Мануалы на kawasaki z1000sx

Материал из BikesWiki — энциклопедия японских мотоциклов

Перейти к: навигация, поиск

Z1000SX
Z1000SX ABS
Ninja 1000
Ninja 1000 ABS
Motorcycle
Service Manual
Quick Reference Guide
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number 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 specific topic required.
General Information
1 j
Periodic Maintenance
2 j
Fuel System (DFI)
3 j
Cooling System
4 j
Engine Top End
5 j
Clutch
6 j
Engine Lubrication System
7 j
Engine Removal/Installation
8 j
Crankshaft/Transmission
9 j
Wheels/Tires
10 j
Final Drive
11 j
Brakes
12 j
Suspension
13 j
Steering
14 j
Frame
15 j
Electrical System
16 j
Appendix
17 j
Z1000SX
Z1000SX ABS
Ninja 1000
Ninja 1000 ABS
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Motorcycle & Engine 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.
© 2010 Kawasaki Heavy Industries, Ltd.
2nd Edition (0) : Jun. 20, 2011
LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L
ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)
lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
Ω
pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)
COUNTRY AND AREA CODES
AT
Austria
AU
Australia
BR
CA
Brazil
Canada
CAL
California
CH
Switzerland
DE
Germany
United Kingdom
Southeast Asia B1 (with Evaporative
Emission Control System)
SEA-B2
Southeast Asia B2
US
United States
WVTA
WVTA Model with Honeycomb
(FULL H) Catalytic Converter (Full Power)
GB WVTA WVTA Model with Honeycomb Catalytic
(FULL H) Converter (Left Side Traffic, Full Power)
WVTA
WVTA Model with Honeycomb
(78.2 H)
Catalytic Converter (78.2 Kw Power)
GB
SEA-B1
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, 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 knowingly 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 following its sale and delivery to the ultimate purchaser...”
NOTE
○The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
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 standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10 000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
•
•
•
•
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully 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 adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle.
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.
•
•
•
•
•
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see symbols, heed their instructions! Always follow safe operating and
maintenance practices.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.
NOTE
○This note symbol indicates points of particular interest for more efficient and convenient operation.
a procedural step or work to be
• Indicates
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
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 specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Unit Conversion Table ............................................................................................................
1
1-2
1-7
1-10
1-13
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the 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, disconnect the battery cables from the battery to prevent the engine 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 (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, 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 beyond its service limit.
Replacement Parts
Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified sequence 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 quarter 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 damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and
cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication 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. Rotate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
ZX1000GB (United States and Canada) Left Side View
ZX1000GB (United States and Canada) Right Side View
Frame Number
Engine Number
1-8 GENERAL INFORMATION
Model Identification
ZX1000GB (Europe) Left Side View
ZX1000GB (Europe) Right Side View
GENERAL INFORMATION 1-9
Model Identification
ZX1000HB Left Side View
ZX1000HB Right Side View
1-10 GENERAL INFORMATION
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height/High Position
Wheelbase
Road Clearance
Seat Height
Curb Mass:
ZX1000G
ZX1000H
Front:
ZX1000G
ZX1000H
Rear:
ZX1000G
ZX1000H
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
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
Valve Timing:
Intake:
Open
Close
ZX1000GB ∼ GC/HB ∼ HC
2 105 mm (82.87 in.)
790 mm (31.1 in.)
1 170 mm (40.06 in.)/1 230 mm (48.43 in.)
1 445 mm (56.89 in.)
135 mm (5.31 in.)
820 mm (32.28 in.)
228 kg (503 lb)
231 kg (509 lb)
117 kg (258 lb)
118 kg (260 lb)
111 kg (245 lb)
113 kg (249 lb)
19 L (5.0 US gal.)
3.1 m (10.1 ft)
4-stroke, DOHC, 4-cylinder
Liquid-cooled
77.0 × 56.0 mm (3.03 × 2.20 in.)
1 043 cm³ (63.64 cu in.)
11.8 : 1
101.5 kW (138 PS) @9 600 r/min (rpm)
(SEA-B1/B2) 100 kW (136 PS) @9 000 r/min (rpm)
(WVTA (78.2 H)) 78.2 kW (106 PS) @9 100 r/min (rpm)
(CA, US) – – –
110 N·m (11.2 kgf·m, 81.1 ft·lb) @7 800 r/min (rpm)
(WVTA (78.2 H)) 95 N·m (9.7 kgf·m, 70 ft·lb) @7 500 r/min (rpm)
(CA, US) – – –
FI (Fuel Injection) KEIHIN TTK38 × 4
Electric starter
Battery and coil (transistorized)
Electronically advanced (digital igniter)
From 10° BTDC @1 100 r/min (rpm) to 40.2° BTDC
@5 200 r/min (rpm)
NGK CR9EIA-9
Left to right, 1-2-3-4
1-2-4-3
31° BTDC
65° ABDC
GENERAL INFORMATION 1-11
General Specifications
Items
Duration
Exhaust:
Open
Close
Duration
Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rim Size
Rear Tire:
Type
Size
Rim Size
Front Suspension:
Type
Wheel Travel
ZX1000GB ∼ GC/HB ∼ HC
276°
58° BBDC
18° ATDC
256°
Forced lubrication (wet sump)
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
4.0 L (4.2 US qt)
Gear
1.627 (83/51)
Wet multi disc
6-speed, constant mesh, return shift
2.600
1.950
1.600
1.389
1.238
1.136
(39/15)
(39/20)
(24/15)
(25/18)
(26/21)
(25/22)
Chain drive
2.733 (41/15)
5.055 @Top gear
Tubular, diamond
24.5°
102 mm (4.02 in.)
Tubeless
120/70 ZR17 M/C (58W)
J17M/C × MT3.50
Tubeless
190/50 ZR17 M/C (73W)
J17M/C × MT6.00
Telescopic fork (upside-down)
120 mm (4.72 in.)
1-12 GENERAL INFORMATION
General Specifications
Items
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
Rear
Electrical Equipment
Battery
Headlight:
Type
High Beam
Low Beam
Tail/Brake Light
Alternator:
Type
ZX1000GB ∼ GC/HB ∼ HC
Swingarm
138 mm (5.43 in.)
Dual discs
Single disc
12 V 8 Ah
Semi-sealed beam
12 V 55 W
12 V 55 W
LED
Three-phase AC
Specifications are subject to change without notice, and may not apply to every country.
GENERAL INFORMATION 1-13
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro
Units of Length:
Symbol
M
k
c
m
µ
×
×
×
×
×
Power
1 000 000
1 000
0.01
0.001
0.000001
Units of Mass:
kg
g
×
×
2.205
0.03527
=
=
lb
oz
=
=
=
=
=
=
=
=
=
gal (US)
gal (IMP)
qt (US)
qt (IMP)
pint (US)
pint (IMP)
oz (US)
oz (IMP)
cu in
=
=
=
=
kg
lb
N
lb
Units of Volume:
L
L
L
L
L
L
mL
mL
mL
×
×
×
×
×
×
×
×
×
0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
×
×
×
×
×
×
×
0.6214
3.281
0.03937
=
=
=
mile
ft
in
=
=
=
=
=
=
kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb
=
=
=
=
=
=
kgf/cm²
psi
cmHg
kPa
psi
kPa
=
mph
=
=
=
=
PS
HP
kW
HP
Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m
×
×
×
×
×
×
0.1020
0.7376
8.851
9.807
7.233
86.80
Units of Pressure:
Units of Force:
N
N
kg
kg
km
m
mm
0.1020
0.2248
9.807
2.205
Units of Temperature:
kPa
kPa
kPa
kgf/cm²
kgf/cm²
cmHg
×
×
×
×
×
×
0.01020
0.1450
0.7501
98.07
14.22
1.333
Units of Speed:
km/h
×
0.6214
Units of Power:
kW
kW
PS
PS
×
×
×
×
1.360
1.341
0.7355
0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System (DFI)................................................................................................................
Throttle Control System Inspection...................................................................................
Engine Vacuum Synchronization Inspection.....................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................
Evaporative Emission Control System (CAL and SEA-B1 Models) Inspection.................
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ..........
Engine Top End ...................................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Air Suction System Damage Inspection............................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection..............................................................................................
Wheels/Tires ........................................................................................................................
Air Pressure Inspection.....................................................................................................
Wheel/Tire Damage Inspection.........................................................................................
Tire Tread Wear Inspection...............................................................................................
Wheel Bearing Damage Inspection ..................................................................................
Final Drive............................................................................................................................
Drive Chain Lubrication Condition Inspection ...................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection .............................................................................................
Wheel Alignment Adjustment............................................................................................
Drive Chain Wear Inspection ............................................................................................
Chain Guide Wear Inspection ...........................................................................................
Brakes..................................................................................................................................
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................
Brake Hose and Pipe Damage and Installation Condition Inspection...............................
Brake Operation Inspection ..............................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Brake Light Switch Operation Inspection ..........................................................................
Suspension ..........................................................................................................................
Front Forks/Rear Shock Absorber Operation Inspection ..................................................
Front Fork Oil Leak Inspection..........................................................................................
Rear Shock Absorber Oil Leak Inspection ........................................................................
Rocker Arm Operation Inspection.....................................................................................
Tie-Rod Operation Inspection ...........................................................................................
Steering ...............................................................................................................................
Steering Play Inspection ...................................................................................................
Steering Play Adjustment..................................................................................................
2-3
2-7
2-13
2-15
2-17
2-17
2-17
2-17
2-21
2-22
2-22
2-23
2-24
2-24
2-24
2-24
2-24
2-26
2-29
2-30
2-30
2-31
2-31
2-31
2-31
2-32
2-33
2-33
2-33
2-34
2-34
2-34
2-35
2-35
2-36
2-36
2-37
2-37
2-37
2-38
2-39
2-40
2-40
2-40
2-40
2-40
2-41
2-41
2-41
2-41
2
2-2 PERIODIC MAINTENANCE
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Lights and Switches Operation Inspection........................................................................
Headlight Aiming Inspection .............................................................................................
Sidestand Switch Operation Inspection ............................................................................
Engine Stop Switch Operation Inspection.........................................................................
Others ..................................................................................................................................
Chassis Parts Lubrication .................................................................................................
Bolts, Nuts and Fasteners Tightness Inspection...............................................................
Replacement Parts ..............................................................................................................
Air Cleaner Element Replacement....................................................................................
Fuel Hose Replacement ...................................................................................................
Coolant Change ................................................................................................................
Radiator Hose and O-ring Replacement...........................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Brake Hose Replacement .................................................................................................
Brake Fluid Change ..........................................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
Caliper Rubber Parts Replacement ..................................................................................
Spark Plug Replacement ..................................................................................................
2-43
2-44
2-44
2-46
2-47
2-48
2-49
2-49
2-51
2-52
2-52
2-52
2-54
2-56
2-57
2-57
2-58
2-59
2-61
2-62
2-66
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
FREQUENCY Whichever
comes
first
1
ITEM
Fuel System
Throttle control system (play,
smooth return, no drag) - inspect
Engine vacuum synchronization inspect
year
year
year
year
Coolant leak (water hose and
pipe) - inspect
year
Water hose damage - inspect
year
Tire air pressure - inspect
year
12
18
24
30
36
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2-17
•
2-23
•
•
•
•
2-24
•
•
year
Tire tread wear, abnormal wear inspect
year
2-17
2-21
2-22
2-22
2-22
2-24
2-24
2-24
2-24
Every 42 000 km (26 250 mile)
Wheel/tire damage - inspect
Wheel bearing damage - inspect
•
•
Coolant level - inspect
Water hose installation condition inspect
Engine Top End
US, CA, CAL
Model
Valve clearance Other than
inspect
US, CA, CAL
Models
Air suction system damage inspect
Clutch
Clutch operation (play,
disengagement, engagement) inspect
Wheels and Tires
6
See
Page
Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Idle speed - inspect
Fuel leak (fuel hose and pipe) inspect
Fuel hose and pipe damage inspect
Fuel hose and pipe installation
condition - inspect
Evaporative emission control
system function (CAL), (SEA-B1)
- inspect
Cooling System
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
2-24
•
•
•
2-29
•
•
•
2-30
•
•
•
•
•
•
•
•
•
•
•
•
2-31
2-31
2-31
2-32
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
1
ITEM
Final Drive
Drive chain lubrication condition inspect #
Drive chain slack - inspect #
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
6
30
36
2-33
Every 1 000 km (600 mile)
2-33
•
•
year
year
year
year
6
months
•
•
•
•
•
Brake pad wear - inspect #
Brake light switch operation inspect
Suspension
Front forks/rear shock absorber
operation (damping and smooth
stroke) - inspect
Front forks/rear shock absorber
oil leak - inspect
24
Every 600 km (400 mile)
Drive chain guide wear - inspect
Brake fluid level - inspect
18
Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Drive chain wear - inspect #
Brakes
Brake fluid leak (brake hose and
pipe) - inspect
Brake hose and pipe damage inspect
Brake hose and pipe installation
condition - inspect
Brake operation (effectiveness,
play, no drag) - inspect
12
See
Page
•
year
Rocker arm operation - inspect
Tie-rods operation - inspect
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2-35
•
•
•
•
•
•
•
2-36
2-35
2-37
2-37
2-37
2-37
2-38
2-39
•
•
•
2-40
•
•
•
•
•
•
•
•
•
2-40
•
•
•
•
2-41
•
•
•
•
•
•
•
•
•
•
•
•
2-44
•
•
•
•
•
•
2-49
2-40
2-41
Steering
Steering play - inspect
year
•
Steering stem bearings - lubricate 2 years
Electrical System
Lights and switches operation inspect
Headlight aiming - inspect
Sidestand switch operation inspect
Engine stop switch operation inspect
Others
Chassis parts - lubricate
Bolts and nuts tightness - inspect
year
year
year
year
year
•
2-43
2-46
2-47
2-48
2-51
PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
#: 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.
2-6 PERIODIC MAINTENANCE
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever
comes
first
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
1
12
24
36
48
ITEM
Air cleaner element # - replace
Fuel hose - replace
Every (0.6) (7.5) (15) (22.5) (30)
Every 18 000 km (11 250 mile)
5 years
Coolant - change
3 years
Radiator hose and O-ring - replace
3 years
Engine oil # - change
year
Oil filter - replace
year
Brake hose - replace
4 years
Brake fluid - change
2 years
Rubber parts of master cylinder and caliper replace
4 years
Spark plug - replace
•
•
•
•
•
•
•
•
•
•
•
•
•
•
See
Page
2-52
2-52
2-54
2-56
•
•
•
•
•
•
2-57
2-57
2-58
2-59
2-61,
2-62
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.
PERIODIC MAINTENANCE 2-7
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.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
SS: Apply silicone sealant.
Fastener
Fuel System (DFI)
Upper Air Cleaner Housing Screws
Throttle Body Assy Holder Clamp Bolts
Air Cleaner Duct Clamp Bolts
Delivery Pipe Assy Mounting Screws
Oxygen Sensor (Equipped Models)
Intake Air Temperature Sensor Mounting Screw
Water Temperature Sensor
Exhaust Butterfly Valve Actuator Pulley Bolt
Exhaust Butterfly Valve Actuator Mounting
Screws
Fuel Pump Bolts
Cooling System
Hot Windshield Mounting Bolts
Coolant By-pass Fitting Bolt
Thermostat Housing Bolts
Radiator (Water) Hose Clamp Screws
Water Pipe Bolts
Water Pump Impeller Bolt
Water Pump Cover Bolts
Coolant Drain Bolt
Engine Top End
Air Suction Valve Cover Bolts
Spark Plugs
Cylinder Head Cover Bolts
Hot Windshield Mounting Bolts
Camshaft Sprocket Bolts
Front Camshaft Chain Guide Bolt (Upper)
Rear Camshaft Chain Guide Bolt
Front Camshaft Chain Guide Bolt (Lower)
Throttle Body Assy Holder Bolts
N·m
Torque
kgf·m
ft·lb
1.1
2.9
2.0
3.4
44
1.2
30
5.0
0.11
0.30
0.20
0.35
4.5
0.12
3.0
0.51
9.7 in·lb
26 in·lb
18 in·lb
30 in·lb
32
11 in·lb
22
44 in·lb
1.2
0.12
11 in·lb
9.8
1.0
87 in·lb
9.8
8.8
5.9
2.9
12
9.8
11
11
1.0
0.90
0.60
0.30
1.2
1.0
1.1
1.1
87 in·lb
78 in·lb
52 in·lb
26 in·lb
106 in·lb
87 in·lb
97 in·lb
97 in·lb
9.8
13
9.8
9.8
15
25
25
12
12
1.0
1.3
1.0
1.0
1.5
2.5
2.5
1.2
1.2
87 in·lb
115 in·lb
87 in·lb
87 in·lb
11
18
18
106 in·lb
106 in·lb
Remarks
L
L
L
L
L
S
L
L
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Cylinder Head Bolts (M6)
Upper Camshaft Chain Guide Bolts
Plugs
Camshaft Cap Bolts
Cylinder Head Bolts (M10) (First)
Cylinder Head Bolts (M10) (Final)
Camshaft Chain Tensioner Mounting Bolts
Camshaft Chain Tensioner Cap Bolt
Exhaust Butterfly Valve Actuator Pulley Bolt
Exhaust Butterfly Valve Actuator Bolts
Muffler Body Mounting Bolts
Premuffler Chamber Mounting Bolt
Muffler Body Clamp Bolts
Clutch
Clutch Lever Assembly Clamp Bolts
Clutch Cover Bolts
Oil Filler Plug
Clutch Spring Bolts
Clutch Hub Nut
Engine Lubrication System
Oil Filler Plug
Oil Cooler Bolts
Oil Passage Plug
Radiator (Water) Hose Clamp Screws
Oil Pressure Switch
Oil Pressure Relief Valve
Oil Filter
Oil Filter Pipe
Oil Pan Bolts
Engine Oil Drain Bolt
Engine Removal/Installation
Upper Engine Bracket Bolts
Lower Engine Bracket Bolts
Upper Adjusting Collar
Upper Engine Mounting Bolt (L = 65)
Upper Adjusting Collar Locknut
Upper Engine Mounting Bolt (L = 40)
Lower Engine Mounting Nut
Lower Adjusting Collar Locknut
Middle Engine Bracket Bolts
Middle Engine Mounting Nut
Lower Adjusting Collar
N·m
12
12
19.6
12
20
54
11
20
5.0
1.2
34
34
21
Torque
kgf·m
1.2
1.2
2.0
1.2
2.0
5.5
1.1
2.0
0.51
0.12
3.5
3.5
2.1
ft·lb
106 in·lb
106 in·lb
14
106 in·lb
15
40
97 in·lb
15
44 in·lb
11 in·lb
25
25
15
7.8
9.8
2.0
9.0
135
0.80
1.0
0.20
0.90
13.8
69 in·lb
87 in·lb
18 in·lb
80 in·lb
99.6
2.0
12
20
3.0
15
15
17
25
12
29
0.20
1.2
2.0
0.31
1.5
1.5
1.7
2.5
1.2
3.0
18 in·lb
106 in·lb
15
27 in·lb
11
11
13
18
106 in·lb
21
44
59
9.8
44
49
44
44
49
25
44
9.8
4.5
6.0
1.0
4.5
5.0
4.5
4.5
5.0
2.5
4.5
1.0
32
44
87 in·lb
32
36
32
32
36
18
32
87 in·lb
Remarks
S
S
L
S
S, MO
S, MO
S
R
L
SS
L
G, R
L
S
S
S
S
S
S
S
S
S
L, S
S
S
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Crankshaft/Transmission
Balancer Shaft Clamp Bolt
Balancer Shaft Lever Bolt
Breather Side Plate Bolt
Connecting Rod Big End Nuts
Breather Plate Bolts
Shift Drum Bearing Holder Bolts
Oil Passage Plugs
Oil Passage Plug
Starter Motor Clutch Bolts
Crankcase Bolts (M7)
Crankcase Bolts (M9)
Crankcase Bolts (M6)
Crankcase Bolts (M8)
Gear Positioning Lever Bolt
Shift Drum Cam Bolt
Neutral Switch
Shift Shaft Return Spring Pin
Shift Pedal Mounting Bolt
Wheels/Tires
Front Axle Clamp Bolt
Front Axle
Rear Axle Nut
Final Drive
Engine Sprocket Nut
Drive Chain Guide Bolts
Speed Sensor Mounting Bolt
Chain Adjuster Clamp Bolts
Rear Sprocket Nuts
Brakes
Front Master Cylinder Reservoir Cap Stopper
Screw
Brake Lever Pivot Bolt
Front Master Cylinder Bleed Valve
Front Master Cylinder Clamp Bolts
Brake Lever Pivot Bolt Locknut
Front Brake Light Switch Screw
Brake Hose Banjo Bolts
Front Caliper Assembly Bolts
Front Caliper Mounting Bolts
Bleed Valves
Front Brake Pad Pins
Front Brake Disc Mounting Bolts
N·m
Torque
kgf·m
ft·lb
9.8
25
5.9
see the text
9.8
12
20
9.8
12
20
42
20
27
12
12
15
39
25
1.0
2.5
0.60
←
1.0
1.2
2.0
1.0
1.2
2.0
4.2
2.0
2.8
1.2
1.2
1.5
4.0
2.5
87 in·lb
18
52 in·lb
←
87 in·lb
106 in·lb
15
87 in·lb
106 in·lb
15
31
15
20
106 in·lb
106 in·lb
11
29
18
20
108
98
2.0
11.0
10
15
79.7
72
AL
125
9.8
6.9
64
59
12.7
1.0
0.70
6.5
6.0
92.2
87 in·lb
61 in·lb
47
44
MO
1.2
0.12
11 in·lb
1.0
5.4
11
5.9
1.2
25
22
34
7.8
15
27
0.10
0.55
1.1
0.60
0.12
2.5
2.2
3.5
0.80
1.5
2.8
8.8 in·lb
48 in·lb
97 in·lb
52 in·lb
11 in·lb
18
16
25
69 in·lb
11
20
Remarks
L
L
MO
L
L
L
L
S
S, MO
S
S
L
L
L
Si
S
L
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Rear Master Cylinder Mounting Bolts
Brake Pedal Bolt
Rear Master Cylinder Push Rod Locknut
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
Brake Pipe Joint Nuts
Rear Brake Disc Mounting Bolts (ABS Equipped
Models)
Suspension
Upper Front Fork Clamp Bolts
Lower Front Fork Clamp Bolts
Piston Rod Nuts
Front Fork Top Plugs
Front Axle Clump Bolts
Front Fork Bottom Allen Bolts
Rear Shock Absorber Bolt (Upper)
Tie-rod Nuts
Rear Shock Absorber Nut (Lower)
Rocker Arm Nut
Swingarm Pivot Adjusting Collar Locknut
Swingarm Pivot Shaft Nut
Torque Link Nuts
Steering
Left Switch Housing Screws
Upper Front Fork Clamp Bolts
Handlebar Holder Bolts
Handlebar Bolts
Right Switch Housing Screws
Steering Stem Head Bolt
Steering Stem Nut
Lower Front Fork Clamp Bolts
Frame
Lower Fairing Upper Assembly Screws
Lower Fairing Lower Assembly Screws
Front Fender Mounting Bolts
Stay Assembly Mounting Bolts
Stopper Mounting Bolts
Rear Frame Bracket Bolts
Front Footpeg Bracket Bolts
Rear Footpeg Bracket Bolts
Rear Frame Bolts
Sidestand Switch Bolt
Sidestand Bracket Bolts
N·m
25
8.8
17
27
25
18
Torque
kgf·m
2.5
0.90
1.7
2.8
2.5
1.8
ft·lb
18
78 in·lb
12
20
18
13
27
2.8
20
20
25
20
34
20
35
34
34
34
34
98
108
34
2.0
2.5
2.0
3.5
2.0
3.6
3.5
3.5
3.5
3.5
10
11.0
3.5
15
18
15
25
15
26
25
25
25
25
72
79.7
25
3.5
25
25
34
3.5
108
25
20
0.36
2.5
2.5
3.5
0.36
11.0
2.5
2.0
31 in·lb
18
18
25
31 in·lb
79.7
18
15
1.2
1.2
3.9
6.9
4.2
44
25
25
25
8.8
49
0.12
0.12
0.40
0.70
0.42
4.5
2.5
2.5
2.5
0.90
5.0
11 in·lb
11 in·lb
35 in·lb
61 in·lb
37 in·lb
32
18
18
18
78 in·lb
36
Remarks
L
L
L
AL
AL
R
R
R
L
AL
L
L
L
L
PERIODIC MAINTENANCE 2-11
Torque and Locking Agent
Fastener
Sidestand Bolt
Grab Rail Mounting Bolts
Electrical System
Switch Housing Screws
Oxygen Sensor (Equipped Models)
Front Brake Light Switch Screw
Front Turn Signal Light Mounting Screws
Licence Plate Light Mounting Screws
Intake Air Temperature Sensor Mounting Screw
Spark Plugs
Crankshaft Sensor Cover Bolts
Water Temperature Sensor
Timing Rotor Bolt
Crankshaft Sensor Bolts
Starter Motor Cable Terminal Nut
Starter Motor Terminal Locknut
Starter Motor Mounting Bolts
Alternator Rotor Bolt
Stator Coil Bolts
Starter Motor Through Bolts
Brush Holder Screw
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Alternator Cover Bolts
Alternator Lead Holding Plate Bolt
Neutral Switch
Engine Ground Cable Terminal Bolt
Sidestand Switch Bolt
Speed Sensor Mounting Bolt
N·m
44
25
Torque
kgf·m
4.5
2.5
ft·lb
32
18 ft·lb
3.5
44
1.2
1.2
1.2
1.2
13
12
30
39
5.9
5.9
11
9.8
155
12
4.9
3.8
15
2.0
12
12
15
9.8
8.8
6.9
0.36
4.5
0.12
0.12
0.12
0.12
1.3
1.2
3.0
4.0
0.60
0.60
1.1
1.0
15.8
1.2
0.50
0.39
1.5
0.20
1.2
1.2
1.5
1.0
0.90
0.70
31 in·lb
32
11 in·lb
11 in·lb
11 in·lb
11 in·ib
115 in·lb
106 in·lb
22
29
52 in·lb
52 in·lb
97 in·lb
87 in·lb
114
106 in·ib
43 in·lb
34 in·ib
11
18 in·ib
106 in·lb
106 in·ib
11
87 in·lb
78 in·lb
61 in·lb
Remarks
L
SS
G
L
L
L
2-12 PERIODIC MAINTENANCE
Torque and Locking Agent
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads Diameter
(mm)
5
6
8
10
12
14
16
18
20
N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼ 19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325
Torque
kgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼ 1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23.0 ∼ 33.0
ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240
PERIODIC MAINTENANCE 2-13
Specifications
Item
Fuel System (DFI)
Throttle Grip Free Play
Idle Speed
Bypass Screws (Turn Out)
Throttle Body Vacuum
Air Cleaner Element
Cooling System
Coolant:
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Engine Top End
Valve Clearance:
Exhaust
Intake
Clutch
Clutch Lever Free Play
Engine Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Wheels/Tires
Tread Depth:
Front
Rear
Air Pressure (when Cold):
Front
Rear
Final Drive
Drive Chain Slack
Standard
Service Limit
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
1 100 ±50 r/min (rpm)
2 1/2 (for reference)
40.7 ±1.3 kPa (305 ±10 mmHg) at idle
speed
Viscous paper element
– – –
– – –
– – –
Permanent type of antifreeze
Green
Soft water 50%, Coolant 50%
–35°C (–31°F)
2.9 L (3.1 US qt)
–
–
–
–
–
0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)
0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
– – –
– – –
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
– – –
API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2
SAE 10W-40
3.2 L (3.4 US qt) (when filter is not
removed)
3.8 L (4.0 US qt) (when filter is removed)
4.0 L (4.2 US qt) (when engine is
completely dry)
– – –
3.6 mm (0.14 in.)
5.3 mm (0.21 in.)
– – –
– – –
–
–
–
–
–
–
–
–
–
–
– – –
– – –
– – –
– – –
1 mm (0.04 in.),
(AT, CH, DE)
1.6 mm (0.06 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.),
Over 130 km/h (80 mph):
3 mm (0.12 in.)
Up to 180 kg (397 lb) load:
250 kPa (2.5 kgf/cm², 36 psi)
Up to 180 kg (397 lb) load:
290 kPa (2.9 kgf/cm², 42 psi)
– – –
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
– – –
– – –
2-14 PERIODIC MAINTENANCE
Specifications
Item
Drive Chain Wear (20-link
Length)
Standard Chain:
Make
Type
Link
Brakes
Brake Fluid:
Grade
Brake Pad Lining
Thickness:
Front
Rear
Brake Light Timing:
Front
Rear
Electrical System
Spark Plug:
Type
Standard
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit
319 mm (12.56 in.)
ENUMA
EK525ZX
112 Links
– – –
– – –
– – –
DOT4
– – –
4.0 mm (0.16 in.)
5.0 mm (0.20 in.)
1 mm (0.04 in.)
1 mm (0.04 in.)
Pulled ON
ON after about 10 mm (0.39 in.) of
pedal travel
– – –
NGK CR9EIA-9
– – –
– – –
PERIODIC MAINTENANCE 2-15
Special Tools
Inside Circlip Pliers:
57001-143
Attachment Jack:
57001-1252
Steering Stem Nut Wrench:
57001-1100
Spark Plug Wrench, Hex 16:
57001-1262
Jack:
57001-1238
Vacuum Gauge:
57001-1369
Pilot Screw Adjuster, A:
57001-1239
Throttle Sensor Setting Adapter:
57001-1538
Oil Filter Wrench:
57001-1249
Fuel Hose:
57001-1607
2-16 PERIODIC MAINTENANCE
Special Tools
Jack Attachment:
57001-1608
PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
Fuel System (DFI)
Throttle Control System Inspection
that the throttle grip [A] moves smoothly from full
• Check
open to close, and the throttle closes quickly and com-
•
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
Check the throttle grip free play [B].
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
•
•
•
•
•
•
If the free play is incorrect, adjust the throttle cable as
follows.
Loosen the locknuts [A] [B].
Screw both throttle cable adjusters [C] [D] to give the
throttle grip plenty of play.
Turn the decelerator cable adjuster [C] until 2 ∼ 3 mm
(0.08 ∼ 0.12 in.) of throttle grip play is obtained.
Tighten the locknut [A].
Turn the accelerator cable adjuster [D] until 2 ∼ 3 mm
(0.08 ∼ 0.12 in.) of throttle grip play is obtained.
Tighten the locknut [B].
If the free play can not be adjusted with the adjusters,
replace the cable.
Engine Vacuum Synchronization Inspection
NOTE
○These procedures are explained on the assumption that
the intake and exhaust systems of the engine are in
good condition.
the motorcycle so that it is vertical.
• Situate
Remove
air cleaner housing (see Air Cleaner Housing
• Removalthe
in the Fuel System (DFI) chapter).
off the rubber caps [A] and vacuum hose [B] from the
• Pull
fittings of each throttle body.
the California and Southeast Asia Models, pull off the
• For
vacuum hose [A].
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Plug the vacuum hose end [A].
a vacuum gauge (special tool) and hoses [A] to
• Connect
the fittings on the throttle body.
Special Tool - Vacuum Gauge: 57001-1369
a highly accurate tachometer [B] to one of the
• Connect
stick coil primary leads.
the air switching valve hose end [A] and air cleaner
• Plug
housing fitting [B].
the air cleaner housing (see Air Cleaner Housing
• Install
Installation in the Fuel System (DFI) chapter).
the fuel hose (see Fuel Hose Replacement).
• Remove
the following parts temporary.
• Connect
Fuel Pump Lead Connector [A]
Fuel Hose [B]
Special Tool - Fuel Hose: 57001-1607
PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
the engine and warm it up thoroughly.
• Start
Check
• [A]. the idle speed, using a highly accurate tachometer
Idle Speed
Standard:
1 100 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it with
the adjusting screw (see Idle Speed Adjustment).
NOTICE
Do not measure the idle speed by the tachometer of
the meter unit.
idling the engine, inspect the throttle body vacuum,
• While
using the vacuum gauge [B].
Throttle Body Vacuum
Standard: 40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed
If any vacuum is not within specifications, first synchronize the balance of the left (#1, #2 throttle valves) and
right (#3, #4 throttle valves) assemblies.
Example:
#1: 260 mmHg
#2: 300 mmHg
#3: 250 mmHg
#4: 280 mmHg
With the engine at the correct idle speed, equalize higher
vacuum of #1 or #2 (for example 300 mmHg) to higher
vacuum of #3 or #4 (for example 280 mmHg) by turning
the center adjusting screw [A].
•
○After adjustment,
NOTE
the final vacuum measurement between the highest throttle valves may not be 290 mmHg
(for example). The goal is to have the highest two vacuums between the left (#1 and #2) and right (#3 and #4)
banks be the same.
and close the throttle after each measurement, and
• Open
adjust the idle speed as necessary.
the throttle valves have been synchronized, inspect
• Once
output voltage of the main throttle sensor to ensure proper
operation (procedure is explained at the end of this section).
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If any one vacuum measurement is out of the specified
range after left (#1, #2) and right (#2, #3) synchronization,
adjust the bypass screws [A].
Special Tool - Pilot Screw Adjuster, A [B]: 57001-1239
the lower vacuum between #1 and #2 to the higher
• Adjust
vacuum of #1 and #2.
the lower vacuum between #3 and #4 to the higher
• Adjust
vacuum of #3 and #4.
and close the throttle valves after each measure• Open
ment, and adjust the idle speed as necessary.
the vacuums as before.
• Check
If all vacuums are within the specification range, finish the
engine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
remove the bypass screws #1 ∼ #4 and clean them.
in the bypass screw [A] with counting the number of
• Turn
turns until it seals fully but not tightly. Record the number
of turns.
NOTICE
Do not over tighten them. They could be damaged,
requiring replacement.
• Remove:
Bypass Screw
•
•
•
•
Spring [B]
Washer [C]
O-ring [D]
Check the bypass screw and its hole for carbon deposits.
If 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.
Replace the O-ring with a new one.
Check the tapered portion [E] of the bypass screw for
wear or damage.
If the bypass screw is worn or damaged, replace it.
Turn in the bypass screw until it seats fully but not tightly.
PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
out the same number of turns counted when first
• Back
turned in. This is to set the screw to its original position.
NOTE
○A throttle body has different “turns out” of the bypass
screw for each individual unit. On setting the bypass
screw, use the “turns out” determined during disassembly.
the same procedure for other bypass screws.
• Repeat
Repeat
the synchronization.
• If the vacuums
are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
Main Throttle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor BL/W) lead
Digital Meter (–) → BK (sensor BR/BK) lead
Standard:
DC 0.985 ∼ 1.015 V at idle throttle opening
If the output voltage is out of the standard, check the input voltage of the main throttle sensor (see Main Throttle
Sensor Input Voltage Inspection in the Fuel System (DFI)
chapter).
the vacuum gauge hoses and install the rubber
• Remove
caps on the original position.
the California and Southeast Asia Models, install the
• For
vacuum hoses.
○Run 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.
Idle Speed Inspection
the engine and warm it up thoroughly.
• Start
With
the
• [A]. engine idling, turn the handlebar to both sides
If 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 Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.
• Check the idle speed.
Idle Speed
Standard:
1 100 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it.
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Idle Speed Adjustment
the engine and warm it up thoroughly.
• Start
the adjusting screw [A] until the idle speed is correct.
•○Turn
Open 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)
○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Support the fuel tank with a suitable bar
(see Fuel Hose Replacement) and check the fuel hoses.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
that the hoses are routed according to Cable, Wire,
• Check
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]
that the hose joints are securely connected.
•○Check
Push and pull [A] the hose joint [B] back and forth more
than two times, and make sure it is locked and does not
come off.
Fuel Pump Side [C]
Throttle Body Assy Side [D]
WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is installed correctly on the delivery pipe.
If it comes off, reinstall the hose joint.
PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
Evaporative Emission Control System (CAL and
SEA-B1 Models) Inspection
the canister as follows.
•○Inspect
Remove the front seat (see Front Seat Removal in the
Frame chapter).
○Remove the canister [A], and disconnect the hoses from
the canister.
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.
NOTE
○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under
normal conditions.
the liquid/vapor separator as follows.
•○Check
Lift up the fuel tank front side, and support the fuel tank
with the suitable bar (see Fuel Hose Replacement).
○Disconnect the hoses from the separator, and remove the
separator [A] from the motorcycle right side.
○Visually inspect the separator for cracks and other damage.
If the separator has any cracks or damage, replace it with
a new one.
○To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
Check the hoses of the evaporative emission control system as follows.
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. Refer to the diagram
of the evaporative emission control system in the Fuel
System (DFI) chapter too.
○When 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.
•
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambient temperature).
the coolant level in the reserve tank [A] with the
• Check
motorcycle held perpendicular (Do not use the sidestand.).
If the coolant level is lower than the “L” level line [B], unscrew the reserve tank cap and add coolant to the “F”
level line [C].
“L”: low
“F”: full
NOTICE
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine 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)
○The high pressure inside the radiator hose can cause
•
•
coolant to leak [A] or the hose to burst if the line is not
properly maintained.
Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator (Water) Hose Clamp Screws: 2.9 N·m
(0.30 kgf·m, 26 in·lb)
Engine Top End
Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (room temperature).
• Remove:
Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter)
Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)
PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
the crankshaft, align the #1, 4 mark on the timing
• Turn
rotor with the crankcase timing mark.
TDC Mark [A] for #1, 4 Pistons
Timing Mark [B] (Crankcase Halves Mating Surface)
the thickness gauge [A], measure the valve clear• Using
ance between the cam and the valve lifter.
Valve Clearance
Standard:
Exhaust
0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)
Intake
0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
NOTE
○Thickness gauge is horizontally inserted on the valve
lifter.
Appropriateness [A]
Inadequacy [B]
Thickness Gauge [C]
Horizontally Inserts [D]
Cam [E]
Valve Lifter [F]
Hits the Valve Lifter Ahead [G]
○When positioning #4 piston TDC
at the end of the
compression stroke:
Intake Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [A]
○When positioning #1 piston TDC
at the end of the
compression stroke:
Intake Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [A]
If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Valve Clearance Adjustment
change the valve clearance, remove the camshaft
• To
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.
NOTE
○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.
○Besides the standard shims in the valve clearance adjustment charts, the following shims may be installed at the
factory. Although they are not available as spare parts,
they can be used to adjust valve clearance.
Adjustment Shims
Thickness
3.225 mm
3.275 mm
3.325 mm
2.675 mm
2.725 mm
2.775 mm
2.825 mm
2.875 mm
2.925 mm
2.975 mm
3.025 mm
3.075 mm
3.125 mm
3.175 mm
the shim to remove any dust or oil.
• Clean
• Measure the thickness of the removed shim [A].
PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE
1.
2.
3.
4.
Measure the clearance (when engine is cold).
Check present shim size.
Match clearance in vertical column with present shim size in horizontal column.
Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example:
Present shim is 2.95 mm
Measured clearance is 0.45 mm
Replace 2.95 mm shim with 3.20 mm shim.
5. Remeasure the valve clearance and readjust if necessary.
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE
1.
2.
3.
4.
Measure the clearance (when engine is cold).
Check present shim size.
Match clearance in vertical column with present shim size in horizontal column.
Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example:
Present shim is 2.95 mm.
Measured clearance is 0.47 mm.
Replace 2.95 mm shim with 3.15 mm shim.
5. Remeasure the valve clearance and readjust if necessary.
PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
NOTICE
Be sure to remeasure the clearance after selecting
a shim according to the table. If the clearance is out
of the specified range, use the additional shim.
○If there is no valve clearance, use a shim that is a few
•
sizes smaller, and remeasure the valve clearance.
When installing the shim, face the marked side toward the
valve lifter.
NOTICE
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing extensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.
engine oil to the valve lifter surface and install the
• Apply
lifter.
the camshaft (see Camshaft Installation in the En• Install
gine Top End chapter).
the valve clearance and readjust if necessary.
• Recheck
Install
the
removed parts (see appropriate chapters).
•
Air Suction System Damage Inspection
the air switching valve hose [A] out of the air cleaner
• Pull
housing.
• Start the engine and run it at idle speed.
[A] the air switching valve hose end with your finger
• Plug
and feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch
Clutch Operation Inspection
the clutch lever just enough to take up the free play
• Pull
[A].
the gap between the lever and the lever holder.
• Measure
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B]
• ofTurnthreads
are visible.
the dust cover [A] at the clutch cable lower end out
• Slide
of place.
both adjusting nuts [B] at the clutch cover as far
• Loosen
as they will go.
the clutch outer cable [C] tight and tighten the adjust• Pull
ing nuts against the clutch cover [D].
the dust cover back onto place.
• Slip
the adjuster at the clutch lever until the free play is
• Turn
correct.
the release lever [A] toward the front of the motor• Push
cycle until it becomes hard to turn.
○At this time, the release lever should have the proper an-
gle shown.
60° [B]
If the angle is wrong, check the clutch and release parts
for wear.
WARNING
Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.
the adjustment, start the engine and check that the
• After
clutch does not slip and that it releases properly.
PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
Wheels/Tires
Air Pressure Inspection
the air valve cap.
• Remove
the tire air pressure with an air pressure gauge
• Measure
[A] when the tires are cold (that is, when the motorcycle
•
has not been ridden more than a mile during the past 3
hours).
Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front:
Up to 180 kg (397 lb)
250 kPa (2.5 kgf/cm², 36 psi)
Rear:
Up to 180 kg (397 lb)
290 kPa (2.9 kgf/cm², 42 psi)
Wheel/Tire Damage Inspection
any imbedded stones [A] or other foreign parti• Remove
cles [B] from tread.
inspect the tire for cracks and cuts, and replace
• Visually
the tire if necessary. Swelling or high spots indicate inter-
•
nal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents damage.
If any damage is found, replace the wheel if necessary.
Tire Tread Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).
•
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tread Depth
Standard:
Front
3.6 mm (0.14 in.)
Rear
5.3 mm (0.21 in.)
Service Limit:
Front
1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)
Rear
2 mm (0.08 in.)
Up to 130 km/h (80 mph)
3 mm (0.12 in.)
Over 130 km/h (80 mph)
WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for
replacement, inflated to the standard pressure.
NOTE
○Most countries may have their own regulations a minimum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.
Wheel Bearing Damage Inspection
the front wheel off the ground with the jack (see
• Raise
Front Wheel Removal in the Wheels/Tires chapter).
the handlebar all the way to the right or left.
• Turn
Inspect
roughness of the front wheel bearing by push• ing and the
pulling [A] the wheel.
[B] the front wheel lightly, and check for smoothly
• Spin
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
the rear wheel off the ground with the stand (see
• Raise
Rear Wheel Removal in the Wheels/Tires chapter).
the roughness of the rear wheel bearing by push• Inspect
ing and pulling [A] the wheel.
[B] the rear wheel lightly, and check for smoothly
• Spin
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).
PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
Final Drive
Drive Chain Lubrication Condition Inspection
a special lubricant is not available, a heavy oil such as
• IfSAE
90 is preferred to a lighter oil because it will stay on
•
the chain longer and provide better lubrication.
If the chain appears especially dirty, clean it before lubrication.
NOTICE
The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubricant, 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 deterioration and swelling of the O-ring. Immediately
blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within
10 minutes.
oil to the sides of the rollers so that oil will penetrate
• Apply
to the rollers and bushings. Apply the oil to the O-rings so
•
that the O-rings will be coated with oil.
Wipe off any excess oil.
Oil Applied Areas [A]
O-rings [B]
Drive Chain Slack Inspection
NOTE
○Check the slack with the motorcycle setting on its sidestand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
the wheel alignment (see Wheel Alignment Inspec• Check
tion).
the rear wheel to find the position where the chain
• Rotate
is tightest.
the vertical movement (chain slack) [A] midway
• Measure
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard:
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Chain Slack Adjustment
the left and right chain adjuster clamp bolts [A].
• Loosen
an Allen wrench [B], turn the adjusters [C] forward
• Using
or rearward until the drive chain has the correct amount
•
of chain slack.
Tighten:
Torque - Chain Adjuster Clamp Bolts: 64 N·m (6.5 kgf·m, 47
ft·lb)
Wheel Alignment Inspection
that the left and right notches [A] the swingarm
• Check
should point to the same marks or positions [B] on the
left and right adjuster.
If they do not, adjust the chain slack (see Drive Chain
Slack Adjustment) and align the wheel alignment.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
Wheel Alignment Adjustment
the right retaining ring [A] from the axle shaft.
• Remove
the axle nut [B].
• Loosen
Loosen
right chain adjuster clamp bolt [C], and turn
• the rightthechain
adjuster [D] so that the left and right
•
notches on the swingarm may point to the same marks
or positions on the left and right adjusters.
Tighten:
Torque - Chain Adjuster Clamp Bolt: 64 N·m (6.5 kgf·m, 47
ft·lb)
Rear Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb)
PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
Drive Chain Wear Inspection
the chain cover (see Drive Chain Removal in the
• Remove
Final Drive chapter).
the rear wheel to inspect the drive chain for dam• Rotate
aged rollers, and loose pins and links.
•
•
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.
Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard:
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit: 319 mm (12.56 in.)
WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain.
Standard Chain
Make:
ENUMA
Type:
EK525ZX
Link:
112 Links
Chain Guide Wear Inspection
the swingarm (see Swingarm Removal in the
• Remove
Suspension chapter).
inspect the chain guide [A].
• Visually
Replace the chain guide if it shows any signs of abnormal
wear or damage.
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brakes
Brake Fluid Leak (Brake Hose and Pipe) Inspection
ABS equipped models, remove the fuel tank (see Fuel
• For
Tank Removal in the Fuel System (DFI) chapter).
the brake lever or pedal and inspect the brake fluid
• Apply
leak from the brake hoses [A], pipes (ABS equipped models) [B] and fittings [C].
If the brake fluid leaked from any position, inspect or replace the problem part.
PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
Brake Hose and Pipe Damage and Installation
Condition Inspection
ABS equipped models, remove the fuel tank (see Fuel
• For
Tank Removal in the Fuel System (DFI) chapter).
the brake hoses and fittings for deterioration,
• Inspect
cracks and signs of leakage.
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose, pipe (ABS equipped models) to burst
if the line is not properly maintained. Bend and twist the
rubber hose while examining it.
Replace the hose and pipe (ABS equipped models) if any
crack [B], bulge [C] or leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)
(ABS Equipped Models)
the brake hose routing.
• Inspect
If any brake hose routing is incorrect, route the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.
Brake Operation Inspection
the operation of the front and rear brake by run• Inspect
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
WARNING
When test riding the vehicle, be aware of surrounding traffic for your safety.
Brake Fluid Level Inspection
that the brake fluid level in the front brake reservoir
• Check
[A] is above the lower level line [B].
NOTE
○Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
○Remove the stopper [D].
Tighten:
•
Torque - Front Master Cylinder Reservoir Cap Stopper
Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb)
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
that the brake fluid level in the rear brake reservoir
• Check
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
○Remove the stopper [D].
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
Recommended Disc Brake Fluid
Grade:
DOT4
procedure below to install the front/rear brake fluid
• Follow
reservoir cap correctly.
○First, tighten the rear 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].
Brake Pad Wear Inspection
the brake pads (see Front/Rear Brake Pad Re• Remove
moval in the Brakes chapter).
the lining thickness [A] of the pads in each caliper.
• Check
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
[C] Front Brake Pad
[D] Rear Brake Pad
Pad Lining Thickness
Standard:
Front
4.0 mm (0.16 in.)
Rear
5.0 mm (0.20 in.)
Service Limit:
1 mm (0.04 in.)
PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
Brake Light Switch Operation Inspection
on the ignition switch.
• Turn
brake light [A] should go on when the brake lever is
• The
applied or after the brake pedal is depressed about 10
mm (0.39 in.).
If it does not, adjust the brake light switch as follows.
• Remove:
Rear Lower Fairing (see Rear Lower Fairing Removal in
the Frame chapter)
Rear Master Cylinder Mounting Bolts [A]
Footpeg Bracket Bolts [B]
Footpeg Bracket [C]
holding the switch body, turn the adjusting nut to
• While
adjust the switch.
Switch Body [A]
Adjusting Nut [B]
Light sooner as the body rises [C]
Light later as the body lowers [D]
NOTICE
To avoid damaging the electrical connections inside the switch, be sure that the switch body does
not turn during adjustment.
•
If it does not go on, inspect or replace the following items.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Brake Light (see Tail/Brake Light Removal in the Electrical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Tighten:
Torque - Front Footpeg Bracket Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)
Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Suspension
Front Forks/Rear Shock Absorber Operation
Inspection
the forks down and up [A] 4 or 5 times, and inspect
• Pump
the smooth stroke.
If the forks do not smoothly or noise is found, inspect the
fork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).
the seat down and up [A] 4 or 5 times, and inspect
• Pump
the smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection).
Front Fork Oil Leak Inspection
inspect the front forks [A] for oil leakage.
• Visually
Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
inspect the shock absorber [A] for oil leakage.
• Visually
If the oil leakage is found on it, replace the shock absorber
with a new one.
Rocker Arm Operation Inspection
the seat down and up 4 or 5 times, and inspect the
• Pump
smooth stroke.
If the rocker arms [A] do not smoothly stroke or noise is
found, inspect the fasteners and bearings (see Rocker
Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspension chapter).
PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
Tie-Rod Operation Inspection
the seat down and up 4 or 5 times, and inspect the
• Pump
smooth stroke.
If the tie-rod [A] does not smoothly stroke or noise is
found, inspect the fasteners and tie-rod bearings (see
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the
Suspension chapter).
Steering
Steering Play Inspection
the lower fairing (see Lower Fairing Removal in
• Remove
the Frame chapter).
the front wheel off the ground with the jack (see
• Raise
Front Wheel Removal in the Wheels/Tires chapter).
the front wheel pointing straight ahead, alternately
• With
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.
If the wheel binds or catches before the stop, the steering
is too tight.
Feel for steering looseness by pushing and pulling [A] the
forks.
If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the motion of the fork which must be taken into account.
○Be sure the leads and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
Steering Play Adjustment
• Remove:
Upper Fairing Bracket (see Upper Fairing Bracket Removal in the Frame chapter)
Handlebar (see Handlebar Removal in the Steering
chapter)
Steering Stem Head Bolt Plug [A]
Steering Stem Head Bolt [B]
Upper Front Fork Clamp Bolts [C] (Loosen)
Stem Head [D]
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the claws [A] of the claw washer back.
• Bend
Remove
• [C]. the steering stem locknut [B] and claw washer
• Adjust the steering.
Special Tool - Steering Stem Nut Wrench [A]: 57001-1100
If the steering is too tight, loosen the stem nut a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
○Turn the stem nut 1/8 turn at time maximum.
the claw washer [A] so that its bent side [B] faces
• Install
upward, and engage the bent claws with the grooves of
•
•
•
•
stem locknut [C].
Hand tighten the stem locknut until the claw washer
touches the steering stem nut.
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].
Install the stem head.
Tighten:
Torque - Steering Stem Head Bolt: 108 N·m (11.0 kgf·m,
79.7 ft·lb)
Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
the steering again.
• Check
If the steering is still too tight or too loose, repeat the ad-
•
justment.
Install the removed parts (see appropriate chapters).
PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Steering Stem Bearing Lubrication
the steering stem (see Stem, Stem Bearing Re• Remove
moval in the Steering chapter).
a high-flash point solvent, wash the upper and
• Using
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.
Visually check the outer races and the ball bearings.
Replace the bearing assemblies if they show wear or
damage.
Pack the upper and lower ball bearings [A] in the cages
with grease, and apply a light coat of grease to the upper
and lower outer races.
Install the steering stem (see Stem, Stem Bearing Installation in the Steering chapter).
Adjust the steering (see Steering Play Adjustment).
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Electrical System
Lights and Switches Operation Inspection
First Step
Turn on the ignition switch.
The following lights should go on according to below table.
•
•
City Lights [A]
goes on
Taillight [B]
goes on
License Plate Light [C]
goes on
Meter Panel LCD [D]
goes on
Neutral Indicator Light (LED) [E]
goes on
Warning Symbol and Warning Indicator Light (LED)
[F]
goes on
ABS Indicator Light (LED) [G] (ABS Equipped Models) goes on
If the light does not go on, inspect or replace the following
item.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Applicable Bulb (see Wiring Diagram in the Electrical
System chapter)
Meter Unit for Meter Panel LCD (see Electronic Combination Meter Unit Inspection 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)
ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
ABS Indicator Light (LED) (ABS Equipped Models) (see
ABS Indicator Light (LED) Inspection in the Brakes chapter)
off the ignition switch.
• Turn
all lights should go off.
• The
If the light does not go off, replace the ignition switch.
Second Step
Turn the ignition switch to P (Park) position.
The city light, taillight and license plate light should go on.
If the light does not go on, inspect or replace the following
item.
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
•
•
PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
Third Step
Turn on the turn signal switch [A] (left or right position).
The left or right turn signal lights [B] (front and rear) according to the switch position should flash.
The turn signal indicator light (LED) [C] in the meter unit
should flash.
If the each light does not flash, inspect or replace the
following item.
Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter)
Meter Unit for Turn Signal Indicator Light (LED) (see Meter 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 Electrical System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Push the turn signal switch.
The turn signal lights and indicator light (LED) should go
off.
If the light does not go off, inspect or replace the following
item.
Turn Signal Switch (see Switch Inspection in the Electrical System chapter)
•
•
•
•
•
Fourth Step
Set the dimmer switch [A] to low beam position.
Start the engine.
The low beam headlight should go on.
If the low beam headlight does not go on, inspect or replace the following item.
Headlight Low Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
•
•
•
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the dimmer switch to high beam position.
• Set
The
• go on.low beam [A] and high beam [B] headlights should
high beam indicator light (LED) [C] should go on.
• The
If the 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 Replacement in the Electrical System chapter)
Meter Unit for High Beam Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Turn off the engine stop switch.
The low beam and high beam headlights should stay going on.
If the headlights and high beam indicator light (LED) does
go off, inspect or replace the following item.
Headlight Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter)
Turn off the ignition switch.
The headlights and high beam indicator light (LED) should
go off.
Headlight Aiming Inspection
the headlight beam for aiming.
• Inspect
If the headlight beam is off the point, adjust the headlight
aiming.
Headlight Beam Horizontal Adjustment
Remove the meter cover (see Upper Fairing Removal in
the Frame chapter.)
Turn the horizontal adjuster [A] in both headlights with the
screwdriver in or out until the beam points straight ahead.
If the headlight beam points too low or high, adjust the
vertical beam.
Headlight Beam Vertical Adjustment
Turn the vertical adjuster [B] in both headlights in or out
to adjust the headlight vertically.
•
•
•
NOTE
○On high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper angle according to local regulations.
PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
NOTE
○For 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]
7.6 m (25 ft) [C]
Height of Headlight Center [D]
Sidestand Switch Operation Inspection
the sidestand switch [A] operation accordance to
• Inspect
the following table.
Sidestand Switch Operation
Sidestand
Gear
Position
Clutch
Lever
Engine
Start
Engine
Run
Up
Neutral
Released
Starts
Continue
running
Up
Neutral
Pulled in
Starts
Continue
running
Up
In Gear
Released
Doesn’t
start
Continue
running
Up
In Gear
Pulled in
Starts
Continue
running
Down
Neutral
Released
Starts
Continue
running
Down
Neutral
Pulled in
Starts
Continue
running
Down
In Gear
Released
Doesn’t
start
Stops
Down
In Gear
Pulled in
Doesn’t
start
Stops
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If the sidestand switch operation does not work, inspect
or replace the following item.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the Electrical
System chapter)
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Electrical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
If the all parts are good condition, replace the ECU (see
ECU Removal/Installation in the Fuel System (DFI) chapter).
Engine Stop Switch Operation Inspection
First Step
Turn on the ignition switch.
Set the neutral position.
Turn the engine stop switch to stop position [A].
Push the starter button.
The engine does not start.
If the engine starts, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
•
•
•
•
•
Second Step
Turn on the ignition switch.
Set the neutral position.
Turn the engine stop switch to run position [A].
Push the starter button and run the engine.
Turn the engine stop switch to stop position.
Immediately the engine should be stop.
If the engine does not stop, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
•
•
•
•
•
•
PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures
Others
Chassis Parts Lubrication
lubricating each part, clean off any rusty spots with
• Before
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
○Whenever
NOTE
the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubrication.
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cables
Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
•
2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the cable disconnected at both ends, the cable
• With
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures
Bolts, Nuts and Fasteners Tightness Inspection
the tightness of the bolts and nuts listed here. Also,
• Check
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are removed, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Bolt Locknut
Engine Mounting Bolts and Nuts
Exhaust Pipe Manifold Holder Nuts
Exhaust Pipe Mounting Bolt
Muffler Body Clamp Bolts
Muffler Body Mounting Bolt and Nuts
Radiator Upper and Lower Bolts
Subframe Bolts
Wheels:
Front Axle
Front Axle Clamp Bolt
Rear Axle Nut
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 Bolt and Nut
Swingarm Pivot Shaft Locknut
Swingarm Pivot Shaft Nut
Tie-Rod Nuts
Rocker Arm Nut
Steering:
Handlebar Holder Bolts
Steering Stem Head Bolt
Others:
Footpeg Bracket Bolts
Front Fender Bolts
Sidestand Bolt
2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Replacement Parts
Air Cleaner Element Replacement
NOTE
○In dusty areas, the element should be replaced more
frequently than the recommended interval.
WARNING
If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident. Replace the air cleaner
element according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Connector Bracket [A]
Screws [B]
Upper Air Cleaner Housing [C]
• Discard the air cleaner element [A].
a new element so that flat side faces forward.
• Install
• Tighten:
Torque - Upper Air Cleaner Housing Screws: 1.1 N·m (0.11
kgf·m, 9.7 in·lb)
Fuel Hose Replacement
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
sure to place a piece of cloth [A] around the fuel hose
• Be
joint.
a thin blade screwdriver [B] into the slit [C] on the
• Insert
joint lock [D].
• Turn the driver to disconnect the joint lock.
• Pull the fuel hose joint [A] out of the delivery pipe.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. 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 connection with a clean shop
towel to prevent fuel spillage.
the fuel hose with a new one.
• Replace
Run
the
fuel
hose correctly (see Cable, Wire, and Hose
• Routing section
in the Appendix chapter).
Insert
the
fuel
hose
joint [A] straight onto the delivery pipe
• until the hose joint clicks.
• Push [B] the joint lock [C].
and pull [A] the fuel hose joint [B] back and forth
• Push
more than two times and make sure it is locked and does
not come off.
WARNING
Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.
If it comes off, reinstall the hose joint.
the fuel hose correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
the fuel tank (see Fuel Tank Installation in the Fuel
• Install
System (DFI) chapter).
• Start the engine and check the fuel hose for leaks.
2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Coolant Change
WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.
the left lower fairing (see Lower Fairing Removal
• Remove
in the Frame chapter).
a container under the coolant drain bolt [A], then
• Place
remove the drain bolt.
the right center fairing (see Center Fairing Re• Remove
moval in the Frame chapter).
the radiator cap [A] in two steps. First turn the
• Remove
cap counterclockwise to the first stop. Then push and turn
it further in the same direction and remove the cap.
○The coolant will drain from the radiator and engine.
• Remove:
Right Lower Fairing Assembly (see Lower Fairing As•
•
•
•
sembly Removal in the Frame chapter)
Hose [A]
Reserve Tank Bolts [B]
Turn over the reserve tank, remove the cap, and pour the
coolant into a suitable container.
Install the reserve tank.
Replace the drain bolt gasket with a new one.
Tighten the drain bolt with the gasket.
Torque - Coolant Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
PERIODIC MAINTENANCE 2-55
Periodic Maintenance Procedures
filling the coolant, choose a suitable mixture ratio
• When
by referring to the coolant manufacturer’s directions.
NOTICE
Soft or distilled water must be used with the antifreeze in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:
50%
Freezing Point:
–35°C (–31°F)
Total Amount:
2.9 L (3.1 US qt)
• Fill the radiator up to the filler neck [A] with coolant.
NOTE
○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
the cooling system for leaks.
• Check
Tap
the
• inside. radiator hoses to force any air bubbles caught
• Fill the radiator up to the filler neck with coolant.
the reserve tank up to the “F” (full) level line [A] with
• Fill
coolant and install the cap [B].
the engine, warm it up thoroughly until the radiator
• Start
fan turns on and then stop the engine.
the coolant level in the reserve tank after the en• Check
gine cools down.
If the coolant level is lower than the “L” (low) level line [C],
add coolant to the “F” level line.
NOTICE
Do not add more coolant above the “F” level line.
2-56 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Radiator Hose and O-ring Replacement
the coolant (see Coolant Change).
• Drain
• Remove:
Thermostat Housing [A] (see Thermostat Removal in the
•
•
•
Cooling System chapter)
Water Pump Cover [B] (see Water Pump Removal in the
Cooling System chapter)
Oil Cooler [C] (see Oil Cooler Removal in the Engine
Lubrication System chapter)
Replace the hoses [D] and O-rings [E] with new ones.
Apply grease to the O-rings and install them.
Install the hoses and tighten the clamps securely.
Torque - Radiator (Water) Hose Clamp Screws: 2.9 N·m
(0.30 kgf·m, 26 in·lb)
the coolant (see Coolant Change).
• Fill
Check
the cooling system for leaks.
•
PERIODIC MAINTENANCE 2-57
Periodic Maintenance Procedures
Engine Oil Change
the motorcycle so that it is vertical after warming
• Situate
up the engine.
the engine oil drain bolt [A] to drain the oil.
•○Remove
The oil in the oil filter can be drained by removing the filter
•
•
(see Oil Filter Replacement).
Replace the drain bolt gasket with a new one.
Tighten:
Torque - Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)
• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity:
SAE 10W-40
Capacity:
3.2 L (3.4 US qt) (when filter is not
removed)
3.8 L (4.0 US qt) (when filter is removed)
4.0 L (4.2 US qt) (when engine is
completely dry)
NOTE
○Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
○Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
the oil level (see Oil Level Inspection in the Engine
• Check
Lubrication System chapter).
Oil Filter Replacement
the engine oil (see Engine Oil Change).
• Drain
Remove
the oil filter with the oil filter wrench [A].
•
Special Tool - Oil Filter Wrench: 57001-1249
the filter with a new one.
• Replace
grease to the gasket [A] before installation.
• Apply
Tighten
the filter with the oil filter wrench.
•
Torque - Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb)
NOTE
○Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.
in the specified type and amount of oil (see Engine
• Pour
Oil Change).
2-58 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose Replacement
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Brake Hose Fitting Bolt [A]
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
the brake hose banjo bolts [A].
• Remove
When
removing
brake hose, take care not to spill the
• brake fluid on thethepainted
or plastic parts.
When
removing
the
brake
[B], temporarily secure
• the end of the brake hose tohoses
some high place to keep fluid
loss to a minimum.
Immediately wash away any brake fluid that spills.
○There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
Fit the projection of the brake hose end to the calipers and
master cylinders, and tighten the brake hose banjo bolts
to the specified torque.
•
•
•
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
installing the hoses, avoid sharp bending, kink• When
ing, flatting or twisting, and route the hoses according to
•
Cable, Wire, and Hose Routing section in the Appendix
chapter.
Fill the brake line after installing the brake hose (see
Brake Fluid Change).
PERIODIC MAINTENANCE 2-59
Periodic Maintenance Procedures
ABS equipped models; note the following.
• For
Remove:
• Air Cleaner Housing (see Air Cleaner Housing Removal
•
•
•
•
•
in the Fuel System (DFI) chapter)
Battery Case (see Battery Case Removal in the Frame
chapter)
Brake Pipe Joint Nuts [A]
Bolts [B]
Clamps [C]
Open the band [D].
Clear the brake pipe from the holder [E].
Remove the exhaust butterfly valve cable clamp [F].
There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
Before installing the brake pipe, check to see that there is
no damage on the threads of the brake pipe joint nut.
If there is any damage, replace the damaged parts with
new ones.
NOTE
○Hand tighten the brake pipe joint nuts at both ends of
the brake pipe temporarily and then tighten them to the
specified torque.
○Tighten the brake pipe joint nuts with the flare nut
wrench.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)
installing the hoses, avoid sharp bending, kink• When
ing, flatting or twisting, and route the hoses according to
•
Cable, Wire, and Hose Routing section in the Appendix
chapter.
Fill the brake line after installing the brake hose (see
Brake Fluid Change).
Brake Fluid Change
NOTE
○The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for
the front brake.
2-60 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the brake fluid reservoir.
• Level
Remove
reservoir cap.
• Remove the
• caliper. the rubber cap from the bleed valve [A] on the
a clear plastic hose [B] to the bleed valve, and run
• Attach
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
the brake fluid.
•○Change
Repeat this operation until fresh brake fluid comes out
1.
2.
3.
4.
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 [C].
Release the brake [D].
NOTE
○The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
○Front Brake: Repeat the above steps for the other
caliper.
• Tighten:
Torque - Front Master Cylinder Reservoir Stopper Screw:
1.2 N·m (0.12 kgf·m, 11 in·lb)
the procedure below to install the front/rear brake
• Follow
fluid reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
changing the fluid, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.
PERIODIC MAINTENANCE 2-61
Periodic Maintenance Procedures
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).
Remove the seal cover [A], circlip [B], connector [C] and
O-ring [D].
•
•
Special Tool - Inside Circlip Pliers: 57001-143
the locknut [E] and pivot bolt [F], and remove the
• Unscrew
brake lever.
the bleed valve [G] and rubber cap [H].
• Remove
Remove
piston assembly [I] as follows.
•○Remove the
the dust cover and push rod.
○Remove the circlip [J].
○Pull out the piston (with primary cup and secondary cup).
○Remove the return spring and spring guide.
• Replace:
Seal Cover [A]
Circlip [B]
O-ring [D]
Rubber Cap [H]
Piston Assembly [I]
Circlip [J]
Diaphragm [K]
Rear Master Cylinder Disassembly
Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).
Remove the circlip [A], connector [B] and O-ring [C].
•
•
Special Tool - Inside Circlip Pliers: 57001-143
the dust cover [D] out of place, and remove the cir• Slide
clip [E].
out the push rod assy [F].
• Pull
Take
• off the piston assy [G] and return spring [H].
NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.
• Replace:
Circlip [A]
O-ring [C]
Circlip [E]
Push Rod Assy [F]
Piston Assy [G]
Diaphragm [I]
2-62 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Master Cylinder Assembly
Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
•
NOTICE
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
brake fluid to the new parts and to the inner wall of
• Apply
the cylinder.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
the front master cylinder, apply a non-permanent lock• For
ing agent to the reservoir screw and bolt.
silicone grease to the contact portion of the push
• Apply
rod and brake lever pivot bolt.
• Tighten:
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.8
in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Caliper Rubber Parts Replacement
Front Caliper Disassembly
Loosen the front caliper pad pins [A] and banjo bolt [B]
and tighten them loosely.
Remove:
Front Caliper (see Front Caliper Removal in the Brakes
chapter)
Brake Pads (see Front Brake Pad Removal in the brakes
chapter)
•
•
• Remove:
Front Caliper Assembly Bolts [A]
Split
• the front caliper.
PERIODIC MAINTENANCE 2-63
Periodic Maintenance Procedures
• Remove:
Pad Spring
O-ring [A]
compressed air, remove the pistons.
• Using
remove the pistons is as follows.
One way to
○Install a rubber gasket [A] and a wooden board [B] more
than 10 mm (0.4 in.) thick on the caliper half.
○For inside caliper half [C], fasten them together with a
suitable bolt and nut [D] as shown. Leave one of the oil
passage [E] open.
○Lightly apply compressed air [F] to the oil passage until
the pistons hit the rubber gasket.
Push down [G]
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
○Pull out the pistons by hand.
the dust seals [A] and fluid seals [B].
• Remove
Remove
bleed valve [C] and rubber cap [D].
• Repeat thetheprevious
step to remove the pistons from the
• other side of the caliper
body.
NOTE
○If compressed air is not available, do as follows for both
calipers coincidentally, with the brake hose connected
to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the pad springs and pads (see Front Brake
Pad Removal in the Brakes chapter).
○Pump the brake lever until the pistons come out of the
cylinders, and then disassemble the caliper.
2-64 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Front Caliper Assembly
Clean the caliper parts except for the pads.
•
NOTICE
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
• Install the bleed valve and rubber cap.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the fluid seals [A] with new ones.
•○Replace
Apply silicone grease to the fluid seals, and install them
into the cylinders by hand.
Replace the dust seals [B] with new ones if they are damaged.
○Apply silicone grease to the dust seals, and install them
into the cylinders by hand.
•
the O-ring [A] and install it.
• Replace
Apply
brake
fluid to the outside of the pistons, and push
• them into each
cylinder by hand.
sure to install the O-ring.
• Be
Tighten:
•
Torque - Front Caliper Assembly Bolts: 22 N·m (2.2 kgf·m,
16 ft·lb)
the pad spring [A] as shown.
• Install
Install
the
pads (see Front Brake Pad Installation in
• the Brakesbrake
chapter).
Wipe
up
any
spilled brake fluid on the caliper with wet
• cloth.
Rear Caliper Disassembly
Remove:
Rear Caliper (see Rear Caliper Removal in the Brakes
chapter)
Brake Pads (see Rear Brake Pad Removal in the Brakes
chapter)
Caliper Holder
•
PERIODIC MAINTENANCE 2-65
Periodic Maintenance Procedures
a rear caliper mounting bolt [A], screw the thread
• Using
hole for banjo bolt to remove the piston [B].
• Remove the pad spring [C].
• Remove:
Dust Seal [A] and Fluid Seal [B]
Bleed Valve [C] and Rubber Cap [D]
Dust Boot [E]
Friction Boot [F]
Rear Caliper Assembly
Clean the caliper parts except for the pads.
•
NOTICE
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
• Install the bleed valve and rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
brake fluid to the cylinder bore.
• Apply
Replace
the fluid seal [A] with a new one.
•○Apply silicone
grease to the fluid seal, and install it into
the cylinder by hand.
Replace the dust seal [B] with a new one.
Apply brake fluid to the outside of the piston, and push it
into the cylinder by hand as far as it will go.
Replace the friction boot [C] and dust boot [D] with new
ones.
Apply silicone grease to the sliding surface of the caliper
holder shafts [E].
Check that the guide [F] is in place on the caliper holder.
Install the pad spring [G].
•
•
•
•
•
•
the pads (see Rear Brake Pad Installation in the
• Install
Brakes chapter).
up any spilled brake fluid on the caliper with wet
• Wipe
cloth.
2-66 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Spark Plug Replacement
the stick coils (see Stick Coil Removal in the
• Remove
Electrical System chapter).
the spark plugs [A] using the plug wrench [B]
• Remove
vertically.
Special Tool - Spark Plug Wrench, Hex 16: 57001-1262
• Replace the spark plug with a new one.
Standard Spark Plug
Type:
NGK CR9EIA-9
new spark plug in the plug wrench.
• Insert
Using
the plug wrench vertically, tighten the plug.
•
NOTICE
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)
the stick coils securely.
•○Install
Be sure the stick coils are installed by pulling up it lightly.
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)
Table of Contents
Exploded View........................................................................................................................
DFI System.............................................................................................................................
DFI Parts Location..................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
DFI Servicing Precautions ......................................................................................................
DFI Servicing Precautions ...................................................................................................
Troubleshooting the DFI System ............................................................................................
Outline .................................................................................................................................
Inquiries to Rider..................................................................................................................
DFI System Troubleshooting Guide .......................................................................................
Self-Diagnosis ........................................................................................................................
Self-diagnosis Outline..........................................................................................................
Self-diagnosis Procedures...................................................................................................
Service Code Reading ......................................................................................................
Service Code Erasing .......................................................................................................
Backups ...............................................................................................................................
Main Throttle Sensor (Service Code 11) ................................................................................
Main Throttle Sensor Removal/Adjustment ......................................................................
Main Throttle Sensor Input Voltage Inspection .................................................................
Main Throttle Sensor Output Voltage Inspection ..............................................................
Main Throttle Sensor Resistance Inspection ....................................................................
Intake Air Pressure Sensor #1 (Service Code 12)..................................................................
Intake Air Pressure Sensor #1 Removal...........................................................................
Intake Air Pressure Sensor #1 Installation........................................................................
Intake Air Pressure Sensor #1 Input Voltage Inspection...................................................
Intake Air Pressure Sensor #1 Output Voltage Inspection................................................
Intake Air Temperature Sensor (Service Code 13).................................................................
Intake Air Temperature Sensor Removal/Installation........................................................
Intake Air Temperature Sensor Output Voltage Inspection ...............................................
Intake Air Temperature Sensor Resistance Inspection .....................................................
Water Temperature Sensor (Service Code 14) ......................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Output Voltage Inspection.....................................................
Water Temperature Sensor Resistance Inspection...........................................................
Intake Air Pressure Sensor #2 (Service Code 16)..................................................................
Intake Air Pressure Sensor #2 Removal...........................................................................
Intake Air Pressure Sensor #2 Installation........................................................................
Intake Air Pressure Sensor #2 Input Voltage Inspection...................................................
Intake Air Pressure Sensor #2 Output Voltage Inspection................................................
Crankshaft Sensor (Service Code 21)....................................................................................
Crankshaft Sensor Removal/Installation...........................................................................
Crankshaft Sensor Resistance Inspection ........................................................................
Crankshaft Sensor Peak Voltage Inspection.....................................................................
Speed Sensor (Service Code 24, 25).....................................................................................
Speed Sensor Removal/Installation..................................................................................
Speed Sensor Inspection..................................................................................................
Speed Sensor Input Voltage Inspection............................................................................
Speed Sensor Output Voltage Inspection .........................................................................
Vehicle-down Sensor (Service Code 31)................................................................................
3-4
3-10
3-16
3-18
3-20
3-22
3-22
3-24
3-24
3-28
3-31
3-36
3-36
3-37
3-40
3-41
3-42
3-45
3-45
3-45
3-46
3-48
3-49
3-49
3-49
3-50
3-51
3-55
3-55
3-55
3-56
3-58
3-58
3-59
3-60
3-61
3-61
3-61
3-62
3-63
3-65
3-65
3-65
3-65
3-66
3-66
3-66
3-66
3-67
3-69
3
3-2 FUEL SYSTEM (DFI)
Vehicle-down Sensor Removal .........................................................................................
Vehicle-down Sensor Installation ......................................................................................
Vehicle-down Sensor Input Voltage Inspection.................................................................
Vehicle-down Sensor Output Voltage Inspection ..............................................................
Subthrottle Sensor (Service Code 32)....................................................................................
Subthrottle Sensor Removal/Adjustment ..........................................................................
Subthrottle Sensor Input Voltage Inspection.....................................................................
Subthrottle Sensor Output Voltage Inspection ..................................................................
Subthrottle Sensor Resistance Inspection ........................................................................
Oxygen Sensor - not activated (Service Code 33, Equipped Models) ...................................
Oxygen Sensor Removal/Installation................................................................................
Oxygen Sensor Inspection................................................................................................
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)..................................................
Exhaust Butterfly Valve Actuator Sensor Removal/Installation.........................................
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection...................................
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection ................................
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection ......................................
Immobilizer Amplifier (Service Code 35, Equipped Models) ..................................................
Antenna Resistance Inspection ........................................................................................
Amplifier Input Voltage Inspection.....................................................................................
Blank Key Detection (Service Code 36, Equipped Models) ...................................................
Ignition Key Inspection......................................................................................................
ECU Communication Error (Service Code 39) .......................................................................
ECU Communication Line Inspection ...............................................................................
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)........................................................
Stick Coil Removal/Installation..........................................................................................
Stick Coil Primary Winding Resistance Inspection ...........................................................
Stick Coil Input Voltage Inspection....................................................................................
Radiator Fan Relay (Service Code 56)...................................................................................
Radiator Fan Relay Removal/Installation..........................................................................
Radiator Fan Relay Inspection..........................................................................................
Subthrottle Valve Actuator (Service Code 62) ........................................................................
Subthrottle Valve Actuator Removal .................................................................................
Subthrottle Valve Actuator Inspection ...............................................................................
Subthrottle Valve Actuator Resistance Inspection ............................................................
Subthrottle Valve Actuator Input Voltage Inspection .........................................................
Exhaust Butterfly Valve Actuator (Service Code 63) ..............................................................
Exhaust Butterfly Valve Actuator Removal .......................................................................
Exhaust Butterfly Valve Actuator Installation ....................................................................
Exhaust Butterfly Valve Actuator Inspection .....................................................................
Exhaust Butterfly Valve Actuator Resistance Inspection ..................................................
Air Switching Valve (Service Code 64) ...................................................................................
Air Switching Valve Removal/Installation ..........................................................................
Air Switching Valve Inspection ..........................................................................................
Oxygen Sensor Heater (Service Code 67, Equipped Models) ...............................................
Oxygen Sensor Heater Removal/Installation ....................................................................
Oxygen Sensor Heater Resistance Inspection .................................................................
Oxygen Sensor Heater Power Source Voltage Inspection ...............................................
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) .................
Oxygen Sensor Removal/Installation................................................................................
Oxygen Sensor Inspection................................................................................................
Warning Indicator Light (LED) ................................................................................................
Light (LED) Inspection ......................................................................................................
ECU ........................................................................................................................................
ECU Identification .............................................................................................................
ECU Removal ...................................................................................................................
ECU Installation ................................................................................................................
3-69
3-70
3-70
3-71
3-74
3-74
3-74
3-75
3-77
3-78
3-78
3-78
3-81
3-81
3-81
3-82
3-83
3-84
3-84
3-85
3-86
3-86
3-87
3-87
3-88
3-88
3-88
3-88
3-90
3-90
3-90
3-91
3-91
3-91
3-91
3-92
3-94
3-94
3-94
3-96
3-96
3-98
3-98
3-98
3-99
3-99
3-99
3-100
3-102
3-102
3-102
3-105
3-105
3-106
3-106
3-106
3-106
FUEL SYSTEM (DFI) 3-3
ECU Power Supply Inspection..........................................................................................
DFI Power Source ..................................................................................................................
ECU Fuse Removal ..........................................................................................................
ECU Fuse Installation .......................................................................................................
ECU Fuse Inspection ........................................................................................................
ECU Main Relay Removal/Installation ..............................................................................
ECU Main Relay Inspection ..............................................................................................
Fuel Line.................................................................................................................................
Fuel Pressure Inspection ..................................................................................................
Fuel Flow Rate Inspection ................................................................................................
Fuel Pump ..............................................................................................................................
Fuel Pump Removal .........................................................................................................
Fuel Pump Installation ......................................................................................................
Fuel Pump Operation Inspection ......................................................................................
Fuel Pump Operating Voltage Inspection .........................................................................
Pressure Regulator Removal............................................................................................
Pump Screen, Fuel Filter Cleaning ...................................................................................
Fuel Pump Relay Removal/Installation .............................................................................
Fuel Pump Relay Inspection .............................................................................................
Fuel Injectors ..........................................................................................................................
Fuel Injector Removal/Installation.....................................................................................
Fuel Injector Audible Inspection........................................................................................
Fuel Injector Resistance Inspection ..................................................................................
Fuel Injector Power Source Voltage Inspection ................................................................
Fuel Injector Output Voltage Inspection ............................................................................
Fuel Injector Fuel Line Inspection .....................................................................................
Throttle Grip and Cables ........................................................................................................
Free Play Inspection .........................................................................................................
Free Play Adjustment........................................................................................................
Cable Installation ..............................................................................................................
Cable Lubrication ..............................................................................................................
Throttle Body Assy .................................................................................................................
Idle Speed Inspection/Adjustment ....................................................................................
Synchronization Inspection/Adjustment ............................................................................
Throttle Body Assy Removal.............................................................................................
Throttle Body Assy Installation..........................................................................................
Throttle Body Assy Disassembly ......................................................................................
Throttle Body Assy Assembly ...........................................................................................
Air Cleaner..............................................................................................................................
Air Cleaner Element Removal/Installation ........................................................................
Air Cleaner Element Inspection ........................................................................................
Air Cleaner Oil Draining ....................................................................................................
Air Cleaner Housing Removal...........................................................................................
Air Cleaner Housing Installation........................................................................................
Fuel Tank ................................................................................................................................
Fuel Tank Removal ...........................................................................................................
Fuel Tank Installation ........................................................................................................
Fuel Tank and Cap Inspection ..........................................................................................
Fuel Tank Cleaning ...........................................................................................................
Evaporative Emission Control System (CAL and SEA-B1 Models)........................................
Parts Removal/Installation ................................................................................................
Hose Inspection ................................................................................................................
Separator Inspection.........................................................................................................
Separator Operation Test..................................................................................................
Canister Inspection ..........................................................................................................
3-107
3-110
3-110
3-110
3-110
3-110
3-110
3-111
3-111
3-112
3-114
3-114
3-115
3-115
3-116
3-116
3-117
3-117
3-117
3-119
3-119
3-119
3-119
3-120
3-121
3-122
3-124
3-124
3-124
3-124
3-124
3-125
3-125
3-125
3-125
3-127
3-128
3-129
3-130
3-130
3-130
3-130
3-130
3-131
3-132
3-132
3-135
3-137
3-137
3-138
3-138
3-138
3-138
3-139
3-139
3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
No.
1
2
3
4
Fastener
Upper Air Cleaner Housing Screws
Throttle Body Assy Holder Clamp Bolts
Air Cleaner Duct Clamp Bolts
Delivery Pipe Assy Mounting Screws
5. Throttle Cable (Accelerator)
6. Throttle Cable (Decelerator)
7. Air Cleaner Element
8. Air Switching Valve
9. Intake Air Pressure Sensor #2
10. Intake Air Pressure Sensor #1
11. Fuel Injectors
12. other than CAL and SEA-B1 Models
CL: Apply cable lubricant.
EO: Apply engine oil
G: Apply grease.
R: Replacement Parts
N·m
1.1
2.9
2.0
3.4
Torque
kgf·m
0.11
0.30
0.20
0.35
ft·lb
9.7 in·lb
26 in·lb
18 in·lb
30 in·lb
Remarks
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
No.
Fastener
1
Oxygen Sensor (Equipped Models)
Intake Air Temperature Sensor Mounting
Screw
Water Temperature Sensor
Exhaust Butterfly Valve Actuator Pulley Bolt
Exhaust Butterfly Valve Actuator Mounting
Screws
2
3
4
5
6. Crankshaft Sensor
7. Speed Sensor
8. Intake Air Temperature Sensor
9. Stick Coils
10. Vehicle-down Sensor
11. Relay Box
12. ECU
R: Replacement Parts
N·m
44
Torque
kgf·m
4.5
ft·lb
32
1.2
0.12
11 in·lb
30
5.0
3.0
0.51
22
44 in·lb
1.2
0.12
11 in·lb
Remarks
3-8 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-9
Exploded View
No.
1
Fastener
Fuel Pump Bolts
2. Other than CAL and SEA-B1 Models
3. CAL and SEA-B1 Models
4. Separator
5. Canister
6. Blue Hose (Breather)
7. Green Hose (Purge)
8. Red Hose (Return)
9. White Hose (Vacuum)
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
9.8
Torque
Remarks
kgf·m
ft·lb
1.0
87 in·lb
L
3-10 FUEL SYSTEM (DFI)
DFI System
DFI System
FUEL SYSTEM (DFI) 3-11
DFI System
1. ECU
2. Battery 12 V 8 Ah
3. Air Switching Valve
4. Intake Air Pressure Sensor #1
5. Intake Air Pressure Sensor #2
6. Crankshaft Sensor
7. Subthrottle Valve Actuator
8. Subthrottle Sensor
9. Intake Air Temperature Sensor
10. Main Throttle Sensor
11. Water Temperature Sensor
12. Fuel Injectors
13. Delivery Pipe Assy
14. Oxygen Sensor (Equipped Models)
15. Exhaust Butterfly Valve Actuator
16. Speed Sensor
17. Fuel Pump
18. Pressure Regulator
19. Fuel Filter
20. Vehicle-down Sensor
21. Air Flow
22. Fuel Flow
3-12 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram
FUEL SYSTEM (DFI) 3-13
DFI System
Part Names
1. ECU
2. Exhaust Butterfly Valve Actuator
3. Water Temperature Sensor
4. Crankshaft Sensor
5. Intake Air Pressure Sensor #1
6. Frame Ground
7. Meter Ground
8. Intake Air Pressure Sensor #2
9. Intake Air Temperature Sensor
10. Speed Sensor
11. Oxygen Sensor
12. Main Throttle Sensor
13. Subthrottle Sensor
14. Fuel Injectors
15. Subthrottle Valve Actuator
16. Air Switching Valve
17. Stick Coils
18. Fuse Box 2
19. Fan Fuse 15 A
20. Ignition Fuse 15 A
21. Radiator Fan Motor
22. Fuel Pump/Fuel Level Sensor
23. Starter Button
24. Engine Stop Switch
25. Ignition Switch
26. Meter Unit
27. Oil Pressure/FI/Immobilizer Warning Indicator Light (LED)
28. Water-proof Joint C
29. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
30. Engine Ground
31. Battery 12 V 8 Ah
32. Main Fuse 30 A
33. FI Fuse 15 A
34. Starter Relay
35. Vehicle-down Sensor
36. Relay Box
37. Fuel Pump Relay
38. ECU Main Relay
39. Radiator Fan Relay
40. Water-proof Joint A
○Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green
G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
3-14 FUEL SYSTEM (DFI)
DFI System
Terminal Numbers of ECU Connectors
Terminal Names
1. Subthrottle Valve Actuator: LG/R
2. Exhaust Butterfly Valve Actuator (–): GY
3. Exhaust Butterfly Valve Actuator (+): G/R
4. Fuel Pump Relay: BR/Y
5. Power Supply to Sensors: BL
6. Power Supply to ECU (from ECU Main Relay): BR/W
7. Air Switching Valve: R/BL
8. Power Supply to ECU (from Battery): W/BK
9. Oxygen Sensor Heater (Equipped Models): R
10. Fuel Injector #4: BL/Y
11. Fuel Injector #3: BL/W
12. Subthrottle Valve Actuator: P/BL
13. Unused
14. Unused
15. Intake Air Temperature Sensor: Y
16. Intake Air Pressure Sensor #2: G/W
17. Intake Air Pressure Sensor #1: Y/BL
18. Radiator Fan Relay: P/BL
19. Vehicle-down Sensor: Y/G
20. Crankshaft Sensor (+): Y/BK
21. Crankshaft Sensor (–): BK
22. Speed Sensor: P
23. Subthrottle Valve Actuator: G
24. Subthrottle Valve Actuator: W/BL
25. Sidestand Switch: G/R
26. Main Throttle Sensor: BL/W
27. Subthrottle Sensor: BR
28. Exhaust Butterfly Valve Actuator Sensor: R/BK
29. Water Temperature Sensor: O
30. Ground for ECU: BK/Y
31. Warning Indicator Light (LED) (Meter Unit): W/R
32. Oxygen Sensor (Equipped Models): W/BL
33. Ground for Sensors: BR/BK
34. Fuel Injector #2: BL/O
FUEL SYSTEM (DFI) 3-15
DFI System
35. Starter Button: BK/R
36. Fuel Injector #1: BL/R
37. Engine Stop Switch: R
38. Stick Coil #4: BK/O
39. Stick Coil #3: BK/W
40. Stick Coil #1: BK
41. External Communication Line (Immobilizer System, Equipped Models/*KDS): LG/BK
42. Unused
43. Neutral Switch: LG
44. Starter Lockout Switch: R/G
45. Immobilizer Amplifier (Equipped Models): V
46. Unused
47. Stick Coil #2: R/W
48. Ground: P
49. Unused
50. External Communication Line (Immobilizer System, Equipped Models/*KDS): LB
51. Meter Unit (Tachometer): R/Y
52. Immobilizer Amplifier (Equipped Models): P/BK
53. Ground for Fuel System: BK/Y
54. Ground for Ignition System: BK/Y
*: KDS (Kawasaki Diagnostic System)
3-16 FUEL SYSTEM (DFI)
DFI Parts Location
Main Throttle Sensor [A]
Subthrottle Sensor [B]
Crankshaft Sensor [A]
Oxygen Sensor [B] (Equipped Models)
Ignition Key (Transponder, Equipped Models) [A]
Ignition Switch [B]
Immobilizer Antenna [C] (Equipped Models)
Warning Indicator Light (LED) [D]
Stick Coils [A]
Air Switching Valve [B]
Intake Air Pressure Sensor #1 [C]
Intake Air Pressure Sensor #2 [D]
Subthrottle Valve Actuator [E]
Fuel Injectors [F]
Water Temperature Sensor [A]
Speed Sensor [B]
Engine Ground [C]
FUEL SYSTEM (DFI) 3-17
DFI Parts Location
Immobilizer Amplifier [A] (Equipped Models)
Intake Air Temperature Sensor [A]
Frame Ground [B]
Exhaust Butterfly Valve Actuator [A]
Battery 12 V 8 Ah [B]
Vehicle-down Sensor [C]
FI Fuse 15 A [D]
Relay Box (ECU Main Relay, Radiator Fan Relay, Fuel
Pump Relay) [A]
ECU [B]
Immobilizer (Equipped Models)/Kawasaki Diagnostic
System Connector [C]
Fuel Pump [A]
3-18 FUEL SYSTEM (DFI)
Specifications
Item
Digital Fuel Injection System
Idle Speed
Throttle Body Assy:
Throttle Valve
Bore
Throttle Body Vacuum
Bypass Screws (Turn Out)
ECU:
Make
Type
Fuel Pressure (High Pressure Line)
Fuel Pump:
Type
Discharge
Fuel Injectors:
Type
Nozzle Type
Resistance
Main Throttle Sensor:
Input Voltage
Output Voltage
Resistance
Intake Air Pressure Sensor #1/Intake Air
Pressure Sensor #2:
Input Voltage
Output Voltage
Intake Air Temperature Sensor:
Output Voltage
Resistance
Water Temperature Sensor:
Output Voltage
Speed Sensor:
Input Voltage
Output Voltage
Vehicle-down Sensor:
Input Voltage
Output Voltage
Standard
1 100 ±50 r/min (rpm)
Dual throttle
38 mm (1.42 in.)
40.7 ±1.3 kPa (305 ±10 mmHg)
2 1/2 (for reference)
DENSO
Digital memory type, with built in IC igniter, sealed
with resin
294 kPa (3.0 kgf/cm², 43 psi) with engine idling
In-tank friction pump
50 mL (1.7 US oz.) or more for 3 seconds
INP-289
Fine atomizing type with 8 holes
About 11.7 ∼ 12.3 Ω at 20°C (68°F)
DC 4.75 ∼ 5.25 V
DC 1.02 ∼ 1.06 V at idle throttle opening
DC 4.22 ∼ 4.42 V at full throttle opening (for reference)
4 ∼ 6 kΩ
DC 4.75 ∼ 5.25 V
DC 3.80 ∼ 4.20 V at standard atmospheric pressure
(see this text for details)
About DC 2.25 ∼ 2.50 V at 20°C (68°F)
5.4 ∼ 6.6 kΩ at 0°C (32°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
About DC 2.80 ∼ 2.97 V at 20°C (68°F)
About DC 9 ∼ 11 V
Less than DC 0.6 V or Over than 4.8 V at ignition
switch ON and 0 km/h
DC 4.75 ∼ 5.25 V
With sensor tilted 60 ∼ 70° or more right or left: DC
0.65 ∼ 1.35 V
With sensor arrow mark pointed up: DC 3.55 ∼ 4.45 V
FUEL SYSTEM (DFI) 3-19
Specifications
Item
Subthrottle Sensor:
Input Voltage
Output Voltage
Resistance
Exhaust Butterfly Valve Actuator Sensor:
Input Voltage
Output Voltage
Resistance
Immobilizer Antenna (Equipped Models):
Resistance
Exhaust Butterfly Valve Actuator:
Resistance
Subthrottle Valve Actuator:
Resistance
Input Voltage
Oxygen Sensor (Equipped Models):
Output Voltage (Rich)
Output Voltage (Lean)
Heater Resistance
Throttle Grip and Cables
Throttle Grip Free Play
Air Cleaner
Element
Standard
DC 4.75 ∼ 5.25 V
DC 1.08 ∼ 1.12 V at subthrottle valve full close
position
DC 4.2 ∼ 4.4 V at subthrottle valve full open position
(for reference)
4 ∼ 6 kΩ
DC 4.75 ∼ 5.25 V
DC 3.46 ∼ 3.76 V at pulley original position
4 ∼ 6 kΩ
About 3.0 ∼ 4.6 Ω
5 ∼ 200 Ω (for reference)
About 5.2 ∼ 7.8 Ω
About DC 11.5 ∼ 13.5 V
DC 0.7 V or more
DC 0.2 V or less
11.7 ∼ 14.5 Ω at 20°C (68°F)
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Viscous paper element
3-20 FUEL SYSTEM (DFI)
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²:
57001-125
Throttle Sensor Setting Adapter #1:
57001-1400
Carburetor Drain Plug Wrench, Hex 3:
57001-1269
Peak Voltage Adapter:
57001-1415
Fork Oil Level Gauge:
57001-1290
Needle Adapter Set:
57001-1457
Vacuum Gauge:
57001-1369
Throttle Sensor Setting Adapter:
57001-1538
Hand Tester:
57001-1394
Fuel Pressure Gauge Adapter:
57001-1593
FUEL SYSTEM (DFI) 3-21
Special Tools and Sealant
Fuel Hose:
57001-1607
Measuring Adapter:
57001-1700
Liquid Gasket, TB1211:
56019-120
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.
○This DFI system is designed to be used with a 12 V sealed
battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
○Do not reverse the battery cable connections. This will
damage the ECU.
○To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is ON, or while the engine is running.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.
○Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the engine.
○Connect these connectors until they click [A].
○Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memorizes service codes.
○Do not spray water on the electrical parts, DFI parts, connectors, leads and wiring.
○If a transceiver is installed on the motorcycle, make sure
that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.
○When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
○Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.
○When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
○When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and run the fuel hoses with a
minimum of bending so that the fuel flow will not be obstructed.
○Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
○To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.
FUEL SYSTEM (DFI) 3-23
DFI Servicing Precautions
○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose
to burst. Remove the fuel tank (see Fuel Tank Removal)
and check the fuel hose [A].
Replace the fuel hose if any fraying, cracks or bulges are
noticed.
○To maintain the correct fuel/air mixture (F/A), there must
be no intake air leaks in the DFI system. Be sure to install
the oil filler plug [A] after filling the engine oil.
3-24 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
The warning indicator light (LED) [A] is used for the FI
indicator, immobilizer indicator (equipped models) and oil
pressure warning indicator.
Outline
When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] blinks to
alert the rider. In addition, the condition of the problem is
stored in the memory of the ECU. For models equipped with
an immobilizer system, the warning indicator light (LED)
and immobilizer warning symbol [C] blinks, when a problem occurs in the system.
With the engine stopped and turned in the self-diagnosis
mode, the service code [A] is displayed on the LCD (Liquid
Crystal Display) by the number of two digits.
If the problem is with the following parts, the ECU can not
recognize these problem. Therefore, the warning indicator
light (LED), FI and/or immobilizer warning symbols do not
blinks, and service code is not displayed.
LCD for Meter Unit
Fuel Pump
Fuel Pump Relay
Fuel Injectors
Stick Coil Secondary Wiring and Ground Wiring
ECU Main Relay
ECU Power Source Wiring and Ground Wiring
FUEL SYSTEM (DFI) 3-25
Troubleshooting the DFI System
When the service code [A] is displayed, for first ask the
rider about the conditions [B] of trouble, and then start to
determine the cause [C] of problem.
As a pre-diagnosis inspection, check the ECU for ground
and power supply, the fuel line for no fuel leaks, and for
correct pressure. The pre-diagnosis items are not indicated
by the warning indicator light (LED) and FI warning symbol.
Don’t rely solely on the DFI self-diagnosis function, use
common sense.
Even when the DFI system is operating normally, the
warning indicator light (LED) and FI warning symbol may
blink under strong electrical interference. Additional measures are not required. Turn the ignition switch OFF to stop
the indicator light and symbol.
If the warning indicator light (LED) and FI warning symbol
of the motorcycle brought in for repair still blinks, check the
service code.
When the repair has been done, the FI warning symbol
goes off. 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.
When the motorcycle is down, the vehicle-down sensor
operates and the ECU shuts off the fuel pump relay, fuel injectors and ignition system. The ignition switch is left ON. If
the starter button is pushed, the electric starter turns but the
engine does not start. When the starter button is pushed,
the warning indicator light (LED) and FI warning symbol
blink but the service code is not displayed. To start the
engine again, raise the motorcycle, turn the ignition switch
OFF, and then ON.
Much of the DFI system troubleshooting work consists
of confirming continuity of the wiring. The DFI parts are
assembled and adjusted with precision, and it is impossible
to disassemble or repair them.
3-26 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
checking the DFI parts, use a digital meter which
• When
can be read two decimal place voltage or resistance.
○The DFI part connectors [A] have seals [B], including the
ECU. When measuring the input or output voltage with the
connector joined, use the needle adapter set [C]. Insert
the needle adapter inside the seal until the needle adapter
reaches the terminal.
Special Tool - Needle Adapter Set: 57001-1457
NOTICE
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
sure that measuring points are correct in the con• Make
nector, noting the position of the lock [D] and the lead
•
•
color before measurement. Do not reverse connections
of a digital meter.
Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters.
Turn the ignition switch ON and measure the voltage with
the connector joined.
NOTICE
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.
○After measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B]
for waterproofing.
Sealant - Liquid Gasket, TB1211: 56019-120
check battery condition before replacing the DFI
• Always
parts. A fully charged battery is a must for conducting
•
•
•
accurate tests of the DFI system.
Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
Measure coil winding resistance when the DFI part is cold
(at room temperature).
Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, short,
etc. Deteriorated leads and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.
FUEL SYSTEM (DFI) 3-27
Troubleshooting the DFI System
each connector [A] apart and inspect it for corrosion,
• Pull
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect the connectors securely.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
•
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the main harness or the subharness.
○If both ends of a harness [A] are far apart, ground [B] the
one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness
is open, repair or replace the harness.
○When checking a harness [A] for short circuit, open one
end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or replaced.
down suspicious locations by repeating the con• Narrow
tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.
3-28 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
DFI Diagnosis Flow Chart
Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.
○Try to find out exactly what problem occurred under exactly what conditions by asking the rider;
knowing this information may help you reproduce the problem.
○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.
FUEL SYSTEM (DFI) 3-29
Troubleshooting the DFI System
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.):
Year of initial registration:
Model:
Engine No.:
Frame No.:
Date problem occurred:
Mileage:
Environment when problem occurred.
Weather
□ fine, □ cloudy, □ rain, □ snow, □ always, □ other:
Temperature □ hot, □ warm, □ cold, □ very cold, □ always, □ other:
Problem
□ chronic, □ often, □once
frequency
Road
□ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble
Altitude
□ normal, □ high (about 1 000 m or more)
Motorcycle conditions when problem occurred.
Warning
□ Starts blinking about 3 seconds after from ignition switch ON, and goes off after
indicator light
engine pressure becomes high enough (with engine running).
(LED)
□ Starts blinking about 3 seconds after from ignition switch ON, and the FI warning
symbol on the LCD starts blinking (DFI system problem).
□ Starts blinking about 3 seconds after from ignition switch ON, and the immobilizer
warning symbol on the LCD starts blinking (immobilizer system problem).
□ Starts blinking about 3 seconds after from ignition switch ON, and about
10 seconds after, the FI warning symbol on the LCD starts blinking (ECU
communication error).
□ Does not blink about 3 seconds after ignition switch ON.
□ light up (ECU or meter unit replace).
Starting
□ starter motor not rotating.
difficulty
□ starter motor rotating but engine do not turn over.
□ starter motor and engine do not turn over.
□ no fuel flow (□ no fuel in tank, □ no fuel pump sound).
□ no spark.
□ other:
Engine stalls □ right after starting.
□ when opening throttle grip.
□ when closing throttle grip.
□ when moving off.
□ when stopping the motorcycle.
□ when cruising.
□ other:
3-30 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Poor running
at low speed
Poor running
or no power at
high speed
□ very low idle speed, □ very high idle speed, □ rough idle speed.
□ battery voltage is low (charge the battery).
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ backfiring.
□ afterfiring.
□ hesitation when acceleration.
□ engine oil viscosity too high.
□ brake dragging.
□ engine overheating.
□ clutch slipping.
□ other:
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ spark plug incorrect (replace it).
□ knocking (fuel poor quality or incorrect, → use high-octane gasoline).
□ brake dragging.
□ clutch slipping.
□ engine overheating.
□ engine oil level too high.
□ engine oil viscosity too high.
□ other:
FUEL SYSTEM (DFI) 3-31
DFI System Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties in
DFI system.
○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits are checked out good, be sure to check the ECU for ground and power supply. If the
ground and power supply are checked good, replace the ECU.
Engine Won’t Turn Over
Symptoms or Possible Causes
Neutral, starter lockout or sidestand switch
trouble
Immobilizer system trouble
Vehicle-down sensor operated
Vehicle-down sensor trouble
Crankshaft sensor trouble
Stick coil shorted or not in good contact
Stick coil trouble
Spark plug dirty, broken or gap maladjusted
Spark plug incorrect
ECU ground and power supply trouble
ECU trouble
No or little fuel in tank
Fuel injector trouble
Fuel pump not operating
Fuel pump relay trouble
Fuel filter or pump screen clogged
Fuel pressure regulator trouble
Fuel line clogged
Actions (chapter)
Inspect each switch (see chapter 16).
Inspect (see chapter 3).
Turn ignition switch OFF (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 16).
Inspect or Reinstall (see chapter 16).
Inspect (see chapter 16).
Inspect and replace (see chapter 2).
Replace it with the correct plug (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Supply fuel (see Owner’s Manual).
Inspect and replace (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 16).
Inspect and replace fuel pump (see chapter 3).
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Inspect and repair (see chapter 3).
Poor Running at Low Speed
Symptoms or Possible Causes
Spark weak:
Stick coil shorted or not in good contact
Stick coil trouble
Spark plug dirty, broken or gap maladjusted
Spark plug incorrect
ECU trouble
Fuel/air mixture incorrect:
Little fuel in tank
Air cleaner clogged, poorly sealed, or missing
Air duct loose
Throttle body assy holder loose
Throttle body assy dust seal damage
Fuel injector O-ring damage
Fuel filter or pump screen clogged
Actions (chapter)
Inspect or reinstall (see chapter 16).
Inspect (see chapter 16).
Inspect and replace (see chapter 2).
Replace it with the correct plug (see chapter 2).
Inspect (see chapter 3).
Supply fuel (see Owner’s Manual).
Clean element or inspect sealing (see chapter 2).
Reinstall (see chapter 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Replace (see chapter 3).
Inspect and replace fuel pump (see chapter 3).
3-32 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Fuel pressure regulator trouble
Fuel line clogged
Intake air pressure sensor #1 trouble
Intake air pressure sensor #2 trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
Main throttle sensor trouble
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Unstable (rough) idling:
Fuel pressure too low or too high
Fuel injector trouble
Main throttle sensor trouble
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Engine vacuum not synchronizing
Intake air pressure sensor #1 trouble
Intake air pressure sensor #2 trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
Engine stalls easily:
Spark plug dirty, broken or gap maladjusted
Stick coil trouble
Main throttle sensor trouble
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Intake air pressure sensor #1 trouble
Intake air pressure sensor #2 trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
Fuel pump trouble
Fuel injector trouble
Fuel pressure too low or too high
Fuel pressure regulator trouble
Fuel line clogged
Poor acceleration:
Fuel pressure too low
Water or foreign matter in fuel
Fuel filter or pump screen clogged
Fuel pump trouble
Fuel injector trouble
Main throttle sensor trouble
Actions (chapter)
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Inspect and repair (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and adjust (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 2).
Inspect (see chapter 16).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Inspect and repair (see chapter 3).
Inspect (see chapter 3).
Change fuel. Inspect and clean fuel system (see
chapter 3).
Inspect and replace fuel pump (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-33
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Intake air pressure sensor #1 trouble
Intake air pressure sensor #2 trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
Spark plug dirty, broken or gap maladjusted
Stick coil trouble
Stumble:
Fuel pressure too low
Fuel injector trouble
Main throttle sensor trouble
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Intake air pressure sensor #1 trouble
Intake air pressure sensor #2 trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
Surge:
Unstable fuel pressure
Fuel injector trouble
Water temperature sensor trouble
Backfiring when deceleration:
Spark plug dirty, broken or gap maladjusted
Fuel pressure too low
Fuel pump trouble
Main throttle sensor trouble
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Intake air pressure sensor #1 trouble
Intake air pressure sensor #2 trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
Air switching valve trouble
Air suction valve trouble
After fire:
Spark plug burned or gap maladjusted
Fuel injector trouble
Intake air pressure sensor #1 trouble
Intake air pressure sensor #2 trouble
Water temperature sensor trouble
Intake air temperature sensor trouble
Actions (chapter)
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 2).
Inspect (see chapter 16).
Inspect
Inspect
Inspect
Inspect
Inspect
Inspect
Inspect
Inspect
Inspect
(see
(see
(see
(see
(see
(see
(see
(see
(see
chapter
chapter
chapter
chapter
chapter
chapter
chapter
chapter
chapter
3).
3).
3).
3).
3).
3).
3).
3).
3).
Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and replace fuel pump) (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 16).
Inspect and replace (see chapter 5).
Replace (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
3-34 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Other:
Intermittent any DFI fault and its recovery
Actions (chapter)
Check that DFI connectors are clean and tight,
and examine leads for signs of burning or fraying
(see chapter 3).
Poor Running or No Power at High Speed
Symptoms or Possible Causes
Firing incorrect:
Stick coil shorted or not in good contact
Stick coil trouble
Spark plug dirty, broken or gap maladjusted
Spark plug incorrect
ECU trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Air duct loose
Throttle body assy holder loose
Throttle body assy dust seal damage
Water or foreign matter in fuel
Actions (chapter)
Inspect or Reinstall (see chapter 16).
Inspect (see chapter 16).
Inspect and replace (see chapter 2).
Replace it with the correct plug (see chapter 2).
Inspect (see chapter 3).
Clean element or inspect sealing (see chapter 2).
Reinstall (see chapter 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel injector O-ring damage
Replace (see chapter 3).
Fuel injector clogged
Inspect and repair (see chapter 3).
Fuel line clogged
Inspect and repair (see chapter 3).
Fuel pump operates intermittently and often DFI Fuel pump bearings may wear. Replace the fuel
fuse blows.
pump (see chapter 3).
Fuel pump trouble
Inspect (see chapter 3).
Intake air pressure sensor #1 trouble
Inspect (see chapter 3).
Intake air pressure sensor #2 trouble
Inspect (see chapter 3).
Cracked or obstructed intake air pressure sensor Inspect and repair or replace (see chapter 3).
hose
Water temperature sensor trouble
Inspect (see chapter 3).
Intake air temperature sensor trouble
Inspect (see chapter 3).
Main throttle sensor trouble
Inspect (see chapter 3).
Subthrottle sensor trouble
Inspect (see chapter 3).
Subthrottle valve actuator trouble
Inspect (see chapter 3).
Knocking:
Fuel poor quality or incorrect
Fuel change (Use the gasoline recommended in
the Owner’s Manual).
Spark plug incorrect
Replace it with the correct plug (see chapter 2).
Stick coil trouble
Inspect (see chapter 16).
ECU trouble
Inspect (see chapter 3).
Engine vacuum not synchronizing
Inspect and adjust (see chapter 2).
Intake air pressure sensor #1 trouble
Inspect (see chapter 3).
Intake air pressure sensor #2 trouble
Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-35
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Intake air temperature sensor trouble
Miscellaneous:
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Speed sensor trouble
Throttle valves will not fully open
Actions (chapter)
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect throttle cables and lever linkage (see
chapter 3).
Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in
crankshaft sensor or speed sensor trouble
chapter 17)
Air switching valve trouble
Inspect and replace (see chapter 16).
Air suction valve trouble
Inspect and replace (see chapter 5).
Exhaust Smokes Excessively:
(Black smoke)
Air cleaner element clogged
Clean element (see chapter 2).
Fuel pressure too high
Inspect (see chapter 3).
Fuel injector trouble
Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).
Intake air temperature sensor trouble
Inspect (see chapter 3).
(Brown smoke)
Air duct loose
Reinstall (see chapter 3).
Fuel pressure too low
Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).
Intake air temperature sensor trouble
Inspect (see chapter 3).
3-36 FUEL SYSTEM (DFI)
Self-Diagnosis
The warning indicator light (LED) [A] is used for the FI
indicator, immobilizer indicator (equipped models) and oil
pressure warning indicator.
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, ignition system and immobilizer system by blinking the warning
indicator light (LED) [A], FI warning symbol [B] and immobilizer warning symbol [C] when DFI, ignition and immobilizer
system parts are faulty, and initiates fail-safe function. In
case of serious troubles ECU stops the injection and ignition operations.
FUEL SYSTEM (DFI) 3-37
Self-Diagnosis
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.
Self-diagnosis Procedures
○When a problem occurs with the DFI system and ignition
system, the warning indicator light (LED) [A] and FI warning symbol [B] blink.
○For models equipped with an immobilizer system, when
a problem occurs with the system, the warning indicator
light (LED) and immobilizer warning symbol [C] blink.
○Use
NOTE
a fully charged battery when conducting
self-diagnosis. Otherwise, the light (LED) and symbol
blink very slowly or do not blink.
3-38 FUEL SYSTEM (DFI)
Self-Diagnosis
the ignition switch ON.
• Turn
Push
• the MODE button [A] to display the odometer.
the MODE button [A] for more than two seconds.
• Push
The
service
code [B] is displayed on the LCD by the num• ber of two digits.
of the following procedures ends self-diagnosis.
•○Any
When the service code is displayed on the LCD, push the
left button for more than two seconds.
○When the ignition switch is turned OFF.
FUEL SYSTEM (DFI) 3-39
Self-Diagnosis
Self-Diagnosis Flow Chart
3-40 FUEL SYSTEM (DFI)
Self-Diagnosis
Service Code Reading
○The service code(s) is displayed on the LCD by the number of two digits.
○When there are a number of problems, all the service codes can be stored and the display will begin
starting from the lowest number service code in the numerical order.
○Then after completing all codes, the display is repeated until the ignition switch is turned OFF or
MODE button is pushed for more than two seconds.
○For example, if three problems occurred in the order of 56, 15, 35, the service codes are
displayed (each two seconds) from the lowest number in the order listed as shown below.
(15→35→56)→(15→35→56)→· · ·(repeated)
○If there is no problem or when the repair has been done, FI and/or immobilizer symbols go off and
service code is not displayed.
FUEL SYSTEM (DFI) 3-41
Self-Diagnosis
Service Code Erasing
○When repair has been done, FI and/or immobilizer warning symbols go off and service code is not
displayed.
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.
Service Code Table
Service Code
11
12
13
14
16
21
24
and
25
31
32
33
34
35
36
39
51
52
53
54
56
62
63
64
67
94
Problems
Main throttle sensor malfunction, wiring open or short
Intake air pressure sensor #1 malfunction, wiring open or short
Intake air temperature sensor malfunction, wiring open or short
Water temperature sensor malfunction, wiring open or short
Intake air pressure sensor #2 malfunction, wiring open or short
Crankshaft sensor malfunction, wiring open or short
Speed sensor malfunction, wiring open or short
First 24 is displayed and then 25, repeatedly
Vehicle-down sensor malfunction, wiring open or short
Subthrottle sensor malfunction, wiring open or short
Oxygen sensor inactivation, wiring open or short (Equipped Models)
Exhaust butterfly valve actuator sensor malfunction, wiring open or short
Immobilizer amplifier malfunction (Equipped Models)
Blank Key detection (Equipped Models)
ECU communication error
Stick coil #1 malfunction, wiring open or short
Stick coil #2 malfunction, wiring open or short
Stick coil #3 malfunction, wiring open or short
Stick coil #4 malfunction, wiring open or short
Radiator fan relay malfunction, wiring open or short
Subthrottle valve actuator malfunction, wiring open or short
Exhaust butterfly valve actuator malfunction, wiring open or short
Air switching valve malfunction, wiring open or short
Oxygen sensor heater malfunction, wiring open or short (Equipped Models)
Oxygen sensor malfunction, wiring open or short (Equipped Models)
Notes:
○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to check the ECU for ground and power supply. If the ground and power supply are checked good,
replace the ECU.
○When no service code is displayed, the electrical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.
3-42 FUEL SYSTEM (DFI)
Self-Diagnosis
Backups
○The ECU takes the following measures to prevent engine damage when the DFI, ignition or immobilizer system parts have troubles.
Service
Codes
11
12
Parts
Output Signal Usable
Range or Criteria
Main Throttle Output Voltage
0.2 ∼ 4.8 V
Sensor
Intake Air
Pressure
Sensor #1
Intake Air Pressure
(Absolute)
Pv = 100 ∼ 900 mmHg
13
Intake Air
Intake Air Temperature
Temperature
Ta = – 47 ∼ + 178°C
Sensor
14
Water
Water Temperature
Temperature
Tw = – 30 ∼ + 120°C
Sensor
16
Intake Air
Pressure
Sensor #2
21
Crankshaft
Sensor
24
and
25
Speed
Sensor
Atmospheric Pressure
(Absolute)
Pa = 100 ∼ 900 mmHg
Crankshaft sensor must
send 22 signals to the ECU
at the 1 cranking.
Speed sensor must send
23 signals to the ECU at
the one rotation of the drive
shaft.
The gear position is
decided by the signal of the
speed sensor.
31
Vehicle
-down
Sensor
Output Voltage
0.10 ∼ 4.84 V
32
Subthrottle
Sensor
Output Voltage
0.15 ∼ 4.85 V
33
Oxygen
Sensor
(Equipped
Models)
The oxygen sensor is
active and sensor must
send signals (output
voltage) continuously to
the ECU.
Backups by ECU
If the main throttle sensor system fails (the
output voltage is out of the usable range,
wiring short or open), the ECU locks ignition
timing into the ignition timing at closed throttle
position and sets the DFI in the D-J method (1).
If the intake air pressure sensor #1 system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets the DFI
in the α-N method (2).
If the intake air temperature sensor system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets Ta at 40°C.
If the water temperature sensor system fails
(the signal is out of the usable range, wiring
short or open), the ECU sets Tw at 80°C and
radiator fan operates.
If the intake air pressure sensor #2 system
fails (the signal is out of the usable range,
wiring short or open), the ECU sets Pa at 760
mmHg (the standard atmospheric pressure).
If the crankshaft sensor generates less than
22 or more signals, the engine stops by itself.
If the speed sensor system fails (no signal,
wiring short or open), the speedometer shows
0.
If the vehicle-down sensor system has failures
(the output voltage is out of the usable range,
wiring short or open), the ECU shuts off the
fuel pump relay, the fuel injectors and the
ignition system.
If the subthrottle sensor system fails (the
output voltage is out of the usable range, wiring
short or open), the ECU drive the subthrottle
valve to the full closed position, and it stops
the current to the subthrottle valve actuator.
If the oxygen sensor is not activated, the ECU
stops the feedback mode of the oxygen sensor.
FUEL SYSTEM (DFI) 3-43
Self-Diagnosis
Service
Codes
Parts
34
Exhaust
Butterfly
Valve
Actuator
Sensor
35
36
39
51
52
53
54
56
62
63
64
Output Signal Usable
Range or Criteria
Output Voltage
0.1 ∼ 4.8 V
Immobilizer
Amplifier
–
(Equipped
Models)
Ignition Key
The ignition key must use
(Equipped
register key.
Models)
The ECU send the data
(for service code and key
ECU
registration) to the meter
unit.
The stick coil primary
winding must send
Stick Coil #1*
signals (output voltage)
continuously to the ECU.
The stick coil primary
winding must send
Stick Coil #2*
signals (output voltage)
continuously to the ECU.
The stick coil primary
winding must send
Stick Coil #3*
signals (output voltage)
continuously to the ECU.
The stick coil primary
winding must send
Stick Coil #4*
signals (output voltage)
continuously to the ECU.
When the relay OFF
Radiator Fan
condition, the fan relay is
Relay
open.
The actuator operates
Subthrottle
open and close of the
Valve
subthrottle valve by the
Actuator
pulse signal from the ECU.
The actuator operates
Exhaust
open and close of the
Butterfly
exhaust butterfly valve by
Valve
the pulse signal from the
Actuator
ECU.
The air switching valve
controls the flow of the
Air Switching
secondary air by opening
Valve
and shutting the solenoid
valve.
Backups by ECU
If the exhaust butterfly valve sensor system
fails (the output voltage is out of the usable
range, wiring short or open), the ECU locks
the exhaust butterfly valve at full open position
near, and it stops the current to the exhaust
butterfly valve actuator.
If the immobilizer system fails (no signal, wiring
short or open), the vehicle is no start and run.
If the blank key or broken key is used, the
vehicle is no start and run.
–
If the stick coil #1 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #1 to stop fuel to the
cylinder #1, though the engine keeps running.
If the stick coil #2 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #2 to stop fuel to the
cylinder #2, though the engine keeps running.
If the stick coil #3 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #3 to stop fuel to the
cylinder #3, though the engine keeps running.
If the stick coil #4 primary winding has failures
(no signal, wiring short or open), the ECU
shuts off the injector #4 to stop fuel to the
cylinder #4, though the engine keeps running.
–
If the subthrottle valve actuator fails (the
signal is out to the usable range, wiring short
or open), the ECU stops the current to the
actuator.
If the exhaust butterfly valve actuator fails (the
signal is out to the usable range, wiring short
or open), the ECU stops the current to the
actuator.
–
3-44 FUEL SYSTEM (DFI)
Self-Diagnosis
Service
Codes
67
94
Parts
Oxygen
Sensor
Heater
(Equipped
Models)
Oxygen
Sensor
(Equipped
Models)
Output Signal Usable
Range or Criteria
Backups by ECU
The oxygen sensor heater
raise temperature of
the sensor for its earlier
activation.
If the oxygen sensor heater fails (wiring short
or open), the ECU stops the current to the
heater, and it stops the feedback mode of the
oxygen sensor.
The oxygen sensor must
send signals (output
voltage) continuously to
the ECU
If the oxygen sensor output voltage is incorrect,
the ECU stops the feedback mode of the
oxygen sensor.
Note:
(1) D-J 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 (intake air pressure sensor output voltage) and engine speed (crankshaft sensor
output voltage). This method is called D-J method.
(2) α-N Method: As the engine speed increases, and the engine load turns middle to heavy, the
ECU determines the injection quantity by calculating from the throttle opening (main throttle sensor
output voltage) and the engine speed. This method is called α-N method.
*: This depends on the number of stopped cylinders.
FUEL SYSTEM (DFI) 3-45
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 injection 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
NOTICE
Do not remove or adjust the main throttle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the main throttle sensor can damage it.
Main Throttle Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the right lower fairing (see Lower Fairing Re• moval in the
Frame chapter).
the main throttle sensor connector and con• Disconnect
nect the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
• Connect a digital meter to the harness adapter leads.
Main Throttle Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Main Throttle Sensor Output Voltage Inspection).
3-46 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
BL lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Main Throttle Sensor Output Voltage Inspection
the output voltage at the main throttle sensor in
• Measure
the same way as input voltage inspection, note the following.
○Disconnect the main throttle sensor connector and connect the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
Main Throttle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL/W) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the engine and warm it up thoroughly.
• Start
Check
idle speed to ensure the throttle opening is correct.
•
Idle Speed
Standard:
1 100 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it
(see Idle Speed Inspection in the Periodic Maintenance
chapter).
FUEL SYSTEM (DFI) 3-47
Main Throttle Sensor (Service Code 11)
the ignition switch OFF.
• Turn
Measure
the output voltage with the engine stopped and
• with the connector
joined.
Turn
the
ignition
switch
ON.
•
Output Voltage
Standard: DC 1.02 ∼ 1.06 V at idle throttle opening
DC 4.22 ∼ 4.42 V at full throttle opening (for
reference)
○Open
NOTE
the throttle, confirm the output voltage will be
raise.
○The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.02 × 4.75 ÷ 5.00 = 0.969 V
1.06 × 4.75 ÷ 5.00 = 1.007 V
Thus, the valid range is 0.969 ∼ 1.007 V
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the main throttle sensor resistance (see Main Throttle Sensor Resistance Inspection).
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness side
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
BL/W lead (ECU terminal 26) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-48 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Resistance Inspection
the ignition switch OFF.
• Turn
the main throttle sensor connector.
•○Disconnect
Disconnect the main throttle sensor connector and connect the harness adapter [A] to the sensor connector only.
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
Main Throttle Sensor Resistance
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
Standard:
4 ∼ 6 kΩ
If the reading is out of the standard, replace the throttle
body assy.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Main Throttle Sensor Circuit
1. ECU
2. Main Throttle Sensor
FUEL SYSTEM (DFI) 3-49
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Removal
NOTICE
Never drop the intake air pressure sensor #1 especially on a hard surface. Such a shock to the sensor
can damage it.
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Intake Air Pressure Sensor #1 Connector [A]
the intake air pressure sensor #1 [A] from the
• Remove
rubber damper [B] in the bracket and separate the vacuum hose [C].
Intake Air Pressure Sensor #1 Installation
NOTE
○The intake air pressure sensor #1 is the same part as
the intake air pressure sensor #2.
is the reverse of removal.
•○Installation
Position the intake air pressure sensor #1 [A] between the
projections [B] on the rubber damper.
3-50 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
• Removal).the air cleaner housing (see Air Cleaner Housing
the intake air pressure sensor #1 connector
• Disconnect
and connect the harness adapter [A] between these connectors.
[B] Main Harness
[C] Intake Air Pressure Sensor #1
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Intake Air Pressure Sensor #1 Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the intake voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Intake Air Pressure Sensor #1 Output Voltage
Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #1 Connector [B]
BL lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-51
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Output Voltage
Inspection
the output voltage at the intake air pressure sen• Measure
sor #1 in the same way as input voltage inspection, note
the following.
○Disconnect the intake air pressure sensor #1 connector
and connect the harness adapter [A] between these connectors.
[B] Main Harness
[C] Intake Air Pressure Sensor #1
[D] Digital Meter
Special Tool - Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #1 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor Y/BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Usable Range:
DC 3.80 ∼ 4.20 V at standard
atmospheric pressure (101.32 kPa,
76 cmHg)
NOTE
○The output voltage changes according to local atmospheric pressure.
the ignition switch OFF.
• Turn
If the reading is out of the usable range, replace the sensor.
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connector.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #1 Connector [B]
Y/BL lead (ECU terminal 17) [C]
BR/BK lead (ECU terminal 33) [D]
3-52 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12)
If the wiring is good, check the sensor for various vacuum.
Remove the intake air pressure sensor #1 [A] and disconnect the vacuum hose from the sensor.
Connect an auxiliary hose [B] to the intake air pressure
sensor #1.
Temporarily install the intake air pressure sensor #1.
○Connect a digital meter [C], vacuum gauge [D], the fork
oil level gauge [E] and the harness adapter to the intake
air pressure sensor #1.
•
•
•
Special Tools - Fork Oil Level Gauge: 57001-1290
Vacuum Gauge: 57001-1369
Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #1 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor Y/BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
○Turn the ignition switch ON.
○Measure the intake air pressure sensor #1 output voltage
from various vacuum readings, while pulling the handle of
the fork oil level gauge.
○Check the intake air pressure sensor #1 output voltage,
using the following formula and chart.
Suppose:
Pg: Vacuum Pressure (Gauge) of Throttle Body
Pl: Local Atmospheric Pressure (Absolute) measured by
a barometer
Pv: Vacuum Pressure (Absolute) of Throttle Body
Vv: Sensor Output Voltage (V)
then
Pv = Pl – Pg
For example, suppose the following data is obtained:
Pg = 8 cmHg (Vacuum Gauge Reading)
Pl = 70 cmHg (Barometer Reading)
Vv = 3.2 V (Digital Meter Reading)
then
Pv = 70 – 8 = 62 cmHg (Absolute)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.
Usable range = 3.08 ∼ 3.48 V
Plot Vv (3.2 V) on the vertical line. → Point [3].
Results: In the chart, Vv is within the usable range and
the sensor is normal.
If the reading is out of the usable range, replace the sensor.
If the reading is within the usable range, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-53
Intake Air Pressure Sensor #1 (Service Code 12)
ID: Idling
Ps: Standard Atmospheric Pressure (Absolute)
Pv: Throttle Vacuum Pressure (Absolute)
ST: Standard of Sensor Output Voltage (V)
TO: Throttle Full Open
UR: Usable Range of Sensor Output Voltage (V)
Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
3-54 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Circuit
1. ECU
2. Intake Air Pressure Sensor #1
FUEL SYSTEM (DFI) 3-55
Intake Air Temperature Sensor (Service Code 13)
Intake Air Temperature Sensor Removal/Installation
NOTICE
Never drop the intake air temperature sensor especially on a hard surface. Such a shock to the sensor
can damage it.
the fuel tank (see Fuel Tank Removal).
• Remove
Disconnect
• ature sensorthe[B].connector [A] from the intake air temper• Remove:
Screw [C]
Intake Air Temperature Sensor
sure to install the O-ring [A].
• Be
Install
• Tighten:the intake air temperature sensor.
•
Torque - Intake Air Temperature Sensor Mounting Screw:
1.2 N·m (0.12 kgf·m, 11 in·lb)
Intake Air Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
fuel tank (see Fuel Tank Removal).
• Disconnectthethe
air temperature sensor connector
• and connect theintake
harness adapter [A] between these connectors as shown.
Main Harness [B]
Intake Air Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Intake Air Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor Y) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the output voltage with the engine stopped and
• Measure
the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 2.25 ∼ 2.50 V at 20°C (68°F)
NOTE
○The output voltage changes according to the intake air
temperature.
3-56 FUEL SYSTEM (DFI)
Intake Air Temperature Sensor (Service Code 13)
the ignition switch OFF.
• Turn
If the reading is within the standard, check the ECU for
its ground, and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Intake Air Temperature Sensor Connector [B]
Y lead (ECU terminal 15) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the intake air temperature sensor resistance (see Intake Air Temperature Sensor Resistance Inspection).
Intake Air Temperature Sensor Resistance
Inspection
the intake air temperature sensor (see Intake Air
• Remove
Temperature Sensor Removal/Installation).
the sensor [A] in a container of machine oil so
• Suspend
that the heat-sensitive portion is submerged.
a thermometer [B] with the heat-sensitive por• Suspend
tion [C] located in almost the same depth with the sensor.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradually
• Place
raise the temperature of the oil while stirring the oil gently
•
for even temperature.
Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the following.
Intake Air Temperature Sensor Resistance
Standard: 5.4 ∼ 6.6 kΩ at 0°C (32°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-57
Intake Air Temperature Sensor (Service Code 13)
Intake Air Temperature Sensor Circuit
1. ECU
2. Intake Air Temperature Sensor
3-58 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
NOTICE
Never drop the water temperature sensor especially
on a hard surface. Such a shock to the sensor can
damage it.
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
•
Frame chapter)
Connector [A]
Water Temperature Sensor [B]
Replace the gasket with a new one, and tighten the water
temperature sensor.
Torque - Water Temperature Sensor: 30 N·m (3.0 kgf·m, 22
ft·lb)
the engine with coolant and bleed the air from the cool• Fill
ing system (see Coolant Change in the Periodic Maintenance chapter).
FUEL SYSTEM (DFI) 3-59
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the left lower fairing (see Lower Fairing Removal
• in the Frame
chapter)
Disconnect
the
water temperature sensor connector and
• connect the harness
adapter [A] between these connectors as shown.
Sub Harness [B]
Water Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Water Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor W/R) lead
Digital Meter (–) → BK (sensor W/BL) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 2.80 ∼ 2.97 V at 20°C (68°F)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.
the ignition switch OFF.
• Turn
If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main and sub
harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Sub Harness Connector [B]
O lead (ECU terminal 29) [C]
BR/BK lead (ECU terminal 33) [D]
3-60 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14)
Sub Harness Connector [A] ←→
Sub Harness Connector [B]
W/R lead [C]
W/BL lead [D]
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).
Water Temperature Sensor Resistance Inspection
to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Water Temperature Sensor Circuit
1. ECU
2. Water Temperature Sensor
3. To Meter Unit
FUEL SYSTEM (DFI) 3-61
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Removal
NOTICE
Never drop the intake air pressure sensor #2 especially on a hard surface. Such a shock to the sensor
can damage it.
the air cleaner housing (see Air Cleaner Housing
• Remove
Removal).
• Disconnect the sensor connector [A].
the intake air pressure sensor #2 [A] from the
• Remove
rubber damper [B] in the bracket and separate the vacuum hose [C].
Intake Air Pressure Sensor #2 Installation
NOTE
○The intake air pressure sensor #2 is the same part as
the intake air pressure sensor #1.
is the reverse of removal.
•○Installation
Position the intake air pressure sensor #2 [A] between the
projection [B] on the rubber damper.
3-62 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
• Removal).the air cleaner housing (see Air Cleaner Housing
the intake air pressure sensor #2 connector
• Disconnect
and connect the harness adapter [A] between these connectors.
[B] Main Harness
[C] Intake Air Pressure Sensor #2
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Intake Air Pressure Sensor #2 Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Intake Air Pressure Sensor #2 Output Voltage
Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #2 Connector [B]
BL lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-63
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Output Voltage
Inspection
the output voltage at the intake air pressure sen• Measure
sor #2 in the same way as input voltage inspection, note
the following.
○Disconnect the intake air pressure sensor #2 connector
and connect the harness adapter [A] between these connectors.
[B] Main Harness
[C] Intake Air Pressure Sensor #2
[D] Digital Meter
Special Tool - Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #2 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor G/W) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Usable Range: DC 3.80 ∼ 4.20 V at standard
atmospheric pressure (101.32 kPa, 76
cmHg absolute)
NOTE
○The output voltage changes according to the local atmospheric pressure.
the ignition switch OFF.
• Turn
If the reading is out of the usable range, replace the sensor.
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connector.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #2 Connector [B]
G/W lead (ECU terminal 16) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the sensor for various vacuum (see Intake Air Pressure Sensor #1 Output Voltage
Inspection).
3-64 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Circuit
1. ECU
2. Intake Air Pressure Sensor #2
FUEL SYSTEM (DFI) 3-65
Crankshaft Sensor (Service Code 21)
The crankshaft sensor has no power source, and when
the engine stops, the crankshaft sensor generates no signals.
Crankshaft Sensor Removal/Installation
to the Crankshaft Sensor Removal/Installation in
• Refer
the Electrical System chapter.
Crankshaft Sensor Resistance Inspection
to the Crankshaft Sensor Inspection in the Electrical
• Refer
System chapter.
If the reading is within the standard, check the peak voltage (see Crankshaft Sensor Peak Voltage Inspection).
Crankshaft Sensor Peak Voltage Inspection
to the Crankshaft Sensor Peak Voltage Inspection
• Refer
in the Electrical System chapter.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Crankshaft Sensor Connector [B]
Y/BK lead (ECU terminal 20) [C]
BK lead (ECU terminal 21) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Crankshaft Sensor Circuit
1. ECU
2. Crankshaft Sensor
3-66 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24, 25)
Speed Sensor Removal/Installation
to the Speed Sensor Removal/Installation in the
• Refer
Electrical System chapter.
Speed Sensor Inspection
to the Speed Sensor Inspection in the Electrical
• Refer
System chapter.
Speed Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
tank (see Fuel Tank Removal).
• Disconnectthethefuelspeed
sensor connector and connect the
• harness adapter [A] between
these connectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
• Connect a digital meter to the harness adapter leads.
Speed Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → BL (sensor P) lead
Digital Meter (–) → BK/BL (sensor BK) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: About DC 9 ∼ 11 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Speed Sensor Output Voltage Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Speed Sensor Connector [B]
BL lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-67
Speed Sensor (Service Code 24, 25)
Speed Sensor Output Voltage Inspection
the stand, raise the rear wheel off the ground.
• Using
the output voltage at the speed sensor in the
• Measure
same way as input voltage inspection, note the following.
○Disconnect the speed sensor connector and connect the
harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
Speed Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → Y/W (sensor Y) lead
Digital Meter (–) → BK/BL (sensor BK) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: Less than DC 0.6 V or over than 4.8 V at
ignition switch ON and 0 km/h
NOTE
○Rotate the rear wheel by hand, confirm the output voltage will be raise or lower.
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the speed sensor (see Speed Sensor Inspection in the Electrical System
chapter).
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Speed Sensor Connector [B]
P lead (ECU terminal 22) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-68 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24, 25)
Speed Sensor Circuit
1. ECU
2. Speed Sensor
3. Meter Unit
4. Meter Ground
FUEL SYSTEM (DFI) 3-69
Vehicle-down Sensor (Service Code 31)
This sensor has a weight [A] with two magnets inside,
and sends a signal to the ECU. But when the motorcycle
banks 60 ∼ 70° or more to either side (in fact falls down),
the weight turns and the signal changes. The ECU senses
this change, and stops the fuel pump relay, the fuel injectors
and the ignition system.
Hall IC [B]
When the motorcycle is down, the ignition switch is left
ON. If the starter button is pushed, the electric starter turns
but the engine does not start. To start the engine again,
raise the motorcycle, turn the ignition switch OFF, and then
ON.
Vehicle-down Sensor [A]
Ground Terminal BR/BK [B]
Output Terminal Y/G [C]
Power Source Terminal BL [D]
Vehicle-down Sensor Removal
NOTICE
Never drop the vehicle-down sensor especially on
a hard surface. Such a shock to the sensor can
damage it.
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Fuel Tank (See Fuel Tank Removal)
Bolts [A]
Fuel Tank Bracket [B]
• Remove:
Connector [A]
Bolts [B] and Bracket [C]
Vehicle-down Sensor [D]
3-70 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Installation
sure to install the rubber dampers [A] and collars [B]
• Be
on the battery case.
• The UP mark [A] of the sensor should face upward.
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situations for an accident resulting in injury or death.
Ensure that the vehicle-down sensor is held in
place by the battery case.
Vehicle-down Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Disconnect
the vehicle-down sensor connector and con• nect the harness
adapter [A] between these connectors
as shown.
Main Harness [B]
Vehicle-down Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Vehicle-down Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Vehicle-down Sensor Output Voltage Inspection).
FUEL SYSTEM (DFI) 3-71
Vehicle-down Sensor (Service Code 31)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connections.
Wiring Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
BL lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Vehicle-down Sensor Output Voltage Inspection
the vehicle-down sensor (see Vehicle-down
• Remove
Sensor Removal).
the harness adapter [A] to the vehicle-down sen• Connect
sor connectors as shown.
Special Tool - Measuring Adapter: 57001-1700
•
Main Harness [B]
Vehicle-down Sensor [C]
Connect a digital meter [D] to the harness adapter leads.
Vehicle-down Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor Y/G) lead
Digital Meter (–) → BK (sensor BR/BK) lead
3-72 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
the sensor vertically.
• Hold
Measure
the output voltage with the engine stopped and
• with the connector
joined.
Turn
the
ignition
switch
• Tilt the sensor 60 ∼ 70° orON.more [A] right or left, then hold
• the sensor almost vertical with the arrow mark pointed up
[B], and measure the output voltage.
Output Voltage
Standard: With sensor tilted 60 ∼ 70° or more right or
left: DC 0.65 ∼ 1.35 V
With sensor arrow mark pointed up: DC
3.55 ∼ 4.45 V
NOTE
○If you need to test again, turn the ignition switch OFF,
and then ON.
the ignition switch OFF.
• Turn
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
Y/G lead (ECU terminal 19) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-73
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Circuit
1. ECU
2. Vehicle-down Sensor
3-74 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 injection quantity, and ignition timing according to engine rpm,
and throttle opening.
Input Terminal [A]
Output Terminal [B]
Ground Terminal [C]
Subthrottle Sensor Removal/Adjustment
NOTICE
Do not remove or adjust the subthrottle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the subthrottle sensor can damage it.
Subthrottle Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the right lower fairing (see Lower Fairing Re• moval in the
Frame chapter).
the subthrottle sensor and connect the har• Disconnect
ness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
• Connect a digital meter to the harness adapter leads.
Subthrottle Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Subthrottle Sensor Output Voltage Inspection).
FUEL SYSTEM (DFI) 3-75
Subthrottle Sensor (Service Code 32)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Subthrottle Sensor Connector [B]
BL lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Subthrottle Sensor Output Voltage Inspection
the output voltage at the subthrottle sensor in
• Measure
the same way as input voltage inspection, note the following.
○Disconnect the subthrottle sensor connector and connect
the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
Subthrottle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BR) lead
Digital Meter (–) → BK (sensor BR/BK) lead
the air cleaner housing (see Air Cleaner Housing
• Remove
Removal).
the subthrottle valve actuator harness con• Disconnect
nector [A].
3-76 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32)
the output voltage with the engine stopped with
• Measure
the connector joined.
the left lower side fairing (see Left Lower Side
• Remove
Fairing Removal in the Frame chapter).
the ignition switch ON.
• Turn
Measure
output voltage when the subthrottle valve is
• completelytheclosed
by turning the lever [A] fully clockwise
[B].
Output Voltage
Standard: DC 1.08 ∼ 1.12 V at subthrottle valve full
close position
DC 4.2 ∼ 4.4 V at subthrottle valve full open
position (for reference)
NOTE
○Turn the lever counterclockwise, confirm the output voltage will be raise.
○The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.08 × 4.75 ÷ 5.00 = 1.03 V
1.12 × 4.75 ÷ 5.00 = 1.06 V
Thus, the valid range is 1.03 ∼ 1.06 V
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the subthrottle sensor resistance (see Subthrottle Sensor Resistance
Inspection).
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Subthrottle Sensor Connector [B]
BR lead (ECU terminal 27) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-77
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Resistance Inspection
the ignition switch OFF.
• Turn
the subthrottle sensor connector.
•○Disconnect
Disconnect the subthrottle sensor connector and connect
the harness adapter [A] to the sensor connector only.
Special Tool - Throttle Sensor Setting Adapter:
-1538
57001
Subthrottle Sensor Output Resistance
Connections to Adapter:
Digital Meter (+) → W (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
Standard:
4 ∼ 6 kΩ
If the reading is out of the standard, replace the throttle
body assy.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Subthrottle Sensor Circuit
1. ECU
2. Subthrottle Sensor
3-78 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
Oxygen Sensor Removal/Installation
to the Oxygen Sensor Removal/Installation in the
• Refer
Electrical System chapter.
Oxygen Sensor Inspection
up the engine thoroughly until the radiator fan
• Warm
starts.
the ignition switch OFF.
• Turn
Remove
right fairing (see Lower Fairing Removal in
• the Framethechapter).
the clamp [A], and pull out the oxygen sensor lead
• Open
connector [B].
the oxygen sensor lead connector (4 pins
• Disconnect
connector) and connect the harness adapter [A] between
these connectors.
[B] Main Harness
[C] Oxygen Sensor
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (−) → BK (sensor W) lead
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
the stick coil connectors [A].
• Disconnect
Separate
the
air switching valve hoses [B] from the air
• suction valve covers.
○Do not disconnect the air switching valve connector [C].
FUEL SYSTEM (DFI) 3-79
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
the suitable plugs [A] on the fitting of the air suction
• Install
valve covers, and shut off the secondary air.
the stick coil connectors.
• Connect
Install
the
air cleaner housing temporarily (see Air Cleaner
• Housing Installation).
the fuel hose (see Fuel Hose Replacement in the
• Remove
Periodic Maintenance chapter).
the following parts temporary.
• Connect
Fuel Pump Lead Connector [A]
Fuel Hose [B]
Special Tool - Fuel Hose: 57001-1607
the engine, and let it idle.
• Start
Measure
the output voltage with the connector joined.
•
Output Voltage (with Plugs)
Standard: DC 0.7 V or more
remove the air cleaner housing to take out the plugs
• Next,
from the fittings [A] of the air suction valve covers.
the air cleaner housing.
• Install
Start
the
and let it idle.
• Measure engine,
the output voltage with the connector joined.
•
Output Voltage (without Plugs)
Standard: DC 0.2 V or less
• Turn the ignition switch OFF.
If the reading is out of the standard (with plugs: DC 0.7
V or more, without plugs: DC 0.2 V or less), remove the
ECU and check the wiring for continuity between main
harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connectors [A] ←→
Oxygen Sensor Connector [B]
W/BL lead (ECU terminal 32) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, replace the sensor.
If the reading is within the standard (with plugs: DC 0.7 V
or more, without plugs: DC 0.2 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-80 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
Oxygen Sensor Circuit
1. ECU
2. Meter Ground
3. Frame Ground
4. Oxygen Sensor
5. Ignition Switch
6. Relay Box
7. ECU Main Relay
8. Starter Relay
9. FI Fuse 15 A
10. Main Fuse 30 A
11. Battery 12 V 8 Ah
12. Water-proof Joint C
FUEL SYSTEM (DFI) 3-81
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor
Removal/Installation
The exhaust butterfly valve actuator sensor is built in the
exhaust butterfly valve actuator. So, the sensor itself can
not be removed. Remove the exhaust butterfly valve actuator (see Exhaust Butterfly Valve Actuator Removal).
Exhaust Butterfly Valve Actuator Sensor Input
Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the front seat (see Front Seat Removal in the
• Frame chapter).
the exhaust butterfly valve actuator sensor
• Disconnect
lead connector (3 pins connector) and connect the harness adapter [A] between these connector.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
• Connect a digital meter to the harness adapter leads.
Exhaust Butterfly Valve Actuator Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → Y/W (actuator W) lead
Digital Meter (−) → BK/BL (actuator BK) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Exhaust Butterfly Valve Actuator Sensor Output
Voltage Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Exhaust Butterfly Valve Actuator Sensor Connector [B]
BL lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-82 FUEL SYSTEM (DFI)
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor Output
Voltage Inspection
NOTE
○Before this inspection, confirm the pulley [A] is original
position (see Exhaust Butterfly Valve Actuator Installation).
• Disconnect:
2 pins Connector [B]
3 pins Connector [C]
the harness adapter [A] between the 3 pins con• Connect
nectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
• Connect a digital meter to the harness adapter leads.
Exhaust Butterfly Valve Actuator Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → BL (actuator Y) lead
Digital Meter (−) → BK/BL (actuator BK) lead
the output voltage at the 3 pins connector of the
• Measure
exhaust butterfly valve actuator when the pulley is original
•
position.
Turn the ignition switch ON.
Output Voltage
Standard: DC 3.46 ∼ 3.76 V at pulley original position
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the exhaust
butterfly valve actuator sensor resistance (see Exhaust
Butterfly Valve Actuator Sensor Resistance Inspection).
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Exhaust Butterfly Valve Actuator Sensor Connector [B]
R/BK lead (ECU terminal 28) [C]
BR/BK lead (ECU terminal 33) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-83
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor
Resistance Inspection
the ignition switch OFF.
• Turn
Disconnect
butterfly valve actuator sensor
• connector (3thepinsexhaust
connector) [A].
a digital meter [B] to the exhaust butterfly valve
• Connect
actuator sensor connector.
the exhaust butterfly valve actuator sensor re• Measure
sistance.
Exhaust Butterfly Valve Actuator Sensor Resistance
Connections: W lead [C] ←→ BK lead [D]
Standard: 4 ∼ 6 kΩ
If the reading is out of the standard, replace the exhaust
butterfly valve actuator.
If the reading within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Exhaust Butterfly Valve Actuator Sensor Circuit
1. ECU
2. Exhaust Butterfly Valve Actuator
3-84 FUEL SYSTEM (DFI)
Immobilizer Amplifier (Service Code 35, Equipped Models)
Antenna Resistance Inspection
the ignition switch OFF.
• Turn
the left lower fairing (see Lower Fairing Removal
• Remove
in the Frame chapter).
• Remove the band [A].
the antenna lead connector [A].
• Disconnect
• Measure the antenna resistance.
Antenna Resistance
Connections: BK lead ←→ BK/W lead
Standard: About 3.0 ∼ 4.6 Ω
If the reading is out of the standard, replace the antenna
(see Immobilizer System Parts Replacement in the Electrical System chapter).
If the reading is within the standard, check the wiring to
the amplifier (see wiring diagram in next section).
If the wiring is good, check the input voltage of the amplifier (see Amplifier Input Voltage Inspection).
FUEL SYSTEM (DFI) 3-85
Immobilizer Amplifier (Service Code 35, Equipped Models)
Amplifier Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the left lower fairing (see Lower Fairing Removal
• in the Frame
chapter).
○Do not disconnect the connectors.
a digital meter to the amplifier connector [A] with
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Amplifier Input Voltage
Connections to Amplifier Connector:
Digital Meter (+) → BR/W lead
Digital Meter (–) → BK/Y lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: Battery Voltage
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the wiring (see
wiring diagram in next section).
If the reading is within the standard, check the wiring to
ECU (see wiring diagram in next section).
If the wiring is good, replace the amplifier (see Immobilizer System Parts Replacement in the Electrical System
chapter).
3-86 FUEL SYSTEM (DFI)
Blank Key Detection (Service Code 36, Equipped Models)
code appears in the following conditions.
•○This
The transponder [A] in the ignition key is malfunction.
○When the spare ignition key of unregistration is used.
○When the ignition key is registered in the registered ECU.
the service code 36 will disappear when the
• Therefore,
above issue is solved.
Ignition Key Inspection
the ignition key correctly (see Key Registration
• Register
in the Electrical System chapter).
If the service code 36 appears again, the transponder in
the key is malfunction, replace it.
Immobilizer System Circuit
1. Fuse Box
2. Ignition Fuse 15 A
3. Meter Ground
4. Frame Ground
5. ECU
6. Ignition Switch
7. Immobilizer Antenna
8. Immobilizer Amplifier
9. Meter Unit
10. Oil Pressure/FI/Immobilizer Warning Indicator
Light (LED)
11. Relay Box
12. ECU Main Relay
13. FI Fuse 15 A
14. Main Fuse 30 A
15. Battery 12 V 8 Ah
16. Immobilizer/Kawasaki Diagnostic System Connector
17. Water-proof Joint C
FUEL SYSTEM (DFI) 3-87
ECU Communication Error (Service Code 39)
ECU Communication Line Inspection
○When the data is not sent from the ECU to the meter unit
for more than about 10 seconds, the service code 39 is
displayed.
○The service code 39 is detected with meter unit.
Remove the ECU and meter unit, check the wiring for
continuity between main harness connector.
○Disconnect the ECU and meter unit connectors.
•
Wiring Inspection
ECU Connector [A] ←→ Meter Unit Connector [B]
W/R lead (ECU terminal 31) [C]
If the wiring is good, check the meter unit (see Meter Unit
Inspection in the Electrical System chapter).
If the meter unit is normal, replace the ECU (see ECU
Removal/Installation).
ECU Communication Line Circuit
1. ECU
2. Meter Unit
3. Warning Indicator Light (LED)
4. Meter Ground
3-88 FUEL SYSTEM (DFI)
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
Stick
Stick
Stick
Stick
Coil
Coil
Coil
Coil
#1:
#2:
#3:
#4:
Service
Service
Service
Service
Code
Code
Code
Code
51
52
53
54
Stick Coil Removal/Installation
to the Stick Coil Removal/Installation in the Electri• Refer
cal System chapter.
Stick Coil Primary Winding Resistance Inspection
to the Stick Coil Inspection in the Electrical System
• Refer
chapter.
If the reading is within the standard, check the input voltage (see Stick Coil Input Voltage Inspection).
Stick Coil Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the ECU (see ECU Removal).
•○Do not disconnect
the ECU connectors.
Connect
a
digital
meter
• needle adapter set. [A] to the connector [B] with the
Special Tool - Needle Adapter Set: 57001-1457
Stick Coil Input Voltage
Connections to ECU Connector:
For Stick Coil #1
Digital Meter (+) → BK lead (terminal 40)
Digital Meter (–) → BK/Y lead (terminal 54)
For Stick Coil #2
Digital Meter (+) → R/W lead (terminal 47)
Digital Meter (–) → BK/Y lead (terminal 54)
For Stick Coil #3
Digital Meter (+) → BK/W lead (terminal 39)
Digital Meter (–) → BK/Y lead (terminal 54)
For Stick Coil #4
Digital Meter (+) → BK/O lead (terminal 38)
Digital Meter (–) → BK/Y lead (terminal 54)
the input voltage to each primary winding of the
• Measure
stick coils with the engine stopped and with the connec-
•
•
tors joined.
Turn the engine stop switch to run position.
Turn the ignition switch ON.
Input Voltage
Standard: Battery Voltage
FUEL SYSTEM (DFI) 3-89
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
the ignition switch OFF.
• Turn
If the input voltage is out of the standard, check the wiring
for continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the input voltage is within the standard, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Stick Coil Circuit
1. ECU
2. Frame Ground
3. Water-proof Joint C
4. Stick Coil #1, #2, #3, #4
5. Engine Stop Switch
6. Fuse Box 2
7. Ignition Fuse 15 A
8. Ignition Switch
9. Main Fuse 30 A
10. Battery 12 V 8 Ah
3-90 FUEL SYSTEM (DFI)
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation
○The radiator fan relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System
• Refer
chapter.
Radiator Fan Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer
tem chapter.
If the radiator fan relay is normal, check the wiring for
continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Radiator Fan Relay Circuit
1. ECU
2. Frame Ground
3. Water-proof Joint C
4. Fuse Box 2
5. Fan Fuse 15 A
6. Relay Box
7. Radiator Fan Relay
8. Ignition Switch
9. Main Fuse 30 A
10. Battery 12 V 8 Ah
11. Radiator Fan Motor
12. Water-proof Joint A
FUEL SYSTEM (DFI) 3-91
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Removal
NOTICE
Do not remove the subthrottle valve actuator [A]
since it has been adjusted and set with precision
at the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the subthrottle valve
actuator can damage it.
Subthrottle Valve Actuator Inspection
NOTE
○Be sure the battery is fully charged.
the air cleaner housing (see Air Cleaner Housing
• Remove
Removal).
the ignition switch ON.
• Turn
Check
to see that all the subthrottle valves [A] open and
• close smoothly.
the ignition switch OFF.
• Turn
If the subthrottle valves do not operate, check the subthrottle valve actuator resistance (see Subthrottle Valve
Actuator Resistance Inspection).
Subthrottle Valve Actuator Resistance Inspection
the ignition switch OFF.
• Turn
• Disconnect the subthrottle valve actuator connector [A].
a digital meter to the subthrottle valve actuator
• Connect
connector [A].
• Measure the subthrottle valve actuator resistance.
Subthrottle Valve Actuator Resistance
Connections: LG/R lead [1] ←→ P/BL lead [2]
G lead [3] ←→ W/BL lead [4]
Standard:
About 5.2 ∼ 7.8 Ω
If the reading is out of the standard, replace the throttle
body assy.
If the reading is within the standard, check the input voltage (see Subthrottle Valve Actuator Input Voltage Inspection).
3-92 FUEL SYSTEM (DFI)
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Disconnect
subthrottle valve actuator connector and
• connect the the
harness adapter [A] between these connectors as shown in the figure.
Main Harness [B]
Subthrottle Valve Actuator [C]
Special Tool - Measuring Adapter: 57001-1700
the peak voltage adapter [D] and a digital meter
• Connect
[E] to the harness adapter leads.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Subthrottle Valve Actuator Input Voltage
Connections to Adapter:
(I) Digital Meter (+) → R (actuator W/BL) lead
Digital Meter (–) → Battery (–) terminal
(II) Digital Meter (+) → BK (actuator G) lead
Digital Meter (–) → Battery (–) terminal
(III) Digital Meter (+) → W (actuator P/BL) lead
Digital Meter (–) → Battery (–) terminal
(IV) Digital Meter (+) → Y (actuator LG/R) lead
Digital Meter (–) → Battery (–) terminal
the actuator input voltage with
• Measure
stopped and with the connector joined.
• Turn the ignition switch ON.
the engine
Input Voltage
Standard: About DC 11.5 ∼ 13.5 V
the ignition switch OFF.
• Turn
If the reading is in specification, but the actuator does not
operate, replace the throttle body assy.
If the reading is out of the specification, remove the ECU
and check the wiring for continuity between main harness
connector.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and actuator connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subthrottle Valve Actuator Connector [B]
LG/R lead (ECU terminal 1) [C]
P/BL lead (ECU terminal 12) [D]
G lead (ECU terminal 23) [E]
W/BL lead (ECU terminal 24) [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-93
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Circuit
1. ECU
2. Subthrottle Valve Actuator
3-94 FUEL SYSTEM (DFI)
Exhaust Butterfly Valve Actuator (Service Code 63)
Exhaust Butterfly Valve Actuator Removal
NOTICE
Never drop the exhaust butterfly valve actuator especially on a hard surface. Such a shock to the actuator can damage it.
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Exhaust Butterfly Valve Cables (see Exhaust Butterfly
Valve Cable Removal in the Engine Top End chapter)
Connectors [A]
Screws [B]
Exhaust Butterfly Valve Actuator [C]
the pulley bolt while holding the pulley [A] with
• Remove
the suitable tool [B].
NOTICE
If the pulley bolt is removed without holding, the
actuator damage will occur.
• Remove the pulley from the actuator.
Exhaust Butterfly Valve Actuator Installation
the pulley [A] on the actuator so that the hole side
• Install
[B] align with the groove [C] on the shaft.
○Make sure that the groove on the shaft is pointing toward
the center of the screw [D].
the shaft position is incorrect, refer to the following
NOTE and procedures to electrically adjust the shaft
position.
○If
the pulley [A] on the actuator as shown.
• Install
Tighten
pulley bolt [B] while holding the pulley with the
• suitable the
tool [C].
Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 5.0
N·m (0.51 kgf·m, 44 in·lb)
NOTICE
If the pulley bolt is tightened without holding, the
actuator damage will occur.
FUEL SYSTEM (DFI) 3-95
Exhaust Butterfly Valve Actuator (Service Code 63)
tightening the pulley bolt, confirm whether pulley [A]
• After
is an angle shown in the figure.
41.7° ±7° [B]
○This position is original position of the pulley.
NOTE
○Correct the position electrically after confirming the use
is discontinued and there is no damage when differing
from the angle of shown in the figure.
NOTICE
Do not correct the pulley position with the tool,
forcibly. The actuator damage will occur.
If the pulley angle is wrong, adjust the angle as follows.
○Connect:
2 pins Connector
3 pins Connector
○Turn the ignition switch ON.
○Confirm the pulley turns clockwise or counterclockwise
then it stops at the original position.
If the pulley position has not been returned to the original
position, electrically adjust the shaft position as follows.
○Remove:
2 pins Connector
3 pins Connector
○Turn the pulley to the original position by turning it clockwise or counterclockwise by connecting the battery to the
2 pins connector terminals. To turn the pulley gradually,
intermittently connect the battery positive (+) terminal to
the 2 pins connector terminal while connecting the battery
negative (–) terminal to the connector.
Pink (–) lead terminal [A]
Gray (+) lead terminal [B]
Clockwise:
Pink (–) lead terminal to battery (–) terminal
Gray (+) lead terminal to battery (+) terminal
Counterclockwise:
Pink (–) lead terminal to battery (+) terminal
Gray (+) lead terminal to battery (–) terminal
○Reconnect the 2 pins connector and 3 pins connector, and
turn the ignition switch ON.
○Make sure that the pulley turns clockwise and then counterclockwise.
○The pulley should returns to the original position.
○Turn the ignition switch OFF.
If the pulley does not return to the original position, check
the exhaust butterfly valve actuator resistance (see Exhaust Butterfly Valve Actuator Resistance Inspection).
3-96 FUEL SYSTEM (DFI)
Exhaust Butterfly Valve Actuator (Service Code 63)
sure to install the washers [A] on the exhaust butterfly
• Be
valve actuator [B].
• Tighten:
Torque - Exhaust Butterfly Valve Actuator Mounting
Screws [C]: 1.2 N ·m (0.12 kgf ·m, 11 in·lb)
the close cable first and then open cable (see Ex• Install
haust Butterfly Valve Cable Installation in the Engine Top
End chapter).
Exhaust Butterfly Valve Actuator Inspection
NOTE
○Be sure the battery is fully charged
the front seat (see Front Seat Removal in the
• Remove
Frame chapter).
the ignition switch ON.
• Turn
In
the
left side view of the motorcycle, check to see
• the pulley
[A] clockwise [B] and counterclockwise [C]
smoothly.
○The pulley turns clockwise and then counterclockwise,
•
and clockwise again.
Turn the ignition switch OFF.
If the pulley does not operate, check the exhaust butterfly
valve cable installation (see Butterfly Valve Cable Installation in the Engine Top End chapter) and the exhaust
butterfly valve actuator resistance (see Exhaust Butterfly
Valve Actuator Resistance Inspection).
Exhaust Butterfly Valve Actuator Resistance
Inspection
the ignition switch OFF.
• Turn
Disconnect
exhaust butterfly valve actuator lead con• nector (2 pinstheconnector)
[A].
the hand tester to the × 1 Ω range and connect it to
• Set
the exhaust butterfly valve actuator connector.
Special Tool - Hand Tester: 57001-1394
• Measure the exhaust butterfly valve actuator resistance.
Exhaust Butterfly Valve Actuator Resistance
Connections:
P lead ←→ GY lead
Standard:
Any Reading Resistance (reference
5 ∼ 200 Ω)
If the reading is 0 or infinity (∞) Ω, replace the exhaust
butterfly valve actuator.
FUEL SYSTEM (DFI) 3-97
Exhaust Butterfly Valve Actuator (Service Code 63)
If the reading is in specification, remove the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and actuator connectors.
Wiring Inspection
ECU Connector [A] ←→
Exhaust Butterfly Valve Actuator Connector [B]
GY lead (ECU terminal 2) [C]
G/R lead (ECU terminal 3) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Exhaust Butterfly Valve Actuator Circuit
1. ECU
2. Exhaust Butterfly Valve Actuator
3-98 FUEL SYSTEM (DFI)
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation
to the Air Switching Valve Removal/Installation in
• Refer
the Engine Top End chapter.
Air Switching Valve Inspection
to the Air Switching Valve Unit Test in the Electrical
• Refer
System chapter.
If the air switching valve is normal, check the wiring for
continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Air Switching Valve Circuit
1. ECU
2. Meter Ground
3. Frame Ground
4. Air Switching Valve
5. Engine Stop Switch
6. Fuse Box 2
7. Ignition Fuse 15 A
8. Ignition Switch
9. Relay Box
10. ECU Main Relay
11. Fuel Pump Relay
12. Starter Relay
13. FI Fuse 15 A
14. Main Fuse 30 A
15. Battery 12 V 8 Ah
16. Water-proof Joint C
FUEL SYSTEM (DFI) 3-99
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Removal/Installation
The oxygen sensor heater is built in the oxygen sensor.
So, the heater itself can not be removed. Remove the oxygen sensor (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter).
Oxygen Sensor Heater Resistance Inspection
the ignition switch OFF.
• Turn
Remove
the right lower fairing (see Lower Fairing Re• moval in the
Frame chapter).
the clamp [A], and pull out the oxygen sensor lead
• Open
connector [B].
• Disconnect the oxygen sensor lead connector.
a digital meter [A] to the oxygen sensor lead con• Connect
nector [B].
• Measure the oxygen sensor heater resistance.
Oxygen Sensor Heaters Resistance
Connections: BK lead [C] ←→ BK lead [D]
Standard: 11.7 ∼ 14.5 Ω at 20° C (68°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, check the power
source voltage (see Oxygen Sensor Heater Power
Source Voltage Inspection).
3-100 FUEL SYSTEM (DFI)
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Power Source Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Disconnect
the oxygen sensor lead connector and con• nect the harness
adapter [A] between these connectors.
[B] Main Harness
[C] Oxygen Sensor
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter lead.
Oxygen Sensor Power Source Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor BK) lead
Digital Meter (–) → Battery (–) terminal
the power source voltage with
• Measure
stopped and with the connector joined.
• Turn the ignition switch ON.
the engine
Power Source Voltage
Standard: Battery Voltage
the ignition switch OFF.
• Turn
If the reading is in specification, but the problem still exists, replace the ECU (see ECU Removal/Installation).
If the reading is out of the standard, check the following.
FI Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
Power Source Wiring (see wiring diagram in this section)
If the fuse and wiring are good, remove the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Inspection
ECU Connector [A] ←→
Oxygen Sensor Connector [B]
R lead (ECU terminal 9) [C]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-101
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Circuit
1. ECU
2. Meter Ground
3. Frame Ground
4. Oxygen Sensor
5. Ignition Switch
6. Relay Box
7. ECU Main Relay
8. Starter Relay
9. FI Fuse 15 A
10. Main Fuse 30 A
11. Battery 12 V 8 Ah
12. Water-proof Joint C
3-102 FUEL SYSTEM (DFI)
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
Oxygen Sensor Removal/Installation
to the Oxygen Sensor Removal/Installation in the
• Refer
Electrical System chapter.
Oxygen Sensor Inspection
up the engine thoroughly until the radiator fan
• Warm
starts.
the ignition switch OFF.
• Turn
Remove
the right lower fairing (see Lower Fairing Re• moval in the
Frame chapter).
the clamp [A], and pull out the oxygen sensor lead
• Open
connector [B].
the oxygen sensor lead connector (4 pins
• Disconnect
connector) and connect the harness adapter [A] between
these connectors.
[B] Main Harness
[C] Oxygen Sensor
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (−) → BK (sensor W) lead
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
the stick coil connectors [A].
• Disconnect
Separate
the
air switching valve hoses [B] from the air
• suction valve covers.
○Do not disconnect the air switching valve connector [C].
FUEL SYSTEM (DFI) 3-103
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
the suitable plugs [A] on the fitting of the air suction
• Install
valve covers, and shut off the secondary air.
the stick coil connectors.
• Connect
Install
the
air cleaner housing temporarily (see Air Cleaner
• Housing Installation).
the fuel hose (see Fuel Hose Replacement in the
• Remove
Periodic Maintenance chapter).
the following parts temporary.
• Connect
Fuel Pump Lead Connector [A]
Fuel Hose [B]
Special Tool - Fuel Hose: 57001-1607
the engine, and let it idle.
• Start
Measure
the output voltage with the connector joined.
•
Output Voltage (with Plugs, Rich)
Standard: DC 0.7 V or more
remove the air cleaner housing to take out the plugs
• Next,
from the fittings [A] of the air suction valve covers.
the air cleaner housing.
• Install
Start
the
and let it idle.
• Measure engine,
the output voltage with the connector joined.
•
Output Voltage (without Plugs, Lean)
Standard: DC 0.2 V or less
• Turn the ignition switch OFF.
If the reading is out of the standard (with plugs: DC 0.7
V or more, without plugs: DC 0.2 V or less), check the
following.
Fuel Pressure (see Fuel Pressure Inspection)
Fuel Injector (see Fuel Injectors section)
If the fuel pressure and fuel injectors are good, replace
the sensor.
If the reading is within the standard (with plugs: DC 0.7 V
or more, without plugs: DC 0.2 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-104 FUEL SYSTEM (DFI)
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
Oxygen Sensor Circuit
1. ECU
2. Meter Ground
3. Frame Ground
4. Oxygen Sensor
5. Ignition Switch
6. Relay Box
7. ECU Main Relay
8. Starter Relay
9. FI Fuse 15 A
10. Main Fuse 30 A
11. Battery 12 V 8 Ah
12. Water-proof Joint C
FUEL SYSTEM (DFI) 3-105
Warning Indicator Light (LED)
Light (LED) Inspection
○The warning indicator light (LED) [A] is used for the FI
indicator, immobilizer indicator (immobilizer models) and
oil pressure warning indicator.
○In this model, the warning indicator light (LED) (FI/immobilizer) blink by the data sent from the ECU.
Refer to the Meter Unit Inspection in the Electrical System
chapter for the warning indicator light (LED) (FI/immobilizer) inspection.
•
Warning Indicator Light (LED) (FI/Immobilizer) Circuit
1. ECU
2. Meter Unit
3. Warning Indicator Light (LED)
4. Meter Ground
3-106 FUEL SYSTEM (DFI)
ECU
ECU Identification
○Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with
each other and use only the ECU for your model. Otherwise, the motorcycle cannot clear the regulation.
ECU Identification
Part Number [A]
Specification
21175-0333
WVTA (Full H), with immobilizer
GB WVTA (Full H), with immobilizer
Australia, with immobilizer
21175-0334
US (except California), without immobilizer
US (California), without immobilizer
Canada, without immobilizer
21175-0704
WVTA (78.2H), with immobilizer
21175-0335
Southeast Asia, with immobilizer
Full: Full Power
H: Honeycomb Type Catalyst
78.2: Maximum Horsepower 78.2 kW (106.3 PS)
ECU Removal
NOTICE
Never drop the ECU especially on a hard surface.
Such a shock to the ECU can damage it.
NOTE
○Refer to the Immobilizer System Parts Replacement in
the Electrical System chapter for the immobilizer models (see Immobilizer System Parts Replacement in the
Electrical System chapter).
• Remove:
Relay Box (see Relay Box Removal in the Electrical System chapter)
ECU Connectors [A]
ECU [B]
ECU Installation
the ECU connectors [A].
• Connect
Install
the
[B] into the rubber protector [C].
• Insert the ECU
slits
of
• [D] of the bracket.the rubber protector to the projections
FUEL SYSTEM (DFI) 3-107
ECU
ECU Power Supply Inspection
inspect the ECU connectors.
• Visually
If the connector is clogged with mud or dust, blow it off
•
•
with compressed air.
Remove the ECU (see ECU Removal).
Visually inspect the terminals [A] of the ECU connectors.
If the terminals of the main harness connectors are damaged, replace the main harness.
If the terminals of the ECU connectors are damaged, replace the ECU.
the ignition switch OFF.
• Turn
Disconnect
ECU connectors [A].
• Set the handthetester
[B] to the × 1 Ω range and check the
• following wiring for continuity.
Special Tool - Hand Tester: 57001-1394
ECU Grounding Inspection
Connections:
(I) BK/Y leads (ECU
terminal 30, 53 or 54)
←→ Battery (–) Terminal
(II) Engine Ground
←→ Battery (–) Terminal
Criteria:
Both: 0 Ω
If no continuity, check the connectors, the engine ground
lead, or main harness, and repair or replace them if necessary.
3-108 FUEL SYSTEM (DFI)
ECU
If the wiring is good, check the power source voltage of
the ECU.
NOTE
○Be sure the battery is fully charged.
the ECU and relay box connectors.
• Connect
Connect
a
digital meter [A] to the connectors [B] with the
• needle adapter
set.
Special Tool - Needle Adapter Set: 57001-1457
ECU Power Supply Inspection
Connections:
(I) Digital Meter (+) → Terminal 6 (BR/W)
Digital Meter (–) → Battery (–) terminal
(II) Digital Meter (+) → Terminal 8 (W/BK)
Digital Meter (–) → Battery (–) terminal
Ignition Switch OFF:
Terminal 6 (BR/W): 0 V
Terminal 8 (W/BK): Battery Voltage
Ignition Switch ON:
Both: Battery Voltage
If the reading is out of the specification, check the following.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
FI Fuse 15 A (see Fuse Inspection Electrical System
chapter)
ECU Main Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Power Source Wiring (see wiring diagram in this section )
If the fuse, wiring and relay are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-109
ECU
ECU Power Source Circuit
1. ECU
2. Meter Ground
3. Frame Ground
4. Ignition Switch
5. Relay Box
6. ECU Main Relay
7. Starter Relay
8. FI Fuse 15 A
9. Main Fuse 30 A
10. Battery 12 V 8 Ah
11. Water-proof Joint C
3-110 FUEL SYSTEM (DFI)
DFI Power Source
ECU Fuse Removal
to the 15 A FI Fuse Removal in the Electrical Sys• Refer
tem chapter.
ECU Fuse Installation
•
If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.
Refer to the Fuse Installation in the Electrical System
chapter.
ECU Fuse Inspection
to the Fuse Inspection in the Electrical System
• Refer
chapter.
ECU Main Relay Removal/Installation
○The ECU main relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System
• Refer
chapter.
ECU Main Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer
tem chapter.
FUEL SYSTEM (DFI) 3-111
Fuel Line
Fuel Pressure Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Support the fuel tank with a suitable bar (see Fuel Tank
Removal in the Fuel System (DFI) chapter).
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.
•
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. 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.
the fuel pressure gauge adapter [A] and fuel hoses
• Install
(Special Tool: 57001-1607) [B] between the fuel outlet
•
•
pipe and delivery pipe.
Secure the fuel hoses with the clamps.
Connect the pressure gauge [C] to the fuel pressure
gauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607
WARNING
Fuel is extremely flammable and can be explosive
under certain conditions resulting in serious injury
or death. Do not try to start the engine with the fuel
hoses disconnected.
the fuel pump lead connector.
• Connect
Turn
the
engine
switch run position.
• Turn the ignition stop
switch ON.
•○The fuel pump should
operate for 3 seconds, and then
should stop.
○After
NOTE
turning on the engine stop switch and ignition
switch, inspect the fuel leakage from the connected
portion of the special tools.
NOTICE
Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
3-112 FUEL SYSTEM (DFI)
Fuel Line
the engine, and let it idle.
• Start
Measure
the fuel pressure with the engine idling.
•
Fuel Pressure (with Engine Idling)
Standard: 294 kPa (3.0 kgf/cm², 43 psi)
NOTE
○The gauge needle will fluctuate. Read the pressure at
the average of the maximum and minimum indications.
the ignition switch OFF.
• Turn
If the fuel pressure is much higher than specified, replace
•
•
•
•
•
the fuel pump because the fuel pressure regulator in the
fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check
the following.
Fuel Line Leakage (see Fuel Injector Fuel Line Inspection)
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
After above checks, measure the fuel pressure again.
Remove the fuel pressure gauge, hoses and adapter.
Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)
Confirm that the drain hose and clamp are installed securely and run the hose correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
Start the engine and check for fuel leakage.
Fuel Flow Rate Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the
potential for serious burns. 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.
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Wait
until
cools down.
• Prepare athefuelengine
hose
• measuring cylinder. (Special Tool:
57001-1607) and a
Special Tool - Fuel Hose: 57001-1607
the fuel tank with a suitable bar (see Fuel Tank
• Support
Removal in the Fuel System (DFI) chapter).
FUEL SYSTEM (DFI) 3-113
Fuel Line
the fuel tank cap [A] to lower the pressure in the
• Open
tank.
the fuel hose from the fuel pump (see Fuel Tank
• Remove
Removal).
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. 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.
the prepared fuel hose [A] to the fuel outlet pipe.
• Connect
the fuel hose with a clamp.
• Secure
Insert
the
fuel hose into the measuring cylinder [B].
•
WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
the fuel tank cap.
• Close
Turn
the
stop switch to run position.
• Turn the engine
ignition
switch ON.
•○The fuel pump should
operate for 3 seconds, and then
should stop.
NOTICE
Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
the discharge for 3 seconds.
•○Measure
Repeat this operation several times.
Amount of Fuel Flow
Standard: 50 mL (1.7 US oz.) or more for 3 seconds
the ignition switch OFF.
• Turn
If the fuel flow is much less than the specified, replace the
•
•
•
fuel pump (see Fuel Pump Removal/Installation).
Install the fuel tank (see Fuel Tank Installation).
Confirm that the drain hose and clamp are installed securely and run the hose correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
Start the engine and check for fuel leakage.
3-114 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the
potential for serious burns. 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 avoid fuel
spills, draw it from the tank when the engine is
cold. Be prepared for fuel spillage; any spilled fuel
must be completely wiped up immediately.
NOTICE
Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it.
the fuel out from the fuel tank with a commercially
• Draw
available electric pump.
the fuel tank (see Fuel Tank Removal).
•○Remove
Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
the fuel tank upside down.
• Turn
Remove
• pump [B].the fuel pump bolts [A], and take out the fuel
NOTICE
Do not pull the leads of the fuel pump. If they are
pulled, the lead terminals may be damaged.
• Discard the fuel pump gasket [A].
FUEL SYSTEM (DFI) 3-115
Fuel Pump
Fuel Pump Installation
dirt or dust from the fuel pump [A] by lightly ap• Remove
plying compressed air.
• Replace the fuel pump gasket with a new one.
that the fuel pump terminal [A] and band [B] are in
• Check
place.
a non-permanent locking agent to the threads of
• Apply
the fuel pump bolts.
the fuel pump bolts [C] to a snug fit.
• Tighten
Tighten
the
fuel pump bolts alternating diagonally.
•
Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Tighten the pump bolts again to check the tightness.
Fuel Pump Operation Inspection
NOTE
○Be sure the battery is fully charged.
the engine stop switch to run position.
• Turn
Turn
ignition switch ON and make sure that the fuel
• pumptheoperates
(make light sounds) for 3 seconds, and
•
then stops.
Turn the ignition switch OFF.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).
3-116 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Operating Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the front seat (see Front Seat Removal in the
• Frame chapter).
the fuel pump lead connector and connect the
• Disconnect
harness adapter [A] between these connectors as shown.
Main Harness [B]
Fuel Pump [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Fuel Pump Operating Voltage
Connections to Adapter:
Digital Meter (+) → R (pump BK/Y) lead
Digital Meter (–) → BK (pump BK/W) lead
the operating voltage with engine stopped and
• Measure
with the connector joined.
the engine stop switch run position.
• Turn
Turn
• the ignition switch ON.
Operating Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch OFF.
• Turn
If the reading is not the standard, check the ECU main
relay and fuel pump relay (see Relay Circuit Inspection in
the Electrical System chapter).
If the main relay and pump relay are normal, check the
wiring for continuity (see Fuel Pump Circuit).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Pressure Regulator Removal
○The pressure regulator [A] is built into the fuel pump [B]
and can not be removed.
FUEL SYSTEM (DFI) 3-117
Fuel Pump
Pump Screen, Fuel Filter Cleaning
○The pump screen [A] and fuel filter [B] are built into the
pump and can not be cleaned or checked.
If the pump screen or fuel filter is suspected of clogging
or being damaged, replace it with the fuel pump as a set.
Fuel Pump Relay Removal/Installation
○The fuel pump relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System
• Refer
chapter.
Fuel Pump Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer
tem chapter.
3-118 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Circuit
1. ECU
2. Meter Ground
3. Frame Ground
4. Engine Stop Switch
5. Fuel Pump/Fuel Level Sensor
6. Fuse Box 2
7. Ignition Fuse 15 A
8. Ignition Switch
9. Meter Unit
10. Relay Box
11. ECU Main Relay
12. Fuel Pump Relay
13. Starter Relay
14. FI Fuse 15 A
15. Main Fuse 30 A
16. Battery 12 V 8 Ah
17. Water-proof Joint C
FUEL SYSTEM (DFI) 3-119
Fuel Injectors
Fuel Injector Removal/Installation
• Refer to the Throttle Body Assy Disassembly/Assembly.
Fuel Injector Audible Inspection
NOTE
○Be sure the battery is fully charged.
the lower side fairing (see Lower Side Fairing
• Remove
Removal in the Frame chapter).
the engine, and let it idle.
• Start
Apply
of a screwdriver [A] to the fuel injector [B].
• Put thethegriptipend
onto your ear, and listen whether the fuel
injector is clicking or not.
○A sound scope can also be used.
○The click interval becomes shorter as the engine speed
•
•
rises.
Do the same for the other fuel injectors.
If all the fuel injectors click at a regular intervals, the fuel
injectors are normal.
Turn the ignition switch OFF.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).
Fuel Injector Resistance Inspection
the throttle body assy with the connectors in• Remove
stalled (see Throttle Body Assy Removal).
the injector connector.
• Disconnect
Connect
a
digital
to the terminals [A] of the injector.
• Measure the fuel meter
injector resistance.
•
Fuel Injector Resistance
Connections:
For Fuel Injector #1
W/R ←→ BL/R terminal
For Fuel Injector #2
W/R ←→ BL/O terminal
For Fuel Injector #3
W/R ←→ BL/W terminal
For Fuel Injector #4
W/R ←→ BL/Y terminal
Standard: About 11.7 ∼ 12.3 Ω at 20°C (68°F)
If the reading is out of the standard, replace the injector.
3-120 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Power Source Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the air cleaner housing (see Air Cleaner Housing
• Remove
Removal).
the ignition switch OFF.
• Turn
the injector connector and connect the har• Disconnect
ness adapter [A] between these connectors as shown.
Main Harness [B]
Fuel Injector #1 [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter lead.
Fuel Injector Power Source Voltage
Connections to Adapter:
For Fuel Injector #1, #2, #3, #4
Digital Meter (+) → R (injector W/R) lead
Digital Meter (–) → Battery (–) terminal
the power source voltage with
• Measure
stopped.
the engine stop switch to run position.
• Turn
Turn
• the ignition switch ON.
the engine
Power Source Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch OFF.
• Turn
If the reading is not the standard, check the ECU main
relay and fuel pump relay (see Relay Circuit Inspection in
the Electrical System chapter).
If the main relay and pump relay are normal, check the
wiring (see Fuel Injector Circuit).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-121
Fuel Injectors
Fuel Injector Output Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove
the ECU (see ECU Removal).
•○Do not disconnect
the ECU connector.
○Connect the relay box connectors.
a digital meter [A] to the connectors [B] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Fuel Injector Output Voltage
Connections to ECU Connector:
For Fuel Injector #1
Digital Meter (+) → BL/R lead (ECU terminal 36)
Digital Meter (–) → Battery (–) terminal
For Fuel Injector #2
Digital Meter (+) → BL/O lead (ECU terminal 34)
Digital Meter (–) → Battery (–) terminal
For Fuel Injector #3
Digital Meter (+) → BL/W lead (ECU terminal 11)
Digital Meter (–) → Battery (–) terminal
For Fuel Injector #4
Digital Meter (+) → BL/Y lead (ECU terminal 10)
Digital Meter (–) → Battery (–) terminal
the output voltage with the engine stopped and
• Measure
with the connector joined.
the engine stop switch to run position.
• Turn
Turn
• the ignition switch ON.
Output Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch OFF.
• Turn
If the reading is not the standard, check the ECU main
relay and fuel pump relay (see Relay Circuit Inspection in
the Electrical System chapter).
If the main relay and pump relay are normal, check the
wiring (see Fuel Injector Circuit).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If there is still no battery voltage, check the fuel injector
resistance (see Fuel Injector Resistance Inspection) and
wiring (see Fuel Injector Circuit).
3-122 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Fuel Line Inspection
• Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Be
○ sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. 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.
the injector fuel line for leakage as follows.
•○Check
Connect a commercially available vacuum/pressure
pump [A] to the nipple of the delivery pipe [B] with the
fuel hose [C] (both ends with the clamps [D]) as shown
in the figure.
Lower Side View [E]
○Apply soap and water solution to the areas [F] as shown
in the figure.
○Watching the pressure gauge, squeeze the pump lever
[G], and build up the pressure until the pressure reaches
the maximum pressure.
Injector Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm², 43 psi)
NOTICE
During pressure testing, do not exceed the maximum pressure for which the system is designed.
○Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once or if bubbles are found in the
area, the fuel line is leaking. Replace the delivery pipe
assy, injectors and related parts.
○Repeat the leak test, and check the fuel line for no leakage.
Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)
Confirm that the drain hose and clamp are installed securely and run the hose correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
Start the engine and check for fuel leakage.
•
•
•
FUEL SYSTEM (DFI) 3-123
Fuel Injectors
Fuel Injector Circuit
1. ECU
2. Meter Ground
3. Frame Ground
4. Fuel Injectors
5. Engine Stop Switch
6. Fuse Box 2
7. Ignition Fuse 15 A
8. Ignition Switch
9. Relay Box
10. ECU Main Relay
11. Fuel Pump Relay
12. Starter Relay
13. FI Fuse 15 A
14. Main Fuse 30 A
15. Battery 12 V 8 Ah
16. Water-proof Joint C
3-124 FUEL SYSTEM (DFI)
Throttle Grip and Cables
Free Play Inspection
to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.
Free Play Adjustment
to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.
Cable Installation
the throttle cables in accordance with the Cable,
• Install
Wire, and Hose Routing section in the Appendix chapter.
the lower ends of the throttle cables in the throttle
• Install
pulley on the throttle body assy after installing the upper
•
ends of the throttle cables in the grip.
After installation, adjust each cable properly (see Throttle
Control System Inspection in the Periodic Maintenance
chapter).
WARNING
Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition. Be sure the cables are routed correctly and
properly adjusted.
Cable Lubrication
to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.
FUEL SYSTEM (DFI) 3-125
Throttle Body Assy
Idle Speed Inspection/Adjustment
to the Idle Speed Inspection/Adjustment in the Pe• Refer
riodic Maintenance chapter.
Synchronization Inspection/Adjustment
to the Engine Vacuum Synchronization Inspection
• Refer
in the Periodic Maintenance chapter.
Throttle Body Assy Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the
potential for serious burns. 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.
NOTICE
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the body assy can
damage it.
• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
• Disconnect:
Intake Air Pressure Sensor #1 Connector [A]
•
Intake Air Pressure Sensor #2 Connector [B]
Subthrottle Valve Actuator Connector [C]
For California and Southeast Asia Models, pull off the vacuum hose [D].
• Disconnect:
Main Throttle Sensor Connector [A]
Subthrottle Sensor Connector [B]
3-126 FUEL SYSTEM (DFI)
Throttle Body Assy
the locknuts [A].
• Loosen
Turn
the
adjusters [B] to give the more free play.
•
• Remove:
Lower Side Fairing (see Lower Side Fairing Removal in
the Frame chapter)
Throttle Cable Holder Clamp [A]
Throttle Cable Lower Ends [B]
• Loosen the throttle body assy holder clamp bolts [A].
Special Tool - Carburetor Drain Plug Wrench, Hex 3:
57001-1269
FUEL SYSTEM (DFI) 3-127
Throttle Body Assy
the throttle body assy [A] from the throttle body
• Remove
assy holders.
the injector connectors [B].
• Disconnect
Remove
the
[C].
• After removingclamps
the
throttle
body assy, stuff pieces of lint
• -free, clean cloth into the throttle
body assy holders.
WARNING
If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident.
NOTICE
If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.
Throttle Body Assy Installation
sure to position the throttle body assy holder clamp in
• Be
original position (see Throttle Body Assy Holder Installa-
•
•
•
•
tion in the Engine Top End chapter).
Connect the injector connectors [A].
Install the throttle body assy to the throttle body assy holders.
Install the clamps [B].
Tighten:
Torque - Throttle Body Assy Holder Clamp Bolts: 2.9 N·m
(0.30 kgf·m, 26 in·lb)
Special Tool - Carburetor Drain Plug Wrench, Hex 3:
57001-1269
a thin coat of grease to the throttle cable lower ends.
• Apply
Fit
the
cable end [A] and the decelerator cable
• end [B]accelerator
into the throttle pulley.
○The accelerator cable has a clamp [C].
• Install the clamp securely.
the throttle grip and make sure that the throttle pulley
• Turn
moves smoothly and return by spring force.
the leads and hoses correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
• Adjust:
Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
3-128 FUEL SYSTEM (DFI)
Throttle Body Assy
Throttle Body Assy Disassembly
1. Subthrottle Valve Actuator
2. Subthrottle Sensor
3. Main Throttle Sensor
4. Throttle Body Assy
5. Fuel Injectors
6. Delivery Pipe Assy
NOTICE
Do not remove, disassemble or adjust the main
throttle sensor, subthrottle sensor, subthrottle
valve actuator, throttle link mechanism and throttle
body assy, because they are adjust or set surely at
the manufacturer. Adjustment of these parts could
result in poor performance, requiring replacement
of the throttle body assy.
the throttle body assy (see Throttle Body Assy
• Remove
Removal).
the delivery pipe assy mounting screws [A] to
• Remove
pull out the fuel injectors [B] from the throttle body assy
together with the delivery pipe assy [C].
NOTE
○Do not damage the insertion portions of the injectors
when they are pulled out from the throttle body.
FUEL SYSTEM (DFI) 3-129
Throttle Body Assy
out the fuel injectors [A] from the delivery pipe assy
• Pull
[B].
NOTE
○Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.
NOTICE
Never drop the primary fuel injector, especially on
a hard surface. Such a shock to the injector can
damage it.
Throttle Body Assy Assembly
assembling, blow away dirt or dust from the throttle
• Before
body and delivery pipe assy by applying compressed air.
the O-rings [A] of each fuel injector [B] with new
• Replace
ones.
engine oil to the new O-rings, insert them to the
• Apply
delivery pipe assy [C] and confirm whether the injectors
turn smoothly or not.
the dust seals [A] with new ones.
• Replace
engine oil to the new dust seals.
• Apply
Install
the fuel injectors along with the delivery pipe assy
• to the throttle
body.
Tighten:
•
Torque - Delivery Pipe Assy Mounting Screws: 3.4 N·m
(0.35 kgf·m, 30 in·lb)
the throttle body assy (see Throttle Body Assy In• Install
stallation).
3-130 FUEL SYSTEM (DFI)
Air Cleaner
Air Cleaner Element Removal/Installation
to the Air Cleaner Element Replacement in the Pe• Refer
riodic Maintenance chapter.
Air Cleaner Element Inspection
the air cleaner element (see Air Cleaner Element
• Remove
Replacement in the Periodic Maintenance chapter).
check the element [A] for tears or breaks.
• Visually
If the element has any tears or breaks, replace the element.
Air Cleaner Oil Draining
A drain hose is connected to the bottom of the air cleaner
to drain water or oil accumulated in the cleaner part.
Visually check the catch tank [A] of the drain hose, if the
water or oil accumulates in the tank.
If any water or oil accumulates in the catch tank, remove
the catch tank from the drain hose and drain it.
•
WARNING
Oil on tires will make them slippery and can cause
an accident and injury. Be sure to reinstall the catch
tank after draining.
Air Cleaner Housing Removal
• Remove:
Fuel Tank (see Fuel Tank Removal)
•
Connector Bracket [A]
Breather Hose [B]
Disconnect the intake air temperature sensor connector
[C].
• Remove the bolt [A].
FUEL SYSTEM (DFI) 3-131
Air Cleaner
• Loosen the both air cleaner duct clamp bolts [A].
up the air cleaner housing, and remove the air switch• Lift
ing valve hose [A].
removing the air cleaner housing, cover the clean
• After
cloth on the throttle body assy.
WARNING
If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident.
Air Cleaner Housing Installation
the air switching valve hose [A] to the air cleaner
• Install
housing.
the air cleaner housing on the throttle body assy.
•○Install
Install the clamp bolt heads [B] outside as shown in the
•
figure.
Tighten:
Torque - Air Cleaner Duct Clamp Bolts: 2.0 N·m (0.20 kgf·m,
18 in·lb)
the air cleaner housing mounting bolts [C].
• Tighten
Install
the
breather hose [D].
• Run the leads
and hoses correctly (see Cable, Wire, and
• Hose Routing section
in the Appendix chapter).
Install
the
removed
parts
(see appropriate chapters).
•
3-132 FUEL SYSTEM (DFI)
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the
potential for serious burns. 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 avoid fuel
spills, draw it from the tank when the engine is
cold. Be prepared for fuel spillage; any spilled fuel
must be completely wiped up immediately.
the ignition switch OFF.
• Turn
until the engine cools down.
• Wait
Disconnect
the battery (–) terminal (see Battery Removal
• in the Electrical
System chapter).
• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Front Fuel Tank Bolts [A]
• Disconnect the fuel pump lead connector [A].
the fuel tank cap [A] to lower the pressure in the
• Open
tank.
○During tank removal, keep the tank cap open to release
pressure in the tank. This makes fuel spillage less.
FUEL SYSTEM (DFI) 3-133
Fuel Tank
the fuel out from the fuel tank with a commercially
• Draw
available pump [A].
○Use a soft plastic hose [B] as a pump inlet hose in order
to insert the hose smoothly.
○Put the hose through the fill opening [C] into the tank and
draw the fuel out.
WARNING
Spilled fuel is flammable and can be explosive under certain conditions. The fuel can not be removed
completely from the fuel tank. Be careful for remained fuel spillage.
the both side cover (see Side Cover Removal in
• Remove
the Frame chapter).
• Lift up the fuel tank, and support it with a suitable bar [A].
• Remove the drain hose [A] and clamp from the fuel tank.
sure to place a piece of cloth [A] around the fuel hose
• Be
joint.
a thin blade screwdriver [B] into the slit [C] on the
• Insert
joint lock [D].
• Pry the screwdriver to disconnect the joint lock.
3-134 FUEL SYSTEM (DFI)
Fuel Tank
• Pull [A] the fuel hose joint [B] out of the outlet pipe.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. 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.
• Close the fuel tank cap.
the bar which supported fuel tank.
• Remove
For
other
California and Southeast Asia models, re• move the than
fuel tank breather hose [A] and rear fuel tank
bolt [B].
the California and Southeast Asia models, remove the
• For
following.
Fuel Return Hose [A] (red)
Fuel Tank Breather Hose [B] (blue)
Rear Fuel Tank Bolt [C]
the fuel tank, and place it on a flat surface.
•○Remove
Do not apply the load to the fuel pipe of the fuel pump.
FUEL SYSTEM (DFI) 3-135
Fuel Tank
the California and Southeast Asia models, note the
• For
following.
NOTICE
For the California and Southeast Asia models, 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.
○Be sure to plug the evaporative fuel return hose to prevent
fuel spilling before fuel tank removal.
WARNING
Spilled fuel is flammable and can be explosive under certain conditions. For California and Southeast Asia models, be careful not to spill fuel through
the return hose.
If liquid or gasoline flows into the breather hose, remove
the hose and blow it clean with compressed air.
○Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump.
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. 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
the above WARNING (see Fuel Tank Removal).
• Note
that the dampers [A], pad [B] and trims [C] are in
• Check
place on the frame and the fuel tank.
•
•
If the dampers, pad or trims are damaged or deteriorated,
replace them.
Install the drain hose and clamp securely.
Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
3-136 FUEL SYSTEM (DFI)
Fuel Tank
the California and Southeast Asia models, note the
• For
following.
○To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
○Connect the hoses according to the diagram of the evaporative emission control system. Make sure they do not
get pinched or kinked.
○Run hoses with a minimum of bending so that the air or
vapor will not be obstructed.
the fuel hose joint [A] straight onto the fuel outlet
• Insert
pipe until the hose joint clicks.
• Push [B] the joint lock [C] until the hose joint clicks.
and pull [A] the hose joint [B] back and forth more
• Push
than two times, and make sure it is locked and does not
come off.
WARNING
Make sure the hose joint is installed correctly on the
delivery pipe or the fuel could leak.
•
If it comes off, reinstall the hose joint.
Connect the fuel pump lead connector and the battery (–)
terminal (see Battery Installation in the Electrical System
chapter).
○Be careful not to pinch the leads, cables or harnesses
around rear part of the fuel tank [A].
FUEL SYSTEM (DFI) 3-137
Fuel Tank
Fuel Tank and Cap Inspection
the tank cap.
• Open
inspect the gasket [A] on the tank cap for any
• Visually
damage.
•
Replace the tank cap if gasket is damaged.
Check to see if the water drain pipe [B] and fuel breather
pipe [C] in the tank are not clogged. Check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.
NOTICE
Do not apply compressed air to the air vent holes
[D] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.
Fuel Tank Cleaning
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame anywhere near the working area. Do not use gasoline
or low-flash point solvents to clean the tank.
• Remove:
Fuel Tank (see Fuel Tank Removal)
•
•
•
•
Fuel Pump (see Fuel Pump Removal)
Pour some high-flash point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
Draw the solvent out of the fuel tank.
Dry the tank with compressed air.
Install:
Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)
3-138 FUEL SYSTEM (DFI)
Evaporative Emission Control System (CAL and SEA-B1 Models)
The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
Parts Removal/Installation
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
NOTICE
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
prevent the gasoline from flowing into or out of the
• To
canister, hold the separator perpendicular to the ground.
the hoses according to the diagram of the sys• Connect
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.
Hose Inspection
to the Evaporative Emission Control System In• Refer
spection in the Periodic Maintenance chapter.
Separator Inspection
to the Evaporative Emission Control System In• Refer
spection in the Periodic Maintenance chapter.
FUEL SYSTEM (DFI) 3-139
Evaporative Emission Control System (CAL and SEA-B1 Models)
Separator Operation Test
WARNING
Gasoline is extremely flammable and can be explosive 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.
the hoses to the separator, and install the sepa• Connect
rator on the motorcycle.
the breather hose from the separator, and in• Disconnect
ject about 20 mL (0.68 US oz.) of gasoline [A] into the
•
•
•
separator [B] through the hose fitting.
Disconnect the fuel return hose [C] from the fuel tank [D].
Run the open end of the return hose into the container
and hold it level with the tank top [E].
Start the engine, and let it idle.
If the gasoline in the separator comes out of the hose, the
separator works well. If it does not, replace the separator
with a new one.
Canister Inspection
to the Evaporative Emission Control System (CAL
• Refer
and SEA-B1 Models) Inspection in the Periodic Maintenance chapter.
3-140 FUEL SYSTEM (DFI)
Evaporative Emission Control System (CAL and SEA-B1 Models)
1. Fuel Tank
2. Green Hose (Purge)
3. Clamps
4. White Hose (Vacuum)
5. Blue Hose (Breather)
6. Canister
7. Blue Hose (Breather)
8. Separator
9. Damper (for Separator)
10. Bracket (for Separator)
11. Red Hose (Return)
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................
Coolant Flow Chart.................................................................................................................
Specifications .........................................................................................................................
Special Tools .........................................................................................................................
Coolant ...................................................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Level Inspection...................................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Pressure Testing ...............................................................................................................
Cooling System Flushing ..................................................................................................
Coolant Reserve Tank Removal/Installation .....................................................................
Water Pump............................................................................................................................
Water Pump Removal .......................................................................................................
Water Pump Installation ....................................................................................................
Water Pump Inspection.....................................................................................................
Water Pump Impeller Disassembly/Assembly ..................................................................
Water Pump Impeller Inspection .......................................................................................
Water Pump Housing Disassembly ..................................................................................
Water Pump Housing Assembly .......................................................................................
Mechanical Seal Inspection ..............................................................................................
Radiator ..................................................................................................................................
Radiator and Radiator Fan Removal ................................................................................
Radiator and Radiator Fan Installation .............................................................................
Radiator Inspection ...........................................................................................................
Radiator Cap Inspection ...................................................................................................
Radiator Filler Neck Inspection .........................................................................................
Thermostat .............................................................................................................................
Thermostat Removal.........................................................................................................
Thermostat Installation......................................................................................................
Thermostat Inspection ......................................................................................................
Hose and Pipes ......................................................................................................................
Hose Installation ...............................................................................................................
Hose Inspection ................................................................................................................
Water Temperature Sensor ....................................................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Inspection .............................................................................
4-2
4-4
4-6
4-7
4-8
4-8
4-8
4-8
4-8
4-8
4-9
4-9
4-10
4-10
4-10
4-12
4-12
4-12
4-12
4-13
4-13
4-14
4-14
4-16
4-17
4-17
4-18
4-19
4-19
4-19
4-20
4-21
4-21
4-21
4-22
4-22
4-22
4
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
No.
1
2
3
4
5
6
7
8
Fastener
Hot Windshield Mounting Bolts
Coolant By-pass Fitting Bolt
Thermostat Housing Bolts
Radiator (Water) Hose Clamp Screws
Water Pipe Bolts
Water Pump Impeller Bolt
Water Pump Cover Bolts
Coolant Drain Bolt
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
9.8
8.8
5.9
2.9
12
9.8
11
11
Torque
kgf·m
1.0
0.90
0.60
0.30
1.2
1.0
1.1
1.1
ft·lb
87 in·lb
78 in·lb
52 in·lb
26 in·lb
106 in·lb
87 in·lb
97 in·lb
97 in·lb
Remarks
L
L
L
4-4 COOLING SYSTEM
Coolant Flow Chart
1. Radiator Cap
2. Radiator Fan
3. Radiator
4. Oil Cooler
5. Cylinder Head Jacket
6. Cylinder Jacket
7. Inlet Pipe
8. Water Pump
9. Outlet Pipe
10. Water Temperature Sensor
11. Thermostat Housing
12. Reserve Tank Overflow Hose
13. Reserve Tank
14. Hot Coolant
15. Cold Coolant
COOLING SYSTEM 4-5
Coolant Flow Chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and 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 100°C (212°F), the radiator fan relay conducts to
operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the
coolant temperature is below 97.5°C (208°F), the fan relay opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure
escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi).
When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the
coolant from the reserve tank to enter the radiator.
4-6 COOLING SYSTEM
Specifications
Item
Coolant Provided when Shipping
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Radiator Cap
Relief Pressure
Thermostat
Valve Opening Temperature
Valve Full Opening Lift
Standard
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)
2.9 L (3.1 US qt) (reserve tank full level, including radiator
and engine)
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
58 ∼ 62°C (136 ∼ 144°F)
8 mm (0.31 in.) or more at 75°C (167°F)
COOLING SYSTEM 4-7
Special Tools
Bearing Driver Set:
57001-1129
Oil Seal Driver:
57001-1660
4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection
the right lower fairing (see Lower Fairing Re• Remove
moval in the Frame chapter).
inspect the coolant [A] in the reserve tank.
• Visually
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
to the Coolant Level in the Periodic Maintenance
• Refer
chapter.
Coolant Draining
to the Coolant Change in the Periodic Maintenance
• Refer
chapter.
Coolant Filling
to the Coolant Change in the Periodic Maintenance
• Refer
chapter.
Pressure Testing
the right lower fairing (see Lower Fairing Re• Remove
moval in the Frame chapter).
the radiator cap, and install a cooling system
• Remove
pressure tester [A] on the filler neck [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
up pressure in the system carefully until the pres• Build
sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
NOTICE
During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
the gauge for at least 6 seconds.
• Watch
If the pressure holds steady, the system is all right.
•
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
water pump.
Remove the pressure tester, replenish the coolant, and
install the radiator cap.
COOLING SYSTEM 4-9
Coolant
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the efficiency of the cooling system.
Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter).
Fill the cooling system with fresh water mixed with a flushing compound.
•
•
NOTICE
Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.
up the engine, and run it at normal operating tem• Warm
perature for about ten minutes.
the engine, and drain the cooling system.
• Stop
Fill
the
with fresh water.
• Warm upsystem
the
engine
and drain the system.
• Repeat the previous two
steps once more.
• Fill the system with a permanent
type coolant and bleed
• the air from the system (see Coolant
Change in the Periodic Maintenance chapter).
Coolant Reserve Tank Removal/Installation
coolant reserve tank is removed and installed dur• The
ing coolant change (see Coolant Change in the Periodic
Maintenance chapter).
4-10 COOLING SYSTEM
Water Pump
Water Pump Removal
• Drain:
Coolant (see Coolant Change in the Periodic Mainte•
nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Engine Sprocket Cover (see Engine Sprocket Cover Removal in the Final Drive chapter)
Remove the water pipe bolts [A] to pull out the water pipes
[B] from the water pump cover.
Disconnect the neutral switch connector [C].
Loosen the clamp bolt [D] to remove the water hose [E].
•
•
•
• Remove:
Water Pump Cover Bolts [A]
Water Pump Cover [B]
• Remove:
Water Pump Impeller Bolt [A] and Washer
Water Pump Impeller [B]
Water Pump Housing [C]
Water Pump Installation
• Replace the O-ring [A] with a new one, and install it.
COOLING SYSTEM 4-11
Water Pump
• Be sure to install the dowel pins [A].
• Install:
Water Pump Housing [A]
•
Water Pump Impeller [B]
Tighten:
Torque - Water Pump Impeller Bolt [C]: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Be sure to install the dowel pins [D].
• Replace the O-ring [A] with a new one, and install it.
the water pump cover [A].
• Install
• Tighten:
Torque - Water Pump Cover Bolts [B]: 11 N·m (1.1 kgf·m, 97
in·lb)
• Replace the O-ring [C] with new ones.
the water pipes [A] to the water pump cover.
• Install
a non-parmanent locking agent to the threads of
• Apply
the water pipe bolts [B], and tighten them.
Torque - Water Pipe Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
the water hose [C].
• Install
Tighten:
•
Torque - Water Hose Clamp Screw [D]: 2.9 N·m (0.30 kgf·m,
26 in·lb)
• Connect the neutral switch connector [E].
4-12 COOLING SYSTEM
Water Pump
Water Pump Inspection
the left lower fairing (see Lower Fairing Removal
• Remove
in the Frame chapter).
the drainage outlet passage [A] at the bottom of
• Check
the water pump body for coolant leaks.
If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passage. Replace the mechanical seal unit.
Water Pump Impeller Disassembly/Assembly
the water pump impeller (see Water Pump Re• Remove
moval).
sealing seat and rubber seal may be removed easily
• The
by hand.
coolant around the surfaces of the rubber seal and
• Apply
sealing seat.
the rubber seal [A] and sealing seat [B] into the
• Install
impeller by pressing them by hand until the seat stops at
•
the bottom of the hole.
Install the water pump impeller (see Water Pump Installation).
Water Pump Impeller Inspection
the water pump cover (see Water Pump Re• Remove
moval).
inspect the water pump impeller [A].
• Visually
If the surface is corroded or if the blades are damaged,
replace the impeller.
Water Pump Housing Disassembly
NOTICE
Do not damage the hole wall of the water pump
housing.
a bar [A] into the pump housing [B], and hammer
• Insert
evenly around the circumference of the mechanical seal
bottom [C].
COOLING SYSTEM 4-13
Water Pump
• Take the oil seal [A] out of the housing [B] with a hook [C].
Water Pump Housing Assembly
NOTICE
Do not reuse the mechanical seal and oil seal.
high-temperature grease to the oil seal lips [A].
• Apply
Press
the new oil seal into the housing with a bearing
• driver [B]
until it stops at the bottom surface [C] of the
housing.
Special Tool - Bearing Driver Set: 57001-1129
NOTICE
Be careful not to damage the sealing surface of the
mechanical seal.
the new mechanical seal into the housing with the
• Press
oil seal driver [A] until its flange [B] touches the surface
[C] of the housing.
Special Tool - Oil Seal Driver: 57001-1660
Mechanical Seal Inspection
the water pump impeller (see Water Pump Re• Remove
moval).
inspect the mechanical seal.
• Visually
If any one of the parts is damaged, replace the mechanical seal as a unit.
Impeller Sealing Seat Surface [A]
Rubber Seal [B]
Mechanical Seal [C]
4-14 COOLING SYSTEM
Radiator
Radiator and Radiator Fan Removal
• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
• Remove:
Radiator Hose Clamp [A]
Radiator Cap Mounting Bolt [B]
Radiator Hose [C]
• Remove:
Radiator Upper Bolt [A]
the radiator right ward [A] to clear the frame projec• Move
tion [B].
• Remove:
Rubber Band [A]
COOLING SYSTEM 4-15
Radiator
the connector cover [A] to disconnect the radiator
• Slide
fan motor lead connector [B].
• Remove:
Radiator Hose Clamp Screw [A] (Loosen)
Radiator Hose [B]
Radiator Lower Bolt [C]
NOTICE
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling efficiency.
• Remove:
Radiator Fan Mounting Bolts [A]
Radiator Fan [B]
4-16 COOLING SYSTEM
Radiator
Radiator and Radiator Fan Installation
is the reverse of removal.
• Installation
the rubber dampers [A] and radiator bracket collars
• Install
[B] as shown in the figure.
[C] Larger
[D] Smaller
the slits [A] of the heat insulation rubber plate to the up• Fit
per mounting brackets [B] and fan bracket [C] as shown.
the upper right mounting bracket [A] to the frame
• Insert
projection [B].
the radiator bolts securely.
• Tighten
Connect
radiator fan connector.
• Install thetheremoved
parts (see appropriate chapter).
•
COOLING SYSTEM 4-17
Radiator
Radiator Inspection
the radiator core.
• Check
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
NOTICE
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage:
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular [C] (not oblique
[D]) to the core surface.
Run the steam gun, following the core fin direction.
Radiator Cap Inspection
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
•
Frame chapter)
Radiator Cap
Check the condition of the bottom [A] and top [B] valve
seals and valve spring [C].
If any one of them shows visible damage, replace the cap
with a new one.
• Install the cap [A] on a cooling system pressure tester [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
the pressure gauge, pump the pressure tester
• Watching
to build up the pressure until the relief valve opens: the
gauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within
the specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi)
If the cap can not hold the specified pressure or if it holds
too much pressure, replace it with a new one.
4-18 COOLING SYSTEM
Radiator
Radiator Filler Neck Inspection
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
•
•
Frame chapter)
Radiator Cap
Check the radiator filler neck for signs of damage.
Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
COOLING SYSTEM 4-19
Thermostat
Thermostat Removal
• Remove:
Coolant (Drain,
see Coolant Change in the Periodic
Maintenance chapter)
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
Harness Holder Clamp [A]
Water Hose Clamp [B]
Water Hose [C]
Water Pipe Bolts [D]
Water Pipe [E]
the water hose clamp screw [A].
• Loosen
Clear
the
starter motor cable from the holder [B].
•
• Remove:
Thermostat Housing Bolts [A]
Thermostat Housing Cover [B]
Thermostat
Thermostat Installation
the thermostat [A] in the housing so that the air
• Install
bleeder hole [B] is on top.
4-20 COOLING SYSTEM
Thermostat
the O-ring [A] with a new one.
• Replace
Apply
grease
to the O-ring, and install it.
• Install the thermostat
housing cover.
•
NOTE
○Note that the thermostat does not move at the place
when installing the thermostat housing cover.
• Tighten:
Torque - Thermostat Housing Bolts: 5.9 N·m (0.60 kgf·m,
52 in·lb)
a non-parmanent locking agent to the threads of
• Apply
the water pipe bolt.
• Tighten:
Torque - Water Pipe Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
Radiator (Water) Hose Clamp Screws: 2.9 N·m
(0.30 kgf·m, 26 in·lb)
the hoses correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
the radiator with coolant (see Coolant Change in the
• Fill
Periodic Maintenance chapter).
Thermostat Inspection
the thermostat (see Thermostat Removal), and
• Remove
inspect the thermostat valve [A] at room temperature.
If the valve is open, replace the thermostat with a new
one.
check valve opening temperature, suspend the ther• To
mostat [A] in a container of water and raise the temperature of the water.
○The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
58 ∼ 62°C (136 ∼ 144°F)
COOLING SYSTEM 4-21
Hose and Pipes
Hose Installation
the hoses and pipes, being careful to follow bend• Install
ing direction. Avoid sharp bending, kinking, flattening or
twisting.
Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts.
•
•
Torque - Radiator (Water) Hose Clamp Screws: 2.9 N·m
(0.30 kgf·m, 26 in·lb)
Hose Inspection
to the Radiator Hose Damage and Installation Con• Refer
dition Inspection in the Periodic Maintenance chapter.
4-22 COOLING SYSTEM
Water Temperature Sensor
NOTICE
The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to the
water temperature sensor can damage it.
Water Temperature Sensor Removal/Installation
to the Water Temperature Sensor Removal/Instal• Refer
lation in the Fuel System (DFI) chapter.
Water Temperature Sensor Inspection
to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.
ENGINE TOP END 5-1
Engine Top End
Table of Contents
Exploded View...................................
Exhaust System Identification ...........
Specifications ....................................
Special Tools and Sealant .................
Clean Air System...............................
Air Suction Valve Removal...........
Air Suction Valve Installation........
Air Suction Valve Inspection ........
Air Switching Valve Removal .......
Air Switching Valve Installation ....
Air Switching Valve Operation
Test............................................
Air Switching Valve Unit Test .......
Clean Air System Hose
Inspection..................................
Cylinder Head Cover .........................
Cylinder Head Cover Removal ....
Cylinder Head Cover Installation .
Camshaft Chain Tensioner ................
Camshaft Chain Tensioner
Removal ....................................
Camshaft Chain Tensioner
Installation .................................
Camshaft, Camshaft Chain ...............
Camshaft Removal ......................
Camshaft Installation ...................
Camshaft, Camshaft Cap Wear
Inspection..................................
Camshaft Runout Inspection........
Cam Wear Inspection ..................
Camshaft Chain Removal ............
Cylinder Head....................................
Cylinder Compression
Measurement ............................
Cylinder Head Removal ...............
Cylinder Head Installation ............
Cylinder Head Warp Inspection ...
Valves ................................................
5-2
5-6
5-8
5-10
5-12
5-12
5-12
5-13
5-13
5-13
5-13
5-13
5-14
5-15
5-15
5-16
5-19
5-19
5-19
5-20
5-20
5-21
5-24
5-24
5-25
5-25
5-26
5-26
5-27
5-27
5-29
5-30
Valve Clearance Inspection .........
Valve Clearance Adjustment........
Valve Removal .............................
Valve Installation ..........................
Valve Guide Removal ..................
Valve Guide Installation ...............
Valve-to-Guide Clearance
Measurement (Wobble
Method) .....................................
Valve Seat Inspection ..................
Valve Seat Repair ........................
Cylinder, Pistons................................
Cylinder Removal.........................
Cylinder Installation......................
Piston Removal............................
Piston Installation.........................
Cylinder Wear Inspection.............
Piston Wear Inspection ................
Piston Ring, Piston Ring Groove
Wear Inspection ........................
Piston Ring Groove Width
Inspection..................................
Piston Ring Thickness Inspection
Piston Ring End Gap Inspection ..
Throttle Body Assy Holder.................
Throttle Body Assy Holder
Removal ....................................
Throttle Body Assy Holder
Installation .................................
Muffler................................................
Muffler Body Removal..................
Muffler Body Installation...............
Exhaust Pipe Removal.................
Exhaust Pipe Installation..............
Exhaust Butterfly Valve Cable
Removal ....................................
Exhaust Butterfly Valve Cable
Installation .................................
5-30
5-30
5-30
5-30
5-30
5-31
5-32
5-32
5-33
5-38
5-38
5-38
5-39
5-40
5-40
5-41
5-41
5-41
5-42
5-42
5-43
5-43
5-43
5-44
5-44
5-45
5-47
5-47
5-47
5-48
5
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Fastener
Air Suction Valve Cover Bolts
Spark Plugs
Cylinder Head Cover Bolts
Hot Windshield Mounting Bolts
Camshaft Sprocket Bolts
Front Camshaft Chain Guide Bolt (Upper)
Rear Camshaft Chain Guide Bolt
Front Camshaft Chain Guide Bolt (Lower)
Throttle Body Assy Holder Bolts
Cylinder Head Bolts (M6)
Upper Camshaft Chain Guide Bolts
Plugs
Camshaft Cap Bolts
Cylinder Head Bolts (M10) (First)
14
Cylinder Head Bolts (M10) (Final)
15 Camshaft Chain Tensioner Mounting Bolts
16 Camshaft Chain Tensioner Cap Bolt
N·m
9.8
13
9.8
9.8
15
25
25
12
12
12
12
19.6
12
20
54
11
20
Torque
kgf·m
1.0
1.3
1.0
1.0
1.5
2.5
2.5
1.2
1.2
1.2
1.2
2.0
1.2
2.0
5.5
1.1
2.0
ft·lb
87 in·lb
115 in·lb
87 in·lb
87 in·lb
11
18
18
106 in·lb
106 in·lb
106 in·lb
106 in·lb
14
106 in·lb
15
40
97 in·lb
15
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
Remarks
L
S
L
L
S
S
L
S
S, MO
S, MO
5-4 ENGINE TOP END
Exploded View
ENGINE TOP END 5-5
Exploded View
No.
1
2
3
4
5
Fastener
Exhaust Butterfly Valve Actuator Pulley Bolt
Exhaust Butterfly Valve Actuator Bolts
Muffler Body Mounting Bolts
Premuffler Chamber Mounting Bolt
Muffler Body Clamp Bolts
R: Replacement Parts
N·m
5.0
1.2
34
34
21
Torque
kgf·m
0.51
0.12
3.5
3.5
2.1
ft·lb
44 in·lb
11 in·lb
25
25
15
Remarks
5-6 ENGINE TOP END
Exhaust System Identification
Exhaust Pipe Mark Position [A]
Left Muffler Body Mark Position [A]
ENGINE TOP END 5-7
Exhaust System Identification
Right Muffler Body Mark Position [A]
Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C]
(Equipped Models)
Honeycomb Type Catalyst Positions [A]
5-8 ENGINE TOP END
Specifications
Item
Camshafts
Cam Height:
Exhaust
Intake
Camshaft Journal, Camshaft
Cap Clearance
Camshaft Journal Diameter
Camshaft Bearing Inside
Diameter
Camshaft Runout
Cylinder Head
Cylinder Compression
Cylinder Head Warp
Valves
Valve Clearance:
Exhaust
Intake
Valve Head Thickness:
Exhaust
Intake
Valve Stem Bend
Valve Stem Diameter:
Exhaust
Intake
Valve Guide Inside Diameter:
Exhaust
Intake
Valve/Valve Guide
Clearance (Wobble Method):
Exhaust
Intake
Valve Seat Cutting Angle
Valve Seating Surface:
Width:
Exhaust
Intake
Outside Diameter:
Exhaust
Intake
Valve Spring Free Length:
Exhaust
Intake
Standard
Service Limit
33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.)
34.743 ∼ 34.857 mm (1.3678 ∼ 1.3723 in.)
0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.)
33.64 mm (1.324 in.)
34.64 mm (1.364 in.)
0.17 mm (0.0067 in.)
23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.) 23.91 mm (0.9413 in.)
24.000 ∼ 24.021 mm (0.9449 ∼ 0.9457 in.) 24.08 mm (0.9480 in.)
TIR 0.02 mm (0.0008 in.) or less
(Usable Range)
966 ∼ 1 478 kPa (9.9 ∼ 15.1 kgf/cm², 140 ∼
214 psi) at 280 r/min (rpm)
– – –
0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)
0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
0.8 mm (0.031 in.)
0.5 mm (0.020 in.)
TIR 0.01 mm (0.0004 in.) or less
TIR 0.1 mm (0.004 in.)
– – –
0.05 mm (0.002 in.)
– – –
– – –
0.6 mm (0.024 in.)
0.3 mm (0.012 in.)
TIR 0.05 mm (0.002 in.)
4.455 ∼ 4.470 mm (0.1754 ∼ 0.1760 in.)
4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.)
4.44 mm (0.175 in.)
4.46 mm (0.176 in.)
4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
4.58 mm (0.180 in.)
4.58 mm (0.180 in.)
0.08 ∼ 0.14 mm (0.0031 ∼ 0.0055 in.)
0.03 ∼ 0.10 mm (0.0012 ∼ 0.0039 in.)
32°, 45°, 60°
0.31 mm (0.012 in.)
0.29 mm (0.011 in.)
– – –
0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)
0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)
– – –
– – –
24.7 ∼ 24.9 mm (0.972 ∼ 0.980 in.)
28.9 ∼ 29.1 mm (1.138 ∼ 1.146 in.)
– – –
– – –
36.62 mm (1.442 in.)
36.62 mm (1.442 in.)
35.2 mm (1.39 in.)
35.2 mm (1.39 in.)
ENGINE TOP END 5-9
Specifications
Item
Cylinder, Pistons
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Piston Ring/Groove
Clearance:
Top
Second
Piston Ring Groove Width:
Top
Second
Piston Ring Thickness:
Top
Second
Piston Ring End Gap:
Top
Second
Standard
Service Limit
76.990 ∼ 77.006 mm (3.0311 ∼ 3.0317 in.)
76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.)
0.010 ∼ 0.032 mm (0.0004 ∼ 0.0013 in.)
77.09 mm (3.035 in.)
76.82 mm (3.024 in.)
– – –
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
0.17 mm (0.0067 in.)
0.16 mm (0.0063 in.)
0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.)
0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
0.92 mm (0.0362 in.)
0.91 mm (0.0358 in.)
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
0.70 mm (0.028 in.)
0.70 mm (0.028 in.)
0.20 ∼ 0.30 mm (0.0079 ∼ 0.0118 in.)
0.38 ∼ 0.48 mm (0.0150 ∼ 0.0189 in.)
0.6 mm (0.024 in.)
0.8 mm (0.031 in.)
5-10 ENGINE TOP END
Special Tools and Sealant
Compression Gauge, 20 kgf/cm²:
57001-221
Valve Seat Cutter, 32° 57001-1119
Valve Spring Compressor Assembly:
57001-241
Valve Seat Cutter Holder Bar:
57001-1128
Piston Pin Puller Assembly:
57001-910
Valve Seat Cutter, 32° 57001-1199
Valve Seat Cutter, 45° 57001-1114
27.5:
Valve Seat Cutter Holder,
57001-1330
Valve Seat Cutter, 45° 57001-1115
32:
Valve Guide Arbor,
57001-1331
4.5:
28:
33:
4.5:
ENGINE TOP END 5-11
Special Tools and Sealant
Valve Guide Reamer,
57001-1333
4.5:
Valve Spring Compressor Adapter,
57001-1586
24:
Valve Seat Cutter, 60° 57001-1334
33:
Compression Gauge Adapter, M10 × 1.0:
57001-1601
Valve Seat Cutter, 60° 57001-1409
27:
L-Shape Hose:
57001-1606
Engine Mount Nut Wrench:
57001-1450
Washer:
57001-1612
Valve Guide Driver:
57001-1564
Liquid Gasket, TB1216B:
92104-1064
5-12 ENGINE TOP END
Clean Air System
Air Suction Valve Removal
• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Air Switching Valve (see Air Switching Valve Removal)
Stick Coil Connector (see Stick Coil Removal in the Electrical System chapter)
Connector [A] (from Bracket [B] at Left Side)
Air Suction Valve Cover Bolts [C] and Bracket
Air Suction Valve Covers [D] (Both Sides)
• Remove the air suction valves [A] on both sides.
Air Suction Valve Installation
the air suction valve so that opening [A] of the reed
• Install
faces the front and downward.
the bracket [A] as shown in the figure.
• Install
a non-permanent locking agent to the threads of
• Apply
the air suction valve cover bolts [B], and tighten them.
Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
ENGINE TOP END 5-13
Clean Air System
Air Suction Valve Inspection
the air suction valve (see Air Suction Valve Re• Remove
moval).
inspect the reeds [A] for cracks, folds, warps,
• Visually
heat damage or other damage.
•
If there is any doubt as to the condition of the reeds, replace the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high-flash point solvent.
NOTICE
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
Air Switching Valve Removal
NOTICE
Never drop the air switching valve especially on a
hard surface. Such a shock to the air switching
valve can damaged it.
the stick coils (see Stick Coil Removal in the
• Remove
Electrical System chapter).
the connector [A].
• Disconnect
Clear
the
harness
the clamp [C].
• Separate the hoses[B][D]from
from
the air switching valve [E] to
• remove the air switching valve.
Air Switching Valve Installation
the air switching valve [A] as shown in the figure.
• Install
[B] Viewed Left Side
[C] About 40°
Air Switching Valve Operation Test
to the Air Suction System Damage Inspection in the
• Refer
Periodic Maintenance chapter.
Air Switching Valve Unit Test
to the Air Switching Valve Unit Test in the Electrical
• Refer
System chapter.
5-14 ENGINE TOP END
Clean Air System
Clean Air System Hose Inspection
certain that all the hoses are routed without being flat• Be
tened or kinked, and are connected correctly to the air
cleaner housing, air switching valve and air suction valve
covers.
If they are not, correct them. Replace them if they are
damaged.
ENGINE TOP END 5-15
Cylinder Head Cover
Cylinder Head Cover Removal
• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
•
•
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
Remove:
Radiator Cap Mounting Bolt [A]
Clamp [B]
Water Hose [C]
• Remove:
Bolts [A]
Quick Rivets [B]
Brackets [C]
Right Side [D]
Left Side [E]
• Remove:
Air Switching Valve (see Air Switching Valve Removal)
•
Stick Coils (see Stick Coil Removal in the Electrical System chapter)
Quick Rivets [A]
Pull up the rubber cover [B] forward.
5-16 ENGINE TOP END
Cylinder Head Cover
• Remove:
Air Suction Valves [A] (see Air Suction Valve Removal)
Hot Windshield [B] and Air Suction Valve Cover Bracket
[C]
• Remove:
Cylinder Head Cover Bolts [A]
Cylinder Head Cover
Cylinder Head Cover Installation
• Install:
Dowel Pins [A]
Plug Hole Gaskets [B]
liquid gasket [A] to the cylinder head as shown.
•○Apply
Using a high-flash point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
Sealant - Liquid Gasket, TB1216B: 92104-1064
ENGINE TOP END 5-17
Cylinder Head Cover
the head cover gasket [A] with a new one.
• Replace
Install
the
gasket to the cylinder head cover [B].
•
pulling up the water hose on radiator cap, install the
• While
cylinder head cover from the right side.
sorp and water solution or rubber lubricant to the
• Apply
both surface of the washers.
• Install the washers with the metal side [A] faces upward.
the cover bolts following the specified tightening
• Tighten
sequence.
Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
• Install:
Air Suction Valves [A] (see Air Suction Valve Installation)
Hot Windshield [B] and Air Suction Valve Cover Bracket
[C]
If the air suction valve cover bracket [A] and hot windshield [B] has been disassembled, assemble them and
note the following.
○Tighten the hot windshield mounting bolts [C].
Torque - Hot Windshield Mounting Bolts:
kgf·m, 87 in·lb)
9.8 N·m (1.0
5-18 ENGINE TOP END
Cylinder Head Cover
the quick rivets [A].
• Install
Position
• as shown.the rubber cover [B] on the cylinder head cover
• Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-19
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
NOTICE
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below.
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in “Camshaft Chain Tensioner Installation”.
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing, and damage the valves.
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Cap Bolt [A]
Washer [B]
Spring [C]
Rod [D]
Mounting Bolts [E]
Camshaft Chain Tensioner [F]
Bracket [G]
Camshaft Chain Tensioner Installation
the O-ring [A] with a new one.
• Replace
grease to the new O-ring.
• Apply
Release
the stopper [B] and push the push rod [C] into
• the tensioner
body [D].
Install
the
tensioner
body so that the stopper faces up• ward.
the Bracket [A].
• Install
• Tighten:
Torque - Camshaft Chain Tensioner Mounting Bolts [B]: 11
N·m (1.1 kgf·m, 97 in·lb)
the rod, spring and washer.
• Install
Tighten:
•
Torque - Camshaft Chain Tensioner Cap Bolt [C]: 20 N·m
(2.0 kgf·m, 15 ft·lb)
the crankshaft 2 turns clockwise to allow the ten• Turn
sioner to expand and recheck the camshaft chain timing.
5-20 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Removal
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Re•
moval)
Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter)
Turn the crankshaft clockwise, align the #1, 4 mark on the
timing rotor with the crankcase timing mark.
TDC mark [A] for #1, 4 Pistons
Timing Mark (Crankcase Halves Mating Surface) [B]
the camshaft chain tensioner (see Camshaft
• Remove
Chain Tensioner Removal).
the upper chain guide bolts and camshaft cap
• Loosen
bolts as shown sequence [1 ∼ 20] in the figure, and re-
•
•
move them.
Remove:
Upper Chain Guide [A]
Camshaft Caps [B]
Camshafts [C]
Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.
• Remove:
Camshaft Sprocket Mounting Bolts [A]
Camshaft Sprockets [B]
NOTICE
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.
ENGINE TOP END 5-21
Camshaft, Camshaft Chain
Camshaft Installation
sure to install the following parts.
• BePlug
Hole Gaskets [A]
Dowel Pins [B]
NOTE
○The exhaust camshaft has a 8943 EX mark [A] and the
intake camshaft has a 8943 IN mark [B]. Be careful not
to mix up these shafts.
the camshaft sprockets so that position the timing
• Install
marks [A] outside.
○The
•
intake camshaft sprocket and exhaust camshaft
sprocket are identical.
Apply a non-permanent locking agent to the threads of
the camshaft sprocket bolts and tighten them.
Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11
ft·lb)
molybdenum disulfide oil solution to all cam parts
• Apply
and journals.
a wrench on the timing rotor bolt [A], turn the crank• Using
shaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor is aligned with the timing mark
[C] (Crankcase Halves Mating Surface).
NOTICE
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.
5-22 ENGINE TOP END
Camshaft, Camshaft Chain
the tension side (exhaust side) [A] of the chain taut
• Pull
to install the chain.
the camshaft chain with the sprockets so that tim• Engage
ing marks on the sprockets are positioned as shown in the
figure.
○The timing marks must be aligned with the cylinder head
upper surface [B].
EX mark [C]
IN mark [D]
#1 pin [E]
#2 pin [F]
#29 pin [G]
#30 pin [H]
ENGINE TOP END 5-23
Camshaft, Camshaft Chain
installing the camshaft caps and upper chain
• Before
guide, install the camshaft chain tensioner body tem-
•
•
porarily (see Camshaft Chain Tensioner Installation).
Install the camshaft caps and upper camshaft chain guide
[A] as shown in the figure.
Identification No. 1 ∼ 4 (Camshaft Cap) [B]
First tighten the all camshaft cap bolts and upper
camshaft chain guide bolts evenly to seat the camshaft
in place, then tighten all bolts following the specified
tightening sequence.
Torque - Camshaft Cap Bolts [1 ∼ 18]: 12 N·m (1.2 kgf·m,
106 in·lb)
Upper Camshaft Chain Guide Bolts [19, 20]: 12
N·m (1.2 kgf·m, 106 in·lb)
the camshaft chain tensioner (see Camshaft Chain
• Install
Tensioner Installation).
the crankshaft 2 turns clockwise to allow the ten• Turn
sioner to expand and recheck the camshaft chain timing.
the cylinder head cover (see Cylinder Head Cover
• Install
Installation).
5-24 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft, Camshaft Cap Wear Inspection
• Remove:
Upper Chain Guide (see Camshaft Removal)
•
•
•
Camshaft Caps (see Camshaft Removal)
Cut strips of plastigage (press gauge) to journal width.
Place a strip on each journal parallel to the camshaft installed in the correct position.
Measure each clearance between the camshaft journal
and the camshaft cap using plastigage [A].
Tighten the camshaft cap bolts (see Camshaft Installation).
NOTE
○Do not turn the camshaft when the plastigage is between the journal and camshaft cap.
Camshaft Journal, Camshaft Cap Clearance
Standard:
0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.)
Service Limit:
0.17 mm (0.0067 in.)
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard:
23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.)
Service Limit:
23.91 mm (0.9413 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the limit, replace the
cylinder head unit.
Camshaft Runout Inspection
the camshafts (see Camshaft Removal).
• Remove
the camshaft in a camshaft alignment jig or on V
• Set
blocks.
runout with a dial gauge at the specified place
• Measure
as shown in the figure.
If 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.)
ENGINE TOP END 5-25
Camshaft, Camshaft Chain
Cam Wear Inspection
the camshafts (see Camshaft Removal).
• Remove
the height [A] of each cam with a micrometer.
• Measure
If the cams are worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust
33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.)
Intake
34.743 ∼ 34.857 mm (1.3678 ∼ 1.3723 in.)
Service Limit:
Exhaust
33.64 mm (1.324 in.)
Intake
34.64 mm (1.364 in.)
Camshaft Chain Removal
the crankcase (see Crankcase Splitting in the Crank• Split
shaft/Transmission chapter).
the camshaft chain [A] from the crankshaft
• Remove
sprocket.
5-26 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
NOTE
○Use the battery which is fully charged.
up the engine thoroughly.
• Warm
Stop
the
• Remove: engine.
• Stick Coils (see Stick Coil Removal in the Electrical System chapter)
Spark Plugs (see Spark Plug Replacement in the Periodic Maintenance chapter)
the compression gauge [A] and adapter [B] firmly
• Attach
into the spark plug hole.
○Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1601
L-Shape Hose: 57001-1606
Cylinder Compression
Usable Range:
966 ∼ 1 478 kPa (9.9 ∼ 15.1 kgf/cm²,
140 ∼ 214 psi) at 280 r/min (rpm)
the measurement for the other cylinders.
• Repeat
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 compression reading is not within the usable range.
Problem
Diagnosis
Cylinder compression Carbon accumulation on piston and in
is higher than usable combustion chamber possibly due to
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
Cylinder compression Gas leakage around cylinder head
is lower than usable
range
Bad condition of valve seating
Incorrect valve clearance
Incorrect piston/cylinder clearance
Piston seizure
Bad condition of piston ring and/or
piston ring grooves.
Remedy (Action)
Remove the carbon deposits
and replace damaged parts if
necessary.
Replace the gasket with a standard
part.
Replace damaged check gasket
and cylinder head warp.
Repair if necessary.
Adjust the valve clearance.
Replace the piston and/or cylinder.
Inspect the cylinder and
replace/repair the cylinder and/or
piston as necessary.
Replace the piston and/or the
piston rings.
ENGINE TOP END 5-27
Cylinder Head
Cylinder Head Removal
• Remove:
Coolant (Drain,
see Coolant Change in the Periodic
Maintenance chapter)
Camshafts (see Camshaft Removal)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Exhaust Pipe (see Exhaust Pipe Removal)
the water temperature sensor connector [A].
• Disconnect
• Remove:
Clamps [B]
Water Hoses [C]
• Remove:
Timing Rotor (see Timing Rotor Removal in the Electrical
System chapter)
Front Camshaft Chain Guide Bolts [A]
Front Camshaft Chain Guide [B]
Rear Camshaft Chain Guide Bolt [C]
Rear Camshaft Chain Guide [D]
• Loosen:
Lower Engine Bracket Bolts (Both Sides) [A]
•
•
Upper Engine Mounting Bolts (Left)
Remove:
Upper Engine Mounting Bolts (Right) [B]
Loosen:
Upper Adjusting Collar Locknut [C]
Special Tool - Engine Mount Nut Wrench: 57001-1450
• Loosen:
Upper Adjusting Collar [D]
the M6 cylinder head bolts [A].
• Remove
Loosen
the
cylinder head bolts as shown sequence
• [1 ∼ 10] in theM10figure,
and remove them with washers.
Remove
the
cylinder
head.
•
Cylinder Head Installation
NOTE
○The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.
5-28 ENGINE TOP END
Cylinder Head
the cylinder head gasket [A] with a new one.
• Replace
Install
the
dowel pins [B] and cylinder head gasket.
•
the cylinder head bolt washers [A] with new ones.
• Replace
Apply
molybdenum
oil solution to both sides [B]
• of the cylinder headdisulfide
bolt washers and threads [C] of the
bolts.
the M10 cylinder head bolts following the tighten• Tighten
ing sequence [1 ∼ 10].
Torque - Cylinder Head Bolts (M10):
First
20 N·m (2.0 kgf·m, 15 ft·lb)
Final
54 N·m (5.5 kgf·m, 40 ft·lb)
• Tighten:
Torque - Cylinder Head Bolts (M6) [A]: 12 N·m (1.2 kgf·m,
106 in·lb)
Upper Adjusting Collar: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Upper Adjusting Collar Locknut: 4.9 N·m (5.0
kgf·m, 36 ft·lb)
Upper Engine Mounting Bolts: 44 N·m (4.5 kgf·m,
32 ft·lb)
Lower Engine Bracket Bolts: 59 N·m (6.0 kgf·m,
44 ft·lb)
ENGINE TOP END 5-29
Cylinder Head
• Install:
Front Camshaft Chain Guide [A]
Rear Camshaft Chain Guide [B]
New O-rings [C]
Collar [D]
Apply
grease to the new O-ring.
○
Tighten:
•
Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25
N·m (2.5 kgf·m, 18 ft·lb)
Front Camshaft Chain Guide Bolt (Lower) [F]: 12
N·m (1.2 kgf·m, 106 in·lb)
Rear Camshaft Chain Guide Bolt [G]: 25 N·m (2.5
kgf·m, 18 ft·lb)
• Install the removed parts (see appropriate chapters).
Cylinder Head Warp Inspection
the cylinder head.
• Clean
Lay
a
straightedge
across the lower surface of the cylinder
• head at several positions.
a thickness gauge [A] to measure the space between
• Use
the straightedge [B] and the head.
Cylinder Head Warp
–––
Standard:
Service Limit:
0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).
5-30 ENGINE TOP END
Valves
Valve Clearance Inspection
to the Valve Clearance Inspection in the Periodic
• Refer
Maintenance chapter.
Valve Clearance Adjustment
to the Valve Clearance Adjustment in the Periodic
• Refer
Maintenance chapter.
Valve Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Valve Lifter and Shim
○Mark and record the valve lifter and shim locations so they
•
can be installed in their original positions.
Using the valve spring compressor assembly, remove the
valve.
Special Tools - Valve Spring Compressor Assembly [A]:
57001-241
Valve Spring Compressor Adapter, 24 [B]:
57001-1586
Valve Installation
the oil seal with a new one.
• Replace
Apply
a
thin
coat of molybdenum disulfide grease to the
• valve stem before
valve installation.
Install
the
springs
so
that the closed coil end faces down• wards.
Valve Stem [A]
Oil Seal [B]
Spring Seat [C]
Closed Coil End [D]
Valve Spring [E]
Retainer [F]
Split Keepers [G]
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
•
Oil Seal
Spring Seat
Heat the area around the valve guide to 120 ∼ 150°C (248
∼ 302°F), and hammer lightly on the valve guide arbor [A]
to remove the guide from the top of the head.
NOTICE
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Special Tool - Valve Guide Arbor,
4.5: 57001-1331
ENGINE TOP END 5-31
Valves
Valve Guide Installation
oil to the valve guide outer surface before installa• Apply
tion.
the area around the valve guide hole to about 120 ∼
• Heat
150°C (248 ∼ 302°F).
NOTICE
Do not heat the cylinder head with a torch. This Will
warp the cylinder head. Soak the cylinder head and
heat the oil.
the valve guide driver [A] and two washers [B],
• Using
press and insert the valve guide in until the valve guide
driver surface [C] touches the head surface [D].
12.8 ∼ 13.0 mm (0.504 ∼ 0.512 in.) [E]
Special Tools - Valve Guide Driver: 57001-1564
Washer: 57001-1612
the valve guide with valve guide reamer [A], even
• Ream
if the old guide is reused.
Special Tool - Valve Guide Reamer,
4.5: 57001-1333
5-32 ENGINE TOP END
Valves
Valve-to-Guide Clearance Measurement (Wobble
Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve
guide clearance.
Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
•
•
•
NOTE
○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
Exhaust
0.08 ∼ 0.14 mm (0.0031 ∼ 0.0055 in.)
Intake
0.03 ∼ 0.10 mm (0.0012 ∼ 0.0039 in.)
Service Limit:
Exhaust
0.31 mm (0.012 in.)
Intake
0.29 mm (0.011 in.)
Valve Seat Inspection
the valve (see Valve Removal).
• Remove
Check
the
valve seating surface [A] between the valve [B]
• and valve seat
[C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust
24.7 ∼ 24.9 mm (0.972 ∼ 0.980 in.)
Intake
28.9 ∼ 29.1 mm (1.138 ∼ 1.146 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust
0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)
Intake
0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)
ENGINE TOP END 5-33
Valves
Valve Seat Repair
• Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder Bar [B]: 57001
-1128
Valve Seat Cutter Holder, 4.5 [C]: 57001
-1330
[For Exhaust Valve Seat]
Valve Seat Cutter, 45° -
27.5: 57001-1114
Valve Seat Cutter, 32° -
28: 57001-1119
Valve Seat Cutter, 60° -
27: 57001-1409
[For Intake Valve Seat]
Valve Seat Cutter, 45° -
32: 57001-1115
Valve Seat Cutter, 32° -
33: 57001-1199
Valve Seat Cutter, 60° -
33: 57001-1334
If the manufacturer’s instructions are not available, use
the following procedure.
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond 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
○Do 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
○Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
37.5 ....................... Outer diameter of cutter [C]
5-34 ENGINE TOP END
Valves
Operating Procedures
Clean the seat area carefully.
Coat the seat with machinist’s dye.
Fit a 45° cutter into the holder and slide it into the valve
guide.
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
•
•
•
•
NOTICE
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylinder head must be replaced.
the outside diameter of the seating surface with
• Measure
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the specified 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]
the outside diameter of the seating surface with
• Measure
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machinist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
ENGINE TOP END 5-35
Valves
If the outside diameter [A] of the seating surface is too
large, make the 32° grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described below.
Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
•
NOTICE
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to prevent overgrinding.
○After making the 32° grind, return to the seat outside di-
•
ameter measurement step above.
To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.
If the seat width is too wide, make the 60° [A] grind described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
Grind the seat at a 60° angle until the seat width is within
the specified range.
○To make the 60° grind, fit 60° cutter into the holder, and
slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° grind, return to the seat width measurement step above.
Correct Width [B]
•
5-36 ENGINE TOP END
Valves
the valve to the seat, once the seat width and outside
• Lap
diameter are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with a fine grinding compound.
Lapper [A]
Valve Seat [B]
Valve [C]
The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Inspection in the Periodic
Maintenance chapter).
•
•
•
ENGINE TOP END 5-37
Valves
5-38 ENGINE TOP END
Cylinder, Pistons
Cylinder Removal
• Remove:
Lower Radiator Bolt [A]
Radiator Bracket Bolt [B]
Radiator Bracket [C]
Cylinder Head (see Cylinder Head Removal)
Engine Bracket (see Engine Removal in the Engine Removal/Installation chapter)
• Remove:
Water Hose Clamp Screw (Loosen) [A]
Water Hose [B]
• Remove:
Upper Engine Mounting Bolts (Both Sides) [A]
• Loosen:
Upper Adjusting Collar Locknut [B]
Special Tool - Engine Mount Nut Wrench [C]: 57001-1450
• Loosen:
Upper Adjusting Collar [D]
• Remove:
Cylinder [A]
NOTE
○If it is hard to remove it, tap lightly using a plastic-faced
mallet [B].
Cylinder Installation
NOTE
○If a new cylinder is used, use new piston ring.
the cylinder gasket [A] with a new one.
• Replace
Install
the
dowel pins [B] and new cylinder gasket.
• Apply molybdenum
disulfide oil solution to the cylinder
• bore.
ENGINE TOP END 5-39
Cylinder, Pistons
piston ring openings must be positioned as shown in
• The
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]
Upper Oil Ring Steel Rail [C]
Oil Ring Expander [D]
Lower Oil Ring Steel Rail [E]
Dent [F]
30 ∼ 40° [G]
the crankshaft at #2, 3 piston TDC.
• Position
Prepare
two
head bolts with their head cut.
•○Install the twoauxiliary
cylinder head bolts [A] diagonally in the
crankcase.
Install the cylinder block [B].
Pistons [C]
○First insert the #2, 3 pistons, and then rotate the crankshaft at 90° angle.
Tighten the upper engine mounting bolts and engine
bracket bolts after cylinder head bolts tightend.
•
•
Piston Removal
the cylinder (see Cylinder Removal).
• Remove
Place
a
clean
cloth under the pistons and remove the pis• ton pin snap ring
[A] from the outside of each piston.
• Remove the piston pins.
Special Tool - Piston Pin Puller Assembly [A]: 57001-910
• Remove the pistons.
spread the ring opening with your thumbs and
• Carefully
then push up on the opposite side of the ring [A] to remove
•
it.
Remove the 3-piece oil ring with your thumbs in the same
manner.
5-40 ENGINE TOP END
Cylinder, Pistons
Piston Installation
molybdenum disulfide oil solution to the oil ring ex• Apply
pander, and install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] not butt together.
Apply molybdenum disulfide oil solution to the oil ring steel
rails, and install the oil ring steel rails, one above the expander and one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
•
NOTE
○The oil ring rails have no “top” or “bottom”.
not mix up the top and second ring.
• Do
Install
the top ring [A] so that the “1T” mark [B] faces up.
• Install the
second ring [C] so that the “2T” mark [D] faces
• up.
○Apply
molybdenum disulfide oil solution to the piston
rings.
NOTE
○If a new piston is used, use new piston ring.
• Install the piston with its dent mark facing forward.
a new piston pin snap ring into the side of the piston
• Fit
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○Apply molybdenum disulfide oil solution to the piston pins
and piston journals.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
NOTICE
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
• Install the cylinder (see Cylinder Installation).
Cylinder Wear Inspection
there is a difference in cylinder wear in different di• Since
rections, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) as shown in the figure.
If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.
10 mm (0.39 in.) [A]
60 mm (2.36 in.) [B]
Cylinder Inside Diameter
Standard:
76.990 ∼ 77.006 mm (3.0311 ∼ 3.0317 in.)
Service Limit:
77.09 mm (3.035 in.)
ENGINE TOP END 5-41
Cylinder, Pistons
Piston Wear Inspection
the outside diameter [A] of each piston 11 mm
• Measure
(0.43 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the piston.
Piston Diameter
Standard:
76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.)
Service Limit: 76.82 mm (3.024 in.)
Piston Ring, Piston Ring Groove Wear Inspection
for uneven groove wear by inspecting the ring seat• Check
ing.
•
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
Second
0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
Service Limit:
Top
0.17 mm (0.0067 in.)
Second
0.16 mm (0.0063 in.)
Piston Ring Groove Width Inspection
the piston ring groove width.
•○Measure
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard:
Top [A]
0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.)
Second [B]
0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
Service Limit:
Top [A]
0.92 mm (0.0362 in.)
Second [B]
0.91 mm (0.0358 in.)
If the width of any of the two grooves are wider than the
service limit at any point, replace the piston.
5-42 ENGINE TOP END
Cylinder, Pistons
Piston Ring Thickness Inspection
the piston ring thickness.
•○Measure
Use the micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top [A]
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Second [B]
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Service Limit:
Top [A]
0.70 mm (0.028 in.)
Second [B]
0.70 mm (0.028 in.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
○When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
Piston Ring End Gap Inspection
the piston ring [A] inside the cylinder, using the pis• Place
ton to locate the ring squarely in place. Set it close to the
•
bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top
0.20 ∼ 0.30 mm (0.0079 ∼ 0.0118 in.)
Second
0.38 ∼ 0.48 mm (0.0150 ∼ 0.0189 in.)
Service Limit:
Top
0.6 mm (0.024 in.)
Second
0.8 mm (0.031 in.)
If the end gap of either ring is greater than the service
limit, replace all the rings.
ENGINE TOP END 5-43
Throttle Body Assy Holder
Throttle Body Assy Holder Removal
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Clamps [A]
Bolts [B]
Throttle Body Assy Holders [C]
Throttle Body Assy Holder Installation
the O-rings [A] with new ones.
• Replace
grease to the O-rings, and install them.
• Apply
Apply
a
non-parmanent locking agent to the throttle body
• assy holder
bolts.
Tighten:
•
Torque - Throttle Body Assy Holder Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
the clamps [A] so that their projections [B] fit on the
• Install
holes [C] of the holders.
○Be sure that the clamp bolt heads [A] face as shown in
the figure.
5-44 ENGINE TOP END
Muffler
WARNING
The exhaust pipe or muffler body can become extremely hot during normal operation and cause severe burns. Do not remove the exhaust pipe or muffler body while it is hot.
Muffler Body Removal
Left Muffler Body
Loosen the muffler body clamp bolt [A].
Remove:
Left Muffler Body Mounting Bolt [B] and Nut
Left Muffler Body [C]
•
•
Right Muffler Body
Clear the exhaust butterfly valve cables [A] from the clamp
[B].
•
• Remove:
Rear Lower Fairing (see Rear Lower Fairing Removal in
•
the Frame chapter)
Remove the holder clamp bolt [A] to free the holder clamp
[B] from the frame.
the dust covers [A].
• Slide
the locknuts [B], and turn the adjusters [C] to give
• Loosen
the cable plenty of play.
ENGINE TOP END 5-45
Muffler
• Remove:
Muffler Body Clamp Bolt [A] (Loosen)
Right Muffler Body Mounting Bolt [B] and Nut
Right Muffler Body [C] (with the cable installed)
• Remove:
Bolts [A]
Exhaust Butterfly Valve Pulley Cover [B]
the locknuts [A].
• Loosen
Remove
the cable lower ends [B].
•
Muffler Body Installation
the muffler body gaskets [A] with new ones.
• Replace
Install
the
body gaskets until it is bottomed so that
• the inside muffler
chamfer side faces rear [B].
the muffler body clamps [C] so that the insert the
• Install
projection [D] into the clamp slit [E].
•
•
•
•
Downside [F]
Inside [G]
Viewed from Rear [H]
Install the exhaust butterfly valve cables (see Exhaust
Butterfly Valve Cable Installation).
Install the muffler bodies until it stops at the bottom surface of the exhaust pipe.
Install the muffler body mounting bolts and nuts.
Tighten:
Torque - Muffler Body Mounting Bolts [I]: 34 N·m (3.5 kgf·m,
25 ft·lb)
the muffler body clamps outward until it stops at the
• Turn
slit ends.
• Tighten:
Torque - Muffler Body Clamp Bolt [J]: 21 N·m (2.1 kgf·m, 15
ft·lb)
5-46 ENGINE TOP END
Muffler
warm up the engine, wait until the engine
• Thoroughly
cools down, retighten all the bolts and nuts.
the removed parts (see appropriate chapters).
•○Install
When installing, run the cables correctly (see Cable, Wire,
and Hose Routing section in the Appendix chapter).
ENGINE TOP END 5-47
Muffler
Exhaust Pipe Removal
• Remove:
Muffler Bodies (see Muffler Body Removal)
•
•
Oxygen Sensor (see Oxygen Sensor Removal
(Equipped Models) in the Electrical System chapter)
Support the premuffler chamber with the suitable stand
[A].
Loosen the premuffler chamber mounting bolt [B].
• Remove:
Exhaust Pipe Holder Nuts [A]
Exhaust Pipe (Premuffler Chamber) [B]
(In the photo, the radiator has been removed for clarity)
Exhaust Pipe Installation
the exhaust pipe gaskets [A] with new ones and
• Replace
install them.
the exhaust pipe.
• Install
Tighten
• bolt [C]. the exhaust pipe holder nuts [B] and mounting
Torque - Premuffler Chamber Mounting Bolt [C]: 34 N·m
(3.5 kgf·m, 25 ft·lb)
the muffler bodies (see Muffler Body Installation).
• Install
Thoroughly
up the engine, wait until the engine
• cools down, warm
retighten all the bolts and nuts.
the removed parts (see appropriate chapters).
•○Install
When installing, run the cables and leads correctly (see
Cable, Wire, and Hose Routing section in the Appendix
chapter).
Exhaust Butterfly Valve Cable Removal
• Remove:
Clamp [A]
•
Exhaust Butterfly Valve Cable Upper Ends [B]
Exhaust Butterfly Valve Cables [C]
Remove the cable lower ends (see Muffler Body Removal).
5-48 ENGINE TOP END
Muffler
Exhaust Butterfly Valve Cable Installation
whether pulley [A] is an angle as shown in the
• Confirm
figure.
41.7° ±0.7° [B]
○This position is original position of the pulley.
NOTE
○Correct the position electrically after confirming use is
discontinued and there is no damage when differing
from the angle of shown in the figure.
NOTICE
Do not correct the pulley position with the tool,
forcibly. The actuator damage will occur.
If the angle is wrong, adjust the pulley (see Exhaust Butterfly Valve Actuator Installation in the Fuel System (DFI)
chapter).
the exhaust butterfly valve cables correctly (see
• Run
Cable, Wire, and Hose Routing section in the Appendix
chapter).
Install the lower ends of the exhaust butterfly valve cables
to the pulley of the right muffler body as shown in the
figure.
○Make sure fit the guides [A] on the cable to the holder
grooves [B].
Open Cable (White) [C]
Close Cable (Black) [D]
Tighten the cable locknut securely.
Install the right muffler body (see Muffler Body Installation).
•
•
•
ENGINE TOP END 5-49
Muffler
the upper ends of the exhaust butterfly valve ca• Install
bles to the pulley of the exhaust butterfly valve actuator,
following the specified installing sequence.
○First, install the close cable (black) [A].
○Second, install the open cable (white) [B].
○Third, stretch the open cable (white) by using the adjuster
[C].
○Turn the adjuster counterclockwise until the play of the
open cable becomes no play.
NOTICE
To keep the correct exhaust butterfly valve position,
be sure to adjust the open cable first. Do not overstretch the cable.
○Fourth, tighten the adjuster locknut (white) [D] of the open
cable securely.
○Fifth, stretch the close cable (black) by using the adjuster
[E].
○Turn the adjuster counterclockwise until the play of the
close cable becomes no play.
○Sixth, turn the adjuster of the close cable (black) clockwise by 1/2 to 1 rotation.
○Seventh, tighten the adjuster locknut (black) [F] of the
close cable securely.
After installation, cover the dust covers on the adjusters.
Fix the exhaust butterfly valve cables with the clamps [G].
Run the exhaust butterfly cables into the holder clamps,
and install the holder clamps.
After connecting the cables, turn the ignition switch ON
and make sure that the pulley turns clockwise and counterclockwise, then it returns clockwise slightly.
•
•
•
•
CLUTCH 6-1
Clutch
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tool and Sealant ........................................................................................................
Clutch Lever and Cable ..........................................................................................................
Clutch Lever Free Play Inspection ....................................................................................
Clutch Lever Free Play Adjustment ..................................................................................
Clutch Cable Removal ......................................................................................................
Clutch Cable Installation ...................................................................................................
Clutch Cable Lubrication...................................................................................................
Clutch Lever Assembly Installation ...................................................................................
Clutch Cover...........................................................................................................................
Clutch Cover Removal ......................................................................................................
Clutch Cover Installation ...................................................................................................
Release Shaft Removal ....................................................................................................
Release Shaft Installation .................................................................................................
Clutch Cover Disassembly................................................................................................
Clutch Cover Assembly.....................................................................................................
Clutch .....................................................................................................................................
Clutch Removal.................................................................................................................
Clutch Installation..............................................................................................................
Clutch Plate Assembly Inspection.....................................................................................
Clutch Plate Assembly Adjustment ...................................................................................
Clutch Plate, Wear, Damage Inspection ...........................................................................
Clutch Plate Warp Inspection............................................................................................
Clutch Spring Free Length Measurement .........................................................................
Clutch Housing Finger Inspection .....................................................................................
Clutch Housing Spline Inspection .....................................................................................
6-2
6-4
6-5
6-6
6-6
6-6
6-6
6-6
6-6
6-6
6-7
6-7
6-7
6-7
6-8
6-8
6-9
6-10
6-10
6-10
6-13
6-13
6-14
6-14
6-14
6-14
6-14
6
6-2 CLUTCH
Exploded View
CLUTCH 6-3
Exploded View
No.
1
2
3
4
5
Fastener
Clutch Lever Assembly Clamp Bolts
Clutch Cover Bolts
Oil Filler Plug
Clutch Spring Bolts
Clutch Hub Nut
N·m
7.8
9.8
2.0
9.0
135
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
Torque
kgf·m
0.80
1.0
0.20
0.90
13.8
ft·lb
69 in·lb
87 in·lb
18 in·lb
80 in·lb
99.6
Remarks
S
R
6-4 CLUTCH
Specifications
Item
Clutch Lever Free Play
Clutch
Clutch Plate Assembly Length
Friction Plate Thickness
Friction and Steel Plate Warp
Clutch Spring Free Length
Standard
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
51.1 ∼ 51.7 mm (2.01 ∼ 2.04 in.)
2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.)
0.15 mm (0.0059 in.) or less
64.8 mm (2.55 in.)
Service Limit
– – –
– – –
2.4 mm (0.094 in.)
0.3 mm (0.012 in.)
61.8 mm (2.43 in.)
CLUTCH 6-5
Special Tool and Sealant
Clutch Holder:
57001-1243
Liquid Gasket, TB1211F:
92104-0004
6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection
to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.
Clutch Lever Free Play Adjustment
to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.
Clutch Cable Removal
the right lower fairing (see Lower Fairing Re• Remove
moval in the Frame chapter).
the dust cover [A] at the clutch cable lower end out
• Slide
of place.
the nuts [B], and slide the lower end of the clutch
• Loosen
cable to give the cable plenty of play.
in the adjuster [A].
• Screw
Line
up
[B] in the clutch lever and adjuster, and
• then freethetheslots
cable from the lever.
Free
the
clutch
inner cable tip from the clutch release
• lever.
• Pull the clutch cable out of the frame.
Clutch Cable Installation
the clutch cable correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
the clutch cable (see Clutch Operation Inspection
• Adjust
in the Periodic Maintenance chapter).
Clutch Cable Lubrication
to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.
Clutch Lever Assembly Installation
the clutch lever so that the mating surface [A] of the
• Install
clutch lever clamp is aligned with the punch mark [B].
the upper clamp bolt first, and then the lower
• Tighten
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
CLUTCH 6-7
Clutch Cover
Clutch Cover Removal
• Remove:
Rear Lower Fairing (see Rear Lower Fairing Removal in
the Frame chapter)
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Clutch Cable Lower End
Clutch Cover Mounting Bolts [A]
the release lever [A] toward the rear as shown in the
• Turn
figure, and remove the clutch cover [B].
About 90° [C]
Clutch Cover Installation
sure to dowel pins [A].
• Be
silicone sealant to the area [B] where the mating
• Apply
surface of the crankcase touches the clutch cover gasket.
○Using a high-flash point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
Sealant - Liquid Gasket, TB1211F: 92104-0004
the clutch cover gasket with a new one and install
• Replace
it.
• Tighten:
Torque - Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Release Shaft Removal
NOTICE
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required.
the clutch cover (see Clutch Cover Removal).
• Remove
Pull
the
release
lever and shaft assembly [A] straight out
• of the clutch cover.
6-8 CLUTCH
Clutch Cover
Release Shaft Installation
grease to the oil seal lips on the upper ridge of the
• Apply
clutch cover.
engine oil to the needle bearings in the hole of the
• Apply
clutch cover.
molybdenum disulfide grease to the pusher-holding
• Apply
portion [A] on the release shaft.
the washer [B] and spring [C].
• Install
Insert
the
release shaft straight into the upper hole of the
• clutch cover.
NOTICE
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
the spring [A] as shown in the figure.
• FitViewed
from Rear [B]
Release Shaft [C]
Clutch Cover [D]
Clutch Cover Disassembly
• Remove:
Clutch Cover (see Clutch Cover Removal)
Release Lever and Shaft Assembly (see Release Shaft
Removal)
Oil Filler Plug [A]
Oil Seal [B]
Needle Bearing [C]
• Remove:
Needle Bearing [A]
Oil Level Gauge [B]
CLUTCH 6-9
Clutch Cover
Clutch Cover Assembly
• Replace the needle bearings and oil seal with new ones.
NOTE
○Install the needle bearings so that the manufacture’s
mark face out.
the needle bearings [A] and oil seal [B] position as
• Install
shown in the figure.
Press the needle bearing until the bottom [C].
Press the needle bearing so that the bearing surface [D]
is flush with the housing end of clutch cover [E].
water to the rubber portion [A] of the oil level gauge.
• Apply
Press
the gauge until the bottom so that its projection [B]
• faces inside
of the clutch cover [C].
the O-ring [A] of the oil filler plug [B] with a new
• Replace
one.
grease to the O-ring.
• Apply
• Tighten:
Torque - Oil Filler Plug: 2.0 N·m (0.20 kgf·m, 18 in·lb)
6-10 CLUTCH
Clutch
Clutch Removal
• Remove:
Clutch Cover (see Clutch Cover Removal)
•
Clutch Spring Bolts [A]
Clutch Springs
Clutch Spring Plate [B] (with Washer, Needle Bearing
and Pusher [C])
Remove:
Friction Plates and Steel Plates
Spring and Spring Seat
NOTE
○The two plates at both ends are different from the plate
installed between these plates.
However, it is impossible to identify it on externals.
○Mark and record the locations of the friction plates so
that they can be reinstalled in their original positions.
the clutch hub [A], remove the nut [B] and wash• Holding
ers.
Special Tool - Clutch Holder [C]: 57001-1243
• Remove:
Clutch Hub
Spacer ( 47 ×
25.5)
the two M4 bolts or screws [A], pull out the sleeve
• Using
[B], and then remove the needle bearing [C] and clutch
•
housing.
Remove the spacer ( 56 ×
25).
Clutch Installation
the spacer (
• Install
[B] faces inward.
56 × 25) [A] so that the tapered side
CLUTCH 6-11
Clutch
the clutch housing [A] to the drive shaft.
• Install
While
holding
the clutch housing, install the needle bear• ing [B] and sleeve
[C].
○The holes [D] of the sleeve face outward.
the following parts to the drive shaft.
• Install
Spacer ( 47 × 25.5) [A]
Clutch Hub
the washer [A] so that the “OUTSIDE” mark [B]
• Install
faces outward.
the clutch hub nut with a new one.
• Replace
• Holding the clutch hub, tighten the clutch hub nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 135 N·m (13.8 kgf·m, 99.6 ft·lb)
the spring seat [A] and spring [B] as shown in the
• Install
figure.
Clutch Hub [C]
6-12 CLUTCH
Clutch
the friction plates and steel plates, starting with a
• Install
friction plate and alternating them.
NOTE
○Install the both ends marked two friction plates at disassembled to the their original position.
○When replace the friction plates with new ones, mark
the both ends two friction plates so that the two kinds of
friction plates do not mix up at opening the package.
NOTICE
If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
○Install
the last friction plate [A] fitting the tangs in the
grooves in the housing as shown in the figure.
molybdenum disulfide grease to the pusher shaft
• Apply
[A].
engine oil to the needle bearing [B].
• Apply
the pusher [C], needle bearing and washer [D] in
• Install
the clutch spring plate [E].
the clutch spring plate so that there are no gap [A].
• Install
If it has gap [B], turn the clutch spring plate to install it
•
•
again.
[C] Correct
[D] Wrong
Install:
Clutch Springs
Tighten:
Torque - Clutch Spring Bolts: 9.0 N·m (0.90 kgf·m, 80 in·lb)
• Install the clutch cover (see Clutch Cover Installation).
CLUTCH 6-13
Clutch
Clutch Plate Assembly Inspection
the friction plate thickness (see Clutch Plate,
• Inspect
Wear, Damage Inspection).
the length [A] of the clutch plate assembly as
• Measure
shown in the figure.
○Assemble:
Clutch Hub [B]
Spring Seat [C]
Spring [D]
Friction Plates [E]
Steel Plates [F]
Clutch Spring Plate [G]
Clutch Springs [H]
Clutch Spring Bolts [I]
NOTE
○Install the both ends marked two friction plates at disassembled to the their original position.
Torque - Clutch Spring Bolts: 9.0 N·m (0.90 kgf·m, 80 in·lb)
Clutch Plate Assembly Length
Standard: 51.1 ∼ 51.7 mm (2.01 ∼ 2.04 in.)
If the length is not within the specified range, adjust the
length (see Clutch Plate Assembly Adjustment).
Clutch Plate Assembly Adjustment
the clutch plate assembly length, and then re• Inspect
place the steel plate(s) which brings the length within the
•
•
specified range.
Remove:
Clutch Spring Bolts
Clutch Springs
Clutch Spring Plate
Replace the following steel plate(s).
Thickness
Part Number
2.3 mm (0.091 in.)
13089-0008
2.6 mm (0.102 in.)
13089-0009
2.9 mm (0.114 in.)
13089-1093
NOTE
○Do not use the steel plate of 2.3 mm (0.091 in.) and 2.9
mm (0.114 in.) thickness at the same time.
the removed parts, and inspect the clutch plate as• Install
sembly length.
Torque - Clutch Spring Bolts: 9.0 N·m (0.90 kgf·m, 80 in·lb)
6-14 CLUTCH
Clutch
Clutch Plate, Wear, Damage Inspection
inspect the friction and steel plates for signs of
• Visually
seizure, overheating (discoloration), or uneven wear.
the thickness of each friction plate [A] at several
• Measure
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard:
2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.)
Service Limit: 2.4 mm (0.094 in.)
Clutch Plate Warp Inspection
each friction plate or steel plate on a surface plate
• Place
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
Standard:
0.15 mm (0.0059 in.) or less
Service Limit: 0.3 mm (0.012 in.)
Clutch Spring Free Length Measurement
the free length of the clutch springs [A].
• Measure
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard:
64.8 mm (2.55 in.)
Service Limit:
61.8 mm (2.43 in.)
Clutch Housing Finger Inspection
inspect the clutch housing fingers [A] where the
• Visually
friction plate tangs [B] hit them.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.
Clutch Housing Spline Inspection
inspect where the teeth [A] on the steel plates
• Visually
wear against the clutch hub splines [B].
If there are notches worn into the splines, replace the
clutch hub. Also, replace the steel plates if their teeth are
damaged.
ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
Engine Oil Flow Chart.............................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealants ....................................................................................................
Engine Oil and Oil Filter..........................................................................................................
Oil Level Inspection...........................................................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Oil Pan....................................................................................................................................
Oil Pan Removal ...............................................................................................................
Oil Pan Installation ............................................................................................................
Oil Screen...............................................................................................................................
Oil Screen Removal ..........................................................................................................
Oil Screen Installation .......................................................................................................
Oil Screen Cleaning ..........................................................................................................
Oil Pressure Relief Valve........................................................................................................
Oil Pressure Relief Valve Removal ...................................................................................
Oil Pressure Relief Valve Installation ................................................................................
Oil Pressure Relief Valve Inspection.................................................................................
Oil Pump.................................................................................................................................
Oil Pump Removal ............................................................................................................
Oil Pump Installation .........................................................................................................
Oil Pump Drive Gear Removal..........................................................................................
Oil Pump Drive Gear Installation.......................................................................................
Oil Cooler................................................................................................................................
Oil Cooler Removal...........................................................................................................
Oil Cooler Installation........................................................................................................
Oil Pressure Measurement.....................................................................................................
Oil Pressure Measurement ...............................................................................................
Oil Pressure Switch ................................................................................................................
Oil Pressure Switch Removal ...........................................................................................
Oil Pressure Switch Installation ........................................................................................
Oil Pipe ...................................................................................................................................
Oil Pipe Removal ..............................................................................................................
Oil Pipe Installation ...........................................................................................................
7-2
7-4
7-5
7-6
7-7
7-7
7-7
7-7
7-8
7-8
7-8
7-10
7-10
7-10
7-10
7-11
7-11
7-11
7-11
7-12
7-12
7-12
7-13
7-13
7-14
7-14
7-14
7-15
7-15
7-16
7-16
7-16
7-17
7-17
7-17
7
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
ENGINE LUBRICATION SYSTEM 7-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
Fastener
Oil Filler Plug
Oil Cooler Bolts
Oil Passage Plug
Radiator (Water) Hose Clamp Screws
Oil Pressure Switch
Oil Pressure Relief Valve
Oil Filter
Oil Filter Pipe
Oil Pan Bolts
Engine Oil Drain Bolt
N·m
2.0
12
20
3.0
15
15
17
25
12
29
Torque
kgf·m
0.20
1.2
2.0
0.31
1.5
1.5
1.7
2.5
1.2
3.0
ft·lb
18 in·lb
106 in·lb
15
27 in·lb
11
11
13
18
106 in·lb
21
Remarks
11. Apply molybdenum disulfide oil solution to the hole of the oil pump drive gear shaft.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
L
SS
L
G, R
L
S
7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
1. Oil Screen
2. Oil Pump
3. Output Shaft Oil Passage
4. Drive Shaft Oil Passage
5. Crankshaft Oil Passage
6. Oil Pipe
7. Camshaft Oil Passage
8. Balancer Oil Passage
9. Oil Pressure Switch
10. Main Oil Passage
11. Oil Cooler
12. Oil Filter
13. Oil Pressure Relief Valve
14. Oil
15. Blowby Gas
ENGINE LUBRICATION SYSTEM 7-5
Specifications
Item
Engine Oil
Type
Viscosity
Capacity:
Level
Oil Pressure Measurement
Oil Pressure
Standard
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
3.2 L (3.4 US gt) (when filter is not removed)
3.8 L (4.0 US gt) (when filter is removed)
4.0 L (4.2 US gt) (when engine is completely dry)
Between upper and lower level lines (Wait several minutes after
idling or running)
255 ∼ 304 kPa (2.6 ∼ 3.1 kgf/cm², 37 ∼ 44 psi) at 4 000 r/min (rpm),
Oil Temperature 50°C (122°F)
7-6 ENGINE LUBRICATION SYSTEM
Special Tools and Sealants
Liquid Gasket, TB1211:
56019-120
Oil Pressure Gauge Adapter, PT3/8:
57001-1233
Outside Circlip Pliers:
57001-144
Liquid Gasket, TB1207B:
92104-2068
Oil Pressure Gauge, 10 kgf/cm²:
57001-164
ENGINE LUBRICATION SYSTEM 7-7
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
Oil Level Inspection
that the engine oil level is between the upper [A]
• Check
and lower [B] levels in the gauge.
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground.
○If the motorcycle has just been used, wait several minutes for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil
pump or oil passages clog up or otherwise do not
function properly, the warning indicator light (LED)
and oil pressure warning symbol will blink. If this
blink stays on when the engine is running above
idle speed, stop the engine immediately and find
the cause.
If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.
NOTE
○If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Engine Oil Change
to the Engine Oil Change in the Periodic Mainte• Refer
nance chapter.
Oil Filter Replacement
to the Oil Filter Replacement in the Periodic Main• Refer
tenance chapter.
7-8 ENGINE LUBRICATION SYSTEM
Oil Pan
Oil Pan Removal
• Remove:
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
•
Top End chapter)
Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)
Oil Pan Bolts [A]
Oil Pan [B]
Remove the following parts if necessary.
Oil Screen (see Oil Screen Removal)
Oil Pipe (see Oil Pipe Removal)
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
Removal)
Oil Pan Installation
the following parts if removed.
• Install
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
•
•
•
Installation)
Oil Pipe (see Oil Pipe Installation)
Oil Screen (see Oil Screen Installation)
Replace the O-rings [A] with new ones.
Apply grease to the O-rings, and install them.
Install the dowel pins [B].
liquid gasket [A] to the mating surface of the oil pan.
•○Apply
Using a high-flash point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
Sealant - Liquid Gasket, TB1207B: 92104-2068
NOTE
○Especially, apply liquid gasket so that it shall be filled up
on the grooves [B].
ENGINE LUBRICATION SYSTEM 7-9
Oil Pan
NOTE
○Make the application finish within 7 minutes when the
liquid gasket to the mating surface of the oil pan is applied.
○Moreover fit the oil pan and tighten the bolts just after
application of the liquid gasket.
• Tighten the oil pan bolts following sequence [1 ∼ 20].
Torque - Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
• Install the removed parts (see appropriate chapters).
7-10 ENGINE LUBRICATION SYSTEM
Oil Screen
Oil Screen Removal
• Remove:
Oil Pan (see Oil Pan Removal)
Oil Screen [A]
Oil Screen Installation
the oil screen (see Oil Screen Cleaning).
• Clean
Replace
the O-ring [A] with a new one, and install it.
• Apply grease
to the O-ring.
• Install the rubber
damper [B] to the oil pressure relief
• valve.
• Install the oil screen.
Oil Screen Cleaning
the oil screen (see Oil Screen Removal).
• Remove
Clean
the
screen with a high-flash point solvent and
• remove theoilparticles
stuck.
Blow
away
the
particles
by applying compressed air [A]
• from the inside to the outside
(from the clean side to the
dirty side).
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low-flash point solvent to clean the screen.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
the screens carefully for any damage.
• Check
If the screen is damaged, replace the oil screen.
ENGINE LUBRICATION SYSTEM 7-11
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
• Remove:
Oil Screen (see Oil Screen Removal)
Oil Pressure Relief Valve [A]
Oil Pressure Relief Valve Installation
a non-parmanent locking agent to the threads of
• Apply
the oil pressure relief valve, and tighten it.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11
ft·lb)
Oil Pressure Relief Valve Inspection
to see if the valve [A] slides smoothly when push• Check
ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] pressure.
NOTE
○Inspect the valve in its assembled state.
Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high-flash point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the oil pressure relief valve in a
well-ventilated area, and take care that there are no
sparks or flame anywhere near the working area;
this includes any appliance with a pilot light. Do
not use gasoline or a low-flash point solvent to
clean the oil pressure relief valve.
If cleaning does not solve the problem, replace the oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for replacement of individual parts.
7-12 ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
• Remove:
Water Pump (see Water Pump Removal in the Cooling
System chapter)
Oil Pump Cover [A]
• Remove:
Oil (Water) Pump Shaft [A] with Inner Rotor [B]
Outer Rotor [C]
Oil Pump Installation
• Install the outer rotor [A] into the crankcase.
the pin [A], inner rotor [B] and oil (water) pump
• Assemble
shaft [C].
the pump shaft so that the slot [A] in its shaft fits onto
• Turn
the projection [B] of the pump drive gear shaft.
ENGINE LUBRICATION SYSTEM 7-13
Oil Pump
the dowel pin [A].
• Install
Install
the
cover [B] so that the dowel pin fits into
• the hole [C]oilofpump
the oil pump cover.
Install
the
water
(see Water Pump Installation in the
• Cooling Systempump
chapter).
Oil Pump Drive Gear Removal
• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Oil Pan (see Oil Pan Removal)
Circlip [A] and Washer [B]
Special Tool - Outside Circlip Pliers: 57001-144
• Remove:
Oil Pump Drive Gear [A]
Washer [B]
Oil Pump Drive Gear Installation
molybdenum disulfide oil solution to the hole of the
• Apply
oil pump drive gear shaft in the crankcase.
molybdenum grease to the journal portion [A] on
• Apply
the oil pump drive gear shaft [B].
• Install the washer [C] to the shaft.
the circlip [A] with a new one.
• Replace
the oil pump drive gear to the lower crankcase.
• Insert
Install
the washer [B] and circlip.
•
Special Tool - Outside Circlip Pliers: 57001-144
the projection on the shaft and oil (water) pump shaft
• Fit
slot.
• Set the circlip original position.
7-14 ENGINE LUBRICATION SYSTEM
Oil Cooler
Oil Cooler Removal
• Remove:
Left Lower Fairing Assembly (see Lower Fairing Assembly Removal in the Frame chapter)
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Water Hose Clamp Screws (Loosen) [A]
Water Hoses [B]
Oil Cooler Bolts [C]
Oil Cooler [D]
Oil Cooler Installation
the O-ring [A] with a new one.
• Replace
Apply
grease
to the O-ring and install it.
• Install the oil cooler.
• Tighten:
•
Torque - Oil Cooler Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
the water hoses [A] and clamps as shown in the
• Install
figure.
• Tighten:
Torque - Radiator (Water) Hose Clamp Screws [B]: 3.0 N·m
(0.31 kgf·m, 27 in·lb)
• Install the removed parts (see appropriate chapters).
ENGINE LUBRICATION SYSTEM 7-15
Oil Pressure Measurement
Oil Pressure Measurement
the right lower fairing (see Lower Fairing Re• Remove
moval in the Frame chapter).
• Remove the oil passage plug [A].
• Attach the adapter [A] and gauge [B] to the plug hole.
Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164
Oil Pressure Gauge Adapter, PT3/8: 57001
-1233
the engine and warm up the engine.
• Start
Run
the
at the specified speed, and read the oil
• pressureengine
gauge.
If the oil pressure is much lower than the standard, check
the oil pump, relief valve, and/or crankshaft bearing insert
wear immediately.
If the reading is much higher than the standard, check the
oil passages for clogging.
Oil Pressure
Standard:
255 ∼ 304 kPa (2.6 ∼ 3.1 kgf/cm², 37 ∼ 44
psi) at 4 000 r/min (rpm), oil temperature
50°C (122°F)
the engine.
• Stop
Remove
the oil pressure gauge and adapter.
•
WARNING
Take care against burns form hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
a non-permanent locking agent to the oil passage
• Apply
plug, and tighten it.
Torque - Oil Passage Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)
7-16 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
• Remove:
Left Lower Fairing Assembly (see Lower Fairing Assembly Removal in the Frame chapter)
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Switch Cover [A]
Switch Terminal Bolt [B]
Oil Pressure Switch [C]
Oil Pressure Switch Installation
silicone sealant to the threads of the oil pressure
• Apply
switch and tighten it.
○Using a high-flash point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
Sealant - Liquid Gasket, TB1211: 56019-120
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
the switch lead.
• Install
Tighten:
•
Torque - Oil Pressure Switch Terminal Bolt: 2.0 N·m (0.20
kgf·m, 18 in·lb)
• Apply grease to the terminal.
ENGINE LUBRICATION SYSTEM 7-17
Oil Pipe
Oil Pipe Removal
• Remove:
Oil Pan (see Oil Pan Removal)
Oil Pipe [A]
Oil Pipe Installation
the O-rings [A] with new ones.
• Replace
Apply
grease
to the O-rings, and install them.
•
ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................
Special Tool ............................................................................................................................
Engine Removal/Installation ...................................................................................................
Engine Removal................................................................................................................
Engine Installation.............................................................................................................
8-2
8-4
8-5
8-5
8-8
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
Fastener
Upper Engine Bracket Bolts
Lower Engine Bracket Bolts
Upper Adjusting Collar
Upper Engine Mounting Bolt (L = 65)
Upper Adjusting Collar Locknut
Upper Engine Mounting Bolt (L = 40)
Lower Engine Mounting Nut
Lower Adjusting Collar Locknut
Middle Engine Bracket Bolts
Middle Engine Mounting Nut
Lower Adjusting Collar
L: Apply a non-permanent locking agent.
S: Follow the specified tightening sequence.
N·m
44
59
9.8
44
49
44
44
49
25
44
9.8
Torque
kgf·m
4.5
6.0
1.0
4.5
5.0
4.5
4.5
5.0
2.5
4.5
1.0
ft·lb
32
44
87 in·lb
32
36
32
32
36
18
32
87 in·lb
Remarks
S
S
S
S
S
S
S
S
L, S
S
S
8-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Engine Mount Nut Wrench:
57001-1450
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
Engine Removal
the rear part of the swingarm with a stand.
• Support
the brake lever slowly and hold it with a band
• Squeeze
[A].
WARNING
Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the engine.
NOTICE
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Clutch Cable Lower End (see Clutch Cable Removal in
the Clutch chapter)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Air Switching Valve (see Air Switching Valve Removal in
the Engine Top End chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
• Remove:
Clamps [A]
Water Hoses [B]
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
the connector [A] from the bracket on the air suc• Remove
tion valve cover.
the connector.
• Disconnect
Disconnect:
• Starter Motor Cable (see Starter Motor Removal in the
Electrical System chapter)
Alternator Lead Connector (see Alternator Cover Removal in the Electrical System chapter)
Crankshaft Sensor Lead Connector (see Crankshaft
Sensor Removal in the Electrical System chapter)
• Remove:
Engine Ground Cable Terminal Bolt [A]
• Remove the drive chain [A] from the output shaft [B].
(Both Sides)
• Remove:
Bolts [A]
Brackets [B]
Quick Rivets [C]
(Left Side)
• Remove:
Upper Engine Bracket Bolts [A]
Lower Engine Bracket Bolt [B] and Washer
Engine Bracket [C]
ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
(Right Side)
• Remove:
Coolant Reserve Tank (see Coolant Change in the Periodic Maintenance chapter)
Upper Engine Bracket Bolts [A]
Lower Engine Bracket Bolt [B] and Washer
Engine Bracket [C]
the engine with a suitable stand [A].
•○Support
Put a plank [B] onto the suitable stand for engine balance.
• Remove:
Upper Engine Mounting Bolt [A] (Both Sides)
Middle Engine Mounting Nut [B] and Bolt
Lower Engine Mounting Nut [C]
the nut wrench [A], loosen the upper adjusting collar
• Using
locknut [B].
Special Tool - Engine Mount Nut Wrench: 57001-1450
the Hexagon Wrench, turn the adjusting collar [C]
• Using
counterclockwise to make the gap between the engine
and adjusting collar.
the nut wrench [A], loosen the lower adjusting collar
• Using
locknut [B].
Special Tool - Engine Mount Nut Wrench: 57001-1450
the lower engine mounting bolt [C].
• Remove
Using
the
Hexagon Wrench, turn the adjusting collar [D]
• counterclockwise
to make the gap between the engine
•
and adjusting collar.
Using the stand, take out the engine.
8-8 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Installation
the engine with a suitable stand.
•○Support
Put a plank onto the suitable stand for engine balance.
• Screw the adjusting collars [A] to the frame.
the engine mounting bolts and nuts, following the specified installing sequence.
•○Install
First, hang the drive chain over the output shaft just before moving the engine into its final position
in the frame.
○Second, apply a non-parmanent locking agent to the threads of the middle engine bracket bolts [A].
Install the middle engine bracket [B] and tighten the bolts.
Torque - Middle Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
○Third, insert the lower engine mounting bolt [C].
○Forth, install the collar [D], and insert the middle engine mounting bolt [E].
○Fifth, tighten:
Torque - Left Upper Engine Mounting Bolt [F]: 44 N·m (4.5 kgf·m, 32 ft·lb)
○Sixth, tighten the upper adjusting collar locknut [G] and right upper engine mounting bolt [H] temporarily.
○Seventh, tighten the lower adjusting collar [I] until the clearance between the engine and frame
comes to 0 mm.
○Eighth, tighten the lower adjusting collar locknut [J] and lower engine mounting nut [K].
Torque - Lower Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb)
Lower Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb)
Special Tool - Engine Mount Nut Wrench: 57001-1450
○Ninth, tighten:
Torque - Middle Engine Mounting Nut [L]: 44 N·m (4.5 kgf·m, 32 ft·lb)
○Tenth, install the left engine bracket [M], and tighten the mounting bolts evenly.
Torque - Upper Engine Bracket Bolts [N]: 44 N·m (4.5 kgf·m, 32 ft·lb)
Lower Engine Bracket Bolts [O]: 59 N·m (6.0 kgf·m, 36 ft·lb)
○Eleventh, install the right engine bracket [P] just like the left engine bracket.
○Twelfth, remove the right upper engine mounting bolt [H].
○Thirteenth, tighten the upper adjusting collar [Q] until the clearance between the engine and frame
comes to 0 mm.
○Fourteenth, tighten the upper adjusting collar locknut [G].
Torque - Upper Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb)
Special Tool - Engine Mount Nut Wrench: 57001-1450
○Lastly, tighten:
Torque - Right Upper Engine Mounting Bolt [H]: 44 N·m (4.5 kgf·m, 32 ft·lb)
ENGINE REMOVAL/INSTALLATION 8-9
Engine Removal/Installation
the leads, cables and hoses correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
Torque - Engine Ground Cable Terminal Bolt: 9.8 N·m (1.0
kgf·m, 87 in·lb)
• Adjust:
Throttle Cables (see Throttle Control System Inspection
in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Operation Inspection in the Periodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Inspection in the
Periodic Maintenance chapter)
8-10 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
the engine with engine oil (see Engine Oil Change in
• Fill
the Periodic Maintenance chapter).
the engine with coolant (see Coolant Change in the
• Fill
Periodic Maintenance chapter).
CRANKSHAFT/TRANSMISSION 9-1
Crankshaft/Transmission
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools and Sealants ...............
Crankcase Splitting............................
Crankcase Splitting ......................
Crankcase Assembly ...................
Crankshaft and Connecting Rods......
Crankshaft Removal ....................
Crankshaft Installation .................
Connecting Rod Removal ............
Connecting Rod Installation .........
Crankshaft/Connecting Rod
Cleaning ....................................
Connecting Rod Bend Inspection
Connecting Rod Twist Inspection.
Connecting Rod Big End Side
Clearance Inspection ................
Connecting Rod Big End
Bearing Insert/Crankpin Wear
Inspection..................................
Crankshaft Side Clearance
Inspection..................................
Crankshaft Runout Inspection......
Crankshaft Main Bearing
Insert/Journal Wear Inspection .
Balancer ............................................
Balancer Removal........................
Balancer Installation.....................
Balancer Adjustment....................
Balancer Damper Inspection........
Starter Motor Clutch ..........................
Starter Motor Clutch
Removal/Installation..................
Starter Motor Clutch Inspection ...
9-2
9-6
9-8
9-9
9-9
9-10
9-16
9-16
9-16
9-16
9-16
9-20
9-20
9-20
9-20
9-21
9-22
9-23
9-23
9-25
9-25
9-25
9-26
9-26
9-27
9-27
9-27
Starter Motor Clutch Disassembly
Starter Motor Clutch Assembly ....
External Shift Mechanism..................
Shift Pedal Removal ....................
Shift Pedal Installation .................
External Shift Mechanism
Removal ....................................
External Shift Mechanism
Installation .................................
External Shift Mechanism
Inspection..................................
Transmission .....................................
Transmission Shaft Removal .......
Transmission Shaft Installation ....
Transmission Shaft Disassembly .
Transmission Shaft Assembly......
Shift Drum and Fork Removal......
Shift Drum and Fork Installation...
Shift Drum Disassembly...............
Shift Drum Assembly ...................
Shift Fork Bending Inspection ......
Shift Fork/Gear Groove Wear
Inspection..................................
Shift Fork Guide Pin/Drum
Groove Wear Inspection ...........
Gear Dog and Gear Dog Hole
Damage Inspection ...................
Ball Bearing, Needle Bearing, and Oil
Seal.................................................
Ball and Needle Bearing
Replacement .............................
Ball and Needle Bearing Wear.....
Oil Seal Inspection .......................
9-27
9-27
9-28
9-28
9-28
9-28
9-29
9-30
9-32
9-32
9-32
9-32
9-33
9-38
9-38
9-38
9-38
9-38
9-39
9-39
9-39
9-40
9-40
9-40
9-40
9
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Fastener
Balancer Shaft Clamp Bolt
Balancer Shaft Lever Bolt
Breather Side Plate Bolt
Connecting Rod Big End Nuts
Breather Plate Bolts
Shift Drum Bearing Holder Bolts
Oil Passage Plugs
Oil Passage Plug
Starter Motor Clutch Bolts
Crankcase Bolts (M7)
Crankcase Bolts (M9)
Crankcase Bolts (M6)
Crankcase Bolts (M8)
Torque
N·m
kgf·m
9.8
1.0
25
2.5
5.9
0.60
see the text
←
9.8
1.0
12
1.2
20
2.0
9.8
1.0
12
1.2
20
2.0
42
4.2
20
2.0
27
2.8
ft·lb
87 in·lb
18
52 in·lb
←
87 in·lb
106 in·lb
15
87 in·lb
106 in·lb
15
31
15
20
15. Do not apply any grease or oil.
EO: Apply engine oil.
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
WS: Apply water-soluble lubricant (ThreeBond:TB2720C).
Remarks
L
L
MO
L
L
L
L
S
S, MO
S
S
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-5
Exploded View
No.
1
2
3
4
5
Fastener
Gear Positioning Lever Bolt
Shift Drum Cam Bolt
Neutral Switch
Shift Shaft Return Spring Pin
Shift Pedal Mounting Bolt
N·m
12
12
15
39
25
Torque
kgf·m
1.2
1.2
1.5
4.0
2.5
ft·lb
106 in·lb
106 in·lb
11
29
18
EO: Apply engine oil.
G: Apply grease.
HG: Apply high-temperature grease.
MO: Apply molybdenum disulfide oil.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
L: Apply a non-permanent locking agent.
R: Replacement Parts
Remarks
L
L
9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankcase, Crankshaft, Connecting
Rods
Connecting Rod Bend
–––
Connecting Rod Twist
Connecting Rod Big End Side
Clearance
Connecting Rod Big End Bearing
Insert/Crankpin Clearance
Crankpin Diameter:
Marking:
None
Standard
Service Limit
TIR 0.2/100 mm
(0.008/3.94 in.)
–––
TIR 0.2/100 mm
(0.008/3.94 in.)
0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.)
0.58 mm
(0.023 in.)
0.10 mm
0.030 ∼ 0.060 mm (0.0012 ∼ 0.0024 in.)
(0.0039 in.)
34.47 mm
34.484 ∼ 34.500 mm (1.3576 ∼ 1.3583 in.)
(1.357 in.)
34.484 ∼ 34.492 mm (1.3576 ∼ 1.3579 in.)
34.493 ∼ 34.500 mm (1.3580 ∼ 1.3583 in.)
– – –
– – –
37.500 ∼ 37.516 mm (1.4764 ∼ 1.4770 in.)
– – –
37.500 ∼ 37.508 mm (1.4764 ∼ 1.4766 in.)
37.509 ∼ 37.516 mm (1.4767 ∼ 1.4770 in.)
– – –
– – –
– – –
– – –
– – –
Crankshaft Side Clearance
1.478 ∼ 1.483 mm (0.05819 ∼ 0.05839 in.)
1.483 ∼ 1.488 mm (0.05839 ∼ 0.05858 in.)
1.488 ∼ 1.493 mm (0.05858 ∼ 0.05878 in.)
(Usable Range)
0.20 ∼ 0.32 mm (0.0079 ∼ 0.0126 in.)
0.09 ∼ 0.19 mm (0.0035 ∼ 0.0075 in.)
Crankshaft #3 Main Journal Width
Crankshaft Runout
23.49 ∼ 23.54 mm (0.9248 ∼ 0.9267 in.)
TIR 0.02 mm (0.0008 in.) or less
Crankshaft Main Bearing
Insert/Journal Clearance
Crankshaft Main Journal Diameter:
0.010 ∼ 0.034 mm (0.0004 ∼ 0.0013 in.)
○
Connecting Rod Big End Inside
Diameter:
Marking:
None
○
Connecting Rod Big End Bearing
Insert Thickness:
Brown
Black
Blue
Connecting Rod Bolt Stretch
Marking:
None
1
Crankcase Main Bearing Inside
Diameter:
Marking
None
○
34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.)
– – –
0.39 mm
(0.0153 in.)
– – –
TIR 0.05 mm
(0.0020 in.)
0.06 mm
(0.0024 in.)
34.96 mm
(1.3764 in.)
34.984 ∼ 34.992 mm (1.3773 ∼ 1.3776 in.)
34.993 ∼ 35.000 mm (1.3777 ∼ 1.3780 in.)
38.000 ∼ 38.016 mm (1.4961 ∼ 1.4967 in.)
– – –
– – –
– – –
38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.)
38.000 ∼ 38.008 mm (1.4961 ∼ 1.4963 in.)
– – –
– – –
CRANKSHAFT/TRANSMISSION 9-7
Specifications
Item
Crankshaft Main Bearing Insert
Thickness:
Brown
Black
Blue
Transmission
Shift Fork Ear Thickness
Standard
Service Limit
1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.)
1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.)
1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.)
– – –
– – –
– – –
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Gear Groove Width
6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.)
Shift Fork Guide Pin Diameter
6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)
Shift Drum Groove Width
7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.)
5.8 mm
(0.228 in.)
6.25 mm
(0.246 in.)
6.8 mm
(0.268 in.)
7.3 mm
(0.287 in.)
Connecting Rod Big End Bearing Insert Selection
Bearing Insert
Con-rod Big End
Inside Diameter
Marking
Crankpin Diameter
Marking
Size Color
Part Number
None
○
Brown
92139-0124
None
None
○
○
○
Black
92139-0123
None
Blue
92139-0122
Crankshaft Main Bearing Insert Selection
Crankcase Main Crankshaft Main
Bearing Inside Journal Diameter
Diameter Marking
Marking
○
1
None
1
○
None
None
None
Bearing Insert*
Size Color
Brown
Black
Blue
Part Number
Journal Nos.
92139-0034
92139-0219
92139-0033
2, 4
1, 3, 5
2, 4
92139-0218
1, 3, 5
92139-0032
92139-0217
2, 4
1, 3, 5
*: The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.
9-8 CRANKSHAFT/TRANSMISSION
Special Tools and Sealants
Bearing Puller:
57001-135
Bearing Driver Set:
57001-1129
Outside Circlip Pliers:
57001-144
Flywheel Holder:
57001-1313
Bearing Puller Adapter:
57001-317
Liquid Gasket, TB1216B:
92104-1064
Bearing Driver,
57001-382
Liquid Gasket, TB1207B:
92104-2068
32:
CRANKSHAFT/TRANSMISSION 9-9
Crankcase Splitting
Crankcase Splitting
the engine (see Engine Removal in the Engine
• Remove
Removal/Installation chapter).
the engine on a clean surface and hold the engine
• Set
steady while parts are being removed.
• Remove:
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Clutch (see Clutch Removal in the Clutch chapter)
External Shift Mechanism (see External Shift Mechanism Removal)
Starter Motor (see Starter Motor Removal in the Electrical System chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter)
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)
Oil Cooler (see Oil Cooler Removal in the Engine Lubrication System chapter)
Oil Pipe (see Oil Pipe Removal in the Engine Lubrication
System chapter)
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
Removal in the Engine Lubrication System chapter)
If the crankshaft is to be removed, remove the pistons
(see Piston Removal in the Engine Top End chapter).
• Remove:
Balancer Shaft Clamp Bolt [A]
Balancer Shaft Clamp Lever Bolt [B]
the upper crankcase bolts following the specified
• Remove
sequence.
○First, loosen the M6 bolts [A].
○Second, loosen the M7 bolts [B].
○Lasty, loosen the M8 bolts [C].
9-10 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
the lower crankcase bolts, following the specified
• Remove
sequence.
○First, loosen the M7 bolts [A].
○Lastly, loosen the M9 bolts as shown sequence [1 ∼ 10]
in the figure.
Tap lightly around the crankcase mating surface with a
plastic mallet, and split the crankcase.
○Take care not to damage the crankcase.
•
Crankcase Assembly
NOTICE
The upper and lower crankcase halves are machined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
a high-flash point solvent, clean off the mating sur• With
faces of the crankcase halves and wipe dry.
compressed air, blow out the oil passages in the
• Using
crankcase halves.
liquid gasket to the breather plate mating surface
• Apply
[A] 1 mm (0.04 in.) or more thick, and then install the
breather plate.
○Using a high-flash point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
Sealant - Liquid Gasket, TB1207B: 92104-2068
NOTE
○Make the application finish within 7 minutes when the
liquid gasket to the mating surface of the breather plate
is applied.
○Moreover fit the plate and tighten the bolts just after
application of the liquid gasket.
CRANKSHAFT/TRANSMISSION 9-11
Crankcase Splitting
a non-permanent locking agent to the threads of
• Apply
the breather plate bolts [A] and tighten them.
Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the breather side plate [A] so that the plate hole [B]
• Install
fit the projection [C] of the upper crankcase.
a non-parmanent locking agent to the threads of
• Apply
the breather side plate bolt [D] and tighten it.
Torque - Breather Side Plate Bolt: 5.9 N·m (0.60 kgf·m, 52
in·lb)
and insert the fitting [A] in the upper crankcase [B]
• Press
until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129
and insert the plug [C] in the upper crankcase so
• Press
that the plug is deeper than crankcase surface.
and insert the new needle bearing [A] for the shift
• Press
shaft so that its marked side faces outside and its surface
•
•
[B] is flush with the end of the hole.
Install the new oil seal [C] so that its surface [D] is flush
with the end of the hole.
Apply grease to the oil seal lips.
9-12 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
a non-parmanent locking agent to the oil passage
• Apply
plugs [A], and tighten them.
Torque - Oil Passage Plugs: 20 N·m (2.0 kgf·m, 15 ft·lb)
the oil passage plug [B] in the lower crankcase, and
• Install
tighten it.
Torque - Oil Passage Plug: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install:
Crankshaft (see Crankshaft Installation)
Connecting Rods (see Connecting Rod Installation)
Camshaft Chain [A]
Transmission Shafts and Gears (see Transmission Shaft
Installation)
Dowel Pins [B]
Shift Drum (see Shift Drum and Fork Installation)
Shift Forks and Shift Rods (see Shift Drum and Fork Installation)
Before fitting the lower case on the upper case, check the
following.
○Be sure to hang the camshaft chain on the crankshaft.
○Check to see that the shift drum and transmission gears
are in the neutral position.
•
CRANKSHAFT/TRANSMISSION 9-13
Crankcase Splitting
liquid gasket [A] to the mating surface of the lower
• Apply
crankcase half.
○Using a high-flash point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
Sealant - Liquid Gasket, TB1216B: 92104-1064
NOTE
○Especially, apply a sealant so that it shall be filled up on
the grooves [B].
○Do not apply liquid gasket to the inside of the groove
[C].
NOTICE
Do not apply liquid gasket around the crankshaft
main bearing inserts and oil passage holes.
• Fit the lower crankcase to the upper crankcase.
NOTE
○Make the application finish within 20 minutes when the
liquid gasket to the mating surface of the crankcase half
is applied.
○Moreover fit the case and tighten the bolts just after
application of the liquid gasket.
M9 bolts have copper plated washers, replace them
• The
with new ones.
9-14 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
molybdenum disulfide oil solution to the lower
• Apply
seating surface [A] on the copper plated washer [B] and
threads [C] of the M9 bolts [D].
the lower crankcase bolts using the following
• Tighten
steps.
○Following the sequence numbers on the lower crankcase
half, tighten the M9 bolts [1 ∼ 10] with copper plated washers.
Torque - Crankcase Bolts (M9): 42 N·m (4.2 kgf·m, 31 ft·lb)
○Tighten the M7 bolts [A].
Torque - Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
the upper crankcase bolts follow in the specified
• Tighten
sequence.
○First, tighten the M8 bolts [A].
Torque - Crank Case Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb)
○Second, tighten the M7 bolts.
L = 85 mm (3.35 in.) [B]
L = 50 mm (1.97 in.) [C]
Torque - Crank Case Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
○Lasty, tighten the M6 bolts.
L = 68 mm (2.69 in.) [D]
L = 40 mm (1.57 in.) [E]
Torque - Crank Case Bolts (M6): 12 N·m (1.2 kgf·m, 106
in·lb)
CRANKSHAFT/TRANSMISSION 9-15
Crankcase Splitting
tightening all crankcase bolts, check the following
• After
items.
○Wipe
up the liquid gasket that seeps out around the
crankcase mating surface.
○Crankshaft and transmission shafts turn freely.
○While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
○When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.
Install the removed parts (see appropriate chapters).
•
9-16 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Removal
the crankcase (see Crankcase Splitting).
• Split
• Remove:
Balancer (see Balancer Removal)
Crankshaft [A]
Crankshaft Installation
NOTICE
If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage
(press gauge) before assembling engine to be sure
the correct bearing inserts are installed.
molybdenum disulfide oil solution to the crankshaft
• Apply
main bearing inserts.
the crankshaft with the camshaft chain [A] hanging
• Install
on it.
• Install the balancer (see Balancer Installation).
Connecting Rod Removal
the crankcase (see Crankcase Splitting).
• Split
Remove
connecting rod big end nuts [A].
• Remove the
the
crankshaft.
•
NOTE
○Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.
• Remove the connecting rods from the crankshaft.
NOTICE
Discard the connecting rod bolts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins.
Connecting Rod Installation
NOTICE
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]: “○” or no mark
NOTICE
If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select the
bearing insert and check clearance with a plastigage (press gauge) before assembling engine to be
sure the correct bearing inserts are installed.
CRANKSHAFT/TRANSMISSION 9-17
Crankshaft and Connecting Rods
molybdenum disulfide oil solution [A] to the inner
• Apply
surfaces of upper and lower bearing inserts.
not apply any grease or oil to the cap inside and cap
• Do
insert outside [B].
the inserts so that their nails [C] are on the same
• Install
side and fit them into the recess of the connecting rod and
cap.
NOTICE
Wrong application of oil and grease could cause
bearing damage.
○When installing the inserts [A], be careful not to damage
•
•
•
the insert surface with the edge of the connecting rod [B]
or the cap [C]. One way to install inserts is as follows.
Installation [D] to Cap
Installation [E] to Connecting Rod
Push [F]
Spare Dowel Pin [G]
Connecting Rod Bolts [H]
Install the cap on the connecting rod, aligning the weight
and diameter marks.
Remove debris and clean the surface of inserts.
Apply molybdenum disulfide oil solution [MO] to the
threads and seating surfaces of the big end nuts and
bolts.
the crankshaft (see Crankshaft Installation).
• Install
each connecting rod on its original crankpin.
•○Install
The connecting rod big end is bolted using the “plastic
region fastening method”.
○This method precisely achieves the needed clamping
force without exceeding it unnecessarily, allowing the
use of thinner, lighter bolts further decreasing connecting
rod weight.
○There are two types of the plastic region fastening. One is
a bolt length measurement method and other is a rotation
angle method. Observe one of the following two, but the
bolt length measurement method is preferable because
this is a more reliable way to tighten the big end nuts.
NOTICE
The connecting rod bolts are designed to stretch
when tightened. Never reuse the connecting rod
bolts. See the table below for correct bolt and nut
usage.
NOTICE
Be careful not to overtighten the nuts.
The bolts must be positioned on the seating surface
correctly to prevent the bolt heads from hitting the
crankcase.
9-18 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
(1) Bolt Length Measurement Method
Be sure to clean the bolts, nuts, and connecting rods
thoroughly with a high-flash point solvent, because the
new connecting rods, bolts, and nuts are treated with an
anti-rust solution.
•
WARNING
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 includes 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.
NOTICE
Immediately dry the bolts and nuts with compressed air after cleaning.
Clean and dry the bolts and nuts completely.
new bolts and nuts in reused connecting rod.
• Install
If the connecting rod assy was replaced, use the bolts and
•
nuts attached to the new connecting rod assy.
Apply a small amount of molybdenum disulfide oil solution
to the following portions.
Threads [A] of Bolts and Nuts
Seating Surfaces [B] of Nuts and Connecting Rod Caps
both bolt head and bolt tip with a punch as shown in
• Dent
the figure.
tightening, use a point micrometer to measure the
• Before
length of new connecting rod bolts and record the values
•
to find the bolt stretch.
Connecting Rod [A]
Dent here with a punch [B].
Nuts [C]
Fit micrometer pins into dents [D].
Tighten the big end nuts until the bolt elongation reaches
the length specified as follows.
Bolt Length after
tightening
–
Bolt Length before
tightening
=
Bolt Stretch
Connecting Rod Bolt Stretch
Usable Range:
0.20 ∼ 0.32 mm (0.0079 ∼ 0.0126 in.)
the length of the connecting rod bolts.
• Check
If the stretch is more than the usable range, the bolt has
stretched too much. An overelongated bolt may break in
use.
CRANKSHAFT/TRANSMISSION 9-19
Crankshaft and Connecting Rods
(2) Rotation Angle Method
If you do not have a point micrometer, you may tighten
the nuts using the “Rotation Angle Method”.
Be sure to clean the bolts, nuts and connecting rods thoroughly with a high-flash point solvent, because the new
connecting rods, bolts and nuts are treated with an anti
-rust solution.
•
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the bolts, nuts, and connecting rods
in a well-ventilated area, and take care that there
are no sparks or flame anywhere near the working
area; this includes any appliance with a pilot light.
Do not use gasoline or a low-flash point solvent to
clean them.
NOTICE
Immediately dry the bolts and nuts with compressed air after cleaning.
Clean and dry the bolts and nuts completely.
new bolts and nuts in reused connecting rods.
• Install
If the connecting rod assy was replaced, use the bolts and
•
nuts attached to the new connecting rod assy.
Apply a small amount of molybdenum disulfide oil solution
to the following portions.
Threads [A] of Bolts and Nuts
Seating Surfaces [B] of Nuts and Connecting Rod Caps
tighten the nuts to the specified torque. See the
• First,
table below.
tighten the nuts 120° ±5° .
•○Next,
Mark [A] the connecting rod big end caps and nuts so that
nuts can be turned 120° [B] properly.
○Tighten the hexagon nut by 2 corners.
Connecting
Rod Assy
Bolt
New
Use the bolts
attached to
new con-rod.
Nut
Attached to
Used
Replace the
bolts with new
ones.
Torque + Angle
N·m (kgf·m, ft·lb)
22 (2.2, 16)
new con-rod + 120°
New
Used
New
20 (2.0, 15)
+ 120°
26 (2.7, 19)
+ 120°
26 (2.7, 19)
+ 120°
9-20 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft/Connecting Rod Cleaning
removing the connecting rods from the crankshaft,
• After
clean them with a high-flash point solvent.
the crankshaft oil passages with compressed air to
• Blow
remove any foreign particles or residue that may have
accumulated in the passages.
Connecting Rod Bend Inspection
the connecting rod big end bearing inserts, and
• Remove
reinstall the connecting rod big end cap.
an arbor [A] of the same diameter as the connect• Select
ing rod big end, and insert the arbor through the connect-
•
•
•
ing rod big end.
Select an arbor of the same diameter as the piston pin
and at least 100 mm (3.94 in.) long, and insert the arbor
[B] through the connecting rod small end.
On a surface plate, set the big-end arbor on V block [C].
With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If connecting rod bend exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Bend
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist Inspection
the big-end arbor [A] still on V block [C], hold the
• With
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 determine the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Big End Side Clearance
Inspection
connecting rod big end side clearance.
•○Measure
Insert a thickness gauge [A] between the big end and either crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard:
0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.)
Service Limit:
0.58 mm (0.023 in.)
If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.
If clearance is too large after connecting rod replacement,
the crankshaft also must be replaced.
CRANKSHAFT/TRANSMISSION 9-21
Crankshaft and Connecting Rods
Connecting Rod Big End Bearing Insert/Crankpin
Wear Inspection
the bearing insert/crankpin [A] clearance with
• Measure
plastigage [B].
the big end nuts to the specified torque (see Con• Tighten
necting Rod Installation).
NOTE
○Do not move the connecting rod and crankshaft during
clearance measurement.
NOTICE
After measurement, replace the connecting rod
bolts.
Connecting Rod Big End Bearing Insert/Crankpin Clearance
Standard:
0.030 ∼ 0.060 mm (0.0012 ∼ 0.0024 in.)
Service Limit: 0.10 mm (0.0039 in.)
If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.061 mm (0.0024 in.) and
the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard:
34.484 ∼ 34.500 mm (1.3576 ∼ 1.3583 in.)
Service Limit: 34.47 mm (1.357 in.)
If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameters 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
34.484 ∼ 34.492 mm (1.3576 ∼ 1.3579 in.)
○
34.493 ∼ 34.500 mm (1.3580 ∼ 1.3583 in.)
: Crankpin Diameter Marks, “○” or no mark.
9-22 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
the connecting rod big end inside diameter, and
• Measure
mark each connecting rod big end in accordance with the
•
inside diameter.
Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).
NOTE
○The mark already on the big end should almost coincide
with the measurement.
Connecting Rod Big End Inside Diameter Marks
None
37.500 ∼ 37.508 mm (1.4764 ∼ 1.4766 in.)
○
37.509 ∼ 37.516 mm (1.4767 ∼ 1.4770 in.)
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: “○” or no
mark
the proper bearing insert [A] in accordance with the
• Select
combination of the connecting rod and crankshaft coding.
Size Color [B]
Con-rod Big End
Inside Diameter
Marking
Crankpin
Diameter
Marking
Size Color
Part Number
None
○
Brown
92139-0124
None
None
○
○
○
Black
92139-0123
None
Blue
92139-0122
Bearing Insert
the new inserts in the connecting rod and check
• Install
insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance Inspection
a thickness gauge [A] between the crankcase main
• Insert
bearing and the crank web at the No.3 journal to determine clearance.
If the clearance exceeds the service limit, replace the
crankcase halves as a set.
NOTE
○The upper and lower crankcase halves are machined
at the factory in the assembled state, so the crankcase
halves must be replaced as a set.
Crankshaft Side Clearance
Standard:
0.09 ∼ 0.19 mm (0.0035 ∼ 0.0075 in.)
Service Limit:
0.39 mm (0.0153 in.)
CRANKSHAFT/TRANSMISSION 9-23
Crankshaft and Connecting Rods
Crankshaft Runout Inspection
the crankshaft runout.
• Measure
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.) or less
Service Limit:
TIR 0.05 mm (0.0020 in.)
Crankshaft Main Bearing Insert/Journal Wear
Inspection
a plastigage (press gauge) [A], measure the bear• Using
ing insert/journal [B] clearance.
NOTE
○Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
○Do not turn the crankshaft during clearance measurement.
○Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.
Crankshaft Main Bearing Insert/Journal Clearance
Standard:
0.010 ∼ 0.034 mm (0.0004 ∼ 0.0013 in.)
Service Limit: 0.06 mm (0.0024 in.)
If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.035 mm (0.0014 in.) and the
service limit (0.06 mm, 0.0024 in.), replace the bearing inserts [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 minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.
Crankshaft Main Journal Diameter
Standard:
34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.)
Service Limit: 34.96 mm (1.3764 in.)
If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None
34.984 ∼ 34.992 mm (1.3773 ∼ 1.3776 in.)
1
□:
34.993 ∼ 35.000 mm (1.3777 ∼ 1.3780 in.)
Crankshaft Main Journal Diameter Marks, “1” or no
mark.
9-24 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
the main bearing inside diameter, and mark the
• Measure
upper crankcase half in accordance with the inside diam-
•
eter.
Crankcase Main Bearing Inside Diameter Marks: “○” or
no mark.
Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
NOTE
○The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks
38.000 ∼ 38.008 mm (1.4961 ∼ 1.4963 in.)
○
None
38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.)
the proper bearing insert [A] in accordance with the
• Select
combination of the crankcase and crankshaft coding.
Size Color [B]
Crankcase Main
Bearing Inside
Diameter Marking
Crankshaft Main
Journal Diameter
Marking
Size Color
○
1
Brown
None
1
○
None
None
None
Bearing Insert*
Black
Blue
Part Number
92139-0034
92139-0219
92139-0033
Journal Nos.
2, 4
1, 3, 5
2, 4
92139-0218
1, 3, 5
92139-0032
92139-0217
2, 4
1, 3, 5
* The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.
the new inserts in the crankcase halves and check
• Install
insert/journal clearance with the plastigage.
CRANKSHAFT/TRANSMISSION 9-25
Balancer
Balancer Removal
the crankcase (see Crankcase Splitting).
• Split
• Unscrew:
Balancer Shaft Clamp Bolt [A]
•
Balancer Shaft Lever [B]
Oil Seal [C]
Remove the balancer [D] from the upper crankcase half.
Balancer Installation
that the rubber dampers [A] are in place as shown
• Check
in the figure.
molybdenum disulfide oil solution to the damper
• Apply
contact portions of the balancer weight.
the balancer weight [A] into the gear [B].
•○Install
Align the punch mark [C] of the balancer weight with the
groove [D] of the gear.
molybdenum disulfide oil solution to the needle
• Apply
bearings. Insert the needle bearings.
the copper washers [A] on both ends of the weight and
• Fit
gear assembly. The projected sides [B] face inward.
the pin [A] as shown in the figure.
• Insert
the balancer on the upper crankcase half.
•○Set
Align the punch mark [B] on the balancer gear [C] with the
mark [D] on the balancer drive gear [E] of crankshaft.
9-26 CRANKSHAFT/TRANSMISSION
Balancer
the crankcase (see Crankcase Assembly).
• Assemble
Fill
the
oil
seal
lips with grease.
• Install the new oil
[A] so that its surface is flush with
• the surface of the seal
crankcase.
the balancer shaft so that its mark [B] faces down• Turn
ward (This photo is shown with the upside down).
the balancer shaft lever [A].
• Install
Apply
a
non-parmanent locking agent to the threads of
• the balancer
shaft clamp lever bolt [B].
Tighten:
•
Torque - Balancer Shaft Clamp Lever Bolt: 25 N·m (2.5
kgf·m, 18 ft·lb)
Balancer Shaft Clamp Bolt [C]: 9.8 N·m (1.0 kgf·m,
87 in·lb)
Balancer Adjustment
the lower fairing (see Lower Fairing Removal in
• Remove
the Frame chapter).
the engine and warm it up thoroughly.
• Start
Adjust
the balancer gear backlash with the engine idling.
• The amount
of backlash can be changed by turning the
balancer shaft which has eccentric journals.
○Start the engine and let it idle.
○Loosen the clamp bolt [A] and turn the balancer shaft [B]
clockwise [C] until the balancer gear makes a whining
sound.
○Turn the shaft counterclockwise [D] until the balancer gear
whining sound disappears and tighten the clamp bolt.
Torque - Balancer Shaft Clamp Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
Balancer Damper Inspection
the balancer and disassemble the weight and
• Remove
gear assembly.
inspect the rubber dampers [A].
• Visually
If they appear damaged or deteriorated, replace them.
CRANKSHAFT/TRANSMISSION 9-27
Starter Motor Clutch
Starter Motor Clutch Removal/Installation
to the Alternator Rotor Removal/Installation in the
• Refer
Electrical System chapter.
Starter Motor Clutch Inspection
• Remove:
Alternator Cover (see Alternator Cover Removal in the
•
•
Electrical System chapter)
Starter Idle Gear and Shaft
Turn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, but
should not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.
NOTE
○Examine the starter motor clutch gear as well. Replace
it if it worn or damaged.
Starter Motor Clutch Disassembly
• Remove:
Alternator Rotor (see Alternator Rotor Removal in the
•
Electrical System chapter)
Hold the alternator rotor with the flywheel holder [A].
Special Tool - Flywheel Holder: 57001-1313
• Remove the starter motor clutch bolts [B].
• Remove:
Starter Motor Clutch Housing [A]
Starter Motor Clutch [B]
Starter Motor Clutch Assembly
the starter motor clutch to the housing so that the
• Install
flange [A] fit to the housing groove [B].
a non-permanent locking agent to the threads of
• Apply
the starter motor clutch bolts and tighten them.
Torque - Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)
9-28 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
Shift Pedal Removal
• Remove:
Shift Lever Bolt [A]
Shift Lever [B]
Shift Pedal Mounting Bolt [C]
Shift Pedal [D] with Tie-rod [E]
Shift Pedal Installation
• Tighten:
Torque - Shift Pedal Mounting Bolt [A]: 25 N·m (2.5 kgf·m,
18 ft·lb)
Shift Pedal [B]
Washer [C]
the punch mark [A] on the shift shaft with the slit [B]
• Align
of the shift lever.
• Tighten the shift lever bolt [C].
installation, confirm that the shift pedal [A] is posi• After
tioned as shown in the figure.
About 90° [B]
If the pedal position is different, adjust it as follows.
○To adjust the pedal position, loosen the front locknut [C]
(left-hand threads) and rear locknut [D], and then turn the
tie-rod [E].
External Shift Mechanism Removal
• Remove:
Shift Lever (see Shift Pedal Removal)
Circlip [A]
Washer [B]
Clutch (see Clutch Removal in the Clutch chapter)
Special Tool - Outside Circlip Pliers: 57001-144
CRANKSHAFT/TRANSMISSION 9-29
External Shift Mechanism
• Pull out the shift shaft assembly [A].
• Remove:
Gear Positioning Lever Bolt [A]
Gear Positioning Lever [B]
Collar and Spring [C]
• Remove:
Shift Drum Cam Bolt [A]
Shift Drum Cam [B]
External Shift Mechanism Installation
sure to install the dowel pin [A].
• Be
Align
• cam. the dowel pin with the hollow [B] of the shift drum
a non-permanent locking agent to the threads of
• Apply
the shift drum cam bolt, and tighten it.
Torque - Shift Drum Cam Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
the following parts as shown.
• Assemble
[A] Gear Positioning Lever
[B] Spring
[C] Collar
[D] Gear Positioning Lever Bolt
○Hang the spring end [E] to the gear positioning lever.
9-30 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
prying the gear positioning lever [A], tighten the
• While
gear positioning lever bolt [B].
Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m,
106 in·lb)
the shift shaft [A] so that the return spring pin [B]
• Install
fits between the spring [C].
the washer [A].
• Install
Replace
the circlip [B] with a new one, and install it.
•
Special Tool - Out side Circlip Pliers: 57001-144
External Shift Mechanism Inspection
the shift shaft [A] for any damage.
• Examine
If the shaft is bent, straighten or replace it.
If the serration [B] are damaged, replace the shaft.
If the springs [C] are damaged in any way, replace them.
If the shift mechanism arm [D] is damaged in any way,
replace the shift shaft.
the return spring pin [A] is not loose.
• Check
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 39 N·m (4.0 kgf·m,
29 ft·lb)
CRANKSHAFT/TRANSMISSION 9-31
External Shift Mechanism
the gear positioning lever [A] and its spring for
• Check
breaks or distortion.
•
If the lever or spring are damaged in any way, replace
them.
Visually inspect the shift drum cam [B].
If it is badly worn or shows any damage, replace it.
9-32 CRANKSHAFT/TRANSMISSION
Transmission
Transmission Shaft Removal
the crankcase (see Crankcase Splitting).
• Split
• Remove the drive shaft [A] and output shaft [B].
Transmission Shaft Installation
to see that the set pins [A] and set rings [B] are in
• Check
place.
the drive shaft and output shaft into the upper
• Install
crankcase half.
engine oil to the bearings.
•○Apply
The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When
they are properly matched, there is no clearance [A] between the crankcase and the bearing outer races.
the crankcase (see Crankcase Assembly).
• Assemble
high-temperature grease to the oil seal lips.
• Apply
Apply
water-soluble
lubricant to the out side surface of the
• oil seal [A].
Sealant - ThreeBond: TB2720C
in the oil seal onto collar [B] so that the surface of
• Press
the oil seal is flush with the surface [C] of the crankcase.
Transmission Shaft Disassembly
the transmission shafts (see Transmission Shaft
• Remove
Removal).
the circlips, and disassemble the transmission
• Remove
shafts.
Special Tool - Outside Circlip Pliers: 57001-144
5th gear [A] on the output shaft has three steel balls
• The
assembled into it for the positive neutral finder mechanism. Remove the 5th gear.
○Set the output shaft in a vertical position holding the 3rd
gear [B].
○Spin the 5th gear quickly [C] and pull it off upward.
CRANKSHAFT/TRANSMISSION 9-33
Transmission
• Remove the ball bearing [A] from each shafts.
Special Tools - Bearing Puller [C]: 57001-135
Bearing Puller Adapter [D]: 57001-317
the bearing.
•○Discard
For output shaft, remove the collar [B] together with the
ball bearing.
Transmission Shaft Assembly
the new ball bearing [A] and collar [B] (output shaft)
• Install
on the each shaft, using the bearing driver.
Spacial Tool - Bearing Driver,
32: 57001-382
engine oil to the bushings, ball bearings and shafts.
• Apply
Install
the gear bushings [A] on the shaft with their holes
• [B] aligned.
any circlips removed with new ones.
• Replace
the circlips [A] so that the opening [B] is aligned
• Install
with a spline groove [C].
9-34 CRANKSHAFT/TRANSMISSION
Transmission
drive shaft gears can be recognized by size: the gear
• The
with the smallest diameter is 1st gear, and the largest one
•
•
•
•
•
is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in
place.
Install the 3rd/4th gear onto the drive shaft with their oil
holes aligned.
Install the 6th gear bushing onto the drive shaft with their
oil holes aligned.
The output shaft gears can be recognized by size: the
gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and washers are
properly in place.
Install the 6th gear onto the output shaft with their oil holes
aligned.
Install the 3rd/4th gear bushings onto the output shaft with
their oil holes aligned.
NOTE
○When the toothed washers are assembled onto the output shaft, note the following.
○When the tangs [A] of the toothed washer shall be assembled, they should be installed into the notch [B] of
the toothed washer (see Page 9-36).
the steel balls into the 5th gear holes in the output
• Fit
shaft, aligning the hole as shown in the figure.
5th Gear [A]
Output Shaft [B]
Steel Balls [C]
Hole [D]
NOTICE
Do not apply grease to the balls to hold them in
place. This will cause the positive neutral finder
mechanism to malfunction.
○After assembling the 5th gear with steel balls in place on
•
the output shaft, check the ball-locking effect that the 5th
gear doesn’t come out of the output shaft when moving it
up and down by hand.
Check that each gear spins or slides freely on the transmission shafts without binding after assembly.
CRANKSHAFT/TRANSMISSION 9-35
Transmission
This page intentionally left blank.
9-36 CRANKSHAFT/TRANSMISSION
Transmission
CRANKSHAFT/TRANSMISSION 9-37
Transmission
1. Output Shaft
2. Collar
3. Bearing
4. Bushing
5. 2nd Gear (39 T)
6. Washer ( 34 × 28.1)
7. Circlips ( 33 × 25.9)
8. Top Gear (25 T)
9. Toothed Washer ( 34)
10. 4th/3rd Gear (25 T/24 T)
11. Bushing
12. Toothed Washer ( 40.5)
13. Toothed Washer ( 37)
14. Steel Balls
15. 5th Gear (26 T)
16. Low Gear (39 T)
17. Washers ( 31 × 20.5)
18. Races
19. Needle Bearings
20. Circlips ( 22.2 × 18.7)
21. Needle Bearing
22. Low Gear (15 T) (Drive Shaft)
23. Bushing
24. 5th Gear (21 T)
25. Toothed Washer ( 31)
26. Circlip ( 29 × 22.6)
27. 3rd/4th Gear (15 T/18 T)
28. Bushing
29. Top Gear (22 T)
30. Toothed Washer ( 34.2)
31. Toothed Washer ( 32)
32. 2nd Gear (20 T)
33. Washer ( 30 × 20.5)
9-38 CRANKSHAFT/TRANSMISSION
Transmission
Shift Drum and Fork Removal
• Remove:
Lower Crankcase Half (see Crankcase Splitting)
•
•
Transmission Shafts (see Transmission Shaft Removal)
Gear Positioning Lever (see External Shift Mechanism
Removal)
Bolts [A]
Shift Drum Bearing Holder [B]
Pull out the shift rods [C], and take off the shift forks.
Pull out the shift drum [D].
Shift Drum and Fork Installation
engine oil to the shift drum, forks and rods.
• Apply
the shift rods [A], noting the groove position.
•○Install
The rods are identical.
○Position the one with shortest ears [B] on the drive shaft
and place the pin in the center groove in the shift drum
[C].
○The two forks [D] on the output shaft are identical.
Install the forks so that its “0061” and “0062” side faces
engine left side.
Apply a non-permanent locking agent to the threads of
the shift drum bearing holder bolts, and tighten them.
•
•
Torque - Shift Drum Bearing Holder Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
Shift Drum Disassembly
the shift drum (see Shift Drum and Fork Re• Remove
moval).
holding the shift drum with a vise, remove the shift
• While
drum cam bolt [A].
• Remove:
Shift Drum Cam [B]
Dowel Pin [C]
Bearing [D]
Shift Drum Assembly
sure to install the dowel pin.
• Be
Apply
non-permanent locking agent to the threads of
• the shifta drum
bearing holder bolt, and tighten it.
Torque - Shift Drum Cam Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
Shift Fork Bending Inspection
inspect the shift forks, and replace any fork that is
• Visually
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
CRANKSHAFT/TRANSMISSION 9-39
Transmission
Shift Fork/Gear Groove Wear Inspection
the thickness of the shift fork ears [A], and mea• Measure
sure the width of the gear grooves [B].
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Service Limit:
5.8 mm (0.228 in.)
If the gear groove is worn over the service limit, the gear
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
Inspection
the diameter of each shift fork guide pin [A], and
• Measure
measure the width of each shift drum groove [B].
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard:
6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)
Service Limit:
6.8 mm (0.268 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard:
7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.)
Service Limit:
7.3 mm (0.287 in.)
Gear Dog and Gear Dog Hole Damage Inspection
inspect the gear dogs [A] and gear dog holes [B].
• Visually
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
9-40 CRANKSHAFT/TRANSMISSION
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
NOTICE
Do not remove the ball or needle bearings unless it
is necessary. Removal may damage them.
a press or puller, remove the ball bearing and/or
• Using
needle bearings.
NOTE
○In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing
in or out.
NOTICE
Do not heat the case with a torch. This will warp the
case. Soak the case in oil and heat the oil.
a press and the bearing driver set [A], install the
• Using
new ball bearing until it stops at the bottom of its housing.
○The
new needle bearings must be pressed into the
crankcase so that the end is flush with the end of the
hole.
Special Tool - Bearing Driver Set: 57001-1129
Ball and Needle Bearing Wear
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
the ball bearings.
•○Check
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
○Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
Check the needle bearings.
○The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of a needle bearing, replace it.
•
Oil Seal Inspection
the oil seals.
• Inspect
Replace it if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.
WHEELS/TIRES 10-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Wheel Inspection ..............................................................................................................
Axle Inspection..................................................................................................................
Balance Inspection............................................................................................................
Balance Adjustment ..........................................................................................................
Balance Weight Removal..................................................................................................
Balance Weight Installation...............................................................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Inspection ..................................................................................................................
Tire Removal.....................................................................................................................
Tire Installation..................................................................................................................
Tire Repair ........................................................................................................................
Hub Bearing............................................................................................................................
Hub Bearing Removal.......................................................................................................
Hub Bearing Installation....................................................................................................
Hub Bearing Inspection.....................................................................................................
Hub Bearing Lubrication ...................................................................................................
10-2
10-4
10-5
10-6
10-6
10-6
10-7
10-9
10-10
10-10
10-11
10-11
10-11
10-11
10-13
10-13
10-13
10-13
10-13
10-15
10-16
10-16
10-16
10-17
10-17
10
10-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 10-3
Exploded View
No.
1
2
3
Fastener
Front Axle Clamp Bolt
Front Axle
Rear Axle Nut
N·m
20
108
98
Torque
kgf·m
2.0
11.0
10
ft·lb
15
79.7
72
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
HG: Apply high-temperature grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
Remarks
AL
10-4 WHEELS/TIRES
Specifications
Item
Wheels (Rims)
Rim Runout:
Axial
Radial
Axle Runout/100 mm
(3.94 in.)
Wheel Balance
Balance Weights
Rim Size:
Front
Rear
Tires
Air Pressure (when
Cold):
Front
Rear
Tread Depth:
Front
Rear
Standard Tires:
Front
Rear
Standard
Service Limit
TIR 0.5 mm (0.02 in.) or less
TIR 0.8 mm (0.03 in.) or less
TIR 0.1 mm (0.004 in.) or less
TIR 1.0 mm (0.04 in.)
TIR 1.0 mm (0.04 in.)
TIR 0.2 mm (0.008 in.)
10 g (0.35 oz.) or less
10 g (0.35 oz.), 20 g (0.71 oz.),
30 g (1.06 oz.)
– – –
– – –
J17M/C × MT3.50
J17M/C × MT6.00
– – –
– – –
Up to 180 kg (397 lb) load: 250 kPa
(2.5 kgf/cm², 36 psi)
Up to 180 kg (397 lb) load: 290 kPa
(2.9 kgf/cm², 42 psi)
– – –
3.6 mm (0.14 in.)
5.3 mm (0.21 in.)
Make, Type
BRIDGESTONE, BATTLAX BT016F
BB
BRIDGESTONE, BATTLAX BT016R
BB
– – –
1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.)
Over 130 km/h (80 mph):
3 mm (0.12 in.)
Size
120/70 ZR17 M/C (58 W)
190/50 ZR17 M/C (73 W)
WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in
serious injury or death. To ensure proper handling and stability, use only the recommended
standard tires for replacement, inflated to the standard pressure.
WHEELS/TIRES 10-5
Special Tools
Inside Circlip Pliers:
57001-143
Bearing Remover Head,
57001-1293
20 ×
Bearing Driver Set:
57001-1129
Bearing Remover Shaft,
57001-1377
13:
Jack:
57001-1238
Jack Attachment:
57001-1608
Attachment Jack:
57001-1252
22:
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Remove:
Front Caliper Mounting Bolts [A] (Both Sides)
•
Front Calipers [B] (Both Sides)
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
For the ABS equipped Models, remove the bolt [C] and
front wheel rotation sensor [D].
• Loosen:
Front Axle Clamp Bolts [A] (Loosen)
Front Axle [B]
the oxygen sensor equipped Models, remove the
• For
oxygen sensor (see Oxygen Sensor Removal (Equipped
•
Models) in the Electrical System chapter).
Raise the front wheel off the ground.
Special Tools - Jack [A]: 57001-1238
Attachment Jack [B]: 57001-1252
Jack Attachment [C]: 57001-1608
out the axle to the right and drop the front wheel out
• Pull
of the forks.
NOTICE
Do not lay the wheel down on one of the discs. This
can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the
ground.
Front Wheel Installation
NOTE
○The direction of the wheel rotation [A] is shown by an
arrow [B] on the wheel spoke.
the wheel rotation mark on the front wheel and
• Check
install it.
WHEELS/TIRES 10-7
Wheels (Rims)
high-temperature grease to the grease seal lips.
• Apply
Fit
the
collars [A] on the both sides of the hub.
•○The collars
are identical.
Insert
the
front
axle.
• Tighten:
•
Torque - Front Axle: 108 N·m (11.0 kgf·m, 79.7 ft·lb)
tightening the axle clamp bolts [A] on the right front
• Before
fork leg, pump the front fork up and down 4 or 5 times to
allow the right front fork leg to seat on the front axle.
NOTE
○Put a block in front of the front wheel to stop moving.
• Tighten:
Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
NOTE
○Tighten the two clamp bolts alternately two times to ensure even tightening torque.
the removed parts (see appropriate chapters).
• Install
Check
the front brake effectiveness (see Brake Operation
• Inspection
in the Periodic Maintenance chapter).
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
Rear Wheel Removal
• Raise the rear wheel off the ground with the stand [A].
10-8 WHEELS/TIRES
Wheels (Rims)
the torque link nuts [A] lightly for chain adjuster
• Loosen
turn easily.
• Remove:
Rear Caliper Mounting Bolts [A]
Rear Caliper [B]
ABS equipped Models, remove the bolt [A], clamp [B]
• For
and rear wheel rotation sensor [C].
the chain adjuster clamp bolts [A] (Both Sides).
• Loosen
the chain adjuster [B] to make the chain slack.
• Turn
Remove:
• Retaining Rings [C] (Both Sides)
Rear Axle Nut [D]
Washer
• Remove:
Rear Axle [A] (from Left Side)
WHEELS/TIRES 10-9
Wheels (Rims)
the drive chain [A] from the rear sprocket toward
• Remove
the left.
• Move the rear wheel back and remove it.
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Rear Wheel Installation
high-temperature grease to the grease seal lips.
• Apply
collars on the both sides of the hub.
• FitLefttheSide
Collar [A] ( 40 × 35)
Right Side Collar [B] ( 44 ×
28)
the drive chain with the rear sprocket.
• Engage
Insert
the
axle from the left side of the wheel.
• Align the hole
of the brake holder with hole of the rear
• wheel.
• Install:
Washer
•
•
Rear Axle Nut [A]
Before tightening the rear axle nut, check that the scale
on the left and right adjusters set the same position.
Tighten:
Torque - Rear Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb)
the retaining rings [B] with new ones, and install
• Replace
them.
the drive chain slack after installation (see Drive
• Adjust
Chain Slack Inspection in the Periodic Maintenance chap-
•
ter).
Tighten:
Torque - Torque Link Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
the rear caliper (see Caliper Installation in the
• Install
Brakes chapter).
the rear brake effectiveness (see Brake Operation
• Check
Inspection in the Periodic Maintenance chapter).
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
10-10 WHEELS/TIRES
Wheels (Rims)
Wheel Inspection
• Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
Attachment Jack: 57001-1252
the wheel lightly, and check for roughness or binding.
• Spin
If roughness or binding is found, replace the hub bearings
•
•
•
(see Hub Bearing Removal/Installation).
Inspect the wheel for small cracks, dents, bending, or
warp.
If there is any damage to the wheel, replace the wheel.
Remove the wheel, and support it with the tire by the axle.
Measure the rim runout, axial [A] and radial [B], with a dial
gauge.
If rim runout exceeds the service limit, check the hub bearings (see Hub Bearing Inspection).
If the problem is not due to the bearings, replace the
wheel.
Rim Runout (with tire installed)
Standard:
Axial
TIR 0.5 mm (0.02 in.) or less
Radial
TIR 0.8 mm (0.03 in.) or less
Service Limit:
Axial
TIR 1.0 mm (0.04 in.)
Radial
TIR 1.0 mm (0.04 in.)
WARNING
Damaged wheel parts may fail and cause an accident resulting in serious injury or death. Never attempt to repair a damaged wheel part. If the wheel
part is damaged, it must be replaced with a new one.
Axle Inspection
the front and rear axles (see Front/Rear Wheel
• Remove
Removal).
inspect the front and rear axle for damages.
• Visually
If the axle is damaged or bent, replace it.
the axle in V blocks that are 100 mm (3.94 in.) [A]
• Place
apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and
lowest dial readings is the amount of runout.
If axle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)
Standard:
TIR 0.1 mm (0.004 in.) or less
Service Limit:
TIR 0.2 mm (0.008 in.)
WHEELS/TIRES 10-11
Wheels (Rims)
Balance Inspection
the front and rear wheels (see Front/Rear Wheel
• Remove
Removal).
the wheel so that it can be spun freely.
• Support
Spin
the
lightly, and mark [A] the wheel at the top
• when thewheel
wheel stops.
○Repeat this procedure several times.
If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance (see Balance Adjustment).
Balance Adjustment
the wheel always stops in one position, provisionally
• Ifattach
a balance weight [A] on the rim at the marking using
•
•
•
•
adhesive tape.
Rotate the wheel 1/4 turn [B], and see whether or not the
wheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size. If the wheel rotates and
the weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.
Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.
Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
Permanently install the balance weight.
Balance Weight Removal
a standard tip screwdrivers [A] [B] between the rib
• Insert
[C] and weight [D] as shown in the figure.
the balance weight with two screwdrivers and remove
• Pry
the balance weight.
• Discard the used balance weight.
NOTICE
Do not tap the screwdrivers. The rim could be damaged.
Balance Weight Installation
if the weight portion has any play on the blade [A]
• Check
and clip [B].
If it does, discard it.
WARNING
Unbalanced wheels can create an unsafe riding
condition. If the balance weight has any play on
the rib of the rim, the blade and/or clip have been
stretched. Replace the loose balance weight. Do
not reuse used balance weight.
10-12 WHEELS/TIRES
Wheels (Rims)
Balance Weight
Part Number
Weight
41075-0007
10 g (0.35 oz.)
41075-0008
20 g (0.71 oz.)
41075-0009
30 g (1.06 oz.)
NOTE
○Balance weights are available from Kawasaki dealers
in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes.
An imbalance of less than 10 grams (0.35 oz.) will not
usually affect running stability.
○Do not use four or more balance weight (more than 90
gram, 3.2 oz.). If the wheel requires an excess balance
weight, disassemble the wheel to find the cause.
the balance weight [A] onto the rib [B] by pushing or
• Slip
lightly hammering [C] the clip [D].
Left Side [E]
Right Side [F]
sure to install the balance weight.
•○Be
Check that the blade [A] and clip [B] are fully seated on
the rim [C] and that the clip is hooked over the rib [D].
Left Side [E]
Right Side [F]
WHEELS/TIRES 10-13
Tires
Air Pressure Inspection/Adjustment
to the Air Pressure Inspection in the Periodic Main• Refer
tenance chapter.
Tire Inspection
to the Wheel/Tire Damage Inspection in the Peri• Refer
odic Maintenance chapter.
Tire Removal
• Remove:
Wheels (see Front/Rear Wheel Removal)
•
Valve Core (Let out the air)
To maintain wheel balance, mark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]
the tire beads and rim flanges on both sides with
• Lubricate
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
NOTICE
Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire.
the tire from the rim using a suitable commer• Remove
cially available tire changer.
NOTE
○The tires cannot be removed with hand tools because
they fit the rims too tightly.
Tire Installation
WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for
replacement, inflated to the standard pressure.
the rim and tire, and replace them if necessary.
• Inspect
the sealing surfaces of the rim and tire, and smooth
• Clean
the sealing surfaces of the rim with a fine emery cloth if
•
necessary.
Remove the air valve and discard it.
NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
10-14 WHEELS/TIRES
Tires
a new valve in the rim.
•○Install
Remove the valve cap, lubricate the stem seal [A] with a
soap and water solution or rubber lubricant, and pull [B]
the valve stem through the rim from the inside out until it
snaps into place.
NOTICE
Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the
rubber.
○The 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]
the tire rotation mark on the front and rear tires and
• Check
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotating Direction [B]
the tire on the rim so that the valve [A] align with
• Position
the tire balance mark [B] (the chalk mark made during
•
•
•
removal, or the yellow paint mark on a new tire).
Install the tire bead over the rim flange using a suitable
commercially available tire changer.
Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.
WARNING
Overinflating a tire can cause it to explode, causing
serious injury or death. Be sure to install the valve
core whenever inflating the tire, and do not inflate
the tire to more than 400 kPa (4.0 kgf/cm², 57 psi).
WHEELS/TIRES 10-15
Tires
to see that the rim lines [A] on both sides of the tire
• Check
sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall rim lines are not parallel,
remove the valve core.
Lubricate the rim flanges and tire beads.
Install the valve core and inflate the tire again.
After the tire beads seat in the rim flanges, check for air
leakage.
○Inflate the tire slightly above standard inflation.
○Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chapter).
Install the air valve cap.
Adjust the wheel balance (see Balance Adjustment).
•
•
•
•
•
•
Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) repair 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 understood that higher running durability is obtained by permanent (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 (external) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.
10-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Removal
the wheels (see Front/Rear Wheel Removal),
• Remove
and take out the following.
Collars [A]
Coupling [B] (Out of rear hub)
Grease Seals [C]
Circlip [D]
Special Tool - Inside Circlip Pliers: 57001-143
• Use the bearing remover to remove the hub bearings [A].
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Special Tools - Bearing Remover Head,
57001-1293
Bearing Remover Shaft,
-1377
20 ×
22 [B]:
13 [C]: 57001
Hub Bearing Installation
installing the hub bearings, blow any dirt or foreign
• Before
particles out of the hub with compressed air to prevent
•
•
contamination of the bearings.
Replace the bearings with new ones.
Install the bearings by using the bearing driver set which
does not contact the bearing inner race.
NOTE
○Install the bearings so that the marked side faces out.
• Press in each right the bearing [A] until they are bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129
WHEELS/TIRES 10-17
Hub Bearing
• Replace the circlip with a new one.
Special Tool - Inside Circlip Pliers: 57001-143
the grease seals with new ones.
• Replace
Press
in
the
grease seals [A] so that the seal surface flush
• [B] with the end
of the hole.
○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set [C]: 57001-1129
Hub Bearing Inspection
Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with
new ones.
each bearing in the hub back and forth [A] while
• Turn
checking for plays, roughness, or binding.
•
If bearing play, roughness, or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication
NOTE
○Since the hub bearings are packed with grease and
sealed, lubrication is not required.
FINAL DRIVE 11-1
Final Drive
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Drive Chain.............................................................................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection/Adjustment ..........................................................................
Drive Chain Wear Inspection ............................................................................................
Drive Chain Lubrication.....................................................................................................
Drive Chain Removal ........................................................................................................
Drive Chain Installation .....................................................................................................
Drive Chain Replacement .................................................................................................
Sprocket, Coupling .................................................................................................................
Engine Sprocket Cover Removal......................................................................................
Engine Sproket Cover Installation.....................................................................................
Engine Sprocket Removal ................................................................................................
Engine Sprocket Installation .............................................................................................
Rear Sprocket Removal....................................................................................................
Rear Sprocket Installation.................................................................................................
Coupling Installation..........................................................................................................
Coupling Bearing Removal ...............................................................................................
Coupling Bearing Installation ............................................................................................
Coupling Bearing Inspection .............................................................................................
Coupling Bearing Lubrication............................................................................................
Coupling Damper Inspection.............................................................................................
Sprocket Wear Inspection.................................................................................................
Rear Sprocket Warp Inspection ........................................................................................
11-2
11-4
11-5
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-7
11-7
11-11
11-11
11-11
11-12
11-12
11-12
11-13
11-13
11-13
11-14
11-14
11-14
11-14
11-15
11-15
11
11-2 FINAL DRIVE
Exploded View
FINAL DRIVE 11-3
Exploded View
No.
1
2
3
4
5
Fastener
Engine Sprocket Nut
Drive Chain Guide Bolts
Speed Sensor Mounting Bolt
Chain Adjuster Clamp Bolts
Rear Sprocket Nuts
N·m
125
9.8
6.9
64
59
Torque
kgf·m
12.7
1.0
0.70
6.5
6.0
ft·lb
92.2
87 in·lb
61 in·lb
47
44
Remarks
HG: Apply high-temperature grease.
HO: Apply heavy oil.
MO: Apply molybdenum disulfide oil.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
MO
L
11-4 FINAL DRIVE
Specifications
Item
Drive Chain
Drive Chain Slack
Drive Chain Wear (20-link Length)
Standard Chain:
Make
Type
Link
Link Pin Outside Diameter
(When drive chain replacing)
Link Plates Outside width
(When drive chain replacing)
Sprockets
Rear Sprocket Warp
Standard
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit
– – –
319 mm (12.56 in.)
ENUMA
EK525ZX
112 links
– – –
– – –
– – –
5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.)
– – –
20.35 ∼ 20.55 mm (0.8012 ∼ 0.8091 in.)
– – –
0.4 mm (0.016 in.) or less
0.5 mm (0.020 in.)
FINAL DRIVE 11-5
Special Tools
Inside Circlip Pliers:
57001-143
Bearing Driver Set:
57001-1129
11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
to the Drive Chain Slack Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Slack Adjustment
to the Drive Chain Slack Adjustment in the Periodic
• Refer
Maintenance chapter.
Wheel Alignment Inspection/Adjustment
to the Wheel Alignment Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Wear Inspection
to the Drive Chain Wear Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Lubrication
to the Drive Chain Lubrication Condition Inspection
• Refer
in the Periodic Maintenance chapter.
Drive Chain Removal
• Remove:
Mud Guard (see Mud Guard Removal in the Frame
chapter)
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Chain Cover Bolt [A]
• Remove:
Clamp [A]
Chain Cover [B]
Swingarm (see Swingarm Removal in the Suspension
chapter)
• Remove:
Engine Sprocket Cover (see Engine Sprocket Cover)
Remove
drive chain [A] from the engine sprocket [B],
• and take the
it off the chassis.
FINAL DRIVE 11-7
Drive Chain
Drive Chain Installation
the drive chain to the engine sprocket.
• Install
• Install:
Swingarm (see Swingarm Installation in the Suspension
•
•
chapter)
Rear Wheel (see Rear Wheel Installation in the
Wheels/Tires chapter)
Engine Sprocket Cover (see Engine Sprocket Cover Installation)
Insert the projection [A] on the chain cover into the
swingarm hole [B].
Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
Drive Chain Replacement
• Remove:
Chain Cover (see Drive Chain Removal)
Engine Sprocket Cover (see Engine Sprocket Removal)
NOTICE
For safety, if the drive chain shall be replaced, replace it using a recommended tool.
Recommended Tool - Type: EK Joint Tool #50
Brand: ENUMA
Body [A]
Handlebar [B]
Cutting and Riveting Pin [C]
For Cutting [D]
For Riveting [E]
Plate Holder (A) [F]
Plate Holder (B) [G]
Gauge [H]
[A] the pin head to make it flat.
• Grind
• Set the cutting and riveting pin [B] as shown in the figure.
11-8 FINAL DRIVE
Drive Chain
the pin holder until it touches chain pin.
• Screw
Be
sure
that the cutting pin hits center of chain pin.
•
the handlebar [A] into body.
• Screw
Turn
the
• chain pin.pin holder with wrench [B] clockwise to extract
the link pin, link plate and grease seals.
• Replace
Apply
grease
to the link pins [A] and grease seals [B] [C].
• Engage the drive
on the engine and rear sprockets.
• Insert the link pinschain
in
the
• Install the grease seals. drive chain ends.
• Install the link plate [D] so that the mark faces out.
• Push the link plate by hand or plier to fix it.
• In case of grease seals chain, be sure to set the grease
• seals correctly.
the plate holder (A) [A] and plate holder (B) [B] on the
• Set
body.
the plate holder (A) [A] to link plate.
• Fit
the pin holder by hand until plate holder (B) [B]
• Turn
touches the other link plate.
FINAL DRIVE 11-9
Drive Chain
the pin holder [A] by wrench clockwise until two pins
• Turn
of link come into groove of plate holders [B].
• Take off the plate holder.
the plate holder (B) [A] and cutting and riveting pin [B]
• Set
as shown in the figure.
• Turn the pin holder until riveting pin touches link pin.
the wrench clockwise until tip of riveting pin hits to
• Turn
the link pin.
it.
• Rivet
Same
work for the other link pin.
•
11-10 FINAL DRIVE
Drive Chain
staking, check the staked area of the link pin for
• After
cracks.
the outside diameter [A] of the link pin and link
• Measure
plates width [B].
Link Pin Outside Diameter
Standard: 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.)
Link Plates Outside Width
Standard: 20.35 ∼ 20.55 mm (0.8012 ∼ 0.8091 in.)
•
•
If the reading exceeds the specified length, cut and rejoin
the chain again.
Check:
Movement of the Rollers
Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
FINAL DRIVE 11-11
Sprocket, Coupling
Engine Sprocket Cover Removal
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Engine Sprocket Inner Cover Bolts [A]
Engine Sprocket Inner and Outer Cover [B]
the engine sprocket outer cover screws [A] to
• Remove
sparate the outer and inner cover [B].
• Remove the speed sensor bolt [A].
Engine Sproket Cover Installation
sure to install the drive chain guide [A].
• Be
Tighten:
•
Torque - Drive Chain Guide Bolts [B]: 9.8 N·m (1.0 kgf·m, 87
in·lb)
a non-parmanent locking agent to the thread of the
• Apply
speed senor mounting bolt.
• Tighten:
Torque - Speed Sensor Mounting Bolt: 6.9 N·m (0.70 kgf·m,
61 in·lb)
the engine sprocket outer cover to the inner cover.
• Install
Be
sure
install the dowel pins [A].
• Install thetoengine
sprocket inner cover.
•
11-12 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Removal
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
•
•
Frame chapter)
Engine Sprocket Cover (see Engine Sprocket Cover Removal)
Flatten out the bended washer [A].
Remove the engine sprocket nut [B] and washer.
NOTE
○When loosening the engine sprocket nut, hold the rear
brake on.
the rear wheel off the ground with the stand.
• Raise
the drive chain (see Drive Chain Slack Adjust• Loosen
ment in the Periodic Maintenance chapter).
the drive chain from the rear sprocket toward the
• Remove
right.
the drive chain [A] from the engine sprocket
• Disengage
[B].
• Pull the engine sprocket off the output shaft [C].
Engine Sprocket Installation
the sprocket washer.
• Replace
Install
the
engine sprocket so that “OUT SIDE” letters [A]
• face outward.
molybdenum disulfide oil solution to the threads
• Apply
and the seating surface of the engine sprocket nut.
• Tighten:
Torque - Engine Sprocket Nut: 125 N·m (12.7 kgf·m, 92.2
ft·lb)
NOTE
○Tighten the nut while applying the rear brake.
torquing the engine sprocket nut, bend the one side
• After
of the washer over the nut.
the drive chain slack after installing the engine
• Adjust
sprocket (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
Rear Sprocket Removal
the rear wheel (see Rear Wheel Removal in the
• Remove
Wheels/Tires chapter).
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
the rear sprocket nuts [A].
• Remove
Remove
the rear sprocket [B].
•
FINAL DRIVE 11-13
Sprocket, Coupling
Rear Sprocket Installation
the sprocket facing the tooth number marking [A]
• Install
outward.
the rear sprocket nuts with new ones.
• Replace
Tighten:
•
Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
the rear wheel (see Rear Wheel Installation in the
• Install
Wheels/Tires chapter).
Coupling Installation
high-temperature grease to the following parts.
• Apply
Coupling Grease Seal Lip [A]
Coupling Internal Surface [B]
• Install:
Collar [A]
Coupling [B]
Coupling Bearing Removal
• Remove:
Coupling
Grease Seal
Circlip [A]
Special Tool - Inside Circlip Pliers: 57001-143
• Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set [B]: 57001-1129
11-14 FINAL DRIVE
Sprocket, Coupling
Coupling Bearing Installation
the bearing with a new one.
• Replace
• Press in the bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129
the bearing with high-temperature grease.
• Pack
Replace
the circlip with a new one.
•
Special Tool - Inside Circlip Pliers: 57001-143
the grease seal with a new one.
• Replace
Press
in
the
seal so that the seal surface is flush
• with the end grease
of the hole.
○Apply high-temperature grease to the grease seal lip.
Special Tool - Bearing Driver Set: 57001-1129
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
○It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
the bearing in the coupling back and forth [A] while
• Turn
checking for plays, roughness or binding.
•
If the bearing play, roughness or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn ot is leaking, replace the bearing.
Coupling Bearing Lubrication
NOTE
○Since the coupling bearing is packed with grease and
sealed, lubrication is not required.
Coupling Damper Inspection
the rear wheel coupling, and inspect the rubber
• Remove
dampers [A].
the damper if it appears damaged or deterio• Replace
rated.
FINAL DRIVE 11-15
Sprocket, Coupling
Sprocket Wear Inspection
inspect the engine and rear sprocket teeth for
• Visually
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
NOTE
○If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the
chain.
Rear Sprocket Warp Inspection
the rear wheel off the ground with the stand so that
• Raise
it will turn freely.
a dial gauge [A] against the rear sprocket [B] near the
• Set
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).
If 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.)
BRAKES 12-1
Brakes
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Brake Lever, Brake Pedal.......................................................................................................
Brake Lever Position Adjustment......................................................................................
Brake Pedal Position Inspection .......................................................................................
Brake Pedal Position Adjustment......................................................................................
Brake Pedal Removal .......................................................................................................
Brake Pedal Installation ....................................................................................................
Calipers ..................................................................................................................................
Front Caliper Removal ......................................................................................................
Rear Caliper Removal.......................................................................................................
Caliper Installation ............................................................................................................
Front Caliper Disassembly................................................................................................
Front Caliper Assembly.....................................................................................................
Rear Caliper Disassembly ................................................................................................
Rear Caliper Assembly .....................................................................................................
Caliper Fluid Seal Damage ...............................................................................................
Rear Caliper Dust Boot and Friction Boot Damage ..........................................................
Caliper Piston and Cylinder Damage................................................................................
Rear Caliper Holder Shaft Wear .......................................................................................
Brake Pads .............................................................................................................................
Front Brake Pad Removal.................................................................................................
Front Brake Pad Installation..............................................................................................
Rear Brake Pad Removal ................................................................................................
Rear Brake Pad Installation ..............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Master Cylinder ......................................................................................................................
Front Master Cylinder Removal ........................................................................................
Front Master Cylinder Installation .....................................................................................
Rear Master Cylinder Removal.........................................................................................
Rear Master Cylinder Installation......................................................................................
Front Master Cylinder Disassembly ..................................................................................
Rear Master Cylinder Disassembly...................................................................................
Master Cylinder Assembly ................................................................................................
Master Cylinder Inspection (Visual Inspection).................................................................
Brake Disc ..............................................................................................................................
Brake Disc Removal .........................................................................................................
Brake Disc Installation ......................................................................................................
Brake Disc Wear ...............................................................................................................
Brake Disc Warp ...............................................................................................................
Brake Fluid .............................................................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Fluid Change ..........................................................................................................
Brake Line Bleeding..........................................................................................................
Brake Hose.............................................................................................................................
Brake Hose Removal/Installation......................................................................................
Brake Hose and Pipe Inspection.......................................................................................
Anti-Lock Brake System (Equipped Models) ..........................................................................
Parts Location ...................................................................................................................
12-3
12-10
12-11
12-12
12-12
12-12
12-12
12-12
12-13
12-14
12-14
12-14
12-15
12-15
12-15
12-15
12-15
12-16
12-16
12-16
12-17
12-18
12-18
12-18
12-19
12-19
12-19
12-20
12-20
12-20
12-20
12-21
12-21
12-21
12-21
12-22
12-23
12-23
12-23
12-23
12-23
12-24
12-24
12-24
12-24
12-28
12-28
12-28
12-29
12-29
12
12-2 BRAKES
ABS Servicing Precautions ...............................................................................................
ABS Troubleshooting Outline............................................................................................
Inquiries to Rider...............................................................................................................
Self-diagnosis Outline .......................................................................................................
Self-diagnosis Procedures ................................................................................................
Service Code Clearing Procedures...................................................................................
How to Read Service Codes.............................................................................................
How to Erase Service Codes ............................................................................................
ABS Indicator Light (LED) Inspection ...............................................................................
Solenoid Coil Temperature Abnormal [High-Temperature] (Service Code 11)..................
Solenoid Valve Inspection (Service Code 13, 14, 17, 18).................................................
ABS Solenoid Valve Relay Inspection (Service Code 19) ................................................
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) ..............................
ABS Motor Relay Inspection (Service Code 35) ...............................................................
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) ..................................
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) ................................
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)...................................
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)..................................
Power Supply Voltage Abnormal (Low-Voltage) (Service Code 52) .................................
Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) ................................
ECU Inspection (Service Code 55) ...................................................................................
Wheel Rotation Sensor Signal Abnormal [Too High Speed] (Service Code 93) ..............
ABS Hydraulic Unit Removal ............................................................................................
ABS Hydraulic Unit Installation .........................................................................................
ABS Hydraulic Unit Inspection ..........................................................................................
Front Wheel Rotation Sensor Removal ............................................................................
Front Wheel Rotation Sensor Installation .........................................................................
Rear Wheel Rotation Sensor Removal .............................................................................
Rear Wheel Rotation Sensor Installation ..........................................................................
Wheel Rotation Sensor Inspection....................................................................................
Wheel Rotation Sensor Air Gap Inspection ......................................................................
Wheel Rotation Sensor Rotor Inspection..........................................................................
ABS Solenoid Valve Relay Fuse (20 A) Removal.............................................................
ABS Motor Relay Fuse (30 A) Removal ...........................................................................
ABS ECU Fuse (10 A) Removal .......................................................................................
Fuse Installation................................................................................................................
Fuse Inspection.................................................................................................................
12-33
12-35
12-38
12-40
12-40
12-41
12-44
12-44
12-46
12-46
12-46
12-47
12-47
12-48
12-48
12-49
12-50
12-50
12-51
12-51
12-52
12-52
12-52
12-54
12-54
12-55
12-55
12-56
12-56
12-57
12-57
12-58
12-58
12-58
12-58
12-59
12-59
BRAKES 12-3
Exploded View
This page intentionally left blank.
12-4 BRAKES
Exploded View
BRAKES 12-5
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
Fastener
Front Master Cylinder Reservoir Cap Stopper
Screw
Brake Lever Pivot Bolt
Front Master Cylinder Bleed Valve
Front Master Cylinder Clamp Bolts
Brake Lever Pivot Bolt Locknut
Front Brake Light Switch Screw
Brake Hose Banjo Bolts
Front Caliper Assembly Bolts
Front Caliper Mounting Bolts
Bleed Valves
Front Brake Pad Pins
Front Brake Disc Mounting Bolts
13. ZX1000GB Early Model
14. Face the lock portion of the clamp backward.
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
N·m
Torque
kgf·m
ft·lb
1.2
0.12
11 in·lb
1.0
5.4
11
5.9
1.2
25
22
34
7.8
15
27
0.10
0.55
1.1
0.60
0.12
2.5
2.2
3.5
0.80
1.5
2.8
8.8 in·lb
48 in·lb
97 in·lb
52 in·lb
11 in·lb
18
16
25
69 in·lb
11
20
Remarks
Si
S
L
12-6 BRAKES
Exploded View
BRAKES 12-7
Exploded View
No.
1
2
3
4
5
6
7
Fastener
Brake Hose Banjo Bolts
Rear Master Cylinder Mounting Bolts
Brake Pedal Bolt
Bleed Valve
Rear Master Cylinder Push Rod Locknut
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).
N·m
25
25
8.8
7.8
17
27
25
Torque
kgf·m
2.5
2.5
0.90
0.8
1.7
2.8
2.5
ft·lb
18
18
78 in·lb
69 in·lb
12
20
18
Remarks
L
L
12-8 BRAKES
Exploded View
ABS Equipped Models
BRAKES 12-9
Exploded View
No.
1
2
3
4
Fastener
N·m
27
25
18
27
Front Brake Disc Mounting Bolts
Brake Hose Banjo Bolts
Brake Pipe Joint Nuts
Rear Brake Disc Mounting Bolts
Torque
kgf·m
2.8
2.5
1.8
2.8
ft·lb
20
18
13
20
Remarks
L
L
5. Front Wheel Rotation Sensor
6. Rear Wheel Rotation Sensor
7. ABS Hydraulic Unit
8. ZX1000HB Early Model
9. Face the lock portion of the clamp backward.
L: Apply a non-permanent locking agent.
R: Replacement Parts
NOTE
○When disassembling the brake hose and pipe, disassemble them by the unit as shown in the
exploded view.
12-10 BRAKES
Specifications
Item
Brake Lever, Brake Pedal
Brake Lever Position
Brake Lever Free Play
Pedal Free Play
Pedal Position
Brake Pads
Lining Thickness:
Front
Rear
Brake Discs
Thickness:
Front
Rear
Runout
Brake Fluid
Grade
ABS (Equipped Models)
Wheel Rotation Sensor
Air Gap:
Front
Rear
Standard
6-way adjustable (to suit rider)
Non-adjustable
Non-adjustable
About 62 mm (2.4 in.) below footpeg top
4.0 mm (0.16 in.)
5.0 mm (0.20 in.)
5.3 ∼ 5.7 mm (0.21 ∼ 0.22 in.)
5.8 ∼ 6.2 mm (0.23 ∼ 0.24 in.)
TIR 0.15 mm (0.006 in.) or less
Service Limit
–
–
–
–
–
–
–
–
–
–
–
–
1 mm (0.04 in.)
1 mm (0.04 in.)
5.0 mm (0.20 in.)
5.5 mm (0.22 in.)
TIR 0.3 mm (0.01 in.)
DOT4
– – –
1.98 ∼ 2.86 mm (0.0780 ∼ 0.113 in.)
1.12 ∼ 1.85 mm (0.0441 ∼ 0.0728 in.)
– – –
– – –
BRAKES 12-11
Special Tools
Jack:
57001-1238
Attachment Jack:
57001-1252
Jack Attachment:
57001-1608
12-12 BRAKES
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever adjuster has 6 positions so that the brake
lever position can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A] to align
the number with the arrow mark [B] on the lever holder.
○The distance from the grip to the lever is minimum at number 6 and maximum at number 1.
•
Brake Pedal Position Inspection
that the brake pedal [A] is in the correct position.
• Check
[B] Footpeg
Pedal Position
Standard: About 62 mm (2.4 in.) [C] below top of
footpeg
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when the push rod locknut has been
loosened.
the locknut [A] and turn the push rod with the hex
• Loosen
head [B] to achieve the correct pedal position.
•
If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), the
pedal position will be within the standard range.
Tighten:
Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m
(1.7 kgf·m, 12 ft·lb)
the brake light switch operation (see Brake Light
• Check
Switch Operation Inspection in the Periodic Maintenance
chapter).
Brake Pedal Removal
• Remove:
Rear Lower Fairing (see Rear Lower Fairing Removal in
the Frame chapter)
Right Front Footpeg Bracket Bolts [A]
BRAKES 12-13
Brake Lever, Brake Pedal
• Remove:
Cotter Pin [A]
Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D]
Brake Pedal Bolt [E]
Brake Pedal [F]
Brake Pedal Installation
grease to the footpeg pivot shaft [A].
• Apply
• Install:
Washer [B]
•
Brake Pedal [C]
Washer [D]
Apply a non-permanent locking agent to the threads of
the brake pedal bolt [E], and tighten it.
Torque - Brake Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
the longer end of the rear brake light switch spring
• Hook
[A] on the brake light switch.
the upper end of the return spring [B] on the footpeg
• Hook
bracket hook.
○Face the both lower spring ends forward.
the cotter pin [A] with a new one.
• Replace
the cotter pin and bend the pin ends [B].
• Insert
Install
• Tighten:the front footpeg bracket.
•
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
the brake pedal position (see Brake Pedal Position
• Check
Inspection).
12-14 BRAKES
Calipers
Front Caliper Removal
the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the caliper mounting bolts [B], and detach the
• Unscrew
caliper [C] from the disc.
NOTICE
Do not loosen the caliper assembly bolts [D]. Take
out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will
cause brake fluid leakage.
the banjo bolt and remove the brake hose [E]
• Unscrew
from the caliper (see Brake Hose and Pipe Replacement
in the Periodic Maintenance chapter).
NOTICE
Immediately wash away any brake fluid that spills.
NOTE
○If 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 Caliper Rubber
Parts Replacement in the Periodic Maintenance chapter).
• Remove the collars [A] from the fork leg.
Rear Caliper Removal
the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the caliper mounting bolts [B], and detach the
• Unscrew
caliper [C] from the disc.
the banjo bolt and remove the brake hose [D]
• Unscrew
from the caliper (see Brake Hose and Pipe Replacement
in the Periodic Maintenance chapter).
NOTICE
Immediately wash away any brake fluid that spills.
NOTE
○If 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 Caliper Rubber
Parts Replacement in the Periodic Maintenance chapter).
BRAKES 12-15
Calipers
Caliper Installation
the caliper and brake hose lower end.
•○Install
For the front caliper, install the collars [A] on the fork leg
and fit the holes [B] of the front caliper to the collars.
○Replace the washers on each side of hose fitting with new
•
ones.
Tighten:
Torque - Caliper Mounting Bolts
Front: 34 N·m (3.5 kgf·m, 25 ft·lb)
Rear: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
the brake line (see Brake Line Bleeding).
• Bleed
Check
brake for good braking power, no brake drag,
• and nothe
fluid leakage.
WARNING
After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.
Front Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Front Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Rear Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Rear Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
12-16 BRAKES
Calipers
Caliper Fluid Seal Damage
The fluid seal (piston seal) [A] is placed around the piston 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 temperature of the discs or the brake fluid to increase.
Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.
Front Caliper [C]
Rear Caliper [D]
•
Rear Caliper Dust Boot and Friction Boot Damage
that the dust boot [A] and friction boot [B] are not
• Check
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
Caliper Piston and Cylinder Damage
inspect the pistons [A] and cylinder surfaces [B].
• Visually
Replace the caliper if the cylinder and piston are badly
scores or rusty.
Front Caliper [C]
Rear Caliper [D]
BRAKES 12-17
Calipers
Rear Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
Check to see that the caliper holder shafts are not badly
worn or stepped, and that the rubber friction boots are not
damaged.
If the rubber friction boot is damaged, replace the rubber
friction boot. To replace the friction boot, remove the pads
and the caliper bracket.
If the caliper holder shaft is damage, replace the caliper
bracket.
•
12-18 BRAKES
Brake Pads
Front Brake Pad Removal
• Loosen the pad pins [A].
the front caliper with the hose installed (see Front
• Remove
Caliper Removal).
• Remove:
Pad Pins [A]
Brake Pads [B]
Front Brake Pad Installation
that the pad spring [A] is in place on the caliper.
• Check
• Push the caliper pistons in by hand as far as they will go.
the brake pads [A] on the pad spring correctly.
•○Install
Fit the pad into the groove of the caliper as shown in the
•
•
•
•
figure.
Install the pad pins while pushing the brake pads lightly.
Tighten the pad pins temporarily.
Install the front caliper (see Caliper Installation).
Tighten:
Torque - Front Brake Pad Pins: 15 N·m (1.5 kgf·m, 11 ft·lb)
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
BRAKES 12-19
Brake Pads
Rear Brake Pad Removal
the rear caliper with the hose installed (see Rear
• Remove
Caliper Removal).
• Remove:
Clip [A]
•
Pad Pin [B]
Remove the brake pad [C] of the jaw side from the holder
shaft [D], then remove the other pad [E].
Rear Brake Pad Installation
that the pad spring [A], guide [B] and insulator [C]
• Check
are in place on the caliper and holder.
• Push the caliper piston in by hand as far as it will go.
the brake pad [A] on the piston side first, then install
• Install
the other pad on the holder shaft.
○Fit the projections [B] of the piston side pad into the recesses [C] of the caliper holder.
Install the pad pin while pushing the brake pad of the jaw
side lightly.
Install a new clip.
○The clip must be “outside” of the pad.
Install the rear caliper (see Rear Caliper Installation).
•
•
•
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
Brake Pad Wear Inspection
to the Brake Pad Wear Inspection in the Periodic
• Refer
Maintenance chapter.
12-20 BRAKES
Master Cylinder
Front Master Cylinder Removal
the rear view mirror (see Rear View Mirror Re• Remove
moval in the Frame chapter).
the banjo bolt [A] to disconnect the brake hose
• Remove
from the master cylinder (see Brake Hose Removal/In-
•
•
stallation).
Unscrew the clamp bolts [B], and take off the master cylinder [C] as an assembly with the reservoir, brake lever, and
brake switch installed.
Disconnect the front brake light switch connector [D].
NOTICE
Immediately wash away any brake fluid that spills.
Front Master Cylinder Installation
the front master cylinder to match its mating surface
• Set
[A] to the punch mark [B] of the handlebar.
master cylinder clamp must be installed with the ar• The
row mark [C] upward.
the upper clamp bolt first, and then the lower
• Tighten
clamp bolt.
Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1
kgf·m, 97 in·lb)
the washers that are on each side of the hose
• Replace
fitting with new ones.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
the brake line (see Brake Line Bleeding).
• Bleed
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
Rear Master Cylinder Removal
the rear lower fairing (see Rear Lower Fairing
• Remove
Removal in the Frame chapter).
• Looen:
Brake Hose Banjo Bolt [A]
•
Rear Master Cylinder Mounting Bolts [B]
Remove the footpeg bracket bolts [C].
• Remove:
Rear Master Cylinder Mounting Bolts [A]
•
•
Cotter Pin [B]
Joint Pin [C]
Brake Hose Banjo Bolt [D]
Brake Hose [E]
Slide out the clamp [F].
Pull off the reservoir hose lower end, and drain the brake
fluid into a container.
BRAKES 12-21
Master Cylinder
Rear Master Cylinder Installation
the cotter pin [A] with a new one.
• Replace
• Insert the cotter pin and bend the pin ends [B].
the washers on each side of hose fitting with new
• Replace
ones.
the brake pedal [A] to align the holes of the mas• Depress
ter cylinder, then install the master cylinder mounting bolts
•
[B].
Tighten the following bolts.
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
NOTE
○After installation, check that the rear brake light switch
spring is hooked on the return spring.
the brake line (see Brake Line Bleeding).
• Bleed
Check
brake for good braking power, no brake drag,
• and nothe
fluid leakage.
Front Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
Master Cylinder Assembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
12-22 BRAKES
Master Cylinder
Master Cylinder Inspection (Visual Inspection)
the master cylinders (see Front/Rear Master
• Remove
Cylinder Removal).
the front and rear master cylinders (see
• Disassemble
Master Cylinder Rubber Parts Replacement in the Peri-
•
•
•
•
•
odic Maintenance chapter).
Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.
Check the dust covers [E] for damage.
If they are damaged, replace them.
Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Front Master Cylinder [J]
Rear Master Cylinder [K]
BRAKES 12-23
Brake Disc
Brake Disc Removal
the wheels (see Front/Rear Wheel Removal in
• Remove
the Wheels/Tires chapter).
the mounting bolts [A], and take off the disc [B].
• Unscrew
Remove
the
gaskets.
•
Brake Disc Installation
the gaskets with new ones.
• Replace
the brake disc on the wheel so that the marked side
• Install
[A] faces out.
a non-permanent locking agent to the threads of
• Apply
the front and rear brake disc mounting bolts, and tighten
them.
Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20
ft·lb)
Brake Disc Wear
the thickness of each disc [A] at the point where
• Measure
it has worn the most.
If the disc has worn past the service limit, replace it.
Measuring Area [B]
Brake Discs Thickness
Standard:
Front
5.3 ∼ 5.7 mm (0.21 ∼ 0.22 in.)
Rear
5.8 ∼ 6.2 mm (0.23 ∼ 0.24 in.)
Service Limit:
Front
5.0 mm (0.20 in.)
Rear
5.5 mm (0.22 in.)
Brake Disc Warp
• Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238
Attachment Jack: 57001-1252
Jack Attachment: 57001-1608
○For front disc inspection, turn the handlebar fully to one
•
side.
Set up a dial gauge against the disc [A] as shown in
the figure and measure disc runout, while turning [B] the
wheel by hand.
If 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.)
12-24 BRAKES
Brake Fluid
Brake Fluid Level Inspection
to the Brake Fluid Level Inspection in the Periodic
• Refer
Maintenance chapter.
Brake Fluid Change
to the Brake Fluid Change in the Periodic Mainte• Refer
nance chapter.
Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake lever or pedal has a soft or
"spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
• Remove:
Screw [A]
Stopper [B]
Front Brake Reservoir Cap [C]
Diaphragm Plate
Diaphragm
Fill the reservoir with fresh brake fluid to the upper level
line in the reservoir.
Slowly pump the brake lever several times until no air
bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.
○Bleed the air completely from the master cylinder by this
operation.
•
•
BRAKES 12-25
Brake Fluid
the rubber cap from the bleed valve on the front
• Remove
master cylinder.
a clear plastic hose [A] to the bleed valve, and run
• Attach
the other end of the hose into a container.
the brake line and the master cylinder.
•○Bleed
Repeat this operation until no more air can be seen coming 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 holding the brake applied.
3. Release the brake [C].
NOTE
○The fluid level must be checked often during the bleeding 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.
the clear plastic hose.
• Remove
Tighten
the
bleed valve, and install the rubber cap.
•
Torque - Front Master Cylinder Bleed Valve: 5.4 N·m (0.55
kgf·m, 48 in·lb)
the rubber cap [A] from the bleed valve on the
• Remove
caliper.
a clear plastic hose [B] to the bleed valve, and run
• Attach
the other end of the hose into a container.
12-26 BRAKES
Brake Fluid
the brake line and the caliper.
•○Bleed
Repeat this operation until no more air can be seen coming 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 holding the brake applied.
3. Release the brake [C].
NOTE
○The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding.
○Front Brake: First bleeding the right caliper then repeat
the above steps for the left caliper.
the clear plastic hose.
• Remove
Install:
• Diaphragm
Diaphragm Plate
Front Brake Reservoir Cap
the procedure below to install the front/rear brake
• Follow
fluid reservoir cap correctly.
○First, tighten the brake fluid reservoir cap [B] clockwise
•
[C] by hand until slight resistance is felt indicating that
the cap is seated on the reservoir body, then tighten the
cap an additional 1/6 turn [D] while holding the brake fluid
reservoir body [A].
Tighten the rear brake reservoir cap stopper screw securely.
• Tighten:
Torque - Front Master Cylinder Reservoir Cap Stopper
Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb)
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the fluid level (see Brake Fluid Level Inspection in
• Check
the Periodic Maintenance chapter).
bleeding is done, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
BRAKES 12-27
Brake Fluid
WARNING
When working with the disc brake, observe the precautions 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
wind is blowing.
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 deterioration 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 satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up immediately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
12-28 BRAKES
Brake Hose
Brake Hose Removal/Installation
to the Brake Hose Replacement in the Periodic
• Refer
Maintenance chapter.
Brake Hose and Pipe Inspection
to the Brake Hose and Pipe Damage and Instal• Refer
lation Condition Inspection in the Periodic Maintenance
chapter.
BRAKES 12-29
Anti-Lock Brake System (Equipped Models)
Parts Location
Front Wheel Rotation Sensor [A]
Front Wheel Rotation Sensor Rotor [B]
Rear Wheel Rotation Sensor [A]
Rear Wheel Rotation Sensor Rotor [B]
ABS Indicator Light [A]
ABS Hydraulic Unit [A]
Fuse Box 1 [A] (ABS Fuses and Accessory Fuse)
12-30 BRAKES
Anti-Lock Brake System (Equipped Models)
ABS Kawasaki Diagnostic System Connector [A]
ABS Self-diagnosis Terminal [B]
BRAKES 12-31
Anti-Lock Brake System (Equipped Models)
ABS System Wiring Diagram
1. ABS Self-diagnosis Terminal
2. Fuse Box 1
3. ABS Motor Relay Fuse 30 A
4. ABS Solenoid Valve Relay Fuse 20 A
5. ABS ECU Fuse 10 A
6. Fuse Box 2
7. Ignition Fuse 10 A
8. Front Brake Light Switch
9. Meter Ground
10. Frame Ground
11. Water-proof Joint C
12. Rear Brake Light Switch
13. Battery 12 V 8 Ah
14. Starter Relay
15. Main Fuse 30 A
16. Water-proof Joint D
17. Meter Unit
18. ABS Indicator Light (LED)
19. Ignition Switch
20. ABS Hydraulic Unit
21. ABS Kawasaki Self-diagnosis System Connector
22. Front Wheel Rotation Sensor
23. Rear Wheel Rotation Sensor
○Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green
G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
12-32 BRAKES
Anti-Lock Brake System (Equipped Models)
ABS Hydraulic Unit Terminal Names
1. Power Supply to ABS Motor
2. Power Supply to ABS Solenoid Valve Relay
3. Ground
4. Ground
5. ABS Self-diagnosis Terminal
6. Unused
7. Unused
8. Front and Rear Brake Light Switch
9. Unused
10. Unused
11. Unused
12. Unused
13. Unused
14. Unused
15. Unused
16. Power Supply
17. Unused
18. Unused
19. Unused
20. Unused
21. Unused
22. Unused
23. Power Supply to Front Wheel Rotation Sensor
24. ABS Kawasaki Self-diagnosis System Terminal
25. ABS Indicator Light (LED)
26. Power Supply to Rear Wheel Rotation Sensor
27. Front Wheel Rotation Sensor Signal
28. Unused
29. Unused
30. Rear Wheel Rotation Sensor Signal
31. Unused
32. Unused
BRAKES 12-33
Anti-Lock Brake System (Equipped Models)
ABS Servicing Precautions
There are a number of important precautions that should
be followed servicing the ABS system.
○This ABS system is designed to be used with a 12 V
sealed battery as its power source. Do not use any
other battery except for a 12 V sealed battery as a power
source.
○Do not reverse the battery cable connections. This will
damage the ABS hydraulic unit.
○To prevent damage to the ABS parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is ON or while the engine is
running.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Do not turn the ignition switch ON while any of the ABS
electrical connectors are disconnected. The ABS hydraulic unit memorizes service codes.
○Do not spray water on the electrical parts, ABS parts, connectors, leads and wiring.
○If a transceiver is installed on the motorcycle, make sure
that the operation of the ABS system is not influenced
by electric wave radiated from the antenna. Locate the
antenna as far as possible away from the ABS hydraulic
unit.
○Whenever the ABS electrical connections are to be disconnected, first turn off the ignition switch.
○The ABS parts should never be struck sharply, as with
a hammer, or allowed to fall on a hard surface. Such a
shock to the parts can damage them.
○The ABS parts cannot be disassembled. Even if a fault is
found, do not try to disassemble and repair the ABS parts,
replace it.
○The ABS has many brake lines, pipes, and leads. And
the ABS cannot detect problems with the conventional
braking system (brake disc wear, unevenly worn brake
pad, and other mechanical faults). To prevent trouble,
check the brake lines and pipes for correct routing and
connection, the wiring for correct routing, and the brakes
for proper braking power. Be sure to check for fluid leakage, and bleed the brake line thoroughly.
12-34 BRAKES
Anti-Lock Brake System (Equipped Models)
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If any of the brake line fittings, including the
ABS hydraulic unit joint nuts, or the bleed valve is
opened at any time, the air must be bled completely
from the brake line. If the brake lever has a soft
or "spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.
NOTICE
Do not ride the motorcycle with air in the brake line,
or the ABS could malfunction.
○The ABS indicator light (LED) [A] may light if the tire pressure is incorrect, a non-recommended tire is installed, or
the wheel is deformed. If the indicator light lights, remedy
the problem and clear the service code.
WARNING
Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended braking
distance resulting in an accident causing serious
injury or death. Always use recommended standard tires for this motorcycle.
BRAKES 12-35
Anti-Lock Brake System (Equipped Models)
○The ABS indicator light (LED) may come on if the engine
is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn the
ignition switch OFF, then clear service code 42, which indicates a “Faulty front wheel rotation sensor”.
○When the ABS operates, the ABS makes noise and the
rider feels the reaction force on the brake lever and brake
pedal. This is a normal condition. It informs the rider that
the ABS is operating normally.
○Service codes detected once by the ABS hydraulic unit
will be memorized in the ABS hydraulic unit. Therefore,
after maintenance work is finished, be sure to erase the
service codes. Do not erase the service codes during
troubleshooting. Wait until all the checks and repair work
are finished to prevent duplication of previous service
codes and unnecessary maintenance work.
○Before delivering the motorcycle to the customer, be
sure to erase any service codes which might be stored in
the ABS hydraulic unit. Using the self-diagnosis feature,
make sure that the 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 motorcycle at a speed of more than 30 km/h (20 mph) and
brake suddenly to see that the motorcycle stops without
loss of steering control and the ABS operates normally
(The reaction force generated is felt in the brake lever
and pedal.). This completes the final inspection.
ABS Troubleshooting Outline
When an abnormality in the system occurs, the ABS indicator 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 service 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.
12-36 BRAKES
Anti-Lock Brake System (Equipped Models)
Even when the ABS is operating normally, the ABS indicator light (LED) may light up under the conditions listed below. 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.
○After continuous riding on a rough road.
○When the engine is started with the stand raised and the
transmission engaged, and the rear wheel turns.
○When accelerating so abruptly that the front wheel leaves
the ground.
○When the ABS has been subjected to strong electrical
interference.
○When tire pressure is abnormal. Adjust tire pressure.
○When a tire different in size from the standard size is being
used. Replace with standard size.
○When the wheel is deformed. Replace the wheel.
Much of the ABS troubleshooting work consists of confirming continuity of the wiring. The ABS parts are assembled and adjusted by the manufacturer, so there is no need
to disassemble or repair them. Replace the ABS hydraulic
unit.
The basic troubleshooting procedures are listed below.
Carry out pre-diagnosis inspections as a preliminary inspection.
Determine the fault using the self-diagnosis function.
Check wiring and connections from the ABS hydraulic
unit connector to the suspected faulty ABS part, using the
hand tester.
•
•
•
Special Tool - Hand Tester: 57001-1394
inspect the wiring for signs of burning or fraying.
• Visually
If any wiring is poor, replace the damaged wiring.
each connector [A] apart and inspect it for corrosion,
• Pull
dirt and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
•
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the main harness [B] if necessary.
down suspicious parts and close in on the faulty
• Narrow
ABS part by repeating the continuity tests.
If no abnormality is found in the wiring or connectors, the
ABS parts are the next likely suspects. Check each part
one by one.
If an abnormality is found, replace the affected ABS part.
BRAKES 12-37
Anti-Lock Brake System (Equipped Models)
ABS Diagnosis Flow Chart
12-38 BRAKES
Anti-Lock Brake System (Equipped Models)
Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of condition
the rider is dissatisfied with.
○Try to find out exactly what problem occurs under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem in the shop.
○The diagnosis sheet will help prevent you from overlooking any keys, so always use it.
Sample Diagnosis Sheet
Rider name:
Year of initial registration:
Engine No.:
Date problem occurred:
Weather:
□ Brake
lever
vibration
or noise
Registration No. (license plate No.):
Model:
Frame No.:
Frequency:
Mileage:
□ Indicator □ Braking □ Abnor- □ ABS not □ ABS
□ ABS oplight
distance
mal
working
works
erating
blinks
too long
brake
but
too frelever
indicator
quently
movelight
Phenomement
doesn’t
non
light up
□ Pedal □ Indicator
□ Abnorvibration
light
mal
or noise
remains
pedal
lit up
movement
□ At start-up
□ After starting
□ At 5 000 r/min (rpm)
Engine conditions at
problem
or more
Road conditions
□ Slippery road
(□ snow, □ gravel, □ other
)
□ Rough surface
□ Other
Driving conditions
□ High-speed cornering
□ Driving 10 km/h (6 mph) or above
□ Driving below 10 km/h (6 mph)
□ When stopping
□ When turning
Brake application
□ Gradual
□ Abrupt
Other conditions
□ Large brake lever stroke
□ Large pedal stroke
BRAKES 12-39
Anti-Lock Brake System (Equipped Models)
Pre-Diagnosis Inspection 1
12-40 BRAKES
Anti-Lock Brake System (Equipped Models)
Pre-Diagnosis Inspection 2
Self-diagnosis Outline
When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the
service code (17 codes including “Normal Code”) for the service person to troubleshoot easily. The
service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
The ABS hydraulic unit can memorize up to all service codes (17 codes). Further service codes are
memorized after erasing the preceding all service codes (17 codes). If there is no fault, only the start
code 12 is shown, indicating that “The ABS is normal”.
Self-diagnosis Procedures
○When a problem occurs with the ABS system, the ABS
indicator light (LED) [A] lights.
○Use
NOTE
a fully charged battery when conducting
self-diagnosis. Otherwise, the light blinks very slowly
or doesn’t blink.
○The motorcycle is stopped.
○Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.
BRAKES 12-41
Anti-Lock Brake System (Equipped Models)
the rear seat (see Rear Seat Removal in the
• Remove
Frame chapter).
on the ignition switch.
• Turn
Ground
the self-diagnosis terminal [A] (Gray) to the bat• tery (–) terminal,
using a suitable lead.
○Count 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
the service code erase mode with the following pro• Start
cedure.
○The erase mode starts when the ABS self-diagnosis terminal is disconnected from the ground terminal after starting the self-diagnosis mode.
○The service code can be erased by grounding and ungrounding (each time for at least one second) the ABS
self-diagnosis terminal three times within about 12.5 seconds after starting the erase mode.
○The ABS indicator light (LED) remains lit during the erase
mode.
○After erasing, the ABS indicator light (LED) blinks and
lights.
○Once erasing is finished, enter the self-diagnosis mode
again to confirm that the service codes have been
erased. If the ABS has been reset and all codes have
been erased, only start code 12 will be shown.
12-42 BRAKES
Anti-Lock Brake System (Equipped Models)
BRAKES 12-43
Anti-Lock Brake System (Equipped Models)
Self-diagnosis Flow Chart
12-44 BRAKES
Anti-Lock Brake System (Equipped Models)
How to Read Service Codes
○Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as
shown below.
○Read 10th digit and unit digit as the ABS indicator light (LED) blinks.
○When there are a number of faults, a maximum of all service codes (17 codes) can be stored and
the display will begin starting from the small number code entered.
○For the display pattern, first the smallest number code is shown, next up to all service codes (17
codes) starting with the last one stored, then the display is repeated from the smallest number code
once again.
○If there is no fault, the ABS indicator light (LED) lights as shown in the figure.
How to Erase Service Codes
○Even if the ignition switch is turned OFF, the battery or the ABS hydraulic unit are disconnected, all
service codes remain in the ABS hydraulic unit.
○Refer to the Service Code Clearing Procedure for the service code erasure.
BRAKES 12-45
Anti-Lock Brake System (Equipped Models)
Service Code Table
Service
Code
ABS Indicator Light (LED)
Problems
Light
State
11
Rise in heat of solenoid coil by ABS
continuousness operation
12
Start code (not fault)
13
Rear inlet solenoid valve trouble (shorted
or open, stuck valve)
ON
14
Rear outlet solenoid valve trouble (shorted
or open, stuck valve)
ON
17
Front inlet solenoid valve trouble (shorted
or open, stuck valve)
ON
18
Front outlet solenoid valve trouble (shorted
or open, stuck valve)
ON
19
ABS solenoid valve relay trouble (wiring
shorted or open, stuck relay)
ON
25
Front, rear tire abnormal (substandard
tire, deformation wheel, sensor rotor teeth
number wrong)
ON
35
ABS motor relay trouble (wiring shorted,
open or lock, stuck relay)
ON
42
Front wheel rotation sensor signal
abnormal (sensor or rotor missing, too
large clearance, rotor tooth worn or
missing)
ON
43
Front wheel rotation sensor wiring
abnormal (wiring shorted or open)
ON
44
Rear wheel rotation sensor signal
abnormal (sensor or rotor missing, too
large clearance, rotor tooth worn or
missing)
ON
45
Rear wheel rotation sensor wiring
abnormal (wiring shorted or open)
ON
52
Power supply voltage abnormal
(low-voltage)
ON
53
Power supply voltage abnormal
(low-voltage)
ON
55
ECU trouble (ECU operation abnormal)
ON
93
Wheel rotation sensor signal abnormal
(too high speed, special road running,
substandard tire)
ON
ON
After
starts,
turn off
12-46 BRAKES
Anti-Lock Brake System (Equipped Models)
ABS Indicator Light (LED) Inspection
○In this model, the ABS indicator light (LED) [A] goes on or
•
blinks by the control of the ABS hydraulic unit.
Turn the ignition switch ON.
If the ABS indicator light (LED) lights, it is normal.
If the ABS indicator light (LED) does not light, refer to the
Meter Unit Inspection in the Electrical System chapter.
If the meter is good, check the wiring continuity of the
BK/W lead in the main harness.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
Meter Connector [A]
←→
ABS Hydraulic Unit
Connector [B]
BK/W Lead [C]
If there is not the continuity in the lead, replace or repair
the main harness.
If there is the continuity in the lead, replace the ABS hydraulic unit.
Solenoid Coil Temperature Abnormal
[High-Temperature] (Service Code 11)
○When the temperature of the solenoid coil rises more than
a prescribed value by the ABS continuousness operation,
this service code is detected. Therefore, check it after
leaving the motor cycle for tens of minutes or more.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
Solenoid Valve Inspection (Service Code 13, 14,
17, 18)
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] light, the solenoid valve
in the ABS hydraulic unit has trouble. Replace the ABS
hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
BRAKES 12-47
Anti-Lock Brake System (Equipped Models)
ABS Solenoid Valve Relay Inspection (Service
Code 19)
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Check the ABS solenoid valve relay fuse (20 A) [A] (see
Fuse Inspection in the Electrical System chapter).
If the fuse is good, check the wiring continuity that relates
to the LG lead in the main harness referring to the ABS
System Wiring Diagram.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
ABS Hydraulic Unit
←→
Connector [A]
Fuse Box Terminal [B]
LG Lead [C]
If there is not the continuity in the lead, replace or repair
the main harness.
If there is the continuity in the lead, go to next stemp.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
Front, Rear Wheel Rotation Difference Abnormal
(Service Code 25)
○Check the following and correct the faulty part.
Incorrect Tire Pressure
Tires not recommended for the motorcycle were installed
(incorrect tire size).
Deformation of Wheel or Tire
Missing Teeth and Clogging with Foreign Matter of Sensor Rotor (see Wheel Rotation Sensor Inspection)
If the all parts correct, recheck the service code indication; erase the service code, perform the pre-diagnosis
inspection 1 and 2, and retrieve the service code.
12-48 BRAKES
Anti-Lock Brake System (Equipped Models)
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
ABS Motor Relay Inspection (Service Code 35)
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Check the ABS motor relay fuse (30 A) [A] (see Fuse
Inspection in the Electrical System chapter).
If the fuse is good, check the wiring continuity that relates
to the R lead in the main harness referring to the ABS
System Wiring Diagram.
Special Tool - Hand Tester 57001-1394
Wiring Continuity Inspection
ABS Hydraulic Unit
←→
Connector [A]
Fuse Box Terminal [B]
R Lead [C]
If there is not the continuity in the lead, replace or repair
the main harness.
If there is the continuity in the lead, go to next step.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
Front Wheel Rotation Sensor Signal Abnormal
(Service Code 42)
the air gap between the front wheel rotation sen• Measure
sor and sensor rotor (see Wheel Rotation Sensor Air Gap
•
Inspection).
Check the front wheel rotation sensor (see Wheel Rotation Sensor Inspection).
If both inspections are good, go to next step.
BRAKES 12-49
Anti-Lock Brake System (Equipped Models)
that there is iron or other magnetic deposits be• Check
tween the sensor [A] and sensor rotor [B], and the sensor
•
•
rotor slots for obstructions.
Check the installation condition of the sensor for looseness.
Check the sensor rotor tip for deformation or damage
(e.g., chipped sensor rotor teeth).
If the sensor rotor in bad condition, remove the any deposits. Install the proper part or replace faulty part.
If the all items are good, go to next step.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
Front Wheel Rotation Sensor Wiring Inspection
(Service Code 43)
• Disconnect:
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal)
Front Wheel Rotation Sensor Connector (see Front
Wheel Rotation Sensor Removal)
• Check the wiring continuity of the G lead and BK/R lead.
Special Tool - Hand Tester 57001-1394
Wiring Continuity Inspection
ABS Hydraulic Unit
←→
Connector [A]
Front Wheel Rotation
Sensor Connector [B]
BK/R Lead Terminal [C]
G Lead Terminal [D]
If there is not the continuity in the lead, replace or repair
the main harness.
If the wiring is good, go to next step.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, replace the front
wheel rotation sensor (see Front Wheel Rotation Sensor
Removal).
Still, when it is not good, replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
12-50 BRAKES
Anti-Lock Brake System (Equipped Models)
Rear Wheel Rotation Sensor Signal Abnormal
(Service Code 44)
the air gap between the rear wheel rotation sen• Measure
sor and sensor rotor (see Wheel Rotation Sensor Air Gap
•
Inspection).
Check the rear wheel rotation sensor (see Rear Wheel
Rotation Sensor Inspection).
If both inspections are good, go to next step.
that there is iron or other magnetic deposits be• Check
tween the sensor [A] and sensor rotor [B], and the sensor
•
•
rotor slots for obstructions.
Check the installation condition of the sensor for looseness.
Check the sensor rotor tip for deformation or damage
(e.g., chipped sensor rotor teeth).
If the sensor rotor in bad condition, remove the any deposits. Install the proper part or replace faulty part.
If the all items are good, go to next step.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
Rear Wheel Rotation Sensor Wiring Inspection
(Service Code 45)
• Disconnect:
ABS Hydraulic Unit Connector (see ABS Hydraulic Unit
Removal)
Rear Wheel Rotation Sensor Connector (see Rear
Wheel Rotation Sensor Removal)
the wiring continuity of the BK lead and BR/BK
• Check
lead.
Special Tool - Hand Tester 57001-1394
Wiring Continuity Inspection
ABS Hydraulic Unit
←→
Connector [A]
Rear Wheel Rotation
Sensor Connector [B]
BK Lead Terminal [C]
BR/BK Lead Terminal [D]
If there is not the continuity in the lead, replace or repair
the main harness.
If the wiring is good, go to next step.
BRAKES 12-51
Anti-Lock Brake System (Equipped Models)
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, replace the rear
wheel rotation sensor (see Rear Wheel Rotation Sensor
Removal).
Still, when it is not good, replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
Power Supply Voltage Abnormal (Low-Voltage)
(Service Code 52)
• Check:
Battery Condition (see Charging Condition Inspection in
the Electrical System chapter)
Charging Voltage (see Charging Voltage Inspection in
the Electrical System chapter)
If the battery and charging voltage are good condition, go
to next step.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
Power Supply Voltage Abnormal (Over-Voltage)
(Service Code 53)
the charging voltage (see Charging Voltage In• Check
spection in the Electrical System chapter).
If the charging voltage is good, go to next step.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
12-52 BRAKES
Anti-Lock Brake System (Equipped Models)
ECU Inspection (Service Code 55)
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not lgiht, ABS system
is normal (service code is not stored; temporary failure.).
Wheel Rotation Sensor Signal Abnormal [Too
High Speed] (Service Code 93)
○When the wheel rotation sensor signal detects 340 km/h
or more at a motor cycle speed of 264 km/h or more, this
service code is detected. Therefore, this service code
might be detected by a special operation condition or using the substandard tire.
the service code indication; erase the service
• Recheck
code, perform the pre-diagnosis inspection 1 and 2, and
retrieve the service code.
If the ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) does not light, ABS system
is normal (service code is not stored; temporary failure.).
ABS Hydraulic Unit Removal
NOTICE
The ABS hydraulic unit [A] has been adjusted
and set with precision at the factory. Therefore, it
should be handled carefully, never struck sharply,
as with a hammer, or allowed to fall on a hard
surface.
Be careful not to get water or mud on the ABS hydraulic unit.
the brake fluid from the front and rear brake lines.
•○Drain
Drain the brake fluid through the bleed valve by pumping
the brake lever and pedal.
BRAKES 12-53
Anti-Lock Brake System (Equipped Models)
• Remove:
Battery Case (see Battery Case Removal in the Frame
•
chapter)
Brake Hose (see Brake Hose Replacement in the Periodic maintenance chapter)
Clean the ABS hydraulic unit.
NOTICE
Clean all fittings on the ABS hydraulic unit and the
rear master cylinder because dirt around the banjo
bolts could contaminate the brake fluid in the line
during removal/installation.
Spread over a shop towel around the ABS hydraulic
unit before removing the brake line so that brake
fluid does not leak on the parts.
the clamp [A].
• Open
Disconnect
the regulator/rectifier connector [B].
•
the bolts [A].
• Remove
Pull
up
the
ABS hydraulic unit [B].
•
pushing the stopper [A], unlock the connector lock
• While
[B] upward.
• Disconnect the connector [C].
12-54 BRAKES
Anti-Lock Brake System (Equipped Models)
• Remove:
Bolts [A]
ABS Hydraulic Unit [B]
NOTICE
The ABS hydraulic unit [A] has been adjusted and
set with precision at the factory. Do not try to disassemble and repair the ABS hydraulic unit.
ABS Hydraulic Unit Installation
• Install the ABS hydraulic unit to the bracket.
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
the lead correctly, and connect the connector [A] se• Run
curely.
○Lock the connector lock [B] as shown in the figure.
the brake hoses correctly (see Brake Hose Re• Install
placement in the Periodic Maintenance chapter).
the brake line (see Brake Line Bleeding).
• Bleed
Check
brake for good braking power, no brake drag,
• and nothe
fluid leakage.
• Install the removed parts (see appropriate chapters).
ABS Hydraulic Unit Inspection
the ABS hydraulic unit (see ABS Hydraulic Unit
• Remove
Removal).
inspect the ABS hydraulic unit.
• Visually
Replace the ABS hydraulic unit if any of them are cracked,
or otherwise damaged.
BRAKES 12-55
Anti-Lock Brake System (Equipped Models)
inspect the connector terminals [A].
• Visually
Replace the ABS hydraulic unit or main harness if either
of the terminals are cracked, bent, or otherwise damaged.
If the ABS hydraulic unit connector is clogged with mud
or dust, blow it off with compressed air.
Front Wheel Rotation Sensor Removal
NOTICE
The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation 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 rotation sensor.
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Connector [A] (Disconnect)
Grommet [B]
Clamp [C]
• Remove:
Clamp [A]
Clear
the sensor lead from the clamps [B].
• Remove:
• Bolt [C]
Front Wheel Rotation Sensor [D]
Front Wheel Rotation Sensor Installation
is the reverse of removal.
•○Installation
Replace the brake hose clamp with
a new one
(ZX1000HB Early Model).
○For ZX1000HB Late Model ∼, face the lock portion [A] of
the brake hose clamp backward.
○Run the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
12-56 BRAKES
Anti-Lock Brake System (Equipped Models)
Rear Wheel Rotation Sensor Removal
NOTICE
The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation 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 rotation sensor.
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
(DFI) chapter)
Connector [A] (Disconnect)
Clear the sensor lead from the clamps [B].
the sensor lead from the clamps [A].
• Clear
• Remove:
Grommet [B]
Bolt [C]
Clamp [D]
Rear Wheel Rotation Sensor [E]
Rear Wheel Rotation Sensor Installation
is the reverse of removal.
•○Installation
Run the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
BRAKES 12-57
Anti-Lock Brake System (Equipped Models)
Wheel Rotation Sensor Inspection
the front wheel rotation sensor [A] from the front
• Remove
fork.
the rear wheel rotation sensor [B] from the
• Remove
caliper bracket.
inspect the wheel rotation sensors.
• Visually
Replace the wheel rotation sensor if it is cracked, bent, or
otherwise damaged.
Wheel Rotation Sensor Air Gap Inspection
the front/rear wheel off the ground (see Front/Rear
• Raise
Wheel Removal in the Wheels/Tires chapter).
the air gap between the sensor and sensor rotor
• Measure
at several points by turning the wheel slowly.
Thickness Gauge [A]
Air Gap
Standard:
Front
1.98 ∼ 2.86 mm (0.0780 ∼ 0.113 in.)
Rear
1.12 ∼ 1.85 mm (0.0441 ∼ 0.0728 in.)
NOTE
○The sensor air gap cannot be adjusted.
If the air gap is not within the specification, inspect the hub
bearing (see Hub Bearing Inspection in the Wheels/Tires
chapter), sensor installation condition and sensor (see
Wheel Rotation Sensor Inspection).
12-58 BRAKES
Anti-Lock Brake System (Equipped Models)
Wheel Rotation Sensor Rotor Inspection
• Remove:
Wheels
(see Front/Rear Wheel Removal in the
Wheels/Tires chapter)
Brake Disc Mounting Bolts [A]
Sensor Rotor [B]
Front Wheel [C]
Rear Wheel [D]
inspect the wheel rotation sensor rotor.
• Visually
If the rotor is deformed or damaged (chipped teeth [A]),
replace the sensor rotor with a new one.
If there is iron or other magnetic deposits [B], remove the
deposits.
ABS Solenoid Valve Relay Fuse (20 A) Removal
to the Fuse Box Fuse Removal in the Electrical Sys• Refer
tem chapter.
ABS Motor Relay Fuse (30 A) Removal
to the Fuse Box Fuse Removal in the Electrical Sys• Refer
tem chapter.
ABS ECU Fuse (10 A) Removal
to the Fuse Box Fuse Removal in the Electrical Sys• Refer
tem chapter.
BRAKES 12-59
Anti-Lock Brake System (Equipped Models)
Fuse Installation
fails during operation, inspect the electrical sys• Iftema fuse
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
the fuses (see ABS Solenoid Valve Relay Fuse
• Remove
(20 A)/ABS Motor Relay Fuse (30 A)/ABS ECU Fuse (10
•
A) Removal).
Refer to the Fuse Inspection in the Electrical System
chapter.
SUSPENSION 13-1
Suspension
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Front Fork ...............................................................................................................................
Rebound Damping Force Adjustment ..............................................................................
Spring Preload Adjustment ...............................................................................................
Compression Damping Force Adjustment (Right Side Only)............................................
Front Fork Removal (Each Fork Leg) ...............................................................................
Front Fork Installation .......................................................................................................
Fork Oil Change................................................................................................................
Front Fork Disassembly ....................................................................................................
Front Fork Assembly.........................................................................................................
Inner Tube, Outer Tube Inspection ...................................................................................
Dust Seal Inspection .........................................................................................................
Spring Tension Inspection.................................................................................................
Rear Shock Absorber .............................................................................................................
Rebound Damping Force Adjustment...............................................................................
Spring Preload Adjustment ...............................................................................................
Rear Shock Absorber Removal ........................................................................................
Rear Shock Absorber Installation .....................................................................................
Rear Shock Absorber Inspection ......................................................................................
Rear Shock Absorber Scrapping ......................................................................................
Rear Shock Absorber Bearing Removal ...........................................................................
Rear Shock Absorber Bearing Installation ........................................................................
Swingarm................................................................................................................................
Swingarm Removal...........................................................................................................
Swingarm Installation........................................................................................................
Swingarm Bearing Removal .............................................................................................
Swingarm Bearing Installation ..........................................................................................
Swingarm Bearing, Sleeve Inspection ..............................................................................
Swingarm Bearing Lubrication ..........................................................................................
Chain Guide Inspection.....................................................................................................
Tie-Rod, Rocker Arm..............................................................................................................
Tie-Rod Removal ..............................................................................................................
Tie-Rod Installation ...........................................................................................................
Rocker Arm Removal........................................................................................................
Rocker Arm Installation.....................................................................................................
Tie-Rod and Rocker Arm Bearing Removal......................................................................
Tie-Rod and Rocker Arm Bearing Installation...................................................................
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection .............................................................
Rocker Arm/Tie-Rod Bearing Lubrication .........................................................................
13-2
13-6
13-7
13-9
13-9
13-9
13-10
13-10
13-11
13-11
13-17
13-18
13-19
13-19
13-19
13-20
13-20
13-20
13-21
13-21
13-22
13-22
13-22
13-22
13-23
13-23
13-24
13-25
13-25
13-26
13-26
13-26
13-27
13-27
13-27
13-27
13-27
13-28
13-28
13-29
13-29
13
13-2 SUSPENSION
Exploded View
SUSPENSION 13-3
Exploded View
No.
1
2
3
4
5
6
Fastener
Upper Front Fork Clamp Bolts
Lower Front Fork Clamp Bolts
Piston Rod Nuts
Front Fork Top Plugs
Front Axle Clump Bolts
Front Fork Bottom Allen Bolts
N·m
20
25
20
34
20
35
Torque
kgf·m
2.0
2.5
2.0
3.5
2.0
3.6
ft·lb
15
18
15
25
15
26
7. ABS Equipped Models
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
R: Replacement Parts
Remarks
AL
AL
13-4 SUSPENSION
Exploded View
SUSPENSION 13-5
Exploded View
No.
1
2
3
4
5
6
7
Fastener
Rear Shock Absorber Bolt (Upper)
Tie-rod Nuts
Rear Shock Absorber Nut (Lower)
Rocker Arm Nut
Swingarm Pivot Adjusting Collar Locknut
Swingarm Pivot Shaft Nut
Torque Link Nuts
G: Apply grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
N·m
34
34
34
34
98
108
34
Torque
kgf·m
3.5
3.5
3.5
3.5
10
11.0
3.5
ft·lb
25
25
25
25
72
79.7
25
Remarks
R
R
R
13-6 SUSPENSION
Specifications
Item
Front Fork (Per One Unit)
Fork Inner Tube Diameter
Air Pressure
Rebound Damper Setting
Compression Damper Setting
(Right Side Only)
Fork Spring Preload Setting
Fork Oil:
Recommend Oil
Amount:
When Changing Oil
After Disassembly and
Completely Dry
Fork Oil Level: (Fully
Compressed, without Spring,
below from the Top of the Outer
Tube)
Fork Spring Free Length
Rear Shock Absorber
Rebound Damper Setting
Spring Preload Setting Position
Gas Pressure
Standard
41 mm (1.6 in.)
Atmospheric pressure (non-adjustable)
2 turns out from the fully clockwise position
(Usable range: 0 ←→ 3 1/2 turns out)
1 1/4 turns out from the fully clockwise position
(Usable range: 0 ←→ 3 turns out)
7 turns in from the fully counterclockwise position
(Usable range: 0 ←→ 15 turns in)
SHOWA SS-47 or equivalent
Approx. 420 mL (14.2 US oz.)
492 ±2.5 mL (16.6 ±0.085 US oz.)
91 ±2 mm (3.58 ±0.08 in.)
313 mm (12.3 in.) (Service Limit: 307 mm (12.1 in.))
1 1/4 turns out from the fully clockwise position
(Usable Range: 0 ←→ 2 1/2 turns out)
4th position (from the weakest position)
(Adjustable Range: 0 ∼ 10th position)
980 kPa (10 kgf/cm², 142 psi, Non-adjustable)
SUSPENSION 13-7
Special Tools
Inside Circlip Pliers:
57001-143
Fork Oil Seal Driver,
57001-1288
Oil Seal & Bearing Remover:
57001-1058
Fork Piston Rod Puller, M12 × 1.25:
57001-1289
Bearing Driver Set:
57001-1129
Fork Oil Level Gauge:
57001-1290
Jack:
57001-1238
Fork Spring Stopper:
57001-1374
Bearing Remover Head,
57001-1267
15 ×
17:
41:
Bearing Remover Shaft,
57001-1377
13:
13-8 SUSPENSION
Special Tools
Hook Wrench T=3.2 R37:
57001-1539
Needle Bearing Driver,
57001-1609
17/ 18:
Fork Spring Compressor:
57001-1587
Needle Bearing Driver,
57001-1610
28:
Swingarm Pivot Nut Wrench:
57001-1597
Clamp:
57001-1693
Jack Attachment:
57001-1608
Bar:
57001-1751
SUSPENSION 13-9
Front Fork
Rebound Damping Force Adjustment
adjust the rebound damping force, turn the rebound
• To
damping adjuster [A] until you feel a click.
○The standard adjuster setting is the 2 turns out from the
fully clockwise position.
WARNING
If both adjusters are not adjusted equally, handling
may be impaired and a hazardous condition may
result. Be sure the adjusters are set equally.
○The damping force can be left soft for average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the damping feels too soft or too stiff,
adjust it in accordance with the following table.
Rebound Damping Force Adjustment
Adjuster
Position
Damping
Force
Setting
Load
Road
Speed
3 1/2 turns out
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
0
Strong
Hard
Heavy
Bad
High
Spring Preload Adjustment
the spring preload adjuster [A] to change spring
• Turn
preload setting.
○The standard adjuster setting is the 7 turns in from the
fully counterclockwise position.
WARNING
If both adjusters are not adjusted equally, handling
may be impaired and a hazardous condition may
result. Be sure the adjusters are set equally.
○The spring preload can be left soft for average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the spring action feels too soft or too
stiff, adjust it in accordance with the following table.
Spring Action
Adjuster
Position
Damping
Force
Setting
Load
Road
Speed
0
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
15 turns in
Strong
Hard
Heavy
Bad
High
13-10 SUSPENSION
Front Fork
Compression Damping Force Adjustment (Right
Side Only)
adjust the compression damping force, turn the com• To
pression damping adjuster [A] until you feel a click.
○The standard adjuster setting is the 1 1/4 turns out from
the fully clockwise position.
WARNING
If both adjusters are not adjusted equally, handling
may be impaired and a hazardous condition may
result. Be sure the adjusters are set equally.
○The damping force can be left soft for average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the damping feels too soft or too stiff,
adjust it in accordance with the following table.
Compression Damping Force Adjustment
Adjuster Damping
Position
Force
Setting
Load
Road
Speed
3 Turns
out
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
0
Strong
Hard
Heavy
Bad
High
Front Fork Removal (Each Fork Leg)
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
the handle bar holder bolt [A].
• Remove
Loosen
the
front fork clamp bolts [B] and lower front
• clamp boltsupper
[C].
○If fork leg is to be disassembled, loosen the upper and
lower front fork clamp bolts to lower the fork leg [A] as
shown. And retighten the lower front fork clamp bolts.
Then, loosen the top plug beforhand.
NOTE
○Loosen the top plug after loosening the upper front fork
clamp bolt.
○Loosen the lower front fork clamp bolts.
• With a twisting motion, work the fork leg down and out.
SUSPENSION 13-11
Front Fork
Front Fork Installation
the fork so that the top end [A] of the outer tube as
• Install
shown in the figure.
•
28 mm (1.10 in.) [B]
Tighten:
Torque - Lower Front Fork Clamp Bolts : 25 N·m (2.5 kgf·m,
18 ft·lb)
Front Fork Top Plugs: 34 N·m (3.5 kgf·m, 25 ft·lb)
Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
NOTE
○Tighten the top plug before tightening the upper front
fork clamp bolt.
○Tighten the two clamp bolts (lower) alternately two times
to ensure even tightening torque.
the removed parts (see appropriate chapters).
• Install
Adjust:
• Spring Preload (see Spring Preload Adjustment)
Rebound Damping Force (see Rebound Damping Force
Adjustment)
Compression Damping Force (see Compression Damping Force Adjustment)
Fork Oil Change
the front fork (see Front Fork Removal).
• Remove
the inner tube lower end in a vice.
• Hold
Unscrew
the top plug [A] out of the outer tube.
•
the top plug [A] with a wrench [B], tighten the
• Holding
spring preload adjuster [C].
NOTE
○After tightening, lift the top plug to make the space.
• Slide down the damper [D].
13-12 SUSPENSION
Front Fork
• Install the clamps [A] as shown in the figure.
NOTE
○Set the cutout [B] of the clamp to the groove [C] of collar
[D], pull up the outer tube [E] to hold it by the clamps,
and then tighten the two bolts [F]. The outer tube is used
as a guide.
Special Tools - Fork Spring Compressor: 57001-1587
Clamp : 57001-1693
the holder bar [A] into the axle hole of the front fork
• Insert
[B].
Special Tool - Bar: 57001-1751 (For Left Fork Leg)
○Position the bar left and right and evenly.
the compression shaft and install the nut.
• Insert
the lower end of the compression shaft [A] into the
• Insert
hole [B] of the holder bar.
the adjust nut [A] onto the compression shaft as
• Screw
shown in the figure.
the locknut [B].
• Screw
Set
the
other side compression shaft same process.
•
SUSPENSION 13-13
Front Fork
• Set the holder bar [A] and compression shafts [B].
• Screw in the nuts [A] until the piston rod nut comes out.
holding up the top plug [A], insert the fork spring
• While
stopper [B] between the piston rod nut [C] and the slider.
Special Tool - Fork Spring Stopper: 57001-1374
the spring preload adjuster [A] with a wrench [B],
• Holding
loosen the piston rod nut [C].
• Remove:
Top Plug with the Rebound Damping Adjuster Rod
Damper [A]
Slider [B]
Collar [C]
Fork Spring [D]
13-14 SUSPENSION
Front Fork
the fork oil into a suitable container.
•○Drain
Pump 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 × 1.25 [B]:
57001-1289
the fork tube upright, press the outer tube [A] and
• Hold
the piston rod all the way down.
• Pour in the type and amount of fork oil specified.
Fork Oil
Recommended Oli:
SHOWA SS-47 or equivalent
Amount (Per Side):
When changing oil:
Approx. 420 mL (14.2 US oz.)
After disassembly and completely dry:
492 ±2.5 mL (16.6 ±0.085 US oz.)
If necessary, measure the oil level as follows.
○Hold the inner tube vertically in a vise.
○Using 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 × 1.25 [A]:
57001-1289
○Remove the piston rod puller.
○Wait until the oil level settles.
○With 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 outer
tube to the oil.
SUSPENSION 13-15
Front Fork
Oil Level (fully compressed, without spring)
Standard:
91 ±2 mm (3.58 ±0.08 in.) (from the top of the outer
tube)
NOTE
○Fork oil level may also be measured using the fork oil
level gauge.
Special Tool - Fork Oil Level Gauge [A]: 57001-1290
○With 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 outer tube [D].
○Set the gauge stopper [E] so that its lower side shows the
oil level distance specified [F].
○Pull the handle slowly to pump out the excess oil until the
oil no longer comes out.
If no oil is pumped out, there is insufficient oil in the inner
tube. Pour in enough oil, then pump out the excess oil as
shown above.
• Screw on the rod nut [A] fully to the piston rod [B].
the fork piston rod puller onto the end of the piston
• Screw
rod.
Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289
the puller up above the outer tube top.
• Pull
Install
• upward.the fork spring [A] with the smaller end [B] facing
• Install:
Collar [A]
Damper [B]
Slider [C]
13-16 SUSPENSION
Front Fork
the distance between the upper end [A] of the
• Check
spring preload adjuster [B] and rebound damping adjuster
[C] with a pair of vernier caliper.
1.5 mm (0.059 in.) [D]
the fork spring compressor on the slider [A] using the
• Set
outer tube as a guide.
Special Tools - Fork Spring Compressor: 57001-1587
Clamp: 57001-1693
NOTE
○Set the cutout of the clamp to the slider.
holding up the piston rod puller, insert the fork
• While
spring stopper between the piston rod nut and the slider.
Special Tool - Fork Spring Stopper: 57001-1374
the piston rod puller.
• Remove
the rebound damping adjuster rod into the holes of
• Insert
the piston rod.
• Screw in the top plug until it stops onto the piston rod.
the O-ring [A] on the top plug and replace top plug
• Check
with a new one if damaged.
○Apply grease to the new O-ring.
the spring preload adjuster [B] with a wrench [C],
• Holding
tighten the piston rod nut [D] against the top plug.
Torque - Piston Rod Nuts: 20 N·m (2.0 kgf·m, 15 ft·lb)
holding up the top plug [A], pull out the fork spring
• While
stopper [B].
the fork spring compressor.
• Remove
Raise
the
tube and screw the top plug into it.
• Install the outer
fork (see Front Fork Installation).
• Adjust thefront
spring
preload (see Spring Preload Adjust• ment)
SUSPENSION 13-17
Front Fork
Front Fork Disassembly
the front fork (see Front Fork Removal).
• Remove
the fork oil (see Fork Oil Change).
• Drain
Install
• unit. the suitable pipe ( 26 ∼ 32) [A] into the cylinder
the fork leg inverted.
• Set
pushing down [B] the fork leg, loosen the bottom
• While
Allen bolt.
• Remove the Allen bolt and gasket.
the cylinder unit [A] and center ring plate [B] out of
• Take
the inner tube.
○Do not disassemble the cylinder unit.
the inner tube from the outer tube as follows.
•○Separate
Slide up the dust seal [A].
○Remove the retaining ring [B] from the outer tube.
○Holding the outer tube [A] by hand, pull the inner tube [B]
several times to pull out the outer tube.
the inner tube guide bushing [A], outer tube
• Remove
guide bushing [B], washer [C], oil seal [D] from the inner
tube.
13-18 SUSPENSION
Front Fork
Front Fork Assembly
the following parts with new one.
• Replace
Oil Seal [A]
•
Outer Tube Guide Bushing [B]
Inner Tube Guide Bushing [C]
Dust Seal [D]
Retaining Ring [E]
Bottom Allen Bolt Gasket
Install the following parts onto the inner tube.
Dust Seal
Retaining Ring
Oil Seal
Washer [F]
Outer Tube Guide Bushing
Inner Tube Guide Bushing
the inner tube to the outer tube.
• Insert
Fit
the
• tube. new outer tube guide bushing [A] into the outer
NOTE
○When assembling the new outer tube guide bushing,
hold the washer against the new outer tube guide bushing and tap the washer with the fork oil seal driver [B]
until it stops.
Special Tool - Fork Oil Seal Driver,
41: 57001-1288
• Install the oil seal by using the fork oil seal driver.
Special Tool - Fork Oil Seal Driver,
41: 57001-1288
•
the center ring plate [A] on the cylinder unit.
• Install
Insert
the
center ring plate and cylinder unit as a set into
• the inner tube.
Install the retaining ring and dust seal into the outer tube.
the suitable pipe into the cylinder unit.
• Insert
While
pushing
down [A] the fork leg, tighten the front fork
• bottom Allen bolt
[B].
Tighten:
•
Torque - Front Fork Bottom Allen Bolts: 35 N·m (3.6 kgf·m,
26 ft·lb)
• Pour in the specified type of oil (see Fork Oil Change).
SUSPENSION 13-19
Front Fork
Inner Tube, Outer Tube Inspection
inspect the inner tube [A], and repair any dam• Visually
age.
or rust damage can sometimes be repaired by using
• Nick
a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If 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.
NOTICE
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
assemble the inner tube [A] and outer tube
• Temporarily
[B], and pump [C] them back and forth manually to check
for smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident resulting in serious injury or death. Replace a badly bent or damaged inner or outer tube and inspect the other tube
carefully before reusing it.
Dust Seal Inspection
the dust seal [A] for any signs of deterioration or
• Inspect
damage.
Replace it if necessary.
Spring Tension Inspection
a spring becomes shorter as it weakens, check its
• Since
free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Spring Free Length
Standard:
313 mm (12.3 in.)
Service Limit: 307 mm (12.1 in.)
13-20 SUSPENSION
Rear Shock Absorber
Rebound Damping Force Adjustment
adjust the rebound damping force, turn the lower
• To
damping adjuster [A] to the desired position, until you
feel a click.
○The standard adjuster setting is the 1 1/4 turns out from
the fully clockwise position.
Rebound Damping Force Adjustment
Adjuster
Position
Damping
Force
Setting
Load
Road
Speed
2 1/2 turns
out
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
0
Strong
Hard
Heavy
Bad
High
Spring Preload Adjustment
the hook wrench [A], turn the adjusting ring [B] to
• Using
adjust the spring preload.
Special Tool - Hook Wrench T = 3.2 R37: 57001-1539
○The standard adjusting ring is 4th step from the weakest
position.
Spring Preload Setting
Standard Position:
4th position
0 ∼ 10th position
Adjustable Range:
If the compression of the spring is not suited to the operating conditions, adjust it to an appropriate position by
referring to the table below.
Spring Preload Adjustment
Shock
Adjuster Damping
Absorber
Position
Force
Hardness
Load
Road
Conditions
Driving
Speed
0
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
10th
Strong
Hard
Heavy
Bad
Highway
SUSPENSION 13-21
Rear Shock Absorber
Rear Shock Absorber Removal
the motorcycle with the stand.
• Support
• Remove:
Bolts [A]
Sidestand Bracket [B] with the Sidestand
the brake lever slowly and hold it with a band
• Squeeze
[A].
• Raise the rear wheel off the ground with the jack.
Special Tools - Jack [A]: 57001-1238
Jack Attachment [B]: 57001-1608
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.
• Remove:
Lower Rear Shock Absorber Nut and Bolt [A]
•
Upper Rear Shock Absorber Bolt [B]
Remove the rear shock absorber [C] from rearside.
Rear Shock Absorber Installation
• Tighten:
Torque - Rear Shock Absorber Bolt and Nut (Upper and
Lower ): 34 N·m (3.5 kgf·m, 25 ft·lb)
13-22 SUSPENSION
Rear Shock Absorber
Rear Shock Absorber Inspection
the rear shock absorber (see Rear Shock Ab• Remove
sorber Removal).
inspect the following items.
• Visually
Smooth Stroke
•
Oil Leakage
Crack or Dent
If there is any damage to the rear shock absorber, replace
it.
Visually inspect the rubber bushing.
If it show any signs of damage, replace it.
Rear Shock Absorber Scrapping
WARNING
Since the rear shock absorber contains nitrogen
gas, do not incinerate the rear shock absorber without first releasing the gas or it may explode. Before
a rear shock absorber is scrapped, drill a hole at the
point [A] shown to release the nitrogen gas completely. Wear safety glasses when drilling the hole,
as the gas may blow out bits of drilled metal when
the hole opens.
Rear Shock Absorber Bearing Removal
• Remove:
Rear Shock Absorber (see Rear Shock Absorber Removal)
Sleeve [A]
Grease Seals [B]
the needle bearing [A], using the bearing re• Remove
mover head [B] and bearing remover shaft [C].
Special Tools - Bearing Remover Head, 15 × 17: 57001
-1267
Bearing Remover Shaft 13: 57001-1377
Rear Shock Absorber Bearing Installation
the needle bearing [A] and grease seals [B] with
• Replace
new ones.
plenty of grease to the lips of the grease seals.
• Apply
Install
bearing position as shown.
• [C] 7.5themmneedle
(0.30 in.)
• Install the grease seals and sleeve [D].
SUSPENSION 13-23
Swingarm
Swingarm Removal
• Remove:
Rear Brake Hose Lower End (see Rear Caliper Removal
in the Brakes chapter)
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Mud Guard (see Mad Guard Removal in the Frame
chapter)
Rocker Arm (see Rocker Arm Removal)
• Remove:
Cotter Pin [A]
•
Bolt and Nut [B]
Move the torque link [C] downward.
• Remove:
Brake Hose Clamp Bolt [A]
Clear
the brake hose [B] from
• swingarm.
the guide [C] on the
• Unscrew the swingarm pivot shaft nut [A].
the swingarm pivot nut wrench [A], loosen the
• Using
swingarm pivot adjusting collar locknut [B].
Special Tool - Swingarm Pivot Nut Wrench: 57001-1597
13-24 SUSPENSION
Swingarm
the swingarm pivot shaft [A] counterclockwise to free
• Turn
the adjusting collar from the swingarm.
○Make the gap between the adjusting collar and swingarm.
out the pivot shaft to the right side and remove the
• Pull
swingarm.
Swingarm Installation
inspect the chain guide [A].
• Visually
Replace the chain guide if it shows any signs of abnormal
wear or damage.
grease to the lips of the grease seals [A].
• Apply
Be
sure
• swingarm.to install the grease seals and sleeve [B] to the
• Fit the collar [C] on the grease seal of the left side.
the swingarm pivot adjusting collar [A] into the
• Screw
frame [B] so that the collar does not project the swingarm
mating surface [C].
the swingarm and insert the swingarm pivot shaft
• Install
[A] into the adjusting collar [B] from the right side, and
tighten the pivot shaft.
NOTE
○Tighten the swingarm pivot shaft until the clearance [C]
between the ball bearing [D] and collar comes to 0 mm
(0 in.).
Torque - Swingarm Pivot Shaft: 20 N·m (2.0 kgf·m, 15 ft·lb)
the swingarm pivot nut wrench,
• Using
swingarm pivot adjusting collar locknut [E].
tighten the
Special Tool - Swingarm Pivot Nut Wrench: 57001-1597
Torque - Swingarm Pivot Adjusting Collar Locknut: 98 N·m
(10 kgf·m, 72 ft·lb)
SUSPENSION 13-25
Swingarm
• Tighten the swingarm pivot shaft nut.
Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m,
79.7 ft·lb)
the swingarm up and down to check for abnormal
• Move
friction.
• Install the removed parts (see appropriate chapters).
Swingarm Bearing Removal
• Remove:
Swingarm (see Swingarm Removal)
Collar [A]
Grease Seals [B]
Sleeve [C]
Circlip (Right Side) [D]
Special Tool - Inside Circlip Pliers: 57001-143
• Remove the ball bearing and needle bearings.
Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058
Swingarm Bearing Installation
the needle bearings [A], ball bearing [B], grease
• Replace
seals [C] and circlip [D] with new ones.
the needle bearings as shown in the figure.
• Install
[E] Left Side
[F] Right Side
[G] 27 mm (1.1 in.)
[H] 9.5 mm (0.37 in.)
[I] 29.5 mm (1.16 in.)
NOTE
○Install the needle bearings so that the marked side
faces out.
Special Tool - Needle Bearing Driver,
28: 57001-1610
○Press in the ball bearing until it bottomed.
Special Tool - Bearing Driver Set: 57001-1129
○Install the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
○Press in the grease seals so that seal surface is flushed
with the end of housing.
Special Tool - Bearing Driver Set: 57001-1129
13-26 SUSPENSION
Swingarm
Swingarm Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
the needle bearings [A] and ball bearing [B] in• Inspect
stalled in the swingarm.
○The rollers and ball in a bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
visually inspect the bearing for abrasion, discoloration, or
other damage.
If the needle bearing and sleeve [C] show any sings of
abnormal wear, discoloration, or damage, replace them
as a set.
the bearing in the swingarm back and forth [A] while
• Turn
checking for plays, roughness, or binding.
•
If bearing play, roughness, or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Swingarm Bearing Lubrication
NOTE
○Since the bearings are packed with grease and sealed,
lubrication is not required.
Chain Guide Inspection
to the Chain Guide Wear Inspection in the Periodic
• Refer
Maintenance chapter.
SUSPENSION 13-27
Tie-Rod, Rocker Arm
Tie-Rod Removal
• Remove:
Mud Guard (see Mud Guard Removal in the Frame
•
chapter)
Squeeze the brake lever slowly and hold it with a band
[A].
the rear wheel off the ground with the jack (see
• Raise
Rear Shock Absorber Removal).
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove:
Upper Tie-Rod Bolt and Nut [A]
Lower Tie-Rod Bolt and Nut [B]
Tie-Rod [C]
Tie-Rod Installation
grease to the inside of the grease seals.
• Apply
the tie-rod.
• Install
Replace
• Tighten: the tie-rod nuts with new ones.
•
Torque - Tie-Rod Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Rocker Arm Removal
• Remove:
Mud Guard (see Mud Guard Removal in the Frame
•
•
chapter)
Squeeze the brake lever slowly and hold it with a band.
Raise the rear wheel off the ground with the jack (see
Rear Shock Absorber Removal).
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove:
Lower Rear Shock Absorber Bolt and Nut [A]
Upper Tie-Rod Bolt and Nut [B]
Rocker Arm Bolt and Nut [C]
Rocker Arms [D]
Rocker Arm Installation
grease to the inside of the oil seals.
• Apply
Replace
rocker arm nut and rear shock absorber nut
• respectivethenew
one.
Tighten:
•
Torque - Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb)
Tie-Rod Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Rear Shock Absorber Nut (Lower): 34 N·m (3.5
kgf·m, 25 ft·lb)
• Install the removed parts (see appropriate chapters).
13-28 SUSPENSION
Tie-Rod, Rocker Arm
Tie-Rod and Rocker Arm Bearing Removal
• Remove:
Tie-Rods (see Tie-Rod Removal)
•
Rocker Arm (see Rocker Arm Removal)
Sleeves [A]
Oil Seals [B]
Swingarm [C] (see Swingarm Removal)
Remove the needle bearings [D], using the bearing remover head and bearing remover shaft.
Special Tools - Bearing Remover Head, 15 × 17: 57001
-1267
Bearing Remover Shaft, 13: 57001-1377
Tie-Rod and Rocker Arm Bearing Installation
the needle bearing [A] and oil seals with new
• Replace
ones.
plenty of grease to the lips of the oil seals.
• Apply
Install
needle bearings and oil seals position as shown
• in the the
figure.
○Screw the needle bearing driver into the driver holder.
○Insert the needle bearing driver into the needle bearing
and press the needle bearing.
7.5 mm (0.30 in.) [B]
NOTE
○For a bearing of inner diameter
17, select the pressing
side of the needle bearing driver according to its pressing depth.
Special Tools - Bearing Driver Set: 57001-1129
Needle Bearing Driver,
17/ 18:
-1609
NOTE
57001
○Install the needle bearings so that the marked side
faces in.
SUSPENSION 13-29
Tie-Rod, Rocker Arm
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
inspect the rocker arm, or tie-rod sleeves [A] and
• Visually
needle bearings [B].
rollers in a needle bearing normally wear very little,
• The
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of any of the needle bearings or sleeve, replace the sleeve and needle
bearings as a set.
Rocker Arm/Tie-Rod Bearing Lubrication
NOTE
○Since the bearings are packed with grease, lubrication
is not required.
STEERING 14-1
Steering
Table of Contents
Exploded View........................................................................................................................
Special Tools ..........................................................................................................................
Steering ..................................................................................................................................
Steering Inspection ...........................................................................................................
Steering Adjustment..........................................................................................................
Steering Stem.........................................................................................................................
Stem, Stem Bearing Removal...........................................................................................
Stem, Stem Bearing Installation........................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Steering Stem Warp..........................................................................................................
Stem Cap Deterioration, Damage.....................................................................................
Handlebar ...............................................................................................................................
Handlebar Removal ..........................................................................................................
Handlebar Installation .......................................................................................................
14-2
14-4
14-5
14-5
14-5
14-6
14-6
14-7
14-8
14-9
14-9
14-10
14-10
14-10
14
14-2 STEERING
Exploded View
STEERING 14-3
Exploded View
No.
1
2
3
4
5
6
7
8
Fastener
Left Switch Housing Screws
Upper Front Fork Clamp Bolts
Handlebar Holder Bolts
Handlebar Bolts
Right Switch Housing Screws
Steering Stem Head Bolt
Steering Stem Nut
Lower Front Fork Clamp Bolts
N·m
3.5
25
25
34
3.5
108
25
20
Torque
kgf·m
0.36
2.5
2.5
3.5
0.36
11.0
2.5
2.0
ft·lb
31 in·lb
18
18
25
31 in·lb
79.7
18
15
AD: Apply adhesive.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
R: Replacement Parts
L: Apply a non-permanent locking agent.
Remarks
L
AL
14-4 STEERING
Special Tools
Head Pipe Outer Race Press Shaft:
57001-1075
Steering Stem Bearing Driver,
57001-1344
Head Pipe Outer Race Driver,
57001-1077
Steering Stem Bearing Driver Adapter,
57001-1345
Steering Stem Nut Wrench:
57001-1100
54.5:
Head Pipe Outer Race Driver,
57001-1446
42.5:
55:
41.5:
STEERING 14-5
Steering
Steering Inspection
to the Steering Play Inspection in the Periodic Main• Refer
tenance chapter.
Steering Adjustment
to the Steering Play Adjustment in the Periodic
• Refer
Maintenance chapter.
14-6 STEERING
Steering Stem
Stem, Stem Bearing Removal
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Upper Fairing Bracket (see Upper Fairing Bracket Removal in the Frame chapter)
Meter Unit (see Meter Unit Removal in the Electrical System chapter)
Handlebar (see Handlebar Removal)
Steering Stem Head Bolt Plug [A]
Steering Stem Head Bolt [B] and Washer
• Remove:
Front Forks (see Handlebar Removal in the Suspension
chapter)
Steering Stem Head
Brake Hose Fitting Bolt [A]
the claws [A] of claw washer back.
• Bend
Remove
the steering stem locknut [B].
•
Special Tool - Steering Stem Nut Wrench: 57001-1100
• Remove the claw washer.
up the stem base, and remove the steering stem
• Pushing
nut [A] with stem cap [B].
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100
• Remove:
Steering Stem [D]
Upper Ball Bearing Inner Race and Ball Bearing
remove the ball bearing outer races [A] pressed into
• To
the head pipe [B], insert a bar [C] into the recesses of
head pipe, and applying it to both recess alternately hammer it to drive the race out.
NOTE
○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.
STEERING 14-7
Steering Stem
the lower ball bearing inner race (with its oil seal)
• Remove
[A] which is pressed onto the steering stem with a suitable
commercially available chisel [B].
Stem, Stem Bearing Installation
the bearing outer races with new ones.
• Replace
• Drive them into the head pipe at the same time.
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver, 54.5 [B]:
57001-1077
Head Pipe Outer Race Driver, 55: 57001
-1446
• Apply grease to the outer races.
the bearing inner races and oil seal with new
• Replace
ones.
grease to the oil seal.
• Apply
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, 42.5 [C]:
57001-1344
Steering Stem Bearing Driver Adapter,
41.5 [D]: 57001-1345
the lower ball bearing [A] onto the stem.
• Install
the following.
• Grease
Inner and Outer Races
Lower and Upper Ball Bearings
The
○ lower and upper ball bearings are identical.
the stem [A] through the head pipe and install the
• Install
ball bearing [B] and inner race [C] on it.
• Install:
Stem Cap [D]
Steering Stem Nut [E]
14-8 STEERING
Steering Stem
the bearings in place as follows.
•○Settle
Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a steering stem nut wrench [A].
Special Tool - Steering Stem Nut Wrench: 57001-1100
Torque - Steering Stem Nut: 25 N·m (2.5 kgf·m, 18 ft·lb)
the claw washer [A] so that its bent side [B] faces
• Install
upward, and engage the bent claws with the grooves of
•
•
•
•
•
stem locknut [C].
Hand tighten the stem locknut until the claw washer
touches the steering stem nut.
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].
Install the stem head.
Install the washer, and temporary tighten the steering
stem head bolt.
Install the front forks (see Front Fork Installation in the
Suspension chapter).
NOTE
○Tighten the lower front fork clamp bolts first, next the
stem head bolt, last the upper front fork clamp bolts.
○Tighten the front fork clamp bolts (upper and lower) alternately two times to ensure even tightening torque.
Torque - Upper Front Fork Clamp Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Steering Stem Head Bolt: 108 N·m (11.0 kgf·m,
79.7 ft·lb)
Lower Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
WARNING
If the handlebar does not turn to the steering stop it
may cause an accident resulting in injury or death.
Be sure the cables,harnesses and hoses are routed
properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
• Install the removed parts (see appropriate chapters).
Steering Stem Bearing Lubrication
to the Steering Stem Bearing Lubrication in the Pe• Refer
riodic Maintenance chapter.
STEERING 14-9
Steering Stem
Steering Stem Warp
the steering stem is removed, or if the steering
• Whenever
can not be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
Stem Cap Deterioration, Damage
Replace the stem cap if its oil seal [A] shows damage.
14-10 STEERING
Handlebar
Handlebar Removal
• Remove:
Clutch Lever Clamp Bolts [A]
Clutch Lever Assembly [B]
Left Switch Housing [C]
Handlebar Weight [D]
• Remove:
Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter)
Right Switch Housing [B]
Throttle Case [C]
Handlebar Weight [D]
Throttle Grip [E]
• Remove:
Handlebar Bolt [A]
Handlebar
the upper front fork clamp bolt [A].
• Loosen
• Remove:
Handlebar Holder Bolt [B]
Handlebar Holder [C]
Handlebar Installation
the handlebar holder on the steering stem head.
• Install
Tighten
• bolt [B]. the handlebar holder bolt [A] and front fork clamp
Torque - Handlebar Holder Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
Upper Front Fork Clamp Bolt: 25 N·m (2.5 kgf·m,
18 ft·lb)
STEERING 14-11
Handlebar
adhesive cement to the inside of the left handlebar
• Apply
grip.
the pin [A] of the handlebar to the recess [B] of the
• Fit
handlebar holder.
a non-permanent locking agent to the threads of
• Apply
the handlebar bolts.
• Tighten:
Torque - Handlebar Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Install:
Front Master Cylinder (see Front Master Cylinder Installation in the Brake chapter)
Throttle Grip
Throttle Cable Tips [A]
Throttle Cases [B]
○Fit the projection [C] into a hole [D] in the handlebar.
Apply a non-permanent locking agent to the threads of
the handlebar weight bolts, and tighten them.
•
the clutch lever (see Clutch Lever Installation in the
• Install
Clutch chapter).
the left and right switch housings.
•○Install
Fit the projection [A] into a hole [B] in the handlebar.
Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31
in·lb)
FRAME 15-1
Frame
Table of Contents
Exploded View...................................
Seats .................................................
Rear Seat Removal......................
Rear Seat Installation...................
Front Seat Removal .....................
Front Seat Installation ..................
Fairings..............................................
Lower Fairing Removal ................
Lower Fairing Installation .............
Lower Fairing Disassembly..........
Lower Fairing Assembly...............
Rear Lower Fairing Removal .......
Rear Lower Fairing Installation ....
Windshield Removal ....................
Windshield Installation .................
Upper Fairing Removal ................
Upper Fairing Installation .............
Upper Fairing Disassembly..........
Upper Fairing Assembly...............
Windshield Bracket Disassembly.
Windshield Bracket Assembly......
Windshield Bracket Assembly
Removal ....................................
Windshield Bracket Assembly
Installation .................................
Side Covers .......................................
Side Cover Removal ....................
15-2
15-8
15-8
15-8
15-8
15-8
15-9
15-9
15-10
15-11
15-12
15-13
15-13
15-13
15-13
15-13
15-14
15-15
15-15
15-15
15-16
15-18
15-18
15-19
15-19
Side Cover Installation .................
Left Lower Side Fairing Removal.
Left Lower Side Fairing
Installation .................................
Seat Covers.......................................
Seat Cover Removal....................
Seat Cover Installation.................
Fenders .............................................
Front Fender Removal .................
Front Fender Installation ..............
Flap and Rear Fender Removal...
Flap and Rear Fender Installation
Frame ................................................
Frame Inspection .........................
Rear Frame Removal...................
Rear Frame Installation................
Rear Frame Bracket Removal .....
Rear Frame Bracket Installation ..
Battery Case......................................
Battery Case Removal .................
Battery Case Installation ..............
Guard.................................................
Mud Guard Removal....................
Mud Guard Installation.................
Sidestand...........................................
Sidestand Removal......................
Sidestand Installation...................
15-19
15-19
15-19
15-20
15-20
15-20
15-21
15-21
15-21
15-21
15-22
15-23
15-23
15-23
15-23
15-23
15-23
15-24
15-24
15-24
15-25
15-25
15-25
15-26
15-26
15-26
15
15-2 FRAME
Exploded View
FRAME 15-3
Exploded View
No.
1
2
3
4
5
Fastener
Lower Fairing Upper Assembly Screws
Lower Fairing Lower Assembly Screws
Front Fender Mounting Bolts
Stay Assembly Mounting Bolts
Stopper Mounting Bolts
6. US, CA and CAL Models
G. Apply grease.
L: Apply a non-permanent locking agent.
N·m
1.2
1.2
3.9
6.9
4.2
Torque
kgf·m
0.12
0.12
0.40
0.70
0.42
ft·lb
11 in·lb
11 in·lb
35 in·lb
61 in·lb
37 in·lb
Remarks
15-4 FRAME
Exploded View
FRAME 15-5
Exploded View
No.
1
2
3
4
5
6
7
Fastener
Rear Frame Bracket Bolts
Front Footpeg Bracket Bolts
Rear Footpeg Bracket Bolts
Rear Frame Bolts
Sidestand Switch Bolt
Sidestand Bracket Bolts
Sidestand Bolt
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
44
25
25
25
8.8
49
44
Torque
kgf·m
4.5
2.5
2.5
2.5
0.90
5.0
4.5
ft·lb
32
18
18
18
78 in·lb
36
32
Remarks
L
L
L
15-6 FRAME
Exploded View
FRAME 15-7
Exploded View
No.
1
Fastener
Grab Rail Mounting Bolts
2. AT Model
3. US, CA, and CAL Models
R: Replacement Parts
N·m
25
Torque
kgf·m
2.5
ft·lb
18 ft·lb
Remarks
15-8 FRAME
Seats
Rear Seat Removal
the ignition switch key [A] into the seat lock, turning
• Insert
the key clockwise, pulling the front part of the seat [B] up,
and pull the seat forward.
Rear Seat Installation
the rear seat hook [A] under the rear frame [B].
• Insert
the seat hook [C] into the latch hole [D].
• Insert
Push
down
the front part of the seat until the lock clicks.
•
Front Seat Removal
the rear seat (see Rear Seat Removal).
• Remove
the front seat bolts [A], and then remove the front
• Remove
seat [B] by pulling the rear of it up and backward.
Front Seat Installation
the front seat hooks [A] under the brace of the fuel
• Insert
tank bracket [B].
• Install the front seat bolts.
FRAME 15-9
Fairings
Lower Fairing Removal
• Remove:
Quick Rivets [A]
• Remove:
Quick Rivets [A] (Both Sides)
• Remove:
Bolts [A]
•
•
Right Side [B]
Left Side [C]
Pull out the lower fairing [D] outward to clear the projections [E].
Pull out the lower fairing upward to clear the projection [F]
(right side only).
the projection [A] (Both Sides).
• Clear
the lower fairing [B] rearward to clear the hook por• Pull
tions [C], and remove the lower fairing by moving it downward (Both Sides).
15-10 FRAME
Fairings
the turn signal light lead connector [A] (Both
• Disconnect
Sides).
Lower Fairing Installation
sure to install the dampers [A] and pad [B] (right side
• Be
only).
Right Lower Fairing [C]
Left Lower Fairing [D]
the turn signal light lead connector [A] (Both
• Connect
Sides).
the hook portions [A] into the slits [B] on the upper
• Insert
fairing (Both Sides).
FRAME 15-11
Fairings
the hook portions [A] into the slits [B] on the lower
• Insert
fairing (Both Sides).
the stoppers [A] into the dampers [B] on the lower
• Insert
fairing (Both Sides).
left lower fairing installation, insert the stopper [A] into
• For
the damper [B] on the left lower side fairing.
right lower fairing installation, insert the damper [A]
• For
into the projection [B] on the rear lower fairing.
Lower Fairing Disassembly
• Remove:
Lower Fairing (see Lower Fairing Removal)
Screws [A]
Lower Fairing Lower [B]
15-12 FRAME
Fairings
• Remove:
Quick Rivet [A]
Screws [B]
Inner Fairing [C]
• Remove:
Screws [A]
Slat Fairing [B]
Lower Fairing Upper [C]
Lower Fairing Assembly
is the reverse of disassembly, note the follow• Installation
ing.
○Insert the projection [A] into the hole [B].
○Tighten:
Torque - Lower Fairing Lower Assembly Screws: 1.2 N·m
(0.12 kgf·m, 11 in·lb)
○Insert the tabs [A] into the slots [B].
○Tighten:
Torque - Lower Fairing Upper Assembly Screws [A]: 1.2
N·m (0.12 kgf·m, 11 in·lb)
FRAME 15-13
Fairings
Rear Lower Fairing Removal
the bolt [A].
• Remove
out the rear lower fairing [B] outward to clear the pro• Pull
jections [C].
Rear Lower Fairing Installation
the projection [A] into the damper [B] on the right
• Insert
lower fairing.
• Insert the projection [C] into the damper [D].
Windshield Removal
• Remove:
Bolts [A] with Washers
Windshield [B]
Windshield Installation
• Installation is the reverse of removal.
Upper Fairing Removal
• Remove:
Lower Fairing (see Lower Fairing Removal)
Windshield (see Windshield Removal)
Bolts [A] with Washers
Meter Cover [B]
15-14 FRAME
Fairings
• Remove:
Bolts [A] with Washers
Windshield Bracket Cover [B]
• Remove:
Nuts [A] (Both Sides)
Rear View Mirror [B] (Both Sides)
• Remove:
Bolt [A] (Both Sides)
Clamp [B] (Left Side only)
• Disconnect:
Headlight Lead Connectors [A]
•
City Light Lead Connectors [B]
Remove the upper fairing with the headlight.
Upper Fairing Installation
• Installation is the reverse of removal.
FRAME 15-15
Fairings
Upper Fairing Disassembly
• Remove:
Upper Fairing (see Upper Fairing Removal)
Screws [A]
Clamp [B]
Headlights [C]
• Remove:
Screw [A]
• Separate the upper fairing.
Upper Fairing Assembly
• Fit the projections [A] into the slots [B].
Windshield Bracket Disassembly
• Remove:
Upper Fairing (see Upper Fairing Removal)
•
Meter Unit (see Meter Unit Removal in the Electrical System chapter)
Remove the springs [A].
• Remove:
Stay Assembly Mounting Bolt [A] and Collars (Both
Sides)
Bolt [B], Damper, Collar and Washers (Both Sides)
Stay Assembly [C]
Adjust Knob Assembly [D]
15-16 FRAME
Fairings
• Remove:
Bolts [A]
Adjust Knob [B]
Adjust Knob Bracket [C]
• Remove:
Bolts [A]
Stay Shaft [B]
Lower Stays [C]
Upper Stays [D]
Stoppers [E]
Windshield Bracket Assembly
that the upper fairing bracket has been firmly in• Confirm
stalled by the mounting bolts [A].
the adjust knob assembly as shown in the fig• Assemble
ure.
Adjust Knob Bracket [A]
Adjust Knob [B]
Bolts [C]
a non-permanent locking agent to the threads of
• Apply
the stay shaft mounting bolts [A].
the stay assembly as shown in the figure.
• Assemble
Upper Stay [B]
Stopper [C]
Stay Shaft [D]
Stay Shaft Mounting Bolts
Stopper Mounting Bolts [E]
Do
○ not tighten firmly the stopper mounting bolts at this
time.
FRAME 15-17
Fairings
grease to the dampers [A] and washers [B].
• Apply
Apply
a non-permanent locking agent to the threads of
• the adjust
knob assembly bolts [C].
Install:
• Adjust Knob Assembly [D]
Washers
Dampers
Collars [E]
the stay assembly [A].
•○Install
Fit the pis [B] of the adjust knob assembly into the grooves
[C] of the stopper (Both Sides).
• Install:
Stay Assembly Mounting Bolts [A] and Collars
the following bolts while the pins fit in the stop• Tighten
pers.
Torque - Stay Assembly Mounting Bolts: 6.9 N·m (0.70
kgf·m, 61 in·lb)
Stopper Mounting Bolts [B]: 4.2 N·m (0.42 kgf·m,
37 in·lb)
• Install:
Lower Stay [A]
Bolts [B]
15-18 FRAME
Fairings
• Install:
Springs [A]
that the position of the windshield stoppers [B]
• Confirm
change smoothly and surely.
○Push the adjust knob [C] and change the positions of the
windshield stoppers.
If the windshield stoppers do not move smoothly reassemble the windshield bracket.
Windshield Bracket Assembly Removal
• Remove:
Upper Fairing (see Upper Fairing Assembly Removal)
Meter Unit (see Meter Unit Removal in the Electrical System chapter)
Horn Lead Connectors [A]
Turn Signal Relay [B]
Clamp [C] (Main Harness)
Bolt [D]
• Remove:
Bolts [A]
Windshield Bracket Assembly [B]
Windshield Bracket Assembly Installation
is the reverse of removal, note the following.
•○Installation
Run the cables and leads correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
FRAME 15-19
Side Covers
Side Cover Removal
• Remove:
Lower Fairing (see Lower Fairing Removal)
•
Bolts [A] with Washers
Pull the side cover [B] outward to clear the stoppers [C].
Side Cover Installation
• Be sure to install the pads [A].
the hooks [A] to the frame.
• Hang
Insert
projections [B] into the holes [C].
• Install the
the bolts.
•
Left Lower Side Fairing Removal
• Remove:
Left Lower Fairing (see Lower Fairing Removal)
Bolts [A] with Washers
Lower Side Fairing [B]
Left Lower Side Fairing Installation
is the reverse of removal, note the following.
•○Installation
Be sure to install the damper [A].
15-20 FRAME
Seat Covers
Seat Cover Removal
• Remove:
Seats (see Rear/Front Seat Removal)
Bolts [A] with Collars and Washers (Both Sides)
Grab Rail [B] (Both Sides)
• Remove:
Bolts [A]
Seat Cover [B]
Seat Cover Installation
is the reverse of removal, note the following.
•○Installation
Fit the craws [A] into the slits [B] on the rear fender.
○Install:
Bolts [A] with Collars and Washers (Both Sides)
Grab Rail [B] (Both Sides)
○Tighten:
Torque - Grab Rail Mounting Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
FRAME 15-21
Fenders
Front Fender Removal
• Remove:
Brake Hose Clamps [A] (Both Sides)
Bolts [B] with Washers (Both Sides)
Reflectors [C] (Both Sides, US, CA and CAL Models)
Front Fender [D]
Front Fender Installation
is the reverse of removal, note the following.
•○Installation
Install the front fender to the front fork.
○Tighten:
Torque - Front Fender Mounting Bolts: 3.9 N·m (0.40 kgf·m,
35 in·lb)
○Replace
the brake hose clamps with new ones
(ZX1000GB/HB Early Models).
Install the brake hose clamps to the front fender holes.
•
ZX1000GB/HB Late Models ∼, face the lock portion
• For
[A] of the brake hose clamp backward.
Flap and Rear Fender Removal
• Remove:
Seats (see Front/Rear Seat Removal)
Seat Cover (see Seat Cover Removal)
Owner’s Tool [A]
• Remove:
Bolts [A]
15-22 FRAME
Fenders
• Remove:
Bolts [A]
the rear fender [A] downward.
• Push
Remove:
• Relay Box [B]
•
•
ECU [C]
Disconnect:
Turn Signal Light Lead Connectors [D]
Licence Plate Light Lead Connector [E]
Tali Light Lead Connector [F]
Remove the rear fender rearward.
Flap and Rear Fender Installation
is the reverse of removal, note the following.
•○Installation
Replace the rear fender mounting bolts [A] with new ones.
○Run the cables, leads, harness and hose correctly (see
Cable, Wire, and Hose Routing section in the Appendix
chapter).
○Tighten:
Torque - Grab Rail Mounting Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
FRAME 15-23
Frame
Frame Inspection
inspect the frame for cracks, dents, bending, or
• Visually
warp.
○If there is any damage to the frame, replace it.
WARNING
A repaired frame may fail in use, possibly causing
an accident resulting in injury or death. If the frame
is bent, dented, cracked, or warped, replace it.
Rear Frame Removal
• Remove:
Rear Fender (see Rear Fender Removal)
Rear Frame Bolts [A] (Both Sides)
Rear Frame [B]
Rear Frame Installation
a non-parmanent locking agent to the thread of the
• Apply
rear frame bolts.
• Tighten:
Torque - Rear Frame Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Rear Frame Bracket Removal
• Remove:
Side Cover (see Side Cover Removal)
Battery Case (see Battery Case Removal)
Rear Frame (see Rear Frame Removal)
Bolts [A]
Clamp [B] (Left Side Only)
• Remove:
Rear Footpeg Bracket Bolts [A] (Both Sides)
Rear Frame Bracket Bolts [B] (Both Sides)
Rear Frame Bracket [C]
Rear Frame Bracket Installation
• Tighten:
Torque - Rear Frame Bracket Bolts: 44 N·m (4.5 kgf·m, 32
ft·lb)
Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
15-24 FRAME
Battery Case
Battery Case Removal
• Remove:
Battery (see Battery Removal in the Electrical System
•
•
chapter)
Exhaust Butterfly Valve Actuator [A] (see Exhaust Butterfly Valve Actuator Removal in the Fuel System (DFI)
chapter)
Seat Bracket
Disconnect:
Vehicle-down Sensor Connector [B]
Starter Relay Connector [C]
Remove:
Fuse Box 2 [D]
Fuse Box 1 [E]
Bolts [F]
Clamp [G]
Pull the battery case rearward.
•
the clamp [A] (regulator/rectifier lead) from the
• Remove
battery case.
• Remove the battery case.
Battery Case Installation
is the reverse of removal.
• Installation
Install
the
removed
parts (see appropriate chapters).
• Replace the regulator/rectifier
with a new one.
• Run the cables, leads, harnessleadandclamp
hose correctly (see
• Cable, Wire, and Hose Routing section
in the Appendix
chapter).
FRAME 15-25
Guard
Mud Guard Removal
• Remove:
Rear Lower Fairing (see Rear Lower Fairing Removal)
Right Front Footpeg Bracket Bolts [A]
• Remove:
Bolts [A]
• Remove:
Quick Rivets [A]
Mud Guard [B]
Mud Guard Installation
• Installation is the reverse of removal, note the following.
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
15-26 FRAME
Sidestand
Sidestand Removal
the rear wheel off the ground with the stand.
• Raise
• Remove:
Sidestand Switch Bolt [A] and Nut [B]
Sidestand Switch [C]
• Remove:
Spring [A]
Sidestand Nut [B]
Sidestand Bolt [C]
Sidestand [D]
Sidestand Installation
grease to the sliding area [A] of the sidestand [B].
• Apply
the sidestand nut [C] with a new one.
• Replace
Tighten
the
bolt with the nut.
•
Torque - Sidestand Bolt [D]: 44 N·m (4.5 kgf·m, 32 ft·lb)
the spring [E] so that the long spring end faces up• Hook
ward.
○Install the spring hook direction as shown in the figure.
the sidestand switch.
•○Install
Fit the slit [A] on the sidestand switch to the pin [B] on the
•
sidestand.
Apply a non-permanent locking agent to the thread of the
switch bolt, and tighten it.
Torque - Sidestand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78
in·lb)
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Parts Location.........................................................................................................................
Wiring Diagram (US, CA and CAL Models)............................................................................
Wiring Diagram (Other than US, CA and CAL Models)..........................................................
Wiring Diagram (CA with ABS Models) ..................................................................................
Wiring Diagram (Other than CA with ABS Models) ................................................................
Precautions.............................................................................................................................
Electrical Wiring......................................................................................................................
Wiring Inspection ..............................................................................................................
Battery ....................................................................................................................................
Battery Removal ...............................................................................................................
Battery Installation ............................................................................................................
Battery Activation ..............................................................................................................
Precautions .......................................................................................................................
Interchange .......................................................................................................................
Charging Condition Inspection..........................................................................................
Refreshing Charge............................................................................................................
Charging System ....................................................................................................................
Alternator Cover Removal.................................................................................................
Alternator Cover Installation..............................................................................................
Stator Coil Removal ..........................................................................................................
Stator Coil Installation .......................................................................................................
Alternator Rotor Removal .................................................................................................
Alternator Rotor Installation ..............................................................................................
Alternator Inspection .........................................................................................................
Regulator/Rectifier Inspection...........................................................................................
Charging Voltage Inspection .............................................................................................
Ignition System .......................................................................................................................
Crankshaft Sensor Removal .............................................................................................
Crankshaft Sensor Installation ..........................................................................................
Crankshaft Sensor Inspection...........................................................................................
Crankshaft Sensor Peak Voltage Inspection.....................................................................
Timing Rotor Removal ......................................................................................................
Timing Rotor Installation ...................................................................................................
Stick Coil Removal............................................................................................................
Stick Coil Installation.........................................................................................................
Stick Coil Inspection..........................................................................................................
Stick Coil Primary Peak Voltage .......................................................................................
Spark Plug Removal .........................................................................................................
Spark Plug Installation ......................................................................................................
Spark Plug Condition Inspection.......................................................................................
Interlock Operation Inspection ..........................................................................................
IC Igniter Inspection ..........................................................................................................
Electric Starter System ...........................................................................................................
Starter Motor Removal......................................................................................................
Starter Motor Installation...................................................................................................
Starter Motor Disassembly................................................................................................
Starter Motor Assembly ....................................................................................................
16-3
16-10
16-11
16-13
16-16
16-18
16-20
16-22
16-24
16-25
16-25
16-26
16-26
16-26
16-26
16-29
16-30
16-30
16-30
16-32
16-32
16-32
16-33
16-33
16-33
16-34
16-36
16-37
16-39
16-41
16-41
16-42
16-43
16-43
16-44
16-44
16-44
16-44
16-45
16-45
16-46
16-46
16-46
16-46
16-47
16-50
16-50
16-51
16-51
16-52
16
16-2 ELECTRICAL SYSTEM
Brush Inspection ...............................................................................................................
Commutator Cleaning and Inspection...............................................................................
Armature Inspection..........................................................................................................
Brush Lead Inspection ......................................................................................................
Right-hand End Cover Inspection .....................................................................................
Starter Relay Inspection....................................................................................................
Lighting System ......................................................................................................................
Headlight Beam Horizontal Adjustment ............................................................................
Headlight Beam Vertical Adjustment.................................................................................
Headlight Bulb Replacement ............................................................................................
Headlight Removal/Installation .........................................................................................
City Light Bulb Replacement.............................................................................................
Tail/Brake Light (LED) Removal........................................................................................
Tail/Brake Light (LED) Installation.....................................................................................
License Plate Light Bulb Replacement .............................................................................
Turn Signal Light Bulb Replacement ................................................................................
Turn Signal Relay Inspection ............................................................................................
Air Switching Valve .................................................................................................................
Air Switching Valve Operation Test ...................................................................................
Air Switching Valve Unit Test ............................................................................................
Radiator Fan System..............................................................................................................
Fan Motor Inspection ........................................................................................................
Meter, Gauge, Indicator Unit...................................................................................................
Meter Unit Removal/Installation ........................................................................................
Meter Unit Disassembly ....................................................................................................
Electronic Combination Meter Unit Inspection ..................................................................
Fuel Level Sensor Line Self-Diagnosis Mode Inspection..................................................
Immobilizer System (Equipped Models) .................................................................................
Operational Cautions ........................................................................................................
Key Registration................................................................................................................
Immobilizer System Parts Replacement ...........................................................................
Immobilizer System Inspection .........................................................................................
Immobilizer System (Equipped Models) .................................................................................
Switches and Sensors ............................................................................................................
Brake Light Timing Inspection...........................................................................................
Brake Light Timing Adjustment .........................................................................................
Switch Inspection ..............................................................................................................
Water Temperature Sensor Inspection .............................................................................
Speed Sensor Removal ....................................................................................................
Speed Sensor Installation .................................................................................................
Speed Sensor Inspection..................................................................................................
Oxygen Sensor Removal (Equipped Models)...................................................................
Oxygen Sensor Installation (Equipped Models)................................................................
Oxygen Sensor Inspection (Equipped Models).................................................................
Fuel Level Sensor Inspection............................................................................................
Relay Box ...............................................................................................................................
Relay Box Removal ..........................................................................................................
Relay Circuit Inspection ....................................................................................................
Diode Circuit Inspection ....................................................................................................
Fuse........................................................................................................................................
30 A Main Fuse Removal..................................................................................................
Fuse Box Fuse Removal...................................................................................................
15 A FI Fuse Removal ......................................................................................................
Fuse Installation................................................................................................................
Fuse Inspection.................................................................................................................
16-54
16-54
16-55
16-55
16-55
16-55
16-58
16-58
16-58
16-58
16-59
16-60
16-60
16-60
16-61
16-63
16-64
16-67
16-67
16-67
16-69
16-69
16-71
16-71
16-71
16-72
16-81
16-83
16-83
16-83
16-101
16-102
16-103
16-104
16-104
16-104
16-104
16-105
16-105
16-106
16-106
16-106
16-107
16-107
16-107
16-108
16-108
16-108
16-109
16-111
16-111
16-111
16-111
16-111
16-112
ELECTRICAL SYSTEM 16-3
Exploded View
This page intentionally left blank.
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
No.
1
2
3
4
5
Fastener
Switch Housing Screws
Oxygen Sensor (Equipped Models)
Front Brake Light Switch Screw
Front Turn Signal Light Mounting Screws
Licence Plate Light Mounting Screws
N·m
3.5
44
1.2
1.2
1.2
Torque
kgf·m
0.36
4.5
0.12
0.12
0.12
ft·lb
31 in·lb
32
11 in·lb
11 in·lb
11 in·lb
6. Install the rear brake light switch spring so that the longer side [A] faces upward.
7. Starter Lockout Switch
L: Apply a non-permanent locking agent.
Remarks
16-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-7
Exploded View
No.
Fastener
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Intake Air Temperature Sensor Mounting Screw
Spark Plugs
Crankshaft Sensor Cover Bolts
Water Temperature Sensor
Timing Rotor Bolt
Crankshaft Sensor Bolts
Starter Motor Cable Terminal Nut
Starter Motor Terminal Locknut
Starter Motor Mounting Bolts
Alternator Rotor Bolt
Stator Coil Bolts
Starter Motor Through Bolts
Brush Holder Screw
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Alternator Cover Bolts
Alternator Lead Holding Plate Bolt
18. Immobilizer Model
19. Immobilizer Amplifier
20. Starter Relay
21. WVTA (78.2H) and GB WVTA (FULL H) Models
22. ZX1000GB GB WVTA (FULL H) Early Model
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
SS: Apply silicone sealant.
N·m
1.2
13
12
30
39
5.9
5.9
11
9.8
155
12
4.9
3.8
15
2.0
12
12
Torque
kgf·m
0.12
1.3
1.2
3.0
4.0
0.60
0.60
1.1
1.0
15.8
1.2
0.50
0.39
1.5
0.20
1.2
1.2
ft·lb
11 in·ib
115 in·lb
106 in·lb
22
29
52 in·lb
52 in·lb
97 in·lb
87 in·lb
114
106 in·ib
43 in·lb
34 in·ib
11
18 in·ib
106 in·lb
106 in·ib
Remarks
L
SS
G
L
16-8 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-9
Exploded View
No.
1
2
3
4
Fastener
Neutral Switch
Engine Ground Cable Terminal Bolt
Sidestand Switch Bolt
Speed Sensor Mounting Bolt
5. Air Switching Valve
6. Turn Signal Relay
7. Fuel Box
8. ABS Equipped Models
9. Relay Box
10. ECU
L: Apply a non-permanent locking agent.
N·m
15
9.8
8.8
6.9
Torque
kgf·m
1.5
1.0
0.90
0.70
ft·lb
11
87 in·lb
78 in·lb
61 in·lb
Remarks
L
L
16-10 ELECTRICAL SYSTEM
Specifications
Item
Battery
Type
Model Name
Capacity
Voltage
Charging System
Type
Alternator Output Voltage
Stator Coil Resistance
Charging Voltage
(Regulator/Rectifier Output Voltage)
Ignition System
Crankshaft Sensor Resistance
Crankshaft Sensor Peak Voltage
Stick Coil:
Primary Winding Resistance
Secondary Winding Resistance
Primary Peak Voltage
Spark Plug:
Type
Gap
Electric Starter System
Starter Motor:
Brush Length
Air Switching Valve
Resistance
Switches and Sensors
Rear Brake Light Switch Timing
Engine Oil Pressure Switch Connections
Water Temperature Sensor Resistance
Fuel Level Sensor Resistance:
Full Position
Empty Position
Standard
Sealed Battery
YTX9-BS
12 V 8 Ah
12.8 V or more
Three-phase AC
43 V or more at 4 000 rpm
0.18 ∼ 0.28 Ω at 20°C (68°F)
14.2 ∼ 15.2 V
376 ∼ 564 Ω
2.0 V or more
1.1 ∼ 1.5 Ω
10.8 ∼ 16.2 kΩ
100 V or more
NGK CR9EIA-9
0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)
12 mm (0.47 in.) [Service limit: 6.5 mm, 0.26 in.]
18 ∼ 22 Ω at 20°C (68°F)
ON after about 10 mm (0.39 in.) pedal travel
When engine is stopped: ON
When engine is running: OFF
in the text
9.6 ∼ 12.4 Ω
222 ∼ 228 Ω
ELECTRICAL SYSTEM 16-11
Special Tools and Sealant
Hand Tester:
57001-1394
Grip:
57001-1591
Peak Voltage Adapter:
57001-1415
Flywheel & Pulley Holder:
57001-1605
Lead Wire - Peak Voltage Adapter:
57001-1449
Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:
57001-1615
Needle Adapter Set:
57001-1457
Stopper:
57001-1679
Key Registration Unit:
57001-1582
Rotor Holder:
57001-1690
16-12 ELECTRICAL SYSTEM
Special Tools and Sealant
Key Registration Adapter:
57001-1746
Rotor Holder:
57001-1757
Liquid Gasket, TB1211F:
92104-0004
ELECTRICAL SYSTEM 16-13
Parts Location
1. Timing Rotor
2. Crankshaft Sensor
3. Oxygen Sensor (Equipped Models)
4. Horn
5. Turn Signal Relay
6. Relay Box
7. ECU
8. Rear Brake Light Switch
9. Regulator/Rectifier
16-14 ELECTRICAL SYSTEM
Parts Location
10. Water Temperature Sensor
11. Speed Sensor
12. Alternator
13. Stator Coil
14. Radiator Fan Motor
15. Neutral Switch
16. Oil Pressure Switch
17. Sidestand Switch
18. Fuse Boxes
19. Battery 12 V 8 Ah
20. Starter Relay
21. Air Switching Valve
22. Stick Coils
23. Spark Plugs
24. Immobilizer Amplifier (Immobilizer Models)
ELECTRICAL SYSTEM 16-15
Parts Location
25. Starter Lockout Switch
26. Ignition Switch
(Immobilizer Model: Including Immobilizer Antenna)
27. Meter Unit
28. Front Brake Light Switch
16-16 ELECTRICAL SYSTEM
Wiring Diagram (US, CA and CAL Models)
ELECTRICAL SYSTEM 16-17
Wiring Diagram (US, CA and CAL Models)
16-18 ELECTRICAL SYSTEM
Wiring Diagram (Other than US, CA and CAL Models)
ELECTRICAL SYSTEM 16-19
Wiring Diagram (Other than US, CA and CAL Models)
16-20 ELECTRICAL SYSTEM
Wiring Diagram (CA with ABS Models)
ELECTRICAL SYSTEM 16-21
Wiring Diagram (CA with ABS Models)
16-22 ELECTRICAL SYSTEM
Wiring Diagram (Other than CA with ABS Models)
ELECTRICAL SYSTEM 16-23
Wiring Diagram (Other than CA with ABS Models)
16-24 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and observe all the rules below.
○Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is ON, or while the engine is
running.
○Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor windings.
○Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they must be repaired or replaced, or
the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
ELECTRICAL SYSTEM 16-25
Electrical Wiring
Wiring Inspection
inspect the wiring for signs of burning, fraying,
• Visually
etc.
If any wiring is poor, replace the damaged wiring.
Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
•
•
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness [B] if necessary.
16-26 ELECTRICAL SYSTEM
Battery
Battery Removal
off the ignition switch.
• Turn
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
•
ter)
Disconnect the negative (–) cable [A].
NOTICE
Be sure to disconnect the negative (–) cable first.
out the positive (+) terminal cap [B] and disconnect
• Slide
the positive (+) cable [C].
• Remove the battery.
Battery Installation
off the ignition switch.
• Turn
Put
the
into the battery case.
• Install thebattery
positive
[A] first.
• Install the negative(+)(–)cable
cable
[B].
• Apply a light coat of grease on
the terminals to prevent
• corrosion.
• Cover the Positive (+) terminal with the cap [C].
Battery Activation
Electrolyte Filling
Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These
names must be the same.
•
Battery Model Name
ZX1000G/H: YTX9-BS
NOTICE
Each battery comes with its own specific electrolyte container; using the wrong container may
overfill the battery with incorrect electrolyte, which
can shorten battery life and deteriorate battery performance. Be sure to use the electrolyte container
with the same model name as the battery since the
electrolyte volume and specific gravity vary with
the battery type.
ELECTRICAL SYSTEM 16-27
Battery
NOTICE
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
DANGER
Sulfuric acid in battery electrolyte can cause severe
burns. To prevent burns, wear protective clothing
and safety glasses when handling electrolyte. If
the electrolyte comes in contact with your skin or
eyes, wash the area with liberal amounts of water
and seek medical attention for more severe burns.
the battery on a level surface.
• Place
Check
• or holestoinseeit. that the sealing sheet has no peeling, tears,
• Remove the sealing sheet.
NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
the electrolyte container from the vinyl bag.
• Remove
Detach
the
of caps [A] from the container and set
• aside, thesestrip
will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
the electrolyte container upside down with the six
• Place
sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container.
16-28 ELECTRICAL SYSTEM
Battery
the electrolyte flow.
• Check
If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.
NOTE
○Be careful not to have the battery fall down.
the container in place. Don’t remove the container
• Keep
from the battery, the battery requires all the electrolyte
from the container for proper operation.
NOTICE
Removal of the container before it is completely
empty can shorten the service life of the battery.
Do not remove the container until it is completely
empty.
filling, let the battery sit for 20 ∼ 60 minutes with the
• After
electrolyte container kept in place, which is required for
•
the electrolyte to fully permeate into the plates.
Make sure that the container cells have emptied completely, and remove the container from the battery.
the strip of caps [A] loosely over the filler ports,
• Place
press down firmly with both hands to seat the strip of caps
into the battery (don’t pound or hammer). When properly
installed, the strip of caps will be level with the top of the
battery.
NOTICE
Once the strip of caps is installed onto the battery,
never remove the caps, nor add water or electrolyte
to the battery.
NOTE
○Charging the battery immediately after filling can
shorten service life.
ELECTRICAL SYSTEM 16-29
Battery
Initial Charge
Newly activated sealed batteries require an initial charge.
•
Standard Charge: 0.9 A × 5 ∼ 10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO2
Yuasa MB-2040/2060
Christie C10122S
•
If the above chargers are not available, use equivalent
one.
Let battery sit 30 minutes after initial charge, then check
voltage using a voltmeter. (Voltage immediately after
charging becomes temporarily high. For accurate measuring, let the battery sit for given time.)
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. If voltage is not at least 12.8 V, repeat
charging cycle.
○To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V the
battery is defective.
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. 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 Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced noticeably 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 removed. Give a refresh charge once a month during storage.
4) Battery life.
If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem).
16-30 ELECTRICAL SYSTEM
Battery
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite
any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medial attention for more severe burns.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
○Battery charging condition can be checked by measuring
•
•
battery terminal voltage with a digital voltmeter [A].
Remove:
Seats (see Seats section in the Frame chapter)
Disconnect the battery terminals.
NOTICE
Be sure to disconnect the negative (–) cable first.
• Measure the battery terminal voltage.
NOTE
○Measure with a digital voltmeter which can be read one
decimal place voltage.
If the reading is 12.8 V or more, no refresh charge is required, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
Standard:
12.8 V or more
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]
Refreshing Charge
the battery [A] (see Battery Removal).
• Remove
Do
refresh
charge by following method according to the
• battery terminal
voltage.
WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.
ELECTRICAL SYSTEM 16-31
Battery
Terminal Voltage: 11.5 ∼ less than 12.8 V
Standard
0.9 A × 5 ∼ 10 h (see following chart)
Charge:
Quick Charge:
4A×1h
NOTICE
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
Charging Method: 0.9 A × 20 h
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
the battery condition after refresh charge.
•○Determine
Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria
Judgement
12.8 V or higher
Good
12.0 ∼ lower than 12.8 V
Charge insufficient → Recharge
lower than 12.0 V
Unserviceable → Replace
16-32 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
•
Frame chapter)
Support the fuel tank with a suitable bar (see Fuel Tank
Removal in the Fuel System (DFI) chapter).
up the connector bracket [A].
• Pull
Remove
• bracket. the alternator lead connector
• Disconnect the alternator lead connector.
[B] from the
a suitable container under the alternator cover [A].
• Place
Remove:
• Alternator Cover Bolts [B]
Bracket [C]
Alternator Cover
Alternator Cover Installation
silicone sealant to the alternator lead grommet and
• Apply
crankcase halves mating surface [A] on the front and rear
sides of the cover mount.
Sealant - Liquid Gasket, TB1211F: 92104-0004
that dowel pins [B] are in place on the crankcase.
• Check
Install
a
• Tighten: new gasket and the alternator cover.
•
Torque - Alternator Cover Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)
the alternator lead correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
that the drain hose and clamp are installed se• Confirm
curely and run the hose correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
ELECTRICAL SYSTEM 16-33
Charging System
Stator Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
•
Holding Plate Bolt [A] and Plate
Alternator Lead Grommet [B]
Stator Coil Bolts [C]
Remove the stator coil [D] from the alternator cover.
Stator Coil Installation
a non-permanent locking agent to the threads of
• Apply
the stator coil bolts and tighten them.
Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
the alternator lead with a holding plate.
• Secure
Apply
a
locking agent to the threads of
• the platenon-permanent
bolt and tighten it.
Torque - Alternator Lead Holding Plate Bolt: 12 N·m (1.2
kgf·m, 106 in·lb)
silicone sealant to the circumference of the alterna• Apply
tor lead grommet [A], and fit the grommet into the notch
[B] of the cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004
the alternator cover (see Alternator Cover Installa• Install
tion).
Alternator Rotor Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Starter Idle Gear [A]
the alternator rotor steady with the rotor holder [A]
• Hold
and stopper [B].
• Remove the rotor bolt [C] and washer.
Special Tools - Grip [D]: 57001-1591
Stopper: 57001-1679
Rotor Holder: 57001-1690
16-34 ELECTRICAL SYSTEM
Charging System
If using the rotor holder (57001-1757).
Hold the alternator rotor steady with the rotor holder [A].
Remove the rotor bolt [B] and washer.
•
•
Special Tool - Rotor Holder: 57001-1757
the flywheel puller [A], remove the alternator rotor
• Using
[B] from the crankshaft.
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1615
NOTICE
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.
Alternator Rotor Installation
a thin coat of molybdenum disulfide grease to the
• Apply
crankshaft [A] and the outer surface [B] of the starter
clutch gear [C].
the starter clutch gear [A].
• Install
a cleaning fluid, clean off any oil or dirt on the fol• Using
lowing portions and dry them with a clean cloth.
•
Crankshaft Tapered Portion [B]
Alternator Rotor Tapered Portion [C]
Fit the woodruff key [D] securely in the slot in the crankshaft before installing the alternator rotor.
the alternator rotor [A] while turning [B] the starter
• Install
clutch gear [C] clockwise.
ELECTRICAL SYSTEM 16-35
Charging System
a cleaning fluid, clean off any oil or dirt on the
• Using
washer [A] and dry it with a clean cloth.
• Install the washer.
NOTE
○Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.
the rotor bolt [B] and tighten it with 70 N·m (7.0
• Install
kgf·m, 52 ft·lb) of torque.
the rotor bolt and washer.
• Remove
Check
the
tightening torque with flywheel puller [A].
•
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1615
If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them with
a clean cloth. Then, confirm that it is not pulled out with
above torque.
the washer and rotor bolt.
• Install
the alternator rotor bolt [A] while holding the alter• Tighten
nator rotor steadily with the holder [B].
Special Tools - Grip [C]: 57001-1591
Rotor Holder: 57001-1690
Stopper [D]: 57001-1679
Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114
ft·lb)
If using rotor holder (57001-1757).
Install the washer and rotor bolt.
Tighten the alternator rotor bolt [A] while holding the alternator rotor steadily with the holder [B].
•
•
Special Tool - Rotor Holder: 57001-1757
Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114
ft·lb)
16-36 ELECTRICAL SYSTEM
Charging System
a thin coat of molybdenum disulfide grease to the
• Apply
shaft [A], and install it and starter idle gear [B].
the alternator cover (see Alternator Cover Installa• Install
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.
check the alternator output voltage, do the following
• To
procedures.
○Turn off the ignition switch.
○Disconnect the alternator lead connector [A] (see alternator Cover Removal).
○Connect the hand tester as shown in the table 1.
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage
Tester
Range
Connections
Tester (+) to
Tester (–) to
Reading
at 4 000 rpm
250 V AC One Black lead Another Black lead 43 V or more
If the output voltage shows the value in the table, the alternator operates properly.
If the output voltage shows a much higher than the value
in the table, the regulator/rectifier is damaged. A much
lower reading than that given in the table indicates that
the alternator is defective.
Check the stator coil resistance as follows.
○Stop the engine.
○Connect the hand tester as shown in the table 2.
○Note the readings (total 3 measurement).
•
Table 2 Stator Coil Resistance
Connections
Tester
Range
Tester (+) to
Tester (–) to
×1Ω
One Black lead
Another Black lead
at 20°C (68°F)
Reading
0.18 ∼ 0.28 Ω
ELECTRICAL SYSTEM 16-37
Charging System
•
If there is more resistance than shown in the table, or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
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.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Special Tool - Hand Tester: 57001-1394
Regulator/Rectifier Inspection
ZX1000G Model
Remove:
Bolts [A] and Nuts [B]
Connector [C] (Disconnect)
Regulator/Rectifier [D]
•
ZX1000H Model
Remove:
ABS Hydraulic Unit (see ABS Hydraulic Unit Removal in
the Brakes chapter)
Bolts [A] and Nuts [B]
Regulator/Rectifier [C]
•
Rectifier Circuit Check
Check conductivity of the following pair of terminals.
•
Rectifier Circuit Inspection
Tester connection
W1-BK1,
W1-BK2,
W1-BK3
BK/Y-BK1,
BK/Y-BK2,
BK/Y-BK3
The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
terminals are low or high in both directions, the rectifier is
defective and the regulator/rectifier must be replaced.
NOTE
○The actual meter reading varies with the meter used
and the individual rectifier, but, generally speaking the
lower reading should be from zero to one half the scale.
16-38 ELECTRICAL SYSTEM
Charging System
Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 ∼ 6 W bulb in a socket with leads).
NOTICE
The test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of
a test light.
to be sure the rectifier circuit is normal before con• Check
tinuing.
the 1st step regulator circuit test.
•○Do
Connect the test light and the 12 V battery to the regulator/rectifier as shown in the figure.
○Check the BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
the 2nd step regulator circuit test.
•○Do
Connect the test light and the 12 V battery in the same
manner as specified in the “Regulator Circuit Test-1st
Step”.
○Apply 12 V to the W2 terminal.
○Check the BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
the 3rd step regulator circuit test.
•○Do
Connect the test light and the 12 V battery in the same
manner as specified in the “Regulator Circuit Test-1st
Step”.
○Momentarily apply 24 V to the W2 terminal by adding a
12 V battery.
○Check the BK1, BK2 and BK3 terminals respectively.
NOTICE
Do not apply more than 24 V. If more than 24 V is applied, the regulator/rectifier may be damaged. Do
not apply 24 V more than a few seconds. If 24 V
is applied for more than a few seconds, the regulator/rectifier may be damaged.
If the test light did not light when the 24 V was applied
momentarily to the voltage monitoring terminal, the regulator/rectifier is defective. Replace it.
If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
ELECTRICAL SYSTEM 16-39
Charging System
Charging Voltage Inspection
the battery condition (see Charging Condition In• Check
spection).
up the engine to obtain actual alternator operating
• Warm
conditions.
that the ignition switch is turned off, and connect
• Check
the hand tester [A] to the battery terminals [B].
Special Tool - Hand Tester: 57001-1394
the engine, and note the voltage readings at var• Start
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
Tester Range
25 V DC
Connections
Tester (+) to
Tester (–) to
Battery (+)
Battery (–)
Reading
14.2 ∼ 15.2 V
off the ignition switch to stop the engine, and discon• Turn
nect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
16-40 ELECTRICAL SYSTEM
Charging System
Charging System Circuit
1. Regulator/Rectifier
2. Alternator
3. Ignition Switch
4. Load
5. Main Fuse 30 A
6. Battery 12 V 8 Ah
ELECTRICAL SYSTEM 16-41
Ignition System
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil or ignition coil lead while the engine is running, or you
could receive a severe electrical shock.
NOTICE
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
ON, or while the engine is running. This is to prevent ECU damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
ECU.
Crankshaft Sensor Removal
NOTICE
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.
the right lower fairing (see Lower Fairing Re• Remove
moval in the Frame chapter).
the fuel tank with a suitable bar (see Fuel Tank
• Support
Removal in the Fuel System (DFI) chapter).
up the connector bracket [A].
• Pull
the rear wheel rotation sensor connector [B]
• Remove
(ABS equipped models) and crankshaft sensor lead
connector [C] from the bracket.
Disconnect the crankshaft sensor lead connector.
•
• Clear the crankshaft sensor lead from the clamps [A].
• Remove:
Crankshaft Sensor Cover Bolts [A]
Crankshaft Sensor Cover [B]
16-42 ELECTRICAL SYSTEM
Ignition System
• Remove:
Crankshaft Sensor Bolts [A]
Crankshaft Sensor [B]
Crankshaft Sensor Installation
• Tighten:
Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52
in·lb)
silicone sealant [A] to the crankshaft sensor lead
• Apply
grommet and crankcase halves mating surface on the
front and rear sides of the crankshaft sensor cover mount.
Sealant - Liquid Gasket, TB1211F: 92104-0004
the O-ring [A] in the crankshaft sensor cover with
• Replace
a new one.
• Install:
Crankshaft Sensor Cover [A]
Tighten:
•
Torque - Crankshaft Sensor Cover Bolts [B]: 12 N·m (1.2
kgf·m, 106 in·lb)
the crankshaft sensor lead correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).
that the drain hose and clamp are installed se• Confirm
curely and run the hose correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
ELECTRICAL SYSTEM 16-43
Ignition System
Crankshaft Sensor Inspection
• Remove:
Crankshaft Sensor Lead Connector [A] (see Crankshaft
•
Sensor Removal)
Set the hand tester [B] to the × 100 Ω range and connect
(+) lead to the yellow lead and (–) lead to the black lead
in the connector.
Special Tools - Hand Tester: 57001-1394
Needle Adapter Set [C]: 57001-1457
Crankshaft Sensor Resistance: 376 ∼ 564 Ω
•
If 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.
Using the highest resistance range of the tester, measure
the resistance between the crankshaft sensor leads and
chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the crankshaft sensor assembly.
Crankshaft Sensor Peak Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
•
(DFI) chapter)
Crankshaft Sensor Lead Connector [A] (see Crankshaft
Sensor Removal)
Set the hand tester [B] to the DC 10 V range.
Connect the peak voltage adapter [C] to the hand tester
and crankshaft sensor leads in the connector.
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Needle Adapter Set [D]: 57001-1457
Connections:
Crankshaft
Sensor Lead
Peak Voltage
Adapter
Hand Tester
Yellow
←
Red
→
(+)
Black
←
Black
→
(–)
the ignition switch and engine stop switch ON.
• Turn
Pushing
starter button, turn the engine 4 ∼ 5 sec• onds withthe
the transmission gear in neutral to measure the
•
crankshaft sensor peak voltage.
Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
2.0 V or more
Standard:
If the tester reading is not specified one, inspect the crankshaft sensor (see Crankshaft Sensor Inspection).
16-44 ELECTRICAL SYSTEM
Ignition System
Timing Rotor Removal
the crankshaft sensor (see Crankshaft Sensor
• Remove
Removal).
the timing rotor [A].
•○Remove
Holding the timing rotor with the flywheel & pulley holder
[B] and remove the rotor bolt [C].
Special Tool - Flywheel & Pulley Holder: 57001-1605
Timing Rotor Installation
the timing rotor [A] with the their theeth [B] aligned.
• Install
• Tighten:
Torque - Timing Rotor Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
Special Tool - Flywheel & Pulley Holder: 57001-1605
Stick Coil Removal
NOTICE
Never drop the stick coils, especially on a hard surface.
Such a shock to the stick coils can damage it.
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
•
•
in the Fuel System (DFI) chapter)
Disconnect the stick coil connectors [A].
Pull the stick coils [B].
NOTICE
Do not pry the connector part of the coil while removing the coil.
Stick Coil Installation
the coil as shown being careful of the coil heads [A]
• Insert
direction.
sure the stick coils are installed by pulling up it lightly.
• Be
• Connect the connectors.
NOTICE
Do not tap the coil head while installing the coil.
the hoses and harness correctly (see Cable, Wire,
• Run
and Hose Routing section in the Appendix chapter).
ELECTRICAL SYSTEM 16-45
Ignition System
Stick Coil Inspection
the stick coils (see Stick Coil Removal).
• Remove
the primary winding resistance [A] as follows.
•○Measure
Connect the hand tester between the coil terminals.
○Set the tester to the × 1 Ω range, and read the tester.
the secondary winding resistance [B] as follows.
•○Measure
Connect the tester between the plug terminal and (–) coil
terminal.
○Set the tester to the × 1 kΩ range and read the tester.
Stick Coil Winding Resistance
Primary Windings:
1.1 ∼ 1.5 Ω
Secondary Windings:
10.8 ∼ 16.2 kΩ
If the tester does not read as specified, replace the coil.
Stick Coil Primary Peak Voltage
NOTE
○Be sure the battery is fully charged.
the stick coils (see Stick Coil Removal), but do
• Remove
not remove the spark plugs.
the primary peak voltage as follows.
•○Measure
Install the new spark plug [A] into each stick coil [B], and
ground them onto the engine.
○Connect the peak voltage adapter [C] into the hand tester
[D] which is set to the DC 250 V range.
○Connect the adapter to the lead wire-peak voltage
adapter [E] which is connected between the stick coil
connector and stick coil.
ECU [F]
Battery [G]
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Lead Wire-Peak Voltage Adapter:
-1449
57001
Primary Lead Connection
Adapter (R, +) to lead wire-peak voltage adapter (W)
Adapter (BK, –) to lead wire-peak voltage adapter (R)
16-46 ELECTRICAL SYSTEM
Ignition System
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
the ignition switch and the engine stop switch ON.
• Turn
the starter button, turn the engine 4 ∼ 5 seconds
• Pushing
with the transmission in neutral to measure the primary
•
peak voltage.
Repeat the measurements 5 times for one stick coil.
Stick Coil Primary Peak Voltage
100 V or more
Standard:
the test for the other stick coil.
• Repeat
If the reading is less than the specified value, check the
following.
Stick Coils (see Stick Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)
Spark Plug Removal
to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.
Spark Plug Installation
to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.
Spark Plug Condition Inspection
the spark plugs (see Spark Plug Replacement).
• Remove
inspect the spark plugs.
• Visually
If the spark plug center electrode [A] and/or side elec-
•
trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.
Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap:
0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)
• Use the standard spark plug or its equivalent.
Spark Plug:
NGK CR9EIA-9
Interlock Operation Inspection
the rear wheel off the ground with stand.
• Raise
Turn
the
•1st Check engine stop switch ON (run position).
• Start the engine to the following conditions.
Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Sidestand → Down or Up
○Turn the ignition switch ON and push the starter button.
○Then the starter motor should not turn when the starter
system circuit is normality.
If the engine is start, inspect the starter lockout switch,
sidestand switch, neutral switch and relay box.
ELECTRICAL SYSTEM 16-47
Ignition System
2nd Check
Start the engine to the following conditions.
•
Condition:
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Sidestand → Up
○Turn the ignition switch ON and push the starter button.
○Then the starter motor should turn when the starter system circuit is normality.
If the starter motor is not turn, inspect the starter lockout
switch, sidestand switch, relay box, and starter relay.
3rd Check
Inspect the engine for its secure stop after the following
operations are completed.
Run the engine to the following conditions.
•
•
Condition:
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Sidestand → Up
the sidestand on the ground, then the engine will stop.
• Set
If the engine does not stop, inspect the neutral switch,
sidestand switch and relay box.
If their parts are normality, replace the ECU.
IC Igniter Inspection
○The IC igniter is built in the ECU [A].
to the following items.
• Refer
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)
16-48 ELECTRICAL SYSTEM
Ignition System
ELECTRICAL SYSTEM 16-49
Ignition System
Ignition System Circuit
1. Ignition Switch
2. Fuse Box 2
3. Ignition Fuse 15 A
4. Engine Stop Switch
5. Stick Coils
6. Spark Plugs
7. Subthrottle Sensor
8. Main Throttle Sensor
9. Oxygen Sensor (Equipped Models)
10. Speed Sensor
11. to Meter Unit
12. Frame Ground
13. Crankshaft Sensor
14. Sidestand Switch
15. Neutral Switch
16. ECU
17. Starter Lockout Switch
18. Relay Box
19. ECU Main Relay
20. Vehicle-down Sensor
21. FI Fuse 15 A
22. Main Fuse 30 A
23. Battery 12 V 8 Ah
24. Water-proof Joint C
16-50 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Removal
NOTICE
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
•
•
Frame chapter)
Engine Sprocket Cover (see Engine Sprocket Cover Removal in the Final Drive chapter)
Harness Holder [A]
Loosen the water hose clamp screw [B].
Remove:
Water Hose [C]
Neutral Switch Connector [D]
Water Pipe Bolt [E]
Water Pipe [F]
the starter motor cable [A] from the cable holder
• Remove
[B].
the mounting bolts [A].
• Remove
Pull
out
the
starter motor [B] with the cable connected.
•
the rubber cap [A].
• Slide
the starter motor cable terminal nut [B] and ca• Remove
ble.
ELECTRICAL SYSTEM 16-51
Electric Starter System
Starter Motor Installation
NOTICE
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
installing the starter motor, clean the starter mo• When
tor legs [A] and crankcase [B] where the starter motor is
grounded.
the starter motor cable [A] as shown.
• Install
[B] Upward
• Tighten:
Torque - Starter Motor Cable Terminal Nut [C]: 5.9 N·m (0.60
kgf·m, 52 in·lb)
• Slide back the rubber cap to the original position.
the O-ring [A] with a new one.
• Replace
Apply
grease
• Tighten: to the O-ring.
•
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
the water hose and pipe (see Water Pump Instal• Install
lation in the Cooling System chapter).
Starter Motor Disassembly
the starter motor (see Starter Motor Removal).
• Remove
Take
off
the
motor through bolts [A] and remove
• the both endstarter
covers [B].
• Pull out the armature [A] out of the yoke [B].
NOTE
○Do not remove the circlip [C] from the shaft.
16-52 ELECTRICAL SYSTEM
Electric Starter System
• Remove the starter motor terminal locknut [A].
out the brushes from the brush holder [A].
• Pull
Remove:
• Brush Springs [B]
Starter Motor Terminal [C]
Positive Brush Assy [D]
Screw [E]
Negative Brush Assy [F]
Brush Holder
Starter Motor Assembly
the hole [A] of the brush holder [B] to the boss [C]
• Align
of the right-hand end cover [D].
the stoppers [A] of the negative brush assy [B] to
• Align
the guides [C] of the brush holder [D].
• Tighten the screw securely.
the jagged porition [A] on the starter motor terminal
• Insert
[B] to the slit [C] on the positive brush assy [D].
• Install the starter motor terminal to the brush holder.
ELECTRICAL SYSTEM 16-53
Electric Starter System
the O-ring [A] with a new one.
• Replace
Install
the
following parts to the starter motor terminal [B].
• New O-ring
Collar [C]
Washer [D]
Starter Motor Terminal Locknut [E]
○Install the collar so that stepped side faces outward.
Tighten:
•
Torque - Starter Motor Terminal Locknut:
kgf·m, 97 in·lb)
11 N·m (1.1
• Install the brush springs [A] and insert the brushes [B].
• Apply thin coat of grease to the oil seal [A].
the O-rings [A] with new ones.
• Replace
Insert
the
[B] so that commutator side [C] faces
• hollow sidearmature
[D] of the yoke [E].
the stopper [A] and hollow [B] to assemble the yoke
• Align
and end cover.
16-54 ELECTRICAL SYSTEM
Electric Starter System
the marks [A] to assemble the yoke and the end
• Align
cover [B].
• Tighten:
Torque - Starter Motor Through Bolts [A]: 4.9 N·m (0.50
kgf·m, 43 in·lb)
Brush Inspection
the length of each brushes [A].
• Measure
If any is worn down to the service limit, replace the brush
assy.
Starter Motor Brush Length
Standard:
12 mm (0.47 in.)
Service Limit: 6.5 mm (0.26 in.)
Commutator Cleaning and Inspection
the metallic debris off the between commutator
• Clean
segments [A].
NOTE
○Do not use emery or sand paper on the commutator.
the commutator for damage or abnormal wear.
• Check
Replace the starter motor with a new one if there is any
•
damage or wear.
Visually inspect the commutator segments for discoloration.
Replace the starter motor with a new one if discoloration
is noticed.
ELECTRICAL SYSTEM 16-55
Electric Starter System
Armature Inspection
the × 1 Ω hand tester range, measure the resis• Using
tance between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394
•
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
Using the highest hand tester range, measure the resistance between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
NOTE
○Even 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
the × 1 Ω hand tester range, measure the resis• Using
tance as shown.
Right-hand End Cover and Negative Brushes [A]
Terminal Bolt and Positive Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is not close to zero ohms, the brush lead has an
open. Replace the brush plate assy.
Right-hand End Cover Inspection
the highest hand tester range, measure the resis• Using
tance as shown.
Terminal Bolt and Right-hand End Cover [A]
Terminal Bolt and Negative Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is any reading, the brush assy and/or terminal bolt
assy have a short. Replace the starter motor.
Starter Relay Inspection
• Remove:
Battery Negative (–) Cable (see Battery Removal)
16-56 ELECTRICAL SYSTEM
Electric Starter System
• Remove the cable terminal cover [A].
• Disconnect:
Connector [A]
•
Cable Terminals [B]
Remove:
Starter Relay [C]
the hand tester [A] and 12 V battery [B] to the
• Connect
starter relay [C] as shown in the figure.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Tester Range:
Criteria:
× 1 Ω range
When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
ELECTRICAL SYSTEM 16-57
Electric Starter System
Electric Starter Circuit
1. Ignition Switch
2. Fuse Box 2
3. Ignition Fuse 15 A
4. Engine Stop Switch
5. Starter Button
6. Frame Ground
7. Sidestand Switch
8. Neutral Switch
9. Starter Lockout Switch
10. Relay Box
11. Starter Circuit Relay
12. Starter Motor
13. Starter Relay
14. Main Fuse 30 A
15. Battery 12 V 8 Ah
16. Water-proof Joint B
16-58 ELECTRICAL SYSTEM
Lighting System
This motorcycle adopt the daylight system and have a
headlight relay in the relay box. The headlight does not
go on when the ignition switch and the engine stop switch
are first turned on. The headlight comes on after the starter
button is released and stays on until the ignition switch is
turned off. The headlight will go out momentarily whenever
the starter button is pressed and come back on when the
button is released.
Headlight Beam Horizontal Adjustment
to the Headlight Aiming Inspection in the Periodic
• Refer
Maintenance chapter.
Headlight Beam Vertical Adjustment
to the Headlight Aiming Inspection in the Periodic
• Refer
Maintenance chapter.
Headlight Bulb Replacement
• Remove:
Meter Cover (see Upper Fairing Removal in the Frame
chapter)
Headlight Lead Connector [A]
Headlight Bulb Dust Cover [B]
• Remove:
Hook [A]
Headlight Bulb [B]
• Replace the headlight bulb.
NOTICE
When handling the quartz-halogen bulb [A], 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
○Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.
ELECTRICAL SYSTEM 16-59
Lighting System
the projection [A] of the bulb in the hollow [B] of the
• Fit
headlight.
• Install the hook [A].
the dust cover [A] firmly onto the bulb so that the TOP
• Fit
mark [B] is aligned with the arrow mark [C] on the headlight.
sure to fit the dust cover [A] onto the bulb [B] firmly as
• Be
shown in the figure.
•
Good [C]
Bad [D]
After installation, adjust the headlight aim (see Headlight
Aiming Inspection in the Periodic Maintenance chapter).
Headlight Removal/Installation
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
•
chapter)
Bolts [A]
Clamp [B]
Headlight Assy [C]
Installation is the reverse of removal.
16-60 ELECTRICAL SYSTEM
Lighting System
City Light Bulb Replacement
• Remove:
Meter Cover (see Upper Fairing Removal in the Frame
•
chapter)
Pull out the socket [A] and remove it with the bulb.
• Pull out the bulb [A] straight from the socket.
NOTICE
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage then the specified valve.
the bulb with a new one.
• Replace
Install
the
socket securely.
•
Tail/Brake Light (LED) Removal
• Remove:
Seat Cover (see Seat Cover Removal in the Frame
chapter)
Tail/Brake Light Mounting Bolts [A]
the tail/brake light lead connector [A] to re• Disconnect
move the tail/brake light (LED).
Tail/Brake Light (LED) Installation
is the reverse of removal.
• Installation
Tighten
the
tail/brake light mounting bolts securely.
•
ELECTRICAL SYSTEM 16-61
Lighting System
License Plate Light Bulb Replacement
• Remove:
Screws [A]
License Plate Light Cover [B] and Lens
out the bulb [A].
• Pull
Replace
new one.
• Insert thethenewbulbbulbwithintoa the
socket.
•
the projections [A] on the lens to the cover grooves [B].
• Fit
Tighten
the license plate light cover screws.
•
16-62 ELECTRICAL SYSTEM
Lighting System
Headlight/Tail Light Circuit
1. Fuse Box 2
2. Turn Signal Relay Fuse 10 A
3. Headlight Fuse 10 A
4. Alternator
5. Meter Ground
6. Frame Ground
7. Ignition Switch
8. Meter Unit
9. High Beam Indicator Light (LED)
10. City Light 12 V 5 W
11. Headlight (High) 12 V 55 W
12. Headlight (Low) 12 V 55 W
13. Joint Connector
14. Water-proof Joint A
15. Dimmer Switch
16. Passing Button (Other than US, CA and CAL
Models)
17. Relay Box
18. Headlight Circuit Relay
19. Starter Relay
20. Main Fuse 30 A
21. Battery 12 V 8 Ah
22. Water-proof Joint B
23. License Plate Light 12 V 5 W
24. Tail/Brake Light (LED)
ELECTRICAL SYSTEM 16-63
Lighting System
Turn Signal Light Bulb Replacement
Front Turn Signal Light
Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Inner Fairings (see Inner Fairing Removal in the Frame
chapter)
Turn the socket [A] counterclockwise and pull out the
socket together with the bulb.
•
•
and turn the bulb [A] counterclockwise and remove
• Push
it.
the new bulb [A] by aligning its upper and lower pins
• Insert
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
○Turn the bulb about 15°.
the socket and turn it clockwise.
•○Pushing
Fit the projections [A] of the socket into the grooves [B] of
•
the turn signal light.
Install the removed parts (see appropriate chapters).
Rear Turn Signal Light
Unscrew the screw [A] and remove the lens.
•
16-64 ELECTRICAL SYSTEM
Lighting System
and turn the bulb [A] counterclockwise and remove
• Push
it.
the new bulb [A] by aligning its upper and lower pins
• Insert
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
○Turn the bulb about 15°.
the projection [A] on the lens to the groove [B] on the
• Fit
socket.
• Tighten the screw.
Turn Signal Relay Inspection
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
•
•
Frame chapter)
Pull up the turn signal relay [A].
Disconnect the turn signal relay connector [B].
ELECTRICAL SYSTEM 16-65
Lighting System
one 12 V battery and turn signal lights as indi• Connect
cated in the figure, and count how many times the lights
flash for one minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not flash as specified, replace the turn signal relay.
Testing Turn Signal Relay
Load
The Number of Turn
Signal Lights
Wattage (W)
Flashing Times
(c/m*)
1**
10
140-250
2
20
75-95
*: Cycle(s) per minute
**: Correspond to “one light burned out”
16-66 ELECTRICAL SYSTEM
Lighting System
Turn Signal Light Circuit
1. Fuse Box 2
2. Turn Signal Relay Fuse 10 A
3. Meter Ground
4. Frame Ground
5. Ignition Switch
6. Meter Unit
7. Right Turn Signal Indicator Light (LED)
8. Left Turn Signal Indicator Light (LED)
9. Front Right Turn Signal Light 12 V 21 W
10. Front Left Turn Signal Light 12 V 21 W
11. Water-proof Joint A
12. Hazzard Switch
13. Turn Signal Switch
14. Turn Signal Relay
15. Starter Relay
16. Main Fuse 30 A
17. Battery 12 V 8 Ah
18. Water-proof Joint B
19. Rear Right Turn Signal Light 12 V 10 W
20. Rear Left Turn Signal Light 12 V 10 W
ELECTRICAL SYSTEM 16-67
Air Switching Valve
Air Switching Valve Operation Test
to the Air Suction System Damage Inspection in the
• Refer
Periodic Maintenance chapter.
Air Switching Valve Unit Test
the air switching valve (see Air Switching Valve
• Remove
Removal in the Engine Top End chapter).
the hand tester [A] to the × 1 Ω range and connect it
• Set
to the air switching valve terminals as shown in the figure.
Special Tool - Hand Tester: 57001-1394
Air Switching Valve Resistance
Standard:
18 ∼ 22 Ω at 20°C (68°F)
If the tester does not read as specified value, replace it
with a new one.
the 12 V battery [A] to the air switching valve
• Connect
terminals as shown in the figure.
the air to the intake air duct [A], and make sure does
• Blow
not flow the blown air from the outlet air duct [B].
the 12 V battery.
• Disconnect
Blow
the
air
to the intake air duct [A] again, and make sure
• flow the blown
air from the outlet air duct [B].
If the air switching valve does not operate as described,
replace it with a new one.
NOTE
○To check air flow through the air switching valve, just
blow through the air switching valve hose (intake side)
[C].
16-68 ELECTRICAL SYSTEM
Air Switching Valve
Air Switching Valve Circuit
1. Ignition Switch
2. Fuse Box 2
3. Ignition Fuse 15 A
4. Engine Stop Switch
5. Air Switching Valve
6. Frame Ground
7. ECU
8. Relay Box
9. ECU Main Relay
10. Fuel Pump Relay
11. FI Fuse 15 A
12. Main Fuse 30 A
13. Battery 12 V 8 Ah
14. Water-proof Joint C
ELECTRICAL SYSTEM 16-69
Radiator Fan System
Fan Motor Inspection
the left lower fairing (see lower Fairing Removal
• Remove
in the Frame chapter).
• Remove the rubber band [A].
the dust cover [A].
• Slide
Disconnect
the connector [B].
• Using an auxiliary
leads, supply battery power to the fan
• motor.
If the fan does not rotate, the fan motor is defective and
must be replaced.
16-70 ELECTRICAL SYSTEM
Radiator Fan System
Radiator Fan Circuit
1. Radiator Fan Motor
2. Fuse Box 2
3. Fan Fuse 15 A
4. Meter Ground
5. Frame Ground
6. Water Temperature Sensor
7. ECU
8. Ignition Switch
9. Water-proof Joint A
10. Relay Box
11. Radiator Fan Relay
12. FI Fuse 15 A
13. Main Fuse 30 A
14. Battery 12 V 8 Ah
15. Water-proof Joint C
ELECTRICAL SYSTEM 16-71
Meter, Gauge, Indicator Unit
Meter Unit Removal/Installation
• Remove:
Windshield Bracket Cover (see Upper Fairing Removal
•
•
in the Frame chapter)
Slide the dust cover [A] and disconnect the connector.
Pull the meter unit [B] forward to remove it from the
bracket [C].
NOTICE
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.
• Installation is the reverse of removal.
Meter Unit Disassembly
• Remove:
Meter Unit (see Meter Unit Removal/Installation)
Screws [A]
Lower Meter Cover [B]
the meter assembly [A] and upper meter cover
• Separate
[B].
16-72 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Electronic Combination Meter Unit Inspection
the meter unit [A].
• Remove
[1] Neutral Indicator Light (LED) Ground (–)
[2] Right Turn Signal indicator Light (LED) (+)
[3] High Beam Indicator Light (LED) (+)
[4] Water Temperature Sensor
[5] Unused
[6] Unused
[7] Unused
[8] Unused
[9] Unused
[10] Left Turn Signal indicator Light (LED) (+)
[11] Warning Indicator Light (LED) (–)
[12] Tachometer Pulse
[13] Speed Sensor Pulse
[14] ECU Communication Pulse
[15] Fuel Level Sensor
[16] Ignition
[17] Battery (+)
[18] Unused
[19] Ground (–)
[20] ABS Indicator Light (LED) (–) (Equipped Models)
NOTICE
Do not drop the meter unit. Place the meter unit so
that it faces upward. If the meter unit is left upside
down or sideways for a long time or dropped, it will
malfunction. Do not short each terminals.
Check 1: Meter Unit Primary Operation Check
Using the auxiliary leads, the 12 V battery [A] to the meter
unit connector as follows.
○Connect the battery positive (+) terminal to the terminal
[14].
○Connect the battery negative (–) terminal to the terminal
[12].
•
that the tachometer needle [A] momentarily points
• Check
their last readings and back to the minimum position.
If the meter unit does not work, replace the meter assembly.
ELECTRICAL SYSTEM 16-73
Meter, Gauge, Indicator Unit
• Connect the terminal [15] to the battery (+) terminal.
the following items.
•○Check
The tachometer needle momentarily points their last readings and back to the minimum position.
○All the LCD (Liquid Crystal Display) segments [A] and
warning indicator light (LED) [B] blink 1 time, then appear
for about 1 second.
○After the following LCD (Liquid Crystal Display) will display the action (1, 2) within about 2 seconds.
Fuel Gauge [C]
Speedometer [D],
Odometer [E] and
Clock [F]
Action 1
Segments appear
from up.
Segments appear
from left.
Action 2
Segments display
current valve.
Segments display
current valve.
○The all segments of the fuel gauge in the display will flash.
(This function is Fuel Level Sensor Line Self-Diagnosis
Mode. Refer to Fuel Level Sensor Line Self-Diagnosis
Mode Inspection.)
○The ABS indicator light (LED) [G] goes on. (Equipped
Models)
If the meter unit does not work, replace the meter assembly.
NOTE
○Currently, the wiring that relates to flashing has been
disconnected for the meter is removed from main harness. Therefore, the above flash has occurred.
the terminal [15].
•○Disconnect
All the LCD segments and LED warning indicator lights
disappear.
If the meter unit does not work, replace the meter assembly.
16-74 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 2: Meter Communication Line (Service Code 39)
Check
Connect the leads in the same circuit as Check 1.
Wait 10 seconds and the FI in the display and warning
indicator light (LED) flash.
•
•
the ODO mode [A] by pushing the MODE button [B].
• Set
Push
• the MODE button for more than 2 seconds.
the following items.
•○Check
The number 39 [A] and FI [B] in the display appear and
flash.
○The warning indicator light (LED) [C] flashes.
the MODE button for more than 2 seconds.
• Push
Check
the following items.
•○The display
returns ODO mode from number 39.
○The FI in the display and warning indicator light (LED)
flash.
If the meter unit does not work, replace the meter assembly.
NOTE
○The number 39 is service code of Self-Diagnosis (see
Fuel System chapter). It is the service code of the meter
communication line error.
○The number 39 and FI in the display disappear when the
meter unit is connected to main harness of the normal
motorcycle.
Check 3: MODE Button Operation Check
Connect the leads in the same circuit as Check 1.
•
ELECTRICAL SYSTEM 16-75
Meter, Gauge, Indicator Unit
pushing the MODE button [A] each time, check that
• By
the display [B] changes as follows.
If the display function does not work, replace the meter
assembly.
Check 4: Clock Setting Check
Connect the leads in the same circuit as Check 1.
•
the ODO mode [A] by pushing the MODE button [B].
• Set
Push
the RESET button [C] for more than two seconds.
•○The clock
setting menu (hour and minute) [D] should
•
flash.
Push the RESET button.
○The hour display [A] starts flashing.
pushing the MODE button each time, check that the
• By
hour display changes.
pushing the RESET button, check that the hour display
• By
decides and minute display [A] starts flashing.
pushing the MODE button each time, check that the
• By
minute display changes.
16-76 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
pushing the RESET button, check that the hour and
• By
minute display start flashing.
pushing the MODE button, check that the hour and
• By
minute display decide.
both hour and minute display is flashing, by push• When
ing the RESET button, check that the hour display start
flashing. This flashing returns the hour setting display.
If the display function does not work, replace the meter
assembly.
○If the terminal 15 disconnected when the clock is setting,
clock is set at time of that time.
Check 5: Immobilizer Flashing Mode Inspection
(Equipped Models)
Connect the leads in the same circuit as Check 1.
Disconnect the terminal [15].
•
•
that the warning indicator light (LED) [A] starts
• Check
flashing (Immobilizer Warning Indicator Light Flashing
•
•
Mode).
Push the MODE [B] and RESET [C] buttons more than 2
second, within 20 seconds after the terminal [15] disconnected.
Check that the warning indicator light (LED) goes on one
second, and then the light goes off (Immobilizer Warning
Indicator Light No Flashing Mode).
○For this inspection,
NOTE
be sure the battery is 12.2 V or
more. Immobilizer Warning Indicator Light Flashing
Mode does not work, when the battery voltage is less
than 12 ±0.2 V.
the terminal [15] to the battery (+) terminal.
• Connect
• And then, disconnect the terminal [15].
ELECTRICAL SYSTEM 16-77
Meter, Gauge, Indicator Unit
the MODE [A] and RESET [B] buttons more than 2
• Push
second, within 20 seconds after the terminal [15] discon-
•
nected.
Check that the warning indicator light (LED) [C] goes on
one second, and then the light starts flashing (Immobilizer
Warning Indicator Light Flashing Mode).
If the meter function does not work, replace the meter
assembly.
Check 6: Left Turn Signal Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [1] to the battery (+) terminal.
•
•
that the left turn signal indicator light (LED) [A]
• Check
goes on.
If the indicator light (LED) does not go on, replace the
meter assembly.
Check 7: High Beam Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [8] to the battery (+) terminal.
•
•
that the high beam indicator light (LED) [A] goes
• Check
on.
If the indicator light (LED) does not go on, replace the
meter assembly.
16-78 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 8: Right Turn Signal Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [9] to the battery (+) terminal.
•
•
that the right turn signal indicator light (LED) [A]
• Check
goes on.
If the indicator light (LED) does not go on, replace the
meter assembly.
Check 9: Neutral Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [10] to the battery (–) terminal.
•
•
that the neutral indicator light (LED) [A] goes on.
• Check
If the indicator light (LED) does not go on, replace the
meter assembly.
Check 10: ABS Indicator Light (LED) Inspection
(Equipped Models)
Connect the leads in the same circuit as Check 1.
○The ABS indicator light (LED) goes on.
Connect the terminal [11] to the battery (–) terminal.
•
•
ELECTRICAL SYSTEM 16-79
Meter, Gauge, Indicator Unit
that the ABS indicator light (LED) [A] goes off.
• Check
If the indicator light (LED) does not go off, replace the
meter assembly.
Check 11: Oil Pressure Warning Indicator Light (LED)
Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [20] to the battery (–) terminal.
•
•
that the oil symbol [A] and oil pressure warning
• Check
indicator light (LED) [B] flash.
If the oil symbol and indicator light (LED) do not flash,
replace the meter assembly.
Check 12: Water Temperature Warning Indicator Light
(LED)
Connect the leads in the same circuit as Check 1.
○The “– –” indication in the display of the water temperature
meter appears.
Connect the terminal [7] to the battery (–) terminal.
•
•
that the water temperature symbol [A] and water
• Check
temperature warning indicator light (LED) [B] flash.
If the water temperature symbol and indicator light (LED)
do not flash, replace the meter assembly.
16-80 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 13: Fuel Gauge Inspection
Connect the leads in the same circuit as Check 1.
○The all segments of the fuel gauge in the display will flash.
Connect the variable rheostat [A] to the terminal [16] and
the battery (–) terminal.
•
•
that the segments number of the fuel level gauge
• Check
[A] matches the resistance value of the variable rheostat.
○When the terminal [16] is connected, one segment in the
fuel level gauge should appear about every 15 seconds.
Variable Rheostat
Resistance (Ω)
Display Condition
10
6 segments go on
about 80
1 segment goes on
100
1 segment and Fuel Symbol [B] flash
If the display function does not work, replace the meter
assembly.
Check 14: Speedometer Inspection
Connect the leads in the same circuit as Check 1.
The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave is input into terminal
[18].
○Indicates approximately 60 km/h if the input frequency is
approximately 189 Hz.
○Indicates approximately 60 mph if the input frequency is
approximately 303 Hz.
If the meter function does not work, replace the meter
assembly.
•
•
NOTE
○The input frequency of the oscillator adds the integrated
value of the odometer.
○The integrated value of the odometer cannot be reset.
Check 15: Odometer Check
Check the odometer with the speedometer check in the
same way.
If value indicated in the odometer is not added, replace
the meter unit.
•
NOTE
○The data is maintained even if the battery is disconnected.
○When the figures come to 999999, they are stopped and
locked.
ELECTRICAL SYSTEM 16-81
Meter, Gauge, Indicator Unit
Check 16: Trip A/B Meter Check
Check the trip meter with the speedometer in the same
way.
If value indicated in the trip meter is not added, replace
the meter unit.
Check that when the RESET button is pushed for more
than two seconds, the figure display turns to 0.0.
If the figure display does not indicate 0.0, replace the meter unit.
•
•
Check 17: Tachometer Inspection
Connect the leads in the same circuit as Check 1.
The engine speed (rpm) equivalent to the input frequency
is indicated in the oscillator [A], if the square wave is input
into terminal [19].
○Indicates approximately 4 000 rpm if the input frequency
is approximately 133.3 Hz.
If the meter function does not work, replace the meter
assembly.
•
•
the terminal [15].
• Disconnect
Check
that
the
• mum (0) position.tachometer needle [A] back to the miniIf the meter unit does not work, replace the meter assembly.
Fuel Level Sensor Line Self-Diagnosis Mode
Inspection
NOTE
○Usually when the open or short of the fuel level sensor
circuit is detected, it becomes the Fuel Level Sensor
Line Self-Diagnosis Mode.
○The
all segments of the fuel gauge [A] in the display
will flash. (This function is Fuel Level Sensor Line
Self-Diagnosis Mode.)
If the meter enters the self-diagnostic mode when the meter is installed in the motorcycle, check the fuel level sensor (see Fuel Level Sensor Inspection) and wiring.
If the fuel level sensor and wiring are good, replace the
meter assembly.
16-82 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Circuit
1. Meter Unit
2. to Turn Signal Switch (Right)
3. to Turn Signal Switch (Left)
4. to Dimmer Switch and Passing Button
(Equipped Models)
5. Ignition Switch
6. ABS Hydrauric Unit (Equipped Models)
7. to France Ground
8. Fuel Level Gauge
9. Fuse Box 2
10. Meter Fuse 10 A
11. Ignition Fuse 15 A
12. Speed Sensor
13. Meter Ground
14. Water Temperature Sensor
15. Neutral Switch
16. Oil Pressure Switch
17. ECU
18. to Frame Ground
19. Main Fuse 30 A
20. Battery 12 V 8 Ah
ELECTRICAL SYSTEM 16-83
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, subthrottle
valve actuator and exhaust butterfly valve actuator will not operate and the engine will not start.
Abstract
Do not keep more than one immobilizer key of any system on a key ring. Jamming of the key code
signal may occur and the operation of the system may be affected.
The 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
left and right buttons down for two seconds within twenty seconds of switching the ignition off.
If all coded keys are lost the ECU and ignition switch will have to be replaced.
The immobilizer system can not function until the ignition key code is registered in the ECU.
A total of five keys can be registered in the ECU at any one time.
•
•
•
•
•
Operational Cautions
1.
2.
3.
4.
5.
6.
7.
8.
9.
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 ignition key is lost, the user should go to his dealer to invalidate the lost key registration
in the ECU.
10.When the all ignition key is lost, the user should go to his dealer and have a new ECU installed
and register the ignition keys.
NOTE
○No.9 and 10 are strongly recommended to the customer to ensure security of the motorcycle.
Key Registration
Case 1: When additional spare ignition key is required.
Prepare a new spare ignition key.
Cut the key in accordance with the shape of the current
ignition key.
Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Remove the immobilizer/Kawasaki diagnostic system
connector cap [A].
•
•
•
•
the key registration adapter [A] and key registra• Connect
tion unit [B].
Special Tools - Key Registration Unit: 57001-1582
Key Registration Adapter: 57001-1746
16-84 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
the registered ignition key into the ignition switch,
• Insert
and turn it to ON.
Verified
warning indicator light (LED) and the immobilizer
warning symbol [A] blink to display the registration mode
(go to the next step).
○The
Not Verified
○The warning indicator light (LED) and the immobilizer
warning symbol [A] blink to display the collation error
(refer to the following failure illustrations).
Immobilizer Amplifier Failure
Registered Ignition Key Collation Error
to OFF the ignition switch and remove the registered
• Turn
ignition key.
If there are other registered ignition keys, they should all
do the procedure above.
○The warning indicator light (LED) [A] then blinks for 15
seconds; it means the ECU is in the registration mode.
○The immobilizer warning symbol [B] disappears.
○After 15 seconds, the ECU ends the registration mode
and stops blinking the warning indicator light (LED).
NOTE
○Insert and turn on the next key between 15 seconds that
the ECU is in the registration mode.
○When a registration mode was ended,
do the registered ignition key(s) verification procedure over again
to restart it. This applies to all ignition key registration.
the ignition key 1 into the ignition switch, and turn
• Insert
it to ON.
NOTE
○Keep other ignition keys away from the immobilizer antenna.
ELECTRICAL SYSTEM 16-85
Immobilizer System (Equipped Models)
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
ignition key 1 is successfully registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
warning symbol [A] blink 3 times and stop for 1 second
and then repeat this cycle.
to OFF the ignition switch and remove the ignition
• Turn
key 1.
○The immobilizer warning symbol [A] disappears.
○The warning indicator light (LED) then blinks for 15 seconds.
○After 15 seconds, the ECU ends the registration mode
and stops blinking the warning indicator light (LED).
NOTE
○This procedure registered
the registered ignition key
and one ignition key.
If more keys registration is needed, go to next procedures
within the registration mode.
16-86 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
the ignition key 2 to the ignition switch and turn it to
• Insert
ON.
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
ignition key 2 is successfully registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
warning symbol [A] blink 4 times and stop for 1 second
and then repeat this cycle.
○This procedure has registered the 2 ignition keys.
Continue with the procedure if neccesary to register an
additional one ignition key.
•
NOTE
○The ECU can store up the five key codes.
Ignition Key Indicator Flashes
Ignition Key 3
Indicator
Light Blinks
Indicator
Light Stops
Remarks
5 times
1 second
Repeat
to OFF the ignition switch and wait for period of more
• Turn
than 15 seconds.
• The registration mode automatically ends.
ELECTRICAL SYSTEM 16-87
Immobilizer System (Equipped Models)
• The warning indicator light (LED) [A] goes off.
the key registration unit, key registration adapter
• Remove
and install the immobilizer/Kawasaki diagnostic system
connector cap.
NOTE
○Turn the ignition switch to ON with the registered ignition
key.
○Check that the engine can be started using all registered ignition keys.
16-88 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
Spare Ignition Key Registration Flow Chart
ELECTRICAL SYSTEM 16-89
Immobilizer System (Equipped Models)
Case 2: When the ignition switch is faulty and has to
be replaced.
Prepare a new ignition switch [A] and two new ignition
keys [B].
○These parts are available as a set. Prepare the current
registered ignition key [C].
•
• Remove:
Ignition Switch (see Immobilizer System Parts Replace•
•
ment)
Front Seat (see Front Seat Removal in the Frame chapter)
Remove the immobilizer/Kawasaki diagnostic system
connector cap.
Connect the key registration adapter [A] and key registration unit [B].
Special Tools - Key Registration Unit: 57001-1582
Key Registration Adapter: 57001-1746
• Connect:
New Ignition Switch Lead Connector [A]
Immobilizer Antenna Lead Connector [B] (of Current Ignition Switch)
NOTE
○Keep the antenna [C] more than 15 cm (5.9 in.) from
the new ignition switch [D].
the current registered ignition key [A] into the cur• Insert
rent ignition switch [B].
the new ignition key 1 [C] into the new ignition
• Insert
switch [D], and turn it to ON.
16-90 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
Verified
○The warning indicator light (LED) and the immobilizer
warning symbol [A] blink to display the ECU is in the
registration mode (go to the next step).
Not Verified
○The warning indicator light (LED) and the immobilizer
warning symbol [A] blink to display the collation error.
Immobilizer Amplifier Failure
Registered Ignition Key Collation Error
to OFF the ignition switch and remove the new igni• Turn
tion key 1.
○The immobilizer warning symbol [B] disappears.
○The warning indicator light (LED) [A] then blinks for 15
seconds; it means the ECU is in the registration mode.
○After 15 seconds, the ECU ends the registration mode
and stops blinking the warning indicator light (LED).
the antenna lead connector of the current ig• Disconnect
nition switch and connect the antenna lead connector of
•
the new ignition switch [A].
Insert the ignition key 1 [B] again into the new ignition
switch, and turn it to ON.
NOTE
○Insert and turn on the ignition key within 15 seconds that
the ECU is in the registration mode.
○When a registration mode was ended, do the registered
ignition key verification procedure over again to restart
it. This applies to all ignition key registration.
○Keep other ignition keys away from the immobilizer antenna.
ELECTRICAL SYSTEM 16-91
Immobilizer System (Equipped Models)
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
ignition key 1 is successfully registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
warning symbol [A] blink 3 times and stop for 1 second
and then repeat this cycle.
to OFF the ignition switch and remove the ignition
• Turn
key 1.
○The immobilizer warning symbol [B] disappears.
○The warning indicator light (LED) [A] then blinks for 15
seconds.
○After 15 seconds, the ECU ends the registration mode
and stops blinking the warning indicator light (LED).
NOTE
○This procedure registered
the registered ignition key
and one ignition key.
•
If more keys registration is needed, go to next procedures
within the registration mode.
Insert the ignition key 2 into the ignition switch, and turn
it to ON.
16-92 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
ignition key 2 is successfully registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
warning symbol [A] blink 4 times and stop for 1 second
and then repeat this cycle.
○This procedure has registered the registered ignition key
and 2 ignition keys.
Turn to OFF the ignition switch and wait for period of more
than 15 seconds.
The registration mode automatically ends.
•
•
• The warning indicator light (LED) [A] goes off.
ELECTRICAL SYSTEM 16-93
Immobilizer System (Equipped Models)
the key registration unit, key registration adapter
• Remove
and install the immobilizer/Kawasaki diagnostic system
connector cap.
NOTE
○Turn the ignition switch to ON with the registered ignition
key.
○Check that the engine can be started using all registered ignition keys.
the new ignition switch (see Immobilizer System
• Install
Parts Replacement).
Case 3: When the ECU is faulty and has to be replaced.
Prepare a new ECU [A] and current ignition key(s) [B].
•
NOTE
○The key registration unit is not required.
○After replacing the ECU, be sure to register the 2 ignition
keys. If the 2 keys are not registered, the engine can
not be started.
• Replace:
ECU (see Immobilizer System Parts Replacement)
the current registered ignition key into the ignition
• Insert
switch and turn it to ON.
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
Registered Ignition Key Collation Error
16-94 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
registered ignition key is successfully registered in
• The
the ECU.
○The
warning indicator light (LED) and the immobilizer
warning symbol [A] blink 1 time and stop for 1 second
and then repeat this cycle.
to OFF the ignition switch and remove the registered
• Turn
ignition key.
○The immobilizer warning symbol [B] disappears.
○The warning indicator light (LED) [A] then blinks for 15
seconds; it means the ECU is in the registration mode.
○After 15 seconds, the ECU ends the registration mode
and stops blinking the warning indicator light (LED).
NOTE
○Insert and turn on the next key between 15 seconds that
the ECU is in the registration mode.
○When a registration mode was ended, do the registered
ignition key verification procedure over again to restart
it. This applies to all ignition key registration.
the other remaining registered ignition key into the
• Insert
ignition switch, and turn it to ON.
NOTE
○Keep other ignition keys away from the immobilizer antenna.
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
ELECTRICAL SYSTEM 16-95
Immobilizer System (Equipped Models)
Ignition Key Collation Error
other remaining ignition key is registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
warning symbol [A] blink 2 times and stop for 1 second
and then repeat this cycle.
to OFF the ignition switch and remove the other re• Turn
maining ignition key.
○The immobilizer warning symbol [B] disappears.
○The warning indicator light (LED) [A] then blinks for 15
seconds.
○After 15 seconds, the ECU ends the registration mode
and stops blinking the warning indicator light (LED).
NOTE
○This procedure registered
the registered ignition key
and one ignition key.
If more keys registration is needed, go to next procedures
within the registration mode.
the ignition key 1 into the ignition switch, and turn
• Insert
it to ON.
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error code.
Immobilizer Amplifier Failure
16-96 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
When Registered Ignition Key is Inserted.
Ignition Key Collation Error
ignition key 1 is successfully registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
warning symbol [A] blink 3 times and stop for 1 second
and then repeat this cycle.
○This procedure has registered the registered ignition key
and 2 ignition keys.
Turn to OFF the ignition switch and wait for period of more
than 15 seconds.
The registration mode automatically ends.
•
•
• The warning indicator light (LED) [A] goes off.
NOTE
○Turn the ignition switch to ON with the registered ignition
key.
○Check that the engine can be started using all registered ignition keys.
ELECTRICAL SYSTEM 16-97
Immobilizer System (Equipped Models)
Case 4: When all registered ignition keys are faulty or
lost.
The all registered ignition keys replacement is considered
very rare case. However if it is required, the following is
necessary.
NOTE
○The ECU must be replaced with a new one because
the registered ignition key code that is registered in the
current ECU can not be rewritten.
• Prepare a new ECU [A] and 2 new ignition keys [B].
NOTE
○The key registration unit is not required.
○The key registration process is same as the case 3.
the first ignition key into the ignition switch and turn
• Insert
it ON.
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
Ignition Key Collation Error
16-98 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
first ignition key is successfully registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
warning symbol [A] blink 1 time and stops for 1 second
and the repeats this cycle to indicate successful registration of the first ignition key.
to OFF the ignition switch and remove the first igni• Turn
tion key.
○The immobilizer warning symbol [B] disappears.
○The warning indicator light (LED) [A] then blinks for 15
seconds; it means the ECU is in the registration mode.
○After 15 seconds, the ECU ends the registration mode
and stops blinking the warning indicator light (LED).
NOTE
○Insert and turn on the next key between 15 seconds that
the ECU is in the registration mode.
○When a registration mode was ended, do the registered
ignition key verification procedure over again to restart
it. This applies to all ignition key registration.
the second ignition key into the ignition switch, and
• Insert
turn it to ON.
NOTE
○Keep other ignition keys away from the immobilizer antenna.
○If there is any problem in the registration,
the warning
indicator light (LED) and the immobilizer warning symbol
[A] blink to display the collation error.
Immobilizer Amplifier Failure
When Registered Ignition Key is Inserted.
ELECTRICAL SYSTEM 16-99
Immobilizer System (Equipped Models)
Ignition Key Collation Error
second ignition key is registered in the ECU.
•○The
The warning indicator light (LED) and the immobilizer
•
•
warning symbol [A] blinks 2 time and stops for 1 second
and the repeats this cycle to indicate successful registration of the second ignition key.
Turn to OFF the ignition switch and wait for period more
than 15 seconds.
The registration mode automatically ends.
• The warning indicator light (LED) [A] goes off.
NOTE
○Turn the ignition switch ON with the registered ignition
key.
○Check that the engine can be started using all registered ignition keys.
16-100 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
All Keys Initial Registration Flow Chart
ELECTRICAL SYSTEM 16-101
Immobilizer System (Equipped Models)
Immobilizer System Parts Replacement
Ignition Switch (Immobilizer Antenna) Replacement
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Handlebar Holder (see Handlebar Removal in the Steering chapter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Disconnect the lead connectors [A].
•
•
the steering stem (see Stem, Stem Bearing Re• Remove
moval in the Steering chapter).
a small chisel or punch [A], turn out the Torx bolts.
• Using
Remove
the ignition switch [B].
•
a new Torx bolt [A] until the bolt head [B] is broken
• Tighten
[C].
the leads correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
Immobilizer Amplifier Replacement
Remove:
Left Center Fairing (see Center Fairing Removal in the
Frame chapter)
Immobilizer Amplifier connector [A]
Immobilizer Amplifier [B]
•
the slits [A] on the damper to the bracket projections
• Fit
[B].
16-102 ELECTRICAL SYSTEM
Immobilizer System (Equipped Models)
ECU (Electronic Control Unit) Replacement (for Immobilizer Models)
NOTICE
Never drop the ECU, especially on a hard surface.
Such a shock to the ECU can damage it.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Using a small chisel or other suitable tool, remove the
screws [A] and ECU guard [B].
• Remove:
Relay Box (see Relay Box Removal)
ECU Connectors [A]
ECU [B]
the connectors to the ECU.
• Connect
Install
the
ECU guard [A].
•
NOTICE
Do not pinch the leads.
the new screws [B] using the Kawasaki genuine
• Tighten
screws of which threads are coated with locking agent.
Immobilizer Relational Parts Replacement Chart
Failed or Lost Part
Ignition
Key
(Black)
Ignition
Key
(Black)
Ignition
Switch
•
○
Ignition
Switch
*
○
*
Replacement Part
•
Main Replacement Part
○
ECU
•
Amplifier
ECU
Amplifier
•
•
Additional Replacement Part
Immobilizer System Inspection
to the Immobilizer Amplifier and Blank Key Detec• Refer
tion section in the Fuel System (DFI) chapter.
ELECTRICAL SYSTEM 16-103
Immobilizer System (Equipped Models)
Immobilizer System Circuit
1. Fuse Box 2
2. Ignition Fuse 15 A
3. Meter Ground
4. Frame Ground
5. ECU
6. Ignition Switch
7. Immobilizer Antenna
8. Immobilizer Amplifier
9. Meter Unit
10. Water Temperature/Oil Pressure/FI/Immobilizer Warning Indicator Light (LED)
11. Relay Box
12. ECU Main Relay
13. FI Fuse 15 A
14. Main Fuse 30 A
15. Battery 12 V 8 Ah
16. Immobilizer/Kawasaki Diagnostic System Connector
17. Water-proof Joint C
16-104 ELECTRICAL SYSTEM
Switches and Sensors
Brake Light Timing Inspection
to the Brake Light Switch Operation Inspection in
• Refer
the Periodic Maintenance chapter.
Brake Light Timing Adjustment
to the Brake Light Switch Operation Inspection in
• Refer
the Periodic Maintenance chapter.
Switch Inspection
a hand tester, check to see that only the con• Using
nections shown in the table have continuity (about zero
ohms).
○For the switch housings and the ignition switch, refer to
the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Special Tool - Hand Tester: 57001-1394
Rear Brake Light Switch Connections
Sidestand Switch Connections
Neutral Switch Connections
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.
ELECTRICAL SYSTEM 16-105
Switches and Sensors
Water Temperature Sensor Inspection
the water temperature sensor (see Water Tem• Remove
perature Sensor Removal/Installation in the Fuel System
•
•
(DFI) chapter).
Suspend the sensor [A] in a container of coolant so that
the threaded portion is submerged.
Suspend an accurate thermometer [B] with temperature
sensing portions [C] located in almost the same depth.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradu• Place
ally raise the temperature of the coolant while stirring the
coolant gently.
Using the hand tester, measure the internal resistance of
the sensor.
○The sensor sends electric signals to the ECU and coolant
temperature gauge in the meter unit.
○Measure the resistance across the terminals and the body
(for the gauge) at the temperatures shown in the table.
If the hand tester does not show the specified values, replace the sensor.
•
Water Temperature Sensor
Resistance for ECU [D]
Resistance (kΩ)
Temperature
(Terminal [1]-[3])
+ 0.155
20°C (68°F)
2.46
80°C (176°F)
0.32 ±0.011
110°C (230°F)
0.1426 ±0.0041
– 0.143
Resistance for Water Temperature Gauge [E]
Resistance (Ω)
Temperature
(Terminal [2]-Body)
50°C (122°F)
210 ±40
120°C (248°F)
21.2 ±1.5
Speed Sensor Removal
NOTICE
Never drop the sensor especially on a hard surface.
Such a shock to the sensor can damage it.
the fuel tank with suitable bar (see Fuel Tank Re• Support
moval in the Fuel System (DFI) chapter).
• Remove:
Speed Sensor Connector (Disconnect) [A]
Engine Sprocket Cover (see Engine sprocket Cover Removal in the Final Drive chapter)
Speed Sensor
16-106 ELECTRICAL SYSTEM
Switches and Sensors
Speed Sensor Installation
a non-parmanent locking agent to the speed sensor
• Apply
mounting bolt [A].
the speed sensor [B] to the inner engine sprocket
• Install
cover.
• Tighten:
Torque - Speed Sensor Mounting Bolt: 6.9 N·m (0.70 kgf·m,
61 in·lb)
the engine sprocket cover (see Engine Sprocket
• Install
Cover Installation in the Final Drive chapter).
the speed sensor lead connector.
• Connect
Install
the
fuel tank (see Fuel Tank Installation in the Fuel
• System (DFI)
chapter).
Confirm
that
the
hose and clamp are installed se• curely and run thedrain
hose correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
Speed Sensor Inspection
the speed sensor (see Speed Sensor Removal).
• Remove
Connect
speed sensor connector [A] with the battery
• [B], 10 kΩtheresistor
[C] and hand tester [D] as shown in the
•
figure.
Set the tester to the DC 25 V range.
Special Tool - Hand Tester: 57001-1394
[A] of the speed sensor surface with the screw• Trace
driver.
○Then the tester indicator should flick [B].
If the tester indicator does not flick, replace the speed
sensor.
Oxygen Sensor Removal (Equipped Models)
NOTICE
Never drop the sensor especially on a hard surface.
Such a shock to the sensor can damage it.
NOTICE
Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open.
the oxygen sensor lead from the clamp [A].
• Clear
• Disconnect the oxygen sensor lead connector [B].
ELECTRICAL SYSTEM 16-107
Switches and Sensors
the oxygen sensor lead from the clamp [A].
• Clear
Remove
the oxygen sensor [B].
•
Oxygen Sensor Installation (Equipped Models)
NOTICE
Never drop the oxygen sensor [A] especially on a
hard surface. Such a shock to the unit can damage
it. Do not touch the sensing part [B] and filter holes
[C] of the sensor to prevent oil contact. Oil contamination from hands can reduce sensor performance.
• Tighten:
Torque - Oxygen Sensor: 44 N·m (4.5 kgf·m, 32 ft·lb)
the oxygen sensor lead correctly (see Cable, Wire,
• Run
and Hose Routing section in the Appendix chapter).
Oxygen Sensor Inspection (Equipped Models)
to the Oxygen Sensor Inspection in the Fuel System
• Refer
(DFI) chapter.
Fuel Level Sensor Inspection
• Remove:
Fuel Pump (see Fuel Pump Removal in the Fuel System
•
(DFI) chapter)
Check that the float moves up and down smoothly without
binding. It should go down under its own weight.
If the float does not move smoothly, replace the fuel pump.
Float in Full Position [A]
Float in Empty Position [B]
Float Arm Stoppers [C]
the hand tester [A], measure the resistance across
• Using
the terminals in the fuel level sensor lead connector [B].
Special Tools - Hand Tester: 57001-1394
Needle Adapter set: 57001-1457
If the tester readings are not as specified, or do not
change smoothly according as the float moves up and
down, replace the fuel pump.
Fuel Level Sensor Resistance
Standard: Full position: 9.6 ∼ 12.4 Ω
Empty position: 222 ∼ 228 Ω
16-108 ELECTRICAL SYSTEM
Relay Box
The relay box [A] has relays and diodes. The relays and
diodes can not be removed.
Relay Box Removal
NOTICE
Never drop the relay box especially on a hard surface.
Such a shock to the relay box can damage it.
the rear fender from the battery case and rear
• Remove
frame (see Flap and Rear Fender Removal in the Frame
•
•
chapter).
Disconnect:
Connectors [A]
Remove:
Relay Box [B]
Relay Circuit Inspection
the relay box (see Relay Box Removal).
• Remove
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 in this
section).
If the tester does not read as specified, replace the relay
box.
Relay Circuit Inspection (with the battery disconnected)
Headlight Relay
ECU Main Relay
Fuel Pump Relay
Starter Circuit Relay
Fan Relay
Tester Connection
Tester Reading (Ω)
1-3
∞
7-6
∞
4-5
Not ∞*
7-8
∞
9-10
Not ∞*
11-16
∞
11-12
∞
17-20
∞
18-19
Not ∞*
*: The actual reading varies with the hand tester used.
ELECTRICAL SYSTEM 16-109
Relay Box
Relay Circuit Inspection (with the battery connected)
Battery
Connection
(+) (–)
Tester
Connection
Tester
Reading (Ω)
2-11
1-3
0
4-5
7-6
0
Fuel Pump Relay
9-10
7-8
0
Fan Relay
18-19
17-20
0
ECU Main Relay
Battery
Connection
(+) (–)
Tester Connection
DC 25 V Range
(+) (–)
Tester
Reading (V)
16-12
11-12
Battery
Voltage
Starter
Circuit Relay
(+): Apply positive lead.
(–): Apply negative lead.
Diode Circuit Inspection
the relay box (see Relay Box Removal).
• Remove
Check
conductivity
of the following pairs of terminals (see
• Relay Box Internal Circuit
in this section).
Diode Circuit Inspection
Tester Connection
1-11, 2-11, 12-13, 12-15, 12-16, 13-14,
13-15
The resistance should be low in one direction and more
than ten times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the relay box must be replaced.
NOTE
○The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking,
the lower reading should be from zero to one half the
scale.
16-110 ELECTRICAL SYSTEM
Relay Box
Relay Box Internal Circuit
A: Headlight Relay
B: ECU Main Relay
C: Fuel Pump Relay
D: Starter Circuit Relay
E: Fan Relay
ELECTRICAL SYSTEM 16-111
Fuse
30 A Main Fuse Removal
• Remove:
Starter Cable Terminal Cover (see Starter Relay Inspec•
tion)
Pull out the main fuse [A] from the starter relay with a
needle nose pliers.
Fuse Box Fuse Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Unlock the hooks [A] to lift up the lids [B].
the fuses [A] straight out of the fuse box with needle
• Pull
nose pliers.
15 A FI Fuse Removal
• Remove:
Starter Cable Terminal Cover (see Starter Relay Inspec•
tion )
Pull out the fuse [A].
Fuse Installation
fails during operation, inspect the electrical sys• Iftema fuse
to determine the cause, and then replace it with a
•
new fuse of proper amperage.
Install the fuse box fuses on the original position as specified on the lid.
16-112 ELECTRICAL SYSTEM
Fuse
Fuse Inspection
the fuse.
• Remove
the fuse element.
• Inspect
If it is blown out, replace the fuse.
Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTICE
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
APPENDIX 17-1
Appendix
Table of Contents
Cable, Wire, and Hose Routing ..............................................................................................
Troubleshooting Guide ...........................................................................................................
17-2
17-76
17
17-2 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Headlight Lead
2. Run the brake hose to the rear side of the headlight lead.
3. Brake Hose
4. Run the front right turn signal light lead through the air switching valve. And run to the rear side
of the light switch housing.
5. Air Switching Valve Clamp
6. Air Switching Valve
7. Air Switching Valve Hose
8. Run the air switching valve hose to the upside of the stick coil lead.
9. Stick Coil Lead
10. Run the injector lead to the front side of the breather hose.
11. Injector Lead
12. Breather Hose
13. Hold the injector lead with clamp
14. Run the intake air temperature sensor to the upside of the crankshaft sensor lead.
15. Intake Air Temperature Sensor Lead
16. Crankshaft Sensor Lead
17. Connect the horn lead connectors so that the horn lead comes upside.
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Insert the clamp on the main harness to the rib of the frame as shown.
2. Run the headlight lead, right and left light switch housing lead, ignition switch lead, immobilizer
amplifier lead (equipped models) and radiator fan motor lead to the front side of engine mount
bracket, right turn signal light lead and air switching valve, and run them under the throttle cable
and outside of frame.
3. Left Switch Housing Lead
4. Ignition Switch Lead
5. Throttle Cables
6. Right Switch Housing Lead
7. Immobilizer Amplifier Lead
8. Headlight Lead
9. Run the clutch cable under the other lead and front side of radiator.
10. Run the main harness to the outside of the between engine mount bracket and frame.
11. Run the radiator fan motor lead, right switch housing and throttle cable in order from the frame.
12. Radiator Fan Motor Lead
13. Run the starter motor cable (+) to the upside of the battery negative (–) cable.
14. Run the frame ground lead to the front side of the starter motor cable and battery negative (–)
cable.
15. Run the alternator lead to the under the main harness.
16. Alternator Lead
17. Run the alternator lead and crankshaft sensor lead to the rear side of breather hose.
18. Main Harness
19. Hold the alternator lead and crankshaft sensor lead with clamp.
20. Battery Negative (–) Cable
21. Starter Motor (+) Cable
22. Frame Ground Lead
23. Crankshaft Sensor Lead
17-6 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Run the fuel pump lead to the upside of the exhaust butterfly valve cables, to the outside of the
fuse box, and to under the fuel tank bracket.
2. Run the rear of main harness to inside of the battery case, to underside of the fuel pump lead,
to rear of the battery case mounting and to the outside of the battery case as shown.
3. Hold the fuel pump lead (main harness side) with the clamp.
4. Hold the main harness with the clamp.
5. Run the regulator/rectifier harness to the under the battery case.
6. Run the starter motor cable to the upside of the main harness.
7. Run the starter motor cable to between the main relay and battery, and to inside of the starter
motor cable.
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Run the oxygen sensor lead (equipped models), crankshaft sensor lead and rear brake light
switch lead to the outside of main harness.
2. Crankshaft Sensor Lead
3. Hold the rear brake light switch connector with the clamp.
4. Rear Brake Light Switch Lead
5. Oxygen Sensor Lead
6. Main Harness
7. Insert the clamps to the ribs of the inside of the frame, hold the oxygen sensor lead and crankshaft sensor lead.
8. Run the regulator/rectifier harness from the cutout on the battery case to under side of the battery case.
9. Regulator/Rectifier Harness
17-10 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Kawasaki Diagnostic System Connector
2. ABS Self-diagnosis Connector (ABS Equipped Models)
3. Relay Box
4. Rear Left Turn Signal Light Lead
5. Rear Right Turn Signal Light Lead
6. ECU
7. Run the leads to forward of the rear fender wall connect them.
8. Run the turn signal light leads to the inside of ECU rib under the ECU and connect them.
9. Run the right and left turn signal light leads to forward of the rear frame wall and connect them.
10. Run the seat lock cable to front side of the frame wall and upside of the turn signal light lead
and license plate light lead.
11. Rear Left and Right Turn Signal Light Lead
12. Run the license plate light lead to right side of the frame and connect them at position as shown.
13. Tail/Brake Light (LED) Lead
14. Run the licence plate light lead and tail/brake light (LED) lead reward to under of the rear frame
after connected. Be careful not to pinch the leads with rear fender.
15. License Plate Light Lead
16. Run the licence plate light lead (main harness side) and tail/brake light (LED) lead (main harness
side) reward to under of the rear flame (for prevention to pinch the leads with rear fender).
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Throttle Cable (Accelerator)
2. Throttle Cable (Decelerator)
3. Right Switch Housing Lead
4. Brake Hose
5. Clamp the brake hose, throttle cable (decelerator), throttle cable (accelerator) and right switch
housing lead in order from the outside of frame.
6. Run the brake hose comes to the most front side of the other lead. Run the right switch housing
lead comes to the most rear side of the other lead.
7. Front Right Turn Signal Light Lead
8. Run the throttle cables, clutch cable, front turn signal light lead, right switch housing leads
through this point to the inside of the frame.
9. Clutch Cable
10. Run the throttle cables and right switch housing leads through the inside of front fork.
11. Clamp
17-14 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Run the exhaust butterfly valve cables to inside of the main harness.
2. Exhaust Butterfly Valve Close Cable
3. Exhaust Butterfly Valve Open Cable
4. Main Harness
17-16 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Bend the clamp upward to secure the harness at the portion of the taped.
2. Install the main harness clamp at the headlight bracket.
3. Bend the clamp reward to inside to secure the harness at the portion of the taped.
4. Main Harness
17-18 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Clamp
2. Run the clutch cable and left switch housing lead in order from the inside of clamp.
3. Clamp
4. Run the left switch housing leads, ignition switch lead, immobilizer antenna lead (equipped models), and clutch cables to the inside of the front fork.
5. Immobilizer Antenna Lead
6. Clutch Cable
7. Left Switch Housing Lead
8. Ignition Switch Lead
9. Run the ignition switch lead and immobilizer antenna lead inside of clamp.
10. Clamp
11. Run the clutch cable outside through the lower side of the radiator mounting position, and to the
under of the other leads.
12. Clamp
13. Run the ignition switch lead, immobilizer antenna lead and left switch housing lead to the inside
of the clamp.
17-20 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-21
Cable, Wire, and Hose Routing
1. Insert the hole on the engine top heat protector into the slit on the radiator side pad.
2. Connect the left turn signal light lead at the rear of radiator side pad, and push its connector into
the cutout on the pad.
3. Band
4. Cover the right switch housing lead, ignition switch lead, immobilizer antenna lead (equipped
models) and radiator fan motor lead with the rubber cover, and tie the rubber cover and main
harness and neutral switch/oil pressure switch with the band then secure them to the heat insulation plate. Cut the band excess length after tying them.
5. Main Harness
6. Neutral Switch/Oil Pressure Switch Lead
7. Ignition Switch Lead
8. Right Switch Housing Lad
9. Radiator Fan Motor Lead
10. Rubber Cover
11. Immobilizer Antenna Lead
12. Hold the engine top heat protector to the heat insulation plate with the rivets from the front side
(the right side is same as the left side).
13. Heat Insulator
14. Run the neutral switch/oil pressure switch lead to inside of rubber cover and connect them. Then
hold the neutral switch/oil pressure switch lead with clamp on the engine bracket.
15. Clamp
16. Hold the neutral switch/oil pressure switch lead with clamp on the bracket.
17-22 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-23
Cable, Wire, and Hose Routing
1. Air Cleaner Drain Hose
2. Neutral Switch/Oil Pressure Switch Lead
3. Idle Adjusting Screw
4. Run the starter motor cable to the upside of the idle adjusting screw.
5. Sidestand Switch Lead
6. Speed Sensor Lead
7. Fuel Tank Breather Hose (other than CAL and SEA-B1 models)
8. Fuel Tank Drain Hose
9. Starter Motor Cable
10. Run the alternator lead to the outside of air cleaner drain hose and inside of neutral switch/oil
pressure switch lead.
11. Run the speed sensor lead and sidestand switch lead to the inside of the breather hose and fuel
tank drain hose (other than CAL and SEA-B1 models).
12. Run the end of fuel tank drain hose is as shown.
13. Hold the sidestand switch lead with the clamp.
14. Clamp
15. Alternator Lead
17-24 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-25
Cable, Wire, and Hose Routing
1. Air Cleaner Drain Hose
2. Idle Adjusting Screw
3. Run the idle adjusting screw to the under of the starter motor cable, outside of the air cleaner
drain hose.
4. Starter Motor Cable
5. Run the fuel hose, starter motor cable, and alternator lead in order from the inside of the frame.
6. Fuel Hose
7. Alternator Lead
8. Fuel Tank Drain Hose
9. Sidestand Switch Lead
10. Fuel Tank Breather Hose (other than CAL and SEA-B1 Models)
11. Run the fuel tank breather hose (other than CAL and SEA-B1 models), sidestand switch lead
and fuel tank drain hose to the inside of the chain cover.
17-26 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-27
Cable, Wire, and Hose Routing
1. Air Cleaner Housing
2. Air Switching Valve Hose
3. Air Switching Valve
4. Tighten the clamp bolt from left side.
5. Tighten the clamp bolt from right side.
6. Intake Air Temperature Sensor
7. Install the clamp so that knob of the clamp faces rear side of the frame as shown.
8. Breather Hose
9. Clamp
10. Clamps
11. Air Cleaner Drain Hose
12. Catch Tank
13. White Paint Mark
14. Right
15. Left
16. Viewed from A
17-28 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-29
Cable, Wire, and Hose Routing
1. Insert the subharness connector to the clamp on the air suction valve cover.
2. Run the subharness under the hose.
3. Hose
4. Subharness
5. Run the subharness between the #1 and #2 throttle body holders so as not to pinch the lead
with the throttle body assy.
6. Install the clamp as shown in the direction.
7. Water Hose
8. Starter Motor Cable
9. Viewed from B
10. Water Temperature Sensor Lead
11. Hold the neutral switch/oil pressure switch lead with the clamp at the upside of the separate
pipe of the water pipe.
12. Run the neutral switch/oil pressure switch lead with the clamp at the rear side of the separate
pipe of the water pipe.
13. Connect the neutral switch lead to the neutral switch. Do not stretch the lead after connected.
14. Run the oil pressure switch lead to the inside of the water pipe.
15. Cover the oil pressure switch with the switch cover.
16. Hold the crankshaft sensor lead with the clamp.
17. Crankshaft Sensor Lead
18. Water pipe
19. Run the alternator lead between the crankcase and water pipe.
20. Viewed from A
17-30 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-31
Cable, Wire, and Hose Routing
1. Regulator/Rectifier Harness
2. Hold the regulator/rectifier harness with clamp.
3. Rear Brake Light Switch Lead
4. Exhaust Butterfly Valve Open Cable
5. Exhaust Butterfly Valve Close Cable
6. Oxygen Sensor Lead (Equipped Models)
7. Run the rear brake light switch lead through the clamp to outside of exhaust butterfly valve
cables.
8. Run the exhaust butterfly valve open cable and close cable through the clamp in order from the
front.
9. Clamp (for Exhaust Butterfly Valve Cables)
10. Clamp (for Oxygen Sensor Lead and Crankshaft Sensor Lead)
11. Bend the clamp reaward to secure the oxygen sensor lead and crankshaft sensor lead.
12. Crankshaft Sensor Lead
13. Clamp (for Exhaust Butterfly Valve Cable)
14. Run the exhaust butterfly valve open cable and close cable through the clamp in order from the
front.
17-32 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-33
Cable, Wire, and Hose Routing
1. Install the clamps as shown in the direction.
2. Reserve Tank Hose
3. Radiator Hose
4. Water Hose
5. Water Hose
6. Reserve Tank
7. Reserve Tank Overflow Hose
8. Thermostat
9. Radiator
10. Radiator Hose
11. Water Pipe
12. Oil Cooler
13. Water Hose
14. Water Hose
15. Water Pipe
16. Water Hose
17-34 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-35
Cable, Wire, and Hose Routing
1. Install the clamps so that its opening facing the direction indicated with arrow.
2. Clamp (for Water Hose)
3. Clamp (for Radiator Hose)
4. Hold the clutch cable with clamp.
5. Run the front right turn signal light lead to the upside of the reserve tank overflow hose.
6. Front Turn Signal Light Lead
7. Reserve Tank Overflow Hose
8. Clamp (for Clutch Cable)
9. Clutch Cable
10. Viewed From A
11. About 45°
12. Viewed From B
13. About 90°
17-36 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-37
Cable, Wire, and Hose Routing
1. Run the reserve tank overflow hose to the inside of the frame.
2. Reserve Tank Overflow Hose
3. Run the water hose, reserve tank overflow hose, water hose in order the outside of frame.
4. Water Hose
5. Water Hose
6. Connect the right turn signal light lead at the rear of radiator side pad, and push its connector
into the cutout on the pad.
7. Right Turn Signal Light Lead
8. Run the reserve tank overflow hose to behind of the adjusting bolt, and between the adjusting
bolt and frame, and directs it to underside of the frame.
9. Hold the oxygen sensor lead (equipped models) and crankshaft sensor lead with clamp.
10. Oxygen Sensor Lead
11. Crankshaft Sensor Lead
12. Run the clutch cable to front of engine bracket through the clamp on the front of the crankshaft
sensor cover and inside of upper radiator hose.
13. Clutch Cable
17-38 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-39
Cable, Wire, and Hose Routing
1. Radiator Hose
2. Install the clamps as shown, noting its screw head direction.
3. White Paint Mark (Install the water hose so that the white paint mark faces upside of the engine.)
4. Water Hose
5. White Paint Mark (Install the water hose so that the white paint mark faces outside of the engine.)
6. Water Hose
7. Straight Side
8. Install the radiator hose until the rised portion of the water pipe.
9. Curve Side
10. Viewed from A
11. Install the clamp so that the tab of the clamp faces rear side of the engine.
12. Install the clamp at the thermostat housing so that the tab of the clamp faces rear side of the
engine.
13. Viewed from B
14. Breather Hose
15. Water Hose
16. White Paint Mark
17. Install the clamp so that the tab of the clamp faces right side of the engine.
18. Water Hose
19. White Paint Mark (Install the water hose and water pipe so that the white paint mark faces
outside of the engine.)
17-40 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-41
Cable, Wire, and Hose Routing
1. Front Wheel Rotation Sensor Lead
2. Clamps (for Brake Hose and Front Wheel Rotation Sensor Lead)
3. Front Wheel Rotation Sensor Connector
4. Headlight Lead
5. Run the front wheel rotation sensor lead to the outside of the headlight lead, and connect the
front wheel rotation sensor connector at the front fork bracket.
17-42 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-43
Cable, Wire, and Hose Routing
1. Hold the brake hose inside the front wheel rotation sensor lead with clamp. Install the clamp
with its closed side facing forward.
2. Hold the brake hose at the rubber portions with the clamp.
3. Run the front wheel rotation sensor lead to the rear side of the brake hose. Install the clamp
with its closed side facing outside.
4. Clamp (for Front Wheel Rotation Sensor Lead and Brake Hose)
5. Brake Hose
6. Front Wheel Rotation Sensor Lead
7. Run the brake hose to the most forward side, and the right switch housing lead to the most
behind of the other leads and run them into the clamp.
8. Run the brake hose, right switch housing lead, throttle cable (accelerator) and throttle cable
(decelerator) in order from the outside of frame.
9. Right Switch Housing Lead
10. Throttle Cable (Accelerator)
11. Throttle Cable (Decelerator)
12. Run the brake hose, throttle cable (decelerator), throttle cable (accelerator) and right switch
housing lead in order from the outside of frame.
13. Brake Hose
14. Run the right switch housing lead to the inside of brake hose.
15. Run the brake hose to the most outside of the other lead.
16. Front
17-44 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-45
Cable, Wire, and Hose Routing
1. Brake Pipe
2. Brake Pipe
3. Brake Hose
4. Front
5. Clamp (Hold the brake pipes)
6. Hold the brake pipes at the rubber portions with the clamps.
7. Rear Wheel Rotation Sensor Lead
8. Run the rear wheel rotation sensor lead to the outside of the main harness and upper the intake
air temperature sensor lead.
9. Intake Air Temperature Sensor Lead
10. Run the brake pipes under the harnesses.
17-46 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-47
Cable, Wire, and Hose Routing
1. Rear Wheel Rotation Sensor
2. Run the rear wheel rotation sensor lead into the clamp.
3. Rear Wheel Rotation Sensor Lead
4. Run the rear wheel rotation sensor lead upper the brake hose, and hold the brake hose at the
attaching mark with the clamp.
5. Clamp (for Brake Hose and Rear Wheel Rotation Sensor Lead)
6. Brake Hose
7. Front
8. Clamp (for Rear Wheel Rotation Sensor Lead)
17-48 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-49
Cable, Wire, and Hose Routing
1. Front
2. Rear Wheel Rotation Sensor Lead
3. Run the exhaust butterfly valve close cable, exhaust butterfly valve open cable, brake hose,
brake light switch lead, rear wheel rotation sensor lead in order from the inside of frame.
4. Exhaust Butterfly Valve Open Cable
5. Exhaust Butterfly Valve Close Cable
6. Brake Hose
7. Brake Hose
8. Clamp
9. Hold the brake light switch lead and rear wheel rotation sensor lead with clamp.
10. Run the ABS hydraulic unit harness under the battery case so that the harness has no play in
this position (Run the under the battery case).
11. Clamp (for ABS Hydraulic Unit Harness)
12. ABS Hydraulic Unit Harness
13. Run the ABS hydraulic unit harness as shown.
17-50 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-51
Cable, Wire, and Hose Routing
1. Air Cleaner Drain Hose
2. Breather Hose
3. Run the breather hose and air cleaner drain hose through the front side of frame ground lead
and outside of the starter motor cable.
4. Starter motor (+) Cable
5. Run the brake pipe through the inside of the starter motor (+) cable and battery negative (–)
cable and under the frame ground lead.
6. Frame Ground Lead
7. Battery Negative (–) Cable
8. Front
9. Run the brake hoses under the other harnesses.
10. Run the wheel rotation sensor lead and rear brake light switch lead to the outside of the oxygen
sensor lead and crankshaft sensor lead.
11. Wheel Rotation Sensor Lead
12. Oxygen Sensor Lead
13. Crankshaft Sensor Lead
17-52 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-53
Cable, Wire, and Hose Routing
1. Clamp (Hold the each harness.)
2. Regulator/Rectifier Harness
3. Run the regulator/rectifier harness from the cutout on the battery case to underside of the battery
case.
4. ABS Hydraulic Unit Harness
5. Run the rear of main harness to upside of the battery case, to rear of the battery case mount
portion, and to outside of the battery case.
6. Main Harness
7. Front
17-54 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-55
Cable, Wire, and Hose Routing
1. ABS Hydraulic Unit
2. Clamps
3. Brake Hose (between Front Master Cylinder and ABS Hydraulic Unit)
4. Brake Hose (between ABS Hydraulic Unit and Right Front Caliper)
5. Clamp (Hold the grommet of the brake hose only. For ZX1000HB late model ∼, face the lock
portion of the clamp backward.)
6. Hold the front brake hose and the front wheel rotation sensor lead with the clamp at the white
painted portion of the sensor lead.
7. Brake Hose (between ABS Hydraulic Unit and Left Front Caliper)
8. Front Wheel Rotation Sensor
17-56 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-57
Cable, Wire, and Hose Routing
1. ABS Hydraulic Unit
2. Clamps
3. Brake Hose (between Rear Master Cylinder and ABS Hydraulic Unit)
4. Brake Hose (between ABS Hydraulic Unit and Rear Caliper)
5. Rear Wheel Rotation Sensor
6. Rear Wheel Rotation Sensor Lead
7. Section A-A
8. Section B-B
17-58 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-59
Cable, Wire, and Hose Routing
1. Brake Hose
2. Headlight Lead
3. Run the brake hose to the rear side of the headlight lead.
4. Run the brake hose to the most front side of the other leads and cables, and through it to the
clamp.
5. Clamp
6. Front
17-60 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-61
Cable, Wire, and Hose Routing
1. (ZX1000GB Early Model) Hold the brake hose with the clamp at the grommet of the brake hose,
and insert it to the front fender.
(ZX1000GB Late Model ∼) Hold the brake hose with the clamp at the grommet of the brake
hose. Face the lock portion of the clamp backward.
2. Clamp (for Brake Hose)
3. Brake Hose
17-62 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-63
Cable, Wire, and Hose Routing
1. Clamp (for Brake Hose)
2. Brake Hose
3. Clamp (for Brake Hose)
4. Front
5. Fit the brake pipe to the stopper of the caliper as shown, and tighten the brake hose banjo bolt
to the specified torque.
6. Clamp (for Brake Hose)
17-64 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-65
Cable, Wire, and Hose Routing
1. Viewed From A
2. Fit the projection of the brake hose end to the stopper as shown, and tighten the brake hose
banjo bolt to the specified torque.
3. Front
17-66 APPENDIX
Cable, Wire, and Hose Routing
1. Brake Hoses
2. Clamps (Hold the grommet of the brake hose only. For ZX1000GB late model ∼, face the lock
portion of the clamp backward.)
APPENDIX 17-67
Cable, Wire, and Hose Routing
1. Brake Hose
2. Clamps
17-68 APPENDIX
Cable, Wire, and Hose Routing
CAL and SEA-B1 Models
APPENDIX 17-69
Cable, Wire, and Hose Routing
1. Run the purge hose to the inside of the sidestand switch lead and speed sensor lead, upside of
the main harness and frame ground lead.
2. Sidestand Switch Lead
3. Speed Sensor Lead
4. Front
5. Main Harness
6. Vacuum Hose (between Separator and Throttle Body)
7. Run the vacuum hose to the under the delivery pipe of the throttle body assy. Crankshaft sensor
lead and alternator lead. And run to the vacuum hose to upside of the main harness.
8. Alternator Lead
9. Frame Ground
10. Purge Hose (between Canister and Fitting for Air Switching Valve)
11. Crankshaft Sensor Lead
12. Run the purge hose to the upside of the other lead.
13. Regulator/Rectifier Harness
14. Run the return hose to the front side of the regulator/rectifier harness.
15. Return Hose (between Separator and Fuel Tank)
16. Separator
17. Breather Hose (between Separator and Canister)
18. Battery Negative (–) Lead
19. Run the Battery Negative (–) Lead to the upside of the breather hose and inside of the purge
hose.
17-70 APPENDIX
Cable, Wire, and Hose Routing
CAL and SEA-B1 Models
APPENDIX 17-71
Cable, Wire, and Hose Routing
1. Run the water hose, reserve tank overflow hose, purge hose in order from the outside of frame.
2. Purge Hose (between Canister and Fitting for Air Switching Valve)
3. Front
4. Reserve Tank Overflow Hose
5. Water Hose
6. Air Switching Valve Hose (between Air Cleaner and Fitting for Air Switching Valve)
7. Run the air switching valve hose to the upside of the stick coil lead.
8. Run the purge hose under the engine mount bracket.
9. Hold the water hose, purge hose in order the outside of frame with clamp.
10. Stick Coil Lead
17-72 APPENDIX
Cable, Wire, and Hose Routing
CAL and SEA-B1 Models
APPENDIX 17-73
Cable, Wire, and Hose Routing
1. Canister
2. Install the canister hose clamps with its tabs facing upward.
3. Main Relay Lead
4. Run the breather hose and purge hose to the under the main relay lead.
5. Breather Hose (between Canister and Separator)
6. Run the breather hose under the purge hose.
7. Run the breather hose and purge to the upside of the main harness and to the outside of the
starter motor cable.
8. Purge Hose (between Canister and Fitting for Air Switching Valve)
9. Starter Motor (+) Cable
10. Front
17-74 APPENDIX
Cable, Wire, and Hose Routing
CAL and SEA-B1 Models
APPENDIX 17-75
Cable, Wire, and Hose Routing
1. Air Switching Valve
2. Hoses
3. Fitting
4. Install the purge hose as shown in the direction.
5. Run the vacuum hose to the front side of the vacuum hose.
6. Vacuum Hose
7. Front
17-76 APPENDIX
Troubleshooting Guide
NOTE
○Refer to the Fuel System chapter for most
of DFI trouble shooting guide.
○This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:
Ignition and engine stop switch not ON
Starter lockout switch or neutral switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Starter system wiring shorted or open
Ignition switch trouble
Engine stop switch trouble
Main 30 A or ignition fuse blown
Starter motor rotating but engine doesn’t
turn over:
Vehicle-down sensor (DFI) coming off
Immobilizer system trouble (Equipped Models)
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 neutral
Battery voltage low
Immobilizer system trouble (Equipped Models)
Spark plug dirty, broken, or gap maladjusted
Spark plug incorrect
Stick coil shorted or not in good contact
Stick coil trouble
ECU trouble
Neutral, starter lockout, or sidestand switch
trouble
Crankshaft sensor trouble
Ignition switch or engine stop switch
shorted
Starter system wiring shorted or open
Main 30 A or ignition fuse blown
Fuel/air mixture incorrect:
Bypass screw and/or idle adjusting screw
maladjusted
Air passage clogged
Air cleaner clogged, poorly sealed, or missing
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,
worn, or carbon accumulation on the
seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Immobilizer system trouble (Equipped Models)
Stick coil trouble
Stick coil shorted or not in good contact
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
ECU trouble
Crankshaft sensor trouble
Fuel/air mixture incorrect:
Bypass screw maladjusted
Air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or missing
Fuel tank air vent obstructed
Fuel pump trouble
APPENDIX 17-77
Troubleshooting Guide
Throttle body assy holder loose
Air cleaner duct loose
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Camshaft cam worm
Run-on (dieseling):
Ignition switch trouble
Engine stop switch trouble
Fuel injector trouble
Loosen terminal of battery (–) cable or ECU
ground lead
Carbon accumulating on valve seating surface
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 missing
Air cleaner duct 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 facility 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 ignition switch ON and run the engine)
ECU trouble
Fuel/air mixture incorrect:
Throttle body assy holder loose
17-78 APPENDIX
Troubleshooting Guide
Air cleaner duct loose
Air cleaner poorly sealed, or missing
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Oil cooler incorrect:
Oil cooler clogged
Gauge incorrect:
Water temperature 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
No clutch lever play
Clutch inner cable trouble
Clutch release mechanism trouble
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
Clutch hub spline damaged
Clutch friction plate installed wrong
Clutch lever play excessive
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift pawl broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or broken
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 excessive
Connecting rod big end clearance excessive
Piston ring/groove clearance excessive
Piston ring worn, broken, or stuck
APPENDIX 17-79
Troubleshooting Guide
Piston ring groove worn
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
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)
Exhaust butterfly valve cable loose
Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Balancer rubber damper damaged
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
Clutch housing/friction plate clearance excessive
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 Indicator Light
(LED) 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:
Air cleaner duct 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 inadequate
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
17-80 APPENDIX
Troubleshooting Guide
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
cylinder
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery cable making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty
MODEL APPLICATION
Year
Model
2011
ZX1000GB
2011
ZX1000HB
2012
ZX1000GC
2012
ZX1000HC
Beginning Frame No.
JKAZXCG1□BA000001
JKAZXT00GGA000001
JKAZXCH1□BA000001
JKAZXT00GHA000001
JKAZXCG1□CA013001
JKAZXT00GGA013001
JKAZXCH1□CA003001
JKAZXT00GHA013001
□:This digit in the frame number changes from one machine to another.
Part No.99924-1442-02
Printed in Japan

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---