreventdamagetoelectricalparts,donotdisconnect thebatterycablesoranyotherelectricalconnections whentheignitionswitchison,orwhiletheengineis running.
  ○Becauseofthelargeamountofcurrent,neverkeepthe starterbuttonpushedwhenthestartermotorwillnotturn over,orthecurrentmayburnoutthestartermotorwindings.
• Donotuseameterilluminationbulbratedforotherthan voltageorwattagespecifiedinthewiringdiagram,asthe meterorgaugepanelcouldbewarpedbyexcessiveheat radiatedfromthebulb.
  ○Takecarenottoshortthecablesthataredirectlyconnectedtothebatterypositive(+)terminaltothechassis ground.
  ○Troublesmayinvolveoneorinsomecasesallitems. Neverreplaceadefectivepartwithoutdeterminingwhat CAUSEDthefailure.Ifthefailurewascausedbysome otheritemoritems,theymustberepairedorreplaced,or thenewreplacementwillsoonfailagain.
  ○Makesureallconnectorsinthecircuitarecleanandtight, andexaminewiresforsignsofburning,fraying,etc.Poor wiresandbadconnectionswillaffectelectricalsystemoperation.
  ○Measurecoilandwindingresistancewhenthepartiscold (atroomtemperature).
  ○ColorCodes:

BK:Black

BL:Blue

BR:Brown

CH:Chocolate

DG:DarkGreen

G:Green

GY:Gray

LB:LightBlue

LG:LightGreen

O:Orange

P:Pink

PU:Purple

R:Red

W:White

Y:Yellow

○ElectricalConnectors FemaleConnectors[A]

Precautions

MaleConnectors[B]

• Visuallyinspectthewiringforsignsofburning,fraying, etc.
  ★Ifanywiringispoor,replacethedamagedwiring.
• Pulleachconnector[A]apartandinspectitforcorrosion, dirt, and damage.
  ★Iftheconnectoriscorrodedordirty,cleanitcarefully.Ifit isdamaged,replaceit.
• Checkthewiringforcontinuity.
  OUsethewiringdiagramtofindtheendsoftheleadwhich issuspectedofbeingaproblem.
  ○Connectthehandtesterbetweentheendsoftheleads.

SpecialTool-HandTester:57001-1394

○Setthetestertothe×1Ω range,andreadthetester.
★Ifthetesterdoesnotread0Ω, theleadisdefective. Re-placetheleadorthewiringharness[B]ifnecessary.

Technical line drawing of a mechanical assembly with multiple connectors and a labeled component (B), no readable text or symbols present.

Battery

BatteryRemoval

• Remove: Seat(seeSeatRemovalintheFramechapter)
• Disconnectthenegative(−)cable[A].
• Slideoutthepositive(+)terminalcap[B]andthendisconnectthepositive(+)cable.

CAUTION

Besuretodisconnectthenegative(−)cablefirst.

- Removethebattery.

Battery Installation

• Putthebatteryintotherearfenderfront.
• Applyalightcoatofgreaseontheterminalstoprevent corrosion.
  • Installthepositive(+)cable[A]first.
• Coverthepositive(+)terminalwiththecap[B].
• Installthenegative(−)cable[C].

BatteryActivation

ElectrolyteFilling

- Makesurethatthemodelname[A]oftheelectrolytecontainermatchesthemodelname[B]ofthebattery. These namesmustbethesame.

BatteryModelNameforER650A:YTX12-BS

CAUTION

Besuretousetheelectrolytecontainerwiththe samemodelnameasthebatterysincetheelectrolytevolumeandspecificgravityvarywiththe batterytype.Thisistopreventoverfillingofthe electrolyte,shortingthebatterylife,anddeteriorationofthebatteryperformance.

CAUTION

Donotremovethealuminumsealingsheet[A]from thefillerports[B]untiljustpriortouse.Besureto usethededicatedelectrolytecontainerforcorrect electrolytevolume.

• Placethebatteryonalevelsurface.
• Checktoseethatthesealingsheethasnopeeling, tears, orholesinit.
• Removethesealingsheet.

Isometric line drawing of a battery with mounting holes and a labeled component (B), no text or symbols present.

QP180204S1 C

OP18003BS1 C

NOTE

○ Thebatteryisvacuumsealed. If thesealingsheethas leakedairintothebattery, it may require alonger initial charge.

Battery

• Removetheelectrolytecontainerfromthevinylbag.
• Detachthestripofcaps[A]fromthecontainerandset aside,thesewillbeusedlatertosealthebattery.

NOTE

○ Donotpierceorotherwiseopenthesealedcells[B] of theelectrolytecontainer.Donotattemptoseparate individualcells.

- Placethelectrolytecontainerupsidedownwiththesix sealedcellsintothefillerportsofthebattery.Holdthe containerlevel,pushdowntobreakthesealsofallsix cells.Youwillseeairbubblesrisingintoeachcellasthe portsfill.

NOTE

○ Donottilttheelectrolytecontainer

• Checktheelectrolyteflow.
  ★Ifnoairbubbles[A]arecomingupfromthefillerports,or ifthecontainercellshavenotemptiedcompletely,tapthe container[B]afewtimes.
• Keepthecontainerinplacefor20minutesormore. Don't removethecontainerfromthebatteryuntil'sempty, the batteryrequiresalltheelectrolytefromthecontainerfor properoperation.

CAUTION

Removalofthecontainerbeforeitiscompletely emptycanshortentheservicelifeofthebattery.Do notremovetheelectrolytecontaineruntilitiscom- pletelyemptyand20minuteshaveelapsed.

• Gentlyremovethecontainerfromthebattery.
• Letthebatterysitfor30minutespriortochargingtoallow theelectrolytetopermeateintotheplatesforoptimum performance.

NOTE

○ Chargingthebatteryimmediatelyafterfillingcan shortenservicelife.Letthebatterysitforatleast30 minutesafterfilling.

Battery

InitialCharge

• Placethestrip[A]ofcapslooselyoverthefillerports.
• Newlyactivatedsealedbatteriesrequireaninitialcharge.

StandardCharge: 1.2A×5\~10hours

★Ifusingarecommendedbatterycharger, followthe charger'sinstructionsfornewlyactivatedsealedbattery.

Kawasaki-recommendedchargers

Optimatell

Yuasa1.5AmpAutomaticCharger

BatteryMate150-9

★ Iftheabovechargersarenotavailable,useequivalent one.

NOTE

○Chargingrateswillvarydependingonhowlongthe batteryhasbeenstored,temperature,andthetypeof chargerused.Letbatterysit30minutesafterinitial charge,thencheckvoltageusingavoltmeter.Ifitis notatleast12.8V,repeatchargingcycle.

- Afterchargingiscompleted, pressdownfirmlywithboth handstoseatthestripofcaps[A]intothebattery(don't poundorhammer.). Whenproperlyinstalled, thestripof thecapswillbelevelwiththetopofthebattery.

CAUTION

Oncethestripofthecaps[A]isinstalledontothe battery,neverremovethecaps,noraddwaterorelectrolytetothebattery.

Technical line drawing of a battery and its internal components with no visible text or symbols

NOTE

Toensuremaximumbatterylifeandcustomersatisfaction, it is recommended the battery beload tested at threetimesitsamp-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.

Battery

Precautions

1) Noneedoftopping-up

Notopping-upisnecessaryinthisbatteryuntilitendsitslifeundernormaluse.F offthesealcaptoaddwaterisverydangerous.Neverdothat.

orciblyprying

2) Refreshingcharge.

Ifanenginewillnotstart,ahornsoundsweak,orlampsaredim,itindicatesthebatteryhasbeen discharged.Giverefreshchargefor5to10hourswithchargecurrentshowninthespecification (seeSpecifications).

When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.

CAUTION

Thisbatteryisdesignedtosustainnounusualdeteriorationifrefresh-chargedaccording tothemethodspecifiedabove.H _owever,thebattery'sperformancemaybereducednoticeablyifchargedunderconditionsotherthangivenabove.Neverremovethesealcap duringrefreshcharge.

If by chance an excessive amount of gas is generated due to overcharging, thereelief valve releases the gastokee the battery normal.

3) When you donotus the motorcycle form months.

Give are fresh charge before you store them motorcycle and store it with the negative cabler removed. Give a refresh charge once a month during storage.

4) Batterylife.

If the battery will not start the engine even after several refresh charges, the battery has exceeded its use full life. Replace it (Provided, however, the vehicle's startingsystem has no problem).

WARNING

Keepthebatteryawayfromsparksandopenflamesduringcharging,sincethebattery givesoffanexplosivegasmixtureofhydrogenandoxygen.Whenusingabatterycharger, connectthebatterytothechargerbeforeturningonthecharger.

This procedure preventssparksatthebatteryterminals which could ignite any battery gases.

Nofireshouldbedrawnnearthebattery,ornoterminalsshouldhavethetighteningloosened.

Theelectrolytecontainssulfuricacid.Becarefulnottohaveittouchyourskinoreyes.If touched,washitoffwithliberalamountofwater.Getmedialattentionifsevere.

Interchange

Asealed 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.

Becareful, ifasealedbattery is installed on a motorcycle which had an ordinary battery as original equipment, thesealedbattery's lifewill beshortened.

Battery

ChargingConditionInspection

○Batterychargingconditioncanbecheckedbymeasuring batteryterminalvoltagewithadigitalvoltmeter[A].

- Remove:

Seat(seeSeatRemovalintheFramechapter) BatteryCableCap(seeBatteryRemoval)

- Disconnectthebatteryterminals.

CAUTION

Besuretodisconnectthenegative(−)cablefirst.

- Measurethebatteryterminalvoltage.

NOTE

○Measurewithadigitalvoltmeterwhichcanbereadone decimalplacevoltage.

★ Ifthereadingis12.8Vormore, norefreshchargeisrequired, however, ifthereadisbelowthespecified, refresh chargeisrequired.

BatteryTerminalVoltage

Standard: 12.8Vormore

TerminalVoltage(V)[A]

BatteryChargeRate(%)[B]

Good[C]

Refreshchargeisrequired[D]

RefreshingCharge

• RemovethebatteryA.
• Dorefreshchargebyfollowingmethodaccordingtothe batteryterminalvoltage.

WARNING

Thisbatteryissealedtype.Neverremovesealing cap[B]evenatcharging.Neveraddwater.Charge withcurrentandtimeasstatedbelow.

Battery

TerminalVoltage:11.5\~ lessthan12.8V

StandardCharge1.2A×5\~ 10h(seefollowingchart)

QuickCharge 5 A × 1 h

CAUTION

If possible, donot quick charge. If quick charge is done unavoidably, dostandard chargelateron.

TerminalVoltage:lessthan11.5V

ChargingMethod 1.2 A × 20 h

NOTE

○ Increase the charging voltage to a maximum voltage of 25V if the battery will not accept current initially. Charge for 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 minutes, replace the battery.

Battery[A]

BatteryCharger[B]

StandardValue[C]

• Determinethebatteryconditionafterrefreshcharge.
  ○Determinetheconditionof thebatteryleftfor30minutes aftercompletionofthechargebymeasuringtheterminal voltageaccording to thetable below.

Criteria	Judgement
12.8 Vor higher	Good
12.0 ~ lower than 12.8 V	Chargeinsufficient→ Recharge
lower than 12.0 V	Unserviceable → Replace

graph TD
    A["Switch A"] --> B["Diode D"]
    B --> C["Switch C"]
    C --> D["Power Supply"]
    subgraph Power Source
        E["16μF"] --> F["Ground"]
        G["25μF"] --> H["Ground"]
    end
    style E fill:#f9f,stroke:#333
    style F fill:#ccf,stroke:#333
    style G fill:#cfc,stroke:#333
    note right of E: 25μF (green arc) or 16μF (red arc)
    note right of G: 16μF (green arc) or 25μF (red arc)

ChargingSystem

AlternatorCoverRemoval

- Remove:

LowerFairing(seeLowerFairingRemovalintheFrame chapter)

AlternatorLeadConnector[A]

• Placeasuitablecontainerunderthealternatorcover[A], andremovethecoverbolts[B].
• Pullthealternatorcoveroutside.

Close-up mechanical assembly showing a brake caliper and suspension components (no visible text or symbols)

AlternatorCoverInstallation

- Applysiliconesealanttothealternatorleadgrommetand crankcasehalvesmatingsurface[A]onthefrontandrear sidesofthecovermount.

Sealant-KawasakiBond(SiliconeSealant):92104-0004

• Checkthatdowelpins[B]areinplaceonthecrankcase.
  • Installanewgasketandthealternatorcover.
• Tighten:

Torque-AlternatorCoverBolts:9.8N·m(1.0kgf·m,87in·lb)

StatorCoilRemoval

- Remove:

AlternatorCover(seeAlternatorCoverRemoval) HoldingPlateBolt[A]andPlate

AlternatorLeadGrommet[B] StatorCoilBolts[C]

- Removethestatorcoil[D]fromthealternatorcover.

ChargingSystem

StatorCoilInstallation

- Applyanon-permanentlockingagenttothethreadsof thestatorcoilboltsandtightenthem.

Torque-StatorCoilBolts:12N·m(1.2kgf·m,106in·lb)

- Securethealternatorleadwithaholdingplate, and tightenthebolt.

○Applyanon-permanentlockingagenttothethreadsof theholdingplatebolt.

Torque-AlternatorLeadHoldingPlateBolt:9.8N·m(1.0 kgf·m,87in·lb)

- Applysilicones equalant to the circumference of the alternator lead grommet, and fitthegrommet into thenotch of the cover securely.

Sealant-KawasakiBond(SiliconeSealant):92104-0004

- Installthealternatorcover(seeAlternatorCoverInstallation).

AlternatorRotorRemoval

- Removethealternatorcover(seeAlternatorCoverRemoval).

- Removethestarteridlegear, torquelimiterandshafts.

- Wipeoilofftheoutercircumferenceoftherotor.

- Holdthealternatorrotorsteadywiththerotorholder[A], andremovetherotorbolt[B]andwasher.

SpecialTools-Grip:57001-1591

RotorHolder:57001-1658

- Usingtheflywheelpuller[A],removethealternatorrotor fromthecrankshaft.

SpecialTool-FlywheelPullerAssembly, M38×1.5/M35×1.5:57001-1405

CAUTION

Donotattempttostrikethealternatorrotoritself. Strikingtherotorcancausethemagnetstolose theirmagnetism.

AlternatorRotorInstallation

- Usingacleaningfluid,cleanoffanyoilordirtonthefollowingportionsanddrythemwithacleancloth.

CrankshaftTaperedPortion[A]

AlternatorRotorTaperedPortion[B]

- Applyathincoatofmolybdenumdisulfidegreasetothe crankshaft[C].

Mechanical gear assembly with labeled component A (no readable text or symbols)

Technical drawing of a mechanical component with cross-sectional view and labeled section B (no text or symbols beyond label)

GP09141851 C

ChargingSystem

• Installthestartergear[A]andwasher[B].
- Again, cleanthecrankshaft tapered portion [C] and dry there.
- Installthealternatorrotor[A]whileturning[B]itcounterclockwise.

- Installthewasher[A].

NOTE

○Confirmthealternatorrotorfitornottothecrankshaft beforetighteningitwithspecifiedtorque.

• Applymolybdenumdisulfideoilsolutiontothethreads andseatingsurfaceoftherotorbolt.
• Installtherotorbolt[B]andtightenitwith70N·m(7.0 kgf·m,52ft·lb)oftorque.
• Removetherotorboltandwasher.
• Checkthetighteningtorquewithflywheelpuller.
  ★ Iftherotoris not pulled out with 20N·m (2.0kgf·m, 15 ft·lb) of drawing torque, it is installed correctly.
  ★Iftherotorispulledoutwithunder20N·m(2.0kgf·m,15ft·lb)ofdrawingtorque,cleanoffanyoidirtorflawofthecrankshaftandrotortaperedportion,anddrythemwithacleancloth.Then,confirmthatitisnotpulledoutwithabovetorque.
• Tightenthealternatorrotorboltwhileholdingthealternatorrotorsteadywiththerotorholder.

SpecialTools-Grip:57001-1591

RotorHolder:57001-1658

Torque-AlternatorRotorBolt:155N·m(15.8kgf·m,114ft·lb)

ChargingSystem

• Applyathincoatofmolybdenumdisulfidegreasetothe shafts[A], and install them.
  • Installthetorquelimiter[B]andstarteridlegear[C].
• Installthealternatorcover(seeAlternatorCoverInstallation).

AlternatorInspection

Therearethreetypesofalternatorfailures:short,open (wireburnedout),orlossinrotormagnetism.Ashortor openinoneofthecoilwireswillresultineitheralowoutput,ornooutputatall.Alossinrotormagnetism,whichmaybe causedbydroppingorhittingthealternator,byleavingit nearanelectromagneticfield,orjustbyaging,willresultin lowoutput.

• Tocheckthealternatoroutputvoltage,dothefollowing procedures.
  ○Turnofftheignitionswitch.
  ○Disconnectthealternatorleadconnector[A].
  ○Connectthehandtesterasshowninthetable1.
  ○Starttheengine.
  ○Runitatherpmgiveninthetable1.
  ○Notethevoltagereadings(total3measurements).

Table1 AlternatorOutputVoltage

Tester Range	Connections		Reading at4000rpm
	Tester(+)toTester(-)to
250VACOne	Blacklead	Another Blacklead42	Vormore

★ If the output voltages show the value in the table, the alternator operates properly.
★Iftheoutputvoltageshowsamuchhigherthanthevalueinthetable,theregulator/rectifierisdamaged. Amuch lowerreadingthanthatgiveninthetableindicatesthat thealternatorisdefective.
- Checkthestatorcoilresistanceasfollows.
○Stoptheengine.
○Connectthehandtesterasshowninthetable2.
○Notethereadings(total3measurement).

Table2StatorCoilResistance

Tester Range	Connections		Reading
	Tester(+)toTester(-)to
×1Ω	OneBlacklead	AnotherBlacklead	0.18~0.27Ω

Mechanical assembly diagram showing components like gears and springs (no readable text or symbols)

ChargingSystem

★ Ifthereismoreresistancethanshowninthetable,orno handtesterreading(infinity)foranytwoleads,thestator hasanopenleadandmustbereplaced.Muchlessthan thisresistancemeansthestatorisshorted,andmustbe replaced.
- Using the highest resistancer range of the hand tester, measure the resistance between each of the black leads and chassis ground.
★Anyhandtesterreadinglessthaninfinity(∞)indicatesa short, necessitatingstatorreplacement.
★ Ifthestatorcoilshavenormalresistance, but the voltage check showed the alternatortobedefective; then therotor magnet shave probably weakened, and therotormust be replaced.

SpecialTool-HandTester:57001-1394

Regulator/RectifierInspection

- Remove: Bolts[A]

• Disconnecttheconnector[A].
• Removetheregulator/rectifier[B].

Close-up of a car interior showing a metallic heating element labeled 'A' (no readable text or symbols beyond the label)

RectifierCircuitCheck

- Checkconductivityofthefollowingpairofterminals.

RectifierCircuitInspection

★The resistance should be low in one direction and more thantentimesasmuchintheotherdirection. Ifanytwo leadsareloworhighinbothdirections,therectifieris defectiveandtheregulator/rectifiermustbereplaced.

NOTE

○Theactualmeterreadingvarieswiththemeterused and the individual rectifier, but, generally speaking the lowerreadingsshouldbefromzerotoonehalfthescale.

ChargingSystem

RegulatorCircuitCheck

Totesttheregulatoroutofcircuit, usethree12Vbatteries andatestlight(12V3\~6Wbulbinasocketwithleads).

CAUTION

Thetestlightworksasanindicatorandalsoacurrentlimitertoprotecttheregulator/rectifierfromexcessivecurrent.Donotuseanammeterinsteadof atestlight.

• Checktobesuretherectifiercircuitisnormalbeforecontinuing.
• Dothe1ststepregulatorcircuittest.
  ○Connectthetestlightandthe12Vbatterytotheregulator/rectifierasshown.
  ○ChecktheBK1,BK2andBK3terminalrespectively.
  ★Ifthetestlightturnson,theregulator/rectifierisdefective. Replaceit.
  ★Ifthetestlightdoesnotturnon,continuethetest.

- Dothe2ndstepregulatorcircuittest.

○Connectthetestlightandthe12Vbatteryinthesame mannerasspecifiedinthe“RegulatorCircuitTest-1st Step”.

○Apply12VtothevoltageBRterminal.

○ChecktheBK1,BK2andBK3terminalrespectively.

★Ifthetestlightturnson,theregulator/rectifierisdefective. Replaceit.
★Ifthetestlightdoesnotturnon,continuethetest.

- Dothe3rdstepregulatorcircuittest.

○Connectthetestlightandthe12Vbatteryinthesame mannerasspecifiedinthe“RegulatorCircuitTest-1st Step”.

- Momentarilyapply24VtothevoltageBRterminalby addinga12Vbattery.

○ChecktheBK1,BK2andBK3terminalsrespectively.

CAUTION

Donotapplymorethan24V.Ifmorethan24Visapplied,theregulator/rectifiermaybedamaged.Do notapply24Vmorethanafewseconds.If24V isappliedformorethanafewseconds,theregulator/rectifiermaybedamaged.

★Ifthetestlightdidnotlightwhenthe24Vwasapplied momentarilytothevoltagemonitoringterminal,theregulator/rectifierisdefective.Replaceit.
★Iftheregulator/rectifierpassesallofthetestsdescribed, itmaystillbedefective. Ifthechargingsystemstilldoes notworkproperlyaftercheckingallofthecomponents andthebattery,testtheregulator/rectifierbyreplacingit withaknowngoodunit.

Pure electrical circuit lines without any symbols

ChargingSystem

Charging Voltage Inspection

• Checkthebatterycondition(seeChargingConditionInspection).
• Warmuptheenginetoobtainactualalternatoroperating conditions.
• Removetheseat(seeSeatRemovalintheFramechapter).
• Check that the ignition switch is turned off, and connect the hand tester[A] to the battery terminals[B].

SpecialTool-HandTester:57001-1394

- Starttheengine, and not the voltage readings at various enginespeeds with the headlight turned on and then turned off (Toturnoff the headlight, disconnect the headlight connector on the headlight unit.). The reading should show nearly battery voltage when the enginespeed is slow, and, astheenginespeed rises, the reading should also rise. But they must be kept under the specified voltage.

ChargingVoltage

TesterRange	Connections		Reading
	Tester(+) to Tester(-) to
25 V DC	Battery (+)	Battery (-)	14.2 ~ 15.2 V

• Turn off the ignition switch to stop the engine, and disconnectthehandtester.
  ★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, theregulator/rectifier is defective or theregulator/rectifier leads are loose or open.
  ★If the charging voltaged does not rise as the enginespeed increases, thenteregulator/rectifier is defective or the alternator output is insufficient fortheloads. Check the alternator and regulator/rectifier to determine which part is defective.

Close-up of hands working on an automotive engine with labeled components (A and B), no visible text or symbols beyond labels.

ChargingSystemCircuit

GP09144BH2 C

1. IgnitionSwitch
2. Alternator
3. Regulator/Rectifier
4. Water-proof JointC
   5.MainFuse30A
   6.Battery12V10Ah
   7.Load

StarterMotorClutch

StarterMotorClutchRemoval/Installation

- RefertotheAlternatorRotorRemoval/Installation.

StarterMotorClutchInspection

- Remove:

AlternatorCover(seeAlternatorCoverRemoval) StarterIdleGearandTorqueLimiter Shafts

• Turnthestartermotorclutchgear[A]byhand. Thestarter motorclutchgearshouldturnclockwise[B]freely, but shouldnotturncounterclockwise[C].
  ★ Ifthestartermotorclutchdoesnotoperateasitshouldor ifitmakesnoise, gotothenextstep.
• Disassemblethestartermotorclutch, and visually inspect the clutchparts.
  ★ If thereisanywornordamagedpart, replaceit.

NOTE

○Examinethestartermotorclutchgearaswell.Replace itifitwornordamaged.

StarterMotorClutchDisassembly

- Remove:

AlternatorRotor(seeAlternatorRotorRemoval) StarterMotorClutchBolts[A]

- Remove:

StarterMotorClutch[A]

Close-up of a metallic mechanical component with labeled points A and a small hole, no readable text or symbols present.

Close-up of a metallic mechanical component with a labeled section A and reference number 6107B036 P (no readable text or symbols beyond label)

StarterMotorClutchAssembly

- Applyanon-permanentlockingagenttothethreadsof thestartermotorclutchboltsandtightenthem.

Torque-StarterMotorClutchBolts:34N·m(3.5kgf·m,25ft·lb)

IgnitionSystem

WARNING

Theignitionsystemproducesextremelyhighvoltage.Donottouchthesparkplugsorstickcoils whiletheengineisrunning,oryoucouldreceive asevereelectricalshock.

CAUTION

Donotdisconnectthebatterycablesoranyother electricalconnectionswhentheignitionswitchis on,orwhiletheengineisrunning.Thisistoprevent ECU(ElectricControlUnit)damage. Donotinstallthebatterybackwards.Thenegative sideisgrounded.Thisistopreventdamagetothe ECU.

CrankshaftSensorRemoval

- Remove:

LowerFairing(seeLowerFairingRemovalintheFrame chapter)

RightFrameCover(seeFrameCoverRemovalinthe Framechapter)

CrankshaftSensorLeadConnector[A]

- Remove:

RubberBoot(SlideOut)[A]

OilPressureSwitchLeadTerminal[B]

ClutchCover(seeClutchCoverRemovalintheClutch chapter)

- Remove:

Bolts[A]

CrankshaftSensor[B]

- Pulloutthegrommet[C].

Close-up mechanical assembly showing internal components and a labeled section (A), no readable text or symbols present.

Mechanical assembly diagram showing two labeled components A and B connected to a central mechanical component (no text or symbols beyond labels)

IgnitionSystem

CrankshaftSensorInstallation

• Routethecrankshaftsensorleadcorrectly(seeCable, Wire,andHoseRoutingsectionintheAppendixchapter).
• Tighten:

Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.60 kgf·m, 53 in·lb)

- Applysiliconesealant[A]tothecrankshaftsensorlead grommet.

Sealant-KawasakiBond(SiliconeSealant):92104-0004

- Installtheremovedparts(seeappropriatechapters).

CrankshaftSensorInspection

- Remove:

RightFrameCover(seeFrameCoverRemovalinthe Framechapter) CrankshaftSensorLeadConnector[A]

- Setthehandtestertothe×100Ω rangeandconnect(+) leadtotheblackleadand(−)leadtotheyellowleadin theconnector.

SpecialTool-HandTester:57001-1394

★ Ifthereismoreresistancethanthespecifiedvalue,the coilhasanopenleadandmustbereplaced.Muchless thanthisresistancemeansthecoilisshorted,andmust bereplaced.

Crankshaft Sensor Resistance: 376 \~ 564 Ω

- Using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground.

★Anytesterreadinglessthaninfinity(∞)indicatesashort, necessitatingreplacementofthecrankshaftsensorassembly.

CrankshaftSensorPeakVoltageInspection

NOTE

○Besurethebatteryisfullycharged.

○Usingthepeakvoltageadapter[A]isamorereliable waytodeterminetheconditionofthecrankshaftsensorhancrankshaftsensorinternalresistancemeasurements.

- Remove:

CrankshaftSensorLeadConnector(seeCrankshaft SensorRemoval)

- Setthehandtester[B]tothe×DC10Vrange, and connectitpeakvoltageadapter.

- Connecttheblackleadoftheadaptertoyellowleadand redleadtoblackleadinthecrankshaftsensorconnector.

- TurntheignitionswitchandenginestopswitchON.

Close-up mechanical assembly with labeled component A (no readable text or symbols)

Close-up mechanical assembly showing internal components and a labeled section (A), no readable text or symbols present.

IgnitionSystem

• Pushingthestarterbutton,turntheengine4\~5 secondswiththetransmissiongearinneutraltomeasurethe crankshaftsensorpeakvoltage.
• Repeatthemeasurement5ormoretimes.

CrankshaftSensorPeakVoltage

Standard:1.9Vormore

SpecialTools-HandTester:57001-1394

PeakVoltageAdapter:57001-1415

Type:KEK-54-9-B

★ Ifthetesterreadingisnotspecifiedone, checkthecrank-shaftsensor.

TimingRotorRemoval

- Remove:

ClutchCover(seeClutchCoverRemovalintheClutch chapter)

CrankshaftSensor(seeCrankshaftSensorRemoval)

- Removethetimingrotor[A].

○Holding the timing rotor with the flywheel & pulley holder [B]andunscrewtherotorbolt[C].

Special Tool - Flywheel & Pulley Holder: 57001-1605

TimingRotorInstallation

• Fittherotortothecrankshaft.
• Tightentherotorbolt.

Torque-TimingRotorBolt:40N·m(4.1kgf·m,30ft·lb)

- Install the removed parts (see appropriate chapters).

StickCoil(IgnitionCoiltogetherwithSparkPlugCap) Removal

• Removetheaircleanerhousing(seeAirCleanerHousing Removal in the Fuel System (DFI) chapter).
• Disconnect thestickcoilconnectors [A].
• Pull the stick coils [B] off the spark plugs.

CAUTION

Donotprytheconnectorpartofthecoilwhilere-movingthecoil.

StickCoil(IgnitionCoiltogetherwithSparkPlugCap) Installation

• Insertthecoilasshownbeingcarefulofthecoilheads[A] direction.
• Connecttheconnectors.

CAUTION

Do not tap the coil head while installing the coil.

• Runthehosesandharnesscorrectly(seeCable, Wire, and Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

Technical line drawing of a mechanical component with mounting holes and a central housing (no text or symbols)

GP10281BS1 C

IgnitionSystem

StickCoil(IgnitionCoiltogetherwithSparkPlugCap) Inspection

• Removethestickcoils(seeStickCoil(IgnitionCoiltogetherwithSparkPlugCap)Removal).
• Measure the primary winding resistance [A] as follows.
  ○Connectthehandtesterbetweenthecoilterminals.
  ○Setthetestertothe×1Ω range,andreadthetester.
• Measurethesecondarywindingresistance[B]asfollows.
  ○Connectthetesterbetweentheplugterminaland(−)coil terminal.
  ○Setthetestertothe×1kΩ rangeandreadthetester.

IgnitionCoilWindingResistance

PrimaryWindings: 1.1\~1.5Ω

Secondary Windings: 10.8 \~ 16.2 kΩ

★ Ifthetesterdoesnotreadasspecified, replacethecoil.

StickCoilPrimaryPeakVoltage

NOTE

○Besurethebatteryisfullycharged.

• Removethestickcoils(seeStickCoil(IgnitionCoiltogetherwithSparkPlugCap)Removal),butdonotremove thesparkplugs.
• Measure the primary peak voltage as follows.
  ○Installthenewsparkplug[A]intoeachstickcoil[B], and groundthemontotheengine.
  ○Connectthepeakvoltageadapter[C]intothehandtester[D]whichissettothe×DC250Vrange.
  ○Connecttheadaptertotheleadwire-peakvoltage adapter[E]whichisconnectedbetweenthestickcoil connectorandstickcoil.

ECU[F]

Battery[G]

SpecialTools-HandTester:57001-1394

PeakVoltageAdapter:57001-1415

Type:KEK-54-9-B

Lead Wire-Peak Voltage Adapter: 57001-1449

PrimaryLeadConnection

Adapter(R,+)toleadwire-peakvoltageadapter(W)

Adapter (BK, -) to lead wire-peak voltage adapter (R)

graph TD
    A["Component A"] --> B["Valve B"]
    B --> C["Actuator C"]
    C --> D["Valve D"]
    D --> E["Component E"]
    E --> F["Valve F"]
    F --> G["Ground"]
    H["Component G"] --> I["Valve I"]
    J["Component H"] --> K["Actuator K"]
    L["Component I"] --> M["Valve M"]
    N["Component J"] --> O["Actuator O"]
    P["Component K"] --> Q["Actuator Q"]
    R["Component L"] --> S["Valve S"]
    T["Component M"] --> U["Actuator U"]
    V["Component N"] --> W["Valve W"]
    X["Component O"] --> Y["Actuator Y"]

IgnitionSystem

WARNING

Toavoidextremelyhighvoltageshocks, donot touchthesparkplugsortesterconnections.

• TurntheignitionswitchandtheenginestopswitchON.
• Pushingthestarterbutton,turntheengine4\~ 5seconds withthetransmissioninneutraltomeasuretheprimary peakvoltage.
• Repeatthemeasurements5timesforonestickcoil.

StickCoilPrimaryPeakVoltage

Standard: 88Vormore

• Repeatthetestfortheotherstickcoil.
  ★Ifthereadingislessthanthespecifiedvalue,checkthe following.
  StickCoils(seeStickCoil(IgnitionCoiltogetherwith SparkPlugCap)Inspection) CrankshaftSensor(seeCrankshaftSensorInspection) ECU(seeECUPowerSupplyInspectionintheFuelSys- tem(DFI)chapter)

SparkPlugRemoval

- RefertotheSparkPlugReplacementinthePeriodic Maintenancechapter.

SparkPlugInstallation

- RefertotheSparkPlugReplacementinthePeriodic Maintenancechapter.

SparkPlugConditionInspection

- RefertotheSparkPlugConditionInspectioninthePeriodicMaintenancechapter.

IgnitionSystem

InterlockOperationInspection

- Raisetherearwheeloffthegroundwithstand.

1stCheck

- Starttheenginetothefollowingconditions.

Condition

TransmissionGear→ 1stPosition

ClutchLever→ Release

Sidestand→ DownorUp

○TurntheignitionswitchONandpushthestarterbutton.

○Thenthestartermotorshouldnotturnwhenthestarter systemcircuitisnormality.

★ Iftheengineisstart, inspectthestarterlockoutswitch, neutralswitchandrelaybox.

★ If their parts are normality replace the ECU.

2ndCheck

- Starttheenginetothefollowingconditions.

Condition

TransmissionGear→ 1stPosition

Clutch Lever → Pulled in

Sidestand→ Up

○TurntheignitionswitchONandpushthestarterbutton.

○Thenthestartermotorshouldturnwhenthestartersystemcircuitisnormality.

★ Ifthestartermotorisnotturn, inspectthestarterlockout switch, neutralswitchandrelaybox.

★ If their parts are normality replace the ECU.

3rdCheck

- Inspecttheengineforitssecurestopafterthefollowing operationsarecompleted.

- Runtheenginetothefollowingconditions.

Condition

TransmissionGear→ 1stPosition

Clutch Lever → Pulled in

Sidestand→ Up

- Setthesidestandontheground,thentheenginewillstop.

★Ifwhichevermaynotbestopped,inspecttheneutral switch,starterlockoutswitch,sidestandswitchandrelay box.

★ If their parts are normality, replace the ECU.

IgnitionSystem

ICIgniterInspection

○TheICigniterisbuiltintheECU[A].

- RefertotheInterlockOperationInspection, IgnitionSystemTroubleshootingchartandFuelSystem(DFI)chapter forECUPowerSupplyInspection.

Close-up of a mechanical component with labeled section A (no readable text or symbols beyond label)

IgnitionSystem

Ignition System Troubleshooting

graph TD
    A["Faulty ignition (No spark)"] --> B["Battery Inspection"]
    B -->|Good| C["Ignition system wiring and connector inspection"]
    B -->|No good| D["Charge or replace battery."]
    C -->|Good| E["Spark plug inspection"]
    C -->|No good| F["Repair or replace damaged part."]
    E -->|Good| G["Stick coil winding resistance inspection"]
    E -->|No good| H["Replace spark plug."]
    G -->|Good| I["Stick coil primary peak voltage inspection"]
    G -->|No good| J["Replace stick coil."]
    I -->|Good| K["Stick coil is defective. Replace stick coil."]
    I -->|No good| L["Voltage is zero or almost zero."]
    L --> M["Inspect: 1. Adapter connection is incorrect, or adapter is defective.<br>2. Ignition switch and engine stop switch<br>3. Crankshaft sensor peak voltage"]
    M --> N["Replace bad parts."]
    M --> O["ECU is defective. Replace ECU."]
    N --> P["Replace bad parts."]
    N --> Q["ECU is defective. Replace ECU."]
    L --> R["Inspect: 2. Crankshaft sensor peak voltage"]
    R --> S["Replace bad parts or inspect them with KAWASAKI Hand Tester."]
    S --> T["No good"]
    R --> U["Replace bad parts or inspect them with KAWASAKI Hand Tester."]

GP10280B F

IgnitionSystemCircuit

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    G --> H["8"]
    H --> I["9"]
    I --> J["10"]
    J --> K["11"]
    K --> L["12"]
    L --> M["13"]
    M --> N["14"]
    N --> O["15"]
    O --> P["31"]
    P --> Q["32"]
    Q --> R["30"]
    R --> S["29"]
    S --> T["28"]
    T --> U["27"]
    U --> V["26"]
    V --> W["25"]
    W --> X["24"]
    X --> Y["23"]
    Y --> Z["22"]
    Z --> AA["21"]
    AA --> AB["20"]
    AB --> AC["19"]
    AC --> AD["18"]
    AD --> AE["17"]
    AE --> AF["16"]
    AF --> AG["15"]

1. IgnitionSwitch

2. EngineStopSwitch

3.SparkPlugs

4.StickCoils

1. Water-proof JointC

6.SpeedSensor

7.SubthrottleSensor

8.MainThrottleSensor

1. Water-proof JointD

2. Vehicle-downSensor

3. Water-proof JointE

4. WaterTemperatureSensor

5. NeutralSwitch

14.CrankshaftSensor

15.OxygenSensor

16.MeterUnit

1. Water-proof JointA

2. Water-proofJointB

3. StarterLockoutSwitch

20.OxygenSensorHeaterFuse 10 A

21.ECUFuse15A

22.IgnitionFuse10A

23.FuseBox

24.ECUMainRelay

25.RelayBox

26.MainFuse30A

1. StarterRelay

28.Battery12V10Ah

29.FrameGround

30.SidestandSwitch

31.JointConnector

32.ECU

ElectricStarterSystem

StarterMotorRemoval

CAUTION

Donottapthestartermotorshaftorbody.Tapping theshaftorbocoulddamagethemotor.

• Removethefueltank(seeFuelTankRemovalintheFuel System(DFI)chapter).
• Slidebacktherubbercap[A].
• Removethestartermotorcableterminalnut[B].
• Removethemountingbolts[A].
• Pulloutthestartermotor[B].

StarterMotorInstallation

CAUTION

Donottapthestartermotorshaftorbody.Tapping theshaftorbocoulldamagethemotor.

• Wheninstallingthestartermotor,cleanthestartermotorlegs[A]andcrankcase[B]wherethestartermotoris grounded.
• ReplacetheO-ring[A]withanewone.
• ApplygreasetotheO-ring.
• Applyanon-permanentlockingagenttothethreadsof theboltsandtightenthebolts.

Torque-StarterMotorMountingBolts:9.8N·m(1.0kgf·m, 87in·lb)

• Installthestartermotorcable.

- Tighten:

Torque-StarterMotorCableTerminalNut:6.0N·m(0.60 kgf·m,53in·lb)

Close-up of a mechanical component with labeled parts A and B, showing assembly details (no readable text or symbols)

Mechanical component with labeled section A, no visible text or symbols on the body itself

StarterMotorDisassembly

• Removethestartermotor(seeStarterMotorRemoval).
• Takeoffthestartermotorthroughbolts[A]andremove thebothendcovers[B]andpullthearmatureoutofthe yoke[C].

ElectricStarterSystem

- Remove:

TerminalLocknutandWashers

O-ring

- Removethebrushplateassy[A]fromtheyoke[B].

- Removethebrushplate[A]fromtheplatecover[B].

NOTE

○ Donotremovethenegativecarbonbrushesformthe brushplate.

StarterMotorAssembly

- Installthebrushplate[A]totheplatecover[B]asshown.

• Installthebrushplateassytotheyoke.

- Clampthesprings[A]withtheclips[B].

- Fitthearmature[C]tothebrushplateassy[D].

- Removetheclips.

• InstallthenewO-ring[A]asshown.

- Install:

Washers[B]andTerminalLocknut[C]

- Tighten:

Torque-StarterMotorTerminalLocknut:11N·m(1.1 kgf·m,97in·lb)

Cross-sectional view of a mechanical device with labeled parts (A, B), no visible text or symbols beyond labels

Close-up of a mechanical component with labeled parts A and B, no readable text or symbols beyond labels

Close-up of a mechanical component with labeled parts A and B, no readable text or symbols beyond labels

graph TD
    A["Component A"] --> B["Component B"]
    B --> C["Component C"]
    B --> D["Component D"]
    B --> E["Component E"]
    B --> F["Component F"]
    B --> G["Component G"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#cfc,stroke:#333

ElectricStarterSystem

• Alignthelines[A]ontheyokewiththeendcoverlines[B].
  ● Tightenthethroughbolts.

Torque-StarterMotorThroughBolts:4.9N·m(0.50kgf·m, 43in·lb)

BrushInspection

● Measurethelengthofeachbrush[A].
★Ifanyisworndowntotheservicelimit,replacebrush plateassy[B]andtheterminalboltassy[C].

StarterMotorBrushLength

Standard:12mm(0.47in.)

ServiceLimit:6.0mm(0.24in.)

CommutatorCleaningandInspection

- Smooththecommutatorsurface[A]ifnecessarywithfine emerycloth[B],andcleanoutthegrooves.

• Measurethediameter[A]ofthecommutator[B].
  ★ If the commutator diameter is less than the service limit, replace the starter motor with anewone.

CommutatorDiameter

Standard:28mm(1.10in.)

ServiceLimit:27mm(1.06in.)

ArmatureInspection

- Usingthe×1Ω handtesterrange,measuretheresistancebetweenanytwocommutatorsegments[A].

SpecialTool-HandTester:57001-1394

★ If there is a high resistance on noreading ( ) between any two segments, awinding is open and the starter motor must bere placed.
- Using the highest hand test range, measure the resistance between these segments and the shaft [B].
★ If there is any reading at all, the immature has a short and the starter motorm must be replaced.

NOTE

Eveniftheforegoingchecksshowthearmaturetobe good, itmaybedefectiveinsomemannernotreadily detectablewiththehandtester. Ifallotherstartermotor andstartermotorcircuitcomponentscheckgood, but thestartermotorstilldoesnotturnoveroronlyturns overweakly, replacetheartermotorwithanewone.

BrushLeadInspection

- Usingthe×1Ω handtesterrange,measuretheresistanceasshown.

TerminalBoltandPositiveBrushes[A]

BrushPlateandNegativeBrushes[B]

SpecialTool-HandTester:57001-1394

★Ifthereisnotclosetozeroohms,thebrushleadhasan open.Replacetheterminalboltassyand/orthebrush plateassy.

BrushPlateandTerminalBoltInspection

- Using the highest and test range, measure the resistance as shown.

TerminalBoltandBrushPlate[A]

TerminalBoltandNegativeBrushHolders[B]

TerminalBoltandYoke[C]

SpecialTool-HandTester:57001-1394

★Ifthereisanyreading,thebrushplateassyand/orterminalboltassyhaveashort.Replacehebrushplateassy andtheterminalboltassy.

StarterRelayInspection

- Remove:

Bolt[A]andCover[B]

Close-up of a cylindrical electronic component with a digital multimeter connected to its top terminal (no visible text or symbols)

ElectricStarterSystem

• Disconnecttheconnector[A].
• Disconnectthestartermotorcable[B]andbatterypositive (+)cable[C]fromthestarterrelay[D].

CAUTION

Thebatterypositive(+)cablewiththerubbercapis connecteddirectlytothebatterypositive(+)terminalevenwhentheignitionswitchoff,sotakecare nottoshorttheremovedcabletochassisground.

- Connectthehandtester[A]and12Vbattery[B]tothe starterrelay[C]asshown.

SpecialTool-HandTester:57001-1394

★ Iftherelaydoesnotworkasspecified,therelayisdefective.Replacetherelay.

TestingRelay

TesterRange: ×1Ω range

Criteria: When battery is connected → 0Ω

When battery is disconnected → ∞ Ω

ElectricStarterCircuit

1. IgnitionSwitch
2. Water-proof JointB
3. StarterLockoutSwitch
4. IgnitionFuse10A
   5.FuseBox
   6.StarterCircuitRelay
5. RelayBox
   8.StarterMotor
6. StarterRelay
   10.MainFuse30A
   11.Battery12V10Ah
   12.SidestandSwitch
   13.FrameGround
   14.JointConnector
7. NeutralSwitch
   16.Water-proofJointC
   17.StarterButton
8. EngineStopSwitch

LightingSystem

Thismotorcycleadoptthedaylightsystemandhavea headlightrelayintherelaybox. Theheadlightdoesnot goonwhentheignitionswitchandtheenginestopswitch arefirstturnedon. Theheadlightcomesonafterthestarter buttonisreleasedandstaysonuntiltheignitionswitchis turnedoff. Theheadlightwillgooutmomentarilywhenever thestarterbuttonispressedandcomebackonwhenthe buttonisreleased.

HeadlightBeamHorizontalAdjustment

- RefertotheHeadlightAimingInspectioninthePeriodic Maintenancechapter.

HeadlightBeam Vertical Adjustment

- RefertotheHeadlightAimingInspectioninthePeriodic Maintenancechapter.

HeadlightBulbReplacement

- Remove: HeadlightAssy(seeHeadlightRemoval/Installation) HeadlightBulbDustCover[A]

- Remove: Hook[A] HeadlightBulb[B]

CAUTION

Whenhandlingthequartz-halogenbulb,never touchtheglassportionwithbarehands.Always useacleancloth.Oilcontaminationfromhandsor dirtyragscanreducebulblifeorcausethebulbto explode.

NOTE

○Cleanoffanycontaminationthatinadvertentlygetson thebulbwithalcoholorsoapandwatersolution.

• Replacetheheadlightbulb.
• Fittheprojection[A]ofthebulbinthehollow[B]oftheheadlight.
• Installthehook[C].

Close-up of a mechanical component with textured surface and labeled point A (no readable text or symbols)

LightingSystem

- Fitthedustcover[A]withthe"Top"markupwardontothe bulb[B]firmlyasshown.

Good[C]

Bad[D]

TopMark[E]

- Afterinstallation, adjusttheheadlightaim(seeHeadlight AimingInspectioninthePeriodicMaintenancechapter).

Close-up of a mechanical component with no visible text or symbols

CityLightBulbReplacement

• Removetheheadlightassy(seeHeadlightRemoval/Installation).
• Pulloutthesocket[A]togetherwiththebulb.

Close-up medical image of a mechanical device with labeled component A (no readable text or symbols)

- Pullthebulb[A]outofthesocket.

CAUTION

Donotturnthebulb.Pullthebulbouttoprevent damagetothebulb.Donotusebulbratedfor greaterwattagethenthespecifiedvalve.

- Replacethebulbwithanewone.

LightingSystem

HeadlightRemoval/Installation

- Remove: MountingBolts[A]

Close-up of a mechanical component with a dial indicator and label 'A' (no readable text or symbols beyond the label)

• Disconnecttheheadlightconnectors[A]andcitylightconnector[B].
• Removetheheadlightassy.
• Removetheupperfairings(seeUpperFairingRemoval intheFramechapter).
• Installationisthereverseofremoval.

Tail/BrakeLightRemoval

• Remove:
  SeatCovers(seeSeatCoverRemovalintheFrame chapter)
• Disconnecttheconnector[A].
• Unscrewthemountingbolts[B].
• Removethetail/brakelight[C].

Tail/BrakeLightInstallation

- Installationisthereverseofremoval.

LightingSystem

LicensePlateLightBulbReplacement

- Remove:

Screws[A]

LicensePlateLightCover[B]

- Pushandturnthebulbcounterclockwiseandremoveit.

- Insertthenewbulb[A]byaligningitsupperandlowerpins[B]withtheupperandlowergrooves[C]inthesocket,and turnthebulbclockwise.

○Turnthebulbabout15°.

• Installthelicenseplatelightcover.

- Tighten:

Torque-LicensePlateLightCoverScrews:0.90N·m (0.090kgf·m,8in·lb)

LightingSystem

Headlight/TailLightCircuit

graph TD
    A["①"] --> B["②"]
    B --> C["③"]
    C --> D["④"]
    D --> E["⑤"]
    E --> F["⑥"]
    F --> G["⑦"]
    G --> H["⑧"]
    H --> I["⑨"]
    I --> J["⑩"]
    J --> K["⑪"]
    K --> L["⑫"]
    L --> M["⑬"]
    M --> N["⑭"]
    N --> O["⑮"]
    O --> P["⑯"]
    P --> Q["⑰"]
    Q --> R["⑱"]
    R --> S["⑲"]
    S --> T["⑳"]
    T --> U["㉑"]
    U --> V["㉒"]
    V --> W["㉓"]
    W --> X["㉔"]
    X --> Y["㉕"]
    Y --> Z["㉖"]
    Z --> AA["㉗"]
    AA --> AB["㉘"]
    AB --> AC["㉙"]
    AC --> AD["㉚"]
    AD --> AE["㉛"]
    AE --> AF["㉜"]
    AF --> AG["㉝"]
    AG --> AH["㉟"]
    AH --> AI["㉟A"]
    AI --> AJ["㉟B"]
    AJ --> AK["㉟C"]
    AK --> AL["㉟D"]
    AL --> AM["㉟E"]
    AM --> AN["㉟F"]
    AN --> AO["㉟G"]
    AO --> AP["㉟H"]
    AP --> AQ["㉟I"]
    AQ --> AR["㉟J"]
    AR --> AS["㉟K"]
    AS --> AT["㉟L"]
    AT --> AU["㉟M"]
    AU --> AV["㉟N"]
    AV --> AW["㉟O"]
    AW --> AX["㉟P"]
    AX --> AY["㉟Q"]

1. IgnitionSwitch
2. Water-proofJointA
3. Water-proofJointB
   4.PositionLight
   5.Headlight(HighBeam)
   6.Headlight(LowBeam)
   7.DimmerSwitch
   8.PassingSwitch
   9.HeadlightRelay
   10.RelayBox
   11.StarterRelay

TurnSignalLightBulbReplacement

- Unscrewthescrew[A]andremovethelens[B].

12.MainFuse30A
13.Battery12V10Ah
14.FrameGround
15. Tail/BrakeLight
16. LicensePlateLight12V5W
17.JointConnector
18. Water-proof JointC
19. Regulator/Rectifier
20.FuseBox
21.HeadlightFuse10A
22.TailLightFuse10A

LightingSystem

- Pushandturnthebulb[A]counterclockwiseandremove it.

- Insertthenewbulb[A]byaligningitsupperandlowerpins [B]withtheupperandlowergrooves[C]inthesocket,and turnthebulbclockwise.

○Turnthebulbabout15°.

- Install the projection of theelenstothedintsoftheturn signallight.

TurnSignalRelayInspection

- Remove: LeftCenterFairing(seeCenterFairingRemovalinthe Framechapter) TurnSignalRelay[A]

- Connectone12Vbatteryandturnsignallightsasindicatedinthefigure,andcounthowmaytimesthelights flashforoneminute.

TurnSignalRelay[A]

TurnSignalLights[B]

12VBattery[C]

★Ifthelightsdonotflashasspecified, replacetheturnsignalrelay.

TestingTurnSignalRelay

Load		FlashingTimes (c/m*)
TheNumberofTurn SignalLights	Wattage(W)
1**	21or23140~250
2	42 or 46	75 ~ 95

(*):Cycle(s)perminute

(**):Correctedto"onelightburnedout".

Close-up of a mechanical component with a labeled section A pointing to a spherical object (no text or symbols beyond label)

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

LightingSystem

TurnSignalLightCircuit

graph TD
    A["①"] --> B["②"]
    B --> C["③"]
    C --> D["④"]
    D --> E["⑤"]
    E --> F["⑥"]
    F --> G["⑦"]
    G --> H["⑧"]
    H --> I["⑨"]
    I --> J["⑩"]
    J --> K["⑪"]
    K --> L["⑫"]
    L --> M["⑬"]
    M --> N["⑭"]
    N --> O["⑮"]
    O --> P["⑯"]
    P --> Q["⑰"]
    Q --> R["⑱"]
    R --> S["⑲"]
    S --> T["⑳"]
    T --> U["㉑"]
    U --> V["㉒"]
    V --> W["㉓"]
    W --> X["㉔"]
    X --> Y["㉕"]
    Y --> Z["㉖"]
    Z --> AA["㉗"]
    AA --> AB["㉘"]
    AB --> AC["㉙"]
    AC --> AD["㉚"]
    AD --> AE["㉛"]
    AE --> AF["㉜"]
    AF --> AG["㉝"]
    AG --> AH["㉟"]
    AH --> AI["㉟c"]
    AI --> AJ["㉞"]
    AJ --> AK["㉟d"]
    AK --> AL["㉟e"]
    AL --> AM["㉟f"]
    AM --> AN["㉟g"]
    AN --> AO["㉟h"]
    AO --> AP["㉟i"]
    AP --> AQ["㉟j"]
    AQ --> AR["㉟k"]
    AR --> AS["㉟l"]
    AS --> AT["㉟m"]
    AT --> AU["㉟n"]
    AU --> AV["㉟o"]
    AV --> AW["㉟p"]
    AW --> AX["㉟q"]
    AX --> AY["㉟r"]
    AY --> AZ["㉟t"]
    AZ --> BA["㉟u"]
    BA --> BB["㉟v"]
    BB --> BC["㉟w"]
    BC --> BD["㉟x"]
    BD --> BE["㉟y"]
    BE --> BF["㉟z"]

1.MeterUnit
2. Water-proof JointA
3. Water-proofJointB
4.FrontRightTurnSignalLight
5.FrontLeftTurnSignalLight
6. TurnSignalRelay
7.HazardButton
8. TurnSignalSwitch
9.FuseBox
10.TurnSignalRelayFuse10A
11.MainFuse30A
12.Battery12V10Ah
13.FrameGround
14. RearRightTurnSignalLight
15.RearLeftTurnSignalLight
16.JointConnector
17.Water-proofJointC
18.IgnitionSwitch
19.FrameGround

AirSwitchingValve

AirSwitching ValveOperationTest

• Removethefueltank(seeFuelTankRemovalintheFuel System(DFI)chapter).

• Pulltheairswitchingvalvehose[A]outoftheaircleaner base.

• Taketheairswitchingvalvehoseendoutsideofthe frame.

• Reinstallthefueltank(seeFuelTankInstallationinthe FuelSystem(DFI)chapter).
• Starttheengineandrunitatidlespeed.
• Plug[A]theairswitchingvalvehose[B]endwithyour fingerandfeelvacuumpulsinginthehose.
  ★Ifthereisnovacuumpulsation,checkthehoselinefor leak.Ifthereisnoleak,checktheairswitchingvalve(see AirSwitchingValveUnitTest).
• Applyasoapandwatersolutionorrubberlubricanttothe endoftheairswitchinghoseandinstallthehoseonthe fitting.

AirSwitchingValveUnitTest

- Removetheairswitchingvalve(seeAirSwitchingValveRemovalintheEngineTopEndchapter).

- Setthehandtester[A]tothe×Ω rangeandconnectitto theairswitchingvalveterminalsasshown.

SpecialTool-HandTester:57001-1394

AirSwitchingValveResistance

Standard: 18 \~ 22 Ω at 20°C (68°F)

★Iftheresistancereadingisexceptthespecifiedvalue,replaceitwithanewone.

- Connectthe12Vbattery[A]totheairswitchingvalve terminalsasshown.

Close-up of a mechanical component with labeled parts (A and CP108704), no readable text or symbols beyond labels

AirSwitchingValve

- Blowtheairtotheinletairduct[A], and makesuredoes notflowtheblownairfromtheoutletairduct[B].

• Disconnectthe12Vbattery.
• Blowtheairtotheinletairduct[A], and makesuredoes not flow the blownair from the outlet air duct[B].
  ★ If the air switching valued does not operate as described, replace it with anewone.

NOTE

○ Tocheckairflowthroughtheairswitchingvalve, just blowthroughtheaircleanerhose[C].

RadiatorFanSystem

FanMotorInspection

• Disconnecttheconnector[A].
• Usinganauxiliaryleads, supplybatterypowertothefan motor.
  ★Ifthefandoesnotrotate, thefanmotorisdefective and mustbereplaced.

Close-up of a mechanical component with labeled point A (no readable text or symbols beyond label)

RadiatorFanCircuit

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    G --> H["8"]
    H --> I["9"]
    I --> J["10"]
    J --> K["11"]
    K --> L["12"]
    L --> M["13"]
    M --> N["14"]
    N --> O["15"]
    O --> P["16"]
    style A fill:#f9f,stroke:#333
    style K fill:#f9f,stroke:#333
    style L fill:#f9f,stroke:#333
    style M fill:#f9f,stroke:#333
    style N fill:#f9f,stroke:#333
    style O fill:#f9f,stroke:#333
    style P fill:#f9f,stroke:#333
    style Q fill:#f9f,stroke:#333
    style R fill:#f9f,stroke:#333
    style S fill:#f9f,stroke:#333
    style T fill:#f9f,stroke:#333
    style U fill:#f9f,stroke:#333
    style V fill:#f9f,stroke:#333
    style W fill:#f9f,stroke:#333
    style X fill:#f9f,stroke:#333
    style Y fill:#f9f,stroke:#333
    style Z fill:#f9f,stroke:#333
    style AA fill:#f9f,stroke:#333
    style AB fill:#f9f,stroke:#333
    style AC fill:#f9f,stroke:#333
    style AD fill:#f9f,stroke:#333
    style AE fill:#f9f,stroke:#333
    style AF fill:#f9f,stroke:#333
    style AG fill:#f9f,stroke:#333
    style AH fill:#f9f,stroke:#333
    style AI fill:#f9f,stroke:#333
    style AJ fill:#f9f,stroke:#333
    style AK fill:#f9f,stroke:#333
    style AL fill:#f9f,stroke:#333
    style AM fill:#f9f,stroke:#333
    style AN fill:#f9f,stroke:#333
    style AO fill:#f9f,stroke:#333
    style AP fill:#f9f,stroke:#333
    style AQ fill:#f9f,stroke:#333
    style AR fill:#f9f,stroke:#333
    style AS fill:#f9f,stroke:#333
    style AT fill:#f9f,stroke:#333
    style AU fill:#f9f,stroke:#333
    style AV fill:#f9f,stroke:#333
    style AW fill:#f9f,stroke:#333

1. RelayBox

2. RadiatorFanRelay

3.ECUMainRelay

4.FuseBox

5.FanFuse15A

6.ECUFuse15A

7.MainFuse30A

8.Battery12V10Ah

9.FrameGround

10.JointConnector

11.ECU

1. WaterTemperatureSensor

13.Water-proofJointE

14.Water-proofJointC

15.RadiatorFan

1. IgnitionSwitch

2. Water-proof JointA

3. Water-proof JointB

Meter, Gauge, Indicator Unit

MeterUnitRemoval

- Remove:

HeadlightAssy(seeHeadlightRemoval/Installation) Screws[A]andCover[B]

• Slidethedustcover[A]andremovetheconnector[B].
• Removethemeterunitbytakingoffthemountingscrews [C]withthewashers.

CAUTION

Placethemeterunitsothatthefaceisup.Ifameter unitisleftupsidedownorsidewaysforanylength oftime,itwillmalfunction.

Meter, GaugeDisassembly

• Remove:
  MeterUnit(seeMeterUnitRemoval) Screws[A] LowerMeterCover[B]

- Separatethemeterassembly[A]anduppermetercover [B].

Meter, Gauge, Indicator Unit

ElectronicCombinationMeterUnitInspection

- RemovethemeterunitA.

[1]Battery(+)
[2]Ignition
[3]Ground(-)
[4]Unused
[5]SpeedSensorSignal
[6]TachometerSignal
[7]WaterTemperatureSensor(−)
[8]OilPressureWarningIndicatorLight(LED)(−)
[9]FuelLevelWarningIndicatorLight(LED)(−)

[10]SpeedSensorSupplyVoltage
[11]HighBeamIndicatorLight(LED)(+)
[12]NeutralIndicatorLight(LED)(−)
[13]Unused
[14]RightTurnSignalIndicatorLight(LED)(+)
[15]LeftTurnSignalIndicatorLight(LED)(+)
[16]FllIndicatorLight(LED)(−)

CAUTION

Donotdrophemeterunit.Placethemeterunitso thatitfacesupward.Ifthemeterunitisleftupside downorsidewaysforalongtimeordropped,itwill malfunction.Donotshorteachterminals.

LiquidCrystalDisplay(LCD)SegmentsCheck

• Usingtheauxiliarywires,connectthe12Vbatterytothe meterunitconnectorasfollows.
  ○Connectthebatterypositiveterminaltotheterminal[1].
  ○Connectthebatterynegativeterminaltotheterminal[3].

- Connecttheterminal[2]totheterminal[1].

Meter, Gauge, Indicator Unit

○Whentheterminalsareconnected, alltheLCDsegments [A]andLEDwarninglights[B]appear(Flwarninglight appearfortwoseconds).

★ IftheLCDsegmentsandLEDwarninglightswillnotappear, replacethemeterassembly.
- Disconnecttheterminal[2].
○AlltheLCDsegmentsandLEDwarninglightdisappear.
★ If these segments donot disappear, replacethemeteras-sembly.

MODEANDRESETBUTTONOperationCheck

• Connectthe12Vbatteryandterminalsinthesamemannerasspecifiedinthe"LiquidCrystalDisplay(LCD)SegmentsCheck".
• CheckthatthedisplaychangetotheCLOCK,ODO,TRIP AandTRIPBdisplayseachtimetheMODEbutton[A]is pressed.
  Olfthefuellevelgaugeflashed, displaychangetoCLOCK, ODO, TRIPA, TRIPBandFUEL.
  ★ Ifthedisplayfunctiondoesnotwork, replacethemeter assembly.

graph TD
    A["CLOCK"] --> B["1:23"]
    B --> C["8756 ODO"]
    C --> D["TRIPA"]
    D --> E["23.5"]
    E --> F["TRIP B"]
    F --> G["138"]
    G --> H["FUEL"]
    H --> I["GP17298B52 C"]

• Indicatetheclockmode.
• Check that when the RESET button in CLOCK mode is pushed from more than two seconds, the meter display turnstotheclockset mode.
  ○Boththehourandminutedisplaystartflashing.

Meter, Gauge, Indicator Unit

• IntheHOUR/MINUTEsettingmode, press the RESET button again to effect the HOUR setting mode.
  ○Thehourdisplayflashesonthedisplay.

• PresstheMODEbuttontosetthehour.

• IntheHOURsettingmode, presstheRESETbuttonto effecttheMINUTEsettingmode.
  ○Theminutedisplayflashesonthedisplay.

• PresstheMODEbuttontosetheminute.

• IntheMINUTEsettingmode, presstheRESETbuttonto returntotheHOUR/MINUTEsettingmode.

• PresstheMODEbuttontocompletethetimesetting process.
  ○Theclockstartscountingthesecondsassoonasthe MODEbuttonispressed.

- IndicatetheODOmode.

- Checkthatthedisplay[A]changetothemileandkmdisplayeachtimebypushingtheRESETbuttonwhileMODE buttonpushedin.

NOTE

○ Mile/KmdisplaycanalternatebetweenEnglishand metricmodes(mileandkm)inthedigitalmeter.Make surethatkmormileaccordingtolocalregulationsis correctlydisplayedbeforeriding.

★ Ifthedisplayfunctiondoesnotworkandadjust,replace themeterassembly.

SpeedometerCheck

• Connectthe12Vbatteryandterminalsinthesamemannerasspecifiedinthe"LiquidCrystalDisplay(LCD)SegmentsCheck".
• Thespeedequivalenttotheinputfrequencyisindicatedin theoscillator[A],ifthesquarewave(illustratedasshown) wouldbeinputintotheterminal[5].
  ○Indicatesapproximately60mphincasetheinputfrequencywouldbeapproximately169.0Hz.
  ○Indicatesapproximately60km/hincasetheinputfrequencywouldbeapproximately105.6Hz.

Meter, Gauge, Indicator Unit

- If the oscillator is not available, the speedometer can be checked as follows.

○Installthemeterunit.

○Raisetherearwheeloffthegroundwithstand.

○Turnontheignitionswitch.

○Rotatetherearwheelbyhand.

○Checkthatthespeedometershowsthespeed.

★ If the speedometer does not work, check the speed sensor are electric source voltage and speed sensor.
★Theelectricsourcevoltageandspeedsensorarenormal, replacethemeterassembly.

SpeedSensorElectricSourceCheck

• Connectthe12Vbatteryandterminalsinthesamemannerasspecifiedinthe"LiquidCrystalDisplay(LCD)SegmentsCheck".
• SetthehandtestertotheDC25Vrangeandconnectit totheterminals[10]and[3].
  ★ If the voltage is less than 8V, replacethemeter assembly.

OdometerCheck

• Checktheodometerwiththespeedometerinthesame way.
  ★ Ifvalueindicatedintheodometerisnotadded,replace themeterassembly.

NOTE

○ Thedataismaintainedevenifthebatteryisdisconnected.
○ Whenthefigurescometo999999, theyarestopped and locked.

TripA/BMeterCheck

• CheckthetripAorBmeterswiththespeedometerinthe sameway.
  ★IfvalueindicatedinthetripA/Bmetersisnotadded,re-placethemeterassembly.
• Check that when the RESET button is pushed more than two seconds, the configured display turnsto 0.0.
  ★ If the figured display does not indicate 0.0, replacethemeterassembly.

TachometerCheck

• Connectthe12Vbatteryandterminalsinthesamemannerasspecifiedinthe"LiquidCrystalDisplay(LCD)SegmentsCheck".
• Therevolutionsperminute(rpm)equivalenttotheinput frequencyisindicatedintheoscillator[A]ifthesquare wave(illustratedasshown)wouldbeinputintotheterminal[6].

○Indicatesapproximately6000rpmincasetheinputfrequencywouldbeapproximately200Hz.

Meter, Gauge, Indicator Unit

• If the oscillator is not available, the tachometer can be checked as follows.
  ○Connectthe12Vbatteryandterminalsinthesamemannerasspecifiedinthe"LiquidCrystalDisplay(LCD)SegmentsCheck".
  ○Usinganauxiliarywire, quickopenandconnecttheter- minal[2]totheterminal[6]repeatedly.
  ○Thenthetachometerneedle[A]shouldflick[B].
  ★Iftheneedledoesnotflick, replacethemeterassembly.

IndicatorLightsInspection

• Connectthe12Vbatteryandterminalsinthesamemannerasspecifiedinthe"LiquidCrystalDisplay(LCD)Segmentscheck".
  NeutralIndicatorLight(LED)[A]
  FllIndicatorLight(LED)[B]
  OilPressure/WaterTemperatureWarningIndicatorLight (LED)[C]
  RightTurnSignalIndicatorLight(LED)[D]
  LeftTurnSignalIndicatorLight(LED)[E]
  HighBeamIndicatorLight(LED)[F]
  FuelLevelWarningIndicatorLight(LED)[G]

- Usingtheauxiliaryleads,connecta12Vbatterytothe meterunitconnectorasfollows.

WaterTemperatureWarningIndicatorLight(LED)

BatteryNegative(−)TerminaltoTerminal[7]

OilPressureWarningIndicatorLight(LED)

BatteryNegative(−)TerminaltoTerminal[8]

Meter, Gauge, Indicator Unit

FuelLevelWarningIndicatorLight(LED)

BatteryNegative(−)TerminaltoTerminal[9]

HighBeamIndicatorLight(LED)

BatteryPositive(+)TerminaltoTerminal[11]

NeutralIndicatorLight(LED)

BatteryNegative(−)TerminaltoTerminal[12]

RightandLeftTurnSignalIndicatorLight(LED)

ForRightTurnSignalIndicatorLight(LED)

BatteryPositive(+)TerminaltoTerminal[14]

ForLeftTurnSignalIndicatorLight(LED)

BatteryPositive(+)TerminaltoTerminal[15]

FllIndicatorLight(LED)

BatteryNegative(−)TerminaltoTerminal[16]

- Ifeachlights(LED)doesnotgoon,replacethemeter assembly.

MeterCircuit

graph TD
    A["Generator ①"] --> B["Resistors"]
    B --> C["Control Unit ③"]
    C --> D["Relays ②"]
    D --> E["Ground"]
    C --> F["Control Unit ④"]
    F --> G["Resistors"]
    G --> H["Control Unit ⑤"]
    H --> I["Relays ⑥"]
    I --> J["Control Unit ⑦"]
    J --> K["Output ⑧"]
    K --> L["Control Unit ⑩"]
    L --> M["Output ⑪"]
    M --> N["Control Unit ⑫"]
    N --> O["Output ⑬"]
    O --> P["Control Unit ⑭"]
    P --> Q["Output ⑮"]
    Q --> R["Control Unit ⑮"]
    R --> S["Output ⑯"]
    S --> T["Control Unit ⑰"]
    T --> U["Output ⑰"]
    U --> V["Control Unit ⑱"]
    V --> W["Output ⑱"]
    W --> X["Control Unit ⑲"]
    X --> Y["Output ⑲"]
    Y --> Z["Control Unit ⑳"]
    Z --> AA["Output ⑳"]
    AA --> AB["Control Unit ⑪"]
    AB --> AC["Output ⑪"]
    AC --> AD["Control Unit ⑫"]
    AD --> AE["Output ⑫"]
    AE --> AF["Control Unit ⑬"]
    AF --> AG["Output ⑬"]
    AG --> AH["Control Unit ⑭"]
    AH --> AI["Output ⑮"]
    AI --> AJ["Control Unit ⑮"]
    AJ --> AK["Output ⑮"]
    AK --> AL["Control Unit ⑯"]
    AL --> AM["Output ⑯"]
    AM --> AN["Control Unit ⑰"]
    AN --> AO["Output ⑰"]
    AO --> AP["Control Unit ⑱"]
    AP --> AQ["Output ⑱"]
    AQ --> AR["Control Unit ⑲"]
    AR --> AS["Output ⑲"]
    AS --> AT["Control Unit ⑳"]
    AT --> AU["Output ⑳"]
    AU --> AV["Control Unit ⑪"]
    AV --> AW["Output ⑪"]

1. IgnitionSwitch

2.FrameGround

3.MeterUnit

1. Water-proofJointB

5.ECUFuse15A

6.IgnitionFuse10A

7.FuseBox

8.MainFuse30A

9.Battery12V10Ah

10.FrameGround

11.FuelReserveSwitch

12.JointConnector

13.ECU

14.OilPressureSwitch

1. NeutralSwitch

2. Water Temperature Sensor

17.Water-proofJointE

18.SpeedSensor

19.Water-proofJointC

SwitchesandSensors

BrakeLightTimingInspection

- RefertotheBrakeLightSwitchOperationInspectionin thePeriodicMaintenancechapter.

BrakeLightTimingAdjustment

- RefertotheBrakeLightSwitchOperationInspectionin thePeriodicMaintenancechapter.

SwitchInspection

- Usingahandtester, checktoseethatonlytheconnectionsshowninthetablehavecontinuity(aboutzero ohms).

○Fortheswitchhousingsandtheignitionswitch,referto thetablesintheWiringDiagram.

★ Iftheswitchhasanopenorshort,repairitorreplaceit withanewone.

SpecialTool-HandTester:57001-1394

RearBrakeLightSwitchConnections

Rear Brake Light Switch Connections
Color	BR	BL
When brake pedal is pushed down
When brake pedal is released

SidestandSwitchConnections

Sidestand Switch Connections
Color	BK	G
When sidestand is down
When sidestand is up	○	○

NeutralSwitchConnections

Neutral Switch Connections
Color	SW.Terminal	Ground
When transmission is in neutral
When transmission is not in neutral

OilPressureSwitchConnections*

Oil Pressure Switch Connections *
Color	SW.Terminal	Ground
When engine is stopped	○	○
When engine is running

*:Enginelubricationsystemisingoodcondition.

SwitchesandSensors

WaterTemperatureSensorInspection

• Removethewatertemperaturesensor(seeRemoval/InstallationintheFuelSystem(DFI)chapter).
• Suspendthesensor[A]inacontainerofcoolantsothat thetemperature-sensingprojection[C]andthreadedportion[C]aresubmerged.
• Suspendanaccuratethermometer[B]withtemperature-sensingprojectionlocatedinalmostthesamedepth.

NOTE

○ Thesensorandthermometermustnottouchthecontainersideorbottom.

• Placethecontaineroverasourceofheatandgraduallyraisethetemperatureofthecoolantwhilestirringthe coolantgently.
• Usingthehandtester,measuretheinternalresistanceof thesensor.
  ★Ifthehandtesterdoesnotshowthespecifiedvalues,re-placethesensor.

WaterTemperatureSensorResistance

Temperature	Resistance(kΩ)
-20°C(-4°F)*18.80±2.37
0°C(32°F)*(about6.544)
40°C(104°F)	1.136±0.095
100°C(212°F)	0.1553±0.0070

*:ReferenceInformation

SpeedSensorRemoval

• Disconnectthespeedsensorleadconnector[A].
• Removetheenginesprocketcover(seeEngineSprocketRemovalintheFinalDrivechapter).

- Remove: Bolt[A] SpeedSensor[B]

Close-up mechanical assembly showing hoses, springs, and a labeled component (A), no readable text or symbols present.

SpeedSensorInstallation

• Installationisthereverseofremoval.
- Applyanon-permanentlockingagenttothesensorbolt, andtightenit.

Torque-SpeedSensorBolt:7.8N·m(0.80kgf·m,69in·lb)

SwitchesandSensors

SpeedSensorInspection

• Removethespeedsensor(seeSpeedSensorRemoval).
• Connectthespeedsensorconnector[A]withthebattery [B],10kΩ resistor[C]andhandtester[D]asshown.
• SetthetestertotheDC25Vrange.

SpecialTool-HandTester:57001-1394

• Trace[A]eachsideofthespeedsensorsurfacewiththe screwdriver.
  ○Thenthetesterindicatorshouldflick[B].
  ★ Ifthetesterindicatordoesnotflick, replacethespeed sensor.

OxygenSensorRemoval(EuropeModels)

• Remove: LowerFairing(seeLowerFairingRemovalintheFrame chapter)
• Disconnecttheoxygenensorleadconnector[A].

Close-up of mechanical components with labeled parts (A) and connectors, no readable text or symbols beyond labels

- Removetheoxygen sensor[A].

Close-up of a mechanical assembly with a labeled component (A) and bolted joint, no readable text or symbols present.

OxygenSensorInstallation(EuropeModels)

CAUTION

Neverdroptheoxygen sensor[A],especiallyona hardsurface.Suchashocktotheunitcandamage it.Donottouchthesensingpart[B]andfilterholes [C]ofthesensortopreventoilcontact.Oilcontaminationfromhandscanreducesensorperformance.

• Tighten:
  Torque-OxygenSensor:44.1N·m(4.50kgf·m,32.5ft·lb)
• Runtheoxygen sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

SwitchesandSensors

OxygenSensorInspection(EuropeModels)

- RefertotheOxygenSensorInspectionintheFuelSystem (DFI)chapter.

FuelReserveSwitchInspection

• Fillthefueltankwithfuel.
• Closethefueltankcapsurely.
• Removethefueltank(seeFuelTankRemovalintheFuel System(DFI)chapter).
• ConnectthetestlightAandthe12Vbattery[B]tothefuelpumpconnector [C].

Connections:

Battery(+)→ 12V3.4WBulb(OneSide)

12V3.4WBulb(OtherSide)→ BLLeadTerminal

Battery(-)→ BKLeadTerminal

★Ifthetestlightturnon,thereserveswitchisdefective. Replacethefuellevelsensor.
- Removethefuelpump(seeFuelPumpRemovalinthe FuelSystem(DFI)chapter).
- Connectthetestlight(12V3.4Wbulbinasocketwith leads)andthe12Vbatterytothefuelpumpconnectoras shown.

12VBattery[A]

TestLight[B]

FuelPumpConnector[C]

FuelReserveSwitch[D]

★Ifthetestlightdoesn'tlight,replacethefuelpump.

NOTE

Olt may take along timetoturnonthetestlightincase that the fuel reserves switch is inspected just after the fuel pump is removed. Leav the fuel reserves switch with leads for inspection connected for few minutes.

RelayBox

Therelaybox[A]hasrelaysanddiodes. Therelaysand diodescannotberemoved.

RelayBoxRemoval

• Remove:
  FuelTank(seeFuelTankRemovalintheFuelSystem (DFI)chapter)
• Takeouttherelaybox[A]anddisconnecttheconnectors [B].

Close-up of a mechanical assembly with visible components and a labeled component (A), no readable text or symbols present.

RelayCircuitInspection

• Removetherelaybox(seeRelayBoxRemoval).
• Checkconductivityofthefollowingnumberedterminals byconnectingthehandtesterandone12Vbatterytothe relayboxasshown(seeRelayBoxInternalCircuitinthis section).
  ★ Ifthetesterdoesnotreadasspecified, replacetherelay box.

RelayCircuitInspection(withthebatterydisconnected)

RelayCircuitInspection(withthebatteryconnected)

		Battery Connection (+)(-)		Tester Connection	Tester Reading(Ω)
ECUMainRelay		2-111-30
		4-57-60
FuelPumpRelay9-107-80
FanRelay18-1917-200
	Battery Connection (+)(-)		TesterConnection DC25V Range		Tester Reading(V)
Starter CircuitRelay	16-1211-12				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).

DiodeCircuitInspection

TesterConnection

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 ten times as much in the other direction. If any diode shows low or high in both directions, the diode is defective and the relay box must be replaced.

NOTE

○ 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.

RelayBox

RelayBoxInternalCircuit

GP19010B72 C

A:HeadlightRelay
B:ECUMainRelay
C:FuelPumpRelay
D:StarterCircuitRelay
E:FanRelay

Fuse

30AMainFuseRemoval

- Remove:

LeftSideCover(seeSideCoverRemovalintheFrame chapter) Cover(seeStarterRelayInspection) Connector[A]

- Pulloutthemainfuse[B]fromthestarterrelaywithneedle nosepliers.

FuseBoxFuseRemoval

• Removetheseat(seeSeatRemovalintheFramechapter).
• Unlockthehook[A]toliftupthelid[B].

- Pullthefuses[A]straightoutofthefuseboxwithneedle nosepliers.

15AECUFuseRemoval

- Remove:

Seat(seeSeatRemovalintheFramechapter)

- Unlockthehook[A]topullthelid[B].

- PullouttheECUfuse[A]fromthefusebox.

Close-up of a vehicle engine compartment with a highlighted component labeled 'A' (no readable text or symbols beyond label)

Fuse

FuseInstallation

• Ifafusefailsduringoperation,inspecttheelectricalsystemtodeterminethecause,andthenreplaceitwithanewfuseofproperamperage.
• Installthefuseboxfusesontheoriginalpositionasspecifiedonthelid.

FuseInspection

• Removethefuse(see30AMain/FuseBox/15AECU FuseRemoval).
• Inspectthefuseelement.
  ★Ifitisblownout, replacethefuse. Before replacing a blownfuse, always check the amperage in the affected circuit. If the amperage is equal to greater than the fuserating, check the wiring and related components for ashort circuit.
  Housing[A]
  FuseElement[B]
  Terminals[C]
  BlownElement[D]

CAUTION

Whenreplacingafuse, besurethenewfuse matchesthespecifiedfuseratingforthatcircuit. Installationofafusewithahigherratingmaycause damagetowiringandcomponents.

Appendix

TableofContents

Cable, Wire, and Hose Routing.... 17-2

Troubleshooting Guide 17-26

17-2 APPENDIX

Cable, Wire, and HoseRouting

Cable, Wire, and HoseRouting

1. Clamp (From the on sequentially, through the left switch housing lead, ignition switch lead and mainharness.)
   2.LeftSwitchHousingLeadConnector
2. Clamp(Inserttheclampfromaircleanerside.)
3. AirSwitching Valve Lead Connector
   5.MainHarness
4. Clamp
5. Clamp(Inserttheclampintheframe.)
6. Clamp(Inserttheclampintheframe.)
7. Clamp
   10.InletTemperatureSensorLeadConnector
8. Clamp(Inserttheclampfromaircleanerside.)
9. IgnitionSwitchLeadConnector
10. Clamp(Clamptheleftswitchhousinglead(mainharnessside)andignitionswitchlead(mainharnessside).)

17-4APPENDIX

Cable, Wire, and HoseRouting

Cable, Wire, and HoseRouting

1. RelayBox
   2.MainHarness
2. Clamp(Inserttheclampinthebracket.)
   4.BatteryNegativeCable
   5.BatteryPositiveCable
   6.ECUConnectors
3. Clamp
4. Clamp
5. TailLightConnector
6. LicensePlateLightConnector
7. RearLeftTurnSignalLightConnector
8. RearRightTurnSignalLightConnector
9. Clamp(Inserttheclampintherearfenderrear.)
   14.FrameGround
   15.Clamp
   16.Water-proofJoint
   17.Clamp
   18.FuseBox
   19.Clamp
   20.Clamp
   21.Band
   22.Band
   23.Clamp
   24.TotheVehicle-downSensor,CrankshaftSensorandRearBrakeSwitch
10. Clamp (Clamp the regulator/rectifier lead and battery negative cable, and insert the clamp in the rearfenderfront.)
    26.BatteryNegativeLeadConnector
    27.FuelPumpLead
    28.StarterMotorCable
    29.ToStarterRelay

Cable, Wire, and HoseRouting

1. InletPressureSensor
2. TurnSignalRelay
3. Clamp(Inserttheclampintheframe.)
   4.HornLead
4. TotheWaterTemperatureSensor
   6.OxygenSensorLeadConnector
5. Clamp(Throughthesidestandswitchleadandoxygensensorleadintheclamp.)
   8.OxygenSensorLead
6. Clamp(Throughthedrainhoseintheclamp.)
   10.DrainHose
   11.SidestandSwitchLead
   12.CorrugatedTube
7. Alternator Lead Connector
   14.SidestandSwitchLeadConnector
   15.SpeedSensorLeadConnector
   16.MainThrottleSensorLeadConnector
   17.Tube
8. NeutralSwitchLead
9. Clamp(Inserttheclampintheenginebracket.)
10. Clamp(Inserttheclampinthecrosspipe.)
    21.DrainHose(Throughthedrainhosebetweenmainharnessandaircleaner.)

17-8APPENDIX

Cable, Wire, and HoseRouting

Cable, Wire, and HoseRouting

1. RadiatorFanConnector
2. Clamp(Throughthemainharnessandradiatorfanlead, and inserttheclampintheframe.)
3. Through the horn lead between water pipe and frame.
4. To Front Left Turn Signal Light
5. Clamp(Inserttheclampinthebracket.)
6. Clamp(Inserttheclampintheframe.)
7. Clamp(Inserttheclampintheenginebracket.)

17-10APPENDIX

Cable, Wire, and HoseRouting

Cable, Wire, and HoseRouting

1. Clamp(Throughtherightswitchhousinglead, and insert the clamp in the frame.)
2. ClutchCable
   3.ThrottleCables
3. Clamp
   5.RightSwitchHousingLead
4. Clamp(Inserttheclampinthebracket.)
5. Clamp(Inserttheclampintheframe.)
   8.About45°
6. Clamp(Inserttheclampintheframe.)
   10.CoolantHose
   11.Clamp
7. Clamp(Throughtheclutchcableintheclamp.)

17-12APPENDIX

Cable, Wire, and HoseRouting

GEO9860B \$

Cable, Wire, and HoseRouting

1. Crankshaft Sensor Lead Connector
2. Clamp(Inserttheclampinthebracket.)

17-14APPENDIX

Cable, Wire, and HoseRouting

Cable, Wire, and HoseRouting

1. TailLightConnector
2. LicensePlateLightConnector
3. RearRightTurnSignalLightConnector
4. RearLeftTurnSignalLightConnector
5. Clamp(Inserttheclampintherearfenderrear.)
6. Clamp(Inserttheclampintherearfenderrear.)
   7.DiagnosisConnector
7. Clamp(Inserttheclampintherearfenderfront.)
8. RearBrakeLightSwitchLead
   10.Band(Clampthemainharnesswiththeframe.)
   11.Band

Cable, Wire, and HoseRouting

1. RightSwitchHousingLead

2. ThrottleCables

3.Headlight(LO)Connector

1. Headlight(HI) Connector

2. BrakeHose

3. Clamp

4. IgnitionSwitchLead

8.MainHarness

9.LeftSwitchHousingLead

10.ClutchCable

11.CityLightConnector

1. Clamp(Inserttheclampinthebracket.)

2. Clamp(Alightheclampwiththewhitetapeoftheharness.)

3. From the left sequentially, through the clutch cable, left switch housing lead, ignition switch lead and mainharness.

15.Clamp(Throughtheignitionswitchlead,andinserttheclampinthebracket.)

Cable, Wire, and HoseRouting

1. Clamp
2. Clamp
3. Clamp
4. Clamp (Clamp the main harness, subthrottle sensor lead and subthrottle valve actuator lead to thedeliverypipe.)
   5.GroundLead
5. Clamp
   7.SubthrottleSensorLeadConnector
6. Subthrottle Valve Actuator Lead Connector
7. Clamp(Clamptheharness.)
   10.Clamp
   11.Clamp
   12.StickCoilLeadConnector
8. Clamp(Clampthestickcoillead.)

17-20APPENDIX

Cable, Wire, and HoseRouting

Cable, Wire, and HoseRouting

1. Regulator/RectifierLead
2. Clamp(Inserttheclampintheframe.)
3. RearBrakeLightSwitchLeadConnector
4. Through therearbrakelightswitchleadandvehicle-downsensorleadfromthefrontsideoftherarshockabsorberinstallationpart.
5. Throughtheregulator/rectifierleadtothefrontopeningoftherearfenderfront.
6. Vehicle-downSensorLead
   7.FuelPumpLeadConnector
7. Through the fuelpumplead to the hook of there arfender front.
8. Through the fuelpumplead to the slit of the cover.

Cable, Wire, and HoseRouting

1. Clamp(Inserttheclampinthefrontfender.)
   2.BrakeHose
2. Clamp

Cable, Wire, and HoseRouting

Cable, Wire, and HoseRouting

1. BrakeHose
2. Clamp
3. Clamp

TroubleshootingGuide

NOTE

○ RefertotheFuelSystemchapterformost ofDFItroubleshootingguide.
○ Thisisnotanexhaustivelist, giving every possible cause foreach problem listed. It is meant simply as a rough guideto assist the troubleshooting for some of them more common difficulties.

EngineDoesn'tStart, Starting Difficulty:

Startermotornotrotating:

Starterlockoutswitchorneutralswitchtrouble
Startermotortrouble
Batteryvoltagelow
Starterrelaynotcontactingoroperating
Starterbuttonnotcontacting
Wiringopenorshorted
Ignitionswitchtrouble
Enginestopswitchtrouble
Fuseblown

Startermotorrotatingbutenginedoesn't

turnover:

Starterclutchtrouble

Vehicle-downsensor(DFI)comingoff

Transmissiongearorbearingseizure

Camshaftseizure

Starteridlegearseizure

Nofuelflow:

Nofuelintank

Fuelpumptrouble

Fueltankairventobstructed

Fuelfilterclogged

Fuellineclogged

Engineflooded:

Cleansparkplugandadjustpluggap

Startingtechniquefaulty

(When flooded, donotcrank the engine with the throttle fully opened. This promotes engine flood because more fuel supply is automatically by DFI.)

Nospark;sparkweak:

Vehicle-downsensor(DFI)comingoff IgnitionswitchnotON

EnginestopswitchturnedOFF

Clutchlevernotpulledinorgearnotinneutral

Batteryvoltagelow

Sparkplugdirty, broken, orgapmaladjusted

Stickcoilshortedornotingoodcontact

Stickcoiltrouble

Sparkplugincorrect

ICigniterinECUtrouble

Neutral, starterlockout, or sidestandswitch trouble

Crankshaftsensortrouble

Ignition switch or engine stop switch shorted

Wiringshortedoropen

Fuseblown

Fuel/airmixtureincorrect:

Bypassscrewand/oridleadjustingscrew maladjusted

Airpassageclogged

Aircleanerclogged,poorlysealed,ormissing

CompressionLow:

Sparkplugloose

Cylinder head not sufficiently tightened down

Novalveclearance

Cylinder, pistonworn

Piston ring bad (worn, weak, broken, or sticking)

Pistonring/grooveclearanceexcessive

Cylinderheadgasketdamaged

Cylinderheadwarped

Valve spring broken or weak

Valve not seating properly (valve bent, worn, orcarbonaccumulation on the seatingsurface)

PoorRunningatLowSpeed:

Sparkweak:

Batteryvoltagelow

Sparkplugdirty,broken,ormaladjusted

Stickcoilwiringtrouble

Stickcoilnotingoodcontact

Sparkplugincorrect

ICigniterinECUtrouble

Crankshaftsensortrouble

Stickcoiltrouble

Fuel/airmixtureincorrect:

Bypassscrewmaladjusted

Airpassageclogged

Airbleedpipebleedholesclogged

Pilotpassageclogged

Aircleanerclogged,poorlysealed,ormissing

Fueltankairventobstructed

Fuelpumptrouble

Throttlebodyassyholderloose

Aircleanerductloose

TroubleshootingGuide

Compressionlow:

Sparkplugloose

Cylinderheadnotsufficientlytightened down

Novalveclearance

Cylinder, pistonworn

Pistonringbad(worn,weak,broken,or sticking)

Pistonring/grooveclearanceexcessive

Cylinderheadwarped

Cylinderheadgasketdamaged

Valvespringbrokenorweak

Valvenotseatingproperly(valvebent, worn,orcarbonaccumulationonthe seatingsurface)

Other:

ICigniterinECUtrouble

Throttlebodyassynotsynchronizing

Engineoilviscositytoohigh

Drivetraintrouble

Brakedragging

Airsuctionvalvetrouble

Airswitchingvalvetrouble

Engineoverheating

Clutchslipping

PoorRunningorNoPoweratHigh

Speed:

Firingincorrect:

Sparkplugdirty,broken,ormaladjusted

Stickcoilwiringtrouble

Stickcoilnotingoodcontact

Sparkplugincorrect

Camshaftpositiontrouble

ICigniterinECUtrouble

Crankshaftsensortrouble

Stickcoiltrouble

Fuel/airmixtureincorrect:

Aircleanerclogged,poorlysealed,ormissing

AircleanerO-ringdamaged

Aircleanerductloose

Waterorforeignmatterinfuel

Throttlebodyassyholderloose

Fueltoinjectorinsufficient(DFI)

Fueltankairventobstructed

Fuellineclogged

Fuelpumptrouble

Compressionlow:

Sparkplugloose

Cylinderheadnotsufficientlytightened down

Novalveclearance

Cylinder, pistonworn

Pistonringbad(worn,weak,broken,or sticking)

Pistonring/grooveclearanceexcessive

Cylinderheadgasketdamaged

Cylinderheadwarped

Valvespringbrokenorweak

Valvenotseatingproperly(valvebent, worn,orcarbonaccumulationonthe seatingsurface)

Knocking:

Carbonbuiltupincombustionchamber

Fuelpoorqualityorincorrect

Sparkplugincorrect

ICigniterinECUtrouble

Crankshaftsensortrouble

Miscellaneous:

Throttlevalewon'tfullyopen

Brakedragging

Clutchslipping

Engineoverheating

Engineoilleveltoohigh

Engineoilviscositytoohigh

Drivetraintrouble

Airsuctionvalvetrouble

Airswitchingvalvetrouble

Catalytic converter melt down due to muffler overheating(KLEEN)

Overheating:

Firingincorrect:

Sparkplugdirty, broken, ormaladjusted

Sparkplugincorrect

ICigniterinECUtrouble

Muffleroverheating:

ForKLEEN, donotruntheengine even if with only one cylinder misfiring or poor running (Requestthenearestservicefacilitytocorrectit)

ForKLEEN, donotpush-startwithadead battery (Connect another full-charged battery with jumpercables, and start the engine using the electric starter)

ForKLEEN, donotstarttheengineunder misfireduetosparkplugfoulingorpoor connectionofthestickcoil

For KLEEN, do not coast the motorcycle withtheignitionswitchoff(TurntheignitionswitchONandruntheengine)

ICigniterinECUtrouble

Fuel/airmixtureincorrect:

Throttlebodyassyholderloose

Aircleanerductloose

Aircleanerpoorlysealed,ormissing

AircleanerO-ringdamaged

Aircleanerclogged

Compressionhigh:

Carbonbuiltupincombustionchamber

Engineloadfaulty:

Clutchslipping

Engineoilleveltoohigh

TroubleshootingGuide

Engineoilviscositytoohigh

Drivetraintrouble

Brakedragging

Lubricationinadequate:

Engineoilleveltoolow

Engineoilpoorqualityorincorrect

Gaugeincorrect:

Watertemperaturegaugebroken

Watertemperaturesensorbroken

Coolantincorrect:

Coolantleveltoolow

Coolantdeteriorated

Wrongcoolantmixedratio

Coolingsystemcomponentincorrect:

Radiatorfindamaged

Radiatorclogged

Thermostattrouble

Radiatorcaptrouble

Radiatorfanrelaytrouble

Fanmotorbroken

Fanbladedamaged

Waterpumpnotturning

Waterpumpimpellerdamaged

OverCooling:

Gaugeincorrect:

Watertemperaturegaugebroken

Watertemperaturesensorbroken

Coolingsystemcomponentincorrect:

Radiatorfanrelaytrouble

Thermostattrouble

ClutchOperationFaulty:

Clutchslipping:

Frictionplatewornorwarped

Steelplatewornorwarped

Clutchspringbrokenorweak

Clutchhuborhousingunevenlyworn

Noclutchleverplay

Clutchinnercabletrouble

Clutchreleasemechanismtrouble

Clutchnotdisengagingproperly:

Clutchplatewarpedortoorough

Clutchspringcompressionuneven

Engineoildeteriorated

Engineoilviscositytoohigh

Engineoilleveltoohigh

Clutchhousingfrozenondriveshaft

Clutchhubnutloose

Clutchhubsplinedamaged

Clutchfrictionplateinstalledwrong

Clutchleverplayexcessive

Clutchreleasemechanismtrouble

GearShiftingFaulty:

Doesn'tgointogear;shiftpedaldoesn't

return:

Clutchnotdisengaging

Shiftforkbentorseized

Gearstuckontheshaft

Gearpositioningleverbinding

Shiftreturnspringweakorbroken

Shiftreturnspringpinloose

Shiftmechanismarmspringbroken

Shiftmechanismarmbroken

Shiftpawlbroken

Jumpsoutofgear:

Shiftforkearworn,bent

Geargrooveworn

Geardogsand/ordogholesworn

Shiftdrumgrooveworn

Gearpositioningleverspringweakorbroken

Shiftforkguidepinworn

Driveshaft, outputshaft, and/orgear splinesworn

Overshifts:

Gearpositioningleverspringweakorbroken

Shiftmechanismarmspringbroken

AbnormalEngineNoise:

Knocking:

ICigniterinECUtrouble

Carbonbuiltupincombustionchamber

Fuelpoorqualityorincorrect

Sparkplugincorrect

Overheating

Pistonslap:

Cylinder/pistonclearanceexcessive

Cylinder, pistonworn

Connectingrodbent

Pistonpin,pistonpinholeworn

Valvenoise:

Valveclearanceincorrect

Valvespringbrokenorweak

Camshaftbearingworn

Valvelifterworn

Othernoise:

Connectingrodsmallendclearanceexcessive

Connectingrodbigendclearanceexcessive

Pistonring/grooveclearanceexcessive

Pistonringworn,broken,orstuck

Crankshaftrunoutexcessive

TroubleshootingGuide

Enginemountloose

Crankshaftbearingworn

Primarygearwornorchipped

Camshaftchaintensionertrouble

Camshaftchain, sprocket, guideworn

Airsuctionvalvedamaged

Airswitchingvalvedamaged

Alternatorrotorloose

Catalyticconvertermeltdownduetomuffler overheating(KLEEN)

AbnormalDriveTrainNoise:

Clutchnoise:

Clutchhousing/frictionplateclearanceexcessive

Clutchhousinggearworn

Wronginstallationofoutsidefrictionplate

Transmissionnoise:

Bearingsworn

Transmissiongearwornorchipped

Metalchipsjammedingearteeth

Engineoilinsufficient

Drivelinenoise:

Drivechainadjustedimproperly

Drivechainworn

Rearand/orenginesprocketworn

Chainlubricationinsufficient

Rearwheelmisaligned

AbnormalFrameNoise:

Frontforknoise:

Oilinsufficientortoothin

Springweakorbroken

Rearshockabsorbernoise:

Shockabsorberdamaged

Discbrakenoise:

Padinstalledincorrectly

Padsurfaceglazed

Discwarped

Calipertrouble

Othernoise:

Bracket, nut, bolt, etc. not properly mountedortightened

OilPressureWarningLightGoesOn:

Engineoilpumpdamaged

Engineoilscreenclogged

Engineoilfilterclogged

Engineoilleveltoolow

Engineoilviscositytoolow

Camshaftbearingworn

Crankshaftbearingworn

Oilpressureswitchdamaged

Wiringfaulty

Reliefvalvestuckopen

O-ringattheoilpassageinthecrankcase damaged

ExhaustSmokesExcessively:

Whitesmoke:

Pistonoilringworn

Cylinderworn

Valveoilsealdamaged

Valveguideworn

Engineoilleveltoohigh

Blacksmoke:

Aircleanerclogged

Brownsmoke:

Aircleanerductloose

AircleanerO-ringdamaged

Aircleanerpoorlysealedormissing

Handling and/or Stability Unsatisfactory:

Handlebarhardtoturn:

Cableroutingincorrect

Hoseroutingincorrect

Wiringroutingincorrect

Steeringstemnuttootight

Steeringstembearingdamaged

Steeringstembearinglubricationinadequate

Steeringstembent

Tireairpressuretoolow

Handlebarshakesorexcessivelyvibrates:

Tireworn

Swingarmpivotbearingworn

Rimwarped,ornotbalanced

Wheelbearingworn

Handlebarholderboltloose

Steeringstemnutloose

Front, rearaxlerunoutexcessive

Enginemountingboltloose

Handlebarpullstooneside:

Framebent

Wheelmisalignment

Swingarmbentortwisted

Swingarmpivotshaftrunoutexcessive

Steeringmaladjusted

Frontforkbent

Rightandleftfrontforkoilleveluneven

Shockabsorptionunsatisfactory:

(Toohard)

Frontforkoilexcessive

Frontforkoilviscositytoohigh

Rearshockabsorberadjustmenttoohard

Tireairpressuretoohigh

Frontforkbent

(Toosoft)

Tireairpressuretoolow

Frontforkoilinsufficientand/orleaking

Frontforkoilviscositytoolow

TroubleshootingGuide

Rearshockadjustmenttoosoft

Frontfork, rearshockabsorberspringweak

Rearshockabsorberoilleaking

BrakeDoesn'tHold:

Airinthebrakeline

Padordiscworn

Brakefluidleakage

Discwarped

Contaminatedpad

Brakefluiddeteriorated

Primaryorsecondarycupdamagedinmaster cylinder

Mastercylinderscratchedinside

BatteryTrouble:

Batterydischarged:

Chargeinsufficient

Batteryfaulty(toolowterminalvoltage)

Batteryleadmakingpoorcontact

Loadexcessive(e.g.,bulbofexcessive wattage)

Ignitionswitchtrouble

Alternatortrouble

Wiringfaulty

Regulator/rectifiertrouble

Batteryovercharged:

Alternatortrouble

Regulator/rectifiertrouble

Batteryfaulty

MODELAPPLICATION

YearModel	BeginningFrameNo.
2006ER6	50A6F	JKAEREA1□6A000001ER650A-000001
2006ER6	50A6SJKAER650AAA	000001

□: Thisdigitintheframenumberchangesfromonemachinetoanother.