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VULCAN 1600 NOMAD VN1600 CLASSIC TOURER
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
VULCAN 1600 NOMAD VN1600 CLASSIC TOURER
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 Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
© 2004 Kawasaki Heavy Industries, Ltd.
First Edition (1) : Oct. 31, 2004 (M)
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) (mass) hour(s) liter(s)
lb m min N Pa PS psi r r/min, 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)
Read OWNER’S MANUAL before operating.
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 inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California 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 inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.
• • • •
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic 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 Special Tool Catalog or 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 these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury or loss of life.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of 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
1
Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................
1-2 1-7 1-9 1-12
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 wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (–) wire 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 or cotter pins 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 new gaskets and replace 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 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.
GENERAL INFORMATION 1-7 Model Identification VN1600-D1 (US and Canada) Left Side View
VN1600-D1 (US and Canada) Right Side View
1-8 GENERAL INFORMATION Model Identification VN1600-D1 (Europe) Left Side View
VN1600-D1 (Europe) Right Side View
GENERAL INFORMATION 1-9 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Fuel 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 Plugs Cylinder Numbering method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System
VN1600-D1 2 515 mm (99.02 in.) 1 040 mm (40.9 in.), (AU) 990 mm (39 in.) 1 460 mm (57.5 in.) 1 690 mm (66.5 in.) 150 mm (5.91 in.) 720 mm (28.3 in.) 350 kg (675 lb) 164 kg (362 lb) 213 kg (470 lb) 20 L (5.3 US gal) Unleaded and high-octane gasoline (see VN1600-D1 Owner’s Manual) 3.5 m (11.5 ft) 4-stroke, SOHC, V2-cylinder Liquid-cooled 102 × 95 mm (4.02 × 3.74 in.) 1 552 mL (94.70 cu in.) 9.0 : 1 49 kW (67 PS) @4 700 r/min (rpm), (CA) (CAL) (US) – – – 127 N·m (12.95 kgf·m, 93.7 ft·lb) @2 700 r/min (rpm), (CA) (CAL) (US) – – – DFI (Digital Fuel Injection) System Electric starter Battery and coil (transistorized) Electronically advanced (digital) From 5° BTDC @950 r/min (rpm) ∼ 25° BTDC @4 500 r/min (rpm) NGK DPR6EA-9 or ND X20EPR-U9 Front to Rear, 1-2 1-2
22° BTDC 66° ABDC 268° 66° BBDC 26° ATDC 272° Forced lubrication (wet sump)
1-10 GENERAL INFORMATION General Specifications Items Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th Final Drive System: Type Reduction Ratio Overall Drive Ratio Final Gear Case Oil: Grade Viscosity Capacity Frame Type Caster (Rake Angel) Trail Front Tire: Type Size Rear Tire: Type Size Front Suspension: Type Wheel travel Rear Suspension: Type Wheel travel
VN1600-D1 API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 3.5 L (3.7 US qt, when engine is completely disassembled and dry)
Gear 1.517 (85/56) Wet multi disc 5-speed, constant mesh, return shift 2.500 1.590 1.192 0.965 0.781
(40/16) (35/22) (31/26) (28/29) (25/32)
Shaft 2.619 (15/21 × 33/9) 3.105 @Top gear API Service Classification: GL-5 Hypoid gear oil SAE90 (above 5°C), SAE80 (below 5°C) 200 mL (6.76 US oz) Tubular, double cradle 32° 184 mm (7.24 in.) Tubeless 150/80 - 16 M/C 71H Tubeless 170/70B16 M/C 75H Telescopic fork 150 mm (5.91 in.) Swingarm, Shock absorber 99 mm (3.90 in.)
GENERAL INFORMATION 1-11 General Specifications Items Brake Type: Front Rear Electrical Equipment Battery: Capacity Headlight: Type Bulb Tail/Brake Light Alternator: Type Rated output
VN1600-D1 Dual disc Single disc
12 V 18 Ah Semi-sealed beam 12 V 60/55 W (quartz-halogen) 12 V 5/21 W Three-phase AC, twin rotor 42 A × 14 V @6 000 r/min (rpm)
Specifications subject to change without notice, and may not apply to every country. AU: Australia CA: Canada CAL: California US: United States of America
1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro
Symbol M k c m µ
Units of Length:
× × × × ×
Power 1 000 000 1 000 0.01 0.001 0.000001
Units of Mass: kg g
× ×
2.205 0.03527
= =
lb oz
km m mm
× × ×
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 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
= = = = = = = = =
gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in.
Units of Force: N N kg kg
× × × ×
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: = = = =
kgf lb N lb
kW kW PS PS
× × × ×
1.360 1.341 0.7355 0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance 2
Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Periodic Maintenance Procedures.......................................................................................... Fuel System......................................................................................................................... Air Cleaner Element Cleaning........................................................................................... Throttle Control System Inspection................................................................................... Idle Speed Inspection ....................................................................................................... Idle Speed Adjustment...................................................................................................... Choke Knob Operation ..................................................................................................... Fuel Hose Inspection (Fuel Leak, Damage, Installation Condition) .................................. Cooling System.................................................................................................................... Coolant Level Inspection................................................................................................... Radiator Hose Inspection (Coolant Leak, Damage, Installation Condition) ...................... Evaporative Emission Control System................................................................................. Evaporative Emission Control System Inspection (CAL) .................................................. Air Suction System .............................................................................................................. Air Suction System Damage Inspection............................................................................ Clutch and Drive Train ......................................................................................................... Clutch Operation Inspection.............................................................................................. Clutch Fluid Level Inspection ............................................................................................ Clutch Fluid Leak (Clutch Hose and Pipe) ........................................................................ Clutch Hose Damage and Installation Condition Inspection ............................................. Final Gear Case Oil Level Inspection ............................................................................... Wheel and Tires................................................................................................................... Tire Air Pressure Inspection.............................................................................................. Wheel/Tire Damage Inspection......................................................................................... Tire Tread Wear, Abnormal Wear Inspection .................................................................... Wheel Bearing Damage Inspection .................................................................................. Brakes System..................................................................................................................... Brake Fluid Leak (Brake Hose and Pipe).......................................................................... Brake Hose Damage and Installation Condition Inspection.............................................. Brake Pad Wear Inspection .............................................................................................. Brake Fluid Level Inspection............................................................................................. Brake Operation Inspection .............................................................................................. Brake Light Switch Operation ........................................................................................... Suspension .......................................................................................................................... Front Forks/Rear Shock Absorber Operation Inspection .................................................. Front Fork Oil Leak Inspection.......................................................................................... Rear Shock Absorber Oil Leak Inspection ....................................................................... Swingarm Pivot Lubrication .............................................................................................. Steering System .................................................................................................................. Steering Play Inspection ................................................................................................... Steering Play Adjustment.................................................................................................. Stem Bearing Lubrication..................................................................................................
2-3 2-6 2-13 2-15 2-16 2-16 2-16 2-16 2-17 2-17 2-18 2-18 2-19 2-19 2-19 2-20 2-20 2-21 2-21 2-21 2-21 2-22 2-22 2-22 2-23 2-24 2-24 2-24 2-24 2-25 2-25 2-25 2-26 2-26 2-26 2-27 2-27 2-28 2-28 2-29 2-29 2-29 2-30 2-30 2-30 2-31
2-2 PERIODIC MAINTENANCE Electrical System ................................................................................................................. Lights and Switches Operation ......................................................................................... Headlight Aiming Inspection ............................................................................................. Side Stand Switch Operation Inspection........................................................................... Engine Stop Switch Operation Inspection......................................................................... Others .................................................................................................................................. Chassis Parts Lubrication ................................................................................................. Bolts, Nuts and Fastener Tightness Inspection ................................................................ Replacement Parts .............................................................................................................. Air Cleaner Element Replacement.................................................................................... Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Fuel Hose Replacement ................................................................................................... Coolant Change ................................................................................................................ Radiator Hose and O-ring Replacement........................................................................... Brake Hose and Pipe Replacement.................................................................................. Brake Fluid Change .......................................................................................................... Brake Master Cylinder Rubber Parts Replacement .......................................................... Caliper Rubber Parts Replacement .................................................................................. Spark Plug Replacement .................................................................................................. Final Gear Case Oil Change............................................................................................. Clutch Hose and Pipe Replacement ................................................................................. Clutch Fluid Change ......................................................................................................... Clutch Master Cylinder Rubber Parts Replacement ......................................................... Clutch Slave Cylinder Piston Seal Replacement ..............................................................
2-32 2-32 2-34 2-36 2-37 2-37 2-37 2-38 2-40 2-40 2-41 2-42 2-43 2-44 2-47 2-48 2-48 2-50 2-51 2-55 2-56 2-56 2-57 2-58 2-59
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
* ODOMETER READING × 1 000 km (× 1 000 mile) 1
INSPECTION Fuel System
Every
6
12
year
Fuel leak (fuel hose and pipe) - inspect
year
Fuel hose and pipe damage - inspect
year year
Coolant level - inspect Coolant leak (radiator hose and pipe) inspect
year
Radiator hose damage - inspect
year
Radiator hose installation condition inspect Evaporative Emission Control System (CAL) Evaporative emission control system function - inspect Air Suction System
year
Clutch and Drive Train Clutch operation (play, disengagement, engagement) - inspect Clutch fluid level - inspect
6 months
Clutch fluid leak - inspect
year
Clutch hose damage - inspect
year
Clutch hose installation condition inspect
year
Final gear case oil level - inspect Wheels and Tires year
Wheel/tire damage - inspect Tire tread wear, abnormal wear - inspect Wheel bearing damage - inspect
year
36
• • • • •
• • • • •
• • • • •
• • • • • •
• • • •
• • • •
• • • •
• • • •
2-19
• • • • • • •
2-20
Air suction system damage - inspect
Tire air pressure - inspect
30
•
Idle speed - inspect
Fuel hose and pipe installation condition - inspect Cooling System
24
(0.6) (4) (7.5) (12) (15) (20) (24)
Air cleaner element - clean Throttle control system (play, smooth return, no drag) - inspect
18
See Page
• • • • •
• • • •
2-16 2-16 2-17 2-18 2-18 2-18
2-19 2-19 2-19
•
•
•
2-21
• • • • • •
• • • • • •
• • • • • •
2-21
• • • •
2-24
• • • •
• • • •
• • • •
• • • •
2-22 2-22 2-22 2-22 2-23
2-24 2-24 2-25
2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first
* ODOMETER READING × 1 000 km (× 1 000 mile) 1
INSPECTION Brake System Brake fluid leak (brake hose and pipe) - inspect
Every
Brake hose and pipe damage - inspect
year
year
Brake pad wear - inspect # Brake hose installation condition inspect Brake fluid level - inspect Brake operation (effectiveness, play, no drag) - inspect
year 6 months year
Brake light switch operation - inspect Suspensions Front forks/rear shock absorber operation (damping and smooth stroke) - inspect Front forks/rear shock absorber oil leak - inspect
6
12
• • • • • • • • • • • • • • • • • • • •
year
Steering stem bearings - lubricate
2 years year
Headlight aiming - inspect
year
Side stand switch operation - inspect
year
Engine stop switch operation - inspect
year
•
Others Chassis parts - lubricate Bolts and nuts tightness - inspect
36
year
•
• • • • • • •
• • • • • • •
• • • • • • •
• • • • • • •
2-25 2-26 2-26 2-26 2-26 2-27 2-27
•
•
2-28
•
• •
•
2-29
•
• •
•
2-30
• • • •
• • • •
• • • •
2-32
• •
• •
• •
2-37
Electrical System Lights and switches operation - inspect
30
•
Steering System year
24
(0.6) (4) (7.5) (12) (15) (20) (24)
Swingarm pivot - lubricate Steering play - inspect
18
See Page
2-29
2-31
2-34 2-36 2-37
2-38
*: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. CAL: California Model
PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever come first
* ODOMETER READING × 1 000 km (× 1 000 mile) 1
CHANGE/REPLACE ITEM
Every
12
(0.6) (7.5)
24
36
48
(15)
(24)
(30)
• •
• • •
Air cleaner element # Engine oil #
year
Oil filter
year
Fuel hose
4 years
Coolant
3 years
Radiator hose and O-ring
3 years
Brake hose and pipe
4 years
Brake fluid
2 years
Rubber parts of master cylinder and caliper
4 years
• •
• • •
Spark plug Final gear case oil Clutch hose and pipe
4 years
Clutch fluid
2 years
Clutch slave cylinder piston seal
4 years
• •
•
• •
• • •
• • •
See Page
2-40
• • •
2-41 2-42 2-43 2-44 2-47
• • • •
2-48
• • •
2-56
2-48 2-50 2-55 2-56 2-57 2-59
*: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.
2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease to the threads. L: Apply a non-permanent locking agent to the threads. LH: Left-hand-threads M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution (The molybdenum disulfide oil solution is a mixture of the engine oil and molybdenum disulfide grease weight ratio 10 :1). O: Apply oil to the threads and seating surface. R: Replacement parts S: Tighten the fasteners following the specified sequence. SI: Apply silicone grease (ex. PBC grease). SS: Apply silicone sealant. ST: Stake the fasteners to prevent loosening. WL: Apply a soap and water solution or rubber lubricant. Fastener Fuel System Air Cleaner Duct Holder Bolts Choke Cable Plate Screw Fuel Pump Mounting Bolts Inlet Air Temperature Sensor Nut Inlet Manifold Bolts ISC Pipe Holder Bolts Left Air Cleaner Base Bolt Left Air Cleaner Base Screws Left Air Cleaner Cover Allen Bolt Right Air Cleaner Allen Bolts Right Air Cleaner Base Bolt Right Air Cleaner Base Screws Right Air Cleaner Cover Allen Bolt Spark Plug Lead Holder Bolts Throttle Body Assy Holder Bolts Water Temperature Sensor Cooling System Radiator Drain Bolt Radiator Fan Bolts Radiator Fan Switch Water Hose Clamp Screws Water Pipe Bolts Water Pump Air Bleeder Bolt Water Pump Cover Bolts Water Pump Drain Bolt Water Pump Impeller Bolt Water Temperature Sensor
N·m
Torque kgf·m
ft·lb
10 2.9 9.8 7.8 12 11 11 2.2 16 11 11 2.2 16 11 11 18
1.0 0.30 1.0 0.80 1.2 1.1 1.1 0.22 1.6 1.1 1.1 0.22 1.6 1.1 1.1 1.8
89 in·lb 26 in·lb 87 in·lb 69 in·lb 104 in·lb 97 in·lb 97 in·lb 19 in·lb 12 97 in·lb 97 in·lb 19 in·lb 12 97 in·lb 97 in·lb 13
2.2 8.3 18 2.5 11 11 11 11 8.8 18
0.22 0.85 1.8 0.25 1.1 1.1 1.1 1.1 0.90 1.8
19 in·lb 73 in·lb 13 22 in·lb 97 in·lb 97 in·lb 97 in·lb 97 in·lb 78 in·lb 13
Remarks
L L, S
L
L
SS
LH SS
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Water Temperature Switch Engine Top End Air Suction Valve Cover Bolts Camshaft Chain Guide Bolts Camshaft Chain Guide Retainer Bolts Camshaft Sprocket Bolts Chain Tensioner Cap Chain Tensioner Lockbolts Chain Tensioner Mounting Bolts Cylinder Head Nuts Cylinder Nuts Exhaust Pipe Cover Clamp Screws Muffler Stay Mounting Bolts Oil Hose Flange Bolts Plugs Premuffler Chamber Bolts Rocker Case Bolts Rocker Case Cover Bolts Rocker Case Nuts (M12) Rocker Case Nuts (M8) Rocker Shafts Rotor Bolt Cap Spark Plug Retainers Spark Plugs Timing Inspection Cap Water Pipe Bolts Clutch Clutch Cover Bolts Clutch Damper Cover Bolts Clutch Damper Plate Bolt Clutch Hose Banjo Bolt (Upper) Clutch Hose Banjo Bolt (Lower) Clutch Hub Nut Clutch Lever Pivot Bolt Clutch Lever Pivot Bolt Locknut Clutch Master Cylinder Clamp Bolts Clutch Reservoir Cap Screws Clutch Slave Cylinder Bleed Valve Clutch Slave Cylinder Bolts Oil Filler Cap Starter Lockout Switch Screw Engine Lubrication System Oil Baffle Bolt
N·m 7.8
Torque kgf·m 0.80
ft·lb 69 in·lb
7.4 11 11 15 20 4.9 11 25 25 6.9 25 9.8 20 29 8.8 8.8 78 25 25 1.5 12 18 1.5 11
0.75 1.1 1.1 1.5 2.0 0.50 1.1 2.5 2.5 0.70 2.5 1.0 2.0 3.0 0.90 0.90 8.0 2.5 2.5 0.15 1.2 1.8 0.15 1.1
65 in·lb 97 in·lb 97 in·lb 11 15 43 in·lb 97 in·lb 18 18 61 in·lb 18 87 in·lb 15 21 78 in·lb 78 in·lb 58 18 18 13 in·lb 104 in·lb 13 13 in·lb 97 in·lb
11 9.8 9.8 25 25 145 1.0 5.9 11 1.5 7.8 6.9 1.5 1.2
1.1 1.0 1.0 2.5 2.5 14.8 0.10 0.60 1.1 0.15 0.80 0.70 0.15 0.12
97 in·lb 87 in·lb 87 in·lb 18 18 107 8.9 in·lb 52 in·lb 97 in·lb 13 in·lb 69 in·lb 61 in·lb 13 in·lb 11 in·lb
11
1.1
97 in·lb
Remarks SS
L L L S S S S S
L S S MO, S S M
L EO
MO SI S
L
L
2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Oil Drain Plug Oil Filter Oil Filter Pipe Oil Hose Banjo Bolt Oil Hose Flange Bolts Oil Hose Nozzle Oil Nozzles Oil Pipe Clamp Bolts Oil Pipe Holder Bolts Oil Pressure Switch Oil Pressure Switch Terminal Screw Oil Pump Mounting Bolts Oil Return Pipe Clamp Bolts Oil Screen Plug Relief Valve Engine Removal/Installation Downtube Bolts Engine Ground Terminal Bolt Engine Mounting Bracket Bolts Engine Mounting Nuts Crankshaft/Transmission Bearing Retainer Bolts Camshaft Chain Guide Bolts Camshaft Chain Guide Retainer Bolts Clutch Push Rod Guide Bolts Connecting Rod Big End Nuts Crankcase Bolt (M10, L = 115) Crankcase Bolts (M10, L = 105) Crankcase Bolts (M6, L = 80) Crankcase Bolts (M6, L = 70) Crankcase Bolts (M6, L = 40) Crankcase Bolts (M8) Damper Cam Nut Frame Ground Bracket Bolt Gear Set Lever Bolt Idle Shaft Holder Bolt Left Balancer Gear Bolt Oil Baffle Bolt Oil Drain Plug Oil Filter Oil Hose Nozzle Oil Nozzles Oil Pressure Switch
N·m 20 18 25 9.8 9.8 2.9 2.9 11 11 15 1.5 11 11 20 15
Torque kgf·m 2.0 1.8 2.5 1.0 1.0 0.30 0.30 1.1 1.1 1.5 0.15 1.1 1.1 2.0 1.5
ft·lb 15 13 18 87 in·lb 87 in·lb 26 in·lb 26 in·lb 97 in·lb 97 in·lb 11 13 in·lb 97 in·lb 97 in·lb 15 11
59 7.8 25 44
6.0 0.80 2.5 4.5
44 69 in·lb 18 32
11 11 11 11 59 39 39 11 11 11 21 195 11 11 8.3 85 11 20 18 2.9 2.9 15
1.1 1.1 1.1 1.1 6.0 4.0 4.0 1.1 1.1 1.1 2.1 20.0 1.1 1.1 0.85 8.5 1.1 2.0 1.8 0.30 0.30 1.5
97 in·lb 97 in·lb 97 in·lb 97 in·lb 44 29 29 97 in·lb 97 in·lb 97 in·lb 15 144 97 in·lb 97 in·lb 73 in·lb 63 97 in·lb 15 13 ft·lb 26 in·lb 26 in·lb 11
Remarks
EO, R SS
LH L L SS G L L
L L L L MO S S S S S S MO, R L
MO L EO, R LH SS
PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Oil Return Pipe Clamp Bolts Primary Gear Bolt Rear Shift Lever Clamp Bolt Shift Drum Bearing Holder Bolts Shift Drum Cam Bolt Shift Pedal Clamp Bolt Shift Rod Locknut (Front) Shift Rod Locknut (Rear) Shift Shaft Return Spring Pin Starter Clutch Bolt Starter Clutch Coupling Bolts Water Pump Chain Guide Bolt Water Pump Chain Guide Spring Hook Bolt Water Pump Drainage Hose Fitting Water Pump Impeller Bolt Wheels/Tires Front Axle Clamp Bolts Front Axle Shaft Front Brake Disc Bolts Muffler Stay Mounting Bolts Rear Axle Nut Rear Brake Disc Bolts Tire Air Valve Nuts Final Drive Bearing Retainer Bolts (Front Gear) Bearing Retainer Bolt (Final Gear) Damper Cam Nut Drive Gear Nut Driven Gear Assy Mounting Bolts Driven Gear Bolt Final Gear Case Cover Bolt (M10) Final Gear Case Cover Bolt (M8) Final Gear Case Drain Plug Final Gear Case Mounting Nut Front Gear Case Bolts (M8) Front Gear Case Bolts (M6) Neutral Switch Oil Nozzle (Front) Oil Nozzle (Right) Oil Pipe Banjo Bolts Pinion Gear Nut Speed Sensor Mounting Bolt
N·m 11 145 12 11 15 29 11 11 39 85 15 8.3 2.9 9.8 8.8
Torque kgf·m 1.1 14.5 1.2 1.1 1.5 3.0 1.1 1.1 4.0 8.7 1.5 0.85 0.30 1.0 0.90
ft·lb 97 in·lb 107 106 in·lb 97 in·lb 11 21 97 in·lb 97 in·lb 29 63 11 73 in·lb 26 in·lb 87 in·lb 78 in·lb
Remarks L MO L L
LH L MO L
LH
29 108 27 25 108 27 1.5
3.0 11.0 2.8 2.5 11.0 2.8 0.15
21 80 20 18 80 20 13 in·lb
AL
8.8 6.9 195 265 25 120 34 23 8.8 34 29 12 15 2.9 18 12 130 9.8
0.90 0.70 20.0 27.0 2.5 12.2 3.5 2.3 0.90 3.5 3.0 1.2 1.5 0.30 1.8 1.2 13.2 1.0
78 in·lb 61 in·lb 144 195 18 89 25 17 78 in·lb 25 21 106 in·lb 11 26 in·lb 13 106 in·lb 96 87 in·lb
L L MO, R MO, R, ST MO, R, ST L L
S S
MO, R, ST L
2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Brakes Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Pedal Clamp Bolt Front Brake Disc Bolts Front Brake Hose Banjo Bolt Front Brake Light Switch Screw Front Brake Reservoir Cap Screw Front Caliper Bleed Valves Front Caliper Mounting Bolts Front Footboard Bracket Bolts Front Master Cylinder Clamp Bolt Rear Brake Disc Bolts Rear Brake Hose Banjo Bolts Rear Caliper Bleed Valves Rear Caliper Holder Bolt Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Front Fork Inner Cover Bolts Front Fork Top Plugs Rear Shock Absorber Nuts Swingarm Pivot Shaft Steering Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Handlebar Clamp Bolts Handlebar Holder Nuts Steering Stem Head Nut Steering Stem Nut Frame Downtube Bolts Engine Mounting Bracket Bolts Front Footboard Bracket Bolts Rear Footboard Bracket Bolts Side Stand Nut Side Stand Switch Mounting Bolt Tandem Grip Mounting Bolts
N·m
Torque kgf·m
ft·lb
Remarks
1.0 5.9 25 27 34 1.2 1.5 7.8 34 34 8.8 27 25 7.8 64 34 25 18
0.10 0.60 2.5 2.8 3.5 0.12 0.15 0.80 3.5 3.5 0.90 2.8 2.5 0.80 6.5 3.5 2.5 1.8
8.9 in·lb 52 in·lb 18 20 25 11 in·lb 13 in·lb 69 in·lb 25 25 78 in·lb 20 18 69 in·lb 47 25 18 13
SI
29 30 29 29 4.0 22 34 127
3.0 3.1 3.0 3.0 0.40 2.2 3.5 13.0
21 22 21 21 35 in·lb 16 25 94
AL L
29 29 34 34 88 4.9
3.0 3.0 3.5 3.5 9.0 0.50
21 21 25 25 65 43 in·lb
59 25 34 25 44 8.8 25
6.0 2.5 3.5 2.5 4.5 0.90 2.5
44 18 25 18 32 78 in·lb 18
L
S L
AL
AL O, S
S
L
PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Fastener Electrical System Alternator Cover Bolts Alternator Inner Cover Bolts Alternator Outer Cover Assembly Bolts Alternator Outer Cover Bolts Alternator Outer Cover Damper Bolts Alternator Outer Cover Joint Bolts Alternator Rotor Bolt Alternator Stator Bolts Crankshaft Sensor Lead Holder Bolt Crankshaft Sensor Screws Front Brake Light Switch Screw Fuel Level Sensor Mounting Bolts Fuel Pump Mounting Bolts Headlight Rim Screws Headlight Unit Bracket Screws Inside Starter Holder Bolts Neutral Switch Oil Pressure Switch Oil Pressure Switch Terminal Screw Radiator Fan Bolts Radiator Fan Switch Regulator/Rectifier Bolts Rotor Bolt Cap Side Stand Switch Mounting Bolt Spark Plugs Speed Sensor Mounting Bolt Stater Lockout Switch Screw Stater Motor Assembly Bolts Stater Motor Mounting Bolts Stater Motor Terminal Locknut Stater Motor Terminal Nut Stator Lead Holder Screw Tail/Brake Light Assembly Screws Tail/Brake Light Lens Screws Tail/Brake Light Mounting Nuts Timing Inspection Cap Turn Signal Light Lens Screws Turn Signal Light Mounting Screws Water Temperature Sensor Water Temperature Switch
N·m 11 11 6.9 6.9 6.9 6.9 78 13 2.9 2.9 1.2 6.9 9.8 2.9 1.0 11 15 15 1.5 8.3 18 6.5 1.5 8.8 18 9.8 1.2 4.9 11 11 4.9 11 1.2 1.2 5.9 1.5 1.0 6.9 18 7.8
Torque kgf·m 1.1 1.1 0.70 0.70 0.70 0.70 8.0 1.3 0.30 0.30 0.12 0.70 1.0 0.30 0.10 1.1 1.5 1.5 0.15 0.85 1.8 0.66 0.15 0.90 1.8 1.0 0.12 0.50 1.1 1.1 0.50 1.1 0.12 0.12 0.60 0.15 0.10 0.70 1.8 0.80
ft·lb 97 in·lb 97 in·lb 61 in·lb 61 in·lb 61 in·lb 61 in·lb 58 115 in·lb 26 in·lb 26 in·lb 11 in·lb 61 in·lb 87 in·lb 26 in·lb 8.9 in·lb 97 in·lb 11 11 13 in·lb 73 in·lb 13 57 in·lb 13 in·lb 78 in·lb 13 87 in·lb 11 in·lb 43 in·lb 97 in·lb 97 in·lb 43 in·lb 97 in·lb 11 in·lb 11 in·lb 52 in·lb 13 in·lb 8.9 in·lb 61 in·lb 13 69 in·lb
Remarks
WL L L MO L L
L S L L SS G
L L
L
SS SS
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 dia. (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 Air Cleaner Element Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Clutch Clutch Fluid: Grade Clutch Lever Free Play Engine Lubrication System Engine Oil: Type Viscosity Capacity
Level Tires Tread Depth: Front
Rear
Standard
Service Limit
2 ∼ 3 mm (0.08 ∼ 0.12 in.) 950 ±50 r/min (rpm) Paper filter
– – – – – – – – –
Permanent type antifreeze Green Soft water 50%, Coolant 50% –35°C (–31°F) 2.3 L (2.4 US qt)
– – – – –
Non-adjustable (hydraulic lash adjusters)
– – –
DOT4 Non-adjustable
– – – – – –
API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.7 US qt, when engine is completely disassembled and dry) Between upper and lower level lines (Wait 2 ∼ 3 minutes after idling or running)
– – –
BRIDGESTONE EXEDRA G721: 4.5 mm (0.18 in.) BRIDGESTONE EXEDRA G722 G: 7.2 mm (0.28 in.)
Air Pressure: (When Cold) Front Up to 185 kg (408 lb) load: 225 kPa (2.25 kgf/cm², 32 psi) Rear Up to 185 kg (408 lb) load: 280 kPa (2.8 kgf/cm², 40 psi)
– – – –
– – – – –
– – – –
– – – – –
– – – –
– – –
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 (0.1 in.) – – – – – –
2-14 PERIODIC MAINTENANCE Specifications Item Final Drive Final Gear Case Oil: Grade Viscosity Oil Level Amount Brakes Brake Fluid: Grade Brake Pad Lining Thickness: Front Rear Brake Light Timing: Front Rear Electrical System Spark Plug: Type AT: Austria Model CH: Switzerland Model DE: Germany Model
Standard
API Service Classification: GL-5 hypoid gear oil When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Filler opening bottom 200 mL (6.76 US oz.)
DOT4
4.5 mm (0.18 in.) 7.0 mm (0.28 in.)
Service Limit
– – – – – – – – – – – –
– – –
1 mm (0.04 in.) 1 mm (0.04 in.)
Pulled ON ON after about 10 mm (0.39 in.) of pedal travel
– – – – – –
NGK DPR6EA-9, ND X20EPR-U9
– – –
PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: 57001-143
Oil Filter Wrench: 57001-1249
Steering Stem Nut Wrench: 57001-1100
Attachment Jack: 57001-1398
Jack: 57001-1238
Filler Cap Driver: 57001-1454
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Air Cleaner Element Cleaning NOTE
○In dusty areas, the element should be cleaned more frequently than the recommended interval.
○After riding through rain or on muddy roads, the element should be cleaned immediately.
• Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B] the element [A]. • Remove Push a clean, towel into the lower air cleaner duct • to keep dirt orlint-free other foreign material from entering.
WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. the element by tapping it lightly to loosen dust. • Clean Blow away the remaining dust by applying compressed • air [A] from the inside to the outside (from the clean side
• •
to the dirty side). Visually check the element for no tears or no breaks and check the sponge gasket [B] also. If the element or gasket has any tears or breaks, replace the element. Install the left air cleaner cover. Torque - Left Air Cleaner Cover Allen Bolt: 16 N·m (1.6 kgf·m, 12 ft·lb)
Throttle Control System Inspection Throttle Grip Play Inspection Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables.
•
Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
that the throttle grip moves smoothly from close to • Check full open, and the throttle closes quickly and completely
•
in all steering positions by the return spring. If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed doesn’t change. If the idle speed increases, check the throttle grip free play and the cable routing.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures necessary, adjust the throttle cable as follows: •○IfLoosen the locknuts [A] and screw the adjusters [B] all the
way in so as to give the throttle grip plenty of play. ○Turn out the adjuster of the decelerator cable [C] until there is no play. ○Tighten the locknut against the adjuster. ○Turn the adjuster of the accelerator cable [D] until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.
Idle Speed Inspection
the engine and warm it up thoroughly. •○Start At first the engine will run fast to decrease warm up time
(fast idle). ○Gradually the fast idle will lower to a certain RPM automatically. This is the idle speed. With the 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 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. the idle speed. • Check If the idle speed is out of the specified range, adjust it (see Idle Speed Adjustment in this chapter). Idle Speed Standard: 950 ±50 r/min (rpm)
Idle Speed Adjustment
the engine and warm it up thoroughly. •○Start Wait until fast idle speed lowers to a certain value. 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. Front [B]
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Choke Knob Operation
○Do not use the choke knob except when the engine has
a starting difficulty, like in cold weather (10°C or below) or at high altitude. The DFI system has an automatic choke system, using ISC valves, a water temperature sensor, and an atmospheric pressure sensor, which provide start ability.
NOTE
○Pull the choke knob [A] fully when using.
The choke lever [B] doesn’t work with the choke knob halfway.
Front [C] When flooded, do not crank the engine with the throt○ tle fully opened. This promotes engine flooding because more fuel is supplied automatically by the DFI system.
Fuel Hose Inspection (Fuel Leak, Damage, Installation Condition)
○The fuel hoses are designed to be used throughout the
• • •
motorcycle’s life without any maintenance, however, 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. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps are tightened correctly. When installing, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed. Replace the hose if it has been sharply bent or kinked.
PERIODIC MAINTENANCE 2-19 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 with the motor• Check cycle held upright. The coolant level should be between the “F” (full) level and the “L” (low) level (In the photo, the right side cover has been removed for clarity). Front [A] Reserve Tank [B] “F” Level [C] “L” Level [D] If the coolant level is lower than the “L” level, remove the right side cover and the reserve tank cap, then add coolant to the ”F” level.
CAUTION For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water 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 reserve 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 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 - Water Hose Clamp Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb)
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Evaporative Emission Control System Inspection (CAL)
the canister as follows: •○Inspect Remove the left side cover (see Left Side Cover Removal in the Frame chapter).
○Remove the band [A] and take out the canister [B]. ○Visually inspect the canister for cracks and other damage.
If the canister has any cracks or bad damage, replace it with a new one.
NOTE
○The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under normal conditions.
○Run
the purge hose (green) [A] above the canister breather hose (blue) [B] through the hole [C] into the tool case [D]. ○Do not run these hoses side by side on the battery side of the canister. This prevents hoses from being flattened when installing the left side cover. ○Install the canister and the left side cover (see Left Side Cover Installation in the Frame chapter). ○Face the white mark [E] left as shown. the liquid/vapor separator as follows: •○Check Disconnect the hoses from the separator, and remove the
separator [A] from the motorcycle right side. Front [B] ○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. ○Route 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 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.
•
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Air Suction System Air Suction System Damage Inspection
the vacuum switch hose [A] out of the right air cleaner • Pull base. the engine and run it at idle speed. • Start the vacuum switch hose end with your finger and feel • Plug vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the vacuum switch valve (see Vacuum Switch Valve Unit Test in the Engine Top End chapter). a soap and water solution or rubber lubricant to • Apply the end of the vacuum switch hose [A] and put the hose into the right air cleaner base [B] with the white mark [C] faced forward until the white mark aligns with the top of the grommet [D].
Clutch and Drive Train Clutch Operation Inspection
the engine idling, make sure that there is no noise • With or abnormally heavy feeling when pulling [A] in the clutch
•
lever fully. Also, make sure that the shift lever operates smoothly. When moving off the motorcycle by releasing the clutch lever gradually, make sure that the clutch does not slip and that the clutch engages smoothly. If the clutch operation is insufficiency, inspect the clutch system.
WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Level Inspection
the clutch fluid reservoir horizontal. • Hold Check clutch fluid level of the clutch reservoir is • betweenthatthethelower [A] and the upper [B] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir. ○Since the clutch fluid is the same as the brake fluid, refer to the Brake Fluid Level Inspection in this chapter for further details. Torque - Clutch Reservoir Cap Screws: kgf·m, 13 in·lb)
1.5 N·m (0.15
WARNING Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Mixing different types and brands of fluid lowers the fluid boiling point and could cause the clutch to be ineffective. It may also cause the rubber clutch parts to deteriorate.
Clutch Fluid Leak (Clutch Hose and Pipe)
the clutch lever and inspect the clutch fluid leak • Apply from the clutch hose [A] and fitting. If the clutch fluid leaked from any position, inspect or replace the problem part.
Clutch Hose Damage and Installation Condition Inspection
high pressure inside the clutch line can cause fluid • The to leak [A] or the hose to burst if the line is not properly
•
maintained. Bend and twist the rubber hose while examining it. Replace it if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and banjo bolts are tightened correctly. Torque - Clutch Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
installing the clutch hose, route the hoses accord• When ing to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked.
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Final Gear Case Oil Level Inspection
WARNING Motorcycle operation with insufficient, deteriorated, or contaminated oil causes accelerated wear and may result in seizure of the pinion and ring gears. Seizure can lock the rear wheel and skid the rear tire, with consequent less of control. the motorcycle perpendicular to the ground. • Support Remove left saddlebag (see Saddlebag Removal in • the Framethechapter). the left muffler clamp bolt. • Loosen Remove muffler stay mounting bolts [A]. • Lower thetheleftleftmuffler [B]. • • Unscrew the filler cap [A], using the filler cap driver [B]. Special Tool - Filler Cap Driver: 57001-1454
oil level [A] should come to the bottom of the filler • The opening.
•
If it is low, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case. Install the filler cap. Special Tool - Filler Cap Driver: 57001-1454
the left • Tighten mounting bolts.
muffler clamp bolts and muffler stay
Torque - Muffler Stay Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel and Tires Tire Air Pressure Inspection
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.) Adjust the tire air pressure according to the specifications if necessary. Air Pressure (When Cold) Front Up to 185 kg (408 lb)
225 kPa (2.25 kgf/cm², 32 psi)
Rear Up to 185 kg (408 lb)
280 kPa (2.8 kgf/cm², 40 psi)
WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. Use the same manufacture’s tires on both front and rear wheels.
NOTE
○Most countries may have their own regulations requiring a minimum tire tread depth; be sure to follow them. ○Check and balance the wheel when a tire is replaced with a new one (see Balance Inspection in the Wheels/Tires chapter).
Wheel/Tire Damage Inspection
any imbedded stones [A] or other foreign parti• Remove cles [B] from the tread. inspect the tire for cracks and cuts, replacing the • Visually tire in case of damage. Swelling or high spots indicate internal damage, requiring tire replacement.
Tire Tread Wear, Abnormal 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.
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures the tread depth at the center of the tread with a • Measure 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 and Installation in the Wheels/Tires chapter). Tread Depth Standard: Front
4.5 mm (0.18 in.)
Rear
7.2 mm (0.28 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 (0.1 in.): Over to 130 km/h (80 mph)
Wheel Bearing Damage Inspection
a jack and attachment, raise the front wheel off the • Using ground (see Front Wheel Removal in the Wheels/Tires
• • •
chapter). Turn the handlebar all the way to the left or right. Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. Spin [B] the front wheel lightly, and check for smoothly turn, roughness, binding or noise. If roughness, binding or noise is found, remove the front wheel and inspect the wheel bearing (see Hub Bearings Inspection in the Wheels/Tires chapter).
a jack and attachment, raise the rear wheel off the • Using ground (see Rear Wheel Removal in the Wheels/Tires
• •
chapter). Inspect the roughness of the rear wheel bearing by pushing and pulling [A] the wheel. Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Hub Bearings Inspection in the Wheels/Tires chapter) and coupling.
Brakes System Brake Fluid Leak (Brake Hose and Pipe)
the brake lever or pedal and inspect the brake fluid • Apply leak from the brake hoses [A] and fitting. If the brake fluid leaked from any position, inspect or replace the problem part.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Damage and Installation Condition Inspection the brake hose and • Inspect cracks and signs of leakage.
fittings for deterioration,
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose if any cracks [B] or bulges [C] are noticed. Tighten any loose fittings.
Brake Pad Wear Inspection
the brake pads (see Front and Rear Brake Pad • Remove Removal 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 (see Front and Rear Brake Pad Installation in the Brakes chapter). Pad Lining Thickness Standard: Front
4.5 mm (0.18 in.)
Rear
7.0 mm (0.28 in.)
Service Limit: 1 mm (0.04 in.)
Brake Fluid Level Inspection
that the brake fluid level in the front brake reservoir • Check [A] is above the lower [B] level line.
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 [A] in the reservoir [B].
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures that the brake fluid level in the rear brake reservoir • Check [A] is between the upper [B] and the lower [C] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line. ○Use extra heavy-duty brake fluid only from a container marked DOT4. ○Brake fluid of DOT4 is installed in the brake system when shipped.
WARNING Do not mix two brands of 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. After changing the fluid, use only the same type and brand of fluid thereafter.
• Install the front brake reservoir cap.
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the procedure below to install the rear brake reser• Follow voir cap correctly.
○First, tighten the rear brake reservoir cap [B] clockwise [C] by hand until the 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 rear brake reservoir body [A].
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 inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.
Brake Light Switch Operation
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.).
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures
•
If it does not, adjust the brake light switch. While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] Bottom View [E]
CAUTION 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 item. Battery (see Charging Condition Inspection in the Electrical System chapter) Brake Light Bulb (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 Electrical System chapter)
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.
the seat down and up [A] 4 or 5 times, and inspect • Pump the smooth stroke. If the shock absorber does not smoothly or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection in this chapter) or shock absorber mounting condition.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Front Fork Oil Leak Inspection
the bolts [A] on both sides and then slide the front • Remove fork inner covers downward.
inspect the front forks [A] for oil leakage, scoring • Visually or scratches on the outer surface of the inner tubes. Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
the Saddlebags (see Saddlebag Removal in the • Remove Frame chapter). inspect the shock absorbers [A] for oil leakage. • Visually If they are oil leaked, one unit feels weaker than the other,
•
replace both shock absorber as a set (see Rear Shock Absorber Removal and Installation in the Suspension chapter). Install the Saddlebags (see Saddlebag Installation in the Frame chapter)
Swingarm Pivot Lubrication
the swingarm (see Swingarm Removal in the • Remove Suspension chapter). the old grease out of the bearings. • Clean Apply grease to the inner surface of the needle bearings • [A]. a thin coat of grease to the lips [B] of the grease • Apply seals. the swingarm (see Swingarm Installation in the • Install Suspension chapter).
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering System Steering Play Inspection
steering as follows. •○Check Use the jack [A], the attachment jack [B] under the frame
pipe ribs [C], and a commercially available jack [D] under the engine [E] to lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
○With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully right and left 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 fork. If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the mo-
tion of the fork which must be taken into account. Be sure the wires 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
the stem head (see Steering Stem Removal in • Remove the Steering chapter). the claw washer. • Remove Adjust the nut [A] with the stem nut wrench [B] by • tightening tostem the specified torque. Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
the stem head (see Steering Stem Installation in • Install the Steering chapter). • Tighten the following in the order listed.
Torque - Stem Head Nut: 88 N·m (9.0 kgf·m, 65 ft·lb) Front Fork Clamp Bolts (Upper): 29 N·m (2.9 kgf·m, 21 ft·lb)
○Run the throttle cables, brake hose, and clutch hose in
•
accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. Check and adjust the steering and throttle cables after installation.
WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done.
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Stem Bearing Lubrication
the steering stem. (see Steering Stem Removal • Remove in the Steering chapter). a high-flash point solvent, wash the upper and • Using lower tapered roller bearings [A] in the cages, and wipe
• • •
the upper and lower outer races, which are press-fitted into the frame head pipe, clean of grease and dirt. Visually check the outer races and the rollers. If the rollers or races are worn, or if either race is dented, replace both races and all the roller bearings as a set (see Stem Bearing Installation in the Steering chapter). Pack the upper and lower tapered roller bearings in the cages with grease, and apply a light coat of grease to the upper and lower outer races. Install the steering stem, and adjust the steering (see Steering Stem Installation in the Steering chapter and Steering Play Adjustment in this chapter).
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation First Step Turn on the ignition switch. The following lights should go on according to below table.
• •
Models Position Lights [A] City Light [B]
United States
Canada Europe
goes on goes on –
–
Australia
–
–
goes on
–
Taillight [C]
goes on goes on goes on goes on
Licence Plate Light [D]
goes on goes on goes on goes on
Meter Panel LCD [E]
goes on goes on goes on goes on
Neutral Indicator LED [F] goes on goes on goes on goes on FI Indicator LED [G]
goes on goes on goes on goes on
Fuel Level Warning Indicator LED [H]
goes on goes on goes on goes on (about (about (about (about 2 sec- 2 sec- 2 sec- 2 seconds) onds) onds) onds)
• •
If the light does not go on, inspect or replace the following item. Battery (see Charging Condition Inspection in the Electrical System chapter) Applicable Bulb (see Wiring Diagram in the Electrical System chapter) Meter Unit for Meter Panel LCD (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Neutral Indicator LED (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Fuel Level Warning Indicator LED (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for FI Indicator LED (see Meter Unit Inspection in the Electrical System chapter) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter) Headlight Fuse 10A (see Fuse Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) Turn off the ignition switch. The all lights should go off. If the light does not go off, replace the ignition switch.
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Second Step Turn the ignition switch to P (Park) position. The 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)
• •
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 [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) Turn Signal Light Indicator Bulb (see Meter Unit Assembly in the Electrical System chapter) Turn Signal Control Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Turn Signal Switch (see Turn Signal Switch Electrical System chapter) Turn Signal Control Relay (see Turn Signal Control Relay Inspection Electrical System chapter) Harness (see Wiring Inspection in the Electrical System Inspection in the chapter) Push the turn signal switch. The turn signal lights and indicator light should go off. If the light does not go off, inspect or replace the following item. Turn Signal Switch (see Turn Signal Switch Inspection in the Electrical System chapter) Turn Signal Control Relay (see Turn Signal Control Relay Inspection in the Electrical System chapter)
• • •
• •
NOTE
○Refer to the Electrical system chapter for the automatic turn signal canceling system. 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 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)
• • •
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures the dimmer switch to high beam position. • Set The high beam headlight should go on. • The high indicator light [A] should go on. • If the highbeam beam headlight and/or high beam indicator light
• •
• •
does not go on, inspect or replace the following item. Headlight Bulb (see Headlight Bulb Replacement 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 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 should go off.
Headlight Aiming Inspection
the headlight beam for aiming. • Inspect If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight Beam Horizontal Adjustment Turn the horizontal adjuster [A] on the headlight with a screwdriver in or out until the beam points straight ahead. ○Turn the adjuster clockwise to face the headlight to the left.
•
If the headlight beam points too low or high, adjust the vertical beam. Headlight Beam Vertical Adjustment Turn the vertical adjuster [A] in the headlight in or out with a screwdriver to adjust the headlight vertically. ○Turn the adjuster clockwise to face the headlight up.
•
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures 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. ○For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2.0 in.) drop at 7.6 m (24.93 ft.) measured from the center of the headlight with the motorcycle on its wheels and the rider seated. 50 mm (2.0 in.) [A] Center of Brightest Spot [B] 7.6 m (24.93 ft.) [C]
2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Side Stand Switch Operation Inspection
the side stand switch [A] operation accordance to • Inspect below table. Side stand Switch Operation Side Stand
Gear Position
Clutch Lever
Engine Start
Engine Run
Up
Neutral
Released
Starts
Continue running
Up
Neutral
Pulled in
Starts
Continue running
Up
In Gear
Released
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
If the side stand 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 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Side Stand Switch (see Switch Inspection in the 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 Control Relay (see Starter Relay Inspection in the Electrical System chapter) Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Starter Control Relay (see Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) If the all parts are good condition, replace the ECU.
PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step Turn on the ignition switch. Set the neutral position. Turn the engine stop switch [A] to stop position. Push the start 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. Push the start 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 Electrical System chapter) If the engine stop switch is good condition, replace the ECU.
• • • • • •
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 Motor Oil. Rear Brake Rod Joint Points: Lubricate with Grease. Throttle Inner Cable Upper Ends [A] Clutch Lever Pivot (Apply silicone grease) Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Side stand
2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cable: Lubricate with Cable Lubricant. Choke 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.
•
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.
Bolts, Nuts and Fastener 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 in this chapter. For each fastener, first loosen it by 1/2 turn, then tighten it. If cotter pins are damaged, replace them with new ones.
PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Wheels: Front Axle Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin Front and Rear Fender Mounting Bolts Final Drive: Final Gear Case Mounting Nuts Brakes: Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Caliper Holder Bolt Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Suspension: Front Fork Clamp Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Steering: Stem Head Nut Handlebar Clamp Bolts Engine: Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Shift Pedal Bolts Muffler Stay Mounting Bolts Exhaust Pipe Holder Nuts Clutch Master Cylinder Clamp Bolts Clutch Lever Pivot Nut Radiator Mounting Bolt Radiator Bracket Bolts Others: Side stand Bolt and Nut Front and Rear Footboard Bracket Bolts Tandem Grip Mounting Bolts Downtube Bolts Windshield Bolts Saddlebag Bolts
2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement
WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
• Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B]
the element [A]. • Remove Push a clean, towel into the lower air cleaner duct • to keep dirt orlint-free other foreign material from entering.
the air cleaner element with a new one. • Replace Install a new • facing outside.element [A] with the smaller gasket [B] side
CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-1305). Using another air cleaner element will wear the engine prematurely or lower the engine performance.
PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Engine Oil Change
the motorcycle so that it is vertical after warming • Situate up the engine. • Remove the engine oil drain plug [A] and drain the oil.
• Remove: Oil Screen Plug [A] (Right Side)
the oil screen [A], the spring [B], and the washer • Remove [C]. the oil screen with a high-flash point solvent and • Clean remove any particles stuck to it. the screen thoroughly whenever the engine oil is • Clean changed.
WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents.
NOTE
○While cleaning the screen, check for any metal particles that might indicate internal engine damage.
the screen carefully for any damage: • Check broken wires.
• •
holes and
If the screen is damaged, replace it. Be sure to put in the oil screen with the rubber gasket end inside. Replace the screen plug O-ring with new one. Torque - Oil Screen Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)
○The oil in the filter can be drained by removing the filter
•
(see Oil Filter Replacement in this chapter). Replace the drain plug gasket with a new one.
Torque - Engine Oil Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb) Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)
2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures the oil filler cap [A] with the filler cap driver [B] • Remove and pour in the specified type and amount of oil. Clutch Cover [C] Special Tool - Filler Cap Driver: 57001-1454 Torque - Oil Filler Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb)
Engine Oil Type:
API SE, SF or SG API SH or SJ with JASO MA
Viscosity: SAE 10W-40 Amount:
2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.7 US qt, when engine is completely disassembled and dry)
NOTE
○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.
Oil Filter Replacement
the engine oil (see Engine Oil Change in this chap• Drain ter). the oil filter [A] with the oil filter wrench [B] and • Remove discard the oil filter. Special Tool - Oil Filter Wrench: 57001-1249
NOTE
○The filter has an oil filter bypass valve which can not be removed. the oil filter with a new one. • Replace Apply engine • installation. oil to the gasket [A] of the new filter before • Tighten the filter with the oil filter wrench. Special Tool - Oil Filter Wrench: 57001-1249
Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)
in the specified type and amount of oil (see Engine • Pour Oil Change in this chapter).
PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Fuel Hose Replacement
the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). • Disconnect the #2 fuel injector connector [A].
the lock of the fuel hose joint #2 with fingers, dis• Pinch connect the joint [A] and take out the fuel hose assy [B]. Front [C]
WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage. the fuel hose with a new one. • Replace the fuel hose joint #2 [A] onto the pipe (for delivery • Fit joint) until the joint clicks [B].
○Insert the hose joint straight along the pipe. Front [C]
and pull [A] the fuel hose joint #2 [B] back and • Push forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.
• • • •
If it comes off, reinstall the hose joint. Connect the #2 fuel injector connector. Run the fuel hose in accordance with the Cable, Wire and Hose Routing section in the Appendix chapter. Install the fuel tank (see Fuel Tank Installation in the Fuel System (DFI) chapter). Start the engine and check the fuel hose for leaks.
2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change
WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury. Since coolant is harmful to the human body, do not use for drinking. a container under the radiator drain bolt [A], then • Place remove the drain bolt. the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) 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. Front [B]
the water pump drain bolt [A]. The remaining • Remove coolant will drain from the water pump [B].
○Place a conduit under the drain hole of the pump cover. The conduit leads to a container. Front [C]
• Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) Coolant Reservoir Tank Bolts [A]
PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures over the reservoir tank [A], remove the cap [B], and • Turn pour the coolant into a suitable container. • Install the reservoir tank.
CAUTION
Soft or distilled water must be used with the antifreeze (see Specifications in this chapter) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Water and Coolant Mixture Ratio (Recommended) : 50% Soft Water Coolant
: 50%
Freezing Point
: –35°C (–31°F)
Total Amount
: 2.3 L (2.4 US qt)
• Tighten the drain bolts.
Torque - Radiator Drain Bolt: 2.2 N·m (0.22 kgf·m, 19 in·lb) Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
• Fill the coolant into the radiator. ○Choose
NOTE
a suitable mixture ratio by referring to the coolant manufacturer’s directions. ○Fill in the coolant slowly so that it can expel the air from the engine and radiator.
• Check the cooling system for leaks. the air from the water pump [A]. •○Bleed Loosen the air bleeder bolt [B] until the coolant seeps out around the bolt, then tighten it.
Torque - Water Pump Air Bleeder Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
the radiator hoses to force any air bubbles caught • Tap inside. the radiator up to the filler neck [A] with coolant. • Fill • Install the radiator cap.
2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures the reservoir tank up to the “F” (full) level line [A] with • Fill coolant and install the cap. the fuel tank (see Fuel Tank Installation in the Fuel • Install System (DFI) chapter). the engine and warm it up thoroughly until the radi• Start ator fan turns on and then stop the engine. the coolant level in the reserve tank several times • Check while the engine is cooling down, and replenish as necessary. If the coolant level is lower than the “L” level line, add coolant to the “F” level line.
CAUTION Do not add more coolant above the “F” level line.
PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Radiator Hose and O-ring Replacement
the coolant (see Coolant Change in the Periodic Maintenance chapter). • Drain Remove: • Thermostat Housing [A] with Bracket [B] (see Thermostat Removal in the Cooling System chapter)
• • • •
Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Right Side Cover (see Right Side Cover Removal in the Frame chapter) Loosen the radiator hose clamps and remove the hoses [C]. Unscrew the bolts and remove the water pipes [D] and O-rings [E]. Apply grease to the new O-ring and install the water pipes. Torque the water pipe bolts [F]. Torque - Water Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the new radiator hose and tighten the hose clamps securely. Torque - Water Hose Clamp Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb)
the coolant (see Coolant Change in this chapter). • Fill Check the cooling system for leaks. •
2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. removing the brake hose, take care not to spill the • When brake fluid on the painted or plastic parts. removing the brake hose [A], temporarily secure • When the end of the brake hose to some high place to keep
• • • •
fluid loss to a minimum. Install new brake hoses and pipes. Immediately wash away any brake fluid that spills. There are washers [B] on each side of the brake hose fitting. Replace them with new ones when installing. Tighten the banjo bolts [C] on the hose fittings. Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18.0 ft·lb)
installing the hoses [A], avoid sharp bending, kink• When ing, flattening 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 in this chapter).
Brake Fluid Change NOTE
○The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is almost the same as for the front brake.
the brake fluid reservoir. • Level • Remove: Reservoir Cap [A] Plate [B] Diaphragm [C]
PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures the rubber cap from the bleed valve [A] on the • Remove front caliper [B]. a clear plastic hose [C] 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 as follows: •○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 chang-
ing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line. ○Front Brake: Repeat the above steps for the other caliper.
the clear plastic hose. • Remove Install the brake reservoir cap. • Tighten thefront bleed valves, and install the rubber caps. •
Torque - Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) Front Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the procedure below to install the rear brake reser• Follow voir cap correctly.
○First, tighten the rear brake reservoir cap [B] clockwise
[C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [D] while holding the rear brake reservoir [A] body.
2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures
○For the rear brake caliper [A], change the brake fluid for
•
two bleed valves [B]. After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage. If necessary, bleed the air from the lines (see Brake Line Bleeding in the Brakes chapter).
Brake 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 reservoir cap [A], plate [B] and diaphragm [C]. Unscrew the locknut [D] and pivot bolt [E], and remove the brake lever. Pull the dust cover [F] out of place, and remove the circlip [G].
• • • •
Special Tool - Inside Circlip Pliers: 57001-143
out the piston assy [H] (piston [I], primary cup [J], • Pull secondary cup [K]), and return spring [L]. • Replace: Piston Assy Dust Cover Diaphragm Circlip
Rear Master Cylinder Disassembly
NOTE
○Do not remove the push rod clevis [A] for master cylinder disassembly since removal requires brake pedal position adjustment.
the rear master cylinder (see Rear Master Cylin• Remove der Removal in the Brakes chapter). the reservoir cap [B] plate [C] and diaphragm [D]. • Remove Slide the cover [E] on the push rod out of place, and • remove thedustcirclip [F]. Special Tool - Inside Circlip Pliers: 57001-143
out the push rod with the piston stop. • Pull Take off the piston assy [G] (piston [H] primary cup [I], • secondary cup [J]), and return spring [K]. Replace: • Piston Assy Dust Cover Brake Hose [L] Diaphragm O-ring [M] Circlips
PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Master Cylinder Assembly Before assembly, clean all parts including the master cylinder with brake fluid or alcohol.
•
CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake. brake fluid to the removed parts and to the inner • Apply wall of the cylinder. care not to scratch the piston or the inner wall of the • Take cylinder.
CAUTION Do not remove the secondary cup from the piston since removal will damage it.
• Tighten the brake lever pivot bolt and the locknut. Silicone Grease -
Brake Lever Pivot Bolt, Brake Lever Pivot Contact, Push Rod Contact, Dust Cover
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.7 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 Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Cotter Pin [A] Pin [B] Pads [C] Push the piston in.
•
•
• Remove: Pad Springs [A] Caliper Holder [B]
2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures
• Using compressed air, remove the piston. WARNING
To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
○Insert a wooden board [A] 5 mm (0.2 in.) thick inside the
caliper opening. ○Apply compressed air [B] to the banjo bolt hole to allow the pistons [C] to protrude and stop at the wooden board. ○Remove the wooden board and pull out the piston by hand. If compressed air is not available, with the brake hose still attached, apply the brake lever to remove the pistons. The remaining process is as described above.
• Remove: Dust Seals [A] Fluid Seals (Piston Seals) [B] Friction Boot [C] Bleed Valve
CAUTION Immediately wash away any brake fluid that spills.
Front Caliper Assembly Clean all parts other than the outer and inner pads.
•
CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.
• Install the bleed valve [A] and the rubber cap [B].
Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the fluid seals [A] with new ones, apply brake • Replace fluid to them, and install them in the caliper body. Either
•
side of the fluid seal may face outboard. Check the dust seals [B] and replace them with new ones if they are damaged.
PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures brake fluid to the inside of the cylinders and to the • Apply outside of the pistons and push the pistons [A] into the
• •
cylinders. Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged. Apply a thin coat of silicon grease to the holder shafts [D] and the holder holes.
the pad springs [A]. • Install Install pads (see Front Brake Pad Installation in the • Brakesthechapter). the caliper with water to remove brake fluid and • Wash wipe it off.
Rear Caliper Disassembly Remove the rear caliper with the hose installed (see Rear Caliper Removal in the Brakes chapter). Remove the pads (see Rear Brake Pad Removal in the Brakes chapter).
• •
• Pull out the caliper holder [A].
a wooden board [A] 5 mm (0.2 in.) thick inside the • Insert caliper opening. the brake pedal until the pistons [B] push the • Pump wooden board.
2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures the board and pull out the pistons [A] by hand. •○Remove These pistons can also be removed by disconnecting the
hose and applying compressed air to the hose joint opening using the same wooden board. But be careful not to put your fingers or palm inside the caliper opening during work.
WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the pistons may crush your hand or fingers.
CAUTION Immediately wash away any brake fluid that spills.
• Remove: Anti Rattle Spring [A] Dust Seals [B] and Fluid Seals [C] Rubber Friction Boots [D] Bleed Valves [E] and Rubber Caps [F]
Rear Caliper Assembly Tighten the bleed valve.
•
Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
○It is recommended that the fluid seal (piston seal) which
• •
is removed, be replaced with a new one. Replace the dust seals [A] if they are damaged. Install the fluid seal [B]. Either side of the seal may face outboard.
the antirattle spring [A] in the caliper as shown. • Install brake fluid to the cylinders, pistons, and fluid seals • Apply (piston seals), and push the pistons into the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched.
PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures the caliper holder shaft rubber friction boot [A] • Replace and dust boot [B] if they are damaged. a thin coat of silicone or PBC grease to the caliper • Apply holder shafts [C] and holder holes (Silicone or PBC
•
grease is a special high temperature, water-resistance grease). Install the pads (see Rear Brake Pad Installation in the Brakes chapter).
Spark Plug Replacement
• Remove: Fuel Tank (for Rear Spark Plug, see Fuel System chap•
ter) Spark Plug Caps [A] Remove the spark plug using the 18 mm (0.7 in.) plug wrench vertically. Special Tool - Spark Plug Wrench, Hex18: 57001-1024
CAUTION The insulator [A] of the spark plug may break if when the wrench is inclined during loosening. Inclined Spark Plug Wrench [B] Contact (Spark Plug and Plug Wrench) [C] Bad [D] Vertically Spark Plug Wrench [E] Good [F]
• Replace the spark plug with a new one. Standard Spark Plug Type: NGK DPR6EA-9 or ND X20EPR-UP
new spark plug in the plug hole, and finger-tighten • Insert it first. • Using the plug wrench [A] vertically, tighten the plug.
CAUTION
The insulator of the spark plug may break if when the wrench is inclined during tightening. Special Tool - Spark Plug Wrench, Hex18: 57001-1024 Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)
the spark plug caps securely. •○Install Be sure the spark plug caps are installed by pulling up it lightly.
2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Gear Case Oil Change
the left saddlebag (see Saddlebag Removal in • Remove the Frame chapter). up the oil by running the motorcycle so that the • Warm oil will pick up any sediment and drain easily. Stop the
•
motorcycle and turn the ignition switch OFF. Place an oil pan beneath the final gear case, and remove the filler cap and drain plug [A].
WARNING When draining or filling the final gear case, be careful that no oil gets on the tire, spoke, or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent. the oil has completely drained out, install the drain • After plug with a new gasket. Torque - Final Gear Case Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Fill the final gear case with the specified oil and quantity. Final Gear Case Oil Amount: 200 mL (6.76 US oz) Grade:
API GL-5 hypoid gear oil
Viscosity:
When above 5°C (41°F) SAE 90 When below 5°C (41°F) SAE 80
NOTE
○The term “GL-5” indicates a quality and additive rating. A “GL-6” rated hypoid gear oil can also be used.
sure the O-ring is in place, and install the filler plug. • Be Install the left saddlebag (see Saddlebag Installation in • the Frame chapter).
Clutch Hose and Pipe Replacement
○Since the clutch hose is the same as the brake hose, refer to the Brake Hose Replacement in this chapter for clutch hose and Pipe Replacement.
PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Clutch Fluid Change
the clutch fluid reservoir and remove the reservoir • Level cap. the alternator outer cover (see Alternator Outer • Remove Cover Removal in the Electrical System chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder. Attach a clear plastic hose [A] to the bleed valve and run the other end of the hose into a container. Fill the reservoir with fresh fluid. Change the clutch fluid as follows. 1. Open [B] the bleed valve, using a wrench. 2. Pump the clutch lever and hold [C] it. 3. Close [D] the bleed valve. 4. Release [E] the clutch lever. ○Repeat this operation until fresh fluid comes out from the plastic hose or the color of the fluid changes. ○Check the fluid level in the reservoir often, replenishing it as necessary.
• • •
NOTE
○If the fluid in the reservoir runs completely out any time during fluid changing, the bleeding operation must be done over again from the beginning since air will have entered the line.
WARNING Do not mix two brands of fluid. changing the fluid, check the clutch for good clutch • After power and no fluid leakage.
• • •
If necessary, bleed the air from the lines (see Clutch Line Bleeding in the Clutch chapter). Remove the clear plastic hose. Install the reservoir cap. Tighten the bleed valve, and install the rubber cap. Torque - Clutch Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Master Cylinder Rubber Parts Replacement
the clutch master cylinder (see Clutch Master • Remove Cylinder Removal in the Clutch chapter). the reservoir cap [A] and diaphragm [B], and • Remove pour the clutch fluid into a container. the locknut [C] and pivot bolt [D], and remove • Unscrew the clutch lever [E]. the dust cover [F] out of place, and remove the circlip • Pull [G]. Special Tool - Inside Circlip Pliers: 57001-143
out the piston assy [H] (primary cup [I], piston [J], • Pull secondary cup [K]), and return spring [L]. • Replace: Piston Assy Dust Cover Diaphragm Circlip
CAUTION Do not remove the secondary cup from the piston since removal will damage it. the parts of the clutch master cylinder (see Clutch • Check Master Cylinder Inspection in the Clutch chapter). If any part shows signs of damage, replace it. assembly, clean all parts including the master • Before cylinder with clutch fluid or alcohol.
CAUTION Use only disc brake fluid, isopropyl alcohol or ethyl alcohol, for cleaning parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil or any other petroleum distillate will cause 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 cylinder. clutch fluid to the parts removed and to the inner • Apply wall of the cylinder. care not to scratch the piston or the inner wall of the • Take cylinder. the push rod with the dust seal fitted into the • Install groove.
○The push rod round end must be faced inwards.
Torque - Clutch Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9 in·lb) Clutch Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb)
the clutch master cylinder (see Clutch Master Cylin• Install der Installation in the Clutch chapter).
PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement
the alternator outer cover (see Alternator Outer • Remove Cover Removal in the Electrical System). the banjo bolt [A] at the clutch pipe lower end, and • Loosen tighten it loosely. the slave cylinder bolts [B] and detach the slave • Unscrew cylinder with the pipe installed from the engine. the clutch lever until the piston comes out of the • Pump cylinder. • Unscrew the banjo bolt and remove the slave cylinder [C].
CAUTION
Immediately wash away any clutch fluid that spills. It may damage painted surfaces.
NOTE
○If the clutch slave cylinder is removed and left alone, the piston will be pushed out by spring force.
• Remove: Piston [A] Piston Seal [B] Spring [C]
the piston seal with a new one. • Replace Before assembly, apply clutch fluid to the outside of the • piston and the piston seal. Install the piston seal as shown. • Cylinder [A] Piston [B] Piston Seal [C] Spring [D]
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI) Table of Contents Exploded View................................... DFI System........................................ DFI Parts Location............................. DFI Wiring Diagram ........................... Specifications .................................... Special Tools and Sealant ................. DFI Servicing Precautions ................. Troubleshooting the DFI System ....... Outline ............................................ Inquiries to Rider............................. DFI System Troubleshooting Guide .. Self-Diagnosis ................................... Self-diagnosis Procedures ........... Service Code Reading ................. Service Code Erasing .................. Throttle Sensor (Service Code 11) .... Removal/Adjustment.................... Input Voltage Inspection............... Output Voltage Inspection............ Resistance Inspection.................. Inlet Air Pressure Sensor (Service Code 12) ......................................... Removal....................................... Installation.................................... Input Voltage Inspection............... Output Voltage Inspection............ Inlet Air Temperature Sensor (Service Code 13) ......................................... Removal/Installation..................... Output Voltage Inspection............ Resistance Inspection.................. Water Temperature Sensor (Service Code 14) ......................................... Removal/Installation..................... Output Voltage Inspection............ Resistance Inspection.................. Atmospheric Pressure Sensor (Service Code 15)........................... Removal....................................... Installation.................................... Input Voltage Inspection............... Output Voltage Inspection............ Crankshaft Sensors (#1, #2: Service Code 21, 22) ................................... Crankshaft Sensor Removal/Installation..................
3-4 3-8 3-10 3-14 3-18 3-20 3-21 3-22 3-22 3-27 3-30 3-39 3-39 3-40 3-41 3-45 3-45 3-45 3-45 3-46 3-48 3-48 3-48 3-48 3-49 3-54 3-54 3-54 3-55 3-56 3-56 3-56 3-57 3-58 3-58 3-58 3-58 3-59 3-62 3-62
Crankshaft Sensor Inspection...... Vehicle-down Sensor (Service Code 31)................................................... Removal....................................... Installation.................................... Vehicle-down Sensor Inspection.. Fuel Injectors (#1, #2: Service Code 41, 42)............................................. Injector Removal .......................... Injector Installation ....................... Audible Inspection........................ Power Source Voltage Inspection Output Voltage Inspection............ Injector Signal Test....................... Injector Resistance Inspection ..... Injector Unit Test .......................... Fuel Pump (Service Code 45) ........... Fuel Pump Removal .................... Fuel Pump Installation ................. Pressure Regulator Removal....... Pump Screen, Fuel Filter Cleaning .................................... Operation Inspection.................... Operating Voltage Inspection....... Power Source Voltage Inspection Ignition Coils (#1, #2: Service Code 51, 52)............................................. Removal/Installation..................... Input Voltage Inspection............... FI Indicator LED Light........................ LED Light Inspection.................... ECU ................................................... ECU Identification ........................ ECU Removal .............................. ECU Installation ........................... ECU Power Supply Inspection..... DFI Power Source ............................. DFI Fuse Removal ....................... DFI Fuse Inspection..................... DFI Main Relay Removal ............. DFI Main Relay Inspection........... ISC Valves ......................................... Removal/Installation..................... Power Source Voltage Inspection Output Voltage Inspection............ Resistance Inspection..................
3-62 3-63 3-63 3-64 3-64 3-67 3-67 3-68 3-70 3-70 3-71 3-72 3-72 3-73 3-74 3-74 3-74 3-75 3-75 3-75 3-76 3-77 3-79 3-79 3-79 3-80 3-81 3-82 3-82 3-82 3-83 3-83 3-85 3-85 3-85 3-85 3-85 3-87 3-87 3-87 3-88 3-88
3
3-2 FUEL SYSTEM (DFI) Fuel Line............................................ Fuel Pressure Inspection ............. Fuel Flow Rate Inspection ........... Throttle Grip and Cables ................... Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment ................................ Choke Knob Operation ................ Choke Cable Free Play Inspection.................................. Cable Removal/Installation .......... Cable Lubrication and Inspection. Throttle Body Assy ............................ Idle Speed Check......................... Idle Speed Adjustment................. High Altitude Performance Adjustment ................................ Throttle Body Assy Removal........ Throttle Body Assy Installation..... Throttle Body Assy Disassembly/Assembly ............. Air Cleaner......................................... Air Cleaner Element Removal......
3-90 3-90 3-92 3-94 3-94 3-94 3-94 3-94 3-94 3-94 3-95 3-95 3-95 3-95 3-95 3-98 3-99 3-102 3-102
Air Cleaner Element Cleaning...... Left Air Cleaner Housing Removal/Installation.................. Right Air Cleaner Housing Removal .................................... Right Air Cleaner Housing Installation ................................. Lower Air Cleaner Duct Removal/Installation.................. Fuel Tank ........................................... Fuel Tank Removal ...................... Fuel Tank Installation ................... Fuel Tank and Cap Inspection ..... Fuel Tank Cleaning ...................... Evaporative Emission Control System............................................ Parts Removal/Installation ........... Canister Installation ..................... Canister Inspection ...................... Separator Inspection.................... Hose Inspection ........................... Separator Operation Test.............
3-102 3-102 3-103 3-103 3-104 3-105 3-105 3-108 3-109 3-110 3-111 3-111 3-111 3-111 3-111 3-112 3-112
FUEL SYSTEM (DFI) 3-3 Dummy Page
3-4 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-5 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11
Fastener Air Cleaner Duct Holder Bolts Left Air Cleaner Base Bolt Left Air Cleaner Base Screws Left Air Cleaner Cover Allen Bolt Right Air Cleaner Allen Bolts Right Air Cleaner Base Bolt Right Air Cleaner Base Screws Right Air Cleaner Cover Allen Bolt Spark Plug Lead Holder Bolts Throttle Body Assy Holder Bolts Water Temperature Sensor
N·m 10 11 2.2 16 11 11 2.2 16 11 11 18
12. Air Cleaner Drain Hose 13. Air Cleaner Duct Holder 14. Air Cleaner Element 15. Crankcase Breather Hose 16. Left Air Cleaner Base 17. Right Air Cleaner Base 18. Right Spark Plug Lead Holder 19. Throttle Body Assy 20. Vacuum Switch Valve L: Apply a non-permanent locking agent. SS: Apply silicone sealant (Kawasaki Bond: 56019-120). CA: Canada Model CAL: California Model US: United States Model
Torque kgf·m 1.0 1.1 0.22 1.6 1.1 1.1 0.22 1.6 1.1 1.1 1.8
ft·lb 89 in·lb 97 in·lb 19 in·lb 12 97 in·lb 97 in·lb 19 in·lb 12 97 in·lb 97 in·lb 13
Remarks
L
L
SS
3-6 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-7 Exploded View No. 1 2 3 4 5 6 7
Fastener Choke Cable Plate Screw Fuel Pump Mounting Bolts Inlet Air Temperature Sensor Nut Inlet Manifold Bolts ISC Pipe Holder Bolts Spark Plug Lead Holder Bolts Throttle Body Assy Holder Bolts
8. Atmospheric Pressure Sensor 9. Battery Case 10. Choke Cable 11. Delivery Joint 12. DFI Main Relay 13. ECU (Electronic Control Unit) 14. Fuel Tank 15. Injector #1 (for Front Cylinder) 16. Injector #2 (for Rear Cylinder) 17. Inlet air Pressure Sensor 18. Inlet Air Temperature Sensor 19. Inlet Manifold 20. ISC Valve #2 (for Front Cylinder) 21. ISC Valve #1 (for Rear Cylinder) 22. O-ring 23. Right Air Cleaner Base 24. Seal 25. Throttle Body 26. Throttle Cable (Accelerator) 27. Throttle Cable (Decelerator) 28. Vehicle-down Sensor CL: Apply cable lubricant. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence.
N·m 2.9 9.8 7.8 12 11 11 11
Torque kgf·m 0.30 1.0 0.80 1.2 1.1 1.1 1.1
ft·lb 26 in·lb 87 in·lb 69 in·lb 104 in·lb 97 in·lb 97 in·lb 97 in·lb
Remarks L L, S
3-8 FUEL SYSTEM (DFI) DFI System
FUEL SYSTEM (DFI) 3-9 DFI System #1: for Front Cylinder #2: for Rear Cylinder 1. ECU (Electronic Control Unit) 2. Crankshaft Sensor #1 3. Crankshaft Sensor #2 4. Pressure Regulator 5. Throttle Sensor 6. Atmospheric Pressure Sensor 7. Inlet Air Pressure Sensor 8. Water Temperature Sensor 9. Inlet Air Temperature Sensor 10. FI Indicator LED Light 11. Fuel Filter 12. Delivery Joint 13. Injector #1 14. Injector #2 15. Fuel Pump 16. ISC Valve #2 (Front Side) 17. ISC Valve #1 (Rear Side) 18. Vehicle-down Sensor 19. Fuel Tank 20. Alternator Rotor 21. Sealed Battery 22. Left Air Cleaner Housing 23. Right Air Cleaner Housing 24. Lower Air Cleaner Duct 25. Thermostat Housing 26. Throttle Valves 27. Fuel Flow 28. Air Flow 29. Speed Sensor 30. Fuel Hose Joint (Fuel Pump Side) 31. Fuel Hose Joint (Delivery Joint Side)
3-10 FUEL SYSTEM (DFI) DFI Parts Location
FUEL SYSTEM (DFI) 3-11 DFI Parts Location DFI: DFI Parts F: Front 1. Atmospheric Pressure Sensor (DFI) 2. Water Temperature Sensor (DFI) 3. Ignition Coils 4. Ignition Switch (see next page) 5. Starter Motor 6. Water Temperature Switch 7. Regulator/Rectifier 8. Crankshaft Sensors 9. Alternator 10. Side stand Switch 11. Neutral Switch 12. Oil Pressure Switch 13. Fuel Pump (DFI) (see next page) 14. Vehicle-down Sensor (DFI) 15. ECU (DFI) 16. DFI Fuse 15 A 17. Sealed Battery 18. Junction Box 19. Starter Relay 20. Turn Signal Control Unit 21. DFI Main Relay 22. Oil Pressure Light Delay Unit 23. ISC Valve #2 (DFI, for Front Cylinder) 24. ISC Valve #1 (DFI, for Rear Cylinder) 25. Inlet Air Temperature Sensor (DFI) 26. Injectors (DFI) 27. Inlet Air Pressure Sensor (DFI) 28. FI Indicator LED Light (DFI) (see next page) 29. Throttle Sensor (DFI) 30. Rear Brake Light Switch 31. Radiator Fan 32. Radiator Fan Switch 33. Delivery Joint (DFI) 34. Pump Screen (see next page) 35. Fuel Filter (see next page) 36. Fuel Tank (Reverse Side)
3-12 FUEL SYSTEM (DFI) DFI Parts Location
FUEL SYSTEM (DFI) 3-13 DFI Parts Location
3-14 FUEL SYSTEM (DFI) DFI Wiring Diagram
FUEL SYSTEM (DFI) 3-15 DFI Wiring Diagram DFI and Electrical Parts DFI: DFI Parts 1. ECU (Electronic Control Unit): (DFI) 2. Self-diagnosis Terminal 3. Engine Stop Switch 4. Starter Button 5. Ignition Coils 6. Crankshaft Sensors 7. Joint Connector 2 8. Speed Sensor 9. Interlock Diodes 10. Starter Circuit Relay 11. Ignition Fuse 10 A 12. Junction Box 13. LCD (Liquid Crystal Display) 14. Speedometer 15. FI Indicator LED Light: (DFI) 16. MODE Button 17. RESET Button 18. Ignition Switch 19. Stater Relay 20. Main Fuse 30 A 21. Sealed Battery 22. Fuel Pump: (DFI) 23. Fuel Injector #1: (DFI) 24. Fuel Injector #2: (DFI) 25. Throttle Sensor: (DFI) 26. DFI Fuse 15 A: (for ECU, Injectors, Fuel Pump, DFI Main Relay, and ISC Valves) 27. ISC Valve #2: (DFI) 28. ISC Valve #1: (DFI) 29. Inlet Air Temperature Sensor: (DFI) 30. Water Temperature Sensor: (DFI) 31. Inlet Air Pressure Sensor: (DFI) 32. Atmospheric Pressure Sensor: (DFI) 33. Vehicle-down Sensor: (DFI) 34. DFI Main Relay: (for ECU, Injectors, Fuel Pump, and ISC Valves) 35. Frame Ground
3-16 FUEL SYSTEM (DFI) DFI Wiring Diagram Terminal Numbers of ECU Connectors
FUEL SYSTEM (DFI) 3-17 DFI Wiring Diagram Terminal Names #1: for Front Cylinder #2: for Rear Cylinder 1. Starter Lockout Switch Signal 2. Interlock Circuit Signal 3. Self-diagnosis Signal (Generated by grounding this terminal and shown by FI indicator LED light.) 4. Tachometer Signal 5. Electric Starter Button Signal 6. – 7. Water Temperature Sensor (+) 8. Power Source for Diagnosis Tool 9. – 10. ECU Power Source Circuit Ground to Battery (–) Terminal 11. Ground of Inlet Air Temperature, Water Temperature, Inlet Air Pressure, Atmospheric Pressure, and Throttle Sensors 12. Neutral Switch 13. DFI Main Relay Solenoid Ground in ECU 14. Crankshaft Sensor #2 Signal 15. Crankshaft Sensor #1 Signal 16. Com. Line A 17. FI Indicator LED Light Signal 18. ISC Valve #2 Signal 19. – 20. Ignition Control Circuit Ground to Battery (–) Terminal 22. – 23. – 24. Vehicle-down Sensor Signal 25. – 26. Throttle Sensor Signal 27. Speed Sensor Signal 28. Atmospheric Pressure Sensor Signal 29. Inlet Air Pressure Sensor Signal 30. Power Supply to ECU, ISC Valves, Injectors, and Fuel Pump, Vehicle-down Sensor 31. Inlet Air Temperature Sensor (+) 32. ECU Power Source Circuit Ground to Battery (–) Terminal (The same as No.10.) 33. Power Source Ground for Diagnosis Tool 34. – 35. Power Supply to Sensors (Inlet Air Pressure, Atmospheric Pressure, And Throttle Sensors) from ECU 36. Com. Line B 37. Fuel Pump Signal 38. – 39. Injector #2 Signal 40. Injector #1 Signal 41. ISC Valve #1 Signal 42. Ignition Control Circuit Ground to Battery (–) Terminal 43. Ignition Coil #2 Signal 44. Ignition Coil #1 Signal
3-18 FUEL SYSTEM (DFI) Specifications Item Throttle Grip Free Play Air Cleaner Element DFI System Make: Idle Speed: Throttle Body Assy: Type × Bore ECU (Electronic Control Unit): Type Usable Engine Speed ISC Valves: Maximum Air Flow Rate Solenoid Resistance Fuel Pressure (High Pressure Line): Right after Ignition Switch ON
Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Paper filter Mitsubishi Electric 950 ±50 r/min (rpm) Two barrel type ×
36 mm (1.4 in.)
Digital memory type, with built in IC igniter, sealed with resin 100 ∼ 5 900 r/min (rpm) (Idle Speed Control Valve, or Fast Idle Solenoid Valve) 75 ±7 L (19.8 ±1.8 US gal)/min 13.6 ∼ 20.4 Ω
304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running After Pump Runs 3 seconds and Stops 280 kPa (2.9 kgf/cm², 41 psi) with fuel pump stopped With Engine Idling 304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running Pressure Regulator: Regulated Fuel Pressure 294 ±4.9 kPa (3.00 ±0.05 kgf/cm², 43 ±0.73 psi) Throttle Sensor: Input Voltage 4.75 ∼ 5.25 V DC between BL/W and BR/BK leads Output Voltage at Idle Throttle Opening 0.584 ∼ 0.604 V DC between Y/W and BR/BK leads Output Voltage at Full Throttle Opening 4.29 ∼ 4.59 V DC between Y/W and BR/BK leads Resistance 4 ∼ 6 kΩ between BL/W and BR/BK leads Atmospheric Pressure Sensor/Inlet Air Pressure Sensor: Input Voltage 4.75 ∼ 5.25 V DC Output Voltage 3.74 ∼ 4.26 V DC at standard atmospheric pressure Inlet Air Temperature Sensor: Resistance 5.4 ∼ 6.6 kΩ at 0°C (32°F) 2.26 ∼ 2.86 kΩ at 20°C (68°F) 0.29 ∼ 0.39 kΩ at 80°C (176°F) Water Temperature Sensor: Resistance 2.162 ∼ 3.112 kΩ at 20°C (68°F) 0.785 ∼ 1.049 kΩ at 50°C (122°F) 0.207 ∼ 0.253 kΩ at 100°C (212°F) Vehicle-down Sensor: Detection Angle More than 45° ±5° for each bank Detection Time Within 0.5 ∼ 1.0 second
FUEL SYSTEM (DFI) 3-19 Specifications Item Fuel Injectors: Type Static Injection Quantity Nozzle Type × Diameter Resistance Fuel Pump: Type Discharge
Standard INP-281 273.0 ∼ 289.8 mL (9.23 ∼ 9.80 US oz)/min One spray type with 4 holes 11.7 ∼ 12.3 Ω at 20°C (68°F) Friction pump 67 mL (2.27 US oz) or more for 3 seconds
3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Needle Adapter Set: 57001-1457
Fork Oil Level Gauge: 57001-1290
Fuel Pressure Gauge Adapter: 57001-1593
Hand Tester: 57001-1394
Fuel Hose: 57001-1607
Filler Cap Driver: 57001-1454
Kawasaki Bond (Silicone Sealant): 56019-120
FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system.
○To maintain the correct fuel-air mixture (F/A), there must
be no inlet air leaks in the DFI system. Be sure to install the oil filler cap [A] after filling the engine oil, using the filler cap driver [B]. Clutch Cover [C] Front [D] Special Tool - Filler Cap Driver: 57001-1454 Torque - Oil Filler Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb)
○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 lead connections. This will damage the ECU. ○Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. Otherwise, surge damages the connector terminals or the DFI parts. ○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 dis-
connected, 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 fault codes. ○Do not spray water on the electrical parts, DFI parts, connectors, leads, and wiring. Never water a vehicle with connectors unplugged because seals don’t work and terminals could corrode. ○To prevent corrosion and deposits in the fuel system, do not add any fuel antifreeze chemicals to fuel. ○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.
3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indicator LED light [A] and FI symbol [B] go on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator LED light blinks. When due to a malfunction, the FI indicator LED light and FI symbol remains lit, ask the rider about the conditions [B] under which the problem occurred and try to determine the cause. Don’t rely solely on the DFI self-diagnosis function, use common sense. First conduct a self-diagnosis inspection, and then a non -self-diagnosis. The non-self-diagnosis items are not indicated by the FI indicator LED light. Even when the DFI system is operating normally, the FI indicator LED light and FI symbol may light up under strong electrical interference. No repair needed. Turn the ignition switch OFF to stop the indicator light and FI symbol. When the FI indicator LED light and FI symbol go on and the motorcycle is brought in for repair, check the service codes. When the repair has been done, the LED light and FI symbol do not go on.
○There are two ways to inspect the DFI system.
One is Voltage Check Method and the other is Resistance Check Method. Voltage Check Method ○This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor. ○Sometime this method can detect a fault of the ECU. ○Refer to the each Sensor Inspection section for detail in this chapter. Use a fully charged battery, and a digital meter [D] which can be read two decimal places voltage or resistance.
•
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System
○The DFI part connectors [A] have seals [B], including the
•
ECU (except for ISC valves). Join the connector [A] and insert the needle adapter (special tool) [C] inside the seal [B] from behind the connector until the adapter reaches the terminal. Special Tool - Needle Adapter Set: 57001-1457
CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals. 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 the hand tester or 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.
CAUTION Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts.
○After measurement, remove the needle adapters and ap-
ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of Connector
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.
3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System Resistance Check Method ○This method is simple. No need for a fully charged battery and the needle adapter. Just do the following especially when a sensor [A] is suspect. Turn the ignition switch OFF and disconnect the connectors. Inspect the sensor resistance, using a digital meter (see each Sensor Inspection in this chapter). Inspect the wiring and connections [B] for continuity, using the hand tester [C] (special tool, analog tester) rather than a digital meter.
• • •
Special Tool - Hand Tester: 57001-1394
If the sensor, the wiring and connections are good, inspect the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter). If the ground and power supply are good, the ECU is suspect. Replace the ECU.
may involve one or in some cases all items. • Trouble 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 wires for signs of burning, fraying, short, etc. Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system.
If any wiring is deteriorated, replace the 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. 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. ○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.
• •
FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System
○If both ends of a harness [A] are far apart, ground [B]
the one end [C], using an auxiliary wire [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. ○The following diagnosis flow chart illustrates the above procedures.
○Wire Color Codes: BK: Black BL: Blue BR: Brown CH: Chocolate DG: Dark green
○Electric Connectors:
G: Green GY: Gray LB: Light blue LG: Light green O: Orange
Female Connectors [A]
P: Pink PU: Purple R: Red W: White Y: Yellow
3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System Male Connectors [B]
FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System DFI Diagnosis Flow Chart
Inquiries to Rider
to the next sample diagnosis chart. •○Refer 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 diagnosis sheet will help prevent you from overlooking any areas, and will help you decide if it is a DFI system problem, or a general engine problem.
3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Temperature □ hot, □ warm, □ cold, □ very cold, □ always Problem □ chronic, □ often, □ once frequency Road □ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble Altitude □ normal, □ high (about 1 000 m (3 281 ft) or more) Motorcycle conditions when problem occurred. FI indicator □ light up immediately after ignition switch ON, and goes off after engine oil LED light pressure is high enough (with engine running) (normal). □ lights up immediately after ignition switch ON, and stays on after engine oil pressure is high enough (with engine running) (DFI problem) □ lights up immediately after ignition switch ON, but goes off after about 10 seconds though engine oil pressure is high enough (with engine running) (DFI problem).
Starting difficulty
Engine stops
Poor running at low speed
□ unlights (LED light, ECU or its wiring fault). □ sometimes lights up (probably wiring fault). □ starter motor not rotating. □ starter motor rotating but engine doesn’t turn over. □ starter motor and engine don’t turn over. □ no fuel flow ( □ no fuel in tank, □ no fuel pump sound). □ engine flooded (do not crank engine with throttle opened, which promotes
engine flooding). □ no spark. □ choke knob is not pulled fully when using the knob (pull it fully when using). □ other: □ right after starting. □ when opening throttle grip. □ when closing throttle grip. □ when moving off. □ when stopping the motorcycle. □ when cruising. □ other: □ choke knob left pulled out fully (push it in fully). □ very low fast idle 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 (adjust it). □ backfiring. □ afterfiring. □ hesitation when acceleration.
FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System
Poor running or no power at high speed
□ engine oil viscosity too high. □ brake dragging. □ engine overheating. □ clutch slipping. □ other: □ choke knob left pulled out fully (push it in fully). □ 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:
3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed.
It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○The ECU may be involved in the DFI electrical and ignition system troubles. If these 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.
Engine Doesn’t Start, Starting Difficulty Symptoms or Possible Causes Starter motor not rotating Ignition and engine stop switches not ON Starter lockout switch or neutral switch trouble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter button not contacting Starter system wiring open or shorted Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn’t turn over Starter clutch trouble Starter idle gear trouble Engine won’t turn over Valve seizure Rocker arm seizure Cylinder, piston seizure Camshaft seizure Connecting rod small end seizure Connecting rod big end seizure Crankshaft seizure Transmission gear or bearing seizure Balancer bearing seizure No fuel flow No or little fuel in tank Fuel pump not rotating Fuel injector trouble Fuel tank air vent obstructed Fuel filter or pump screen clogged Fuel pressure regulator clogged Fuel line clogged Engine flooded Spark plug dirty, broken or gap maladjusted Starting technique faulty
Actions (chapter) Turn both switches ON. Inspect (see chapter 16). Inspect (see chapter 16). Inspect and charge (see chapter 16). Inspect the starter relay (see chapter 16). Inspect and replace (see chapter 16). Inspect the wiring (see chapter 16). Inspect and replace (see chapter 16). Inspect and repair or replace (see chapter 16). Inspect and replace (see chapter 16).
Inspect (see chapter 9). Inspect (see chapter 9). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 9). Inspect and replace (see chapter 9). Inspect and replace (see chapter 9). Inspect and replace (see chapter 9). Inspect and replace (see chapter 9). Supply fuel (see Owner’s Manual). Inspect (see chapter 3). Inspect and replace (see chapter 3). Inspect and repair (see chapter 3). Inspect and replace fuel pump (see chapter 3) Inspect and replace fuel pump (see chapter 3). Inspect and repair (see chapter 3). Clean spark plugs and adjust plug gap (see chapter 2). When flooded, don’t crank engine with throttle fully opened.
FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes No spark or spark weak Ignition and engine stop switches not ON Clutch lever not pulled in and gear not in neutral whether side stand up or not Though clutch lever pulled in but side stand up and gear not in neutral Vehicle-down sensor coming off Vehicle-down sensor trouble ECU ground or power supply trouble Battery voltage low Spark plug dirty, broken or gap maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Neutral, starter lockout or side stand switch trouble Crankshaft sensor trouble Ignition coil trouble Ignition switch shorted Engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Fuel/air mixture incorrect Air cleaner clogged, poorly sealed or missing Leak from oil filler cap, crankcase breather hose or air cleaner drain hose Water or foreign matter in fuel Fuel pressure regulator trouble Throttle sensor trouble Fuel pressure may be low Fuel pump trouble Fuel injector trouble Inlet air pressure sensor trouble Atmospheric pressure sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble ISC valve trouble Crankshaft sensor trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down
Actions (chapter) Turn both switches ON. Pull the lever in and shift the gear in neutral. Side stand down and clutch lever pulled in whether gear in neutral, or not. Reinstall (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect and charge (see chapter 16). Clean spark plug and adjust plug gap (see chapter 2). Inspect the ignition coil (see chapter 16). Reinstall or inspect the cap (see chapter 16). Replace it with the correct plug (see chapter 16). Inspect (see chapter 16). Inspect each switch (see chapter 16). Inspect (see chapter 16). Inspect (see chapter 16). Inspect and replace (see chapter 16). Inspect and repair or replace (see chapter 16). Inspect and repair or replace (see chapter 16). Inspect and replace (see chapter 16). Clean or reinstall (see chapter 3). Inspect and repair or replace (see chapter 3). Change fuel. Inspect and clean fuel system (see chapter 3). Inspect fuel pressure and replace fuel pump (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). Reinstall (see chapter 16). Tighten (see chapter 5).
3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Cylinder, piston worn Piston ring bad (worn, weak, broken or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve guide worn Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulating on seating surface) KACR (compression release cam) sticks open (Engine stalls when moving off) HLA ( hydraulic lash adjuster) damaged (worn, seizure or spring broken) HLA oil passage clogged
Actions (chapter) Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and repair or replace (see chapter 5). Inspect and repair or replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and repair or replace (see chapter 5).
Poor Running at Low Speed Symptoms or Possible Causes Spark weak Battery voltage low Spark plug dirty, broken, or gap maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel/air mixture incorrect Little fuel in tank Air cleaner clogged, poorly sealed, or missing Air cleaner duct loose Air cleaner O-ring damaged Fuel tank air vent obstructed Throttle body assy loose Throttle body assy O-ring damage Choke knob left pulled out Fuel filter or pump screen clogged Fuel pressure regulator clogged Fuel line clogged Thermostat trouble Inlet air temperature sensor trouble Inlet air pressure sensor trouble Unstable (rough) idling ISC valve trouble Fuel injector trouble
Actions (chapter) Inspect and charge (see chapter 16). Clean spark plugs and adjust plug gap (see chapter 2). Inspect the ignition coil (see chapter 16). Reinstall or inspect the cap (see chapter 16). Replace it with the correct plug (see chapter 16). Inspect (see chapter 16). Inspect (see chapter 16). Inspect (see chapter 16). Supply fuel (see Owner’s Manual). Clean element or inspect sealing (see chapter 3). Reinstall (see chapter 3). Replace (see chapter 3). Inspect and repair (see chapter 3). Reinstall (see chapter 3). Replace (see chapter 3). Push in (see chapter 3). Inspect and replace fuel pump (see chapter 3). Inspect fuel pressure and replace fuel pump (see chapter 3). Inspect and repair (see chapter 3). Inspect and replace (see chapter 4). Inspect (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 Throttle sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Fuel pressure too low or too high Battery voltage low Incorrect idle speed Water temperature sensor trouble Throttle sensor trouble ISC valve trouble Engine stalls easily Fuel pump trouble Fuel injector trouble Throttle sensor trouble (engine stops when opening the throttle) Fuel pressure too low or too high Inlet air temperature sensor trouble Fuel pressure too low or too high Fuel pressure regulator trouble Crankshaft sensor trouble Ignition coil trouble 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 guide worn or stem seal damaged Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulating on seating surface) Camshaft cam worn KACR (compression release cam) sticks open HLA (hydraulic lash adjuster) damaged HLA oil passage clogged Hesitation Too low fuel pressure Clogged fuel line Cracked or obstructed inlet air pressure sensor hose Fuel pump trouble Fuel injector trouble Inlet 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 and charge (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 and replace (see chapter 3). Inspect (see chapter 16). Inspect (see chapter 16). Reinstall (see chapter 16). Tighten (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and repair or replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and repair or replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and repair or replace (see chapter 5). Inspect (see chapter 3). Inspect and repair (see chapter 3). Inspect and repair or replace (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 Throttle sensor malfunction Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor trouble Ignition coil trouble Loose terminal of battery (–) lead or engine ground lead Delay of ignition timing Poor acceleration Choke knob left pulled out Too low fuel pressure Water or foreign matter in fuel Clogged fuel filter Fuel pump trouble Fuel injector trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Ignition coil trouble Engine oil level too high Spark plug dirty, broken or gap maladjusted Stumble Too low fuel pressure Fuel injector trouble Throttle sensor malfunction Water temperature sensor trouble Inlet air pressure sensor trouble Surge Unstable fuel pressure
Fuel injector trouble Water temperature sensor trouble Backfiring when deceleration Spark plug dirty, broken or gap maladjusted Too low fuel pressure Crankshaft sensor trouble Fuel pump trouble Throttle sensor malfunction
Actions (chapter) Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Remedy (see chapter 3). Inspect and repair or replace (see chapter 16). Inspect and repair or replace (see chapter 16). Inspect and repair (see chapter 16). Inspect pickup coil and IC igniter in ECU (see chapter 16). Push in (see chapter 3). Inspect (see chapter 3). Change fuel. Inspect and clean fuel system (see chapter 3). Inspect (see chapter 3) and replace fuel pump. 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). Repair (see chapter 7) Clean spark plugs and adjust plug gap (see chapter 2) Inspect Inspect Inspect Inspect Inspect
(see (see (see (see (see
chapter chapter chapter chapter chapter
3). 3). 3). 3). 3).
Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and repair fuel line) (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Clean spark plugs and adjust plug gap (see chapter 2) Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Vacuum switch valve broken Air suction valve trouble After fire Spark plug burned or gap maladjusted Crankshaft sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Fuel injector trouble Run-on (dieseling) Ignition switch trouble Engine switch trouble Fuel injector trouble Engine overheating Other Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too high Brake dragging
Clutch slipping Engine overheating Vacuum switch valve trouble Air suction valve trouble Intermittent any DFI fault and its recovery
Actions (chapter) Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Adjust plug gap or replace plug (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 and replace (see chapter 16). Inspect and repair or replace (see chapter 16). Inspect (see chapter 3). (see Overheating of Troubleshooting Guide, see chapter 17) Change (see chapter 2). Inspect tightness of bolts and nuts (see chapter 2) or bearing wear (see chapter 11). Change (see chapter 2). Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12). Inspect friction plates for wear (see chapter 6). (see Overheating of Troubleshooting Guide in chapter 17) Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Check that DFI connectors are clean and tight, and examine wires for signs of burning or fraying (see chapter 3).
3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Firing incorrect Spark plug dirty, broken or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel/mixture incorrect Choke knob left pulled out Air cleaner clogged, poorly sealed, or missing Air cleaner duct loose Air cleaner O-ring damaged Water or foreign matter in fuel
Actions (detailed reference) Clean spark plug and adjust plug gap (see chapter 2). Inspect plug cap and ignition coil (see chapter 16). Reinstall or inspect the cap (see chapter 16). Replace it with the correct plug (see chapter 16) Inspect (see chapter 16). Inspect (see chapter 16). Inspect (see chapter 16).
Push in (see chapter 3). Clean element or inspect sealing (see chapter 3). Reinstall (see chapter 3). Replace (see chapter 3). Change fuel. Inspect and clean fuel system (see chapter 3). Throttle body assy loose Reinstall (see chapter 3). Throttle body assy O-ring damaged Replace (see chapter 3). Fuel tank air vent obstructed Inspect and repair (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Fuel pump operates intermittently and often DFI Pump bearings may wear. Replace the pump (see chapter 3). fuse blows. Fuel pump trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Throttle sensor malfunction Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Cracked or obstructed inlet air pressure sensor Inspect and repair or replace (see chapter 3) hose Injector clogged Visually inspect and replace (see chapter 3) Compression low Spark plug loose Reinstall (see chapter 16). Cylinder head not sufficiently tightened down Tighten (see chapter 5). Cylinder, piston worn Inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5). Cylinder head gasket damaged Replace (see chapter 5). Cylinder head warped Inspect and replace (see chapter 5). Valve spring broken or weak Inspect and replace (see chapter 5). Valve not seating properly (valve bent , worn or Inspect and repair or replace (see chapter 5). carbon accumulating on the seating surface) KACR (compression release cam) sticks open Inspect and repair or replace (see chapter 5). (engine stalls when moving off)
FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes HLA ( hydraulic lash adjuster) damaged (worn, seizure or spring broken) Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect (Use high-octone gasoline recommended in the Owner’s Manual) Spark plug incorrect Ignition coil trouble IC igniter in ECU trouble Inlet air temperature sensor trouble Atmospheric pressure sensor trouble Miscellaneous Throttle valves won’t fully open Brake dragging
Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too high Camshaft cam worn Vacuum switch valve trouble Air suction valve trouble Catalytic converters melt down due to muffler overheating (KLEEN) Exhaust Smokes Excessively White smokes Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Choke knob left pulled out Too high fuel pressure Injection stuck open Water temperature sensor trouble Inlet air temperature sensor trouble Brown smoke Air cleaner duct loose
Actions (detailed reference) Inspect and replace (see chapter 5).
Repair (see chapter 5). Change fuel (see chapter 3). Replace it with the correct plug (see chapter 16) Inspect (see chapter 16). Inspect (see chapter 16). Inspect (see chapter 3). Inspect (see chapter 3). Inspect throttle cable and lever linkage (see chapter 3). Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12). Inspect friction plates for wear (see chapter 6). (see Overheating of Troubleshooting Guide in chapter 17) Repair (see chapter 7). Change (see chapter 3). Inspect tightness of bolts and nuts (see chapter 2) or bearing wear (see chapter 11). Change (see chapter 2). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Replace muffler (see chapter 5).
Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Replace (see chapter 5). Replace the guide (see chapter 5). Repair (see chapter 7). Clean (see chapter 3). Push in (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace (see chapter 3). Reinstall (see chapter 3).
3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Air cleaner O-ring damaged Too low fuel pressure Water temperature sensor trouble Inlet air temperature sensor trouble
Actions (detailed reference) Replace (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace (see chapter 3).
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-diagnosis Procedures
○When a problem occurs with the DFI system, the FI indicator LED light [A] and FI symbol [B] go on.
the front seat (see Front Seat Removal in the • Remove Frame chapter). [A] the self-diagnosis terminal [B] (yellow lead) to • Ground the battery (–) terminal [C], using a wire [D].
the ignition switch ON. • Turn Push MODE button [A] and display the odo meter. • Push the the button [B] for more than two seconds. • The LCD FIRESET characters [C] are displayed. Count the blinks of the LED light [D] to read the service • code.
○Use
NOTE
a fully charged battery when conducting self-diagnosis. Otherwise, the LED light blinks very slowly or doesn’t blink. ○Keep the self-diagnosis female connector grounded during self-diagnosis, using a wire. of the following procedures (conditions) ends self • Any -diagnosis.
○When pushing the RESET button more than 2 seconds
and 2 seconds passed. ○When the ignition switch is turned to OFF. ○Pushing the MODE button and the trip meter is displayed. ○When the ECU receives the speed sensor signal.
3-40 FUEL SYSTEM (DFI) Self-Diagnosis
Service Code Reading
○Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below.
○Read 10th digit and unit digit as the FI indicator LED light blinks. ○When there are a number of problems, all the fault codes can be stored and the display will be-
gin 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. ○For example, if four problems occurred in the order of 31, 15, 41, 12, the fault codes are displayed from the lowest number in the order listed. (12 → 15 → 31 → 41) → (12 → 15 → 31 → 41) → · · · (repeated) ○If there is no problem or when the repair has been done, no service code is shown. If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator LED light doesn’t go on, and no fault codes can be displayed. FI Indicator LED Light ISC Valves DFI Main Relay Ignition Coil Secondary Wiring (check the internal resistance, see Electrical System chapter) ECU Power Source Wiring and Ground Wiring (see ECU Inspection in this chapter) ○For example, if two problems of 12 and 15 occur, the service code 12 and 15 are shown as follows.
FUEL SYSTEM (DFI) 3-41 Self-Diagnosis
○Each service code is continuously repeated three times until the ignition switch is turned OFF.
Service Code Erasing
○When the repair has been done, the LED light will not show fault codes any more.
But even if the repair has been done, the ignition switch is turned OFF, or the battery is disconnected, all the fault codes remain in the ECU, which need not be absolutely erased.
3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code
FI Indicator LED Light
Problems (1)
11
Throttle sensor malfunction, wiring open or short
12
Vacuum sensor malfunction, wiring open or short
13
Inlet air temperature sensor malfunction, wiring open or short
14
Water temperature sensor malfunction, wiring open or short
15
Atmospheric pressure sensor malfunction, wiring open or short
21
Crankshaft sensor #1 malfunction, wiring open or short
22
Crankshaft sensor #2 malfunction, wiring open or short
31
Vehicle-down sensor malfunction wiring open or short
41
Injector #1 malfunction, wiring open or short
42
Injector #2 malfunction, wiring open or short
45
Fuel pump malfunction, wiring open or short
51
Ignition coil primary winding #1 malfunction, wiring open or short
52
Ignition coil primary winding #2 malfunction, wiring open or short
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. #1: for Front Cylinder #2: for Rear Cylinder
FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Backups ○The ECU takes the following measures to prevent engine damage when the DFI electronical or the ignition system parts have troubles. Service Codes
Parts
Output Signal Usable Range or Criteria
11
Throttle Sensor
Throttle Valve Opening Angle α = –4° ∼ +85°
12
Vacuum Sensor
Absolute Vacuum Pv = 63 mmHg ∼ 860 mmHg
13
14
15
Inlet Air Temperature Sensor Water Temperature Sensor Atmospheric Pressure Sensor
21
Crankshaft Sensor #1
22
Crankshaft Sensor #2
31
Vehicle -down Sensor
41
42
45
Inlet Air Temperature Ta = –47°C ∼ +178°C Water Temperature Tw = –28C° ∼ +161°C Absolute Atmospheric Pressure Pa = 63 mmHg ∼ 860 mmHg Either crankshaft sensor must send signals (output voltage) 8 or more times continuously to the ECU. Vehicle-down Sensor Output Voltage (signal) Vd = 0.2 V ∼ 4.6 V
The injector must send signals (output Fuel Injector voltage) 16 or more #1 times continuously to the ECU. The injector must send signals (output Fuel Injector voltage) 16 or more #2 times continuously to the ECU. The pump must send signals (output voltage) Fuel Pump continuously to the ECU.
Backups by ECU If the throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at full throttle open position and sets the DFI in the D-J method (1). If the inlet air pressure sensor system fails (the signal Pv is out of the usable range, wiring short or open), the ECU sets the DFI in the α-N method (1). If the inlet air temperature sensor fails (the signal is out of the usable range, wiring short or open), the ECU sets Ta at 45°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 86°C. If the atmospheric pressure sensor 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 either crankshaft sensor generates 8 or more signals, the ECU runs the engine by the signal of the good crankshaft sensor, but neither crankshaft sensors generate signals, the engine stops by itself. If the vehicle-down sensor system has failures (the output voltage Vd is out of the usable range, wiring short or open), the ECU shuts off the fuel pump, the fuel injectors and the ignition system. If the injector #1 fails (signals less than 16 times, wiring short or open), the ECU shuts off the signal to the injector. Fuel is not supplied to the cylinder #1, though the engine keeps running. If the injector #2 fails (signals less than 16 times, wiring short or open), the ECU shuts off the signal to the injector. Fuel is not supplied to the cylinder #2, though the engine keeps running. If the fuel pump fails (no signals to ECU, wiring short or open), the ECU shuts off the pump, and then the engine stops because of fuel pressure drop.
3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Codes
51
52
Output Signal Usable Range or Criteria The ignition coil primary winding must send Ignition Coil signals (output voltage) #1 continuously to the ECU. The ignition coil primary winding must send Ignition Coil signals (output voltage) #2 continuously to the ECU. Parts
Backups by ECU If the ignition primary winding #1 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 ignition primary winding #2 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.
Note: (1) When the engine load is light like at idling or low speed, the ECU determines injection quantity by calculating from throttle vacuum (inlet air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method (low-speed mode). As engine speed increases, and the engine load turns middle to heavy, the ECU determines injection quantity by calculating from throttle opening (throttle sensor output voltage) and engine speed. This method is called α-N method (high-speed mode).
FUEL SYSTEM (DFI) 3-45 Throttle Sensor (Service Code 11) Removal/Adjustment CAUTION Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
Input Voltage Inspection NOTE
○Be sure the battery is fully charged. ○The inspection is the same as “Input Voltage Inspec-
tion” of the inlet air pressure sensor or the atmospheric pressure sensor.
the ignition switch OFF. • Turn Remove the ECU (see ECU Removal in this chapter). •○Do not disconnect the ECU connector. a digital meter [A] to the connector [B], using two • Connect needle adapters [C]. Special Tool - Needle Adapter Set: 57001-1457 Throttle Sensor Input Voltage Connections to ECU Connector Meter (+) → BL/W lead (terminal 35) Meter (–) → BR/BK lead (terminal 11)
the input voltage to the throttle sensor with the • Measure engine stopped, and with the connectors joined. • Turn the ignition switch ON. Input Voltage at ECU Standard: 4.75 ∼ 5.25 V DC
the ignition switch OFF. • Turn If the reading of input voltage is less than the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection in this chapter). If the input voltage is within the standard range, remove the fuel tank, and check the wiring from the ECU to the throttle sensor for continuity. If the wiring is good, check the output voltage of the throttle sensor.
Output Voltage Inspection
the engine and warm it up thoroughly. • Start idle speed to make sure the throttle opening is cor• Check rect. Idle Speed Standard: 950 ± 50 r/min (rpm)
•
If the idle speed is out of the specified range, adjust the idle speed (see Idle Speed Inspection in the Periodic Maintenance chapter). Turn off the ignition switch.
3-46 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) the ECU (see ECU Removal in this chapter). •○Remove Do not disconnect the ECU connector. a digital meter [A] to the connector [B], using the • Connect needle adapters [C]. Special Tool - Needle Adapter Set: 57001-1457 Throttle Sensor Output Voltage Connections to ECU Connector Meter (+) → Y/W lead (terminal 26) Meter (–) → BR/BK lead (terminal 11)
CAUTION Insert the needle adapter straight along the lead in the connector to prevent short circuit between terminals. the output voltage of the sensor with the engine • Measure stopped, and with the connector joined. • Turn the ignition switch ON. Output Voltage at ECU Standard: 0.584 ∼ 0.604 V DC (at idle throttle opening) 4.29 ∼ 4.59 V DC (at full throttle opening)
If the output voltage is normal, replace the ECU. If the reading is out of the standard range, inspect the throttle sensor resistance. throttle sensor inspection, remove the needle • After adapters, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connector
56019-120
Resistance Inspection
the ignition switch OFF. • Turn Disconnect the throttle sensor connector. • Connect a digital meter [A] to the throttle sensor connector • [B]. • Measure the throttle sensor resistance. Throttle Sensor Resistance Connections: BL/W lead [C] ←→ BR/BK lead [D] Standard:
4 ∼ 6 kΩ
If the reading is out of the range, replace the throttle sensor along with the throttle body. If the reading is within the range, but the problem still exists, the ECU is suspect. Replace the ECU.
FUEL SYSTEM (DFI) 3-47 Throttle Sensor (Service Code 11)
1. ECU 2. Throttle Sensor
3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. the fuel tank (see Fuel Tank Removal in this • Remove chapter). the inlet air pressure sensor connector [A]. • Disconnect Unscrew the • the sensor [C].inlet air pressure sensor bolt [B] and remove the vacuum hose from the sensor. • Disconnect Front [D]
Installation NOTE
○The inlet air pressure sensor is the same part as the atmospheric pressure sensor except for a vacuum hose and different wiring.
the vacuum hose correctly (see Cable, Wire, and • Route Hose Routing section in the Appendix chapter). Make sure it doesn’t get pinched or kinked. Install the inlet air pressure sensor [A]. ○The stopper [B] must not be on the sensor holder [C]. Rear View [D] Tighten the inlet air pressure sensor nut securely. Install the fuel tank (see Fuel Tank Installation in this chapter).
• • •
Input Voltage Inspection NOTE
○Be sure the battery is fully charged. ○The inspection is the same as “Input Voltage Inspection” of the throttle sensor or the atmospheric pressure sensor. the ignition switch OFF. • Turn Remove the ECU (see ECU Removal in this chapter). •○Do not disconnect the ECU connector. Connect a digital meter • needle adapters [C]. [A] to the connector [B], using two Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter (+) → BL/W lead (terminal 35) Meter (–) → BR/BK lead (terminal 11)
FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) the input voltage to the inlet air pressure sensor • Measure with the engine stopped, and with the connectors joined. • Turn the ignition switch ON. Input Voltage at ECU Standard: 4.75 ∼ 5.25 V DC
the ignition switch OFF. • Turn If the reading is less than the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection in this chapter). If the ground and power supply are good, the ECU is suspect. Replace the ECU. If the reading is within the standard range, check the sensor output voltage.
Output Voltage Inspection NOTE
○The output voltage changes according to the local atmospheric pressure.
the output voltage of the sensor at the ECU con• Check nector [A]. Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) → W/BL lead (terminal 29) Meter (–) → BR/BK lead (terminal 11)
the output voltage with the engine stopped, and • Measure with the connector joined.
•
Needle Adapters [B] Turn the ignition switch ON. Output Voltage at ECU Usable Range: 3.74 ∼ 4.26 V DC at the standard atmospheric pressure (101.32 kPa, or 76 cmHg absolute)
• •
If the output voltage is at about 4.8 V, the ECU is normal. Remove the fuel tank and check the wiring between the ECU and the sensor. If the output voltage is at about 4.8 V and out of the usable range, remove the fuel tank and check the wiring. If the wiring is good, check the sensor itself as follows. Turn the ignition switch OFF and remove the needle adapters. Apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connector
56019-120
3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the output voltage is normal, check the inlet air pressure sensor itself. ○Check the output voltage for vacuum as follows. If the output voltage changes within the usable range as vacuum changes, the sensor is normal and the ECU is suspect. Check the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter). Remove the inlet air pressure sensor [D] and disconnect the vacuum hose from the sensor. Connect an auxiliary hose [E] to the inlet air pressure sensor. Temporarily install the inlet air pressure sensor. ○Connect a commercially available digital meter [A], the needle adapters [F], vacuum gauge [B], and the fork oil level gauge [C] to the inlet air pressure sensor. Front [G]
• • •
Special Tools - Fork Oil Level Gauge: 57001-1290 Needle Adapter Set: 57001-1457 Digital Meter Connections Meter (+) → W/BL lead of Inlet Air Pressure Sensor Meter (–) → BR/BK lead of Inlet Air Pressure Sensor
○Turn the ignition switch ON. ○Measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. ○Inspect the inlet air pressure sensor output voltage, using the following formula and charts for Pv = 24 ∼ 55 cmHg and 55 ∼ 86 cmHg.
FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Suppose: Pg: Vacuum (gauge) of Throttle Assy Pl: Local Atmospheric Pressure (absolute) measured by a barometer Pv: Vacuum (absolute) of Throttle Assy Vv: Sensor Output Voltage (v) then Pv = Pl – Pg For example, suppose the following data is obtained in the chart of the next page. Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.2 V (digital volt meter reading) then Pv = 70 – 8 = 62 cmHg (abs) Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage. Usable range = 3.04 ∼ 3.49 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.
Pv = 24 ∼ 55 cmHg
3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg
ID: Idling Ps: Standard Atmospheric Pressure (absolute) Pv: Throttle Vacuum (absolute) ST: Standard of Sensor Output Voltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (v) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12)
1. ECU 2. Inlet Air Pressure Sensor
3-54 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the right air cleaner base (see Right Air Cleaner • Remove Housing Removal in this chapter). the connector [A] from the inlet air tempera• Disconnect ture sensor, and unscrew the nut [B]. • Remove the inlet air temperature sensor. Torque - Inlet Air Temperature Sensor Nut: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Output Voltage Inspection NOTE
○Be sure the battery is fully charged. ○The output voltage changes according to the inlet air temperature.
the ECU (see ECU Removal in this chapter). •○Remove Do not disconnect the ECU connector. a digital meter [A] to the ECU connector [B], us• Connect ing two needle adapters [C]. Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter (+) → P lead (terminal 31) Meter (–) → BR/BK lead (terminal 11)
the output voltage of the sensor with the engine • Measure stopped and the connector joined. • Turn the ignition switch ON. Output Voltage at ECU Standard: 2.4 V at inlet air temperature 25°C (77°F)
the ignition switch OFF. • Turn If the output voltage is normal but there is still trouble,
•
check the sensor resistance. If the output voltage is about 4.8 V, the ECU is normal. Remove the right air cleaner base and check the wiring between the ECU and the sensor. If the output voltage is not about 4.8 V and out of the specified, remove the right air cleaner base, check the wiring between the ECU and the inlet air temperature sensor. If the wiring is good, check the sensor resistance. Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connector
56019-120
FUEL SYSTEM (DFI) 3-55 Inlet Air Temperature Sensor (Service Code 13) Resistance Inspection
the inlet air temperature sensor (see Re• Remove moval/Installation in this section). the sensor [A] in a container of machine oil so • Suspend that the heat-sensitive portion and threaded portion are
•
submerged. Suspend a thermometer [B] with the heat-sensitive portion [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 table. Inlet Air Temperature Sensor Resistance Standard: 5.4 ∼ 6.6 kΩ at 0°C (32°F) 2.26 ∼ 2.86 kΩ at 20°C (68°F) 0.29 ∼ 0.39 kΩ at 80°C (176°F)
•
If the measurement is out of the range, replace the sensor. If the measurement is within the specified, check the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter). Clean off machine oil that inadvertently gets on the sensor, especially on the terminals with a high-flush point solvent.
1. ECU 2. Inlet Air Temperature Sensor
3-56 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the thermostat housing [A] (see Thermostat Re• Remove moval in the Cooling System chapter). the sensor connector [B], and unscrew the • Disconnect water temperature sensor [C]. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 -Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 18 N·m (1.8 kgf·m, 13 ft·lb)
the engine with coolant and bleed the air from the cool• Fill ing system (see Coolant Change in the Periodic Maintenance chapter).
Output Voltage Inspection NOTE
○Be sure the battery is fully charged. ○The output voltage changes according to the coolant temperature in the engine.
the ECU (see ECU Removal in this chapter). •○Remove Do not disconnect the ECU connector. a digital meter [A] to the ECU connector [B], us• Connect ing two needle adapters [C]. Special Tool - Needle Adapter Set: 57001-1457 Water Temperature Sensor Output Voltage Connections to ECU Meter (+) → O lead (terminal 7) Meter (–) → BR/BK lead (terminal 11)
the output voltage of the sensor with the engine • Measure stopped, and the connector joined. • Turn the ignition switch ON. Output Voltage at ECU Standard: 3.38 V at coolant temperature 25°C (77°F)
If the output voltage is normal but there is still trouble, check the sensor resistance. If the output voltage is about 4.8 V, the ECU is normal. Remove the fuel tank and check the wiring between the ECU and the sensor. the ignition switch OFF. • Turn If the output voltage is not about 4.8 V and out of the spec-
•
ified, remove the fuel tank and check the wiring between the ECU and the water temperature sensor for continuity. If the wiring is good, check the water temperature sensor resistance. Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connector
56019-120
FUEL SYSTEM (DFI) 3-57 Water Temperature Sensor (Service Code 14) Resistance Inspection
the water temperature sensor (see Removal in • Remove this section). the sensor [A] in a container of machine oil so • Suspend that the heat-sensitive portion and threaded portion are
•
submerged. Suspend a thermometer [B] with the heat-sensitive portion [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 table. Water Temperature Sensor Resistance Standard: 2.162 ∼ 3.112 kΩ at 20°C (68°F) 0.785 ∼ 1.049 kΩ at 50°C (122°F) 0.207 ∼ 0.253 kΩ at 100°C (212°F)
•
If the measurement is out of the range, replace the sensor. If the measurement is within the specified, check the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter). Clean off machine oil that inadvertently gets on the sensor, especially on the terminals with a high-flush point solvent.
1. ECU 2. Water Temperature Sensor
3-58 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal in this • Remove chapter). the atmospheric pressure sensor connector • Disconnect [A]. the sensor nut [B]. • Remove Remove the • Front [D] atmospheric pressure sensor [C].
Installation NOTE
○The atmospheric pressure sensor is the same part as the inlet air pressure sensor except for different wiring and no hose.
the atmospheric pressure sensor [A]. •○Install The stopper [B] must not be on the sensor holder [C].
• •
Rear View [D] Tighten the atmospheric pressure sensor nut securely. Install the fuel tank (see Fuel Tank Installation in this chapter).
Input Voltage Inspection NOTE
○Be sure the battery is fully charged. ○The inspection is the same as “Input Voltage Inspection” of the throttle sensor or the inlet air pressure sensor.
the ignition switch OFF. • Turn Remove the ECU (see ECU Removal in this chapter). •○Do not disconnect the ECU connector. Connect a digital meter • needle adapters [C]. [A] to the connector [B], using two Special Tool - Needle Adapter Set: 57001-1457 Atmospheric Pressure Sensor Input Voltage Connections to ECU Meter (+) → BL/W lead (terminal 35) Meter (–) → BR/BK lead (terminal 11)
the input voltage to the sensor with the engine • Measure stopped, and with the connectors joined. • Turn the ignition switch ON. Input Voltage at ECU Standard: 4.75 ∼ 5.25 V DC
the ignition switch OFF. • Turn If the reading is less than the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection in this chapter). If the reading is within the standard range, check the sensor output voltage.
FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) the needle adapters. • Remove Apply silicone • waterproofing. sealant to the seals of the connector for Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connector
56019-120
Output Voltage Inspection NOTE
○The output voltage changes according to the local atmospheric pressure.
Check the output voltage of the sensor at the ECU connector [A]. Needle Adapters [B] Special Tool - Needle Adapter Set: 57001-1457 Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter (+) → BL/Y lead (terminal 28) Meter (–) → BR/BK lead (terminal 11)
the output voltage with the engine stopped and • Measure the connector joined. • Turn the ignition switch ON. Output Voltage at ECU Usable Range: 3.74 ∼ 4.26 V DC at the standard atmospheric pressure (101.32 kPa, or 76 cmHg abs)
• •
If the output voltage is about 4.8 V, the ECU is normal. Remove the fuel tank and check the wiring between the ECU and the sensor. If the output voltage is not about 4.8 V and out of the usable range, remove the fuel tank and check the wiring. If the wiring is good, check the sensor itself as follows. If the output voltage is normal, check the output voltage for vacuum (see Inlet Air Pressure Sensor section in this chapter). If the output voltage changes within the usable range as vacuum changes, the sensor is normal and the ECU is suspect. Check the ECU for its ground and power supply. Turn the ignition switch OFF and remove the needle adapters. Apply silicone sealant the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connector
56019-120
3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15)
1. ECU 2. Atmospheric Pressure Sensor If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for Pv (Throttle Vacuum) in the inlet air pressure sensor chart (see Output Voltage Inspection in the Inlet Air Pressure Sensor section). ○Get the usable range of the atmospheric pressure sensor output voltage in the same way as Output Voltage Inspection of the inlet air pressure sensor and check if Va (output voltage) is within the usable range or not. If you know the local altitude, use the following chart. For example: Suppose the local altitude is 1 300 m (4 200 ft) and the sensor output voltage Va is 3.3 V. Plot this H (1 300 m) at a point [1] on the following chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage. Usable Range = 3.2 ∼ 3.64 V Plot Va (3.3 V) on the vertical line → Point [3] Results: In the chart, Va is within the usable range and the sensor is normal.
FUEL SYSTEM (DFI) 3-61 Atmospheric Pressure Sensor (Service Code 15)
H: Altitude (m or feet) SL: Sea Level (0 m) ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v) Va: Atmospheric Pressure Sensor Output Voltage (v)
3-62 FUEL SYSTEM (DFI) Crankshaft Sensors (#1, #2: Service Code 21, 22) Crankshaft Sensor #1: for Front Cylinder (Service Code 21) Crankshaft Sensor #2: for Rear Cylinder (Service Code 22)
Crankshaft Sensor Removal/Installation
See Crankshaft Sensor Removal/Installation in the Electrical System chapter. •Crankshaft Sensor Inspection
○The crankshaft sensors have no power source, and when the engine stops, the crankshaft sensors
• •
generates no signals. Remove the alternator outer cover and check the wiring for continuity, using the following diagram. Crank the engine and measure the peak voltage of the crankshaft sensors (see Crankshaft Sensor Inspection in the Electrical System chapter) in order to check the coils.
1. ECU 2. Crankshaft Sensors 3. Joint Connector 2
FUEL SYSTEM (DFI) 3-63 Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. the fuel tank (see Fuel Tank Removal in this • Remove chapter). • Remove the bolts [A] and take out the covers [B].
• Remove: Bracket Nut [A] Inlet Air Pressure Sensor Bolt [B]
the bracket nuts [A] and pull the vehicle down • Remove sensor [B] with the bracket [C] out of the frame.
the screws [A] and disconnect the connector [B]. • Unscrew Remove the vehicle down sensor [C]. •
3-64 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Installation
the vehicle-down sensor assy [A] in the original po• Install sition. The arrow mark [B] on the sensor must be on the
• • •
front and point upward. Do not install the sensor upside down. Tighten the sensor bracket nuts [C] securely. Front [D] Install the Fuel Tank (see Fuel Tank Installation in this chapter).
WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situations, like leaning over in a turn, with the potential for an accident resulting in injury or death. Ensure that the down sensor is held in place by the bracket and its bolt as shown.
Vehicle-down Sensor Inspection NOTE
○Be sure the battery is fully charged.
out the vehicle-down sensor [A] (see Removal in this • Take section).
○Do not disconnect the connector [B].
a digital volt meter [C] to the connector (natural, • Connect 3-pin), using two needle adapters [D]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down Sensor Power Source Voltage Connections to Sensor Meter (+) → BR lead [E] Meter (–) → BK/Y lead [F]
the ignition switch ON, and measure the power • Turn source voltage with the connector joined. Output Voltage at Sensor Standard: Battery Voltage (12.5 V or more)
the ignition switch OFF. • Turn If there is no battery voltage, check the DFI power source circuit (see DFI Power Source Circuit in the DFI Power Source section).
FUEL SYSTEM (DFI) 3-65 Vehicle-down Sensor (Service Code 31)
•
If the power source is normal, check the output voltage of the sensor. Connect a digital volt meter [A] to the connector (natural, 3-pin), using two needle adapters [B]. Vehicle-down Sensor Output Voltage Connections to Sensor Meter (+) → Y/G lead [E] Meter (–) → BK/Y lead [F]
the ignition switch ON, and measure the output volt• Turn age with the connector joined.
○Tilt the sensor (40 ∼ 50°) or more [C] right or left, then hold
the sensor almost vertical [D] with the arrow mark pointed up, and measure the output voltage.
Output Voltage at Sensor Standard: with sensor tilted 40 ∼ 50° or more right or left: 3.7 ∼ 4.4 V with sensor arrow mark pointed up: 0.4 ∼ 1.4 V
NOTE
○If you need to test again, turn the ignition switch OFF, and then ON. the ignition switch OFF. • Turn the needle adapters, and apply silicone sealant • Remove to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 -Seals of Vehicle-down Sensor Connector
If the output voltage is out of the specified, replace the vehicle-down sensor. If the output voltage is normal, the wiring is suspect. Check the wiring. If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter).
3-66 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31)
1. ECU 2. Junction Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Frame Ground 6. Starter Relay 7. Main Fuse 30 A 8. Battery 9. Vehicle-down Sensor 10. DFI Main Relay 11. DFI Fuse 15 A 12. Joint Connector 2
FUEL SYSTEM (DFI) 3-67 Fuel Injectors (#1, #2: Service Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Service Code 41) Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Service Code 42)
CAUTION Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it.
Injector Removal
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) lead terminal. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. to see that the battery (–) lead terminal is discon• Check nected. • Remove: Fuel Tank (see Fuel Tank Removal in this chapter) Front and Rear Injector Connectors [A]
the fuel hose joint #2 [A] from the pipe for the • Remove delivery joint and take out the fuel hose assy (outlet hose) [B].
the delivery joint screw [A] and bolts [B], and lift • Unscrew up the delivery joint [C] with the injectors [D]. • Remove the injectors from the delivery joint.
3-68 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) Injector Installation
○The front and rear injectors are the same.
the seal [A] and, O-ring [B] with new ones, and • Replace install them onto the injector [C]. engine oil to the O-ring, and install them onto the • Apply injector.
CAUTION To avoid air and fuel leak, be careful not to get dirt or dust on the O-ring. Be careful not to damage the O-ring. engine oil to the O-ring [A], and install each injector • Apply [B] into the delivery joint [C].
that there is no dirt or dust on the injector seating • Check surface [A] of the inlet manifold [B]. that the two dowel pins [C] are in place in the inlet • Check manifold. the end of the injector into the delivery joint [D], and • Fit install them into the inlet manifold [B].
the projection [A] on the delivery joint [B] with the • Align hole [C] of the left side bracket [D].
[A] the connectors [B] of the injector into the bracket • Fit recesses [C]. • Tighten the delivery joint screw and bolts securely.
FUEL SYSTEM (DFI) 3-69 Fuel Injectors (#1, #2: Service Code 41, 42) 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 a high-pressure fuel hose [C] (both ends connected with clamps [D]) as shown. Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
○Apply a soap and water solution to the areas [E] shown. ○Watching the pressure gauge, squeeze the pump lever
[F], 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)
CAUTION During pressure testing, do not exceed the maximum pressure for which the system is designed. the gauge for at least 6 seconds. • Watch If the pressure holds steady, the system is good. If the pressure drops at once, or if bubbles are found in the area, the line is leaking. Perform the following as necessary. ○Retighten the fuel hose clamps [D]. Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
○Replace:
O-ring, and Seal Ring of Injectors [G]
○Repeat the leak test, and check the fuel line for no leakage.
the fuel outlet hose (see Fuel Tank Installation in • Install this chapter). the hoses correctly (see Cable, Wire, and Hose Rout• Run ing section in the Appendix chapter). the fuel hose joint #2 [A] onto the pipe (for delivery • Fit joint) until the joint clicks [B].
○Insert the hose joint #2 straight along the pipe. Front [C]
3-70 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) and pull [A] the fuel hose joint #2 [B] back and • Push forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak. the fuel tank (see Fuel Tank Installation in this chap• Install ter) and connect the battery (–) terminal.
Audible Inspection
the left air cleaner housing (see Left Air Cleaner • Remove Housing Removal in this chapter). the engine. • Start Apply of a screwdriver [A] to the injector [C]. Put • the griptheendtiponto your ear, and listen whether the injector is clicking or not. ○A sound scope [B] can also be used. Do the same for the other injector. Front [D] If all the injectors click at a regular intervals, the injectors are good. The trouble may be related to the fuel line, requiring fuel pressure inspection (see Fuel Pressure Inspection in this chapter). ○The click interval becomes shorter as the engine speed rises. If either injector doesn’t click, the DFI circuit or the injector is suspect. Perform “Power Source Voltage Inspection”, first.
•
Power Source Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Remove the reserve tank (see Coolant Change in the Pe• riodic Maintenance chapter). Connect a digital meter to the DFI main relay connec• tor [B], using the needle[A]adapter [C]. Battery [D] in the frame Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage at DFI Main Relay Connections Meter (+) → W/R Lead Terminal [E] Meter (–) → Battery (–) Terminal
the power source voltage of the injector with the • Measure engine stopped, and with the connectors joined. • Turn the ignition switch ON. Power Source Voltage at DFI Main Relay Standard: Battery Voltage (12.5 V or more)
FUEL SYSTEM (DFI) 3-71 Fuel Injectors (#1, #2: Service Code 41, 42) If the power source voltage is incorrect, check the DFI power source (see DFI Main Relay Inspection in this chapter). If the DFI power source is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter). If the ground and power supply of the ECU are good, the ECU is suspect. Replace the ECU. If the power source voltage is normal, check the output voltage of the injector.
Output Voltage Inspection
the ECU (see ECU Removal in this chapter). •○Remove Do not disconnect the ECU connector. the output voltage of the injector at the ECU con• Measure nector in the same way as power source voltage inspection. Needle Adapter [A] Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at ECU Connections for Injector #1 Meter (+) → BL/R lead (terminal 40) Meter (–) → Battery (–) Terminal Connections for Injector #2 Meter (+) → BL/G lead (terminal 39) Meter (–) → Battery (–) Terminal Output Voltage at ECU Standard: Battery Voltage (12.5 V or more)
If the output voltage is normal, perform “Injector Signal Test”. If the output voltage is out of the standard, turn the ignition switch OFF, remove the fuel tank, and check the injector wiring for continuity. Injector Wiring Inspection ECU Connector
• •
Injector Connectors
Terminal 30
→
Injector #1 Terminal (W/R)
Terminal 30
→
Injector #2 Terminal (W/R)
Terminal 40
→
Injector #1 Terminal (BL/R)
Terminal 39
→
Injector #2 Terminal (BL/G)
If the wiring is good, inspect the resistance of the injectors (see Injector Resistance Inspection in this section). Remove the needle adapter. Apply silicone sealant to the seals of the ECU connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connectors
56019-120
3-72 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) Injector Signal Test
two test light sets with male terminals as shown. • Prepare Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.03 in.)
CAUTION Do not use larger terminals than specified above. A larger terminal could damage the injector main harness connector (female), leading to harness repair or replacement. Be sure to connect bulbs in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current. the fuel tank (see Fuel Tank Removal in this • Remove chapter). the fuel hose ends. • Plug connectors for injector [A]. • Remove Connect each • connector [C].test light set [B] to the injector main harness the battery (–) lead terminal. • Connect cranking the engine with the starter motor, watch • While the test lights. If the test lights flicker at regular intervals, the injector circuit in the ECU, and the wiring are good. Perform the “Injector Resistance Inspection”.
○Injector signals can be also confirmed by connecting the
hand tester (× 10 V AC) instead of the test light set to the injector main harness (female) connector. Crank the engine with the starter motor, and check to see if the needle oscillates at regular intervals. Special Tool - Hand Tester: 57001-1394
If the test light doesn’t flicker (or the tester needle doesn’t oscillates), check the wiring and connectors again. If the wiring is good, the ECU is suspect. Replace the ECU.
Injector Resistance Inspection
the fuel tank (see Fuel Tank Removal in this • Remove chapter). the connector from the injector [A] (see Injec• Disconnect tor Removal in this chapter). the injector resistance with a digital meter [B]. • Measure Front [C] Injector Resistance Connections to Injector Meter (+)
Meter (–)
#1: W/R
←→
BL/R Terminal
#2: W/R
←→
BL/G Terminal
Standard: 11.7 ∼ 12.3 Ω at 20°C (68°F)
If the reading is out of the range, perform the “Injector Unit Test”. If the reading is normal, perform the “Injector Unit Test” for confirmation.
FUEL SYSTEM (DFI) 3-73 Fuel Injectors (#1, #2: Service Code 41, 42) Injector Unit Test
two wires [A] and the same test light set [B] as in • Use “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V Sealed Battery [D]
CAUTION Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current. the test light set to the injector [E] as shown. • Connect Open and [F] the end of the wire to the battery • (–) terminalconnect repeatedly. The injector should click. If the injector does not click, replace the injector. If the injector clicks, check the wiring again. If the wiring is good, replace the injector (may be clogged) or ECU.
1. ECU 2. Junction Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Stater Relay 6. Main Fuse 30 A
7. Battery 8. Fuel Injector #1 9. Fuel Injector #2 10. DFI Main Relay 11. DFI Fuse 15 A
3-74 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (–) terminal. To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. the fuel tank (see Fuel Tank Removal in this • Remove chapter).
○Be careful of fuel spillage from the fuel tank since fuel still
• • • •
remains in the fuel tank and fuel pump. Plug the fuel pipe of the fuel tank. Turn the fuel tank upside down. Remove the fuel pump inlet hose. Unscrew the fuel pump bolts [A], and take out the fuel pump [B] and gasket. Discard the fuel pump gasket.
CAUTION Do not pull the leads [C] of the fuel pump. If they are pulled, the lead terminals may be damaged.
Fuel Pump Installation
dirt or dust from the fuel pump [A] by lightly ap• Remove plying compressed air.
• Replace the fuel pump gasket [A] with a new one.
FUEL SYSTEM (DFI) 3-75 Fuel Pump (Service Code 45) that the fuel pump (–) terminals [A] and band [B] • Check are in place.
• • •
Front [C] Apply a non-permanent locking agent to the threads of the fuel pump bolts. Tighten the fuel pump bolts to a snug fit, following the tightening sequence shown. Following the tightening sequence, tighten the pump bolts to the specified torque. Torque - Fuel Pump Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the pump bolts again to check the tightness in the • Tighten order shown.
Pressure Regulator Removal
○The pressure regulator [A] is built into the fuel pump [B] and cannot be removed.
Pump Screen, Fuel Filter Cleaning
○The pump screen [A] and fuel filter [B] are built into the
pump and cannot 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.
Operation Inspection NOTE
○Be sure the battery is fully charged. ○Just listen to the pump sound in the fuel tank to confirm pump operation.
the ignition switch ON and make sure that the fuel • Turn pump operates (make light sounds) for 3 seconds, and
•
then stops. Turn the ignition switch OFF. If the pump does not work as described above, inspect the power source voltage.
3-76 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Operating Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn the front seat (see Front Seat Removal in the • Remove Frame chapter). the hand tester (25 V DC) [B] to the fuel pump • Connect connector [A] with two needle adapters [C]. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Pump Operating Voltage at Pump Connections to Pump Connectors Tester (+) → Y/R Lead [D] Tester (–) → BK/W Lead [E]
the operating voltage with the engine stopped, • Measure and with the connector joined. the ignition switch ON. •○Turn The tester needle should indicate battery voltage for 3 seconds, and then 0 V.
Operating Voltage at Pump Connector Standard: Battery Voltage (12.6 V or more) for 3 seconds, and then 0 V.
•
If the reading stays on battery voltage, and never shows 0 V. Check the ECU and DFI main relay. If the voltage is in specification, but the pump doesn’t work, replace the pump. If there is still no battery voltage, check the DFI main relay (see DFI Main Relay Inspection in this chapter). After inspection, remove the needle adapter, and apply silicone sealant to the seal of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of Fuel Pump Connector
56019-120
FUEL SYSTEM (DFI) 3-77 Fuel Pump (Service Code 45) Power Source Voltage Inspection NOTE
○Be sure the battery is fully charged.
the front seat (see Front Seat Removal in the • Remove Frame chapter). a digital meter [A] to the fuel pump connector [B] • Connect (2-pin), using the needle adapter [C]. Special Tool - Needle Adapter Set: 57001-1457 Pump Power Source Voltage Connections to Pump Connector Tester (+) → Y/R lead [D] Tester (–) → Battery (–) Terminal [E]
the power source voltage with the • Measure stopped, and with the pump connector joined. • Turn the ignition switch ON.
engine
Power Source Voltage at Pump Connector Standard: Battery Voltage (12.5 V or more)
Fuel Pump [F] If the reading is good, the power source voltage is normal. Inspect operating source voltage (see Operating Voltage Inspection in this chapter). If the reading is incorrect, check the following: Battery Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) DFI Fuse 15 A (see DFI Fuse Inspection this chapter) Ignition Fuse 10 A in Junction Box (see Fuse Inspection in the Electrical System chapter) DFI Main Relay (see DFI Main Relay Inspection in this chapter) Wiring for Fuel Pump Power Source (see next page) Vehicle-down Sensor (see vehicle-down Sensor Inspection in this chapter)
3-78 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45)
1. ECU 2. Junction Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Starter Relay 6. Main Fuse 30 A 7. Battery 8. Fuel Pump 9. DFI Main Relay 10. DFI Fuse 15 A
FUEL SYSTEM (DFI) 3-79 Ignition Coils (#1, #2: Service Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Service Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Service Code 52)
Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can damage it. Ignition Coil Removal/Installation of the Ignition Sys• See tem section in the Electrical System chapter.
Input Voltage Inspection NOTE
○Be sure the battery is fully charged. the ignition switch OFF. • Turn Remove the ECU (see ECU Removal in this chapter). •○Do not disconnect the ECU connector. a digital meter [A] as shown, using two needle • Connect adapters [B]. Special Tool - Needle Adapter Set: 57001-1457 Ignition Coil Input Voltage at ECU Connections for Ignition Coil #1 Meter (+) → BK lead (terminal 44) Meter (–) → Battery (–) Terminal Connections for Ignition Coil #2 Meter (+) → BK/G lead (terminal 43) Meter (–) → Battery (–) Terminal
the input voltage to each primary winding of the • Measure ignition coils with the engine stopped, and with the con-
•
nectors joined. Turn the ignition switch ON. Input Voltage at ECU Standard: Battery Voltage (12.5 V or more)
• •
If the reading is out of the standard, check the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter). If the reading is good remove the fuel tank and check the wiring between the ECU and the primary lead terminals at the ignition coils. If the wiring is good, crank the engine, and check the peak voltage of the ignition coils (see Ignition Coil Primary Peak Voltage in the Electrical System chapter) in order to check the primary coils. Remove the needle adapters. Apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): -Seals of ECU Connector
56019-120
3-80 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart
FUEL SYSTEM (DFI) 3-81 FI Indicator LED Light The FI indicator LED light [A] goes ON when the ignition switch is turned ON and the LED light goes OFF when the engine oil pressure is high enough (the engine is running). This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly.
LED Light Inspection
to the Meter, Gauge section in the Electrical System • Refer chapter for LED Light Inspection.
WARNING This inspection may produce sparks. Keep the battery and the meter unit away from the fuel tank. If the LED light is abnormal, replace the meter unit. If the FI indicator LED light is normal, the wiring or ECU has trouble. Check the wiring (see next diagram). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection in this chapter).
1. ECU 2. Junction Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Meter Unit 6. FI Indicator LED Light 7. Starter Relay 8. Main Fuse 30 A 9. Battery
3-82 FUEL SYSTEM (DFI) ECU ECU Identification
○Most countries have their own regulations, so each ECU
has different characteristic of fuel injection according to each country. So, do not confuse ECU’s with each other and use only the ECU’s for your country. Otherwise, the motorcycle could not clear the emission regulation.
ECU Identification Models
Type [A]
Part No. [B]
CA and US
F8T97373
21175-0048
EUR
F8T37974
21175-0078
AU
F8T97373
21175-0048
AU: Australia Model CA: Canada Model EUR: Europe Model US: United States Model
ECU Removal CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. the front seat (see Front Seat Removal in the • Remove Frame chapter). • Disconnect: Fuel Pump Connector [A]
•
Fuel Level Sensor Connector [B] Battery (–) Lead Connector [C] Rear Turn Signal/Taillight Lead Connector [D] Remove: DFI Fuse [E] Nuts [F] Battery Holder [G]
the ECU [A] out along with the harness. • Pull If necessary, push the lock and disconnect the ECU connectors.
FUEL SYSTEM (DFI) 3-83 ECU ECU Installation
the ECU connector. • Connect Fit the ECU behind the left side rib [C] of the battery • case [B] until[A]thein ECU bottoms. Front [D]
ECU Power Supply Inspection
the ECU (see ECU Removal in this section). • Remove Visually inspect terminals of the ECU connector. • If the connector the is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals [A] of the main harness connectors are cracked, bent, or otherwise damaged. Replace the ECU if the terminals of the ECU connector are cracked, bent, or otherwise damaged. the ECU connector [A] joined, check the following • With ground leads for continuity with the ignition switch OFF, using a digital meter [B]. Battery [C] in the Frame Special Tool - Needle Adapter Set: 57001-1457 ECU Grounding Inspection Meter Connections: 10, 20, 32, or 42 (BK/Y) Terminal
←→
Battery (–) Terminal
Engine Ground Terminal Battery (–) Terminal ←→ [D] Readings: 0 Ω
If no continuity, check the connector, the engine ground lead, or main harness, and repair or replace them if necessary.
3-84 FUEL SYSTEM (DFI) ECU the power source voltage of the ECU with a digital • Check meter [A]. Battery [B] in the Frame Special Tool - Needle Adapter Set: 57001-1457 ECU Power Source Inspection Meter Connection: between 30 (W/R) Terminal and Battery (–) Terminal Ignition Switch OFF: 0 V Ignition Switch ON:
Battery Voltage (12.5 V or more)
If the digital meter does not read as specified, check the following: Power Source Wiring (see wiring diagram of DFI Power Source section in this chapter). DFI Fuse 15 A (see DFI Fuse Inspection in this chapter) DFI Main Relay (see DFI Main Relay Inspection) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) If the inspection checks good, the ECU is damaged. Replace the ECU. The ECU itself cannot be checked or serviced.
FUEL SYSTEM (DFI) 3-85 DFI Power Source DFI Fuse Removal
the front seat (see Front Seat Removal in the • Remove Frame chapter). the lock [A] and open the lid [B]. • Pull Pull • pliers.out the DFI fuse [C] from the case with needle nose Front [D] 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.
DFI Fuse Inspection
the fuse (see DFI Fuse Removal in this section). • Remove Inspect the element. • If it is open,fuse 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] and Blown Element [D] Terminals [C]
CAUTION When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Do not use a fuse rated for other than amperage and voltage specified in the Wiring Diagram.
DFI Main Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it.
• Remove: Right Side Cover (see Right Side Cover Removal in the •
Frame chapter) Coolant Reservoir Tank (see Coolant Change in the Periodic Maintenance chapter) Remove the DFI main relay [A] and disconnect the connector. Front [B]
DFI Main Relay Inspection
the DFI main relay (see DFI Main Relay Removal • Remove in this section). the hand tester [A] and one 12 V battery [B] to • Connect the relay connector [C] as shown. Special Tool - Hand Tester: 57001-1394
Relay Coil Terminals [1] and [2] Relay Switch Terminals [3] and [4] Testing Relay Tester range: Criteria:
1 Ω range When battery is connected → 0 Ω When battery is disconnected → ∞ Ω
If the relay does not work as specified, replace the relay.
3-86 FUEL SYSTEM (DFI) DFI Power Source DFI Power Source Circuit
1. ECU 2. Junction Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Starter Relay 6. Main Fuse 30 A 7. Battery 8. Fuel Pump 9. Fuel Injector #1 10. Fuel Injector #2 11. ISC Valves #2 12. ISC Valves #1 13. DFI Main Relay (Actuators: Fuel Pump, Fuel Injectors #1 and #2, ISC Valves #1 and #2) 14. DFI Fuse 15 A 15. Joint Connector 2
FUEL SYSTEM (DFI) 3-87 ISC Valves Removal/Installation CAUTION Never drop the ISC valves, especially on a hard surface. Such a shock to the valve can damage it.
○The ISC valves are removed during right air cleaner hous-
ing removal (see Right Air Cleaner Housing Removal in this chapter). ○The ISC valve itself is the same for front and rear, but wiring is different. Be careful not to reverse the leads. ISC Valve #1 [A] → G/Y, W/R leads [B] ISC Valve #2 [C] → G/BL, W/R leads [D] Front [E] Install the ISC hoses as shown. ISC Hose #1 with the red paint mark on the top ISC Hose #2 with the blue paint mark [F] on the top
•
Power Source Voltage Inspection NOTE
○Be sure the battery is fully charged. ○The inspection is the same as “Power Source Voltage Inspection” of the fuel pump. the ignition switch OFF. • Turn Remove right air cleaner cover (see Right Air Cleaner • Housing the Removal in this chapter). a digital voltmeter [A] to the connectors [B] of • Connect each ISC valve. Power Source Voltage at ISC Valve Connector Connections to ISC Valve #1, #2 Meter (+) → W/R Lead Terminal Meter (–) → Battery (–) Terminal
the power source voltage with • Measure stopped, and with the connectors joined. • Turn the ignition switch ON.
the engine
Power Source Voltage at ISC Valve Connector Standard: Battery Voltage (12.5 V or more)
the ignition switch OFF. • Turn If there is no battery voltage, check the DFI power source circuit (see DFI Power Source Circuit in the DFI Power Source section). If the reading is normal, the power supply voltage is normal. Check the output voltage.
3-88 FUEL SYSTEM (DFI) ISC Valves Output Voltage Inspection
the output voltage at the connectors [A] of the ISC • Check Valves. the right air cleaner cover (see Right Air Cleaner • Remove Housing Removal this chapter). Special Tool - Hand Tester [B] : 57001-1394 Output Voltage of ISC Valves Connections for ISC Valve #1 [C] Tester (+) → W/R lead Tester (–) → G/Y lead Connections for ISC Valve #2 [D] Tester (+) → W/R lead Tester (–) → G/BL lead
the output voltage with the engine stopped, and • Measure with the connector joined. • Turn the ignition switch ON. Output Voltage at ISC Valve Reading: The needle points battery voltage (12.5 V or more) and 11 seconds later 0 V.
If the reading is incorrect, check the resistance of the ISC valve (see Resistance Inspection in this chapter). If the reading of the resistance is normal, check the wiring for continuity (see next page). If the wiring is normal, check the ECU for its ground, and power supply (see ECU Power Supply Inspection in this chapter).
Resistance Inspection
the connectors from the ISC valve. • Disconnect the resistance between the terminals of the ISC • Measure valve with a digital meter. ISC Valve Solenoid Resistance (#1, #2) Standard: 13.6 ∼ 20.4 Ω
If the reading is out of the standard range, replace the ISC valve.
FUEL SYSTEM (DFI) 3-89 ISC Valves
1. ECU 2. Junction Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Starter Relay 6. Main Fuse 30 A 7. Battery 8. ISC Valve #2 9. ISC Valve #1 10. DFI Main Relay 11. DFI Fuse 15 A
3-90 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE
○This inspection can determine which trouble the DFI system has, mechanical or electrical trouble.
○It is preferable to measure the fuel pressure while running the motorcycle when the trouble has occurred in order to know symptom well. ○Be sure the battery is fully charged.
the fuel tank (see Fuel Tank Removal in this • Remove chapter). the #2 fuel injector connector [A]. • Disconnect Pinch the lock fuel hose joint #2 with fingers, dis• connect the jointof[B]theand take out the fuel hose assy [C]. Front [D]
WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage. the fuel pressure gauge adapter [A] (special tool) • Install and Fuel Hoses [B] (special tool) between the fuel tank outlet pipe [C] and the inlet pipe [D] to the delivery joint [E]. ○Put the fuel pressure gauge adapter outside the frame. Connect the pressure gauge [F] (special tool) to the fuel pressure gauge adapter. Fuel Tank [G] Fuel Pump [H] Front [I] →: Fuel Flow
•
Special Tools - Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hoses: 57001-1607 Oil Pressure Gauge: 57001-125
the #2 fuel injector connector. • Connect Temporarily, • Connect: install the fuel tank. • Fuel Pump Connector (2-pin) Battery Lead (–) Terminal
WARNING Do not try to start the engine with the fuel hoses disconnected.
FUEL SYSTEM (DFI) 3-91 Fuel Line the ignition switch ON. The fuel pump will turn for 3 • Turn seconds, and then stop. • Measure the fuel pressure with the engine stopped. Fuel Pressure right after Ignition Switch ON, with pump running: Standard: 304 kPa (3.1 kgf/cm², 44 psi) after 3 seconds from Ignition Switch ON, with pump stopped: Standard: 280 kPa (2.9 kgf/cm², 41 psi, residual fuel pressure) The system should hold the residual pressure about 30 seconds.
the engine, and let it idle. • Start Measure the fuel pressure with the engine idling. • Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi)
NOTE
○The gauge needle will fluctuate.
Read the pressure at the average of the maximum and minimum indications.
• •
If the fuel pressure is normal, the fuel circulation system (fuel pump, pressure regulator, and oil passage) is no faults. Check the DFI electronic control system (injectors, sensors, crankshaft sensors, and ECU). If the fuel pressure is much higher than the specified, check the following: Delivery Pipe Clogging Injector Clogging If the fuel pressure is much lower than specified, check the following: Fuel Pump for Operation (Check the sound of the pump.) Fuel Line Leakage or Clogging Amount of Fuel Flow (see Fuel Flow Rate Inspection in this section) If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the fuel pump assy (the fuel filter may be clogged) and measure the fuel pressure again. If the residual pressure 260 ∼ 280 kPa drops at once, the high pressure fuel line could be leaking. Remove the fuel pressure gauge and adapter. Run the fuel hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter
3-92 FUEL SYSTEM (DFI) Fuel Line the fuel hose joint #2 [A] onto the pipe (for delivery • Fit joint) until the joint clicks [B].
○Insert the hose joint straight along the pipe. Front [C]
and pull [A] the fuel hose joint #2 [B] back and • Push forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.
Fuel Flow Rate Inspection NOTE
○Be sure the battery is fully charged. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. both ignition switch, and engine stop switch OFF. • Turn Wait until engine cools down. • Open the the • tank. fuel tank cap [A] to lower the pressure in the Front [B]
FUEL SYSTEM (DFI) 3-93 Fuel Line a plastic hose of the inside diameter 7.5 mm • Prepare (0.30 in.) × L = about 400 mm (15.7 in.) and a measuring cylinder. Remove: Front Seat (see Front Seat Removal in the Frame chapter) Meter Cover (see Fuel Tank Removal in this chapter). Fuel Tank Bolts Raise the fuel tank. Stuff a clean shop towel around the fuel outlet hose joint. ○While pinching the locks of the hose joint #1 with fingers, disconnect the joint (see Fuel Tank Removal in this chapter) and insert the plastic hose [A] quickly onto the tank outlet pipe. Secure the plastic hose with a clamp [B]. Run the other side of the plastic hose into the measuring cylinder [C]. Temporarily install the fuel tank and close the fuel tank cap.
• • • • • •
WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. the engine stopped, turn the ignition switch ON. The • With fuel pump should operate for 3 seconds, and then should
•
stop. Repeat this several times until the plastic hose is filled with fuel. Measure the discharge for 3 seconds with the plastic hose filled with fuel. Amount of Fuel Flow Standard: 67 mL (2.27 US oz) or more for 3 seconds
• •
If the fuel flow is much less than the specified, check the battery condition (see Charging Condition Inspection in the Electrical System chapter). If the battery is good, replace the fuel pump. After inspection, connect the fuel hoses, and install the fuel tank (see Fuel Tank Installation in this chapter). Start the engine and check for no fuel leakage.
3-94 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection
to the Throttle Control System Check in the Periodic • Refer Maintenance Chapter.
Throttle Grip Free Play Adjustment
the locknuts [A] and screw the adjusters [B] all the • Loosen way in so as to give the throttle grip plenty of play. out the adjuster of the decelerator cable [C] until • Turn there is no play. the locknut against the adjuster. • Tighten Turn the adjuster of the accelerator cable [D] until the • proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.
WARNING Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.
Choke Knob Operation
to the Choke Knob Operation in the Periodic Main• Refer tenance chapter.
Choke Cable Free Play Inspection
○Choke cable free play cannot be adjusted.
that the choke inner cable slides smoothly by • Check pulling and pushing the choke knob lightly. If there is any irregularity, or the choke lever doesn’t work when the choke knob is pulled fully, replace the choke cable.
Cable Removal/Installation
○See
Throttle Body Assy section in this chapter for removal/installation of the throttle cables and choke cable.
Cable Lubrication and Inspection
the choke cable or the throttle cables are re• Whenever moved or in accordance with the Periodic Maintenance Chart, lubricate the these cables. Refer to the General Lubrication in the Periodic Maintenance Chapter. ○Use a commercially available pressure cable lubricator to lubricate these cables. ○With the cable disconnected at both ends, the cable should move freely in the cable housing.
FUEL SYSTEM (DFI) 3-95 Throttle Body Assy Idle Speed Check
to the Idle Speed Inspection in the Periodic Main• Refer tenance Chapter.
Idle Speed Adjustment
to the Idle Speed Adjustment in the Periodic Main• Refer tenance Chapter.
High Altitude Performance Adjustment
○Any modification is not necessary in this model since the
atmospheric pressure sensor senses pressure change due to high altitude and the ECU compensates the change.
Throttle Body Assy Removal
the fuel tank (see Fuel Tank Removal in this • Remove chapter).
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (–) terminal. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
• Remove: Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Left Air Cleaner Base (see Left Air Cleaner Housing Removal/Installation in this chapter) Right Air Cleaner Base (see Right Air Cleaner Housing Removal in this chapter) Spark Plug Lead Holder Bolts [A] Spark Plug Lead Holder [B] and Spark Plug Caps [C] Throttle Body Assy Holder Bolts [D] Throttle Body Assy Holder [E] Front [F]
• Disconnect: Throttle Sensor Connector [A] Vacuum Hose [B] (From Inlet Air Pressure Sensor) Vacuum Hose [C] (Between Vacuum Switch Valve and Throttle Body Assy)
3-96 FUEL SYSTEM (DFI) Throttle Body Assy the front and rear injector connectors [A]. • Disconnect Front [B]
the following from the choke cable holder [A]. • Remove Screw [B] Choke Cable Plate [C]
pushing the choke lever [A] forward, remove the • While cable housing from the choke cable holder [B] and the
•
inner cable out of the holder slit [C]. Take off the lower end [D] from the choke lever. Front [E]
the screws [A] and take off the right switch hous• Remove ing [B].
the accelerator cable end [A] and decelerator • Remove cable end [B] at the throttle grip.
FUEL SYSTEM (DFI) 3-97 Throttle Body Assy the cable clip [A]. • Remove Turn the throttle pulley [B] as shown, and pull out the ac• celerator cable housing [C] from the cable holder [D]. the pulley, and pull out the decelerator cable hous• Return ing [E] from the cable holder. the decelerator cable end [F] and the accelerator • Remove cable end [G] from the throttle pulley [B].
the lock of the fuel hose joint #2 [A] with fingers, • Pinch pull the joint #2 out along the pipe (for delivery joint), and take out the fuel hose assy [B]. Front [C]
the inlet manifold bolts [A]. • Unscrew Inlet Manifold [B] Front [C]
out the throttle body assy [A] from the right side, • Take while tilting it up.
○Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts.
○Do not drop the throttle body assy, especially on a hard surface.
WARNING The throttle body assy should never be allowed to fall. Throttle may become stuck, possibly causing an accident. a piece of lint-free, clean cloth into the throttle body • Stuff assy, and the inlet ports of the cylinder heads to keep dirt out of the engine.
WARNING If dirt or dust is allowed to pass through into the throttle bore, the throttle may become stuck, possibly causing an accident.
CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
3-98 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Installation
the lower air cleaner duct between cylinders. • Install Replace the flange seal [A] with a new one. • With a high-flash solvent, clean off the flange sur• face of the cylinderpoint head and wipe dry. the flange [B] and the seal in the direction shown. • Install Face the ribs [C] of the flange and the smaller diameter end upwards.
○The seal should be centered on the flange.
• Tighten the inlet manifold bolts [D] to a snag fit. tighten the throttle body assy holder bolts [A], • First, secondly the inlet manifold bolts [B] and spark plug lead holder bolts [C] to the specified torque. Torque - Throttle Body Assy Holder Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Inlet Manifold Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Spark Plug Lead Holder Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
the lower ends of the throttle cables in the throttle • Install pulley.
• • • •
Accelerator Cable [A] and Decelerator Cable [B] Run the throttle cables correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Stake [C] the cable clip [D] on the throttle cable holder [E]. Rear View [F] Install the lower end of the choke cable in the choke lever. Apply a non-permanent locking agent to the threads of the choke cable plate screw. Torque - Choke Cable Plate Screw: 2.9 N·m (0.30 kgf·m, 26 in·lb)
the choke cable correctly (see Cable, Wire, and Hose • Run Routing section in the Appendix chapter) and check that the choke knob moves smoothly.
a thin coating of grease to the throttle cable upper • Apply ends. the upper ends of the throttle cables in the grip. • Install Fit the [A] of the right switch housing into the • hole [B]projection of the handlebar. the throttle grip and make sure that the throttle valves • Turn move smoothly and return by spring force. the throttle grip free play (see Throttle Control Sys• Check tem Play Inspection in the Periodic Maintenance chapter).
WARNING Operation with an incorrectly routed cable could result in an unsafe riding condition.
FUEL SYSTEM (DFI) 3-99 Throttle Body Assy the fuel hose joint #2 [A] onto the pipe (for delivery • Fit joint) until the joint clicks [B].
○Insert the hose joint straight along the pipe. Front [C]
and pull [A] the fuel hose joint #2 [B] back and • Push forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.
• Install the removed parts (see appropriate chapters). Throttle Body Assy Disassembly/Assembly
the throttle body assy (see Throttle Body Assy • Remove Removal in this section). two bolts [A], and pull out the ISC pipe #1 [B], • Unscrew and ISC pipe #2 [C] from the hoses [D]. Bottom View [E]
• Remove the three throttle body flange bolts [A].
3-100 FUEL SYSTEM (DFI) Throttle Body Assy the throttle body assy into the throttle body [A] and • Split the inlet manifold [B]. The gasket [C] comes off. • Discard the gasket.
○Do not remove or adjust the following parts. These parts are set at the factory and cannot be readjusted.
CAUTION Adjustment of some of these parts could result in poor performance, requiring replacement of the throttle body. Throttle Sensor [A]: Turning the sensor body could spoil the ignition timing and injection quantity. Front View [B] Throttle Stop Screw [A]: Tampering with this screw could spoil the idling performance since the screw sets the gap between the throttle valves and the throttle bore with throttle grip closed. Rear View [B]
Choke Lever Stop Screw [A]: This screw sets the throttle valve opening when the choke knob is pulled fully. Tampering with the screw could cause malfunction of the choke lever. Throttle Cable Holder [B]: This is sold with a throttle body as a unit. Rear View [C] Throttle Valve and Throttle Shaft: They are not allowed to remove because of difficulty of removal.
FUEL SYSTEM (DFI) 3-101 Throttle Body Assy the delivery joint and injectors (see Injector Re• Remove moval in this chapter). the butterfly valves [A], and wipe any carbon off • Open the throttle bores [B] around the valves, using a piece of
• •
lint-free cloth penetrated with a high-flash point solvent. Clean the bores [C] of the inlet manifold [D] as well. Blow away dirt or dust from the throttle body and the inlet manifold by applying compressed air.
CAUTION Do not immerse the throttle body (or throttle assy) in a high-flash point solvent for cleaning. This could damage the throttle sensor on the throttle body. assembly, visually inspect the mating surfaces [A] • Before for any damage, like dent, nick, rust, flaw, and crack. or rust damage can sometimes be repaired by using • Nick emery paper (first No. 200, then 400) to remove sharp edges or raised areas. If the damage is not repairable, replace the throttle body and/or the inlet manifold to prevent leakage. With a high-flash point solvent, clean off the mating surfaces and wipe dry. Be sure to install the dowel pins [B]. Fit the new gasket [C] into the groove. Be careful not to pinch the gasket between the mating surfaces. Tighten the flange bolts evenly.
• • • • the throttle pulley [A] to check that the throttle valves • Turn [B] move smoothly and return by spring force.
If the throttle valves do not move smoothly, replace the throttle body.
3-102 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal
• Remove: Allen Bolt and Washer [A]
Left Air Cleaner Cover [B]
the element [A]. • Remove Push a clean, towel into the lower air cleaner duct • to keep dirt orlint-free other foreign material from entering.
WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possibly causing an accident.
CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
Air Cleaner Element Cleaning
to the Air Cleaner Element Cleaning in the Periodic • Refer Maintenance Chapter.
Left Air Cleaner Housing Removal/Installation
• Remove: Air Cleaner Element (see Air Cleaner Element Removal •
in this section) Air Cleaner Base Bolts [A] and Screws [B] Remove the air cleaner base [C].
○Be careful not to lose the air cleaner base mounting nuts
•
[A]. These nuts and lower air cleaner duct are sold as a unit. Apply a non-permanent locking agent to the threads of the air cleaner base screws.
Torque - Left Air Cleaner Base Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Left Air Cleaner Base Screws: 2.2 N·m (0.22 kgf·m, 19 in·lb) Left Air Cleaner Cover Allen Bolt: 16 N·m (1.6 kgf·m, 12 ft·lb)
FUEL SYSTEM (DFI) 3-103 Air Cleaner Right Air Cleaner Housing Removal
• Remove: Allen Bolt and Washer [A]
Right Air Cleaner Cover [B]
• Remove: ISC Valve Hoses [A] ISC Valve Lead Connectors [B] Air Cleaner Allen Bolts [C] and Screws [D] Air Cleaner Base Bolt [E] Choke Knob [F]
• Remove: Air Cleaner Base [A] Inlet Air Temperature Sensor Connector [B] ISC Valve Leads [C] Crankcase Breather Hose [D] Air Cleaner Drain Hose [E] (separate from the base [A]) Vacuum Switch Valve Air Hose [F] ○Be careful not to lose the air cleaner base mounting nuts [G]. These nuts and lower air cleaner duct are sold as a unit.
Right Air Cleaner Housing Installation
to see that the seals [A], [B] and the ISC pipe O • Check -rings [C] are in place. a non-permanent locking agent to the threads of • Apply the right air cleaner base screws. • Tighten: Torque - Right Air Cleaner Base Bolt [D]: 11 N·m (1.1 kgf·m, 97 in·lb), Right Air Cleaner Allen Bolts [E]: 11 N·m (1.1 kgf·m, 97 in·lb), Right Air Cleaner Base Screws [F]: 2.2 N·m (0.22 kgf·m, 19 in·lb)
3-104 FUEL SYSTEM (DFI) Air Cleaner If the air cleaner drain hose [A] has been removed with it attached to the right air cleaner base, pull the drain hose off the right air cleaner base. Remove the left air cleaner base and insert the drain hose under the lower air cleaner duct.
the inlet air temperature sensor [A], the ISC valve • Install #1 [B], ISC valve #2 [C], and the crankcase breather hose [D]. Torque - Inlet Air Temperature Sensor Nut [E]: 7.8 N·m (0.80 kgf·m, 69 in·lb)
○The ISC valve #1 is connected to W/R and G/Y leads, and the hose [F] marked red.
○The ISC valve #2 is connected to W/R and G/BL leads, and the hose [G] marked blue. ○The ISC valve #1 and #2 are the same parts. Top Marks [H]
Torque - Right Air Cleaner Cover Allen Bolt: 16 N·m (1.6 kgf·m, 12 ft·lb)
Lower Air Cleaner Duct Removal/Installation
• Remove: Left Air Cleaner Housing (see Left Air Cleaner Housing
•
Removal/Installation in this section) Right Air Cleaner Housing (see Right Air Cleaner Housing Removal in this section) Throttle Body Assy (see Throttle Body Assy Removal in this chapter) Remove: Oil Hose Clamps [A] Lower Air Cleaner Duct [B] Air Cleaner Duct Holder [C] Torque - Air Cleaner Duct Holder Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)
FUEL SYSTEM (DFI) 3-105 Fuel Tank Fuel Tank Removal
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (–) terminal. To avoid fire, do not remove the fuel tank when the engine is still hot. Wait until it cools down. To make fuel spillage minimum, draw the fuel out from the fuel tank with a pump as much as possible when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. both ignition switch, and engine stop switch OFF. • Turn Wait until engine cools down. • Open the the fuel cap [A] to lower the pressure in the • tank, and drawtank the fuel out from the fuel tank with a commercially available pump.
WARNING The fuel cannot be removed completely from the fuel tank. Be careful for remained fuel spillage. the Allen bolts [A] and take out the meter cover • Remove [B].
the meter [A] and ignition switch [B] connec• Disconnect tors.
3-106 FUEL SYSTEM (DFI) Fuel Tank
• Remove the bolts [A] and take out the meter unit [B]. CAUTION
Place the meter so that the face is up. If a meter is left upside down or sideways for any length of time, it will malfunction.
• Remove: Front Seat (see Front Seat Removal in the Frame chap•
ter) Fuel Tank Bolts [A] Disconnect the battery (–) terminal.
• Disconnect: Fuel Pump Connector (2-pin) [A] Fuel Level Sensor Connector (3-pin) [B]
NOTE
○During tank removal, keep the fuel tank cap [A] open
to release pressure in the fuel tank. This makes fuel spillage less.
the fuel out from the fuel tank with a commercially • Draw available pump.
○Put the soft plastic hose [A] into the drain pipe [B] and draw the fuel out.
FUEL SYSTEM (DFI) 3-107 Fuel Tank Prepare rubber hoses of the inside diameter 5 ∼ 5.8 mm • (0.20 ∼ 0.23 in.) [e.g. Rubber Tube: Part No. 92191
• •
-1272] × L = 80 mm (3.1 in.) and make plug hoses [A] of the rubber hose with one end tied with a wire [B]. Raise the rear of the tank up, and disconnect the hoses on the bottom. Plug these pipes [C] with plug hoses to prevent fuel spillage.
the fuel drain hose [A]. • Disconnect Front [B]
a rubber hose of the inside diameter 7.3 ∼ 7.5 • Prepare mm (0.29 ∼ 0.30 in.) [e.g. Part No. 92191-1264] × L = 100 mm (3.9 in.) and make a plug hose [A] with one end tied with a wire [B].
the fuel tank [A] up, and make sure that the shop • Raise towel [B] is around the fuel hose joint #1 [C]. person should pinch the hose joint locks [D] with fingers, • Adisconnect the joint [E], and plug the tank outlet pipe with the plug hose. Front [F]
WARNING Immediately wipe up fuel that spills.
3-108 FUEL SYSTEM (DFI) Fuel Tank the fuel tank cap. • Close Remove the fuel tank from the vehicle, and place it on a • flat surface.
CAUTION For California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one. California Model, note the following: •○For To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.
WARNING For California model, be careful not to spill the gasoline through the return hose. Spilled fuel is hazardous. If liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air (California Model).
○Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump.
WARNING Store the fuel tank in an area which is well -ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage.
Fuel Tank Installation
the above WARNING. • Read Route hoses correctly (see Cable, Wire, and Hose • Routingthesection in the Appendix chapter). For California Model, note the 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 system (see the last page of this chapter or Cable, Wire, and Hose Routing section in the Appendix chapter). Make sure they do not get pinched or kinked. ○Route hoses with a minimum of bending so that the air or vapor will not be obstructed.
FUEL SYSTEM (DFI) 3-109 Fuel Tank that the rubber dampers [A] are in place. • Check If the dampers are damaged or deteriorated,
replace them. ○Remove the plug hoses, and 8 mm (0.03 in.) plug, then quickly install the fuel hoses one by one. Be sure the hoses are clamped securely to prevent leakage.
•
the fuel hose joint #1 [A] straight onto the tank outlet • Insert pipe [B] until the hose joint clicks [C] Front [D]
and pull [A] the hose joint [B] back and forth more • Push than two times and make sure it is locked and doesn’t come off. When the hose joint is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.)
WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.
•
If it does not slide, reinstall the hose joint. Connect the fuel pump and the fuel level sensor connectors and the battery (–) lead terminal.
Fuel Tank and Cap Inspection
inspect the gasket [A] on the tank cap for any • Visually damage.
•
Replace the gasket if it is damaged. Check to see if the breather pipe [B] in the tank is not clogged. If the breather pipe is clogged, blow the breather free with compressed air. If the tank cap breather is clogged, replace the tank cap. Front [C]
CAUTION Do not apply compressed air to the air vent holes [D] in the tank cap. This could damage and clog the labyrinth in the cap.
3-110 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning
WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the tank. the fuel tank (see Fuel Tank Removal in this • Remove chapter). the fuel pump from the fuel tank (see Fuel Pump • Remove Removal in this chapter). the fuel tank with some high-flash point solvent, and • Fill shake the tank to remove dirt and fuel deposits. the solvent out of the tank. • Draw Dry the compressed air. • Install thetankfuelwith pump on the fuel tank (see Fuel Pump In• stallation in this chapter). the fuel tank (see Fuel Tank Installation in this chap• Install ter).
FUEL SYSTEM (DFI) 3-111 Evaporative Emission Control System The Evaporative Emission Control System for California Model 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. 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.
CAUTION 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. sure to plug the return hose to prevent fuel spilling • Be before fuel tank removal.
WARNING When removing the fuel tank, be careful not to spill the gasoline through the return hose. Spilled fuel is hazardous.
• •
If liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air. Connect the hoses according to the diagram of the system (see Cable, Wire, and Hose Routing section in the Appendix chapter). Make sure they do not get pinched or kinked. Route hoses with a minimum of bending so that the air or vapor will not be obstructed.
Canister Installation
the purge hose (green) [A] above the canister • Run breather hose (blue) [B] through the hole [C] into the tool case [D]. ○Do not run these hoses side by side on the battery side of the canister. This prevents hoses from being flattened when installing the left side cover. Install the canister and the left side cover (see Left Side Cover Installation in the Frame chapter). Face the white mark [E] left as shown.
• •
Canister 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.
3-112 FUEL SYSTEM (DFI) Evaporative Emission Control System Hose Inspection
to the Evaporative Emission Control System In• Refer spection in the Periodic Maintenance Chapter.
Separator Operation Test
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.
• Remove: Front Seat (see Front Seat Removal in the Frame chap• • • • •
ter) Left Side Cover (see Left Side Cover Removal in the Frame chapter) Connect the hoses to the separator. Disconnect the breather hose from the separator, and inject about 20 mL (0.68 US oz.) of gasoline [A] into the separator [B] through the hose fitting. Disconnect the evaporative fuel return hose [C] from the fuel tank [D] Run the open end of the return hose into the container 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.
FUEL SYSTEM (DFI) 3-113 Evaporative Emission Control System
1. Fuel Tank 2. White Hose (Vacuum) 3. Throttle Body 4. Green Hose (Purge) 5. Lower Air Cleaner Duct 6. Canister 7. Band (for Canister) 8. Inlet 9. Red Hose (Rear, Return) 10. Fitting 11. Band (for Separator) 12. Bracket 13. Separator 14. Blue Hose (Breather) 15. Blue Hose (Front, Breather)
COOLING SYSTEM 4-1
Cooling System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Coolant Flow Chart................................................................................................................. Coolant ................................................................................................................................... Coolant Deterioration Inspection....................................................................................... Coolant Level Inspection................................................................................................... Coolant Draining ............................................................................................................... Coolant Filling ................................................................................................................... Pressure Testing ............................................................................................................... Cooling System Flushing .................................................................................................. Water Pump............................................................................................................................ Water Pump Removal ....................................................................................................... Water Pump Installation .................................................................................................... Water Pump Inspection..................................................................................................... Mechanical Seal Replacement ......................................................................................... Radiator .................................................................................................................................. Radiator Removal ............................................................................................................. Radiator Installation .......................................................................................................... Radiator Inspection ........................................................................................................... Radiator Cap Inspection ................................................................................................... Radiator Filler Neck Inspection ......................................................................................... Thermostat ............................................................................................................................. Thermostat Removal......................................................................................................... Thermostat Installation...................................................................................................... Thermostat Inspection ...................................................................................................... Hoses and Pipes .................................................................................................................... Hose Installation ............................................................................................................... Hose Inspection ................................................................................................................
4-2 4-4 4-5 4-6 4-8 4-8 4-8 4-8 4-8 4-8 4-9 4-10 4-10 4-10 4-11 4-11 4-14 4-14 4-15 4-15 4-16 4-16 4-17 4-17 4-17 4-17 4-18 4-18 4-18
4
4-2 COOLING SYSTEM Exploded View
COOLING SYSTEM 4-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11
Fastener Radiator Drain Bolt Radiator Fan Bolts Radiator Fan Switch Water Hose Clamp Screws Water Pipe Bolts Water Pump Air Bleeder Bolt Water Pump Cover Bolts Water Pump Drain Bolt Water Pump Impeller Bolt Water Temperature Sensor Water Temperature Switch
N·m 2.2 8.3 18 2.5 11 11 11 11 8.8 18 7.8
12. Ball Bearing 13. Double Seal Bearing 14. Mechanical Seal 15. Oil Seal 16. Radiator 17. Radiator Cap 18. Thermostat G: Apply grease. LH: Left-hand threads R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
Torque kgf·m 0.22 0.85 1.8 0.25 1.1 1.1 1.1 1.1 0.90 1.8 0.80
ft·lb 19 in·lb 73 in·lb 13 22 in·lb 97 in·lb 97 in·lb 97 in·lb 97 in·lb 78 in·lb 13 69 in·lb
Remarks
LH SS SS
4-4 COOLING SYSTEM Specifications 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
Permanent type 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) 2.3 L (2.4 US qt) (Reserve tank full level including radiator and engine) 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13.5 ∼ 17.8 psi) 58 ∼ 62°C (136 ∼ 144°F) 8 mm (0.3 in.) or more @ 75°C (167°F)
COOLING SYSTEM 4-5 Special Tools and Sealant Bearing Driver Set: 57001-1129
Bearing Remover Shaft, 57001-1265
Bearing Remover Head, 57001-1266
9:
10 ×
12:
Kawasaki Bond (Silicone Sealant): 56019-120
4-6 COOLING SYSTEM Coolant Flow Chart
1. Water Pump 2. Water Jacket 3. Cylinder Head 4. Water Pipe 5. Water Hose 6. Radiator Cap 7. Thermostat 8. Reserve Tank Hose
9. Radiator 10. Radiator Fan 11. Throttle Body Assy 12. Front 13. Cold Coolant 14. Hot Coolant 15. Reserve Tank 16. Reserve Tank Overflow Hose
COOLING SYSTEM 4-7 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 as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is below 58 ∼ 62°C (136 ∼ 144°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 ∼ 110°C (212 ∼ 230°F), the radiator fan switch 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 temperature is below 97 ∼ 103°C (207 ∼ 217°F), the fan switch 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, 13.5 ∼ 17.8 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, 13.5 ∼ 17.8 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to from a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.
4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection
the right side cover (see Right Side Cover Re• Remove moval in the Frame chapter). inspect the coolant [A] in the reservoir 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, flash 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 Inspection in the Periodic Main• Refer tenance 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 fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). the radiator cap, and install a cooling system • Remove pressure tester [A] on the radiator filler neck [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
up pressure in the system carefully until the pres• Build sure reaches 123 kPa (1.25 kgf/cm², 17.8 psi).
CAUTION During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 17.8 psi). the gauge for at least 6 seconds. • Watch If the pressure holds 93 kPa (0.95 kgf/cm², 13.5 psi) or
•
more, the system is all right. If the pressure drops and no external source is found, check for internal leakage. Droplets in the engine oil indicate internal leakage. Check the cylinder head and cylinder gaskets 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 considerably 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.
• •
CAUTION 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).
4-10 COOLING SYSTEM Water Pump Water Pump Removal
the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C]
• Remove: Water Pump Cover Bolts [A] Water Pump Cover [B]
• Remove: Impeller Bolt [A] Impeller [B]
NOTE
○The impeller bolt has left-hand threads.
Turn the bolt
clockwise and remove it.
Water Pump Installation
the water pump impeller bolt by turning the bolt • Tighten counterclockwise. Torque - Water Pump Impeller Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
the water pump cover gasket with a new one. • Replace There are gasket [A] on rear side of the water • pump coveraluminum [B]. Replace them with new ones when installing. Front [C] Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
COOLING SYSTEM 4-11 Water Pump the pump inlet hose until the hose end [A] touches • Insert the pump inlet step [B]. • Tighten the hose clamp screw securely.
Torque - Water Hose Clamp Screw: 2.5 N·m (0.25 kgf·m, 22 in·lb)
Water Pump Inspection
the water pump drainage outlet hose [A] at the • Check bottom of the water pump for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drain through the passage. Replace the mechanical seal.
inspect the impeller [A]. • Visually If the surface is corroded, or if the blades are damaged, replace the impeller.
Mechanical Seal Replacement
the water pump impeller (see Water Pump Re• Remove moval in this section). the mechanical seal flange off with a small chisel [A]. • Pry Pull the mechanical seal out of the right crankcase with • needle nose pliers. Discard the mechanical seal.
CAUTION Be careful not to damage the water pump shaft and the inner sealing surface of the crankcase.
• Replace the mechanical seal with a new one. NOTE
○Since the replacement mechanical seal has an adhesive coated body, do not apply a liquid gasket to the exterior surface of the body.
4-12 COOLING SYSTEM Water Pump [A] the mechanical seal [B] by using a suitable 28 • Press mm socket [C] and a bearing driver [D] until its flange touches the step [E]. Gap [F] Special Tool - Bearing Driver Set: 57001-1129
• • • •
If the coolant still leaks through the drainage outlet hose, the seal and ball bearings is probably damaged. Replace the mechanical seal, ball bearings, and oil seal by splitting the crankcase. Split the crankcase (see Crankcase Disassembly in the Crankshaft/Transmission chapter). Remove the water pump impeller (see Water Pump Removal in this section). Pull out the water pump shaft from the inside of the right crankcase. Take the bearing [A] out of the right crankcase, using the bearing remover. Special Tools - Bearing Remover Shaft [B]: 57001-1265 Bearing Remover Head 10 × 12 [C]: 57001 -1266
a thin-bladed screwdriver, pry out the oil seal. • Using out the mechanical seal [A] and ball bearing [B] • Press from the inside of the right crankcase with the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001-1129
○Be sure to replace the mechanical seal, oil seal, O-ring,
• • •
and ball bearings with new ones because these parts will be damaged by removal. Apply plenty of high-temperature grease to the oil seal lips. Apply oil to the outer circumference of the oil seal. Press the oil seal [A] into the hole from the inside of the right crankcase with the bearing driver set so that the spring side of the seal lips is toward the inside of the crankcase. Special Tool - Bearing Driver Set: 57001-1129
the oil seal in until the seal end is even with step • Press [B] of the hole as shown.
○Use the bearing driver which has a larger diameter than
•
the oil seal. Press in each ball bearing [C] with its manufacturer’s mark facing out until it bottoms out.
COOLING SYSTEM 4-13 Water Pump [A] the mechanical seal [B] by using a suitable 28 • Press mm socket [C] and a bearing driver [D] until its flange
•
touches the step [E]. Gap [F] Install the water pump shaft from the inside of the right crankcase. Special Tool - Bearing Driver Set: 57001-1129
both sliding surfaces of a new mechanical seal with • Clean a high-flash point solvent (e.g. ethyl alcohol), and apply a
• •
little coolant to the sliding surface to give the mechanical seal initial lubrication. Apply coolant to the surface of the rubber seal [A] and sealing seat [B], and press the rubber seal and sealing seat into the impeller by hand until the seat bottoms out. Tighten the water pump impeller bolt by turning the bolt counterclockwise. Torque - Water Pump Impeller Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
4-14 COOLING SYSTEM Radiator WARNING The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
Radiator Removal
the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Cover Bolts [A] Cover [B] Front [C]
• Pry the plastic clamps [A].
• Remove: Nut [A] Radiator Fan Motor Connector [B]
• Remove: Radiator Hose Clamps [A] Radiator Hoses [B]
COOLING SYSTEM 4-15 Radiator the mounting bolt [A]. • Remove Lift up the to clear the stoppers. • Remove theradiator radiator. •
CAUTION
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
• Remove: Radiator Fan Bolts [A] Radiator Fan [B]
Radiator Installation
• Be sure to install the radiator fan ground lead terminal [A]. Torque - Radiator Fan Bolts: 8.3 N·m (0.85 kgf·m, 73 in·lb)
the radiator stoppers [A] into the left and right grom• Fit mets [B]. the pump inlet hose and position the hose clamp • Install (see Water Pump Installation in this chapter). • Tighten the hose clamp screw securely. Torque - Water Hose Clamp Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb)
Radiator Inspection
the radiator (see Radiator Removal in this sec• Remove tion). 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.
4-16 COOLING SYSTEM Radiator CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. 1.Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. 2.Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface and run the steam gun following the core fin direction.
Radiator Cap Inspection
the radiator cap (see Coolant Change in the Pe• Remove riodic Maintenance chapter). the condition of the top and bottom valve seals of • Check the radiator cap. If any one of them shows visible damage, replace the cap. Bottom Valve Seal [A] Top Valve Seal [B] Valve Spring [C]
• Install the cap [A] on a cooling system pressure tester [B]. NOTE
○Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
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 needle must remain within the same range at least 6 seconds. Radiator Cap Relief Pressure Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13.5 ∼ 17.8 psi)
If the cap holds too much pressure or cannot hold the specified pressure, replace it with a new one.
Radiator Filler Neck Inspection
the radiator cap (see Coolant Change in the Pe• Remove riodic Maintenance chapter). the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats • Check [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly. Front [B]
COOLING SYSTEM 4-17 Thermostat Thermostat Removal
the coolant (about 200 mL, 6.8 US oz.). • Drain Remove: • Fuel Tank (see Fuel Tank Removal in the Fuel System
•
(DFI) chapter) Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector [C] Remove the thermostat housing [D] along with the bracket. Front [E]
the bolts [A], take off the cap [B], and take out • Remove the thermostat.
Thermostat Installation
the thermostat [A] in the housing so that the air • Install bleeder hole [B] is on top. a new O-ring into the housing. • Install Fill the with coolant (see Coolant Change in the • Periodicradiator Maintenance chapter).
Thermostat Inspection
the thermostat (see Thermostat Removal in this • Remove section), and inspect the thermostat valve at room tem-
•
perature. If the valve is open, replace the valve with a new one. To check valve opening temperature, suspend the thermostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth.
NOTE
○The thermostat must be completely submerged and the thermostat and thermometer must not touch the container sides or bottom.
raise the temperature of the water while stirring • Gradually the water gently for even temperature. If the measurement is out of the range, replace the thermostat. Thermostat Valve Opening Temperature 58 ∼ 62°C (136 ∼ 144°F)
4-18 COOLING SYSTEM Hoses and Pipes Hose Installation
the hoses and pipes being careful to follow bend• Install ing direction. Avoid sharp bending, kinking, flattening, or twisting. Install the clamps [A] as near as possible to the hose end to clear the raised rib on 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 - Water Hose Clamp Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb)
Hose Inspection
the radiator or water hoses are removed or in • Whenever accordance with the Periodic Maintenance Chart, check the radiator or water hoses and their connections. Refer to the Radiator Hose Inspection (Coolant Leak, Damage, Installation Condition) in the Periodic Maintenance chapter.
ENGINE TOP END 5-1
Engine Top End Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealants ............... Clean Air System............................... Air Suction Valve Removal........... Air Suction Valve Installation........ Air Suction Valve Check............... Vacuum Switch Valve Removal ... Vacuum Switch Valve Installation Vacuum Switch Valve Operation Test............................................ Vacuum Switch Valve Unit Test.... Clean Air System Hose Inspection.................................. Camshaft Chain Tensioner ................ Camshaft Chain Tensioner Removal .................................... Camshaft Chain Tensioner Installation ................................. Rocker Case Cover ........................... Rocker Case Cover Removal ...... Rocker Case Cover Installation ... Rocker Case Cover Assembly ..... Rocker Case...................................... Rocker Case Removal ................. Rocker Case Installation .............. Rocker Arm Assembly ................. HLA Removal............................... HLA Air Bleeding.......................... HLA Installation............................ Camshafts ......................................... Camshaft Removal ...................... Camshaft Installation ................... Camshaft Sprocket Installation .... Camshaft/Rocker Case Wear ...... Front Camshaft Chain Removal... Front Camshaft Chain Installation Rear Camshaft Chain Removal ... Rear Camshaft Chain Installation
5-2 5-9 5-12 5-15 5-15 5-15 5-15 5-16 5-16 5-16 5-16 5-17 5-18 5-18 5-18 5-20 5-20 5-20 5-21 5-22 5-22 5-23 5-24 5-25 5-25 5-25 5-26 5-26 5-26 5-28 5-28 5-29 5-30 5-30 5-31
KACR (Kawasaki Automatic Compression Release) Inspection.................................. Cylinder Head.................................... Cylinder Compression Measurement ............................ Cylinder Head Removal ............... Cylinder Head Installation ............ Cylinder Head Warp..................... Valve Clearance Adjustment........ Valve Removal ............................. Valve Installation .......................... Valve Guide Removal .................. Valve Guide Installation ............... Valve Guide Wear (Wobble Method) ..................................... Valve Seat Inspection .................. Valve Seat Repair ........................ Cylinders, Piston................................ Cylinder Removal......................... Piston Removal............................ Cylinder, Piston Installation.......... Cylinder Wear .............................. Piston Wear ................................. Piston/Cylinder Clearance ........... Cylinder Boring and Honing ......... Piston Ring, Piston Ring Groove Wear.......................................... Piston Ring Groove Width............ Piston Ring Thickness ................ Piston Ring End Gap ................... Mufflers.............................................. Exhaust Pipe Removal................. Muffler Removal........................... Exhaust Pipe, Muffler Installation. Chamber Removal/Installation..... Chamber Assembly...................... Chamber Identification .................
5-31 5-32 5-32 5-33 5-34 5-35 5-35 5-35 5-35 5-36 5-36 5-36 5-37 5-37 5-41 5-41 5-41 5-41 5-44 5-44 5-44 5-45 5-45 5-46 5-46 5-46 5-47 5-47 5-48 5-48 5-49 5-49 5-50
5
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View No. 1 2 3 4 5 6 7
Fastener Air Suction Valve Cover Bolts Plugs Rocker Case Cover Bolts Rocker Case Bolts Rocker Case Nuts (M12) Rocker Case Nuts (M8) Spark Plug Retainers
N·m 7.4 20 8.8 8.8 78 25 12
Torque kgf·m 0.75 2.0 0.90 0.90 8.0 2.5 1.2
ft·lb 65 in·lb 15 78 in·lb 78 in·lb 58 18 104 in·lb
Remarks
8. Air Suction Valves 9. HLA (Hydraulic Lash Adjuster) Oil Filters 10. Vacuum Switch Valve AD: Apply adhesive. EO: Apply engine oil. 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 specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).
L S S MO, S S
5-4 ENGINE TOP END Exploded View
ENGINE TOP END 5-5 Exploded View No. 1 2 3 4 5 6 7 8
Fastener Camshaft Chain Guide Bolts Camshaft Chain Guide Retainer Bolts Camshaft Sprocket Bolts Chain Tensioner Cap Chain Tensioner Lockbolts Chain Tensioner Mounting Bolts Cylinder Head Nuts Cylinder Nuts
N·m 11 11 15 20 4.9 11 25 25
Torque kgf·m 1.1 1.1 1.5 2.0 0.50 1.1 2.5 2.5
ft·lb 97 in·lb 97 in·lb 11 15 43 in·lb 97 in·lb 18 18
9. KACR (Kawasaki Automatic Compression Release) Unit 10. “R” marked side faces up. 11. “RN” marked side faces up. 12. Each circle mark points to the front side. 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 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence.
Remarks L L L S S S S S
5-6 ENGINE TOP END Exploded View
ENGINE TOP END 5-7 Exploded View No. 1 2 3 4
Fastener Exhaust Pipe Cover Clamp Screws Muffler Stay Mounting Bolts Premuffler Chamber Bolts Rocker Shafts
N·m 6.9 25 29 25
5. Front Exhaust Pipe 6. Rear Exhaust Pipe 7. Left Muffler 8. Right Muffler 9. Premuffler Chamber 10. HLA (Hydraulic Lash Adjusters) EO: Apply engine oil. M: Apply molybdenum disulfide grease. R: Replacement Parts WL: Apply a soap and water solution or rubber lubricant.
Exhaust System
Full: Full Power H: Honeycomb Type Catalyst GB: United Kingdom Model
Torque kgf·m 0.70 2.5 3.0 2.5
ft·lb 61 in·lb 18 21 18
Remarks
M
5-8 ENGINE TOP END Exploded View Chamber Mark Position [A]
Silencer Mark Position [A]
ENGINE TOP END 5-9 Specifications Item Clean Air System Vacuum Switch Valve Closing Pressure: Camshafts Cam Height: Exhaust Inlet
Standard Open → Close 49.3 ∼ 65.3 kPa (370 ∼ 490 mmHg)
33.487 ∼ 33.601 mm (1.3184 ∼ 1.3229 in.) 33.805 ∼ 33.919 mm (1.3309 ∼ 1.3354 in.)
Service Limit – – –
33.39 mm (1.315 in.) 33.71 mm (1.327 in.)
Camshaft/Rocker Case Clearance: 25 0.020 ∼ 0.062 mm 0.15 mm (0.0059 in.) (0.0008 ∼ 0.0024 in.) 17 0.016 ∼ 0.055 mm 0.14 mm (0.0055 in.) (0.0006 ∼ 0.0022 in.) Camshaft Journal Diameter: 25 24.959 ∼ 24.980 mm 24.93 mm (0.981 in.) (0.9826 ∼ 0.9835 in.) 17 16.966 ∼ 16.984 mm 16.94 mm (0.667 in.) (0.6680 ∼ 0.6687 in.) Rocker Case Bearing Inside Diameter: 25 25.000 ∼ 25.021 mm 25.08 mm (0.987 in.) (0.9843 ∼ 0.9851 in.) 17 17.000 ∼ 17.021 mm 17.08 mm (0.672 in.) (0.6693 ∼ 0.6701 in.) Camshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.004 in.) Rocker Arm Inside Diameter 16.000 ∼ 16.018 mm 16.05 mm (0.632 in.) (0.6299 ∼ 0.6306 in.) 15.966 ∼ 15.984 mm Rocker Shaft Diameter 15.94 mm (0.628 in.) (0.6286 ∼ 0.6293 in.) Cylinder Head Cylinder Compression Usable 340 ∼ 590 kPa (3.5 ∼ 6.0 kg/cm², Range 50 ∼ 85 psi) @300 r/min (rpm) with – – – electric starter Cylinder Head Warp ––– 0.05 mm (0.002 in.) Valve Valve Clearance Non-adjustable (Auto adjuster) – – – Valve Head Thickness: Exhaust 0.9 ∼ 1.1 mm (0.03 ∼ 0.04 in.) 0.7 mm (0.03 in.) Inlet 0.9 ∼ 1.1 mm (0.03 ∼ 0.04 in.) 0.5 mm (0.02 in.) Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm (0.002 in.) Valve Stem Diameter: Exhaust 6.955 ∼ 6.970 mm 6.94 mm (0.273 in.) (0.2738 ∼ 0.2744 in.) Inlet 6.965 ∼ 6.980 mm 6.95 mm (0.274 in.) (0.2742 ∼ 0.2748 in.)
5-10 ENGINE TOP END Specifications Item Valve Guide Inside Diameter: Exhaust Inlet Valve/Valve Guide Clearance (Wobble Method): Exhaust Inlet
Cam Height
Cam Height (maximum) [A] Valve Head Thickness
Valve Head Thickness [A] Valve Stem Diameter [B] 45° [C]
Standard
Service Limit
7.000 ∼ 7.015 mm (0.2756 ∼ 0.2762 in.) 7.000 ∼ 7.015 mm (0.2756 ∼ 0.2762 in.)
7.08 mm (0.279 in.)
0.08 ∼ 0.15 mm (0.003 ∼ 0.006 in.) 0.05 ∼ 0.13 mm (0.002 ∼ 0.005 in.)
0.35 mm (0.014 in.)
7.08 mm (0.279 in.)
0.33 mm (0.013 in.)
Camshaft Journals and Runout
25 mm (0.984 in.) [A] 17 mm (0.669 in.) [B] Valve Stem Bend
ENGINE TOP END 5-11 Specifications Item Valve Seat Surface: Valve Seat Cutting Angle Outside Diameter: Exhaust Inlet Width: Exhaust Inlet Valve Spring Free Length: Outer (EX, IN) Inner (EX, IN) Cylinder, Piston Cylinder Inside Diameter Piston Diameter Piston/Cylinder Clearance Oversize Piston And Rings Piston Ring/Groove Clearance: Top Second Piston Ring Groove Width: Top Second Piston Ring Thickness: Top Second Piston Ring End Gap: Top Second Oil
Standard
Service Limit
45°, 32°, 55°
– – –
28.9 ∼ 29.1 mm (1.14 ∼ 1.15 in.) 31.9 ∼ 32.1 mm (1.25 ∼ 1.26 in.)
– – – – – –
0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
– – – – – –
44.76 mm (orange) (1.762 in.) 39.82 mm (orange) (1.568 in.)
43.2 mm (1.70 in.) 38.3 mm (1.51 in.)
102.000 ∼ 102.012 mm (4.0157 ∼ 4.0162 in.) 101.942 ∼ 101.957 mm (4.0135 ∼ 4.0140 in.) 0.043 ∼ 0.070 mm (0.0017 ∼ 0.0028 in.) +0.5 mm (0.02 in.)
102.10 mm (4.020 in.) 101.79 mm (4.007 in.) – – – – – –
0.050 ∼ 0.090 mm (0.0020 ∼ 0.0035 in.) 0.030 ∼ 0.070 mm (0.0012 ∼ 0.0028 in.)
0.19 mm (0.0075 in.) 0.17 mm (0.0067 in.)
1.24 ∼ 1.26 mm (0.049 ∼ 0.050 in.) 1.22 ∼ 1.24 mm (0.048 ∼ 0.049 in.)
1.34 mm (0.053 in.) 1.32 mm (0.052 in.)
1.17 ∼ 1.19 mm (0.046 ∼ 0.047 in.) 1.17 ∼ 1.19 mm (0.046 ∼ 0.047 in.)
1.10 mm (0.043 in.) 1.10 mm (0.043 in.)
0.25 ∼ 0.35 mm (0.010 ∼ 0.014 in.) 0.40 ∼ 0.55 mm (0.016 ∼ 0.022 in.) 0.30 ∼ 0.90 mm (0.012 ∼ 0.035 in.)
0.7 mm (0.03 in.) 0.9 mm (0.04 in.) 1.2 mm (0.05 in.)
5-12 ENGINE TOP END Special Tools and Sealants Valve Guide Reamer, 57001-162
Valve Guide Arbor, 57001-163
7:
Piston Pin Puller Assembly: 57001-910
7:
Compression Gauge Adapter, M12 × 1.25: 57001-1018
Compression Gauge, 20 kgf/cm²: 57001-221
Spark Plug Wrench, Hex 18: 57001-1024
Valve Spring Compressor Assembly: 57001-241
Piston Ring Compressor Grip: 57001-1095
Valve Spring Compressor Adapter, 57001-243
Valve Seat Cutter, 45° 57001-1116
28.2:
35:
ENGINE TOP END 5-13 Special Tools and Sealants Valve Seat Cutter, 32° 57001-1121
35:
Piston Pin Puller Adapter, 57001-1211
Valve Seat Cutter, 32° 57001-1122
38.5:
Valve Seat Cutter, 55° 57001-1247
Valve Seat Cutter Holder, 57001-1126
7:
14:
35:
Fork Oil Level Gauge: 57001-1290
Valve Seat Cutter Holder Bar: 57001-1128
Piston Ring Compressor Belt, 57001-1358
Hexagon Wrench, Hex 27: 57001-1210
Filler Cap Driver: 57001-1454
95 ∼
108:
5-14 ENGINE TOP END Special Tools and Sealants Valve Seat Cutter, 45° 57001-1496
40:
Kawasaki Bond (Silicone Sealant): 56019-120
Valve Seat Cutter, 55° 57001-1497
38.5:
Kawasaki Bond (Silicone Sealant): 92104-0004
○Compression
Gauge Adapter, M12 × 1.25: 57001-1183 can also be used. ○Valve Seat Cutter, 32° - 33: 57001-1199 can also be used instead of Valve Seat Cutter, 32° - 35: 57001-1121
ENGINE TOP END 5-15 Clean Air System Air Suction Valve Removal
• Remove: Engine (see Engine Removal in the Engine Removal/In• •
stallation chapter) Vacuum Switch Valve (see Vacuum Switch Valve Removal in this section) Unscrew the mounting bolts [A] and remove the front air suction valve cover [B]. Remove the front air suction valve.
the mounting bolts [A] and remove the rear air • Unscrew suction valve cover [B]. • Remove the rear air suction valve.
Air Suction Valve Installation
the gaskets with new ones. • Replace Install each air suction valve so that its wider side [A] of • the reed faces left.
•
Rear Air Suction Valve [B] Tighten: Torque - Air Suction Valve Cover Bolts: 7.4 N·m (0.75 kgf·m, 65 in·lb)
Air Suction Valve Check
the air suction valve (see Air Suction Valve Re• Remove moval in this chapter). inspect the reeds for cracks, folds, warps, heat • Visually damage or other damage.
•
If there is any doubt as to the condition of the reeds [A], 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.
there is any doubt as to the condition of the reed contact • Ifareas, 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.
CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.
5-16 ENGINE TOP END Clean Air System Vacuum Switch Valve Removal
the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). off the hoses [A] and take out the vacuum switch • Pull valve [B].
Vacuum Switch Valve Installation
the vacuum switch valve [A] so that the inlet vac• Install uum hose [B] faces rear side. the hoses correctly (see Cable, Wire, and Hose • Route Routing section in the Appendix chapter).
Vacuum Switch Valve Operation Test
to the Air Suction System Damage Inspection in the • Refer Periodic Maintenance chapter.
Vacuum Switch Valve Unit Test
the vacuum switch valve (see Vacuum Switch • Remove Valve Removal in this section). a commercially available vacuum gauge [A] and • Connect syringe [B] (or fork oil level gauge) to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001-1290
Air Flow [C] raise the vacuum (lower the pressure) applied • Gradually to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve should permit air to flow. When the vacuum raises to valve closing pressure, it should stop air flow. Spring [A] Diaphragm [B] Valve [C] Low Vacuum [D] Secondary air flows [E].
ENGINE TOP END 5-17 Clean Air System If the vacuum switch valve does not operate as described, replace it with a new one.
NOTE
○To check air flow through the vacuum switch valve, just blow through the air cleaner hose [C].
Vacuum Switch Valve Closing Pressure (Open → Close) Standard: 49.3 ∼ 65.3 kPa (370 ∼ 490 mmHg)
High Vacuum [A] Secondary air cannot flow [B].
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 right air cleaner base, vacuum switch valve, throttle body, and air suction valve covers. If they are not, correct them. Replace them if they are damaged.
5-18 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam 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 cam chain timing, and damage the valves. the front chain tensioner, remove the lower air cleaner • For duct and left air cleaner base holder (see Air Cleaner section in the Fuel System (DFI) chapter).
○The procedure to remove the front chain tensioner is as
• •
follows. Loosen the lockbolt [A] and remove the tensioner cap [B]. Remove the tensioner mounting bolts [C] and take off the chain tensioner.
the rear chain tensioner [A], removal is the same as • For for the front chain tensioner.
Camshaft Chain Tensioner Installation CAUTION Be sure to install the camshaft chain tensioner after camshaft chain is timed. the stopper [A] to release the ratchet and push the • Push push rod [B] into the tensioner body.
ENGINE TOP END 5-19 Camshaft Chain Tensioner the larger spring [A], and then the ball bearing assy • Install [B].
○Fit the ball bearing assy into the body until it bottoms out, using a thin-bladed screwdriver.
in the lockbolt [A] finger-tight to hold the ball bear• Screw ing assy temporarily. • Install the retainer [B].
the tensioner body [A] and tighten the mounting • Install bolts [B] to the specified torque. Torque - Chain Tensioner Mounting Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
the smaller spring [A] and the tensioner cap [B]. •○Install Set the spring end into the hollow [C] of the cap. • Tighten the tensioner cap to the specified torque.
Torque - Chain Tensioner Cap: 20 N·m (2.0 kgf·m, 15 ft·lb)
the lockbolt [A] and check to be sure that the • Remove larger spring clicks, then install the lockbolt. Torque - Chain Tensioner Lockbolt: 4.9 N·m (0.50 kgf·m, 43 in·lb)
5-20 ENGINE TOP END Rocker Case Cover Rocker Case Cover Removal
• Remove: Engine (see Engine Removal in the Engine Removal/In•
stallation chapter) Vacuum Switch Valve (see Vacuum Switch Valve Removal in this chapter) Remove the bolts [A] and take off the cover [B] from the rocker case.
• Take out the oil filter springs [A] and HLA oil filters [B].
Rocker Case Cover Installation
the HLA oil filters [A] with new ones. • Replace Install the oil filter springs [B]. • After installing • engine oil. the rocker case, fill the oil reservoir [C] with the cover gasket [D] with a new one. • Replace Tighten the cover bolts [E] to the specified torque follow• ing the tightening sequence. Dowel Pins [F] Inlet Side [G] Torque - Rocker Case Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
ENGINE TOP END 5-21 Rocker Case Cover Rocker Case Cover Assembly
adhesive to the rubber dampers [A] and install them • Apply on the rocker case cover as shown.
○Insert the projections [B] of the dampers to the holes [C] of the cover. Front Cover [D] Rear Cover [E]
5-22 ENGINE TOP END Rocker Case Rocker Case Removal
• Remove: Engine (see Engine Removal in the Engine Removal/In-
•
stallation chapter) Rocker Case Covers (see Rocker Case Cover Removal in this chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Remove the timing inspection cap [A] and rotor bolt cap [B]. Special Tool - Filler Cap Driver [C]: 57001-1454
the crankshaft counterclockwise [A] and align the “F” • Turn mark (TDC mark for front piston) [B] with the middle of the notch [C].
• Remove: Oil Hose Flange Bolt [A] Oil Hose [B]
the camshaft chain tensioner (see Camshaft • Remove Chain Tensioner Removal in this chapter). the rocker case bolts [A], smaller nuts [B], and • Remove then larger nuts [C].
the pry points [A], take the rocker case out of the • Using cylinder head.
ENGINE TOP END 5-23 Rocker Case the rocker shafts [A], and take the rocker arms • Unscrew [B] out of the rocker case. out the oil filters if necessary. • Take the lash adjuster if necessary (see HLA Removal • Remove in this chapter).
CAUTION The cylinder head and rocker case are machined in the assembled state, so they must be used as a set. Be careful not to mix them up for front and rear cylinders.
Rocker Case Installation
the O-rings [A] with new ones and install them • Replace on the rocker shaft [B]. molybdenum disulfide grease to the rocker shafts. • Apply Install the rocker arms [C] and retaining springs [D] on • each rocker shaft as shown. These retaining springs are the same.
○The rocker arm [E] of the exhaust side [F] next to the chain
tunnel is different from the others. ○Be careful not to tip the rocker arm and not to allow the oil to leak out of HLA. Tighten the rocker shafts to the specified torque.
•
Torque - Rocker Shafts: 25 N·m (2.5 kgf·m, 18 ft·lb)
silicone sealant [A] to the rocker case mating sur• Apply face and the outer circumference of the plugs as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
○Do not apply silicone sealant around the camshaft bearing.
molybdenum disulfide oil solution to the threads • Apply and seating surface of M12 nuts and both sides of washers.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Tighten the rocker case nuts and bolts temporarily following the tightening sequence shown, and then tighten them to the specified torque. Torque - M12 Rocker Case Nuts (1 ∼ 4): 78 N·m (8.0 kgf·m, 58 ft·lb) M8 Rocker Case Nuts (5 ∼ 8): 25 N·m (2.5 kgf·m, 18 ft·lb) Rocker Case Bolts (9, 10): 8.8 N·m (0.90 kgf·m, 78 in·lb)
Inlet Side [A]
5-24 ENGINE TOP END Rocker Case the HLA oil filters [A] with new ones. • Replace After installing • engine oil. the rocker case, fill the oil reservoir [B] with • Tighten:
Torque - Oil Hose Flange Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the cylinder head nuts [A] and cylinder nuts [B] to • Tighten the specified torque. Torque - Cylinder Head Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb) Cylinder Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Rocker Cases [C] Cylinder Heads [D] Cylinders [E] Special Tool - Filler Cap Driver: 57001-1454 Torque - Timing Inspection cap: 1.5 N·m (0.15 kgf·m, 13 in·lb) Rotor Bolt Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb)
• Install: Throttle Body Assy (see Throttle Body Assy Installation in the Fuel System (DFI) chapter) Rocker Case Covers (see Rocker Case Cover Installation in this section) Engine (see Engine Installation in the Engine Removal/Installation chapter)
Rocker Arm Assembly
a flat-end bar [A] and a block [B] with a recess • Prepare [C]. the oil chamber [D] for the HLA into the rocker arm • Press end [E] until the chamber end is even with the step [F] of the hole.
○Install the oil chamber as shown so that the air bleed hole
[G] is placed within 120 degrees [H]. This makes HLA bleeding easier.
ENGINE TOP END 5-25 Rocker Case HLA Removal
the rocker arms (see Rocker Case Removal in • Remove this section). the HLA (hydraulic lash adjuster) [B] out of the rocker • Pull arm [A] with fingers.
CAUTION Be careful not to damage or deform an HLA by tapping it during removal or installation. Do not drop the HLA or hit it sharply. If it is damaged, the plunger will not operate smoothly.
HLA Air Bleeding
the HLA (see HLA Removal in this section). • Remove a container with engine oil. • Fill Prepare thumbtack and cut its needle to 2.1 ∼ 2.3 mm • (0.0827 ∼a 0.0906 in.) long [A]. Grind its cutting edge [B]
•
smooth. Push in the check valve of the HLA [D] with the needle of the tack [C] and move the plunger up and down in the oil bath. If the plunger sinks into the HLA body, repeat the air bleeding procedure and then push the plunger. After air bleeding, if the plunger sinks into the HLA body again, replace the HLA.
CAUTION Do not push the check valve in more than 2.1 ∼ 2.3 mm. Pushing too deep may cause the damage of the HLA.
HLA Installation
that the HLA plunger is not damaged. • Check If the plunger does damage, replace the HLA. HLA Body [A] O-ring [B] Plunger Spring [C] Pivot Plunger [D] Check Valve [E] Check Valve Spring [F] the HLA (see HLA Air Bleeding in this section). • Air-bleed Soak a rocker [A] in engine oil, and then insert the • HLA [B] into thearm rocker arm.
○Be careful not to tip the rocker arm having the HLA, and not to allow engine oil to leak out of the HLA.
5-26 ENGINE TOP END Camshafts Camshaft Removal
• Remove: Rocker Case Covers (see Rocker Case Cover Removal in this chapter) Rocker Cases (see Rocker Case Removal in this chapter) the camshaft [B] along with the KACR [A]. •○Remove Remove the camshaft plug [C]. a clean cloth into the chain tunnel to keep any parts • Stuff from dropping into the crankcase.
CAUTION 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 chain and sprocket.
Camshaft Installation
○The front camshaft [A] and rear camshaft [B] are different. The rear camshaft has a groove [C].
the KACR on each camshaft. •○Install The front KACR [A] and rear KACR [B] are different (inside view). Do not confuse these KACRs.
the pin [A] into the notch [B], and install the KACR [C] • Fit onto the camshaft [D]. molybdenum disulfide oil solution to all cam parts, • Apply including their journals.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Remove the timing inspection cap and check that the “F” mark aligns with the middle of the notch (front piston TDC) (see Camshaft Removal in this section). If necessary, align them.
ENGINE TOP END 5-27 Camshafts install the front camshaft. •○First, Engage the front camshaft sprocket with the camshaft
chain as shown. Timing Marks [A] “F” mark [B] Cylinder Head Upper Surface [C] Front [D] ○Pull the front side (exhaust side) of the chain taut to install the camshaft. ○Install the front chain tensioner (see Camshaft Chain Tensioner Installation in this chapter). The timing marks must be aligned with the cylinder head upper surface. install the rear camshaft. •○Next, Check to be sure that the front camshaft chain timing is correct. ○Turn the crankshaft counterclockwise [A].
Align the “R” mark [A] (TDC mark for the rear piston) with • the middle of the notch [B] (310° turn from the front piston TDC).
the rear camshaft sprocket with the camshaft • Engage chain as shown. Timing Marks [A] and “R” Mark [B] Cylinder Head Upper Surface [C] Front [D] Pull ○ the front side (inlet side) of the chain taut to install the camshaft. Install the rear chain tensioner and check the front/rear chain timing again. ○The timing marks must be aligned with the cylinder head upper surface and positioned as shown after chain tensioner installation. Install: Rocker Cases (see Rocker Case Installation in this chapter) Rocker Case Covers (see Rocker Case Cover Installation in this chapter)
• •
Special Tool - Filler Cap Driver: 57001-1454 Torque - Timing Inspection Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb) Rotor Bolt Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb)
5-28 ENGINE TOP END Camshafts Camshaft Sprocket Installation
Use the sprocket marked “F” for the front camshaft [A] • and the sprocket marked “R” for the rear camshaft [B]. a non-permanent locking agent to the camshaft • Apply sprocket bolts and tighten them to the specified torque. Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb)
Camshaft/Rocker Case Wear
strips of plastigage to journal width. Place a strip • Cut on each journal parallel to the camshaft installed in the
•
correct position. Measure each clearance between the camshaft and the rocker case using plastigage.
NOTE
○Do not turn the camshaft when the plastigage is between the journal and camshaft cap.
molybdenum disulfide oil solution to the threads • Apply and seating surface of M12 nuts and both sides of washers. ○The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10:1). Tighten the rocker case nuts and bolts temporarily following the tightening sequence shown, and then tighten them to the specified torque.
•
Torque - M12 Rocker Case Nuts (1 ∼ 4): 78 N·m (8.0 kgf·m, 58 ft·lb) M8 Rocker Case Nuts (5 ∼ 8): 25 N·m (2.5 kgf·m, 18 ft·lb) Rocker Case Bolts (9, 10): 8.8 N·m (0.90 kgf·m, 78 in·lb)
Inlet Side [A]
ENGINE TOP END 5-29 Camshafts the rocker case again, and measure the plasti• Remove gage width [A] to determine the clearance between each journal and the rocker case. Measure the maximum plastigage width. Camshaft/Rocker Case Clearance Standard: 25
0.020 ∼ 0.062 mm (0.0008 ∼ 0.0024 in.)
17
0.016 ∼ 0.055 mm (0.0006 ∼ 0.0022 in.)
Service Limit: 25
0.15 mm (0.0059 in.)
17
0.14 mm (0.0055 in.)
If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 25
24.959 ∼ 24.980 mm (0.9826 ∼ 0.9835 in.)
17
16.966 ∼ 16.984 mm (0.6680 ∼ 0.6687 in.)
Service Limit: 25
24.93 mm (0.981 in.)
17
16.94 mm (0.667 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 and rocker case.
CAUTION The rocker case and cylinder head are machined in the assembled state, so they must be replaced as a set.
Front Camshaft Chain Removal
• Remove: Front Camshaft (see Camshaft Removal in this section) Spark Plug (see Spark Plug Removal in the Electrical System chapter) Spark Plug Retainer [A] Special Tool - Hexagon Wrench, Hex 27 [B]: 57001-1210
• Remove: Alternator Inner Cover (see Alternator Inner Cover Re-
•
moval in the Electrical System chapter) Alternator Inside Stator (Alternator Inside Stator Removal in the Electrical System chapter) Crankshaft Balancer Gear (see Crankcase Disassembly in the Crankshaft/Transmission chapter) Lower Chain Guide Bolts [A] Lower Chain Guide [B] Take out the front camshaft chain [C].
5-30 ENGINE TOP END Camshafts Front Camshaft Chain Installation
a non-permanent locking agent to the threads of • Apply the chain guide bolts, and tighten them to the specified torque. Torque - Camshaft Chain Guide Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
• Install: Crankshaft Balancer Gear (see Crankcase Assembly in
the Crankshaft/Transmission chapter) Alternator Inside Stator (see Alternator Inside Stator Installation in the Electrical System chapter) Alternator Inner Cover (see Alternator Inner Cover Installation in the Electrical System chapter) grease to the O-ring [A]. • Apply Pull the chain up the chain tunnel, insert the • spark plugcamshaft retainer [B] through the chain loop, and tighten it. Special Tool - Hexagon Wrench, Hex 27: 57001-1210 Torque - Spark Plug Retainer: 12 N·m (1.2 kgf·m, 104 in·lb)
• Install: Spark Plug (see Spark Plug Installation in the Electrical System chapter) Front Camshaft (see Camshaft Installation in this section)
Rear Camshaft Chain Removal
• Remove: Rear Camshaft (see Camshaft Removal in this section) Spark Plug (see Spark Plug Removal in the Electrical System chapter) Spark Plug Retainer (see Front Camshaft Chain Removal in this section) Clutch (see Clutch Removal in the Clutch chapter) Starter Clutch Gear (see Crankcase Disassembly in the Crankshaft/Transmission chapter) Primary Gear (see Primary Gear Removal in the Crankshaft/Transmission chapter)
• Remove: Lower Chain Guide Bolts [A] •
Lower Chain Guide [B] Take out the rear camshaft chain [C].
ENGINE TOP END 5-31 Camshafts Rear Camshaft Chain Installation
a non-permanent locking agent to the threads of • Apply the chain guide bolts, and tighten them to the specified torque. Torque - Camshaft Chain Guide Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
the spark plug retainer (see Front Camshaft Chain • Install Installation in this section). • Install the removed parts (see appropriate chapters).
KACR (Kawasaki Automatic Compression Release) Inspection
○Due to the simplicity of the KACR, no periodic mainte-
nance is needed. There are only two symptoms of problems with the KACR mechanism compression is not released during starting, and compression is released during running. ○The cylinder compression is not released during starting (abnormal): the pin [A] stays within the cam [B] and will not push up the exhaust rocker arm. Remove the KACR unit and visually inspect the spring [C]. If the spring is damaged, deformed, or missing, replace the spring. Remove the spring and move the weights [D] back and forth. If the weights do not move smoothly all the way, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary. Stopper [E]
• •
○The cylinder compression is released while the engine is
•
running (abnormal): the pin [A] stays out the cam [B] and pushes up the exhaust rocker arm. Remove the spring [C] and move the weights [D] back and forth. If the weights do not move easily from the retracted position, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary. Stopper [E]
5-32 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE
○Be sure the battery is fully charged.
up the engine thoroughly. • Warm the engine. • Stop Remove spark plug and attach the compression • gauge andone adapter firmly into the spark plug hole. Do not
•
remove the other spark plug, only the plug lead. For the other cylinder, remove both spark plugs. Special Tool - Spark Plug Wrench, Hex 18 [A]: 57001-1024
the starter motor, turn the engine over with the throt• Using tle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. Special Tools - Compression Gauge [A]: 57001-221 Compression Gauge Adapter, M12 × 1.25 [B]: 57001-1018 (or 57001-1183) Cylinder Compression Usable Range: 340 ∼ 590 kPa (3.5 ∼ 6.0 kg/cm², 50 ∼ 85 psi) @300 r/min (rpm)
○The compression gauge adapter:
• •
57001-1183 can also be used. Repeat the measurement for the other cylinder. Install the spark plugs. Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)
ENGINE TOP END 5-33 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the usable range. Problem Cylinder compression is higher than usable range
Cylinder compression is lower than usable range
Diagnosis Carbon buildup on piston and in combustion chamber possibly due to damaged valve stem, valve guide, stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke). Incorrect cylinder head gasket thickness. Damaged or missing compression release cam spring. Compression release weights do not move smoothly. Gas leakage around cylinder head Bad condition of valve seats, valves, and valve springs. HLA seizure. Incorrect piston/cylinder clearance Piston seizure.
Remedy (Action) Remove the carbon deposits and replace damaged parts if necessary.
Replace the gasket with a standard part. Replace the spring. Replace the compression release unit. Replace damaged gasket and check cylinder head warp. Repair them if necessary.
Replace the HLA. Replace the piston and/or cylinder. Inspect the cylinder and liner and replace/repair the cylinder and/or piston as necessary. Bad condition of piston ring and/or piston Replace the piston and/or the piston ring grooves. rings. Compression release weights do not Replace the compression release unit. move smoothly.
Cylinder Head Removal
• Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Rocker Cases (see Rocker Case Removal in this chapter) Camshafts (see Camshaft Removal in this chapter) Spark Plug Retainers (see Front Camshaft Chain Removal in this chapter) ○The camshaft chain comes off.
• Remove: Air Suction Valves [A] (see Air Suction Valve Removal in this chapter) Cooling Pipes with Hoses [B]
5-34 ENGINE TOP END Cylinder Head the cylinder head nuts [A]. • Remove Take the cylinder head off the cylinder. •
NOTE
○Do not remove the coolant drain plug [B] yet.
Cylinder Head Installation
○The front cylinder head [A] has an “F” mark while the rear
cylinder head [B] has an “R” mark. Be careful not to mix them up. Front [C]
CAUTION The cylinder head and rocker case are machined in the assembled state, so they must be used as a set. the cylinder head gasket with a new one. • Replace Tighten the head nuts temporarily (These nuts • are tightenedcylinder to the specified torque after installing rocker
• •
case installation). Apply grease to the O-ring [A]. Pull the camshaft chain up the chain tunnel, insert the spark plug retainer [B] through the chain loop, and tighten it. Special Tool - Hexagon Wrench, Hex 27: 57001-1210 Torque - Spark Plug Retainer: 12 N·m (1.2 kgf·m, 104 in·lb)
• Install: Spark Plugs (see Spark Plug Installation in the Electrical
•
System chapter) Camshafts (see Camshaft Installation in this chapter) Rocker Cases (see Rocker Case Installation in this chapter) Air Suction Valves (see Air Suction Valve Installation in this chapter) Tighten: Torque - Cylinder Head Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb) Cylinder Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb) Water Pipe Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
ENGINE TOP END 5-35 Cylinder Head Cylinder Head Warp
the cylinder head (see Cylinder Head Removal • Remove in this chapter). a straightedge across the lower surface of the cylinder • Lay head at several positions. a thickness gauge [A] to measure the space between • Use the straight edge [B] and the head. Cylinder Head Warp ––– Standard: Service Limit: 0.05 mm (0.002 in.)
If they cylinder head is warped more than the service limit, replace it. If they 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).
Valve Clearance Adjustment NOTE
○Since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance.
Valve Removal
the cylinder head (see Cylinder Head Removal • Remove in this section). open the rocker arm. • Swing Using the • valve. valve spring compressor assembly, remove the Special Tools - Valve Spring Compressor Assembly [A]: 57001-241 Valve Spring Compressor Adapter, 28.2 [B]: 57001-243
Valve Installation
the stem oil seal with a new one. • Replace Apply a thin coat of molybdenum disulfide grease to the • valve stem before valve installation. the springs so that the closed coil end faces down• Install wards. Valve [A] and Stem Oil Seal [B] Spring Seats [C] Inner Spring [D] and Outer Spring [E] Retainer [F] and Split Keepers [G] Closed Coil End [H]
5-36 ENGINE TOP END Cylinder Head Valve Guide Removal
the valve, stem oil seal and spring seats. • Remove Heat the area the valve guide to 120 ∼ 150°C (248 • ∼ 302°F), and around hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. Special Tool - Valve Guide Arbor,
7: 57001-163
CAUTION Do not heat the cylinder head with a blowtorch. This will warp the head. Soak the cylinder head in engine oil and heat the oil.
Valve Guide Installation
engine oil to the valve guide outer surface before • Apply installation. the area around the valve guide hole to about 120 ∼ • Heat 150°C (248 ∼ 302°F) in the engine oil. the valve guide in from the top of the head using the • Drive valve guide arbor. The flange stops the guide from going in too far. Special Tool - Valve Guide Arbor,
7: 57001-163
until the cylinder head cools down and then ream the • Wait valve guide with the valve guide reamer [A] even if the old guide is reused. ○Turn the reamer in a clockwise direction until the reamer turns freely in the guide. Never turn the reamer counterclockwise or it will be dulled. ○Once the guides are reamed, they must be cleaned thoroughly. Special Tool - Valve Guide Reamer,
7: 57001-162
Valve Guide Wear (Wobble Method)
○If a small bore gauge is not available, inspect the valve
• • •
guide wear by measuring the valve-to-guide clearance with the wobble method as indicated below. The reading is not actual valve-to-guide clearance because the measuring point is above the guide. 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-to -valve guide clearance. Repeat the measurement in a direction at a right angle (90°) to the first. If the reading exceeds the service limit, replace the guide. Valve-to-Guide Clearance (Wobble Method) Standard: Exhaust
0.08 ∼ 0.15 mm (0.003 ∼ 0.006 in.)
Inlet
0.05 ∼ 0.13 mm (0.002 ∼ 0.005 in.)
Service Limit: Exhaust
0.35 mm (0.014 in.)
Inlet
0.33 mm (0.013 in.)
ENGINE TOP END 5-37 Cylinder Head Valve Seat Inspection
the valve (see Valve Removal in this section). • Remove Check the valve seat surface [A] between the valve [B] • and valve seat [C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat with vernier calipers. If the outside diameter is too large or too small, repair the seat (see Valve Seat Repair in this section). Valve Seat Surface Outside Diameter Standard: Exhaust 28.9 ∼ 29.1 mm (1.14 ∼ 1.15 in.) Inlet
31.9 ∼ 32.1 mm (1.25 ∼ 1.26 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with vernier calipers. Good [F] If the width is too wide [G], too narrow [H] or uneven [J], repair the seat (see Valve Seat Repair in this section). Valve Seat Surface Width Standard: Exhaust
0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
Inlet
0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
Valve Seat Repair
• Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder, 7 [B]: 57001-1126 Valve Seat Cutter Holder Bar [C]: 57001 -1128 For Exhaust Valve Seat Valve Seat Cutter, 45° -
35: 57001-1116
Valve Seat Cutter, 32° - 35: 57001-1121 (or 32° - 33: 57001-1199) Valve Seat Cutter, 55° -
35: 57001-1247
For Inlet Valve Seat Valve Seat Cutter, 45° -
40: 57001-1496
Valve Seat Cutter, 32° -
38.5: 57001-1122
Valve Seat Cutter, 55° -
38.5: 57001-1497
○The marks stamped on the back of the cutter [A] represent the following. 55° ........................... Cutter Angle [B] 37.5 ....................... Outer Diameter of Cutter [C] If the manufacturer’s instructions are not available, use the following procedure.
5-38 ENGINE TOP END Cylinder Head 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. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. 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.
CAUTION Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles. 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.
During operation, wash off any ground particles sticking to the cutter with washing oil
After use, wash it with washing oil and apply thin layer of engine oil before storing. Operating Procedures Clean the seat area carefully. Coat the seat with machinist’s dye. Fit a 45° cutter [A] into the holder [B] and slide it into the valve guide. Press down lightly on the handle and turn it right or left [C]. Grind the seat surface only until it is smooth.
• • • •
CAUTION Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, HLA could not work and the cylinder head must be replaced. the outside diameter [A] of the seat surface (seat • Measure O.D.) with vernier calipers. If the seat O.D. is too small, repeat the 45° grind [B] until the diameter is within the specified range. Ground Voluum [C]
NOTE
○Remove all pittings or flaws from 45° ground surface. ○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seat surface. This makes seat surface distinct and 32° and 55° grinding operation easier. ○When the valve guide is replaced, be sure to grind with 45° cutter for centering and good contact. If the seat O.D. is too large, make the 32° grind described below.
ENGINE TOP END 5-39 Cylinder Head
○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.
CAUTION The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. the seat at a 32° angle [A] until the seat O.D. [B] is • Grind within the specified range.
•
• • •
If the seat O.D. is within the specified range, measure the seat width as described below. To measure the seat width, use vernier calipers to measure the width [C] of the 45° angle portion of the seat at several places around the seat. Ground Voluum [D] If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then measure the seat O.D.. If the seat width is too wide, make the 55° grind described below. To make the 55° grind, fit 55° cutter into the holder, and slide it into the valve guide. Turn the holder, while pressing down lightly. Grind the seat at a 55° angle [A] until the seat width [B] is within the specified range. If the seat width is within the specified range, lap the valve to the seat as described below.
the valve to the seat, once the seat width and O.D. • Lap are within the ranges specified above.
○Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the seat and the valve. ○Repeat the process with a fine grinding compound. Lapper [A] Valve Seat [B] Valve [C] seat area should be marked about in the middle of • The 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.
5-40 ENGINE TOP END Cylinder Head
ENGINE TOP END 5-41 Cylinders, Piston Cylinder Removal
the cylinder head (see Cylinder Head Removal • Remove in this chapter). the coolant drain plug [A] and drain the coolant • Remove from the cylinder. out the front camshaft chain guide [B]. • Pull Remove nuts [C]. • Tap lightlytheupcylinder the cylinder with a plastic mallet to separate • from the crankcase. • Remove the cylinder base gasket.
Piston Removal
the cylinder block (see Cylinder Removal in this • Remove section). a piece of clean cloth under the piston and remove • Place the piston pin snap rings [A] from the outside of each piston.
CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. the piston pin puller assembly, remove the piston • Using pins. Special Tools - Piston Pin Puller Assembly [A]: 57001-910 Piston Pin Puller Adapter [B]: 57001-1211
• Remove the piston.
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.
Cylinder, Piston Installation NOTE
○The oil ring rails have no “top” or “bottom”.
the oil ring expander [A] in the bottom piston ring • Install groove so the ends [B] butt together. the oil ring steel rails, one above the expander and • Install 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.
5-42 ENGINE TOP END Cylinders, Piston not mix up the top ring and second ring. • Do Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces • up.
piston ring openings must be positioned as shown in • The the figure. The openings of the oil ring steel rails must be about 30 ∼ 45° [F] of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Oil Ring Steel Rails [C] Oil Ring Expander [D] Circle mark [E] must be faced toward the engine front. Opening Positions [G]
the circle mark [A] on each piston toward the front • Face side [B].
○The front and rear pistons are the same, but they should be installed in their original positions.
CAUTION Incorrect installation of the piston could cause piston seizure and result in severe engine damage.
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 outer surface of the piston pin. ○The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1). ○When installing the piston pin snap ring, compress it only enough to install it and no more. Apply molybdenum disulfide oil solution to the cylinder bore. Apply molybdenum disulfide oil solution to the front and rear of the piston skirt. Install the rear cylinder first, with the rear piston at TDC.
•
• • •
ENGINE TOP END 5-43 Cylinders, Piston NOTE
○If a new piston or cylinder is used, check piston to cylin-
der clearance (see Piston/Cylinder Clearance in this section), and use new piston ring.
the cylinder base gasket [A] with a new one, and • Replace install the gaskets aligning the holes with the crankcase
•
water passages [B]. Be sure to install the dowel pins [C].
the piston ring compressor assembly [A] with the • Using chamfered side [B] upward, install the cylinder block [C]. Special Tools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 95 ∼ 108: 57001-1358
○The front cylinder [A] has an “F” mark and the rear cylinder [B] has an “R” mark. Be careful not to mix them up. Front [C]
the chain guide into the cylinder. •○Insert The front chain guide for the front cylinder has an “F” mark
[A] and the front chain guide for the rear cylinder has an “R” mark [B]. Be careful not to mix up these chain guides since the front chain guide for the rear cylinder is longer.
5-44 ENGINE TOP END Cylinders, Piston the front cylinder in the same way. •○Install Position the front piston at TDC.
○Tighten
the cylinder nuts temporarily (These nuts are tightened to the specified torque after rocker case installation).
Cylinder Wear
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 three locations (total of six measurements) 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] 70 mm (2.76 in.) [B] 20 mm (0.79 in.) [C] Cylinder Inside Diameter Standard: 102.000 ∼ 102.012 mm (4.0157 ∼ 4.0162 in.), and less than 0.01 mm (0.0004 in.) difference between any two measurements. Service Limit: 102.10 mm (4.020 in.) or 0.05 mm (0.002 in.) difference between any two measurements.
Piston Wear
the outside diameter [A] of each piston 5 mm • Measure [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: 101.942 ∼ 101.957 mm (4.0135 ∼ 4.0140 in.) Service Limit: 101.79 mm (4.007 in.)
Piston/Cylinder Clearance
the piston diameter from the cylinder inside di• Subtract ameter to get the piston/cylinder clearance. Piston/Cylinder Clearance Standard: 0.043 ∼ 0.070 mm (0.0017 ∼ 0.0028 in.)
If the piston/cylinder clearance is less than the specified range, use a smaller piston made within the standard diameter or increase the cylinder inside diameter within the standard diameter by honing. If the piston/cylinder clearance is greater than specified range, use a larger piston made within the standard diameter. If only a piston is replaced, the clearance may exceed the standard slightly. But it must not to be less than the minimum of the clearance in order to avoid piston seizure.
ENGINE TOP END 5-45 Cylinders, Piston Cylinder Boring and Honing
○There is an oversize piston available. The oversize piston requires oversize rings.
Oversize Piston and Rings: 0.5 mm (0.02 in.) oversize
boring a cylinder [A], first measure the exact di• Before ameter of the oversize piston, and then, according to the standard clearance in the Specifications, determine the rebore diameter. However, if the amount of boring necessary would make the inside diameter greater than 0.5 mm (0.02 in.), the cylinder block must be replaced. ○Cylinder inside diameter must not vary more than 0.01 mm (0.0004 in.) at any point. ○Be wary of measurements taken immediately after boring since the heat affects cylinder diameter. ○In the case of rebored cylinder and oversize piston, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm (0.004 in.) and the service limit for the piston is the oversize piston original diameter minus 0.15 mm (0.0059 in.). If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder.
Piston Ring, Piston Ring Groove Wear
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
0.050 ∼ 0.090 mm (0.0020 ∼ 0.0035 in.)
Second
0.030 ∼ 0.070 mm (0.0012 ∼ 0.0028 in.)
Service Limit: Top
0.19 mm (0.0075 in.)
Second
0.17 mm (0.0067 in.)
If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both.
5-46 ENGINE TOP END Cylinders, Piston Piston Ring Groove Width
the width of the top [A] and second [B] ring • Measure grooves.
○Use vernier calipers at several points around the piston. Piston Ring Groove Width Standard: Top
1.24 ∼ 1.26 mm (0.049 ∼ 0.050 in.)
Second
1.22 ∼ 1.24 mm (0.048 ∼ 0.049 in.)
Service Limit: Top
1.34 mm (0.053 in.)
Second
1.32 mm (0.052 in.)
If the width of any of the two grooves is wider than the service limit at any point, replace the piston.
Piston Ring Thickness
the thickness of the top [A] and second [B] rings. •○Measure Use a micrometer to measure at several points around the ring.
Piston Ring Thickness Standard: Top
1.17 ∼ 1.19 mm (0.046 ∼ 0.047 in.)
Second
1.17 ∼ 1.19 mm (0.046 ∼ 0.047 in.)
Service Limit: Top
1.10 mm (0.043 in.)
Second
1.10 mm (0.043 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
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 Standard: Top Second Oil Service Limit: Top Second Oil
Gap 0.25 ∼ 0.35 mm (0.010 ∼ 0.014 in.) 0.40 ∼ 0.55 mm (0.016 ∼ 0.022 in.) 0.30 ∼ 0.90 mm (0.012 ∼ 0.035 in.) 0.7 mm (0.03 in.) 0.9 mm (0.04 in.) 1.2 mm (0.05 in.)
If the end gap of either ring is greater than the service limit, replace all the rings.
ENGINE TOP END 5-47 Mufflers Exhaust Pipe Removal
WARNING To avoid a serious burn, do not remove the exhaust pipe or muffler when the engine is still hot. Wait until the muffler cools down. the clamp screws [A] on the rear exhaust pipe • Loosen cover [B]. the clamps [C] by sliding it up. • Detach Remove the rear exhaust pipe cover. •
the clamp screw [A]. • Loosen the clamp [B] by sliding it forward. • Detach Remove • it forward.the lower front exhaust pipe cover [C] by sliding
the clamp screws [A]. • Loosen Detach the [B] by sliding them up or forward. • Remove theclamps front exhaust pipe cover [C]. •
the front exhaust pipe clamp bolt [A]. • Loosen Remove the front exhaust pipe holder nuts [B]. • Take off the front exhaust pipe [C]. •
5-48 ENGINE TOP END Mufflers the left chamber bolt. • Loosen Remove: • Right Chamber Bolt [A]
• •
Rear Exhaust Pipe Holder Nuts [B] Loosen the rear exhaust pipe clamp bolt [C]. Pull the upper end of the rear exhaust pipe outward and twist clockwise a little, and then take off the rear exhaust pipe [D].
Muffler Removal
• Remove: Left and Right Saddlebag (see Saddlebag Removal in • •
the Frame chapter) Lower Front Exhaust Pipe Cover (Right Muffler only, see Exhaust Pipe Removal in this section) Muffler Stay Mounting Bolts [A] (Both Sides) Loosen the left and right muffler clamp bolts [B]. Move the left and right muffler [C] backward and remove it.
Exhaust Pipe, Muffler Installation
the exhaust pipe holder gasket [A] with new • Replace ones.
the exhaust pipe and muffler flange gasket [A] • Replace with new ones. the exhaust pipe and muffler pipe clamps [B] with • Install its bolt downward. • Tighten:
Torque - Premuffler Chamber Bolts [C]: 29 N·m (3.0 kgf·m, 21 ft·lb) Muffler Stay Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
ENGINE TOP END 5-49 Mufflers the lower front exhaust pipe cover [A]. •○Install Fit the two plastic tabs [B] of the front lower exhaust cover into the slots [C] in the lower muffler [D].
the lower and front exhaust pipe cover clamp • Tighten lower screws [A] with they are head inclined at 50° [B] or less to horizontal as shown. This prevents the screw from touching ground when banking. Torque - Exhaust Pipe Cover Clamp Screws: 6.9 N·m (0.70 kgf·m, 61 in·lb)
tighten all the bolts and nuts to a snug fit. • First, Secondary, tighten the exhaust pipe holder nuts evenly. • Finally, tighten • bolts securely. the rest of the mounting bolts and clamp warm up the engine, wait until the engine • Thoroughly cools down, and retighten all the clamp bolts.
Chamber Removal/Installation
• Remove: Front and Rear Exhaust Pipes (see Exhaust Pipe Re• •
moval in this section) Left and Right Mufflers (see Muffler Removal in this section) Left Chamber Bolts [A] Take out the premuffler chamber [B]. Tighten: Torque - Premuffler Chamber Bolts: 29 N·m (3.0 kgf·m, 21 ft·lb)
Chamber Assembly
a soap and water solution or rubber lubricant to the • Apply surface of the rubber bushings and install them into the brackets of the chamber as shown (Top View). Rubber Bushings [A] 24.8 mm (0.98 in.) with a raised ring [B] Rubber Bushings [C] 25.3 mm (1.0 in.) without raised ring
5-50 ENGINE TOP END Mufflers Chamber Identification
○The this models have a premuffler chamber (Identification
No. KHI M 099) with a honeycomb type catalytic converter and without any catalyst protection system. Do not mix up this chamber with the other type chamber (especially with a non-catalyst chamber). The motorcycle could not clear the emission regulation. → : Exhaust Gas Flow Premuffler Chamber [A] Honeycomb Type Catalytic Converter [B] Inlet [C] from Rear Exhaust Pipe Inlet [D] from Front Exhaust Pipe Premuffler Chamber Outlet [E] ○Refer to the VN1500 G/H Service Manual (Part No. 99924 -1241) for more information about the KLEEN (theory, maintenance, and handling precautions), including the secondary air injection system.
CLUTCH 6-1
Clutch Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Clutch Fluid............................................................................................................................. Clutch Fluid Level Inspection ............................................................................................ Clutch Fluid Change ......................................................................................................... Clutch Line Bleeding ......................................................................................................... Clutch Hose Removal/Installation ..................................................................................... Clutch Hose and Connection Check ................................................................................. Clutch Master Cylinder ........................................................................................................... Clutch Lever Adjustment................................................................................................... Clutch Master Cylinder Removal ...................................................................................... Clutch Master Cylinder Installation ................................................................................... Clutch Master Cylinder Disassembly/Assembly................................................................ Clutch Master Cylinder Inspection .................................................................................... Clutch Slave Cylinder ............................................................................................................. Clutch Slave Cylinder Removal ........................................................................................ Clutch Slave Cylinder Installation ..................................................................................... Clutch Slave Cylinder Disassembly/Assembly.................................................................. Clutch ..................................................................................................................................... Clutch Cover Removal ...................................................................................................... Clutch Cover Installation ................................................................................................... Clutch Removal................................................................................................................. Clutch Installation.............................................................................................................. Inner Clutch Hub Disassembly.......................................................................................... Spring Plate Gap Measurement........................................................................................ Spring Plate Gap Adjustment............................................................................................ Friction and Steel Plate Wear, and Damage Inspection ................................................... Friction or Steel Plate Warp .............................................................................................. Clutch Spring Height Measurement .................................................................................. Clutch Housing Finger Inspection ..................................................................................... Outer Clutch Hub Spline Inspection.................................................................................. Cam Damper Inspection ...................................................................................................
6-2 6-4 6-5 6-6 6-6 6-6 6-6 6-6 6-6 6-7 6-7 6-7 6-7 6-7 6-8 6-9 6-9 6-9 6-10 6-11 6-11 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-17 6-17 6-17 6-18 6-18
6
6-2 CLUTCH Exploded View
CLUTCH 6-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Fastener Clutch Cover Bolts Clutch Damper Cover Bolts Clutch Damper Plate Bolts Clutch Hose Banjo Bolt (Upper) Clutch Hose Banjo Bolt (Lower) Clutch Hub Nut Clutch Lever Pivot Bolt Clutch Lever Pivot Bolt Locknut Clutch Master Cylinder Clamp Bolts Clutch Reservoir Cap Screws Clutch Slave Cylinder Bleed Valve Clutch Slave Cylinder Bolts Oil Filler Cap Starter Lockout Switch Screw
N·m 11 9.8 9.8 25 25 145 1.0 5.9 11 1.5 7.8 6.9 1.5 1.2
Torque kgf·m 1.1 1.0 1.0 2.5 2.5 14.8 0.10 0.60 1.1 0.15 0.80 0.70 0.15 0.12
ft·lb 97 in·lb 87 in·lb 87 in·lb 18 18 107 8.9 in·lb 52 in·lb 97 in·lb 13 in·lb 69 in·lb 61 in·lb 13 in·lb 11 in·lb
Remarks
15. Clutch Slave Cylinder 16. Starter Lockout Switch 17. Cup point side faces outside. EO: Apply engine oil. L: Apply a non-permanent locking agent. 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 specific tightening sequence. SI: Apply silicone grease or PBC grease.
L EO
MO SI S
L
6-4 CLUTCH Specifications Item Clutch Fluid Grade Clutch Lever Position Clutch Lever Free Play Clutch Clutch Spring Free Height Spring Plate Gap Friction Plate Thickness Friction or Steel Plate Warp
Standard
Service Limit
DOT4 (provided when shipping) No. 1 (to suit rider) Non-adjustable
– – – 5-way adjustable – – –
4.3 mm (0.17 in.) (Usable Range) 1.95 ∼ 2.45 mm (0.077 ∼ 0.096 in.) 3.3 ∼ 3.5 mm (0.13 ∼ 0.14 in.) 0.2 mm (0.008 in.) or less
4.0 mm (0.16 in.) – – – 3.1 mm (0.12 in.) 0.3 mm (0.01 in.)
CLUTCH 6-5 Special Tools Inside Circlip Pliers: 57001-143
Clutch Spring Compressor: 57001-1162
Gear Holder: 57001-1557
6-6 CLUTCH Clutch Fluid Clutch Fluid Level Inspection
to the Clutch Fluid Level Inspection in the Periodic • Refer Maintenance chapter.
Clutch Fluid Change
to the Clutch Fluid Change in the Periodic Mainte• Refer nance chapter.
Clutch Line Bleeding
the alternator outer cover (see Alternator Outer • Remove Cover Removal in the Electrical System chapter). the reservoir cap off, slowly pump the clutch lever • With several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir. This bleeds the air from the master cylinder end of the line.
NOTE
○Tap the clutch hose lightly going from the lower end to the upper end and bleed the air off at the reservoir.
a clear plastic hose [A] to the bleed valve on the • Attach clutch slave cylinder, and run the other end of the hose into a container. the clutch line as follows. • Bleed Pump the clutch lever a few times until it becomes hard and then hold it applied [B]. Quickly open and close [C] the bleed valve. Release [D] the clutch lever. Check the fluid level in the reservoir often, replenishing it as necessary.
NOTE
○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. ○Repeat this operation until no more air can be seen coming out into the plastic hose.
WARNING Do not mix different grades and brands of fluid. Torque - Clutch Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Clutch Hose Removal/Installation
○Since the clutch hose is the same as the brake hose, refer to the Brake Hoses section in the Brakes chapter for clutch hose removal or installation.
Clutch Hose and Connection Check
to the Clutch Hose Damage and Installation Condi• Refer tion Inspection Check in the Periodic Maintenance chapter.
CLUTCH 6-7 Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 5 positions so that the clutch 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 5 and maximum at number 1.
•
Clutch Master Cylinder Removal
the starter lockout switch connector [A]. • Disconnect Draw out the fluid from the reservoir with a means • like the fork oilclutch level gauge. the banjo bolt [B] to disconnect the clutch hose • Remove from the master cylinder. the clamp bolts [C], and take off the master cylin• Unscrew der [D] as an assembly with the clutch reservoir, clutch lever, and starter lockout switch installed.
CAUTION Clutch fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately.
Clutch Master Cylinder Installation
○The master cylinder clamp must be installed with the rear
• •
view mirror boss [A] upward. Set the clutch master cylinder [B] to match its mating surface [C] to the punch mark [D] of the handlebar. Tighten the upper clamp bolt [E] first, and then the lower clamp bolt [F]. There will be a gap at the lower part of the clamp after tightening. Torque - Clutch Master Cylinder Clamp Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
a new flat washer on each side of the clutch hose • Use fitting. • Tighten the clutch hose banjo bolt. Torque - Clutch Hose Banjo Bolt (Upper): 25 N·m (2.5 kgf·m, 18 ft·lb)
the clutch fluid into the reservoir and bleed the • Replenish clutch line (see Clutch Line Bleeding in this chapter). that the clutch line has proper fluid pressure and • Check no fluid leakage.
Clutch Master Cylinder Disassembly/Assembly
to the Clutch Master Cylinder Rubber Parts Re• Refer placement in the Periodic Maintenance chapter.
6-8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Inspection
the clutch master cylinder (see Clutch Mas• Disassemble ter Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter).
CAUTION Do not remove the secondary cup from the piston since removal will damage it. that there are no scratches, rust or pitting on the • Check inside of the master cylinder [A] and on the outside of the
•
piston [B]. If the 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 clutch lever, the piston assembly should be replaced to renew the cups. Check the dust cover [E] for damage. If it is damaged, replace it.
• • • that the relief and supply ports are not plugged. • Check If the small relief port becomes plugged, the clutch will •
drag. Blow the ports clean with compressed air. Check the piston return spring for any damage. If the spring is damaged, replace it.
CLUTCH 6-9 Clutch Slave Cylinder Clutch Slave Cylinder Removal
• Remove: Alternator Outer Cover (see Alternator Outer Cover Removal in the Electrical System chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C]
CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. the following if the clutch slave cylinder is to be • Perform removed but not disassembled.
CAUTION If the clutch slave cylinder is removed and left alone, the piston will be pushed out by spring force and the clutch fluid will drain out.
○Remove the clutch slave cylinder with the pipe installed. ○Push [A] the piston into the cylinder as far as it will go. ○Apply the clutch lever [A] slowly and hold it with a band [B].
NOTE
○Holding the clutch lever keeps the piston from coming out.
Clutch Slave Cylinder Installation
molybdenum disulfide grease to the flat end [A] of • Apply the push rod [B]. the push rod so that the flat end faces in. • Install Cup Point [C] the spacer [D] of the clutch slave cylinder with a • Replace new one. the spacer so that the stepped side [E] faces out• Install ward. a non-permanent locking agent to the threads of • Apply the clutch slave cylinder bolts [F]. tighten the clutch slave cylinder bolts. • Finger Remove the band from the clutch lever and release the • clutch lever.
6-10 CLUTCH Clutch Slave Cylinder
• Tighten:
Torque - Clutch Slave Cylinder Bolts [A]: 6.9 N·m (0.70 kgf·m, 61 in·lb)
○Put the clamp [B] together the clutch slave cylinder bolt
• •
and bend along the slave cylinder with the end of the clamp straight to the engine side as shown in the figure. This clamp is to prevent the edge of the slave cylinder from damaging the wire, not to clamp the wire. Replace the washers on each side of the clutch hose fitting with new ones. Tighten the banjo bolt [C] to the specified torque.
Torque - Clutch Hose Banjo Bolt (Lower): 25 N·m (2.5 kgf·m, 18 ft·lb)
the fluid level in the master cylinder reservoir, and • Check bleed the air in the clutch line. • Check the clutch operation.
Clutch Slave Cylinder Disassembly/Assembly
to the Clutch Slave Cylinder Piston Seal Replace• Refer ment in the Periodic Maintenance chapter.
CLUTCH 6-11 Clutch Clutch Cover Removal
the rear wheel off the ground (see Rear Wheel Re• Raise moval in the Wheels/Tires chapter). the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter). • Remove: Right Front Guard (see Front Guard Removal/Installation in the Frame chapter) Front Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Downtube (see Downtube Removal in the Frame chapter, but remove the downtube with the right front footboard and rear master cylinder left installed.)
• Unscrew the clutch cover bolts (18) [A].
the pry • Using crankcase.
points [A], take the cover [B] off the
NOTE
○Do not remove the damper cover [C].
Clutch Cover Installation
the clutch cover gasket with a new one. • Replace Tighten: •
Torque - Clutch Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
•
L = 35 mm (1.3 in.) [A] L = 30 mm (1.2 in.) [B] L = 25 mm (1.0 in.) [C] Install the removed parts (see appropriate chapters).
6-12 CLUTCH Clutch Clutch Removal NOTE
○Use an air impact wrench for removal of the clutch hub nut.
the clutch cover (see Clutch Cover Removal in • Remove this section). the retaining ring [A] using a cutout portion [C], • Remove and take the operating plate [B] out of the clutch assembly. Screw Driver [D]
• Remove: Washer [A] Spring Plate Pusher [B] Needle Bearing Washer
the clutch hub nut [A] by using an air impact • Unscrew wrench. the clutch spring [B], and the clutch spring holders • Take [C] out of the clutch hub.
the back torque limiter springs [A], and the clutch • Take spring plate out of the clutch housing.
the friction/steel plate [A], and outer clutch hub [B] • Take out of the clutch housing.
CLUTCH 6-13 Clutch the inner clutch hub [A], collar [B], washer [C] and • Take clutch housing [D] out of the crankcase.
the needle bearing [A], sleeve [B], and thrust washer • Pull [C] off the drive shaft.
Clutch Installation When replacing any one of the following parts, check the spring plate gap (see Spring Plate Gap Measurement in this section). Spring Plate [A] Friction Plates [B] Steel Plates [C]
installing the clutch housing, mesh the oil pump • When drive gear [A] with the oil pump gear [B] so that the pump gear turns smoothly.
CAUTION If new dry steel or friction plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. the friction plates and steel plates, starting with a • Install friction plate and alternating them. install the friction plates, fitting their tangs in the • First, deeper grooves [A], and finally the outermost friction plate [B] in the shallower grooves [C].
6-14 CLUTCH Clutch the clutch spring holder outer [A] on the spring • Install holder [B], and convex direction of outside [C] on the
•
spring holder [D]. Apply grease to the back torque limiter springs [E] and install the each direction them on the spring holder as shown. Clutch Hub Nut [F] (for Reference)
molybdenum disulfide oil solution to the threads • Apply and seating surface of the clutch hub nut.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Tighten the clutch hub nut to the specified torque while holding the primary gear [A] with the gear holder [B]. Torque - Clutch Hub Nut: 145 N·m (14.8 kgf·m, 107 ft·lb) Special Tool - Gear Holder : 57001-1557
spring plate pusher [A] into the clutch hub. Squeeze • The the clutch lever slowly and hold it with a band.
○Install the needle bearing [B] and the washer onto the pusher.
[A] the operating plate [B] into the clutch hub, and • Pushing insert the retaining ring [C] by hand. the clutch cover (see Clutch Cover Installation in • Install this section)
Inner Clutch Hub Disassembly
the inner clutch hub (see Clutch Removal in this • Remove section) a press [A], and the clutch spring compressor [B], • Using push the damper spring holder [C] to remove the retaining ring [D]. Special Tools - Clutch Spring Compressor: 57001-1162 Inside Circlip Pliers [E]: 57001-143
CLUTCH 6-15 Clutch
• Remove: Retaining Ring [A] Spring Holder [B] Damper Spring [C] Spring Holder [D] Spacer [E] Damper Cam [F] Inner Clutch Hub [G]
Spring Plate Gap Measurement Insufficient spring plate gap will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the spring plate gap is excessive, the clutch may slip or the clutch lever may feel “spongy” or pulsate when pulled. sheet gum (chewing gum) or about 5 g (0.176 • Prepare oz) clay [A]. an about 2.5 mm (0.10 in.) thick sheet [B] of gum • Make or clay, using a press and two thickness gauges [C] which
•
are overlapped to about 2.5 mm (0.10 in.). Cut the sheet with scissors into four strips [D] of gum or clay as shown. 7 mm (0.276 in.) [E] 4 mm (0.157 in.) [F]
the clutch (see Clutch Removal in this chapter). • Remove the inner clutch hub, spring holder assy [A], the • Place outer clutch hub [B], and the clutch plates (friction and steel plates) [C] on blocks [D]. ○Do not support the spring holder [E] with the blocks.
6-16 CLUTCH Clutch a soap and water solution to the strips. This is to • Apply separate the strips easily from the clutch spring plate and clutch hub when removing strips. Place these four strips [A] on the raised surface [B] of the outer clutch hub in a criss-cross pattern as shown. Install the clutch spring plate [C] and a block [D]. ○While noting the positions of the spline teeth [E], fit the clutch spring plate into the outer clutch hub smoothly. Be careful not to move these strips. Press [F] the block until the clutch plates [G] seat closely.
• • •
CAUTION Do not press the block too much. This could damage the clutch parts. The maximum press force is 100 kg.
the clutch spring plate. • Remove Peel off these strips with a thin-bladed screwdriver. • Measure the pressed thickness [A] of each strip with • vernier calipers.
○The thickness represents the spring plate gap.
Spring Plate Gap Usable Range: 1.95 ∼ 2.45 mm (0.077 ∼ 0.096 in.)
NOTE
○In case of rear wheel hop, adjust the spring plate gap a bit larger, and in case of clutch slip or “spongy” clutch lever, adjust the gap a bit smaller within the usable range. Spring Plate Gap Adjustment If the plate gap is out of the usable range, change one of the steel plates [A] to a thicker or thinner one to get the correct gap. ○Use the standard steel plates (2.0 mm, 0.079 in. thick) × (6 ∼ 7) plates, and the adjustment steel plate (1.6 or 2.3 mm, 0.063 or 0.090 in. thick) × (0 ∼ 1) plates: total 7 plates. Steel Plates Thickness
Part Number
1.6 mm (0.063 in.)
13089-1080
2.0 mm (0.079 in.) (STD)
13089-1075
2.3 mm (0.090 in.)
13089-1081
CAUTION If new friction or steel plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
CLUTCH 6-17 Clutch Friction and Steel Plate Wear, and Damage Inspection
inspect the friction and steel plates for signs of • Visually seizure, overheating (discoloration), or uneven wear.
•
If any plates show signs of damage, replace the plates. Measure the thickness of the friction plates [A] at several points. If they have worn past the service limit, replace the friction plate and measure the spring plate gap and adjust it if necessary. Friction Plate Thickness Standard: 3.3 ∼ 3.5 mm (0.13 ∼ 0.14 in.) Service Limit:
3.1 mm (0.12 in.)
Friction or Steel Plate Warp
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 friction plate is warped over the service limit, replace it and measure the spring plate gap, and adjust it if necessary. If any steel plate is warped over the service limit, replace it with a new one of the same thickness. Friction or Steel Plate Warp Standard: 0.2 mm (0.008 in.) or less Service Limit:
0.3 mm (0.01 in.)
Clutch Spring Height Measurement
the height [B] of the clutch spring [A]. • Measure If the spring height is less than the service limit, it must be replaced. Clutch Spring Height Standard: Service Limit:
4.3 mm (0.17 in.) 4.0 mm (0.16 in.)
Clutch Housing Finger Inspection
inspect the fingers [A] of the clutch housing where • Visually the tangs [B] of the friction plates 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 and measure the spring plate gap and adjust it if necessary.
6-18 CLUTCH Clutch Outer Clutch Hub Spline Inspection
inspect where the teeth [B] on the steel plates • Visually wear against the splines [A] of the outer clutch hub. If there are notches worn into the splines, replace the outer clutch hub. Also, replace the steel plate with a new one of the same thickness if their teeth are damaged.
Cam Damper Inspection
the clutch (see Inner Clutch Hub Disassem• Disassemble bly in this section). inspect the damper cam [A], damper spring [B], • Visually and cam follower [C]. Replace any damaged parts.
ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Engine Oil Flow Chart............................................................................................................. Engine Oil and Oil Filter.......................................................................................................... Oil Level Inspection........................................................................................................... Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Oil Pump and Oil Line............................................................................................................. Oil Pump Removal ............................................................................................................ Oil Pump Installation ......................................................................................................... Oil Hose Removal ............................................................................................................. Oil Hose Installation .......................................................................................................... Inside Oil Pipe Removal.................................................................................................... Inside Oil Pipe Installation................................................................................................. Blowby Gas System Inspection ........................................................................................ Breather Drain Cleaning ................................................................................................... Oil Pressure............................................................................................................................ Oil Pressure Measurement ............................................................................................... Relief Valve Inspection......................................................................................................
7-2 7-4 7-5 7-6 7-8 7-8 7-8 7-8 7-9 7-9 7-9 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-15 7-16
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 11 12 13 14 15 16
Fastener Oil Baffle Bolt Oil Drain Plug Oil Filter Oil Filter Pipe Oil Hose Banjo Bolt Oil Hose Flange Bolts Oil Hose Nozzle Oil Nozzles Oil Pipe Clamp Bolts Oil Pipe Holder Bolts Oil Pressure Switch Oil Pressure Switch Terminal Screw Oil Pump Mounting Bolts Oil Return Pipe Clamp Bolts Oil Screen Plug Relief Valve
N·m 11 20 18 25 9.8 9.8 2.9 2.9 11 11 15 1.5 11 11 20 15
Torque kgf·m 1.1 2.0 1.8 2.5 1.0 1.0 0.30 0.30 1.1 1.1 1.5 0.15 1.1 1.1 2.0 1.5
ft·lb 97 in·lb 15 13 18 87 in·lb 87 in·lb 26 in·lb 26 in·lb 97 in·lb 97 in·lb 11 13 in·lb 97 in·lb 97 in·lb 15 11
Remarks L EO, R SS
LH L L SS G L L
17. Crankcase Breather Hose 18. HLA Oil Filters 19. Oil Baffle 20. Oil Return Pipes 21. Oil Screen 22. Oil Separator (Smaller side goes first.) 23. To Right Air Cleaner Base EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LH: Left-hand Threads R: Replacement Parts SS: Apply silicone sealant to the threads of the oil pressure switch (Kawasaki Bond: 56019-120). SS: Apply silicone sealant to the threads of the oil filter pipe (Three Bond: TB1401B). SS: Apply silicone sealant to the left crankcase mating surface of the separator (Three Bond: TB1207B).
7-4 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil Type Viscosity Capacity
Level (Wait 2 ∼ 3 Minutes After Idling or Running) Oil Pressure Measurement Oil Pressure @2 000 r/min (rpm), Oil Temperature. 90°C (194°F)
Standard API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 2.9 L (3.1 US qt) (when filter is not removed) 3.1 L (3.3 US qt) (when filter is removed) 3.5 L (3.7 US qt) (when engine is completely disassembled and dry) Between upper and lower level lines
340 ∼ 440 kPa (3.5 ∼ 4.5 kgf/cm², 50 ∼ 64 psi)
ENGINE LUBRICATION SYSTEM 7-5 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Oil Pressure Gauge Adapter, PT 1/8: 57001-1033
Kawasaki Bond (Silicone Sealant): 56019-120
7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 7-7 Engine Oil Flow Chart →: Oil Flow (1 ∼ 30) --→: Blowby Gas 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Filter 5. Bypass Valve 6. Oil Pressure Switch 7. Inside Oil Pipe 8. Banjo Bolts of Right Crankcase Rear 9. Outside Oil Hoses 10. HLA Oil Filter 11. Rocker Shafts 12. Rocker Arms 13. HLA (Hydraulic Lash Adjuster) 14. Camshafts 15. Outside Oil Pipe 16. Front Gear Case 17. Inside Oil Pipe 18. Crankshaft 19. Alternator Rotor 20. Oil Nozzle 21. Front Piston 22. Drive Shaft 23. Output Shaft 24. Rear Piston 25. Front Rocker Case 26. Rear Rocker Case 27. Inside Oil Pipe Fittings 28. Oil Baffle 29. Fitting 30. Left Crankcase 31. Right Air Cleaner Housing 32. Crankcase Breather Hose 33. Oil Separating Chambers 34. Right Crankcase 35. Oil Return Pipes
7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury.
Oil Level Inspection
the motorcycle so that it is vertical. • Situate Check that engine oil level is between the upper [A] • and lower [B]thelevels in the gauge. Clutch Cover [C]
NOTE
○Situate the motorcycle so that it is perpendicular to the ground.
○If the motorcycle has just been used, wait 2 ∼ 3 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 2 ∼ 3 minutes until the oil settles.
CAUTION Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause. 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.
ENGINE LUBRICATION SYSTEM 7-9 Oil Pump and Oil Line Oil Pump Removal
the engine (see Engine Removal in the Engine • Remove Removal/Installation chapter). the crankcase (see Crankcase Disassembly in the • Split Crankshaft/Transmission chapter). the oil pump mounting bolts [A], and take off the • Remove pump [B] out of the right crankcase. • Unscrew the relief valve [C] if necessary.
• Remove: Circlip [A] Washer [B] Pump Shaft [C] Pump Gear [D]
Oil Pump Installation
the position of the oil pump shaft tang [A] and turn • Note the pump gear shaft so that the tang fits into the slot [B]
• • •
of the oil pump gear. Replace the O-rings [C] with new ones if they are damaged. Be sure to install the dowel pins [D]. Tighten: Torque - Oil Pump Mounting Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
that the oil pump gear turns smoothly in the left • Check side of the right crankcase. a non-permanent locking agent to the threads of • Apply the relief valve and install it. Torque - Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb)
Oil Hose Removal
• Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Rocker Case Covers (see Rocker Case Cover Removal in the Engine Top End chapter) Oil Hose Flange Bolts [A] Front [B]
7-10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line
• Remove: Oil Hose Banjo Bolt [A] Front Oil Hose [B] Front Oil Hose [C]
Oil Hose Installation
the front oil hose over the rear oil hose as shown. •○Run Insert the rear oil hose [A] first.
○Next insert the front oil hose [B]. ○Run both oil hoses between the
rocker case and the
rocker case cover.
Torque - Oil Hose Flange Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the front oil hose to the clamps [C]. • Hook Fit the clamp [D] as shown. •
each bottom end of the oil hoses on the right • Install crankcase behind the rear cylinder as shown. Front Oil Hose [A] Rear Oil Hose [B] Front [C] ○Face the paint marks [D] rearward. Replace the copper washers on each side of the banjo bolt with new ones.
•
Torque - Oil Hose Banjo Bolt [E]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters).
ENGINE LUBRICATION SYSTEM 7-11 Oil Pump and Oil Line Inside Oil Pipe Removal
the crankcase (see Crankcase Disassembly in the • Split Crankshaft/Transmission chapter). • Remove: Oil Pipe Clamp Bolt [A]
•
Oil Pipe Holder Bolt [B] Remove the inside oil pipe [C] from the right crankcase.
the oil return pipe clamp bolt [A], and oil return • Remove pipe [B].
• Remove the oil separator [A].
• Remove: Oil Pipe Clamp Bolts [A] Oil Pipe Holder Bolt [B] Remove the inside oil pipe [C] and the oil return pipe [D] from the left crankcase [E]. ○Pull out the large size fittings [F] first, and remove the small size fitting [G] upward.
•
• Remove the bolt [A] and the oil baffle [B].
7-12 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Inside Oil Pipe Installation
that the oil pipe fitting O-rings [A] are in good con• Check dition. grease to the O-rings before installation. • Apply Oil Pipe [B] Fitting [C]
the inside oil pipe [A], separator [B] and the oil re• Install turn pipe [C] to left crankcase [D] as shown.
○Do not apply silicone sealant to the groove of the grommet
and the mating surface of the grommet [E]. ○Apply silicone sealant to the crankcase mating surface [F] of the separator. Sealant - Three Bond: TB1207B
○Apply a non-permanent locking agent to the oil pipe holder bolt [G], oil return pipe clamp bolt [H] oil pipe clamp bolts [I], and oil baffle bolt [J]. ○If the oil nozzles [K] are removed, install them.
Torque - Oil Oil Oil Oil Oil
Pipe Holder Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) Return Pipe Clamp Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) Pipe Clamp Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) Baffle Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) Nozzles: 3.0 N·m (0.30 kgf·m, 26 in·lb)
ENGINE LUBRICATION SYSTEM 7-13 Oil Pump and Oil Line the inside oil pipe [A], separator [B], and the oil • Install return pipe [C] to the right crankcase [D].
○Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E].
○Install the separator so that it’s smaller side [F] faces inside.
○Apply a non-peramanet locking agent to the oil pipe holder
bolt [G], oil return pipe clamp bolt [H] and oil pipe clamp bolts [I]. ○If the oil nozzle [J] is removed, install it. ○The oil hose nozzle [K] has left-hand threads.
Torque - Oil Pipe Holder Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) Oil Return Pipe Clamp Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Oil Pipe Clamp Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) Oil Hose Nozzle: 3.0 N·m (0.30 kgf·m, 26 in·lb) Oil Nozzle: 3.0 N·m (0.30 kgf·m, 26 in·lb)
• Install the removed parts (see appropriate chapters). Blowby Gas System Inspection
certain that all the hoses are routed without being flat• Be tened or kinked, and are connected correctly to the oil reserve tank and right air cleaner base. If they are not, correct them. Inspect the breather hoses [A], breather pipe [B], and the air cleaner drain hose for damage or signs of deterioration. ○These hoses should not be hard and brittle, nor should be soft or swollen. Replace it if any cracks or swelling are noticed. Check that the hoses are securely connected.
•
•
7-14 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Breather Drain Cleaning
○The air cleaner drain hose is provided beneath the right
• • •
air cleaner housing, and catches the water or oil from the crankcase breather hose. Usually water or oil does not collect at the bottom. In the event that rain water is drawn in through the air cleaner or if engine oil is blown back, drain the housing. Remove the left air cleaner housing (see Left Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Remove the drain plug [A] from the air cleaner drain hose [B] to drain the water or breather. Install the plug on its original position.
WARNING Be sure to reinstall the plug in the drain hose after draining. Oil on tires will make them slippery and can cause an accident and injury.
ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Oil Pressure Measurement
out the rubber boot [A]. • Slide Disconnect oil pressure switch lead [B] from the ter• minal screwthe [C]. Unscrew the oil pressure switch [D]. •
NOTE
○Measure the oil pressure after the engine is warmed up.
the oil pressure gauge [B] and adapter [C] to the • Attach switch hole. Oil Pressure Switch [A] Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Oil Pressure Gauge Adapter, PT 1/8: 57001 -1033
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, oil pressure relief valve, and/or crankshaft bearing wear and con-rod big end bearing insert wear immediately. If the reading is much higher than the standard, check the oil screen first, and the oil passages for dirt or clogging. Also, replace the oil filter. Oil Pressure Standard:
340 ∼ 440 kPa (3.5 ∼ 4.5 kgf/cm², 50 ∼ 64 psi) @ 2 000 r/min (rpm), oil temperature 90°C (194°F)
the engine. • Stop Remove the oil pressure gauge and adapter. •
WARNING
Take care against burns from hot engine oil that will drain through the oil passage when the plug is removed. installing the oil pressure switch, apply silicone • When sealant to the threads of the switch, and tighten it to the specified torque. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
• Apply grease to the oil pressure switch terminal screw.
Torque - Oil Pressure Switch Terminal Screw: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the oil pressure switch lead and slide back the • Connect rubber boot to the original position.
7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Inspection
the relief Valve (see Oil Pump Removal in this • Remove chapter). to see if the valve slides smoothly when pushing • Check it in with a wooden or other soft rod, and see if it comes back to its seat by spring 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 Clean the oil pressure relief valve in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent. Valve [A] Spring [B] If cleaning does not solve the problem, replace the relief valve as an assembly. The relief valve is precision made with no allowance for replacement of individual parts.
ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... 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
Fastener Downtube Bolts Engine Mounting Bracket Bolts Engine Mounting Nuts
N·m 59 25 44
WL: Apply a soap and water solution or rubber lubricant.
Torque kgf·m 6.0 2.5 4.5
ft·lb 44 18 33
Remarks
8-4 ENGINE REMOVAL/INSTALLATION Special Tools Jack: 57001-1238
Attachment Jack: 57001-1398
ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal
the rear part of the frame on the jack [A] and the • Support attachment jack [B]. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
○Fit the ribs [C] of the frame into the groove of the attachments.
the brake lever slowly and hold it with a band • Squeeze [A].
WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.
CAUTION Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.
• Drain: Coolant (see Coolant Change in the Periodic Mainte•
nance chapter) Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Remove: Battery Cables (see Battery Removal in the Electrical System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Left Air Cleaner Housing (see Left Air Cleaner Housings Removal/Installation in the Fuel System (DFI) chapter) Right Air Cleaner Housing (see Right Air Cleaner Housings Removal in the Fuel System (DFI) chapter) Throttle Cable (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Front and Rear Exhaust Pipes (see Exhaust Pipe Removal in the Engine Top End chapter) Alternator Outer Cover (see Alternator Outer Cover Removal in the Electrical System chapter) Radiator (see Radiator Removal in the Cooling System chapter) Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Ignition Coil #1 and #2 (see Ignition Coil Removal in the Electrical System chapter) Left and Right Front Guards (see Front Guard Removal/Installation in the Frame chapter)
8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation
• Remove: Right Spark Plug Lead Holder [A] Throttle Body Assy Holder [B] Engine Ground Terminal [C]
• Remove: Throttle Sensor Connector [A] Inlet Air Pressure Sensor Hose [B]
• Remove: Injector Connectors [A] Fuel Hose [B] Connector [C]
• Remove: Horn [A] Choke Knob [B]
• Disconnect: Regulator/Rectifier Lead Connectors [A] Alternator Lead Connectors [B] Crankshaft Sensor Lead Connector [C] Side Stand Switch Lead Connector [D] Speed Sensor Lead Connector [E] Oil Pressure Switch/Neutral Switch Connector [F]
ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation
• Remove: Bracket Bolts [A] Clutch Hose Bracket [B] Clutch Slave Cylinder Bolts [C] Clutch Slave Cylinder [D] (see Clutch Slave Cylinder Removal in the Clutch chapter)
• Remove: Bracket Bolts [A] Regulator/Rectifier Bracket [B] Starter Motor Terminal Nut [C]
• Remove: Brake Reservoir Cover Bolt [A] Brake Reservoir Cover [B]
the engine with a commercially available stand • Support [A]. • Remove: Engine Mounting Nut [B]
•
Engine Mounting Bracket Bolts [C] (Both Sides) Downtube Bolt Cap and Bolts [D] Remove the downtube [E] with the right front footboard and rear master cylinder installed.
• Remove: Engine Mounting Nuts [A] Engine Mounting Bracket Bolts [B] (Both Sides)
8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation the propeller shaft from the engine. •○Disengage Pull off the rubber boot [A] and push on the lockpin [B] a little with a pin. ○Move the engine forward [C] to free it from the rear propeller shaft.
• Remove the engine [A] from the motorcycle right side.
Engine Installation
the engine with a commercially available stand • Support and move them inside the frame in the reverse order of
• • •
removal. Install the rubber boot [A] on the rear end of the front bevel gear case. Fit the spring [B] into the front bevel gear joint. Put the lockpin [C] into the front bevel gear joint.
a thin coat of high temperature grease to the driven • Apply gear joint and to the propeller shaft joint. on the lockpin [A] and move back the engine to en• Push gage the front bevel gear joint with the propeller shaft joint.
the rear mounting bolt from the left side of the en• Insert gine to set the engine into its original position in the frame. • Tighten:
Torque - Downtube Bolts: 59 N·m (6.0 kgf·m, 44 ft·lb) Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb) Engine Mounting Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the leads, cables and hoses correctly (see Cable, • Run Wire and Hose Routing section in the Appendix chapter).
ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation the engine ground lead [A] down to the engine • Connect as shown. Torque - Engine Ground Terminal Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the removed parts (see appropriate chapters). • Install Adjust cables (see Throttle Grip Free Play Ad• justmenttheinthrottle the Fuel System (DFI) chapter). the engine with engine oil (see Engine Oil Change in • Fill the Periodic Maintenance chapter). the engine with coolant and bleed the air from the cool• Fill ing system (see Coolant Change in the Periodic Mainte-
• • •
nance chapter). Adjust the idling (see Idle Speed Inspection in the Periodic Maintenance chapter). Check the clutch operation. Check the brake effectiveness.
WARNING Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brake will not function on the first application of the lever or pedal if this is not done.
CRANKSHAFT/TRANSMISSION 9-1
Crankshaft/Transmission Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Crankcase .............................................................................................................................. Crankcase Disassembly ................................................................................................... Crankcase Assembly ........................................................................................................ Starter Clutch Disassembly............................................................................................... Starter Clutch Assembly ................................................................................................... Starter Clutch Inspection................................................................................................... Starter Torque Limiter Check ............................................................................................ Crankshaft/Connecting Rods.................................................................................................. Connecting Rod Removal ................................................................................................. Connecting Rod Installation .............................................................................................. Crankshaft/Connecting Rod Cleaning............................................................................... Connecting Rod Bend....................................................................................................... Connecting Rod Twist ....................................................................................................... Connecting Rod Big End Side Clearance ......................................................................... Connecting Rod Big End Bearing Wear............................................................................ Crankshaft Runout ............................................................................................................ Crankshaft Main Bearing/Journal Wear ............................................................................ Crankshaft Side Clearance ............................................................................................... Primary Gear .......................................................................................................................... Primary Gear Removal ..................................................................................................... Primary Gear Installation .................................................................................................. Transmission .......................................................................................................................... Shift Pedal Removal ......................................................................................................... Shift Pedal Installation ...................................................................................................... External Shift Mechanism Removal .................................................................................. External Shift Mechanism Installation ............................................................................... External Shift Mechanism Inspection................................................................................ Transmission Removal ..................................................................................................... Transmission Installation .................................................................................................. Shift Drum Disassembly/Assembly ................................................................................... Transmission Disassembly ............................................................................................... Transmission Assembly .................................................................................................... Shift Fork Bending ............................................................................................................ Shift Fork/Gear Groove Wear ........................................................................................... Shift Fork Guide Pin/Drum Groove Wear.......................................................................... Gear Dog and Gear Dog Hole Damage............................................................................ Ball Bearing, Needle Bearing, and Oil Seal............................................................................ Ball Bearing and Outer Race Replacement ...................................................................... Ball and Needle Bearing Wear.......................................................................................... Oil Seal Inspection ............................................................................................................
9-2 9-6 9-8 9-9 9-9 9-13 9-21 9-22 9-22 9-22 9-23 9-23 9-23 9-24 9-24 9-24 9-25 9-25 9-27 9-27 9-27 9-28 9-28 9-28 9-30 9-30 9-30 9-30 9-31 9-31 9-32 9-32 9-33 9-34 9-34 9-37 9-37 9-37 9-37 9-38 9-38 9-38 9-39
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 14 15 16 17 18 19 20 21 22
Fastener Bearing Retainer Bolts Camshaft Chain Guide Bolts Clutch Push Rod Guide Bolts Connecting Rod Big End Nuts Crankcase Bolt (M10, L = 115 mm) Crankcase Bolts (M10, L = 105 mm) Crankcase Bolts (M6, L = 80 mm) Crankcase Bolts (M6, L = 70 mm) Crankcase Bolts (M6, L = 40 mm) Crankcase Bolts (M8) Frame Ground Bracket Bolt Left Balancer Gear Bolt Oil Baffle Bolt Oil Drain Plug Oil Hose Nozzle Oil Nozzles Oil Return Pipe Clamp Bolts Primary Gear Bolt Shift Drum Bearing Holder Bolts Starter Clutch Bolt Starter Clutch Coupling Bolts Water Pump Drainage Hose Fitting
N·m 11 11 11 59 39 39 11 11 11 21 11 85 11 20 2.9 2.9 11 145 11 85 15 9.8
Torque kgf·m 1.1 1.1 1.1 6.0 4.0 4.0 1.1 1.1 1.1 2.1 1.1 8.5 1.1 2.0 0.30 0.30 1.1 14.5 1.1 8.7 1.5 1.0
ft·lb 97 in·lb 97 in·lb 97 in·lb 44 29 29 97 in·lb 97 in·lb 97 in·lb 15 97 in·lb 63 97 in·lb 15 26 in·lb 26 in·lb 97 in·lb 107 97 in·lb 63 11 87 in·lb
23. Left Crankcase 24. Right Crankcase 25. Oil Baffle 26. Water Pump Drainage Hose 27. Apply a non-permanent locking agent to the tap end of this stud only. 28. Do not apply any oil. EO: Apply engine oil. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). LH: Left-hand Threads MO: Apply molybdenum disulfide oil solution to the threads and the seating surface. (mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Three Bond: TB1207B).
Remarks L L L MO S S S S S S L MO L LH L MO L MO L
9-4 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-5 Exploded View No.
Fastener
1 2 3 4 5 6 7 8 9 10 11 12
Damper Cam Nut Gear Set Lever Bolt Idle Shaft Holder Bolts Rear Shift Lever Clamp Bolt Shift Drum Cam Bolt Shift Pedal Clamp Bolts Shift Rod Locknut (Front) Shift Rod Locknut (Rear) Shift Shaft Return Spring Pin Water Pump Chain Guide Bolt Water Pump Chain Guide Spring Hook Bolt Water Pump Impeller Bolt
N·m 195 11 8.3 12 15 29 11 11 39 8.3 2.9 8.8
Torque kgf·m 20.0 1.1 0.85 1.2 1.5 3.0 1.1 1.1 4.0 0.85 0.30 0.90
ft·lb 144 97 in·lb 73 in·lb 104 in·lb 11 21 97 in·lb 97 in·lb 29 73 in·lb 26 in·lb 78 in·lb
Remarks
13. Drive Shaft 14. Output Shaft 15. Align the punch marks. 16. Align the punch mark with the slit. EO: Apply engine oil. L: Apply a non-permanent locking agent. LH: Left-hand Threads MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts
MO, R
L
LH L
LH
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankshaft, Connecting Rods Connecting Rod Bend
Standard – – –
Connecting Rod Twist
– – –
Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert/Crankpin Clearance Crankpin Diameter: Marking: None
○ Connecting Rod Big End Bore Diameter: Marking: None
○ Connecting Rod Big End Bearing Insert Thickness: Brown Black Blue
0.16 ∼ 0.46 mm (0.006 ∼ 0.018 in.) 0.026 ∼ 0.057 mm (0.0010 ∼ 0.0022 in.) 54.981 ∼ 55.000 mm (2.1646 ∼ 2.1654 in.)
Service Limit TIR 0.2/100 mm (0.08/3.94 in.) TIR 0.2/100 mm (0.08/3.94 in.) 0.7 mm (0.03 in.) 0.10 mm (0.004 in.) 54.97 mm (2.164 in.)
54.981 ∼ 54.991 mm (2.1646 ∼ 2.1650 in.) 54.992 ∼ 55.000 mm (2.1650 ∼ 2.1654 in.) 58.000 ∼ 58.020 mm (2.2835 ∼ 2.2842 in.)
– – –
58.000 ∼ 58.010 mm (2.2835 ∼ 2.2839 in.) 58.011 ∼ 58.020 mm (2.2839 ∼ 2.2842 in.)
– – –
1.483 ∼ 1.487 mm (0.0584 ∼ 0.0585 in.) 1.487 ∼ 1.491 mm (0.0585 ∼ 0.0587 in.) 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.)
– – –
– – – – – –
– – –
– – – – – –
Connecting Rod Big End Bearing Insert Selection Con-Rod Big End Bore Diameter Marking
Bearing Insert
Crankpin Diameter Marking
Size Color
Part Number
None
○
Brown
92028-1476
None
None
○
Black
92028-1475
None
Blue
92028-1474
○ ○
Crankshaft Side Clearance Crankshaft Web Length Crankshaft Runout
0.05 ∼ 0.55 mm (0.002 ∼ 0.020 in.) 96.85 ∼ 96.95 mm (3.813 ∼ 3.817 in.) TIR 0.02 mm (0.0008 in.) or less
0.75 mm (0.030 in.) 96.6 mm (3.80 in.) TIR 0.05 mm (0.002 in.)
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Crankshaft Main Bearing/Journal Clearance 0.025 ∼ 0.052 mm (0.0010 ∼ 0.0020 in.) Crankshaft Main Journal Diameter 54.986 ∼ 55.000 mm (2.1648 ∼ 2.1654 in.) Crankcase Main Bearing Bore Diameter 55.025 ∼ 55.038 mm (2.1663 ∼ 2.1668 in.) Transmission 5.9 ∼ 6.0 mm Shift Fork Ear Thickness (0.23 ∼ 0.24 in.) 6.05 ∼ 6.15 mm Gear Shift Fork Groove Width (0.238 ∼ 0.242 in.) Shift Fork Guide Pin Diameter 7.9 ∼ 8.0 mm (0.311 ∼ 0.315 in.) Shift Drum Groove Width 8.05 ∼ 8.20 mm (0.317 ∼ 0.323 in.)
Service Limit 0.10 mm (0.004 in.) 54.96 mm (2.164 in.) 55.07 mm (2.168 in.) 5.8 mm (0.23 in.) 6.25 mm (0.246 in.) 7.8 mm (0.307 in.) 8.30 mm (0.327 in.)
9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Outside Circlip Pliers: 57001-144
Flywheel Holder: 57001-1410
Bearing Driver Set: 57001-1129
Gear Holder, m2.0: 57001-1557
Oil Filter Wrench: 57001-1249
Kawasaki Bond: 92104-1064
Flywheel Holder: 57001-1313
CRANKSHAFT/TRANSMISSION 9-9 Crankcase Crankcase Disassembly
the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter). • Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Water Pump (see Water Pump Removal in the Cooling System chapter) Rocker Case Covers (see Rocker Case Cover Removal in the Engine Top End chapter) Rocker Cases (see Rocker Case Removal in the Engine Top End chapter) Cylinder Heads (see Cylinder Head Removal in the Engine Top End chapter) Cylinder Blocks (see Cylinder Removal in the Engine Top End chapter) Pistons (see Piston Removal in the Engine Top End chapter) Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Clutch (see Clutch Removal in the Clutch chapter) Front Gear Case (see Front Gear Case Removal in the Final Drive chapter) Damper Cam (see Damper Cam Removal in the Final Drive chapter) Alternator Cover (see Alternator Cover Removal/Installation in the Electrical System chapter) Alternator Inner Cover (see Alternator Inner Cover Removal in the Electrical chapter) the shift shaft [A] while pushing [B] the shift • Remove mechanism arm [C] towards the shift shaft. the bolt [D] and remove the gear set lever [E] • Unscrew and its spring [F]. • Remove the shift shaft return spring pin [G].
the starter clutch gear [A] out of the starter clutch. •○Pull The starter clutch gear can be removed with the engine
• •
in the frame. Unscrew the starter clutch bolt [B] while holding the primary gear bolt [C]. Remove the washer [D].
9-10 CRANKSHAFT/TRANSMISSION Crankcase out the torque limiter [A]. • Take Remove • shaft. the following from the right end of the balancer Needle Bearing [B] Collar [C] Copper Washer [D] Starter Clutch [E]
the primary gear bolt [A] while holding the alter• Unscrew nator rotor steady with the flywheel holder.
○The primary gear can be removed with the engine in the frame.
Special Tool - Flywheel Holder: 57001-1410
the end of the spring [A] off the hook and unscrew • Take the bolts [B]. the idle shaft holder [C] and chain guide [D] from • Remove the right crankcase.
○The idle shaft holder can be removed with the engine in the frame.
○Pushing the idle shaft [E], remove the holder. the washer [A]. • Remove Take out the water pump drive sprocket [B], chain [C] and • idle shaft sprocket [D] as a set. the idle shaft [E] out of the crankcase. •○Take The idle shaft has two pins.
the primary gear [A] out of the crankshaft. • Pull Remove the idle shaft sprocket [B] with the flat washer • from the water pump chain [C].
CRANKSHAFT/TRANSMISSION 9-11 Crankcase
• Remove: Lower Chain Guide Bolts [A] Lower Chain Guide [B] Rear Camshaft Chain [C] Rear Chain Guide Bolts [D] Rear Chain Guide [E] Front Chain Guide Retainer Bolt [F] Front Chain Guide Retainer [G]
the left balancer gear bolt [A], using the flywheel • Loosen holder [B].
○The left balancer gear bolt has right-hand threads. Special Tool - Flywheel Holder: 57001-1410
the alternator rotor bolt [C] and the alternator • Remove rotor [D].
the alternator inside stator (see Alternator Inside • Remove Stator Removal in the Electrical System chapter). the balancer drive gear [A]. • Take the left balancer gear bolt. • Remove Take the balancer gear [B], washer, and left balancer off • the balancer shaft as a set.
• Remove: Lower Chain Guide Bolts [A] Lower Chain Guide [B] Front Camshaft Chain [C] Rear Chain Guide Bolts [D] Rear Chain Guide [E] Front Chain Guide Retainer Bolt [F] Front Chain Guide Retainer [G]
the water pump sprocket [A] with it’s chain [B] and • Pull shaft [C].
9-12 CRANKSHAFT/TRANSMISSION Crankcase
• Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249
• Remove the oil pressure switch [C].
• Remove: Oil Hoses (see Oil Hose Removal in the Engine Lubrication chapter) Starter Motor (see Starter Motor Removal in the Electrical System chapter) the right crankcase bolts. • Remove M8 Bolts (5) [A]
○Be sure to remove this bolt [B]. Front [C]
all the left crankcase bolts in the order listed. • Remove M6 Bolts (14) [A] M8 Bolt (1) [B] M10 Bolts (3) [C] Front [D]
the left crankcase down. • Turn up the right crankcase. •○Lift Using the pry points, split the crankcase halves. Pry Point (Front) [A] Pry Point (Rear) [B]
CRANKSHAFT/TRANSMISSION 9-13 Crankcase the following from the left crankcase. • Remove Crankshaft [A] Balancer Shaft [B] Inside Oil Pipe [C] and Oil Return Pipe [D] (see Inside Oil Pipe Removal in the Engine Lubrication System chapter) Oil Baffle [E] Transmission Assy [F] (see Transmission Removal in this chapter) Shift Forks [G] and Shift Rod [H] Shift Drum Assy [I] the following from the right crankcase. • Remove Inside Oil Pipe [A] and Oil Return Pipe [B] (see Inside Oil Pipe Removal in the Engine Lubrication System chapter) Oil Separator [C] Oil Pump [D] (see Oil Pump Removal in the Engine Lubrication System chapter) Water Pump Chain Guide [E]
CAUTION Do not remove the bearings and the oil seals unless it is necessary. Removal may damage them.
Crankcase Assembly CAUTION The left and right 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. the crankcase bearing boss with a suitable re• Support tainer [A]. a press and the bearing driver set [C], install a new • Using bearing [B] or/and race by pushing the bearing outer race until it bottoms out.
CAUTION Support the crankcase bearing boss when pushing the bearing, otherwise the crankcase could be damaged. the three needle bearings with manufacturer’s • Press marks facing out into holes on the right side of the right crankcase. Push the needle bearing outer race until the face of the bearing is even with the end of the hole, using a driver. Special Tool - Bearing Driver Set: 57001-1129
9-14 CRANKSHAFT/TRANSMISSION Crankcase a non-permanent locking agent to the threads of • Apply the bearing retainer bolt. • Install the bearing retainer [A].
Torque - Bearing Retainer Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
Bearings [B] Race [C] Left Crankcase [D]
silicone sealant [A] to the step of the oil separating • Apply chamber [B] in the left crankcase [C]. Sealant - Three Bond: TB1207B
a non-permanent locking agent to the threads of • Apply the oil baffle bolt [F]. the oil baffle [D] on the chamber. • Install Front [E] Torque - Oil Baffle Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
a non-permanent locking agent to the threads of • Apply the bearing retainer bolts. • Install the bearing retainers [A].
Torque - Bearing Retainer Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
Bearings [B] Race [C] Right Crankcase [D]
the following in the left crankcase. • Install Transmission Assy and Shift Drum Assy (see Transmis-
•
sion Installation in this chapter) Shift Fork and Shift Rod (see Transmission Installation in this chapter) Oil Pipe and Oil Return Pipe (see Inside Oil Pipe Installation in the Engine Lubrication System chapter) Apply engine oil to the transmission gears, ball bearings, shift drum, and crankshaft main bearing.
the left crankshaft tapered end (the longer end) into • Insert the left crankcase.
○The left shaft [B] of the crankshaft [A] is longer than the right shaft [C].
CRANKSHAFT/TRANSMISSION 9-15 Crankcase the balancer shaft [A] so that the flanged side [B] • Install faces downward (toward the left crankcase).
to see that the following parts are in place in the • Check left crankcase. Transmission Assy [A] and Shift Drum Assy [B] Shift Fork [C] and Shift Rod [D] Crankshaft [E] Front Connecting Rod [F] (Right) Rear Connecting Rod [G] (Left) Balancer Shaft [H] Dowel Pins [I] O-ring [J] Oil Baffle [K] Oil Pipe [L] Oil Return Pipe [M] the following in the right crankcase. • Install Inside Oil Pipe and Oil Return Pipe (see Inside Oil Pipe Installation in the Engine Lubrication System chapter) Oil Separator (see Inside Oil Pipe Installation in the Engine Lubrication chapter) Oil Pump (see Oil Pump Installation in the Engine Lubrication System chapter) the water pump chain guide [A]. •○Install Be sure to install the collar [B] in the bolt hole. Torque - Water Pump Chain Guide Bolt: 8.3 N·m (0.85 kgf·m, 73 in·lb)
to see that the following parts are in place in the • Check right crankcase. Oil Pipe [A] Oil Pump [B] Oil Separator [C] Oil Return Pipe [D] Water Pump Chain Guide [E]
9-16 CRANKSHAFT/TRANSMISSION Crankcase liquid gasket [A] to the mating surface of the right • Apply crankcase [B]. Sealant - Kawasaki Bond: 92104-1064
○Do not apply liquid gasket to the area [C] around the hole
of the oil screen. ○Do not drop liquid gasket into the oil passage [D]. ○After tightening the crankcase bolts, wipe up the liquid gasket seeping out around the mating surface, especially around the area [E].
○Make
NOTE
the application finish within 30 minutes when the liquid gasket to the mating surface of the right crankcase half is applied. ○Moreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket. the crankcase bolts as follows. •○Tighten Lightly tighten all the bolts to a snug fit.
○Tighten the M8 and M10 bolts in the order shown, and then tighten the M6 bolts to the specified torque.
Torque - M8 Crankcase Bolts (1 ∼ 6): 21 N·m (2.1 kgf·m, 15 ft·lb) M10 Crankcase Bolts (7 ∼ 9): 39 N·m (4.0 kgf·m, 29 ft·lb)
Front [A]
Torque - M6 Crankcase Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
L = 80 mm (3.1 in.) [A] L = 70 mm (2.8 in.) [B] L = 40 mm (1.6 in.) [C] Front [D]
tightening all the crankcase bolts, check the follow• After ing items.
○Wipe
up the liquid gasket that seeps out around the crankcase mating surface. ○Turn the right crankcase down, and check that the drive shaft and output shaft turn freely.
CRANKSHAFT/TRANSMISSION 9-17 Crankcase
○Check that the positive neutral finder operates properly.
•
While spinning [C] the output shaft [A] using an air impact wrench, gears shift smoothly from the 1st, 2nd · · · 5th gear, and 5th, 4th · · · 1st. When the output shaft stays still, the gear can be shifted to only the 1st gear or neutral. It should not be shifted to the 2nd gear or other higher gear positions. Shift Drum [B] Apply a non-permanent locking agent to the shift shaft return spring pin [D], and tighten it. Torque - Shift Shaft Return Spring Pin: 39 N·m (4.0 kgf·m, 29 ft·lb)
the gear set lever to the neutral position. • Set Shift Drum Cam [A]
•
Gear Set Lever [B] Neutral Position [C] Spring [D] Set the spring end to the crankcase as shown [E]. Torque - Gear Set Lever Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
the balancer dampers [A] so that each damper hole • Install [B] is positioned alternately.
the left balancer [A] on the balancer shaft in the • Install engine left side while fitting the alignment tooth [B] onto
•
the alignment notch [C] of the splines. Install the left balancer gear bolt.
a non-permanent locking agent to the threads of • Apply the chain guide bolts and chain guide retainer bolt. • Install: Front Camshaft Chain [A] Lower Chain Guide [B] Front Chain Guide Retainer [C] Rear Chain Guide [D] Torque - Camshaft Chain Guide Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Camshaft Chain Guide Retainer Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
9-18 CRANKSHAFT/TRANSMISSION Crankcase the crankshaft counterclockwise [A] and align the • Turn alignment tooth [B] with the middle of the crankcase rib [C]. This makes the front piston set to its top dead center. Install the crankshaft balancer gear [D] while fitting the alignment notch of the splines onto the alignment tooth. ○Aligning the balancer gear marks (line mark) [E] with the front piston on its top dead center.
•
• Install: Alternator Inside Stator [A] (see Alternator Inside Stator Installation in the Electrical System chapter) Alternator Rotor [B] ○Install the alternator rotor while fitting the alignment notch [C] of the splines onto the alignment tooth [D].
○Be sure to align the balancer gear mark with the alternator
mark (shorter line mark) [A] while keeping the front piston on its top dead center. Top Mark for Rear Piston [B] (Longer Mark) Top Mark for Front Piston [C] (Longer Mark)
molybdenum disulfide oil solution to the threads • Apply and the seating surface of the left balancer gear bolt, and alternator rotor bolt. ○The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10:1). Holding the alternator rotor steady with the flywheel holder [A].
•
Special Tool - Flywheel Holder: 57001-1410
the ratchet [B]. • Install Tighten: •
Torque - Left Balancer Gear Bolt [C]: 85 N·m (8.7 kgf·m, 63 ft·lb) Alternator Rotor Bolt [D]: 78 N·m (8.0 kgf·m, 58 ft·lb)
CRANKSHAFT/TRANSMISSION 9-19 Crankcase a non-permanent locking agent to the threads of • Apply the chain guide bolts and chain guide retainer bolt. • Install: Rear Camshaft Chain [A] Lower Chain Guide [B] Front Chain Guide Retainer [C] Rear Chain Guide [D] Torque - Camshaft Chain Guide Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Camshaft Chain Guide Retainer Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
• Install: Water Pump Sprocket [A] with Shaft [B] Chain [C]
• Install: Washer [A] Idle Shaft Sprocket [B]
○Fit the pin [C] into the slots [D] of the idle shaft sprocket.
the primary gear [A] with the boss [B] facing toward • Install the engine inside.
• Install: Pin [A] Idle Shaft Sprocket [B] Water Pump Drive Sprocket [C] and Chain [D] Dowel Pins [E] ○Stuff the cloth on the holes of the crankcase so that the pin does not drop into the crankcase bottom.
9-20 CRANKSHAFT/TRANSMISSION Crankcase
• Install: Idle Shaft Holder [A] and Water Pump Chain Guide [B] as shown. Torque - Idle Shaft Holder Bolts: 8.3 N·m (0.85 kgf·m, 73 in·lb)
the alignment tooth [A] of the splines of the right bal• Fit ancer onto the alignment notch [B] of the balancer shaft.
the collar [A], copper washer [B], and needle bear• Install ing [C] in the order listed.
○The copper washer must be on the collar.
• Install the starter torque limiter [D].
the primary gear bolt [A]. • Install Tighten the primary gear bolt while holding the alternator • rotor steady with the flywheel holder. Special Tool - Flywheel Holder: 57001-1410 Torque - 143 N·m (14.5 kgf·m, 107 ft·lb)
the starter clutch gear [B] in and turn it clockwise [C] • Push and install it. molybdenum disulfide oil solution to the threads • Apply and seating surface of the starter clutch bolt [D] and tighten it to the specified torque while holding the primary gear bolt. ○The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Torque - Starter Clutch Bolt: 85 N·m (8.7 kgf·m, 63 ft·lb)
○Be sure to install the washer [E] onto the torque limiter.
CRANKSHAFT/TRANSMISSION 9-21 Crankcase engine oil to the gasket [A] of the oil filter before • Apply installation.
• Tighten the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249
Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)
silicone sealant to the threads of the oil pressure • Apply switch [C], and tighten it to the specified torque. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
• Install: Shift Mechanism (see External Shift Mechanism Instal-
•
lation in this chapter) Stater Motor (see Starter Motor Installation in the Electrical System chapter) Oil Hoses (see Oil Hose Installation in the Engine Lucubration chapter) Install the removed parts (see appropriate chapters).
Starter Clutch Disassembly
the starter clutch assy (see Crankcase Disas• Remove sembly in this section). the Allen bolts [A] with the balancer mass [B] • Remove held with the flywheel holder [C]. Special Tool - Flywheel Holder: 57001-1313
the coupling [A] out of the right balancer [B]. • Pull Take • the one-way clutch [C] out of the coupling.
9-22 CRANKSHAFT/TRANSMISSION Crankcase Starter Clutch Assembly
the one way clutch [A] so that its groove [B] faces • Install outward and its flange [C] fits between the right balancer
•
[D] and the coupling [E]. Apply a non-permanent locking agent to the threads of the coupling bolts, and tighten them to the specified torque. Torque - Starter Clutch Coupling Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) Special Tool - Flywheel Holder: 57001-1313
Starter Clutch Inspection
the starter clutch gear [A] and torque limiter, then • Remove reinstall the starter clutch gear into the starter clutch. the starter clutch to both side. •○Turn When viewed from the right side of the engine, the clutch
should turn clockwise [B] freely, but should not turn counterclockwise [C].
If the starter clutch does not operate as it should or if it makes noise, disassemble the starter clutch. If one-way clutch [A] installation is wrong, reinstall it. Visually inspect the one-way clutch, coupling and starter clutch gear for damage. If there is any worn or damaged surface in the following parts, replace it. Sliding Surface [B] and Cage of One-way Clutch Sliding Surface [C] of Starter Clutch Gear Sliding Surface [A] of Coupling
Starter Torque Limiter Check
the torque limiter (see Crankcase Disassembly • Remove in this section) and visually inspect it. If the limiter has wear, discoloration, or other damage, replace it as a set. Gear [A] Friction Plates [B] Spring [C] Pinion [D]
CRANKSHAFT/TRANSMISSION 9-23 Crankshaft/Connecting Rods Connecting Rod Removal
the crankshaft (see Crankcase Disassembly in • Remove this chapter). the connecting rod big end nuts, and take off • Remove the rod and cap along with the bearing inserts from the crankshaft [A].
NOTE
○Mark and record the locations of the connecting rods [B] and their big end caps [C] with the bearing inserts left attached so that they can be installed in their original positions.
CAUTION To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins.
Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: “○” or no mark
CAUTION If the connecting rods, bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed. molybdenum disulfide oil solution to the inside [A] • Apply of the big end bearing inserts.
○The molybdenum disulfide oil solution is a mixture of en-
gine oil and molybdenum disulfide grease with a weight ratio (10 : 1). If bearing inserts are replaced, install them as follows. ○Do not apply molybdenum disulfide oil solution to the outside [B] of the inserts or the inside [C] of the connecting rod and cap. ○Install the inserts so that their nails [D] are on the same side and fit into the recess of the connecting rod and cap.
9-24 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods
○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] 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, seating surfaces of the big end nuts and threads of con-rod bolts. Tighten the big end nuts to the specified torque. Torque - Connecting Rod Big End Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
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
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 more than 105 mm (4.13 in.) long, and insert the arbor [B] through the connecting rod small end. On a surface plate, set the big-end arbor on a 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 (0.08/3.94 in.)
Connecting Rod Twist
the big-end arbor [A] still on the V block [C], hold the • With connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel 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 (0.08/3.94 in.)
CRANKSHAFT/TRANSMISSION 9-25 Crankshaft/Connecting Rods Connecting Rod Big End Side Clearance
the side clearance [B] of the connecting rod big • Measure end [A].
○Insert a thickness gauge between the big end and either crank web to determine clearance.
Connecting Rod Big End Side Clearance Standard: 0.16 ∼ 0.46 mm (0.006 ∼ 0.018 in.) Service Limit: 0.7 mm (0.03 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.
Connecting Rod Big End Bearing Wear
the big end cap and place a strip of plastigage • Remove on the crankpin [A]. molybdenum disulfide oil solution to the threads • Apply and seating surface of the big end nuts.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10:1). Tighten the big end nuts to the specified torque to compress the plastigage and measure the plastigage width [B] to determine the bearing insert/crankpin clearance (see Camshaft/Rocker Case Wear in the Engine Top End chapter). Torque - Connecting Rod Big End Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
○Do not move the connecting rod and crankshaft during clearance measurement.
Connecting Rod Big End Bearing/Crankpin Clearance Standard: 0.026 ∼ 0.057 mm (0.0010 ∼ 0.0022 in.) Service Limit: 0.10 mm (0.004 in.)
If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.057 mm (0.0022 in.) and the service limit (0.10 mm, 0.004 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.
9-26 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance exceeds the service limit, measure the diameter of the crankpin [A]. Crankpin Diameter Standard: 54.981 ∼ 55.000 mm (2.1646 ∼ 2.1654 in.) Service Limit: 54.97 mm (2.1642 in.)
If the crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameter is not less than the service limit, but does not coincide with the original diameter marking on the crankshaft, make a new mark on it. Crankpin Diameter Marks None 54.981 ∼ 54.991 mm (2.1646 ∼ 2.1650 in.)
○
54.992 ∼ 55.000 mm (2.1650 ∼ 2.1654 in.)
Crankpin Diameter Mark: “○” mark or no mark [B] molybdenum disulfide oil solution to the threads • Apply and seating surface of the big end nuts.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10:1). Temporarily, install the big end cap and tighten the big end nuts to the specified torque. Torque - Connecting Rod Big End Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
the connecting rod big end inside diameter, and • Measure mark each connecting rod big end in accordance with the inside diameter.
○The mark already on the big end should almost coincide with the measurement because of little wear.
Connecting Rod Big End Inside Diameter Marks None 58.000 ∼ 58.010 mm (2.2835 ∼ 2.2839 in.)
○
58.011 ∼ 58.020 mm (2.2839 ∼ 2.2842 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] identified by the size • Select color [B] in accordance with the combination of the connecting rod and crankshaft coding. Big End Bearing Insert Selection Bearing Insert
Con-rod Big End Bore Diameter Marking
Crankpin Diameter Mark
Size Color
Part Number
None
○
Brown
92028-1476
None
None
○ ○
○
Black
92028-1475
None
Blue
92028-1474
the new inserts in the connecting rod and check • Install insert/crankpin clearance with the plastigage.
CRANKSHAFT/TRANSMISSION 9-27 Crankshaft/Connecting Rods Crankshaft Runout
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 (0.002 in.)
Crankshaft Main Bearing/Journal Wear
• Measure the diameter [A] of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 54.986 ∼ 55.000 mm (2.1648 ∼ 2.1654 in.) Service Limit: 54.96 mm (2.164 in.)
If any journal has worn past the service limit, replace the crankshaft with a new one.
the main • Measure crankcase halves.
bearing bore diameter [A] in the
Crankcase Main Bearing Bore Diameter Standard: 55.025 ∼ 55.038 mm (2.1663 ∼ 2.1668 in.) Service Limit: 55.07 mm (2.168 in.)
If they are any signs of seizure, damage, or excessive wear, replace the crankcase halves as a set.
Crankshaft Side Clearance
• Measure the crankshaft side clearance. Crankshaft Side Clearance Standard: 0.05 ∼ 0.55 mm (0.002 ∼ 0.020 in.) Service Limit: 0.75 mm (0.030 in.)
Clearance [A] Crankcase [B] Crankshaft [C] If the clearance is greater than the service limit, measure the crankshaft web length [A] to see whether the crankshaft or the crankcase is faulty. Crankshaft Web Length Standard: 96.85 ∼ 96.95 mm (3.813 ∼ 3.817 in.) Service Limit: 96.6 mm (3.80 in.)
If the length measurement is smaller than the service limit, replace the crankshaft. Otherwise, replace the crankcase halves as a set.
CAUTION The right and left crankcase halves are machined at the factory in the assembled state, so they must be replaced as a set.
9-28 CRANKSHAFT/TRANSMISSION Primary Gear Primary Gear Removal
• Remove: Clutch Cover (see Clutch Cover Removal in the Clutch •
chapter) Starter Clutch Gear (see Crankcase Disassembly in this chapter) Using the gear holder [A] to loosen the primary gear bolt [B]. Special Tool - Gear Holder, m2.0: 57001-1557
• Remove: Clutch (see Clutch Removal in the Clutch chapter) •
Bolts [A] Remove the water pump chain guide [B] and water pump idle shaft holder [C] from the right crankcase.
the primary gear bolt [A], water pump drive • Remove sprocket [B], idle shaft [C], and idle shaft sprocket [D]. Water Pump Chain [E] ○Stuff the cloth [F] on the holes of the crankcase so that the pin close not drop into the crankcase bottom.
the primary gear [A] out of the crankshaft, and take • Pull the pin [B] out of the idle shaft.
Primary Gear Installation
the primary gear [A] with the boss [B] facing toward the • Fit engine inside.
CRANKSHAFT/TRANSMISSION 9-29 Primary Gear the pin [A] into the slot [B] of the water pump drive • Fit sprocket boss and install the sprockets.
• Install: Dowel Pins [A] • •
Washer [B] Pulling the chain guide [C] and install the idle shaft holder [D]. Install the clutch (see Clutch Installation in the Clutch chapter). Torque - Idle Shaft Holder Bolts: 8.3 N·m (0.85 kgf·m, 73 in·lb)
molybdenum disulfide oil solution to the threads • Apply and seating surface, and tighten the primary gear bolt [A], while holding the primary gear [B] with the gear holder [C]. ○The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Special Tool - Gear Holder, m2.0: 57001-1557 Torque - Primary Gear Bolt: 145 N·m (14.5 kgf·m, 107 ft·lb)
9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal
the left front footboard (see Front Footboard Re• Remove moval/Installation in the Frame chapter). the rear shift pedal clamp bolt [A] and take off • Unscrew the rear shift pedal [B]. the front shift pedal clamp bolt [C] and pull out • Unscrew the front shift pedal [D].
Shift Pedal Installation
the front shift pedal, install the shift pedal [A] so that • For the punched mark on the shaft is aligned [B] with the
•
punched mark on the shaft. Tighten the clamp bolt. Torque - Shift Pedal Clamp Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)
the rear shift pedal, install the shift pedal [A] so that • For the punched mark on the shaft is aligned [B] with the
•
punched mark on the pedal. Tighten the clamp bolt. Torque - Shift Pedal Clamp Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)
the left front footboard (see Front Footboard Re• Install moval/Installation in the Frame chapter).
External Shift Mechanism Removal
• Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Alternator Cover [A] (see Alternator Outer Cover Removal in the Electrical System chapter) Front and Rear Shift Levers [B] Front Gear Case [C] (see Front Gear Case Removal in the Final Drive chapter) the shift shaft [A] while pushing [B] the shift • Remove mechanism arm [C] towards the shift shaft. the bolt [D] and remove the gear set lever [E] • Unscrew and its spring [F].
CRANKSHAFT/TRANSMISSION 9-31 Transmission External Shift Mechanism Installation
the gear set lever [A] and the spring [B] in the • Install crankcase and tighten the bolt [C]. Torque - Gear Set Lever Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
the shift mechanism arm assy. Be sure to install • Install the washer [D] onto the shift shaft. the front gear case (see Front Gear Case Installa• Install tion in the Final Drive chapter).
• Install: Alternator Cover (see Alternator Cover Removal/Installation) Front and Rear Shift Levers ○Install the rear shift lever [A] on the shift shaft so that the punched mark on the shaft is aligned [B] with the slot of the rear shift lever. Loosen the locknuts [C] and turn the shift rod [D] so that the outside length [E] of the locknuts is 112 ±1 mm (4.4 ±0.04 in.). ○The rear locknut has left-hand threads.
•
Torque - Shift Rod Locknut (Front): 11 N·m (1.1 kgf·m, 97 in·lb) Shift Rod Locknut (Rear): 11 N·m (1.1 kgf·m, 97 in·lb) Rear Shift Lever Clamp Bolt: 12 N·m (1.2 kgf·m, 104 in·lb)
• Install: Engine
(see Engine Installation in the Engine Removal/Installation chapter) Shift Pedal (see Shift Pedal Installation in this section)
External Shift Mechanism Inspection
the shift shaft [A] for any damage. • Examine If the shaft is bent, straighten or replace it. If the serrations [B] are damaged, replace the shaft. If the springs [C] [D] are damaged in any way, replace them. If the shift mechanism arm [E] is damaged in any way, replace the arm.
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)
the gear set lever [B], and its spring [C] for breaks • Check or distortion.
•
If the lever or spring is damaged in any way, replace it. Visually inspect the shift drum pins, pin holder, and pin plate. If they are badly worn or if they show any damage, replace them.
9-32 CRANKSHAFT/TRANSMISSION Transmission Transmission Removal
the engine (see Engine Removal in the Engine • Remove Removal/Installation chapter). the crankcase (see Crankcase Disassembly in this • Split chapter). the crankshaft (see Crankcase Disassembly in • Remove this chapter). remove the oil pipe [A] (see Inside Oil Pipe Removal • First, in the Engine Lubrication System chapter), and then re-
•
move the shift drum bearing holder bolts and holder [B]. Pull out the shift rod [C] and take the shift forks [D] out of the output shaft 4th gear. Output Shaft [E] Drive Shaft [F] Shift Drum Assy [G]
the shift drum cam [A] with the cutoff [B] of the left • Align crankcase by turning the shift drum.
out the transmission shafts [A] and shift drum assy • Take [B] as a set. the drive and output shafts, shift drum, and shift • Separate forks.
Transmission Installation
the drive and output shafts, shift drum assy, and • Install output shaft 5th gear shift fork as a set. Drive Shaft Assy [A] Output Shaft Assy [B] Shift Fork (Drive Shaft, 3rd Gear) [C] and Shift Drum Assy [D] Shift Fork (No. 270, Output Shaft, 5th Gear) [E]
CRANKSHAFT/TRANSMISSION 9-33 Transmission
• Install: Shift Fork (No. 293 Output Shaft, 4th Gear) [A] Shift Rod [B]
○Each output shaft shift fork has an identification number.
•
Do not confuse them. Install the shift forks with each number faced left as shown. Shift Fork (No. 270, 5th Gear) [A] Shift Fork (No. 293, 4th Gear) [B] Front [C].
a non-permanent locking agent to the threads of • Apply the shift drum bearing holder bolts. • Install: Shift Drum Bearing Holder [A] Bolts [B] Torque - Shift Drum Bearing Holder Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
engine oil to the shift rod, the shift forks, and Trans• Apply mission gears.
Shift Drum Disassembly/Assembly
the shift drum assy [A] (see Transmission Re• Remove moval in this section). • Remove: Cotter Pin [B] Pin [C] Drive Shaft Shift Fork (No. 292, Drive Shaft) [D]
the shift drum assy as shown. • Disassemble Shift Drum Cam Bolt [A] Pin Plate [B] Pin [C] Cam [D] Bearing [E] Shaft Drum [F]
9-34 CRANKSHAFT/TRANSMISSION Transmission sure to face the number to the right and insert the • Be cotter pin [A] of the drive shaft shift fork [B] from the right
•
as shown. Shift Drum [C] Pin [D] Bearing [E] Cam [F] Pin Plate [G] Apply a non-permanent locking agent to the threads of the shift drum cam bolt [H]. Torque - Shift Drum Cam Bolt: 15 N·m (1.5 kgf·m, 11 ft·lb)
Transmission Disassembly
the transmission shafts (see Transmission Re• Remove moval in this section). the circlip pliers (special tool), remove the circlips, • Using and disassemble the transmission shaft. Special Tool - Outside Circlip Pliers: 57001-144
○The 4th gear [A] on the output shaft has three steel balls for the positive neutral finder mechanism. Remove the 4th gear as follows. ○Set the output shaft in a vertical position holding the 3rd gear [B]. ○Spin the 4th gear quickly [C] and pull it off upward.
•
Transmission Assembly
to the transmission assembly illustration on ahead. • Refer Align each oil hole with the drive shaft oil hole when • installing thegear 3rd gear [9] and the 5th gear [6]. Align each oil with the output shaft oil hole, when • installing the 3rdhole gear [17], bushing [18], and the 5th gear [16].
CAUTION Do not apply grease to the steel balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction. the three steel balls [A] into the holes [B] of the output • Fit 4th gear [C], and then install the gear on the output shaft so that the steel balls align with the recesses [D] in the shaft. ○After assembling the 4th gear with steel balls in place on the output shaft, check the ball-locking effect that the 4th gear does not come out of the output shaft when moving it up and down by hand.
CRANKSHAFT/TRANSMISSION 9-35 Transmission any circlip [A] that were removed with new ones. • Replace Install the circlips so that the opening [B] is aligned with a • spline groove [C].
9-36 CRANKSHAFT/TRANSMISSION Transmission
1. Circlip, 20 mm (0.79 in.) 2. Needle Bearing 3. Thrust Washer, 22.3 mm (0.88 in.) 4. Three Circlips, 28 mm (1.10 in.) 5. 2nd Gear 6. 5th (Top) Gear 7. Bushing (5th Gear) 8. Two Splined Washers, 28.5 mm (1.12 in.) 9. 3rd Gear 10. 4th Gear 11. 1st Gear 12. Drive Shaft 13. Output Shaft 14. 2nd Gear
15. Three Splined Washers, 30.3 mm (1.20 in.) 16. Three Circlips, 29 mm (1.14 in.) 17. 5th (Top) Gear 18. 3rd Gear 19. Bushing (3rd Gear) 20. Steel Balls 21. 4th Gear 22. Washer, 25.5 mm (1.00 in.) 23. 1st Gear 24. Washer, 25.5 mm (1.00 in.) 25. Needle Bearing 26. Circlip, 25 mm (0.98 in.) 27. Align gear or bushing oil holes with the shaft holes.
CRANKSHAFT/TRANSMISSION 9-37 Transmission Shift Fork Bending
inspect the shift forks, and replace any fork that • Visually is bend. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear under load. 90° [A]
Shift Fork/Gear Groove Wear
the thickness of the shift fork ears [A], and mea• Measure sure the width [B] of the gear grooves. 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 (0.23 ∼ 0.24 in.) Service Limit: 5.8 mm (0.23 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
the diameter of each shift fork guide pin [B], and • Measure measure the width [A] of each shift drum groove. 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: 7.9 ∼ 8.0 mm (0.311 ∼ 0.315 in.) Service Limit: 7.8 mm (0.307 in.)
If any shift drum groove is worn over the service limit, the drum must be replaced. Shift Drum Groove Width Standard: 8.05 ∼ 8.20 mm (0.317 ∼ 0.323 in.) Service Limit: 8.30 mm (0.327 in.)
Gear Dog and Gear Dog Hole Damage
inspect the gear dogs [A] and gear dog holes [B]. • Visually Replace any damaged gears or gears with excessively worn dogs or dog holes.
9-38 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary. Removal may damage them. a press or puller, remove the ball bearing and/or • Using needle bearing outer race.
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. CAUTION Do not heat the case with a blowtorch. 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 bearing or outer race until it stops at the bottom of its housing. Special Tool - Bearing Driver Set: 57001-1129
Ball and Needle Bearing Wear CAUTION Do not remove the ball bearings for inspection. Removal may damage them. the ball bearings. •○Check Since the ball bearings are made to extremely close toler-
ances, 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. the needle bearings. •○Check 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.
CRANKSHAFT/TRANSMISSION 9-39 Ball Bearing, Needle Bearing, and Oil Seal Oil Seal Inspection
the oil seal. • 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 Coupling Removal ................................................................................................. Wheel Coupling Installation .............................................................................................. Wheel Inspection .............................................................................................................. Axle Inspection.................................................................................................................. Wheel Balance.................................................................................................................. Balance Inspection............................................................................................................ Balance Adjustment .......................................................................................................... Balance Weight Removal.................................................................................................. Balance Weight Installation............................................................................................... Tires........................................................................................................................................ Air Pressure Inspection/Adjustment.................................................................................. Tire Inspection .................................................................................................................. Tire Removal..................................................................................................................... Tire Installation.................................................................................................................. Tire Repair ........................................................................................................................ Hub Bearings (Wheel Bearings) ............................................................................................. Hub Bearings Removal ..................................................................................................... Hub Bearings Installation .................................................................................................. Hub Bearings Inspection................................................................................................... Hub Bearings Lubrication..................................................................................................
10-2 10-4 10-5 10-6 10-6 10-7 10-8 10-9 10-11 10-11 10-11 10-12 10-12 10-12 10-13 10-13 10-14 10-16 10-16 10-16 10-16 10-16 10-18 10-19 10-19 10-19 10-20 10-20
10
10-2 WHEELS/TIRES Exploded View
WHEELS/TIRES 10-3 Exploded View No. 1 2 3 4
Fastener Front Axle Clamp Bolts Front Axle Shaft Rear Axle Nut Tire Air Valve Nuts
N·m 29 108 108 1.5
Torque kgf·m 3.0 11.0 11.0 0.15
ft·lb 21 80 80 13 in·lb
Remarks AL
AL: Tighten the two front axle clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES Specifications Item Wheels (Rims) Rim Runout: Axial Radial Axle Runout/100 mm Wheel Balance Balance Weights Tires Air Pressure (When Cold): Front Rear Tread Depth: Front Rear
Standard Tires: Front Rear
Standard
Service Limit
––– ––– TIR 0.05 mm (0.002 in.) or less 10 g (0.4 oz.) or less 10 g (0.4 oz.), 20 g (0.7 oz.), 30 g (1.1 oz.)
TIR 0.5 mm (0.02 in.) TIR 0.8 mm (0.03 in.) TIR 0.2 mm (0.008 in.) – – – – – –
Up to 185 kg (408 lb) load: 225 kPa (2.25 kg/cm², 32 psi) Up to 185 kg (408 lb) load: 280 kPa (2.80 kg/cm², 40 psi) 4.5 mm (0.18 in.) 7.2 mm (0.28 in.)
Make, Type BRIDGESTONE EXEDRA G721 BRIDGESTONE EXEDRA G722 G
– – – – – – 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 (0.1 in.) Size 150/80-16 M/C (71H) 170/70B 16 M/C (75H)
AT: Austria CH: Switzerland DE: Germany
WARNING Use the same manufacturer’s tires on both front and rear wheels.
WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: 57001-143
Bearing Remover Head, 57001-1346
25 ×
Bearing Driver Set: 57001-1129
Bearing Remover Shaft, 57001-1377
13:
Jack: 57001-1238
Attachment Jack: 57001-1398
Bearing Remover Head, 57001-1293
20 ×
22:
28:
10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal
the front fender (see Rear Fender Removal in • Remove the Frame chapter). the front brake caliper mounting bolts [A] and • Unscrew remove the brake calipers [B] with the hose installed.
• Loosen: Front Axle Clamp Bolts [A] Front Axle [B]
○Using the jack [A] and the attachment jack [B] under the
frame pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
CAUTION Be sure to put the rear wheel ON the ground when removing the front wheel, or the motorcycle may fall over. The motorcycle could be damaged.
WARNING Be sure to put the rear wheel ON the ground when removing the front wheel, or the motorcycle may fall over. It could cause an accident and injury. the axle to the right and drop the front wheel [A] • Unscrew out of the fork.
CAUTION Do not lay the wheel directly on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation
grease to the seal lips. • Apply Fit the collars [A] on the both side of the hub. •○The collars are identical.
the axle from the right side of the wheel. • Insert Tighten the axle. •
Torque - Front Axle Shaft: 108 N·m (11.0 kgf·m, 80 ft·lb)
tightening the clamp bolts on the right fork leg, • Before pump the forks up and down [A] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle.
NOTE
○Do not apply the front brake during this process to stop
the motorcycle from rolling forward. Put a block in front of the wheel to stop it from moving.
• Tighten the axle clamp bolts [A] to the specified torque.
Torque - Front Axle Clamp Bolts: 29 N·m (3.0 kgf·m, 21 ft·lb)
NOTE
○Tighten the two front axle clamp bolts alternately two times to ensure even tightening torque.
the clearance [B] between the front axle collar [C] • Check and the right fork leg [D]. The clearance between the front
•
axle collar and the right fork leg should be between 1.05 ∼ 3.19 mm (0.041 ∼ 0.124 in.). If the clearance is out of this range, remove the front wheel again and check the axle, wheel hub and other related parts for damage. Tighten the caliper mounting bolts. Torque - Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Check the front brake effectiveness. WARNING
Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done.
10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal
the jack [A] and attachment jack [B] under the frame • Using pipe ribs [C], lift the rear wheel [D] OFF the ground until the front wheel [E] touches the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
CAUTION Be sure to put the front wheel ON the ground when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged.
WARNING Be sure to put the front wheel ON the ground when removing the rear wheel, or the motorcycle may fall over. It could cause an accident and injury.
• Squeeze the brake lever slowly and hold it with a band [A] CAUTION
Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged.
WARNING Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. It could cause an accident and injury.
• Remove: Left and Right saddlebags (see saddlebag Removal in the Frame chapter) Rear Fender (see Rear Fender Removal in the Frame chapter) the left and right muffler clamp bolts. • Loosen Remove right muffler stay mounting bolts [A]. • Lower thetheleftleftandandright mufflers [B]. •
WHEELS/TIRES 10-9 Wheels (Rims)
• Remove: Bolts [A] (Both Sides) Saddlebag Stay (Lower) [B]
• Remove: Caliper Mounting Bolts [A] Caliper [B]
• Remove: Caliper Holder Bolt [A] Axle Nut Cotter Pin [B] Axle Nut [C] ○Pull the silencer out side and straighten the cotter pin.
out the axle, and slide the rear wheel [A] toward the • Pull right [B] to disengage the wheel from the final gear case. • Move the rear wheel back [C] and remove it.
CAUTION
Do not lay the wheel directly 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
grease to the grease seal of the wheel. • Apply Apply grease to the ring gear hub splines [A] of the final • gear case [B]. Insert the collars [C] on both sides of the hub. •
10-10 WHEELS/TIRES Wheels (Rims) the axle [A] from the left side of the rear wheel. • Insert Slide the wheel to the left side, and engage the ring • gear hub rear splines with the wheel coupling hub splines. the axle little and install the caliper holder. • Pull Tighten: •
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb) Rear Caliper Holder Bolt: 64 N·m (6.5 kgf·m, 47 ft·lb) Rear Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
WARNING If the axle nut is not securely tightened, an unsafe riding condition may result.
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○It should be within 30 degree. ○Loosen once and tighten again when the slot goes past the nearest hole.
• Bend the cotter pin [A] over the nut as shown [B].
the left and right muffler clamp bolts and stay • Tighten mounting bolts. Torque - Muffler Stay Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
inspect the tire for stuck any grease [A]. • Visually If any grease have stuck to the surface of the tire, wash
•
the tire clean with soap and water solution. Check the rear brake effectiveness.
WARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done.
WHEELS/TIRES 10-11 Wheels (Rims) Wheel Coupling Removal
the rear wheel (see Rear Wheel Removal in this • Remove section). the coupling retaining ring [A]. • Remove Remove • necessary.the wheel coupling [B] with a bearing puller if
Wheel Coupling Installation
the O-ring [A] and the retaining ring [B]. • Replace Grease the • O-ring following:
•
Bosses [C] of Rear Drum Hub Install: Rubber Damper [D] Coupling [E] Retaining Ring
Wheel Inspection
• Raise the front or rear wheel off the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
[A] the wheel lightly, and check for roughness or • Spin binding.
• •
If roughness or binding is found, replace the hub bearings. Inspect the front and rear axles for damage (see Axle Inspection in this section). If the axle is damaged or bent, replace it. Inspect the wheel for small cracks, dents, bending, or warp. If there is any damage to the wheel, replace the wheel.
10-12 WHEELS/TIRES Wheels (Rims) the wheel, and support it without the tire by the • Remove axle. the rim runout, radial [A] and axial [B], with a dial • Measure gauge. If the rim runout exceeds the service limit, check the hub bearings. Replace them if they are damaged. If the problem is not due to the bearings, replace the wheel. Rim Runout Service Limit: Axial
0.5 mm (0.02 in.)
Radial
0.8 mm (0.03 in.)
WARNING Never attempt to repair a damaged wheel. If there is any damage besides wheel bearings, the wheel must be replaced to insure safe operational condition.
Axle Inspection
inspect the front and rear axles for damage. • 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 Standard: TIR 0.05 mm (0.002 in.) or less Service Limit: TIR 0.2 mm (0.008 in.)
Wheel Balance
○To improve stability and decrease vibration at high speed,
•
the front and rear wheels must be kept balanced. Check and balance the wheels when required, or when a tire is replaced with a new one.
Balance Inspection
the wheel (see Front/Rear Wheel Removal in • Remove this section). 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.
WHEELS/TIRES 10-13 Wheels (Rims) Balance Adjustment
the wheel always stops in one position, provisionally at• Iftach a balance weight [A] to the rim flange at the marking, using adhesive tape.
WARNING Use only the genuine balance weights. the wheel 1/4 turn [B], and see whether or not the • Rotate 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. If proper balance has been achieved, permanently install the balance weight.
Balance Weight Part Number
Weight (grams)
41075-0014
10 (0.4 oz.)
41075-0015
20 (0.7 oz.)
41075-0016
30 (1.1 oz.)
NOTE
○Balance weights are available from Kawasaki Dealers
in 10, 20, and 30 gram (0.4, 0.7 and 1.1 oz.) sizes. An imbalance of less than 10 grams (0.4 oz.) will not usually affect running stability. ○Do not use four or more balance weights (more than 90 gram, 3.2 oz.). If the wheel requires an excess balance weight, remove and disassemble the wheel to find the cause.
Balance Weight Removal
• •
(a) When the tire is not on the rim. Push [A] the blade portion toward the outside with a regular tip screw driver, and slip the weight off the rim flange. Discard the used balance weight.
10-14 WHEELS/TIRES Wheels (Rims) (b) When the tire is on the rim. Pry [A] the balance weight off the rim flange using a regular tip screw driver as shown in the figure. ○Insert a tip of the screw driver between the tire bead [B] and weight blade [C] until the end of the tip reaches the end of the weight blade. ○Push the driver grip toward the tire so that the balance weight slips off the rim flange. Discard the used balance weight.
•
•
Balance Weight Installation
if the weight portion has any play on the brade-and • Check -clip plate. If it does, discard it.
WARNING If the balance weight has any play on the rim flange, the blade and/or clip have been stretched. Replace the loose balance weight. Do not reuse used balance weight. Unbalanced wheels can create an unsafe riding condition. the balance weight blade, tire bead, and rim • Lubricate flange with a soap and water solution or rubber lubricant. This helps the balance weight slip onto the rim flange.
CAUTION Do not lubricate the tire bead with engine oil or petroleum distillates because they will deteriorate the tire. the balance weight on the rim. •○Install Slip the weight on the rim flange [B] by pushing or lightly
hammering [A] the weight in the direction shown in the figure. Tire Bead [C] Blade [D]
that the blade [A] and weight [B] seat fully on the • Check rim flange [C], and that the clip [D] is hooked over the rim ridge [E] and reaches rim flat portion.
WHEELS/TIRES 10-15 Wheels (Rims) required total weight exceeds 20 g (0.7 oz.), install • When balance weight at both sides of rim flange as shown. Weight Selection
Required Total Weight
One Side [A]
Other Side [B]
10 g (0.4 oz.)
10 g (0.4 oz.)
–
20 g (0.7 oz.)
10 g (0.4 oz.)
10 g (0.4 oz.)
30 g (1.1 oz.)
20 g (0.7 oz.)
10 g (0.4 oz.)
40 g (1.4 oz.)
20 g (0.7 oz.)
20 g (0.7 oz.)
50 g (1.8 oz.)
30 g (1.1 oz.)
20 g (0.7 oz.)
60 g (2.1 oz.)
30 g (1.1 oz.)
30 g (1.1 oz.)
20 g (0.7 oz.) + 20 g 70 g (2.5 oz.) (0.7 oz.)
30 g (1.1 oz.)
80 g (2.8 oz.)
20 g (0.7 oz.) + 20 g (0.7 oz.)
20 g (0.7 oz.) + 20 g (0.7 oz.)
90 g (3.2 oz.)
20 g (0.7 oz.) + 30 g (1.1 oz.)
20 g (0.7 oz.) + 20 g (0.7 oz.)
10-16 WHEELS/TIRES 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
the following. • Remove Wheel (see Front/Rear Wheel Removal in this chapter)
•
Brake Disc (see Brake Disc Removal in the Brakes chapter) Valve Core (Let out the air) To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position. Chalk Mark or Yellow Mark [A] Valve Stem [B] Align [C]
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.
CAUTION Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire. the tire from the rim using a commercially avail• Remove able tire changer.
NOTE
○The tires cannot be removed with hand tools because they fit the rims too tightly.
Tire Installation
WARNING To ensure safe handling and stability, use only the standard tires for replacement, inflated to the standard pressure. Use the same manufacturer’s tires on both front and rear wheels. the rim and tire, and replace them if necessary. • Inspect Clean the surfaces of the rim and tire, and smooth • the sealingsealing surfaces of the rim with a fine emery cloth if
•
necessary. Remove the air valve and discard it.
CAUTION Replace the air valve whenever the tire is replaced. Do not reuse the air valve.
WHEELS/TIRES 10-17 Tires
○Insert the new air valve in the front and rear wheel rim. Valve Cap [A] Valve Body [B] Valve Nuts [C] Valve Washer [D] Rim [E] Valve Grommet [F] Coupling Damper Side (Left Side) [G]
○Remove the valve cap, valve nuts, valve washer and insert the valve stem through the rim from the inside out.
Torque - Tire Air Valve Nuts: 1.5 N·m (0.15 kgf·m, 13 in·lb)
a soap and water solution, or rubber lubricant to the • Apply rim flange and tire beads.
CAUTION Never lubricate with mineral oil (engine oil) or gasoline because they will cause deterioration of the tire. the tire rotation mark on the front and rear tires and • Check install them on the rim accordingly. Tire Rotation Mark [A] Rotation Direction [B] The ○ front rim is no right and left distinction. ○Install the rear tire on the rim so that the damper faces left. the tire on the rim so that the valve [A] is at the tire • Position 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 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 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). Overinflation can explode the tire with possibility of injury and loss of life.
10-18 WHEELS/TIRES Tires to see that the bead lines [A] on both sides of the • Check tire sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall bead 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 Tire Air Pressure Inspection in the Periodic Maintenance chapter). Install the air valve cap.
• • • •
• the brake disc [A] so that the marked side [B] faces • Install out. a non-permanent locking agent, and tighten the • Apply brake disc bolts [C]. Torque - Front Brake Disc Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb) Rear Brake Disc Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb)
• Adjust the wheel balance.
WARNING
Check and balance the wheel when a tire is replaced with a new one. New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 mile) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering.
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.
WHEELS/TIRES 10-19 Hub Bearings (Wheel Bearings) Hub Bearings Removal
the wheel, and take out the following. • Remove Collars Grease Seals [A] Circlips [B] Coupling [C] (Out of Rear Hub) Front Hub [D] Rear Hub [E] Special Tool - Inside Circlip Pliers: 57001-143
• Use the bearing remover to remove the hub bearings [A]. CAUTION
Do not lay the wheel directly 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 -1377 Bearing Remover 57001-1346 (for Bearing Remover 57001-1293 (for
Shaft,
13 [B]: 57001
Head, 25 × Front Hub) Head, 20 × Rear Hub)
28 [C]: 22 [C]:
Hub Bearings Installation
installing the wheel bearings, blow any dirt or for• Before eign particles out of the hub with compressed air to pre-
•
vent contamination of the bearings. Replace the bearings with new ones.
NOTE
○Install the bearings so that the marked side faces out.
the bearings by using a bearing driver. • Install First, press each right bearing [A] in until it bottoms out. • Special Tool - Bearing Driver Set [B]: 57001-1129
install the following. • Next, New Circlip Distance Collar Left Bearing
10-20 WHEELS/TIRES Hub Bearings (Wheel Bearings)
○Replace the circlips with new ones. 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 is • flush [B] with the end of the hole.
○Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129
Hub Bearings Inspection
○Since the hub bearings are made to extremely close tolerance, the clearance cannot 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 Bearings 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 .......................................................................................................................... Final Gear Case and Oil ......................................................................................................... Oil Level Inspection........................................................................................................... Oil Change ........................................................................................................................ Final Gear Case Removal................................................................................................. Final Gear Case Installation.............................................................................................. Final Gear Case Disassembly .......................................................................................... Final Gear Case Assembly ............................................................................................... Pinion Gear Removal........................................................................................................ Pinion Gear Installation..................................................................................................... Pinion Gear Bearing Preload Adjustment ......................................................................... Bevel Gear Inspection....................................................................................................... Pinion Gear Joint Inspection ............................................................................................. Final Bevel Gear Adjustment ............................................................................................ Backlash Adjustment ........................................................................................................ Tooth Contact Adjustment................................................................................................. Propeller Shaft........................................................................................................................ Propeller Shaft Removal ................................................................................................... Propeller Shaft Installation ................................................................................................ Propeller Shaft Joint Lubrication ....................................................................................... Propeller Shaft Inspection................................................................................................. Sliding Joint Inspection ..................................................................................................... Front Bevel Gears .................................................................................................................. Front Gear Case Removal ................................................................................................ Front Gear Case Installation ............................................................................................. Front Gear Case Disassembly.......................................................................................... Front Gear Case Assembly............................................................................................... Driven Gear Disassembly ................................................................................................. Driven Gear Assembly ...................................................................................................... Damper Cam Removal ..................................................................................................... Damper Cam Installation .................................................................................................. Front Bevel Gear Adjustment............................................................................................ Preload Adjustment........................................................................................................... Preload Measurement with Spring Scale.......................................................................... Backlash Adjustment ........................................................................................................ Tooth Contact Adjustment................................................................................................. Bevel Gear Inspection....................................................................................................... Cam Damper Inspection ................................................................................................... Bearing and Oil Seal............................................................................................................... Ball or Needle Bearing Replacement................................................................................ Ball Bearing Wear ............................................................................................................. Tapered Roller Bearing Inspection.................................................................................... Needle Bearing Inspection................................................................................................ Oil Seal Inspection ............................................................................................................
11-2 11-6 11-7 11-9 11-9 11-9 11-9 11-9 11-9 11-11 11-13 11-14 11-16 11-18 11-18 11-18 11-20 11-21 11-23 11-23 11-23 11-24 11-24 11-24 11-25 11-25 11-25 11-25 11-27 11-28 11-28 11-29 11-29 11-30 11-32 11-33 11-34 11-35 11-37 11-37 11-38 11-38 11-38 11-39 11-39 11-39
11
11-2 FINAL DRIVE Exploded View
FINAL DRIVE 11-3 Exploded View Front Gear Case No. 1 2 3 4 5 6 7 8 9 10 11 12
Fastener Bearing Retainer Bolts (Front Gear) Damper Cam Nut Drive Gear Nut Driven Gear Assy Mounting Bolts Driven Gear Bolt Front Gear Case Bolts (M8) Front Gear Case Bolts (M6) Neutral Switch Oil Nozzle (Front) Oil Nozzle (Right) Oil Pipe Banjo Bolts Speed Sensor Mounting Bolt
N·m 8.8 195 265 25 120 29 12 15 2.9 18 12 9.8
Torque kgf·m 0.90 20.0 27.0 2.5 12.2 3.0 1.2 1.5 0.30 1.8 1.2 1.0
ft·lb 78 in·lb 144 195 18 89 21 104 in·lb 11 26 in·lb 13 104 in·lb 87 in·lb
Remarks L MO, R MO, R, ST MO, R, ST S S
13. Drive Gear Shaft 14. Output Shaft EO: Apply engine oil. 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 ST: Stake the fasteners.
L
11-4 FINAL DRIVE Exploded View
FINAL DRIVE 11-5 Exploded View Final Gear Case No. 1 2 3 4 5 6
Fastener Bearing Retainer Bolt (Final Gear) Final Gear Case Cover Bolts (M10) Final Gear Case Cover Bolts (M8) Final Gear Case Drain Plug Final Gear Case Mounting Nuts Pinion Gear Nut
N·m 6.9 34 23 8.8 34 127
Torque kgf·m 0.70 3.5 2.3 0.90 3.5 13.0
ft·lb 61 in·lb 25 17 78 in·lb 25 94
Remarks L L L
MO, R, ST
HG: Apply high-temperature grease. HO: Apply hypoid gear oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts ST: Stake the fasteners.
11-6 FINAL DRIVE Specifications Item Final Gear Case Oil Grade Viscosity Oil Level Amount Final Bevel Gear Backlash Preload for Pinion Gear Bearing Torque Wrench Spring Scale Propeller Shaft Joint Grease Front Bevel Gear Backlash Preload for Front Bevel Gear Bearing Torque Wrench Spring Scale
Standard API GL-5 hypoid gear oil When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Filler opening bottom 200 mL (6.76 US oz.) 0.10 ∼ 0.20 mm (0.0039 ∼ 0.0079 in.) (at ring gear hub splines) 0.6 ∼ 1.0 N·m (0.06 ∼ 0.10 kgf·m, 5.2 ∼ 8.7 in·lb) 3.0 ∼ 5.0 N (0.30 ∼ 0.50 kg, 0.7 ∼ 1.1 lb) 20 mL (0.68 US oz.), high-temperature grease 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.) (at gear tooths) 0.5 ∼ 0.9 N·m (0.05 ∼ 0.09 kgf·m, 4.3 ∼ 7.8 in·lb) 3.0 ∼ 4.0 N (0.30 ∼ 0.50 kg, 0.6 ∼ 1.0 lb)
FINAL DRIVE 11-7 Special Tools Outside Circlip Pliers: 57001-144
Driven Gear Holder, m2: 57001-1027
Bearing Puller: 57001-158
Oil Seal & Bearing Remover: 57001-1058
Bearing Puller Adapter: 57001-317
Bearing Driver Set: 57001-1129
Bearing Driver, 57001-382
Pinion Gear Holder, m1.9: 57001-1165
32:
Damper Cam Holder: 57001-1025
Final Gear Case Holder: 57001-1250
11-8 FINAL DRIVE Special Tools Drive Shaft Holder: 57001-1407
FINAL DRIVE 11-9 Final Gear Case and Oil Oil Level Inspection
to the Oil Level Inspection in the Periodic Mainte• Refer nance chapter.
Oil Change
to the Oil Change in the Periodic Maintenance • Refer chapter.
Final Gear Case Removal
• • •
If the final gear case is to be disassembled, drain the final gear case oil (see Oil Change in the Periodic Maintenance chapter). Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). Remove the left rear shock absorber [A] from its studs by taking off the nuts. Remove the final gear case by taking off the nuts [B]. The spring comes off with the case.
NOTE
○If the final gear case is full of oil, place the case so that the breather hole [C] is on top.
Final Gear Case Installation
the propeller shaft joint (see Propeller Shaft • Lubricate Joint Lubrication in this chapter). the spring so that the smaller diameter end [A] • Install faces toward the final gear case.
the pinion gear splines into the propeller shaft joint • Fit while turning the ring gear hub [A]. the final gear case mounting nuts to the specified • Tighten torque. Torque - Final Gear Case Mounting Nuts: kgf·m, 25 ft·lb)
•
34 N·m (3.5
If the final gear case oil was drained, fill the case with oil (see Oil Change in the Periodic Maintenance chapter). Install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter).
Final Gear Case Disassembly
the final gear case (see Final Gear Case Re• Remove moval in this section). 6 mm (0.2 in.) bolts [A] with 10 mm (0.4 in.) pitch • Using threads, jack up the pinion gear assembly [B]. the pinion gear assembly and shim(s) [C] from • Remove the final gear case.
11-10 FINAL DRIVE Final Gear Case and Oil the final gear case cover bolts [A]. • Remove Use three tapped holes [B] to lift the ring gear assy from • the gear case. The shim(s) comes off with the assy.
NOTE
○Do not disassemble the ring gear assy (ring gear, ring
gear hub, and final gear case cover), but the oil seal can be removed.
remove the ring gear oil seal [A], heat the ring gear • To assy in an oil bath to 120 ∼ 150°C (248 ∼ 302°F), then pry out the oil seal with an awl or other tool. Be careful not to scratch the sealing surface on the ring gear hub.
CAUTION Do not heat the case with a blowtorch. This will warp the case.
the snap ring [A] and pull out the needle bearing • Remove [B]. If the small ring gear oil seal [C] is damaged, remove it using the oil seal and bearing remover.
○Remove the small ring gear oil seal if damaged. Special Tool - Oil Seal & Bearing Remover [D]: 57001-1058
the bearing retainer bolt [A] and washer [B]. • Unscrew Pull out the needle bearing [C]. •
Special Tool - Oil Seal & Bearing Remover: 57001-1058
FINAL DRIVE 11-11 Final Gear Case and Oil Final Gear Case
1. Pinion Gear Nut 2. Washer 3. Shim(s) for Preload 4. Pinion Gear Joint 5. O-ring 6. Ring Gear Hub 7. Ring Gear Oil Seal 8. Ball Bearing 9. Final Gear Case Cover 10. Cover Mounting Bolts 11. Ring Gear Shim(s) 12. Ring Gear
13. Studs 14. Pinion Gear Shim(s) 15. O-ring 16. Oil Seal 17. Tapered Roller Bearings 18. Pinion Gear Bearing Housing 19. Pinion Gear 20. Retainer Bolt 21. Stud 22. Needle Bearing 23. Small Ring Gear Oil Seal 24. Needle Bearing
Final Gear Case Assembly
○The ring gear and pinion gear are lapped as a set in the
•
factory to get the best tooth contact. They must be installed as a pair, and never replace one without the other. Press the small ring gear oil seal [A] until it bottoms out with its spring [B] facing inward. Special Tool - Bearing Driver Set: 57001-1129
a thin coat of high-temperature grease to the oil seal • Apply lip.
11-12 FINAL DRIVE Final Gear Case and Oil the needle bearings [A] with new ones. • Replace Apply a hypoid gear oil to the roller parts of the needle • bearings.
NOTE
○Install the bearing so that the marked side faces out. ○Press in the bearings until they are bottomed. Special Tool - Bearing Driver Set: 57001-1129
the snapring [B] secure. • Install Apply a locking agent to the bearing re• tainer boltnon-permanent [C]. • Install the washer [D] and the bearing retainer bolt.
Torque - Bearing Retainer Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb)
a thin coat of high-temperature grease to the oil seal • Apply lip of the ring gear oil seal. the ring gear oil seal with its spring [A] facing inward • Install using a suitable driver until the face of the seal is even [B] with the end of the hole.
the breather hole [A] in the final gear case cover • Blow clean with compressed air. a non-permanent locking agent to the threads of • Apply each stud and install them to the case if they were removed. Reinstall the original ring gear shim(s) to keep the gear backlash and the tooth contact unchanged. ○When final gear case parts are replaced, the final bevel gear must be adjusted (see Backlash Adjustment and Tooth Contact Adjustment in this section). Apply a non-permanent locking agent to the threads of the final gear case cover bolts. Tighten:
• • •
Torque - Final Gear Case Cover Bolts: M10: 34 N·m (3.5 kgf·m, 25 ft·lb) M8: 23 N·m (2.3 kgf·m, 17 ft·lb)
the pinion gear assembly into the final gear hous• Insert ing.
○Reinstall the pinion gear assembly shim(s) to keep the gear backlash and the tooth contact unchanged.
FINAL DRIVE 11-13 Final Gear Case and Oil Pinion Gear Removal
• Pry open the staking [A] on the pinion gear nut [B].
the nut [A] while holding the pinion gear assem• Unscrew bly [B] with the pinion gear holder [C]. Special Tool - Pinion Gear Holder, m1.9: 57001-1165
• Remove: Washer [A] Shim(s) [B] Pinion Gear Joint [C] with the O-ring [D] Pinion Gear [E] with the Tapered Roller Bearing [F]
out the bearing outer race from the bearing housing • Drive [A]. Special Tool - Oil Seal & Bearing Remover [B]: 57001-1058
out the tapered roller bearing [A] in the bearing • Drive housing [B] and the oil seal [C] using the bearing driver set [D]. Special Tool - Bearing Driver Set: 57001-1129
11-14 FINAL DRIVE Final Gear Case and Oil Pinion Gear Installation
pinion gear and ring gear are lapped as a set in the • The factory to get the best tooth contact. They must be replaced as a set. Check the tapered roller bearing (see Tapered Roller Bearing Inspection in this chapter). Apply a hypoid gear oil to the roller bearings.
• • the tapered roller bearing [A] into the pinion gear • Drive housing [B] using the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001-1129
the tapered roller bearing outer race [A] into the • Drive pinion gear housing [B] using the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001-1129
the pinion gear [A]. •○Insert Install the pinion gear with the tapered roller bearing as
• • •
[B] one unit. Check the O-ring [C] on the pinion gear joint [D] for any kind of damage. Replace it if necessary. Apply a hypoid gear oil to the O-ring. Install the pinion gear joint, shim(s) [E] and washer [F].
FINAL DRIVE 11-15 Final Gear Case and Oil the pinion gear nut with a new one. • Replace Apply molybdenum oil solution to the threads • and seating surface ofdisulfide the pinion gear nut.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Using the pinion gear holder [A], tighten the pinion gear nut [B]. Special Tool - Pinion Gear Holder, m1.9: 57001-1165 Torque - Pinion Gear Nut: 127 N·m (13.0 kgf·m, 94 ft·lb)
○Check the pinion gear bearing preload (see Preload Ad-
•
justment in this chapter). Remove: Pinion Gear Nut Washer Shim(s) Pinion Gear Joint with the O-ring Pinion Gear with the Tapered Roller Bearing
the oil seal with a new one. • Replace • Drive the oil seal [A] using the bearing driver set [B]. Special Tool - Bearing Driver Set [C]: 57001-1129
a thin coat of high-temperature grease to the oil seal • Apply lip.
the above removed parts. •○Reinstall Stake [A] the pinion gear nut with a punch.
CAUTION When staking the nut, be careful not to apply shock to the pinion gear and its bearing. Such a shock could damage the pinion gear and/or bearing.
11-16 FINAL DRIVE Final Gear Case and Oil Pinion Gear Bearing Preload Adjustment Preload Measurement Check and adjust the bearing preload in the following case. ○When any of the parts listed below are replaced with new ones. Tapered Roller Bearings Bevel Gears Bearing Housing Pinion Gear Joint ○When the pinion gear nut is loosened, even if the purpose is not to replace the parts. Assemble the pinion gear bearing housing, and tighten the pinion gear nut to the specified torque. Oil seal installation is not required until the correct bearing preload is obtained.
•
•
CAUTION To start with, choose a shim or shims so that the bearings are just SNUG with NO play but also with NO preload. Any over-preload on the bearings could damage the bearings. a little hypoid gear oil to the bearings, and turn the • Apply gear shaft more than 5 turns to allow the bearings to seat. the bearing preload. Bearing preload is defined • Measure as the force or torque which is needed to start the gear shaft turning. Preload for Pinion Gear Bearing Using Torque Wrench: 0.6 ∼ 1.0 N·m (0.06 ∼ 0.10 kgf·m, 5.2 ∼ 8.7 in·lb) Using Spring Scale: 3.0 ∼ 5.0 N (0.30 ∼ 0.50 kg, 0.7 ∼ 1.1 lb)
NOTE
○Preload can be measured either with a spring scale or a beam-type torque wrench. When measured with a spring scale, the preload is designated by force (N, kg, lb), and when measured with a torque wrench, it is designated by torque N·m, (kgf·m, in·lb). Using Spring Scale Hook the spring scale [A] on the handle at the point 200 mm (7.87 in.) [B] from the center of the gear shaft. Hold the bearing housing in a vise so that the gear shaft axis is vertical. Apply force to the handle horizontally and at a right angle to it.
• • •
Special Tool - Pinion Gear Holder, m1.9 [C]: 57001-1165
If the preload is out of the specified range, replace the shims under the flat washer, and re-check the preload. Refer to the next paragraph to select suitable shims.
FINAL DRIVE 11-17 Final Gear Case and Oil Preload Adjustment To increase preload, decrease the thickness of the size of the shim(s). To decrease preload increase the thickness of the shim(s). Change the thickness a little at a time. Re-adjust the bearing preload, and re-adjust if necessary.
• • •
Shims for Preload Adjustment Thickness
Part Number
0.1 (0.004 in.)
92025-1219
0.2 (0.008 in.)
92025-1220
0.3 (0.012 in.)
92025-1221
0.5 (0.020 in.)
92025-1222
0.6 (0.024 in.)
92025-1223
0.7 (0.028 in.)
92025-1224
0.8 (0.031 in.)
92025-1225
* 0.9 (0.035 in.)
92025-1226
1.0 (0.040 in.)
92025-1227
1.30 (0.051 in.)
92025-1214
1.32 (0.052 in.)
92025-1215
1.34 (0.053 in.)
92025-1216
1.36 (0.054 in.)
92025-1217
1.38 (0.0543 in.)
92025-1218
*: Standard
1. Washer 2. Shim(s) 3. Pinion Gear Joint 4. Bearing Housing 5. Tapered Roller Bearing 6. Tapered Roller Bearing
A. Before Tightening B. After Tightening C. Initial Clearance D. Under No Preload E. No Clearance F. Under Preload
11-18 FINAL DRIVE Final Gear Case and Oil Bevel Gear Inspection
check the bevel gears [A] for scoring, chipping, • Visually or other damage. Replace the bevel gears as a set if either gear is damaged.
Pinion Gear Joint Inspection
inspect the splines [A] of the pinion gear joint. • Visually If they are badly worn or chipped, replace the joint with a new one. Also, inspect the propeller shaft sliding joint.
Final Bevel Gear Adjustment
○The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears. First, adjust backlash, and then tooth contact by replacing shims. ○The amount of backlash is influenced by the ring gear position more than by the pinion gear position. ○Tooth contact locations is influenced by pinion gear position more than by ring gear position.
•
FINAL DRIVE 11-19 Final Gear Case and Oil Backlash-Related Parts
1. Pinion Gear Bearing Housing 2. Pinion Gear Shim(s) 3. Pinion Gear Assy 4. Ring Gear Assy 5. Ring Gear Shim(s) 6. Final Gear Case Ring Gear Shims for Backlash Adjustment Thickness (mm) 0.15 (0.006 in.) 0.5 (0.020 in.) 0.6 (0.024 in.) 0.7 (0.028 in.) 0.8 (0.031 in.) 0.9 (0.035 in.) 1.0 (0.039 in.) 1.2 (0.047 in.)
Part Number 92025-1783 92025-1784 92025-1785 92025-1786 92025-1787 92025-1788 92025-1789 92025-1790
Pinion Gear Shims for Tooth Contact Adjustment Thickness (mm) Part Number 0.15 (0.006 in.) 92180-0009 0.5 (0.020 in.) 92180-0010 0.6 (0.024 in.) 92180-0011 92180-0012 0.7 (0.028 in.) 92180-0013 0.8 (0.031 in.) 92180-0014 0.9 (0.035 in.) 1.0 (0.039 in.) 92180-0015 1.2 (0.047 in.) 92180-0016
11-20 FINAL DRIVE Final Gear Case and Oil Backlash Adjustment
any dirt and oil off the bevel gear teeth with a high • Clean -flash point solvent.
CAUTION Do not install the O-ring or oil seals during adjustment. the pinion gear bearing housing with the primary • Install shim (1.0 mm, 0.04 in. thickness). the pinion gear steady with the pinion gear holder • Hold [A] and tighten the final gear case mounting nuts to the specified torque. Special Tool - Pinion Gear Holder, m1.9: 57001-1165 Torque - Final Gear Case Mounting Nuts: kgf·m, 25 ft·lb)
34 N·m (3.5
the ring gear assy with the primary shim (1.0 mm, • Install 0.04 in. thickness), and tighten the cover bolts to the specified torque. Torque - Final Gear Case Cover Bolts: M10: 34 N·m (3.5 kgf·m, 25 ft·lb) M8: 23 N·m (2.3 kgf·m, 17 ft·lb)
○Check the backlash during tightening of the cover bolts,
and stop tightening them immediately if the backlash disappears. Then, change the ring gear shim to a thicker one.
a dial gage [D] on a vise so that the tip of the gage • Mount is against the splines of the ring gear hub. measure the backlash, turn the ring gear hub [B] back • To and forth [C] while holding the pinion gear steady with the pinion gear holder [A]. The difference between the highest and the lowest gage reading is the amount of backlash. ○Measure backlash at three locations equally spaced on the splines. Final Bevel Gear Backlash: 0.10 ∼ 0.20 mm (0.0039 ∼ 0.0079 in.) (at ring gear hub splines)
•
If the backlash is out of the limit, replace the ring gear shims. To increase backlash, increase the thickness of the shim(s). To decrease backlash, decrease the thickness of the shim(s). Change the thickness a little at a time. Recheck the backlash, and readjust as necessary.
FINAL DRIVE 11-21 Final Gear Case and Oil Tooth Contact Adjustment
any dirt and oil off the bevel gear teeth with a high • Clean -flash point solvent. checking compound to 4 or 5 teeth of the pinion • Apply gear.
NOTE
○Apply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. ○The checking compound must be smooth and firm, with the consistency of tooth paste. ○Special compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact. the pinion gear assembly with the final gear case • Hold holder [A]. Special Tool - Final Gear Case Holder: 57001-1250 Torque - Final Gear Case Mounting Nuts: kgf·m, 25 ft·lb)
34 N·m (3.5
the pinion gear for one revolution [B] back and forth, • Turn while creating a drag on the ring gear hub [C]. the ring gear assy and pinion gear assy to check • Remove the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary.
○If
NOTE
the backlash is out of the standard range after changing the pinion gear shim(s), replace the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.
11-22 FINAL DRIVE Final Gear Case and Oil Correct Tooth Contact Pattern: No adjustment is required.
Heel [A] Bottom [B] Top [C] Toe [D]
Incorrect Tooth Contact Patterns (Example 1)
○Decrease the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.)
to correct the pattern
shown above. Heel [A] Bottom [B] Top [C] Toe [D]
Incorrect Tooth Contact Patterns (Example 2)
○Increase the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) shown above. Heel [A] Bottom [B] Top [C] Toe [D]
to correct the pattern
FINAL DRIVE 11-23 Propeller Shaft Propeller Shaft Removal
• Remove: Final Gear Case (see Final Gear Case Removal in this chapter) Swingarm (see Swingarm Removal in the Suspension chapter) Remove the propeller shaft from the front driven gear joint. ○Turn the propeller shaft so that the lockpin access hole [A] in the propeller shaft comes outside.
•
○Move back the propeller shaft and slip the propeller shaft off the driven gear joint while pushing on the lockpin. Propeller Shaft [A] Universal Joint [B] Lockpin [C] Spring [D] Driven Gear Joint [E]
the circlip [B] from the rear end of the propeller • Remove shaft [A] using a circlip pliers. the washer [C] and pull out the propeller shaft • Remove sliding joint [D].
Propeller Shaft Installation
the O-ring [A] on the rear end of the propeller shaft • Check for any kind of damage, and replace it if necessary. the propeller shaft joint (see Propeller Shaft • Lubricate Joint Lubrication in this section). connecting the propeller shaft to the driven gear • After joint, pull the propeller shaft rearward to check that the
•
shaft is secured in place by the lockpin. Install: Swingarm (see Swingarm Installation in the Suspension chapter) Final Gear Case (see Final Gear Case Installation in this chapter)
11-24 FINAL DRIVE Propeller Shaft Propeller Shaft Joint Lubrication
• Remove: Final Gear Case (see Final Gear Case Removal in this • • •
chapter) Propeller Shaft (see Propeller Shaft Removal in this section) Wipe the old grease off the propeller shaft sliding joint and pinion joint. Pack the propeller shaft sliding joint with 20 mL (0.68 US oz.) of high-temperature grease [A]. Sliding Joint [B] Propeller Shaft [C] Install: Propeller Shaft (see Propeller Shaft Installation in this section) Final Gear Case (see Final Gear Case Installation in this chapter)
Propeller Shaft Inspection
that the universal joint [A] works smoothly without • Check rattling or sticking.
•
If it does not work smoothly, the needle bearings of the universal joint are damaged. Replace the propeller shaft assy with a new one. Visually inspect the bearing of the shaft and the wear of the splines [B] at the rear end of the shaft. If it is bent at all, replace the propeller shaft assy. Do not attempt to straighten a bent shaft.
Sliding Joint Inspection
inspect the internal splines [B] of the propeller • Visually shaft sliding joint [A]. If they are badly worn or chipped, replace the joint with a new one.
FINAL DRIVE 11-25 Front Bevel Gears Front Gear Case Removal
• Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Rear Shift Lever [A] (see External Shift Mechanism Removal in the Crankshaft/Transmission chapter) ○The speed sensor connector [B] is disconnected during engine removal. Unscrew the front gear case bolts [C] and remove the front gear case [D].
•
○The cam follower [A] and the damper spring [B] come off
•
with the gear case. Check that the shift shaft oil seal and replace it if damaged.
Front Gear Case Installation
the front gear case bolts as follows. •○Tighten Tighten the bolt [1] and bolt [2] alternately until contact to the mating surface of the left crankcase.
○Tighten the bolts in the order shown. Torque - M8 Front kgf·m, M6 Front kgf·m,
Gear Case Bolts (1 ∼ 5): 29 N·m (3.0 21 ft·lb) Gear Case Bolts (6 ∼ 11): 12 N·m (1.2 104 in·lb)
• Install the removed parts (see appropriate chapters).
Front Gear Case Disassembly
• Remove: Front Gear Case (see Front Gear Case Removal in this section) Cam Follower [A] Damper Spring [B] Rubber Boot [C]
11-26 FINAL DRIVE Front Bevel Gears the driven gear assy mounting bolts [A] and pry • Remove the assy [B] off the case.
○Raise the driven gear, using the following pry points [A].
the drive gear assy as follows. •○Remove Pry off the gear case cap [A] with a tool.
○Pry open the drive gear nut [A] with a small chisel. ○Install:
Damper Spring Cam Follower [B] ○Unscrew the drive gear nut while holding the drive gear shaft with the drive shaft holder [C] (special tool). Front Gear Case [D] Socket Wrench [E] Vise [F] Special Tool - Drive Shaft Holder: 57001-1407
FINAL DRIVE 11-27 Front Bevel Gears off the drive gear shaft [A], the drive gear [B], and • Pull shim(s) [C]. the bearing holder [D] from the gear case. • Remove the drive gear shaft ball bearing [E] using the • Remove bearing driver set. Front [F] Special Tool - Bearing Driver Set: 57001-1129
Front Gear Case Assembly
○The drive and driven gear are lapped as a set in the fac-
•
tory to get the best tooth contact. They must be replaced as a set. Press the drive gear [B] slowly with the driver [A] onto the shaft [C]. Special Tool - Bearing Driver,
32: 57001-382
a non-permanent locking agent to the threads of • Apply the bearing retainer bolts. Torque - Bearing Retainer Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
sure to check and adjust the bearing preload, the bevel • Be gear backlash, and tooth contact, when any of the backlash-related parts are replaced (see Front Bevel Gear Adjustment in this section). After completing all adjustment, reassemble the front gear case. ○Replace the drive gear nut with a new one. ○Apply molybdenum disulfide oil solution to the threads and seating surface of the nut, and tighten it to the specified torque to settle the bearings in place. ○Loosen the nut completely and retighten it to the specified torque.
•
Torque - Drive Gear Nut: 265 N·m (27.0 kgf·m, 195 ft·lb)
○Stake the nut to secure it in place. CAUTION
When staking the nut, be careful not to apply shock to the shaft and its bearing. Such a shock could damage the shaft and/or bearing. the shim [A]. • Install Install the driven gear assy so that the pry ribs [B] and • machined surfaces [C] align. Tighten the • fied torque. driven gear assy mounting bolts to the speciTorque - Driven Gear Assy Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
11-28 FINAL DRIVE Front Bevel Gears If the oil pipe [A] was removed, use a new flat washer on each side of the fittings, and tighten the banjo bolts to the specified torque. ○Tighten the front banjo bolt [B] first, then the rear banjo bolt [C]. Install the rear shift lever [D], aligning the lever slit [E] with the punch mark of the shaft.
•
Torque - Oil Pipe Banjo Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Rear Shift Lever Clamp Bolt: 12 N·m (1.2 kgf·m, 104 in·lb)
Driven Gear Disassembly
the driven gear joint with the driven gear holder • Holding [A] in a vise, unscrew the driven gear bolt [B]. Special Tool - Driven Gear Holder, m2: 57001-1027
the driven gear joint [A] with the O-ring [B]. • Remove the driven gear from the bearing housing. • Remove Remove the oil seal from the housing with a hook, and • pull the tapered roller bearing out of the housing. Remove the tapered bearing which is pressed onto • the driven gear shaft roller with the bearing puller and adapter. Special Tools - Bearing Puller: 57001-158 Bearing Puller Adapter: 57001-317
Driven Gear Assembly
the driven gear bolt with a new one. •○Replace The drive and driven gears are lapped as a set at the fac-
• •
tory to get the best tooth contact. They must be replaced as a set. Be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth contact (see Front Bevel Gear Adjustment in this section). Drive the tapered roller bearing inner race [B] onto the driven gear shaft [C] using the bearing driver [A]. Special Tool - Bearing Driver,
32: 57001-382
completing the bearing preload • After assemble the driven gear assy.
adjustment, re-
○Using the bearing driver set, press the oil seal in until the
face of the seal is level with the end of the bearing housing hole. Special Tool - Bearing Driver Set: 57001-1129
FINAL DRIVE 11-29 Front Bevel Gears
○Apply molybdenum disulfide oil solution to the threads and the seating surface of the driven gear bolt.
○Tighten the driven gear bolt to the specified torque. Torque - Driven Gear Bolt: 120 N·m (12.2 kgf·m, 89 ft·lb)
○Stake [A] the driven gear bolt to prevent it from loosening. CAUTION When staking the bolt, be careful not to apply shock to the driven gear and their bearings. Such a shock could damage the driven gear and/or bearings.
Damper Cam Removal
the front gear case (see Front Gear Case Re• Remove moval in this section). the circlip [A] and needle bearing [B] of the output • Remove shaft. Special Tool - Outside Circlip Pliers: 57001-144
the crankcase bearing upper retainer bolts [C] • Remove and retainer [D]. Insert a bolt ( 12 mm, L = 100 mm, 0.47 in., L = 3.94 • in.) [A] into the engine mounting bolt hole. Unscrew damper cam nut [B] using a damper cam • holder [C]the (special tool) and deep socket wrench. Special Tool - Damper Cam Holder: 57001-1025
a non-permanent locking agent to the threads of • Apply the retainer bolts. • Install the upper retainer. Torque - Bearing Retainer Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
Damper Cam Installation
the damper cam nut with a new one. • Replace Insert the 12 mm, L = 100 mm, 0.47 in., L = 3.94 • in.) [A] intoboltthe( engine mounting bolt hole. molybdenum disulfide oil solution to the threads • Apply and seating surface of the damper cam nut.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Tighten the damper cam nut [B] to the specified torque. Special Tool - Damper Cam Holder: 57001-1025 Torque - Damper Cam Nut: 195 N·m (20.0 kgf·m, 144 ft·lb)
11-30 FINAL DRIVE Front Bevel Gears
• Install: Needle Bearing [A] Circlip [B] Front Gear Case (see Front Gear Case Installation in this chapter) Special Tool - Outside Circlip Pliers: 57001-144
Front Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load, the tapered roller bearings must be properly preloaded. Also the backlash (the distance one gear will move back and forth without moving the other gear) and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. Above three adjustments are of critical importance and must be carried out in the correct sequence and method. ○Preload adjustment is necessary whenever the driven gear bolt [2] loosened, even if the purpose is not to replace the parts.
FINAL DRIVE 11-31 Front Bevel Gears
Backlash-related Parts 1. Drive Gear 2. Driven Gear Bolt 3. Drive Gear Shim(s) 4. Ball Bearing 5. Drive Gear Shaft 6. Front Gear Case 7. Driven Gear 8. Tapered Roller Bearing 9. Driven Gear Shim(s) 10. Driven Gear Bearing Housing 11. Driven Gear Joint Preload-related Parts 12. Collar (Preload Adjustment) 13. Spacer (Preload Adjustment) 14. Tapered Roller Bearing
11-32 FINAL DRIVE Front Bevel Gears Front Bevel Gear Adjustment
○When any of the backlash-related parts are replaced, or
the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth contact by replacing shims.
Preload Adjustment
the driven gear assy, and tighten the driven gear • Install nut to the specified torque. Torque - Driven Gear Bolt: 120 N·m (12.2 kgf·m, 89 ft·lb)
○Do not install the oil seal, and O-ring, and do not stake the bolt until the correct bearing preload is obtained.
CAUTION To start with, choose a shim or collar so that the bearings are just SNUG with NO play and also with NO preload. Any overpreload on the bearings could damage the bearings. a little engine oil to the bearings, and turn the gear • Apply shaft more than 5 turns to allow the bearings to seat. the bearing preload. Bearing preload is defined • Measure as a force or torque which is needed to start the gear shaft turning. Preload for Driven Gear Bearing Using Torque Wrench: 0.5 ∼ 0.9 N·m (0.05 ∼ 0.09 kgf·m, 4.3 ∼ 7.8 in·lb) Using Spring Scale: 3.0 ∼ 4.0 N (0.30 ∼ 0.50 kg, 0.6 ∼ 1.0 lb)
NOTE
○Preload can be measured either with a spring scale or
a beam-type torque wrench. When measured with a spring scale, the preload is designated by force (N, kg, lb), and when measured with a torque wrench, it is designated by torque (N·m, kgf·m, in·lb).
FINAL DRIVE 11-33 Front Bevel Gears Preload Measurement with Spring Scale
the bearing housing in a vise so that the gear shaft • Hold axis is vertical. [C] the spring scale [B] on the driven gear holder [A] • Hook at a point 200 mm (7.9 in.) [D] apart from the center of the
•
gear shaft. Apply force to the handle horizontally and at a right angle to it. Special Tool - Driven Gear Holder, m2: 57001-1027
•
If the preload is out of specified range, replace the bearing collar and/or spacer. To increase preload, decrease the stack length of the collar and spacer. To decrease preload, increase the stack length of the collar and spacer. Change the stack length a little at a time. Recheck the bearing preload, and readjust if necessary. Collars for Preload Adjustment Length (mm) 22.8 (0.898 in.) 22.9 (0.902 in.) 23.0 (0.906 in.) 23.1 (0.909 in.) 23.2 (0.913 in.) 23.3 (0.917 in.) 23.4 (0.921 in.) 23.5 (0.925 in.) 23.6 (0.929 in.) 23.7 (0.933 in.) 23.8 (0.937 in.) 23.9 (0.941 in.) 24.0 (0.945 in.) 24.1 (0.949 in.)
Part Number 92027-1152 92027-1153 92027-1154 92027-1155 92027-1156 92027-1157 92027-1158 92027-1159 92027-1160 92027-1161 92027-1162 92027-1163 92027-1164 92027-1165
Spacers for Preload Adjustment Thickness (mm) 1.70 (0.0669 in.) 1.72 (0.0677 in.) 1.74 (0.0685 in.) 1.76 (0.0693 in.) 1.78 (0.0701 in.) 1.80 (0.0709 in.)
Part Number 92025-1072 92025-1073 92025-1074 92025-1075 92025-1076 92025-1077
11-34 FINAL DRIVE Front Bevel Gears Bearing Preloading Mechanism
1. Bearing Housing 2. Tapered Roller Bearing 3. Spacer 4. Collar 5. Tapered Roller Bearing A. Before Tightening B. After Tightening C. Under No Preload D. Initial Clearance E. Under Preload F. No Clearance
Backlash Adjustment
any dirt and oil off bevel gear teeth with a high-flash • Clean point solvent. the drive gear with the primary shim (1.0 mm, 0.04 • Install in., thickness), and tighten the nut to the specified torque. Torque - Drive Gear Nut: 265 N·m (27.0 kgf·m, 195 ft·lb)
NOTE
○Do not stake the head of the nut until both backlash and tooth contact adjustments are finished.
the driven gear assy in the front gear case with the • Install primary shim (1.0 mm, 0.04 in., thickness), and tighten the mounting bolts to the specified torque. Torque - Driven Gear Assy Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
○Check backlash during tightening of the mounting bolts,
and stop tightening them immediately if the backlash disappears. Then, change the shim to a thicker one.
FINAL DRIVE 11-35 Front Bevel Gears a holder [A] with 6 mm bolts and nuts on the front • Install gear case to mount a dial gage. up a dial gage against a drive gear tooth to check • Set gear backlash. The gage stem must be in line with the
•
•
direction of tooth travel. To measure the backlash, move the drive gear back and forth [C] while holding [B] the driven gear steady with a tool. The difference between the highest and lowest gage readings is the amount of backlash. If the backlash is not within the limit, replace the gear shim(s) at the drive and/or driven gear. To increase backlash, increase the thickness of the shim(s). To decrease backlash, decrease the thickness of the shim(s). Change the thickness a little at a time. Recheck the backlash, and readjust as necessary.
NOTE
○It is OK to pack two shims. Do not pack three or more shims.
Front Bevel Gear Backlash (at gear tooths) 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.)
Shims for Drive Gear
Shims for Driven Gear
Thickness (mm) 0.15 (0.006 in.) 0.5 (0.020 in.) 0.6 (0.023 in.) 0.7 (0.028 in.) 0.8 (0.031 in.) 0.9 (0.035 in.) 1.0 (0.039 in.) 1.1 (0.043 in.) 1.2 (0.047 in.)
Part Number 92025-1688 92025-1689 92025-1690 92025-1691 92025-1692 92025-1693 92025-1694 92025-1695 92025-1696
Thickness (mm) 0.1 (0.039 in.) 0.15 (0.006 in.) 0.5 (0.020 in.) 0.6 (0.023 in.) 0.7 (0.028 in.) 0.8 (0.031 in.) 0.9 (0.035 in.) 1.0 (0.039 in.) 1.2 (0.047 in.)
Tooth Contact Adjustment
any dirt and oil off the bevel gear teeth with a high • Clean -flash point solvent. checking compound to 4 or 5 teeth on the driven • Apply gear.
NOTE
○Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. ○The checking compound must be smooth and firm, with the consistency of tooth paste. ○Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use this for checking the bevel gears.
Part Number 92025-1826 92025-1818 92025-1819 92025-1820 92025-1821 92025-1822 92025-1823 92025-1824 92025-1825
11-36 FINAL DRIVE Front Bevel Gears the driven gear for 3 or 4 revolutions in the drive and • Turn reverse (coast) directions, while creating a drag on the
•
drive gear. Check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth, and little closer to the toe of the tooth. If the tooth contact pattern is incorrect, replace the shim(s) at the driven gear and shim(s) at the driven gear, following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shims are replaced. Repeat the shim change procedure as necessary.
NOTE
○If the backlash goes out of standard range after changing shims, correct the backlash before checking the tooth contact pattern. ○It is OK to pack two shims. Do not pack three or more shims. Heel [A] Bottom [B] Top [C] Toe [D] Drive Gear [E] Driven Gear [F]
Incorrect Tooth Contact Patterns (Example 1) Increase the thickness of the drive gear shim(s) by 0.05 mm (0.002 in.), and/or increase the thickness of the driven gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below. Repeat in 0.05 mm (0.002 in.) steps if necessary. Heel [A] Bottom [B] Top [C] Toe [D] Drive Gear [E] Driven Gear [F]
•
FINAL DRIVE 11-37 Front Bevel Gears Incorrect Tooth Contact Patterns (Example 2) Decrease the thickness of the drive gear shim(s) by 0.05 mm (0.002 in.), and/or decrease the thickness of the driven gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below. Repeat in 0.05 mm (0.002 in.) steps if necessary. Heel [A] Bottom [B] Top [C] Toe [D] Drive Gear [E] Driven Gear [F]
•
Bevel Gear Inspection
check the bevel gears for scoring, chipping, or • Visually other damage. Replace the bevel gears as a set if either gear is damaged.
Cam Damper Inspection
inspect the spring [A], cam follower [B], damper • Visually cam [C], and output shaft [D]. Replace the damaged parts.
11-38 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Replacement
the bearing driver set or the oil seal and bearing • Using remover, remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129
NOTE
○In the absence of the above mentioned tools, satisfac-
tory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out.
CAUTION Do not heat the case with a blowtorch. This will warp the case. Soak the case in oil and heat the oil. a new needle bearing [A] with the marked side fac• Install ing out until it bottoms out, using the bearing driver set [B]. This prevents bearing damage. Special Tool - Bearing Driver Set: 57001-1129
a press and the bearing driver set [A], install a new • Using ball bearing until it stops at the bottom of the case. Special Tool - Bearing Driver Set: 57001-1129
Ball Bearing Wear CAUTION Do not remove the bearings for inspection. Removal may damage them. the ball bearings. •○Check Since the ball bearings are made to extremely close toler-
ances, 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.
FINAL DRIVE 11-39 Bearing and Oil Seal Tapered Roller Bearing Inspection CAUTION Do not remove the tapered roller bearing for inspection. Removal may damage them. inspect the bearing in the front and final gear • Visually cases for abrasion, color change, or other damage. If there is any doubt as to the condition of the bearing, replace it.
Needle Bearing Inspection CAUTION Do not remove the needle bearing in the final gear case for inspection. Removal may damage them. the needle bearings in the front and final gear • Check cases.
○The rollers in the 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.
BRAKES 12-1
Brakes Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool ............................................................................................................................ Brake Lever, Brake Pedal....................................................................................................... Brake Lever Position Adjustment...................................................................................... 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 ............................................................................................... Caliper Dust Boot and Friction Boot Damage ................................................................... Caliper Piston and Cylinder Damage................................................................................ 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 ............................................................................................... Brake Discs ............................................................................................................................ 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 Hoses ........................................................................................................................... Brake Hose Removal/Installation......................................................................................
12-2 12-6 12-7 12-8 12-8 12-8 12-9 12-10 12-11 12-11 12-11 12-11 12-12 12-12 12-12 12-12 12-12 12-12 12-12 12-12 12-13 12-13 12-13 12-13 12-14 12-14 12-15 12-15 12-15 12-16 12-16 12-17 12-17 12-17 12-17 12-18 12-18 12-18 12-18 12-18 12-19 12-19 12-19 12-19 12-22 12-22
12
12-2 BRAKES Exploded View
BRAKES 12-3 Exploded View No. 1 2 3 4 5 6 7 8 9
Fastener Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Front Brake Disc Bolts Front Brake Hose Banjo Bolts Front Brake Light Switch Screw Front Brake Reservoir Cap Screws Front Caliper Bleed Valves Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts
10. Hose Holders (U.S.A. and Canada Models) B: Apply brake fluid. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specific tightening sequence. SI: Apply silicone grease or PBC grease.
N·m 1.0 5.9 27 34 1.2 1.5 7.8 34 8.8
Torque kgf·m 0.10 0.60 2.8 3.5 0.12 0.15 0.80 3.5 0.90
ft·lb 8.9 in·lb 52 in·lb 20 25 11 in·lb 13 in·lb 69 in·lb 25 78 in·lb
Remarks SI L
S
12-4 BRAKES Exploded View
BRAKES 12-5 Exploded View No. 1 2 3 4 5 6 7 8
Fastener Brake Pedal Clamp Bolt Rear Brake Disc Bolts Rear Brake Hose Banjo Bolts Rear Caliper Bleed Valves Rear Caliper Holder Bolt Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut
B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts SI: Apply silicone grease or PBC grease.
N·m 25 27 34 7.8 64 34 25 18
Torque kgf·m 2.5 2.8 3.5 0.80 6.5 3.5 2.5 1.8
ft·lb 18 20 25 69 in·lb 47 25 18 13
Remarks
L
12-6 BRAKES Specifications Item Brake Lever, Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position Brake Fluid Grade Brake Pads Pad Lining Thickness: Front Rear Brake Discs Thickness: Front Rear Runout
Standard No.1 Non-adjustable Non-adjustable About 110 mm (4.3 in.) (height from pedal top to footpeg top) DOT4
4.5 mm (0.18 in.) 7.0 mm (0.28 in.)
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.) 6.8 ∼ 7.2 mm (0.27 ∼ 0.28 in.) TIR 0.15 mm (0.006 in.) or less
Service Limit 5-way adjustable – – – – – – – – –
– – –
1 mm (0.04 in.) 1 mm (0.04 in.)
4.5 mm (0.18 in.) 6.0 mm (0.24 in.) TIR 0.3 mm (0.01 in.)
BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001-143
12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 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 5 and maximum at number 1.
•
Brake Pedal Position Adjustment
• Check that the brake pedal [A] is in the correct position. Pedal Position Standard:
About 110 mm (4.3 in.) [B] (height from pedal top to footboard top [C])
NOTE
○Usually it’s not necessary to adjust the pedal position,
but always adjust it when push rod locknut has been loosened. ○If the push rod length cannot be adjusted by turning the clevis, the brake pedal may be deformed or incorrectly installed. the brake fluid reservoir cover bolt [A] and re• Unscrew move the brake fluid reservoir cover [B].
the reservoir bolt [A] and take off the brake fluid • Unscrew reservoir [B].
BRAKES 12-9 Brake Lever, Brake Pedal the right front footboard bracket bolts [A] and turn • Remove over the footboard bracket [B].
the locknut [A] and turn the push rod with the hex • Loosen head [B] to achieve the correct pedal position.
•
If the length [C] is 80 ±1 mm (3.1 ±0.04 in.), the pedal position will be within the standard range. Tighten: Torque - Rear Master Cylinder Push Rod Locknut: 18 N·m (1.8 kgf·m, 13 ft·lb) Front Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Brake Pedal Removal
the brake fluid reservoir [A] (see Brake Pedal • Remove Position Adjustment in this section). the rear master cylinder mounting bolts [B]. • Loosen Remove right front footboard bracket bolts [C] and • footboardthe bolts [D], and turn over the footboard bracket [E].
• Remove: Rear Master Cylinder Mounting Bolts [A] Brake Pedal Return Spring [B] Brake Switch Return Spring [C]
the brake pedal clamp bolt [A]. • Unscrew Pull out the • stalled. brake lever [B] with the master cylinder in-
12-10 BRAKES Brake Lever, Brake Pedal out the brake pedal [A] from the right footboard • Pull bracket [B].
Brake Pedal Installation
grease to the brake pedal shaft. • Apply Install pedal shaft [A] so that the punched mark on the • shaft isthealigned [B] with the punched mark on the brake
• •
lever [C]. Install: Brake Pedal Return Spring Brake Switch Return Spring Tighten: Torque - Brake Pedal Clamp Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the fluid in the reservoir, and bleed the brake • Replenish line (see Brake Line Bleeding in this chapter). the brake for proper braking power, no brake drag, • Check and no fluid leakage.
WARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done. the brake pedal position and adjust it if necessary. • Check the rear brake light switch operation and adjust the • Check switch if necessary (see Brake Light Switch Operation in the Periodic Maintenance chapter).
BRAKES 12-11 Calipers Front Caliper Removal
the banjo bolt [A] at the brake hose lower end, • Loosen and tighten it loosely. • Unscrew the caliper mounting bolts [B].
CAUTION
Do not loosen the caliper assembly bolt [C]. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage. Immediately wash away any brake fluid that spills. off the caliper. • Take Unscrew • the caliper.the banjo bolt and remove the brake hose from
Rear Caliper Removal
• Remove: Right Saddlebag (see Saddlebag Removal in the Frame chapter) Caliper Mounting Bolts [A] Brake Hose [B] Rear Caliper [C]
Caliper Installation
the caliper and brake hose lower end. •○Install Replace the washer on each side of hose fitting with new
•
ones. Tighten the caliper mounting bolts and banjo bolt.
Torque - Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Front Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
the fluid level in the brake reservoirs (see Brake • Check Fluid Level Inspection in the Periodic Maintenance chap-
• •
ter). Bleed the brake line (see Brake Line Bleeding in this chapter). Check the brake for good braking power, no brake drag, and no fluid leakage.
WARNING Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first application of the lever or pedal if this is not done.
12-12 BRAKES Calipers 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.
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 [G] Rear Caliper [H]
•
Caliper Dust Boot and Friction Boot Damage
that the dust boot [C] and friction boot [D] are not • Check cracked, worn, swollen, or otherwise damaged. • If they show any damage, replace it.
Caliper Piston and Cylinder Damage
inspect the piston [E] and cylinder surfaces. • Visually Replace the caliper if the cylinder and piston are badly scored or rusty.
Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts. If the body does not slide smoothly, one pad will wear more than the other, and constant drag on the disc may cause the temperature of the discs or the brake fluid to increase. Visually inspect that the caliper holder shafts [F] are not badly worn or bent. If the caliper holder shafts are damaged, replace the entire caliper assembly.
•
BRAKES 12-13 Brake Pads Front Brake Pad Removal
the front caliper with the hose installed (see Front • Remove Caliper Removal in this chapter). • Remove: Snap Pin [A] Pad Pin [B]
the jaw side pad [A], and then remove the piston • Remove side pad [B]. Jaw [C]
Front Brake Pad Installation
the caliper pistons in by hand as far as they will go. • Push Install the brake pads. • Install the and snap pin [A]. The snap pin must be • “outside” ofpadthepinpads.
WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done.
Rear Brake Pad Removal
the rear caliper with the hose installed (see Rear • Remove Caliper Removal in this chapter). • Remove: Snap Pin [A] Pad Pin [B]
12-14 BRAKES Brake Pads the jaw side pad [A], and then remove the piston • Remove side pad [B]. Jaw [C]
Rear Brake Pad Installation
installation, clean the pads with a high-flash point • Before solvent. [A] the caliper pistons in by hand as far as they will • Push go. • Be sure to install the snap pin for the caliper.
WARNING
Do not attempt to ride the motorcycle until a full pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first application of the lever or pedal if this is not done.
Brake Pad Wear Inspection
to the Brake Pad Wear Inspection in the Periodic • Refer Maintenance chapter.
BRAKES 12-15 Master Cylinder Front Master Cylinder Removal
the front brake light switch connectors [A]. • Disconnect Draw out the fluid from the reservoir with a means • like the fork oilbrake level gage. Pull the bolt caps • Remove the banjoout. bolt [B] to disconnect the brake hose • from the master cylinder (see Brake Hose Removal/In-
• •
stallation in this chapter). Remove the clamp bolt caps. Unscrew the clamp bolts [C], and take off the master cylinder as an assembly with the reservoir, brake lever, and brake switch installed.
CAUTION Immediately wash away any brake fluid that spills.
Front Master Cylinder Installation
the front master cylinder [A] to match its mating sur• Set face [B] to the punched mark [C] of the handlebar.
○The master cylinder clamp must be installed with the rear
•
view mirror boss [A] faced upward. Tighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. There will be a gap at the lower part of the clamp after tightening. Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
the clamp bolt caps. • Install a new flat washers [A] on each side of the brake hose • Use fitting. • Tighten the brake hose banjo bolt [B]. Torque - Front Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
the fluid in the reservoir, and bleed the brake • Replenish line (see Bleeding the Brake Line in this chapter). the brake for good braking power, no brake drag, • Check and no fluid leakage.
12-16 BRAKES Master Cylinder Rear Master Cylinder Removal
the brake fluid reservoir cover (see Brake Pedal • Remove Position Adjustment in this chapter). out the brake fluid from the reservoir with a means • Draw like the fork oil level gage. the brake fluid reservoir (see Brake Pedal Posi• Remove tion Adjustment in this chapter). the brake hose banjo bolt [A] on the master cylin• Unscrew der. the master cylinder mounting bolts [B]. • Loosen Unscrew the front footboard bracket bolts [C]. • • Remove: Cotter Pin [A] Joint Pin [B] Rear Master Cylinder Mounting Bolts [C]
the reservoir hose lower end clamp [A]. • Slide Pull out reservoir hose lower end [B], and drain the • brake fluidtheinto a container.
Rear Master Cylinder Installation
the cotter pin with a new one. • Replace Insert the cotter pin [A] to the hole of the joint pin [B] and • separate [C] the cotter pin ends. Use a new flat washer on each side of the brake hose • fitting. • Tighten:
Torque - Front Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
the brake line (see Brake Line Bleeding in this • Bleed chapter). the brake for good braking power, no brake drag, • Check and no fluid leakage.
WARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done.
BRAKES 12-17 Master Cylinder Front Master Cylinder Disassembly
to the Brake Master Cylinder Rubber Parts Re• Refer placement in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
to the Brake Master Cylinder Rubber Parts Re• Refer placement in the Periodic Maintenance chapter.
Master Cylinder Assembly
to the Brake Master Cylinder Rubber Parts Re• Refer placement in the Periodic Maintenance chapter.
Master Cylinder Inspection
the front and rear master cylinders (see • Disassemble Brake Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter).
CAUTION Do not remove the secondary cup from the piston since removal will damage it. that there are no scratches, rust or pitting on the • Check 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 assy should be replaced to renew the cups. If fluid leakage is noted at the brake lever, the piston assy should be replaced to renew the cups. Check the dust covers [E] for damage. If they are damaged, replace them. Check the piston return spring [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]
12-18 BRAKES Brake Discs Brake Disc Removal
the wheel (see Front/Rear Wheel Removal in the • Remove Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc.
Brake Disc Installation
the brake disc [A] on the wheel so that the marked • Install side [B] faces out. a non-permanent locking agent to the threads of • Apply the brake disc bolts [C]. • Tighten:
Torque - Front Brake Disc Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb) Rear Brake Disc 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. Measuring Area [B] Replace the disc if the sliding surface has worn past the service limit. Brake Discs Thickness Standard: Front
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
Rear
6.8 ∼ 7.2 mm (0.27 ∼ 0.28 in.)
Service Limit: Front
4.5 mm (0.18 in.)
Rear
6.0 mm (0.24 in.)
Brake Disc Warp
up the motorcycle so that the wheel is off the ground • Jack (see Front/Rear Wheel Removal in the Wheels/Tires chapter).
○For front disc inspection, turn the handlebar fully to one
•
side. Set up a dial gage against the disc [A] as shown and measure disc runout, while turning [B] the wheel by hand. If the 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.)
BRAKES 12-19 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 Be sure to bleed the air from the brake line whenever brake lever or pedal action feels soft or spongy after the brake fluid is changed, or whenever a brake line fitting has been loosened for any reason.
NOTE
○The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is almost the same as for the front brake.
the reservoir cap, and fill the reservoir with fresh • Remove specified brake fluid to the upper level line in the reservoir. the reservoir cap off, slowly pump the brake lever • With several times until no air bubbles can be seen rising up through the fluid from the holes [A] at the bottom of the reservoir. the rubber cap from the bleed valve [A] on the • Remove front caliper [B]. a clear plastic hose [C] to the bleed valve, and run • Attach the other end of the hose into a container.
12-20 BRAKES Brake Fluid the brake line and the caliper. •○Bleed Repeat this operation until no more air can be seen com-
ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake lever and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake lever applied. 3. Release the brake lever [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: Repeat the above steps for the other caliper. the clear plastic hose. • Remove • Tighten:
Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) Front Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the procedure below to install the rear brake fluid • Follow reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until the 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].
NOTE
○For the rear brake caliper [A], bleed the brake line for two bleed valves [B].
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 12-21 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 [A] 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 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 handing 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 washed away 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.
12-22 BRAKES Brake Hoses Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. removing the brake hose, take care not to spill the • When brake fluid on the painted or plastic parts. removing the brake hose [A], temporarily secure • When the end of the brake hose to some high place to keep
• • •
fluid loss to a minimum. Immediately wash away any brake fluid that spills. There are washers [B] on each side of the brake hose fitting. Replace them with new ones when installing. Tighten the banjo bolts [C] on the hose fittings. Torque - Front Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
installing the hoses [A], avoid sharp bending, kink• When ing, flattening 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 in the Periodic Maintenance chapter).
SUSPENSION 13-1
Suspension Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Front Fork ............................................................................................................................... Fork Oil Change (Each Fork Leg) ..................................................................................... Front Fork Removal .......................................................................................................... Front Fork Installation ....................................................................................................... Front Fork Disassembly .................................................................................................... Front Fork Assembly......................................................................................................... Inner Tube, Outer Tube Inspection ................................................................................... Dust Seal Inspection ......................................................................................................... Spring Tension .................................................................................................................. Rear Shock Absorber (Air Type)............................................................................................. Rebound Damping Adjustment ......................................................................................... Air Pressure Adjustment ................................................................................................... Rear Shock Absorber Removal ........................................................................................ Rear Shock Absorber Installation ..................................................................................... Rear Shock Absorber Inspection ...................................................................................... Rear Shock Absorber Scrapping ...................................................................................... Swingarm................................................................................................................................ Swingarm Removal........................................................................................................... Swingarm Installation........................................................................................................ Swingarm Bearing Removal ............................................................................................. Swingarm Bearing Installation .......................................................................................... Swingarm Bearing, Sleeve Inspection .............................................................................. Grease Seal and Needle Bearing Lubrication...................................................................
13-2 13-6 13-7 13-8 13-8 13-9 13-10 13-11 13-12 13-13 13-14 13-14 13-15 13-15 13-15 13-16 13-17 13-17 13-18 13-19 13-19 13-20 13-20 13-21 13-21 13-21
13
13-2 SUSPENSION Exploded View
SUSPENSION 13-3 Exploded View No. 1 2 3 4 5 6
Fastener Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Front Fork Inner Cover Bolts Front Fork Top Plugs
N·m 29 30 29 29 4.0 22
Torque kgf·m 3.0 3.1 3.0 3.0 0.40 2.2
ft·lb 21 22 21 21 35 in·lb 16
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts
Remarks AL L AL
13-4 SUSPENSION Exploded View
SUSPENSION 13-5 Exploded View No. 1 2
Fastener Rear Shock Absorber Nuts Swingarm Pivot Shaft
N·m 34 127
G: Apply grease. WL: Apply a soap and water solution or rubber lubricant.
Torque kgf·m 3.5 13.0
ft·lb 25 94
Remarks
G
13-6 SUSPENSION Specifications Item Front Fork (Per One Unit) Fork Inner Tube Diameter Fork Spring Setting Air Pressure Rebound Damper Setting Fork Oil: Type Amount: When Changing Oil After Disassembly and Completely Dry Fork Oil Level: (Fully Compressed, Without Fork Spring, below from the top of the Inner Tube) Fork Spring Free Length Rear Shock Absorber Rebound Damper Set Air Pressure: Standard Usable Range
Standard 43 mm ( 1.7 in.) Non-adjustable Atmospheric pressure (Non-adjustable) Non-adjustable KAYABA G10 (SAE 10W-20) or equivalent Approx. 440 mL (14.8 US oz.) 513 ±4 mL (17.3 ±0.1 US oz.) 135 ±2 mm (5.31 ±0.08in.) 393.9 mm (15.50 in.) (Service Limit: 386 mm (15.2 in.)) No.II of 4 positions Atmospheric Pressure Atmospheric Pressure ∼ 290 kPa (3.0 kgf/cm², 43 psi)
SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: 57001-183
Front Fork Oil Seal Driver: 57001-1219
Fork Cylinder Holder Adapter: 57001-1057
Jack: 57001-1238
Oil Seal & Bearing Remover: 57001-1058
Fork Oil Level Gauge: 57001-1290
Bearing Driver Set: 57001-1129
Attachment Jack: 57001-1398
Fork Outer Tube Weight: 57001-1218
13-8 SUSPENSION Front Fork Fork Oil Change (Each Fork Leg)
the front fork (see Front Fork Removal in this • Remove section). the outer tube vertically in a vise. • Hold Remove: • Top Plug [D] (with O-ring [E]) Collar [C] Washer [B] Spring [A] out the fork oil [A] with the fork upside down. • Pour Hold the outer tube vertically in a vise. • Fill the front fork with the specified oil. • Fork Oil Type: KAYABA G10 (SAE 10W-20) or equivalent Amount (per side): When changing oil: approx. 440 mL (14.8 US oz.) After disassembly and completely dry: 513 ±4 mL (17.3 ±0.1 US oz.)
for about five minutes so that any suspended air bub• Wait bles can surface. • Measure the oil level, using the fork oil level gauge [A]. Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the gauge stopper [B] so that its lower side shows the oil level distance specified [C].
○Insert the gage tube into the inner tube [D] and position the stopper across the top of the inner tube [E].
○Pull the handle slowly to draw out the excess oil until no
more oil comes up the tube. If no oil is drawn out from the beginning, there is not enough oil in the fork. Pour in some more oil, then draw out the excess. Front Fork Oil Level (fully compressed, without fork spring) Standard: 135 ±2 mm (5.31 ±0.08 in.) (from the top of the inner tube)
SUSPENSION 13-9 Front Fork
• Install: Fork Spring [A] Washer [B] Spacer [C] Top Plug [D] with O-ring [E]
the front fork (see Front Fork Installation in this sec• Install tion).
Front Fork Removal
the jack [A] and attachment jack [B] under the frame • Using pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
CAUTION Be sure to put the rear wheel on the ground when removing the front fork, or the motorcycle may fall over. The motorcycle could be damaged.
WARNING Be sure to put the rear wheel on the ground when removing the front fork, or the motorcycle may fall over. It could cause an accident and injury.
• Remove: Windshield
(see Windshield Removal in the Frame chapter) Headlight Body (see Headlight Body Removal in the Electrical System chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter)
• Remove: Bolts [A] (Both Sides) Left and Right Windshield Brackets [B] Front Fork Center Cover [C]
13-10 SUSPENSION Front Fork
• Remove: Bolts [A] and Washers Brake Hose Clamp [B] Front Turn Signal Light Bracket [C]
the front fork clamp bolt (upper) [A] and fork top • Loosen plug [B] before hand if the fork leg is to be disassembled.
NOTE
○Loosen the fork top plug after loosening the front fork clamp bolt (upper).
• Remove: Front Fork Clamp Bolts [A] Front Fork [B]
Front Fork Installation
the fork so that the top end [A] of the inner tube is • Install flush with the upper surface [B] of the steering stem head
•
bracket. Tighten: Torque - Front Fork Clamp Bolts (Lower): 29 N·m (3.0 kgf·m, 21 ft·lb) Front Fork Top Plug: 22 N·m (2.2 kgf·m, 16 ft·lb)
○Tighten
NOTE
the top plug before tightening the front fork clamp bolt (upper). ○Tighten the two front fork clamp bolts (lower) alternately two times to ensure even tightening torque.
• Tighten:
Torque - Front Fork Clamp Bolt (Upper): 29 N·m (3.0 kgf·m, 21 ft·lb)
SUSPENSION 13-11 Front Fork the removed parts (see appropriate chapters). • Install Check the front brake effectiveness after installation. •
WARNING
Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done.
Front Fork Disassembly
the front fork (see Front Fork Removal in this • Remove section). the fork oil (see Fork Oil Change in this section). •○Drain The following parts are removed during draining the fork oil. Top Plug [D] with O-ring [E] Spacer [C] Washer [B] Fork Spring [A]
the front fork horizontally in a vise [A]. • Hold Stop the • tools. cylinder unit [B] from turning by using the special the Allen bolt [C], and take the gasket out of the • Unscrew bottom of the outer tube. Special Tools - Fork Cylinder Holder Handle [D]: 57001-183 Fork Cylinder Holder Adapter [E]: 57001-1057
• Take the cylinder unit out of the inner tube. the inner tube from the outer tube as follows: •○Separate Remove the dust seal [A] from the outer tube. ○Remove the retaining ring [B] from the outer tube.
○Use the fork outer tube weight [A] to separate the outer tube [B] from the inner tube [C].
○Holding the inner tube by hand, pull the outer tube several times to pull out the inner tube.
Special Tool - Fork Outer Tube Weight: 57001-1218
○Take out the cylinder base out of the outer tube.
13-12 SUSPENSION Front Fork the inner tube guide bushing [A], outer tube • Remove guide bushing [B], washer [C], and oil seal [D] from the inner tube.
Front Fork Assembly
the following parts with new ones after removal. • Replace Dust Seal [A] Retaining Ring [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Bottom Allen Bolt Gasket [F]
the cylinder unit [A] with the spring into the inner tube • Put [B], protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit. ○Install the cylinder base with the tapered end [D] up. Install the inner tube, cylinder unit, and cylinder base as a set into the outer tube.
•
the new guide bushing [A] with a used guide bush• Install ing [B] on it by tapping the used guide bushing with fork oil seal driver [C] until it stops. ○The split [D] of the bushing should face toward the side [E] of the vehicle. Special Tool - Front Fork Oil Seal Driver: 57001-1219
molybdenum disulfide grease to the oil seal lips and • Apply install the washer [A] and the oil seal [B] into the outer tube.
○Face the flat side [C] of the seal upward. Special Tool - Front Fork Oil Seal Driver [D]: 57001-1219
• Install: Retaining Ring Dust Seal
SUSPENSION 13-13 Front Fork a non-permanent locking agent to the threads of • Apply the Allen bolt and screw the Allen bolt into the bottom of
• •
the outer tube. Hold the front fork horizontally in a vise [A]. Hold the cylinder unit [B] with the special tools and tighten the Allen bolt [C]. Special Tools - Fork Cylinder Holder Handle [D]: 57001-183 Fork Cylinder Holder Adapter [E]: 57001-1057 Torque - Front Fork Bottom Allen Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb)
in the specified type of oil (see Fork Oil Change • Pour (Each Fork Leg) in this section). • Install: Fork Spring [A]
•
Washer [B] Spacer [C] Top Plug [D] with O-ring [E] Install the front fork (see front fork Installation in this section)
Inner Tube, Outer Tube Inspection
inspect the inner tube [A] and repair any damage. • Visually Nick or rust can sometimes be repaired by using • a wet- stonedamage 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.
CAUTION 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 and outer tubes, and • Temporarily pump 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 [B] may fail in use, possibly, causing an accident. Replace a badly bent or damaged inner or outer tube, and inspect the other tube carefully before reusing it.
13-14 SUSPENSION Front Fork Dust Seal Inspection Inspect the dust seal [A] for any signs of deterioration or damage. Replace them if necessary.
Spring Tension
the spring becomes shorter as it weakens, check • Since its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability. Spring Free Length Standard: Service Limit:
393.9 mm (15.50 in.) 386 mm (15.2 in.)
SUSPENSION 13-15 Rear Shock Absorber (Air Type) Rebound Damping Adjustment The rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions. The numbers on the adjuster show the setting position. Turn the adjuster [A] until the desired number [B]. ○The standard adjuster setting is No.II for an average-build rider of 68 kg (150 lb) with no passenger and no accessories. If the damper setting feels too soft or too stiff, adjust it in accordance with the following table.
•
Rebound Damping Adjustment Adjuster
Damping
Position
Force
I
Setting
Load
Road
Speed
Weak
Soft
Light
Good
Low
II
↑
↑
↑
↑
↑
III
↓
↓
↓
↓
↓
IIII
Strong
Hard
Heavy
Bad
High
WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result.
Air Pressure Adjustment The air pressure in the rear shock absorbers can be adjusted for different road and loading conditions. The following table shows an example of air pressure adjustment. To obtain stable handling and a suitable ride, adjust the air pressure as indicated. The standard air pressure is atmospheric pressure for an average-build rider of 68 kg (150 lb) with no passenger and no accessories. Ordinarily, the heavier the total load becomes, the higher the air pressure should be set. Air Pressure Adjustment Air Pressure
Setting
Load
Road
Soft
Light
Good
↑
↑
↑
↑
↓
↓
↓
↓
Hard
Heavy
Bad
Atmospheric Pressure (0 kgf/cm², 0 psi)
290 kPa (3.0 kgf/cm², 43 psi)
• Adjust the air pressure.
NOTE
○Check and adjust the air pressure when the rear shock absorbers are cold (room temperature).
13-16 SUSPENSION Rear Shock Absorber (Air Type) the rear wheel [A] off the ground, using the jack [B], • Raise and the attachment jack [C]. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
off each air valve cap [A] on the right and left shock • Take absorbers.
•
Front [B] Check the air pressure with the air pressure gauge.
NOTE
○Do not use tire gauges for checking air pressure. They may not indicate the correct air pressure because of air leakage that occur when the gauge is applied to the valve. ○To lower the air pressure, push the valve core in slightly. To raise the pressure, inject air through the valve with a tire pump. Change the air pressure within the range specified in the preceding table to suit various riding conditions.
CAUTION Inject air little by little so that air pressure does not rise rapidly. Air pressure exceeding 490 kPa (5.0 kgf/cm², 71 psi) may damage the oil seal. Try to set the air pressure of the right and left shock absorbers as equally as possible.
WARNING Be sure to adjust the air pressure within the usable range. Pressure too high can produce a hazardous riding condition. Only air or nitrogen gas can be used. Never inject oxygen or any kind of explosive gas.
Rear Shock Absorber Removal
the rear wheel off the ground, using the jack and the • Lift attachment jack. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
SUSPENSION 13-17 Rear Shock Absorber (Air Type) the brake lever slowly and hold it with a band • Squeeze [A].
CAUTION Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. The motorcycle could be damaged.
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. the left and right saddlebags (see Saddlebag Re• Remove moval in the Frame chapter). the nuts [A], lock washers, and flat washers from • Remove both ends of the rear shock absorber [B]. • Pull the rear shock absorber off the frame.
Rear Shock Absorber Installation
the sleeve [A] so the flange side faces inside. • Install Install the rear shock absorber so that the air valve [B] • faces forward [C]. the rear shock absorber nuts [D] to the specified • Tighten torque. Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
the left and right saddlebags (see Saddlebag In• Install stallation in the Frame chapter).
Rear Shock Absorber Inspection
the rear shock absorbers [A]. • Remove Visually inspect following items. • Smooth Strokethe [B]
•
Oil Leakage (see Rear Shock Absorber Oil Leak Inspection in the Periodic Maintenance chapter) Crack or Dent If there is any damage to the rear shock absorber, one unit feels weaker than the other, replace both shock absorbers as a set. Visually inspect the rubber bushings [C]. If they show any signs of damage, replace them.
13-18 SUSPENSION Rear Shock Absorber (Air Type) inspect the shock absorber sleeves [A] and nee• Visually dle bearings [B]. roller in a needle bearing normally wear very little, • The and wear is difficult to measure. Instead of measuring, inspect the bearing in the shock absorber for abrasion, color change, or other damage. If there is any doubt as to the condition of any of the needle bearings or sleeves, replace the sleeves, and needle bearings as a set.
Rear Shock Absorber Scrapping
the rear shock absorber (see Rear Shock Ab• Remove sorber Removal in this section).
WARNING Since the rear shock absorber contains air, do not incinerate the rear shock absorber without first releasing the air or it may explode. Before a rear shock absorber is scrapped, remove the air valve [A].
SUSPENSION 13-19 Swingarm Swingarm Removal
the jack [A] and attachment jack [B] under the frame • Using pipe ribs [C], lift the rear wheel [D] OFF the ground until the front wheel [E] touches the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
the brake lever slowly and hold it with a band • Squeeze [A].
CAUTION Be sure to hold the front brake when removing the swingarm, or the motorcycle may fall over. The motorcycle could be damaged.
WARNING Be sure to hold the front brake when removing the swingarm, or the motorcycle may fall over. It could cause an accident and injury.
• Remove: Left and Right Saddlebags (see Saddlebag Removal in the Frame chapter) Rear Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Front Exhaust Pipe Cover (see Exhaust Pipe Removal in the Engine Top End chapter) Swingarm Pivot Cap [A]
removing the swingarm, unscrew the banjo bolt [A] • Before on the rear caliper [B].
○Temporarily secure the end of the brake hose to some
• •
high place to keep fluid loss to a minimum. Immediately wash away any brake fluid that spills. Detach the rear brake hose [C] from the holders [D] on the swingarm.
13-20 SUSPENSION Swingarm
• Remove: Rear Wheel
• •
(see Rear Wheel Removal in the Wheels/Tires chapter) Final Gear Case (see Final Gear Case Removal in the Final Drive chapter) Right Rear Shock Absorber (see Rear Shock Absorber Removal in this chapter) Unscrew the pivot shaft [A], and pull it out while turning. Pull the swingarm [B] rearward, and take it off.
CAUTION Do not tap the swingarm pivot shaft when removing or installing. Push or pull the pivot shaft while turning the shaft. Tapping on the shaft could damage the needle bearings in the swingarm.
Swingarm Installation
grease to the needle bearings and grease seals. • Apply grease to the threads [A] of the swingarm pivot • Apply shaft. Torque - Swingarm Pivot Shaft: 127 N·m (13.0 kgf·m, 94 ft·lb)
the swingarm up and down [A] to check for abnor• Move mal friction, and push and pull [B] it to check for bearing
•
• •
play. Install: Right Rear Shock Absorber (see Rear Shock Absorber Installation in this chapter) Final Gear Case (see Final Gear Case Installation in the Final Drive chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) Install the removed parts (see appropriate chapters). After installing the swingarm, replenish the brake fluid into the reservoir and bleed the brake line (see Brake Line Bleeding in the Brakes chapter).
Swingarm Bearing Removal
• Remove: Swingarm (see Swingarm Removal in this chapter) Propeller Shaft (see Propeller Shaft Removal in the Final Drive chapter) Left and Right Sleeves [A] Left and Right Grease Seals [B]
SUSPENSION 13-21 Swingarm the needle bearings, using the oil seal & bearing • Remove remover [A]. Special Tool - Oil Seal & Bearing Remover: 57001-1058
the bearings and sleeves with new ones. • Replace Remove the other side bearing in the same manner. •
Swingarm Bearing Installation
plenty of grease to the needle bearings, and sleeve. • Apply Be sure install the needle bearings so that the man• ufacturer’sto marks are faced out. This prevents bearing
•
damage. Position the bearings [A] as shown, using a suitable bearing driver in the bearing driver set. Sleeves [B] Grease Seals [C] 5 mm (0.2 in.) [D] Special Tool - Bearing Driver Set: 57001-1129
Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the needle bearings for inspection. Remove may damage them. inspect the swingarm sleeves [A] and needle • Visually bearings [B]. rollers in a needle bearing normally wear very little, • The and wear is difficult to measure. Instead of measuring, inspect the bearing in the swingarm 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.
Grease Seal and Needle Bearing Lubrication
to the Swingarm Pivot Lubrication in the Periodic • Refer Maintenance chapter.
STEERING 14-1
Steering Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Handlebar ............................................................................................................................... Handlebar Removal .......................................................................................................... Handlebar Installation ....................................................................................................... Steering .................................................................................................................................. Steering Check ................................................................................................................. Steering Adjustment.......................................................................................................... Steering Stem......................................................................................................................... Steering Stem Removal .................................................................................................... Steering Stem Installation ................................................................................................. Steering Stem Warp.......................................................................................................... Steering Stem Bearing ........................................................................................................... Stem Bearing Removal ..................................................................................................... Stem Bearing Installation .................................................................................................. Stem Bearing Lubrication.................................................................................................. Stem Cap Deterioration, Damage.....................................................................................
14-2 14-4 14-5 14-5 14-5 14-7 14-7 14-7 14-8 14-8 14-11 14-12 14-13 14-13 14-13 14-14 14-14
14
14-2 STEERING Exploded View
STEERING 14-3 Exploded View No. 1 2 3 4 5 6
Fastener Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Handlebar Clamp Bolts Handlebar Holder Nuts Steering Stem Head Nut Steering Stem Nut
N·m 29 29 34 34 88 4.9
Torque kgf·m 3.0 3.0 3.5 3.5 9.0 0.50
ft·lb 22 22 25 25 65 43 in·lb
Remarks
AL O, S
S
AD: Apply adhesive. AL: Tighten the two front fork clamp bolts (lower) alternately two times to ensure even tightening torque. G: Apply grease. O: Apply 2 stroke oil. R: Replacement Parts S: Follow the specific tightening sequence.
14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: 57001-1075
Jack: 57001-1238
Head Pipe Outer Race Driver, 57001-1077
Steering Stem Bearing Driver, 57001-1344
54.5:
42.5:
Steering Stem Nut Wrench: 57001-1100
Steering Stem Bearing Driver Adapter, 57001-1345
Head Pipe Outer Race Remover ID > 37 mm: 57001-1107
Attachment Jack: 57001-1398
41.5:
STEERING 14-5 Handlebar Handlebar Removal
the straps. • Cut Remove: • Clutch Master Cylinder [A] (see Clutch Master Cylinder Removal in the Clutch chapter) Left Handlebar Switch Housing [B]
the left grip end cap [A] from the handlebar [B]. •○Remove The left grip end cap has left-hand threads. • Remove the left grip [C].
• Remove: Front Brake Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter) Right Handlebar Switch Housing [B] Throttle Grip [C]
the handlebar clamp bolt caps. • Remove Unscrew clamp bolts [A] and remove the • handlebarthe[B]handlebar from the stem head.
Handlebar Installation
2 stroke oil to the threads of the handlebar clamp • Apply bolts. the handlebar clamp [A] together with the handle• Install bar so that the cut side [B] on the clamp points at the rear. the handlebar clamp bolts [C]. •○Tighten Tighten the clamp bolts, front first and then the rear. If the handlebar clamp is correctly installed, there will be no gap at the front and a gap at the rear after tightening.
Torque - Handlebar Clamp Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
14-6 STEERING Handlebar front half of the right handlebar switch housing [A] • The has a small projection [B]. Fit the projection into the small hole [C] in the handlebar.
the left handlebar switch housing [A] to match its mat• Set ing surface [B] to the punched mark [C] of the handlebar. the handlebar switch housings. • Install Install: • Clutch Master Cylinder (see Clutch Master Cylinder Installation in the Clutch chapter) Front Brake Master Cylinder (see Front Master Cylinder Installation in the Brakes chapter)
adhesive the inside the left grip [A]. • Apply Insert the grip until punched mark [B] in the handlebar. • Check andleftadjust cables (see Throttle Control • System Inspectionthein throttle the Periodic Maintenance chapter) and rear view mirrors.
STEERING 14-7 Steering Steering Check
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.
14-8 STEERING Steering Stem Steering Stem Removal
the jack [A] and attachment jack [B] under the frame • Using pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
CAUTION Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over. The motorcycle could be damaged.
WARNING Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over. It could cause an accident and injury.
• Remove: Windshield
(see Windshield Removal in the Frame
chapter) Headlight Body (see Headlight Body Removal in the Electrical System chapter) Front Wheel (see Front Wheel Removal in the Tires/Wheels chapter)
• Remove: Bolts [A] (Both Sides) Left and Right Windshield Brackets [B] Front Fork Center Cover [C]
• Remove: Bolts [A] Brake Hose Clamp [B] Turn Signal Rights Bracket [C]
STEERING 14-9 Steering Stem
• Remove: Bolts [A] (Both Sides) Front Fork Rear Covers [B]
• Remove: Bolt [A] Cable Bracket [B]
• Remove: Bolts [A] Headlight Body Stay [B]
• Remove: Brake Hose Banjo Bolt [A] Brake Hose [B]
• Remove the brake hose joint bolt [A].
14-10 STEERING Steering Stem
• Remove: Handlebar Holder Bolt Cap and Bolts [A] Handlebar [B]
• Remove: Steering Stem Head Nut [A] •
Washer [B] Loosen the front fork clamp bolts (upper) [C].
• Remove: O-ring [A] Steering Stem Head [B] with Handlebar Holder
the front fork clamp bolts (lower) [A]. • Loosen Remove the fork legs [B]. •
• Remove: Bolts [A] (Both Sides) Front Fork Inner Covers [B]
STEERING 14-11 Steering Stem
• Remove: Claw Washer [A] Steering Stem Nut [B] Stem Cap [C] O-ring [D]
NOTE
○Be sure to remove the O-ring for removal of the steering stem.
• Pull out the steering stem [E] from the bottom. Steering Stem Installation
• Install: Steering Stem [A]
•
Bearing [B] New O-ring [C] Stem Cap [D] Stem Nut [E] Claw Washer [F] Tighten: Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
• Install the front fork inner covers [A].
Torque - Front Fork Inner Cover Bolts: 4.0 N·m (0.40 kgf·m, 35 in·lb)
the fork legs [B] and push it up [C] tightly against • Install the stem bottom. • Temporarily tighten the front fork clamp bolts (lower) [D].
• Install: Steering Stem Head [A] with Handlebar Holder •
O-ring [B] Washer [C] Stem Head Nut [D] Temporarily tighten the front fork clamp bolts (upper) [E].
14-12 STEERING Steering Stem
○Check that the top end [A] of the inner tube is flush with the
•
upper surface [B] of the steering stem head. Otherwise reinstall the fork leg. Tighten the front fork clamp bolts (upper) and then the stem head nut, and finally the front fork clamp bolts (lower). Torque - Front Fork Clamp Bolts (Upper): 29 N·m (3.0 kgf·m, 22 ft·lb) Steering Stem Head Nut: 88 N·m (9.0 kgf·m, 65 ft·lb) Front Fork Clamp Bolts (Lower): 29 N·m (3.0 kgf·m, 22 ft·lb)
NOTE
○Tighten the two front fork clamp bolts (lower) alternately two times to ensure even tightening torque.
the removed parts (see appropriate chapters). • Install and adjust the following items after installation. • Check Steering (see Steering Play Inspection in the Periodic
•
Maintenance chapter) Throttle Cables (see Throttle Grip Free Play Adjustment in the Fuel System (DFI) chapter) Headlight Aim (see Headlight Beam Horizontal and vertical Adjustment in the Electrical System chapter) Check the front brake effectiveness.
WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done.
Steering Stem Warp
the steering stem is removed, or if the steering • Whenever cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem.
STEERING 14-13 Steering Stem Bearing Stem Bearing Removal
the steering stem (see Steering Stem Removal • Remove in this chapter). • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover ID > 37 mm [A]: 57001-1107
NOTE
○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) be replaced with new ones. the lower inner race [A] which is pressed onto • Remove the steering stem, using a chisel. Grease Seal [B] Tap here [C]
Stem Bearing Installation
the bearing outer races with new ones. • Replace Apply grease to the outer races, and 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
the stem bearing inner races with new ones. • Replace Apply grease • the stem base.to the lower inner race [A], and drive it onto Special Tools - Steering Stem Bearing Driver, 42.5 [B]: 57001-1344 Steering Stem Bearing Driver Adapter, 41.5 [C]: 57001-1345
the steering stem (see Steering Stem Installation • Install in this chapter).
NOTE
○Do not install the O-rings yet.
the bearings in place as follows: •○Settle Tighten the stem nut to 78 N·m (8.0 kgf·m, 58 ft·lb) of torque. (To tighten the steering stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 440 N (45.0 kg, 99 lb) force in the direction shown.)
Special Tool - Steering Stem Nut Wrench [A]: 57001-1100
180 mm (7.1 in.) [B] Force [C]
14-14 STEERING Steering Stem Bearing
○Check that there is no play and the steering stem turns
• •
smoothly without rattles. If not, the steering stem bearings may be damaged. Remove the stem nut. Install the O-rings and adjust the steering (see Steering Play Adjustment in the Periodic Maintenance chapter). Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
Stem Bearing Lubrication
with the Periodic Maintenance Chart, lubri• Incateaccordance the steering stem bearings. Refer to the Stem Bearing Lubrication in the Periodic Maintenance chapter.
Stem Cap Deterioration, Damage Replace the stem cap if its grease seal [A] shows damage.
FRAME 15-1
Frame Table of Contents Exploded View................................... Special Tools ..................................... Seats ................................................. Rear Seat Removal...................... Rear Seat Installation................... Front Seat Removal ..................... Front Seat Installation .................. Side Covers ....................................... Left Side Cover Removal ............. Left Side Cover Installation .......... Right Side Cover Removal........... Right Side Cover Installation........ Fenders ............................................. Front Fender Removal ................. Rear Fender Removal.................. Rear Fender Installation............... Battery Case...................................... Battery Case Removal ................. Battery Case Installation .............. Tool Box............................................. Tool Box Removal ........................ Footboard .......................................... Front Footboard Removal/Installation.......................................... Front Footboard Disassembly...... Front Footboard Assembly........... Rear Footboard Removal/Installation ............................................ Rear Footboard Disassembly ...... Rear Footboard Assembly ........... Side Stand ......................................... Side Stand Removal ....................
15-2 15-8 15-9 15-9 15-9 15-9 15-9 15-10 15-10 15-10 15-10 15-10 15-11 15-11 15-11 15-12 15-13 15-13 15-14 15-15 15-15 15-16 15-16 15-16 15-17 15-17 15-17 15-17 15-19 15-19
Side Stand Installation ................. Windshield ......................................... Windshield Height Adjustment ..... Windshield Removal .................... Windshield Assembly/Installation. Deflector Removal ....................... Deflector Assembly ...................... Travel Trunk and Saddlebags............ Lid Unlatching .............................. Lid Latching.................................. Saddlebag Removal..................... Saddlebag Installation.................. Guards............................................... Front Guard Removal/Installation Rear Guard Removal ................... Rear View Mirrors.............................. Rear View Mirror Removal (Other than European Model)............... Rear View Mirror Removal (European Model) ..................... Rear View Mirror Installation (Other than European Model) ... Rear View Mirror Installation (European Model) ..................... Downtube ......................................... Downtube Removal...................... Downtube Installation................... Frame ................................................ Tandem Grip Removal/Installation ............................................ Frame Inspection .........................
15-19 15-20 15-20 15-20 15-21 15-22 15-22 15-23 15-23 15-23 15-23 15-23 15-25 15-25 15-25 15-26 15-26 15-26 15-26 15-27 15-28 15-28 15-29 15-30 15-30 15-30
15
15-2 FRAME Exploded View
FRAME 15-3 Exploded View No. 1 2 3 4
Fastener Downtube Bolts Engine Mounting Bracket Bolts Front Footboard Bracket Bolts Side Stand Nut
N·m 59 25 34 44
G: Apply grease. WL: Apply a soap and water solution or rubber lubricant.
Torque kgf·m 6.0 2.5 3.5 4.5
ft·lb 44 18 25 32
Remarks
15-4 FRAME Exploded View
FRAME 15-5 Exploded View No. 1
Fastener Rear Footboard Bracket Bolts
2. Tool Box 3. Battery Case 4. Front Fender 5. Rear Fender 6. Front Seat 7. Rear Seat G: Apply grease.
N·m 25
Torque kgf·m 2.5
ft·lb 18
Remarks
15-6 FRAME Exploded View
FRAME 15-7 Exploded View No. 1
Fastener Tandem Grip Mounting Bolts
2. Saddlebags 3. Windshield 4. Trim (other than US, Canada and Australia)
N·m 25
Torque kgf·m 2.5
ft·lb 18
Remarks
15-8 FRAME Special Tools Jack: 57001-1238
Attachment Jack: 57001-1398
FRAME 15-9 Seats Rear Seat Removal
the rear seat bolt [A] and move the rear seat • Remove backwards [B] and remove it.
Rear Seat Installation
the hook [A] of the rear seat into the bracket [B] on • Slip the rear fender. • Tighten the rear seat bolt.
Front Seat Removal
the rear seat (see Rear Seat Removal in this • Remove section). the front seat bolt [A]. • Remove Pull the front seat [B] backwards and up, then remove it. •
Front Seat Installation
the hook [A] of the seat under the fuel tank bracket. • Insert Tighten bolt. • Install thetherearfrontseatseat (see Rear Seat Installation in this sec• tion). Front [B]
15-10 FRAME Side Covers Left Side Cover Removal
the ignition switch key [A] into the left side cover, • Insert and turn the key clockwise until the key slot is vertical. [B] the rear part of the left side cover, push [C] the left • Pull side cover slightly forward, and remove it.
Left Side Cover Installation
the front stoppers [A] into the grommets [B] first, then • Put put the rear stopper into the grommet.
the ignition switch key [A] counterclockwise until the • Turn key slot is horizontal [B] to secure the left side cover.
Right Side Cover Removal
• Remove the screw [A].
CAUTION
Be careful not to scratch the right side cover surface with the rear exhaust pipe [B] during removal or installation. the rear exhaust pipe with a shop towel and pull • Cover the right side cover evenly outward to clear the stoppers.
Right Side Cover Installation
the stoppers [A] into the grommets [B]. • Put Tighten the screw. •
FRAME 15-11 Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. the mounting bolts [A] on both sides to separate • Remove the fender from the front fork. the fender forwards with the wheel installed and • Move remove it.
Rear Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation.
• Remove: Rear Seat (see Rear Seat Removal in this chapter) Front Seat (see Front Seat Removal in this chapter) Left and Right Saddlebags (see Saddlebag Removal in this chapter) Tandem Grip (see Tandem Grip Removal in this chapter) Remove the left and right rear fender covers [A].
• • Remove: Allen Bolts [A] (Both Sides)
Bolts [B] (Both Sides) Left and Right Saddlebag Stays (Upper) [C]
the rear turn signal and tail/brake lead con• Disconnect nector [A] and pull off the female connector along with
•
the strap [B]. Remove the rear fender bolts [C].
15-12 FRAME Fenders the rear fender bolts [A] on both sides. • Remove Remove the rear fender [B] rearwards. •
Rear Fender Installation
is reverse of removal, note the following. •○Installation Put the grommet [A] of the rear fender into the stopper [B] of the frame. ○Be sure the harness in place (see Cable, Wire, and Hose Routing section in the Appendix chapter).
FRAME 15-13 Battery Case Battery Case Removal
• Remove: Front Seat (see Front Seat Removal in this chapter) Battery (see Battery Removal in the Electrical System chapter) ECU (see ECU Removal in the Fuel System (DFI) chapter) Rear Fender (see Rear Fender Removal in this chapter) Coolant Reservoir Tank (see Coolant Change in the Periodic Maintenance chapter) the following upwards: • Pull Oil Pressure Light Delay Unit [A] DFI Main Relay [B] Turn Signal Control Unit [C] Starter Relay [D]
the bolts [A]. • Remove Front [B]
• Remove: Rear Wheel
(see Rear Wheel Removal in the Wheels/Tires chapter) Screws [A] Rear View [B]
• Remove the battery case [A] towards the rear [B].
15-14 FRAME Battery Case Battery Case Installation
the grommet [B] of the battery case into the stopper • Put [A] of the frame. • Install the removed parts (see appropriate chapters).
FRAME 15-15 Tool Box Tool Box Removal
the left side cover (see Left Side Cover Removal • Remove in this chapter). California model, remove the band [A] and canister • For [B]. the bolts [C]. • Unscrew Pull the tool box [D] out. •
15-16 FRAME Footboard Front Footboard Removal/Installation
• Remove: Footboard Bracket Bolts [A] •
Left Front Footboard [B] Tighten: Torque - Front Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Remove: Footboard Bolts [A] Spring [B] Right Front Footboard [C]
the spring [A] as shown. • Install Right Front Footboard [B] Rear View [C]
Front Footboard Disassembly
the left front footboard (see Front Footboard Re• Remove moval/installation in this section). • Remove: Spring [A] Circlip [B] Pin [C]
the right front footboard (see Front Footboard • Remove Removal/Installation in this section). • Remove: Circlip [A] Pin [B]
FRAME 15-17 Footboard Front Footboard Assembly
the circlip [A] with a new one. • Replace Install: • Left Front Footboard Damper [B] Left Front Footboard [C] Bank Sensor [D] Bank Sensor Bolts [E] Insert the pin [F] from the front side of the footboard bracket [G]. Install the new circlip. Install the spring [H] hook direction as shown.
• • • the circlip [A] with a new one. • Replace Install: • Right Front Footboard Damper [B] • •
Right Front Footboard [C] Bank Sensor [D] Bank Sensor Bolts [E] Insert the pin [F] from the front side of the footboard bracket [G]. Install the new circlip.
Rear Footboard Removal/Installation
• Remove: Allen Bolts [A] •
Rear Footboard [B] Tighten: Torque - Rear Footboard Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Rear Footboard Disassembly
the rear footboard (see Rear Footboard Re• Remove moval in this section). • Remove: Circlip [A] Pin [B]
Rear Footboard Assembly
the circlip [A] with a new one. • Replace • Install: Left Rear Footboard Damper [B]
• • •
Left Rear Footboard [C] Left Rear Footboard Cover [D] Cover Bolt [E] Install the spring [F] and spring cap [G] from the rear side of the left rear footboard. Insert the pin [H] from the front side of the footboard bracket [I]. Install the new circlip.
15-18 FRAME Footboard the circlip [A] with a new one. • Replace Install: • Right Rear Footboard Damper [B]
• • •
Right Rear Footboard [C] Right Rear Footboard Cover [D] Footboard Cover [D] Cover Bolt [E] Install the spring [G] and spring cap [F] from the front side of the right rear footboard. Insert the pin [H] from the front side of the right front footboard. Install the new circlip.
FRAME 15-19 Side Stand Side Stand Removal
the rear wheel [A] off the ground, using the jack [B] • Raise and the attachment jack [C]. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
the alternator outer cover (see Alternator Outer • Remove Cover Removal in the Electrical System chapter).
• Disconnect the side stand switch lead connector [A].
• Remove: Side Stand Switch Bolt [A] Spring [B] Side Stand Bolt [C] Side Stand [D]
Side Stand Installation
grease to the contact surface of the frame and side • Apply stand. • Install: Side Stand [A]
•
Side Stand Mounting Bolt [B] and Nut [C] Tighten the bolt and lock them with the nut. Torque - Side Stand Mounting Nut: 44 N·m (4.5 kgf·m, 33 ft·lb)
the spring [D] so that face the long spring end up• Hook ward.
○Install the spring hook direction as shown.
the side stand switch. •○Install Apply a non-permanent locking agent to the side stand
•
switch mounting bolt [F]. Tighten:
Torque - Side Stand Switch Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
that the side stand switch mounting bolt and nut is • Check not loosening. the side stand switch lead correctly (see Cable, Wire, • Run and Hose Routing section in Appendix chapter). the alternator outer cover (see Alternator Outer • Install Cover Installation in the Electrical chapter).
15-20 FRAME Windshield Windshield Height Adjustment
○The windshield [A] can be adjusted within 45 mm (1.8 in.)
• • •
in height (The sliding range is within 50 mm, 2.0 in.) to suit the rider’s preference. Loosen the upper and lower bolts [B] on both sides and slide the windshield up or down. Check to see that the position marks [C] are in the same relative position on both sides. Tighten the bolts securely.
the subwindshield bolts [A] on both sides and • Loosen slide the subwindshield [B] up or down so the clearance
•
[C] is 10 mm (0.4 in.) between the subwindshield lower edge and the headlight body. Tighten the subwindshield bolts.
Windshield Removal CAUTION Be careful not to damage the surface of the windshield. the upper and lower bolts [A] on both sides and • Remove remove the windshield [B].
FRAME 15-21 Windshield Windshield Assembly/Installation CAUTION Be careful not to damage the surface of the windshield. the following with the bolts and nuts to the windshield [A]. • Install Outer Center Plate [B] and Damper [C] Inner Center Plate [D] and Damper [E] Left and Right Outer Plates [F] Left and Right Stays [G] and Dampers [H] Washers [I] ○The left outer plate has an L mark on its back and the right outer plate an R mark (front view).
the subwindshield [A] between the windshield [B] • Insert and the dampers [C].
the left and right inner plates [A] and dampers [B] • Install between the windshield [C] and left and right outer plates
• •
[D]. First, tighten all the bolts and nuts to a snug fit and finally tighten them evenly. Pull the subwindshield all the way up.
15-22 FRAME Windshield the European Model, install the trim [A] to around the • For windshield. • Install the trim caps [B] to the end of the trim.
the windshield [A] on the brackets with the bolts. • Install Set the windshield all the way down and tighten the bolts • [B] securely.
Deflector Removal
• Remove: Bolts [A]
Deflector [B]
Deflector Assembly
the following with the bolts [A] and nuts [B]. • Assemble Left Stay [C] Right Stay [D] Left [E] and Right [F] Deflectors Left Deflector Bracket [G] Right Deflector Bracket [H] Washers [I]
FRAME 15-23 Travel Trunk and Saddlebags Lid Unlatching
the ignition key into the lid lock [A], turn the key • Insert counterclockwise [B], and pull the knob [C] outward. The lid will open.
Lid Latching
pulling the knob [A] up, close the lid [B], release the • While knob, and then turn the key clockwise [C]. • Pull the knob to make sure the lid is locked.
CAUTION
Do not slam the lid shut. Otherwise the lid will not latch and could damage.
Saddlebag Removal
the lid [A] (see Lid Unlatching in this section). • Open Unscrew bolts [B]. • Close thethe lid (see Lid Latching in this section). • Lift the saddlebag • remove the bag. [C] to clear the bottom stoppers, and
Saddlebag Installation
the stoppers on the bottom of the saddlebag into the • Fit dampers [A] in the saddlebag stay (lower).
the hook [A] behind the bag [B] into the catch [C] on • Fit the saddlebag stay (upper) [D]. At this point, the bag is free to move on the mounts.
15-24 FRAME Travel Trunk and Saddlebags the lid (see Lid Unlatching in this section) and • Open tighten the bag bolts [A].
•
• •
• •
Washer(s) [B] Saddlebag [C] Saddlebag Stay (upper) [D] Front [E] Close the lid (see Lid Latching in this section).
If the lid does not work properly, adjust the bag clearance to mount the bag snugly without being distorted. Remove the bag bolts [G]. Lightly push the bag [A] towards the upper stay [B] and measure each bag clearance [E] between the boss [C] and damper [D] with a thickness gauge. If both clearances are 1.0 mm (0.04 in.) or less (standard clearance), the bag can be mounted snugly and the lid may be locked. If either clearance is more than 1.0 mm (0.04 in.) when the other clearance is 0 mm, insert the washer(s) [F] as shown to get the standard clearance. Install the bag and bag bolts and tighten the bolts securely. Open and close the lid several times to check for smooth operation. Be sure the lid latches and locks securely. If the lid does not work properly, remove the bag bolts and readjust the clearance.
FRAME 15-25 Guards Front Guard Removal/Installation
• Remove: Front Footboard Bracket Bolt [A] •
Front Guard Bolt [B] Front Guard [C] Tighten: Torque - Front Footboard Bracket Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
Rear Guard Removal
• Remove: Saddlebag (see Saddlebag Removal in this chapter) Rear Guard Bolt (Upper) [A] Rear Guard Bolt Cap and Bolt (Middle) [B] Rear Guard Bolts (Lower) [C] Rear Guard [D]
15-26 FRAME Rear View Mirrors Rear View Mirror Removal (Other than European Model)
the locknut [A]. • Loosen the rear view mirror stay [B] counterclockwise to re• Turn move the rear view mirror from the holder [C].
Rear View Mirror Removal (European Model)
the lower hexagonal area [A]. • Loosen Turn the view mirror stay [B] counterclockwise to re• move therear rear view mirror from the holder [C].
CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [A] with a pair of spanners or wrench. Disassembly of this area is not possible. Non-permanent locking agent [B] is already applied to the threads of this inner area. Forcible loosening may damage the adapter and/or the turning mechanism of the stay [C].
Rear View Mirror Installation (Other than European Model)
the locknut all the way up. • Loosen Screw the mounting area of the rear view mirror [A] into • the holder [B] all the way, then back it two turns out. the stay to assure visibility to the rear with the rider • Turn sitting on the motorcycle, and tighten the locknut [C] securely. Adjust the rear view mirror by slightly moving only the mirror portion of the assembly. ○Installation and adjustment of the left side are common with the those of right side. Follow the procedure specified at the right side.
•
FRAME 15-27 Rear View Mirrors Rear View Mirror Installation (European Model)
the mounting area of the rear view mirror [A] into • Screw the holder [B] all the way, and tighten the lower hexagonal area [C] securely.
CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [A] with a pair of spanners or wrench. Disassembly of this area is not possible. Non-permanent locking agent [B] is already applied to the threads of this inner area. Forcible loosening may damage the adapter and/or the turning mechanism of the stay [C]. the stay [A] to assure visibility to the rear with the • Turn rider sitting on the motorcycle. the rear view mirror [B] by slightly moving only the • Adjust mirror portion of the assembly.
○Installation and adjustment of the left side are common with the those of right side. Follow the procedure specified at the right side.
15-28 FRAME Downtube Downtube Removal
the rear wheel [A] off the ground, using the jack [B], • Raise and the attachment jack [C] Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
• Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Cover Bolts [A] Cover [B] Front [C]
• Remove: Nut [A] Rear Brake Light Switch Connector [B]
the front exhaust pipe (see Exhaust Pipe Re• Remove moval in the Engine Top End chapter). • Pry the plastic clamps [A].
• Remove the regulator/rectifier bracket bolt [A].
FRAME 15-29 Downtube the engine with a commercially available stand • Supper [A]. • Remove: Bolt [B] Rear Brake Reservoir Cover [C] Right Front Footboard Bracket Bolt [D]
the rear brake reservoir [A]. • Remove Pry the plastic [B]. • Remove the rightclamp front [C] by taking off the bolt • [D] with brake pedal andfootboard rear master cylinder installed. • Remove: Engine Mounting Bracket Bolts [E] Downtube Bolt Caps and Bolts [F]
• Take off the brake hose [A] from the clamps [B].
Downtube Installation
the brake hose inside the downtube and clamp it. • Run Put left stoppers [A] of the radiator into the grom• mets [B]andof right the downtube. Tighten: •
Torque - Downtube Bolts: 59 N·m (6.0 kgf·m, 44 ft·lb) Engine Mounting Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
15-30 FRAME Frame Tandem Grip Removal/Installation
the left and right saddlebags (see Saddlebag Re• Remove moval in this chapter). • Remove: Bolts [A] (Both Sides) Back Rest [B]
• Remove: Tandem Grip Mounting Bolts [A] (Both Sides) •
Left and Right Tandem Grips [B] Tighten: Torque - Tandem Grip Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Frame Inspection
inspect the frame [A] for cracks, dents, bending, • Visually or warp. If there is any damage to the frame, replace it.
WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
ELECTRICAL SYSTEM 16-1
Electrical System Table of Contents Electrical Parts Location .................... Exploded View................................... Specifications .................................... Special Tools and Sealants ............... Wiring Diagram (United States and Canada) .......................................... Wiring Diagram (Australia) ................ Wiring Diagram (Other than United States, Canada and Australia)........ Servicing Precautions........................ Electrical Wiring................................. Wiring Inspection ......................... Battery ............................................... Battery Removal .......................... Battery Installation ....................... Battery Activation ......................... Precautions .................................. Interchange .................................. Charging Condition Inspection..... Refreshing Charge....................... Charging System ............................... Alternator Outer Cover Removal.. Alternator Outer Cover Installation ................................. Alternator Cover Removal/Installation.......................................... Alternator Cover Assembly .......... Alternator Inner Cover Removal .. Alternator Inner Cover Installation Alternator Rotor Removal ............ Alternator Rotor Installation ......... Alternator Outside Stator Removal .................................... Alternator Outside Stator Installation ................................. Alternator Inside Stator Removal . Alternator Inside Stator Installation ................................. Charging Voltage Inspection ........ Alternator Inspection .................... Regulator/Rectifier Removal ........ Regulator/Rectifier Installation ..... Regulator/Rectifier Inspection...... Regulator Inspection .................... Ignition System .................................. Ignition Coil Removal ...................
16-3 16-6 16-14 16-16 16-18 16-20 16-22 16-24 16-26 16-26 16-27 16-27 16-27 16-28 16-30 16-31 16-31 16-31 16-33 16-33 16-33 16-33 16-34 16-34 16-35 16-35 16-36 16-36 16-36 16-37 16-38 16-38 16-39 16-40 16-40 16-41 16-41 16-44 16-45
Ignition Coil Installation ................ Ignition Coil Inspection................. Spark Plug Removal .................... Spark Plug Installation ................. Spark Plug Cleaning/Inspection... Ignition Coil Primary Peak Voltage ...................................... Crankshaft Sensor Removal ........ Crankshaft Sensor Installation ..... Crankshaft Sensor Inspection...... Ignition Timing Inspection ............ Interlock Operation Inspection ..... IC Igniter Inspection ..................... Starter Motor...................................... Starter Motor Removal................. Starter Motor Installation.............. Starter Motor Disassembly........... Starter Motor Assembly ............... Brush Inspection .......................... Commutator Cleaning and Inspection.................................. Armature Inspection..................... Brush Assy Inspection ................. Brush Plate and Terminal Bolt Inspection.................................. Starter Relay Inspection............... Lighting System ................................. Headlight Beam Horizontal Adjustment ................................ Headlight Beam Vertical Adjustment ................................ Headlight Bulb Replacement ....... Headlight Body Removal ............. City Light Bulb Replacement (Other than US, CA and AU)..... Tail/Brake Light Removal/Installation ............................................ Tail/Brake Light Bulb Replacement ............................. Licence Plate Light Bulb Replacement ............................. Automatic Turn Signal Canceling System............................................ Wiring Inspection ......................... Distance Sensor Inspection ......... Turn Signal Switch Inspection......
16-45 16-46 16-47 16-47 16-47 16-47 16-49 16-49 16-49 16-51 16-51 16-53 16-56 16-56 16-56 16-56 16-57 16-58 16-59 16-59 16-59 16-60 16-60 16-62 16-62 16-62 16-62 16-63 16-64 16-64 16-64 16-65 16-67 16-67 16-68 16-68
16
16-2 ELECTRICAL SYSTEM Turn Signal Control Relay Inspection.................................. Turn Signal Light Removal/Installation.................. Turn Signal Light Bulb Replacement ............................. Radiator Fan System......................... Fan System Circuit Inspection ..... Fan Motor Inspection ................... Oil Pressure Warning System ........... Oil Pressure Light Delay Unit Removal ................................... Oil Pressure Light Delay Unit Inspection.................................. Meter, Gauge..................................... Meter Unit Removal ..................... Meter Unit Installation .................. Meter Unit Disassembly ............... Meter Unit Assembly.................... Meter Unit Inspection ................... LED Light Inspection.................... Indicator Light Inspection ............. Water Temperature Warning System. Water Temperature Warning System Check ........................... Switch and Sensors........................... Fuel Level Sensor Inspection....... Fuel Reserve Switch Inspection...
16-69 16-69 16-70 16-73 16-73 16-73 16-75 16-75 16-75 16-77 16-77 16-78 16-78 16-79 16-80 16-85 16-87 16-90 16-90 16-91 16-91 16-91
Speed Sensor Removal ............... Speed Sensor Installation ............ Speed Sensor Inspection............. Front Brake Light Switch Inspection.................................. Rear Brake Light Switch Check/Adjustment ..................... Radiator Fan Switch Removal ..... Radiator Fan Switch Installation .. Radiator Fan Switch Inspection ... Water Temperature Switch Removal .................................... Water Temperature Switch Installation ................................. Water Temperature Switch Inspection.................................. Switch Inspection ......................... Junction Box ...................................... Junction Box Fuse Circuit Inspection.................................. Starter Circuit/Headlight Relay Inspection.................................. Diode Circuit Inspection ............... Fuse................................................... Main Fuse Removal ..................... Junction Box Fuse Removal ........ Fuse Installation........................... Fuse Inspection............................
16-92 16-92 16-93 16-93 16-93 16-93 16-93 16-94 16-94 16-94 16-95 16-96 16-97 16-97 16-97 16-98 16-100 16-100 16-100 16-100 16-100
ELECTRICAL SYSTEM 16-3 Electrical Parts Location Left Handlebar Switches [A] Starter Lockout Switch [B] Ignition Switch [C] Front Brake Light Switch [D] Right Handlebar Switches [E] Meter Unit [F] Fuel Pump with Fuel Reserve Switch [G]
Water Temperature Sensor [A] Inlet Air Pressure Sensor [B] Vehicle-down Sensor [C] Throttle Sensor [D] Ignition Coil #2 [E]
Spark Plugs [A] ISC Valve #2 (for Rear Cylinder) [B] Inlet Air Temperature Sensor [C] ISC Valve #1 (for Front Cylinder) [D] Rear Brake Light Switch [E]
Starter Relay and Maine Fuse 30 A [A] Turn Signal Control Relay [B] DFI Maine Relay [C] Oil Pressure Light Delay Unit [D] Junction Box [E]
Diode [A] (in main harness) DFI Fuse 15 A [B] Self-diagnosis Terminal [C] ECU (Electronic Control Unit) [D] Battery [E]
16-4 ELECTRICAL SYSTEM Electrical Parts Location Atmospheric Pressure Sensor [A] Ignition Coil #1 [B] Frame Ground Terminal [C] Spark Plugs [D] Injectors [E]
Horn [A] Radiator Fan [B] Water Temperature Switch [C] Radiator Fan Switch [D] Starter Motor [E] Regulator/Rectifiers [F] Alternator [G] Crankshaft Sensors [H] Side stand Switch [I] Speed Sensor [A] Engine Ground Terminal [B] Neutral Switch [C] Oil Pressure Switch [D]
ELECTRICAL SYSTEM 16-5 Electrical Parts Location Dummy Page
16-6 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-7 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Fastener Alternator Cover Bolts Alternator Inner Cover Bolts Alternator Outer Cover Assembly Bolts Alternator Outer Cover Bolts Alternator Outer Cover Damper Bolts Alternator Outer Cover Joint Bolts Alternator Rotor Bolt Alternator Stator Bolts Crankshaft Sensor Lead Holder Bolt Crankshaft Sensor Screws Inside Stator Holder Bolts Neutral Switch Regulator/Rectifier Bolts Rotor Bolt Cap Spark Plugs Speed Sensor Mounting Bolt Stator Lead Holder Screw Timing Inspection Cap
N·m 11 11 6.9 6.9 6.9 6.9 78 13 2.9 2.9 11 15 6.5 1.5 18 9.8 11 1.5
Torque kgf·m 1.1 1.1 0.70 0.70 0.70 0.70 8.0 1.3 0.30 0.30 1.1 1.5 0.66 0.15 1.8 1.0 1.1 0.15
ft·lb 97 in·lb 97 in·lb 61 in·lb 61 in·lb 61 in·lb 61 in·lb 58 115 in·lb 26 in·lb 26 in·lb 97 in·lb 11 57 in·lb 13 in·lb 13 87 in·lb 97 in·lb 13 in·lb
19. Regulator/Rectifier EO: Apply engine oil. HG: Apply high temperature grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution to the threads. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) SI: Apply silicone grease. SS: Apply silicone sealant (Kawasaki Bond: 92104-0004). WL: Apply a soap and water solution or rubber lubricant.
Remarks
WL L L MO L L L
L L
16-8 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-9 Exploded View No. 1 2 3 4 5 6
Fastener Oil Pressure Switch Oil Pressure Switch Terminal Screw Radiator Fan Bolts Radiator Fan Switch Water Temperature Sensor Water Temperature Switch
N·m 15 1.5 8.3 18 18 7.8
7. Atmospheric Pressure Sensor 8. DFI Main Relay 9. ECU (Electronic Control Unit) 10. Horn 11. Inlet Air Pressure Sensor 12. Inlet Air Temperature Sensor 13. Junction Box 14. Oil Pressure Light Delay Unit 15. Starter Relay 16. Turn Signal Control Relay 17. Vehicle-Down Sensor G: Apply grease SS: Apply Silicone Sealant (Kawasaki Bond: 56019-120).
Torque kgf·m 1.5 0.15 0.85 1.8 1.8 0.80
ft·lb 11 13 in·lb 73 in·lb 13 13 69 in·lb
Remarks SS G
SS SS
16-10 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-11 Exploded View No. 1 2 3 4 5 6 7 8 9
Fastener Front Brake Light Switch Screw Fuel Level Sensor Mounting Bolts Fuel Pump Mounting Bolts Side Stand Switch Mounting Bolt Starter Lockout Switch Screw Starter Motor Assembly Bolts Starter Motor Mounting Bolts Starter Motor Terminal Locknut Starter Motor Terminal Nut
10. Starter Relay EO: Apply engine oil. L: Apply a non-permanent locking agent. S: Follow the specific tightening sequence. R: Replacement Parts
N·m 1.2 6.9 9.8 8.8 1.2 4.9 11 11 4.9
Torque kgf·m 0.12 0.70 1.0 0.90 0.12 0.50 1.1 1.1 0.50
ft·lb 11 in·lb 61 in·lb 87 in·lb 78 in·lb 11 in·lb 43 in·lb 97 in·lb 97 in·lb 43 in·lb
Remarks
L S L
16-12 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-13 Exploded View No. 1 2 3 4 5 6 7
Fastener Headlight Rim Screws Headlight Unit Bracket Screws Tail/Brake Light Assembly Screws Tail/Brake Light Lens Screws Tail/Brake Light Mounting Nuts Turn Signal Light Lens Screws Turn Signal Light Mounting Screws
N·m 2.9 1.0 1.2 1.2 5.9 1.0 6.9
8. City Light (Other than US, Canada and Australia Models) 9. Other than US and Canada Models 10. US and Canada Models 11. US Model 12. Canada Model 13. Australia Model 14. Other than US, Canada and Australia Models L: Apply a non-permanent locking agent.
Torque kgf·m 0.30 0.10 0.12 0.12 0.60 0.10 0.70
ft·lb 26 in·lb 8.9 in·lb 11 in·lb 11 in·lb 52 in·lb 8.9 in·lb 61 in·lb
Remarks
L
16-14 ELECTRICAL SYSTEM Specifications Item Battery Type Model Name Capacity Voltage Charging System Alternator Type Battery Charging Voltage Alternator Output Voltage (No Load) Stator Coil (Battery Charging Coil) Resistance Regulator/Rectifier: Type Resistance Ignition System Ignition Coil: 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage: Front Rear Spark Plug: Spark Plug Gap Spark Plug Cap Resistance Crankshaft Sensor: Crankshaft Sensor Peak Voltage: Front Rear Crankshaft Sensor Resistance Crankshaft Sensor Air Gap Electric Starter System Starter Motor: Brush Length Commutator Diameter Switch And Sensor Fuel Level Sensor Resistance
Standard Sealed Battery FTZ16-BS 12 V 18 Ah 12.6 V or more Three-phase AC with delta connection, and rare-earth single magnet rotor 14.2 ∼ 15.2 V @3 000 r/min (rpm) 60 ∼ 90 V @3 000 r/min (rpm) 0.33 ∼ 0.49 Ω
Load dumping regulator with full-wave rectifier in the text
6 mm (0.2 in.) or more 1.9 ∼ 2.9 Ω 18 ∼ 28 kΩ 208 V or more 192 V or more 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.) 3.75 ∼ 6.25 kΩ
2.2 V or more 2.0 V or more 380 ∼ 560 Ω 1.0 mm (0.04 in.) (Non-measurable and non-adjustable)
12 mm (0.47 in.) (Service limit 8.5 mm, 0.33 in.) 28 mm (1.10 in.) (Service limit 27 mm, 1.06 in.)
FULL position: 3 ∼ 5 Ω EMPTY position: 213 ∼ 219 Ω Rear Brake Light Switch Timing ON after about 10 mm (0.4 in.) pedal travel Engine Oil Pressure Switch Resistance When engine is stopped: ON When engine is running: OFF
ELECTRICAL SYSTEM 16-15 Specifications Item Radiator Fan Switch Resistance: Rising Temperature Falling Temperature
Standard From OFF to ON @102 ∼ 108°C (212 ∼ 226°F) From ON to OFF @97 ∼ 103°C (207 ∼ 217°F) ON: Less than 0.5 Ω OFF: More than 1 MΩ
Water Temperature Switch Resistance: Rising Temperature From OFF to ON: 113 ∼ 117°C (235 ∼ 243°F) Falling Temperature From ON to OFF: 108°C (226°F) ∼ temperature less than ON temperature ON: Less than 0.5 Ω OFF: More than 1 MΩ
• Refer to the Fuel System (DFI) chapter for specifications of DFI parts.
16-16 ELECTRICAL SYSTEM Special Tools and Sealants Spark Plug Wrench, Hex 18: 57001-1024
Flywheel Holder: 57001-1410
Jack: 57001-1238
Peak Volt Adapter: 57001-1415
Timing Light: 57001-1241
Filler Cap Driver: 57001-1454
Hand Tester: 57001-1394
Kawasaki Bond (Silicone Sealant): 56019-120
Attachment Jack: 57001-1398
Kawasaki Bond (Silicone Sealant): 92104-0004
ELECTRICAL SYSTEM 16-17 Special Tools and Sealants Dummy Page
16-18 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada)
ELECTRICAL SYSTEM 16-19 Wiring Diagram (United States and Canada)
16-20 ELECTRICAL SYSTEM Wiring Diagram (Australia)
ELECTRICAL SYSTEM 16-21 Wiring Diagram (Australia)
16-22 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada and Australia)
ELECTRICAL SYSTEM 16-23 Wiring Diagram (Other than United States, Canada and Australia)
16-24 ELECTRICAL SYSTEM Servicing Precautions There are a number of important precautions that should be followed servicing electrical systems. ○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 leads 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 leads 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 too 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). ○Wire 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 W: White Y: Yellow
ELECTRICAL SYSTEM 16-25 Servicing Precautions
○Electrical Connectors
Female Connectors [A]
Male Connectors [B]
16-26 ELECTRICAL SYSTEM 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 that the connectors are not loose. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the wire which is suspected of being a problem. ○Connect the hand tester between the ends of the wires.
• • •
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 wire or the wiring harness [B] if necessary.
ELECTRICAL SYSTEM 16-27 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch in ON, as this could damage the ECU (Electronic Control Unit). Never reverse the connections of the battery, this could damage the ECU. off the ignition switch. • Turn Remove the front seat (see Front Seat Removal in the • Frame chapter). • Disconnect: Fuel pump Connector [A]
•
Fuel Level Sensor Connector [B] Battery (–) Lead Connector [C] Rear Turn Signal/Taillight Lead Connector [D] Remove: DFI Fuse [E] Nuts [F] Battery Holder [G]
the black and red caps out. • Slide the negative (–) cable [A] from the battery first • Disconnect and then the positive (+) cable [B] from the battery.
CAUTION Be sure to disconnect the negative (–) cable first. Pull the battery [C] out of the case. Clean the battery using a solution of baking soda and water. Be sure that the wire connections are clean.
Battery Installation
inspect the surface of the battery container. • Visually If any sings of cracking or electrolyte leakage from the
•
sides of the battery. Face the (–) terminal forward [A] and put the battery into the battery case.
CAUTION Do not install the battery backwards. the positive cable [B] (red cap) to the (+) terminal • Connect first , and then the negative cable [C] (black cap) to the
• •
(–) terminal. Apply a light coat of grease on the terminals to prevent corrosion. Cover the terminals with the black and red caps.
CAUTION If each battery cable is not correctly disconnected or connected, sparks can arise at electrical connections, causing damage to electrical and DFI parts.
16-28 ELECTRICAL SYSTEM Battery the battery holder [A] on the battery. • Put Tighten • Connect:the nuts [B] securely. • Fuel Pump Connector (2-pin) [C]
•
Fuel Level Sensor Connector (3-pin) [D] Battery (–) Lead Connector [E] Rear Turn Signal/Taillight Lead Connector [F] Install: DFI Fuse [G] Front Seat (see Front Seat Installation in the Frame chapter)
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 for VN1600-D1: FTZ16-BS
CAUTION 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. This is to prevent overfilling of the electrolyte, shorting the battery life, and deterioration of the battery performance.
CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. 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.
ELECTRICAL SYSTEM 16-29 Battery 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 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. Keep the container in place for 20 minutes or more. Don’t remove the container from the battery until it’s empty, the battery requires all the electrolyte from the container for proper operation.
CAUTION Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the electrolyte container until it is completely empty and 20 minutes have elapsed. remove the container from the battery. • Gently Let the battery sit for 60 minutes prior to charging to allow • the electrolyte to permeate into the plates for optimum performance.
○Charging
NOTE
the battery immediately after filling can shorten service life. Let the battery sit for at least 60 minutes after filling.
Initial Charge Place the strip [A] of caps loosely over the filler ports. Newly activated sealed batteries require an initial charge.
• •
Standard Charge
1.8 A × 5 ∼ 10 hours
If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9
If the above chargers are not available, use equivalent one.
NOTE
○Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. If it is not at least 12.6 volts, repeat charging cycle.
16-30 ELECTRICAL SYSTEM Battery charging is completed, press down firmly with both • After hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery.
CAUTION Once the strip of the caps [A] is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery.
NOTE
○To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.6 volts repeat the charging cycle and load test. If still below 12.6 volts 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 this chapter). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.
CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced 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).
WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medial attention if severe.
ELECTRICAL SYSTEM 16-31 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if the sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
○Battery charging condition can be checked by measuring
• •
battery terminal voltage with a digital meter [A]. Remove the front seat (see Front Seat Removal in the Frame chapter). Disconnect the battery terminals (see Battery Removal in this section).
CAUTION 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 12.6 V or more, no refresh charge is required, however, if the read is below the specified, refresh charge is required. Battery Terminal Voltage 12.6 V or more Standard:
Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Refresh charge is required [C] Good [D]
Refreshing Charge
the battery [A] (see Battery Removal in this sec• Remove tion). refresh charge by following method according to the • Do battery terminal voltage.
WARNING This battery is sealed type. Never remove seal cap [B] even at charging. Never add water. Charge with current and time as stated below.
16-32 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.6 V Standard Charge 1.8 A × 5 ∼ 10 h (see following chart) Quick Charge
9A×1h
CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal Voltage: less than 11.5 V 1.8 A × 20 h Charging Method:
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
12.6 V or higher
Good
12.0 ∼ lower than 12.6 V
Charge insufficient → Recharge
lower than 12.0 V
Unserviceable → Replace
ELECTRICAL SYSTEM 16-33 Charging System Alternator Outer Cover Removal
• Remove: Left Front Footboard (see Front Footboard Removal/Installation in the Frame chapter) Front and Rear Shift Pedals (see Shift Pedal Removal in the Crankshaft/Transmission chapter) the bolts [A] and take off the alternator outer • Unscrew cover [B].
Alternator Outer Cover Installation
insert the upper edge [A] of the alternator outer • First, cover under the left crankcase ribs [B]. This prevents the
•
rib failure. Apply a soap and water solution or rubber lubricant to the body of the alternator outer cover bolts [C] for easy installation and tighten them. Torque - Alternator Outer Cover Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)
•
Front [D] Install: Front and Rear Shift Pedals (see Shift Pedal Installation in the Crankshaft/Transmission chapter) Left Front Footboard (see Front Footboard Removal/Installation in the Frame chapter)
Alternator Cover Removal/Installation
the alternator outer cover (see Alternator Outer • Remove Cover Removal in this section). the crankshaft sensor lead connector [A] and • Disconnect alternator lead connector [B].
16-34 ELECTRICAL SYSTEM Charging System
• Remove: Alternator Cover Bolts [A] Bracket [B] Alternator Cover [C]
the gasket with a new one. • Replace Apply silicone sealant to the area [A] to the crankshaft • sensor wire grommet [B]. Stator Lead Grommet [C] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Tighten the Alternator cover bolts.
Torque - Alternator Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
Alternator Cover Assembly
each shift shaft grease seal [A] with the lip [B] facing • Install inside the alternator cover [C] until the seal side is even
•
[D] with the end of the hole. Apply a little high temperature grease on the lips [E].
Alternator Inner Cover Removal
the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter). the jack [A] and the attachment jack [B], raise the • Using front and rear wheels just off the ground.
•
Frame Pipe Rib [C] Support the front part of the engine bottom [D], using a commercially available jack [E]. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
• Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Alternator Outer Cover (see Alternator Outer Cover Removal in this section) Alternator Cover (see Alternator Cover Removal/Installation in this section) Alternator Rotor (see Alternator Removal in this section) Front and Rear Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter)
ELECTRICAL SYSTEM 16-35 Charging System the front engine mounting bolt [A]. • Remove Loosen the rear engine mounting bolt [B]. • Disconnect the alternator lead connector [C]. •
up [A] the front part of the engine, using the jack until • Lift the lower part of the alternator inner cover clears the lower frame [B].
NOTE
○Turn the propeller shaft so that the engine can be raised as high as possible.
out the shift shaft [C] from the alternator inner cover. • Pull Unscrew • cover [E].the bolts [D] and take off the alternator inner
Alternator Inner Cover Installation
the gasket with a new one. • Replace Apply silicone sealant to the grommet and fit it into the • notch of the alternator inner cover. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Install the alternator inner cover.
Torque - Alternator Inner Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
the engine into its original position and tighten the • Move engine mounting bolts. Torque - Engine Mounting Bolts and Nuts: 44 N·m (4.5 kgf·m, 32 ft·lb)
• Install the removed parts (see appropriate chapters). Alternator Rotor Removal
the alternator cover (see Alternator Cover Re• Remove moval/Installation in this section). the alternator rotor [A] steady with the flywheel • Hold holder [B], and remove the rotor bolt [C]. Special Tool - Flywheel Holder: 57001-1410
the alternator rotor, • Take crankshaft.
washer, and ratchet off the
16-36 ELECTRICAL SYSTEM Charging System Alternator Rotor Installation
the alternator rotor [A] while fitting the alignment • Install notch [B] of the splines onto the alignment tooth [C].
molybdenum disulfide oil solution to the threads of • Apply the alternator rotor bolt.
○The molybdenum disulfide oil solution is a mixture of en-
•
gine oil and molybdenum disulfide grease with a weight ratio (10:1). Tighten: Torque - Alternator Rotor Bolt: 78 N·m (8.0 kgf·m, 58 ft·lb)
the alternator cover (see Alternator Cover Re• Install moval/Installation in this section).
Alternator Outside Stator Removal
the alternator cover [A] (see Alternator Cover • Remove Removal/Installation in this section). the crankshaft sensors [B] (see Crankshaft Sen• Remove sor Removal in this chapter). the Allen bolts [C] and take the stator [D] off the • Unscrew alternator cover.
Alternator Outside Stator Installation
a non-permanent locking agent to the threads of • Apply the alternator stator bolts. the stator [A] with the BK leads on the alternator • Install cover [B]. Torque - Alternator Stator Bolts: 13 N·m (1.3 kgf·m, 115 in·lb)
a non-permanent locking agent to the threads of • Apply the stator lead holder screw. • Install the stator lead holder [C] and tighten the screw [D].
Torque - Stator Lead Holder Screw: 9.8 N·m (1.0 kgf·m, 87 in·lb)
ELECTRICAL SYSTEM 16-37 Charging System up the dampers [A] and crankshaft sensor holders [B] • Set to the pickup coils [C].
the crankshaft sensors as shown. •○Install Crankshaft sensor [A] with shorter leads (BK and BK/Y)
for #1 (front). ○Crankshaft sensor [B] with longer leads (BK/W and BK/R) for #2 (rear). Torque - Crankshaft Sensor Screws: 2.9 N·m (0.30 kgf·m, 26 in·lb)
a non-permanent locking agent to the threads of • Apply the crankshaft sensor lead holder bolt.
○Run the longer crankshaft sensor leads over the shorter crankshaft sensor leads above the alternator leads.
Torque - Crankshaft Sensor Lead Holder Bolt: 2.9 N·m (0.30 kgf·m, 26 in·lb)
silicone sealant to the sides [H] of the grommets as • Apply shown, and fit the grommets into the notch of the alternator cover. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
○First, install the grommet [C] for the alternator leads, and
• •
then the grommet [D] for the crankshaft sensor leads with the round mark [E] up. Pull [F] the alternator leads and crankshaft sensor leads [G] outside the alternator cover, and reduce the slack of leads inside the cover as possible in order to prevent contact with the rotor. Apply silicone sealant to the mating surface [I] of the grommet. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
the outside alternator connector (BK leads) to • Connect the connector (Y leads) of the regulator/rectifire.
Alternator Inside Stator Removal
• Remove: Alternator Rotor (see Alternator Rotor Removal in this •
section) Alternator Inner Cover (see Alternator Inner Cover Removal in this section) Unscrew the inside stator holder bolts [A] and take the inside stator [B] and holder [C] off the left crankcase.
16-38 ELECTRICAL SYSTEM Charging System Alternator Inside Stator Installation
a non-permanent locking agent to the threads of • Apply the inside stator holder bolts. the inside stator with the BK leads on the left • Install crankcase. Torque - Inside Stator Holder Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
silicone sealant to the grommet and fit it into the • Apply notch of the alternator inner cover. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
the inside alternator connector (BK leads) to the • Connect connector (Y/BK leads) of the regulator/rectifier.
Charging Voltage Inspection
the battery condition (see Charging condition In• Check spection in this chapter). up the engine to obtain actual alternator operating • Warm conditions. the front seat (see Front Seat Removal in the • Remove Frame chapter). that the ignition switch is turned off, and connect • Check the hand tester to the battery as shown in the table. Special Tool - Hand Tester: 57001-1394 Battery Charging Voltage Connections
Tester Range
Tester (+) to
Tester (–) to
Reading @3 000 rpm
25 V DC
Battery (+)
Battery (–)
14.2 ∼ 15.2 V
on the ignition switch and start the engine, and note • Turn the voltage readings at various engine speeds with the
•
headlight turned on and then turned off (To turn off the headlight, disconnect the headlight connector in 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. Turn off the ignition switch to stop the engine, and disconnect 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 output 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 battery 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.
ELECTRICAL SYSTEM 16-39 Charging System Alternator Inspection There are three types of alternator failures: short, open (lead burned out), or loss in rotor magnetism. A short or open in one of the stator coil lead 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.
○Remove the alternator outer cover and disconnect the outside alternator connector [A].
○Connect the hand tester to the outer as shown. Special Tool - Hand Tester: 57001-1394
○Start the engine. ○Run it at 3 000 rpm of the engine speed. ○Note the voltage readings. Alternator Output Voltage Tester Range
Connections Tester (+) to
Tester (–) to
250 V AC One black lead Another black lead
Reading @3 000 rpm 60 ∼ 90 V
If the output voltage shows the value in the table, the alternator operates properly and the regulator/rectifier is damaged. A much lower reading than the value in the table indicates that the alternator is defective. ○Repeat the test for the other black leads. Hand Tester [A] the stator coil resistance as follows: •○Check Stop the engine.
○Connect the hand tester [A] to the connector as shown in the table. ○Note the resistance readings. Stator Coil Resistance Tester Range ×1 Ω
Connections Tester (+) to
Tester (–) to
Reading
One black lead Another black lead 0.33 ∼ 0.49 Ω
If there is more resistance than shown in the table, or no hand tester reading (infinity), the stator has an open wire 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 coil has 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. ○Repeat the test for the other black leads. ○Repeat the test for the inside alternator connector.
•
16-40 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal
• Remove: Alternator Outer Cover (see Alternator Outer Cover Removal in this section) Regulator/Rectifier Lead Connectors [A]
• Remove: Regulator/Rectifier Bolts [A] Regulator/Rectifiers [B]
Regulator/Rectifier Installation
the regulator/rectifier leads according to the Cable, • Run Wire, and Hose Routing section in the Appendix chapter. • Tighten: Torque - Regulator/Rectifier Bolts: 6.5 N·m (0.66 kgf·m, 57 in·lb)
ELECTRICAL SYSTEM 16-41 Charging System Regulator/Rectifier Inspection
the alternator outer cover (see Alternator Outer • Remove Cover Removal in this section). the rectifier resistance as follows. • Check Disconnect regulator/rectifier connector. • Connect thethe hand (special tool) to the regulator/rec• tifier as shown in tester the table, and check the resistance in both directions of each diode in the rectifier following the table. The resistance should be low in one direction and more than ten times as much in the other direction. If any two wires are low or high in both directions, the rectifier is defective and the regulator/rectifier must be replaced.
NOTE
○The actual tester reading varies with the hand tester
used and the individual rectifier, but, generally speaking, the lower reading should be from zero to one half the scale.
Rectifier Circuit Inspection No.
Connections Tester (+) to
1
BK1
2
BK2
3
BK3
4
BK1
5
BK2
6
BK3
Tester (–) to
7 8
BK/BL
9
BK3 BK1 BK/W
12
Range
× 10 Ω 1/2 scale
or × 100 Ω
BK2
10 11
Tester
∞
BK/W BK1
BK/BL
Reading
BK2
∞
BK3
• Repeat the test for another regulator/rectifier. Regulator Inspection
○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).
CAUTION The test light works as an indicator and also as a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of a test light.
16-42 ELECTRICAL SYSTEM Charging System the 1st step regulator circuit test. •○Do Connect the test light and the 12 V battery to the regula-
tor/rectifier as shown. ○Check BK1, BK2, BK3 terminals 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 “1st step regulator circuit test”. ○Apply 12 V to the BK/R terminal. ○Check BK1, BK2, and BK3 terminals 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 “1st step regulator circuit test”. ○Momentarily apply 24 V to the BK/R terminal by adding a 12 V battery. ○Check BK1, BK2, and BK3 terminals respectively.
CAUTION Do not apply more than 24 volts. If more than 24 volts is applied, the regulator/rectifier may be damaged. Do not apply 24 V more than a few seconds. If 24 volts is applied for more than a few seconds, the regulator/rectifier may be damaged.
•
If the test light does not light when 24 V is applied momentarily to the BK/R terminal, the regulator/rectifier is defective. Replace it. If the regulator/rectifier passes all the tests described, it may still be defective. If the charging system still does not work properly after checking all the components and the battery, test the regulator/rectifier by replacing it with a known good unit. Repeat the test for another regulator/rectifier.
ELECTRICAL SYSTEM 16-43 Charging System Charging System Circuit
1. Ignition Switch 2. Alternator #2 (inside stator) 3. Regulator/Rectifier #2 4. Alternator #1 (outside stator) 5. Regulator/Rectifier #1 6. Battery 7. Joint Connector 2 8. Main Fuse 30 A 9. Starter Relay 10. Load
16-44 ELECTRICAL SYSTEM Ignition System
ELECTRICAL SYSTEM 16-45 Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs, ignition coils, or spark plug high-tension cables while the engine is running, or you could receive a severe electrical shock.
CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent IC igniter damage in the ECU. Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the IC igniter in the ECU and the diodes.
Ignition Coil Removal
fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). • Remove: Clamps [A] Primary Leads Ignition Coil Mounting Nuts [B] Frame Ground Lead [C] Ignition Coil #1 [D] Front [E]
• Remove: Clamps [A] Primary Leads Ignition Coil Mounting Nuts [B] Ignition Coil #2 [C] Front [D]
Ignition Coil Installation
the primary leads to the ignition coil terminals • Connect and run the high-tension cables according to the Cable,
•
Wire, and Hose Routing section in the Appendix chapter. Install the frame ground lead [A] to the rear mounting bolt of the ignition coil #1.
16-46 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection
the ignition coils (see Ignition Coil Removal in • Remove this chapter). the arcing distance with a commercially avail• Measure able coil tester [A] to check the condition of the ignition
•
coil [B]. Connect the ignition coil (with the spark plug cap left attached at the end of the spark plug terminal) to the tester in the manner prescribed by the manufacturer and measure the arcing distance. 3 Needle Arcing Distance Standard: 6 mm (0.2 in.) or more
WARNING To avoid extremely high voltage shocks, do not touch the coil body or leads.
•
If the distance reading is less than the specified value, the ignition coil or spark plug caps are defective. To determine which part is defective, measure the arcing distance again with the spark plug caps removed from the ignition coil. Remove the caps by turning them counterclockwise. If the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing distance is now normal, the trouble is with the spark plug cap. If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with the hand tester. Special Tool - Hand Tester: 57001-1394
NOTE
○The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. the primary winding resistance 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 as follows. •○Measure Remove the plug caps by turning them counterclockwise.
○Connect the tester between the spark plug High-Tension cables.
○Set the tester to the × 1 kΩ range and read the tester. Measure primary winding resistance [A]. Measure secondary winding resistance [B]. Ignition Coil [C]
Ignition Coil Winding Resistance Primary Windings: 1.9 ∼ 2.9 Ω Secondary Windings:
18 ∼ 28 kΩ
If the tester does not read as specified, replace the coil.
○To install the plug cap, turn it clockwise.
ELECTRICAL SYSTEM 16-47 Ignition System Spark Plug Removal
the spark plug caps. • Remove Remove • wrench. the spark plugs using the 18 mm (0.7 in.) plug Special Tool - Spark Plug Wrench, Hex 18: 57001-1024
Spark Plug Installation
the spark plug vertically into the plug hole with the • Insert plug installed in the plug wrench [A]. • Tighten the plugs. Special Tool - Spark Plug Wrench, Hex 18: 57001-1024 Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)
• Fit the plug caps securely.
Spark Plug Cleaning/Inspection
the spark plug, preferably in a sandblasting device, • Clean and then clean off any abrasive particles. The plug may
• •
also be cleaned using a high-flash point solvent and a wire brush or other tool. If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug. Use the standard spark plug or its equivalent. Measure the gap [D] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode with a tool to obtain the correct gap. Spark Plug Gap:
0.8 ∼ 0.9 mm (0.03 ∼ 0.03 in.)
Ignition Coil Primary Peak Voltage NOTE
○Be sure the battery is fully charged.
the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). all the spark plug caps but do not remove the • Remove spark plugs. new spark plugs into all the spark plug caps, and • Install ground them onto the engine.
16-48 ELECTRICAL SYSTEM Ignition System a commercially available peak voltage adapter [A] • Install into the hand tester [B]. the adapter between the ignition coil primary wire • Connect terminal and the engine ground with the primary lead left connected. Special Tool-Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Brand:
KOWA SEIKI
○Insert the adapter probe into the terminal of the primary lead [C]. ECU [D] Battery [E] Ignition Coil [F] New Spark Plug [G]
Special Tool - Hand Tester: 57001-1394 Hand Tester Range:
DC 1 000 V
Primary Lead Connections: Adapter (R, +)
Adapter (BK, –)
Front Ignition Coil:
BK
←→
Ground
Rear Ignition Coil:
BK/G
←→
Ground
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 Pushing starter button, turn the engine 4 ∼ 5 seconds • with the the transmission in neutral to measure the primary
•
peak voltage. Repeat the measurements 5 or more times for one ignition coil. Ignition Coil Primary Peak Voltage Standard: Front:
208 V or more
Rear:
192 V or more
the test for the other ignition coil. • Repeat If the reading is less than the specified value, check the following: Ignition Coils (see Ignition Coil Inspection in this section) Crankshaft Sensors (see Crankshaft Sensor Inspection in this section) If the ignition coils and crankshaft sensors are normal, check the ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter).
ELECTRICAL SYSTEM 16-49 Ignition System Crankshaft Sensor Removal
the alternator cover [A] (see Alternator Cover • Remove Removal/Installation in this chapter). the holder bolt [B] and take off the crankshaft • Unscrew sensor lead holder [C]. the screws [D] and take off the crankshaft sen• Unscrew sors with the grommet [E].
Crankshaft Sensor Installation
• Refer to the Alternator Stator Installation in this chapter. Crankshaft Sensor Inspection
the alternator outer cover (see Alternator Outer • Remove Cover Removal in this chapter). all the spark plug caps but do not remove the • Remove spark plugs. • Disconnect the crankshaft sensor lead connector [A].
a commercially available peak voltage adapter • Connect [A] to the hand tester [B]. Special Tool- Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Brand:
KOWA SEIKI
Special Tool - Hand Tester: 57001-1394
the adapter probes into the connector [C] of the • Insert crankshaft sensor [D] as shown. Connections: Adapter
Adapter
(R, +)
(BK, –)
Front Crankshaft Sensor:
BK/Y ←→
BK
Rear Crankshaft Sensor:
BK/R ←→
BK/W
16-50 ELECTRICAL SYSTEM Ignition System NOTE
○Be sure the battery is fully charged. Hand Tester Range:
DC 10 V
the ignition switch and the engine stop switch ON. • Turn Pushing the starter button, turn the engine 4 ∼ 5 seconds • with the transmission in neutral to measure the crankshaft
• •
sensor peak voltage. Repeat the measurements 5 or more times for one crankshaft sensor. Repeat the test for the other crankshaft sensor. Crankshaft Sensor Peak Voltage Standard: Front
2.2 V or more
Rear
2.0 V or more
If the reading is less than the specified value, replace the crankshaft sensor. If the reading is normal, check the ECU (see ECU Power Supply Inspection Fuel System (DFI) chapter). If the peak voltage adapter is not available, the coil can be checked for a broken or badly shorted winding with the hand tester (special tool).
NOTE
○Using the peak voltage adapter is a more reliable way
to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements.
• Disconnect the crankshaft sensor lead connector. Set the hand tester [A] to the × 100 Ω range and wire it to • the crankshaft sensor lead connector [B]. Connections: Tester Connections Front Crankshaft Sensor:
BK/Y
←→
BK
Rear Crankshaft Sensor:
BK/R
←→
BK/W
If there is more resistance than the specified value, the coil has an open wire and must be replaced. Much less than this resistance means the coil is shorted, and must be replaced. Crankshaft Sensor Resistance: Standard: 380 ∼ 560 Ω
the highest resistance range of the tester, measure • Using 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 assy.
ELECTRICAL SYSTEM 16-51 Ignition System Ignition Timing Inspection
the alternator outer cover (see Alternator Outer • Remove Cover Removal in this chapter). • Remove the timing inspection cap [A]. Special Tool - Filler Cap Driver: 57001-1454
the timing light [A] to the front ignition coil lead in • Attach the manner prescribed by the manufacturer. Special Tool - Timing Light: 57001-1241
the engine and aim the timing light at the ignition • Start timing mark on the alternator rotor. the engine at the speeds specified and note the align• Run ment of the ignition timing marks.
Ignition Timing Engine speed r/min (rpm) 950
•
Hole notch [A] aligns with: F or R mark [B] on alternator rotor
F Mark: for Front Cylinder R Mark: for Rear Cylinder Repeat the test for the rear cylinder, using the rear ignition coil lead. If the ignition timing is incorrect, check the crankshaft sensor (see Crankshaft Sensor Inspection in this section). If the crankshaft sensor are normal, check the ECU (see ECU Power Supply in the Fuel System (DFI) chapter).
Interlock Operation Inspection
the rear wheel off the ground (see Rear Wheel Re• Raise moval in the Wheels/Tires chapter). the right side cover (see Right Side Cover Re• Remove moval in the Frame chapter).
○Do not disconnect the connectors [A].
16-52 ELECTRICAL SYSTEM Ignition System 1st Check Measure the terminal voltage of the R/W lead in the junction box connector [A] in accordance with the following procedure. ○Set the tester [B] to the 10 V DC range, connect it to the R/W lead and frame ground [C].
•
Connection: Tester (+) Terminal → R/W Lead Terminal Tester (–) Terminal → Frame Ground Condition: Transmission Gear → 1st Position Clutch Lever → Release Side Stand → Down
○Turn the ignition switch on. ○Read the voltage. Interlock Operation Voltage Standard: 4 V or more
If the voltage is lower than the standard, inspect the side stand switch, starter lockout switch, gear position switch and junction box. If their parts are normality, replace the ECU. If the voltage is standard, push the starter button. ○Then the starter motor should not turn when the starter system circuit is normality. If the starter motor turned, ECU is defective. Replace the ECU. 2nd Check Inspect the engine for its secure stop after the following operations are completed. Run the engine to the following conditions.
• •
Condition: Transmission Gear → 1st Position Clutch Lever → Release Side Stand → Up
the side stand on the ground, then the engine will • Set stop. If whichever may not be stopped, inspect the gear position switch, starter lockout switch, side stand switch and junction box. If their parts are normality, replace the ECU.
ELECTRICAL SYSTEM 16-53 Ignition System IC Igniter Inspection
○The IC igniter is built in the ECU [A].
•
Damper [B] Battery Case [C] Groove [D] Front [E] Refer to the Fuel System (DFI) chapter for ECU Inspection.
16-54 ELECTRICAL SYSTEM Ignition System
ELECTRICAL SYSTEM 16-55 Ignition System Ignition System Circuit
1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Ignition Coil #1 (front cylinder) 6. Ignition Coil #2 (rear cylinder) 7. Crankshaft Sensor #1 (front cylinder)
8. Crankshaft Sensor #2 (rear cylinder) 9. DFI Fuse 15 A 10. DFI Main Relay 11. Frame Ground 12. Vehicle-down Sensor 13. Throttle Sensor 14. Electronic Control Unit 15. Joint Connector 2 16. Main Fuse 30 A
17. Battery 18. Junction Box 19. Ignition Fuse 10 A 20. Starter Circuit Relay 21. Interlock Diodes 22. Starter Lockout Switch 23. Side Stand Switch 24. Diode 25. Neutral Switch
16-56 ELECTRICAL SYSTEM Starter Motor Starter Motor Removal
• Remove: Radiator (see Radiator Removal in the Cooling System chapter) Starter Motor Bolts [A]
• Remove the starter motor terminal nut [A] and cable [B]. CAUTION
Never drop the starter motor, especially on a hard surface. Such a shock to the motor can damage it.
Starter Motor Installation CAUTION 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 O-ring [A] with a new one. • Replace Apply a small amount of engine oil to the O-ring. •
Torque - Starter Motor Mounting Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Starter Motor Terminal Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
Starter Motor Disassembly
the starter motor (see Starter Motor Removal in • Remove this section). off the starter motor assembly bolts [A] and remove • Take both end covers [B] and pull the armature out of the yoke.
ELECTRICAL SYSTEM 16-57 Starter Motor the positive carbon brushes [B] out of the brush hold• Take ers [A]. • Take off the brush plate [C] with brush wire from the yoke.
the terminal locknut [B] and remove the terminal • Unscrew bolt [A]. the positive carbon brushes and wire assy [C] out of • Take the yoke.
NOTE
○Do not remove the negative carbon brushes [A] from the brush plate [B].
Starter Motor Assembly
the springs [A] with plastic washers [B], insert the • Holding brushes.
○Fit the brush wire into the holder groove.
• Align the tang [C] with the terminal bolt [D].
the armature [A] among the brushes, and remove the • Put plastic washers [B].
16-58 ELECTRICAL SYSTEM Starter Motor the tang [A] of the brush plate into the left end cover • Fit groove [B].
a thin coat of grease to the oil seal [B] in the right • Apply end cover [A].
a thin coat of grease to the left bearing [A]. • Apply Fit shims onto the right end cover. •
○The line on the yoke should align [A] with the line on the left cover.
Torque - Starter Motor Assembly Bolts: kgf·m, 43 in·lb)
4.9 N·m (0.50
Brush Inspection
the length [A] of each brush. • Measure If any is worn down to the service limit, replace the carbon brush holder assy [B] and the terminal bolt assy [C]. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit:
8.5 mm (0.33 in.)
ELECTRICAL SYSTEM 16-59 Starter Motor Commutator Cleaning and Inspection
the commutator surface [A] if necessary with fine • Smooth emery cloth [B], and clean out the grooves.
the diameter [A] of the commutator [B]. • Measure Replace the starter motor with a new one if the commutator diameter is less than the service limit. Commutator Diameter Standard: 28 mm (1.10 in.) Service Limit:
27 mm (1.06 in.)
Armature Inspection
the × 1 Ω hand tester range, measure the resis• Using tance between any two commutator segments [A].
•
If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced. 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. Special Tool - Hand Tester: 57001-1394
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 components 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 Assy Inspection
the × 1 Ω hand tester range, measure the resis• Using tance as follows. Terminal Bolt and Positive Brushes [A] Brush Plate and Negative Brushes [B] Plastic [C] ○The reading should be zero. If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assembly and the brush holder assembly.
16-60 ELECTRICAL SYSTEM Starter Motor Brush Plate and Terminal Bolt Inspection
the highest hand tester range, measure the resis• Using tance as shown. Terminal Bolt and Brush Plate [A] Terminal Bolt and Negative Brush Holders [B] Terminal Bolt and Yoke [C] ○The reading should be infinite (∞ Ω). If there is any reading, the brush holder assembly and/or terminal bolt assembly have a short. Replace the brush holder assembly and the terminal bolt assembly.
Starter Relay Inspection
the right side covers (see Right Side Cover Re• Remove moval in the Frame chapter). the coolant reserve tank, then the starter relay. • Remove the hand tester [A] and 12 V battery [B] to the • Connect starter relay [C] as shown. If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: × 1 Ω range Criteria:
When battery is connected → 0 Ω When battery is disconnected → ∞ Ω
ELECTRICAL SYSTEM 16-61 Starter Motor Electric Starter Circuit
1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Junction Box 5. Starter Circuit Relay 6. Ignition Fuse 10 A 7. Starter Lockout Switch 8. Side Stand Switch 9. Diode 10. Neutral Switch 11. Starter Motor 12. Starter Relay 13. Main Fuse 30 A 14. Battery 15. Joint Connector 2
16-62 ELECTRICAL SYSTEM Lighting System This model adopts the daylight system and has a headlight relay in the junction box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even if the engine stalls. The headlight goes out when the ignition switch is turned off. It also goes out while the starter button is depressed.
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 the headlight rim screws [A] on both sides.
the headlight unit [A] and drop it out. • Pull Pull the headlight connector [B]. • Remove the headlight dust cover [C]. •
• Push the hook [A] to unlock.
ELECTRICAL SYSTEM 16-63 Lighting System
• Take out the bulb [A].
CAUTION
When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.
○Clean off any contamination that inadvertently gets on the bulb with alcohol or a soap and water solution.
the headlight bulb. • Replace the dust cover [A] with the TOP mark [B] upward onto • Fit the bulb [C] firmly as shown.
•
Good [D] Bad [E] Tighten: Torque - Headlight Rim Screws: 2.9 N·m (0.30 kgf·m, 26 in·lb)
installation, adjust the headlight aim (see Headlight • After Beam Horizontal/Vertical Adjustment in this section).
Headlight Body Removal
the headlight rim screws [A] on both sides. • Remove Pull the headlight unit [B] and drop it out. •
• Remove: Rubber Cover [A] Clamp [B] Connectors [C]
the headlight body bolts [A], then take off the • Remove body [B].
16-64 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement (Other than US, CA and AU) US: United States Model CA: Canada Model AU: Australia Model the headlight unit (see Headlight Body Removal • Remove in this section). • Pull out the socket [A] together with the bulb. the wedge-base type bulb [A], pull the bulb • Remove straight out of the socket [B]. • Replace the bulb with a new one.
CAUTION
Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified value.
Tail/Brake Light Removal/Installation
the rear fender (see Rear Fender Removal in the • Remove Frame chapter). over the rear fender, and remove the cover bolts [A] • Turn and cover [B].
the tail/brake light lead connector [A]. • Disconnect Remove the nuts [B]. • Remove the tail/brake light from the rear fender. • Tighten: •
Torque - Tail/Brake Light Mounting Nuts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Tail/Brake Light Bulb Replacement
the screws [A] in the taillight lens. • Unscrew Pull the lens [B] off. •
ELECTRICAL SYSTEM 16-65 Lighting System the bulb [A] in, turn it counterclockwise [B], and pull • Push it out. • Replace the bulb with a new one.
the front pin [A] up and the rear pin [B] down, insert • With the new bulb by aligning the front pin with the left groove
• •
[C] in the walls of the socket [D]. Push the bulb in, turn it clockwise, and release it. It should lock in position. Tighten: Torque - Tail/Brake Light Lens Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb)
Licence Plate Light Bulb Replacement
the licence plate light lens screws [A] and take • Remove off the lens [B].
the wedge-base type bulb [A], pull the bulb • Remove straight out of the socket [B].
CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified value.
16-66 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit
1. Ignition Switch 2. Alternator 3. Headlight Relay 4. Headlight Fuse 10 A 5. Taillight Fuse 10 A 6. Junction Box 7. High Beam Indicator Light 8. Headlight 9. License Plate Light 10. Tail/Brake Lights 11. Frame Ground 12. Joint Connector 2 13. Joint Connector 1 14. Dimmer Switch 15. Starter Relay 16. Main Fuse 30 A 17. Battery 18. Running Position Lights (US and Canada Models) 19. City Light (Other than US, Canada and Australia Models)
ELECTRICAL SYSTEM 16-67 Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles. So, motorcycles adopt time & distance counting system. The canceling system consists of a battery, turn signal control relay, distance sensor, and turn signal switch. When the turn signal switch is pushed onto the right or left, the turn signals start flashing and the control relay starts counting off 8 seconds. At the end of this time, the control relay starts calculating distance traveled using pulses from the distance sensor in the speedometer. The control relay keeps working even after the tern signal switch was released and returned to the neutral position by spring force. When the motorcycle has traveled an additional 65 meters (213 foots), the control relay shuts off the current, turns off the turn signal lights, and resets itself. If the turn signal canceling system does not function properly, first check all the wiring connections carefully. Secondly, inspect the distance sensor. Thirdly, inspect the turn signal switch in the left handlebar switch. Lastly, check the turn signal control relay.
• • •
Wiring Inspection
all the connectors. • Connect • Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) Coolant Reservoir Tank (see Coolant Change in the Periodic Maintenance chapter) Remove the turn signal control relay [A]. Pull off the 6-pin connector of the relay, the 9-pin and 4-pin meter connectors in the headlight housing, and the 9-pin left handlebar switch connector under the fuel tank. Make sure all connector terminals are clean and tight, and none of them have been bent. ○Clean the dirty terminals, and straighten slightly-bent terminals. Check conductivity or voltage of the numbered terminals with the hand tester. ○The terminal numbers are shown in the wiring diagram of Turn Signal Canceling System.
• • • •
Special Tool - Hand Tester: 57001-1394 Wiring Inspection Connectors
Tester Connection
Turn Signal Control Relay
1 - 8
←→ Distance Sensor
3 - 7
Turn Signal Control Relay
2 - 11
←→ Left Handlebar Switch
Tester Reading
0 Ω
3 -9 4 - 10
Turn Signal Control Relay ←→ Battery
6Battery (+)
Battery Voltage with IG. Switch. ON 0 V with IG. Switch. OFF
IG. Switch: Ignition Switch
16-68 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System If any one of the hand tester readings shows an improper values, check the wiring and connections of the turn signal switch, distance sensor, and turn signal control relay. Check the turn signal control relay (see Turn Signal Control Relay Inspection in this section) if all of them turn out good.
Distance Sensor Inspection Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) Coolant Reservoir Tank (see Coolant Change in the Periodic Maintenance chapter) Remove the turn signal control relay [A]. ○Do not disconnect the connector [B]. Use the jack and the attachment jack to lift the rear wheel (see Rear Wheel Removal in the Wheel/Tires chapter).
• •
Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
the hand tester to the DC25 V range and connect it • Set to the LB lead terminal [A] and battery (–) terminal [B] as shown. Connections Hand Tester (+) → LB Lead Terminal Hand Tester (–) → Battery (–) Terminal
all the spark plugs and shift the gear into 1st. • Remove Turn the rear wheel slowly to see that the tester’s pointer • fluctuates repeated by reading 0.5 V and 12 V. If the tester’s pointer fluctuates, distance sensor is normal. If the tester’s pointer does not fluctuate, inspect the speed sensor and turn signal control relay. If the speed sensor and control relay are good, replace the digital meter assembly.
Turn Signal Switch Inspection
the headlight housing (see Headlight Body Re• Open moval in this chapter). the 9-pin connectors that leads to the left handle• Unplug bar switch. the turn signal switch connections according to the • Check table. If the switch has an open circuit or a short, it can be disassembled for repair. The contact surfaces may be cleaned, but no internal parts are available for replacement. If any parts are not repairable, the left handlebar switch must be replaced as a unit. Turn Signal Switch Connections
ELECTRICAL SYSTEM 16-69 Automatic Turn Signal Canceling System Turn Signal Control Relay Inspection CAUTION Never drop the turn signal control relay, especially on a hard surface. Such a shock to the unit can damage it.
• Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) Reservoir Tank (see Coolant Change in the Periodic Maintenance chapter) 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 Control Relay Connector [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn signal control relay. Testing Turn Signal Control Relay Inspection Load The Number of Turn Signal Lights
Wattage (W)
Flashing Times (c/m*)
1**
21 ∼ 23
140 ∼ 250
2
42 ∼ 46
75 ∼ 95
(*): Cycle(s) per minute (**): corresponds to “one light burned out, and the other lights stay ON”.
NOTE
○Even if the foregoing checks show the turn signal con-
trol relay to be good, it may be defective in some manner especially for automatic turn signal canceling operation not readily detectable with above checks. If all other checks are good, replace the turn signal control relay.
Turn Signal Light Removal/Installation
front turn signal light removal, remove the headlight • For unit (see Headlight Removal in this chapter). • Disconnect the connectors [A].
16-70 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System
• Remove: Front Turn Signal Light Bracket Bolts [A] Front Turn Signal Light Assy [B]
rear turn signal light removal, remove the rear fender • For (see Rear Fender Removal in the Frame chapter). over the rear fender, and remove the cover bolts [A] • Turn and cover [B].
the connectors [A]. • Disconnect Remove the turn signal light bracket bolts [B]. • Remove therear rear turn signal light assy from the rear • fender.
the turn signal light mounting screws [A]. • Remove Remove the • Tighten: turn signal light [B] from the bracket [C]. •
Torque - Turn Signal Light Mounting Screws: 6.9 N·m (0.70 kgf·m, 61 in·lb)
Turn Signal Light Bulb Replacement
the turn signal light lens screw [A] and take off • Remove the lens [B].
ELECTRICAL SYSTEM 16-71 Automatic Turn Signal Canceling System the bulb [A] in the socket and turn the bulb counter• Push clockwise [B]. • Replace the bulb with a new one.
the new bulb [A] by aligning the pins [B] with the • Insert groove in the walls of the socket [C].
the projection [A] in the recess [B] of the lens. • Fit Tighten: •
Torque - Turn Signal Light Lens Screws: 1.0 N·m (0.10 kgf·m, 8.7 in·lb)
16-72 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Turn Signal Cancelling System Circuit
1. Ignition Switch 2. Junction Box 3. Turn Signal Control Relay Fuse 10 A 4. Turn Signal Control Relay 5. Meter Unit 6. Distance Sensor 7. Turn Signal Indicator Light 8. Front Left Turn Signal Light 9. Front Right Turn Signal Light 10. Rear Left Turn Signal Light 11. Rear Right Turn Signal Light 12. Turn Signal Switch 13. Joint Connector 1 14. Joint Connector 2 15. Main Fuse 30 A 16. Battery
ELECTRICAL SYSTEM 16-73 Radiator Fan System WARNING The radiator fan is connected directly to the battery. The fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
Fan System Circuit Inspection
• Remove: Bolts [A]
Regulator/Rectifier Bracket [B]
• Disconnect the radiator fan switch connector [A].
an auxiliary lead [A], connect the radiator fan switch • Using connector [B]. Radiator Fan Switch [C] If the fan rotates, inspect the fan switch (see Radiator Fan Switch Inspection in this chapter). If the fan does not rotate, inspect the following. Leads and Connectors Main Fuse 30 A and Fan Fuse 15 A (see Fuse Inspection in this chapter) Fan Motor (see Fan Motor Inspection in this section)
Fan Motor Inspection
the connector [A] from the radiator fan switch • Disconnect [B]. an auxiliary lead [C], supply battery power to the • Using fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Battery [D]
16-74 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit
1. Radiator Fan 2. Radiator Fan Switch 3. Junction Box 4. Fan Fuse 15 A 5. Main Fuse 30 A 6. Battery
ELECTRICAL SYSTEM 16-75 Oil Pressure Warning System Motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead flicker of the oil pressure warning light because of too rapid response of the oil pressure switch. To improve this operation, the oil pressure light delay unit is adopted, which prevents flicker of the oil pressure warning light by delaying its lighting.
Oil Pressure Warning System Circuit
1. Ignition Switch 2. Junction Box 3. Ignition Fuse 10 A 4. Oil Pressure Light Delay Unit 5. Main Fuse 30 A
6. Battery 7. Oil Pressure Switch 8. Meter Unit 9. Oil Pressure Warning LED Light
Oil Pressure Light Delay Unit Removal
• Remove: Coolant Reservoir Right Side Cover (see Right Side •
Cover Removal in the Frame chapter) Coolant Reservoir Tank (see Coolant Change in the periodic Maintenance chapter) Pull the connectors out of the oil pressure light delay unit [A].
Oil Pressure Light Delay Unit Inspection
the lead [A] of the oil pressure switch [B], and • Disconnect ground [C] it to the engine, using an auxiliary wire. the ignition switch [D] ON. • Turn If the oil pressure warning LED light [E] in the meter unit is lit, check the oil pressure switch connections (see Switch Inspection in this chapter). If the warning LED light is not lit, check the warning LED light and wiring (see Meter Unit Inspection in this chapter). If the LED light and wiring are good, replace the oil pressure light delay unit [F].
16-76 ELECTRICAL SYSTEM Oil Pressure Warning System the ignition switch ON. • Turn Ground the oil pressure switch lead to the engine, then the • oil pressure warning LED light should be lit with a delay. this delay time from grounding of the switch lead • Measure to lighting of the warning LED light. Lighting Delay Time about 3 seconds Standard:
If the lighting delay time is out of the standard too far, replace the oil pressure light delay unit.
ELECTRICAL SYSTEM 16-77 Meter, Gauge Meter Unit Removal
• Remove: Bolts [A] and Washers Meter Cover [B]
• Remove: Cover [A] •
Ignition Switch Lead Connector [B] Meter Unit Lead Connector [C] Remove the connector [D] from the bracket.
• Remove: Bolts [A] Meter Unit [B] with Bracket
• Remove: Nuts [A] and Washers
• Pull out the meter unit [A] from the pins [B] on the bracket. CAUTION
Never drop the meter unit, especially on a hard surface. Such a shock to the unit can damage it. Place the speedometer so that the face is up. If the meter is left upside down or sideways for any length of time, it will malfunction.
16-78 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Installation
• Install: Meter Unit [A]
Damper [B] ( : 22 mm, 0.87 in.) Damper [C] ( : 16 mm, 0.63 in.) Bracket [D] Damper [E] ( : 24 mm, 0.94 in.) Washers [F] (Steel) Nuts [G] Bolts [H] (L = 12 mm, 0.47 in.) Cover [I] Meter Cover [J] Washers [K] (Nylon) Bolts [L] (L = 10 mm, 0.39 in.)
Meter Unit Disassembly
the meter unit (see Meter Unit Removal in this • Remove section). • Remove: Screws [A] Upper Meter Cover [B]
• Remove: Screws [A] •
Holder [B] Remove the grommet [C] from the lower meter cover [D].
NOTE
○The water temperature warning LED light, oil pressure warning LED light and FI indicator LED light can not be exchanged.
ELECTRICAL SYSTEM 16-79 Meter, Gauge out the socket [A] counterclockwise. •○Turn These sockets are for the high beam indicator light, turn signal indicator light and neutral indicator light.
Meter Unit Assembly
the bulb [A] so that the projections [B] align with the • Insert grooves [C] in the panel, and turn in the socket clockwise.
the grommet [A] in the lower meter cover. • Fit Install: • Holder [B]
•
Screws [C] Tighten the band [D] as shown.
16-80 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Inspection LCD Segment Inspection Remove the meter unit (see Meter Unit Removal in this section).
•
CAUTION Do not drop the meter unit. Such a shock to the meter unit can damage it. Place the meter facing up. If a meter is left upside down or sideways for any length of time, it will malfunction. [A] Meter Unit Lead Connector [1] Neutral Indicator Light (–) [2] FI Indicator LED Light (–) [3] Oil Pressure Warning LED Light (–) [4] Water Temperature Warning LED Light (–) [5] Speed Signal for Turn Signal Control Relay [6] Unused [7] Battery (+) [8] Ignition, Neutral Indicator Light (+) and Illumination (+) [9] Battery (–), High Beam Indicator Light (–) and Illumination (–) [10] Speed Sensor Supply Voltage [11] Speed Sensor Signal [12] Fuel Level Sensor Signal [13] Right Turn Signal Indicator Light (±) [14] Left Turn Signal Indicator Light (±) [15] Fuel Level Warning Indicator LED Light (–) [16] High Beam Indicator Light (+)
CAUTION Do not short each terminals. When inspecting the meter unit be sure to connect each connections. Check 1 Using the auxiliary leads, connect a 12 V battery [A] to the meter unit lead connector terminals.
•
Connections Battery Positive Terminal (+) → Terminal [7] Battery Negative Terminal (–) → Terminal [9]
○When the terminals are connected, the speedometer nee-
dle momentary points to the last reading, and then return to the 0 position. If the needle function does not work, replace the meter unit.
ELECTRICAL SYSTEM 16-81 Meter, Gauge Check 2 Using the auxiliary lead, connect the battery positive terminal to terminal [8]. Verify that all the LCD segments (the letters and numbers of the liquid crystal display) to appear for 3 seconds, and the speedometer needle momentary points to the last reading and then return to the 0 position. Then the clock or meters operates normally depending on the mode selected. Disconnect the terminal [8]. Verity that all the LCD segments and symbols disappear. If the display function does not work, replace the meter unit.
• •
• •
Mode Button Operation Checks Connect the lead in the same circuit as for the LCD Segment Inspection, Check 2. Check that the display [A] changes to the CLOCK, ODO, and TRIP display each time the mode button [B] is pushed.
• •
If the display does not work, replace the meter unit. the mode button [A] to TRIP and push the reset • Push button [B] more than 2 seconds. The display shows “0.0”. If the display does not show “0.0”, replace the meter unit.
16-82 ELECTRICAL SYSTEM Meter, Gauge the mode button [A] to CLOCK. • Push Push the reset button [B] more than 2 seconds, then the • display turns to the HOUR/MINUTE mode [C].
○In the HOUR/MINUTE mode, the numbers flash on the
•
display. Check that the flashing number changes to the HOUR or MINUTE display each time the reset button is pushed.
If the display does not work, replace the meter unit.
that the time can be set. • Check If the time cannot be set, replace the meter unit. Clock Setting In the HOUR/MINUTE mode, push the reset button again to effect the HOUR setting mode. ○The hour display flashes on the display. Push the mode button to set the hour.
• •
HOUR mode, push the reset button once to effect • InthetheMINUTE setting mode.
○The minute display flashes on the display.
• Push the mode button to set the minute.
ELECTRICAL SYSTEM 16-83 Meter, Gauge the minute, push the reset button to return to the • Set HOUR/MINUTE mode. the mode button to complete the time setting • Push process.
○The clock starts counting the seconds as soon as the mode button is pushed.
Speedometer Inspection Connect the leads in the same circuit as for the LCD Segment Inspection, check 2. Connect the oscillator [A] to the terminal [11]. The vehicle speed that corresponds to the input frequency will be displayed when a short wave form such as the one show in the diagram is input.
• •
Example An input frequency of 720 Hz will display about 60 mph. An input frequency of 450 Hz will display about 60 km/h.
If the meter does not function correctly, replace the meter unit.
If an oscillator is unavailable, check the speedometer as follows. ○Install the meter unit (see Meter Unit Installation in this section). ○Use the jack and the attachment jack to lift the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398
○Turn the ignition switch ON. ○Turn the rear wheel by hand to see if the speedometer
shows the vehicle speed that corresponds to the wheel rotation. If it does not show properly, inspect the speed sensor and speed sensor power supply voltage. If the speed sensor and speed sensor power supply voltage are normal, replace the meter unit.
16-84 ELECTRICAL SYSTEM Meter, Gauge Speed Sensor Power Supply Voltage Inspection Connect the leads in the same circuit as for the LCD Segment Inspection, Check 2. Set the hand tester [A] to DC25 V, check the voltage between terminal [10] and battery negative lead.
• •
Connections Hand Tester (+) → Terminal [10] Hand Tester (–) → Battery Negative (–) Terminal Special Tool - Hand Tester: 57001-1394
If the voltage is less than 6 V, replace the meter unit. ODO Meter Inspection Connect the leads in the same circuit as for the Speedometer Inspection. Push the mode button to ODO [A]. Raise the input frequency of the oscillator to quickly see the result of this inspection. If the value indicated by the odo meter does not increase, replace the meter unit.
• • •
TRIP Meter Inspection Connect the leads in the same circuit as for the Speedometer Inspection. Push the mode button to TRIP [A]. Rise the input frequency of the oscillator to quickly see the result of this inspection. If the value indicated by the trip meter does not increase, replace the meter unit.
• • •
Fuel Level Gauge Inspection Connect the leads in the same circuit as for the LCD segment inspection, Check 2. Connect a variable rheostat [A] to the terminal [12] and battery negative lead as shown. Check that the number of segments [B] matches the resistance value of the variable rheostat. ○When terminal [12] is connected, one segment should appear about 10 ∼ 15 seconds.
• • •
Resistance (Ω)
Number of Segments
50
5
100
3
210
1
Resistance values are standard and they have tolerance. If this indicator function does not work, replace the meter unit.
ELECTRICAL SYSTEM 16-85 Meter, Gauge LED Light Inspection
the leads in the same circuit as for the LCD Seg• Connect ments Inspection, Check 2. Fuel Level Warning Indicator LED Light Connect an about 30 Ω resistor [A] to the terminal [15] and battery negative lead.
•
Fuel Level Warning Indicator LED Light Connections Battery Negative Lead (–) to Terminal [15]
○The fuel level warning indicator LED light [B] should go
on. If the fuel level warning indicator LED light does not go on, replace the meter unit.
Oil Pressure Warning Indicator LED Light and LCD Symbol Connect the lead to the terminal [3] and battery negative lead.
•
Oil Pressure Warning Indicator LED Light Connections Battery Negative Lead (–) to Terminal [3]
○The oil pressure warning indicator LED light [A] and symbol [B] in the LCD should go on. If the LED light and/or symbol do not go on, replace the meter unit.
16-86 ELECTRICAL SYSTEM Meter, Gauge FI Indicator LED Light and LCD Symbol Connect the lead to the terminal [2] and battery negative lead.
•
FI Indicator LED Light Connections Battery Negative Lead (–) to Terminal [2]
○The FI indicator LED light [A] and symbol [B] in the LCD
should go on. If the LED light and/or symbol do not go on, replace the meter unit.
Water Temperature Warning Indicator LED Light and LCD Symbol Connect the lead to the terminal [4] and battery negative lead.
•
Water Temperature Warning Indicator LED Light Connections Battery Negative Lead (–) to Terminal [4]
○The water temperature warning indicator LED light [A] and
symbol [B] in the LCD should go on. If the LED light and/or symbol do not go on, replace the meter unit.
ELECTRICAL SYSTEM 16-87 Meter, Gauge Indicator Light Inspection
the leads in the same circuit as for the LCD Seg• Connect ments Inspection, Check 2. Neutral Indicator Light Connect the lead to the terminal [1] and battery negative lead.
•
Neutral Indicator Light Connections Battery Negative Lead (–) to Terminal [1]
○The neutral indicator light [A] should go on.
•
If the indicator light does not go on, inspect the bulb. Check conductivity of the bulb with the hand tester. If the bulb is open, replace the bulb. Even if the bulb is replacement but the indicator light does not go on, replace the meter unit.
16-88 ELECTRICAL SYSTEM Meter, Gauge Turn Signal Indicator Light Connect the lead to the terminal [13] and [14] as follows.
•
Neutral Indicator Light Connections: Battery Positive Lead (+) to Terminal [13] Battery Negative Lead (–) to Terminal [14] or Battery Positive Lead (+) to Terminal [14] Battery Negative Lead (–) to Terminal [13]
○The turn signal indicator light [A] should go on.
•
If the indicator light does not go on, inspect the bulb. Check conductivity of the bulb with the hand tester. If the bulb is open, replace the bulb. Even if the bulb is replacement but the indicator light does not go on, replace the meter unit.
High Beam Indicator Light Connect the lead to the terminal [16] and battery positive lead.
•
High Beam Indicator Light Connections: Battery Positive Lead (+) to Terminal [16]
○The high beam indicator light [A] should go on.
•
If the indicator light does not go on, inspect the bulb. Check conductivity of the bulb with the hand tester. If the bulb is open, replace the bulb. Even if the bulb is replacement but the indicator light does not go on, replace the meter unit.
ELECTRICAL SYSTEM 16-89 Meter, Gauge Meter Unit Circuit
1. Meter Unit 2. Odometer/Trip Meter/Clock LCD 3. Speedometer 4. Fuel Meter 5. Illuminator LED 6. Fuel Indicator LED 7. Water Temperature Warning/FI/Oil Pressure Warning Indicator LED 8. Mode Button 9. Reset Button 10. High Beam Indicator Light 11. Turn Signal Indicator Light 12. Neutral Indicator Light 13. Speed Sensor 14. Joint Connector 2
15. Fuel Level Sensor 16. Fuel Reserve Switch 17. Turn Signal Control Relay 18. Frame Ground 19. Water Temperature Switch 20. Oil Pressure Warning Light Delay Unit 21. Neutral Switch 22. Electronic Control Unit 23. Junction Box 24. Ignition Fuse 10 A 25. Ignition Switch 26. Main Fuse 30 A 27. Battery
16-90 ELECTRICAL SYSTEM Water Temperature Warning System Water Temperature Warning System Check The water temperature warning LED light goes on when the ignition switch is turned on and goes off soon to ensure that its circuit functions properly and the warning LED light has not burned out. The warning LED light also goes on whenever the coolant temperature rises to 113 ∼ 117° (235 ∼ 243°F) when the motorcycle is in operation. If it stays on, stop the engine and check the coolant level in the reserve tank after the engine cools down.
• Remove: Bolts [A] Regulator/Rectifier Bracket [B]
the water temperature warning LED light and the • Inspect system wiring.
○Turn on the ignition switch. ○Disconnect the water temperature switch lead [A] then
ground it to the frame or engine using an auxiliary lead. If the water temperature warning LED light is lit, inspect the water temperature switch [B] (see Water Temperature Switch Inspection in this chapter). Replace the switch if damaged. If the warning LED light is not lit, check the warning LED light and wiring.
ELECTRICAL SYSTEM 16-91 Switch and Sensors Fuel Level Sensor Inspection
• Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System • •
(DFI) chapter) Open the clamps [A]. Remove: Bolts [B] Fuel Level Sensor [C]
that the float moves up and down smoothly without • Check binding. It should go down under its own weight. If the float does not move smoothly, replace the sensor. 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]. Black/Yellow [C] White/Yellow [D] 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 sensor. Fuel Level Sensor Resistance Standard: Full position [E]: 3 ∼ 5 Ω Empty position: 213 ∼ 219 Ω
a new gasket [A] on the fuel tank [B] as shown. • Install [C] Hollows
•
[D] Front Side Apply a non-permanent locking agent to the threads of the level sensor mounting bolts and tighten it. Torque - Fuel Level Sensor Mounting Bolts: 6.9 N·m (0.7 kgf·m, 61 in·lb)
Fuel Reserve Switch Inspection
the fuel tank with fuel. • Fill Close the fuel tank cap surely. • Remove: • Front Seat (see Front Seat Removal in the Frame chap-
•
ter) Fuel Level Sensor Lead Connector [A] Connect the test light [B] (12 V 3.4 W bulb in a socket with leads) and the 12 V battery [C] to the fuel level sensor lead connector.
16-92 ELECTRICAL SYSTEM Switch and Sensors Connections Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) → LB Lead Terminal Battery (–) → BK/Y Lead Terminal If the test light turn on, the reserve switch is defective. Replace the fuel level sensor.
• Remove: Fuel Level Sensor (see Fuel Level Sensor Inspection in •
this section) Connect the test light (12 V 3.4 W bulb in a socket with leads) and the 12 V battery to the fuel level sensor lead connector as shown. 12 V Battery [A] Test Light [B] Fuel Level Sensor Connector [C] Fuel Reserve Switch [D] If the test light doesn’t light, replace the fuel level sensor.
NOTE
○It may take a long time to turn on the test light in case
that the fuel reserve switch is inspected just after the fuel level sensor is removed. Leave the fuel reserve switch with leads for inspection connected for few minutes.
Speed Sensor Removal
• Remove: Alternator Outer Cover (see Alternator Outer Cover Removal in this chapter) Speed Sensor Lead Connector [A] Band [B] Bolt [C] Speed Sensor [D]
Speed Sensor Installation
grease to the O-ring [A] on the speed sensor. • Apply Apply a non-permanent locking agent to the threads of • the speed sensor mounting bolt. Tighten: •
Torque - Speed Sensor Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
ELECTRICAL SYSTEM 16-93 Switch and Sensors Speed Sensor Inspection
the speed sensor (see Speed Sensor Removal • Remove in this section). the speed sensor connector [A] with a battery • Connect [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester : 57001-1394
[A] the speed sensor surface with the screw driver. •○Trace Then the tester indicator should flick [B]. If the tester indicator does not flick, replace the speed sensor.
Front Brake Light Switch Inspection
to the Brake Light Switch Operation in the Periodic • Refer Maintenance chapter.
Rear Brake Light Switch Check/Adjustment
to the Brake Light Switch Operation in the Periodic • Refer Maintenance chapter.
Radiator Fan Switch Removal CAUTION Never drop the fan switch, especially on a hard surface. Such a shock to the part can damage it. the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). the fan switch connector (see Fan System Cir• Disconnect cuit Inspection in this chapter). • Unscrew the radiator fan switch [A] from the radiator.
Radiator Fan Switch Installation
• Tighten:
Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb)
the coolant and bleed the air from the cooling system • Fill (see Coolant Change in the Periodic Maintenance chapter).
16-94 ELECTRICAL SYSTEM Switch and Sensors Radiator Fan Switch Inspection
the fan switch from the radiator (see Radiator • Remove Fan Switch Removal in this section). the switch [A] in a container of machine oil so • Suspend that the heat-sensitive portion and threaded portion are
•
submerged. Suspend an accurate thermometer [B] with heat-sensitive portions [C] located in almost the same depth.
NOTE
○The switch and thermometer must not touch the container sides 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 the hand tester (special tool), measure the internal resistance of the switch across the terminals at the temperatures shown in the table. If the measurement is out of the range, replace the switch. Fan Switch Resistance Rising temperature:
○
From OFF to ON at 102 ∼ 108°C (212 ∼ 226°F)
○Falling temperature:
From ON to OFF at 97 ∼ 103°C (203 ∼ 217°F) ON: Less than 0.5 Ω OFF: More than 1 MΩ
Water Temperature Switch Removal CAUTION The water temperature switch should never be allowed to fall on a hard surface. Such a shock to the part can damage it. the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter). the switch connector (see Water Temperature • Disconnect Warning System Inspection in this chapter). the water temperature switch [A] from the radia• Remove tor.
Water Temperature Switch Installation
silicone sealant to the threads of the water temper• Apply ature switch. Sealant - Kawasaki Bond (Silicone Sealant): 59019-120 Torque - Water Temperature Switch: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the engine with coolant and bleed the air from the cool• Fill ing system (see Coolant Change in the Periodic Maintenance chapter).
ELECTRICAL SYSTEM 16-95 Switch and Sensors Water Temperature Switch Inspection
the water temperature switch. • Remove Suspend the switch [A] in a container of machine oil so • that the heat-sensitive portion and threaded portion are
•
submerged. Suspend an accurate thermometer [B] with heat-sensitive portions [C] located in almost the same depth.
NOTE
○The switch 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 the hand tester, measure the internal resistance of the switch across the terminal and the body at the temperatures shown in the table. If the measurement is out of the range, replace the switch. Water Temperature Switch Resistance Rising temperature:
○
From OFF to ON at 113 ∼ 117°C (235 ∼ 243°F)
○Falling temperature:
From ON to OFF at 108°C (226°F) ∼ temperature less than ON temperature ON: Less than 0.5 Ω OFF: More than 1 MΩ
16-96 ELECTRICAL SYSTEM Switch and Sensors 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 handlebar switches 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
*: Engine lubrication system is in good condition
ELECTRICAL SYSTEM 16-97 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed.
Junction Box Fuse Circuit Inspection
the right side cover (see Right Side Cover Re• Remove moval in the Frame chapter). the junction box. • Remove off the connectors from the junction box. • Pull Make all connector terminals are clean and tight, and • none ofsurethem have been bent.
•
Clean the dirty terminals, and straighten slightly-bent terminals. Check conductivity of the numbered terminals with the hand tester (see Junction Box Internal Circuit in this section). If the tester does not read as specified, replace the junction box.
Fuse Circuit Inspection Tester Connection 1 – 1A 1 – 2 3A – 4 6 – 5 6 – 10 6 – 7 6 – 17
Tester Reading (Ω) 0 0 0 0 0 0 0
Tester Connection 1A – 8 2 – 8 3A – 8 6 – 2 6 – 3A 17 – 3A
Starter Circuit/Headlight Relay Inspection
the junction box. • Remove Check conductivity of the following numbered terminals • by connecting the hand tester and one 12 V battery to the junction box as shown (see Junction Box Internal Circuit in this section). If the tester does not read as specified, replace the junction box.
Tester Reading (Ω) ∞ ∞ ∞ ∞ ∞ ∞
16-98 ELECTRICAL SYSTEM Junction Box Relay Circuit Inspection (with the battery disconnected)
Headlight Relay
Tester
Tester
Connection
Reading (Ω)
7
–
8
∞
7
–
13
∞
(+)
(–) –
13
Not ∞*
9
Tester
Tester
Connection
Reading (Ω)
9
–
11
∞
Starter
12
–
13
∞
Circuit
(+)
Relay
13
(–) –
(+)
∞
11 (–)
–
12
Not ∞*
11
(*): The actual reading varies with the hand tester used. (+): Apply tester positive lead. (–): Apply tester negative lead. Relay Circuit Inspection (with the battery connected) Reading
Battery
Tester
Tester
Connection
Connection
Reading
(+) Headlight Relay Starter Circuit Relay
(–)
(Ω) 7 – 8
9 – 13 11 – 12
(+)
(–)
13 – 11
0 Not ∞*
(*): The actual reading varies with the hand tester used. (+): Apply tester positive lead. (–): Apply tester negative lead.
Diode Circuit Inspection
the junction box. • Remove conductivity of the following pairs of terminals (see • Check Junction Box Internal Circuit in this section). Diode Circuit Inspection Tester Connection
13-8, 13 - 9, 12 -11, 12 - 14, 15 -14, 16 - 14
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 junction 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.
ELECTRICAL SYSTEM 16-99 Junction Box Junction Box Internal Circuit
A. Accessory Fuse 10 A B. Fan Fuse 15 A C. Turn Signal Fuse 10 A D. Horn Fuse 10 A E. Ignition Fuse 10 A F. Headlight Fuse 10 A G. Headlight Relay H. Headlight Diodes I. Starter Diode J. Starter Circuit Relay K. Interlock Diodes L. Taillight Fuse 10 A
16-100 ELECTRICAL SYSTEM Fuse Main Fuse Removal
• Remove: Right Side Cover (see Right Side Cover Removal in the • •
Frame chapter) Coolant Reservoir Tank (see Coolant Change in the Periodic Maintenance chapter) Remove the starter relay [A]. Pull out the main fuse [B] from the starter relay with needle nose pliers.
Junction Box Fuse Removal
the right side cover (see Right Side Cover Re• Remove moval in the Frame chapter). the hook to lift up the lid [A]. • Unlock the fuses [B] straight out of the junction box with nee• Pull dle nose pliers.
Fuse Installation
•
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. Install the junction box fuses on the original position as specified on the lid.
Fuse Inspection
the fuse (see Main Fuse/Junction Box Fuse Re• Remove moval in this section). the fuse element. • Inspect If it is down out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Housing [A] Fuse Element [B] Terminals [C] Blown Element [D]
NOTE
○A mass current flows to the battery according to the state of the battery which needs refreshing charge when the engine is turned causing main fuse blown out. CAUTION Do not use a fuse rated for other amperage and voltage specified in the wiring diagram. Installation of a fuse with a higher rating may cause damage to wiring and components, and a fuse of a lower rating will soon blow again.
APPENDIX 17-1
Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. Troubleshooting Guide ...........................................................................................................
17-2 17-28
17
17-2 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Fuel Tank 2. Ignition Coil for Rear Spark Plugs 3. Fuel Tank Water Drain Hose 4. Run the hose over the cooling hose. 5. Plastic Snap-on Clamps (Rear Brake Light Switch and Radiator Fan Leads) 6. Right Frame Pipe 7. Plastic Snap-on Clamp (Rear Brake Light Switch Lead) 8. Rear Brake Light Switch 9. Clutch Hose 10. Left Frame Pipe 11. Choke Knob and Cable 12. Horn 13. Fit the clamp position with the choke knob (Permissible valve: within 10 mm (0.4 in.)) 14. Clamp 15. Welded Clamps 16. 10 ∼ 30 mm (0.4 ∼ 1.2 in.) 17. Clamp 18. Fuel Tank Breather Hose (Except California Model) 19. Marking (Position here.) 20. Run the fuel tank breather hose between the bracket and the right frame pipe. 21. Holder 22. Swingarm Pivot 23. Cross Pipe 24. Run the hose in front of swingarm pivot and cross pipe. 25. Clamp 26. Coolant Reserve Tank Overflow Hose 27. Front
17-4 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-5 Cable, Wire, and Hose Routing
1. Right Rear Spark Plug Lead 2. Left Rear Spark Plug Lead 3. Inlet Air Pressure Hose 4. Ignition Coil for Rear Spark Plugs 5. Choke Cable 6. Clamp 7. To Right Front Spark Plug 8. Plastic Clamps 9. Right Air Cleaner Base 10. Vacuum switch valve hose to the right air cleaner base. 11. Throttle Sensor 12. White Marks faced upwards 13. Left Front Spark Plug Lead 14. Ignition Coil for Front Spark Plugs 15. Plastic Clamp 16. Left Air Cleaner Housing 17. Clamp 18. Front Oil Hose 19. Fuel Pump Outlet Hose 20. Grommet (California Model only) 21. Clamp
22. Radiator Inlet Hose 23. Rear Coolant Hose 24. Front Coolant Hose 25. Reserve Tank Hose (Without Mark) 26. Throttle Cables (Upper: Decelerator, Lower: Accelerator) 27. Plastic Clamp (Align the clamp with the mark faced upward) 28. Rear oil hose into the rear rocker case cover. 29. Canister Purge Hose (Green) for California Model 30. Air Suction Valve 31. Front Vacuum Switch Valve Hose 32. Rear Vacuum Switch Valve Hose 33. Run the crankcase breather hose over the vacuum switch valve 34. Wire Clamps (Face the tab as shown.) 35. Vacuum Switch Valve 36. Rear Rocker Case Cover 37. Vacuum Hose to Throttle Body 38. Front
17-6 APPENDIX Cable, Wire, and Hose Routing
1. Ignition Coil for Front Spark Plugs 2. Inlet Air Pressure Sensor Hose 3. Front Coolant Hose 4. Vacuum Switch Valve Hose (vacuum) 5. Radiator Inlet Hose 6. Thermostat Housing 7. Radiator Cap 8. Coolant Reserve Tank Hose 9. Rear Coolant Hose 10. Rear Oil Hose
11. Radiator 12. Fuel Pump Outlet Hose 13. Clamp 14. Clamp 15. Crankcase Breather Tube 16. Clamp 17. Vacuum Switch Valve 18. To Front Cylinder Head 19. Elbow Joint
APPENDIX 17-7 Cable, Wire, and Hose Routing
20. Front Oil Hose 21. Right Air Cleaner Base 22. Radiator Outlet Hose 23. To Rear Cylinder Head 24. Water Temperature Sensor 25. Align the mark with the clamp end. 26. White Marks on the Coolant Hoses 27. Water Pipes 28. Wire clamp with the tab on the left 29. Main Harness Bracket 30. Coolant Reserve Tank
31. Coolant Reserve Tank Overflow Hose 32. Clamp 33. Holder 34. Rear Vacuum Switch Valve Hose 35. Front Vacuum Switch Valve Hose 36. Vacuum switch valve hose to the right air cleaner base. 37. Note each position and direction of the clamp bolts. 38. Install the ignition coil lead as shown. 39. Front
17-8 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Top 2. Locate the glued joint of the gasket within the angle. 3. Gasket 4. Right Air Cleaner Cover Allen Bolt 5. Clamp (Inlet Air Temperature Sensor and ISC Valve Leads) 6. Inlet Air Temperature Sensor and ISC Valve Leads 7. Vacuum Switch Valve Hose 8. O-ring 9. Right Air Cleaner Base 10. Grommet 11. Lower Air Cleaner Duct between #1 and #2 Cylinders 12. Elbow joint connected to crankcase breather hose 13. Inlet Air Temperature Sensor 14. ISC Valve Inlets 15. Mark faced upward 16. ISC Valve #1 (for Rear Cylinder) 17. ISC Valve #2 (for Front Cylinder) 18. ISC Valve Hose #2 (Red Mark) 19. ISC Valve Hose #1 (Blue Mark) 20. ISC Valve #1 (G/Y, W/R Leads) 21. ISC Valve #2 (G/BL, W/R Leads) 22. 120° 23. Front 24. Air Flow
17-10 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-11 Cable, Wire, and Hose Routing Rear View 1. Fuel pump with the fuel filter and screen belt in. 2. Fuel Pump Bolts 3. Fuel Hose Joint (Delivery Joint) 4. Fuel Tank 5. O-ring 6. Left Air Cleaner Cover 7. Fuel Hose Joint (Fuel Pump) 8. Fuel Pump Outlet Hose 9. Fuel Injector #2 10. Inlet Manifold 11. Injector Lead #2 12. Injector Lead #1 (White Tape) 13. Connector (Black) 14. Frame Pipes 15. Atmospheric Pressure Sensor Lead 16. Inlet Air Pressure Sensor Lead (White Tape) 17. Connector (Natural) 18. Water Temperature Sensor Lead 19. Bend before install. 20. Run the lead inlet air temperature sensor and ISC valve leads inside the rocker case cover. 21. Inlet Air Temperature Sensor and ISC Valve Leads 22. Breather Hose 23. Grommet 24. Right Air Cleaner Base 25. Strap 26. Fuel Pump Outlet Pipe 27. Pressure Regulator 28. Throttle Cables 29. Vacuum Switch Valve Hose 30. Inlet Air Pressure Sensor Hose 31. Rear View 32. Front
17-12 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Rear Fender 2. Grommets 3. Five Clamps 4. Rear Fender Harness 5. Plastic Cover 6. Run the rear fender harness into the cut of plastic cover. 7. Connector for Licence Plate and Tail/Brake Lights 8. License Plate Light 9. Tail/Brake Light 10. Snap-on Strap 11. White Mark of Rear Fender Harness (Position here.) 12. Rear Left Turn Signal Light 13. Rear Right Turn Signal Light 14. Bracket 15. Connector of Rear Left Turn Signal Light (The female plug is fitted into bracket.) 16. Connector of Rear Right Turn Signal Light (The female plug is fitted into bracket.) 17. Press by hands: Clamp the rear fender harness with these clamps and press each end of clamps by hands against the rear fender. 18. Rear View 19. Front
17-14 APPENDIX Cable, Wire, and Hose Routing
1. Left Regulator/Rectifier Connector 2. Inside Alternator Connector 3. Crankshaft Sensor Connector 4. Oil Pressure Switch/Neutral Switch Connector 5. Speed Sensor Connector 6. Outside Alternator Connector 7. Right Regulator/Rectifier Connector
8. Side stand Switch Connector 9. Starter Motor Lead 10. Speed Sensor 11. Strap (Speed Sensor Lead) 12. Insert the oil pressure/neutral switch leads and side stand switch leads in this order between the alternator cover and the clutch slave cylinder.
APPENDIX 17-15 Cable, Wire, and Hose Routing
1. Ignition Switch Connector (Push the lock to disconnect. Join the connector and fit it into the slit of the bracket.) 2. Ignition Switch 3. Speedometer/Fuel Level Sensor Connector 4. Main Harness 5. Fuel Pump 6. Run the fuel level sensor lead between the fuel pump and the fuel pump outlet pipe. 7. Fuel Tank Breather Hose 8. Mark (Position here.)
9. Fuel Tank Bottom View 10. Two Recesses (Position here.) 11. Fuel Level Sensor Lead 12. Inside of Fuel Tank 13. Fuel Pump Outlet Pipe 14. Clamps 15. Clamp 16. Fuel Pump Lead 17. Press the clamps. 18. Raise the lock to disconnect. 19. Front 20. Top
17-16 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-17 Cable, Wire, and Hose Routing ←→: Vacuum Pulsation →: Bypass Air Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Top View 2. Rear View 3. Bottom View 4. Delivery Joint 5. Fuel Injector #2 6. Fuel Injector #1 7. ISC Hose #1 (Blue Mark) 8. Throttle Sensor 9. Vacuum Hose to Inlet Air Pressure Sensor 10. Inlet Manifold 11. ISC Hose #2 (Red Mark) 12. ISC Pipe #1 13. ISC Pipe #2 14. Throttle Cable Holder 15. Choke Lever Stop Screw 16. Throttle Pulley 17. Idle Adjusting Screw 18. Throttle Stop Screw 19. Throttle Body 20. Throttle Body Assy 21. ISC Pipe Damper 22. Throttle Cable (Decelerator) 23. Throttle Cable (Accelerator) 24. Position the white marks here. 25. Cable Clip 26. Stake the cable clip on the throttle cable holder. 27. Rubber Plug (except California) 28. Front
17-18 APPENDIX Cable, Wire, and Hose Routing
1. Rear Brake Caliper 2. Hose Holders 3. Rear Brake Hose 4. Hose White Marks (Position here.) 5. Hose Clamps 6. Run the brake hose between the engine mounting bracket bosses and the oil filter, and then along the downtube towards the front. 7. Oil Filter
APPENDIX 17-19 Cable, Wire, and Hose Routing
8. Rear Brake Reservoir 9. Rear Master Cylinder 10. Brake Pedal 11. Bend both ends of the cotter pin as shown. 12. Clevis 13. Rear Brake Reservoir Cover 14. Downtube 15. Swingarm 16. Cotter Pin 17. Rear Brake Disc 18. Front
17-20 APPENDIX Cable, Wire, and Hose Routing
1. Throttle Body Assy 2. Throttle Cable (Decelerator) 3. Throttle Cable (Accelerator) 4. Front Oil Hose 5. Grommet 6. Fuel Pump Outlet Hose 7. Separator Vacuum Hose (White) 8. Fuel Tank Breather Pipe 9. Filler Drainpipe 10. Fuel Tank Breather Hose (Blue, Rear) 11. Fuel Tank Return Hose (Red, Front) 12. Fuel Tank 13. Main Harness
14. Run the hoses through the hole. 15. Plug 16. Separator Breather Hose (Blue) 17. Lower Air Cleaner Duct 18. Canister Purge Hose (Green) 19. Canister 20. Face the white mark left. 21. Separator 22. Rear Oil Hose 23. Separator Inlet 24. Run these hoses on the left of the main harness. 25. Front
APPENDIX 17-21 Cable, Wire, and Hose Routing
1. Left Handlebar Switch Connectors 2. Accessory Lead Connectors 3. Headlight Body 4. Front Left Turn Signal Light Lead Connectors 5. Front Right Turn Signal Light Lead Connectors 6. Main Harness 7. Right Handlebar Switch Connectors 8. Clutch Hose
9. Run the throttle cables inside the clutch hose. 10. Run the throttle cables inside the head pipe cover. 11. Head Pipe Cover 12. Plastic Snap-on Clamps (Fit them into the frame pipe.) 13. Put the clutch hose into the hole of the head pipe cover. 14. Water Baffle Plats 15. Fuel Tank Water Drain Hose
16. Horn Leads 17. Starter Cable 18. Clamp (Fit it into the engine mount bracket, and clamp the left and right regulator/rectifier leads.) 19. Horn 20. Starter Motor 21. Front Regulator/Rectifier 22. White Mark (Position it here.) 23 Run the clutch hose in the bracket (with white mark outside)
17-22 APPENDIX Cable, Wire, and Hose Routing
24. Side stand Switch Leads (Run the lead through the front and rear hooks and hold them with the snap on clamp a bit tight behind the side stand bracket. 25. Welded Clamp 26. Left Frame Pipe 27. Starter Motor Lead 28. ECU (Fit it into the battery case behind the case rib on the bottom.) 29. Five Clamps 30. Install the alternator outer cover and make sure the sheath of the harness is inside the cover.
31. Connect the ignition primary lead connector as shown. 32. Main Harness 33. Strap (main harness and California purge hose-green) 34. Rear Turn Signal/Taillight Lead Connector 35. Sealed Battery 36. Headlight Connector 37. Run the rear harness under the pipe. 38. Front 39. Left Side
APPENDIX 17-23 Cable, Wire, and Hose Routing
1. Snap-on Straps 2. Front Brake Hose Holders 3. Front Brake Hose Assembly 4. Front Brake Calipers 5. Handlebar 6. Grommets 7. Brake Hose Joint 8. Run the front brake hose through the steering stem bracket. 9. Clamp 10. Front
17-24 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-25 Cable, Wire, and Hose Routing
1. Main Harness (Run it into the headlight body and inside the brake hose.) 2. Throttle Cables 3. Front Brake Hose 4. Rear Brake Light Switch Connector (BR, BL leads, under the radiator fan connector) 5. Radiator Fan Connector (BK/Y, Y/W, BR/W lead, over the brake light switch connector) 6. Plastic Snap-on Clamp (Radiator Fan and Rear Brake Light Switch Leads) 7. Inlet Air Pressure Sensor Connector 8. Plastic Snap-on Clamp (Rear Brake Light Switch Lead) 9. Ignition Coil Primary Lead Connectors (for Rear Cylinder) 10. Inlet Air Temperature Sensor and ISC Valve Leads 11. Water Temperature Sensor Connector 12. Throttle Sensor Connector 13. Clutch Hose 14. Horn Lead 15. Choke Knob 16. Frame Ground Terminal 17. Ignition Coil Primary Lead Connectors (for Front Cylinders) 18. Atmospheric Pressure Sensor Connector 19. Harness Clamp (Fit it into the frame pipe.) 20. Throttle Cables 21. Injector #2 Connector (Rear) 22. Injector #1 Connector (Front) 23. Main Harness Bracket 24. Fit the straps into the frame pipe 25. White Tape for Identification
26. Battery (–) Lead from engine ground lead 27. Oil Pressure Light Delay Unit 28. ECU Main Relay 29. Turn Signal Control Unit 30. Starter Relay 31. Batter Positive (+) Terminal 32. White Tape (Align it with the grommet.) 33. Starter Motor Lead 34. Battery negative (–) Lead Connector 35. Fuel Pump Connector 36. ECU Connector 37. ECU Main Fuse 38. Fuel Level Sensor Connector 39. Plastic Snap-on Clamp (Run the self-diagnosis accessory and rear harness.) 40. Battery Holder (Fit the fuel pump, fuel level sensor connectors, ECU main Fuse and plastic snap on clamp.) 41. Accessory Lead Connectors (Female) 42. Rear Turn Signal/Taillight Lead Connector 43. Self-Diagnosis Terminal 44. Put these connectors into the alternator outer cover. 45. Front Turn Signal Light Leads (Connect them in the headlight body.) 46. Run the front turn signal light leads into the holes of the bracket. 47. Left Handlebar Switch Leads (Connect them in the headlight body.) 48. Straps 49. Right Handlebar Switch Leads 50. Front
17-26 APPENDIX Cable, Wire, and Hose Routing
1. Main Harness 2. Starter Motor Lead 3. Fuel Tank Filler Drain Hose (Except California Model) 4. Engine Ground Lead (Run it downward.) 5. Coolant Reserve Tank Overflow Hose 6. Coolant Reserve Tank Hose (from the radiator cap to the coolant reserve tank) 7. To the inside of the alternator outer cover 8. Through the alternator outer cover to the starter motor. 9. To the engine ground 10. Crankcase
11. To the crankcase backward lower clamp 12. Junction Box Lead 13. ECU Main Relay 14. Turn Signal Control Unit 15. Insert the band attached main harness 16. Band (Fix the main harness and frame joint part only. California model run the green hose inside the band.) 17. Oil Pressure Light Delay Unit 18. Coolant Reserve Tank Hose (Run the upper side of the frame bracket.) 19. Holder
APPENDIX 17-27 Cable, Wire, and Hose Routing
20. Insert the sub harness connector to the frame. 21. Vehicle-down Sensor Connector 22. Vehicle-down Sensor 23. Throttle Cables 24. Right Handlebar Switch Lead 25. Head Pipe Cover 26. Plastic Snap-on Clamps ( 15 mm, Rear Brake Light Switch and Radiator Fan Leads) 27. Plastic Snap-on Clamps ( 15 mm, Rear Brake Light Switch) 28. Right Regulator/Rectifier 29. Rear Brake Light Switch 30. Front
17-28 APPENDIX Troubleshooting Guide NOTE
○Refer to Fuel System chapter for most of
DFI troubleshooting 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 Starter lockout switch or neutral switch trouble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn’t turn over Starter clutch trouble Vehicle-down sensor coming off Engine won’t turn over Valve seizure Rocker arm seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft 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 Engine flooded Clean spark plugs and adjust plug gaps Starting technique faulty (When flooded, do not crank the engine with the throttle fully opened. This promotes engine flood because more fuel is supplied automatically by DFI.) No spark; spark weak Vehicle-down sensor coming off Ignition switch not ON Engine stop switch turned off Clutch lever not pulled in and gear not in neutral whether side stand up or down Though clutch lever pulled in, side stand up and gear not in neutral
Battery voltage low Spark plug dirty, broken, or gap maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Neutral, starter lockout, or side stand switch trouble Crankshaft position sensor trouble Ignition coil trouble Ignition switch or engine stop switch shorted Wiring shorted or open Fuse blown Fuel/air mixture incorrect Air cleaner clogged, poorly sealed, or missing 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 Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) KACR (compression release cam) sticks open (engine stalls when moving off) HLA (hydraulic lash adjuster) damaged (worn, seizure, or spring broken) HLA oil passage clogged
Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel/air mixture incorrect Air cleaner clogged, poorly sealed, or missing Fuel tank air vent obstructed Throttle body assy loose
APPENDIX 17-29 Troubleshooting Guide Choke knob left pulled out Throttle body assy O-ring damage Air cleaner duct loose Air cleaner O-ring damaged Fuel pump trouble 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 warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) KACR sticks open (engine stalls when moving off) HLA seizure Backfiring when deceleration Vacuum switch valve broken Air suction valve trouble Other IC igniter in ECU trouble Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too high Brake dragging Engine overheating Clutch slipping Air suction valve trouble Vacuum switch valve trouble
Poor Running or No Power at High Speed Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel/air mixture incorrect Choke knob left pulled out Air cleaner clogged, poorly sealed, or missing Air cleaner duct loose Air cleaner O-ring damaged Water or foreign matter in fuel Throttle body assy loose Throttle body assy O-ring damage
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 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.) KACR sticks open (engine stalls when moving off) HLA seizure Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect (Be sure to use high-octane gasoline recommended by Owner’s Manual) Spark plug incorrect IC igniter in ECU trouble Miscellaneous Throttle valves won’t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too high Air suction valve trouble Vacuum switch valve trouble Catalytic converters melt down due to muffler overheating (KLEEN)
Overheating Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug incorrect IC igniter in 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)
17-30 APPENDIX Troubleshooting Guide For KLEEN, do not start the engine under misfire due to spark plug fouling or poor connection of the spark plug For KLEEN, do not coast the motorcycle with the ignition switch off (Turn the ignition switch ON and run the engine) IC igniter in ECU trouble Fuel/air mixture incorrect Throttle body assy loose Throttle body assy O-ring damage Air cleaner duct loose Air cleaner poorly sealed, or missing Air cleaner O-ring damaged Air cleaner clogged Compression high Carbon built up in combustion chamber KACR sticks close Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Final gear case oil viscosity too high Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Water temperature warning system incorrect Water temperature warning light broken Water temperature switch 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 switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged
Over Cooling Cooling system component incorrect Radiator fan switch trouble Thermostat trouble
Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Spring plate free play maladjustment Clutch spring broken or weak
Clutch slave cylinder trouble Clutch hub or housing unevenly worn Clutch master cylinder trouble Clutch not disengaging properly Clutch plate warped or too rough Spring plate free play maladjustment Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch slave cylinder trouble Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch fluid leakage Clutch fluid deteriorated Clutch master cylinder primary or secondary cup damaged Clutch master cylinder scratched inside Air in the clutch fluid line
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 set lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm 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 set lever spring weak or broken Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts Gear set lever spring weak or broken Shift mechanism arm spring broken
Abnormal Engine Noise Knocking IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect (Be sure to use high-octane gasoline recommended in Owner’s Manual) Spark plug incorrect Overheating Piston slap Cylinder/piston clearance excessive Cylinder, piston worn
APPENDIX 17-31 Troubleshooting Guide Connecting rod bent Piston pin, piston pin hole worn Valve noise Engine not sufficiently warmed up after HLA installation HLA damaged (worn, seizure, or spring broken) HLA aeration due to low oil level Air in HLA Metal chips or dust jammed in HLA Engine operated in red zone Valve spring broken or weak Camshaft bearing portion worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring worn, broken, or stuck Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged Vacuum switch valve damaged Alternator rotor loose Catalytic converters melt down due to muffler overheating (KLEEN) Balancer gear worn or chipped Balancer shaft position maladjusted Balancer bearing worn Balancer shaft coupling rubber damper damaged Water pump chain, sprocket worn
Abnormal Drive Train Noise Clutch noise Clutch rubber 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 gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted
Rear wheel coupling damaged Final gear case oil level too low or oil too thin Insufficient grease in propeller shaft joint
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 Master cylinder damaged Other noise Bracket, nut, bolt, etc. not properly mounted or tightened
Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing portion worn Crankshaft bearings worn Oil pressure switch damaged Oil pressure switch lead damaged Relief valve stuck open O-ring at the oil pipe 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 Choke knob left pulled out Brown smoke Air cleaner duct loose Air cleaner O-ring damaged Air cleaner poorly sealed or missing
Handling and/or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect
17-32 APPENDIX Troubleshooting Guide 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 sleeve or pivot bearings worn Wheel rim warped, or not balanced Wheel bearing worn Handlebar nuts loose Steering stem head nut loose Front, rear axle runout excessive Handlebar pulls to one side Frame bent Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and/or left front fork oil level incorrect 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 leads 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
2005
VN1600-D1
Beginning Frame No. JKBVNKD1□5A000001 or JKBVNT60ADA013001
□:This digit in the frame number changes from one machine to another.
Part No.99924-1343-01
Printed in Japan
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