ZZR 1400 - Motorcycle KAWASAKI - Free user manual and instructions

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USER MANUAL ZZR 1400 KAWASAKI

Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix This quick reference guide will assist you in locating a desired topic or pro- cedure. +Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. -Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required.

ZZR 1400 à ZZR1400 ABS Kawasaki Ninja ZX-14 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, Without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2006 Kawasaki Heavy Industries, Ltd. First Edition (1): Mar. 3, 2006 (M)

A ampere(s) Ib pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h hour(s) Q ohm(s) L liter(s)

COUNTRY AND AREA CODES

AT Austria FR France AU Australia GB United Kingdom CA Canada MY Malaysia CAL California US United States CH Switzerland WVTA Whole Vehicle Type Approval DE Germany

To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi- tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

1. Crankcase Emission Control System

This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California in- cludes a catalytic converter system.

3. Evaporative Emission Control System

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In- stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act's “tampering provisions”. “Sec. 203(a) The following acts and the causing thereof are prohibited.… (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know- ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow- ing its sale and delivery to the ultimate purchaser...” NOTE OThe phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows.

1. Tampering does not include the temporary removal or rendering inoperative of de-

vices or elements of design in order to perform maintenance.

2. Tampering could include.

a.Maladjustment of vehicle components such that the emission standards are ex- ceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the stan- dards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below. e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. e Removal of the muffler(s) or any internal portion of the muffler(s). + Removal of the air box or air box cover. e Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. À basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance With this manual may void the warranty. To get the longest life out of your vehicle. + Follow the Periodic Maintenance Chart in the Service Manual. eBe alert for problems and non-scheduled maintenance. e Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. e Follow the procedures in this manual care- fully. Don't take shortcuts. + Remember to keep complete records of main- tenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta- ble of Contents. For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. À WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa- tion. NOTE OThis note symbol indicates points of par- ticular interest for more efficient and con- venient operation. e Indicates a procedural step or work to be done. Olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. xindicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly.

General Information Table of Contents Before Servicing Model Identification. General Specifications. Technical Information-CA Unit Conversion Table

Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following. Battery Ground Before completing any service on the motorcycle, discon- nect the battery cables from the battery to prevent the en- gine from accidentally turning over. Disconnect the ground cable (—) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (—) ca- ble to the negative terminal. DISASSEMBLY ASSEMBLY co s Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. œne s Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer. ao s Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during ve- hicle disassembly can cause excessive wear and decrease performance of the vehicle. 02008 s

Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuse of worn or damaged parts may lead to serious ac- cident. Visually inspect removed parts for corrosion, discol- oration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is be- yond its service limit. Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassem- bly, however, if assembly order is provided in this Service Manual, follow the procedures given. 0200 s 02006 s cons s œoons s

Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quar- ter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair dam- age. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material re- mains. Install the new gaskets and replace the used O-rings when re-assembling Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them exces- sively. Excessive application can clog oil passages and cause serious damage. & y RS “C0 se &

Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is CS à m absolutely necessary. Replace with new ones whenever JL À ) all D removed. Press bearings with the manufacturer and size ji N Â marks facing out. Press the bearing into place by putting <R S NX NI pressure on the correct bearing race as shown. pe Eh = 3 Pressing the incorrect race can cause pressure between fé LS il Li the inner and outer race and result in bearing damage. / 2 1——2- Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal | ] is necessary. Replace with new ones whenever removed. L 1 = Press new oil seals with manufacture and size marks facing NM = out. Make sure the seal is aligned properly when installing. K S Ÿ [ À | LÉ

Apply specified grease to the lip of seal before installing the seal. Grease cBozo4snst c Circlips, Cotter Pins Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation. cB020268 5

Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires Atwo-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color. Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thor- oughly before using the meter. Incorrect values may lead to improper adjustments. cons s œozs s Gso20820s1 €

Model Identification ZX1400A6F (United States and Canada) Left Side View

ZX1400A6F (United States and Canada) Right Side View

Model Identification ZX1400A6F (Malaysia) Left Side View CUT ZX1400A6F (Malaysia) Right Side View emu P

General Specifications Items ZX1400A6F, ZX1400B6F Dimensions Overall Length 2 170 mm (85.4 in.) Overall Width 760 mm (29.9 in.) Overall Height 1 170 mm (46.1 in.) Wheelbase 1 460 mm (57.4 in.) Road Clearance 125 mm (4.9 in.) Seat Height 800 mm (31.5 in.) Dry Mass: ZX1400A6F 215 kg (474 Ib) ZX1400B6F 218 kg (481 Ib) Curb Mass: Front ZX1400A6F 125 kg (276 lb) ZX1400B6F 126 kg (278 lb) Rear ZX1400A6F 127 kg (280 lb) ZX1400B6F 129 kg (284 lb) Fuel Tank Capacity 22 L (5.8 US gal) Performance Minimum Turning Radius 3.1 m (10.2 ft) Engine Type 4-stroke, DOHC, 4-cylinder Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Liquid-cooled

154 N:m (15.7 kgf-m, 114 ft-1b) @7 500 r/min (rpm), (FR) 114 N:m (11.6 kgf-m, 84 ft:1b) @4 500 r/min (rpm), (MY) 147.4 Nm (15.0 kgf-m, 109 ft-1b) @7 500 r/min (rpm),

(CA), (CAL), (US) — - -

FI (Fuel injection), MIKUNI 44EIDW * 4 Electric starter Battery and coil (transistorized) Electronically advanced (digital igniter in ECU) From 10° BTDC @1 100 r/min (rpm)

Left to right, 1-2-3-4 1-2-4-3

General Specifications Items ZX1400A6F, ZX1400B6F Valve Timing: Inlet: Open 41° (BTDC) Close 71° (ABDC) Duration 292° Exhaust: Open 64° (BBDC) Close 34° (ATDC) Duration 278° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity 4.5 L (4.8 US qt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 1.541 (94/61) Clutch Type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 1st 2.625 (42/16) 2nd 1.947 (37/19) 3rd 1.545 (34/22) Ath 1.333 (32/24) 5th 1.154 (30/26) 6th 1.036 (29/28) Final Drive System: Type Chain drive Reduction Ratio Overall Drive Ratio

General Specifications Items ZX1400A6F, ZX1400B6F Rim Size: Front Rear Front Suspension: 17 x 3.50 17 x 6.00 Rated Output Type Telescopic fork (upside-down) Wheel Travel 117 mm (4.6 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 122 mm (4.8 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 14 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 65 W (quartz-halogen) x 2 Low 12 V 55 W (quartz-halogen) *x 2 Tail/Brake Light 12 V 0.5/4.9 W (LED) Alternator: Type Three-phase AC 35 A/14 V @5 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country.

Technical Information-CAN (Controller Area Network) Communication System Overview The CAN communication system is used for transmitting and receiving data that is sent to the meter unit and ECU. A LCD (liquid crystal display) display in the meter unit displays information such as bat- tery voltage, fuel consumption, and service codes in addition to the conventional indicator functions.

1. Fuel Mileage Range 5. Gear Position

2. Fuel Consumption (Current) 6. Service Code

3. Fuel Consumption (Average) 7. Immobilizer Registration

4. Battery Voltage 8. Clutch Engagement Timing

2. CANis a multi-cast serial bus standard (ISO protocol). Data is transmitted by changing the voltage

signal of the two bus leads which are composed of high and low voltage wires twisted together. Since the high-speed ISO standard is used (transmission speeds of up to 500 kbps“), large quan- tities of data can be transmitted and received in a short period of time. *bps: bit/sec — the number of signals (0 or 1) transmittable/receivable per second

1-16 GENERAL INFORMATION

Technical Information-CAN (Controller Area Network) Communication System Structure and Function

1. In the CAN communication system, anti-noise twisted pair leads are used (two leads).

Communication Lead(High) Sensor function CINE Twisted Pair Leads [A] (In the main harness)

2. Data is transmitted from the two nodes-the ECU and meter unit-on the CAN bus and does not

contain specific bus addresses of either node. Instead, the content of a data stream, such as engine rpm, is labeled with an identifier that is unique throughout the network. All nodes on the network receive the data and each performs an acceptance test on the identifier to determine if the message (and its data) is relevant to that particular node. If a message is relevant to a particular node (meter unit), it will be processed and displayed other- wise it is ignored. The unique data identifier also determines the priority of the message. In situations where the two nodes attempt to transmit at the same time, a non-destructive arbitration technique guarantees that the messages are sent in order of importance.

3. The CAN data that is transmitted from the ECU to the meter unit are engine rpm, water temper-

ature, gear position, starter lockout switch, self-diagnosis information and “fuel injected volume. And the data transmitted from the meter to the ECU is vehicle speed. *Fuel injected volume is converted into the fuel consumption by the meter unit.

GENERAL INFORMATION 1-17

Technical Information-CAN (Controller Area Network) Communication System System failure and maintenance

1. Detection of a system failure

When the DFI or immobilizer system fails, the information will be shown on the LCD under the "ig- nition switch ON" condition.

2. System maintenance

1. Do not add a by-pass lead to the twisted pair lead. This can damage components.

© ss eut @ Engine CITFECUEN

2. Do not modify the twisted pair lead or loosen/tighten the number of twists. Such modifications of

the leads can cause the deterioration of the anti-noise characteristics resulting in communication errors.

Periodic Maintenance Table of Contents Periodic Maintenance Chart 2-3 Torque and Locking Agen 2-6 Specifications 2-12 Special Tools 2-14 Maintenance Procedure 2-15 Fuel System (DFI). 2-15 Throttle Control System Inspectiol 2-15 Engine Vacuum Synchronization Inspection 2-15 Idle Speed Inspection 2-19 Idle Speed Adjustment.. 2-19 Fuel Hose Inspection (fuel leak, damage, installation condition). 2-19 Cooling System 2-20 Coolant Level Inspectio 2-20 Radiator Hose and Pipe Inspection . 2-20 Evaporative Emission Control System (California Model). 2-21 Evaporative Emission Control System Inspection . 2-21 Air Suction System 2-21 Air Suction System Damage Inspection. 2-21 Engine Top End 2-22 Valve Clearance Inspection 2-22 Clutch and Drive Train 2-27 Clutch Operation Inspection 2-27 Clutch Fluid Level Inspection. 2-27 Clutch Fluid Leak Inspection. 2-28 Clutch Hose and Pipe Damage and Installation Condition Inspection 2-28 Wheels/Tires 2-29 Air Pressure Inspection. 2-29 Wheel/Tire Damage Inspection. 2-29 Tire Tread Wear Inspection 2-29 Wheel Bearing Damage Inspection . 2-30 Drive Train 2-30 Drive Chain Lubrication Condition Inspection. 2-30 Drive Chain Slack Inspection. 2-31 Drive Chain Slack Adjustment 2-31 Wheel Alignment Inspection 2-32 Drive Chain Wear Inspection . 2-32 Chain Guide Wear Inspection 2-33 Brake System 2-34 Brake Fluid Leak (Brake Hose and Pipe) Inspection 2-34 Brake Hose and Pipe Damage and Installation Condition Inspection 2-35 Brake Operation Inspection … 2-35 Brake Fluid Level Inspection. 2-35 Brake Pad Wear Inspection 2-36 Brake Light Switch Operation Inspection 2-37 Suspensions 2-37 Front Forks/Rear Shock Absorber Operation Inspection 2-37 Front Fork Oil Leak Inspection 2-38 Rear Shock Absorber Oil Leak Inspection 2-38 Rocker Arm Operation Inspection. 2-38 Tie-Rod Operation Inspection … 2-38

Steering System Steering Play Inspection . Steering Play Adjustment Steering Stem Bearing Lubrication . Electrical System Lights and Switches Operation Inspection Headlight Aiming Inspection Sidestand Switch Operation Inspection … Engine Stop Switch Operation Inspection Others Bolts, Nuts and Fasteners Tightness Inspection Replacement Parts Air Cleaner Element Replacement Fuel Hose Replacement . Coolant Change. Radiator Hose and O-ring Replacemen Engine Oil Change... Oil Filter Replacement . Brake Hose and Pipe Replacemen Brake Fluid Change Master Cylinder Rubber Parts Replacement . Caliper Rubber Parts Replacement Rear Caliper Assembly Clutch Hose and Pipe Replacement Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement Clutch Fluid Change . Spark Plug Replacement ss 2-39 2-39 2-39 2-40 2-41 2-41 2-44 2-45 2-46 2-46 2-46 2-47 2-48 2-48 2-49 2-51 2-53 2-53 2-54 2-55 2-57 2-58 2-59 2-62 2-63 2-64 2-66 2-66

Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY | Whichever * ODOMETER comes READING first => x 1000 km See (* 1000 mile) Page + 1.16)12 |18|24 | 30 | 36 INSPECTION Every |(0.6)/(4)/(7.5) (12) (15) (20)| (24) Fuel System 10 drag) De (play, smooth return, year . . . 2-15 Engine vacuum synchronization-inspect e e e |2-15 Idle speed-inspect e e e e |2-19 Fuel leak (fuel hose and pipe) - inspect year e e e e |2-19 Fuel hose and pipe damage-inspect year 0 0 0 e |2-19 Condition rene à installation year . . . e 2-19 Cooling System Coolant level - inspect 0 0 0 e |2-20 Coolant leak (radiator hose and pipe) -inspect| year e e e e |2-20 Radiator hose damage - inspect year e e e e |2-20 Radiator hose installation condition - inspect year e e e e |2-20 Evaporative Emission Control System (CAL) Fred emission control system function lolo lolo ele 221 Air Suction System Air suction system damage - inspect e e e |2-21 Engine Top End Valve clearance - inspect |US, CA, AU Model e CR AU Rod Every 42 000 km (26 000 mile) 222 Clutch and Drive Train San O en on De disengagement, . . . e | 2-27 Clutch fluid level - inspect 6months| e | ee |e|e|e|e |2-27 omis leak (clutch hose and pipe) - year lolo lolo ele 2238 Clutch hose and pipe damage - inspect year ele) ee ele )e le 2-28 Clutch hose installation condition - inspect year ele. ee ele |e)e 2-28 Wheels and Tires Tire air pressure - inspect year e e e | 2-29 Wheels/tires damage - inspect e e e | 2-29 Tire tread wear abnormal wear - inspect 0 0 e |2-29 Wheel bearing damage - inspect year 0 0 e |2-30

Periodic Maintenance Chart FREQUENCY | Whichever * ODOMETER comes READING Î x first > & 1000 mie) pe + 1 |[6| 12 |18|24 | 30 | 36 INSPECTION Every |(0.6)/(4)|(7.5) (12}(15) (20) (24) Final Drive Drive chain lubrication condition - inspect # Every 600 km (400 mile) after driving in rain | 2-30 Drive chain slack - inspect # Every 1 000 km (600 mile) 2-31 Drive chain wear - inspect # e e e |2-32 Drive chain guide wear - inspect e e e | 2-33 Brake System a leak (brake hose and pipe) - year eloloelelole le l23 Brake hose and pipe damage - inspect year e lee ee |e)e |2-35 Brake hose installation condition - inspect year ele. ele le)le |2-35 porto (effectiveness, play, no drag) year ele lolo le + 235 Brake fluid level - inspect 6months| e |e|[e |e.)e]|e)e |2-35 Brake pad wear - inspect # ee | .)e]e)e |2-36 Brake light switch operation - inspect ele. ele |e)e |2-37 Suspensions Front forks/rear shock absorber operation . . ° | 2-37 (damping and smooth stroke) - inspect Front forks/rear shock absorber oil leak - inspect year e e e |2-38 Rocker arm operation - inspect e e e |2-38 Tie-rods operation - inspect e e e |2-38 Steering System Steering play - inspect year e e e e |2-39 Steering stem bearings-lubricate 2 years 0 2-39 Electrical System Lights and switches operation - inspect year 0 0 e |2-41 Headlight aiming - inspect year e e e |2-44 Sidestand switch operation - inspect year e e e |2-45 Engine stop switch operation - inspect year e e e |2-46 Others Chassis parts-lubricate year e e e |2-46 Bolts, nuts and fasteners tightness - inspect 0 0 0 e |2-47 #: 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.

Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY | Whichever * ODOMETER READING come D x 1000 km first (* 1000 mile)| See + 1 [12/18 | 24 | 36 | 48 | Page CHANGE/REPLACEMENT Every |(0.6)/(7.5)| (12) | (15) | (24) | (30) Air cleaner element # Every 18 000 km (12 000 mile) | 2-48 Fuel hose 4 years e 2-49 Coolant 3 years e 2-51 Radiator hoses and O-rings 3 years 0 2-53 Engine oil # year 0 0 0 0 0 2-53 Oil filter year e e e e e 2-54 Brake hose and pipe 4 years e 2-55 Brake fluid 2 years e e 2-57 Rubber parts of brake master cylinder/caliper| 4 years 0 2-58 Clutch hose and pipe 4 years 0 2-63 ra of clutch master cylinder/slave 4 years . 2-64 Clutch fluid 2 years 0 0 2-66 Spark plugs e e e e 2-66 #: 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.

Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease to the threads. L: Apply a non-permanent locking agent to the threads. M: Apply molybdenum disulfied grease. MO: Apply molybdenum disulfide grease oil (mixture of engine oil and molybdenum disulfide grease in a weight ration is 10 : 1). R: Replacement Parts S: Tighten the fasteners following the specified sequence. Si: Apply silicone grease (ex. PBC grease). SS: Apply silicone sealant. Torque Fastener Remarks Nm kgf:m ft:lb Fuel System Air Cleaner Element Cover Bolts 6.9 0.70 61 in‘lb Air Cleaner Element Holder Screws 6.9 0.70 61 in‘lb Bypass Screws 0.2 0.02 1.8 in-lb Camshaft Position Sensor Bolt 9.8 1.0 87 in‘lb Crankshaft Sensor Bolts 5.9 0.60 52 in‘lb L Delivery Pipe Mounting Screws 5.0 0.51 44 in‘lb Duct Clamp Bolts 2.0 0.20 18 in-lb Front Air Inlet Duct Mounting Bolts 9.8 1.0 87 in-lb Fuel Pump Bolts 9.8 1.0 87 in:lb L,S Gear Position Switch Lead Clamp Bolts 9.8 1.0 87 inlb Gear Position Switch Screws 2.9 0.30 26 in-lb L Inlet Air Pressure Sensor Bracket Screws 3.5 0.36 31 in‘lb Middle Air Inlet Duct Clamp Bolts 2.9 0.30 26 in-lb Middle Air Inlet Duct Mounting Bolts 9.8 1.0 87 in-lb Rear Air Inlet Duct Mounting Bolts 9.8 1.0 87 in-lb Speed Sensor Bolt 3.9 0.40 35 in:lb L Throttle Body Assy Holder Bolts 9.8 1.0 87 in-lb Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in-lb Vehicle-down Sensor Bolts 5.9 0.60 52 in-lb Water Temperature Sensor 25 2.5 18 Cooling System Coolant Drain Plug 12 1.2 106 in-lb Coolant Fitting Bolts 8.8 0.90 78 in-lb L Oil Cooler Mounting Bolts 12 1.2 106 in-lb Radiator Hose Clamp Screws 2.0 0.20 18 in‘lb Thermostat Housing Cover Bolts 5.9 0.60 52 in-lb Thermostat Housing Mounting Bolts 9.8 1.0 87 in-lb Water Pump Cover Bolts 9.8 1.0 87 inlb Water Temperature Sensor 25 2.5 18

3.7 L (3.9 US qt) (when filter is not removed)

4.1 L (4.3 US qft) (when filter is removed)

4.5 L (4.8 US qt) (when engine is completely

dry) Between upper and lower level lines (Wait 2 — 3 minutes after idling or running) Wheels/Tires Tread Depth: Front Rear Air Pressure (when Cold): Front Rear

323 mm (12.7 in.) Make DAIDO ——- Type DID50ZVM4 GC&B = Link 116 links ——- Brakes Brake Fluid: Grade DOT4 ——- Brake Pad Lining Thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.) Rear 5.0 mm (0.20 in.) 1 mm (0.04 in.) Brake Light Timing': Front Pulled ON ——- Rear On after about 10 mm (0.39 in.) of pedal travel ——- Electrical System Spark Plug: Type NGK CRSEIA-9

STS7187287 © Oil Filter Wrench: 57001-1249 Jack Attachment: S187124987 © 57001-1608

Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection e Check the throttle grip free play [A]. xlf the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2 —3 mm (0.08 —-0.12 in.) e Check that the throttle grip [B] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. xlfthe throttle grip does not return properly, check the throt- tle cables routing, grip free play, and cable damage. Then lubricate the throttle cable. e Run the engine at the idle speed, and turn the handlebar allthe way to the right and left to ensure that the idle speed does not change. xlf the idle speed increases, check the throttle cable free play and the cable routing. xlf necessary, adjust the throttle cable as follows. e Loosen the locknuts [A] [B]. e Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play. e Turn the decelerator cable adjuster [C] until 2 —3 mm (0.08 —0.12 in.) of throttle grip play is obtained. e Tighten the locknut [A]. e Turn the accelerator cable adjuster [D] until 2 —3 mm (0.08 —0.12 in.) of throttle grip play is obtained. e Tighten the locknut [B]. xlf the free play cannot be adjusted with the adjusters, re- place the cable. Engine Vacuum Synchronization Inspection NOTE OThese procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. e Situate the motorcycle so that it is vertical. e Remove: Fuel Tank Cover (see Fuel Tank Removal in the Fuel System (DFI) chapter) Left and Right Middle Fairings (see Middle Fairing Re- moval in the Frame chapter) Pull off the rubber caps [A] from the fittings of each throttle body. Front [B] esososons:

Maintenance Procedure e For the California Model, pull off the vacuum hoses [A]. e Pull offthe air switching valve hose [A] from the air cleaner housing. e Plug the air switching valve hose end and air cleaner housing hole. e Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 © Connect a highly accurate tachometer [B] to one of the stick coil primary leads. e Start the engine and warm it up thoroughly. e Check the idle speed, using a highly accurate tachometer [AÏ. x lfthe idle speed is out of the specified range, adjust it with the adjust screw. CAUTION Do not measure the idle speed by the tachometer of the meter unit. e While idling the engine, inspect the throttle body vacuum, using the vacuum gauge [B]. Throttle Body Vacuum Standard: 39 +1.33 kPa (293 +10 mmHg) at Idle Speed 1 100 +50 r/min (rpm)

Maintenance Procedure xIf any vacuum is not within specifications, first synchro- nize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies. Example: #1: 260 mmHg #2: 290 mmHg #3: 250 mmHg #4: 270 mmHg e With the engine at the correct idle speed, equalize higher vacuum of #1 or #2 (for example 290 mmHg) to higher vacuum of #3 or #4 (for example 270 mmHg) by turning the center adjusting screw [A]. Right Side View [B] Oln this photo [C], the throttle body has been removed for clarity. Special Tool - Pilot Screw Adjuster, C: 57001-1292 Pilot Screw Adjuster Adapter, 95: 57001

NOTE OAfter adjustment, the final vacuum measurement be- tween the highest throttle valves may not be 290 mmHg (for example). The goal is to have the highest two vac- uums between the left (#1 and #2) and right (#3 and #4) banks be the same and be within the service limits. e Open and close the throttle after each measurement, and adjust the idle speed as necessary. e Once the throttle valves have been synchronized, inspect output voltage of the main throttle sensor to ensure proper operation (procedure is explained at the end of this sec- tion). xlf a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, C: 57001-1292 Pilot Screw Adjuster Adapter, 95: 57001

Rear View [B] e Adjust lower vacuum between #1 and #2 to higher vac- uum of #1 and #2. e Adjust the lower vacuum between #3 and #4 to higher vacuum of #3 and #4. e Open and close the throttle valves after each measure- ment, and adjust the idle speed as necessary. e Check the vacuums as before. xlfall vacuums are within the specification range, finish the engine vacuum synchronization. xlfany vacuum cannot be adjusted within the specification, remove the bypass screws #1 —#4 and clean them. esosioonss

Maintenance Procedure e Turn in the bypass screw [A] with counting the number of turns until it seals fully but not tightly. Record the number of turns. Torque - Bypass Screw: 0.2 N:m (0.02 kgf-m, 1.8 in-lb) CAUTION Do not over tighten them. They could be damaged, requiring replacement. e Remove: Bypass Screw Spring [B] Washer [C] O-ring [D] e Check the bypass screw and its hole for carbon deposits. xlf any carbons accumulate, wipe the carbons off from the bypass screw and the hole, using a cotton pad penetrated With a high-flash point solvent. e Replace the O-ring with a new one. © Check the tapered portion [E] of the bypass screw for wear or damage. xlf the bypass screw is worn or damaged, replace it. e Turn in the bypass screw until it seats fully but not tightly. Torque - Bypass Screw: 0.2 N:m (0.02 kgf-m, 1.8 in-lb) e Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE OA throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, use the “turns out” determined during disassem- bly. e Repeat the same procedure for other bypass screws. e Repeat the synchronization. xlf the vacuums are correct, check the output voltage of the main throttle sensor (see Output Voltage Inspection of Main Throttle Sensor in the Fuel System (DFI) chapter). Main Throttle Sensor Output Voltage Connections to ECU Meter (+) — Y/W lead (terminal 26) Meter (-) — BR/BK lead (terminal 34) Standard: DC 0.63 —-0.65 V (at idle throttle opening) xlf the output voltage is out of the range, check the throttle input voltage of the main throttle sensor (see Input Volt- age Inspection in the Main Throttle Sensor section in the Fuel System (DFI) chapter). e Remove the vacuum gauge hoses and install the rubber caps on the original position. e For the California Model, install the vacuum hoses. ORoute the vacuum hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System (DFI) chapter too. ssosoisast

Maintenance Procedure Idle Speed Inspection e Start the engine and warm it up thoroughly. e With the engine idling, turn the handlebar to both sides [AÏ. xlf handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter). À WARNING Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an un- safe riding condition. e Check the idle speed. xlf the idle speed is out of specified range, adjust it. Idle Speed Standard: 1 100 +50 r/min (rpm) Idle Speed Adjustment e Start the engine and warm it up thoroughly. e Turn the adjusting screw [A] until the idle speed is correct. OOpen and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary. Fuel Hose Inspection (fuel leak, damage, installation condition) Off the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Re- moval in the Fuel System (DFI) chapter) and left middle fairing (see Middle Fairing Removal in the Frame chap- ter), and check the fuel hose. xReplace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.

esosoosess © e Check that the hoses are routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. *Replace the hose if it has been sharply bent or kinked. Hose Joints [A] Fuel Hose [B]

Maintenance Procedure © Check that the hose joints are securely connected. OPush and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked. xlf it does not locked, reinstall the hose joint. À WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak. Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold (room or ambi- ent temperature). e Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). xlf the coolant level is lower than the “L” level line [B], un- screw the reserve tank cap and add coolant to the “F” level line [C]. “L”: low “F’: full CAUTION For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum en- gine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Coolant ruins painted surfaces. immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts. Radiator Hose and Pipe Inspection (Coolant leak, damage, Installation Condition) OThe high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. e Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. x*Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. e Check that the hoses are securely connected and clamps are tightened correctly. Torque - Radiator Hose Clamp Screws: 2.0 N-m (0.20 kgf-m, 18 in-lb) esosoosess ssosoconst

Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection e Inspect the canister as follows. ORemove the seat (see Seat Removal in the Frame chap- ter). ORemove the canister [A], and disconnect the hoses from the canister. OVisually inspect the canister for cracks or other damage. xlf the canister has any cracks or bad damage, replace it with a new one. NOTE OThe canister is designed to work well through the motor- cycle's life without any maintenance if it is used under normal conditions. e Check the liquid/vapor separator as follows. ORemove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). ODisconnect the hoses from the separator, and remove the separator [A] from the motorcycle right side. OVisually inspect the separator for cracks and other dam- age. xlfthe separator has any cracks or damage, replace it with a new one. OTo prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. e Check the hoses of the evaporative emission control sys- tem as follows. OCheck that the hoses are securely connected and clips are in position. OReplace any kinked, deteriorated or damaged hoses. ORoute the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. Refer to the di- agram of the evaporative emission control system in the Fuel System (DFI) chapter too. OWhen installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses with a minimum of bending so that the emission flow will not be obstructed. Air Suction System Aïr Suction System Damage Inspection e Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). e Pull the air switching vale hose [A] out of the air cleaner housing. e Start the engine and run it at idle speed. Plug [B] the air switching valve hose end with your finger and feel vaccum pulsing in the hose. xlf there is no vaccum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test in the Electrical Sys- tem chapter) or air suction valve (see Air Suction Valve Inspection in the Engine Top End chapter).

Maintenance Procedure Engine Top End Valve Clearance Inspection Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold (at room temperature). e Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Crankshaft Sensor Cover Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) e Position the crankshaft at 1, 4 piston TDC. TDC Mark [A] for #1, 4 Pistons Timing Mark [B] (crankcase halves mating surface) e Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter. Valve Clearance Standard: Exhaust 0.22 —0.27 mm (0.0087 —0.0106 in.) Inlet 0.15 —0.20 mm (0.0059 —0.0079 in.) NOTE OThickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] ET ETS

Maintenance Procedure OWhen positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] OWhen positioning #4 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders Measuring Valve [A] xlf the valve clearance is not within the specified range, first record the clearance, and then adjust it. Valve Clearance Adjustment e To change the valve clearance, remove the camshañt chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.

Maintenance Procedure

EXHAUST- VALVE CLEARANCE ADJUSTMENT CHART

10.22 0. 27 Specified Clearance/No Change Required

shim will give the proper clearance. SN = Example: Present shim is 2.60 mm. Measured clearance is 0.33 mm. Replace 2.60 mm shim with 2.70 mm shim.

Maintenance Procedure

INLET- VALVE CLEARANCE ADJUSTMENT CHART

NOTES 2.75/2. 80/2. 85/2. 90/2. os &[0. 5611.00 2.802. 85/2. 90/2. 95f3. 0! 2[1071:08 2-9/2- 9012-9919. 0 Install the shim of this thickness (mm) ©|1.0641.10 2. 90/2. 95]3 Sfr 16.20 3.00 Sso7o9oëns € SDS Measure the clearance (with engine cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.55 mm. Measured clearance is 0.36 mm. Replace 2.55 mm shim with 2.75 mm shim.

Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim according to the table. Ifthe clearance is out of the specified rage, use the additional shim. Of there is no valve clearance, use a shim that is a few sizes smaller, and remeaasure the valve clearance. e Wheninstalling the shim, face the marked side toward the valve lifter. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation. CAUTION Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing ex- tensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage. e Apply engine oil to the valve lifter surface and install the lifter. e Install the camshaft (see Camshaft Installation in the En- gine Top End chapter). e Recheck the valve clearance and readjust if necessary. e Install the removed parts (see appropriate chapters). Clutch and Drive Train Clutch Operation Inspection e Start the engine and check that the clutch does not slip and that it releases properly. xlf the clutch operation is insufficiency, inspect the clutch system. À WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety. Clutch Fluid Level Inspection e Hold the clutch fluid reservoir [A] horizontal. e Check that the clutch fluid level of the clutch reservoir is between the lower [B] and the upper [C] level lines. xlf the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir. OSince the clutch fluid is the same as the brake fluid, refer to Brake Fluid Section in the Brake chapter for further details.

Maintenance Procedure Follow the procedure below to instal the clutch fluid reser- voir cap correctily. OfFirst, tighten the clutch fluid reservoir cap [B] clockwise [C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [D] while holding the clutch fluid reservoir body [A]. Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Clutch Fluid Leak Inspection e Apply the clutch lever and inspect the clutch fluid leak from the clutch hose/pipe [A] and fittings. xlf the clutch fluid leaked form any position, inspect or re- place the problem part. Clutch Hose and Pipe Damage and Installation Condition Inspection e Inspect the clutch hoses and fittings for deterioration, cracks, corrosion and signs of leakage. OThe high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while exam- ining it. x Replace it if any fraying, cracks [B] or bulges [C] are no- ticed. e Check that the hoses are securely connected and banjo bolts are tightened correctly. Torque - Clutch Hose Banjo Bolts: 25 N-m (2.5 kgf-m, 18 ft-Ilb) e Inspect the clutch hose routing. xlf any clutch hose routing is incorrect, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. xReplace the hose if the has been sharply bent or kinked. ss130248 $ esosooanst

Maintenance Procedure Wheels/Tires Aïir Pressure Inspection e Remove the air valve cap. e Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). e Install the air valve cap. *Adjust the tire air pressure according to the specifications if necessary. ssosoosst Air Pressure (when Cold) Front: Up to 180 kg (397 Ib) 290 kPa (2.9 kgf/cm?, 42 psi) Rear: Up to 180 kg (397 Ib) 290 kPa (2.9 kgf/cm?, 42 psi) Wheel/Tire Damage Inspection e Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. e Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement. e Visually inspect the wheel for cracks, cuts and dents dam- age. xlf any damage is found, replace the wheel if necessary. Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% oftread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. e Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. xlf any measurement is less than the service limit, replace the tire (see Tire Removal/Installation in the Wheels/Tires chapter). Tread Depth Standard: Front 3.8 mm (0.15 in.) Rear 4.8 mm (0.19 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3 mm (0.12 in.) (Over 130 km/h (80 mph))

Maintenance Procedure To ensure safe handling and stability, use only the recommended standard tires for replacement, in- flated to the standard pressure. NOTE OMost countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. OCheck and balance the wheel when a tire is replaced with a new one. Wheel Bearing Damage Inspection e Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). e Turn the handlebar all the way to the right or left. e Inspect the roughness of the front wheel bearing by push- ing and pulling [A] the wheel. e Spin [B] the front wheel lightly, and check for smoothly turn, roughness, binding or noise. xlf roughness, binding or noise is found, remove the front wheel and inspect the wheel bearing (see Front Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter). e Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). e Inspect the roughness of the rear wheel bearing by push- ing and pulling [A] the wheel. e Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise. xIf roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Rear Wheel Re- moval, Hub Bearing Inspection in the Wheels/Tires chap- ter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter). Drive Train Drive Chain Lubrication Condition Inspection e If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. e Ifthe chain appears especially dirty, clean it before lubri- cation. CAUTION The O-rings between the side plates seal in the lu- bricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubri- cant, observe the following rules. Use only kerosene or diesel oil for cleaning of the O -ring of the drive chain. Any other cleaning solution such as gasoline or trichloroethylene will cause de- terioration and swelling of the O-ring. Immediately blow the chain dry with compressed air after clean- ing. Complete cleaning and drying the chain within 10 minutes.

Maintenance Procedure e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. e Wipe off any excess oil. Oil Applied Areas [A] O-ring [B] | Gkosoo7st € Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand. OCheck the slack with the motorcycle setting on its center stand (center stand equipped models). OClean the chain if it is dirty, and lubricate it if it appears dry. e Check the wheel alignment (see Wheel Alignment Inspec- tion). e Rotate the rear wheel to find the position where the chain is tightest. e Measure the vertical movement (chain slack) [A] midway between the sprockets. xlfthe chain slack exceeds the standard, adjust it. Chain Slack Standard: 32 —38 mm (1.3 -1.5in.) estzo21mst ce Drive Chain Slack Adjustment + Remove the cotter pin [A], and loosen the axle nut [B]. e Loosen the both chain adjuster locknuts [C]. xlf the chain is too loose, turn out the right and left chain adjusters [D] evenly. xlf the chain is too tight, turn in the right and left chain adjusters evenly, and kick the wheel forward. e Turn both chain adjusters evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch [E] on the right wheel align- ment indicator [F] should align with the same swingarm mark or position [G] that the left indicator notch aligns with. À WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. e Tighten both chain adjuster locknuts securely. e Tighten the axle nut. Torque - Rear Axle Nut: 127 N-m (13.0 kgf-m, 94 ft:lb) e Turn the wheel, measure the chain slack again at the tight- est position, and readjust if necessary.

Maintenance Procedure e Insert a new cotter pin [A]. NOTE OWhen inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. Olt should be within 30°. OLoosen once and tighten again when the slot goes past the nearest hole. e Bend the cotter pin [A] over the nut. À WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. Wheel Alignment Inspection e Check that the notch [A] on the right alignment indicator [B] aligns with the same swingarm mark or position [C] that the left alignment indicator notch aligns with. xlf they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment). NOTE OWheel alignment can be also checked using the straightedge or string method. À WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Drive Chain Wear Inspection e Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). e Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. xlf there is any irregularity, replace the drive chain. x Lubricate the drive chain if it appears dry. e Stretch the chain taut by hanging a 98 N (10 kg, 20 Ib) weight [A] on the chain. e Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. xlfany measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced. Drive Chain 20-link Length Standard: 317.5 —318.2 mm (12.50 —12.53 in.) Service Limit: 323 mm (12.7 in.) Guoaoezess €

Maintenance Procedure If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. For safety, use only the standard chain. It is an end- less type and should not be cut for installation. Standard Chain Make: DAIDO Type: DID50ZVM4 GC&B Link: 116 links Chain Guide Wear Inspection e Remove the swingarm (see Swingarm Removal in the Suspension chapter). e Visually inspect the chain guide [A]. +Replace the chain guide if it shows any signs of abnormal wear or damage.

Maintenance Procedure Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection e For ABS equipped models; note the following. e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped mod- els) [B] and fittings [C]. xlf the brake fluid leaked from any position, inspect or re- place the problem part.

Maintenance Procedure Brake Hose and Pipe Damage and Installation Condition Inspection e For ABS equipped models; note the following. e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) e Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. sttoozerst 0 OThe high pressure inside the brake line can cause fluid to leak [A] or the hose, pipes (ABS equipped models) to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. *Replace the hose and pipe (ABS equipped models) if any crack [B], bulge [C] or leakage is noticed. x Tighten any brake hose banjo bolts. Torque - Brake Hose Banjo Bolts: 25 N:m (2.5 kgf-m, 18 ft:1b) e Inspect the brake hose routing. xlf any brake hose and pipe (ABS equipped models) rout- ing is incorrect, route the brake hose and pipe according to Cable, Wire, and Hose Routing section in the Appendix chapter. Brake Operation Inspection e Inspect the operation of the front and rear brake by run- ning the vehicle on the dry road. xlf the brake operation is insufficiency, inspect the brake system. À WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety. Brake Fluid Level Inspection e Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. xlf the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].

Maintenance Procedure e Follow the procedure below to install the front brake fluid reservoir cap correctly. OfFirst, tighten the front brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A]. e Remove the seat (see Seat Removal in the Frame chap- ter). + Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. xlf the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. À WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser- voir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Recommended Disc Brake Fluid Grade: DOT4 e Follow the procedure below to install the rear brake fluid reservoir cap correctly. OfFirst, tighten the rear brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A]. Brake Pad Wear Inspection e Remove the brake pads (see Front/Rear Brake Pad Re- moval in the Brakes chapter). e Check the lining thickness [A] of the pads in each caliper. x lfthe lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad Lining Thickness Standard: Front 4.0 mm (0.16 in.) Rear 5.0 mm (0.20 in.) Service Limit: 1 mm (0.04 in.) esiatasess €

Maintenance Procedure Brake Light Switch Operation Inspection e Turn on the ignition switch. e The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). xlfit does not, adjust the brake light switch. e While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections in- side the switch, be sure that the switch body does not turn during adjustment. xlfit does not go on, inspect or replace the following items. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (see Tail/Brake Light Removal in the Electri- cal System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In- spection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in the Electrical System chapter) Rear Brake Light Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) Suspensions Front Forks/Rear Shock Absorber Operation Inspection e Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. xlf the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).

Maintenance Procedure e Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. xlf the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection). Front Fork Oil Leak Inspection e Visually inspect the front forks [A] for oil leakage. x Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absorber [A] for oil leakage. xlfthe oil leakage is found onit, replace the shock absorber with a new one. Rocker Arm Operation Inspection e Remove the rear fairing (see Rear Fairing Removal in the Frame chapter). e Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. xlf the rocker arm [A] does not smoothly stroke or noise is found, inspect the fasteners and bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen- sion chapter). Tie-Rod Operation Inspection e Remove the rear fairing (see Rear Fairing Removal in the Frame chapter). e Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. xlfthe tie-rods [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen- sion chapter).

Maintenance Procedure Steering System Steering Play Inspection e Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). e Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 e With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop. xlfthe wheel binds or catches before the stop, the steering is too tight. e Feel for steering looseness by pushing and pulling the forks. xlf you feel looseness, the steering is too loose. NOTE OThe cables and wiring will have some effect on the mo- tion of the fork which must be taken into account. OBe sure the leads and cables are properly routed. OThe bearings must be in good condition and properly lubricated in order for any test to be valid. Steering Play Adjustment e Remove: Handlebars (see Handlebar Removal in the Steering chapter) Stem Head Nut [A] and Washer [B] Upper Fork Clamp Bolts [C] (Loosen) Stem Head [D] e Bend the claws [A] of the claw washer straighten. e Remove the steering stem locknut [B] and claw washer ICI.

Maintenance Procedure e Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 xlf the steering is too tight, loosen the stem nut a fraction of a turn. xlf the steering is too loose, tighten the stem nut a fraction of a turn. NOTE OTurn the stem nut 1/8 turn at time maximum. e Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. e Hand tighten the stem locknut until it touches the claw washer. e Tighten the stem locknut clockwise until the claws are aligned with the grooves (ranging from 2nd to 4th) of stem nut [D], and bend the 2 claws downward [E]. e Install the stem head. e Install the washer, and tighten the stem head nut. e Tighten: Torque - Upper Front Fork Clamp Bolts: 20 N-m (2.0 kgf-m, 15 ft:lb) Steering Stem Head Nut: 78 N-m (8.0 kgf-m, 58 ft-lb) e Check the steering again. xlf the steering is still too tight or too loose, repeat the ad- justment. e Install the handlebars (see Handlebar Installation in the Steering chapter). Steering Stem Bearing Lubrication e Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). e Using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. e Visually check the outer races and the ball bearings. xReplace the bearing assemblies if they show wear or damage. e Pack the upper and lower ball bearings [A] in the cages With grease, and apply a light coat of grease to the upper and lower outer races. e Install the steering stem (see Stem, Stem Bearing Instal- lation in the Steering chapter). e Adjust the steering (see Steering Play Adjustment). esisos4nss €

Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step e Turn on the ignition switch. e The following lights should go on according to below table. City Light [A] goes on Taillight [B] goes on License Plate Light [C] goes on Meter Panel Illumination Light (LED) [D] goes on Meter Panel LCD [E] goes on Neutral Indicator Light (LED) [F] goes on Oil Pressure Warning Indicator Light (LED) [G] goes on Mode 7 Light (LED) [H] (Equipped goes on xlfthe light does not go on, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Applicable Bulb (see Wiring Diagram in the Electrical System chapter) Meter Unit for Meter Panel LCD (see Meter Unit Inspec- tion in the Electrical System chapter) Meter Unit for Neutral Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Warning Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Oil Pressure Warning Indicator Light (LED) (see Meter Unit Inspection in the Electrical Sys- tem chapter) Meter Unit for Illumination Light (LED) (see Meter Unit Inspection in the Electrical System chapter) ECU (see ECU Power Supply Inspection in the Fuel Sys- tem (DFI) chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In- spection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Gear Position Switch (see Gear Position Switch Inspec- tion in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) ABS Indicator Light (LED) (Equipped Models) (see ABS Indicator Light (LED) Inspection in the Brakes chapter) e Turn off the ignition switch. e The all lights should go off. e For the immobilizer model, Warning Indicator Light (LED) Will blinks (see Immobilizer System (Equipped Models) section in the Electrical System chapter). xlf the light does not go off, replace the ignition switch. esi7o74ns: €

Maintenance Procedure Second Step e Turn the ignition switch to P (Park) position. e The city light, taillight and license plate light should go on. xlfthe light does not go on, inspect or replace the following item. Ignition Switch (see Switch Inspection in the Electrical System chapter) Third Step e Turn on the ignition switch. e Turn on the turn signal switch [A] (left or right position). e The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. e The either of turn signal indicator lights (LED) [C] in the meter unit should flash. xlf the each light does not flash, inspect or replace the following item. Turn Signal Light Bulb (see Turn Signal Light Bulb Re- placement in the Electrical System chapter) Meter Unit for Turn Signal Indicator Light (LED) (see Me- ter Unit Inspection in the Electrical System chapter) Turn Signal Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Turn Signal Switch (see Switch Inspection in the Electri- cal System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) e Push the turn signal switch. e The turn signal lights and indicator light (LED) should go off. x lfthe light does not go off, inspect or replace the following item. Turn Signal Switch (see Switch Inspection in the Electri- cal System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) Gsi70728s: €

Maintenance Procedure Fourth Step e Set the dimmer switch [A] to low beam position. e Start the engine. e The low beam headlights [B] should go on. xlf the low beam headlight does not go on, inspect or re- place the following item. Headlight Low Beam Bulb (see Headlight Bulb Replace- ment in the Electrical System chapter) Headlight Fuse (Low) 15 A (see Fuse Inspection in the Electrical System chapter) Headlight Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Headlight Circuit Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Headlight Relay (Low) (see Headlight Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) e Push the passing button (equipped models) or set the dimmer switch to high beam position. e The low beam [A] and high beam [B] headlights should go on. e The high beam indicator light (LED) [C] should go on. xlfthe high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item. Headlight High Beam Bulb (see Headlight Bulb Replace- ment in the Electrical System chapter) Headlight Fuse (High) 15 A (see Fuse Inspection in the Electrical System chapter) Headlight Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Passing Button (Equipped Models) (see Switch Inspec- tion in the Electrical system chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) Headlight Circuit Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Headlight Relay (High) (see Headlight Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) e Turn off the engine stop switch. e The low beam and high beam headlights should stay go- ing on. xlfthe headlights and high beam indicator light (LED) does go off, inspect or replace the following item. Headlight Circuit Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) e Turn off the ignition switch. e The headlights and high beam indicator light (LED) should go off. esi7o7smss €

Maintenance Procedure Headlight Aiming Inspection e Inspect the headlight beam for aiming. xlf the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster [A] in both headlights in or out until the beam points straight ahead. xlf the headlight beam points too low or high, adjust the vertical beam. Headlight Beam Vertical Adjustment e Turn the vertical adjuster [A] in both headlights in or out to adjust the headlight vertically. NOTE OON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. OFor US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated. 50 mm (2 in.) [A] Center of Brightest Spot [B]

Maintenance Procedure Sidestand Switch Operation Inspection e Inspect the sidestand switch [A] operation accordance to table the below. Sidestand Switch Operation : Gear Clutch Engine Engine Sidestand Position Lever Start Run Up Neutral Released Starts Continue running ; Continue Up Neutral Pulled in Starts : running Up In Gear Released Doesn't Continue start running Up In Gear Pulled in Starts Continue running Down Neutral Released Starts Continue running Down Neutral Pulled in Starts Continue running Down In Gear Released Doesn't Stops start Down In Gear Pulled in Doesn't Stops start xlf the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) ECU Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Sidestand Switch (see Switch Inspection in the Electrical System chapter) Starter Lockout Switch (see Switch Inspection in the Electrical System chapter) Engine Stop Switch (see Switch Inspection in the Elec- trical System chapter) Starter Button (see Switch Inspection in the Electrical System chapter) Gear Position Switch (see Gear Position Switch Inspec- tion in the Electrical System chapter) Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter) Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Starter Circuit Relay (see Relay Circuit Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) xlf the all parts are in good condition, replace the ECU.

Maintenance Procedure Engine Stop Switch Operation Inspection First Step e Turn on the ignition switch. e Set the neutral position. e Turn the engine stop switch to stop position [A]. e Push the starter button. e The engine does not start. xlfthe engine starts, inspect or replace the following item. Engine Stop Switch (see Switch Inspection in the Elec- trical System chapter) Second Step e Turn on the ignition switch. e Set the neutral position. e Turn the engine stop switch to run position [A]. e Push the starter button and run the engine. e Turn the engine stop switch to stop position. e Immediately the engine should be stop. xlf the engine does not stop, inspect or replace the follow- ing item. Engine Stop Switch (see Switch Inspection in the Elec- trical System chapter) Others Chassis Parts Lubrication e Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. e Lubricate the points listed below with indicated lubricant. NOTE OWhenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubri- cation. Pivots: Lubricate with Grease. Brake Lever Brake Pedal Clutch Lever Center Stand (Equipped Models) Rear Brake Joint Pin Sidestand Points: Lubricate with Grease. Throttle Inner Cable Upper and Lower Ends [A] Goosogosst €

Maintenance Procedure Cables: Lubricate with Rust Inhibitor. Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing. OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant. Gcosortast € e With the cable disconnected at both ends, the inner cable should move freely [A] within the cable housing. xlf cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is Kinked [C], replace the cable. Gooso2o1s2 © Bolts, Nuts and Fasteners Tightness Inspection e Check the tightness ofthe bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE OFor the engine fasteners, check the tightness of them when the engine is cold (at room temperature). xlf there are loose fasteners, retorque them to the spec- ified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table. For each fastener, first loosen it by 1/2 turn, then tighten it. xlf cotter pins are damaged, replace them with new ones.

Maintenance Procedure Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts Muffler Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Suspension: Front Fork Clamp Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Uni-Trak Link Nuts Steering: Handlebar Holder Bolts Steering Stem Head Nut Others: Center Stand (Equipped Models) Footpeg Bracket Bolts Sidestand Bolt Replacement Parts Aïir Cleaner Element Replacement NOTE Oin dusty areas, the element should be replaced more frequently than the recommended interval. OAfter riding through rain or on muddy roads, the element should be replaced immediately. À WARNING If dirt or dust is allowed to pass through into the throttle assembly, the throttle may become stuck, possibly causing an accident. CAUTION If dirt gets through into the engine, excessive en- gine wear and possibly engine damage will occur.

Maintenance Procedure ° Remove: Fuel Tank Cover (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Element Cover Bolts [A] Air Cleaner Element Cover [B] e Discard the air cleaner element [A]. e Install a new element [A] so that screen side [B] faces upward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0014). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. e Install the air cleaner element cover [A] so that arrow mark [B] faces foward. e Tighten: Torque - Air Cleaner Element Cover Bolts: 6.9 N-m (0.70 kgf-m, 61 in-lb) Fuel Hose Replacement e Pull out the throttle body assy [A] from the holder (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). e Be sure to place a piece of cloth [B] around the fuel hose joint. e Push the joint lock claws [CI].

Maintenance Procedure e Pull the joint lock [A] as shown. e Pull the fuel hose joint [B] out of the delivery pipe. e Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). e Pull out the fuel hose to foward [C]. À WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connec- tion with a clean shop towel to prevent fuel spillage. e Install the new fuel hose so that the white mark [A] side faces throttle body assy. e Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). e Pull [B] the joint lock [C] fully as shown. Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. e Push [B] the joint lock [C] until the hose joint clicks. e Push and pull the fuel hose joint [A] back and forth more than two times and make sure it is locked and doesn't come off. À WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak. xlfit comes off, reinstall the hose joint. e Install the throttle body assy (see Throttle Body Assy In- stallation in the Fuel System (DFI) chapter). e Start the engine and check the fuel hose for leaks.

Maintenance Procedure Coolant Change À WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine, or other painted parts. Since coolant is harmful to the human body, do not use for drinking. e Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap [A] ORemove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. e Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Left Middle Fairing (see Frame chapter) e Place a containers under the drain plug [A] at the bottom of the water pump cover. Drain the coolant from the radiator and engine by remov- ing the drain plug. ° Remove: Hoses [A] Mounting Bolts [B] Coolant Reserve Tank [C] e Remove the cap [D] and pour the coolant into a container. e Install the reserve tank, and reconnect the reserve tank hose and overflow hose correctly (see Cable, Wire, and Hose Routing in the Appendix chapter). e Tighten the drain plug with the washer. OReplace the drain plug gasket with a new one. Torque - Coolant Drain Plug: 12 N-m (1.2 kgf-m, 106 in-Ib) esosos2nss

Maintenance Procedure e Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator. e Fill the reserve tank up to the full level line with coolant, and install the cap. CAUTION Soft or distilled water must be used with the an- tifreeze (see below for antifreeze) in the cooling sys- tem. If hard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system. Water and Coolant Mixture Ratio (Recommended) Soft Water: 50% Coolant: 50% Freezing Point: —35°C (-31°F) Total Amount: 3.4 L (3.6 US qt) NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer's directions. e Bleed the air from the cooling system as follows. OStart the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. OTap the radiator hoses to force any air bubbles caught inside. OStop the engine and add coolant up to the radiator filler neck. e Install the radiator cap. e Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. + Check the coolant level in the reserve tank after the en- gine cools down. xlf the coolant level is lower than the low level line, add coolant to the full level line. eposoiosst ce CAUTION Do not add more coolant above the full level line.

Maintenance Procedure Radiator Hose and O-ring Replacement e Drain the coolant (see Coolant Change). e Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing [A] Fitting [B] Hoses [C] O-rings [D] e Apply grease to the new O-rings and install them. e Instal the new hoses and tighten the clamps securely. e Fillthe coolant (see Coolant Change in the Periodic Main- tenance chapter). e Check the cooling system for leaks. Engine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine. e Remove the engine oil drain bolt [A] to drain the oil. OThe oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement). *xReplace the drain bolt gasket [B] with a new one. e Tighten the drain bolt. Torque - Engine Oil Drain Bolt: 30 N-m (3.0 kgf-m, 22 ft:Ib) e Pour in the specified type and amount of oil. Gsososasss © esososonss

4.1 L (4.3 US qt) (when filter is removed) .

-20 -10 0 10 20 30 40(%)

4.5 L (4.8 US at) (when engine is -47 14 82 50 68 86 1O4(F)

completely dry) —sosoomst € NOTE OAlthough 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Oil Filter Replacement ED) e Drain the engine oil (see Engine Oil Change). e Remove: Lower Fairing (see Frame chapter) + Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249 esomiis P e Replace the filter with a new one. e Apply engine oil to the gasket [A] before installation. e Tighten the filter with the oil filter wrench. Torque - Oil Filter: 31 N-m (3.2 kgf-m, 23 ft:lb) NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque. e Pour in the specified type and amount of oil (see Engine Oil Change). Gcoso4ozst ce

Maintenance Procedure Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. e Remove the brake hose banjo bolts [A]. e When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. e When removing the brake hoses [B], temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum. e immediately wash away any brake fluid that spills.

Maintenance Procedure e For ABS equipped models; note the following. e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Bolts [B] Bracket [C] e There are washers on each side of the brake hose fitting. Replace them with new ones when installing. e Tighten: Torque - Brake Hose Banjo Bolts: 25 N-m (2.5 kgf-m, 18 ft-Ilb) Brake Pipe Joint Nuts: 18 N-m (1.8 kgf-m, 13 ft-Ib) (ZX1400B Models) e When installing the hoses, avoid sharp bending, kink- ing, flatting or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. e Fill the brake line after installing the brake hose (see Brake Fluid Change).

Maintenance Procedure Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. e Level the brake fluid reservoir. e Remove the reservoir cap and diaphragm. e Remove the rubber cap from the bleed valve [A] on the caliper. e Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. e Fill the reservoir with fresh specified brake fluid. e Change the brake fluid. ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. . Open the bleed valve [A]. . Apply the brake and hold it [B]. . Close the bleed valve [CI]. . Release the brake [D]. NOTE OThe fluid level must be checked often during the chang- ing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line. OFront Brake: Repeat the above steps for the other caliper. © ND = e Remove the clear plastic hose. e Install the diaphragm and reservoir cap. e Follow the procedure below to install the front brake fluid reservoir cap correctily. OfFirst, tighten the front brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A]. esist4omse € ss130248 $

Maintenance Procedure e Tighten: Torque - Front Brake Reservoir Cap Stopper Screw: 1.2 N-m (0.12 kgf-m, 11 in:lb) e Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valve: 7.8 N-m (0.80 kgf-m, 69 in-Ib) e After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage. xlf necessary, bleed the air from the lines. Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). e Remove the seal cover [A], circlip [B], connector [C] and ©-ring [D]. Special Tool - Inside Circlip Pliers: 57001-143 e Unscrew the locknut [E] and pivot bolt [F], and remove the brake lever. e Remove the circlip [G]. e Pull out the piston assy [H]. e Replace: Seal Cover [A] Circlip [B] O-ring [D] Circlip [G] Piston Assy [H] Diaphragm [1] Rear Master Cylinder Disassembly e Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter). e Remove the circlip [A], connector [B] and O-ring [C]. Special Tool - Inside Circlip Pliers: 57001-143 e Slide the dust cover [D] out of place, and remove the cir- clip [E]. e Pull out the push rod assy [F]. e Take off the piston assy [G] and return spring [H]. CAUTION Do not remove the secondary cup from the piston since removal will damage it. e Replace: Circlip [A] O-ring [C] Circlip [E] Push Rod Assy [F] Piston Assy [G] Diaphragm [1] esisismse €

Maintenance Procedure Master Cylinder Assembly eBefore assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be diffi- cult to wash off completely, and will eventually de- teriorate the rubber used in the disc brake. e Apply brake fluid to the new parts and to the inner wall of the cylinder. e Take care not to scratch the piston or the inner wall of the cylinder. e Apply silicone grease to the brake lever pivot bolt. e Tighten the brake lever pivot bolt and the locknut. Torque - Brake Lever Pivot Bolt: 1.0 N-m (0.10 kgf-m, 9 in<lb) Brake Lever Pivot Bolt Locknut: 5.9 N:m (0.60 kgf-m, 52 in-Ib) Caliper Rubber Parts Replacement Front Caliper Disassembly e Loosen the front caliper pad pins [A] and banjo bolt [B] and tighten them loosely. ° Remove: Front Caliper [C] (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the brakes chapter) Front Caliper Assembly Bolts O-ring e Using compressed air, remove the pistons. One way to remove the pistons is as follows. Olnstall a rubber gasket [A] and a wooden board [B] more than 10 mm (0.4 in.) thick on the caliper half, and fas- ten them together with a suitable bolt and nut as shown. SA — Leave one of the oil passages [C] open. OLightly apply compressed air [D] to the oil passage until the pistons hit the rubber gasket. Block the hose joint opening [E] during this operation if the caliper half has the opening. Bolt [F] and Nut Push down [G]. esisis2nss

Maintenance Procedure To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. OPull out the pistons by hand. e Remove the dust seals [A] and fluid seals [B]. e Remove the bleed valve [C] and rubber cap [D]. e Repeat the previous step to remove the pistons from the other side of the caliper body. NOTE Olfcompressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. OPrepare a container for brake fluid, and perform the work above it. ORemove the pad springs and pads (see Front Brake Pad Removal in the Brakes chapter). OPump the brake lever until the pistons come out of the cylinders, and then disassemble the caliper. Front Caliper Assembly e Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. e Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N-m (0.80 kgf-m, 69 in:Ib) e Replace the fluid seals [A] with new ones. OApply silicone grease to the fluid seals, and install them into the cylinders by hand. e Replace the dust seals [B] with new ones if they are dam- aged. OApply silicone grease to the dust seals, and install them into the cylinders by hand. e Replace the O-ring [A]. e Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. e Be sure to install the O-ring. e Apply a non-permanent locking agent to the threads of the front caliper assembly bolts, and tighten them. Torque - Front Caliper Assembly Bolts: 27 N-m (2.8 kgf-m, 20 ft-lb) esiaissnss GLoso4ozst € esiaisanss

Maintenance Procedure e Install the pads (see Front Brake Pad Installation in the Brakes chapter). e Wipe up any spilled brake fluid on the caliper with wet cloth. Rear Caliper Disassembly e Loosen the rear caliper pad pin [A] and banjo bolt [B], and tighten them loosely. e Remove: Rear Caliper [C] (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Rear Caliper Assembly Bolts O-ring e Remove the left side piston as follows. e Removal of the left side piston is the same as for the front caliper. Left Side Caliper [A] Rubber Gasket [B] Wooden Board [C] Bolt [D] and Nut Apply compressed air [E] À WARNING To avoid serious injury, never place your fingers or palm in rear of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. esiaissess e Remove the right side piston as follows. e Using the rear caliper assembly bolt [A], remove the pis- ton [B] as shown in the figure. esiaissnss

Maintenance Procedure e Remove the dust seals [A] and fluid seals [B]. + Remove the bleed valves [C] and rubber caps [D]. NOTE Olfcompressed air is not available, do as follows with the brake hose connected to the caliper. OPrepare a container for brake fluid, and perform the work above it. ORemove the pads and pad spring (see Rear Brake Pad Removal in the Brakes chapter). OPump the brake pedal to remove the caliper piston. Rear Caliper Assembly e Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. e Install the bleed valves and rubber caps. Torque - Bleed Valves: 7.8 N-m (0.80 kgf-m, 69 in:Ib) e Apply brake fluid to the cylinder bores. e Replace the fluid seals [A] with new ones. OApply silicone grease to the fluid seals, and install them into each cylinder by hand. e Replace the dust seals [B] with new ones. esis1s7ms2 € GLoso4ozst €

Maintenance Procedure e Replace the O-ring [A]. e Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. «Be sure to install the O-ring. e Apply a non-permanent locking agent to the threads of the rear caliper assembly bolts, and tighten them. Torque - Rear Caliper Assembly Bolts: 37 N-m (3.8 kgf-m, 27 ftIb) esisissnss e Install the pads (see Rear Brake Pad Installation in the Brakes chapter). e Wipe up any spilled brake fluid on the caliper with wet cloth. Clutch Hose and Pipe Replacement CAUTION Clutch fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. e When removing the clutch hose, take care not to spill the clutch fluid on the painted or plastic parts. e When removing the clutch hose [A], temporarily secure the end of the clutch hose to some high place to keep fluid loss to a minimum. e immediately wash away any clutch fluid that spills. e There are washers on each side ofthe clutch hose fittings. Replace them with new ones when installing. e Tighten: Torque - Clutch Hose Banjo Bolts: 25 N-m (2.5 kgf-m, 18 ft-Ib) e When installing the hoses [A], avoid sharp bending, kink- ing, flatting or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in Appendix chap- ter. eFill the clutch line after installing the clutch hose (see Clutch Fluid Change).

Maintenance Procedure Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement Clutch Master Cylinder Cup and Dust Seal Replacement e Remove the clutch master cylinder (see Clutch Master Cylinder Removal in the Clutch chapter). e Remove the seal cover [A], circlip [B], connector [C] and ©-ring [D]. Special Tool - Inside Circlip Pliers: 57001-143 e Unscrew the locknut [E] and pivot bolt [F], and remove the clutch lever. e Pull the circlip [G]. e Pull out the piston assy [H]. e Replace: Seal Cover [A] Circlip [B] O-ring [D] Circlip [G] Piston Assy [H] Diaphragm [1] e Before assembly, clean all parts including the master cylinder with clutch fluid or alcohol. CAUTION Use only disc brake fluid, isopropyl alcohol or ethyl alcohol for cleaning parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil or any other petroleum distillate will cause deterio- ration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventu- ally deteriorate the rubber used in the cylinder. e Apply clutch fluid to the parts removed and to the inner wall of the cylinder. e Take care not to scratch the piston or the inner wall of the cylinder. Torque - Clutch Lever Pivot Bolt: 1.0 N-m (0.10 kgf-m, 8.9 in-lb) Clutch Lever Pivot Bolt Locknut: 5.9 N-m (0.60 kgf-m, 52 in-Ib) e Install the clutch master cylinder (see Clutch Master Cylin- der Removal in the Clutch chapter). esosoz7Bs2 €

Maintenance Procedure Clutch Slave Cylinder Piston Seal Replacement e Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). e Remove the coolant reserve tank. e Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely. e Unscrew the slave cylinder bolts [B] and detach the slave cylinder with the pipe installed from the engine. e Pump the clutch lever until the piston comes out of the cylinder. e Unscrew the banjo bolt and remove the slave cylinder [C]. CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. NOTE Olfthe clutch slave cylinder is removed and left alone, the piston will be pushed out by spring force. e Remove the spring and piston seal. CAUTION Replace the piston seal with a new one if it was re- moved from the piston. e Before assembly, apply clutch fluid to the outside of the piston and the piston seal. e Install the piston seal as shown. Cylinder [A] Piston [B] Piston Seal [C] SOS € Spring [D] À WARNING Motorcycle operation with insufficient, deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury.

Maintenance Procedure Clutch Fluid Change e Level the clutch fluid reservoir and remove the reservoir cap. e Remove the left lower fairing (see Frame chapter). e Remove the rubber cap from the bleed valve on the clutch slave cylinder. e Attach a clear plastic hose [A] to the bleed valve and run the other end of the hose into a container. e Fill the reservoir with fresh fluid. e Change the clutch fluid as follows. Open [B] the bleed valve, using a wrench. Pump the clutch lever and hold [C] it. Close [D] the bleed valve. Release [E] the clutch lever. ORepeat this operation until fresh fluid comes out from the plastic hose or the color of the fluid changes. OCheck the fluid level in the reservoir often, replenishing it as necessary. NOTE Off the fluid in the reservoir runs completely out any time during fluid changing, the bleeding operation must be done over again from the beginning since air will have entered the line. À WARNING Do not mix two brands of fluid. e After changing the fluid, check the clutch for good clutch power and no fluid leakage. xlf necessary, bleed the air from the lines (see Clutch Line Bleeding in the Clutch chapter). e Remove the clear plastic hose. e Install the reservoir cap. e Tighten the bleed valve, and install the rubber cap. Torque - Clutch Slave Cylinder Bleed Valve: 7.8 N-m (0.80 kgf-m, 69 in-lb) Spark Plug Replacement e Remove: Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) e Remove the spark plug using the 16 mm (0.63 in.) plug wrench [A] vertically.

Maintenance Procedure e Replace the spark plug with a new one. Standard Spark Plug Type: NGK CR9IEIA-9 e Insert new spark plug in the plug hole, and finger-tighten it first. e Using the plug wrench [A] vertically, tighten the plug. CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening. Torque - Spark Plugs: 13 N-m (1.3 kgf-m, 115 in-lb) e Install the stick coils securely. OBe sure the stick coils are installed by pulling up it lightly.

Exploded View Torque No. Fastener Remarks Nm | kgfm | ftlb 1 {Front Air Inlet Duct Mounting Bolts 9.8 1.0 |87inlb 2 |Middle Air Inlet Duct Mounting Bolts 9.8 1.0 |87inlb 3 |Middle Air Inlet Duct Clamp Bolts 2.9 0.30 |26in-lb 4 |Rear Air Inlet Duct Mounting Bolts 9.8 1.0 |87inlb 5 |Air Cleaner Element Holder Screws 6.9 0.70 |61inlb 6 |Air Cleaner Element Cover Bolts 6.9 0.70 |61inlb 7 |Duct Clamp Bolts 2.0 0.20 |18in-lb

L: Apply a non-permanent locking agent. WL: Apply a soap and water solution or rubber lubricant.

3-6 FUEL SYSTEM (DFI) Exploded View Gco22288#5 ©

20. Throttle Cable (Decelerator)

1. CAN Communication Line (High)

7. Power Supply to Sensors

15. Power Supply to ECU (from Battery)

32. Power Supply to ECU (from Battery)

34. Ground for Sensors

External Communication Line (Immobilizer/*KDS) Immobilizer Amplifier Unused Engine Ground Starter Lockout Switch Unused Starter Button Unused Injector #3 Stick Coil #3 Injector #1 Stick Coil #1 Unused Immobilizer Amplifier Immobilizer Amplifier Unused Engine Ground Sidestand Switch Unused Ground Unused Injector #4 Ignition Coil #4 Injector #2 Ignition Coil #2 KDS that runs on Windows personal computer (PC) diagnostic tool for motorcycle with Kawasaki DFI system.

3-16 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Subthrottle Valve Actuator [C] Water Temperature Sensor [D] Battery [E] Fuel Injectors #1, #2, #3, #4 [A] Relay Box (Fuel Pump Relay) [A] Immobilizer/Kawasaki Diagnostic System Connector [B] Atmospheric Pressure Sensor [C] ECU [D] Fuse Box (ECU Fuse 15 A) [E] Stick Coils #1, #2, #3, #4 [A] Inlet Air Temperature Sensor [A]

DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Speed Sensor [A] Gear Position Switch [B] Ignition Key [A] (Transponder, Immobilizer Models) Ignition Switch [B] Immobilizer Antenna [C] (Immobilizer Models) Immobilizer Amplifier [D] (Immobilizer Models) Vehicle-down [E] Inlet Air Pressure Sensor [A] Fuel Pump [A]

3-18 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore Throttle Body Vacuum Bypass Screws ECU: Make Type Usable Engine Speed Fuel Pressure (high pressure line): Right after Ignition Switch ON, with fuel pump running for 3 seconds with engine idling Fuel Pump: Type Discharge Fuel Injectors: Type Nozzle Type Resistance Main Throttle Sensor: Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor/Atmo- spheric Pressure Sensor: Input Voltage Output Voltage Inlet Air Temperature Sensor: Resistance Output Voltage at ECU Water Temperature Sensor: Resistance Output Voltage at ECU Speed Sensor: Input Voltage at Sensor Output Voltage at Sensor 1 100 +50 r/min (rpm) Four barrel type 44 mm (1.7 in.) 39 +1.33 kPa (293 +10 mmHg) Mitsubishi Electric Digital memory type, with built in IC igniter, sealed with resin 100 —12 000 r/min (rpm) 304 kPa (3.1 kgf/cm?, 44 psi) with fuel pump running 280 kPa (2.9 kgf/cm?, 41 psi) with fuel pump stopped 304 kPa (3.1 kgf/cm?, 44 psi) with fuel pump running In-tank pump (in fuel tank), or Wesco pump (friction pump) 67 mL (2.26 US oz.) or more for 3 seconds INP-286 One spray type with 10 holes About 11.7 —12.3 Q at 20°C (68°F) Non-adjustable and non-removable DC 4.75 5.25 V between BL and BR/BK leads DC 0.63 —3.91 V between Y/W and BR/BK leads (at idle throttle opening to full throttle opening) 4-6kQ DC 4.75 5.25 V between BL and BR/BK leads DC 3.80 —4.20 V at standard atmospheric pressure (see this text for details)

Specifications Item Standard Vehicle-down sensor: Detection Method Detection Angle Output Voltage Subthrottle Sensor: Input Voltage Output Voltage Resistance Immobilizer Antenna: Resistance Subthrottle Valve Actuator: Resistance Input Voltage CAN Communication Line: Resistance Magnetic flux detection method More than 60 —70° for each bank With sensor arrow mark pointed up: 3.55 —4.45 V with sensor tilted 60 —70° or more: 0.65 —1.35 V Non-adjustable and non-removal DC 4.75 —5.25 V between BL and BR/BK leads DC 0.62 —4.14 V between BL/W and BR/BK leads (at idle throttle opening to full throttle opening) 4-6 kQ About 0.6 —0.9 Q About 5 —-7 Q About DC 10.5 —12.5 V 114 —-126 Q at ECU Connector Throttle Grip and Cables Throttle Grip Free Play 2 3 mm (0.08 —0.12 in.)

3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. OThis DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ODo not reverse the battery cable connections. This will damage the ECU. OTo prevent damage to the DFI parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. OTake care not to short the leads that are directly con- nected to the battery positive (+) terminal to the chassis ground. OWhen charging, remove the battery from the motorcycle. This is to prevent ECU damage by excessive voltage. OWhenever the DFI electrical connections are to be dis- connected, first turn off the ignition switch, and disconnect the battery (-) terminal. Do not pull the lead, only the con- nector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the en- gine. OConnect these connectors until they click [A] ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected. The ECU memo- rizes service codes. ODo not spray water on the electrical parts, DFI parts, con- nectors, leads, and wiring. OIf a transceiver is installed on the motorcycle, make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU. OWhen any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose. ODo not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure. Gctrosssst €

DFI Servicing Precautions OBefore removing the fuel system parts, blow the outer sur- faces of these parts clean with compressed air. OWhen any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage. OWhen installing the fuel hoses, avoid sharp bending, kink- ing, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob- structed. ORoute the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. OTo prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals. OReplace the fuel hose ifit has been sharply bent or kinked. Off the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose [A] to burst. Bend and twist the fuel hose while examining it. xReplace the hose if any cracks or bulges are noticed. OTo maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Clutch Cover [B] Torque - Oil Filler Plug: Hand-tighten

3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When a problem occurs with DFI system, the warning in- dicator (LED) [A] goes on and FI warning message [B] and Fl warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider. For models equipped with an immobilizer system, the warning indicator light [A] blinks and immobilizer warning message [B] and immobilizer warning symbol [C] are alternately displayed on the LCD, when a problem occurs in the system. Can T0 | 12:00 E FI A F

Troubleshooting the DFI System With the engine stopped and turned in the self-diagnosis mode, the service code (error code) [A] is displayed on the LCD by the number of two digits. When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the cause [C] of problem. As a pre-diagnosis inspection, check the ECU for ground and power supply, the fuel line for no fuel leaks, and for correct pressure. The pre-diagnosis items are not indicated by the warning indicator light (LED), FI warning message and FI warning symbol. Don't rely solely on the DFI self-diagnosis function, use common sense.

3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System Even when the DFI system is operating normally, the warning indicator light (LED) goes on and FI warning message and F1 warning symbol may be displayed under strong electrical interference. Additional measures are not required. Turn the ignition switch OFF to stop the indicator light, message and symbol. If the warning indicator light (LED) of the motorcycle brought in for repair still goes on, check the service code. When the repair has been done, the warning indicator light (LED) goes off and FI warning message and FI warning symbol are not displayed on the LCD. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them. e When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. OThe DFI part connectors have seals, including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set. Insert the needle adapter inside the seal until the needle adapter reaches the terminal. Special Tool - Needle Adapter Set: 57001-1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals. OAfter measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 -Seals of Connector Gctrosrast €

Troubleshooting the DFI System e Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. e Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem. If the problem was caused by some other item or items, they too must be repaired or replaced, or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold (at room temperature) e Do not adjust or remove the throttle sensor. e Do not directly connect a 12 V battery to a fuel injector. Insert a resistor (5 —7 Q ) or a bulb (12 V x 3 —3.4 W)in series between the battery and the injector. e The DFI parts have been adjusted and set with precision. Therefore, they should be handied carefully, never strike sharply, as with a hammer, or allowed to drop on a hard surface. Such a shock to the parts can damage them. e Check wiring and connections from the ECU connector to the suspected faulty DFI parts, using the hand tester (special tool, analog tester) rather than a digital tester. Special Tool - Hand Tester: 57001-1394 e Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Dete- riorated leads and bad connections can cause reappear- ance of problems and unstable operation of the DFI sys- tem. xlf any wiring is deteriorated, replace the wiring. e Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. xlf the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. e Check the wiring for continuity. OUse the wiring diagram to find the ends of the lead which is suspected of being a problem. OConnect the hand tester between the ends of the leads. OSet the tester to the *x 1 Q range, and read the tester. xlf the tester does not read 0 Q, the lead is defective. Re- place the lead or the main harness or the sub harness. gcrrasses2 €

3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Of both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con- tinuity between the end [E] and the ground [F]. This en- ables to check a long harness for continuity. Ifthe harness is open, repair or replace the harness. OWhen checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed. e Narrow down suspicious locations by repeating the con- tinuity tests from the ECU connectors. xlf no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages. However, there is no way to check the ECU itself. xlf an abnormality is found, replace the affected DFI part. xlf no abnormality is found in the wiring, connectors, and DFI parts, replace the ECU. OThe diagnosis flow chartillustrates the above procedures. OAfter inspection, be sure to connect all the DFI electrical connectors. Do not turn the ignition switch ON while the DFI electrical connectors and ignition system connectors are disconnected. Otherwise, the ECU memorizes ser- vice codes as open circuit. OLead Color Codes: BK: Black G: Green P: Pink BL: Blue GY: Gray PU: Purple BR: Brown LB: Light Blue R: Red CH: Chocolate LG: Light Green W: White DG: Dark Green O: Orange Y: Yellow gctrosist €

Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs. Confirm problems. Gather information from rider. Turn the ignition switch ON. 4 N Warning indicator light does not go on or blink and warning message and warning symbol are not Warning indicator light goes on and FI warning message and FI warning symbol are displayed alternately on the Warning indicator light blinks and immobilizer warning message and immobilizer warning symbol are displayed displayed on the LCD.

Conduct non-self-diagnosis inspection. alternately on the LCD.

Conduct self-diagnosis inspection (DFI system). Conduct general fuel system inspection. General fuel system: throttle body n End. assy, air cleaner, fuel tank etc. 6174820 F Inquiries to Rider OEach rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. OTry to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem. OThe diagnosis sheet will help prevent you from overlooking any areas, and will help you decide if it is a DFI system problem, or a general engine problem.

3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: [Registration No. (license plate No.): [Year of initial registration: Model: [Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather D fine, D cloudy, O rain, O snow, D always, O other: Temperature | hot, D warm, O cold, [ very cold, D always, CO other: Problem © chronic, O often, a once frequency Road D street, D highway, D mountain road (O uphill, D downhill), O bumpy, E pebble Altitude D normal, D high (about 1000 m or more) Motorcycle conditions when problem occurred. Warning O Goes on about 3 seconds after from ignition switch ON, and FI warning message indicator light and FI warning symbol are displayed alternately on the LCD (DFI system (LED) problem). © Starts blinking about 3 seconds after from ignition switch ON, and immobilizer warning message and immobilizer warning symbol are displayed alternately on the LCD (Immobilizer system problem). D Does not go on or blink about 3 seconds after ignition switch ON. Starting D starter motor not rotating. difficulty O starter motor rotating but engine doesn't turn over. D starter motor and engine don't turn over. © no fuel flow (O1 no fuel in tank, O no fuel pump sound). D engine flooded (do not crank engine with throttle opened, which promotes engine flooding). D no spark. D other: Engine stalls |O right after starting. D when opening throttle grip. © when closing throttle grip. O when moving off. D when stopping the motorcycle. D when cruising. D other:

Troubleshooting the DFI System Poor running at low speed D very low idle speed, O1 very high idle speed, CO rough idle speed. © battery voltage is low (charge the battery). D spark plug loose (tighten it). D spark plug dirty, broken, or gap maladjusted (remedby it). D backfiring. D afterfiring. D hesitation when acceleration. D engine oil viscosity too high. D brake dragging. D engine overheating. D clutch slipping. D other: Poor running or no power at high speed D spark plug loose (tighten it). D spark plug dirty, broken, or gap maladjusted (remedby it). D spark plug incorrect (replace it). D knocking (fuel poor quality or incorrect, — use high-octane gasoline). D brake dragging. D clutch slipping. D engine overheating. D engine oil level too high. D engine oil viscosity too high. D other:

3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system. OThe ECU may be involved in the DFI electrical and ignition system troubles. If these parts and circuits are checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU. Engine Won'’t Turn Over Symptoms or possible Causes Actions (chapter) Gear position, starter lockout or sidestand switch trouble Inspect each switch (see chapter 16). Immobilizer system trouble Inspect (see chapter 3). Vehicle-down sensor coming off Reinstall (see chapter 3). Vehicle-down sensor trouble Inspect (see chapter 3). Crankshaft sensor trouble Inspect (see chapter 16). Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU ground and power supply trouble Inspect (see chapter 3). ECU trouble Inspect (see chapter 3). No or little fuel in tank Supply fuel (see Owner's Manual). Fuel Injector trouble Inspect and replace (see chapter 3). Fuel pump not operating Inspect (see chapter 3). Fuel pump relay trouble Inspect and replace (see chapter 3). Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3). Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see

Fuel line clogged Inspect and repair (see chapter 3). Poor Running at Low Speed Symptoms or Possible Causes Actions (chapter) Spark weak: Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU trouble Inspect (see chapter 3). Fuel/air mixture incorrect: Little fuel in tank Supply fuel (see Owner's Manual). Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3). Aïir duct holder loose Reinstall (see chapter 3). Throttle body assy holder loose Reinstall (see chapter 3). Throttle body assy dust seal damage Replace (see chapter 3). Fuel Injector O-ring damage Replace (see chapter 3). Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).

DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see

Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3 Water temperature sensor trouble Inspect (see chapter 3 Inlet air temperature sensor trouble Inspect (see chapter 3 Main throttle sensor trouble Subthrottle sensor trouble Inspect (see chapter 3 Subthrottle valve actuator trouble

Inspect (see chapter 3 Unstable (rough) idling: Fuel pressure too low or too high Inspect (see chapter 3 Fuel Injector trouble Inspect (see chapter 3 Main throttle sensor trouble Inspect (see chapter 3 Subthrottle sensor trouble

Inspect (see chapter 3 Subthrottle valve actuator trouble Inspect (see chapter 3). Engine vacuum not synchronizing Inspect and adjust (see chapter 2). Inlet air pressure sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3 Water temperature sensor trouble Inlet air temperature sensor trouble

Inspect (see chapter 3). Inspect (see chapter 3). Engine stalls easily: Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Stick coil trouble Inspect (see chapter 16). Camshaft position sensor trouble Inspect (see chapter 16). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inlet air temperature sensor trouble Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Fuel Injector trouble Inspect (see chapter 3). Fuel pressure too low or too high

Inspect (see chapter 3). Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see

Fuel line clogged Inspect and repair (see chapter 3). Poor acceleration Fuel pressure too low Inspect (see chapter 3). Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see

Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Fuel Injector trouble Inspect (see chapter 3).

Inspect (see chapter 3). Surge: Unstable fuel pressure Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line Inspect (Inspect and replace fuel pump) (see chapter 3). Fuel Injector trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Backfiring when deceleration: Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Fuel pressure too low Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inlet air pressure sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble

DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Other: intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Spe ed: Symptoms or Possible Causes Actions (chapter) Firing incorrect: Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU trouble Inspect (see chapter 3). Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3). Air duct holder loose Reinstall (see chapter 3). Throttle body assy holder loose Reinstall (see chapter 3). Throttle body assy dust seal damage Replace (see chapter 3). Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see

Fuel Injector O-ring damage Visually inspect and replace (see chapter 3). Fuel Injector clogged Inspect and repair (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Fuel pump operates intermittently and often DFI fuse blows. Fuel Pump bearings may wear. Replace the fuel pump (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Cracked or obstructed inlet air pressure sensor hose Inspect and repair or replace (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble

Inspect (see chapter 3). Knocking: Fuel poor quality or incorrect Fuel chage (Use the gasoline recommended in the Owner's Manual). Spark plug incorrect Replace it with the correct plug (see chapter 2). Stick coil trouble Inspect (see chapter 16). ECU trouble Inspect (see chapter 3). Engine vacumm not synchronizing Inspect and adjust (see chapter 2). Inlet air pressure sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).

3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Speed sensor trouble Inspect (see chapter 3). Throttle valves will not fully open Inspect throttle cables and lever linkage (see

Engine overheating - Water temperature sensor , crankshaft sensor or speed sensor trouble (see Overheating of Troubleshooting Guide in

Air switching valve trouble Inspect and replace (see chapter 16). Aïir suction valve trouble Inspect and replace (see chapter 5). Exhaust Smokes Excessively: (White smokes) Air cleaner clogged Clean element (see chapter 3). Fuel pressure too high Inspect (see chapter 3). Fuel Injector trouble Inspect (see chapter 3). Water temperature sensor trouble Inlet air temperature sensor trouble

Inspect (see chapter 3). Inspect (see chapter 3). (Brown smoke) Aïir duct holder loose Reinstall (see chapter 3). Fuel pressure too low Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3).

Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system , igni- tion system and immobilizer system by lighting up or blink- ing the warning indicator light (LED) [A] and displaying the warning message [B] and warning symbol [C] alternately on the LCD (Liquid Crystal Display) when DFI, ignition and immobilizer system parts are faulty, and initiates fail-safe function. In case of serious troubles ECU stops the injec- tion/ignition/starter motor operation. Dealer Mode The LCD (Liquid Crystal Display) display the service code(s) [A] to show the problem(s) which the DFI system, ignition system and immobilizer system has at the moment of diagnosis.

3-38 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Procedures OWhen a problem occurs with DFI system and ignition sys- tem, the warning indicator (LED) [A] goes on and FI warn- ing message [B] and FI warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider. OFor models equipped with an immobilizer system, the warning indicator light (LED) [A] blinks and immobilizer warning message [B] and immobilizer warning symbol [C] are alternately displayed on the LCD, when a problem occurs in the system. Can T0 | 12:00 E FI A F

Self-Diagnosis e Turn the ignition switch ON. e Push the MODE button [A] and RESET button [B] for more than two seconds. e The service code [C]is displayed on the LCD by the num- ber of two digits. po OWhen pushing and holding the MODE button while the warning massage and warning symbol are displayed al- ternately on the LCD, the display on the LCD is shifted to the previous display with the warning indicator light (LED) goes on. OAïfter switching to the previous display, the service code can not be displayed even if pushing the MODE button and RESET button for more than two seconds. ERROR CODE” =

12:00 COS e Any of the following procedures ends self-diagnosis. OWhen the service code is displayed on the LCD, push the MODE button and RESET button for more than two seconds. OWhen the ignition switch is turned OFF.

Turn the ignition switch ON. Push the MODE button and RESET button for more than two seconds. Then self-diagnosis mode starts. The service code(s) is displayed on the LCD (Liquid Crystal Display). Turn the ignition switch OFF Locate the problem with the service code table and inspect and repair DFI, ignition and immobilizer system (immobilizer models) according to inspection procedure on all the service codes. Turn the ignition switch ON.

Make sure the warning indicator light goes off and warning message and NG warning symbol are not displayed on the LCD. Ÿ ok Run the engine for several minutes at idling and run the motorcycle NG at 30 km/h (18 mph) or above in order to confirm no problem.

Self-Diagnosis Service Code Reading OThe service code(s) is displayed on the LCD by the number of two digits. OWhen there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. OThen after completing all codes, the display is repeated until the ignition switch is turned OFF or MODE button and RESET button are pushed for more than two seconds. OFor example, if three problems occurred in the order of 46, 15, 35, the service codes are displayed (each two seconds) from the lowest number in the order listed as shown below. (15—35—46)—(15—35—46)—: : -(repeated)

" ERROR CODE " ERROR CODE

> CS Ë 12:00 12:00 crue $ Oln the case more than two service codes are available, you may push the MODE button to shift into the other code too. Off the no problem or when the repair has done, warning indicator light (LED) goes off and warning message and warning symbol are not displayed, and no service code is displayed. Off the problem is with the following parts, the ECU can not memorize these problem, he warning indicator light (LED) do not lights up or blinks and warning message and warning symbol are not displayed, and no service codes can be displayed. Warning Indicator Light (LED) Meter Panel LCD Stick Coil Secondary Wiring and Ground Wiring (see Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection in the Electrical System chapter) ECU Power Source Wiring and Ground Wiring (see ECU power Supply Inspection) Service Code Erasing OWhen repair has been done, warning indicator light (LED) goes off and warning message and warn- ing symbol are not displayed, and no service code is displayed. x But the service codes stored in memory of the ECU are not erased to preserve the problem history. In this model, the problem history can not be erased.

3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code Problems 11 Main throttle sensor malfunction, wiring open or short 12 Inlet air pressure sensor malfunction, wiring open or short 13 Inlet air temperature sensor malfunction, wiring open or short 14 Water temperature sensor malfunction, wiring open or short 15 Atmospheric pressure sensor malfunction, wiring open or short 21 Crankshaft sensor malfunction, wiring open or short 23 Camshaft position sensor malfunction, wiring open or short 24 Speed sensor malfunction 25 Gear position switch malfunction, wiring open or short 31 Vehicle-down sensor malfunction, wiring open or short 32 Subthrottle sensor malfunction, wiring open or short 35 Immobilizer amplifier malfunction 36 Blank key detection 46 Fuel pump relay malfunction, relay is stuck 51 Stick (Ignition) coil #1 malfunction, wiring open or short 52 Stick (Ignition) coil #2 malfunction, wiring open or short 53 Stick (Ignition) coil #3 malfunction, wiring open or short 54 Stick (Ignition) coil #4 malfunction, wiring open or short 62 Subthrottle valve actuator malfunction, wiring open or short 75 ECU main relay malfunction, relay is stuck Notes: OThe ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU. OWhen no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical parts of the DFI system and the engine are suspect.

FUEL SYSTEM (DFI) 3-43

Self-Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. User Key must use register key. Service Output Signal Usable Codes Parts Range or Criteria Backups by ECU If the main throttle sensor system fails (the Main Throttle Main Throttle Sensor signal is out of the usable range, wiring short 11 Sensor Output Voltage or open), the ECU locks ignition timing into the

0.2 -4.8 V ignition timing at closed throttle position and

sets the DFI in the D-J method. : Inlet Air Pressure If the inlet air pressure sensor system fails (the Inlet Air : : ue 12 Pressure (absolute) signal Pv is out of the usable range, wiring Pv = 100 mmHg —900 short or open), the ECU sets the DFI in the Sensor mmHg a-N method (1). Inlet Air : If the inlet air temperature sensor fails (the Inlet Air Temperature : : mn 13 Temperature Ta = — 30°C —+ 100°C signal is out of the usable range, wiring short Sensor or open), the ECU sets Ta at 30°C. Water Water Temperature If the water temperature sensor system fails 14 Temperature Tw=- 30e + 120°C (the signal is out of the usable range, wiring Sensor short or open), the ECU sets Tw at 80°C. :. [Absolute Atmospheric If the atmospheric pressure sensor system Atmospheric : : : 15 Pressure Pressure fails (the signal is out of the usable range, Pa = 100 mmHg —900 wiring short or open), the ECU sets Pa at 760 Sensor : mmHg mmHjg (the standard atmospheric pressure). Crankshaft sensor cannot : : 21 Crankshaft send the signal to the ECU ff crankshaft sensor fails, the engine stops by Sensor : : itself. during 8 crankings. Camshaïft position sensor |lf the camshaïft position sensor system fails Camshaft : : ie mice es 23 Position cannot send the signal (the signal is missing, wiring short or open), to the ECU during 24 the ECU continues to ignite cylinders in the Sensor : à : crankings. same sequence following the last good signal. Speed sensor must send : : za | Speed |#Sralfouput gra to | spot sens sen gra Sensor |the ECU at the one rotation g pen), P A 0 of the drive shaft. Gear Gear Position Switch If the speed sensor system fails (no signal, 25 Position | Output Voltage (signal) Wiring short or open), the ECU set the top (6) Switch Vg=0.2-48V gear position. If the vehicle-down sensor system has failures Vehicle Vehicle-down Sensor (the output voltage Vd is more than usable 31 -down Output Voltage (signal) range, wiring open), the ECU shuts off the Sensor |Vd=02-48V fuel pump, the fuel injectors and the ignition system. If the subthrottle sensor system fails (the Subthrottle Subthrotile Sensor Output signal is out of the usable range, wiring short 32 Voltage Sensor or open), the actuator locks subthrottle valve

at full open position. 35 Immobilizer | _ If the immobilizer system fails (no signal, wiring Amplifier short or open), the vehicle is no start and run. 36 Master or |The user or master key If the blank key or broken key is used, the vehicle is no start and run.

3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Codes Parts Range or Criteria Backups by ECU Fuel Pum When the relay ON 46 Rela p condition, battery monitor |lfthe relay fails, battery monitor voltage 12 V. y voltage 5 V or more Stick Coil VAR MUST Sen elgpals If the ignition primary winding #1 has failures 51 #1 (Ignition | (output voltage) 32 or more (no signal, wiring short or open), the ECU Col)" times continuously to the shuts off the injector #1 to stop fuel to the ECU cylinder #1, though the engine keeps running. Stick Coil VnAQ must aan algpals If the ignition primary winding #2 has failures 52 #2 (Ignition | (output voltage) 32 or more (ro gra wrng on open). me Fou Coil)* times continuously to the snuïs off Me InJeclor 0 stop lue lo ie ECU cylinder #2, though the engine keeps running. Stick Coil VAR MUST Sen elgpals If the ignition primary winding #3 has failures 53 #3 (Ignition | (output voltage) 32 or more (ro gra wrng on open). me Fou Coil)* times continuously to the snuïs off Ie ImJeclor 0 stop lue lo ne ECU cylinder #3, though the engine keeps running. The ignition coil prima Lo : Pr : Stick Coil winding must Send Signals If the ignition primary winding #4 has failures 54 #4 (Ignition | (output voltage) 32 or more (no signal, wiring short or open), the ECU Coil)* times continuously to the shuts off the injector #4 to stop fuel to the ECU cylinder #4, though the engine keeps running. Subthrottle The actuator operates If the subthrottle valve actuator fails (the 62 Valve open and close of the signal is out to the usable range, wiring short Actuator subthrottle valve by the or open), the ECU stops the current to the pulse signal from the ECU. | actuator. .__ [When the relay OFF 75 Eco Main condition, the main relay is |— elay open. Note: (1) a-N Method: the DFI control method from medium to heavy engine load. When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (vacuum sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method. As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle sensor output voltage) and the engine speed. This method is called a-N method.

• This depends on the number of stopped cylinders.

Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening. Input Terminal [A] Output Terminal [B] Ground Terminal [C] Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can dam- age it. Input Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] to the connectors [B], using the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Input Voltage Connections to ECU Connector Meter (+) — BL lead (terminal 7) Meter (-) — BR/BK lead (terminal 34) e Measure the input voltage with the engine stopped, and With the connectors joined. e Turn the ignition switch ON. Input Voltage at ECU Connector Standard: DC 4.75 5.25 V e Turn the ignition switch OFF. xlf the reading of input voltage is less than the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection) and wiring shorted. xlfthe input voltage is within the standard range, check the input voltage at the main throttle sensor connector. (G60) cctriarast € Goiriasess

3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) e Remove the right fairing cover (see Fairing Cover Re- moval in the Frame chapter). e Disconnect the main throttle sensor connector [A]. e Connect the harness adapter [A] between the harness connector and main throttle sensor connector. Special Tool - Throttle Sensor Setting Adapter: 57001

e Connect a digital meter to the harness adapter leads. Main Throttle Sensor Input Voltage Connections to Adapter Meter (+)— W (sensor BL) lead Meter (-)— BK (sensor BR/BK) lead e Measure the input voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. Input Voltage at Sensor Standard: DC 4.75 —5.25 V e Turn the ignition switch OFF. xlf the reading is out of the range, check the wiring (see Wiring diagram in this section). xlf the reading is good, check the output voltage of the sensor.

Main Throttle Sensor (Service Code 11) Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU Connector Meter (+) — Y/W lead (terminal 26) Meter (-) — BR/BK lead (terminal 34) e Start the engine and warm it up thoroughly. e Check idle speed to ensure throttle opening is correct. Idle Speed Standard: 1 100 r/min (rpm) xlf the idle speed is out of the specified range, adjust the idle speed (see Idle Speed Inspection in Periodic Mainte- nance chapter). e Turn the ignition switch OFF. e Measure the output voltage with the engine stopped, and With the connector joined. e Turn the ignition switch ON. e Measure the output voltage when the throttle is fully opened or completely closed. Output Voltage at ECU Standard: DC 0.63 —3.91 V (at idle throttle opening to full throttle opening) NOTE OThe throttle sensor is operating correctly if the following voltages are obtained: + DC 0.63 V (or slightly higher) with the throttle at the idle position. + DC 3.91 V (or slightly lower) with the throttle at the fully open position. CAUTION Do not remove or adjust the main throttle sensor. It has been adjusted and set with precision at the factory. Never drop the sensor can especially on a hard sur- face. A shock to the sensor can damage it. Gorriagess

3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) NOTE OThe standard voltage refers to the value when the volt- age reading at the Input Voltage Inspection shows 5V exactly. OWhen the input voltage reading shows other than 5V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V.

0.63 x 4.75 + 5.00 = 0.60 V

3.91 x 4.75 + 5.00 = 3.71 V

Thus, the valid range is 0.60 —3.71 V xlf the output voltage is within the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). xlfthe ground and power supply are good, replace the ECU (see ECU section). xlf the output voltage is far out of the standard range (e.g. when the wiring is open, the reading is O V), check the output voltage again at the sensor connector.

Main Throttle Sensor (Service Code 11) e Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between the harness con- nector and main throttle sensor connector. Special Tool - Throttle Sensor Setting Adapter: 57001

e Connect a digital meter to the harness adapter leads. Throttle Sensor Output Voltage Connections to Adapter Meter (+) — R (sensor Y/W) lead Meter (-) — BK (sensor BR/BK) lead e Measure the sensor output voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. e Measure the output voltage when the throttle is fully opened or completely closed. Output Voltage at Sensor Standard: DC 0.63 —3.91 V (at idle throttle opening to full throttle opening) NOTE OThe throttle sensor is operating correctly if the following voltages are obtained: + DC 0.63 V (or slightly higher) with the throttle at the idle position. + DC 3.91 V (or slightly lower) with the throttle at the fully open position. CAUTION Do not remove or adjust the main throttle sensor. It has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. A shock to the sensor can damage it. NOTE OThe standard voltage refers to the value when the voilt- age reading at the Input Voltage Inspection shows 5V exactly. OWhen the input voltage reading shows other than 5V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V.

0.63 x 4.75 + 5.00 = 0.60 V

3.91 x 4.75 + 5.00 = 3.71 V

Thus, the valid range is 0.60 —3.71 V e Turn the ignition switch OFF. xlf the reading is out of the standard range, inspect the main throttle sensor resistance. xlf the output voltage is normal, check the wiring for conti- nuity (see wiring diagram in this section).

3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection e Turn the ignition switch OFF. e Disconnect the main throttle sensor connector. e Connect a digital meter [A] to the main throttle sensor connector [B]. e Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] <—-—BR/BK lead [D] Standard: 4-6kQ x lfthe reading is out of the range, replace the throttle body assy (see Throttle Body Assy section). xlf the reading is within the range, but the problem still exists, replace the ECU (see ECU section). Main Throttle Sensor Circuit gcirieoess

Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal ° Remove: Fuel Tank Cover (see Fuel Tank Removal) Bolt [A] Bracket [B] e Remove: Inlet Air Pressure Sensor Connector [A] Inlet Air Pressure Sensor [B] Vacuum Hose [C] Installation NOTE OThe inlet air pressure sensor is the same part as the at- mospheric sensor except that the sensor has a vacuum hose and different wiring. e Install the vacuum hose. e Put the inlet air pressure sensor in the stay plate [A] of throttle body assy.

3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Input Voltage Inspection NOTE OBe sure the battery is fully charged. OThe inspection is the same as “Input Voltage Inspection ofthe throttle sensor and the atmospheric pressure sen- SOr. e Turn the ignition switch OFF. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] to the connector [B], with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Input Voltage Connections to ECU Connector Meter (+) — BL lead (terminal 7) Meter (-) — BR/BK lead (terminal 34) e Measure the input voltage with the engine stopped, and With the connectors joined. e Turn the ignition switch ON. Input Voltage at ECU Standard: DC 4.75 —-5.25 V xlf the reading is less than the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). xlfthe ground and power supply are good, replace the ECU (see ECU section). xlf the reading is within the standard range, and check the input voltage again at the sensor connector. e Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the harness connector and inlet air pressure sensor connector. Special Tool - Sensor Harness Adapter: 57001-1561 e Connect a digital meter to the harness adapter leads. Inlet Air Pressure Sensor [B] Inlet Air Pressure Sensor Input Voltage Connections to Adapter Meter (+) — G (sensor BL) lead [C] Meter (-) — BK (sensor BR/BK) lead [D] e Measure the input voltage with the engine stopped, and With the connector joined. e Turn the ignition switch ON. Input Voltage at Sensor Connector Standard: DC 4.75 —5.25 V e Turn the ignition switch OFF. xlf the reading is out of the standard range, check the Wiring (see wiring diagram in this section). xlfthe reading is good, the input voltage is normal. Check the output voltage. Goiriasess Gctriazsst €

FUEL SYSTEM (DFI) 3-53

Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) — Y/BL lead (terminal 28) Meter (-) — BR/BK lead (terminal 34) Output Voltage at ECU Usable Range: DC 3.80 —4.20 V at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.) NOTE OThe output voltage changes according to the local at- mospheric pressure. OThe vacuum sensor output voltage is based on a nearly perfect vacuum in the small chamber ofthe sensor. So, the sensor indicates absolute vacuum pressure. xlfthe output voltage is within the usable range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). xlfthe ground and power supply are good, replace the ECU (see ECU section). xlf the output voltage is far out of the usable range, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 V). e Connect a digital meter to the harness adapter leads. Inlet Air Pressure Sensor [B] Special Tool - Sensor Harness Adapter: 57001-1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter Meter (+) — G/W (sensor Y/BL) lead [C] Meter (-) — BK (sensor BR/BK) lead [D] xMeasure the input voltage with the engine stopped, and With the connector joined.

• Turn the ignition switch ON. Output Voltage at Sensor Connector Usable Range: DC 3.80 —4.20 V at the standard atmospheric pressure (101.32 kPa or 76 cmHg abs.) e Turn the ignition switch OFF. xlf the output voltage is normal, check the wiring for conti- nuity (see wiring diagram in this section). xlf the output voltage is out of the usable range, replace the sensor. Gorriagess cctriassst €

xlf you need to check the inlet air pressure sensor for vac- uum other than 76 cmHg (abs.), check the output voltage as follows.

Inlet Air Pressure Sensor (Service Code 12) + Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. e Connect an auxiliary hose [B] to the inlet air pressure sen- Sor. e Temporarily install the inlet air pressure sensor. OConnect a digital meter [C], vacuum gauge [D], and the fork oil level gauge [E] to the inlet air pressure sensor. Special Tools -Fork Oil Level Gauge: 57001-1290 Vacuum Gauge: 57001-1369 Sensor Harness Adapter: 57001-1561 Inlet Air Pressure Sensor Output Voltage Connection to Adapter Meter (+) — G/W (sensor Y/BL) lead Meter (-) — BK (sensor BR/BK) lead OTurn the ignition switch ON. OMeasure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. OCheck the inlet air pressure sensor output voltage, using the following formula and chart. Suppose: Pg : Vacuum Pressure (gauge) of Throttle Assy PI: Local Atmospheric Pressure (abs.) measured by a barometer Pv : Vacuum Pressure (abs.) of Throttle Assy Vv : Sensor Output Voltage (v) then Pv=Pl-Pg For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) PI = 70 cmHg (barometer reading) Vv = 3.2 V (digital volt meter reading) then Pv = 70 — 8 = 62 cmHg (abs.) Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage. Usable range = 3.08 —3.48 V Plot Vv (3.2 V) on the vertical line. — Point [3]. Results: In the chart, Vv is within the usable range and the sensor is normal. ectriissse c

Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. e Remove the fuel tank (see Fuel Tank Removal). e Open the clamp [A] e Disconnect the connector [B] from the inlet air tempera- ture sensor. Pull out the inlet air temperature sensor [C]. e Install the inlet air temperature sensor [A] in the grommet [BI Output Voltage Inspection NOTE OBe sure the battery is fully charged. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter to the ECU connector, using nee- dle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter (+) — Y lead (terminal 8) Meter (-) — BR/BK lead (terminal 34) e Measure the sensor output voltage with the engine stopped and the connector joined. e Turn the ignition switch ON. Output Voltage at ECU Standard: About 2.25 —-2.50 V at inlet air temperature 20°C (68°F) NOTE OThe output voltage changes according to the inlet air temperature. e Turn the ignition switch OFF. Goirisoess

3-58 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) x lfthe output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). xlfthe ground and power supply are good, replace the ECU (see ECU section). xlf the output voltage is far out of the specified (e.g. when the wiring is open, the voltage is about 4.6 V), check the Wiring (see wiring diagram in this section). xlfthe wiring is good, check the sensor resistance. Sensor Resistance Inspection e Remove the inlet air temperature sensor (see Re- moval/Installation). 1 e Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. ++ B e Suspend a thermometer [B] with the heat-sensitive por- tion [C] located in almost the same depth with the sensor. (©) | NOTE Ch Ë OThe sensor and thermometer must not touch the con- DC A tainer side or bottom. e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently ; \ for even temperature. \®, y e Using a digital meter, measure the internal resistance V7 of the sensor across the terminals at the temperatures shown in the table. Inlet Air Temperature Sensor Resistance Standard: 2.09 —2.81 kQ at 20°C (68°F) About 0.322 kQ at 80°C (176°F) (reference COUR value) x lfthe measurement is out of the range, replace the sensor. xlf the measurement is within the specified, replace the ECU (see ECU section).

3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. e Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). e Remove: Throttle Body Assy (see Throttle Body Assy Removal) Connector [A] Water Temperature Sensor [B] e Replace the gasket with a new one, and tighten the water temperature sensor. Torque - Water Temperature Sensor: 25 N-m (2.5 kgf-m, 18 ft-Ilb) e Fillthe engine with coolant and bleed the air from the cool- ing system (see Coolant Change in the Periodic Mainte- nance chapter). Output Voltage Inspection NOTE OBe sure the battery is fully charged. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] to the ECU connectors [B], With the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Water Temperature Sensor Output Voltage Connections to ECU Meter (+) — O lead (terminal 25) Meter (-) — BR/BK lead (terminal 34) e Measure the sensor output voltage with the engine stopped and the connector joined. e Turn the ignition switch ON. Output Voltage at ECU Standard: About 2.80 —2.97 V at 20°C (68°F) NOTE OThe output voltage changes according to the coolant temperature in the engine. e Turn the ignition switch OFF. x lfthe output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). x lfthe ground and power supply are good, replace the ECU (see ECU section). xlf the output voltage is far out of the specified (e.g. when the wiring is open, the voltage is about 5V), check the Wiring (see wiring diagram in this section). xlfthe wiring is good, check the water temperature sensor resistance. CHER

Water Temperature Sensor (Service Code 14) Sensor Resistance Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter (see Water Temperature Sen- sor Inspection in the Electrical System chapter). Water Temperature Sensor Circuit Gcr7427cH2 ©

3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal e Remove: Seat (see Seat Removal in the Frame chapter) Atmospheric Pressure Sensor Connector [A] Damper [B] Atmospheric Pressure Sensor [C] Installation NOTE OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has a inlet air pressure hose and dif- ferent wiring. e Installation is reverse of removal. Input Voltage Inspection NOTE OBe sure the battery is fully charged. OThe inspection is the same as “Input Voltage Inspection of the throttle sensor and the inlet air pressure sensor. e Turn the ignition switch OFF. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] to the connector [B], with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Atmospheric Pressure Sensor Input Voltage Connections to ECU Connector Meter (+) — BL lead (terminal 7) Meter (-) — BR/BK lead (terminal 34) e Measure the input voltage with the engine stopped, and With the connectors joined. e Turn the ignition switch ON. Input Voltage at ECU Standard: DC 4.75 -5.25 V xlf the reading of input voltage is less than the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). xlfthe ground and power supply are good, replace the ECU (see ECU section). Goiriasess

Atmospheric Pressure Sensor (Service Code 15) xlf the reading is within the standard range, remove the seat, and check the input voltage again at the sensor con- nector. e Disconnect the atmospheric pressure sensor connector and connect the harness adapter [A] between the harness connector and atmospheric pressure sensor connector. Special Tool - Sensor Harness Adapter: 57001-1561 e Connect a digital meter to the harness adapter leads. Atmospheric Pressure Sensor [B] Atmospheric Pressure Sensor Input Voltage Connections to Adapter Meter (+) — G (sensor BL) lead [C] Meter (-) — BK (sensor BR/BK) lead [D] e Measure the input voltage with the engine stopped, and With the connector joined. e Turn the ignition switch ON. Input Voltage at Sensor Connector Standard: DC 4.75 5.25 V e Turn the ignition switch OFF. xlf the reading is out of the standard range, check the Wiring (see wiring diagram in this section). xlf the reading is good, the input voltage is normal. Check the output voltage. Gctriazsst € Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Atmospheric Pressure Sensor Output Voltage Connections to ECU Connector Meter (+) — G/W lead (terminal 11) Meter (-) — BR/BK lead (terminal 34) Goiriséess Output Voltage Usable Range: DC 3.80 —4.20 V at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.) NOTE OThe output voltage changes according to the local at- mospheric pressure. OThe atmospheric sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor. So, the sensor indicates absolute atmospheric pressure. xlfthe output voltage is within the usable range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). xlfthe ground and power supply are good, replace the ECU (see ECU section).

3-64 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) xlf the output voltage is far out of the usable range, check the output voltage at the sensor connector [A] (when the Wiring is open, the output voltage is about 1.8 V). e Connect a digital meter [A] to the harness adapter leads. Atmospheric Pressure Sensor [B] Special Tool - Sensor Harness Adapter: 57001-1561 Atmospheric Pressure Sensor Output Voltage Connections to Adapter Meter (+) — G/W (sensor G/W) lead [C] Meter (-) — BK (sensor BR/BK) lead [D] Output Voltage at Sensor Usable Range: DC 3.80 —4.20 V at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs.) e Turn the ignition switch OFF. xlf the output voltage is normal, check the wiring for conti- nuity (see wiring diagram in this section). xlf the output voltage is out of the usable range, replace cctriassst € the sensor. Atmospheric Pressure Sensor Circuit (oO) eu — ax À

xIf you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows. ODetermine the local altitude (Elevation).

Atmospheric Pressure Sensor (Service Code 15) xlf you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output Voltage Inspection of the inlet air pressure sensor. xlf you know the local altitude, use the following chart. Atmospheric Pressure/Altitude Relationship

3-66 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation e Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter (see Crankshaft Sensor Re- moval/Installation in the Electrical System chapter). Crankshaft Sensor Inspection OThe crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals. e Crank the engine and measure the peak voltage of the crankshaft sensor (see Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter) in order to check the sensor. e Check the wiring for continuity (see wiring diagram in this section). Crankshaft Sensor Circuit

Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. e Refer to the Camshaïft Position Sensor Removal/Installa- tion in the Electrical System chapter (see Camshaft Posi- tion Sensor Removal/Installation in the Electrical System chapter). Camshaft Position Sensor Inspection OThe camshaft position sensor have no power source, and when the engine stops, the camshaft position sensor gen- erates no signal. e Crank the engine and measure the peak voltage of the camshaft position sensor (see Camshaft Position Sensor Peak Voltage Inspection in the Electrical System chapter) in order to check the sensor. e Check the wiring for continuity (see wiring diagram in this section). Camshaft Position Sensor Circuit

3-68 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation e Refer to the Speed Sensor Removal/installation in the Electrical System chapter (see Speed Sensor Re- moval/Installation in the Electrical System chapter). Speed Sensor Inspection e Refer to the Speed Sensor Inspection in the Electrical System chapter (see Speed Sensor Inspection in the Electrical System chapter). Input Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Disconnect the speed sensor connector [A]. e Connect the harness adapter [A] between the harness connector and speed sensor connector. Special Tool - Throttle Sensor Setting Adapter #1: 57001

e Connect a digital meter to the harness adapter leads. Speed Sensor Input Voltage Connections to Adapter Meter (+) — BL (sensor P) lead [B] Meter (-) — BK/BL (sensor BK) lead [C] e Measure the input voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. Input Voltage Standard: About DC 9 —-11 V e Turn the ignition switch OFF. xlf the reading is out of the range, check the wiring (see Wiring diagram in this section), and meter unit (see Elec- tronic Combination Meter Unit Inspection in the Electrical System chapter). xlf the reading is good, check the output voltage. gcrrasiess €

Speed Sensor (Service Code 24) Output Voltage Inspection e Before this inspection, inspect the input voltage (see Input Voltage Inspection in this section). NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Using the stand, raise the rear wheel off the ground. e Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and speed sensor connector. e Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter #1: 57001

Speed Sensor Output Voltage Connections to Adapter Meter (+) — BY (sensor BL/Y) lead [C] Meter (-) — BK/BL (sensor BK) lead [D] e Measure the output voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. Output Voltage at Sensor Standard: About DC 0.05 —0.09 V or DC 4.5 —-4.9 e Rotate the rear wheel by hand, confirm the output voltage will be raise or lower. e Turn teh ignition switch OFF. xlfthe reading is out of the range, check the speed sensor (see Speed Sensor Inspection in the Electrical System chapter) and the wiring to ECU (see wiring diagram in this section). xlfthe reading, speed sensor and wiring are good, replace the ECU (see ECU section).

Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation e Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter (see Gear Position Switch Removal/Installation in the Electrical System chapter). Gear Position Switch Inspection e Refer to the Gear Position Switch Inspection in the Electri- cal System chapter (see Gear Position Switch Inspection in the Electrical System chapter). Input Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] to the connector, with the nee- dle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Gear Position Switch Input Voltage at 1 -6 Gear Positions Connections to ECU Connector Meter (+) — G/R lead (terminal 4) Meter (-) — Engine Ground e Measure the switch input voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. Input Voltage at 1 -6 Gear Positions Standard: ist About 3.0 V 2nd About 2.5 V 3rd About 2.0 V ath About 1.5 V 5th About 1.1 V 6th About 0.7 V e Turn the ignition switch OFF. xlf the reading is out of the range, check the gear position switch (see Gear Position Switch Inspection in the Elec- trical System chapter). xlf the switch is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). xlfthe ground and power supply are good, replace the ECU (see ECU section).

Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 —70° or more to either side (in fact falls down), the weight turns and shuts off the signal. The ECU senses this change, and stops the fuel pump, the fuel injectors, and the ignition system. Hall IC [B] When the motorcycle is down, the ignition switch is left ON. If the starter button is pushed, the electric starter turns but the engine doesn't start. To start the engine again, raise the motorcycle, turn the ignition switch OFF, and then ON. When the ignition switch is turned ON, current flows through the latch-up circuit and the transistor in the circuit is turned ON to unlock the latch-up circuit. Vehicle-down Sensor [A] Ground Terminal BR/BK [B] Output Terminal Y/G [C] Power Source Terminal BL [D] Removal CAUTION Never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. e Remove: Windshield (see Windshield Removal in the Frame chapter) Bolts [A] e Remove: Connector [A] Bolts [B] Vehicle-down Sensor [C] Installation e The UP mark [A] of the sensor should face upward. À WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situ- ations, like leaning over in a turn, with the potential for an accident resulting in injury or death. Ensure that the vehicle-down sensor is held in place by the sensor brackets. Gctrasanst € Gctrassast € Gctrasenst € e Tighten: Torque - Vehicle-down Sensor Bolts: 5.9 N-m (0.60 kgf-m, 53 in-lb)

3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Inspection NOTE OBe sure the battery is fully charged. + Remove the Windshield (see Windshield Removal in the Frame chapter). e Connect a digital meter [A] to the connector of the vehicle -down sensor [B], with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down sensor Power Source Voltage Connections to Sensor Meter (+) — BL lead [D] Meter (-) — BR/BK lead [E] e Turn the ignition switch ON, and measure the power source voltage with the connector joined. Power Source Voltage at Sensor Standard: DC 4.75 —5.25 V e Turn the ignition switch OFF. xlf there is no voltage, check the following. Battery (see Charging Condition Inspection in the Elec- trical System chapter) ECU Fuse 15 A (see Fuse Inspection in the Electrical System chapter) xlf the power source is normal, check the output voltage. ectrss78s2 €

Vehicle-down Sensor (Service Code 31) e Turn the ignition switch OFF. e Remove the vehicle-down sensor. ODo not disconnect the sensor connector. e Connect a digital meter [A] to the connector, with needle adapter set [B]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down sensor Output Voltage Connections to Sensor Meter (+) — Y/G lead [C] Meter (-) — BR/BK lead [D] e Hold the sensor vertically. e Turn the ignition switch ON, and measure the output volt- age with the connector joined. OTilt the sensor 60 —70° or more [E] right or left, then hold the sensor almost vertical with the arrow mark pointed up, and measure the output voltage. Output Voltage at Sensor Standard: with sensor arrow mark pointed up: 3.55 — 445V with sensor tilted 60 —70° or more right or left: 0.65 —1.35 V NOTE OIf you need to test again, turn the ignition switch OFF, and then ON. e Turn the ignition switch OFF. xlf the output voltage is out of the specified, replace the vehicle-down sensor. Vehicle-down Sensor Circuit corrss8sa ©

3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening. Input Terminal [A] Output Terminal [B] Ground Terminal [C] Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can dam- age it. Input Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] to the connector [B], using the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Subthrottle Sensor Input Voltage Connections to ECU Connector Meter (+) — BL lead (terminal 7) Meter (-) — BR/BK lead (terminal 34) e Measure the input voltage with the engine stopped, and With the connectors joined. e Turn the ignition switch ON. Input Voltage at ECU Connector Standard: DC 4.75 —5.25 V e Turn the ignition switch OFF. xlf the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted. % lfthe ground and power supply are good, replace the ECU (see ECU section). xlfthe input voltage is within the standard range, check the input voltage at the subthrottle sensor connector. (G60) cctriarast € Goiriasess

Subthrottle Sensor (Service Code 32) e Remove the right fairing cover (see Fairing Cover Re- moval in the Frame chapter). e Disconnect the subthrottle sensor connector [A]. e Connect the harness adapter [A] between the harness connector and subthrottle sensor connector. Special Tool - Throttle Sensor Setting Adapter: 57001

e Connect a digital meter to the harness adapter leads. Subthrottle Sensor Input Voltage Connections to Adapter Meter (+) — BK (sensor BL) lead Meter (-) — W (sensor BR/BK) lead eMeasure the sensor input voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. Input Voltage at Sensor Standard: DC 4.75 —5.25 V e Turn the ignition switch OFF. xlf the reading is out of the range, check the wiring (see Wiring diagram in this section). xlf the reading is good, check the output voltage of the sensor.

3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Subthrottle Sensor Output Voltage Connections to ECU Connector Meter (+) — BL/W lead (terminal 27) Meter (-) — BR/BK lead (terminal 34) e Remove the air cleaner caps (see Throttle Body Assy Re- moval). e Turn the ignition switch ON. e Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand. Output Voltage at ECU Standard: DC 0.62 —4.14 V (at subthrottle valve full opening to closing) NOTE OThe throttle sensor is operating correctly if the following voltages are obtained: + DC 0.62 V (or slightly higher) with the subthrottle valve at the closed position. + DC 4.14 V (or slightly lower) with the subthrottle valve at the fully open position. CAUTION Do not remove or adjust the subthrottle sensor. It has been adjusted and set with precision at the fac- tory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can dam- age it. xlf the output voltage is within the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). x lfthe ground and power supply are good, replace the ECU (see ECU Removal). xlf the output voltage is far out of the standard range (e.g. when the wiring is open, the reading is O V), check the output voltage again at the sensor connector. CHIOTS

Subthrottle Sensor (Service Code 32) e Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and subthrottle sensor connector. Special Tool - Throttle Sensor Harness Adapter: 57001

e Connect a digital meter to the harness adapter leads. Subthrottle Sensor Output Voltage Connections to Adapter Meter (+) — R (sensor BL/W) lead Meter (-) — W (sensor BR/BK) lead + Measure the output voltage with the engine stopped, and With the connector joined. e Turn the ignition switch ON. + Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand. Output Voltage at Sensor Standard: DC 0.62 —-4.14 V (at subthrottle valve full opening to closing) NOTE OThe throttle sensor is operating correctly if the following voltages are obtained: + DC 0.62 V (or slightly higher) with the subthrottle valve at the closed position. + DC 4.14 V (or slightly lower) with the subthrottle valve at the fully open position. CAUTION Do not remove or adjust the subthrottle sensor. It has been adjusted and set with precision at the fac- tory. Never drop the throttle body assy, especially on a hard surface. Such a shock to the sensor can dam- age it. NOTE OThe standard voltage refers to the value when the voilt- age reading at the Input Voltage Inspection shows 5V exactly. OWhen the input voltage reading shows other than 5V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V.

0.62 x 4.75 + 5.00 = 0.59 V

4.14 x 4.75 + 5.00 = 3.93 V

Thus, the valid range is 0.59 —3.93 V e Turn the ignition switch OFF. xlf the reading is out of the standard range, inspect the subthrottle sensor resistance. xlf the output voltage is normal, check the wiring for conti- nuity (see wiring diagram in this section).

3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection e Turn the ignition switch OFF. e Disconnect the subthrottle sensor connector. e Connect a digital meter [A] to the subthrottle sensor con- nector [B]. e Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] <—-— BR/BK lead [D] Standard: 4-6kQ x lfthe reading is out of the range, replace the throttle body assy (see Throttle Body Assy section). xlf the reading is within the range, but the problem still exists, replace the ECU (see ECU section). Subthrottle Sensor Circuit GciTa4ess €

Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection e Remove the left inner cover (see Inner Cover Removal in the Frame chapter). e Disconnect the antenna lead connector [A]. e Measure the resistance of the antenna coil in the ignition switch as follows. Antenna Resistance Connections to Antenna Meter — BK lead Meter — BK lead Standard: About 0.6 —0.9 Q xlf the resistance is out of the standard range, replace the ignition switch. Amplifier Input Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Remove the windshield (see Windshield Removal in the Frame chapter). e Connect a digital meter to the amplifier connector [A], us- ing the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Amplifier Input Voltage Connections to Connector Meter (+) — BR/W lead Meter (-) — BK/Y lead e Measure the input voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. Input Voltage Standard: Battery Voltage e Turn the ignition switch OFF. xlf the reading is out of the range, check the wiring (see Wiring diagram in next section). xlf the reading and antenna resistance are good, replace the amplifier (see Immobilizer System Parts Replacement in the Electrical System chapter). CLR]

3-82 FUEL SYSTEM (DFI) Blank Key Detection (Service Code 36) e This code appears in the following conditions. OThe transponder [A] in the master and/or user key is mal- function. OWhen the spare key of unregistration is used. OWhen the master key is registered in the registered ECU. e Therefore, the service code 36 will disappear when the above issue is solved. User Key Inspection e Register the user key correctly (see Key Registration in the Electrical System chapter). xlf the service code 36 appears again, the transponder in the key is malfunction, replace it. Immobilizer System Circuit

Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. OThe fuel pump relay is included in the relay box. e Remove the seat (see Seat Removal in the Frame chap- ter). e Remove the relay box [A] from the bracket and disconnect the connectors. Fuel Pump Relay Inspection e Remove the relay box (see Fuel Pump Relay Removal). e Connect the hand tester [A] and one 12 V battery to the relay connector as shown. Special Tool - Hand Tester: 57001-1394 Relay Coil Terminals [1] and [2] Relay Switch Terminals [3] and [4] Testing Relay Tester range: 1 Q range ecvens P Criteria: When battery is connected — 0 Q When battery is disconnected — + Q xlf the relay does not work as specified, replace the relay box.

Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coil can damage it. e Refer to the Stick Coil (Ignition Coil together with Spark Plug Cap) Removal/Installation in the Electrical System chapter (see Stick Coil (Ignition Coil together with Spark Plug Cap) Removal/Installation in the Electrical System chapter). Input Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] as shown, with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Stick Coil Input Voltage at ECU Connections for Stick Coil #1 Meter (+) — W/R lead (terminal 47) Meter (-) — BK/Y lead (terminal 52) Connections for Stick Coil #2 Meter (+) — W/BL lead (terminal 60) Meter (-) — BK/Y lead (terminal 52) Connections for Stick Coil #3 Meter (+) — W/G lead (terminal 45) Meter (-) — BK/Y lead (terminal 52) Connections for Stick Coil #4 Meter (+) — W/Y lead (terminal 58) Meter (-) — BK/Y lead (terminal 52) e Measure the input voltage to each primary winding of the stick coils with the engine stopped, and with the connec- tors joined. e Turn the ignition switch ON. Input Voltage at ECU Standard: Battery Voltage xlfthe reading is out of the standard, check the wiring (see Wiring diagram in this section). xlf the reading is good, the input voltage is normal. Crank the engine, and check the peak voltage of the stick coils (see Stick Coil Primary Peak Voltage Inspection in the Electrical System chapter) in order to check the primary coils. Goirissess

Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face. Such a shock to the actuator can damage it. Subthrottle Valve Actuator Inspection e Remove: Fuel Tank (see Fuel Tank Removal) Left and Right Air Cleaner Caps (see Throttle Body Assy Removal) e Turn the ignition switch ON. e Check to see that all subthrottle valves [A] open and close smoothly. xlfthe subthrottle valves do not operate, check the actuator internal resistance (see Resistance Inspection). Resistance Inspection e Turn the ignition switch OFF. e Disconnect the subthrottle valve actuator connector [A]. e Connect a digital meter to the connector [A]. e Measure the subthrottle valve actuator resistance. Subthrottle Valve Actuator Resistance Connections: Y lead [1] —— P lead [2] BK lead [3] «—-— G lead [4] Standard: About 5 —-7 Q xlfthe reading is out of the range, replace the throttle body assy (see Throttle Body Assy section). xlf the reading is within the range, check the input voltage (see Input Voltage Inspection in this section). gcirirocss €

3-88 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. © Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D]. Special Tools - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Needle Adapter Set: 57001-1457 Subthrottle Valve Actuator Input Voltage Connections to Harness Connector (1) Meter (+) — BK/BL lead [1] Meter (-) — Frame Ground 2 [E] (ll) Meter (+) — G lead [2] Meter (-) — Frame Ground 2 [E] (li) Meter (+) — Y/BK lead [3] Meter (-) — Frame Ground 2 [E] (IV) Meter (+) — P lead [4] Meter (-) — Frame Ground 2 [E] e Measure the input voltage with the engine stopped, and With the connector joined. e Turn the ignition switch ON. Input Voltage Standard: About DC 10.5 —12.5 V xlfthe reading is out of the range, check the wiring to ECU (see wiring diagram in this section). xlfthe wiring is good, replace the ECU (see ECU section).

3-90 FUEL SYSTEM (DFI) ECU Main Relay (Service Code 75) ECU Main Relay Inspection OThe ECU main relay function is included in the ECU [A]. So, the ECU main relay function cannot be inspected. e When the service code 75 is displayed on the LCD, re- place the ECU (see ECU section).

ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification OMost countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identification Part Number Specification [A] P Europe, WVTA, Full, H, with Immobilizer U.K., WVTA, Full, H, with Immobilizer U.S.A (except California), without Immobilizer 21175-0076 21175-0084 Canada, without Immobilizer 21175-0089 |U.S.A (California), without Immobilizer 21175-0101 |Malaysia, with Immobilizer 21175-0090 | Australia, with Immobilizer 21175-0102 |France, WVTA, 78.2, H, with Immobilizer Full: Full Power H: Honeycomb Type Catalyst 78.2: Maximum Horsepower 78.2 KW (106.3 PS) ECU Removal e Remove the seat (see Seat Removal in the Frame chap- ter). e Pull the hook [A] to lift up the lid [B] of the tool kit case. e Remove the tool kit [A]. LE] Gci744oess

3-92 FUEL SYSTEM (DFI) ECU e Remove: Fuse Box [A] Bolts [B] Tool Kit Case [C] e Remove the relay box [A]. e Lift up the ECU [B] with rubber protector [C]. e Remove: ECU Connectors [A] ECU [B] e Refer to the Immobilizer System Parts Replacement in the Electrical System chapter for the immobilizer models (see Immobilizer System Parts Replacement in the Electrical System chapter). ECU Installation e Install: ECU TA] (In rubber protector [B]) ECU Connectors [C] e Insert the slits of the rubber protector to the projections [A] of the rear fender front. cum P

ECU e Install: Connector Holder [A] Relay Box [B] e Install the plate [A] to the tool kit case [B] and tighten the bolts [C]. e Insert the stopper [D] of the fuse box [E] into the groove of the tool case. ECU Power Supply Inspection e Remove the ECU (see ECU Removal). e Visually inspect the terminals [A] of the ECU connectors. xlf the connector is clogged with mud or dust, blow it off with compressed air. xReplace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged. xReplace the ECU if the terminals of the ECU connectors are cracked, bent, or otherwise damaged. e With the ECU connectors [B] connected, check the fol- lowing ground lead for continuity with the ignition switch OFF, using a digital meter [A] and needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 ECU Grounding Inspection 17, 39, or 52 Terminal +<— Frame Ground 2 [C]: 0 Q Engine Ground <-— Frame Ground 2 [C]: 0 Q xlf no continuity, check the connector, the engine ground lead, or main harness, and repair or replace them if nec- essary. Gorraaiess

3-94 FUEL SYSTEM (DFI) ECU © Check the ECU power source voltage with a digital meter [AÏ. OPosition the terminal in accordance with terminal numbers of ECU connectors [B] in the figure. ECU Power Source Inspection Tester Connections: between 33 (BR) Terminal and Frame Ground 2 [C] between 15 (W/BK) Terminal and Frame Ground 2 [C] between 32 (W/BK) and Frame Ground 2 [C] Ignition Switch OFF: 33 (BR) Terminal, 0 V 15 (W/BK) Terminal, Battery Voltage 32 (W/BK) Terminal, Battery Voltage Ignition Switch ON: 33 (BR) Terminal, Battery Voltage 15 (W/BK) Terminal, Battery Voltage 32 (W/BK) Terminal, Battery Voltage xlf the tester does not read as specified, check the follow- ing. Power Source Wiring (see wiring diagram in this section) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) ECU Fuse 15 À (see ECU Fuse Inspection) x lfthe wiring and fuse are good, replace the ECU (see ECU section). CTI

© © HN O O1 À & ND = CAN Communication Line Resistance Inspection Oln this model, resistors for CAN communication line are built in the ECU and meter unit. e Turn the ignition switch OFF. e Disconnect the ECU connector [A] (see ECU Removal).

3-96 FUEL SYSTEM (DFI) ECU © Connect a digital meter [A] to the ECU connector [B]. e Measure the resistance of the CAN communication line resistor. CAN Communication Line Resistance (at ECU Connector) Connections: Terminal 1 <—-—Terminal 18 Standard: 114 —-126 Q xlf the reading is out of the range, replace the ECU (see ECU section). xlf the reading is within the range, resistor of the ECU for CAN communication line is normal. © Check the wiring for continuity of the CAN communication line (see wiring diagram in this section). xlf the wiring is open, replace the main harness. e Refer to the Meter Unit Inspection in the Electrical System chapter for the resistor in the meter unit (see Meter Unit Inspection in the Electrical System chapter). CAN Communication Line Circuit gcirassess €

4. Resistor (In the ECU)

DFI Power Source ECU Fuse Removal e Refer to the ECU Fuse 15 À Removal in the Electrical Sys- tem chapter (see 15 À ECU Fuse Removal in the Electri- cal System chapter). ECU Fuse Installation xlf a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. e Refer to the Fuse installation in the Electrical System chapter (see Fuse Installation in the Electrical System chapter). ECU Fuse Inspection e Refer to the Fuse Inspection in the Electrical System chapter (see Fuse Inspection in the Electrical System chapter).

3-98 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Light (LED) Inspection OThe warning indicator light (LED) [A] is used for the F1 indicator and immobilizer indicator (immobilizer models). Oln this model, the warning indicator light (LED) goes on or blinks by the special signal sent from the ECU. e Refer to the fuel level warning inspection procedure (see Meter Unit Inspection in the Electrical System chapter) for the warning indicator light (LED) inspection. GciTa44ess Warning Indicator Light (LED) Circuit

Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged. e Remove the fuel tank (see Fuel Tank Removal). eBe sure to place a piece of cloth around the fuel supply pipe of the throttle body assy. e Remove the fuel hose from the fuel supply pipes of the throttle body assy (see Fuel Hose Replacement in the Periodic Maintenance chapter). À WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. e Connect the following parts temporary. Fuel Pump Lead Connector Fuel Level Sensor Lead Connector e Install the fuel pressure gauge adapter [A] and fuel hoses (Special Tool: 57001-1607) [B] between the fuel supply pipes of the fuel pump and throttle body assy. e Connect the pressure gauge [C] to the fuel pressure gauge adapter. Special Tools - Oil Pressure Gauge, 5 kgf/cm’: 57001-125 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607 À WARNING Do not try to start the engine with the fuel hoses disconnected. e Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop. CAUTION Do not drive the fuel pump 3 seconds or more with- out the fuel in the fuel tank. Ifthe fuel pumpis driven without the fuel, it may be damaged. e Measure the fuel pressure with the engine stopped. Fuel Pressure right after Ignition Switch ON, with pump running: Standard: 304 kPa (3.1 kgf/cm?, 44 psi) after 3 seconds from Ignition Switch ON, with pump stopped: Standard: 280 kPa (2.9 kgf/cm’, 41 psi) , residual fuel pressure The system should hold the residual pressure about 30 seconds.

3-100 FUEL SYSTEM (DFI) Fuel Line e Start the engine, and let it idle. e Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm’, 44 psi) NOTE OThe gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. xlf the fuel pressure is much higher than the specified, re- place the fuel pump (see Fuel Pump section). xlf the fuel pressure is much lower than specified, check the following. Fuel Line Leakage Amount of Fuel Flow (see Fuel Flow Rate Inspection) xlf the fuel pressure is much lower than specified, and if inspection above checks out good, replace the throttle body assy, or the fuel pump and measure the fuel pres- sure again (see appropriate sections). e Remove the fuel pressure gauge, hoses and adapter. e Install: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Installation) Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged. Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. e Turn the ignition switch and engine stop switch OFF. e Wait until the engine cools down. e Prepare a fuel hose (Special Tool: 57001-1607) and a measuring cylinder. Special Tool - Fuel Hose: 57001-1607 e Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank Cover (see Fuel Tank Removal) Fuel Tank Bolts [A]

Fuel Line e Remove the fuel tank bolts [A]. e Open the fuel tank cap [A] to lower the pressure in the tank. eBe sure to place a piece of cloth around the fuel supply pipe of the fuel pump. + Remove the fuel hose from the fuel pump (see Fuel Tank Removal). À WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. e Connect the prepared fuel hose [A] to the fuel supply pipe of the fuel pump. e Secure the fuel hose with a clamp. Insert the fuel hose into the measuring cylinder [B].

3-102 FUEL SYSTEM (DFI) Fuel Line À WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. e Close the fuel tank cap. e With the engine stopped, turn the ignition switch ON. The fuel pump should operate for 3 seconds, and then should stop. CAUTION Do not drive the fuel pump 3 seconds or more with- out the fuel in the fuel tank. Ifthe fuel pumpis driven without the fuel, it may be damaged. e Measure the discharge for 3 seconds. ORepeat this operation several times. Amount of Fuel Flow Standard: 67 mL (2.26 US oz.) or more for 3 seconds xlf the fuel flow is much less than the specified, check the following. Battery Condition (see Charging Condition Inspection in the Electrical System chapter) e After inspection, connect the fuel hose (see Fuel Tank Installation). e Start the engine and check for fuel leakage.

Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. À WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (-) terminal. To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. e Draw the fuel out from the fuel tank with a commercially available electric pump. e Remove the fuel tank (see Fuel Tank Removal). OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. Plug the fuel pipe of the fuel tank. e Turn the fuel tank upside down. e Unscrew the fuel pump bolts [A], and take out the fuel pump assembly [B] and gasket. e Discard the fuel pump gasket. CAUTION Do not pull the leads [C] of the fuel pump and fuel reserve switch. If they are pulled, the lead terminals may be damaged. Fuel Pump Installation e Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. e Replace the fuel pump gasket with a new one.

3-104 FUEL SYSTEM (DFI) Fuel Pump © Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Front [D] e Apply a non-permanent locking agent to the threads of the fuel pump bolts. e Tighten the fuel pump bolts to a snug fit following the tight- ening sequence shown. e Following the tightening sequence, tighten the pump bolts to the specified torque. Torque - Fuel Pump Bolts: 9.8 N-m (1.0 kgf-m, 89 in-lb) e Tighten the pump bolts again to check the tightness in the order shown. Operation Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch ON and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops. e Turn the ignition switch OFF. xlf the pump does not work as described above, inspect the operating voltage. Operating Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Remove the seat (see Seat Removal in the Frame chap- ter). © Connect the hand tester (x 25 V DC) to the 4 pins con- nector [A], with needle adapter set. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Pump Operating Voltage at Pump Connections to Pump Connector Tester (+) — BK/Y Lead Tester (-) — BK/W Lead e Measure the operating voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. OThe tester needle should indicate battery voltage for 3 seconds, and then 0 V. Operating Voltage at Pump Connector Standard: Battery Voltage for 3 seconds, and then 0 V xlf the reading stays on battery voltage, and never shows 0 V. Check the ECU and fuel pump relay. xlf the voltage is in specification, but the pump doesn't work, replace the pump. xlf there is still no battery voltage, check the pump relay (see Fuel Pump Relay Inspection). cctrssonst €

Fuel Pump Fuel Pump Circuit

3-106 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation e Refer to the Throttle Body Assy Disassembly/Assembly (see Throttle Body Assy Disassembly/Assembly). CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Power Source Voltage Inspection NOTE OBe sure the battery is fully charged. e Turn the ignition switch OFF. e Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. e Connect a digital meter [A] to the connector [B], with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage at ECU Connector Connections to ECU Connector Meter (+) — W/R lead (terminal 14) Meter (-) — Frame Ground 2 [C] e Measure the power source voltage with the engine stopped, and with the connectors joined. e Turn the ignition switch ON. Power Source Voltage at ECU Standard: Battery Voltage for 3 seconds, and then 0 V xlf the power source voltage is less than the standard, check the fuel pump relay (see Fuel Pump Relay Inspec- tion), wiring (see wiring diagram in this section), and the ECU for its ground, and power supply (see ECU Power Supply Inspection chapter). xlf the reading is normal, check the power source voltage at the injector connector. e Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Bolts [A] gciTaagess

Fuel Injectors © Connect a digital meter [A] to the throttle body subharness connector [B], using the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage at Injector Connections to Injector #1, #2, #3, #4 Meter (+) — W/R lead [E] Meter (-) — Ground [D] e Measure the power source voltage with the engine stopped, and with the connector joined. e Turn the ignition switch ON. Power Source Voltage at Injector Connector Standard: Battery Voltage for 3 seconds, and then 0 V e Turn the ignition switch OFF. xlfthe reading is out of the standard, check the wiring (see Wiring diagram in this section). xlf the reading is good, and the power source voltage is normal, check the output voltage. Output Voltage Inspection e Measure the output voltage at the ECU connector in the same way as power source voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at ECU Connections for Injector #1 Meter (+) — BL/R lead (terminal 46) Meter (-) — Frame Ground 2 [C] Connections for Injector #2 Meter (+) — BL/G lead (terminal 59) Meter (-) — Frame Ground 2 [C] Connections for Injector #3 Meter (+) — BL/BK lead (terminal 44) Meter (-) — Frame Ground 2 [C] Connections for Injector #4 Meter (+) — BL/Y lead (terminal 57) Meter (-) — Frame Ground 2 [C] e Turn the ignition switch ON. Output Voltage at ECU Standard: Battery Voltage for 3 seconds, and then 0 V xlf the output voltage is normal, check the ECU for its ground, and power supply (see ECU Power Supply In- spection). xlfthe ground and power supply are good, replace the ECU (see ECU section). Gorraa7ess

3-108 FUEL SYSTEM (DFI) Fuel Injectors xlf the output voltage is out of the standard, check the out- put voltage at the throttle body subharness connector [B] using a digital meter [A] and needle adapter set [C] (when the lead is open, the output voltage is O V). Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at Injector Connections to Injector #1 Meter (+) — BL/R lead [E] Meter (-) — Ground [D] Connections to Injector #2 Meter (+) — BL/G lead [F] Meter (-) — Ground [D] Connections to Injector #3 Meter (+) — BL/BK lead [G] Meter (-) — Ground [D] Connections to Injector #4 Meter (+) — BL/Y lead [H] Meter (-) — Ground [D] e Turn the ignition switch ON. Output Voltage at Injector Connector Standard: Battery Voltage for 3 seconds, and then 0 V %lf the output voltage is normal, check the wiring for conti- nuity (see wiring diagram in this section). xlfthe wiring is good, perform “Audible Inspection” for con- firmation. xlf the output voltage is out of the standard, perform “Au- dible Inspection” for confirmation. Audible Inspection e Remove the left and right fairing cover (see Fairing Cover Removal in the Frame chapter). e Start the engine. e Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not. e À sound scope can also be used. e Do the same for the other injector. xlf all the injectors click at a regular intervals, the injectors are good. OThe click interval becomes shorter as the engine speed rises. xlf either injector doesn't click, perform the “Injector Signal Test” for injector operation.

Fuel Injectors Injector Signal Test e Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V x 3 - 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.03 in.) CAUTION Do not use larger terminals than specified above. A larger terminal could damage the injector main har- ness connector (female), leading to harness repair or replacement. Be sure to connect bulbs in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current. e Disconnect the connectors for injector [A]. e Connect each test light set [B] to the injector sub harness connector [C]. e Turn the ignition switch ON. e While cranking the engine with the starter motor, watch the test lights. xlf the test lights flicker at regular intervals, the injector circuit in the ECU, and the wiring are good. Perform the “Injector Resistance Inspection”. Olnjector signals can be also confirmed by connecting the hand tester (x 10 V AC) instead of the test light set to the injector main harness (female) connector. Crank the engine with the starter motor, and check to see ifthe hand oscillates at regular intervals. Special Tool - Hand Tester: 57001-1394 xlf the test light does not flicker (or the test hand doesn't oscillates), check the wiring and connectors again. xlfthe wiring is good, replace the ECU (see ECU section). Injector Resistance Inspection e Remove the throttle body assy (see Throttle Body Assy Removal). e Disconnect the connector from the injector [A] (see Throt- tle Body Disassembly/Assembly). e Measure the injector resistance with a digital meter. Injector Resistance Connections to Injector Meter (+) Meter (-) #1: WIR —— BL/R Terminal #2: WIR —— BL/G Terminal #3: WIR —— BL/BK Terminal #4: WIR —— BL/Y Terminal Standard: about 11.7 -12.3 Q at 20°C (68°F) xlfthe reading is out of the range, perform the “Injector Unit Test”. xlf the reading is normal, perform the “Injector Unit Test” for confirmation. Gctro2é2st © Gctrozesst €

3-110 FUEL SYSTEM (DFI) Fuel Injectors Injector Unit Test e Use two leads [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V x (3 -3.4) W 12 V MF Battery [D] CAUTION Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current. ectro24sst € e Connect the test light set to the injector [E] as shown. e Open and connect [F] the end of the lead to the battery (-) terminal repeatedly. The injector should click. xlf the injector does not click, replace the injector. Injector Fuel Line Inspection e Remove the throttle body assy (see Throttle Body Assy Removal). © Check the injector fuel line for leakage as follows. OConnect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends connected with the clamps [D]) as shown. OApply soap and water solution to the areas [E] as shown. OWatching the pressure gauge, squeeze the pump lever [F], and build up the pressure until the pressure reaches the maximum pressure. Fuel Line Maximum Pressure Standard: 300 kPa (3.06 kgf/cm?, 43 psi) CAUTION During pressure testing, do not exceed the maxi- mum pressure for which the system is designed. e Watch the gauge for at least 6 seconds. xlf the pressure holds steady, the system is good. xlf the pressure drops at once, or if bubbles are found in the area, the line is leaking. Replace the delivery pipe, injectors and related parts. ORepeat the leak test, and check the fuel line for no leak- age. e Install the throttle body assy (see Throttle Body Assy In- stallation). e Runthe hoses correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). gcrrissese €

3-112 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Cable Installation e Install the throttle cables in accordance with the Cable , Wire, and Hose Routing section in the Appendix chapter. e Install the lower ends of the throttle cables in the cable bracket on the throttle assy after installing the upper ends of the throttle cables in the grip. e After installation, adjust each cable properly (see Throttle Control System Inspection in the Periodic Maintenance chapter). À WARNING Operation with incorrectly routed or improperly ad- justed cables could result in an unsafe riding con- dition. Cable Lubrication e Refer to the Chassis Parts Lubrication Perform in the Peri- odic Maintenance chapter (see Chassis Parts Lubrication Perform in the Periodic Maintenance chapter).

Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Mainte- nance chapter (see Idle Speed Inspection in the Periodic Maintenance chapter). Throttle Bore Cleaning e Check the throttle bore for cleanliness as follows. ORemove the throttle body assy (see Throttle Body Assy Removal). OCheck the main throttle valves and throttle bores [A] for carbon deposits by opening the main throttle valves. xlf any carbon accumulates, wipe the carbon off the throt- tle bores around the throttle bores and the throttle valves, using a cotton pad penetrated with a high-flash point sol- vent. Synchronization Inspection e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter (see Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter). Synchronization Adjustment e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter (see Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter). Throttle Body Assy Removal À WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (-) cable ter- minal. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Be prepared for fuel spillage: any spilled fuel must be completely wiped up immediately. e Remove: Fuel Tank Cover (see Fuel Tank Removal) Left and Right Middle Fairings (see Middle Fairing Re- moval in the Frame chapter) Bolts [A] Subframe Bolts [B] and Washers

3-114 FUEL SYSTEM (DFI) Throttle Body Assy e Disconnect the throttle body subharness connector [A]. e Remove the connector [A] from the connector bracket. Olnsert the thin blade screw driver into the connector stop- per portion from the right side of motorcycle. e For the California Model, pull off the vacuum hoses [A]. e Disconnect the crankshaft sensor lead connector [A]. e Loosen the duct clamp bolts [A] on both sides.

Throttle Body Assy e Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Temperature Sensor [A] Bolts [B] Left and Right Air Cleaner Caps [C] ODo not disconnect the inlet air temperature sensor lead connector. e Remove the duct clamps from the ducts [A], and pull out the ducts upward. ORemove the grommets [A] as necessary. e Remove the throttle case [A] to make a throttle cable slack. e Remove: Clamp [A] Throttle Cable Lower Ends [B]

3-116 FUEL SYSTEM (DFI) Throttle Body Assy e Remove the adjuster screw [A] from the clamp [B]. e Loosen the throttle body assy holder clamp bolts [A] on both sides. e Pull out the throttle body assy [B] from the holder. e Disconnect the fuel hose joint from the delivery pipe of the throttle body assy (see Fuel Hose Replacement in the Periodic Maintenance chapter). e Remove the throttle body assy [A] to the left side of mo- torcycle. e After removing the throttle body assy, stuff pieces of lint -free, clean cloths into the throttle body assy holders. CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur. Throttle Body Assy Installation e Install the holder clamp bolts [A] in the direction as shown. Bolt Heads [B] e Connect the fuel hose joint to the delivery pipe of the throt- tle body assy (see Fuel Hose Replacement in the Periodic Maintenance chapter). e Tighten: Torque - Throttle Body Assy Holder Clamp Bolts: 2.0 N-m (0.20 kgf-m, 18 in-lb)

Throttle Body Assy xlf the grommet [A] was removed, install it. Olnstall the grommet from the inside of the frame. e Insert the duct [B] to the grommet. OApply a soap and water solution or rubber lubricant to the oblique portion [C] on the duct for easy installation. e Fit the projections [D] of the duct into the holes [E] in the clamp. e Install the duct clamp bolts [A] in the direction as shown. Front [B] Upside View [C] e Tighten: Torque - Duct Clamp Bolts: 2.0 N-m (0.20 kgf-m, 18 in-lb) e Install the air cleaner caps. OThe right air cleaner cap [A] has a R mark [B]. e Replace the subframe bolts with new ones, and tighten it. Torque - Subframe Bolts: 23 N-m (2.3 kgf-m, 17 ft-lb) e Run the leads and hoses as shown in the Cable, Wire, and Hose Routing section of the Appendix chapter. e Adjust: Throttle Grip Free Play (see Throttle Control System In- spection in the Periodic Maintenance chapter) Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter) gerra5ocs2 € gcrrasiess

3-118 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly Gcr7a2cm? © . Subthrottle Valve Actuator . Subthrottle Sensor . Main Throttle Sensor . Throttle Body Assy . Injector . Delivery Pipe . Throttle Body Subharness CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy. NO 01 B & ND = e Remove the throttle body assy (see Throttle Body Assy Removal). e Disconnect the injector connectors [A].

Throttle Body Assy e Disconnect the main throttle sensor [A] and subthrottle sensor [B] connector. e Disconnect: Subthrottle Valve Actuator Lead Connector [A] Inlet Air Pressure Sensor Connector [B] e Separete the hoses [A] from the throttle body fittings and inlet air pressure sensor. e Remove the screws [B] to pull out the injector assies from the throttle body assy together with the delivery pipe [C]. NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the throttle body. e Pull out the injectors [A] from the delivery pipe [B]. NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe. Throttle Body Assy Assembly e Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air. e Apply daphne oil or engine oil to the new O-rings [A] of each injector, insert them to the delivery pipe [B] and con- firm whether the injectors turn smoothly or not. NOTE OReplace the O-rings of injectors to new ones.

3-120 FUEL SYSTEM (DFI) Throttle Body Assy e Apply daphne oil or engine oil to the new dust seals [A], and insert the injectors into the throttle body, which in- stalled to the delivery pipe. NOTE OReplace the dust seals ofthe throttle body to new ones. e Install the delivery pipe to the throttle body. Torque - Delivery Pipe Mounting Screws: 5.0 N-m (0.50 kgf-m, 44 in:lb) e Connect the injector connectors. Insert the each hoses to the throttle body fittings and inlet air pressure sensor. e Install the throttle body assy (see Throttle Body Assy In- stallation).

Air Line Element Removal e Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter). Element Installation e Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter). Air Cleaner Element Inspection e Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). e Visually check the element [A] for tears or breaks. xlf the element has any tears or breaks, replace the ele- ment. Air Cleaner Element Holder Removal e Remove: Air Cleaner Element (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) Screws [A] Pull out the air cleaner element holder [A] from the hous- ing. Air Cleaner Element Holder Installation e Install the air cleaner element holder [A] so that the holder ends [B] insert along the rib [C] in the housing. e Tighten: Torque - Air Cleaner Element Holder Screws: 6.9 N-m (0.70 kgf-m, 61 in‘lb) | im ju x

3-122 FUEL SYSTEM (DFI) Air Line Oil Draining A drain hose is connected to the bottom of the air cleaner part to drain water or oil accumulated in the cleaner part. e Visually check the catch tank of the drain hose [A], if the water or oil accumulates in the tank. xlf any water or oil accumulates in the tank, remove the plug [B] from the tank and drain it. Be sure reinstall the plug in the tank after draining. Oil on tires will make them slippery and can cause an accident and injury. Rear Air Inlet Duct Removal e Remove: Left and Right Inner Covers (see Inner Cover Removal in the Frame chapter) Fuel Tank Cover (see Fuel Tank Cover Removal) e Loosen the clamp bolt [A] on both sides. e Remove the mounting bolts [B] and, pull off the right rear air inlet ducts [C] to backward. e Remove the left rear air inlet duct in the same way as right. Rear Air Inlet Duct Installation e Insert the projections [A] of the holder [B] in the holes [C] of rear air inlet duct [D]. e Insert the rear air inlet duct [A] until the duct end [B] align the line [C] of middle air inlet duct [D]. e Tighten Torque - Rear Air inlet Duct Mounting Bolts: 9.8 N-m (1.0 kgf-m, 87 in-Ib)

Air Line e Install the clamp bolts [A] so that bolt heads [B] faces direction as shown. Left Clamp [C] Right Clamp [D] About 30° [E] Rear View [F] e Tighten: Torque - Middle Air inlet Duct Clamp Bolts: 2.9 N-m (0.30 kgf:m, 26 in:lb) Front and Middle Air Inlet Duct Removal e Remove the upper fairing (see Upper Fairing Removal in the Frame chapter). e Open the clamps [A]. e Open the clamps [A]. e Remove: Bolts [A] Front Air inlet Duct [B] Rubber Seal [C] e Loosen the clamp bolts [D] on both sides. e Remove the bolts [E] on both sides. e Pull off the left and right middle air inlet ducts [F] to for- ward. Front and Middle Air Inlet Duct Installation NOTE OThe left middle air inlet duct has a L mark [A] and the right middle air inlet duct has a R mark.

3-124 FUEL SYSTEM (DFI) Air Line e Insert the middle air inlet duct [A] until the line [B] align the duct end [C] of rear air inlet duct [D]. e Tighten: Torque - Middle Air Inlet Duct Mounting Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb) e Install the clamp bolt [A] so that bolt heads [B] faces di- rection as shown. Left Clamp [C] Right Clamp [D] About 30° [E] Rear View [F] e Tighten: Torque - Middle Air Inlet Duct Clamp Bolts: 2.9 N-m (0.30 kgf-m, 26 in-Ib) Install the rubber seal [A] so that the hollow side [B] faces forward. Insert the front air inlet duct to the rubber seal, and tighten the bolts. Torque - Front Air Inlet Duct Mounting Bolts: 9.8 N-m (1.0 kgf-m, 87 in-Ib) e Run the leads correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter).

Fuel Tank Fuel Tank Removal À WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. e Turn the ignition switch OFF. e Remove the left and right fairing covers (see Fairing Cover Removal in the Frame chapter). e Disconnect the battery (—) terminal (see Battery Removal in the Electrical System chapter). e Remove: Left and Right Inner Covers (see Inner Cover Removal in the Frame chapter) Bolt [A] e Pull the fuel tank cover [A] evenly outward to clear the projections [B] on both sides. e Remove the fuel tank cover to forward [C]. e Remove the bolts [A]. e Remove: Bolts [A] Drain Hose [B] e For the California model, remove the following. Fuel Return Hose [C] (right side, red) Fuel Tank Breather Hose [D] (left side, blue)

3-126 FUEL SYSTEM (DFI) Fuel Tank + Disconnect: Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] e Open the fuel tank cap [A] to lower the pressure in the tank. ODuring tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. e Draw the fuel out from the fuel tank with a commercially available pump [A]. OUse a soft plastic hose [B] as a pump inlet hose in order to insert the hose smoothly. OPut the hose through the fill opening [C] into the tank and draw the fuel out. Front [D] The fuel could not be removed completely from the fuel tank. Be careful for remained fuel spillage. e Be sure to place a piece of cloth [A] around the fuel hose joint [B]. e Push the joint lock claws [C]. e Pull the joint lock [A] as shown. e Pull [B] the fuel hose joint [C] out of the delivery pipe. À WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. e Close the fuel tank cap. e Remove the fuel tank, and place a it on a flat surface. ODo not apply the load to the delivery pipe of the fuel pump. Gcososssst

Fuel Tank e For the California Model, note the following. CAUTION For the California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one. OBe sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal. À WARNING For the California model, be careful not to spill the gasoline through the return hose. Spilled fuel is hazardous. xlf liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air (California model). OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. À WARNING Store the fuel tank in an area which is well -ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage. Fuel Tank Installation e Note the above WARNING (see Fuel Tank Removal). e Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). e Check that the dampers [A] and pad [B] are in place on the fuel tank as well. xlf the dampers are damaged or deteriorated, replace them. e For the California Model, note the following. OTo prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. OConnect the hoses according to the diagram of the sys- tem (see Cable, Wire, and Hose Routing section in the Appendix chapter). Make sure they do not get pinched or kinked. ORoute hoses with a minimum of bending so that the air or vapor will not be obstructed. gcrrassese €

3-128 FUEL SYSTEM (DFI) Fuel Tank e Pull the joint lock [A] as shown. e Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. e Push the joint lock [B] until the hose joint clicks. e Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn't come off. When the hose joint is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.). À WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak. xlf it does not slide, reinstall the hose joint. © Connect the fuel pump, fuel level sensor lead connectors and the battery (—) terminal (see Battery Installation in the Electrical System chapter). e For models equipped with an ABS, fit the grooves of the damper [A] on the brake pipes [B].

Fuel Tank e Fit the dampers [A] of the fuel tank into the slots [B] of the fuel tank cover [C]. Fuel Tank and Cap Inspection e Visually inspect the gasket [A] on the tank cap for any damage. xReplace the gasket if it is damaged. e Check to see if the water drain pipe [B] and fuel breather pipe [C] (California Model) in the tank are not clogged. Check the tank cap breather also. xlfthey are clogged, remove the tank and drain it, and then blow the breather free with compressed air. CAUTION Do not apply compressed air to the air vent holes [D] in the tank cap. This could cause damage and clogging of the labyrinth in the cap. Fuel Tank Cleaning À WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank. e Remove: Fuel Tank (see Fuel Tank Removal) Fuel Pump (see Fuel Pump Removal) e Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. e Draw the solvent out of the fuel tank. e Dry the tank with compressed air. e Install: Fuel Pump (see Fuel Pump Installation) Fuel Tank (see Fuel Tank Installation)

3-130 FUEL SYSTEM (DFI) Evaporative Emission Control System The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart. Parts Removal/Installation À WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. CAUTION If gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capac- ity is greatly reduced. If the canister does become contaminated, replace it with a new one. e To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. e Connect the hoses according to the diagram of the sys- tem. Make sure they do not get pinched or kinked. Hose Inspection e Refer to the Evaporative Emission Control System In- spection in the Periodic Maintenance chapter (see Evapo- rative Emission Control System Inspection in the Periodic Maintenance chapter). Separator Inspection e Refer to the Evaporative Emission Control System In- spection in the Periodic Maintenance chapter (see Evapo- rative Emission Control System Inspection in the Periodic Maintenance chapter). Separator [A]

Evaporative Emission Control System Separator Operation Test À WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. + Connect the hoses to the separator, and install the sepa- rator on the motorcycle. e Disconnect the breather hose from the separator, and in- ject about 20 mL (0.68 US oz.) of gasoline [A] into the separator [B] through the hose fitting. e Disconnect the fuel return hose [C] from the fuel tank [D]. e Run the open end of the return hose into the container and hold it level with the tank top [E]. e Start the engine, and let it idle. xlfthe gasoline in the separator comes out of the hose, the separator works well. If it does not, replace the separator with a new one. Canister Inspection e Refer to the Evaporative Emission Control System In- spection in the Periodic Maintenance chapter (see Evapo- rative Emission Control System Inspection in the Periodic Maintenance chapter). NOTE OThe canister [A] is designed to work well through the motorcycle's life without any maintenance if it is used under normal conditions.

3-132 FUEL SYSTEM (DFI) Evaporative Emission Control System Gc130248#4 € . Fuel Tank . White Hose (Vacuum) . Throttle Body Assy . Green Hose (Purge) Canister . Band (for Canister) . Red Hose (Right, Return) . Fitting . Bracket (for Separator) . Separator . Blue Hose (Breather) . Blue Hose (Left, Breather) © © HO O1 & D =

Cooling System Table of Contents Exploded View... sise Coolant Flow Chart Specifications Coolant Coolant Deterioration Inspection Coolant Level Inspectio Coolant Draining Coolant Filling Pressure Testing. Cooling System Flushing . Coolant Reserve Tank Removal/Installation Water Pump... Water Pump Removal Water Pump Installation Water Pump Impeller Inspection Radiator Radiator and Radiator Fan Remova Radiator and Radiator Fan Installation Radiator Inspection …. Radiator Cap Inspection Radiator Filler Neck Inspection. Thermostat Thermostat Remova Thermostat Installatio: Thermostat Inspection Hoses and Pipes … Hose Installation . Hose Inspection Water Temperature Sensor Water Temperature Sensor Remova Water Temperature Sensor Inspection

Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is less than 55°C (131°F), the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant temperature is more than 58 —62°C (136 —-144°F), the thermostat opens and the coolant flows. When the coolant temperature goes up beyond 95°C (203°F), the radiator fan relay conducts to op- erate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the coolant temperature is below 90°C (194°F), the fan relay opens and the radiator fan stops. In this way, this system controls the engine temperature within narrow limits where the engine op- erates most efficiently even if the engine load varies. The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank. The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 93 —123 kPa (0.95 —1.25 kgf/cm?, 13 —-18 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 93 —123 kPa (0.95 —-1.25 kgf/cm?, 13 —18 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.

Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Green Soft water 50%, coolant 50% 35°C (-31°F)

Coolant Coolant Deterioration Inspection e Visually inspect the coolant in the reserve tank. xIf whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. lf the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. xlf the coolant gives off an abnormal smell, check for a cooling system leak. lt may be caused by exhaust gas leaking into the cooling system. Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main- tenance chapter. Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter. Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter. Pressure Testing e Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). + Remove the radiator cap, and install the cooling system pressure tester [A] on the filler neck. NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks. e Build up pressure in the system carefully until the pres- sure reaches 142 kPa (1.45 kgf/cm?, 21 psi). CAUTION During pressure testing, do not exceed the pres- sure for which the system is designed. The maxi- mum pressure is 142 kPa (1.45 kgf/cm?, 21 psi). e Watch the gauge for at least 6 seconds. xlf the pressure holds steady, the system is all right. xlf the pressure drops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump. e Remove the pressure tester, replenish the coolant, and install the radiator cap. eposoitist €

Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system. e Drain the cooling system (see Coolant Change in the Pe- riodic Maintenance chapter). e Fillthe cooling system with fresh water mixed with a flush- ing compound. CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer ofthe cleaning product. e Warm up the engine, and run it at normal operating tem- perature for about ten minutes. e Stop the engine, and drain the cooling system. e Fill the system with fresh water. e Warm up the engine and drain the system. e Repeat the previous two steps once more. e Fill the system with a permanent type coolant and bleed the air from the system (see Coolant Change in the Peri- odic Maintenance chapter). Coolant Reserve Tank Removal/Installation e The coolant reserve tank is removed and installed dur- ing coolant change (see Coolant Change in the Periodic Maintenance chapter).

Water Pump Water Pump Removal e Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) e Remove: Clutch Slave Cylinder (see Clutch Slave Cylinder Re- moval in the Clutch chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) e Remove: Radiator Hose [A] Water Pump Cover Bolts [B] Water Pump Cover [C] e Remove the radiator hose [A] and the air bleeder hose [B] for the water pump body. e Remove the water pump body [C] with impeller [D]. Water Pump Installation e Turn the pump drive gear shaft so that the slot [A] in its shaft fits onto the projection [B] of the impeller shaft. e Install the radiator hose [A] and the air bleeder hose [B] for the water pump body as shown.

Water Pump Install the water pump cover [A]. e Tighten: Torque - Water Pump Cover Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb) e Install the water hose [B] as shown. Water Pump Impeller Inspection e Visually inspect the water pump impeller [A]. xlf the surface is corroded or if the blades are damaged, replace the water pump assy.

Radiator Radiator and Radiator Fan Removal e Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Reservoir Tank Hose [A] Air Bleeder Hose [B] for Thermostat Housing Radiator Hose [C] Oil Cooler Outlet Hose [D] Radiator Upper Bolt [E] e Remove: Radiator Fan Lead Connector [A] Radiator Hose [B] Radiator Lower Bolt [C] Radiator Upper Bolt [D] e Remove the radiator [E]. CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. e Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B]

Radiator Radiator and Radiator Fan Installation e Be sure that the trim seals [A] are in position on the radi- ator as shown. e Install the dampers [B], radiator bracket collars [C] and bolts as shown. Gporo46sss © Radiator Inspection e Check the radiator core. %xlf there are obstructions to air flow, remove them. xlf the corrugated fins [A] are deformed, carefully straighten them. xlf the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one. eporoio4st € CAUTION x O ok When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: w Keep the steam gun [A] away more than 0.5 m (1.6 À ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique n © [D]) to the core surface. Run the steam gun, following the core fin direction. Cd D NN | epo7azoïst €

Radiator Radiator Cap Inspection e Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap e Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. xlf any one of them shows visible damage, replace the cap with a new one. e Install the cap [A] on a cooling system pressure tester [B]. NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks. e Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and mea- sure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds. Radiator Cap Relief Pressure Standard: 93 —-123 kPa (0.95 —1.25 kgf/cm?, 13 —-18 psi) xlfthe cap can not hold the specified pressure or if it holds too much pressure, replace it with a new one. Radiator Filler Neck Inspection e Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). e Remove the radiator cap. e Check the radiator filler neck for signs of damage. e Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly. eporoissst € eporaoisst €

Thermostat Thermostat Removal e Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing Mounting Bolts [A] Radiator Hose [B] Air Bleeder Hoses [C] Thermostat Housing [D] e Remove: Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermostat Thermostat Installation e Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top. e Install a new O-ring into the housing. e Tighten the thermostat housing cover bolts and the ther- mostat housing mounting bolts. Torque - Thermostat Housing Cover Bolts: 5.9 N-m (0.60 kgf-m, 52 in-lb) Thermostat Housing Mounting Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb) e Fill the radiator with coolant (see Coolant Change in the Periodic Maintenance chapter). Thermostat Inspection e Remove the thermostat, and inspect the thermostat valve [A] at room temperature. xlf the valve is open, replace the thermostat with a new one.

Thermostat e To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. OThe thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth. It must not touch the container, either. xlf the measurement is out of the specified range, replace the thermostat with a new one. Thermostat Valve Opening Temperature 58 —62°C (136 —-144°F) eDosozo2s2 ©

Hoses and Pipes Hose Installation Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. e Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). e Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting. This will prevent the hoses from working loose. OThe clamp screws should be positioned correctly to pre- vent the clamps from contacting the other parts. Torque - Radiator Hose Clamp Screws: 2.0 N-m (0.20 kgf-m, 18 in-lb) Hose Inspection e Refer to the Radiator Hose and Connection Inspection in the Periodic Maintenance chapter. eptogzoïst €

Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water Temperature Sensor Removal e Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter. Water Temperature Sensor [A] Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.

Exploded View GE022548#5 ©

Full: Full Power H: Honeycomb Type Catalyst 78.2: Hosepower 78.2 KW (106.3 ps) Manifold Mark Position [A]

Exhaust System Silencer Mark Position [A] Honeycomb Type Catalyst [A] GEXOISS 6

23.940 —23.962 mm (0.9425 —0.9434 in.)

24.000 —24.021 mm (0.9449 —0.9457 in.)

TIR 0.02 mm (0.0008 in.) or less

0.17 mm (0.0067 in.)

23.91 mm (0.941 in.)

24.08 mm (0.948 in.)

TIR 0.1 mm (0.004 in.) Cylinder Head Cylinder Compression Cylinder Head Warp (Usable Range) 1 030 —1 569 kPa (10.5 —16.0 kgf/cm?, 149 —228 psi) @300 r/min (rpm)

38.72 mm (1.524 in.)

Clean Air System Air Suction Valve Removal e Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) e Pull out the hoses [AI]. e Disconnect the connector [B]. e Remove the air switching valve [C] with the hoses. e Remove the following from the bracket [A]. Rivets [B] Bolts [C] e Remove: Air Suction Valve Cover Bolts [A] Air Suction Valve Cover [B] Air Suction Valve [C] Air Suction Valve Installation e Install the air suction valve so that opening [A] of the reed faces the rear and downward. e Apply a non-permanent locking agent to the threads of the air suction valve cover bolts, and tighten them with the specified torque. Torque - Air Suction Valve Cover Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb) Geo4ossess

Clean Air System Aïir Suction Valve Inspection e Remove the air suction valve (see Air Suction Valve Re- moval). e Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. x lfthere is any doubt as to the condition of the reed, replace the air suction valve as an assembly. e Check the reed contact areas [B] of the valve holder for grooves, scratches, any sings of separation from the holder, or heat damage. xlfthere is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly. e If any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly with a high flash-point solvent. CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly. Air Switching Valve Removal e Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Connector [A] Air Switching Valve [B] CAUTION Never drop the switch especially on a hard surface. Such a shock to the switch can damage it. Aïir Switching Valve Installation e Install the air switching valve so that the air duct [A] faces left side. e Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Air Switching Valve Operation Test e Refer to the Air Switching Valve Operation Test in the Electrical System chapter. Air Switching Valve Unit Test e Refer to the Air Switching Valve Unit Test in the Electrical System chapter. Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers. xlf they are not, correct them. Replace them if they are damaged.

Cylinder Head Cover Cylinder Head Cover Removal e Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Air Switching Valve (see Air Switching Valve Removal) e Free the heat insulation rubber plate. e Remove: Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chap- ter) Air Suction Valve Covers (see Air Suction Valve Re- moval) + Remove the cylinder head cover bolts [A]. e Remove the cylinder head cover to backward floating it a little up. Cylinder Head Cover Installation e Replace the head cover gasket with a new one. e Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 e Install: Dovwel Pins [A] Plug Hole Gaskets [B] Geoso4sess GEoso47ess € Geoso4sess €

Cylinder Head Cover e Install the washer [A] with the metal side faces upward. e Tighten the cover bolts, following the sequence numbers on the cover. Torque - Cylinder Head Cover Bolts [B]: 9.8 N-m (1.0 kgf-m, 87 in-lb) e Install the removed parts (see appropriate chapters). GEoso4onss €

Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. e Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). e Remove the mounting bolts [A] and take off the camshaîñt chain tensioner [B]. Camshaft Chain Tensioner Installation e Remove the cylinder head cover (see Cylinder Head Cover Removal). e Pinching [A] the stopper [B], release it and push [C] the push rod [D] into the interior of tensioner body [E]. e Pushing [A] the push rod, slide the snap ring [B] into the groove [C] of smaller diameter from the groove [D] of larger diameter. e Install the tensioner body so that the stopper [A] faces upward. e Tighten the tensioner mounting bolts. Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb)

Camshaft Chain Tensioner e Lightly hit the push rod head [A] with a minus screw driver [B] to move out the push rod. NOTE OYou hear of the sound from which the push rod moves out. e Turn the crankshaft 2 turns clockwise to allow the ten- sioner to expand and recheck the camshaft chain timing.

Camshaft, Camshaft Chain Camshaft Removal e Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover e Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (crankcase halves mating surface) [B] e Remove: Camshaft Chain Tensioner (see Camshaft Chain Ten- sioner Removal) Camshaft Cap Bolts [A] Chain Guide Camshaft Caps [B] Camshafts [C] e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase. e Remove the cam sprocket mounting bolts [A]. e Remove the cam sprocket. CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket. Camshaft Installation «Be sure to install the following parts. Plug Hole Gaskets [A] Dovwel Pins [B] e Install the cam sprockets as shown in figure. #4 Cam Positions [A] Inlet Cam Sprocket [B] Exhaust Cam Sprocket [C] e Apply a non-permanent locking agent to the threads and tighten the bolts. Torque - Cam Sprocket Mounting Bolts: 15 N-m (1.5 kgf-m, 11 ftb) Gertieonss € Gestioress €

Camshaft, Camshaft Chain e Apply engine oil to all cam parts and journals. e Ifanew camshaftis to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces. NOTE OThe exhaust camshaft has a 1090 EX mark [A] and the inlet camshaft has a 1090 IN mark [B]. Be careful not to mix up these shafts. NOTE OThe exhaust camshaft has the projection [A] for camshaft position sensor. e Position the crankshaft at #1, 4 piston TDC. e Pull the tension side (exhaust side) [A] of the chain taut to install the chain. e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown. OThe timing marks of #1, 4T must be aligned with the lower surface of crankcase of rear side [B]. Gestie2ess € Gestiosess

Camshaft, Camshaft Chain OThe timing marks must be aligned with the cylinder head upper surface [A]. EX mark [B] IN mark [C] GErttoase? ©

Camshaft, Camshaft Chain e Install the camshaft cap, following the identification No. [A] and chain guide [B]. OfFirst tighten the camshaft cap and all chain guide bolts evenly to seat the camshaft in place, then tighten all bolts following the specified tightening sequence. Torque - Camshaft Cap Bolts (1 —16, 17, 18): 12 N-m (1.2 kgf-m, 106 in-Ib) Camshaft Chain Guide Bolts (19, 20): 12 N-m (1.2 kgf-m, 106 in-Ib) e Install the camshaîft chain tensioner (see Camshaft Chain Tensioner Installation).

Camshaft, Camshaft Chain xlf any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.940 —23.962 mm (0.9425 —0.9434 in.) Service Limit: 23.91 mm (0.941 in.) xlf the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again. xlf the clearance still remains out of the limit, replace the cylinder head unit. Camshaft Runout e Remove the camshaft (see Camshaft Removal). e Set the camshaft in a camshaft alignment jig or on V blocks. e Measure runout with a dial gauge at the specified place as shown. xlf the runout exceeds the service limit, replace the shaft. Camshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.1 mm (0.004 in.) Cam Wear e Remove the camshaft (see Camshaft Removal). e Measure the height [A] of each cam with a micrometer. xlfthe cams are worn down past the service limit, replace the camshaft. Cam Height Standard: Exhaust 34.442 —34.556 mm (1.3560 —1.3605 in.) Inlet 34.943 —-35.057 mm (1.3757 —-1.3802 in.) Service Limit: Exhaust 34.34 mm (1.352 in.) Inlet 34.84 mm (1.372 in.) Camshaft Chain Removal e Remove: Camshafts (see Camshaft Removal) Timing Rotor [A] (see Timing Rotor Removal in the Elec- trical System chapter) Front Camshaft Chain Guide Bolts [B] Front Camshaft Chain Guide [C] Dovwel Pin [D] Rear Camshaft Chain Guide [E] Getiosonst € Getioiz2st €

Camshaft, Camshaft Chain e Remove the crankshaft sprocket [A]. e Pull out the camshaft chain [B] from downward. Camshaft Chain Installation e Install the camshaft chain from head side. e Install the crankshaft sprocket [A] on the crankshaft [B] With their teeth [C] aligned. e Install the front camshaft chain guide, and tighten the bolts. Torque - Front Camshaft Chain Guide Bolt (Upper): 25 N-m (2.5 kgf-m, 18 ft:lb) Front Camshaft Chain Guide Bolt (Lower): 12 N-m (12 kgf-m, 106 in-lb) e Install the removed parts (see appropriate chapters). Getiosesst ce

Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged. e Warm up the engine thoroughly. e Stop the engine. e Remove: Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chap- ter) Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter) Owner’s Tool - Spark Plug Wrench: 92110-1132 e Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole. OUsing the starter motor, turn the engine over with the throt- tle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. Special Tools - Compression Gauge, 20 kgf/cm2: 57001-221 Compression Gauge Adapter, M10 x 1.0: 57001-1601 L-Shape Hose: 57001-1606 [C] Cylinder Compression Usable Range: 1 030 —1 569 kPa (10.5 —-16.0 kgf/cm?, 149 —228 psi) @300 r/min (rpm) e Repeat the measurement for the other cylinders. e Install the spark plugs. Torque - Spark Plugs: 13 N-m (1.3 kgf-m, 115 in-lb) The following table should be consulted if the obtainable able range. compression reading is not within the us- Problem Diagnosis Remedy (Action) Cylinder Carbon accumulation on piston and in Remove the carbon deposits and compression |combustion chamber possibly due to replace damaged parts if necessary. is higher than usable range damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke). Incorrect cylinder head gasket thickness Replace the gasket with a standard part. Cylinder Gas leakage around cylinder head Replace damaged check gasket and compression cylinder head warp. is lower than Bad condition of valve seating Repair if necessary. usable range incorrect valve clearance Adjust the valve clearance. incorrect piston/cylinder clearance Replace the piston and/or cylinder. Piston seizure Inspect the cylinder and replace/repair the cylinder and/or piston as necessary. Bad condition of piston ring and/or piston ring grooves Replace the piston and/or the piston rings.

Cylinder Head Cylinder Head Removal e Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Front Camshaft Chain Guide Rear Camshaft Chain Guide e Remove: Front Engine Mounting Bolts [A] Engine Bracket Mounting Bolts [B] Engine Brackets [C] e Remove the M6 cylinder head bolts [B], and then the M11 cylinder head bolts [A]. e Take off the cylinder head. Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. e Install a new cylinder head gasket and dowel pins. e Replace the cylinder head bolt washers with new ones. e Apply molybdenum disulfide oil solution to both sides [A] of the cylinder head bolt washers [B] and the thread of head bolts [C]. Geraoesess € Getaoz7ast €

Cylinder Head e Tighten the M11 cylinder head bolts following the tighten- ing sequence [1 —10]. Torque - Cylinder Head Bolts (M11): First: 39 N-m (4.0 kgf-m, 29 ft-lb) Final: 71 N:m (7.2 kgf-m, 52 ft:lb) e Tighten the M6 cylinder head bolts [11 —12]. Torque - Cylinder Head Bolts (M6): 12 N-m (1.2 kgf-m, 106 in-lb) e Install: Dovwel Pin [A] Rear Camshaft Chain Guide [B] Front Camshaft Chain Guide [C] ©-ring [D] Collar [E] e Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [F]: 25 N-m (2.5 kgf-m, 18 ft-Ib) Front Camshaft Chain Guide Bolt (Lower) [G]: 12 N-m (1.2 kgf-m, 106 in-lb) e Replace the following bolts with new bolts pre-coated with locking agent and torque them. Engine Bracket Bolts Front Engine Mounting Bolts Subframe Bolts Torque - Front Bracket Bolts: 25 N-m (2.5 kgf-m, 18 ft-Ib) Front Engine Mounting Bolts: 59 N-m (6.0 kgf-m, 44 ft-lb) Subframe Bolts: 23 N-m (2.3 kgf-m, 17 ft:Ib) e Install the removed parts (see appropriate chapters). Cylinder Head Warp e Clean the cylinder head. e Lay a straightedge across the lower surface ofthe cylinder head at several positions. e Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp Standard: ——- Service Limit: 0.05 mm (0.002 in.) xlfthe cylinder head is warped more than the service limit, replace it. xlf the cylinder head is warped less than the service limit, repair the head by rubbing the lower surface on emery paper secured to a surface plate (first No. 200, then No. 400). ceraoe7ast € GEraogeps2 € Getaosnst

Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal e Remove the cylinder head (see Cylinder Head Removal). e Remove the valve lifter and shim. OMark and record the valve lifter and shim locations so they can be installed in their original positions. e Using the valve spring compressor assembly, remove the valve. Special Tools - Valve Spring Compressor Assembly: 57001 -241 [A] Adapter, #24: 57001-1586 [B] Valve Installation CAUTION Do not lap the exhaust valve to the exhaust valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. e Replace the oil seal with a new one. e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation. e Install the springs so that the closed coil end faces down- wards. Valve Stem [A] Oil Seal [B] Spring Seat [C] Closed Coil End [D] Valve Spring [E]: EX-White Paint IN-Red Paint Retainer [F] Split Keepers [G] Valve Guide Removal e Remove: Valve (see Valve Removal) Oil Seal Spring Seat e Heat the area around the valve guide to 120 —150°C (248 —302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. CAUTION Getsoussst e AC)

Getsozsast ce Getsousast ce Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head in oil and heat the oil. Special Tool - Valve Guide Arbor, 65: 57001-1203

Valves Valve Guide Installation e Apply oil to the valve guide outer surface before installa- tion. e Heat the area around the valve guide hole to about 120 — 150°C (248 —302°F). CAUTION Do not heat the cylinder head with a torch. This Will warp the cylinder head. Soak the cylinder head and heat the oil. e Assembly the valve guide driver parts (Holder and attach- ment E). e Insert the rod of the driver into the valve guide bore and hammer the end of the driver until it bottoms. Valve Guide Driver Attachment E [A] Valve Guide Driver (Holder) [B] Valve Guide [C] Cylinder Head [D] Valve Guide installed Height = 13 mm [E] Special Tools - Valve Guide Driver: 57001-1564 Valve Guide Driver Attachment, E: 57001

Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. e Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. e Move the stem back and forth [C] to measure valve/valve guide clearance. + Repeat the measurement in a direction at a right angle to the first. xlfthe reading exceeds the service limit, replace the guide. NOTE OThe reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: Exhaust 0.10 —0.18 mm (0.0039 —0.0071 in.) Inlet 0.03 —-0.12 mm (0.0012 —0.0047 in.) Service Limit: Exhaust 0.39 mm (0.015 in.) Inlet 0.33 mm (0.013 in.) GEtsoo7Bs2 ©

Valves Valve Seat Inspection e Remove the valve (see Valve Removal). @ e Check the valve seating surface [A] between the valve [B] se and valve seat [C]. Z Z OMeasure the outside diameter [D] of the seating pattern rl E on the valve seat. xlfthe outside diameter is too large or too small, repair the seat (see Seat Repair). Valve Seating Surface Outside Diameter Standard: Exhaust 27.6 —-27.8 mm (1.087 —1.094 i

Inlet 32.6 —32.8 mm (1.283 —1.291 in.) OMeasure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper. Good [F] xlf the width is too wide [G], too narrow [H] or uneven [U], repair the seat (see Valve Seat Repair). Valve Seating Surface Width GEioirs2 Standard: Exhaust 0.8 —1.2 mm (0.031 —0.047 in.) Inlet 0.5 —1.0 mm (0.020 —0.039 in.) Valve Seat Repair e Repair the valve seat with the valve seat cutters [A]. Special Tools - Valve Seat Cutter Holder, 65: 57001-1208 valve Seat Cutter Holder Bar: 57001-1128 [c] For Exhaust Valve Seat Valve Seat Cutter, 45° - 630: 57001-1187 Valve Seat Cutter, 32° - 630: 57001-1120 Valve Seat Cutter, 60° - 630: 57001-1123 For Inlet Valve Seat Valve Seat Cutter, 45° - 635: 57001-1116 Valve Seat Cutter, 32° - 635: 57001-1121 Valve Seat Cutter, 60° - 633: 57001-1334 xlf the manufacturer's instructions are not available, use the following procedure. Getsogssst ce

Valves Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve for

repair. Therefore the cutter must not be used for other purposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the dia-

mond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutter

before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil. NOTE ODo not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate

the cutter in one hand. Do not apply too much force to the diamond portion. NOTE OPrior to grinding, apply engine oil to the cutter and dur- ing the operation, wash off any ground particles sticking to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layer

of engine oil before storing. Marks Stamped on the Cutter The marks stamped on the back ofthe cutter [A] represent the following. 60° . p37.5 . Cutter angle [B] . Outer diameter of cutter [C] Operating Procedures e Clean the seat area carefully. © Coat the seat with machinist's dye. e Fit a 45° cutter into the holder and slide it into the valve guide. e Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth. CAUTION Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylin- der head must be replaced. getsorisst €

Valves e Measure the outside diameter of the seating surface with a vernier caliper. xlf the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened Width [A] of engagement by machining with 45° cutter Ground Volume [B] by 32° cutter 32° [C] Correct Width [D] Ground Volume [E] by 60° cutter 60° [F] e Measure the outside diameter of the seating surface with a vernier caliper. xlf the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range. Original Seating Surface [B] NOTE ORemove all pittings of flaws from 45° ground surface. OAfter grinding with 45° cutter, apply thin coat of machin- ist's dye to seating surface. This makes seating surface distinct and 32° and 60° grinding operation easier. OWhen the valve guide is replaced, be sure to grind with 45° cutter for centering and good contact. xlf the outside diameter [A] of the seating surface is too large, make the 32° grind described below. xlfthe outside diameter of the seating surface is within the specified range, measure the seat width as described be- low. e Grind the seat at a 32° angle [B] until the seat O.D. is Within the specified range. OTo make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. OTurn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. CAUTION The 32° cutter removes material very quickly. Check the seat outside diameter frequently to pre- vent overgrinding. OAfter making the 32° grind, return to the seat O.D. mea- surement step above. e To measure the seat width, use a vernier caliper to mea- sure the width of the 45° angle portion of the seat at sev- eral places around the seat. xIf the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat O.D. measurement step above. Getsorisst ce getsoizist € ® Getsoiz2st €

Valves xlf the seat width is too wide, make the 60° [A] grind de- scribed below. xlfthe seat width is within the specified range, lap the valve to the seat as described below. e Grind the seat at a 60° angle until the seat width is within the specified range. OTo make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide. OTurn the holder, while pressing down lightly. OAfter making the 60° grind, return to the seat width mea- surement step above. Correct Width [B] CAUTION Do not lap the exhaust valve to the exhaust valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. e Lap the inlet valve to the inlet valve seat, once the seat width and O.D. are within the ranges specified above. OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head. OSpin the valve against the seat until the grinding com- pound produces a smooth, matched surface on both the seat and the valve. ORepeat the process with a fine grinding compound. Lapper [A] Valve Seat [B] Valve [C] e The seating area should be marked about in the middle of the valve face. xlfthe seat area is not in the right place on the valve, check to be sure the valve is the correct part. Ifitis, it may have been refaced too much; replace it. e Be sure to remove all grinding compound before assem- bly. e When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter). Getsoizast € Getsoizost €

Valves Valve Seat Repair START Ÿ Machinist's dye on seat 45° Grind Tool : 45° Cutter Purpose : make seating area smooth and round. Measure Seating Area O.D. Tool : Vernier Caliper Purpose : check seat O.D. against spec. Requis Too small OK Too big Machinist's dye 45° Grind on seat Tool : 45° Cutter Purpose: increase O.D. of pe seat area to spec. 32° Grind Tool : 32° Cutter _]T — Purpose : reduce O.D. of Measure Seating Width seat area to spec. Tool : Vernier Caliper Purpose : check seat width against spec. Results Too narrow ok Too wide 45° Grind Mechnists dye Tool : 45° Cutter Purpose : increase width of seat area beyond spec. to es increase O.D. 60° Grind Tool : 60° Cutter Purpose : reduce seat Lap Valve width to spec. Tool : Valve Lapper, Grinding Compound Purpose : perfectiy match inlet valve and inlet valve Ç FINISHED D) seat are; check valve head for damage. GE1SOGB

Throttle Body Holder Throttle Body Holder Installation e Be sure to install the O-rings [A]. e Install the clamps [B] as shown. e Tighten the holder bolts following the tightening sequence [1 —3]. Torque - Throttle Body Holder Bolts [C]: 9.8 N-m (1.0 kgf-m, 87 in-lb) Throttle Body Assy Holder Clamp Bolts [D]: 2.0 N:m (0.20 kgf-m, 18 in-Ib) GEraogops2 €

Muffler To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal/Installation e Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Rear Fairing (see Rear Fairing Removal in the Frame chapter) Muffler Clamp Bolts [A] Muffler Mounting Bolts and Nuts [B] e Pull the muffler body [C] backward. GEtgo4oë#2 © e Replace the muffler gaskets [A] with new ones. Olnstall the gaskets until they are bottomed [B]. Olnstall the gaskets so that their chamfer sides [C] face the front. Geieosonss

Muffler e Align [A] the projections on the muffler bodies with the hoses on the muffler clamps. e Tighten: Torque - Muffler Body Mounting Bolts: 34 N-m (3.5 kgf-m, 25 ftlb) Exhaust Pipe Removal e Remove: Radiator (see Radiator Removal in the Cooling System chapter) Right and Left Muffler Body (see Muffler Body Re- moval/Installation) e Remove the exhaust pipe manifold holder nuts [A]. e Remove the exhaust pipe manifold [B]. Exhaust Pipe Installation e Replace the exhaust pipe gaskets [A], muffler gasket with new ones and install them. Olnstall the muffler gasket until it is bottomed so that the chamfer side faces front (see Muffler Body Removal/In- stallation). e Tighten: Torque - Muffler Body Mounting Bolts: 34 N-m (3.5 kgf-m, 25 ftlb) Geieosiess € Geieos2ess €

CLUTCH 6-1 Clutch Table of Contents Exploded View. Specifications Special Tools and Sealan Clutch Master Cylinder … Clutch Lever Adjustmen Clutch Master Cylinder Removal Clutch Master Cylinder Installation . Clutch Master Cylinder Disassembly . Clutch Master Cylinder Assembly. Clutch Master Cylinder Inspection Clutch Slave Cylinder Clutch Slave Cylinder Removal Clutch Slave Cylinder Installation . Clutch Slave Cylinder Disassembly Clutch Slave Cylinder Assembly Clutch Fluid Clutch Fluid Level Inspection. Clutch Fluid Change Bleeding the Clutch Line Clutch Hose Removal/Installation . Clutch Hose and Connection Inspection Clutch Cover... Clutch Cover Remova Clutch Cover Installation Clutch Removal... Clutch Installation Clutch Plate Assembly Inspection. Clutch Plate Assembly Adjustment Clutch Plate, Wear, Damage Inspection Clutch Plate Warp Inspection me Clutch Spring Free Length Measurement...

6-2 CLUTCH Exploded View

0.15 mm (0.005 in.) or less

0.2 mm (0.008 in.) or less

6-6 CLUTCH Clutch Master Cylinder Clutch Lever Adjustment OThe adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operators hand. e Push the lever forward and turn the adjuster [A] to align the number with the triangular mark [B] on the lever holder (front view). OThe distance from the grip to the lever is minimum at Num- ber 5 and maximum at Number 1. Clutch Master Cylinder Removal e Disconnect the starter lockout switch connector [A] (rear view). e Drain the clutch fluid from the reservoir (see Clutch Fluid Change in the Periodic Maintenance chapter). e Remove: Bracket Bolt [A] Clutch Reservoir Bolt [B] + Remove the banjo bolt [C] to disconnect the clutch hose from the master cylinder (rear view). e Unscrew the clamp bolts [D], and take off the master cylin- der as an assembly with the clutch reservoir, clutch lever, and starter lockout switch installed. CAUTION Clutch fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately. Clutch Master Cylinder Installation e Align the punch mark [A] on the handlebar with the mating surface [B] of the master cylinder clamp (left view). Front [C]

CLUTCH 6-7 Clutch Master Cylinder e Install the master cylinder clamp with the triangular mark [A] up. e Tighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. There will be a gap at the lower part of the clamp after tightening. Torque - Clutch Master Cylinder Clamp Bolts: 8.8 N-m (0.90 kgf-m, 78 in-lb) e Use a new flat washer on each side of the clutch hose fitting. Torque - Clutch Hose Banjo Bolt: 25 N-m (2.5 kgf-m, 18 ft-1b) e Replenish the clutch fluid into the reservoir and bleed the clutch line (See Bleeding the Clutch Line in this chapter). e Check that the clutch line has proper fluid pressure and no fluid leakage. Clutch Master Cylinder Disassembly e Refer to the Clutch Master Cylinder Cap and Dust Seal Replacement in the Periodic Maintenance chapter. Clutch Master Cylinder Assembly e Refer to the Clutch Master Cylinder Cap and Dust Seal Replacement in the Periodic Maintenance chapter. Clutch Master Cylinder Inspection e Disassemble the clutch master cylinder (see Clutch Mas- ter Cylinder Cap and Dust Seal Replacement in the Peri- odic Maintenance chapter). Special Tool - Inside Circlip Pliers: 57001-143 e Check that there are no scratches, rust or pitting on the inside of the master cylinder [A] and on the outside of the piston [B]. xlf the master cylinder or piston shows any damage, re- place them. e Inspect the primary cup [C] and secondary cup [D]. xIf a cup is worn, damaged, softened (rotted), or swollen, the piston assembly should be replaced to renew the cup. e If fluid leakage is noted at the clutch lever, the piston as- sembly should be replaced to renew the cup. e Check the dust cover [E] for damage. elfitis damaged, replace the piston assembly. e Check that the relief [F] and supply [G] ports are not plugged. xlf the small relief port becomes plugged, the clutch will drag. Blow the ports clean with compressed air. e Check the piston return spring [H] for any damage. xlf the spring is damaged, replace it.

6-8 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal e Remove: Left Lower Fairing (see Lower Fairing Removal Frame chapter) Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. e Pull off the clutch pipe [A] by prying the dampers [B] out of the grooves of the frame. This prevents the pipe from distorting. e Perform the following if the clutch slave cylinder is to be removed but not disassembled. CAUTION If the clutch slave cylinder is removed and left alone, the piston will be pushed out by spring force and the clutch fluid will drain out. ORemove the clutch slave cylinder from the engine with the pipe installed. Push [A] the piston into the cylinder as far as it will go. OApply the clutch lever [A] slowly and hold it with a band [B]. NOTE O©Holding the clutch lever keeps the piston from coming out. DA Le ertooioïst €

CLUTCH 6-9 Clutch Slave Cylinder Clutch Slave Cylinder Installation e Apply molybdenum disulfide grease to either end [A] of the push rod, and install the push rod so that the greased end faces in. e Replace the spacer [B] of the clutch slave cylinder with a new one. e Install the spacer so that the stepped side [C] faces out- ward. e Apply a non-permanent locking agent to the threads of the slave cylinder bolts [A]. e Finger tighten all the clutch slave cylinder bolts. e Remove the band from the clutch lever and release the clutch lever. e Tighten the slave cylinder bolts. e Replace the washer on each side of the clutch hose fitting with new one. e Tighten the banjo bolt [B] to the specified torque. Torque - Clutch Pipe Banjo Bolt: 25 N-m (2.5 kgf-m, 18 ft:Ib) e Check the fluid level in the master cylinder reservoir, and bleed the air in the clutch line. e Check the clutch operation. e Install the removed parts. Coolant Reserve Tank Left Lower Fairing (see Lower Fairing Installation in the Frame chapter) Clutch Slave Cylinder Disassembly e Refer to Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement in the Periodic Maintenance chap- ter. Clutch Slave Cylinder Assembly e Refer to Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement in the Periodic Maintenance chap- ter.

6-10 CLUTCH Clutch Fluid Clutch Fluid Level Inspection e Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter. Clutch Fluid Change e Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter. Bleeding the Clutch Line À WARNING Be sure to bleed the air from the clutch line when- ever clutch lever action feels soft or spongy after the clutch fluid is changed, or whenever a clutch line fitting has been loosened for any reason. CAUTION Clutch fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. e Remove: Screw [A] Clamp [B] Clutch Reservoir Cap [C] Diaphragm Plate Diaphragm e Fill the reservoir with fresh clutch fluid to the upper level line in the reservoir. NOTE OTap the clutch hose lightly going from the lower end to upper end and bleed the air off the reservoir. e With the reservoir cap off, slowly pump the clutch lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser- voir. OBleed the air completely from the master cylinder by this operation. e Remove the rubber cap from the bleed valve on the mas- ter cylinder. e Attach a clear plastic hose [A] to the bleed valve, and run the other end of the hose into a container.

CLUTCH 6-11 Clutch Fluid e Bleed the clutch line and the master cylinder. ORepeat this operation until no more air can be seen com- ing out into the plastic hose.

1. Pump the clutch lever until it becomes hard, and apply

the clutch lever and hold it [C].

2. Quickly open and close [B] the bleed valve while hold-

ing the clutch lever applied.

3. Release the clutch lever [A].

NOTE OThe fluid level must be checked often during the bleed- ing operation and replenished with fresh clutch fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. e Remove the clear plastic hose. e Tighten the bleed valve, and install the rubber cap. Torque - Clutch Master Cylinder Bleed Valve: 7.8 N-m (0.80 kgf-m, 69 in-Ib) e Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). + Remove the rubber cap from the bleed valve. e Attach a clear plastic hose [A] to the bleed valve on the clutch slave cylinder, and run the other end of the hose into a container. e Bleed the clutch line as follows: ORepeat this operation until no more air can be seen com- ing out into the plastic hose.

1. Pump the clutch lever a few times until it becomes hard

and then hold it applied [D].

2. Quickly open and close [C] the bleed valve.

3. Release the clutch lever [B].

NOTE OCheck the fluid level in the reservoir often, replenishing it as necessary. Offthe fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have en- tered the line. Do not mix different grades and brands of fluid. e Remove the clear plastic hose. Torque - Clutch Slave Cylinder Bleed Valve: 7.8 N-m (0.80 kgf-m, 69 in-Ib) Clutch Hose Removal/Installation e Refer to the Clutch Hose and Pipe Replacement in the Periodic Maintenance chapter. Clutch Hose and Connection Inspection e Refer to the Clutch Hose Damage and Installation Con- nection Inspection in the Periodic Maintenance chapter.

6-12 CLUTCH Clutch Cover Clutch Cover Removal e Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cover Bolts [A] Clutch Cover [B] Clutch Cover Installation e Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 e Replace the clutch cover gasket with a new one. e Tighten the clutch cover mounting bolts. OApply a non-permanent locking agent to only one clutch cover mounting bolt [A] shown in figure. Torque - Clutch Cover Mounting Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb) e lfthe oil gauge [A] is removed, press the gauge so that its projection [B] faces the inside, using lubricant. eFrioo2ess €

CLUTCH 6-13 Clutch Clutch Removal e Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing, pusher [C] and washer) e Remove: Friction Plates [A] Steel Plates Spring Spring Seat OCHolding the clutch hub [A], remove the nut [B] and wash- ers [C] Special Tool - Clutch Holder: 57001-1243 [D] e Remove: Clutch Hub Washer e Insert the clutch gear setting screw to the hole of the clutch housing (see Clutch Installation). OPosition the hole of the clutch housing at the front side of the engine so that the tip of the gear setting does not hit the crankcase wall. OAlign the teeth of the clutch housing gears by the gear setting. Special Tool - Clutch Gear Setting Screw: 57001-1671 e Pull out the sleeve [B] from the clutch housing [D], and remove the housing. Off the sleeve does not pull out easily, insert M4 bolts [A] into the threaded hole of the sleeve, and pull out the sleeve and needle bearing [C]. e Remove the thrust washer.

6-14 CLUTCH Clutch Clutch Installation e Install the thrust washer [A] by facing its chamfered side [B] towards the crankcase. e Align the teeth of the clutch housing gears by the gear setting screw [A]. Olnstall the clutch housing so that the hole position forward of the engine. Special Tool - Clutch Gear Setting Screw: 57001-1671 e Install: Clutch Housing Needle Bearing Sleeve Washer [A] OApply engine oil to the needle bearing and the sleeve be- fore installation. e Install the clutch hub and two washers [A]. OThe outside washer has the OUT SIDE mark [B]. e Replace the clutch hub nut with a new one. e Holding the clutch hub, tighten the clutch hub nut with the torque wrench. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 135 N-m (14 kgf-m, 100 ft-Ib)

CLUTCH 6-15 Clutch e Install the spring seat [A], spring [B], friction plates [C] [D] [E] and steel plates [F] as shown. NOTE OThe inside diameter of first friction plates are larger than the others because the spring seat and spring are equipped to decrease the judder noise as shown. Clutch Hub [G] CAUTION If new dry friction plates and steel plates are in- stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. Olnstall outer-end friction plate, that has the large lining blocks [A] among others. Olnstall the last friction plate [A] fitting the tangs in the grooves in the housing as shown. e Apply molybdenum disulfide grease [M] to the outside sur- face of the pusher [A], then install the pusher into the drive shaft. e Install the spring, and tighten the clutch spring bolts evenly. Torque - Clutch Spring Bolts: 8.8 N-m (0.90 kgf-m, 78 in-lb) e Install the clutch cover (see Clutch Cover Installation).

6-16 CLUTCH Clutch Clutch Plate Assembly Inspection e Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). e Measure the length [A] of the clutch plate assembly as shown. OAssemble: Clutch Hub [B] Spring Seat [C] Spring [D] Friction Plates [E] [F] [G] Steel Plates [H] Spring Plate [] Springs [K] Spring Bolts [L] Torque - Clutch Spring Bolts: 8.8 N-m (0.90 kgf-m, 78 in-lb) Clutch Plate Assembly Length Standard: 53.52 —54.52 mm (2.11 -2.15 in.) xlf the length is not within the specified range, adjust the length (see Clutch Plate Assembly Adjustment). Clutch Plate Assembly Adjustment e Inspect the clutch plate assembly length, and then re- place the steel plate(s) which brings the length within the specified range. ORemove: Spring Bolts Springs Spring Plate Clutch Plates OReplace the following steel plate(s). Part No. Thickness 13089-0019 2.3 mm (0.091 in.) 13089-0018 2.6 mm (0.102 in.) (STD) 13089-0020 2.9 mm (0.114 in.) NOTE ODo not use the steel plate of 2.9 mm (0.114 in.) and 2.3 mm (0.091 in.) thickness at the same time. e Install the removed parts, and inspect the clutch plate as- sembly length. Torque - Clutch Spring Bolts: 8.8 N-m (0.90 kgf-m, 78 in-lb) ébbe eFrioo6ps2 €

CLUTCH 6-17 Clutch Clutch Plate, Wear, Damage Inspection e Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. e Measure the thickness of each friction plate [A] at several points. xlf any plates show signs of damage, or if they have worn past the service limit, replace them with new ones. Friction Plate Thickness (13088-0030, 13088-0031) Standard: 2.92 —3.08 mm (0.115 —-0.121 in.) Service Limit: 2.7 mm (0.106 in.) Friction Plate Thickness (13088-0032) Standard: 3.72 —3.88 mm (0.146 —-0.153 in.) Service Limit: 3.5 mm (0.138 in.) Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. xlfany plate is warped over the service limit, replace it with a new one. Friction and Steel Plate Warp Standard: 0.15 mm (0.0059 in.) or less Service Limit: 0.3 mm (0.012 in.) Friction Plate Warp (only 13088-0030) Standard: 0.2 mm (0.008 in.) or less Service Limit: 0.3 mm (0.012 in.) Clutch Spring Free Length Measurement e Measure the free length of the clutch springs [A]. xlf any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 65.0 mm (2.56 in.) Service Limit: 62.0 mm (2.44 in.) GF0gogozst c

Engine Lubrication System Table of Contents Exploded View Engine Oil Flow Chart Specifications Special Tools and Sealant Engine Oil and Oil Filter. Oil Level Inspection. Engine Oil Change... Oil Filter Replacement Oil Pan Oil Pan Removal.. Oil Pan Installation Oil Pressure Relief Valv Oil Pressure Relief Valve Removal Oil Pressure Relief Valve Installation . Oil Pressure Relief Valve Inspectio Oil Pump Oil Pump Removal... Oil Pump Installation Oil Cooler... Oil Cooler Removal. Oil Cooler Installatio Oil Pressure Measuremen Oil Pressure Measurement Oil Pressure Switch Oil Pressure Switch Removal Oil Pressure Switch Installation

Engine Oil Flow Chart Camshaft Oil Passage Exhaust Camshaft Camshaft Crankshaft Oil Passage —— Main Oil Passage Oil Cooler Oil Pressure Switch Relief Valve Oil Screen Breather Hose "5 for Return Oil Pipe

3.7 L (3.9 US gt) (when filter is not removed)

4.1 L (4.3 US gt) (when filter is removed)

4.5 L (4.8 US gt) (when engine is completely dry)

Engine Oil and Oil Filter Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection © Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge. NOTE OSituate the motorcycle so that it is perpendicular to the ground. Olfthe motorcycle has just been used, wait several min- utes for all the oil to drain down. OIf the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles. CAUTION Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause. Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte- nance chapter. Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main- tenance chapter. Gcosoiosst ce

Oil Pan Oil Pan Removal e Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Muffler Bodies (see Muffler Body Removal/Installation in the Engine Top End chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) e Disconnect the oil pressure switch terminal [A]. e Remove the oil filter [B] (see Oil Filter Replacement in the Periodic Maintenance chapter). e Remove: Oil Pan Bolts [A] Oil Pan [B] e Remove: Oil Screen [A] Oil Pipe [B] Oil Pressure Relief Valve [C] (if necessary) CAUTION Do not remove the relief valve with the oil pipe in- stalled on the lower crankcase half. The oil pipe will be damaged. Oil Pan Installation e Clean the oil screen [A]. e Install the oil screen so that the crankcase rib [B] fits the notch [C] of oil screen. e Apply grease the oil pipe O-rings and install the oil pipe. xlf the oil pressure relief valve was removed, install it. OApply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it. CAUTION Do not apply too much non-permanent locking agent to the threads. This may block the oil pas- sage. Torque - Oil Pressure Relief Valve: 15 N-m (1.5 kgf-:m, 11 ft-Ib)

Oil Pan e Put new O-ring [A] on the lower crankcase [B] as shown. Oil Pipe [C] e Install the brackets [A] as shown. e Replace the oil pan gasket [B] with a new one. e Tighten: Torque - Oil Pan Bolts: 9.8 N-m (1.0 kgf-m, 87 in-Ilb) Gcosozsps2 € Guoozsesi

Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e See Oil Pan Removal. Oil Pressure Relief Valve Installation e See Oil Pan Installation. Oil Pressure Relief Valve Inspection e Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see ifit comes back to its seat by spring [B] pressure. NOTE Olnspect the valve in its assembled state. Disassembly and assembly may change the valve performance. xlf any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and GGogosozst ce blow out any foreign particles that may be in the valve with compressed air. À WARNING Clean the oil pressure relief valve in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent. xlf cleaning does not solve the problem, replace the oil pressure relief valve as an assembly. The oil pressure relief valve is precision made with no allowance for re- placement of individual parts.

Oil Pump Oil Pump Removal e Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) e Remove: Clutch (see Clutch Removal in the Clutch chapter) e Remove the oil pump cover bolts [A]. e Remove the oil pump cover [B] with oil pump shaft. e Remove the outer rotor and inner rotor. Oil Pump Installation e Apply molybdenum disulfide oil solution to the journal por- tions [A] on the oil pump drive gear shaft [B]. e Insert the outer rotor [A] the dowel pin [B] into the crankcase. e Insert the pump cover [A], washer [B], pin [C] and inner rotor [D] to the oil pump shaft [E]. Gcosossess

Oil Pump e Install the oil pump shaft with inner rotor. OTurn the pump shaft [A] so that the projection [B] in its shaft fits onto the slot [C] of the water pump shaft [D]. OFit the pin of the oil pump cover into the hole in the crankcase. (in the photo, the oil pan have been removed for clarity) e Tighten: Torque - Oil Pump Cover Bolts [A]: 9.8 N-m (1.0 kgf-m, 87 in<lb)

Oil Cooler Oil Cooler Removal e Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) e Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) e Remove the water hoses from the oil cooler. + Unscrew the oil cooler mounting bolts [A], and remove the oil cooler [B]. Oil Cooler Installation e Apply grease to new O-ring [A] before installation. + Install the oil cooler to the oil cooler case, and tighten the bolts, following the specified tightening sequence [1 —4]. Torque - Oil Cooler Mounting Bolts [B]: 12 N-m (1.2 kgf-m, 106 in-Ib) e Install the water hoses as shown. White Mark [A] e Tighten: Torque - Water Hose Clamp Screws: 2.0 N-m (0.20 kgf-m, 18 in-lb) e Pour: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter)

Oil Pressure Measurement Oil Pressure Measurement e Remove the left lower fairing (see Lower Fairing Removal }}} ))))) [4] in the Frame chapter). )))}}}}}}} Nù e Remove the oil passage plug, and attach the adapter [A] D à and gauge [B] to the plug hole. } — n Special Tools - Oil Pressure Gauge, 10 kgf/cm’: 57001-164 Oil Pressure Gauge Adapter, PT3/8 x 19/in.: 57001-1233 e Start the engine and warm up the engine. e Run the engine at the specified speed, and read the oil pressure gauge. xlfthe oil pressure is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately. xlfthe reading is much higher than the standard, check the oil passages for clogging. Oil Pressure Standard: 245 —343 kPa (2.5 —3.5 kgf/cm?, 36 -50 psi) @ 4 000 r/min (rpm), oil temperature 90°C (194°F) e Stop the engine. e Remove the oil pressure gauge and adapter. À WARNING Take care against burns form hot engine oil that Will drain through the oil passage when the gauge adapter is removed. e Apply a non-permanent locking agent to the oil passage plug, and install it. Torque - Oil Passage Plug: 20 N-m (2.0 kgf-m, 15 ft-lb)

Oil Pressure Switch Oil Pressure Switch Removal e Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Switch Cover [A] Switch Terminal [B] Oil Pressure Switch [C] Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N-m (1.5 kgf-m, 11 ft:Ib) e Install the switch lead direction [A] upward. e Apply grease [B] to the terminal. e Tighten the terminal bolt. Torque - Oil Pressure Switch Terminal Bolt: 1.5 N-m (0.15 kgf-m, 13 in-lb) NOTE OApply a small amount grease to the terminal so that grease should not close two breather holes [A] for switch diaphragm. Guis0osess EAT(©Q ® Guisoo4nss

Engine Removal/Installation Table of Contents Exploded View 8-2 Engine Removal/Installation … 8-4 Engine Removal..…. 8-4 Engine Installation. 8-6

8-2 ENGINE REMOVAL/INSTALLATION

Exploded View GHo2o748ns ©

ENGINE REMOVAL/INSTALLATION 8-3

8-4 ENGINE REMOVAL/INSTALLATION

Engine Removal/installation Engine Removal e Support the rear part of the swingarm with a stand. e Squeeze the brake lever slowly and hold it with a band [A] À WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury. CAUTION Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged. e Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) e Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Coolant Reserve Tank Clutch Slave Cylinder (see Clutch Slave Cylinder Re- moval in the Clutch chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Muffler Bodies (see Muffler Body Removal/Installation in the Frame chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Shift Pedal (see Shift Pedal Removal in the Crank- shaft/Transmission chapter) + Disconnect: Sidestand Switch Lead Connector [A] Oil Pressure Switch/Gear Position Switch Leads Con- nector [B]

ENGINE REMOVAL/INSTALLATION 8-5

Engine Removal/Installation e Disconnect the alternator lead conductor [A]. e Remove: Connector [A] of Subharness for Sensor and Valve (dis- connect) Subframe Bolts [B] Subframe Bracket Bolt [C] + Remove the subframe [D] with the clutch pipe [E]. + Disconnect: Throttle Body Subharness Connector [A] Breather Hose [B] Fuel Hose [C] on the Delivery Pipe Throttle Cable Lower Ends [D] e Remove the bracket Bolt [A]. e Disconnect: Air Switching Valve Connector [B] Stick Coil Subharness Connector [C] e Remove the air switching valve [A] with hoses. e Remove the air suction cover (see Air Suction Valve Re- moval in the Engine Top End chapter).

Engine Removal/installation e Remove the engine sprocket [A] (see Engine Sprocket Removal in the Final Drive chapter). e Support the engine with a suitable stand [B]. OPut a plank [C] onto the suitable stand for engine balance. e Remove: Engine Bracket Bolts [A] Front Engine Mounting Bolts [B] Engine Bracket [C] e Remove: Engine Mounting Nuts [A] e Disconnect the engine ground terminal [A]. e Using a hexagon wrench, turn the engine mounting bolts [B] clockwise to make the gap between the engine and frame. e Remove the drive chain from the output shaft. e Remove the starter motor cable terminal nut [A]. e Using the stand, take out the engine. Engine Installation e Support the engine with a suitable stand. OPut a plank onto the suitable stand for engine balance. e Install the heat insulation rubber plate.

ENGINE REMOVAL/INSTALLATION 8-7

Engine Removal/Installation GHososssns c A: After installation, set the projection in the hole. : To Water Temperature Sensor : To Breather Hose : To Throttle Body Subharness Bracket : To throttle Body Holder : To Throttle Pulley To Air Suction Valve and Stick Coils : Only put the heat insulation rubber plate on the cylinder head cover. : Bracket on Air Suction Valve Cover cIOnmoouw

8-8 ENGINE REMOVAL/INSTALLATION

Engine Removal/installation e Before installing the engine. Confirm the routing of the water temperature sensor lead [A]. ORun [B] the water temperature sensor lead between the #3 and #4 cylinder and connect the water temperature sensor body. OI . © L 3 D LT, F Ul./ Ÿ ] È l'a 7 : ] SAS ES ] ù @ GHozo7sen2 c e Install the engine mounting bolts and nuts, following the specified installing sequence. OApply molybdenum disulfide grease [A] to the thread of adjusting collars. OfFirst, tighten the adjusting collars fully by hand. Upper Adjusting Collar [B] Upper Crankcase [C] Lower Adjusting Collar [D] Lower Crankcase [E] GHozo7eps2 €

Engine Removal/Installation OSecondly, insert the mounting bolts [A] until they fit [B] in the adjusting collars [C]. OBe sure that the collar [D] is in position. Guozo7onss NOTE OReplace the following bolts with new bolts pre-coated with locking agent. Engine Bracket Bolts (P/No. 92153-1724) Front Engine Mounting Bolts (P/No. 92153-1723) Subframe Bolts (P/No. 92153-1722) OThirdly, install the left engine bracket [A] and temporally tighten the left engine bracket bolts [B]. OFourthly, tighten the left front engine mounting bolt [C]. Guozo76es: OFourthly, turn the mounting bolts [A] counterclockwise with specified torque until the clearance [B] between the crankcase [C] and swingarm [D] comes to zero mm [E]. Adjusting Collars [F] Torque - Adjusting Collars: 25 N-m (2.5 kgf-m, 18 ft-Ib) ODo not exceed the specified torque of adjusting collars. a, #2

Engine Removal/installation Engine Bracket Upper Side This bolt has LL nn) already been fourthly Lower Crankcase Side tightened —# (| ! ! I l [] G GHoz080Bns c OFifthly, tighten the left engine bracket bolts [A]. OSixthly, tighten the upper engine mounting nut [B] and then the lower engine mounting nut [C]. OSeventhly, install the right engine bracket and tighten the right engine bracket bolts [D] and the right front engine mounting bolt [E]. OTorque: Torque - Engine Mounting Nut (M12): 59 N-m (6.0 kgf-m, 44 ft-Ib) NOTE ©Hold the upper and lower engine mounting bolts with an Allen wrench, and torque them. OTorque: Torque - Engine Bracket Bolts (M8): 25 N-m (2.5 kgf-m, 18 ft-lb) Front Engine Mounting Bolts (M10): 59 N-m (6.0 kgf-m, 44 ft-Ib)

Engine Removal/Installation e Run the leads, cable and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chap- ter). e Install the removed parts (see appropriate chapters). e Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Drive Chain (see Drive Chain Slack Inspection in the Periodic Maintenance chapter) e Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter). e Fillthe engine with coolant and bleed the air from the cool- ing system (see Coolant Change in the Periodic Mainte- nance chapter).

Crankshaft/Transmission Table of Contents Exploded View. Specifications Special Tools and Sealants Crankcase Splitting.… Crankcase Splitting. Crankcase Assembly. Crankshaft and Connecting Rods. Crankshaft Removal Connecting Rod Removal Connecting Rod Installation Crankshaft/Connecting Rod Cleaning Connecting Rod Bend Connecting Rod Twist... Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert/Crankpin Wear . Crankshaft Side Clearance . Crankshaft Runout Crankshaft Main Bearing Insert/Journal Wear. Pistons…............. Piston Removal en Piston Installation... Cylinder Wear (Upper Crankcase).......................... Piston Wear Piston Ring Groove Width Piston Ring Thickness Piston Ring End Gap. Balancer Front Balancer Remova Front Balancer Installation 9-2 9-6 9-9 9-10 9-10 9-11 9-15 9-15 9-15 9-16 9-16 9-19 9-19 9-20 9-20 9-20 9-22 9-23 9-23 9-26 9-26 9-27 9-28 9-28 9-28 9-29 9-29 9-29 9-30 9-30 9-30 Rear Balancer Removal.….. Rear Balancer Installation Balancer Adjustment.. Balancer Damper Inspectio: Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal Starter Motor Clutch Installation. Starter Motor Clutch Risassembly Starter Motor Clutch Assembly … Starter Clutch Inspection Torque Limiter Removal… Torque Limiter Installation Transmission Shift Pedal Removal Shift Pedal Installation External Shift Mechanism Removal External Shift Mechanism Installation External Shift Mechanism Inspection Transmission Shaft Removal Transmission Shaft Installatioi Transmission Shaft Disassembly. Transmission Shaft Assembly Shift Drum and Fork Removal Shift Drum and Fork Installation. Shift Drum Disassembly. Shift Drum Assembly . Shift Fork Bending Shift Fork/Gear Groove Wear ….. Shift Fork Guide Pin/Drum 9-31 9-32 9-34 9-34 9-35 9-35 9-35 9-35 9-36 9-36 9-36 9-37 9-38 9-38 9-38 9-38 9-39 9-39 9-39 9-40 9-40 9-41 9-44 9-44 9-44 9-44 9-45 9-45 9-45 9-45

G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence.

12. Install the bearing into the drive shaft cover so that the shield side faces in.

EO: Apply engine oil. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 : 1) G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts

Specifications Marking None Crankcase Main Bearing Inside Diameter:

Crankcase Splitting Crankcase Splitting e Remove the engine (see Engine Removal/Installation in the Engine Removal/Installation chapter). e Set the engine on a clean surface and hold the engine steady while parts are being removed. e Remove: Clutch (see Clutch Removal in the Clutch chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Oil Pump (see Oil Pump Removal in the Engine Lubri- cation System chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Oil Cooler (see Oil Cooler Removal in the Engine Lubri- cation System chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) External Shift Mechanism (see External Shift Mecha- nism Removal) e Remove the upper crankcase bolts. OFirst loosen the M6 bolts. M6 Bolts [A] M7 Bolt [B] M7 Bolt with Clamp [C] M8 Bolts with Washers [D] + Remove the lower crankcase bolts. OfFirst loosen the M7 bolts [A]. ÉE<ÈESESS >

Crankcase Splitting ONext, loosen the M10 Bolts [1-10] (sequence numbers). xlf the crankshaft is to be removed, remove the pistons (see Piston Removal). e Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase. + Remove the front balancer [A] on the lower crankcase half [B] (see Front Balancer Removal). Crankcase Assembly CAUTION The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. NOTE OWhen replacing the crankcase halves, install the thrust washers (t = 2.5 mm, 0.0984 in.) on the upper crankcase half. e With a high-flash point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry. e Using compressed air, blow out the oil passages in the crankcase halves. e Install the new drive shaft bearing [A] so that its stepped side [B] faces as shown using a press. e Install the bearing plate [C] with the screws [D]. OApply a non-permanent locking agent to the bearing plate screw and tighten them. Torque - Bearing Position Plate Screws: 4.9 Nm (0.50 kgf-m, 43 in-Ib) Gi0424285T

Crankcase Splitting e Install the new needle bearing [A] for the shift shaft so that its marked side [B] faces as shown, using a press. e Install the new oil seal [C] so that its surface [D] is flush With the surface of the crankcase [E]. e Install: Crankshaft, Pistons and Connecting Rods Transmission Shaft and Gears Dowel Pins [A] e Install the front balancer [A] on the upper crankcase half [B] (see Balancer Installation). e Before fitting the lower case on the upper case, check the following. OCheck to see that the shift drum and transmission gears are in the neutral position. e Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE OAster tightening the crankcase bolts, wipe up the liquid gasket seeping out the output shaft bearing hole [D]. OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied. CAUTION Do not apply liquid gasket to the grooves [B] inside from the crankshaft main bearing inserts, and bal- ancer bearing. CAUTION Do not plug the inside of breather hole [C] with liq- uid gasket. Giouza4nss Giouzseps2 €

Crankcase Splitting e Fit the lower crankcase half to the upper crankcase half. e Be sure that the breather hole [A] on the upper crankcase [B] is not plugged with liquid gasket. e The M10 bolts have washers, replace them with new ones. e Apply molybdenum disulfide oil solution to the seating sur- faces [A] of the washers and the threads [B] of the M10 bolts. e Tighten the lower crankcase bolts using the following steps. OFollowing the sequence numbers on the lower crankcase half, tighten the M10 bolts [1 —10] with washers. Torque - Crankcase Bolts (M10): 47 N-m (4.8 kgf-m, 35 ft-Ib) OTighten the M7 bolts [A]. Torque - Crankcase Bolts (M7): 20 N-m (2.0 kgf-m, 15 ft-Ib) Go P Giouzssess Giouzsanss loi Giouzsonss

Crankcase Splitting e Tighten the upper crankcase bolts in the order listed. OThe M8 bolts have washers, replace them with new ones. OTighten: M8 Bolts with Washers [A] M7 Bolt with the clamp [B] M7 Bolt [C] M6 Bolts [D] Torque - Crankcase Bolts (M8): 27 N-m (2.8 kgf-m, 20 ft:lb) Crankcase Bolts (M7): 20 N-m (2.0 kgf-m, 15 ft-lb) Crankcase Bolts (M6): 12 N-m (1.2 kgf-m, 106 in:lb) e After tightening all crankcase bolts, check the following items. OCrankshaft and transmission shafts turn freely. OWhile spinning the output shaft, gears shift smoothly from the 1st to neutral, and neutral to 1st. SEE ces

Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase (see Crankcase Splitting). e Remove the crankshaft (see Connecting Rod Removal). Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed. NOTE OWhen replacing the crankcase halves, install the thrust washers (t = 2.5 mm, 0.0984 in.) on the upper crankcase half. e Apply molybdenum disulfide oil solution to the crankshañt main bearing inserts. e Follow the next procedure to insert the thrust washers on the upper crankcase half, after installing connecting rod on the crankshaft (see Connecting Rod Installation). e Apply molybdenum disulfide grease to the outside sur- faces [A] of both thrust washers [B]. e Slide [C] one thrust washer into the upper crankcase half. e Move the crankshaïft to the left or right and then slide the other washer into the upper crankcase half. NOTE OSlide the thrust washers so that the oil grooves [D] face outward. Make sure that the blue-painted edges [E] are positioned as shown in figure. Front [F]

Crankshaft and Connecting Rods Connecting Rod Removal e Split the crankcase (see Crankcase Splitting). e Remove the connecting rod nuts [A]. e Remove the crankshaft. NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions. e Remove the piston (see Piston Removal). CAUTION Discard the connecting rod bolts. To prevent dam- age to the crankpin surfaces, do not allow the con- necting rod bolts to bump against the crankpins. Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D]: “O” or no mark CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plasti- gage (press gauge) before assembling engine to be sure the correct bearing inserts are installed. e Apply molybdenum disulfide oil to the inner surface of the upper and lower bearing inserts [A]. e Apply molybdenum disulfide oil to the threads [B] and seating surface [C] of the connecting rod nuts. e Install the inserts so that their nails [D] are on the same side and fit them into the recess of the connecting rod and cap. CAUTION Wrong application of oil and grease could cause bearing damage. OWhen installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows. Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Spare Dowel Pin [G] Connecting Rod Bolts [H] e Remove debris and clean the surface of inserts. e Install the cap on the connecting rod, aligning the weight and diameter marks. Grososoïst e

Crankshaft and Connecting Rods e Install the crankshaft (see Crankshaïft Installation). e Install each connecting rod on its original crankpin. OThe connecting rod big end is bolted using the “plastic region fastening method”. OThis method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight. OThere are two types of the plastic region fastening. One is a bolt length measurement method and other is a rotation angle method. Observe one of the following two, but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts. CAUTION The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage. CAUTION Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase. (1) Bolt Length Measurement Method eBe sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. À WARNING Clean the bolts, nuts, and connecting rods in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. This in- cludes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean them. CAUTION Immediately dry the bolts and nuts with com- pressed air after cleaning. Clean and dry the bolts and nuts completely.

Crankshaft and Connecting Rods e Install new bolts in reused connecting rods. e Dent both bolt head and bolt tip with a punch as shown. e Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch. Connecting Rod [A] Dent here with a punch [B]. Nuts [C] Fit micrometer pins into dents [D]. e Apply a small amount of molybdenum disulfide oil to the following. Threads of Nuts and Bolts Seating Surfaces of Nuts and Connecting rods e Tighten the big end nuts until the bolt elongation reaches the length specified in the table. e Check the length of the connecting rod bolts. xlf the stretch is more than the usable range, the bolt has stretched too much. An overelongated bolt may break in use. Bolt Length after _ Bolt Length before = Bolt Stretch tightening tightening Connect- Usable Range of ing Rod Bolt Nut Connecting Rod ASSy Bolt Stretch Use the bolts | Attached to |0.25 —0.34 mm New attached to new con-rod |(0.0098 —0.0134 new con-rod. New in.) Replace the Used 0.25 0.34 mm Used bolts with new (0.0098 —0.0134 ones. New in.) (2) Rotation Angle Method xlf you don't have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. e Be sure to clean the bolts, nuts and connecting rods thor- oughly with a high-flash point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution. À WARNING Clean the bolts, nuts and connecting rods in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. This in- cludes any appliance with a pilot light. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean them. CAUTION Immediately dry the bolts and nuts with com- pressed air after cleaning. Clean and dry the bolts and nuts completely. Grosogosst ce

Crankshaft and Connecting Rods e Install new bolts in reused connecting rods. e Apply a small amount of molybdenum disulfide oil to the following. Threads [A] of Nuts and Bolts Lo] | ® LE 4 Seating Surfaces [B] of Nuts and Connecting Rods nn) a TT Grosogosst ce e First, tighten the nuts to the specified torque. See the table below. e Next, tighten the nuts 120° + 5°. OMark [A] the connecting rod big end caps and nuts so that nuts can be turned 120° [B] properly. il T + Angl Connecting Bolt Nut orque ngle Rod Assy N-m (kgf-m, ft-Ib) Attached to 21.6 (2.2, 16) + Use the bolts | jew con-rod 120° Siosoaosst 6 New attached to 216 C2, 16) new con-rod. : ce + New 120°

Replace the Used 6 20° ) Used bolts with new ones New 216 F2, 19) + Crankshaft/Connecting Rod Cleaning e After removing the connecting rods from the crankshaïft, clean them with a high-flash point solvent. e Blow the crankshaîft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages. Connecting Rod Bend + Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. e Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end. e Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [B] through the connecting rod small end. Grosotosst ce e On a surface plate, set the big-end arbor on V block [C]. e With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend. xIf connecting rod bend exceeds the service limit, the con- necting rod must be replaced. Connecting Rod Bend Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Crankshaft and Connecting Rods Connecting Rod Twist e With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist. xlf connecting rod twist exceeds the service limit, the con- necting rod must be replaced. Connecting Rod Twist Service Limit: TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance e Measure connecting rod big end side clearance. Olnsert a thickness gauge [A] between the big end and ei- ther crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.13 —-0.38 mm (0.0051 —0.0150 in.) Service Limit: 0.58 mm (0.023 in.) xlfthe clearance exceeds the service limit, replace the con- necting rod with new one and then check clearance again. Ifclearance is too large after connecting rod replacement, the crankshaîft also must be replaced. Connecting Rod Big End Bearing Insert/Crankpin Wear e Measure the bearing insert/crankpin [B] clearance with plastigage [A]. e Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ODo not move the connecting rod and crankshaft during clearance measurement. CAUTION After measurement, replace the connecting rod bolts. Connecting Rod Big End Bearing Insert/Crankpin Clearance Standard: 0.048 —0.086 mm (0.0019 —-0.0034 in.) Service Limit: 0.12 mm (0.0047 in.) Gtoso4ozst € Grosouisst ce

Crankshaft and Connecting Rods xlfthe clearance is within the standard, no bearing replace- ment is required. xlf the clearance is between 0.087 mm (0.0034 in.) and the service limit (0.12 mm, 0.0047 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage. The clear- ance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. xlf the clearance exceeds the service limit, measure the diameter of the crankpins. s'osoarrst e Crankpin Diameter Standard: 37.984 —38.000 mm (1.4954 —-1.4961 in.) Service Limit: 37.97 mm (1.4949 in.) xlfany crankpin has worn past the service limit, replace the crankshaft with a new one. xlf the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankpin Diameter Marks None 37.984 —37.992 mm (1.4954 —-1.4957 in.) (e] 37.993 —38.000 mm (1.4958 —1.4961 in.) A: Crankpin Diameter Marks, "©" or no mark. Grosiosess e Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. e Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE OThe mark already on the big end should almost coincide with the measurement. Connecting Rod Big End Inside Diameter Marks None 41.000 —41.008 mm (1.6142 —-1.6145 in.) O 41.009 —41.016 mm (1.6145 —1.6148 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: “O” or no mark Grososoïst e

Crankshaft and Connecting Rods e Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaîft coding. Size Color [B] Con-rod Big . . End Inside Crankpin Bearing Insert : Diameter Diameter : Marking Marking Size Color | Part Number None (e] Brown 92139-0131 None None Black 92139-0130 O Q O None Blue 92139-0129 e Install the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage. Crankshaft Side Clearance e Move [A] the crankshaîft to the side of the camshaft chain. e Insert a thickness gauge [B] between the thrust washer [C] and the crank web [D] at the No. 3 main journal to determine clearance. Crankshaft Side Clearance Standard: 0.05 - 0.24 mm (0.0020 - 0.0094 in.) Service Limit: 0.30 mm (0.0118 in.) xlf the clearance exceeds the service limit, replace the thrust washer as a set. e Measure the width [A] of the both thrust washers. xlfthe thrust washers (t = 2.5 mm, 0.0984 in.) are installed on the upper crankcase half, replace them with new thrust washer (t = 2.5 mm, 0.0984 in.) as a set. Grosoarst € = 6 LES € SR © o) o S of] lol. NofTe lo o SO O \ 6} - 1 — 0

Crankshaft and Connecting Rods xlfthe thrust washers (t= 4.0 mm, 0.1575 in.) are installed on the upper crankcase half, replace them with new thrust washer (t = 4.0 mm, 0.1575 in.) as a set. Thrust Washer : PINo. Thickness Edge Colar

92200-03881 |(6.0065 —0.0984 in. Blue

92200-0882 | 4555 01575 in.) Blue NOTE OFor the crankcase, only crankcase set (P/No. 14001 -0089) be available as spare parts. e Check the width of the crankshaft #3 main journal. e Measure the crankshaft #3 main journal width [A]. (@) xlf the measurement exceeds the standard, replace the IN /1 crankshaft [B]. ° | 1° Crankshaft #3 Main Journal Width > | | € Standard: 27.45 —27.50 mm (1.0807 —1.0827 in.) — EF Gioszoimss € Crankshaft Runout e Measure the crankshaft runout. xlfthe measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.03 mm (0.0012 in.) or less Service Limit: TIR 0.08 mm (0.0031 in.) Grosio4nss Crankshaft Main Bearing Insert/Journal Wear e Using a plastigage (press gauge) [A], measure the bear- ing insert/journal [B] clearance. NOTE OTighten the crankcase bolts to the specified torque (see Crankcase Assembly). ODo not turn the crankshaft during clearance measure- ment. OJournal clearance less than 0.025 mm (0.00098 in.) can closogoé s not be measured by plastigage, however, using genuine parts maintains the minimum standard clearance.

Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Clearance Standard: 0.031 —0.063 mm (0.0012 —0.0025 in.) Service Limit: 0.09 mm (0.0035 in.) xlfthe clearance is within the standard, no bearing replace- ment is required. xlfthe clearance is between 0.064 mm (0.0025 in.) and the service limit (0.09 mm, 0.0035 in.), replace the bearing in- serts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the min- imum in order to avoid bearing seizure. xlf the clearance exceeds the service limit, measure the diameter of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 37.984 —38.000 mm (1.4954 —1.4961 in.) Service Limit: 37.96 mm (1.4945 in.) xlf any journal has worn past the service limit, replace the crankshaft with a new one. xlf the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankshaft Main Journal Diameter Marks None 37.984 —37.992 mm (1.4954 —1.4957 in.) 1 37.993 —38.000 mm (1.4958 —1.4961 in.) DO: Crankshaft Main Journal Diameter Marks, "1" or no mark. + Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. A: Crankcase Main Bearing Inside Diameter Marks, "O" mark or no mark. e Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE OThe mark already on the upper crankcase half should almost coincide with the measurement. Crankcase Main Bearing Inside Diameter Marks O 41.000 —41.008 mm (1.6142 —-1.6145 in.) None 41.009 —41.016 mm (1.6145 —1.6148 in.) e Select the proper bearing insert [A] in accordance with the combination of the crankcase and crankshaft coding. Size Color [B] Grosoarst € Giosiosess 1#2#3 #4 #9 Grosiosess Grosoarst €

Pistons Piston Removal e Split the crankcase (see Crankcase Splitting). e Remove the connecting rod nuts [A]. e Remove the connecting rod big end caps. e Remove the crankshaft. e Remove the piston to the cylinder head side. e Remove the piston pin snap ring [A]. e Remove the piston pins. Special Tool - Piston Pin Puller Assembly [A]: 57001-910 e Remove the pistons. e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it. e Remove the 3-piece oil ring with your thumbs in the same manner. Geteoissst €

Pistons Piston Installation e Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. e Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the ex- pander and one below it. OSpread the rail with your thumbs, but only enough to fit the rail over the piston. ORelease the rail into the bottom piston ring groove. NOTE OThe oil ring rails have no “top” or “bottom”. e Do not mix up the top and second ring. e Install the top ring [A] so that the "R" mark [B] faces up. e Install the second ring [C] so that the "RN" mark [D] faces up. OApply molybdenum disulfide oil solution to the piston rings. NOTE Olf a new piston is used, use new piston ring. e Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. OApply molybdenum disulfide oil solution to the piston pins and piston journals. OWhen installing the piston pin snap ring, compress it only enough to install it and no more. GEtgosonst ce GEteosinst € Giostozess € CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. e The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30-40° of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Oil Ring Steel Rails [C] Oil Ring Expander [D] Hollow [E] 30 —40° [F] Geteosenst

Pistons e Install the piston with its marking hollow facing exhaust side. e Using the piston ring compressor assy [A] to install the piston from the cylinder head side. Special Tools -Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 680 — 991: 57001-1320 e Install the crankshaft. e Install the connecting rod to the crankshaft (see Connect- ing Rod Installation). Cylinder Wear (Upper Crankcase) e Since there is a difference in cylinder wear (upper crankcase) in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) shown in the figure. xlf any of the cylinder inside diameter measurements ex- ceeds the service limit, replace the crankcase. 10 mm (0.39 in.) [A] 60 mm (2.36 in.) [B] Cylinder Inside Diameter Standard: 83.994 —-84.006 mm (3.3068 —3.3073 in.) Service Limit: 84.10 mm (3.3110 in.) Piston Wear e Measure the outside diameter [A] of each piston 10 mm (0.39 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. xlfthe measurement is under service limit, replace the pis- ton. Piston Diameter Standard: 83.959 —83.974 mm (3.3055 —3.3061 in.) Service Limit: 83.81 mm (3.2996 in.) Piston Ring, Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat- ing. x The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. e With the piston rings in their grooves, make several mea- surements with a thickness gauge [A] to determine piston ring/groove clearance. Piston Ring/Groove Clearance Standard: Top 0.03 —-0.07 mm (0.0012 —0.0028 in.) Second 0.02 —-0.06 mm (0.0008 —0.0024 in.) Service Limit: Top 0.17 mm (0.0067 in.) Second 0.16 mm (0.0063 in.) Geteosssst ce

Pistons Piston Ring Groove Width e Measure the piston ring groove width. OUse a vernier caliper at several points around the piston. @ Piston Ring Groove Width Standard: Top [A] 0.92 —0.94 mm (0.0362 —0.0370 in.) Second [B] 1.01 —1.03 mm (0.0398 —0.0406 in.) Service Limit: Top [A] 1.02 mm (0.040 in.) SEINOIIN € Second [B] 1.11 mm (0.044 in.) xlf the width of any of the two grooves is wider than the service limit at any point, replace the piston. Piston Ring Thickness e Measure the piston ring thickness. OUse the micrometer to measure at several points around DTA RE Oo] the ring. 5 Piston Ring Thickness Standard: Top [A] 0.87 —0.89 mm (0.0343 —0.0350 in.) LT Second [B] 0.97 —0.99 mm (0.0382 —0.0390 in.) Service Limit: Top [A] 0.80 mm (0.032 in.) Second [B] 0.90 mm (0.035 in.) xlf any of the measurements is less than the service limit on either of the rings, replace all the rings. NOTE OWhen using new rings in a used piston, check for un- even groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Geteorosst ce Piston Ring End Gap ePlace the piston ring [A] inside the cylinder (upper | crankcase), using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where Ü cylinder wear is low. LD e Measure the gap [B] between the ends of the ring with a 2 thickness gauge. Piston Ring End Gap Standard: Getosesst 0 Top 0.20 —0.30 mm (0.0079 —0.0118 in.) Second 0.40 —0.55 mm (0.0157 —0.0217 in.) Service Limit: Top 0.6 mm (0.024 in.) Second 0.8 mm (0.031 in.) xlf the end gap of either ring is greater than the service limit, replace all the rings.

Balancer Front Balancer Removal e Split the crankcase (see Crankcase Splitting). e Unscrew: Balancer Shaft Clamp Bolt [A] Balancer Shaft Clamp Lever Bolt [B] e Remove the front balancer [C] from the lower crankcase half [D] Front Balancer Installation e Check that the rubber dampers [A] are in place as shown. e Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight. e Install the balancer weight [A] into the gear [B]. OAlign the mark [C] of the balancer weight to the groove [D] of the gear. e Apply molybdenum disulfide oil solution to the needle bearings. Insert the needle bearings. e Fitthe copper washers [A] on both ends of the weight and gear assembly. The projected sides [B] face inward. Giogogosst ce

Balancer e Position the crankshaft at 2, 3 position TDC. e Insert the pin [A] as shown. e Set the front balancer on the upper crankcase half. OAlign the punch mark [B] on the balancer gear [C] with the mark [D] on the balancer drive gear [E] of crankshaft. Grogozemt © e Assemble the crankcase (see Crankcase Assembly). e Install the new oil seal [A] so that its surface [B] is flush with the surface of the crankcase [C]. OFill the oil seal lips with grease. e Tighten the balancer shaft clamp lever bolt [D] Torque - Balancer Shaft Clamp Lever Bolt: 25 N-m (2.5 kgf-m, 18 ft-lb) e Turn the balancer shaft so that its mark [E] is aligned with the crankcase mating line [F]. e Tighten the balancer shaft clamp boit [G] Torque - Balancer Shaft Clamp Bolt: 9.8 N-m (1.0 kgf-m, 87 in-lb) Grogozont © Rear Balancer Removal e Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). e Remove: Breather Cover Bolts [A] Breather Cover [B]

Balancer e Unscrew the balancer shaft clamp bolt [A], and balancer shaft clamp lever bolt [B], and pull off the clamp lever [C]. e Pull the balancer shaft [D] out of the crankcase. The bal- ancer weight and gear assembly [E] come off with needle bearings and copper washers. Rear Balancer Installation e Check that the rubber dampers [A] are in place as shown. e Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight. e Install the balancer weight [A] into the gear [B]. OAlign the mark [C] of the balancer weight to the groove [D] of the gear. e Apply molybdenum disulfide oil solution to the needle bearings. Insert the needle bearings. e Fitthe copper washers [A] on both ends of the weight and gear assembly. The projected sides [B] face inward. Giogogosst ce

Balancer Position the crankshaïft at # 2, 3 position TDC or at # 1,4 position TDC. e Aligin the mark [A] on the balancer gear [B] with the mat- ing surface [C] of the upper crankcase half. e Install the balancer shaft [D] and then align the balancer gear with the starter motor clutch gear. e Install the new oil seal [A] so that its surface [B] is flush with the surface of crankcase [C]. OFill the oil seal lips with grease. e Tighten the balancer shaft clamp lever bolt [D]. Torque - Balancer Shaft Clamp Lever Bolt: 25 N-m (2.5 kgf-m, 18 ft-lb) e Turn the balancer shaft so that its mark [E] is in position as shown. e Tighten the balancer shaft clamp boit [F]. Torque - Balancer Shaft Clamp Bolt: 9.8 N-m (1.0 kgf-m, 87 in-lb) Giosbzs8s:

Balancer Balancer Adjustment e First, adjust the front balancer [A], next the rear balancer (BI. OFor the front balancer adjustment, remove the lower fair- ing (see Lower Fairing Removal in the Frame chapter). e Start the engine and warm it up thoroughly. e Adjust the balancer gear backlash with the engine idling. The amount of backlash can be changed by turning the balancer shaft which has eccentric journals. OStart the engine and let it idle. OLoosen the clamp bolt [C] and turn the balancer shaft [D] clockwise [E] until the balancer gear makes a whin- ing sound. OTurn the shaft counter-clockwise [F] until the balancer gear whining sound disappears and tighten the clamp bolt. Torque - Balancer Shaft Clamp Bolt: 9.8 N-m (1.0 kgf-m, 98 inb) Balancer Damper Inspection e Remove the balancer and disassemble the weight and gear assembly. e Visually inspect the rubber dampers [A]. xlf they appear damaged or deteriorated, replace them. Giosozcps2 €

Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal e Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). e Remove the rear balancer (see Rear Balancer Removal). e Unscrew the starter clutch shaft plate boit [A]. e Pull the starter clutch shaft bolt [A] with the shaïft plate [B] and starter clutch shaft holding the starter clutch [C]. e Remove the starter clutch. Starter Motor Clutch Installation e Install: Coller (Long) [A] Starter Motor Clutch [B] Coller (Short) [C] Starter Motor Clutch Shaft [D] OApply molybdenum disulfide grease [E] to the starter mo- tor clutch shaïft. e Align [F] the starter motor clutch gear with the torque lim- iter gear. e Apply a non-permanent locking agent to the threads of the starter clutch shaîft plate bolt, and tighten it. Torque - Starter Clutch Shaft Plate Bolt [G]: 9.8 N-:m (1.0 kgf-m, 87 in-Ib) xlf the shaft bolt removed, tighten it. OApply a non-permanent locking agent to the threads of the shaîft bolt. Torque - Starter Clutch Shaft Bolt [H]: 9.8 N-m (1.0 kgf-m, 87 in-lb)

Giosoo4nss € Starter Motor Clutch Disassembly e Remove the starter motor clutch. e Pull the driven gear out off from the drive gear. e Remove: Flat Washer [A]

Starter Motor Clutch and Torque Limiter e Holding the drive gear [A] with a hand, take off the one -way clutch [B] from the gear by using the screw driver [CI Starter Motor Clutch Assembly e Be sure to install the one-way clutch [A] so that its arrow [B] faces the side of the flat washer. e Turn in the driven gear [A] to the drive gear [B]. Counterclockwise [C] Starter Clutch Inspection e Remove the rear balancer (see Rear Balancer Removal). e Turn the starter idle gear [A] by hand. When viewed from the rear side of the engine, the starter idle gear should turn forward [B] freely, but should not turn backward [C]. xlf the clutch does not operate as it should or if it makes noise, disassemble the starter clutch, examine each part visually, and replace any worn or damaged parts. Torque Limiter Removal e Remove: Rear Balancer (see Rear Balancer Removal) Starter Motor Clutch (see Starter Motor Clutch Re- moval). e Remove the torque limiter bolt [A].

Starter Motor Clutch and Torque Limiter e Holding the torque limiter [A], remove the torque limiter shaft [B] and the torque limiter. Torque Limiter Installation e Replace the O-ring with a new one. e Apply engine oil to the new O-ring. e Apply molybdenum disulfide grease to the torque limiter shaft. e Install the torque limiter bolt. OApply a non-permanent locking agent to the bolt. Torque - Torque Limiter Bolt: 25 N-m (2.5 kgf-m, 18 ft-Ib)

Transmission External Shift Mechanism Installation e Install the gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] e Tighten: Torque - Gear Positioning Lever Bolt: 12 N-m (1.2 kgf-m, 106 in:Ib) External Shift Mechanism Inspection e Examine the shift shaft [A] for any damage. xlfthe shaft is bent, straighten or replace it. xlf the serration [B] are damaged, replace the shaft. xlf the springs [C] are damaged in any way, replace them. xlf the shift mechanism arm [D] is damaged in any way, replace the arm. e Check the return spring pin [A] is not loose. xlfit is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return Spring Pin: 29 N-m (3.0 kgf-m, 21 ft:lb) e Check the gear positioning lever [B] and its spring for breaks or distortion. xlf the lever or spring are damaged in any way, replace them. e Visually inspect the shift drum cam [C]. xlfthey are badly worn or if they show any damage, replace it. Transmission Shaft Removal e Split the crankcase (see Crankcase Splitting). e Remove the output shaft [A]. ps)

Transmission e Remove the cover bolts [A] and cover [B]. e Remove the shift forks (see Shift Drum and Fork Re- moval). e Pull out the drive shaft. Transmission Shaft Installation e Check to see that the set pin [A] and set ring [B] are in place. e Install the output shaft into the upper crankcase half. e Apply engine oil to the bearing. OThe bearing set pin and ring must match properly with the hole or groove in the bearing outer races. When they are properly matched, there is no clearance between the crankcase and the bearing outer races. Install the drive shaft into the lower crankcase half. e Apply grease to the O-ring. e Install the cover. e Apply a non-permanent locking agent to the drive shaft cover bolts and tighten them. Torque - Drive Shaft Cover Bolts [A]: 25 N-m (2.5 kgf-m, 18 ft-lb) e Assemble the crankcase. e Press in the oil seal [A] onto collar [B] so that the surface of the oil seal is flush with the counterbore bottom surface [C] of the crankcase. Transmission Shaft Disassembly e Remove the transmission shafts (see Transmission Shaft Removal). e Remove the circlips, disassemble the transmission shafts. e The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mecha- nism. Remove the 5th gear. OSet the output shaft in a vertical position holding the 3rd gear [B]. OSpin the 5th gear quickly [C] and pull it off upward. 61130828 $

Transmission e Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 e Discard the bearing. Gutsoussst e Transmission Shaft Assembly e Apply engine oil to the bushings, ball bearings and shafts. e Install the gear bushings [A] on the shaft with their holes [B] aligned. Gutsogosst ce e Replace any circlips removed with new ones. e Install the circlips [A] so that the opening [B] ofit is aligned with spline grooves [C]. e Install the circlips so that the mark [D] on them faces to each gear side. eusissust e e The drive shaft gears can be recognized by size: the gear With the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place. e Install the 3rd/4th gear onto the drive shaft with their oil holes aligned. e Install the 6th gear bushing onto the drive shaft with their oil holes aligned. e The output shaft gears can be recognized by size: the gear with the largest diameter is 1st gear, and the small- est one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place. e Install the 5th and 6th gears onto the output shaft with their oil holes aligned. e Install the 3rd/4th gear bushings onto the output shaft with their oil holes aligned.

Transmission e Fit the steel balls into the 5th gear holes in the output shaîft, aligning three oil holes [D]. 5th Gear [A] Output Shaft [B] Steel Balls [C] CAUTION Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction. OAfter assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear doesn't come out of the output shaft when moving it up and down by hand. e Check that each gear spins or slides freely on the trans- mission shafts without binding after assembly. Gutsosssst €

Transmission & 00100 (4) i ® OO) © ®) © © © © cuizozems €

1. Output Shaft 13. 5th Gear

3. Ball Bearing 15. 1st Gear

4. Bushing 16. Needle Bearing

5. 2nd Gear 17. Bearing Outer Race

6. Toothed Washer, #30 mm (1.18 in.) 18. Needle Bearing

7. Circlip 19. Snap Ring, 25.5 mm (1.00 in.)

8. 6th (Top) Gear 20. Toothed Washer, 35.5 mm (1.40 in.)

9. 4th Gear 21. Snap Ring, 33 mm (1.30 in.)

10. Toothed Washer, 43 mm (1.69 in.) 22. Toothed Washer, 40.5 mm (1.59 in.)

11. Toothed Washer, 39.7 mm (1.56 in.) 23. Toothed Washer, 37 mm (1.46 in.)

12. 3rd Gear 24. Drive Shaft

OWhen the tangs [A] of the toothed washer [11] shall be assembled, they shall be installed into the notches [B] of the toothed washer [10]. OWhen the tangs [C] of the toothed washer [23] shall be assembled, they shall be installed into the notches [D] of the toothed washer [22].

Transmission Shift Drum and Fork Removal e Remove: Lower Crankcase Half (see Crankcase Splitting) External Shift Mechanism (see External Shift Mecha- nism Removal) Screws [A] Shift Drum Bearing Holder [B] e Pull out the shift rods [C], and take off the shift forks. e Pull out the shift drum [D]. Shift Drum and Fork Installation e Apply engine oil to the shift drum, forks and rods. e Install the shift rods [A], noting the groove position. OPosition the one with shortest ears [B] on the drive shaft and place the pin in the center groove in the shift drum. OThe two forks [C] on the output shaft are identical. NOTE OThe forks have marks (029 [D], 030 [E]), and position them so that so that their marks face the engine left side. e Install the forks as shown. e Apply a non-permanent locking agent to the threads of the shift drum bearing holder screws and tighten them. Torque - Shift Drum Bearing Holder Screws: 4.9 N-m (0.50 kgf-m, 43 in-lb) Shift Drum Disassembly e Remove the shift drum (see Shift Drum and Fork Re- moval). e While holding the shift drum with a vise, remove the shift drum cam holder bolt. Shift Drum Cam Holder Bolt [A] Dowel Pin [B] Shift Drum Assembly e Be sure to install the dowel pin. e Apply a non-permanent locking agent to the threads of the shift drum cam holder bolt, and tighten it. Torque - Shift Drum Cam Holder Bolt: 12 N-m (1.2 kgf-m, 106 in-Ib) Giia20o8ss Griszormse € Gutsteonst e

Transmission Shift Fork Bending e Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A]

Gusoiésst € Shift Fork/Gear Groove Wear e Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves. xlf the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.

Gusiersst e Shift Fork Ear Thickness Standard: 5.74 —6.000 mm (0.2260 —-0.2362 in.) Service Limit: 5.6 mm (0.220 in.) xlf the gear groove is worn over the service limit, the gear must be replaced. Gear Groove Width Standard: 6.05 —6.15 mm (0.238 —0.242 in.) Service Limit: 6.25 mm (0.246 in.) Shift Fork Guide Pin/Drum Groove Wear e Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. xlf the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift Fork Guide Pin Diameter Standard: 6.9 —7.0 mm (0.272 —-0.276 in.) Service Limit: 6.8 mm (0.268 in.) Gutstezsst € xlf any shift drum groove is worn over the service limit, the drum must be replaced. Shift Drum Groove Width Standard: 7.05 —-7.20 mm (0.278 —0.283 in.) Service Limit: 7.3 mm (0.287 in.) Gear Dog and Gear Dog Hole Damage e Visually inspect the gear dogs [A] and gear dog holes [B]. xReplace any damaged gears or gears with excessively worn dogs or dog holes. Gustessst e

Wheels/Tires Table of Contents Exploded View. 10-2 Specifications 10-4 Special Tools 10-5 Wheels (Rims). 10-6 Front Wheel Removal 10-6 Front Wheel Installation 10-6 Rear Wheel Removal. 10-7 Rear Wheel Installation. 10-8 Wheel Inspection 10-10 Axle Inspection. 10-10 Balance Inspectioi 10-11 Balance Adjustment 10-11 Balance Weight Removal. 10-11 Balance Weight Installation. 10-12 10-14 Air Pressure Inspection/Adjustment. 10-14 Tire Inspection 10-14 Tire Removal.…. 10-14 Tire Installation. 10-14 Tire Repair . 10-16 Hub Bearing.. 10-17 Hub Bearing Removal 10-17 Hub Bearing Installation 10-17 Hub Bearing Inspection. 10-17 Hub Bearing Lubrication 10-18

AL: Tighten the two clamp bolts alternately two time to ensure even tightening. G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.

BRIDGESTONE, 190/50 ZR17 M/C (73 W)

BATTLAX BT014 R RADIAL L

À WARNING Use the same manufacturer’s tires on both front and rear wheels.

Wheels (Rims) Front Wheel Removal e Remove: Front Caliper Mounting Bolts [A] Front Calipers [B] e Loosen: Axle Clamp Bolts [A] (Left Side) Axle Nut [B] Axle Clamp Bolts (Right Side) + Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). e Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 e Remove the axle nut and pull out the axle to the right and drop the front wheel out of the forks. CAUTION Do not lay the wheel down on one of the discs. This can damage or warp the disc. Place blocks un- der the wheel so that the disc does not touch the ground. Front Wheel Installation NOTE OThe direction of the wheel rotation [A] is shown by an arrow [B] on the wheel spoke. e Check the wheel rotation mark on the front wheel and install it. Guo407o8ss

Wheels (Rims) e Apply high-temperature grease to the grease seal lip. e Fit the collars [A] on the both sides of the hub. OThe collars are identical. e Insert the axle from the right side. e Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E] Torque - Front Axle Nut: 127 N-m (13.0 kgf-m, 94 ft-1b) e Before tightening the axle clamp bolts on the right front fork leg, pump the front fork up and down 4 or 5 times to all on the right front fork leg to seat on the front axle. NOTE OPut a block in front of the front wheel to stop moving. e Tighten the axle clamp bolts on the right fork leg first. Next, tighten the left axle clamp bolts. Torque - Front Axle Clamp Bolts: 20 N-m (2.0 kgf-m, 15ft-Ib) NOTE OTighten the two clamp bolts alternately two times to en- sure even tightening torque. e Install the lower fairings (see Lower Fairing Installation in the Frame chapter). e Install the front calipers (see Caliper Installation in the Brakes chapter). e Check the front brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). À WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done. Rear Wheel Removal e Raise the rear wheel off the ground with the stand [A]. suososonss

Wheels (Rims) e Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] e Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter) (ZX1400B Models). e Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] (from Left Side) e Remove the drive chain [A] from the rear sprocket toward the left. e Move the rear wheel back and remove it. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Rear Wheel Installation e Apply high-temperature grease to the grease seal lips. e Fit the collars on the both sides of the hub. Right Side Collar [A] Left Side Collar [B] e Engage the drive chain with the rear sprocket. e Install the caliper bracket [A] onto the swingarm stop [B]. e Insert the axle from the left side of the wheel, and tighten the axle nut. Torque - Rear Axle Nut: 127 N-m (13.0 kgf-m, 94 ft-Ib)

Wheels (Rims) e Insert a new cotter pin [A]. NOTE OWhen inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. Olt should be within 30°. OLoosen once and tighten again when the slot goes past the nearest hole. + Bend the cotter pin [A] over the nut. À WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. e Adjust the drive chain slack after installation (see Drive Chain Slack Inspection in the Periodic Maintenance chap- ter). e Install the rear caliper (see Caliper Installation in the Brakes chapter). e Install the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Installation in the Brakes chapter) (ZX1400B Models). e Check the rear brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). À WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done. euososress Guoaoezess €

Wheels (Rims) Wheel Inspection e Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 e Spin the wheel lightly, and check for roughness or binding. xlfroughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation). e Inspect the wheel for small cracks, dents, bending, or Warp. xlf there is any damage to the wheel, replace the wheel. e Remove the wheel, and support it with the tire by the axle. e Measure the rim runout, axial [A] and radial [B], with a dial gauge. %lfrim runout exceeds the service limit, check the hub bear- ings (see Hub Bearing Inspection). xlf the problem is not due to the bearings, replace the wheel. Rim Runout (with tire installed) Standard: Axial TIR 0.5 mm (0.02 in.) or less Radial TIR 0.8 mm (0.03 in.) or less Service Limit: Axial TIR 1.0 mm (0.04 in.) Radial TIR 1.0 mm (0.04 in.) Never attempt to repair a damaged wheel. If there is any damage besides wheel bearings, the wheel must be replaced to insure safe operational condi- tion. Axle Inspection e Remove the front and rear axles (see Front/Rear Wheel Removal). e Visually inspect the front and rear axle for damages. xlf the axle is damaged or bent, replace it. e Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks. Turn [C] the axle to mea- sure the runout. The difference between the highest and lowest dial readings is the amount of runout. xlf axle runout exceeds the service limit, replace the axle. Axle Runout/100 mm (3.94 in.) Standard: TIR 0.03 mm (0.0012 in.) or less Service Limit: TIR 0.2 mm (0.01 in.) guoatsonss suosogssst €

Wheels (Rims) Balance Inspection e Remove the front and rear wheels (see Front/Rear Wheel Removal). e Support the wheel so that it can be spun freely. e Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops. ORepeat this procedure several times. If the wheel stops of its own accord in various positions, it is well balanced. xlfthe wheel always stops in one position, adjust the wheel balance (see Balance Adjustment). Balance Adjustment elf the wheel always stops in one position, provisionally attach a balance weight [A] on the rim atthe marking using adhesive tape. e Rotate the wheel 1/4 turn [B], and see whether or not the wheel stops in this position. Ifit does, the correct balance weight is being used. xlf the wheel rotates and the weight goes up, replace the weight with the next heavier size. If the wheel rotates and the weight goes down, replace the weight with the next lighter size. Repeat these steps until the wheel remains at rest after being rotated 1/4 turn. + Rotate the wheel another 1/4 turn and then another 1/4 turn to see if the wheel is correctly balanced. e Repeat the entire procedure as many times as necessary to achieve correct wheel balance. e Permanently install the balance weight. Balance Weight Removal e Insert a regular tip screwdrivers [A] [B] between the rib [C] and weight [D] as shown. e Pry the balance weight with two screwdrivers and remove the balance weight. e Discard the used balance weight. CAUTION Do not tap the screwdrivers. The rim could be dam- aged. suosoosess suoaovonss suoso7snst €

Wheels (Rims) Balance Weight Installation e Check if the weight portion has any play on the blade [A] and clip [B]. xlf it does, discard it. À WARNING If the balance weight has any play on the rib of the rim, the blade and/or clip have been stretched. Re- place the loose balance weight. Do not reuse used balance weight. Unbalanced wheels can create an unsafe riding condition. Balance Weight Part Number Weight 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0017 30 g (1.06 oz.) NOTE OBalance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35 oz., 0.71 oz., and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability. ODo not use four or more balance weight (more than 90 gram, 3.2 oz.). lfthe wheel requires an excess balance weight, disassemble the wheel to find the cause. eJouisepse €

Wheels (Rims) e Slip the balance weight [A] on to the rib [B], by pushing or lightly hammering [C] the clip [D]. Olnstall the balance weight at the left side ofthe motorcycle. Left Side [E] Right Side [F] eJouisonse € e Check that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. Left Side [E] Right Side [F] eJouisons2 €

Tires Aïir Pressure Inspection/Adjustment e Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection e Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal e Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) e To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position. Chalk Mark or Yellow Mark [A] Air Valve [B] Align [C] e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant. This helps the tire beadbs slip off the rim flanges. CAUTION Never lubricate with engine oil or petroleum distil- lates because they will deteriorate the tire. e Remove the tire from the rim using a suitable commer- cially available tire changer. NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly. Tire Installation À WARNING Use the same manufacture’s on both front and rear wheels. e Inspect the rim and tire, and replace them if necessary. e Clean the sealing surfaces of the rim and tire, and smooth the sealing surfaces of the rim with a fine emery cloth if necessary. e Remove the air valve and discard it. CAUTION Replace the air valve whenever the tire is replaced. Do not reuse the air valve. suosogonst

Tires e Install a new valve in the rim. ORemove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum distillates to lu- bricate the stem because they will deteriorate the rubber. OThe air valve is shown in the figure. Valve Cap [A] Valve Core [B] Stem Seal [C] Valve Stem [D] Valve Seat [E] Valve Opened [F] e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly. Tire Rotation Mark [A] Rotating Direction [B] e Position the tire on the rim so that the valve [A] align with the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire). e Install the tire bead over the rim flange using a suitable commercially available tire changer. e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire. e Center the rim in the tire beads, and inflate the tire with compressed air until the tire beads seat in the sealing surfaces. Be sure to install the valve core whenever inflating the tire, and do not inflate the tire to more than 400 kPa (4.0 kgf/cm’, 57 psi). Overinflation can explode the tire with possibility of injury and loss of life. suosoaress Guososo7st € suoso4anst ce

Tires © Check to see that the rim lines [A] on both sides of the tire sidewalls are parallel with the rim flanges. xlfthe rim flanges and tire sidewall rim lines are not parallel, remove the valve core. e Lubricate the rim flanges and tire beads. e Install the valve core and inflate the tire again. e After the tire beads seat in the rim flanges, check for air leakage. Olnflate the tire slightly above standard inflation. OUse a soap and water solution or submerge the tire, and check for bubbles that would indicate leakage. e Adjust the air pressure to the specified pressure (see Air Pressure Inspection in the Periodic Maintenance chap- ter). e Install the air valve cap. e Adjust the wheel balance (see Balance Adjustment). Tire Repair Currently two types of repair for tubeless tires have come into wide use. One type is called a temporary (external) re- pair which can be carried out without removing the tire from the rim, and the other type is called permanent (internal) repair which requires tire removal. It is generally under- stood that higher running durability is obtained by perma- nent (internal) repairs than by temporary (external) ones. Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make. Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained. uoso4zsst ce

Hub Bearing Hub Bearing Removal e Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals e Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Special Tools -Bearing Remover Head, 25 x 428 [B]: 57001-1346 auoeoasest c Bearing Remover Shaft, 413 [C]: 57001

Hub Bearing Installation FR e Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. e Replace the bearings with new ones. e Install the bearings by using the bearing driver set which does not contact the bearing inner race. e Press in each right the bearing [A] until they are bottomed. Special Tool - Bearing Driver Set [B]: 57001-1129 suogoossst ce e Replace the grease seals with new ones. Fa e Press in the grease seals [A] so that the seal surface is ©) flush [B] with the end of the hole. OApply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129 a suogoossst Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. NOTE ODo not remove any bearings for inspection. lfany bear- ings are removed, they will need to be replaced with new ones. e Turn each bearing in the hub back and forth [A] while checking for plays, roughness, or binding. coneonst € xlf bearing play, roughness or binding is found, replace the bearing. e Examine the bearing seal [B] for tears or leakage. xlf the seal is torn or is leaking, replace the bearing.

Hub Bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed, lubrication is not required.

• Final Drive Table of Contents Exploded View 11-2 Specifications . 11-4 Special Tools 11-5 Drive Chain. 11-6 Drive Chain Slack Inspection … 11-6 Drive Chain Slack Adjustment . 11-6 Wheel Alignment Inspection/Adjustment . 11-6 Drive Chain Wear Inspection 11-6 Drive Chain Lubrication 11-6 Drive Chain Removal p. 11
• -6 Drive Chain Installation 11-6 Sprocket, Coupling 11-7 Engine Sprocket Removal 11-7 Engine Sprocket Installation . 11-7 Rear Sprocket Removal. 11-8 Rear Sprocket Installation. 11-8 Coupling Installation -8 Coupling Bearing Removal 11-9 Coupling Bearing Installation 11-9 Coupling Bearing Inspection. 11-10 Coupling Bearing Lubrication 11-10 11-10 11-10 11-11 Coupling Damper Inspection. Sprocket Wear Inspection. Rear Sprocket Warp Inspection p. 11

Exploded View Torque No. Fastener Remarks Nm kgf-:m ft:lb 1 [Chain Guide Bolt 12 1.2 106 in-lb L 2 |Chain Guide Bolts 9.8 1.0 87 in:lb L 3 |Engine Sprocket Cover Bolts 9.8 1.0 87 in-lb 4 |Engine Sprocket Nut 125 13.0 92 MO 5 |Rear Axle Nut 127 13.0 94 6 |Rear Sprocket Nuts 69 7.0 51 7 | Speed Sensor Bolt 3.9 0.40 35 in:lb L 8 |Stud Bolts 14.7 1.5 11 L G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts

0.4 mm (0.016 in.) or less

Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment e Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter. Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter. Drive Chain Lubrication e Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter. Drive Chain Removal e Remove the chain cover screws [A] and chain cover [B]. OClear the chain cover from the swingarm. e Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Engine Sprocket (see Engine Sprocket Removal) Swingarm (see Swingarm Removal in the Suspension chapter) e Remove the drive chain [A] from the output shaft [B], and take it off the chassis. Drive Chain Installation e Install the drive chain to the output shaft. e Install: Swingarm (see Swingarm Installation in the Suspension chapter) Engine Sprocket (see Engine Sprocket Installation) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) Chain Cover e Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Mainte- nance chapter).

Sprocket, Coupling Engine Sprocket Removal e Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Speed Sensor [A] (see Speed Sensor Removal in the Electrical System chapter) Clutch Slave Cylinder [B] (see Clutch Slave Cylinder in the Clutch chapter) Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D] e Flatten out the bended washer [A]. e Remove the engine sprocket nut [B]. NOTE OWhen loosening the engine sprocket nut, hold the rear brake on. ° Remove: Washer [A] Chain Guide Bolts [B] Chain Guide [C] e Raise the rear wheel off the ground with the stand. e Remove the axle cotter pin, and loosen the rear axle nut. e Loosen the both chain adjuster locknut to loosen the drive chain. e Remove the drive chain from the rear sprocket toward the right. e Pull the engine sprocket [D] with drive chain [E] off the output shaft [F]. e Disengage the drive chain from the engine sprocket. Engine Sprocket Installation e Replace the sprocket washer and axle cotter pin. e Install the engine sprocket onto the output shaft. e Apply a non-permanent locking agent to the threads of the chain guide bolts. e Install the chain guide, and tighten the bolts. Torque - Chain Guide Bolt: 12 N-m (1.2 kgf-m, 106 in-Ib) Chain Guide Bolts: 9.8 N-m (1.0 kgf-m, 87 in:lb) e Apply molybdenum disulfide oil solution to the threads of the output shaft and the seating surface of the engine sprocket nut. e After torquing the engine sprocket nut, bend the one side of the washer [A] over the nut. NOTE OTighten the nut while applying the rear brake. Torque - Engine Sprocket Nut: 125 N-m (13.0 kgf-m, 92 ft-Ib) e Adjust the drive chain slack after installing the engine sprocket (see Drive Chain Slack Adjustment in the Pe- riodic Maintenance chapter).

Sprocket, Coupling e Install the engine sprocket cover. e Install the clamp [A] as shown in the figure, and tighten the cover bolts. Torque - Engine Sprocket Cover Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb) e Bend the end of axle cotter pin surely after tightening the axle nut (see Rear Wheel Installation in the Wheels/Tires chapter). e Install the removed parts (see appropriate chapters). Rear Sprocket Removal e Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). exososiess CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. e Remove the rear sprocket nuts [A]. e Remove the rear sprocket [B]. Rear Sprocket Installation e Install the sprocket facing the tooth number marking [A] outward. e Tighten the rear sprocket nuts. Torque - Rear Sprocket Nuts: 69 N-m (7.0 kgf-m, 51 ft:1b) e Install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter). Coupling Installation e High-temperature grease the following. Coupling Grease Seal Lips [A] Coupling Internal Surface [B] ckosogonst

Sprocket, Coupling e Install the collar [A]. e Install the coupling. Coupling Bearing Removal e Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 e Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation e Replace the bearing with a new one. NOTE Olnstall the bearing so that the marked side faces out. e Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set [B]: 57001-1129 e Replace the circlip with a new one. Special Tool - Inside Circlip Pliers: 57001-143 e Replace the grease seal with a new one. e Press in the grease seal so that the seal surface is flush With the end of the hole. OApply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 Gkosossust Gkosossast

Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE Olt is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one. e Turn the bearing in the coupling back and forth [A] while checking for plays, roughness or binding. xlfthe bearing play, roughness or binding is found, replace the bearing. e Examine the bearing seal [B] for tears or leakage. xlfthe seal is torn or is leaking, replace the bearing. Coupling Bearing Lubrication NOTE OSince the coupling bearing is packed with grease and sealed, lubrication is not required. Coupling Damper Inspection e Remove the rear wheel coupling, and inspect the rubber dampers [A]. e Replace the damper if it appears damaged or deterio- rated. Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage. xlf the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter). Worn Tooth (Engine Sprocket) [A] Worn Tooth (Rear Sprocket) [B] Direction of Rotation [C] NOTE OIf a sprocket requires replacement, the chain is proba- bly worn also. When replacing a sprocket, inspect the chain. Guogoozsst Gkosoï7ast €

Sprocket, Coupling Rear Sprocket Warp Inspection e Raise the rear wheel off the ground with the stand so that it will turn freely. e Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp). xIf the runout exceeds the service limit, replace the rear sprocket. Rear Sprocket Warp Standard: 0.4 mm (0.016 in.) or less Service Limit: 0.5 mm (0.020 in.) Gkosooonst c

12-4 BRAKES Exploded View ZX1400A Models GLO22078#5 ©

BRAKES 12-7 Exploded View Torque No. Fastener Remarks Nm kgf-:m ft:lb 1 |Bleed Valves 7.8 0.80 69 in-lb 2 |Brake Hose Banjo Bolts 25 2.5 18 3 |Brake Pedal Bolt 8.8 0.90 78 in-lb 4 |Rear Brake Disc Mounting Bolts 27 2.5 18 L 5 |Rear Brake Pad Pin 17.2 1.8 13 6 |Rear Caliper Assembly Bolts 37 3.8 27 L 7 |Rear Caliper Mounting Bolts 25 2.5 18 8 |Rear Master Cylinder Mounting Bolts 25 2.5 18 9 |Rear Master Cylinder Push Rod Locknut 17.2 1.8 13 B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts Si: Apply silicone grease (ex. PBC grease).

BRAKES 12-11 Exploded View Torque No. Fastener Remarks Nm kgf-:m ft'lb 1 |Bleed Valves 7.8 0.80 69 in-lb 2 |Brake Hose Banjo Bolts 25 2.5 18 3 |Brake Pedal Bolt 8.8 0.90 78 in-lb 4 |Brake Pipe Joint Nuts 18 1.8 13 5 |Rear Brake Disc Mounting Bolts 27 2.8 20 L 6 |Rear Brake Pad Pin 17.2 1.8 13 7 |Rear Caliper Assembly Bolts 37 3.8 27 L 8 |Rear Caliper Mounting Bolts 25 2.5 18 9 |Rear Master Cylinder Mounting Bolts 25 2.5 18 10 |Rear Master Cylinder Push Rod Locknut 17.2 1.8 13 B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts Si: Apply silicone grease (ex. PBC grease).

12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position 6-way adjustable (to suit rider) Non-adjustable Non-adjustable About 45 mm (1.8 in.) below footpeg top Brake Pads Lining Thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.) Rear 5.0 mm (0.20 in.) 1 mm (0.04 in.) Brake Discs Thickness: Front 4.8 —5.2 mm (0.19 —0.20 in.) 4.5 mm (0.18 in.) Rear 5.8 —6.2 mm (0.23 —0.24 in.) 5.5 mm (0.22 in.) Runout TIR 0.15 mm (0.006 in.) or less TIR 0.3 mm (0.01 in.) Brake Fluid Grade DOT4

12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator's hand. e Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder. OThe distance from the grip to the lever is minimum at num- ber 6 and maximum at number 1. Brake Pedal Position Inspection e Check that the brake pedal [A] is in the correct position. Footpeg [B] Pedal Position Standard: About 45 mm (1.8 in.) [C] below top of footpeg xlfit is incorrect, adjust the brake pedal position. Brake Pedal Position Adjustment NOTE OUsually it is not necessary to adjust the pedal position, but always adjust it when push rod locknut has been loosened. e Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position. xlf the length [C] shown is 80 +1 mm (3.1 +0.04 in.), the pedal position will be within the standard range. e Tighten: Torque - Rear Master Cylinder Push Rod Locknut: 17.2 N-m (1.8 kgf-m, 13 ft:lb) e Check the brake light switch operation (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter). Brake Pedal Removal e Remove: Rear Master Cylinder Mounting Bolts [A] Right Footpeg Bracket Bolts [B]

BRAKES 12-15 Brake Lever, Brake Pedal e Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] e Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Installation e Apply grease to the pivot shaft [A] and install the washer [B]. e Install: Brake Pedal [C] Washer [D] Brake Pedal Bolt [E] Torque - Brake Pedal Bolt: 8.8 N-m (0.90 kgf-m, 78 in:lb) e Hook the lower end of the rear brake light switch spring [A] on the pedal hook. e Hook the upper end of the return spring [B] on the pedal hook. e Replace the cotter pin with a new one. e Insert the cotter pin [A] and bend the pin ends [B]. e Install the right footpeg bracket. Torque - Front Footpeg Bracket Bolts: 25 N-m (2.5 kgf-m, 18 ft-lb) ODepress the brake pedal [A] and then align the bolts holes of the master cylinder [B]. Torque - Rear Master Cylinder Mounting Bolts: 25 N-m (2.5 kgf-m, 18 ft:lb) e Check the brake pedal position (see Brake Pedal Position Inspection).

12-16 BRAKES Calipers Front Caliper Removal e Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. e Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage. e Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation). CAUTION Immediately wash away any brake fluid that spills. NOTE Off the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Front Caliper Disassembly). Rear Caliper Removal e Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. e Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage. e Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation). CAUTION Immediately wash away any brake fluid that spills. NOTE Off the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Rear Caliper Disassembly).

BRAKES 12-17 Calipers Caliper Installation e Install the caliper and brake hose lower end. OReplace the washers on each side of hose fitting with new ones. e Tighten: Torque - Caliper Mounting Bolts Front: 34 N-m (3.5 kgf-m, 25 ft-lb) Rear: 25 N-m (2.5 kgf-m, 18 ft:1b) Brake Hose Banjo Bolts: 25 N:m (2.5 kgf-m, 18 ft-Ib) e Check the fluid level in the brake reservoirs. e Bleed the brake line (see Brake Line Bleeding). e Check the brake for good braking power, no brake drag, and no fluid leakage. Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done. Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter.

12-18 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase. e Replace the fluid seal if it exhibits any of the conditions listed below. OBrake fluid leakage around the pad. OBrakes overheat. OConsiderable difference in inner and outer pad wear. OSeal and piston are stuck together. xlf the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed. Caliper Dust Seal Damage e Check that the dust seals [A] are not cracked, worn, swollen, or otherwise damaged. x lfthey show any damage, replace the dust seals with new ones. Pistons [B] Fluid Seals [C] eLosissnss GLosissess eLosissnss €

BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage e Visually inspect the pistons [A] and cylinder surfaces [B]. xReplace the caliper if the cylinder and piston are badly scores or rusty. eLosissnss

12-20 BRAKES Brake Pads Front Brake Pad Removal e Loosen the pad pins [A]. e Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go. e Install the outside pad [A] and insert the pad pin [B] as shown in the figure. e Set: Inside Pad [A] Pad Spring [B] OPushing the pin holder [C] to hole of the pad and insert the pad pin. Torque - Front Brake Pad Pins: 17.2 N°m (1.8 kgf-m, 13 ft-Ib) Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever and the pads are against the disc. The brake will not function on the first application of the lever if this is not done.

BRAKES 12-21 Brake Pads Rear Brake Pad Removal e Loosen the pad pin [A]. e Unscrew the caliper mounting bolts [B]. e Remove the caliper with the hose installed. e Remove: Pad Pin [A] Pad Spring [B] Brake Pads [C] Rear Brake Pad Installation e Push the caliper pistons in by hand as far as they will go. e Install the outside pad [A] and insert the pad pin [B] as shown in the figure. e Set: Inside Pad [A] Pad Spring [B] OPushing the pin holder [C] to hole of the pad and insert the pad pin. e Install the caliper (see Caliper Installation). e Tighten the pad pin. Torque - Rear Brake Pad Pin: 17.2 N-m (1.8 kgf-m, 13 ft-lb) Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done. Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter.

12-22 BRAKES Master Cylinder Front Master Cylinder Removal e Remove the reservoir bracket bolt [A]. e Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). e Unscrew the clamp bolts [C], and take off the master cylin- der [D] as an assembly with the reservoir, brake lever, and brake switch installed. e Disconnect the front brake light switch connector [E]. CAUTION Immediately wash away any brake fluid that spills. e Remove: Brake Lever Pivot Bolt [A] and Nut Brake Lever [B] Clamp [C] (Slide Out) Brake Hose [D] Front Brake Light Switch [E] Front Master Cylinder Installation e Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar. e The master cylinder clamp must be installed with the ar- row mark [C] upward. e Tighten the upper clamp boit first, and then the lower clamp boit. Torque - Front Master Cylinder Clamp Bolts: 8.8 N-m (0.90 kgf-m, 78 in-Ib) e Replace the washers that are on each side of the hose fitting with new ones. e Tighten: Torque - Brake Hose Banjo Bolt: 25 N-m (2.5 kgf-m, 18 ft-Ib) e Bleed the brake line (see Brake Line Bleeding). e Check the brake for good braking power, no brake drag, and no fluid leakage. Rear Master Cylinder Removal e Unscrew the brake hose banjo bolt [A] and brake hose [B]. e Remove: Cotter Pin [C] Joint Pin [D] Bolts [E] Foot Guard [F] Rear Master Cylinder e Slide out the clamp [G]. e Pull off the reservoir hose lower end, and drain the brake fluid into a container.

BRAKES 12-23 Master Cylinder Rear Master Cylinder Installation e Replace the cotter pin with a new one. e Replace the washers that are on each side of hose fitting with new ones. e Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N-m (2.5 kgf-m, 18 ft-lb) Brake Hose Banjo Bolt: 25 N-m (2.5 kgf-m, 18 ft-Ib) e Bleed the brake line (see Brake Line Bleeding). e Check the brake for good braking power, no brake drag, and no fluid leakage. Front Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Inspection (Visual Inspection) e Remove the master cylinders (see Front/Rear Master Cylinder Removal). e Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). e Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B]. xlf a master cylinder or piston shows any damage, replace them. e Inspect the primary cup [C] and secondary cup [D]. xlf a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups. xlf fluid leakage is noted at the brake lever, the piston as- sembly should be replaced to renew the cups. Front Master Cylinder [J] eLoroezess €

12-24 BRAKES Master Cylinder © Check the dust covers [E] for damage. xlf they are damaged, replace them. e Check the piston return spring [F] for any damage. xlf the springs are damaged, replace them. e Check that relief port [G] and supply port [H] are not plugged. xlf the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air. Rear Master Cylinder [K] estsosons2 c

BRAKES 12-25 Brake Disc Brake Disc Removal e Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). e Unscrew the mounting bolts, and take off the disc. ORemove the sensor rotor (ZX1400B Models). Brake Disc Installation e Install the brake disc on the wheel so that the marked side [A] faces out. Olnstall the sensor rotor on the brake disc so that the marked side faces out (ZX1400B Models). e Apply a non-permanent locking agent to the threads of the rear brake disc mounting bolts [B]. e Tighten: Torque - Brake Disc Mounting Bolts: 27 N-m (2.8 kgf-m, 20 ft-1b) Brake Disc Wear e Measure the thickness of each disc [A] at the point where it has worn the most. xlf the disc has worn past the service limit, replace it. Measuring Area [B] Brake Discs Thickness Standard: Front 4.8 —5.2 mm (0.19 —0.20 in.) Rear 5.8 —6.2 mm (0.23 -0.24 in.) Service Limit: Front 4.5 mm (0.18 in.) Rear 5.5 mm (0.22 in.) Brake Disc Warp e Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 OFor front disc inspection, turn the handlebar fully to one side. e Set up a dial gauge against the disc [A] as shown and measure disc runout, while turning [B] the wheel by hand. xIf runout exceeds the service limit, replace the disc. Disc Runout Standard: Service Limit: TIR 0.15 mm (0.006 in.) or less TIR 0.3 mm (0.01 in.) GLogor7ast €

12-26 BRAKES Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power. Be sure to bleed the air from the brake line when- ever brake lever or pedal action feels soft or spongy after the brake fluid is changed, or when- ever a brake line fitting has been loosened for any reason. NOTE OThe procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake. e Remove: Screw [A] Clamp [B] Front Brake Reservoir Cap [C] Diaphragm Plate Diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir. e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir. OBleed the air completely from the master cylinder by this operation. e Remove the rubber cap from the bleed valve on the front master cylinder. e Attach a clear plastic hose [A] to the bleed valve, and run the other end of the hose into a container.

BRAKES 12-27 Brake Fluid e Bleed the brake line and the master cylinder. ORepeat this operation until no more air can be seen com- ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [CI].

NOTE OThe fluid level must be checked often during the bleed- ing operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. e Remove the clear plastic hose. e Tighten the bleed valve, and install the rubber cap. Torque - Front Master Cylinder Bleed Valve: 7.8 N-m (0.80 kgf-m, 69 in-Ib) + Remove the rubber cap [A] from the bleed valve on the caliper. e Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. e Bleed the brake line and the caliper. ORepeat this operation until no more air can be seen com- ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [CI].

NOTE OThe fluid level must be checked often during the bleed- ing operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. OTap the brake hose lightly from the caliper to the reser- voir for more complete bleeding. OFront Brake: First bleeding the right caliper then repeat the above steps for the left caliper. e Remove the clear plastic hose. éLosowrBs2 €

12-28 BRAKES Brake Fluid e Install: Diaphragm Diaphragm Plate Front Brake Reservoir Cap [A] Clamp [B] Screw [C] e Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. OfFirst, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A]. e Tighten: Torque - Front Brake Reservoir Cap Stopper Screw: 1.2 N-m (0.12 kgf-m, 11 in:lb) e Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valve: 7.8 N-m (0.80 kgf-m, 69 in-Ib) e Check the fluid level (see Brake Fluid Level Inspection in the Periodic Maintenance chapter). e After bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage. cs130248 $

BRAKES 12-29 Brake Fluid À WARNING When working with the disc brake, observe the pre- cautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left

unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in

the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.

4. Don't leave the reservoir cap off for any length of

time to avoid moisture contamination of the fluid.

5. Don't change the fluid in the rain or when a strong

6. Except for the disc pads and disc, use only disc

brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterio- ration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.

7. When handling the disc pads or disc, be careful that

no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads With new ones if they cannot be cleaned satisfacto- rily.

8. Brake fluid quickly ruins painted surfaces; any

spilled fluid should be completely wiped up imme- diately.

9. If any of the brake line fittings or the bleed valve is

opened at any time, the AIR MUST BE BLED FROM THE BRARKE LINE.

12-30 BRAKES Brake Hose Brake Hose and Pipe Removal/Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection e Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.

[le] 24,25 GLiato78m2 © . Unused . Power Supply to Rear Wheel Rotation Sensor . Front Wheel Rotation Sensor Signal . Front and Rear Brake Light Switch Unused Unused . Unused . Power Supply to ABS Solenoid Valve Relay . Power Supply to ABS Motor Relay

12. Power Supply to Front Wheel Rotation Sensor

12-34 BRAKES Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. OThis ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ODo not reverse the battery cable connections. This will damage the ABS hydraulic unit. OTo prevent damage to the ABS parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running. OTake care not to short the leads that are directly con- nected to the battery positive (+) terminal to the chassis ground. ODo not turn the ignition switch ON while any of the ABS electrical connectors are disconnected. The ABS hy- draulic unit memorizes service codes. ODo not spray water on the electrical parts, ABS parts, con- nectors, leads and wiring. Of a transceiver is installed on the motorcycle, make sure that the operation of the ABS system is not influenced by electric wave radiated from the antenna. Locate the antenna as far as possible away from the ABS hydraulic unit. OWhenever the ABS electrical connections are to be dis- connected, first turn off the ignition switch. OThe ABS parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. OThe ABS parts cannot be disassembled. Even if a fault is found, do not try to disassemble and repair the ABS parts, replace it. OThe ABS has many brake lines, pipes, and leads. And the ABS cannot detect problems with the conventional braking system (brake disc wear, unevenly worn brake pad, and other mechanical faults). To prevent trouble, check the brake lines and pipes for correct routing and connection, the wiring for correct routing, and the brakes for proper braking power. Be sure to check for fluid leak- age, and bleed the brake line thoroughly. À WARNING If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line. CAUTION Do not ride the motorcycle with air in the brake line, or the ABS could malfunction.

BRAKES 12-35 Anti-Lock Brake System (Equipped Models) OThe ABS indicator light (LED) [A] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. lfthe indicator light lights, remedy the problem and clear the service code. À WARNING Use of non-recommended tires may cause malfunc- tioning of ABS and can lead to extended braking distance. The rider could have an accident as a re- sult. Always use recommended standard tires for this motorcycle. OThe ABS indicator light (LED) may come on if the engine is run with the motorcycle on its stand and the transmis- sion in gear. If the indicator light comes on, just turn the ignition switch OFF, then clear service code 42, which in- dicates a “Faulty front wheel rotation sensor”. OWhen the ABS operates, the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal. This is a normal condition. It informs the rider that the ABS is operating normally. OService codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit. Therefore, after maintenance work is finished, be sure to erase the service codes. Do not erase the service codes during troubleshooting. Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work. OBefore delivering the motorcycle to the customer, be sure to erase any service codes which might be stored in the ABS hydraulic unit. Using the self-diagnosis feature, make sure that the ABS indicator light (LED) lights. A fully charged battery is a must for conducting reliable self-diagnosis. Test run the motorcycle at a speed of more than 20 km/h (12 mph) to see that the ABS indicator light (LED) does not come on. Finally, test run the mo- torcycle at a speed of more than 30 km/h (20 mph) and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally (The reaction force generated is felt in the brake lever and pedal.). This completes the final inspection. OColor Codes: BK: Black G: Green P: Pink BL: Blue GY: Gray PU: Purple BR: Brown LB: Light Blue R: Red CH: Chocolate LG: Light Green W: White DG: Dark Green O: Orange Y: Yellow eLiatosess

12-36 BRAKES Anti-Lock Brake System (Equipped Models) ABS Troubleshooting Outline When an abnormality in the system occurs, the ABS in- dicator light (LED) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the ser- vice code [A] is indicated by the number of times the ABS indicator light (LED) blinks. The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected. Therefore, after correcting the problem, always erase the service codes and then run the self-diagnosis program to confirm normal signal output. When, due to a malfunction, the ABS indicator light (LED) remains lit, get a thorough understanding of the background before starting the repair work. Ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C]. Do not rely solely on the ABS self-diagnosis function, use common sense; check the brakes for proper braking power, and brake fluid level, search for leaks, etc. Even when the ABS is operating normally, the ABS indi- cator light (LED) may light up under the conditions listed be- low. Turn the ignition switch OFF to stop the indicator light. If the motorcycle runs without erasing the service code, the light may light up again. OAfter continuous riding on a rough road. OWhen the engine is started with the stand raised and the transmission engaged, and the rear wheel turns. OWhen accelerating so abruptly that the front wheel leaves the ground. OWhen the ABS has been subjected to strong electrical interference. OWhen tire pressure is abnormal. Adjust tire pressure. OWhen a tire different in size from the standard size is being used. Replace with standard size. OWhen the wheel is deformed. Replace the wheel. Much of the ABS troubleshooting work consists of con- firming continuity of the wiring. The ABS parts are assem- bled and adjusted by the manufacturer, so there is no need to disassemble or repair them. Replace the ABS hydraulic unit. The basic troubleshooting procedures are listed below. e Carry out pre-diagnosis inspections as a preliminary in- spection. e Determine the fault using the self-diagnosis function. e Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part, using the hand tester. Special Tool - Hand Tester: 57001-1394 gcrraogess €

BRAKES 12-37 Anti-Lock Brake System (Equipped Models) e Visually inspect the wiring for signs of burning or fraying. xlf any wiring is poor, replace the damaged wiring. e Pull each connector [A] apart and inspect it for corrosion, dirt and damage. xlf the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. e Check the wiring for continuity. OUse the wiring diagram to find the ends of the lead which is suspected of being a problem. OConnect the hand tester between the ends of the leads. Special Tool - Hand Tester: 57001-1394 OSet the tester to the x 1 Q range, and read the tester. If the tester does not read 0 Q, the lead is defective. Re- place the main harness [B] if necessary. e Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests. xlf no abnormality is found in the wiring or connectors, the ABS parts are the next likely suspects. Check each part one by one. xlf an abnormality is found, replace the affected ABS part. eLiatoomss €

12-38 BRAKES Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart Problem occurs. Confirm problems. Gather information from rider. Conduct pre-diagnosis inspection 1, 2. Conduct self-diagnosis. Check by other than self-diagnosis. Check by self-diagnosis. If harness or connector is faulty. IFABS part is faulty. Repair or replace Check ABS parts. Replace Final inspection.

BRAKES 12-39 Anti-Lock Brake System (Equipped Models) Inquiries to Rider OEach rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. OTry to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop. OThe diagnosis sheet will help prevent you from overlooking any keys, so always use it. Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Frequency: Weather: Mileage: O Brake OIndicator | Braking | Abnor- |O ABS not |O ABS DO ABS op- lever light distance | mal working works erating vibration | blinks too long brake but too fre- or noise lever indicator | quently move- light Phenom ment doesn't OPedal |Oindicator D Abnor- light up vibration | light mal or noise remains pedal lit up move- ment Engine conditions at O At start-up O After starting D At 5 000 r/min (rpm) problem or more Road conditions O Slippery road O Rough surface CO Other (E snow, [Ugravel, Uother ) Driving conditions DHigh-speed cornering O Driving 10 km/h (6 mph) or above O Driving below 10 km/h (6 mph) © When stopping © When turning Brake application © Gradual © Abrupt Other conditions D Large brake lever stroke D Large pedal stroke

12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1 There shouldn't be excessive axle bending or disc runout. NG: Check brake fluid level in brake reservoir. Replenish brake fluid. _ NG ; _ Check for brake fluid leakage. >| Repair brake line. |. NG . n Check brake lever and brake pedal function. Repair or replace master cylinder. : NG: Check brake pad and brake disc. Replace faulty parts. Front and rear wheels should rotate smoothly without | NG: Repair or replace caliper. brake drag. There shouldn't be a lot of play in the wheel bearing. NG. Replace wheel bearing or axle.

BRAKES 12-41 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 No (Uniit) Check the ABS indicator light (LED). Check the power source wiring and meter © Does the indicator light light up with unit. the ignition switch ON? Yes (lit) Drive at 6 km/h (3.7 mph) or above for one minute or more: Yes When the motorcycle is running, does the indicator ABS is normal. light go off? Count the number of times the indicator light blinks in Ask the rider if the problem the self-diagnosis mode to find the service code. happens again. CITE Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch. The ABS hydraulic unit can memorize up to all service codes (14 codes). Further service codes are memorized after erasing the preceding all service codes (14 codes). If there is no fault, the ABS indicator light (LED) lights, indicating that “The ABS is normal”. Self-diagnosis Procedures OWhen a problem occurs with the ABS system, the ABS indicator light (LED) [A] lights. NOTE OUse a fully charged battery when conducting self-diagnosis. Otherwise, the light blinks very slowly or doesn't blink. OThe motorcycle is stopped. OKeep the self-diagnosis terminal grounded during self eListossi c -diagnosis, with an auxiliary lead.

12-42 BRAKES Anti-Lock Brake System (Equipped Models) e Remove the seat (see Seat Removal in the Frame chap- ter). e Ground the self-diagnosis terminal [A] (Gray) to the ground terminal [B] (Black/Yellow), using a lead. e Turn on the ignition switch. OCount the blinks of the light to read the service code. Keep the auxiliary lead ground until you finish reading the service code. Service Code Clearing Procedures e Start the service code erase mode with the following pro- cedure. OThe erase mode starts when the ABS self-diagnosis ter- minal is disconnected from the ground terminal after start- ing the self-diagnosis mode. OThe service code can be erased by grounding and un- grounding (each time for at least one second) the ABS self-diagnosis terminal three times or more within about

12.5 seconds after starting the erase mode.

OThe ABS indicator light (LED) remains lit during the erase mode. OAfter erasing, the ABS indicator light (LED) blinks and lights. OOnce erasing is finished, enter the self-diagnosis mode again to confirm that the service codes have been erased. lf the ABS has been reset and all codes have been erased, the ABS indicator light (LED) lights.

12-44 BRAKES Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart Turn the ignition switch OFF. Connect the ABS self-diagnosis terminal to the ground terminal. Turn the ignition switch ON. Self-diagnosis mode starts. The ABS indicator light (LED) blinks to display the service code in about 3.6 seconds after entering the self-diagnosis mode. (1) If no service code is shown, drive at 20 km/h (12 mph) or more for one minute, stop, and try self-diagnosis again. Check the faulty point with the service code table and repair according to fault inspection 1 to 14. Erase the service code memorized in the ABS hydraulic unit. Start the self-diagnosis mode to confirm that erasing has been completed. Disconnect the ABS self-diagnosis terminal to the ground terminal, ending the self-diagnosis mode. Activate the ABS by driving the motorcycle at 20 km/h (12 mph) or | NG (it) x above in order to confirm that the ABS is normal. Repeat self diagnosis. OK (Uniit) Activate the ABS at a safe place in order to confirm that it operates normally. (2)

End (1): The self-diagnosis mode ends following. When the ignition switch is OFF. When the motorcycle is driven while in the self-diagnosis mode. When the self-diagnosis terminal disconnects. (2): Apply brake suddenly at 30 km/h (19 mph)} or more to confirm that the motorcycle stops smoothly and steady with pulsation on the brake lever and pedal. GB F

BRAKES 12-45 Anti-Lock Brake System (Equipped Models) How to Read Service Codes OService codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ORead 10th digit and unit digit as the ABS indicator light (LED) blinks. OWhen there are a number of faults, a maximum of all service codes (14 codes) can be stored and the display will begin starting from the small number code entered. OFor the display pattern, first the smallest number code is shown, next up to all service codes (14 codes) starting with the last one stored, then the display is repeated from the smallest number code once again. Service Service Service Service Service code 13 code 14 code 17 code 53 code 55

Off there is no fault, the ABS indicator light (LED) lights as shown in the figure. Repeat Gtiartasnt © Light (LED) OFF 1 Start Self-diagnosis End Self-diagnosis ï ï ABS Self open ! diagnosis l Terminal Ground

CEA How to Erase Service Codes OEven if the ignition switch is turned OFF, the battery or the ABS hydraulic unit are disconnected, all service codes remain in the ABS hydraulic unit. ORefer to the Service Code Clearing Procedure for the service code erasure.

12-46 BRAKES Anti-Lock Brake System (Equipped Models) Service Code Table Service Code ABS Indicator Light (LED) Problems Light State on Rear inlet solenoid valve trouble (shorted or 18 JLIUUL or open, stuck valve (ON)) ON 14 ALUUUL Rear outlet solenoid valve trouble (shorted ON or open, stuck valve (ON)) 17 NL UUUUUUL Front inlet solenoid valve trouble (shorted ON or open, stuck valve (ON)) 18 AL UUUUUUUL Front outlet solenoid valve trouble (shorted ON or open, stuck valve (ON)) 19 NL UUUUUUUUL ABS solenoid valve relay trouble (wiring ON shorted or open, stuck relay (ON or OFF)) Front, rear tire abnormal (substandard 25 NN AAA tire, deformation wheel, sensor rotor teeth ON number wrong) 35 JUULUUUUL ABS motor relay trouble (wiring shorted, ON open or lock, stuck relay (ON or OFF) Front wheel rotation sensor signal abnormal 42 (sensor or rotor missing, too large ON clearance, rotor tooth worn or missing) Front wheel rotation sensor wiring abnormal 43 a ON (wiring shorted or open) Rear wheel rotation sensor signal abnormal 44 (sensor or rotor missing, too large ON clearance, rotor tooth worn or missing) Rear wheel rotation sensor wiring abnormal 45 Le ON (wiring shorted or open) 52 nnnnn JUL Power supply voltage abnormal oN (under-voltage) 53 Aannnn JUUL Power supply voltage abnormal oN (over-voltage) 55 ANA UUUUL ECU trouble (ECU operation abnormal) ON

BRAKES 12-47 Anti-Lock Brake System (Equipped Models) ABS Indicator Light (LED) Inspection e Turn the ignition switch ON. xlf the ABS indicator light (LED) [A] lights, it is normal. xlf the ABS indicator light (LED) does not light, go to step “ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)". e Turn the ignition switch OFF. xlf the ABS indicator light (LED) [A] does not light, it is normal. xlfthe ABS indicator light (LED) lights, go to step “ABS In- dicator Light (LED) Lights (When the Motorcycle is Run- ning, - No Service Code)”. eLiatosess ABS Indicator Light (LED) is Unlit (When the NT] Ignition Switch turned to ON) e Do the 1st step test. OCheck the terminal voltage between the black/white lead __] terminal of the meter connector [A] and ground. Special Tool - Hand Tester: 57001-1394 OTurn the ignition switch ON. Terminal Voltage Standard: About 10 V GLi4123851 xlf the terminal voltage is not within the specification, 2nd step. xlf the terminal voltage correct, replace the meter assem- bly. e Do the 2nd step test. ODisconnect the meter connector. RJ OCheck for continuity between the black/white lead termi- nal of the main harness side connector [A] and ground. xlf there is the continuity in the lead, replace or repair the 2 LL] main harness. xlf there is not the continuity in the lead, 3rd step. eLiai26ess €

12-48 BRAKES Anti-Lock Brake System (Equipped Models) e Do the 3rd step test. ODisconnect the ABS hydraulic unit connector. OCheck for continuity between the black/white lead termi- nal of the main harness side connector [A] and black/white lead terminal of the main harness side connector [B]. xlf there is the continuity in the lead, replace the ABS hy- draulic unit. xlf there is not the continuity in the lead, replace or repair the main harness. ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code) e Do the 1st step test. ODisconnect the ABS hydraulic unit connector and meter connector. OCheck for continuity between the black/white lead termi- nal of the main harness side connector [A] and black/white lead terminals of the main harness side connector [A]. Special Tool - Hand Tester: 57001-1394 xlf there is the continuity in the lead, replace the ABS hy- draulic unit. xlf there is not the continuity in the lead, replace or repair the main harness. Solenoid Valve Inspection (Service Code 13,14,17,18) e Do the 1st step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlfthe ABS indicator light (LED) [A] lit, faulty solenoid valve in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). ABS Solenoid Valve Relay Inspection (Service Code 19) e Do the 1st step test. OCheck the ABS solenoid valve relay fuse (20 A) [A]. xlf the fuse blown, 2nd step. xlf the fuse correct, 4th step.

BRAKES 12-49 Anti-Lock Brake System (Equipped Models) e Do the 2nd step test. ODisconnect the ABS hydraulic unit connector [A]. OCheck for continuity between the light green and black/yellow lead terminals of the ABS hydraulic unit connector. xlf there is the continuity in the lead, replace the ABS hy- draulic unit. xlf there is not the continuity in the lead, 3rd step. eLiaiz7ess € e Do the 3rd step test. OCheck for continuity between the light green lead terminal Bu) of the main harness side connector [A] and light green î Î lead terminal of the fuse box [B]. xlf there is the continuity in the lead, replace the fuse. @) xlf there is not the continuity in the lead, replace or repair the main harness. œs) cr 1 auratsest o e Do the 4th step test. RAR] OCheck the battery terminal voltage between the light green lead terminal of the fuse box [A] and ground. $% Special Tool - Hand Tester 57001-1394 7 Battery Terminal Voltage Standard: Battery Voltage an xlf the battery terminal voltage is not within the specifica- tion, Sth step. auttzmst 6 xlf the battery terminal voltage correct, 6th step. e Do the 5th step test. OCheck for continuity between the positive cable [A] of the KR] battery and light green lead terminal of the main harness (B) 99 @) side connector [B]. —T xlf there is the continuity in the lead, 4th step. xlf there is not the continuity in the lead, replace or repair En) O the main harness. ee nnnss

eLiatsonss € e Do the 6th step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlfthe ABS indicator light (LED) [A] lit, faulty ABS solenoid valve relay in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). eLiatosess

12-50 BRAKES Anti-Lock Brake System (Equipped Models) Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) e Do the 1st step test. OCheck the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size). Deformation of the wheel or tire. Sensor rotor for missing teeth and clogging with foreign matter. xlf the all parts correct, 2nd step. e Do the 2nd step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). ABS Pump Motor Relay Inspection (Service Code 35) e Do the 1st step test. OCheck the ABS pump motor relay fuse (30 A) [A]. xlf the fuse blown, 2nd step. xlf the fuse correct, 4th step. e Do the 2nd step test. ODisconnect the ABS hydraulic unit connector. OCheck for continuity between the red and light blue lead terminals of the ABS hydraulic unit connector [A]. xlf there is the continuity in the lead, replace the ABS hy- draulic unit. xlf there is not the continuity in the lead, 3rd step. e Do the 3rd step test. OCheck for continuity between the red lead terminal of the main harness side connector [A] and red lead terminal of the fuse box [B]. xlf there is the continuity in the lead, replace the fuse. xlf there is not the continuity in the lead, replace or repair the main harness. eLiaiarmss € eLiata2ess €

BRAKES 12-51 Anti-Lock Brake System (Equipped Models) e Do the 4th step test. OCheck the battery terminal voltage between the red lead BE] terminal of the fuse box [A] and ground. 89 Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage 7, Standard: Battery Voltage —— xlf the battery terminal voltage is not within the specifica- tion, 5th step. xlf the battery terminal voltage correct, 6th step. e Do the 5th step test. eLiatasess OCheck for continuity between the positive cable [A] of the AR] battery and red lead terminal of the main harness side (@) 99 @) connector [B]. —— xlf there is the continuity in the lead, 4th step. xlf there is not the continuity in the lead, replace or repair Ga) O the main harness. Dern

eLiataanss e Do the 6th step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ABS pump motor relay in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlfthe ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) e Do the 1st step test. OMeasure the air gap between the front wheel rotation sen- sor and sensor rotor. Thickness Gauge [A] Air Gap Standard: 0.7 —0.9 mm (0.028 —0.035 in.) xlf the measurement is over standard, check each part for deformation and looseness and correct accordingly. Recheck the air gap. xlfthe measurement is correct, 2nd step.

12-52 BRAKES Anti-Lock Brake System (Equipped Models) e Do the 2nd step test. OCheck that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. OCheck the installation condition of the sensor for loose- ness. OCheck the sensor and sensor rotor tip for deformation or damage (e.g., chipped sensor rotor teeth). x lfthe sensor and sensor rotor in bad condition, remove the any deposits. Install the properly or replace faulty part. xlf the all correct, 3rd step. e Do the 3rd step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) e Do the 1st step test. ODisconnect the ABS hydraulic unit connector and front wheel rotation sensor connector. OShort the brown and green lead terminals of the main har- ness side connector [A] with a jumper lead, and check for continuity between the brown and green lead terminals of the main harness side connector [B]. xlf there is the continuity in the lead, 2nd step. xlf there is not the continuity in the lead, replace or repair the main harness. e Do the 2nd step test. O Check for continuity between the black lead terminal of the sensor connector [A] and ground, and white lead ter- minal of the sensor connector and ground. xlfthere is the continuity in the lead, replace the front wheel rotation sensor. xlf there is not the continuity in the lead, 3rd step. eLiatosess OI,

BRAKES 12-53 Anti-Lock Brake System (Equipped Models) e Do the 3rd step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44) e Do the 1st step test. OMeasure the air gap between the rear wheel rotation sen- sor and sensor rotor. Thickness Gauge [A] Air Gap Standard: 0.7 —0.9 mm (0.028 —0.035 in.) xlf the measurement is over standard, check each part for deformation and looseness and correct accordingly. Recheck the air gap. xlfthe measurement is correct, 2nd step. e Do the 2nd step test. OCheck that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. OCheck the installation condition of the sensor for loose- ness. OCheck the sensor and sensor rotor tip for deformation or damage (e.g., chipped sensor rotor teeth). x lfthe sensor and sensor rotor in bad condition, remove the any deposits. Install the properly or replace faulty part. xlf the all correct, 3rd step. e Do the 3rd step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). eLiatosess

12-54 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) e Do the 1st step test. ODisconnect the ABS hydraulic unit connector and rear wheel rotation sensor connector. OShort the black and white/red lead terminals of the main harness side connector [A] with a jumper lead, and check for continuity between the black and white/red lead termi- nals of the main harness side connector [B]. xlf there is the continuity in the lead, 2nd step. xlf there is not the continuity in the lead, replace or repair the main harness. e Do the 2nd step test. OCheck for continuity between the black lead terminal of the sensor connector [A] and ground, and white lead ter- minal of the sensor connector and ground. xlfthere is the continuity in the lead, replace the rear wheel rotation sensor. xlf there is not the continuity in the lead, 3rd step. e Do the 3rd step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52) e Do the 1st step test. ODisconnect the ignition switch connector and ABS hy- draulic unit connector. OCheck for continuity between the brown lead terminal of the main harness side connector [A] and yellow lead ter- minal of the main harness side connector [B]. xlf there is the continuity in the lead, 2nd step. xlf there is not the continuity in the lead, inspect the ABS ECU fuse (10 A) (see Fuse Inspection in the Electrical System chapter) and replace or repair the main harness. OI,

BRAKES 12-55 Anti-Lock Brake System (Equipped Models) e Do the 2nd step test. OConnect the ignition switch connector and ABS hydraulic unit connector. OCheck the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground. Special Tool - Hand Tester: 57001-1394 OTurn the ignition switch ON. Battery Terminal Voltage Standard: 10 V or more xlf the battery terminal voltage is not within the specifica- tion, 3rd step. xlf the battery terminal voltage correct, 4th step. e Do the 3rd step test. Olnspect the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Main Harness (see Wiring Inspection in the Electrical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) e Do the 4th step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) e Do the 1st step test. ODisconnect the ignition switch connector and ABS hy- draulic unit connector. OCheck for continuity between the brown lead terminal of the main harness side connector [A] and yellow lead ter- minal of the main harness side connector [B]. xlf there is the continuity in the lead, 2nd step. xlf there is not the continuity in the lead, inspect the ABS ECU fuse (10 A) (see Fuse Inspection in the Electrical System chapter) and replace or repair the main harness. eLiaisonss Be] ® CE

12-56 BRAKES Anti-Lock Brake System (Equipped Models) e Do the 2nd step test. OConnect the ignition switch connector and ABS hydraulic unit connector. OCheck the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground. Special Tool - Hand Tester: 57001-1394 OTurn the ignition switch ON. Battery Terminal Voltage Standard: 16 Vor less xlf the battery terminal voltage is not within the specifica- tion, 3rd step. xlf the battery terminal voltage correct, 4th step. e Do the 3rd step test. OCheck the battery condition and regulator/rectifier (see Charging Condition Inspection, Regulator/Rectifier In- spection in the Electrical System chapter). e Do the Ath step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). ECU Inspection (Service Code 55) e Do the 1st step test. ORecheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. xlf the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit. xlf the ABS indicator light (LED) unlit, ABS system is nor- mal (service code is not stored; temporary failure.). ABS Hydraulic Unit Removal eLiaisonss CAUTION The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handied carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface. Be careful not to get water or mud on the ABS hy- draulic unit. e Drain the brake fluid from the front and rear brake lines. ODrain the brake fluid through the bleed valve by pumping the brake lever and pedal.

BRAKES 12-57 Anti-Lock Brake System (Equipped Models) ° Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Bolts [A] Cover [B] e Clean the ABS hydraulic unit. CAUTION Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation. Spread out a shop towel around the ABS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts. + Remove the brake pipe joint nuts [A] [B] [C] [D]. e Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter. CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. e Disconnect the connector [A]. OUnlock the joint lock [B] as shown in the figure. e Remove the bolts [A]. e Remove the ABS hydraulic unit with bracket.

12-58 BRAKES Anti-Lock Brake System (Equipped Models) + Remove the bolts [A] and bracket [B]. CAUTION The ABS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation e Install the ABS hydraulic unit to the bracket. CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. e Insert the bolts [A] into the grommets [B]. e Route the lead correctly, and connector [A] securely. OLock the joint lock [B] as shown in the figure. e Install the brake pipes correctly as shown in the figure. 48° [A] 71° [B] 30° [C] 38.5° [D] e Tighten the joint nuts. Torque - Brake Pipe Joint Nuts: 18 N-m (1.8 kgf-m, 13 ft-Ib) e Bleed the brake line (see Brake Line Bleeding). e Check the brake for good braking power, no brake drag, and no fluid leakage. e Install the removed parts (see appropriate chapters). eLiaioanse €

BRAKES 12-59 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Inspection e Remove the ABS hydraulic unit (see ABS Hydraulic Unit Removal). e Visually inspect the ABS hydraulic unit. x+Replace the ABS hydraulic unit if any ofthem are cracked, or otherwise damaged. e Visually inspect the connector terminals [A]. xReplace the ABS hydraulic unit or main harness if either ofthe terminals are cracked, bent, or otherwise damaged. xlf the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air. Front Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not to get water or mud on the wheel rotation sensor. Do not try to disassemble or repair the wheel rota- tion sensor. e Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Connector [A] (Disconnect) Clamps [B] e Remove: Bolts [A] Bracket Bolt [B] Clamps [C] Front Wheel Rotation Sensor [D] Front Wheel Rotation Sensor Installation e Installation is the reverse of removal. ORoute the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

12-60 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not to get water or mud on the wheel rotation sensor. Do not try to disassemble or repair the wheel rota- tion sensor. e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connector [A] (Disconnect) e Clear the connector from the bracket. e Remove: Bracket Bolts [A] Clamps [B] Bolts [C] Rear Wheel Rotation Sensor [D] Rear Wheel Rotation Sensor Installation e Installation is the reverse of removal. ORoute the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

BRAKES 12-61 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection e Remove the front wheel rotation sensor [A] from the front fork. e Remove the rear wheel rotation sensor [B] from the caliper bracket. e Visually inspect the wheel rotation sensors. x Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged. Wheel Rotation Sensor Air Gap Inspection e Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). e Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly. Thickness Gauge [A] Air Gap Standard: Front 0.7 —0.9 mm (0.028 —-0.035 in.) Rear 0.7 —0.9 mm (0.028 —0.035 in.) NOTE OThe sensor air gap cannot be adjusted. xlfthe air gap is not within the specification, inspect the hub bearing (see Hub Bearing Inspection in the Wheels/Tires chapter), sensor installation condition and sensor (see Wheel Rotation Sensor Inspection).

12-62 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Rotor Inspection e Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] e Visually inspect the wheel rotation sensor rotor. xlf the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one. xlf there is iron or other magnetic deposits [B], remove the deposits. eLiaoo6ess ecttro8st € ABS Solenoid Valve Relay Fuse (20 À) Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys- tem chapter. ABS Motor Relay Fuse (30 A) Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys- tem chapter. ABS ECU Fuse (10 À) Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys- tem chapter.

BRAKES 12-63 Anti-Lock Brake System (Equipped Models) Fuse Installation elfa fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see Fuse Installation in the Electrical System chapter). Fuse Inspection e Remove the fuses (see ABS Solenoid Valve Relay Fuse (20 A) /ABS Motor Relay Fuse (30 A) Removal). e Refer to the Fuse Inspection in the Electrical System chapter.

13-4 SUSPENSION Exploded View

13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Compression Damper Setting Fork Spring Preload Setting Fork Oil: Viscosity Amount Fork Oil Level Fork Spring Free Length 43 mm (1.7 in.) Atmospheric pressure (non-adjustable) 5th click from the 1st click of the fully clockwise position (Usable range: 0 «— 11 clicks) 10th click from the 1st click of the fully clockwise position (Usable range: 0 «<-— 13 clicks) Adjuster protrusion is 15 mm (0.59 in.) (Usable range: 4 —19 mm) (0.16 —-0.75 in.) KAYABA 01 (KHL15-10) or equivalent SAE 5W Approx. 480 mL (16.2 US oz.) (when changing oil) 563 +4 mL (19.0 +0.14 US oz.) (after disassembly and completely dry) 88 +2 mm (3.46 +0.08 in.) (fully compressed, without fork spring, below from inner tube top) 257 mm (10.12 in.) (Service Limit: 252 mm (9.92 in.)) Rear Shock Absorber Rebound Damper Set Compression Damper Set Spring Preload Setting Position: Standard Usable Range Gas Pressure 1 2/4 turns out from the fully clockwise position (Usable range: 0 «<-— 2 2/4 turns out) 2 1/4 turns out from the fully clockwise position (Usable range: 0 «-— 4 turns out) Spring length: 175.5 mm (6.9 in.) Spring length: 175.5 —191.5 mm (6.909 —7.539 in.) (weaker to stronger) 1 080 kPa (11.0 kgf/cm?, 156 psi, non-adjustable)

SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment e To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. OThe standard adjuster setting for the average-build rider of 68 kg (150 Ib) with no passenger and no accessories is the 5th click from the 1st click of the fully clockwise position. If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. OThe damping force can be left soft for average riding. But (Counterclockwise) (Glockwise) it should be adjusted harder for high speed riding or riding SO ft 6 ——#arder With a passenger. If the damping feels too soft or too stiff, STD adjust it in accordance with the following table. Rebound Damping Force Adjustment Adjuster Damping Setting Load Road Speed Î Position | Force s n eated position, 11 Weak Soft Light Good Low adjuster turned fully clockwise. UE TE î î Î Î î î Î | L Î Î Î 0 Strong Hard Heavy Bad High Compression Damping Force Adjustment e To adjust the compression damping force, turn the com- pression damping adjuster [A] until you feel a click. OThe standard adjuster setting for the average-build rider of 68 kg (150 Ib) with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position. À WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. OThe damping force can be left soft for average riding. But (Counterclockwise) (Clockwise) it should be adjusted harder for high speed riding or riding SO Ft er ———##arder with a passenger. If the damping feels too soft or too stiff, STD adjust it in accordance with the following table. Compression Damping Force Adjustment Adjuster Damping Setting Load Road Speed Î Position | Force n Seated position, 13 Weak Soft Light Good Low adjuster turned fully clockwise. CUEL TE î î Î Î î î Î | L Î Î Î 0 Strong Hard Heavy Bad High

13-10 SUSPENSION Front Fork Spring Preload Adjustment e Turn the spring preload adjuster [A] to change spring preload setting. OThe standard adjuster setting for the average-build rider of 68 kg (150 Ib) with no passenger and no accessories is the 15 mm (0.59 in.) [B] from top as shown in the figure. Adjuster Protrusion (from top) Standard: 15 mm (0.59 in.) Usable Range: 4 —19 mm (0.16 —0.75 in.) À WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. OThe spring preload can be left soft for average riding. But it should be adjusted harder for high speed riding or riding With a passenger. [f the spring action feels too soft or too stiff, adjust it in accordance with the following table. Spring Action Adjuster | Damping Position | Force 19 mm Weak Soft Light Good Low Setting Load Road Speed Î Î î î î Î L Î Î | | L 4 mm Strong Hard Heavy Bad High Front Fork Removal (Each Fork Leg) e Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Inner Covers (see Inner Cover Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) x Loosen the upper fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled. NOTE OLoosen the top plug after loosening the upper fork clamp bolt. e Loosen the upper fork clamp bolt and lower fork clamp bolts [C]. e With a twisting motion, work the fork leg down and out.

SUSPENSION 13-11 Front Fork Front Fork Installation e Install the fork so that the top end [A] of the outer tube as sal P shown in the figure.

21.5 mm (0.85 in.) [B] em

e Tighten the lower fork clamp bolts and fork top plug. Torque -Front Fork Clamp Bolts (Lower): 30 N-m (3.1 kgf-m, 22 ft-lb) Front Fork Top Plug: 22 N-m (2.2 kgf-m, 16 ft:Ib) e Tighten the upper fork clamp bolt. Torque - Front Fork Clamp Bolt (Upper): 20 N-m (2.0 kgf-m, 15 ft-lb) Guoassonss NOTE OTighten the two clamp bolts alternately two times to en- sure even tightening torque. OTighten the top plug before tightening the upper fork clamp boit. e Install the removed parts (see appropriate chapters). e Adjust the spring preload and the damping force. Front Fork Oil Change e Remove the front fork (see Front Fork Removal). e Hold the inner tube lower end in a vise. e Unscrew the top plug [A] out of the outer tube. e Install the clamps [A] as shown in the figure. NOTE OSet the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [C] to hold it by the clamps, and then tighten the two bolts [D]. The outer tube is used as a guide. Special Tools -Fork Spring Compressor: 57001-1540 Fork Spring Compressor: 57001-1587

13-12 SUSPENSION Front Fork Insert the holder bar [A] into the axle hole of the front fork [B]. e Insert the compression shaft and install the nut. e Insert the lower end of the compression shaft [A] into the hole [B] of the holder bar. e Screw the adjust nut [A] onto the compression shaft as shown in the figure. e Screw the locknut [B]. About 20 mm (0.79 in.) [C] e Set the other side compression shaft same process. e Set the holder bar [A] and compression shafts [B]. e Screw in nuts [A] come out the piston rod nut.

SUSPENSION 13-13 Front Fork e Holding the piston rod nut with a wrench [A], remove the top plug [B] from the piston rod. e Remove: Washer [A] Collar [B] Rebound Damping Adjuster Rod [C] Fork Spring [D] euoassiess e Drain the fork oil into a suitable container. OPump the piston rod [A] up and down at least ten times to expel the oil from the fork. Special Tool - Fork Piston Rod Puller, M12 x 1.25 [B]: 57001-1289 Guoass2nss e Hold the fork tube upright, press the inner tube [A] and the piston rod all the way down. e Pour in the type and amount of fork oil specified. Fork Oil Viscosity: KAYABA 01 (KHL15-10) or equivalent SAE

Amount (per side): When changing oil: Approx. 480 mL (16.2 US oz.) After disassembly and completely dry: cuoso4zsst © 563 +4 mL (19.0 +0.14 US oz.)

13-14 SUSPENSION Front Fork xlf necessary, measure the oil level as follows. OHold the inner tube vertically in a vise. OPump the inner tube several times to expel air bubbles. OUsing the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil. Special Tool - Fork Piston Rod Puller, M12 x 1.25: 57001

ORemove the piston rod puller. OWait until the oil level settles. OW'ith the fork fully compressed and the piston rod fully pushed in, insert a tape measure or rod into the inner tube, and measure the distance from the top of the inner tube to the oil. Oil Level (fully compressed, without spring) Standard: 88 +2 mm (3.46 +0.08 in.) (from the top of the inner tube) NOTE OFork oil lever may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge [A]: 57001-1290 OW'ith the fork fully compressed and without fork spring, insert the gauge tube into the inner tube [B] and position the stopper across the top end [C] of the inner tube. OSet the gauge stopper [D] so that its lower side shows the oil level distance specified [E]. OPull the handle slowly to pump out the excess oil until the oil no longer comes out. xlf no oil is pumped out, there is insufficient oil in the inner tube. Pour in enough oil, then pump out the excess oil as shown above. e Screw the fork piston rod puller onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M12 x 1.25: 57001

SUSPENSION 13-15 Front Fork e Screw the rod nut [A] onto the piston rod [B] as shown in the figure. 11 mm (0.43 in.) [C] Guoass4nss e Check the distance between the bottom end [A] of the © top plug and rebound damping adjuster [B] with a pair of vernier caliper. 13 mm (0.51 in.) [C] e Set the fork spring compressor on the washer using the outer tube as a guide. Special Tools -Fork Spring Compressor: 57001-1540 Fork Spring Compressor: 57001-1587 NOTE x OSet the clamps so that the cutout of the upper side does | of \ not fit the hole of washer, pull up the outer tube to hold = it by the clamps, and then tighten the two bolts. The |. } L! outer tube is used as a guide. Rates ! 1 e Hold the piston rod nut [A]. + Remove the piston rod puller [B]. e Install the rebound damping adjuster rod. e Screw in the top plug [A] stopped onto the piston rod. e Check the O-ring [B] on the top plug and replace it with a new one if damaged. e Holding the top plug with a wrench, tighten the piston rod nut [C] against the top plug. Torque - Piston Rod Nut: 28 N:m (2.9 kgf-m, 21 ft-Ib) e While holding up the washer with the clamps, loosen the fork spring compressor nuts. e Remove the fork spring compressor.

13-16 SUSPENSION Front Fork e Raise the outer tube and screw the top plug into it and install it to the steering stem. e Screw in the spring preload adjuster [A] of the top plug so that the distance between the adjuster top and the top plug surface is 15 mm (0.59 in.) [B]. e Turn in the rebound damping adjuster until the fully tight- ened position and turn backward the 5th click. e Install the front fork (see Front Fork Installation). Front Fork Disassembly e Remove the front fork (see Front Fork Removal). e Drain the fork oil (see Front Fork Oil Change). e Hold the front fork in a vise [A]. e Stop the cylinder [B] from turning by using the fork cylinder holder [C]. Special Tool - Fork Cylinder Holder: 57001-1287 e Unscrew the Allen bolt [D], then take the bolt and gasket out of the bottom of the inner tube. e Take the cylinder unit [A]. ODo not disassemble the cylinder unit. e Separate the outer tube from the inner tube. e Pull out the dust seal. e Remove the retaining ring [A] from the outer tube. e Remove the oil seal [B] and washer [C]. Front Fork Assembly e Replace the following parts with a new one. Oil Seal Bottom Allen Bolt Gasket e Insert the cylinder unit [A] into the inner tube [B]. e Stop the cylinder from turning by using the fork cylinder holder. Special Tool - Fork Cylinder Holder: 57001-1287 e Apply a non-permanent locking agent to the thread of the Allen bolt, and tighten it. Torque - Front Fork Bottom Allen Bolt: 23 N-m (2.3 kgf-m, 17 ftIb) euoassonss cmosoginst

SUSPENSION 13-17 Front Fork e Install the following parts into the inner tube [A]. Dust Seal [B] Retaining Ring [C] Oil Seal [D] Washer [E] Insert the inner tube to the outer tube. e After installing the washer, install the oil seal [A] by using the fork oil seal driver [B]. Special Tool - Fork Oil Seal Driver, 43: 57001-1530 e Install the retaining ring and dust seal into the outer tube. e Pour in the specified type of oil (see Front Fork Oil Change). Inner Tube Inspection e Visually inspect the inner tube [A], and repair any dam- age. e Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. xlf the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced. CAUTION If the inner tube is badly bent or creased, replace it Excessive bending, followed by subsequent straightening, can weaken the inner tube. e Temporarily assemble the inner and outer tubes, and pump them back and forth manually to check for smooth operation. e If you feel binding or catching, the inner and outer tubes must be replaced. À WARNING A straightened inner or outer fork tube may fall in use, possibly causing an accident. Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it. emoso4isst cuoso4zost Guoasssnss

13-18 SUSPENSION Front Fork Dust Seal Inspection e Inspect the dust seal [A] for any signs of deterioration or damage. xReplace it if necessary. Spring Tension e Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. xlf the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability. Spring Free Length Standard: 257 mm (10.12 in.) Service Limit: 252 mm (9.92 in.) cuost2sust emosoïisst

SUSPENSION 13-19 Rear Shock Absorber Rebound Damping Force Adjustment eTo adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. OThe standard adjuster setting for an average-build rider of 68 kg (150 Ib) with no passenger and no accessories is the 1 2/4 turns out from the fully clockwise position. Rebound Damping Force Adjustment (Counterclockwise) (Clockwise) Adjuster | Damping : Position Force Setting Load Road Speed 224Tums| eax | Soft | Light | Good | Low Out Î î î Î Î î Î | | L L | 0 Strong Hard Heavy Bad High Compression Damping Force Adjustment e To adjust the compression damping force, turn the upper damping adjuster [A] to the desired position until you feel a click. OThe standard adjuster setting for the average-build rider of 68 kg (150 Ib) with no passenger and no accessories is the 2 1/4 turns out from the fully clockwise position. Rebound Damping Force Adjustment 8 0 FL 6 ———#harder Seated position, adjuster turned fully clockmise. CTEETEN Adjuster | Damping : Position Force Setting Load Road Speed 4Tums | eak | Soft | Light | Good | Low Out Î Î Î î î î Î L L | | | 0 Strong Hard Heavy Bad High Spring Preload Adjustment e Remove the rear shock absorber from the frame (see Rear Shock Absorber Removal). e Loosen the locknut and turn out the adjusting nut to free the spring. Special Tool - Hook Wrench T=3.2 R37: 57001-1522 (Gounterclockwise) (Glockwise) Softer Harder STD

Seated position, adjuster turned fully clockwise. Guosz368s:

13-20 SUSPENSION Rear Shock Absorber e To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 175.5 mm (6.9 in.) Usable Range: Spring length 175.5 —191.5 mm (6.909 —7.539 in.) OThe standard adjusting nut setting for an average-build rider of 68 kg (150 Ib) with no passenger and no acces- sories is 175.5 mm (6.9 in.) spring length. e Remove the chain cover [A] (see Drive Chain Removal in the Final Drive chapter). e Remove the bolts [B] and left foot guard [C] for turning the hook wrench easily. e To adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [A] with the rear shock absorber attached the frame. Special Tool - Hook Wrench T=3.2 R37: 57001-1522 xlfthe spring action feels too soft or too stiff, adjust it. Spring Adjustment Adjuster | Damping Position Force 191.5mm| Weak Soft Light Good Low (7.539 in.) Setting Load Road Speed Î Î Î Î î Î L L L L Î L

(6.909 in.)| Strong Hard Heavy Bad High Rear Shock Absorber Removal e Remove: Rear Fairing (see Rear Fairing Removal in the Frame chapter) Bolts [A] (Both Sides) Bracket [B] Lower Fairings (see Lower Fairings Removal in the Frame chapter). e Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 euosza7as:

SUSPENSION 13-21 Rear Shock Absorber e Squeeze the brake lever slowly and it with a band [A]. À WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. emosti7ast © ° Remove: Lower Shock Absorber Nut and Bolt [A] Upper Tie-Rod Nut and Bolt [B] e Remove the upper shock absorber nut and bolt [A] e Remove the shock absorber downward. Rear Shock Absorber Installation e Tighten: Torque - Rear Shock Absorber Nuts: 34 N-m (3.5 kgf-m, 25 ft-Ib) Tie-Rod Nuts: 59 N-m (6.0 kgf-m, 44 ft:1b) Rear Shock Absorber Inspection e Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). e Visually inspect the following items. Smooth Stroke Oil Leakage Crack or Dent xlfthere is any damage to the rear shock absorber, replace it. e Visually inspect the rubber bushing. xlfit show any signs of damage, replace it.

13-22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping À WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas, do not incinerate the reser- voir tank without first releasing the gas or it may explode. e Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). Guoszssnss e Drill the hole [A] of the reservoir tank using about 2 mm (0.08 in.) drillbit. À WARNING Since the high pressure gas is dangerous, do not point the drill toward your face or body.

SUSPENSION 13-23 Swingarm Swingarm Removal e Remove: Chain Cover (see Drive Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Bolts [A] Brackets [B] e Remove: Upper Tie-Rod Nut and Bolt [A] Rear Shock Absorber [B] (see Rear Shock Absorber Re- moval) e Unscrew the swingarm pivot shaft locknut [A]. e Unscrew the swingarm pivot collar locknut [A] using the nut wrench [B]. Special Tool - Swingarm Pivot Nut Wrench: 57001-1597 e Unscrew the swingarm pivot shaft [A] few times. OTurn out the swingarm pivot adjusting collar [B]. e Pull out the pivot shaft right side of the motorcycle and remove the swingarm.

13-24 SUSPENSION Swingarm Swingarm Installation e Apply plenty of grease to the lip of the oil seals [A]. e Install the collar. e Place the adjusting collar [A] the frame [B] as shown in the figure. 11 mm (0.43 in.) [C] Insert the pivot shaft [A] into the frame from the right side. e Tighten the pivot shaft so that the clearance between the adjusting collar [B] and the ball bearing [C] come to 0 mm (O in.). Torque - Swingarm Pivot Adjusting Collar: 20 N-m (2.0 kgf-m, 15 ft-Ib) e Tighten the adjusting collar locknut [A] with the swingarm pivot nut wrench [B]. Special Tool - Swingarm Pivot Nut Wrench: 57001-1597 Torque - Swingarm Pivot Adjusting Collar Locknut: 98 N-m (10.0 kgf-m, 72 ft-Ib) e Tighten the pivot shaft nut [A]. Torque - Swingarm Pivot Shaft Nut: 108 N-m (11.0 kgf-m, 80 ft-lb) e Install the removed parts (see appropriate chapters). euosiosess

SUSPENSION 13-25 Swingarm Swingarm Bearing Removal e Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] (Right Side) Special Tool - Inside Circlip Pliers: 57001-143 e Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 euoso7onss Swingarm Bearing Installation L e Replace the ball and needle bearings [A] with new ones. FF e Install the ball and needle bearings so that the manufac- À turer's marks face out. Special Tools -Bearing Driver Set: 57001-1129 > Needle Bearing Driver, 428 [B]: 57001-1610 Spacer 28: 57001-1663 euoso7imss

13-26 SUSPENSION Swingarm e Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown in the figure. Circlip [D] 32 mm (1.26 in.) [E] 17 mm (0.67 in.) [F]

27.5 mm (1.08 in.) [G]

9.5 mm (0.37 in.) [H]

Guosiossn? c Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. e Inspect the needle bearings [A] and ball bearing installed in the swingarm. OThe rollers and ball in a bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually inspect the bearing for abrasion, discoloration, or other damage. xlf the needle bearing and sleeve [B] show any sings of abnormal wear, discoloration, or damage, replace them as a set.

SUSPENSION 13-27 Swingarm e Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. xlf bearing play, roughness, or binding is found, replace the bearing. e Examine the bearing seal [B] for tears or leakage. xlf the seal is torn or is leaking, replace the bearing. Chain Guide Inspection e Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter.

13-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal e Squeeze the brake lever slowly and hold it with a band [A]: emosti7ast © e Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Rear Fairing (see Rear Fairing Removal in the Frame chapter) Bracket (see Rear Shock Absorber Removal) e Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 e Remove: Upper Tie-Rod Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B] Tie-Rods [C] Tie-Rod Installation e Apply grease to the inside of the grease seals. e Install each tie-rod so that the arrow faces [A] forward. e Tighten: Torque - Tie-Rod Nuts: 59 N-m (6.0 kgf-m, 44 ft:Ib) Rocker Arm Removal e Squeeze the brake lever slowly and hold it with a band. e Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Rear Fairing (see Rear Fairing Removal in the Frame chapter) Bracket (see Rear Shock Absorber Removal) Muffler Bodies (see Muffler Body Removal in the Engine Top End chapter) e Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 e Remove: Lower Rear Shock Absorber Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B] Rocker Arm Nut and Bolt [C] Rocker Arm [D]

SUSPENSION 13-29 Tie-Rod, Rocker Arm Rocker Arm Installation e Apply grease to the inside of the grease seals. e Tighten: Torque - Uni-Trak Rocker Arm Nut: 34 N:m (3.5 kgf-m, 25 ft-Ib) Tie-Rod Nuts: 59 N-m (6.0 kgf-m, 44 ft:1b) Rear Shock Absorber Nut (Lower): 34 N:m (3.5 kgf-m, 25 ft-Ib) Tie-Rod and Rocker Arm Bearing Removal e Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Sleeves [A] Oil Seals [B] Swingarm [C] (see Swingarm Removal) e Remove the needle bearings [D], using the bearing re- mover head and bearing remover shaft. Special Tools - Bearing Remover Head, 920 x 922: 57001 Bearing Remover Shaft, #13: 57001-1377 Guozosoës? c Tie-Rod and Rocker Arm Bearing Installation e Replace the needle bearing and oil seals with new ones. e Apply plenty of grease to the lips of the oil seals. e Install the needle bearings and oil seals position as shown in the figure.

13-30 SUSPENSION Tie-Rod, Rocker Arm OScrew the needle bearing driver [A] into the driver holder (BI. Olnsert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing Pressing Depth: 5.5 mm (0.22 in.) [D]

5.0 mm (0.20 in.) [E]

NOTE OFor a bearing of inner diameter #18, select the pressing side of the needle bearing driver according to its press- ing depth. Special Tools -Bearing Driver Set: 57001-1129 Needle Bearing Driver, 9171918: 57001 Spacer, #18 [F]: 57001-1636 Needle Bearing Driver, 20 & Spacer, 428: 57001-1678 NOTE Olnstall the needle bearings so that the marked side faces in. Needle Bearing [A] Oil Seals [B] Front [C] Right Side [D] Left Side [E] Rear Shock Absorber [F] Tie-Rods [G] Rocker Arm [H]

7.5 mm (0.30 in.) [I]

10 mm (0.39 in.) [J]

5.5 mm (0.22 in.) [K]

5.0 mm (0.20 in.) [L]

SUSPENSION 13-31 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION 6) © Do not remove the bearings for inspection. Re- 2 moval may damage them. à ) y g 6 ® e Visually inspect the locker arm, or tie-rod sleeves [A] and needle bearings [B]. e The rollers in a needle bearing normally wear very little, Q) and wear is difficult to measure. Instead of measuring, smoroïsast © inspect the bearing for abrasion, color change, or other damage. xlf there is any doubt as to the condition of any of the nee- dle bearings or sleeve, replace the sleeve and needle bearings as a set. Rocker Arm/Tie-Rod Bearing Lubrication NOTE OSince the bearings are packed with grease, lubrication is not required.

14-2 STEERING Exploded View

STEERING 14-3 Exploded View Torque No. Fastener Remarks Nm kgf-:m ft:lb 1 |Front Fork Clamp Bolts (Lower) 30 3.1 22 AL 2 |Front Fork Clamp Bolts (Upper) 20 2.0 15 3 |Handlebar Bolts 34 3.5 25 L 4 |Handlebar Holder Bolts 25 2.5 18 AL 5 |Steering Stem Head Nut 78 8.0 58 6 |Steering Stem Nut 23 2.3 17 7 |Switch Housing Screws 3.5 0.36 31 in-lb AD: Apply adhesive. AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts

ST87107587 © sTS7184457 © Steering Stem Nut Wrench: 57001-1100 Steering Stem Bearing Driver Adapter, 441.5: 57001-1345

ST87110087 © ST87134587 © Bearing Driver Set: 57001-1129 Head Pipe Outer Race Driver, 955: 57001-1446 S187112987 © ST87144687 ©

STEERING 14-5 Steering Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment e Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.

14-6 STEERING Steering Stem Stem, Stem Bearing Removal e Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Handlebars (see Handiebar Removal) Front Forks (see Front Fork Removal in the Suspension chapter) Bracket Bolts [A] Cover Bolts [B] and Cover [C] e Remove: Steering Stem Head Nut [A] and Washer [B] Steering Stem Head [C] e Bend the claws [A] of lock washer straighten. e Remove the steering stem locknut [B]. Special Tool - Steering Stem Nut Wrench: 57001-1100 e Remove the lock washer. e Pushing up the stem base, and remove the steering stem nut [A] with stem cap [B]. Special Tool - Steering Stem Nut Wrench [C]: 57001-1100 e Remove: Steering Stem [D] Upper Ball Bearing Inner Race and Ball Bearing e To remove the ball bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses [D] of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE OIf either steering stem bearing is damaged, it is recom- mended that both the upper and lower bearings (includ- ing outer races) should be replaced with new ones.

STEERING 14-7 Steering Stem + Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation e Replace the bearing outer races with new ones. e Drive them into the head pipe at the same time. Special Tools -Head Pipe Outer Race Press Shaft [A]: 57001-1075 Bearing Driver Set: 57001-1129 Head Pipe Outer Race Driver, 655 [B]: 57001

e Apply grease to the outer races. e Replace the bearing inner races and oil seal with new ones. e Apply grease to the oil seal. e Install the oil seal [A] on the steering stem, and drive the lower ball bearing inner race [B] applied the grease onto the stem. Special Tools -Steering Stem Bearing Driver, 942.5 [C]: 57001-1344 Steering Stem Bearing Driver Adapter,

41.5 [D]: 57001-1345

e Install the lower ball bearing [A] onto the stem. e Grease the following. Inner and Outer Races Lower and Upper Ball Bearings OThe lower and upper ball bearings are identical. e Install the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] ont. e Install: © © Stem Cap [D] Ô ® Steering Stem Nut [E] GnoSosest €

14-8 STEERING Steering Stem e Settle the bearings in place as follows. OTighten the steering stem nut with 55 N-m (5.6 kgf-m, 41 ft:1b) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [A]. Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 23 N-m (2.3 kgf-m, 17 ft:lb) e Install the lock washer so that claw [A] of washer fit the notch [B] of steering stem locknut [C]. e First tighten the steering stem locknut by hand until the resistance is felt fully, then tighten the steering stem lock nut so that align the claw [A] of stem lock nut to the notch [B] of stem nut by hand. e Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearing may be damaged. e Bend the claw of lock washer to steering stem nut notch. e Install the stem head [A] to the steering stem [B]. e Install the washer, and temporary tighten the stem head nut [C]. e Install the front forks (see Front Fork Installation in the Suspension chapter). enosoo4st c

STEERING 14-9 Steering Stem NOTE OTighten the upper front fork clamp bolts [A] first, next the stem head nut [B], last the lower front fork clamp bolts [CI. OTighten the two lower fork clamp bolts alternately two times to ensure even tightening torque. Torque - Front Fork Clamp Bolts (Upper): 20 N-m (2.0 kgf-m, 15 ft-Ib) Steering Stem Head Nut: 78 N-m (8.0 kgf-m, 58 ft-lb) Front Fork Clamp Bolts (Lower): 30 N-m (3.1 kgf-m, 22 ft-Ib) À WARNING Do not impede the handlebar turning by routing the cables, harnesses and hoses improperly (see Ca- ble, Wire, and Hose Routing section in the Appen- dix chapter). e Install the removed parts (see appropriate chapters). Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe- riodic Maintenance chapter. Steering Stem Warp e Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. xlfthe steering stem [A] is bent, replace the steering stem. enosossess Stem Cap Deterioration, Damage xReplace the stem cap if its oil seal [A] shows damage.

14-10 STEERING Handlebar Handiebar Removal e Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] e Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Throttle Case [C] Handlebar Weight [D] Throttle Grip [E] e Unscrew the handlebar holder bolts [A]. e Remove each handlebar holder [B] with handlebar [C]. e Hold the handlebar in a vise, and unscrew the handlebar bolt [A]. e Remove the handlebar. e Remove the left handlebar grip. Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip. e Fit the pin [A] of the handlebar to the recess [B] of the handlebar holder. e Apply a non-permanent locking agent to the threads of the handlebar bolts. e Tighten: Torque - Handlebar Bolts: 34 N-m (3.5 kgf-m, 25 ft-lb) enoosonss

STEERING 14-11 Handlebar e Install the handlebar holder with handlebar on the steering stem head. e Tighten the handlebar holder bolts. NOTE OTighten the handlebar holder bolt [A] first, next the han- dlebar holder bolt [B]. OTighten the two handlebar holder bolts alternately two times to ensure even tightening torque. Torque - Handlebar Holder Bolts: 25 N-m (2.5 kgf:m, 18 ft-1b) e Install the front master cylinder (see Front Master Cylinder Installation in the Brakes chapter). e Install: Throttle Grip Throttle Cable Tips [A] Throttle Cases [B] OFit the projection into a small hole in the handlebar. e Apply a non-permanent locking agent to the threads of the handlebar weight bolts, and tighten them. e Install the left and right switch housings. OFit the projection [A] into a small hole [B] in the handlebar. Torque - Switch Housing Screws: 3.5 N-m (0.36 kgf-m, 31 in-lb) e Install the clutch lever (see Clutch Lever Installation in the Clutch chapter).

• FRAME 15-1 Frame Table of Contents Exploded View. 15-2 Seat 15-10 Seat Removal 15-10 Seat Installation 15-10 Fairings 15-11 Lower Fairing Removal. 15-11 Lower Fairing Installation. 15-11 Fairing Cover Removal. 15-11 Middle Fairing Removal 15-11 Middle Fairing Installation 15-12 Windshield Removal 15-12 Windshield Installation … 15-13 Upper Fairing Removal. Upper Fairing Disassembly Upper Fairing Assembly
• … 15-13 Upper Fairing Installation. 15-14 Inner Cover Removal… 15-14 Inner Cover Installation 15-14 Upper Inner Fairing Removal. 15-14 Upper Inner Fairing Installation. 15-15 Upper Fairing Bracket Removal 15-15 Upper Fairing Bracket Installation. 15-15 Inner Fairing Removal 15-15 Inner Fairing Installation 15-15 Rear Fairing Removal… 15-15 Rear Fairing Installation 15-15 Seat Cover -16 Seat Cover Removal 15-16 Seat Cover Installation 15-16 Fenders Front Fender Remova Front Fender Installation 15-18 Flap and Rear Fender Removal 15-18 Flap and Rear Fender Installation. 15-19 Frame 15-20 Rear Frame Removal. 15-20 Rear Frame Installation. 15-20 Frame Inspection … 15-20 Center Stand, Sidestand . 15-21 Center Stand Removal (Equipped Models) . 15-21 Center Stand Installation (Equipped Models) . 15-21 Sidestand Removal 15-21 p. 15

FRAME 15-5 Exploded View Torque No. Fastener Remarks Nm kgf-:m ft:lb 1 _|Rear Fender Mounting Screws 1.2 0.12 11 in:lb 2 |Rear Footpeg Bracket Bolts 25 2.5 18 3 |Rear Frame Bolts 44 4.5 32 L 4 |Rear Frame Pipe Bolts 44 4.5 32 5 |Rear Frame Pipe Nuts 44 4.5 32

15-6 FRAME Exploded View Goo21938#s ©

3. Reflector (United States and Canada Models)

4. Grab Rail (Equipped Models)

5. Seat Cover (Equipped Models)

15-10 FRAME Seat Seat Removal Insert the ignition switch key [A] into the seat lock, turning the key counterclockwise, pulling up on the rear of the seat [B], and pulling the seat backward. e For seat cover equipped models; note the following. e Remove: Bolts [A] Seat Cover [B] Seat Installation Insert the brackets [A] of the fuel tank into the slots [B] of the seat. e Insert the projections [A] of the seat into the slots [B] of the frame, and insert the seat hook [C] into the slot [D] of the frame. e Push down the rear part of the seat until the lock clicks.

FRAME 15-11 Fairings Lower Fairing Removal e Pull up the core by the thin blade driver. e Remove the quick rivet [A]. e Remove the bolts [B] with washers. e Clear the hook portions from the slots. e Separate the left lower fairing from the right lower fairing. Lower Fairing Installation e Insert the hook portions [A] into the slots [B]. e Tighten the bolts with washers. e Set the quick rivet and push the core. Fairing Cover Removal e Remove the bolts [A]. Pull out the fairing cover [B], and clear the stoppers. e Insert the projections [A] into the holes [B]. e Tighten the bolts. Middle Fairing Removal e Remove: Lower Fairings (see Lower Fairing Removal) Fairing Covers (see Fairing Cover Removal) Inner Covers (see Inner Cover Removal) Fuel Tank Cover (see Fuel Tank Removal in the Fuel System (DFI) chapter) e Push the central pin, and then remove the quick rivets [A].

15-12 FRAME Fairings e Remove: Bolts [A] with Washers Turn Signal Lead Connector e Remove each middle fairing. OClear the hook [B] from the bracket. e Remove: Inner Fairing (see Inner Fairing Removal) Screws Bracket Turn Signal Light Middle Fairing Installation e Install the turn signal light to the middle fairing, and tighten the screws. e Install the inner fairing (see Inner Fairing Installation). e Connect the turn signal lead connector. e Hang the hook of the middle fairing to the bracket. e Install the washers and bolts. e Install the quick rivets. e Install the removed parts (see appropriate chapters). Windshield Removal e Remove: Bolts [A] with Washers Windshield [B]

FRAME 15-13 Fairings Windshield Installation e Put the front tongue [A] into the hollow [B]. e Tighten: Torque - Windshield Mounting Bolts: 0.42 Nm (0.043 kgf-m, 3.7 in-lb) Upper Fairing Removal e Remove: Lower Fairings (see Lower Fairing Removal) Fairing Covers (see Fairing Cover Removal) Inner Covers (see Inner Cover Removal) Middle Fairings (see Middle Fairing Removal) Windshield (see Windshield Removal) Vehicle-down Sensor Lead Connector Immobilizer Amplifier Lead Connector (Equipped Mod- els) e Unscrew the bracket screws [A]. e Disconnect: Headlight Lead Connectors [A] (Both Sides) City Light Lead Connectors [B] (Both Sides) e Remove the bolts [A]. Pull out the upper fairing forward. Upper Fairing Disassembly ° Remove: Upper Fairing (see Upper Fairing Removal) Upper Inner Fairing (see Upper Inner Fairing Removal) Headlights [A] (see Headlight Removal in the Electrical System chapter) Nuts [B] and Rear View Mirrors (Both Sides) Upper Fairing Assembly e Installation is the reverse of removal.

15-14 FRAME Fairings Upper Fairing Installation e Installation is the reverse of removal. Inner Cover Removal e Remove the bolts [A]. e Remove the inner cover [B]. OPull the inner cover backward, and clear the hooks. Inner Cover Installation e Insert the hooks [A] into the slots [B]. e Tighten the bolts. Upper Inner Fairing Removal e Remove: Upper Fairing (see Upper Fairing Removal) Bolt [A] Upper Inner Fairing [B] OSlide out the upper inner fairing backward.

FRAME 15-15 Fairings Upper Inner Fairing Installation e Insert the slots [A] of the upper inner fairing into the hooks [B] of the upper fairing. e Tighten the boit. Upper Fairing Bracket Removal e Remove: Upper Fairing (see Upper Fairing Removal) Front and Middle Inlet Ducts (see Front and Middle Inlet Duct Removal in the Fuel System (DFI) chapter) Rear Inlet Ducts (see Rear Inlet Duct Removal in the Fuel System (DFI) chapter) Meter Unit (see Meter Unit Removal in the Electrical Sys- tem chapter) Headlight Relays [A] Bolts [B] Upper Fairing Bracket [C] Upper Fairing Bracket Installation e Installation is the reverse of removal. Inner Fairing Removal e Remove: Middle Fairings (see Middle Fairing Removal) Quick Rivet [A] Bolts [B] Inner Fairing [C] Inner Fairing Installation e Installation is the reverse of removal. Rear Fairing Removal e Remove: Bolts [A] Rear Fairing [B] Rear Fairing Installation e Installation is the reverse of removal.

15-16 FRAME Seat Cover Seat Cover Removal e Remove: Seat (see Seat Removal) Bolts [A] Screws [B] Grab Rail [C] (Equipped Models) Center Seat Cover [D] e Remove the quick rivets [A]. e Remove the bolts [A]. e Clear the side seat covers [B] from the rear fender. e Disconnect the turn signal lead connectors, and remove each side seat cover. e Remove: Screws [A] Turn Signal Light [B] Seat Cover Installation e Connect the turn signal lead connector. e Insert the hole [A] to the projection [B]. e Install the bolts and quick rivets.

FRAME 15-17 Seat Cover e Insert the projection [A] into the hole [B]. e Tighten the screws. e Install the grab rail (equipped models). e Tighten: Torque - Grab Rail Mounting Bolts: 25 N-m (2.5 kgf-m, 18 ft:1b)

15-18 FRAME Fenders Front Fender Removal e Remove: Brake Hose Clamps [A] (Both Sides) Bolts [B] with Washer (Both Sides) Bracket [C] (ZX1400B Models) e Remove the front fender assy [D]. e Remove the screws [A]. e Separate the front fender covers [B] and front fender [C]. Googoïsess Front Fender Installation e Install the front fender covers to the front fender. Olnsert the hooks [A] of the front fender cover into the slots [B] of the front fender. e Install the front fender assy to the front fork. e Install the brake hose clamps to the front fender holes. Flap and Rear Fender Removal e Remove: Seat (see Seat Removal) Seat Covers (see Seat Cover Removal) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Tool Kit Case [A] (see ECU Removal in the Fuel System (DFI) chapter) Relay Box [B] (see Relay Box Removal in the Electrical System chapter) ECU (see ECU Removal in the Fuel System (DFI) chap- ter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Fuse Box [C] Bolts [D] and Cover [E] Seat Lock Bolts [F] Screws [G]

FRAME 15-19 Fenders e Remove: Nuts [A] License Light Connector (Disconnect) Flap (with License Light) Tail/Brake Light (LED) (see Tail/Brake Light (LED) Re- moval in the Electrical System chapter) Pull out the rear fender [B] backward and downward. Flap and Rear Fender Installation e Hang the hook [A] of the rear fender to the slot [B] of the rear frame. e Tighten: Torque - Rear Fender Mounting Screws: 1.2 Nm (0.12 kgf-m, 11 in:lb) e Install the removed parts (see appropriate chapters). e Run the harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

15-20 FRAME Frame Rear Frame Removal e Remove: Rear Fender (see Rear Fender Removal) Regulator/Rectifier [A] (see Regulator/Rectifier Inspec- tion in the Electrical System chapter) Tail/Brake Light (see Tail/Brake Light Removal in the Electrical System chapter) Bolts [B] (Both Sides) Rear Footpeg Bracket Bolts [C] and Brackets (Both Sides) Frame Bolts [D] Rear Frame Installation e Apply a non-permanent locking agent to the thread of the rear frame bolt, and tighten them. Torque - Rear Frame Bolts: 44 N-m (4.5 kgf-m, 32 ft-lb) Rear Footpeg Bracket Bolts: 25 N-m (2.5 kgf-m, 18 ft-Ilb) e Install the removed parts (see appropriate chapters). Frame Inspection e Visually inspect the frame [A] for cracks, dents, bending, or Wwarp. xlf there is any damage to the frame, replace it. A repaired frame may fail in use, possibly causing an accident. lf the frame is bent, dented, cracked, or warped, replace it. G0090268s1

FRAME 15-21 Center Stand, Sidestand Center Stand Removal (Equipped Models) e Remove: Muffler Bodies (see Muffler Body Removal in the Engine Top End chapter) Spring [A] Bolts [B] Bolts [C] and Nuts Center Stand [D] Center Stand Installation (Equipped Models) e Apply grease to the sliding area [A] of the center stand B]. e Lien the bolts [C] and lock them with the nuts. Torque - Center Stand Bolts: 44 N-m (4.5 kgf-m, 32 ft:lb) © Hook the spring [D] so that face the long spring end up- ward. Olnstall the spring hook direction as shown in the figure. Sidestand Removal e Raise the rear wheel off the ground with the stand. e Remove: Sidestand Switch Bolt [A] Spring [B] Sidestand Bolt [C] Sidestand [D] Sidestand Bracket Bolts [E] Sidestand Installation e Apply grease to the sliding area [A] of the sidestand [B]. e Tighten the bolt and lock them with the nut. Torque - Sidestand Bracket Bolts [C]: 49 N-m (5.0 kgf-m, 36 ft-1b) Sidestand Bolt [D]: 44 N-m (4.5 kgf-m, 32 ft:lb) e Hook the spring [E] so that face the long spring end up- ward. Olnstall the spring hook direction as shown in the figure. e Install the sidestand switch. OApply a non-permanent locking agent to the thread of the switch bolt, and tighten it. Torque - Sidestand Switch Bolt [F]: 8.8 N-m (0.90 kgf-m, 78 in<lb) Gozo0168s:

• Electrical System Table of Contents Exploded View sise 16-4 Parts Location 16-10 Wiring Diagram (United States, Canada, New Zealand and Colombia 16-12 Wiring Diagram (Other than United States, Canada, New Zealand and Colombia) 16-14 Wiring Diagram (ZX1400B Models) Specifications Special Tools and Sealan Precautions. Electrical Wiring Wiring Inspection Battery Battery Removal. Battery Installation Battery Activation Precautions Interchange Charging Condition Inspection Refreshing Charge Charging System Alternator Cover Removal Alternator Cover Installation Stator Coil Removal… Stator Coil Installation Alternator Rotor Removal Alternator Rotor Installation Alternator Inspection Regulator/Rectifier Inspection Charging Voltage Inspection Ignition System
• Crankshaft Sensor Removal Crankshaft Sensor Installation Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage Inspection Stick Coil (Ignition Coil together with Spark Plug Cap) Removal. Stick Coil (Ignition Coil together with Spark Plug Cap) Installation. 16-39 Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection 16-40 Stick Coil Primary Peak Voltage 16-40 Spark Plug Removal 16-41 Spark Plug Installation 16-41 Spark Plug Condition Inspection 16-41 Camshaft Position Sensor Removal 16-42 Camshaft Position Sensor Installation 16-42 Camshaft Position Sensor Inspection. 16-42 Camshaft Position Sensor Peak Voltage Inspection. 16-43 Interlock Operation Inspection 16-43 IC Igniter Inspection 16-44 Electric Starter System … p. 16
• -46 Starter Motor Removal 16-46 Starter Motor Installation 16-46 Starter Motor Disassembly -47 p. 16

13. Other than France and Malaysia Models

Left City (Gi © © © © © ©

72 V or more Electric Starter System Starter Motor: Brush Length Commutator Diameter 10 mm (0.39 in.), Service limit 5.0 mm (0.20 in.) 28 mm (1.10 in.), Service limit 27 mm (1.06 in.) Air Switching Valve Resistance 18 22 Q at 20°C (68°F) Meter, Gauge, Indicator Unit Can Communication Line Resistance (at Meter Unit) Speed Sensor Supply Voltage 122 —-126 Q about 12 V Switch and Sensor Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance Fuel Level Sensor Resistance: Full Position Empty Position ON after about 10 mm (0.39 in.) pedal travel When engine is stopped: ON When engine is running: OFF In the text 9-1Q 213 -219Q

Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ODo not reverse the battery cable connections. This will burn out the diodes on the electrical parts. OAlways check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests. OThe electrical parts should never be struck sharply, as With a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. OTo prevent damage to electrical parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. OBecause of the large amount of current, never keep the starter button pushed when the starter motor will not turn over, or the current may burn out the starter motor wind- ings. ODo not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram, as the meter or gauge panel could be warped by excessive heat radiated from the bulb. OTake care not to short the cables that are directly con- nected to the battery positive (+) terminal to the chassis ground. OTroubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSE) the failure. 1f the failure was caused by some other item or items, they must be repaired or replaced, or the new replacement will soon fail again. OMake sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system op- eration. OMeasure coil and winding resistance when the part is cold (at room temperature). OColor Codes: BK: Black G: Green P: Pink BL: Blue GY: Gray PU: Purple BR: Brown LB: Light Blue R: Red CH: Chocolate LG: Light Green W: White DG: Dark Green O: Orange Y: Yellow

Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning, fraying, etc. xlf any wiring is poor, replace the damaged wiring. e Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. xlf the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. e Check the wiring for continuity. OUse the wiring diagram to find the ends of the lead which is suspected of being a problem. OConnect the hand tester between the ends of the leads. Special Tool - Hand Tester: 57001-1394 OSet the tester to the x 1 Q range, and read the tester. x If the tester does not read 0 Q, the lead is defective. Re- place the lead or the wiring harness [B] if necessary. cPoroozsst € Gporoz4nss €

Battery Battery Removal e Turn off the ignition switch. e Remove: Right Fairing Cover (see Fairing Cover Removal in the Frame chapter) Bolt [A] Battery Compartment Cover [B] OClear the stoppers from the frame. e Remove: Bolt [A] Bracket Bolts [B] Bracket [C] Connector [D] (Disconnect) CAUTION Be sure to disconnect the negative (-) cable first. e Slightly pull out the battery tray [A]. e Unhook the band [B]. e Remove the battery cover [C]. e Slide the red cap [A] out. e Disconnect the positive (+) cable [B]. e Remove the battery tray with battery [C]. e Disconnect the negative (—) cable [AÏ. + Remove the battery [B] from the battery tray.

Battery Battery Installation e Place the battery in the tray. e Connect the negative (—) cable to the battery. e Apply a light coat of grease on the terminals to prevent corrosion. e Insert the battery tray along with the battery into the bat- tery compartment. e Connect the positive (+) cable to the battery. e Cover the (+) terminal with its red cap [A]. e Install the battery cover on the battery, and hook the band. e Be sure insert the battery tray along with the battery into the battery compartment. e Put the holes [A] of the bracket to the projections [B] of the battery tray. e Tighten the bracket bolts. e Connect the connector. e Connect the negative (-) cable to the frame. e Put the projections of the battery compartment cover into the holes of the frame. e Install: Bolt Right Fairing Cover (see Fairing Cover Installation in the Frame chapter) Battery Activation Electrolyte Filling e Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name for ZX1400AJ/B: FTZ14-BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec- trolyte volume and specific gravity vary with the battery type. This is to prevent overfilling of the electrolyte, shorting the battery life, and deteriora- tion of the battery performance. CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. e Place the battery on a level surface. e Check to see that the sealing sheet has no peeling, tears, or holes in it. e Remove the sealing sheet. NOTE OThe battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge. GPogazo4st c cPogoossst c

Battery e Remove the electrolyte container from the vinyl bag. e Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE ODo not pierce or otherwise open the sealed cells [B] of the electrolyte container. Do not attempt to separate individual cells. e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill. NOTE ODo not tilt the electrolyte container e Check the electrolyte flow. xlf no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. e Keep the container in place for 20 minutes or more. Don't remove the container from the battery until its empty, the battery requires all the electrolyte from the container for proper operation. CAUTION ePogacosst ce GPosaoosst ce Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the electrolyte container until it is com- pletely empty and 20 minutes have elapsed. e Gently remove the container from the battery. e Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance. NOTE OCharging the battery immediately after filling can shorten service life. Let the battery sit for at least 60 minutes after filling.

Battery Initial Charge e Place the strip [A] of caps loosely over the filler ports. e Newly activated sealed batteries require an initial charge. Standard Charge: 1.4 À x 5 —-10 hours xlf using a recommended battery charger, follow the charger's instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 xlf the above chargers are not available, use equivalent one. NOTE OCharging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. If it is not at least 12.6 volts, repeat charging cycle. e After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don't pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery. cPogoissst c CAUTION Once the strip of the caps is installed onto the bat- tery, never remove the caps, nor add water or elec- trolyte to the battery. NOTE OTo ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.6 volts repeat the charging cycle and load test. If still below 12.6 volts the battery is defective. GPogoiz8st €

1) No need of topping-up

No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that.

2) Refreshing charge

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see this chapter). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery. CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced no- ticeably if charged under conditions other than given above. Never remove the seal cap during refresh charge. If by chance an excessive amount of gas is generated due to overcharging, the relief valve releases the gas to keep the battery normal.

3) When you do not use the motorcycle for months:

Give a refresh charge before you store the motorcycle and store it with the negative cable re- moved. Give a refresh charge once a month during storage.

If the battery will not start the engine even after several refresh charges, the battery has ex- ceeded its useful life. Replace it (Provided, however, the vehicle's starting system has no prob- lem). À WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. No fire should be drawn near the battery, or no terminals should have the tightening loos- ened. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medial attention if severe. Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery's life will be shortened. Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. e Remove: Battery (see Battery Removal) e Measure the battery terminal voltage. NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage. epoorosst &

Battery xlf the reading is 12.6 V or more, no refresh charge is re- T quired, however, if the read is below the specified, refresh (v) n charge is required. 8 ! £ 4 Battery Terminal Voltage £ r Standard: 12.6 V or more El OS Ë 115 RS F 0 25 50 75 100 Refreshing charge_ Battery Charge (%) is required 5 Note Good cposoross:| Refreshing Charge e Remove the battery [A] (see Battery Removal). e Do refresh charge by following method according to the battery terminal voltage. À WARNING This battery is sealed type. Never remove sealing cap [B] even at charging. Never add water. Charge with current and time as stated below. GPoggoï2st € Terminal Voltage: 11.5 -less than 12.6 V Standard Charge 1.4 A x 5 —-10 h (see following chart) Quick Charge 7Axih CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Charge Time (h)

: Battery Terminal Voltage (V) Terminal Voltage: less than 11.5 V éPoñozsust © Charging Method: 14Ax20h NOTE Olncrease the charging voltage to a maximum voltage of 25 Vifthe battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 min- utes, replace the battery. srosoriast € Battery [A] Battery Charger [B] Standard Value [C] Current starts to flow [D] e Determine the battery condition after refresh charge. ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria Judgement

12.6 V or higher Good

12.0 —lower than 12.6 V | Charge insufficient — Recharge

lower than 12.0 V Unserviceable — Replace

Charging System Alternator Cover Removal e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Alternator Lead Connector [A] Fuel Tank Bracket [B] e Remove: Bolts [A] Cover [B] e Pull the alternator lead out of between the engine and frame. Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 e Check that dowel pins [B] are in place on the crankcase. e Install a new gasket and the alternator cover. e Tighten: Torque - Alternator Cover Bolts: 9.8 N-m (1.0 kgf-m, 87 in<lb) Stator Coil Removal e Remove: Alternator Cover (see Alternator Cover Removal) Holding Plate Bolts [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] + Remove the stator coil [D] from the alternator cover.

Charging System Stator Coil Installation e Tighten the stator coil bolts to the specified torque. Torque - Stator Coil Bolts: 12 N-m (1.2 kgf-m, 106 in-Ib) e Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 e Secure the alternator lead with a holding plate [A], and apply a non-permanent locking agent to the thread of the plate bolts and tighten them. Torque - Alternator Lead Holding Plate Bolts: 8.3 N-m (0.85 kgf-m, 73 in-Ib) e Install the alternator cover (see Alternator Cover Installa- tion). Alternator Rotor Removal e Remove the alternator cover (see Alternator Cover Re- moval). + Clean off the oil from the outer circumference of the rotor. e Hold the alternator rotor steady with the rotor holder [A], and remove the rotor bolt [B] and washer. Special Tools - Grip [C]: 57001-1591 Rotor Holder: 57001-1672 Stopper [D]: 57001-1679 e Using the flywheel puller [A], remove the alternator rotor from the crankshaft. Special Tool - Flywheel Puller, M38 x 1.5: 57001-1405 CAUTION Do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism. Alternator Rotor Installation e Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth. Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B] e Install the alternator rotor.

Charging System e Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry if with a clean cloth. e Install the washer so that its chamfer side [B] faces the rotor bolt [C]. NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. e Install the rotor bolt [B] and tighten it with 69 N-m (7.0 kgf-m, 51 ft:Ib) of torque. e Remove the rotor bolt and washer. e Check the tightening torque with flywheel puller [A]. xlf the rotor is not pulled out with 20 N-m (2.0 kgf-m, 15 ft-1b) of drawing torque, it is installed correctly. xlf the rotor is pulled out with under 20 N-m (2.0 kgf-m, 15 ft-1b) of drawing torque, clean off any oil dirt or flaw of the crankshaft and rotor tapered portion, and dry them with a clean cloth. Then, confirm that it is not pulled out with above torque. e Install the rotor bolt and washer. e Tighten the alternator rotor bolt [A] while holding the alter- nator rotor steadily with the holder [B]. Special Tools - Grip [C]: 57001-1591 Rotor Holder: 57001-1672 Stopper [D]: 57001-1679 Torque - Alternator Rotor Bolt: 110 N-m (11.2 kgf-m, 81 ft-Ib) e Install the alternator cover (see Alternator Cover Installa- tion). Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output. Gposis7ess

Charging System e To check the alternator output voltage, do the following procedures. OTurn off the ignition switch. ORemove the right seat cover (see Seat Cover Removal in the Frame chapter). ODisconnect the alternator lead connector [A]. OConnect the hand tester as shown in the table 1. Special Tool - Hand Tester: 57001-1394 OStart the engine. ORun it at the rpm given in the table 1. ONote the voltage readings (total 3 measurements). Table 1 Alternator Output Voltage Tester Connections Reading Range | Tester (+) to Tester (-) to @A4 000 rpm 250 V AC | One Black Lead | Another Black Lead | 51 V or more xlf the output voltage shows the value in the table, the al- ternator operates properly. xlf the output voltage shows a much higher than the value in the table, the regulator/rectifier is damaged. A much lower reading than that given in the table indicates that the alternator is defective. e Check the stator coil resistance as follows. OStop the engine. OConnect the commercially available tester as shown in the table 2. ONote the readings (total 3 measurement). Table 2 Stator Coil Resistance at 20°C (68°F) Tester Connections : Reading Range Tester (+) to Tester (-) to x 1Q | One Black Lead |Another Black Lead | 0.05 —0.5 Q xlf there is more resistance than shown in the table, or no tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. e Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground. %Any hand tester reading less than infinity () indicates a short, necessitating stator replacement. xlfthe stator coils have normal resistance, but the voltage check showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced.

Charging System Regulator/Rectifier Inspection e Remove: Right Seat Cover (see Seat Cover Removal in the Frame chapter) Connectors [A] Regulator/Rectifier Bolts [B] Regulator/Rectifier [C] e Set the hand tester to the x 1 KQ range and make the measurements shown in the table. Special Tool - Hand Tester: 57001-1394 EE HE e Connect the hand tester to the regulator rectifier. al Jo] Jon um r) xlf the tester readings are not as specified, replace the regulator/rectifier. CAUTION BK3BK2BK1 W BK/Y Use only Kawasaki Hand Tester 57001-1394 for this Grootsanss o test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged. Regulator/Rectifier Resistance (Unit: kKQ) Tester (+) Lead Connection Terminal W BK1 BK2 BK3 BK/Y W — [20 —-300|20 -300 | 20 —-200 |20 -750 BK1 0 —5 _ 20 —300 | 20 —-200 | 20 —-750 > BK2 0 —5 |20 —-300 _ 20 —200 |20 -750 BK3 0 —5 |20 —-300 | 20 -300 _ 20 —750 BK/Y 5—20| 5-20 | 5-20 | 5 —-20 _ (-)*: Tester (-) Lead Connection e Install the regulator/rectifier. Torque - Regulator/Rectifier Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb)

Charging System Charging Voltage Inspection © Check the battery condition (see Charging Condition In- spection). e Warm up the engine to obtain actual alternator operating conditions. e Remove the right fairing cover (see Fairing Cover Re- moval in the Frame chapter). e Check that the ignition switch is turned off, and connect the hand tester [A] to the battery (+) terminal and ground. Special Tool - Hand Tester: 57001-1394 e Start the engine, and note the voltage readings at var- ious engine speeds with the headlight turned on and then turned off (To turn off the headlight, disconnect the headlight connector on the headlight unit.). The readings should show nearly battery voltage when the engine speed is low, and, as the engine speed rises, the readings should also rise. But they must be kept under the specified voltage. Charging Voltage Connections : Tester Range Reading Tester (+) to | Tester (-) to 25 V DC Battery (+) Ground 14.2 -152V e Turn off the ignition switch to stop the engine, and discon- nect the hand tester. xlfthe charging voltage is kept between the values given in the table, the charging system is considered to be working normally. xlf the charging voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open. xlfthe charging voltage does not rise as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective.

16-36 ELECTRICAL SYSTEM

Ignition System Ignition System Troubleshooting Faulty ignition (No spark) Battery Inspection No good Charge or replace battery. Good Ignition system wiring No good Repair or replace and connector inspection damaged part. Good N d Spark plug inspection © go0 Replace spark plug. Good . oi . : . No good . . Stick coil winding resistance inspection Replace stick coil. Good . : : No good Voltage is less than Stick coil primary peak voltage inspection the specified value. Good No good Stick coil is defective. Voltage is zero Inspect_ | . Replace stick coil. or almost zero. 1. Lower resistance in a No good hand tester. (Use — KAWASAKI Hand Tester) Inspect: 2. Crankshaft sensor peak voltage

1. Adapter connection is 3. Camshaft position sensor

incorrect, or adapter is peak voltage defective. No good|2. Ignition switch and engine] Good stop switch

3. Crankshaft sensor peak

4. Camshaft position sensor

peak voltage Good Replace bad parts. ECUis defective. Replace ECU. Replace bad parts or inspect them with KAWASAKI Hand Tester.

Ignition System À WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent ECU damage. Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the ECU. Crankshaft Sensor Removal e Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Crankshaft Sensor Lead Connector [A] e Remove: Crankshaft Sensor Cover Bolts Crankshaft Sensor Cover Crankshaft Sensor Bolts [A] Crankshaft Sensor [B]

Ignition System Crankshaft Sensor Installation e Apply a non-permanent locking agent to the threads of the crankshaft sensor bolts [A], and tighten it. Torque - Crankshaft Sensor Bolts: 5.9 N-m (0.60 kgf-m, 52 in-lb) e Apply silicone sealant to the circumference of the crank- shaft sensor lead grommet [B], and fit the grommet into the notch of the crankcase securely. e Apply silicone sealant to the mating surface [C] of crankcase halves. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 e Replace the O-ring [D] with a new one. e Install the crankshaft sensor cover. e Apply a non-permanent locking agent to only one crank- shaft sensor cover bolt [E] shown in figure. e Tighten the crankshaft sensor cover bolts. Torque - Crankshaft Sensor Cover Bolts: 9.8 N:m (1.0 kgf-m, 87 in-Ib) e Route the crankshaft sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). e Install the removed parts (see appropriate chapters). Crankshaft Sensor Inspection e Remove the right fairing cover (see Fairing Cover Re- moval in the Frame chapter). e Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor Removal). e Set the hand tester [A] to the x 100 Q range and connect it to the crankshaft sensor lead connector [B]. Special Tool - Hand Tester: 57001-1394 Crankshaft Sensor Resistance: 376 —564 Q xlf there is more resistance than the specified value, the coil has an open lead and must be replaced. Much less than this resistance means the coil is shorted, and must be replaced. e Using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground. x Any tester reading less than infinity (+) indicates a short, necessitating replacement of the crankshaft sensor. Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged. OUsing the peak voltage adapter is a more reliable way to determine the condition ofthe crankshaft sensor than crankshaft sensor internal resistance measurements. e Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor Removal). GPioss2ess

Ignition System e Set the hand tester [A] to the x 25 V DC range, and con- nect the peak voltage adapter [B]. Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connections: Crankshaft Sensor Connector [C] Adapter Hand Tester Black — Black = re) Yellow — Red = me] e Turn the ignition switch and engine stop switch ON. e Pushing the starter button, turn the engine 4 —5 sec- onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. e Repeat the measurement 5 or more times. Crankshaft Sensor Peak Voltage Standard: 2.4 V or more xlfthe tester reading is not specified one, check the crank- shaft sensor. Stick Coil (Ignition Coil together with Spark Plug Cap) Removal e Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) e Disconnect the stick coil connectors [A]. e Pull the stick coils [B] off the spark plugs. CAUTION Do not pry the connector part of the coil while re- moving the coil. Stick Coil (Ignition Coil together with Spark Plug Cap) Installation e Apply grease to the stick coils. e Insert the stick coils [A] as shown being careful of the coil heads directions. OAlign the lines [B] of the cylinder head cover and coil heads. CAUTION Do not tap the coil head while installing the coil. e Connect the stick coil connectors. e Run the hoses and harness correctly (see Cable, Wire, and Hose Routing section in Appendix chapter). e Install the removed parts (see appropriate chapters). cPiossanss

Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection e Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). e Measure the primary winding resistance [A] as follows. OConnect the hand tester between the coil terminals. OSet the tester to the x 1 Q range, and read the tester. e Measure the secondary winding resistance [B] as follows. OConnect the tester between the plug terminal and (—) coil terminal. OSet the tester to the x 1 kQ range and read the tester. Stick Coil Winding Resistance Primary Windings: 12-16Q Secondary Windings: 8.5 —11.5 kKQ xlf the tester does not read as specified, replace the coil. Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged. e Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). ODo not remove the spark plug. e Measure the primary peak voltage as follows. Olnstall the new spark plug [A] into each stick coil [B], and ground them onto the engine. OConnect the peak voltage adapter [C] to the hand tester [D] which is set to the x 250 V DC range. OConnect the adapter to the lead wire-peak voltage adapter [E] which is connected between the stick coil connector and stick coil. ECU [F] Battery [G] Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Lead Wire-Peak Voltage Adapter: 57001

Primary Lead Connection Adapter (R, +) to lead wire-peak voltage adapter (W) Adapter (BK, -) to lead wire-peak voltage adapter (R)

Ignition System To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. e Turn the ignition switch and engine stop switch ON. e Pushing the starter button, turn the engine 4 —5 seconds With the transmission in neutral to measure the primary peak voltage. e Repeat the measurements 5 times for one stick coil. Stick Coil Primary Peak Voltage Standard: 72 V or more e Repeat the test for the other stick coils. xlf the reading is less than the specified value, check the following. Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection) Crankshaft Sensor (see Crankshaft Sensor Inspection) ECU (see ECU Power Supply Inspection in the Fuel Sys- tem (DFI) chapter) Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter (see Spark Plug Replacement in the Periodic Maintenance chapter). Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter (see Spark Plug Replacement in the Periodic Maintenance chapter). Spark Plug Condition Inspection e Visually inspect the spark plugs. xlf the spark plug center electrode [A] and/or side elec- trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug. xlf the spark plug is dirtied or the carbon is accumulated, replace the spark plug. À e Measure the gap [D] with a wire-type thickness gauge. D xlf the gap is incorrect, replace the spark plug. B estroossst ce Spark Plug Gap: 0.8 —0.9 mm (0.031 —0.035 in.) e Use the standard spark plug or its equivalent. Spark Plug: CR9EIA-9

Ignition System Camshaft Position Sensor Removal e Remove: Fuel Tank Cover (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) e Disconnect the camshaîft position sensor lead connector [A]. e Remove: Camshaft Position Sensor Bolt [A] Camshaft Position Sensor [B] Camshaft Position Sensor Installation e Replace the O-ring of the camshaïft position sensor. e Apply grease to the new O-ring. e Tighten: Torque - Camshaft Position Sensor Bolt: 9.8 N-:m (1.0 kgf-m, 87 inIb) e Route the camshaft position sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Camshaft Position Sensor Inspection e Disconnect the camshaîft position sensor lead connector (see Camshaft Position Sensor Removal). e Set the hand tester to the x 10 Q range and connect it to the terminals. Special Tool - Hand Tester: 57001-1394 Camshaft Position Sensor Resistance: 400 —460 Q xlf there is more resistance than the specified value, the sensor coil has an open lead and must be replaced. Much less than this resistance means the sensor coil is shorted, and must be replaced. e Using the highest resistance range of the tester, mea- sure the resistance between the camshaft position sensor leads and chassis ground. x Any tester reading less than infinity (+) indicates a short, necessitating replacement of the camshaïft position sen- sor.

Ignition System Camshaft Position Sensor Peak Voltage Inspection e Disconnect the camshaft position sensor lead connector [A] (see Camshaft Position Sensor Removal). e Connect the harness adapter [B] between the camshañt position sensor lead connector and harness connector [C]. e Connect the peak voltage adapter [D] to the hand tester [E] which is set to the x 10 V range. e Connect the adapter to the harness adapter. [F] Camshaft Position Sensor Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Harness Adapter: 57001-1562 Connections: Harness Adapter Peak Voltage Hand Tester Adapter Black/White — Black — Q] criossmst c Red — Red _ (+) e Turn the ignition switch and engine stop switch ON. e Pushing the starter button, run the engine with the trans- mission gear in neutral to measure the camshaïft position sensor peak voltage. e Repeat the measurement 5 or more times. Camshaft Position Sensor Peak Voltage Standard: 2.8 V or more xlfthe peak voltage is lower than the standard, inspect the camshaft position sensor. Interlock Operation Inspection e Using the stand [A], raise the rear wheel off the ground. 1st Check e Start the engine to the following conditions. Condition: Transmission Gear — 1st Position Clutch Lever — Release Sidestand — Down or Up OTurn the ignition switch ON and push the starter button. OThen the starter motor should not turn when the starter system circuit is normality. xlf the engine is start, inspect the starter lockout switch, gear position switch, and relay box. xlf their parts are normality replace the ECU.

Ignition System 2nd Check e Start the engine to the following conditions. Condition: Transmission Gear — 1st Position Clutch Lever — Pulled in Sidestand — Up OTurn the ignition switch ON and push the starter button. OThen the starter motor should turn when the starter sys- tem circuit is normality. xlf the starter motor is not turn, inspect the starter lockout switch, gear position switch, sidestand switch and relay box. xlf their parts are normality replace the ECU. 3rd Check e Inspect the engine for its secure stop after the following operations are completed. e Run the engine to the following conditions. Condition: Transmission Gear — 1st Position Clutch Lever — Release Sidestand — Up e Setthe sidestand on the ground, then the engine will stop. xlfwhichever may not be stopped, inspect the gear position switch, starter lockout switch, sidestand switch and relay box. xlf their parts are normality, replace the ECU. IC Igniter Inspection OThe IC igniter is built in the ECU [A]. e Refer to the following items. Interlock Operation Inspection (see Interlock Operation Inspection) Ignition System Troubleshooting (see Ignition System section) ECU Power Supply Inspection (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)

Electric Starter System Starter Motor Removal e Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) e Take off the heat insulation rubber plate [A]. e Slide out the rubber cap [B]. e Remove the starter motor cable terminal nut [C]. e Remove the starter motor mounting bolts [A]. e Pull out the starter motor [B] from the left side. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. e Clean the starter motor legs [A] and crankcase [B] where the starter motor is ground. e Replace the O-ring [C] with a new one. e Apply grease to the new O-ring. e Tighten: Torque - Starter Motor Mounting Bolts: 9.8 N-m (1.0 kgf-m, 87 in-lb) e Install the starter motor cable [A] side by side with starter motor [B]. e Tighten: Torque - Starter Motor Cable Terminal Nut: 5.9 N-m (0.60 kgf-m, 52 in-Ib) e Slide back the rubber cap [C] to the original position. GPrioosess €

Electric Starter System Starter Motor Disassembly e Remove the starter motor (see Starter Motor Removal). e Take off the starter motor through bolts [A] and remove both end covers [B]. e Pull the armature [A] out of the yoke [B]. e Remove: Brush Plate Terminal Nut, Washer and Insulators [A] Brush Plate Assembly [B] Starter Motor Assembly e Pry the spring end [A] and insert the brush [B]. e Install the brush plate assembly [A] into the right-hand end cover [B]. e Replace the O-ring [C] with a new one. e Install: Insulators [D] Washer [E] e Tighten: Torque - Starter Motor Terminal Locknut [F]: 6.9 N:m (0.70 kgf-m, 61 in-lb) GPrio4nss €

Electric Starter System Install the armature [A] into the yoke [B]. e Install thrust washer [C]. e Replace the O-rings [D] with new ones. e Put the armature [E] among the brushes [F]. e Align the marks [A] to assembly the yoke and the end covers. e Replace the O-rings [A] with new ones. e Tighten: Torque - Starter Motor Through Bolts [B]: 3.4 N-m (0.35 kgf-m, 30 in-lb) e Replace the O-ring [A] with new ones. e Apply grease to the new O-ring. Brush Inspection e Measure the length [A] of each brush [B]. xlf any is worn down to the service limit, replace the brush holder assembly. Starter Motor Brush Length Standard: 10 mm (0.39 in.) Service Limit: 5.0 mm (0.20 in.) œneuo P

Electric Starter System Commutator Cleaning and Inspection e Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. GPtiogiost e e Measure the diameter [A] of the commutator [B]. xlf the commutator diameter is less than the service limit, replace the starter motor with a new one. Commutator Diameter Standard: 28 mm (1.10 in.) Service Limit: 27 mm (1.06 in.) Armature Inspection e Using the *x 1 Q hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 xlfthereis a high resistance or no reading (+) between any two segments, a winding is open and the starter motor must be replaced. e Using the highest hand tester range, measure the resis- tance between the segments and the shaft [B]. aPiiosousi ce xlfthere is any reading at all, the armature has a short and the starter motor must be replaced. NOTE OEven if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one. Brush Lead Inspection e Using the *x 1 Q hand tester range, measure the resis- C7 ee LE] tance as shown. Q © ©. © © Terminal Bolt and Positive Brush [A] Right-hand End Cover and Negative Brush [B] Special Tool - Hand Tester: 57001-1394 xlf there is not close to zero ohms, the brush lead has an open. Replace the brush holder assembly.

Electric Starter System Right-hand End Cover Assembly Inspection e Using the highest hand tester range, measure the resis- tance as shown. Terminal and Right-hand End Cover [A] Special Tool - Hand Tester: 57001-1394 x lfthere is any reading, the right-hand end cover assembly have a short. Replace the right-hand end cover assembly. Starter Relay Inspection e Remove the battery (see Battery Removal). e Disconnect the starter motor cable [A] and battery positive (+) cable [B] from the starter relay. e Disconnect the connector [C]. e Pull out the starter relay from the damper. © Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Special Tool - Hand Tester: 57001-1394 xlf the relay does not work as specified, the relay is defec- tive. Replace the relay. Testing Relay Tester Range: x 1 Q range Criteria: When battery is connected — 0 Q When battery is disconnected — « Q e Tighten: Torque - Starter Motor Cable Mounting Bolt: 3.9 N-m (0.40 kgf-m, 35 in-lb) cPtioisest €

Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released. Headlight Beam Horizontal Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Beam Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Bulb Replacement e Remove the inner covers (see Inner Cover Removal in the Frame chapter). e Disconnect the headlight connector [A]. e Turn the headlight bulb [A] counterclockwise and pull out the bulb from the headlight. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution. e Replace the headlight bulb. e Fit the projections [A] of the bulb in the hollows [B] of the headlight. e Turn the headlight bulb clockwise. e Connect the headlight connector. e After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). OOther Bulbs: Repeat the above steps.

Lighting System City Light Bulb Replacement e Remove the inner covers (see Inner Cover Removal in the Frame chapter). e Unscrew the screw [A]. e Disconnect the city light connector [B]. e Turn the city light bulb counterclockwise and pull out the socket [A] together with the bulb. e Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified value. e Replace the bulb with a new one. e Insert the socket and to the headlight. OAlign the projections [A] of the socket and the grooves [B] of the headlight. e Turn the city light bulb clockwise. e Connect the city light connector. Headlight Removal/Installation e Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter) Headlight Mounting Screws [A] Headlights [B] e Tighten: Torque - Headlight Mounting Screws: 1.2 N-m (0.12 kgf-m, 11 indb)

Lighting System Headlight Relay Inspection e Remove the inner covers (see Inner Cover Removal in the Frame chapter). e Take off the headlight relay [A] (both sides). e Set the hand tester to the x 1 Q range and make the measurements shown in the figure. Headlight Relay [A] 12 V Battery [B] Special Tool - Hand Tester [C]: 57001-1394 xlf the tester readings are not as specified, replace the headlight relay. CAUTION Use only Hand Tester 57001-1394 for this test. An ohmmeter other than the Kawasaki Hand Tester may show different readings. If a megger or a meter With a large-capacity battery is used, the headlight relay will be damaged. Testing Relay Criteria When battery is connected — 0 Q When battery is disconnected — « Q Tail/Brake Light (LED) Removal e Remove: Tool Kit Case [A] (see ECU Removal in the Fuel System (DFI) chapter) Relay Box [B] (see Relay Box Removal in the Electrical System chapter) Fuse Box [C] Screws [D] e Disconnect the connector [A]. e Remove the tail/brake light [B]. GPi2247881

Lighting System Tail/Brake Light (LED) Installation e Connect the connector. e Insert the projections [A] of the tail/brake light into the holes [B] of the rear fender. Torque - Tail/Brake Light Mounting Screws: 1.2 N-m (0.12 kgf-m, 11 in:lb) e Install the removed parts (see appropriate chapters). License Plate Light Bulb Replacement e Remove: Screws [A] License Plate Light Cover [B] e Push and turn the bulb [A] counterclockwise wise and re- move it. e Replace the bulb with a new one. Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. OTurn the bulb about 15°. e Tighten: Torque - Licence Plate Light Cover Mounting Screws: 0.9 N-m (0.09 kgf-m, 8 in-lb)

5. Headlight (High Beam)

6. Headlight (Low Beam)

8. Headlight Relay (Low)

9. Headlight Relay (High)

11. Passing Button (Other than US Models)

Turn Signal Light Bulb Replacement Front Turn Signal Light e Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Inner Fairings (see Inner Fairing Removal in the Frame chapter) e Turn the socket [A] counterclockwise and pull out the socket together with the bulb. . Headlight Fuse (Low) 10 A . Fuse Box 1 . Relay Box . Headlight Circuit Relay . Alternator . Main Fuse 30 À . Starter Relay . Battery 12 V 14 Ah . Frame Ground . Tail/Brake Light (LED) . License Plate Light . Joint Connector 2 . Fuse Box 2 .Ignition Fuse 10 A

Lighting System e Push and turn the front turn signal light bulb [A] counter- clockwise and remove it. e Replace the bulb with new ones. Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. OTurn the bulb about 15°. e Pushing the socket and turn it clockwise. OFit the projections [A] of the socket into the grooves [B] of the turn signal light. e Install the middle fairings (see Middle Fairing Installation in the Frame chapter). Rear Turn Signal Light e Remove: Screw [A] Rear Turn Signal Light Lens [B] e Push and turn the rear turn signal light bulb [A] counter- clockwise and remove it.

Lighting System e Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. OTurn the bulb about 15°. e Fit the projections [A] of the lens into the grooves [B] of the turn signal light. e Tighten the screw. Turn Signal Relay Inspection e Remove: Left Seat Cover (see Seat Cover Removal in the Frame chapter) Turn Signal Relay [A] e Disconnect the connector [B]. e Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] %lfthe lights do not flash as specified, replace the turn sig- nal relay. Testing Turn Signal Relay GPt2040281 © Load The Number of Turn Flashing Times Signal Lights Wattage (W) (cm) Lu 21 or 23 140 —250 2 42 or 46 75 —95

• Cycle(s) per minute **: Corrected to “one light burned out”.

Lighting System Turn Signal Light Circuit GPi2244882 © © © HN O O1 À & ND = .Ignition Switch . Joint Connector 1 . Turn Signal Indicator Light (LED) (Right) . Turn Signal Indicator Light (LED) (Left) . Front Right Turn Signal Light . Front Left Turn Signal Light . Other than US Models . Hazard Button . Turn Signal Switch . Turn Signal Fuse 10 A . Fuse Box 1 . Turn Signal Relay . Joint Connector 2 . Frame Ground . Main Fuse 30 A . Battery 12 V 14 Ah . Rear Left Turn Signal Light . Rear Right Turn Signal Light .Ignition Fuse 10 A . Fuse Box 2

Air Switching Valve Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Aïir Switching Valve Unit Test e Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter). e Set the hand tester [A] to the x Q range and connect it to the air switching valve terminals as shown. Special Tool - Hand Tester: 57001-1394 Air Switching Valve Resistance Standard: 18 —22 Q at 20°C (68°F) xlfthe resistance reading is except the specified value, re- place it with a new one. e Connect the 12 V battery [A] to the air switching valve terminals as shown. e Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air ducts [B]. e Disconnect the 12 V battery. + Blow the air to the inlet air duct [A] again, and make sure flow the blown air from the outlet air ducts [B]. xlf the air switching valve dose not operate as described, replace it with a new one. NOTE OTo check air flow through the air switching valve, just blow through the air switching valve hose (inlet side) ICI. Geosoonst ce Geosossust e Geososimst €

Radiator Fan System Fan Motor Inspection e Remove the left fairing cover (see Fairing Cover Removal in the Frame chapter). e Disconnect the connector [A]. e Using an auxiliary leads, supply battery power to the fan motor. xlf the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Circuit

® lo) re Dee cpisoasens €

2. Joint Connector 1 " pate REV EAN

Meter, Gauge, Indicator Unit Meter Unit Removal e Remove: Windshield (see Windshield Removal in the Frame chapter) Immobilizer Amplifier [A] (Equipped Models) e Remove: Immobilizer Amplifier Bracket and Bolt [A] (Equipped Models) Vehicle-down Sensor Bracket and Bolt [B] Meter Lead Connector [C] e Remove: Meter Unit Mounting Nuts [A] and Washers Meter Unit [B] CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction. Meter Unit Installation e Install: Meter Unit [A] Washers [B] and Meter Unit Mounting Nuts [C] e Install: Meter Lead Connector Vehicle-down Sensor Bracket (as shown) and Bolt [A] Immobilizer Amplifier Bracket and Bolt (Equipped Mod- els) Immobilizer Amplifier [B] (Equipped Models) Windshield (see Windshield Installation in the Frame chapter)

Meter, Gauge, Indicator Unit Meter Unit Disassembly e Remove: Meter Unit (see Meter Unit Removal) Screws [A] Lower Meter Cover [B] ° Separate: Upper Meter Cover [A] Middle Meter Cover [B] Meter Assembly [C] Meter Unit Inspection + Remove the meter unit (see Meter Unit Removal). [1] High Beam Indicator Light (LED) [2] Oil Pressure Warning Indicator Light (LED) (—) [3] Right Turn Signal Indicator Light (LED) (+) [4] Neutral Indicator Light (LED) (-) [5] Unused [6] ABS Indicator Light (LED) (-) [7] Unused [8] Unused [9] Ignition (+) [10] Battery (+) [11] Speed Sensor Supply Voltage (+) [12] Ground (—) [13] Speed Sensor Signal [14] Unused [15] Fuel Reserve Switch [16] Fuel Level Sensor [17] CAN Communication Line (Hight) [18] CAN Communication Line (Low) [19] Left Turn Signal Indicator Light (LED) (+) [20] Unused CAUTION Do not drop the meter unit. Place the meter unit so that it faces upward. Ifthe meter assembly is left up- side down or sideways for a long time or dropped, it will malfunction. Do not short each terminals. GPr7427862 €

Meter, Gauge, Indicator Unit Check 1: CAN Communication Line Resistance Inspec- tion e Set the hand tester [A] to the x1 Q range and connect it to the terminal [17] and [18] in the meter unit. Special Tool - Hand Tester: 57001-1394 CAN Communication Line Resistance (at Meter Unit) Standard: 122 -126Q xlf the tester reading is not specified, replace the meter assembly. Check 2: Meter Unit Primary Operation Check e Using the auxiliary leads, the 12 V battery [A] to the meter unit connector as follows. OConnect the battery positive (+) terminal to the terminal [10]. OConnect the battery negative (-) terminal to the terminal [12]. e Check that the speedometer and tachometer needles [A] momentarily point their last readings and back to the min- imum position. xlf the meter unit does not work, replace the meter assem- bly. e Connect terminal [9] to the battery (+) terminal. e Check that the following items. OThe speedometer and tachometer needles momentarily point their last readings and back to the minimum position. OThe ABS indicator light (LED) [A] (equipped models) should go on. OThe K Kawasaki mark [B] in the LCD appears for three seconds.

Meter, Gauge, Indicator Unit OAïfter the K Kawasaki mark appeared, the TRIP A/B meter [A], water temperature gauge [B], fuel level gauge [CI], odometer and clock appear in the display [D]. OThe ABS indicator light (LED) [E] (equipped models) should go on. xlf the meter unit does not work, replace the meter assem- bly. NOTE OThe flashings of the three segments for the water tem- perature gauge and fuel level gauge do not failure ofthe meter unit. OCurrently, for the meter is disconnected from the main harness each flashing occur. OThe flashing of water temperature gauge is communi- cation error to the ECU. OThe flashing of the fuel level gauge is open or short of the fuel reserve switch. ONormally, each flashing disappears when the meter unit is connected to main harness. Check 3: MODE and RESET Button Operation Check e Connect the leads in the same circuit as Check 2. eBy pushing the MODE button [A] each time, check that the display [B] changes as follows. OThis display is ordinary indication. TRIP A Rip B 7 AVERAGE —INST —>RANGE —>BATTERY

xlf the display function does not work, replace the meter assembly. GPr?5438NS € e Push the MODE button [A] and RESET button [B] for more than two seconds. e Check that the display changes to the language setting mode [A]. OThis display is system menu indication. e By pushing the RESET button each time, check that the display selects the ENGLISH or FRANCAIS. xlf the display function does not work, replace the meter assembly. CCE GPA $

Meter, Gauge, Indicator Unit e By pushing the MODE button each time at the language setting mode, check that the display [A] selects as follows.

ENGLISH FRANCAIS xlf the display function does not work, replace the meter assembly. e Select the MILEAGE [A] indication. e Push the MODE button for more than two seconds, check that the unit setting menu [B] flashes. e By pushing the RESET button each time, check that the display changes as follows. KM/L —> L/100KM —=MPG USA —=MPG UK GP175588NS € e Check that the unit setting menu is decided by the MODE button push. xlf the display function does not work, replace the meter assembly. e Select the ENGAGE LAMP [A] indication. e Push the MODE button for more than two seconds, check that the engine speed setting menu [B] flashes. e By pushing the RESET button each time, check that the display changes as follows. OFF —> 3000 —=3100---5900 —=6000

© Check that the engine speed setting menu is decided by the MODE button pushing. xlf the display function does not work, replace the meter assembly. GPr7SS6BNS € e Select the SHIFT LAMP [A] indication. e Push the MODE button for more than two seconds, check that the engine speed setting menu [B] flashes. e By pushing the RESET button each time, check that the display changes as follows.

GP17S578NS € e Check that the engine speed setting menu is decided by the MODE button pushing. xlf the display function does not work, replace the meter assembly. MILEAGE] ENGAGE LAMP © es

l 220 V4 s | aveeeli © [mtese KML (©) (SZ |ENGAGE LamP “OFF | 2 f) | SHIFT LAMP oFF || ©

Meter, Gauge, Indicator Unit e Select the LAMP MODE [A] indication. e Push the MODE button for more than two seconds, check that the lighting mode setting menu [B] flashes. e By pushing the RESET button [C] each time, check that the display changes as follows and the indicator light (LED) [D] goes on according to message.

BRIGHT —= DIM ——BLINK

e Check that the lighting mode setting menu is decided by the MODE button pushing. xlf the display function does not work, replace the meter assembly. e Select the CLOCK [A] indication. + Push the MODE button for more than two seconds. OThe clock setting menu (hour and minute) [B] should flash. cPr7SS8BNS € e Push the RESET button. OThe hour display [A] starts flashing. eBy pushing the MODE button each time, check that the hour display changes. e By pushing the RESET button, check that the hour display decide and minute display [A] starts flashing. eBy pushing the MODE button each time, check that the minute display changes. MILEAGE

Meter, Gauge, Indicator Unit e By pushing the RESET button, check that the hour and minute display [A] starts flashing. e By pushing the MODE button, check that the hour and minute display decide. e When both hour and minute display flashing, by pushing | (©) || MILEAGE e the RESET button, check that the hour display start flash- @ ENGAGE LMP QE ON ing. This flashing returns the hour setting mode. LAMP MODE BRIGHT 9 g 9 CLOCK| - LE xlf the display function does not work, replace the meter ER 2 AS DS Fe So eus _s assembly. 20 Va Check 4: Battery Voltage Inspection + Connect the leads in the same circuit as Check 2. GPi7sa7es: € e 1st, set the BATTERY display. e Check that the display indicates the battery voltage. e 2nd, disconnect the terminal [10]. © Check that the display changes 9.0 V within about 30 sec- onds. GPi7S878s: € e 3rd, connect the terminal [10]. e Check that the display changes the current battery volt- age within about 30 seconds. OThe tolerance of the voltage is +0.4 V. xlf the display function does not work, replace the meter assembly. GPi7sa7es: €

Meter, Gauge, Indicator Unit Check 5: Immobilizer Flashing Mode Inspection (Equipped Models) e Connect the leads in the same circuit as Check 2. e Disconnect the terminal [9]. e Check that the warning light (LED) [A] starts flashing (Im- mobilizer Warning Light Flashing Mode). e Push the MODE [B] and RESET [C] buttons more than 2 second, within 20 seconds after the terminal [9] discon- nected. e Check that the warning light (LED) goes on one second, and then the light goes off (Immobilizer Warning Light No Flashing Mode). NOTE OFor this inspection, be sure the battery is 12.4 V or more. Immobilizer Warning Light Flashing Mode does not work, when the battery voltage is less than 12+0.4

e Connect the terminal [9] to the battery (+) terminal. e And then, disconnect the terminal [9]. e Push the MODE and RESET buttons more than 2 second, Within 20 seconds after the terminal [9] disconnected. e Check that the warning light (LED) goes on one second, and then the light starts flashing (Immobilizer Warning Light Flashing Mode). xlf the meter function does not work, replace the meter assembly. Check 6: High Beam Indicator Light (LED) Inspection e Connect the leads in the same circuit as Check 2. e Connect the terminal [1] to the battery (+) terminal. œsee s GPi7S708S1 €

Meter, Gauge, Indicator Unit © Check that the high beam indicator light (LED) [A] goes on. xlf the indicator light does not go on, replace the meter assembly. Check 7: Right Turn Signal Indicator Light (LED) In- spection + Connect the leads in the same circuit as Check 2. e Connect the terminal [3] to the battery (+) terminal. e Check that the right turn signal indicator light (LED) [A] goes on. xlf the indicator light does not go on, replace the meter assembly. Check 8: Left Turn Signal Indicator Light (LED) Inspec- tion + Connect the leads in the same circuit as Check 2. e Connect the terminal [19] to the battery (+) terminal. e Check that the left turn signal indicator light (LED) [A] goes on. xlf the indicator light does not go on, replace the meter assembly. GPr7S728S1 € USB $

Meter, Gauge, Indicator Unit Check 9: Oil Pressure Warning Indicator Light (LED) Inspection e Connect the leads in the same circuit as Check 2. e Connect the terminal [2] to the battery (-) terminal. e Check that the oil pressure warning indicator light (LED) goes on. xlf the indicator light does not go on, replace the meter assembly. Check 10: Neutral Indicator Light (LED) Inspection e Connect the leads in the same circuit as Check 2. e Connect the terminal [4] to the battery (-) terminal. e Check that the neutral indicator light (LED) goes on. xlf the indicator light does not go on, replace the meter assembly. Check 11: ABS Indicator Light (LED) Inspection (Equipped Models) e Connect the leads in the same circuit as Check 2. e Check that the ABS indicator light (LED) [A] goes on. GPr7576881 € GPTSTRS:

Meter, Gauge, Indicator Unit © Connect the terminal [6] to the battery (-) terminal. © Check that the ABS indicator light (LED) goes off. xlf the indicator light does not go on, replace the meter assembly. Check 12: Fuel Level Warning Inspection + Connect the leads in the same circuit as Check 2. © Connect the variable rheostat [A] (about 22 Q) to the ter- minal [15] and the battery (-) terminal. e After about 5 seconds, check that one segment [A] in the fuel gauge starts flashing. e Check that the FUEL EMPTY [B] and fuel symbol [C] ap- pear alternately in the display. xlf the display function does not work, replace the meter assembly. OThis display is the warning message indication. e Push the MODE button [A] more than 2 seconds. e Check that the warning light (LED) [B] goes on and display changes TRIP A/B meter [C] mode. OThe one segment [D] in the fuel gauge keeps flashing. e Push the MODE button more than 2 seconds. © Check that the warning light (LED) goes off and display changes the warning message indication mode. OThe one segment in the fuel gauge keeps flashing. xlf the display function does not work, replace the meter assembly. e Disconnect the battery to disappear the warning message indication. GPITSERS: ni L

Meter, Gauge, Indicator Unit Check 13: Fuel Gauge Inspection e Connect the leads in the same circuit as Check 2. EXCIOE e Connect the resistor [A] (about 1 kQ) to the terminal [15] and the battery (-) terminal. JU. NI e Connect the variable rheostat [B] to the terminal [16] and ANT" the battery (-) terminal. Œ! e Check that the number of segments matches the resis- tance value of the variable rheostat. TT = + OWhen the terminal [16] is connected, one segment in the fuel level gauge should appear about every 15 seconds. rirseznsi ce Variable Rheostat Resistance (Q)

xlf the display function does not work, replace the meter assembly. Display Segments [A] Check 14: Speedometer Inspection e Connect the leads in the same circuit as Check 2. e The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [13]. Olndicates approximately 60 mph if the input frequency is approximately 131.2 Hz. Olndicates approximately 60 km/h if the input frequency is approximately 82 Hz. [_ xlf the meter function does not work, replace the meter UT 7 + assembly. C1 Duty=50% ——-5V

ePr78078S2 € Check 15: Trip A/B Meter Inspection e Connect the leads in the same circuit as Check 14. e Set the TRIP A/B meter mode in the display. e Raise the input frequency of the oscillator to see the result of this inspection. xlfthe value indicated by the trip meter A/B do notincrease, replace the meter assembly.

Meter, Gauge, Indicator Unit e By pushing the RESET button each time, check that the display starts flashing as follows. ANNE 77 AANN UNIT 77 TRI A at TRIP A xxKM—=TRIP B xxKM—TRIE À XXE PEPPEPPANNNN PA PETER Pan TRIP A xxkM TRIP B xxkM cPr75988NS € e When flushing the display, push the RESET button for more than two seconds, check that the display changes

0.0 (TRIP A) and 0 (TRIP B).

xlfthe display function does not change, replace the meter assembly. Check 16: Odometer Inspection e Connect the leads in the same circuit as Check 14. e Raise the input frequency of the oscillator to see the result of odometer [A] inspection. OExample: Indicates the increase of approximately 1 mile, if the input frequency is approximately 131.2 Hz for one minute. OExample: Indicates the increase of approximately 1 km/h, if the input frequency is approximately 82 Hz for one minute. xlfthe value indicated by the odometer does not increase, replace the meter assembly. Check 17: Speed Sensor Supply Voltage Inspection e Connect the leads in the same circuit as Check 2. e Set the hand tester to the 25 V range and connect it in the meter unit as follows. Special Tool - Hand Tester: 57001-1394 Connections: Hand Tester (+) — Terminal [11] Hand Tester (-) ee Terminal [12] Speed Sensor Supply Voltage Standard: about 12 V xlf the tester reading is not specified, replace the meter assembly. CITE

Meter, Gauge, Indicator Unit Check 18: Water Temperature Gauge Inspection e Connect the leads in the same circuit as Check 2. e Connect the CAN communication lines from meter con- @ a nector [A] to main harness connector [B] as shown. Œ) Connections: Meter Terminal [17] — Main Harness Terminal [17] Meter Terminal [18] — Main Harness Terminal [18]

DEA TO QAR © CIE cpr15088s2 € e Turn the ignition switch ON. e Check that the only symbol [A] appears in the water tem- LI = perature gauge. e Turn the ignition switch OFF. xlf the display function does not work, go to the Check 1 and check the following items. { Wiring (see Wiring Inspection) _- CAN Communication Line Resistance (at ECU) (see SS So PE CAN Communication Line Resistance Inspection in the EN oO) VE Fuel System (DFI) chapter) A 2e $ Water Temperature Sensor (see Water Temperature Sensor (Service Code 14) section in the Fuel System (DFI) chapter) xlf the above items are good, replace the meter assembly and/or ECU. Check 19: FI/IMMOBILIZER Error Inspection e Connect the leads in the same circuit as Check 18. e For example, disconnect the atmospheric pressure sen- sor [A]. e Install the key registration unit [B] (see Key Registration) (Immobilizer equipped model). Special Tool - Key Registration Unit: 57001-1582

Meter, Gauge, Indicator Unit e Turn the ignition switch ON by the current key. © Check that the warning light (LED) [A] starts flashing and the display [B] changes as follows. © O © O IMMOBILIZER— D —r: ERROR > FI ERROR

CEE [C] Warning Message [D] Symbol OThis display is the warning message indication. xlf the display function does not work, go to the Check 1 and check the following items. Wiring (see Wiring Inspection) CAN Communication Line Resistance (at ECU) (see CAN Communication Line Resistance Inspection in the Fuel System (DFI) chapter) Example: Immobilizer System (see Immobilizer Amplifier and Blank Key Detection section in the Fuel System (DFI) chapter) Atmospheric Pressure Sensor (see Atmospheric Pres- sure Sensor (Service Code 15) section in the Fuel Sys- tem (DFI) chapter) ORefer to Troubleshooting the DFI System section in the Fuel System (DFI) chapter for other DFI parts xlf the above items are good, replace the meter assembly and/or ECU. e By pushing the MODE button [A] each time, check that the display changes the error messages [B] only. ODuring this operating, the symbols do not appear. OThe warning indicator light (LED) keeps flashing. e Push the MODE and RESET buttons for more than two seconds, check that each ERROR CODE [JA] and num- bers appears in the display. OThe warning indicator light (LED) keeps flashing. e Again, push the MODE and RESET buttons for more than two seconds, check that the display returns the warning message indication. OThe warning indicator light (LED) keeps flashing. xlf the display function does not work, replace the meter assembly. IMMOBILIZER a VEN

Meter, Gauge, Indicator Unit Check 20: Tachometer Inspection e Connect the leads in the same circuit as Check 18. e Confirm the vehicle down sensor is correct position. e Start the engine. e Check that the needle [A] in the tachometer moves. xIf the needle does not move, go to the Check 1 and in- spect the following items. Wiring (see Wiring Inspection) CAN Communication Line Resistance (at ECU) (see CAN Communication Line Resistance Inspection in the Fuel System (DFI) chapter) Crankshaft Sensor (see Crankshaft Sensor Inspection) xlf the above items are good, replace the meter assembly and/or ECU. Check 21: Gear Position Indication Inspection e Install the meter unit (see Meter Unit Installation). e Turn the ignition switch ON. e Check that the N mark [A] appears in the display and neu- tral indicator light (LED) [B] goes on. e Set the low gear position, check that the display changes to 1 mark. e For the other gear position indication; e Using the stand, raise the rear wheel off the ground (see Interlock Operation Inspection). e Start the engine, change the gear position. e Check that the display corresponding to each gear posi- tion appears. e Turn the ignition switch OFF. xlf the display function does not work, go to the Check 1 and check the following items. Wiring (see Wiring Inspection) CAN Communication Line Resistance (at ECU) (see CAN Communication Line Resistance Inspection in the Fuel System (DFI) chapter) Gear Position Switch (see Gear Position Switch (Service Code 25) section in the Fuel System (DFI) chapter) Speed Sensor (see Speed Sensor (Service Code 24) section in the Fuel System (DFI) chapter) xlf the above items are good, replace the meter assembly and/or ECU. CITE CCE

Meter, Gauge, Indicator Unit Check 22: Other Inspection OThe following items are displayed while running. AVERAGE INST RANGE Engage Lamp/Shift Lamp Indication e When the above item is faulty indication check the follow- ing items. Wiring (see Wiring Inspection) CAN Communication Line Resistance (see Check 1 and CAN Communication Line Resistance Inspection in the Fuel System (DFI) chapter) Fuel Injectors (see Fuel Injectors (Service Code 41, 42, 43, 44) section in the Fuel System (DFI) chapter) Speed Sensor (see Speed Sensor (Service Code 24) section in the Fuel System (DFI) chapter) Crankshaft Sensor (see Crankshaft Sensor Inspection) Fuel Level Sensor (see Fuel Level Sensor Inspection) Fuel Reserve Switch (see Fuel Reserve Switch Inspec- tion) xlf the above items are good, replace the meter assembly and/or ECU.

Meter, Gauge, Indicator Unit Meter Unit Circuit

G 1 G 1 re] 1 G 1 G 1

[E. = | 1 i @ 5 © TT Æ © re à

2. Dimmer Switch (High Beam) 15. Crankshaft Sensor

4. Turn Signal Switch (Left) 17. Frame Ground 1

5. ABS Hydraulic Unit (Equipped Models) 18. Water-proof Joint 1

6. Oil Pressure Switch 19. Ignition Fuse 10 A (in Fuse Box 2)

Immobilizer System (Equipped Models) This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU (Electronic Control Unit). If the code does not match, ignition system, injectors, and sub -throttle valve actuator will not operate and the engine will not start. Abstract e Do not keep more than one immobilizer key of any system on a key ring. Jamming of the key code signal may occur and the operation of the system may be affected. e The warning indicator light (LED) will flash for a period of 24 hours once the ignition switch has been switched off and the key removed. This flashing can be set to on or off as desired by holding the Mode and Reset buttons down for two seconds within twenty seconds of switching the ignition off. e If all coded keys (master key and user keys) are lost the ECU and ignition switch will have to be replaced. e The immobilizer system can not function until the master key code is registered in the ECU. A total of six keys can be registered in the ECU at any one time (one master key and five user keys). e Ifthe master key is lost it is not possible to register new user keys. Operational Cautions . Do not put two keys of any immobilizer system on the same key ring. . Do not submerge any key in water. . Do not expose any key to excessively high temperature. Do not place any key close to magnet. Do not place a heavy item on any key. Do not grind any key or alter its shape. Do not disassemble the plastic part of any key. Do not drop the key and/or apply any shocks to the key. . When a user key is lost, the user should go to his dealer to invalidate the lost key registration in the ECU. 10.When the master key is lost, the user should go to his dealer and have a new ECU installed and register a new master key and user keys. NOTE ONo.9 and 10 are strongly recommended to the customer to ensure security of the motorcycle. Key Registration e Case 1: When the user key has been lost or additional R spare user key is required. / e Prepare a new spare user key. e Cut the key in accordance with the shape of the current user key. e Remove the seat (see Seat Removal in the Frame chap- ter). e Disconnect the immobilizer/Kawasaki diagnostic system connector [A]. DHNEEwN © Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582

Immobilizer System (Equipped Models) e Insert the master key to the ignition switch and turn it ON. Verified OThe warning indicator light (LED) [A] blinks to display the registration mode (go to the next step). Not Verified OThe warning indicator light (LED) [A] blinks to display the collation error (refer to the following failure illustrations). Immobilizer Amplifier Failure Master Key Collation Error e Turn the master key OFF and remove the master key. OThe warning indicator light (LED) [A] blinks continuously to display that the ECU is in the registration mode for 15 seconds. NOTE Olnsert next key and turn ON within 15 seconds after pre- vious key is turned off and removed otherwise registra- tion mode will be ended and the warning indicator light (LED) stops flashing. OTo return to the registration mode start the master key verification procedure. This applies to all user key reg- istration. e Insert the user key 1 to the ignition switch and turn it ON. NOTE OKeep the other user key away from the immobilizer an- tenna. GPsoz778s1 0.2second

Immobilizer System (Equipped Models) OIf there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error e The user key 1 is successfully registered in the ECU. OThe warning indicator light (LED) [A] blinks 2 times and stops for 1 second and then repeats this cycle. e Turn the user key 1 OFF and remove the user key 1. OThe warning indicator light (LED) [A] blinks to display the registration mode. NOTE OTurn off the ignition switch and wait for the period of 15 seconds or more. The registration mode automatically finishes and the warning indicator light (LED) will switch off. OThis procedure registered the master key and one user key. OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed. e Insert the user key 2 to the ignition switch and turn it ON. GPsoz780s1 GPsoz778s1 0.3second ann GPsoz7o8s1 €

Immobilizer System (Equipped Models) Off there is any problem in the registration, the warning indicator light [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error e The user key 2 is registered in the ECU. OThe warning indicator light (LED) [A] blinks 3 times and stops for 1 second and then repeats this cycle. OThis procedure has registered the master key and 2 user keys. e Continue with the procedure to register an additional 3 user keys. NOTE OThe ECU can store up the six key codes (master key * 1 and user key * 5). User Key Indicator Light Flashes Indicator Indicator Remarks Light Blinks | Light Stop User Key 3 4 times 1 seconds Repeat User Key 4 5 times 1 seconds Repeat User Key 5 6 times 1 seconds Repeat e Turn OFF the ignition switch and wait for period of more than 15 seconds. e The registration mode automatically ends. GPsoz780s1 GPsoz778s1 0.3second ann GPsoz7o8s1 €

Immobilizer System (Equipped Models) e Warning indicator light (LED) goes off [AÏ. GPsoze20ss € e Remove the key registration unit and connect the immo- bilizer/Kawasaki diagnostic system connector. NOTE OTurn the ignition switch ON with the registered user key. OCheck that the engine can be started using all regis- tered user keys.

ott-RAHAAR hr © Registered User Key is insertod. Patiemn (2)

Immobilizer System (Equipped Models) Case 2: When the ignition switch is faulty and to be replaced. e Prepare a new ignition switch [A] and two new user keys (BI. OThese parts are available as a set. Prepare the current master key [C]. e Remove: Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts Replacement) Seat (see Seat Removal in the Frame chapter) e Disconnect the immobilizer/Kawasaki diagnostic system connector. © Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 e Connect: New Ignition Switch Lead Connector [A] Immobilizer Antenna Lead Connector [B] NOTE OKeep the antenna more than 15 cm from the ignition switch. e Put the current master key [C] at the antenna [D]. Insert the new user key 1 [E] to the new ignition switch [F] and turn it ON. Verified OThe warning indicator light (LED) [A] blinks to display the ECU is in the registration mode (go to the next step). Not Verified OThe warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure

Immobilizer System (Equipped Models) Master Key Collation Error e Turn OFF and remove the new user key 1. e Temporarily place the antenna [A] on the new ignition switch [B]. e Insert the user key 1 [C] again into the new ignition switch and turn it ON. NOTE OPlace the antenna on the ignition switch, insert the next key and turn ON within 15 seconds after previous key is turned off and removed otherwise registration mode will be ended and the warning indicator light (LED) stops flashing. OTo return to the registration mode start the master key verification procedure. This applies to all user key reg- istration. OKeep other user keys away from the immobilizer an- tenna. Off there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure 0.3second ann GPsoz7o8s1 € 0.2second

Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error e The user key 1 is successfully registered in the ECU. OThe warning indicator light (LED) [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1. e Turn OFF and remove user key 1. OThe warning indicator light (LED) [A] blinks to display the registration mode. NOTE OTurn off the ignition switch and wait for the period more than 15 seconds. The registration mode automatically ends and warning indicator light (LED) goes off. OThis procedure has , registered the master key and one user key. OContinue the procedure to program the second and later keys. e Insert the user key 2 to the ignition switch and turn it ON. 0.3second ann GPsoz7o8s1 € GPsoz778s1

Immobilizer System (Equipped Models) Off there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error e The user key 2 is successfully registered in the ECU. OThe warning indicator light (LED) [A] blinks 3 times and stops for 1 second and then repeat this cycle to indicate successful programming of user key 2. e Turn OFF the ignition switch and wait for period more than 15 seconds. e The registration mode automatically ends. e Warning indicator light (LED) [A] goes off. 0.2second

Immobilizer System (Equipped Models) e Remove the key registration unit and connect the immo- bilizer/Kawasaki diagnostic system connector. NOTE OTurn the ignition switch ON with the registered user key. OCheck that the engine can be started using all regis- tered user keys. e Install the new ignition switch and antenna. Case 3: When the electric control unit (ECU) is faulty and has to be replaced. e Prepare a new ECU [A], current master key [B] and cur- rent user keys [C]. NOTE OThe key registration unit is not required. e Replace: ECU [A] (see Immobilizer System Parts Replacement) e Insert the current master key into the ignition switch and turn it ON. OIf there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure Master Key Collation Error 0.3second ann GPsoz7o8s1 €

Immobilizer System (Equipped Models) e The master key is registered in the ECU. OThe warning indicator light (LED) [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key. e Turn OFF the master key and remove it. OThe warning indicator light (LED) [A] blinks to display the registration mode. NOTE Olnsert next key and turn ON within 15 seconds after pre- vious key is turned off and removed otherwise registra- tion mode will be ended and the warning indicator light (LED) goes off. OTo return to the registration mode start the master key verification procedure. This applies to all user key reg- istration. e Insert the user key 1 to the ignition switch and turn it ON. NOTE OKeep the other user keys away from the immobilizer antenna. Off there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. 0.3second second Ohio cpsozesess GPsoz778s1 GPsoz780s1 GPsoz778s1

Immobilizer System (Equipped Models) User Key Collation Error e The user key 1 is registered in the ECU. OThe warning indicator light (LED) [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key. e Turn OFF and remove the user key 1. OThe warning indicator light (LED) [A] blinks to display the registration mode codes. NOTE Olnsert next key and turn ON within 15 seconds after pre- vious key is turned off and removed otherwise registra- tion mode will be ended and the warning indicator light goes off. OTo return to the registration mode start the master key verification procedure. This applies to all user key reg- istration. Insert the user key 2 to the ignition switch and turn it ON. OIf there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error code. Immobilizer Amplifier Failure 0.3second ann GPsoz7o8s1 € GPsoz778s1 0.2second (OZ GPsoz780s1

Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error e The user key 2 is registered in the ECU. OThe warning indicator light (LED) [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2. e Turn OFF the ignition switch and wait for period more than 15 seconds. e The registration mode automatically ends. e Warning indicator light (LED) [A] goes off. NOTE OTurn the ignition switch ON with the registered user key. OCheck that the engine can be started using all regis- tered user keys. Case 4: When master key is faulty or lost. The master key replacement is considered very rare case. However if it is required, the following is necessary. NOTE OThe ECU must be replaced with a new one because the master key code that is registered in the current ECU can not be rewritten. GPsoz778s1 0.3second ann GPsoz7o8s1 €

Immobilizer System (Equipped Models) e Prepare a new ECU [A], new master key [B] and current user keys [C]. NOTE OThe key registration unit is not required. OThe key registration process is same as the electric con- trol unit replacement. Case 5: When replacing the antenna. e Prepare a new antenna. e Refer to the Immobilizer System Parts Replacement. NOTE ONo key registration is required. Gpsozo4nss €

Insert next key and tum ON within 15 seconds after

+ 4 ECU he following.

Turn OFF and remove user key 2 OTET

Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Immobilizer Antenna e Remove the left inner cover (see Inner Cover Removal in the Frame chapter). e Disconnect the lead connectors [A]. e Remove: Steering Stem Head (see Stem, Stem Bearing Removal in the Steering chapter) e Using a small chisel or punch [A], turn out the Torx bolts. e Cut the band [A]. e Remove the screw [B]. e Remove the antenna [C] with the cover [D]. OPull the lower parts [E] of the cover outside to clear the projection [F] of the ignition switch. Tighten a new Torx bolt [A] until the bolt head [B] is broken. [C] Broken Head of Other Side e Run the leads correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). Immobilizer Amplifier Replacement e Remove the windshield (see Windshield Removal in the Frame chapter). e Disconnect the connector [A]. e Remove the amplifier [B] from the bracket [C].

Immobilizer System (Equipped Models) ECU (Electric Control Unit) Replacement (for Immobilizer Models) e Remove: Seat (see Seat Removal in the Frame chapter) Tool Kit [A] Fuse Box [B] e Using small chisel or other suitable tool, cut off the screws [AI. e Remove: Plate [B] Tool Kit Case [C] e Remove: Relay Box [A] ECU Connectors [B] ECU [C] e Install: ECU Connectors Relay Box e Insert the slits of the rubber protector to the projections [A] of the rear fender front. e Install: Connector Holder [A]

Immobilizer System (Equipped Models) e Install: Tool Kit Case [A] Plate [B] e Tighten the new Kawasaki genuine screws [C] of which threads are coated with locking agent. e Insert the stopper [D] of the fuse box into the groove [E] of the tool kit case. Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master | User ; key | Key Sie | eme | fer | ECU (Red) | (Black) Master Key e. (Red) User Key e. O (Black) + |Ignition Switch ° An- tenna Ampli- fier ° ECU O e

© © HN O O1 À & ND =

Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection e Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). OFor the switch housings and the ignition switch, refer to the tables in the Wiring Diagram. xlf the switch has an open or short, repair it or replace it with a new one. Special Tool - Hand Tester: 57001-1394 Rear Brake Light Switch Connections Rear Brake Light Switch Connections Color BR BL When brake pedal is pushed down ©—+—0 When brake pedal is released Sidestand Switch Connections Sidestand Switch Connections Color BK G When sidestand is down When sidestand is up OS Oil Pressure Switch Connections* Oil Pressure Switch Connections * Color SW. Terminal Ground When engine is stopped O—+—0 When engine is running *: Engine lubrication system is in good condition.

Switches and Sensors Water Temperature Sensor Inspection e Remove the water temperature sensor (see Removal/In- stallation in the Fuel System (DFI) chapter). e Suspend the sensor [A] in a container of coolant so that the threaded portion is submerged. e Suspend an accurate thermometer [B] with temperature sensing portions [C] located in almost the same depth. NOTE OThe sensor and thermometer must not touch the con- tainer side or bottom. e Place the container over a source of heat and gradu- ally raise the temperature of the coolant while stirring the coolant gently. e Using the hand tester, measure the internal resistance of the sensor. OThe sensor sends electric signals to the ECU and coolant temperature gauge in the meter unit. OMeasure the resistance across the terminals and the body (for the gauge) at the temperatures shown in the table. xlf the hand tester does not show the specified values, re- place the sensor. Water Temperature Sensor Resistance for ECU [D] Resistance (kQ) Temperature (Terminal [1]-[3]) 20°C (68°F) 246 015 80°C (176°F) 0.32 40.011 10°C (230°F) 0.1426 +0.0041 Resistance for Water Temperature Gauge [E] Resistance (Q) Temperature (Terminal [2]-Body) 50°C (122°F) 210 +40 120°C (248°F) 212415 Speed Sensor Removal e Loosen the boit [A]. e Disconnect the speed sensor lead connector [B]. e Remove: Bolt [C] Speed Sensor [D] Speed Sensor Installation e Apply a non-permanent locking agent to the sensor bolt. e Install the speed sensor. Torque - Speed Sensor Bolt: 3.9 N-m (0.40 kgf-m, 35 in-lb) Gpie247Bs2 €

Switches and Sensors Speed Sensor Inspection e Remove the speed sensor (see Speed Sensor Removal). © Connect the speed sensor lead connector [A] with the bat- tery [B], 10 kQ resistor [C] and hand tester [D] as shown. e Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001-1394 e Trace [A] each side of the speed sensor surface with the screw driver. OThen the tester indicator should flick [B]. xlf the tester indicator does not flick, replace the speed sensor. Fuel Level Sensor Inspection e Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). e Open the clamps [A]. e Remove: Bolts [B] Fuel Level Sensor [C] e Check that the float moves up and down smoothly without binding. It should go down under its own weight. xlf the float does not move smoothly, replace the sensor. Float in Full Position [A] Float in Empty Position [B] Float Arm Stoppers [C] e Using the hand tester [A], measure the resistance across the terminals in the fuel level sensor lead connector [B]. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 xlf the tester readings are not as specified, or do not change smoothly according as the float moves up and down, replace the sensor. Fuel Level Sensor Resistance Standard: Full position [C]: 9 —-11 Q Empty position: 213 —-219 Q

Switches and Sensors Hollows [B] Front [C] e Apply a non-permanent locking agent to the threads of the level sensor bolts and tighten it. Torque - Fuel Level Sensor Bolts: 6.9 N-m (0.70 kgf-m, 61 in<lb) e Install a new gasket [A] on the fuel level sensor as shown. © Gpiezaess Fuel Reserve Switch Inspection e Fill the fuel tank with fuel. e Close the fuel tank cap surely. e Remove the fuel tank (see Fuel Tank Removal in the Fuel 20 System (DFI) chapter). _- e Connect the test light [A] (12 V 3.4 W bulb in a socket with (4) leads) and the 12 V battery [B] to the fuel pump connector L 7 ICI. ge © * Connections Battery (+) — 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) — BK/R Lead Terminal Battery (-) — BK/W Lead Terminal Special Tool - Needle Adapter Set: 57001-1457 xlf the test light turn on, the reserve switch is defective. Replace the fuel pump. e Remove the fuel pump (see Fuel Pump Removal in the Fuel System (DFI) chapter). e Connect the test light (12 V 3.4 W bulb in a socket with leads) and the 12 V battery to the fuel pump connector as shown. 12 V Battery [A] Test Light [B] Fuel Pump Connector [C] Fuel Reserve Switch [D] xlf the test light doesn't light, replace the fuel pump. NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed. Leave the fuel reserve switch with leads for inspection connected for few minutes. GPiez420s:

Switches and Sensors Gear Position Switch Removal + Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). e Slide out the rubber boot [A]. e Loosen the oil pressure switch terminal bolt [B], and re- move the switch lead [C]. e Open the clamps [A]. e Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Bolt [A] Clamp [B] e Disconnect the oil pressure switch/gear position switch lead connector [C]. e Open the clamp [A]. e Remove: Screws [B] Gear Position Switch [C] e Remove the pin [A] and spring from the shift drum.

Switches and Sensors Gear Position Switch Installation e Securely place the spring [A] and pin [B] into the hole [C] of the shift drum. e Apply grease to the new O-ring [D]. e Apply a non-permanent locking agent to the gear position switch screws. e Tighten: Torque - Gear Position Switch Screws: 3.0 N-m (0.31 kgf-m, 27 in-lb) Gear Position Switch Lead Clamp Bolt: 9.8 Nm (1.0 kgf-m, 87 in-lb) e Run the gear position switch and oil pressure switch lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). e Install the removed parts (see appropriate chapters). Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition. e Disconnect the connector [A]. e Set the hand tester [A] to the 1 KQ or x 100 Q range and connect it to the terminals in the oil pressure switch/gear position switch lead connector [B] and ground. [C] Internal Circuit [1] Light Green Lead [2] Green/Red Lead [3] Black Lead Special Tool - Hand Tester: 57001-1394 Gear Position Switch Resistance kQ Connections PR [t]-Ground | [2]-Ground [3]-Ground Neutral about 0 — — 1st _ 3.00 —3.32 11.63 —12.87 2nd _ 1.70 —1.89 10.33 —11.44 3rd _ 1.07 —1.19 9.70 —10.74 ath — 0.695 —0.769 9.32 —10.32 5th _ 0.430 —-0.476 9.06 —10.03 6th _ 0.248 —0.274 8.89 —9.81 xlf the tester reading is not as specified, replace the gear position switch with a new one. GPiezasess NO ist 2nd Srd Ath 5th 6th

Relay Box The relay box [A] has relays and diodes. The relays and Led diodes can not be removed. Relay Box Removal e Remove the seat (see Seat Removal in the Frame chap- ter). e Take out the relay box [A] and disconnect the connectors [B]. Relay Circuit Inspection NOTE OThe ECU main relay function is included in the ECU. e Remove the relay box (see Relay Box Removal). © Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown (see Relay Box Internal Circuit). xlf the tester does not read as specified, replace the relay box. Relay Circuit Inspection (with the battery disconnected) Tester Connection | Tester Reading (Q) Headlight Circuit 13 = Relay . 6-7 co Main Relay 4-5 Not * 7-8 © Fuel Pump Relay 9-10 Not * 11-16 © Starter Circuit Relay 11-12 © 17-20 © Fan Relay 18-19 Not *

• The actual reading varies with the hand tester used.

Relay Box Relay Circuit Inspection (with the battery connected) cu Tester Tester Connection Reading (Q) . 2-11 1-3 Main Relay 4-5 7-6 Fuel Pump 9-10 78 0 Relay Fan Relay 18-19 17-20 0 cn Tester Connection Tester & © DC 25 V Range |Reading (V) Starter Circuit Battery Relay 16-12 11-12 Voltage (+): Apply positive lead. (-): Apply negative lead. Diode Circuit Inspection e Remove the relay box (see Relay Box Removal). e Check conductivity of the following pairs of terminals (see Relay Box Internal Circuit). Diode Circuit Inspection 1-11, 2-11, 12-13, 12-15, 12-16, 13-14, 13-15 x The resistance should be low in one direction and more than ten times as much in the other direction. If any diode shows low or high in both directions, the diode is defective and the relay box must be replaced. NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes, but generally speaking, the lower reading should be from zero to one half the scale. Tester Connection

Fuse 30 À Main Fuse Removal e Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Bolts [A] Cover [B] e Disconnect the 30 A main fuse connector [A]. e Pull out the main fuse [A] from the starter relay with needle nose pliers. Fuse Box Fuse Removal e Remove the seat (see Seat Removal in the Frame chap- ter). e Unlock the hook [A] to lift up the lid [B].

Fuse e Pull the fuses [A] straight out of the fuse box with needle nose pliers. cms P 15 À ECU Fuse Removal e Remove the seat (see Seat Removal in the Frame chap- ter). e Unlock the hook [A] to lift up the lid [B]. e Pull out the ECU fuse [A] from the fuse box.

Fuse Installation xlf a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. e Install the fuse box fuses on the original position as spec- ified on the lid.

Fuse Fuse Inspection e Remove the fuse (see 30 À Main/Fuse Box/15 À ECU Fuse Removal). e Inspect the fuse element. xlf it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Housing [A] Fuse Element [B] Terminals [C] Blown Element [D] NOTE OA mass current flows to the battery according to the state ofthe battery which needs refreshing charge when the engine is turned causing main fuse blown out. CAUTION When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components. Gp200001$1 €

Appendix Table of Contents Cable, Wire, and Hose Routing Troubleshooting Guide

17-2 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing DHNOHEGN = . Air Cleaner Drain Hose . Gear Position Switch Lead . Air Bleeder Hose for Water Pump . Sidestand Switch Lead Clamp Clamp the leads and hose as shown in the figure. Tube Grommet Install the air switching valve hose until white paint is half hidden level. . Approx. 41 mm (0.02 in.) . Clamp . First, put the clamp to the adjuster screw position of shown in the figure, next fix to the clutch hose. . Clutch Hose .Idle Adjusting Screw . Clamp . Clamp the speed sensor lead. . Speed Sensor Lead . Breather Tube . Clamp . Align the white paint and the end of the plate.

17-4 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing DNOHmBEWN ldle Adjusting Screw Through the air cleaner drain hose to the front of the clamp. Main Harness Through the air cleaner drain hose and idle adjusting screw to the outside of the main harness. . Clamp . Position the clamp so that its pinch heads do not touch the frame and air cleaner drain hose. . Clutch Hose . Through the air cleaner drain hose to the backside of the clutch hose.

17-6 APPENDIX Cable, Wire, and Hose Routing GB09022cH5 ©

Cable, Wire, and Hose Routing © © NN O O1 À & D = . Reserver Tank Hosel . Reserver Tank Overflow Hose . Reserver Tank . Radiator . Right View . Air Bleeder Hose for Thermostat Housing . Thermostat Housing Hose . Air Bleeder Hose for Water Pump . Outlet Hose . Inlet Hose . Oil Cooler . Water Pump . Hose . Hose . Left View . Align the white paint of the hose and mark of the thermostat housing cover. . About 45° . Clamp . Right View . Air Bleeder Hose for Water Pump . Air Bleeder Hose for Thermostat Housing . Align the white paint of the hose and mark of the water pump. . Install the hose so that white paint of the hose faces the front side. . Insert the air bleeder hose so that straight to the center of the impeller shaft. . Left View

17-8 APPENDIX Cable, Wire, and Hose Routing o—E—f

Cable, Wire, and Hose Routing DHNOHmEWN = Clamp Install the clamp so that knob of the clamp faces right side of the frame as shown in the figure. Reserver Tank Clamp Clamp . Install the hose until projection. . Inlet Hose . Install the hose so that white paint of the hose faces the front side. . Install the hose so that white paint of the hose faces the front side. . Outlet Hose . Clamp . Approx. 20 mm (0.79 in.)

17-10 APPENDIX Cable, Wire, and Hose Routing

0! MO OùO 3 I Q | © À © = Où 4 5 = e— Ô OC

Cable, Wire, and Hose Routing

O O1 À © ND RDoLHNHMmBWN = Clamp (Install the clamp from the arrow mark side.) Through the reserver tank hose on the air bleeder hose for thermostat housing. Through the subharness for sensor and valve between the #3 and #4 of the throttle body. Alternator Lead (To the regulator/rectifier connector through the alternator subharness.) Through the alternator lead backside of the air bleeder hose for water pump. Through the reserver tank hose between the air switching valve and bracket. . Connect the gear position switch lead and sidestand switch lead to the main harness. Air Cleaner Drain Hose . Through the air cleaner drain hose between the engine sprocket cover and clutch hose. . Through the air cleaner drain hose on the water pump, put in the space of the lower fairing. . Through the reserver tank overflow hose into the fairing bracket, and through the hose into the clamp. . Hose . Reserver Tank Overflow Hose . Hose . Through the reserver tank overflow hose between the hose and hose. . Through the gear position switch lead backside of the air bleeder hose for water pump.

17-12 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing o® en © ND = Pad Pad . Fit the groove of the pad to the reserver tank, and fix the pad by the middle fairing. . Fit the grooves of the pad to the radiator hose and reserver tank drain hose, and fix the pad by the lower fairing. Pad . Fit the groove of the pad to the radiator hose, and fix the pad by the middle fairing.

17-14 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing {© © I O O1 & N = Band (Clamp the main harness, and insert the band to the rear fender.) Frame Ground Lead (Tighten the bolt with lead and bracket.) . Through the alternator subharness to the outside of the frame ground lead. . Alternator Connector (Install the alternator connector to the bracket.) . Connector (Insert the connector to the bracket.) . Alternator Subharness (Put the alternator subharness between the rear fender and frame.) . Alternator Lead . Through the alternator lead under the main harness. . Align the gray tape and the end of the battery case. . Fuel Hose . Main Harness . Alternator Lead (Through the alternator lead to the inside of the leads and hose.) . Sidestand Switch Lead Connector . Band (Clamp the main harness, and insert the band to the bracket.) . Throttle Body Subharness Connector (Install the connector to the bracket.) . Speed Sensor Lead Connector . Oil Pressure Switch/Gear Position Switch Lead Connector . Through the sidestand switch lead and oil pressure switch/gear position switch lead to the inside of the chain cover from the hole of the notch. . Clamp (Clamp the fan motor lead.) . Through the engine harness to the outside of the clutch hose. . Engine Harness Connector (Install the engine harness connector to the bracket.) . Band (Clamp the main harness, and insert the band to the bracket.) . Stick Coil Lead Connector (Install the stick coil lead connector to the bracket of the cylinder head cover.) . Through the stick coil lead under the throttle cables. . Band (Clamp the engine harness with the subframe.) . Clamp (Clamp the fan motor lead connector, and insert the clamp to the subframe.) . Through the oil pressure switch/gear position switch lead to the inside of the water pump. . Through the sidestand switch lead to the inside of the water pump.

17-16 APPENDIX Cable, Wire, and Hose Routing 12 ‘de

Cable, Wire, and Hose Routing D = . Through the headlight lead into the clamp (both sides). . After ignition switch lead connector and left switch housing lead connector connecting, put the connectors in the water-proof cover. . Clamp (Clamp the main harness, and insert the clamp to the middle air inlet duct.) . Clamp (Clamp the left turn signal lead, and insert the clamp to the middle air inlet duct.) . Left Turn Signal Light Lead Connector . Headlight Lead . Through the left switch housing lead and ignition switch lead into the clamp, and insert the clamp to the bracket. . Through the left switch housing lead to the outside of the front fork, and through the lead into the clamp. . Through the ignition switch lead to the backside of the front fork from the inside of the front fork, and through the lead into the clamp. . Clamp . Left City Light . Headlight (High) . Headlight (Low) . Install the clamp outside as shown in the figure, and clamp the immobilizer amplifier lead. . Immobilizer Amplifier Lead Connector . Vehicle-down Sensor Lead Connector . Meter Unit Lead Connector . Through the main harness and immobilizer amplifier lead into the clamp. . Headlight Relay (High) . Clamp (Clamp the main harness, and insert the clamp to the middle air inlet duct.)

17-18 APPENDIX Cable, Wire, and Hose Routing GORE &

Cable, Wire, and Hose Routing © © HN O O1 À & D =

ü BP © D = © ND == SLoNO N N ND S D = D ND D O O1 À . Right Turn Signal Light Lead Connector . Clamp (Clamp the right turn signal lead, and insert the clamp to the middle air inlet duct.) . “Front Wheel Rotation Sensor Lead Connector . Clamp (Clamp the main harness, and insert the clamp to the middle air inlet duct.) . Headlight Relay (Low) . Clamp (Clamp the main harness, and insert the clamp to the middle air inlet duct.) . Right Switch Housing Lead and Horn Lead . Right Switch Housing Lead Connector . Through the right switch housing lead, horn lead, headlight lead and “front wheel rotation sensor lead into the clamp. . Clamp (Clamp the horn lead, and insert the clamp to the cover.) . Through the horn lead to the outside of the front fork. . Through the right switch housing lead to the outside of the front fork. . Through the right switch housing lead and horn lead into the clamp. . Through the rear wheel rotation sensor lead to the inside of the rear brake reservoir tank. . “Front Wheel Rotation Sensor Lead Connector (Install the front wheel rotation sensor lead con- nector to the bracket.) . Through the main harness lead on the rear brake reservoir tank hose. . Fuse Box 1 . Clamp . Alternator Subharness . Fuel Pump Lead Connector . Fuel Level Sensor Lead Connector . Clamp . Clamp (Clamp the rear brake light switch lead and “rear wheel rotation sensor lead.) . Rear Brake Light Switch Lead Connector . Through the rear brake light switch lead to the outside of the separator. . Rear Brake Light Switch Lead Connector

Clamp (Clamp the rear brake light switch lead.) *ZX1400B Models only

17-20 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing

SDLHNOomBEEN Turn Signal Relay License Plate Light Lead Connector Atomospheric Pressure Sensor Lead Connector . Through the license plate light lead to the inside of the atomospheric pressure sensor. . License Plate Light Lead . Through the turn signal relay lead between the rear frame and rear frame pipe. Rear Left Turn Signal Light Lead Connector . Tail/Brake Light Lead Connector . Rear Right Turn Signal Light Lead Connector “ABS Kawasaki Self-diagnosis System Connector (Fix the ABS Kawasaki self-diagnosis system connector with the sponge.) . Immobilizer/Kawasaki Diagnostic System Connector (Fix the Immobilizer/Kawasaki diagnositic system connector with the sponge.) . Fuse Box 2 . ECU Lead . ECU Lead

Relay Box Leads Alternator Subharness Alternator Lead Clamp (Clamp the alternator lead and alternator subharness.) Through the alternator lead and alternator subharness to the outside of the rear frame. Through the alternator lead and alternator subharness under the rear brake reservoir tank. Fuse Box 1 Through the alternator subharness under the bracket. *ZX1400B Models only

17-22 APPENDIX Cable, Wire, and Hose Routing TL?

Cable, Wire, and Hose Routing © © HN O O1 À & D = . Through the main harness to the hole of the lower side. . Through the inlet air temperature sensor lead to the hole of the upper side. . “ABS Hydraulic Unit Lead . Inlet Air Temperature Sensor Lead . Battery Negative Lead . Starter Relay Lead . Battery Positive Lead Connector (Install the battery positive lead connector to the battery case.) . Starter Motor Cable . Battery Negative Lead Connector (Install the battery negative lead connector to the bracket.) . Battery Positive Cable . Battery Negative Lead . Battery Negative Cable . Direction of Battery Negative Terminal Installation . Tighten the bolt with battery negative cable and battery negative lead. . Battery Negative Cable . Clamp (Clamp the inlet air temperature sensor lead.) .Inlet Air Temperature Sensor

17-24 APPENDIX Cable, Wire, and Hose Routing GORE &

Cable, Wire, and Hose Routing © © NN O O1 À & N = . Fuel Tank Drain Hose . Through the fuel tank drain hose under the bracket. . Position a yellow tape at the rear end of bracket. . Through the fuel tank drain hose to the backside of the clamp. . Through the fuel tank drain hose under the fuel hose. . Through the fuel tank drain hose under the clamp. . Fuel Tank Drain Hose . Through the fuel tank drain hose under the starter motor cable. . Fuel Tank Drain Hose . Through the fuel tank drain hose under the lower fairing. . Through the fuel tank drain hose on the speed sensor lead. . Through the fuel tank drain hose under the heat insulation rubber plate. . Through the fuel tank drain hose under the clutch hose. . Position a yellow tape at the end of lower fairing. . Through the seat lock cable to the rear frame.

17-26 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models GONG

Cable, Wire, and Hose Routing

1. Through the fuel tank drain hose on the brake pipe.

3. Fuel Tank Drain Hose

4. Through the fuel tank drain hose on the brake pipe.

6. Fuel Tank Drain Hose

17-28 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing

1. Through the throttle cables inside of the brake hose.

2. Through the throttle cables to the clamp of the reservoir bracket.

3. Through the throttle cables inside of the brake hose.

4. Through the throttle cables to the clamp.

17-30 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing

Through the clutch hose inside the coolant reserver tank.

2. Through the clutch hose outside the sidestand switch, speed sensor, oil pressure switch/gear

position switch leads. . Install the cluth hose joint as shown in the figure (face the clutch hose joint pipe inside). . Through the clutch hose inside the main harness. . Through the clutch hose outside the sidestand switch, speed sensor and oil pressure switch/gear position switch lead connectors. . Clamp the clutch hose to the clamp of the subframe. . Through the clutch hose inside the radiator fan lead. . Through the clutch hose inside the subframe. . Through the ignition switch lead upper the clutch hose. . Through the clutch hose in the clamp.

17-32 APPENDIX Cable, Wire, and Hose Routing

Cable, Wire, and Hose Routing

1. Install the clutch hose joint as shown in the figure (face the projection of the clutch hose joint

2. Through the clutch fluid reservoir hose inside the bracket.

17-34 APPENDIX Cable, Wire, and Hose Routing Te = 5 G « n =

LES $ 35 © Le 20 =: O x = © D © 5 | @ LS ©

Cable, Wire, and Hose Routing NO O1 B © D = . Brake Hose . Bracket . Clamps (Insert the clamps in the front fender.) . Brake Hose . Clamps . Brake Hose . Face the white paint mark upward.

17-36 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models

Cable, Wire, and Hose Routing © © NN O O1 À & N = . Clamps . Brake Hose . Rear Wheel Rotation Sensor . Rear Wheel Rotation Sensor Lead . Rear Wheel Rotation Sensor Lead Connector . Bracket . ABS Hydraulic Unit . Brake Pipes . Damper . Front Wheel Rotation Sensor Lead Connector . Front Wheel Rotation Sensor Lead . Front Wheel Rotation Sensor . Brake Hose . Approx. 38.5° . Approx. 30° . Approx. 71° . Approx. 48° . Front . Install the brake hose joint pipes as shown in the figure.

17-38 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models

Cable, Wire, and Hose Routing . Clamps (Insert the clamps in the front fender.) . Clamp (Clamp the brake hose, and align the clamp with white tape of the front wheel rotation sensor lead.) . Brake Hose . Brake Hose (Front Master Cylinder —Right Front Caliper) . Clamp (Clamp the front wheel rotation sensor.) Front Wheel Rotation Sensor Lead . Front Wheel Rotation Sensor D = NO 0 PB w

17-40 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models

Cable, Wire, and Hose Routing . ABS Hydraulic Unit Front Bracket . Brake Pipe (One Blue Paint Mark) Brake Pipe (One White Paint Mark) Damper . Brake Hose . Brake Hose (One Blue Paint Mark) . Brake Hose Joint Pipe (One Blue Paint Mark)

14. Clamps (Clamp the brake hose, and align the clamps with white tapes of the front wheel rotation

17-42 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models — 10 Oo > /Ÿ (l Le QUO D © es

Cable, Wire, and Hose Routing

1. ABS Hydraulic Unit

2. Brake Pipe (Two White Paint Marks)

4. Clamps (Through only the brake hose in the clamps.)

5. Rear Wheel Rotation Sensor Lead

6. Clamps (Clamp the brake hose, and align the clamps with white tape of the rear wheel rotation

7. Clamp (Clamp the brake hose and rear wheel rotation sensor.)

8. Clamp (Clamp the brake hose and rear wheel rotation sensor.)

9. Brake Pipe (Two Blue Paint Marks)

12. Viewed Rear Side

13. Brake Hose (Two Blue Paint Marks)

14. Brake Hose Joint Pipe (Two Blue Paint Marks)

17-44 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models

Cable, Wire, and Hose Routing

2. Clamps (Through the brake hose in the clamp on both sides.)

Nous . Clamps (Clamp the brake hose, and align the clamps with white tapes of the front wheel rotation sensor lead.) . Brake Hose . Clamp (Through only the brake hose in the clamp.) Clamp . Front Wheel Rotation Sensor . Install the brake hose joint as shown in the figure (face the projection of the brake hose joint backward.) . Brake Hose . Clamp (Clamp the brake hose, and align the clamp with white tape of the front wheel rotation sensor lead.) . Clamp . Front Wheel Rotation Sensor Lead Connector . Right Middle Air Inlet Duct . Brake Hose . Brake Hose . Clamp . Braket . Braket . Clamp . Bracket . Brake Pipe . Brake Pipe . Brake Hose . Brake Hose

17-46 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models O © GONE &

Cable, Wire, and Hose Routing © © NN O O1 À & N = . Bracket (Push the joint portions of the brake pipe, and clamp them.) . Brake Pipe (One Blue Paint Mark, ABS Hydraulic Unit Side) . Align the brake pipes with groove of the frame. . Brake Pipe (One White Paint Mark, ABS Hydraulic Unit Side) . Brake Hose (Two White Paint Marks) and Brake Hose Joint Pipe (One White Paint) . Brake Hose (One White Paint Mark) and Brake Hose Joint Pipe (One White Paint) . Brake Hose (One Blue Paint Mark) and Brake Hose Joint Pipe (One Blue Paint Mark) . Brake Hose (Two Blue Paint Marks) and Brake Hose Joint Pipe (Two Blue Paint Mraks) . Insert the brake pipes to the holes of damper, and fit the projection of damper into the hole of bracket. . Brake Pipe (Two Blue Paint Marks)

Brake Pipe (Two White Paint Marks)

17-48 APPENDIX Cable, Wire, and Hose Routing ZX1400B Models

Cable, Wire, and Hose Routing . Clamp . Brake Hose . Bracket (Install the bracket from back of the rear frame.) . Rear Wheel Rotation Sensor Lead Connector . Clamp the joint portion of the brake hose into the bracket. Clamp Clamp Clamp . Clamps (Clamp the brake hose, and align the clamps with white tape of the rear wheel rotation sensor lead.)

10. Rear Wheel Rotation Sensor Lead

11. Clamps (Through only the brake hose in the clamps.)

17-50 APPENDIX Cable, Wire, and Hose Routing California Model

Cable, Wire, and Hose Routing © © HN O O1 À & D = . Throttle Body Assy . To the fitting of the throttle body #3. . To the fitting of the throttle body #4. . Clamps . Clamp . Insert the bracket to the holes of clamp. . Hose (White) . Hose (Green) . Hose (White) . Fittings . Hose (Red) . Hose (Blue) . Hose (Blue) . Hose (Green) . Separator . Clamp . Fuel Tank . Canister . Band . Connected position of the white hoses and fitting. . Connected position of the green hoses and fitting. . Face the paint marks upward. . Face the paint marks to the right side. . Through the hoses inside the throttle body subharness. . Viewed Right Side . Viewed Upside

17-52 APPENDIX Troubleshooting Guide NOTE ORefer to the Fuel System chapter for most of DFI trouble shooting guide. OThis is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn't Start, Starting Difficulty: Starter motor not rotating: Ignition and engine stop switch not ON Starter lockout switch or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring open or shorted Ignition switch trouble Engine stop switch trouble Main 30A or ignition fuse blown Starter motor rotating but engine doesn't turn over: Vehicle-down sensor (DFI) coming off Immobilizer system trouble Starter clutch trouble Starter idle gear trouble Engine won't turn over: Valve seizure Valve lifter seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure Balancer bearing seizure No fuel flow: No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark; spark weak: Vehicle-down sensor (DFI) coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu- tral Battery voltage low Immobilizer system trouble Spark plug dirty, broken, or gap malad- justed Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble Camshaft position sensor trouble Gear position, starter lockout, or side stand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30A or ignition fuse blown Fuel/air mixture incorrect: Bypass screw and/or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged, poorly sealed, or miss- ing Leak from oil filler cap, crankcase breather hose or air cleaner drain hose. Compression Low: Spark plug loose Cylinder head not sufficiently tightened down Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly (valve bent, wWorn, or carbon accumulation on the seating surface) Poor Running at Low Speed: Spark weak: Battery voltage low Immobilizer system trouble Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Fuel/air mixture incorrect: Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged, poorly sealed, or miss- ing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air duct holder loose

Troubleshooting Guide Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, wWorn, or carbon accumulation on the seating surface) Camshaft cam worm Run-on (dieseling): Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery (—) cable or ECU ground lead Carbon accumulating on valve seating sur- face Engine overheating Other: ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or miss- ing Air duct holder loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.) Knocking: Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous: Throttle valve won't fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worm Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating (KLEEN) Overheating: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Muffler overheating: For KLEEN, do not run the engine even if With only one cylinder misfiring or poor running (Request the nearest service fa- cility to correct it) For KLEEN, do not push-start with a dead battery (Connect another full-charged battery with jumper cables, and start the engine using the electric starter) For KLEEN, do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN, do not coast the motorcycle With the ignition switch off (Turn the igni- tion switch ON and run the engine) ECU trouble Fuel/air mixture incorrect: Throttle body assy holder loose Aïir duct holder loose Air cleaner poorly sealed, or missing

17-54 APPENDIX Troubleshooting Guide Air cleaner clogged Compression high: Carbon built up in combustion chamber Engine load faulty: Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect: Oil cooler clogged Gauge incorrect: Water temperature gauge broken Water temperature sensor broken Coolant incorrect: Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect: Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling: Gauge incorrect: Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect: Thermostat trouble Clutch Operation Faulty: Clutch slipping: Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn Clutch master cylinder trouble Clutch slave cylinder trouble Clutch not disengaging properly: Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shañt Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch slave cylinder trouble Clutch fluid deteriorated Air in clutch fluid line Clutch master cylinder primary or sec- ondary cup damage Clutch master cylinder scratched inside Gear Shifting Faulty: Doesn't go into gear; shift pedal doesn't return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear: Shift fork ear worn, bent Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro- ken Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts: Gear positioning lever spring weak or bro- ken Shift mechanism arm spring broken Abnormal Engine Noise: Knocking: ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise: Connecting rod small end clearance exces- sive Connecting rod big end clearance exces- sive Piston ring/groove clearance excessive

Troubleshooting Guide Piston ring worn, broken, or stuck Piston ring groove worn Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con- nection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating (KLEEN) Abnormal Drive Train Noise: Clutch noise: Clutch damper weak or damaged Clutch housing/friction plate clearance ex- cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise: Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise: Drive chain adjusted improperly Drive chain worn Rear and/or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise: Front fork noise: Oil insufficient or too thin Spring weak or broken Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise: Bracket, nut, bolt, etc. not properly mounted or tightened Oil Pressure Warning Light Goes On: Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O-ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively: White smoke: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner clogged Brown smoke: Aïir duct holder loose Air cleaner poorly sealed or missing Handling and/or Stability Unsatisfactory: Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade- quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates: Tire worn Swingarm pivot bearing worn Rim warped, or not balanced Wheel bearing worn Handlebar holder bolt loose Steering stem nut loose Front, rear axle runout excessive Engine mounting bolt loose Handlebar pulls to one side: Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory: (Too hard) Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard

17-56 APPENDIX Troubleshooting Guide Tire air pressure too high Front fork bent (Too soft) Tire air pressure too low Front fork oil insufficient and/or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn't Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble: Battery discharged: Charge insufficient Battery faulty (too low terminal voltage) Battery cable making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Alternator trouble Wiring faulty Regulator/rectifier trouble Battery overcharged: Alternator trouble Regulator/rectifier trouble Battery faulty