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VULCAN 1600 CLASSIC
VN1600 CLASSIC

Motorcycle

Service Manual


Quick Reference Guide


This quick reference guide will assist
you in locating a desired topic or pro­
cedure.
•Bend the pages back to match the
black tab of the desired chapter num­
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe­
cific topic required.

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 CLASSIC
VN1600 CLASSIC

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.

© 2003 Kawasaki Heavy Industries, Ltd.

Second Edition (1) : Aug. 25, 2003 (M)

LIST OF ABBREVIATIONS

A
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
kg
kgf
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)
(mass)
(force)
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 emis­
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi­
tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in­
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In­
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know­
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow­
ing its sale and delivery to the ultimate purchaser..."

NOTE

○The phrase "remove or render inoperative any device or element of design" has been generally
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de­
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex­
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan­
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

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

•
•
•
•

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in­
formation to make it useful to the owner who de­
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce­
dures must be understood in order to carry out
maintenance and repair satisfactorily. When­
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust­
ments, maintenance, and repair should be car­
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor­
oughly familiarize yourself with the procedures
before starting work, and then do the work care­
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad­
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Mo­
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual care­
fully. Don’t take shortcuts.
Remember to keep complete records of main­
tenance and repair with dates and any new
parts installed.

•
•
•

•
•

How to Use This Manual

In preparing this manual, we divided the prod­
uct into its major systems. These systems be­
came the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a sin­
gle chapter.
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.
The Periodic Maintenance Chart is located in
the Periodic Maintenance chapter. The chart
gives a time schedule for required maintenance
operations.
If you want spark plug information, for exam­
ple, go to the Periodic Maintenance Chart first.
The chart tells you how frequently to clean and
gap the plug. Next, use the Quick Reference
Guide to locate the Periodic Maintenance chap­
ter. Then, use the Table of Contents on the first
page of the chapter to find the Spark Plug sec­
tion.
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 per­
sonal injury, or loss of life.

CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam­
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa­
tion.

NOTE

○This note symbol indicates points of par­

ticular interest for more efficient and con­
venient 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 inspec­
tion in the procedural step or sub-step it fol­
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec­
ified tightening torque, oil, grease or a locking
agent during assembly.

GENERAL INFORMATION 1-1


General Information

1


Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Unit Conversion Table ............................................................................................................

1-2
1-7
1-9

1-11


1-2 GENERAL INFORMATION

Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera­
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, 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, discon­
nect 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 neg­
ative 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 ve­
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

Inspection
Reuse of worn or damaged parts may lead to serious ac­
cident. Visually inspect removed parts for corrosion, discol­
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be­
yond its service limit.

Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.

Assembly Order
In most cases assembly order is the reverse of disassem­
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing
Tightening Sequence
Bolts, nuts, or screws must be tightened according to the
specified sequence to prevent case warpage or deformation
which can lead to malfunction. 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.
Often, the tightening sequence is followed twice-initial
tightening and final tightening with torque wrench.

Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam­
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per­
formance. 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, Locking Agent
For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains be­
fore applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil pas­
sages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con­
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.

Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Install the circlip with its sharp edge facing outward
and its chamfered side facing inward to prevent the clip from
being pushed out of its groove when loaded. Take care
not to open the clip excessively when installing to prevent
deformation.

Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri­
cation points are called out throughout this manual, apply
the specific oil or grease as specified.

1-6 GENERAL INFORMATION

Before Servicing
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro­
tate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.

GENERAL INFORMATION 1-7

Model Identification
VN1600-A1 (US, and Canada) Left Side View:

VN1600-A1 (US, and Canada) Right Side View:

1-8 GENERAL INFORMATION

Model Identification
VN1600-A1 (Europe) Left Side View:

VN1600-A1 (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
Front
Curb mass:
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
Engine oil:
Type
Viscosity
Capacity

VN1600-A1 ∼
2 505 mm (98.62 in.)
1 040 mm (40.9 in.), (AU) 990 mm (39 in.)
1 130 mm (44.5 in.)
1 680 mm (66.1 in.)
130 mm (5.12 in.)
680 mm (26.8 in.)
306 kg (675 lb), (AU) 307 kg (677 lb)
156 kg (345 lb)
181 kg (399 lb), (AU) 182 kg (401 lb)
20 L (5.3 US gal)
Unleaded and high-octane gasoline
(see VN1600-A1 ∼ 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 0° 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)
API SE, SF or SG class
API SH or SJ class with JASO MA
SAE10W-40
3.5 L (3.7US qt, when engine is completely disassembled
and dry)

1-10 GENERAL INFORMATION

General Specifications
Items
VN1600-A1 ∼
Drive Train:
Primary reduction system:
Type
Gear
Reduction ratio
1.517 (85/56)
Wet multi disc
Clutch type
Transmission:
5-speed, constant mesh, return shift
Type
2.500 (40/16)
Gear ratios:
1st
1.590 (35/22)
2nd
1.192 (31/26)
3rd
0.965 (28/29)
4th
0.781 (25/32)
5th
Final drive system:
Shaft
Type
2.619 (15/21 × 33/9)
Reduction ratio
3.105 @ Top gear
Overall drive ratio
Final gear case oil:
API Service Classification: GL-5 Hypoid gear oil
Grade
SAE90 (above 5°C), SAE80 (below 5°C)
Viscosity
200 mL (6.76 US oz)
Capacity
Frame:
Type
Tubular, double cradle
Caster (rake angel)
32°
Trail
168 mm (6.61 in.)
Tubeless
Front tire:
Type
130/90 - 16 M/C 67H
Size
Tubeless
Rear tire:
Type
170/70B16 M/C 75H
Size
Telescopic fork
Front suspension:
Type
150 mm (5.91 in.)
Wheel travel
Swingarm
Rear suspension:
Type
95 mm (3.74 in.)
Wheel travel
Dual disc
Brake Type:
Front
Single disc
Rear
Electrical Equipment:
Capacity
12 V 18 Ah
Battery
Semi-sealed beam
Headlight:
Type
Bulb
12 V 60/55 W (quartz-halogen)
Tail/brake light
12 V 5/21 W
Three-phase AC, twin rotor
Alternator:
Type
Rated output 42A × 14 V @ 6 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
AU: Australia
CAL: California
CA: Canada
US: United States of America

GENERAL INFORMATION 1-11

Unit Conversion Table
Prefixes for Units:
Prefix

Units of Length:

Symbol

mega
kilo
centi
milli
micro

M
k
c
m
µ

Power
×
×
×
×
×

1 000 000
1 000
0.01
0.001
0.000001

Units of Mass:
kg
g

×
×

2.205
0.03527

=
=

lb
oz

×
×
×
×
×
×
×
×
×

0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102

×
×
×

0.6214
3.281
0.03937

=
=
=

mile
ft
in.

=
=
=
=
=
=

kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb

=
=
=
=
=
=

kgf/cm²
psi
cm Hg
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

km
m
mm

=
=
=
=
=
=
=
=
=

gal (US)
gal (imp)
qt (US)
qt (imp)
pint (US)
pint (imp)
oz (US)
oz (imp)
cu in.

kPa
kPa
kPa
kgf/cm²
kgf/cm²
cm Hg

×
×
×
×
×
×

0.01020
0.1450
0.7501
98.07
14.22
1.333

Units of Speed:
km/h

×

0.6214

Units of Force:
N
N
kg
kg

×
×
×
×

0.1020
0.2248
9.807
2.205

Units of Temperature:

=
=
=
=

kgf
lb
N
lb

Units of Power:
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 (DFI)...........................
Fuel Hose and Connection

Inspection..................................
Throttle Control System

Inspection..................................
Idle Speed Inspection ..................
Air Cleaner Element Cleaning......
Evaporative Emission Control

System Inspection (CAL) ..........
Cooling System...............................
Radiator Hose and Connection

Inspection..................................
Coolant Change ...........................
Engine Top End ..............................
Air Suction Valve Inspection ........
Clutch..............................................
Clutch Hose and Connection

Inspection..................................
Clutch Fluid Level Inspection .......
Clutch Fluid Change ....................
Clutch Master Cylinder Cup and

Dust Seal Replacement ............
Clutch Slave Cylinder Piston Seal

Replacement ............................
Engine Lubrication System .............
Engine Oil Change.......................
Oil Filter Replacement .................
Wheel/Tires.....................................
Tire Inspection .............................

2-2

2-4

2-10

2-12

2-13

2-13

2-13

2-13

2-14

2-15

2-15

2-16

2-16

2-17

2-19

2-19

2-19

2-19

2-20

2-20

2-21

2-22

2-23

2-23

2-24

2-24

2-24


Final Drive.......................................
Oil Level Inspection......................
Oil Change ...................................
Propeller Shaft Joint Lubrication ..
Brakes.............................................
Brake Pad Wear Inspection .........
Brake Hose and Connection
Inspection..................................
Brake Fluid Level Inspection........
Brake Fluid Change .....................
Brake Master Cylinder Cup and
Dust Seal Replacement ............
Caliper Piston/Dust Seals
Replacement .............................
Front Brake Light Switch
Inspection..................................
Rear Brake Light Switch
Check/Adjustment .....................
Suspension .....................................
Front Fork Oil Leak Inspection.....
Rear Shock Absorber Oil Leak
Inspection .................................
Swingarm Pivot Lubrication .........
Steering ..........................................
Stem Bearing Lubrication.............
Steering Check ............................
Steering Adjustment.....................
Electrical System ............................
Spark Plug Cleaning/Inspection...
General Lubrication ........................
Lubrication ...................................
Nut, Bolt, and Fastener Tightness ..
Tightness Inspection ....................

2-25
2-25
2-26
2-26
2-27
2-27
2-27
2-27
2-28
2-29
2-29
2-29
2-30
2-30
2-30
2-31
2-31
2-31
2-31
2-31
2-32
2-33
2-33
2-33
2-33
2-34
2-34

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever
comes
first
→
↓

OPERATION

1 000 km
* ODOMETER
READING
(600 mile)
6 000 km
(4 000 mile)
12 000 km
(7 500 mile)
18 000 km
(12 000 mile)
24 000 km
(15 000 mile)
30 000 km
(20 000 mile)
36 000 km
(24 000 mile)
See Page

Every

Spark plug (e) - clean and gap †
Air suction valve (e) - inspect †
Air cleaner element (e) - clean†#

•
•

Throttle control system (e) - inspect †
Idle speed (e) - inspect †
Fuel hoses, connections - inspect †
Engine oil - change #

year

Oil filter - replace
Evaporative emission control system (e)
(CAL) - inspect †

•
•
•

Final gear case oil level - inspect †

•

Final gear case oil - change
Propeller shaft joint - lubricate

• • •
• • •
•
• • •
•
• • •
•
•
• • •
•

•
• •
• •

Brake pad wear - inspect † #
Brake light switch - inspect †
Steering - inspect †
Rear shock absorber oil leak - inspect †
Front fork oil leak - inspect †

•

Tire wear - inspect †
Swingarm pivot - lubricate
General lubrication - perform

•

Nut, bolt, and fastener tightness - inspect †
Brake/clutch hoses, connections - inspect †
Brake/clutch fluid level - inspect †

month

Coolant hoses, connections - inspect †
Brake/clutch fluid - change

2 years

•
• •
•

•
•
•
•
•
•
•
•
•
•
•
•

•
•
•
•
•
•
•
•
•
•

• •
• •
• •
•
•
• •
•
•
• •
• •
•


• •
• •
•
• •
•
• •
•
•
• •
•
•
•
• •
• •
• •
•
•
• •
•
•
•
• •
• •

2–35
2–20
2–16
2–14
2–15
2–14
2–24
2–26
2–17
2–28
2–28
2–29
2–29
2–32
2–34
2–33
2–33
2–27
2–33
2–36
2–37
2–21, 2–29
2–21, 2–29
2–18
2–22, 2–30

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
→
↓

OPERATION
Brake/clutch master cylinder cup and dust
seal - replace

Every

1 000 km
* ODOMETER
READING
(600 mile)
6 000 km
(4 000 mile)
12 000 km
(7 500 mile)
18 000 km
(12 000 mile)
24 000 km
(15 000 mile)
30 000 km
(20 000 mile)
36 000 km
(24 000 mile)
See Page

4 years

Coolant - change

2 years

Caliper piston seal and dust seal - replace

4 years

Steering stem bearing - lubricate

2 years

Clutch slave cylinder piston seal - replace

4 years

2–23, 2–32

•

2–28

•

2–34

2–32
2–24

# : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
* : For higher odometer readings, repeat at the frequency interval established here.
† : Replace, add, adjust, clean, or torque if necessary.
Throttle control system inspection: Inspection of throttle grip play and throttle bore cleanliness.
(CAL): California
(e): Emission Related Items

2-4 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.

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:
L: Apply a non-permanent locking agent to
the threads.
G: Apply grease to the threads.
MO: Apply molybdenum disulfide grease oil
solution.
O: Apply oil to the threads and seating sur­
face.
S: Tighten the fasteners following the speci­
fied sequence.
SS: Apply silicone sealant.
Si: Apply silicone grease (ex. PBC grease).
R: Replacement parts
Lh: Left-hand-threads
St: Stake the fasteners to prevent loosening.
AL: Tighten the two clamp bolts alternately
two times to ensure even tightening
torque.
Fastener
Fuel System:
Throttle body assy holder bolts
Inlet manifold bolts
Spark plug lead holder bolts
ISC pipe holder bolts
Air cleaner duct holder bolts
Right and left air cleaner base bolts
Right and left air cleaner base screws
Left air cleaner cover Allen bolt 8
Right air cleaner cover Allen bolt 8
Right air cleaner Allen bolts
Choke cable plate screw
Inlet air temperature sensor nut (DFI)
Water temperature sensor (DFI)
Fuel pump bolts
Cooling System:
Radiator hose clamp screws
Radiator fan switch
Radiator fan bolts
Water temperature switch
Water pump impeller bolt
Water pump cover bolts
Water pump air bleeder bolt
Water pump drain bolt
Water pipe bolts

Basic Torque for General Fasteners
Threads
dia. (mm)

5
6
8
10
12
14
16
18
20

N·m

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

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 ∼ 33

ft·lb

11
12
11
11
9.8
11
2.2
16
16
11
2.9
7.8
18
9.8

1.1
1.2
1.1
1.1
1.0
1.1
0.22
1.6
1.6
1.1
0.30
0.80
1.8
1.0

95 in·lb
104 in·lb
95 in·lb
95 in·lb
69 in·lb
95 in·lb
19 in·lb
12
12
95 in·lb
26 in·lb
69 in·lb
13
87 in·lb

2.5
18
8.3
7.8
8.8
11
11
11
11

0.25
1.8
0.85
0.80
0.90
1.1
1.1
1.1
1.1

22 in·lb
13
74 in·lb
69 in·lb
78 in·lb
97 in·lb
97 in·lb
97 in·lb
97 in·lb

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

Remarks

Right Side
on Cyl. Head
Right Side
Left Side
L, Lower Duct

Throttle Body
L, Throttle Body

SS
S, L

SS
Lh

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent
Fastener
Radiator drain bolt
Water temperature sensor (DFI)
Engine Top End:
Spark plugs
Spark plug retainer
Air suction valve cover bolts
Chain tensioner mounting bolts
Chain tensioner cap
Chain tensioner lockbolt
Timing inspection cap
Rotor bolt cap
Camshaft sprocket bolts
Oil hose flange bolts
Rocker shafts
Rocker case nuts:
12 mm
8 mm
Rocker case bolts
6 mm
Cylinder head nuts
Cylinder head jacket plugs
Rocker case cover bolts
Camshaft chain guide bolts
Cylinder nuts
Inlet manifold bolts
Exhaust pipe cover clamp bolts
Chamber bolts
Muffler stay mounting bolts and nuts, 8
Muffler bracket bolt and nut
Clutch:
Clutch lever pivot bolt
Clutch lever pivot bolt locknut
Clutch reservoir cap crews
Clutch slave cylinder bleed valve
Clutch slave cylinder bolts
Clutch hose banjo bolts
Clutch master cylinder clamp bolts
Starter lockout switch screws
Push rod guide bolts
Clutch cover bolts
Clutch damper cover bolts (outside)
Clutch cover damper plate bolts
Clutch cover damper screws
Clutch hub nut

N·m
7.4
18

Torque
kgf·m
0.75
1.8

ft·lb
65 in·lb
13

18
12
7.4
11
20
4.9
1.5
1.5
15
9.8
25
78
25
8.8
25
20
8.8
11
25
12
6.9
29
25
29

1.8
1.2
0.75
1.1
2.0
0.50
0.15
0.15
1.5
1.0
2.5
8.0
2.5
0.90
2.5
2.0
0.90
1.1
2.5
1.2
0.70
3.0
2.5
3.0

13
104 in·lb
65 in·lb
95 in·lb
14
43 in·lb
13 in·lb
13 in·lb
11
87 in·lb
18
58
18
78 in·lb
18
14
78 in·lb
95 in·lb
18
104 in·lb
61 in·lb
22
18
22

1.0
5.9
1.5
7.8
6.9
25
11
1.2
11
11
9.8
9.8
4.9
147

0.10
0.60
0.15
0.80
0.70
2.5
1.1
0.12
1.1
1.1
1.0
1.0
0.50
15.0

8.7 in·lb
52 in·lb
13 in·lb
69 in·lb
61 in·lb
18
95 in·lb
10 in·lb
95 in·lb
95 in·lb
87 in·lb
87 in·lb
43 in·lb
108

Remarks

SS

S
S
S

L

MO, S
S
S
S
L
S
L
S
on Cyl. Head
except US, CA

Si

L
S
L
L
EO (tip)
L
MO

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent
Fastener
Engine Lubrication System:
Oil filler cap
Oil screen plug
Engine oil drain plug
Oil filter (cartridge type)
Oil filter Pipe
Oil pressure relief valve
Oil pressure switch terminal screw
Oil pressure switch
Oil pump mounting bolts
Oil hose banjo bolts
Oil hose flange bolt (outside)
Oil pipe holder bolts (inside)
Oil pipe clamp bolts (inside)
Right & left crankcase oil nozzles
Right crankcase oil nozzle
Oil baffle bolt
Engine Removal/Installation:
Downtube bolts and nuts
Engine mounting bolts and nuts
Engine mounting bracket bolts
Engine ground terminal bolt
Crankshaft/Transmission:
Crankcase bolts:
10 mm
8 mm
6 mm
Frame ground bracket bolt
Crankcase bearing retainer bolts
Camshaft chain guide bolts
Right, left crankcase oil nozzles
Right crankcase oil nozzles
Oil baffle bolt
Connecting rod big end nuts
Oil pressure relief valve
Oil filter Pipe
Oil hose banjo bolts
Primary gear bolt
Water pump chain guide spring hook bolt
Water pump chain guide bolt
Idle shaft holder bolts
Oil pressure switch terminal screw
Oil pressure switch
Oil pipe clamp bolts (inside)

N·m

Torque
kgf·m

ft·lb

1.5
20
20
18
25
15
1.5
15
11
9.8
9.8
11
11
2.9
2.9
11

0.15
2.0
2.0
1.8
2.5
1.5
0.15
1.5
1.1
1.0
1.0
1.1
1.1
0.30
0.30
1.1

13 in·lb
14
14
13
18
11
13 in·lb
11
95 in·lb
87 in·lb
87 in·lb
95 in·lb
95 in·lb
26 in·lb
26 in·lb
95 in·lb

44
44
25
7.8

4.5
4.5
2.5
0.80

33
33
18
69 in·lb

39
21
11
1.1
11
11
2.9
2.9
11
59
15
25
9.8
147
2.9
8.3
8.3
1.5
15
11

4.0
2.1
1.1
1.1
1.1
1.1
0.30
0.30
1.1
6.0
1.5
2.5
1.0
15.0
0.30
0.85
0.85
0.15
1.5
1.1

29
15
95 in·lb
95 in·lb
95 in·lb
95 in·lb
26 in·lb
26 in·lb
95 in·lb
43
11
18
87 in·lb
108
26 in·lb
73 in·lb
73 in·lb
13 in·lb
11
95 in·lb

Remarks

R, EO
SS
L
SS

L
L
× 3
× 1, Lh
L

S
S
S
Left Crankcase
L
L
× 3
× 1, Lh
L
MO
L
SS
MO

SS
L

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent
Fastener
Left balancer gear bolt
Starter clutch bolt
Starter clutch coupling bolts
Gear set lever bolt
Shift shaft return spring pin (bolt)
Shift pedal clamp bolt
Shift pedal clamp bolts (VN1600–A2 ∼)
Rear shift lever clamp bolt
Shift rod locknuts
Shift drum bearing holder bolts
Shift drum cam screw
Damper cam nut (front gear)
Push rod guide bolts
Wheels/Tires:
Front axle clamp bolts
Front axle
Rear axle nut
Tire air valve stem nuts
Tire air valve caps
Air valve cores
Final Drive:
Oil pipe banjo bolts (front gear)
Oil nozzle (front gear)
Oil nozzle (front gear)
Neutral switch
Front gear case bolts:
6 mm
8 mm
Speed sensor bolt
Damper cam nut (front gear)
Drive gear nut (front gear)
Driven gear assy mounting bolts
Driven gear bolt (front gear)
Bearing retainer bolts (front gear)
Final gear case drain plug
Final gear case mounting nuts
Final gear case studs
Final gear case cover bolts:
8 mm
10 mm
Pinion gear nut (final gear)
Bearing retainer bolt
Brakes:
Caliper bleed valves
Brake hose banjo bolts

N·m
85
85
15
11
39
25
30
12
11
11
15
195
9.8

Torque
kgf·m
8.7
8.7
1.5
1.1
4.0
2.5
3.1
1.2
1.1
1.1
1.5
20
1.0

ft·lb
63
63
11
95 in·lb
29
18
22
104 in·lb
95 in·lb
95 in·lb
11
144
87 in·lb

20
108
108
1.5
0.15
0.3

2.0
11.0
11.0
0.15
0.015
0.03

14
79.6
79.6
13 in·lb
1.3 in·lb
2.6 in·lb

12
2.9
18
15
12
29
9.8
195
265
25
137
8.8
8.8
34
–
23
34
130
6.9

1.2
0.30
1.8
1.5
1.2
3.0
1.0
20
27
2.5
14
0.9
0.9
3.5
–
2.3
3.5
13
0.7

104 in·lb
26 in·lb
13
11
104 in·lb
22
87 in·lb
144
195
18
101
78 in·lb
78 in·lb
25
–
17
25
94
61 in·lb

7.8
25

0.8
2.5

69 in·lb
18

Remarks
MO
MO
L
L

(Rear: Lh)
L
L
MO (threads)
L
AL
S

L
MO (threads)
MO, St
MO, St
L

L
L
L
St, MO
L

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent
Fastener
Brake lever pivot bolt
Brake lever pivot bolt locknut
Front brake reservoir cap screws
Front brake light switch screw
Front master cylinder clamp bolts
Front caliper mounting bolts
Rear caliper mounting bolts
Rear caliper holder bolt
Brake disc bolts
Rear master cylinder mounting bolts
Rear master cylinder push rod locknut
Brake pedal clamp bolt
Suspension:
Upper front fork clamp bolts
Lower front fork clamp bolts
Front fork top plugs
Piston rod nuts or joint rod nut
Front fork bottom allen bolt
Front axle clamp bolts
Rear shock absorber nuts
Swingarm pivot shaft
Steering:
Steering stem head nut
Steering stem nut
Handlebar clamp bolts
Handlebar holder nuts
Upper front fork clamp bolts
Lower front fork clamp bolts
Turn signal light mounting nuts
Frame:
Downtube bolts and nuts
Footboard bracket bolts
Footpeg bracket bolts
Sidestand nut
Electrical System:
Spark plugs
Crankshaft sensor screws
Stator lead holder screw
Inside stator holder bolts
Crankshaft sensor lead holder bolt
Alternator outer cover bolts
Alternator outer cover joint bolts
Alternator outer cover damper bolts

N·m
1.0
5.9
1.5
1.2
8.8
34
34
64
27
25
18
25

Torque
kgf·m
0.10
0.60
0.15
0.12
0.9
3.5
3.5
6.5
2.8
2.5
1.8
2.5

ft·lb
8.7 in·lb
52 in·lb
13 in·lb
10 in·lb
78 in·lb
25
25
47
20
18
13
18

20
29
22
20
30
20
34
108

2.0
3.0
2.2
2.0
3.1
2.0
3.5
11.0

14
21
16
14
22
14
25
79.6

88
5
34
34
20
29
5.9

9.0
0.5
3.5
3.5
2.0
3.0
0.6

65
43 in·lb
25
25
14
21
52 in·lb

44
34
25
44

4.5
3.5
2.5
4.5

33
25
18
33

18
2.9
9.8
11
2.9
6.9
6.9
6.9

1.8
0.30
1.0
1.1
0.30
0.70
0.70
0.70

13
26 in·lb
87 in·lb
95 in·lb
26 in·lb
61 in·lb
61 in·lb
61 in·lb

Remarks

G, S

L

AL

L
AL
G

AL

front
rear, L

L
L
L
L
L

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent
Fastener
Alternator outer cover assembly bolts
Alternator cover bolts
Alternator inner cover bolts
Alternator rotor bolt
Alternator stator bolts
Regulator/rectifier bolts
Timing inspection cap
Rotor bolt cap
Starter motor terminal locknut
Starter motor terminal nut
Starter motor assembly bolts
Starter motor mounting bolts
Headlight rim screws
Headlight unit bracket screws
Starter lockout switch screw
Front brake light switch screw
Sidestand switch bolt
Radiator fan switch
Radiator fan bolts
Fuel level sensor mounting bolts
Fuel pump mounting bolts
Water temperature switch
Water temperature sensor
Oil pressure switch terminal screw
Oil pressure switch
Neutral switch
Speed sensor mounting bolt
Turn signal light mounting screws
Turn signal light lens screws
Tail/brake light mounting nuts
Tail/brake light lens screws
Tail/brake light assembly screws

N·m
6.9
11
11
78
13
6.5
1.5
1.5
11
4.9
4.9
11
2.9
1.0
1.2
1.2
8.8
18
8.3
6.9
9.8
7.8
18
1.5
15
15
9.8
6.9
1.0
5.9
1.2
1.2

Torque
kgf·m
0.70
1.1
1.1
8.0
1.3
0.66
0.15
0.15
1.1
0.50
0.50
1.1
0.30
0.10
0.12
0.12
0.90
1.8
0.85
0.70
1.0
0.80
1.8
0.15
1.5
1.5
1.0
0.70
0.10
0.60
0.12
0.12

ft·lb
61 in·lb
95 in·lb
95 in·lb
58
113 in·lb
57 in·lb
13 in·lb
13 in·lb
95 in·lb
43 in·lb
43 in·lb
95 in·lb
26 in·lb
8.7 in·lb
10 in·lb
10 in·lb
78 in·lb
13
7.4 in·lb
61 in·lb
87 in·lb
69 in·lb
13
13 in·lb
11
11
8.7 in·lb
61 in·lb
8.7 in·lb
52 in·lb
10 in·lb
10 in·lb

Remarks

MO
L

L

L

L
S
SS
SS
G
SS
L

2-10 PERIODIC MAINTENANCE

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

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:
4.3 mm (0.17 in.)

1 mm (0.04 in.),

BRIDGESTONE EXEDRA G722:
7.2 mm (0.28 in.)

Up to 130 km/h (80 mph):

(DE, AT, CH): 1.6 mm

(0.063 in.)
Rear

2 mm (0.08 in.)
Over 130km/h (80mph):
3 mm (0.1 in.)

Air pressure: (when cold)
Front
Rear

Up to 186 kg (410 lb) load: 200 kPa
(2.0 kgf/cm², 28 psi)
Up to 186 kg (410 lb) load: 250 kPa
(2.5 kgf/cm², 36 psi)

– – –
– – –

PERIODIC MAINTENANCE 2-11

Specifications
Item
Final Drive:
Final gear case oil:
Grade
Viscosity
Oil level
Amount
Propeller shaft joint grease
Brakes:
Brake fluid
Grade
Brake pad lining thickness:
Front
Rear
Brake light timing:
Front
Rear
Electrical System:
Spark plug gap

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)
20 mL (0.68 US oz), high-temperature
grease

DOT4
4.5 mm (0.18 in.)
7.5 mm (0.295 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

– – –

0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)

– – –

AT: Republic of Austria
CH: Swiss Confederation
DE: Federal Republic of Germany

– – –

2-12 PERIODIC MAINTENANCE

Special Tools
Steering Stem Nut Wrench :
57001–1100

Attachment Jack :
57001–1398

Jack :
57001–1238

Filler Cap Driver :
57001–1454

PERIODIC MAINTENANCE 2-13

Periodic Maintenance Procedures
Fuel System (DFI)
Fuel Hose and Connection Inspection

○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 in­
side the fuel line can cause fuel to leak [A] or the hose to
burst. Remove the fuel tank (see Fuel System 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, kink­
ing, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be ob­
structed.
Replace the hose if it has been sharply bent or kinked.

Throttle Control System Inspection
Throttle Grip Play Inspection
Check the throttle grip free play [A].
If the free play is incorrect, adjust the throttle cable (see
below).

•

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 throt­
tle 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.

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 (rear
view).
○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.

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures
Throttle Bore Cleaning
Check the throttle bore for cleanliness as follows:
○Remove the air cleaner cover Allen bolt [A] and take off
the right air cleaner cover [B].
Front [C]

•

○Check the throttle bores [A] at the throttle valves [B] and
around them for carbon deposits by opening the valves.
If any carbon accumulates, wipe the carbon off the throttle
bores around the throttle valves, using a lint-free cloth [C]
penetrated with a high-flash point solvent.
Front [D]

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 auto­

•
•

matically. This is the idle speed.
Check the idle speed.
Idle Speed

Standard:

950 ± 50 r/min (rpm)


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.
If the idle speed is out of the specified range, adjust it.
Start the engine and warm it up thoroughly.
○Wait until fast idle speed lowers to a certain value.
Turn the adjusting screw [A] until the idle speed is correct.
○Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Front [B]

•
•

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures
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] and Left Air Cleaner Cover [B]

Front [C]

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 en­
gine wear and possibly engine damage will occur.
the element by tapping it lightly to loosen dust.
• Clean
away the remaining dust by applying compressed
• Blow
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)

Evaporative Emission Control System Inspection
(CAL)
the canister as follows:
•○Inspect
Remove the left side cover (see 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 motorcycle’s life without any maintenance if it is used under
normal conditions.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

○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 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 dam­
age.
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 sys­
tem 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 di­
agram 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.

•

Cooling System
Radiator Hose and Connection Inspection

○The

•

high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m,
22 in·lb)

PERIODIC MAINTENANCE 2-17

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 (front view).
the fuel tank (see Fuel System (DFI) chapter).
• Remove
Remove
the radiator cap [A] in two steps. First turn the
• cap counterclockwise
to the first stop. Then push and turn
it further in the same direction and remove the cap.
○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 Frame chapter)

•
•
•

Reserve Tank Bolts
Turn over the reserve tank [A], remove the cap [B], and
pour the coolant into a suitable container.
Install the reserve tank.
When filling the coolant, choose a suitable mixture ratio
by referring to the coolant manufacturer’s directions.

CAUTION
Soft or distilled water must be used with the an­
tifreeze (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 consider­
ably reduces the efficiency of the cooling system.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures
Water and Coolant Mixture Ratio (when shipping)
:
Soft Water
50 %
:
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: 7.4 N·m (0.75 kgf·m, 65 in·lb)
Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 95 in·lb)

• Fill the coolant into the radiator.
NOTE

○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,
95 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.
•

the reserve tank up to the “F” (full) level line [A] with
• Fill
coolant and install the cap.
the fuel tank (see Fuel System (DFI) chapter).
• Install
Start
the
engine and warm it up thoroughly until the radi­
• ator fan turns
on and then stop the engine.
Check
the
coolant
in the reserve tank several times
• while the engine islevel
cooling down, and replenish as nec­
essary.
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 2-19

Periodic Maintenance Procedures
Engine Top End
Air Suction Valve Inspection

the air suction valve (see Engine Top End chap­
• Remove
ter).
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.

Clutch
Clutch Hose and Connection 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 exam­
ining it.
Replace it if any fraying, cracks [B] or bulges [C] are no­
ticed.
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 Ap­
pendix chapter.
Replace the hose if it has been sharply bent or kinked.

2-20 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 Brake Fluid Section in the Brakes 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 Change

the clutch fluid reservoir and remove the reservoir
• Level
cap.
the alternator outer cover (see Electrical System
• Remove
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.

Open [B] the bleed valve, using a wrench.

Pump the clutch lever and hold [C] it.

Close [D] the bleed valve.

Release [E] the clutch lever.

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.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures
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)

Clutch Master
Replacement

Cylinder

Cup

and

Dust

Seal

the clutch master cylinder (see Clutch chapter).
• Remove
Remove
the reservoir cap [A] and diaphragm [B], and
• pour the clutch
fluid into a container.
Unscrew
the
locknut
• the clutch lever [E]. [C] and pivot bolt [D], and remove
the dust cover [F] out of place, and remove the circlip
• Pull
[G].
Special Tool - Inside Circlip Pliers: 57001-143

out the primary cup [H], piston assembly [I], and re­
• Pull
turn spring [J].

CAUTION
Do not remove the secondary cup [K] from the pis­
ton since removal will damage it.
the parts of the clutch master cylinder (see Clutch
• Check
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 deterio­
ration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely, and will eventu­
ally deteriorate the rubber used in the cylinder.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures
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, 8.7
in·lb)
Clutch Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)

• Install the clutch master cylinder (see Clutch chapter).
Clutch Slave Cylinder Piston Seal Replacement

the clutch slave cylinder (see Clutch chapter).
• Remove
Loosen
the
banjo bolt [A] at the clutch pipe lower end, and
• 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 the spring and piston seal.
CAUTION
Replace the piston seal with a new one if it was re­
moved from the piston.
assembly, apply clutch fluid to the outside of the

• Before
piston and the piston seal.

the piston seal as shown.

• Install
Cylinder [A]

Piston [B]

Piston Seal [C]

Spring [D]


PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures
Engine Lubrication System
Engine Oil Change

Situate the motorcycle so that it is vertical after warming
• up
the engine.
Remove
the engine oil drain plug [A] and drain the oil.
•

• Remove:
Oil Screen Plug [A] (Engine right side)

the oil screen [A], the spring [B], and the washer
• Remove
[C].
Clean the oil screen with a high-flash point solvent and
• remove
any particles stuck to it.
Cl
ean
the
• changed. screen thoroughly whenever the engine oil is

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 if it is dam­
aged.
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 Change in this section).
Replace the drain plug gasket with a new one if it is dam­
aged.

Torque - Engine Oil Drain Plug , Oil Screen Plug: 20 N·m
(2.0 kgf·m, 14 ft·lb)
Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures
the oil filler cap [A] with the driver-filler cap [B]
• Remove
and pour in the specified type and amount of oil.

Clutch Cover [C]

Special Tool - Driver-Filler Cap: 57001–1454
Torque - Oil Filler Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb)

Engine Oil

Type:
Viscosity:
Amount:

API SE, SF or SG class

API SH or SJ class 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)

○Although

NOTE

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 sec­
• Drain
tion).
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 the new one.
• Replace
Apply
oil
to the gasket of the new filter before installation.
• Tighten the
filter with the oil filter wrench.
• Pour in the specified
type and amount of oil.
•
Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

Wheel/Tires
Tire Inspection
As the tire tread wears down, the tire becomes more sus­
ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
Remove any imbedded stones or other foreign particles
from the tread.
Visually inspect the tire for cracks and cuts, replacing the
tire in case of damage. Swelling or high spots indicate
internal damage, requiring tire replacement.

•
•

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 Wheels/Tires chapter).
Tread Depth
Front:
Standard:
Service Limit:
Rear:
Standard:
Service Limit:

4.3 mm (0.17 in.)
1 mm (0.04 in.)
(DE, AT, CH) 1.6 mm (0.063 in.)
7.2 mm (0.28 in.)
2 mm (0.08 in.):
Up to 130 km/h (80 mph)
3 mm (0.1 in.):
Over to 130 km/h (80 mph)

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 186 kg (410 lb)

200 kPa (2.0 kgf/cm², 28 psi)

Rear Up to 186 kg (410 lb)

250 kPa (2.5 kgf/cm², 36 psi)

WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, in­
flated 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 Wheels/Tires chapter).

Final Drive
Oil Level Inspection

WARNING
Motorcycle operation with insufficient, deterio­
rated, 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
Unscrew
the filler plug [A], using the driver-filler cap [B].
•
Special Tool - Driver-Filler Cap: 57001–1454

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures
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 open­
ing. Use the same type and brand of oil that is already in
the final gear case.
Install the filler plug.

Oil Change

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 care­
ful 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.

• Be sure the O-ring is in place, and install the filler plug.
Propeller Shaft Joint Lubrication

the final gear case and propeller shaft joint (see
• Remove
Final Drive chapter).
the old grease off the propeller shaft sliding joint and
• Wipe
pinion joint.
the propeller shaft sliding joint with 20 mL (16
• Pack
grams) of high temperature grease [A].

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures
Brakes
Brake Pad Wear Inspection

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
Brakes chapter).
Pad Lining Thickness
Standard:
Front:
4.5 mm (0.18 in.)
Rear:
7.5 mm (0.295 in.)
Service Limit: 1 mm (0.04 in.)

Brake Hose and Connection 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 main­
tained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are no­
ticed.
Tighten any loose fittings.

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].

2-28 PERIODIC MAINTENANCE

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.
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

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.

Brake Fluid Change
NOTE

○The procedure to change the front brake fluid is as fol­
lows. Changing the rear brake fluid is almost the same
as for the front brake.
the brake fluid reservoir.
• Level
Remove
the reservoir cap [A], plate [B] and diaphragm [C]
•
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.
the reservoir with new brake fluid.
• Fill
Temporarily
the reservoir cap.
• Change the install
brake
fluid
as follows:
•

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.

PERIODIC MAINTENANCE 2-29

Periodic Maintenance Procedures

○Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
Open the bleed valve [A].
Pump the brake lever and hold it [B].
Close the bleed valve [C].
Release the brake lever [D].
Front Brake : Repeat the above steps for other caliper.

the clear plastic hose.
• Remove
Install
the
cap.
• Tighten thereservoir
bleed
valves,
and install the rubber caps.
•

Torque - Caliper Bleed Valves: 7.8 N·m (0.8 kgf·m, 69 in·lb)
Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

○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 Brakes
chapter).

Brake Master
Replacement

Cylinder

Cup

and

Dust

Seal

to the Master Cylinder section in the Brakes chapter
• Refer
for Brake/Master Cylinder Cup and Dust Seal Replace­
ment.

Caliper Piston/Dust Seals Replacement

to the Calipers section in the Brakes chapter for
• Refer
Caliper Piston/Dust Seals Replacement.

Front Brake Light Switch Inspection

on the ignition switch.
• Turn
The
brake
• is applied. light should go on when the front brake lever
If it does not, replace the switch.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures
Rear Brake Light Switch Check/Adjustment

on the ignition switch.
• Turn
Check
of the rear brake light switch by de­
• pressingthetheoperation
brake pedal [A]. The brake light should go
on after about 10 mm (0.39 in.) of the pedal travel [B].

•

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]


CAUTION
To avoid damaging the electrical connections in­
side the switch, be sure that the switch body does
not turn during adjustment.

Suspension
Front Fork Oil Leak Inspection

• Remove the bolts [A] and then slide the cover 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.

PERIODIC MAINTENANCE 2-31

Periodic Maintenance Procedures
Rear Shock Absorber Oil Leak Inspection

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.

Swingarm Pivot Lubrication

the swingarm (see Suspension chapter).
• Remove
Clean
the
old grease out of the bearings.
• 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.
• Install the swingarm (see Suspension chapter).

Steering
Stem Bearing Lubrication

the steering stem. (see Steering chapter).
• Remove
Using
a
high-flash point solvent, wash the upper and
• 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
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 chapter).

Steering Check

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.
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.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

○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 Adjustment

•
•
•

Adjust the steering, if necessary.
Loosen the upper fork clamp bolt [A] on both side and
unscrew the stem head nut [B].
Remove the O-ring (see Steering chapter).
Remove the steering stem head [C] together with the han­
dlebar installed.

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: 49 N·m (0.5 kgf·m, 43 ft·lb)

l the stem head.
• Instal
Ti
ghten
the following in the order listed.
•

Torque - Stem Head Nut: 88 N·m (9.0 kgf·m, 65 ft·lb)
Upper Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 14
in·lb)

○Run the throttle cables, brake hose, and clutch hose in

•

accordance with the Cable, Wire, and Hose Routing sec­
tion in the General Information 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 2-33

Periodic Maintenance Procedures
Electrical System
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 elec­
trode [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 (0.031 ∼ 0.035 in.)

General Lubrication
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.

NOTE

○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri­
cation.
Pivots: Lubricate with 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

Sidestand


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 [A] with an aerosol ca­
ble lubricant [B].

•

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures
the cable disconnected at both ends, the cable
• With
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.

Nut, Bolt, and Fastener Tightness
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 spec­
ified torque, following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table 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.
Nut, Bolt and Fastener to be checked
Wheels:

Front Axle

Front Axle Clamp Bolts

Rear Axle Nut

Rear Axle Nut Cotter Pin

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

Front Fender Mounting Bolts

Rear Shock Absorber Mounting Nuts

Swingarm Pivot Shaft

Steering:

Stem Head Nut

Handlebar Clamp Bolts


PERIODIC MAINTENANCE 2-35

Periodic Maintenance Procedures
Engine:
Throttle Cable Adjuster Locknuts
Engine Mounting Bolts and Nuts
Shift Pedal Bolts
Muffler Mounting Bolt and Nut
Exhaust Pipe Holder Nuts
Clutch Master Cylinder Clamp Bolts
Clutch Lever Pivot Nut
Radiator Mounting Bolt
Radiator Bracket Bolts
Others:
Sidestand Bolt and Nut
Footboard Bracket Bolts
Footpeg Bracket Mounting Bolts
Downtube Bolts (Right)

FUEL SYSTEM (DFI) 3-1


Fuel System (DFI)
Table of Contents
Exploded View...................................
DFI Parts Location.............................
DFI System........................................
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) ....
Throttle Sensor

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............
Sensor Resistance Inspection .....
Water Temperature Sensor (Service

Code 14) .........................................
Removal/Installation.....................
Output Voltage Inspection............
Water Temperature Sensor

Resistance Inspection ...............
Atmospheric Pressure Sensor

(Service Code 15)...........................
Removal.......................................
Installation....................................
Input Voltage Inspection...............
Output Voltage Inspection............
Crankshaft Sensors (#1, #2: Service

Code 21, 22) ...................................

3-4

3-8

3-12

3-14

3-17

3-18

3-19

3-20

3-20

3-24

3-27

3-36

3-36

3-37

3-38

3-41

3-41

3-41

3-42

3-43

3-44

3-44

3-44

3-44

3-45

3-49

3-49

3-49

3-50

3-51

3-51

3-51

3-52

3-53

3-53

3-53

3-53

3-54

3-57


Crankshaft Sensor
Removal/Installation..................
Crankshaft Sensor Inspection......
Vehicle-down Sensor (Service Code
31)...................................................
Vehicle-down Sensor 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
Operating 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.....................

3
3-57
3-57
3-58
3-58
3-58
3-59
3-61
3-61
3-61
3-64
3-64
3-65
3-65
3-66
3-66
3-68
3-68
3-68
3-69
3-69
3-69
3-70
3-71
3-71
3-73
3-73
3-73
3-74
3-75
3-76
3-76
3-76
3-76
3-76
3-78
3-78
3-78
3-78
3-78
3-80
3-80

3-2 FUEL SYSTEM (DFI)

Power Source Voltage Inspection
Output Voltage Inspection............
Resistance Inspection..................
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.................
Throttle Bore Cleaning .................
High Altitude Performance

Adjustment ................................
Throttle Body Assy Removal........
Throttle Assy Installation..............
Throttle Assy

Disassembly/Assembly .............
Air Cleaner.........................................

3-80
3-81
3-81
3-83

3-83

3-85

3-86

3-86
3-86

3-86

3-86

3-86
3-86
3-87

3-87
3-87
3-87
3-87

3-87

3-90
3-91

3-94

Element Removal.........................
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 (Periodic

Inspection).................................
Separator Inspection (Periodic

Inspection).................................
Hose Inspection (Periodic

Inspection).................................
Separator Operation Test.............

3-94

3-94

3-94

3-95

3-95

3-96

3-97

3-97

3-100

3-101

3-102

3-103

3-103

3-103

3-103

3-103

3-104

3-104


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
Water temperature sensor
Left air cleaner cover Allen bolt 8
Left air cleaner base bolts
Left air cleaner base screws
Right air cleaner base screws
Right air cleaner base bolt
Right air cleaner Allen bolts
Right air cleaner cover Allen bolt 8
Throttle body assy holder bolts
Spark plug lead holder bolts
Air cleaner duct holder bolts

N·m
18
16
11
2.2
2.2
11
11
16
11
11
9.8

12. Vacuum switch valve
13. Air cleaner element
14. Left air cleaner base
15. Air cleaner duct holder
16. Crankcase breather hose
17. Air cleaner drain hose
18. Right air cleaner base
19. Right spark plug lead holder
20. Throttle body assy

CA: California Model

CN: Canadian Model

U.S.: United States Model
SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
L: Apply a non-permanent locking agent.

Torque
kgf·m
1.8
1.6
1.1
0.22
0.22
1.1
1.1
1.6
1.1
1.1
1.0

ft·lb
13
12
95 in·lb
19 in·lb
19 in·lb
95 in·lb
95 in·lb
12
95 in·lb
95 in·lb
69 in·lb

Remarks
SS

L
L

3-6 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-7

Exploded View
No.
1
2
3
4
5
6
7

Fastener
Fuel pump bolts
Inlet air temperature sensor nut
ISC pipe bolts
Throttle body assy holder bolts
Spark plug lead holder bolts
Choke cable plate screw
Inlet manifold bolt

8. Fuel tank
9. Vehicle-down sensor
10. Atmospheric pressure sensor
11. Inlet air pressure sensor
12. Choke cable
13. Throttle cable (accelerator)
14. Throttle cable (decelerator)
15. ECU (Electronic control unit)
16. DFI main relay
17. Battery case
18. ISC valve #1 (for Front cylinder)
19. ISC valve #2 (for Rear cylinder)
20. Right air cleaner base
21. Inlet air temperature sensor
22. Throttle body
23. Inlet manifold
24. Seal
25. Injector #1 for front cylinder
26. Injector #2 for rear cylinder
27. O-ring
28. Delivery joint
R: Replacement Parts
L: Apply a non-permanent locking agent.
G: Apply grease.
CL: Apply cable lubricant.
S: Follow the specified tightening sequence.

N·m
9.8
7.8
11
11
11
2.9
12

Torque
kgf·m
1.0
0.80
1.1
1.1
1.1
0.30
1.2

ft·lb
87 in·lb
69 in·lb
95 in·lb
95 in·lb
95 in·lb
26 in·lb
104 in·lb

Remarks
S, L

L

3-8 FUEL SYSTEM (DFI)

DFI Parts Location

FUEL SYSTEM (DFI) 3-9

DFI Parts Location
DFI: DFI Parts (this chapter)
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. Sidestand 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 × 32 V
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 #1 (DFI, for Front Cylinder)
24. ISC Valve #2 (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)

3-10 FUEL SYSTEM (DFI)

DFI Parts Location

FUEL SYSTEM (DFI) 3-11

DFI Parts Location

3-12 FUEL SYSTEM (DFI)

DFI System

FUEL SYSTEM (DFI) 3-13

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 (front view)
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 #1 (Idle Speed Control Valve #1, rear side)
17. ISC Valve #2 (Idle Speed Control Valve #2, front side)
18. Vehicle-down Sensor (rear view)
19. Fuel Tank (left view)
20. Alternator Rotor (left view)
21. Sealed Battery (left view)
22. Left Air Cleaner Housing (rear view)
23. Right Air Cleaner Housing (rear view)
24. Lower Air Cleaner Duct (rear view)
25. Thermostat Housing (left view)
26. Throttle Valves
27. Fuel Flow
28. Air Flow
29. Speed Sensor (upper view)
30. Fuel Hose Joint #1
31. Fuel Hose Joint #2

3-14 FUEL SYSTEM (DFI)

DFI Wiring Diagram

FUEL SYSTEM (DFI) 3-15

DFI Wiring Diagram
Terminal Numbers of ECU Connectors

Terminal Names
#1: Front Cylinder, #2: 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 #1 Signal
19. —
20. Ignition Control Circuit Ground to Battery (–) Terminal
21. Engine Stop Signal
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 #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 #2 Signal
42. Ignition Control Circuit Ground to Battery (–) Terminal
43. Ignition Coil #2 Signal

3-16 FUEL SYSTEM (DFI)

DFI Wiring Diagram
44. Ignition Coil #1 Signal
DFI and Electrical Parts
DFI: DFI Parts

ECU [A]: Electronic Control Unit (DFI)

Engine Stop Switch [B]

Starter Button [C]

Ignition Coils [D]

Crankshaft Sensors (Crankshaft Sensors) [E]

Junction Box [F]

Starter Circuit Relay [G]

Interlock Diodes [H]

LCD (Liquid Crystal Display) [J]

MODE Button [K]

FI Indicator LED Light [L]: (DFI)

Speedometer [M]

Ignition Switch [N]

Starter Relay [O]

Main Fuse 30 A × 32 V [P]

Sealed Battery [Q]

Fuel Injector #1 [R]: (DFI)

Fuel Injector #2 [S]: (DFI)

RESET Button [T]

Fuel Pump [U]: (DFI)

DFI Fuse 15 A × 32 V [V]: (for ECU, Injectors, Fuel Pump, DFI Main Relay, and ISC Valves)

ISC Valve #1 [W]: (DFI)

ISC Valve #2 [X]: (DFI)

Inlet Air Temperature Sensor [Y]: (DFI)

Water Temperature Sensor [Z]: (DFI)

Inlet Air Pressure Sensor [a]: (DFI)

Atmospheric Pressure Sensor [b]: (DFI)

Throttle Sensor [g]: (DFI)

Vehicle-down Sensor [d]: (DFI)

DFI Main Relay [e]: (for ECU, Injectors, Fuel Pump, and ISC Valves)

Ignition Fuse 10 A × 32 V [f]

Speed Sensor [i]

ECU Connector [l]

Connector Lock [m]

Self-diagnosis Check Female Connector [n]

Joint Connector 1 [p]

Frame Earth [q]


FUEL SYSTEM (DFI) 3-17

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 SW ON

After pump runs 3 sec. and stops.
With engine idling
Throttle Sensor:
Input voltage
Output voltage at idle throttle opening
Output voltage at full throttle opening
Resistance
Atmospheric Pressure Sensor

or Inlet Air Pressure Sensor:

Input voltage
Output voltage

Inlet Air Temperature Sensor:

Resistance


Water Temperature Sensor:

Resistance


Vehicle-down Sensor:

Detection angle

Detection time

Fuel Injectors:

Type

Static injection quantity

Nozzle type × diameter

Resistance

Fuel Pump:

Type

Discharge


Standard
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Paper filter
Mitsubishi Electric

950 ± 50 r/min (rpm)

Two barrel type ×

36 mm (1.42 in.)


Digital memory type, with built in IC igniter, sealed with
resin
100 ∼ 6 200 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
280 kPa (2.9 kgf/cm², 41 psi) with fuel pump stopped
304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running
4.75 ∼ 5.25 V DC between BL/W and BR/BK leads
0.584 ∼ 0.604 V DC between Y/W and BR/BK leads
4.29 ∼ 4.59 V DC between Y/W and BR/BK leads
4 ∼ 6 kΩ between BL/W and BR/BK leads


4.75 ∼ 5.25 V DC

3.74 ∼ 4.26 V DC at standard atmospheric pressure
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)
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)

More than 45° ± 5° for each bank

Within 0.5 ∼ 1.0 sec.

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

3-18 FUEL SYSTEM (DFI)

Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm² :
57001–125

Filler Cap Driver :
57001–1454

Fork Oil Level Gauge :
57001–1290

Needle Adapter Set :
57001–1457

Hand Tester :
57001–1394

Kawasaki Bond (Silicone Sealant) :
56019–120

Fuel Pressure Gauge Adapter :
57001–1417

FUEL SYSTEM (DFI) 3-19

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
driver-filler cap [B].
Clutch Cover [C]

Front [D]

Special Tool - Driver-Filler Cap: 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 SW (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 con­
nected to the battery positive (+) terminal to the chassis
ground.
○When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.

○Whenever the DFI electrical connections are to be discon­

nected, first turn off the ignition SW (switch), and discon­
nect the battery (–) terminal. Do not pull the lead, only the
connector. Conversely, make sure that all the DFI elec­
trical connections are firmly reconnected before starting
the engine.
○Connect these connectors until they click [A].
○Do not turn the ignition SW ON while any of the DFI elec­
trical connectors are disconnected. The ECU memorizes
fault codes.
○Do not spray water on the electrical parts, DFI parts, con­
nectors, leads, and wiring. Never water a vehicle with
connectors unplugged because seals don’t work and ter­
minals 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 SW. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
○Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer sur­
faces of these parts clean with compressed air.
○When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.

3-20 FUEL SYSTEM (DFI)

Troubleshooting the DFI System
Outline
When an abnormality in the system occurs, the FI indica­
tor 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 indi­
cated 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
SW (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 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) 3-21

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 (spe­
cial 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 elec­
trical system parts by contact between adapters.
Turn the ignition SW 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.
Silicone Sealant-

(Kawasaki Bond: 56019–120)-Seals
of Connector

check battery condition before replacing the DFI
• Always
parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.

3-22 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 SW 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, in­
spect the ECU for its ground and power supply (see 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. Re­
place the lead.

•
•

FUEL SYSTEM (DFI) 3-23

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 re­
placed.

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

G: Green
GY: Gray
LB: Light blue
LG: Light green
O: Orange

P: Pink
PU: Purple
R: Red
W: White
Y: Yellow

3-24 FUEL SYSTEM (DFI)

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.

FUEL SYSTEM (DFI) 3-25

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.
□ fine, □ cloudy, □ rain, □ snow, □ always, □ other:
Weather
□ hot, □ warm, □ cold, □ very cold, □ always
Temperature
Problem
□ chronic, □ often, □ once
frequency
□ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble
Road
□ normal, □ high (about 1 000 m (3 281 ft) or more)
Altitude
Motorcycle conditions when problem occurred.
FI indicator
□ light up immediately after ignition SW ON, and goes off after engine oil pressure
LED light
is high enough (with engine running) (normal).
□ lights up immediately after ignition SW ON, and stays on after engine oil
pressure is high enough (with engine running) (DFI problem)

□ lights up immediately after ignition SW ON, but goes off after about 10 seconds

Starting
difficulty

Engine stops

Poor running
at low speed

though engine oil pressure is high enough (with engine running) (DFI problem).
□ 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.
□ engine oil viscosity too high.

3-26 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Poor running
or no power at
high speed

□ 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:

FUEL SYSTEM (DFI) 3-27

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

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).

Starter system wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Main 30A or ignition fuse blown
Starter motor rotating but engine doesn’t
turn over:
Starter clutch trouble
Starter idle gear trouble
Engine won’t turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure

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).

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

Inspect
Inspect
Inspect
Inspect
Inspect
Inspect

Fuel line clogged
Engine flooded:
Spark plug dirty, broken or gap maladjusted
Starting technique faulty

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).
and
and
and
and
and
and

replace
replace
replace
replace
replace
replace

(see
(see
(see
(see
(see
(see

chapter
chapter
chapter
chapter
chapter
chapter

5).
9).
9).
9).
9).
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.

3-28 FUEL SYSTEM (DFI)

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 sidestand up or not
Though clutch lever pulled in but sidestand 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

Actions (chapter)
Turn both switches ON.
Pull the lever in and shift the gear in neutral.
Sidestand 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).

Spark plug cap shorted or not in good contact
Spark plug incorrect
IC igniter in ECU trouble
Neutral, starter lockout or sidestand switch
trouble
Crankshaft sensor trouble
Ignition coil trouble
Ignition switch shorted
Engine stop switch shorted
Starter system wiring shorted or open
Main 30A or ignition fuse blown
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed or missing

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).

ISC valve trouble
Crankshaft sensor trouble
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down

Inspect (see chapter 3).
Inspect (see chapter 3).

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).
Leak from oil filler cap, crankcase breather hose Inspect and repair or replace (see chapter 3).
or air cleaner drain hose
Water or foreign matter in fuel
Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel pressure regulator trouble
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Throttle sensor trouble
Inspect (see chapter 3).
Fuel pressure may be low
Inspect (see chapter 3).
Fuel pump trouble
Inspect (see chapter 3).
Fuel injector trouble
Inspect (see chapter 3).
Inlet air pressure sensor trouble
Inspect (see chapter 3).
Atmospheric pressure sensor trouble
Inspect (see chapter 3).
Inlet air temperature sensor trouble
Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).

Reinstall (see chapter 16).
Tighten (see chapter 5).

FUEL SYSTEM (DFI) 3-29

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

Actions (chapter)
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Replace (see chapter 5).

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

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).

3-30 FUEL SYSTEM (DFI)

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

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).

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 :

Inspect (see chapter 3).

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

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).

Inlet air temperature sensor trouble

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).

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).

FUEL SYSTEM (DFI) 3-31

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

Inspect
Inspect
Inspect
Inspect

(see
(see
(see
(see

Actions (chapter)
chapter 3).
chapter 3).
chapter 3).
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).

Engine oil level too high
Spark plug dirty, broken or gap maladjusted

Inspect and replace (see chapter 16).
Repair (see chapter 7)
Clean spark plugs and adjust plug gap (see
chapter 2)

Stumble:
Too low fuel pressure
Fuel injector trouble
Throttle sensor malfunction
Water temperature sensor trouble
Inlet air pressure sensor trouble

Inspect
Inspect
Inspect
Inspect

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

(see
(see
(see
(see

chapter
chapter
chapter
chapter

3).
3).
3).
3).

Inspect (see chapter 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).

3-32 FUEL SYSTEM (DFI)

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:

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).

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

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).

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

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).

FUEL SYSTEM (DFI) 3-33

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

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).

Air cleaner O-ring damaged
Water or foreign matter in fuel

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
Inlet air temperature sensor trouble
Throttle sensor malfunction
Atmospheric pressure sensor trouble
Inlet air pressure sensor trouble
Cracked or obstructed inlet air pressure sensor
hose
Injector clogged
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 accumulating on the seating surface)
KACR (compression release cam) sticks open
(engine stalls when moving off)

Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and repair or replace (see chapter 3)
Visually inspect and replace (see chapter 3)
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 repair or replace (see chapter 5).
Inspect and repair or replace (see chapter 5).

3-34 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide
Symptoms or Possible Causes
HLA ( hydraulic lash adjuster) damaged (worn,
seizure or spring broken)
Knocking:
Carbon buit 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).

FUEL SYSTEM (DFI) 3-35

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).

3-36 FUEL SYSTEM (DFI)

Self-Diagnosis
Self-diagnosis Procedures

○When a problem occurs with the DFI system, the FI indi­
cator LED light [A] and FI symbol [B] go on.

the rear and front seats (see Frame chapter).
• Remove
Ground
[A]
the self-diagnosis terminal [B] (yellow lead) to
• the battery (–)
terminal [C], using a wire [D].

the ignition SW 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.
the blinks of the LED light [D] to read the service
• Count
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 SW is turned to OFF.
○Pushing the MODE button and the trip meter is displayed.
○When the ECU receives the speed sensor signal.

FUEL SYSTEM (DFI) 3-37

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 SW 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.

3-38 FUEL SYSTEM (DFI)

Self-Diagnosis

○Each service code is continuously repeated three times until the ignition SW 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 SW is turned OFF, or the battery is disconnected,
all the fault codes remain in the ECU, which need not be absolutely erased.
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

Pickup coil #1 malfunction, wiring open or short

22

Pickup coil #2 malfunction, wiring open or short

31

Vehicle-down sensor malfunction wiring open or short

41

Injector #1 malfunction, wiring open or short

FUEL SYSTEM (DFI) 3-39

Self-Diagnosis
Service
Code

FI Indicator LED Light

Problems (1)

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

Footnotes:
(1) 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.
(2) 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

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

Inlet Air
Temperature
Sensor

Inlet Air Temperature
Ta = – 47°C ∼ + 178°C

14

Water
Temperature
Sensor

Water Temperature
Tw = – 28C° ∼ + 161°C

15

Atmospheric
Pressure
Sensor

Absolute Atmospheric
Pressure
Pa = 63 mmHg ∼ 860 mmHg

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).

3-40 FUEL SYSTEM (DFI)

Self-Diagnosis
Service
Codes

Parts

21

Crankshaft
Sensor #1

22

Crankshaft
Sensor #2

31

Vehicle-down
Sensor

Vehicle-down Sensor
Output Voltage (signal)
Vd = 0.2 V ∼ 4.6 V

41

Fuel Injector
#1

The injector must send
signals (output voltage)
16 or more times
continuously to the ECU.

42

Fuel Injector
#2

The injector must send
signals (output voltage)
16 or more times
continuously to the ECU.

45

Fuel Pump

The pump must send
signals (output voltage)
continuously to the ECU.

51

52

Ignition
Coil #1

Ignition
Coil #2

Output Signal Usable
Range or Criteria
Either crankshaft sensor
must send signals
(output voltage)
8 or more times
continuously to the ECU.

The ignition coil primary
winding must send signals
(output voltage)
continuously
to the ECU.
The ignition coil primary
winding must send signals
(output voltage)
continuously
to the ECU.

Backups by ECU
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.
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 quan­
tity 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) 3-41

Throttle Sensor (Service Code 11)
Throttle Sensor 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.

Front View [B]

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 SW OFF.
• Turn
Remove
ECU (see this chapter). Do not disconnect
• the ECU the
connectors.
a digital voltmeter [A] to the connector [B], using
• Connect
two needle adapters [C].
Special Tool - Needle Adapter Set: 57001–1457

the input voltage to the throttle sensor with the
• Measure
engine stopped, and with the connectors joined.
• Turn the ignition SW ON.
Throttle Sensor Input Voltage
Connections to ECU Connector

Meter (+) → BL/W lead (terminal 35)

Meter (–) → BR/BK lead (terminal 11)

Standard: 4.75 ∼ 5.25 V DC

the ignition SW OFF.
• Turn
If the reading of input voltage is less than the standard,
check the ECU for its ground, and power supply (see ECU
section).
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 throt­
tle sensor.

3-42 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code 11)
Output Voltage Inspection

the engine and warm it up thoroughly.
• Start
Check
• rect. idle speed to make sure the throttle opening is cor­
Idle Speed

Standard:

950 ± 50 r/min (rpm)


If the idle speed is out of the specified range, adjust the
idle speed (see this chapter).
Turn off the ignition switch.

•
the ECU (see this chapter). Do not disconnect
• Remove
the ECU connectors.
a digital meter [A] to the connector [B], using the
• Connect
needle adapters [C].
Special Tool - Needle Adapter Set: 57001–1457

CAUTION
Insert the needle adapter straight along the lead in
the connector to prevent short circuit between ter­
minals.
the output voltage of the sensor with the engine
• Measure
stopped, and with the connector joined.
• Turn the ignition SW ON.
Throttle Sensor Output Voltage
Connections to Sensor

Meter (+) → Y/W lead (terminal 26)

Meter (–) → BR/BK lead (terminal 11)

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 [A] of
the connector [B] for waterproofing.
Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of Connectors


FUEL SYSTEM (DFI) 3-43

Throttle Sensor (Service Code 11)
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 sen­
sor along with the throttle body.
If the reading is within the range, but the problem still
exists, the ECU is suspect. Replace the ECU.

A. ECU

g. Throttle Sensor

3-44 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 section in this chap­
• Remove
ter).
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 this chapter).

•
•
•

Input Voltage Inspection
NOTE

○Be sure the battery is fully charged.
○The inspection is the same as “Input Voltage Inspec­

tion” of the throttle sensor or the atmospheric pressure
sensor.

the ignition SW OFF.
• Turn
Remove
ECU (see this chapter). Do not disconnect
• the ECU the
connector.
a digital voltmeter [A] to the connector [B], using
• Connect
two needle adapters [C].
Special Tool - Needle Adapter Set: 57001–1457

FUEL SYSTEM (DFI) 3-45

Inlet Air Pressure Sensor (Service Code 12)

○Measure the input voltage to the inlet air pressure sensor

•

with the engine stopped, and with the connectors joined.
Turn the ignition SW ON.
Inlet Air Pressure Sensor Input Voltage
Connections to ECU

Meter (+) → BL/W lead (terminal 35)

Meter (–) → BR/BK lead (terminal 11)


•

Standard:

4.75 ∼ 5.25 V DC

Turn the ignition SW OFF.
If the reading is less than the standard range, check the
ECU for its ground, and power supply (see this chapter).
If the ground and power supply are good, the ECU is sus­
pect. Replace the ECU.
If the reading is within the standard range, check the sen­
sor output voltage.

Output Voltage Inspection
NOTE

○The output voltage changes according to the local at­
mospheric pressure.

Check the output voltage of the sensor at the ECU connector [A].
○Measure the output voltage with the engine stopped and
with the connector joined.
Turn the ignition SW ON.
Needle Adapters [B]

•

Inlet Air Pressure Sensor Output Voltage
Connections to ECU

Meter (+) → W/BL lead (terminal 29)

Meter (–) → BR/BK lead (terminal 11)

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 SW OFF and remove the needle
adapters.
Apply silicone sealant to the seals of the connector for
waterproofing.
Silicone Sealant (Kawasaki Bond: 56019-120)

- Connector Seals


3-46 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 vac­
uum changes, the sensor is normal and the ECU is sus­
pect. Check the ECU for its ground and power supply
(see ECU section).
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 sen­
sor.
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 Volt Meter Connections
Meter (+) → W/BL lead of Inlet Air Pressure Sensor
Meter (–) → BR/BK lead of Inlet Air Pressure Sensor

○Turn the ignition SW 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 cm Hg
and 55 ∼ 86 cm Hg.

FUEL SYSTEM (DFI) 3-47

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 cm Hg

3-48 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)
Pv = 55 ∼ 86 cm Hg

Vv: Inlet Air Pressure Sensor Output Voltage (V)
(Digital Meter Reading)
Pv: Throttle Vacuum (absolute)
Ps: Standard Atmospheric Pressure (absolute)
ID: Idling

ECU [A]

TO: Throttle Full Open
ST: Standard of Sensor Output
Voltage (v)
UR: Usable Range of Sensor Output
Voltage (v)

Inlet Air Pressure Sensor [a]

FUEL SYSTEM (DFI) 3-49

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 this chapter). Do not disconnect
• Remove
the ECU connectors.
a digital voltmeter [A] to the ECU connector [B],
• Connect
using two needle adapters [C].
Special Tool - Needle Adapter Set: 57001-1457

the output voltage of the sensor with the engine
• Measure
stopped and the connector joined.
• Turn the ignition SW ON.
Inlet Air Temperature Sensor Output Voltage
Connections to ECU Connector

Meter (+) → P lead (terminal 31)

Meter (–) → BR/BK lead (terminal 11)

Standard:

2.4 V at inlet air temperature 25°C (77°F)

the ignition SW 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 spec­
ified, 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.
Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of Connector


3-50 FUEL SYSTEM (DFI)

Inlet Air Temperature Sensor (Service Code 13)
Sensor Resistance Inspection

the inlet air temperature sensor (see this sec­
• Remove
tion).
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 por­
tion [C] located in almost the same depth with the sensor.

NOTE

○The sensor and thermometer must not touch the con­
tainer side or bottom.

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 section in this
chapter).
Clean off machine oil that inadvertently gets on the sen­
sor, especially on the terminals with a high-flush point sol­
vent.

ECU [A]

Inlet Air Temperature Sensor [Y]

FUEL SYSTEM (DFI) 3-51

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].
Silicone Sealant (Kawasaki Bond: 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
• Fill
cooling system (see Coolant Filling in the Cooling System
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 this chapter). Do not disconnect
• Remove
the connectors.
a digital voltmeter [A] to the ECU connector [B],
• Connect
using two needle adapters [C].
Special Tool - Needle Adapter Set: 57001-1457

the output voltage of the sensor with the engine
• Measure
stopped and the connector joined.
• Turn the ignition SW ON.
Water Temperature Sensor Output Voltage
Connections to ECU
Meter (+) → O lead (terminal 7)
Meter (–) → BR/BK lead (terminal 11)
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 SW 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.
Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of ECU Connector


3-52 FUEL SYSTEM (DFI)

Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Resistance Inspection

the water temperature sensor (see this section).
• Remove
Suspend
the sensor [A] in a container of machine oil so
• that the heat-sensitive
portion and threaded portion are

•

submerged.
Suspend a thermometer [B] with the heat-sensitive por­
tion [C] located in almost the same depth with the sensor.

NOTE

○The sensor and thermometer must not touch the con­
tainer side or bottom.

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 section in this
chapter).
Clean off machine oil that inadvertently gets on the sen­
sor, especially on the terminals with a high-flush point sol­
vent.

A. ECU	

Z. Water Temperature Sensor

FUEL SYSTEM (DFI) 3-53

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 section in this chap­
• Remove
ter).
the atmospheric pressure sensor connector
• Disconnect
[A].
the sensor nut [B].
• Remove
the atmospheric pressure sensor [C].
• Remove
Front [D]

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 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 SW OFF.
• Turn
Remove
ECU (see this chapter). Do not disconnect
• the ECU the
connectors.
a digital voltmeter [A] to the connector [B], using
• Connect
two needle adapters [C].
Special Tool - Needle Adapter Set: 57001-1457

○Measure the input voltage to the sensor with the engine

•

stopped, and with the connectors joined.
Turn the ignition SW ON.

Atmospheric Pressure Sensor Input Voltage
Connections to ECU

Meter (+) → BL/W lead (terminal 35)

Meter (–) → BR/BK lead (terminal 11)

Standard:
4.75 ∼ 5.25 V DC

the ignition SW OFF.
• Turn
If the reading is less than the standard range, check the
ECU for its ground, and power supply (see ECU section
is this chapter).
If the reading is within the standard range, check the sen­
sor output voltage.

3-54 FUEL SYSTEM (DFI)

Atmospheric Pressure Sensor (Service Code 15)
the needle adapters.
• Remove
Apply
silicone
• waterproofing. sealant to the seals of the connector for
Silicone Sealant (Kawasaki Bond: 56019-120)

- ECU Connector Seals


Output Voltage Inspection
NOTE

○The output voltage changes according to the local at­
mospheric pressure.

Check the output voltage of the sensor at the ECU connector [A].

Needle Adapters [B]

○Measure the output voltage with the engine stopped and
the connector joined.
Turn the ignition SW ON.

•

Atmospheric Pressure Sensor Output Voltage
Connections to ECU

Meter (+) → BL/Y lead (terminal 28)

Meter (–) → BR/BK lead (terminal 11)

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 SW OFF and remove the needle
adapters.
Apply silicone sealant the seals of the connector for wa­
terproofing.
Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of Sensor Connector


FUEL SYSTEM (DFI) 3-55

Atmospheric Pressure Sensor (Service Code 15)

A. ECU

b. 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 Inlet Air Pressure Sensor section
in this chapter).
○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.

3-56 FUEL SYSTEM (DFI)

Atmospheric Pressure Sensor (Service Code 15)

Va: Atmospheric Pressure Sensor Output Voltage (v)
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)

FUEL SYSTEM (DFI) 3-57

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 Ignition System section 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 Electrical System
chapter) in order to check the coils.

A. ECU

E. Crankshaft Sensors

p. Joint Connector 1

3-58 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor 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 this chapter).
• Remove
Remove
the
bolts [A] and take out the covers [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].
•

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 seat (see Frame chapter).

WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situ­
ations, like leaning over in a turn, with the potential
for an accident resulting in injury or death. Ensure
that the down sensor is held in place by the bracket
and its bolt as shown.

FUEL SYSTEM (DFI) 3-59

Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Inspection
NOTE

○Be sure the battery is fully charged.

out the vehicle-down sensor [A] (see this section).
• Take
Do not disconnect the connector [B].
a digital volt meter [C] to the connector (natural,
• Connect
3P), using two needle adapters [D].
Special Tool - Needle Adapter Set: 57001-1457

the ignition SW ON, and measure the power source
• Turn
voltage with the connector joined.
Vehicle-down Sensor Power Source Voltage
Connections to Sensor

Meter (+) → BR lead [E]

Meter (–) → BK/Y lead [F]

Standard:
Battery Voltage (12.5 V or more)

the ignition SW OFF.
• Turn
If there is no battery voltage, check the DFI power source
circuit (see DFI Power Source Section in this chapter).
If the power source is normal, check the output voltage of
the sensor.
Connect a digital volt meter [A] to the connector (natural,
3P), using two needle adapters [B].
Turn the ignition SW ON, and measure the output voltage
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.

•
•

Vehicle-down Sensor Output Voltage
Connections to Sensor

Meter (+) → Y/G lead [E]

Meter (–) → BK/Y lead [F]

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 SW OFF, and
then ON.

the ignition SW OFF.
• Turn
Remove
the needle adapters, and apply silicone sealant
• to the seals
of the connector for waterproofing.
Silicone Sealant (Kawasaki Bond: 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 section in this
chapter).

3-60 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31)

A. ECU
d. Vehicle-down Sensor
F. Junction Box
e. DFI Main Relay

N. Ignition Switch
O. Starter Relay
P. Main Fuse 30 A × 32 V
p. Joint Connector 1

Q. Sealed Battery
q. Frame Earth
f. Ignition Fuse 10 A × 32 V
V. DFI Fuse 15A

FUEL SYSTEM (DFI) 3-61

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 sur­
face. Such a shock to the injector can damage it.

Injector Removal

WARNING
Gasoline is extremely flammable and can be ex­
plosive under certain conditions. Turn the ignition
switch OFF. Disconnect the battery (–) lead ter­
minal. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
to see that the battery (–) lead terminal is discon­
• Check
nected.
• Remove:
Fuel Tank (see this chapter)

•

Front and Rear Injector Connectors
Remove the fuel hose joint #2 [A] from the pipe for the
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].

•

Front [E]
Remove the injectors from the delivery joint.

Injector Installation

○The front and rear injectors are the same.

the seal [A], O-ring [B], and seal ring [C] with new
• Replace
ones, and install them onto the injector [D].
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.

3-62 FUEL SYSTEM (DFI)

Fuel Injectors (#1, #2: Service Code 41, 42)
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) 3-63

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 maxi­
mum 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 leak­
○
age.
the fuel outlet hose (see Fuel Tank Installation).
• Install
Run
the
hoses correctly (see Cable, Wire, and Hose Rout­
• ing section
in the General Information 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]

3-64 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 this chapter) and connect the
• Install
battery (–) terminal.

Audible Inspection

the left air cleaner housing (see this chapter).
• Remove
Start
the
• Apply theengine.
of a screwdriver [A] to the injector [C]. Put
• the grip endtiponto
your ear, and listen whether the injector
is clicking or not.

○A sound scope [B] can also be used.
the same for the other injector.
• DoFront
[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 Line section
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 SW OFF.
• Turn
Remove
• chapter). the coolant reserve tank (see Cooling System
a digital voltmeter [B] to the DFI main relay con• Connect
nector [A], using the needle adapter.

Battery [C] in the frame

Special Tool - Needle Adapter Set: 57001-1457

○Measure the power source voltage of the injector with the

•

engine stopped, and with the connectors joined.
Turn the ignition SW ON.

Injector Power Source Voltage at DFI Main Relay
Connections

Meter (+) → W/R Lead Terminal [D]

Meter (–) → Battery (–) Terminal

Standard:
Battery Voltage (12.5 V or more)

FUEL SYSTEM (DFI) 3-65

Fuel Injectors (#1, #2: Service Code 41, 42)
If the power source voltage is incorrect, check the DFI
power source (see DFI Power Source in this chapter).
If the DFI power source is good, check the ECU for its
ground and power supply. 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 section in this chapter). Do
• Remove
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 inspec­
tion. Note the following.
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

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
SW 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 chapter).
Remove the needle adapter.
Apply silicone sealant to the seals of the ECU connector
for waterproofing.

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 har­
ness connector (female), leading to harness repair
or replacement.
Be sure to connect bulbs in series. The bulb works
as a current limiter to protect the solenoid in the
injector from excessive current.

3-66 FUEL SYSTEM (DFI)

Fuel Injectors (#1, #2: Service Code 41, 42)
the fuel tank (see this chapter).
• Remove
Plug
the
hose ends.
• Remove fuel
connectors
[A].
• Connect each test lightforsetinjector
[B]
to
the
injector main harness
• connector [C].
the battery (–) lead terminal.
• Connect
While
cranking
• the test lights. the engine with the starter motor, watch
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 en­
gine 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 this chapter).
• Remove
Disconnect
• tor Removal).the connector from the injector [A] (see Injec­
the injector resistance with a digital voltmeter
• Measure
[B].

Front [C]

Injector Resistance

Connections to Injector

Meter (+)
Meter (–)

←→ BL/R Terminal

#1: W/R
←→ BL/G Terminal

#2: W/R
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.

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.

FUEL SYSTEM (DFI) 3-67

Fuel Injectors (#1, #2: Service Code 41, 42)

A. ECU
F. Junction Box
N. Ignition Switch
O. Starter Relay
P. Main Fuse 30 A × 32 V
Q. Sealed Battery

R. Fuel Injector #1
S. Fuel Injector #2
V. DFI Fuse 15 A × 32 V
e. DFI Main Relay
f. Ignition Fuse 10 A × 32 V

3-68 FUEL SYSTEM (DFI)

Fuel Pump (Service Code 45)
Fuel Pump Removal
CAUTION
Never drop the fuel pump, especially on a hard sur­
face. Such a shock to the pump can damage it.

WARNING
Gasoline is extremely flammable and can be explo­
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Disconnect the battery (–) terminal.
To make fuel spillage minimum, draw the fuel out
from the fuel tank when the engine is cold. Be
prepared for fuel spillage; any spilled fuel must be
completely wiped up immediately.
the fuel tank (see Fuel Tank Removal).
•○Remove
Be careful of fuel spillage from the fuel tank since fuel still

•
•
•
•

remains in the fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
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) 3-69

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 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 SW ON and make sure that the fuel pump
• Turn
operates (make light sounds) for 3 seconds, and then

•

stops.
Turn the ignition SW OFF.
If the pump does not work as described above, inspect
the power source voltage.

3-70 FUEL SYSTEM (DFI)

Fuel Pump (Service Code 45)
Operating Voltage Inspection
NOTE

○Be sure the battery is fully charged.

the ignition switch OFF.
• Turn
Remove
the seat (see Frame chapter).
• Connect the
tester (25 V DC) to the fuel pump con• nector [A] withhand
needle adapter set.
Special Tools - Hand Tester: 57001-1394

Needle Adapter Set: 57001–1457


○Measure the operating voltage with the engine stopped,

and with the connector joined.
Turn the ignition switch ON.
○The tester needle should indicate battery voltage for 3
seconds, and then 0 V.

•

Pump Operating Voltage at Pump
Connections to Pump Connectors
Tester (+) → Y/R Lead
Tester (–) → BK/W Lead
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 fuel pump 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 pump relay
(see this chapter).

FUEL SYSTEM (DFI) 3-71

Fuel Pump (Service Code 45)
Power Source Voltage Inspection
NOTE

○Be sure the battery is fully charged.

the seat (see Frame chapter).
• Remove
Connect
a
digital voltmeter [A] to the fuel pump connector
• [B] (2P), using
the needle adapter [C].
Special Tool - Needle Adapter Set: 57001-1457

the power source voltage with the
• Measure
stopped, and with the pump connector joined.
• Turn the ignition SW ON.

engine

Pump Power Source Voltage
Connections to Pump Connector

Tester (+) → Y/R lead [D]

Tester (–) → Battery (–) Terminal [E]

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 in this section).
If the reading is incorrect, check the following:

Battery

Main Fuse 30 A in Starter Relay (see Electrical System

chapter)

DFI Fuse 15 A (see this chapter)

Ignition Fuse 10 A in Junction Box (see Electrical System

chapter)

DFI Main Relay (see this chapter)

Wiring for Fuel Pump Power Source (see next diagram)

Vehicle-down Sensor (see this chapter)


Operating Voltage Inspection
NOTE

○Be sure the battery is fully charged.

the ignition SW OFF.
• Turn
Remove
seat (see Frame chapter).
• Measure the
the
operating voltage of the fuel pump at the fuel
• pump connector
[A] with the connector joined.

Hand Tester [B]

Needle Adapters [C]

Pump Operating Voltage at Pump Connector
Connections to Pump Connector

Tester (+) → Y/R lead [D]

Tester (–) → BK/W lead [E]

Reading:	
Battery Voltage (12.5 V or more) for 3
seconds, and then 0 V

3-72 FUEL SYSTEM (DFI)

Fuel Pump (Service Code 45)

•

If the measurement is normal, replace the fuel pump.
If the measurement stays on the battery voltage or 0 volt,
turn the ignition SW OFF, and remove the fuel tank. And
inspect the BK/W lead between the ECU connector and
the fuel pump for continuity.
If the wiring is good, inspect the ECU for its ground, and
power supply (see ECU section in this chapter). If the
ground and power supply are good, the ECU is suspect.
Replace the ECU.
After inspection, remove the needle adapter, and apply
silicone sealant to the seal of the connector for water­
proofing.
Silicone Sealant (Kawasaki Bond: 56019-120)

- Sealing of Fuel Pump Connector


A. ECU
F. Junction Box
N. Ignition Switch
O. Starter Relay
P. Main Fuse 30 A × 32 V

Q. Sealed Battery
U. Fuel Pump
V. DFI Fuse 15 A × 32 V
e. DFI Main Relay
f. Ignition Fuse 10 A × 32 V

FUEL SYSTEM (DFI) 3-73

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 dam­
age 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 SW OFF.
• Turn
the ECU (see this chapter). Do not disconnect
• Remove
the ECU connector.
a digital voltmeter [A] as shown, using two nee­
• Connect
dle adapters [B].

○Measure the input voltage to each primary winding of the

•

ignition coils with the engine stopped, and with the con­
nectors joined.
Turn the ignition SW ON.
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

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 section).
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 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.
Silicone Sealant (Kawasaki Bond: 56019-120)

- ECU Connector Seals


3-74 FUEL SYSTEM (DFI)

FI Indicator LED Light
Inspection Flow Chart

FUEL SYSTEM (DFI) 3-75

FI Indicator LED Light
LED Light Inspection

○The FI indicator LED light [A] goes ON when the ignition

SW 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.
○Refer to the Meter, Gauge section in the Electrical System
chapter for LED Light Inspection.

WARNING
This inspection may produce sparks. Keep the bat­
tery and the meter unit away from the fuel tank.
If the LED light is subnormal, 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 section).

A. ECU
F. Junction Box
L. FI Indicator LED Light
N. Ignition Switch

O. Starter Relay
P. Main Fuse 30 A × 32 V
Q. Sealed Battery
f. Ignition Fuse 10 A × 32 V

3-76 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]

CN and US
EU
AU

F8T97371
F8T97372
F8T97372

21175-1099
21175-1100
21175-1100

CN: Canadian Model
US: United States of America Model
EU: European Model
AU: Australian Model

ECU Removal
CAUTION
Never drop the ECU, especially on a hard surface.
Such a shock to the ECU can damage it.

• Remove:

Seat (see Frame chapter)

•

Battery Holder [A] and Bolt [B]

Pull the ECU [C] out along with the harness.
If necessary, push the lock and disconnect the ECU con­
nectors.

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

inspect the terminals of the ECU connector.
• Visually
If the connector 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 dam­
aged.
Replace the ECU if the terminals of the ECU connector
are cracked, bent, or otherwise damaged.

FUEL SYSTEM (DFI) 3-77

ECU

the ECU connector [A] joined, check the following
• With
ground leads for continuity with the ignition SW ON or
OFF, using a digital voltmeter [D].
ECU Grounding Inspection

Meter Connections:

10, 20, 32, or 42 (BK/Y) ←→ Battery (–) Terminal

Terminal
←→ Battery (–) Terminal
21 (BR/BK) Terminal
←→ Battery (–) Terminal
Engine Ground
Terminal [B]
Readings:	

0 Ω (regardless of the ignition SW ON
or OFF)

If no continuity, check the connector, the engine ground
lead, or main harness, and repair or replace them if nec­
essary.
Battery [C] in the Frame
Special Tool - Needle Adapter Set: 57001-1457

the power source voltage of the ECU with a digital
• Check
voltmeter.
ECU Power Source Inspection

Meter Connection: between 30 (W/R) Terminal and

Battery (–) Terminal
0V
Ignition SW OFF:
Ignition SW ON:
Battery Voltage (12.5 V or more)

If the voltmeter does not read as specified, check the fol­
lowing:
Power Source Wiring (see wiring diagram of DFI Power
Source section in this chapter).
DFI Fuse 15 A (see DFI Power Source section)
DFI Main Relay (see DFI Power Source section)
Ignition Fuse 10 A (see Electrical System chapter)
If the inspection checks good, the ECU is damaged. Re­
place the ECU. The ECU itself cannot be checked or ser­
viced.

3-78 FUEL SYSTEM (DFI)

DFI Power Source
DFI Fuse Removal

the seat (see Frame chapter).
• Remove
Pull
the
lock
[A] and open the lid [B].
• Pull out the DFI
fuse [C] from the case with needle nose
• pliers.

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).
• 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 rat­
ing, 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 Frame chapter)

•

Coolant Reserve Tank (see Coolant System chapter)

Remove the DFI main relay [A] and disconnect the con­
nector.

Front [B]


DFI Main Relay Inspection

the DFI main relay (see above).
• Remove
Connect
hand tester [A] and one 12 V battery [B] to
• the relay the
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.

FUEL SYSTEM (DFI) 3-79

DFI Power Source
DFI Power Source Circuit

A. ECU
F. Junction Box
N. Ignition SW
O. Starter Relay
P. Main Fuse 30 A

Q. Sealed Battery
R. Fuel Injector #1
S. Fuel Injector #2
U. Fuel Pump
V. DFI Fuse 15 A

W. ISC Valve #1
X. ISC Valve #2
e. DFI Main Relay
f. Ignition Fuse 10 A
y. Actuators : R, S, U, W, X
p. Joint Connector 2

3-80 FUEL SYSTEM (DFI)

ISC Valves
Removal/Installation
CAUTION
Never drop the ISC valves, especially on a hard sur­
face. Such a shock to the valve can damage it.

○The ISC valves are removed during right air cleaner hous-

ing removal (see 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 #2 [A] → G/Y, W/R leads [B]
ISC Valve #1 [C] → G/BL, W/R leads [D]
Front [E]
Install the ISC hoses as shown.

ISC Hose #2 with the red paint mark on the top

ISC Hose #1 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 SW OFF.
• Turn
Remove
right air cleaner cover (see this chapter).
• Connect the
a
digital
• each ISC valve. voltmeter [A] to the connectors [B] of
the power source voltage with the engine
• Measure
stopped, and with the connectors joined.
• Turn the ignition SW ON.
Power Source Voltage at ISC Valve Connector
Connections to ISC Valve #1, #2

Meter (+) → W/R Lead Terminal

Meter (–) → Battery (–) Terminal


•

Standard: Battery Voltage (12.5 V or more)

Turn the ignition SW OFF.
If there is no battery voltage, check the DFI power source
circuit (see DFI Power Source section in this chapter).
If the reading is normal, the power supply voltage is nor­
mal. Check the output voltage.

FUEL SYSTEM (DFI) 3-81

ISC Valves
Output Voltage Inspection

the output voltage at the connectors [A] of the ISC
• Check
Valves.
• Remove the right air cleaner cover (see this chapter).
Special Tool - Hand Tester [B] : 57001–1394

the output voltage with the engine stopped, and
• Measure
with the connector joined.
• Turn the ignition SW ON.
Output Voltage of ISC Valves
Connections for ISC Valve #2 [C]

Tester (+) → W/R lead

Tester (–) → G/Y lead

Connections for ISC Valve #1 [D]

Tester (+) → W/R lead

Tester (–) → G/BL lead

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 section).
If the reading of the resistance is normal, check the wiring
for continuity (see next diagram).
If the wiring is normal, check the ECU for its ground, and
power supply (see this chapter).

Resistance Inspection

the connectors from the ISC valve.
• Disconnect
Measure
the
resistance between the terminals of the ISC
• valve with a digital
volt 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.

3-82 FUEL SYSTEM (DFI)

ISC Valves

A. ECU
F. Junction Box
N. Ignition Switch
O. Starter Relay
P. Main Fuse 30 A × 32 V
Q. Sealed Battery

V. DFI Fuse 15 A × 32 V
W. ISC Valve #1
X. ISC Valve #2
e. DFI Main Relay
f. Ignition Fuse 10 A × 32 V

FUEL SYSTEM (DFI) 3-83

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 run­

ning the motorcycle when the trouble has occurred in
order to know symptom well.
○Be sure the battery is fully charged.

the fuel tank (see this chapter).
• Remove
Disconnect
the #2 fuel injector connector [A].
•
Pinch the lock of the fuel hose joint #2 with fingers, dis­
• connect
the joint [B] and 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 connec­
tion with a clean shop towel to prevent fuel spillage.
the fuel pressure gauge adapter [A] (special tool)
• Install
between the fuel tank outlet pipe [B] and the inlet pipe [C]
to the delivery joint [D].

○Put the fuel pressure gauge adapter outside the frame.

the pressure gauge [E] (special tool) to the fuel
• Connect
pressure gauge adapter.
Fuel Tank [F]
Fuel Pump [G]
Front [H]
→: Fuel Flow
Special Tools - Fuel Pressure Gauge Adapter: 57001-1417
Oil Pressure Gauge: 57001-125

ly, install the fuel tank.
• Temporari
Connect:
• Fuel Pump Connector 2P
Battery Lead (–) Terminal

WARNING
Do not try to start the engine with the fuel hoses
disconnected.
the ignition SW 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 SW ON, with pump running:

Standard: 304 kPa (3.1 kgf/cm², 44 psi)
after 3 seconds from Ignition SW 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.


3-84 FUEL SYSTEM (DFI)

Fuel Line
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)
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

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 SYSTEM (DFI) 3-85

Fuel Line
Fuel Flow Rate Inspection
NOTE

○Be sure the battery is fully charged.
WARNING
Gasoline is extremely flammable and can be explo­
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
both ignition SW, and engine stop SW OFF.
• Turn
Wait
until
engine cools down.
• Open the the
fuel
tank cap [A] to lower the pressure in the
• tank.

Front [B]

a plastic hose of the inside diameter 7.5 mm
• Prepare
(0.30 in.) × L about 400 mm (15.7 in.) and a measur­
ing cylinder.
Remove:

Seat (see 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) 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 SW 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 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).
Start the engine and check for no fuel leakage.

3-86 FUEL SYSTEM (DFI)

Throttle Grip and Cables
Throttle Grip Free Play Inspection

to 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
the adjuster of the accelerator cable [D] until the
• Turn
proper amount of throttle grip free play is obtained and
tighten the locknut against the adjuster.

WARNING
Operation with incorrectly routed or improperly ad­
justed cables could result in an unsafe riding con­
dition.

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.

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 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 General Lubri­
cation 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) 3-87

Throttle Body Assy
Idle Speed Check

to Idle Speed Check in the Periodic Maintenance
• Refer
Chapter.

Idle Speed Adjustment

to Idle Speed Check in the Periodic Maintenance
• Refer
Chapter.

Throttle Bore Cleaning

to Throttle Control System Check in the Periodic
• Refer
Maintenance 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

• Remove the fuel tank (see this chapter).
WARNING

Gasoline is extremely flammable and can be explo­
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Disconnect the battery (–) terminal.
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)

Right and Left Air Cleaner Base (see this chapter)

Right Spark Plug Lead Holder [A] and Bolts [B] and

Clamp [C]

Throttle Body Assy Holder Bolts [E]

Throttle Body Assy Holder [D]

Front [F]


• Disconnect:

Throttle Sensor Connector [A] (from the throttle sensor)

Vacuum Hose [B] from Inlet Air Pressure Sensor

Vacuum Hose [C] between Vacuum Switch Valve and

Throttle Body Assy


3-88 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 and take off the right switch housing.
• Remove
Remove
cable end [A] and decelerator
• cable endthe[B] accelerator
at the throttle grip.

Front [C]


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].
Return
the
pulley,
and
pull
out the decelerator cable hous• ing [E] from the cable holder.
the decelerator cable end [F] and the accelerator
• Remove
cable end [G] from the throttle pulley [B].

FUEL SYSTEM (DFI) 3-89

Throttle Body Assy
the lock of the fuel hose joint #2 [A] with your fin­
• Pinch
gers, 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, possi­
bly causing an accident.

CAUTION
If dirt gets through into the engine, excessive en­
gine wear and possibly engine damage will occur.

3-90 FUEL SYSTEM (DFI)

Throttle Body Assy
Throttle Assy Installation

l the lower air cleaner duct between cylinders.
• Instal
Replace
flange seal [A] with a new one.
• With a hithe
gh-flash
solvent, clean off the flange sur­
• face of the cylinderpoint
head and wipe dry.
l the flange [B] and the seal in the direction shown.
• Instal
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 assy holder bolts [A], secondly
• First,
the inlet manifold bolts [B] to the specified torque.
Front [C]
Torque - Throttle Assy Holder Bolts: 11 N·m (1.1 kgf·m, 95
in·lb)
Inlet Manifold Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
Right Spark Plug Lead Holder Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)

l the lower ends of the throttle cables in the throttle
• Instal
pulley.

•
•
•

Accelerator Cable [A] and Decelerator Cable [B]
Run the throttle cables correctly (see Cable, Wire, and
Hose Routing section in the General Information 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.
Non-permanent Locking Agent 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 General Information
• Run
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 (front view).
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 Grip Free
• Check
Play Inspection).

WARNING
Operation with an incorrectly routed cable could re­
sult in an unsafe riding condition.

FUEL SYSTEM (DFI) 3-91

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.
the fuel tank and the air cleaner housing (see this
• Install
chapter).

Throttle Assy Disassembly/Assembly

the throttle assy (see this chapter).
• Remove
two bolts [A], and pull out the ISC pipe #1 [B],
• Unscrew
and ISC pipe #2 [C] from the hoses [D].

Bottom View [E]


3-92 FUEL SYSTEM (DFI)

Throttle Body Assy
the three throttle body flange bolts [A].
• Remove
Split
the
throttle
into the throttle body [B] and the inlet
• manifold [C]. Theassy
gasket [D] 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 be­
tween 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 diffi­
culty of removal.

FUEL SYSTEM (DFI) 3-93

Throttle Body Assy
the delivery joint and injectors (see Injector sec­
• Remove
tion 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 sur­
faces 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.

3-94 FUEL SYSTEM (DFI)

Air Cleaner
Element Removal

• Remove:

Allen Bolt and Washer [A]

Left Air Cleaner Cover [B]

Front [C]


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, possi­
bly causing an accident.

CAUTION
If dirt gets through into the engine, excessive en­
gine wear and possibly engine damage will occur.

Element Cleaning

to 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)

•

Air Cleaner Base Bolts [A] and Screws [B]

Remove the air cleaner base [C].

Front [D]


○Be careful not to lose the air cleaner base mounting nuts

[A]. These nuts and lower air cleaner duct are sold as a
unit.
Non-permanent Locking Agent -

Air Cleaner Base Screws

Torque - Left Air Cleaner Base Bolts: 11 N·m (1.1 kgf·m, 95
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) 3-95

Air Cleaner
Right Air Cleaner Housing Removal

• Remove:

Allen Bolt and Washer [A]


Right Air Cleaner Cover [B]

Front [C]


• Remove:

ISC Valve Hoses [A]

ISC Valve Lead Connectors [B]

Air Cleaner Allen Bolts [C] and Screws [D]

Air Cleaner Base Bolt [E]


• 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.
Non-permanent Locking Agent -

Right Air Cleaner Base Screws


• Tighten:

Torque - Right Air Cleaner Base Bolt [D]: 11 N·m (1.1 kgf·m,
95 in·lb),
Right Air Cleaner Allen Bolts [E]: 11 N·m (1.1
kgf·m, 95 in·lb),
Right Air Cleaner Base Screws [F]: 2.2 N·m (0.22
kgf·m, 19 in·lb)

Front [G]

3-96 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
#2 [B], ISC valve #1 [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 #2 is connected to W/R and G/Y leads, and
the hose [F] marked red.

○The ISC valve #1 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:

Right and Left Air Cleaner Housing (see this chapter)

Throttle Assy Holder [A]

Air Cleaner Duct Holder [B]

Throttle Assy (see this chapter)

Inlet Manifold (see this chapter)

Front [C]


• Remove:

Right and Left Air Cleaner Base Mounting Nuts [A]

Lower Air Cleaner Duct [B]

Front [C]

Torque - Air Cleaner Duct Holder Bolts: 9.8 N·m (1.0 kgf·m,
69 in·lb)

FUEL SYSTEM (DFI) 3-97

Fuel Tank
Fuel Tank Removal

WARNING
Gasoline is extremely flammable and can be explo­
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Disconnect the battery (–) terminal.
To 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 draw tank
the fuel out from the fuel tank with a com­
mercially available pump.
Front [B]

WARNING
The fuel cannot be removed completely from the
fuel tank. Be careful for remained fuel spillage.
the Allen bolt [A], and nut [B], and take out the
• Remove
meter cover [C].

the meter [A] and ignition switch [B] connec­
• Disconnect
tors.

3-98 FUEL SYSTEM (DFI)

Fuel Tank

• Remove the Allen 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 Frame chapter)

•

Fuel Tank Bolts [A]

Disconnect the battery (–) terminal.

the fuel pump connector [A] (2p).
• Disconnect
Disconnect
the
fuel level sensor connector (3p) [B].
•

NOTE

○During tank removal, keep the fuel tank cap [A] open
to release pressure in the fuel tank. This makes fuel
spillage less.
Front [B]

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) 3-99

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.

3-100 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
the hoses correctly (see Appendix chapter).
• For California
note the following:
•○To prevent theModel,
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) 3-101

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 plug, then quickly
install the fuel hoses one by one.
Be sure the hoses are clamped securely to prevent leak­
age.

•

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 connec­
tors 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.

3-102 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 this chapter).
• Remove
Remove
the
pump from the fuel tank (see Fuel Pump
• section in thisfuelchapter).
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 this chapter).
• Install the fuel tank (see
Fuel Tank Installation).
•

FUEL SYSTEM (DFI) 3-103

Evaporative Emission Control System
The Evaporative Emission Control System for California
Model routes fuel vapors from the fuel system into the run­
ning engine or stores the vapors in a canister when the en­
gine 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 explo­
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.

CAUTION
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capac­
ity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
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 Frame
chapter).
Face the white mark [E] left as shown.

•
•

Canister Inspection (Periodic Inspection)

○Refer to Evaporative Emission Control System Check in
the Periodic Maintenance Chapter (chapter 2).

Separator Inspection (Periodic Inspection)

to Evaporative Emission Control System Check in
• Refer
the Periodic Maintenance Chapter (chapter 2).

3-104 FUEL SYSTEM (DFI)

Evaporative Emission Control System
Hose Inspection (Periodic Inspection)

to Evaporative Emission Control System Check in
• Refer
the Periodic Maintenance Chapter (chapter 2).

Separator Operation Test

WARNING
Gasoline is extremely flammable and can be explo­
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
the seat and left side cover (see Frame chapter).
• Remove
Connect
to the separator.
• Disconnectthethehoses
breather
from the separator, and in­
• ject about 20 mL (0.68 hose
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.

COOLING SYSTEM 4-1


Cooling System

Table of Contents
Exploded View........................................................................................................................

Coolant Flow Chart.................................................................................................................

Specifications .........................................................................................................................

Special Tools and Sealant ......................................................................................................

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

4-6

4-7

4-8
4-8

4-8

4-8
4-8

4-9
4-9

4-10

4-10

4-10

4-11

4-11

4-13
4-13

4-14
4-14

4-15

4-15

4-16

4-16

4-16

4-16

4-17
4-17
4-17

4

4-2 COOLING SYSTEM

Exploded View

COOLING SYSTEM 4-3

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

1

Water temperature sensor (DFI)

18

1.8

13

2

Water pipe bolts

11

1.1

97 in·lb

3

Radiator fan bolts

8.3

0.85

74 in·lb

4

Radiator drain bolt

7.4

0.75

65 in·lb

5

Water temperature switch

7.8

0.80

69 in·lb

6

Radiator fan switch

18

1.8

13

7

Water pump cover bolts

11

1.1

97 in·lb

8

Water pump impeller bolt

8.8

0.90

78 in·lb

9

Water pump drain bolt

11

1.1

97 in·lb

10 Water pump air bleeder bolt

11

1.1

97 in·lb

11 Radiator hose clamp screws

2.5

0.25

22 in·lb

12. Mechanical seal
13. Double seal bearing
14. Oil seal
15. Ball bearing
16. Thermostat
17. Radiator cap
18. Radiator
R: Replacement parts
Lh: Left-hand threads
G: Apply grease.
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

Remarks
SS

SS

Lh

4-4 COOLING SYSTEM

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 op­
erates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13.5
∼ 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.

COOLING SYSTEM 4-5

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

4-6 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 kg/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 4-7

Special Tools and Sealant
Bearing Driver Set :
57001–1129

Kawasaki Bond (Silicone Sealant) :
56019–120

Bearing Remover Shaft,
57001–1265

9:

Bearing Remover Head,
57001–1266

10 ×

Kawasaki Bond (Silicone Sealant) :
56019–120

12 :

4-8 COOLING SYSTEM

Coolant
Coolant Deterioration Inspection

the right side cover (see Frame chapter).
• Remove
Visually
inspect
the coolant [A] in the reserve tank.
• 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
NOTE

○Check the level when the engine is cold (room or ambi­
ent 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 cor­
rect 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.

Coolant Draining

to Coolant Change in the Periodic Maintenance
• Refer
Chapter .

Coolant Filling

to Coolant Change in the Periodic Maintenance
• Refer
Chapter.

COOLING SYSTEM 4-9

Coolant
Pressure Testing

the fuel tank (see Fuel System chapter).
• Remove
Remove
radiator cap, and install a cooling system
• pressure the
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 kg/cm², 17.8 psi).

CAUTION
During pressure testing, do not exceed the pres­
sure for which the system is designed. The maxi­
mum pressure is 123 kPa (1.25 kg/cm², 17.8 psi).
the gauge for at least 6 seconds.
• Watch
If the pressure holds 93 kPa (0.95 kg/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 indi­
cate internal leakage. Check the cylinder head and cylin­
der gaskets and the water pump.
Remove the pressure tester, replenish the coolant, and
install the radiator cap.

Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool­
ing system. If this accumulation is not removed, it will clog
up the water passage and considerably reduce the effi­
ciency of the cooling system.
Drain the cooling system (see Coolant Change in the Pe­
riodic Maintenance chapter).
Fill the cooling system with fresh water mixed with a flush­
ing compound.

•
•

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 Peri­
odic 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

are aluminum washers [A] on rear side of the wa­
• There
ter pump cover [B]. Replace them with new ones when
installing.
Front [C]
Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95
in·lb)

the pump inlet hose until the hose end [A] touches
• Insert
the pump inlet step [B].
• Tighten the hose clamp screw securely.

COOLING SYSTEM 4-11

Water Pump
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 chapter).
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.

NOTE

○Since the replacement mechanical seal has an adhe­
sive coated body, do not apply a liquid gasket to the
exterior surface of the body.
[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 Crankshaft/Transmission chap­
ter).
Remove the water pump impeller.
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: 57001-1265 [B]
Bearing Remover Head:, 10 × 12: 57001
-1266 [C]

4-12 COOLING SYSTEM

Water Pump
a thin-bladed screwdriver, pry out the oil seal.
• Using
Press
the mechanical seal [A] and ball bearing [B]
• from theoutinside
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.

[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)

COOLING SYSTEM 4-13

Radiator
WARNING
The radiator fan is connected directly to the bat­
tery. 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 this chapter).
• Drain
Remove:

• Fuel Tank (see Fuel System chapter.)

Cover Bolt [A]

Cover [B]

Front [C]


• Pry the plastic clamps [A].

• Remove:

Radiator Fan Motor Connector [A]

Radiator Hoses


the mounting bolt [A].
• Remove
up the radiator to clear the stoppers.
• Lift
• Remove the radiator.

CAUTION

Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi­
ciency.

4-14 COOLING SYSTEM

Radiator

• 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 and Fan Ground Lead Terminal
Bolt: 8.3 N·m (0.85 kgf·m, 74 in·lb)

the radiator stoppers [A] into the right and left grom­
• Fit
mets.
the pump inlet hose and position the hose clamp
• Install
(see Water Pump Installation in this chapter).
• Tighten the hose clamp screw securely.

Radiator Inspection

the radiator core.
• Check
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably de­
formed fins, replace the radiator with a new one.

CAUTION
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular [C] (not oblique
[D]) to the core surface and run the steam gun fol­
lowing the core fin direction.

COOLING SYSTEM 4-15

Radiator
Radiator Cap Inspection

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 mea­
sure leak time at once. The relief valve must open within
the specified range in the table below and the gauge nee­
dle must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard:
93 ∼ 123 kPa (0.95 ∼ 1.25 kg/cm², 13.5 ∼
17.8 psi) for 6 seconds

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.
• Remove
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]


4-16 COOLING SYSTEM

Thermostat
Thermostat Removal

• Remove:

Coolant : Drain about 200 mL


•

Fuel Tank (see Fuel System chapter)

Three Water Hoses [A]

Bracket Bolts [B]

One Water Hose (from #1 cylinder)

Water Temperature Sensor Connector [C]

Remove the thermostat housing [D] along with the
bracket.

Front [E]


the screws [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, and inspect the thermostat valve
• Remove
at room temperature.

•

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 con­
tainer 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 ther­
mostat.
Thermostat Valve Opening Temperature

58 ∼ 62°C (136 ∼ 144°F)


COOLING SYSTEM 4-17

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 pre­
vent 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 Radiator Hose and Connection Check in the Periodic
Maintenance Chapter.

ENGINE TOP END 5-1


Engine Top End

Table of Contents
Specifications ....................................
Exploded View...................................
Special Tools and Sealant .................
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...
Rear Camshaft Chain Removal ...
KACR Inspection..........................
Cylinder Head....................................
Cylinder Compression

Measurement ............................
Cylinder Head Removal ...............
Cylinder Head Installation ............
Cylinder Head Warp.....................
Valve Clearance Adjustment ........

5-3

5-6

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

5-30

5-30

5-31

5-32

5-32

5-33

5-34

5-34

5-35


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(For other
than U.S.A. and Canadian
Models) .....................................
Lower Muffler Removal(For other
than U.S.A. and Canadian
Models) .....................................
Upper Muffler Removal(For other
than U.S.A. and Canadian
Models) .....................................
Muffler, Exhaust Pipe
Installation(For other than
U.S.A. and Canadian Models)...
Chamber Removal(For other than
U.S.A. and Canadian Models)...
Chamber Installation(For other
than U.S.A. and Canadian
Models) .....................................
Chamber Assembly(For other
than U.S.A. and Canadian
Models) .....................................
Chamber Identification(For other
than U.S.A. and Canadian
Models) .....................................

5-35

5-35

5-35

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
5-45
5-46
5-46
5-47
5-47
5-48
5-48
5-48
5-49
5-49
5-49
5-50

5

5-2 ENGINE TOP END

Front Exhaust Pipe

Removal(U.S.A. and Canadian

Models) .....................................
Rear Exhaust Pipe

Removal(U.S.A. and Canadian

Models) .....................................

5-50
5-51

Muffler Removal (U.S.A. and
Canadian Models) .....................
Muffler, Exhaust Pipe

Installation(U.S.A. and
Canadian Models) .....................

5-51

5-51


ENGINE TOP END 5-3

Specifications
Item
Standard
Service Limit
Clean Air System:
Vacuum switch valve closing pressure: Open → Close 49.3 ∼ 65.3 kPa
– – –
(370 ∼ 490 mm Hg)
Camshafts:
Cam height:
Exhaust
33.741 ∼ 33.857 mm
33.64 mm
(1.32839 ∼ 1.33295 in.)
(1.3244 in.)
Inlet
33.928 ∼ 34.044 mm
33.83 mm
(1.3319 in.)
(1.33575 ∼ 1.34031 in.)
Camshaft/rocker case clearance
0.020 ∼ 0.062 mm
0.15 mm
25
(0.000787 ∼ 0.00244 in.)
(0.00591 in.)
17
0.016 ∼ 0.055 mm
0.14 mm
(0.00551 in.)
(0.000630 ∼ 0.00217 in.)
Camshaft journal diameter
24.959 ∼ 24.980 mm
24.93 mm
25
(0.98150 in.)
(0.982638 ∼ 0.983465 in.)
Rocker case bearing inside diameter
25.000 ∼ 25.021 mm
25.08 mm
25
(0.98740 in.)
(0.984252 ∼ 0.985079 in.)
Camshaft journal diameter
16.966 ∼ 16.984 mm
16.93 mm
17
(0.66654 in.)
(0.667953 ∼ 0.668661 in.)
Rocker case bearing inside diameter
17.000 ∼ 17.021 mm
17.08 mm
17
(0.669291 ∼ 0.670118 in.)
(0.67244 in.)
Camshaft runout
TIR 0.02 mm (0.00079 in.)
TIR 0.1 mm
or less
(0.0039 in.)
Rocker arm inside diameter
16.000 ∼ 16.018 mm
16.05 mm
(0.63189 in.)
(0.629921 ∼ 0.630630 in.)
15.966 ∼ 15.984 mm
15.94 mm
Rocker shaft diameter
(0.628583 ∼ 0.629291 in.)
(0.62756 in.)
Cylinder Head:
Cylinder compression usable range
340 ∼ 590 kPa (3.5 ∼ 6.0 kg/cm²,
– – –
50 ∼ 85 psi) @300 r/min (rpm)
with electric starter
Cylinder head warp
–––
0.05 mm (0.0020 in.)
Valve:
Valve clearance
– – –
Non-adjustable (Auto adjuster)
Valve head thickness:
Exhaust
0.7 mm (0.028 in.)
0.9 ∼ 1.1 mm (0.035 ∼ 0.0433 in.)
0.5 mm (0.020 in.)
Inlet
0.9 ∼ 1.1 mm (0.035 ∼ 0.0433 in.)
Valve stem bend
TIR 0.01 mm (0.00039 in.) or less
TIR 0.05 mm
(0.0020 in.)
6.94 mm (0.2732 in.)
Valve stem diameter:
Exhaust
6.955 ∼ 6.970 mm
(0.27382 ∼ 0.27441 in.)

5-4 ENGINE TOP END

Specifications
Item
Inlet
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
6.965 ∼ 6.980 mm
(0.27421 ∼ 0.27480 in.)

Service Limit
6.95 mm (0.2736 in.)

7.000 ∼ 7.015 mm
(0.27559 ∼ 0.27618 in.)
7.000 ∼ 7.015 mm
(0.27559 ∼ 0.27618 in.)

7.08 mm (0.2787 in.)

0.08 ∼ 0.16 mm
(0.0031 ∼ 0.00630 in.)
0.05 ∼ 0.13 mm
(0.0020 ∼ 0.00512 in.)

0.30 mm (0.0118 in.)

7.08 mm (0.2787 in.)

0.27 mm (0.0106 in.)

Camshaft Journals and Runout

25 mm (0.984 in.) [A]
17 mm (0.669 in.) [B]
Valve Stem Bend

ENGINE TOP END 5-5

Specifications
Item
Valve seat surface:
Valve seat cutting angle
Outside diameter:

Standard

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

45°, 32°, 55°
29.9 ∼ 30.1 mm
(1.295 ∼ 1.303 in.)
32.9 ∼ 33.1 mm
(1.177 ∼ 1.185 in.)
0.5 ∼ 1.0 mm
(0.020 ∼ 0.039 in.)
0.5 ∼ 1.0 mm
(0.020 ∼ 0.039 in.)
44.76 mm (orange)
(1.7622 in.)
39.82 mm (orange)
(1.5677 in.)

Service Limit
– – –
– – –
– – –
– – –
– – –
43.2 mm (1.700 in.)
38.3 mm (1.508 in.)

102.000 ∼ 102.012 mm
(4.015748 ∼ 4.016220 in.)
101.942 ∼ 101.957 mm
(4.013457 ∼ 4.014047 in.)
0.043 ∼ 0.070 mm
(0.00169 ∼ 0.00276 in.)
+ 0.5 mm
(0.020 in.)

102.10 mm
(4.01969 in.)
101.79 mm
(4.00748 in.)
– – –

0.05 ∼ 0.09 mm
(0.00197 ∼ 0.00354 in.)
0.03 ∼ 0.07 mm
(0.0012 ∼ 0.0028 in.)
1.24 ∼ 1.26 mm
(0.048819 ∼ 0.049606 in.)
1.22 mm ∼ 1.24 mm
(0.04803 ∼ 0.04882 in.)
1.17 mm ∼ 1.19 mm
(0.04606 ∼ 0.04685 in.)
1.17 mm ∼ 1.19 mm
(0.04606 ∼ 0.04685 in.)
0.25 ∼ 0.35 mm
(0.0098 ∼ 0.0138 in.)
0.40 ∼ 0.55 mm
(0.0157 ∼ 0.0217 in.)
0.3 ∼ 0.9 mm
(0.012 ∼ 0.035 in.)

0.19 mm
(0.00748 in.)
0.17 mm
(0.00669 in.)
1.34 mm
(0.05276 in.)
1.32 mm
(0.05197 in.)
1.10 mm
(0.0433 in.)
1.10 mm
(0.0433 in.)
0.7 mm
(0.028 in.)
0.8 mm
(0.031 in.)
1.2 mm
(0.0472 in.)

– – –

5-6 ENGINE TOP END

Exploded View

ENGINE TOP END 5-7

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Rocker case cover bolts

8.8

0.90

78 in·lb

2

Air suction valve cover bolts

7.4

0.75

65 in·lb

3

Rocker case nuts

12 mm

78

8.0

58

S, MO

4

Rocker case nuts

8 mm

25

2.5

18

S

5

Rocker case bolts

6 mm

8.8

0.90

78 in·lb

S

6

Spark plug retainers

12

1.2

104 in·lb

7

Plugs

20

2.0

14

8. Vacuum Switch Valve
9. Air Suction Valves
10. HLA Oil Filters
AD: Apply adhesive.
EO: Apply engine oil.
MO: Apply molybdenum disulfide oil.
L: Apply a non-permanent locking agent.
S: Follow the specific tightening sequence.
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

S

L

5-8 ENGINE TOP END

Exploded View

ENGINE TOP END 5-9

Exploded View
No.

Torque

Fastener

N·m

kgf·m

ft·lb

1

Rocker shafts

25

2.5

18

2

Exhaust pipe cover clamp screws

6.9

0.70

61 in·lb

3

Premuffler chamber bolts

29

3.0

22

4

Muffler bracket nut

29

3.0

22

5

Muffler stay mounting bolts,

8

25

2.5

18

6

Muffler stay mounting nuts,

8

25

2.5

18

7

Muffler bracket bolt

29

3.0

22

8. Rear Exhaust Pipe
9. Front Exhaust Pipe
10. Upper Muffler
11. Lower Muffler
12. Muffler Assembly
13. Premuffler Chamber
14. Hydraulic Lash Adjusters
PN: Spray a penetrating oil on the nuts and studs if the nuts are difficult to remove.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
WL: Apply a soap and water solution or rubber lubricant.

Remarks

5-10 ENGINE TOP END

Exploded View

ENGINE TOP END 5-11

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Cylinder coolant drain plug

11

1.1

95 in·lb

2

Cylinder head nuts

25

2.5

18

S

3

Cylinder nuts

25

2.5

18

S

4

Chain tensioner cap

20

2.0

14

S

5

Chain tensioner lockbolt

4.9

0.50

43 in·lb

S

6

Chain tensioner mounting bolts

11

1.1

95 in·lb

S

7

Chain guide mounting bolts

11

1.1

95 in·lb

L

8

Camshaft sprocket bolts

15

1.5

11

L

9. KACR Unit
10. “R” marked side faces up.
11. “RN” marked side faces up.
12. Each arrow mark points to the front side.
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil.
R: Replacement Parts
S: Follow the specific tightening sequence.

5-12 ENGINE TOP END

Special Tools and Sealant
Valve Guide Reamer, 7 :
57001–162

Piston Pin Puller Assembly :
57001–910

Valve Guide Reamer,
57001–162

Compression Gauge Adapter, M12 × 1.25 :
57001–1018

Valve Guide Arbor,
57001–163

7:

7:

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 Sealant
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


7:

Fork Oil Level Gauge :
57001–1290

Valve Seat Cutter Holder,
57001–1126

14 :

35 :

Valve Seat Cutter Holder Bar :
57001–1128

Piston Ring Compressor Belt, 95 ∼
57001–1358

Hexagon Wrench, Hex 27 :
57001–1210

Filler Cap Driver :
57001–1454

108 :

5-14 ENGINE TOP END

Special Tools and Sealant
Valve Seat Cutter 45° –
57001–1496

40 :

Valve Seat Cutter 55° –
57001–1497

38.5 :

Kawasaki Bond (Silicone Sealant) :
56019–120

○Compression

Gauge Adapter: 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

rear air suction valve removal, remove the hose [A].
• For
Unscrew
the mounting bolts [B] and remove the rear air
• suction valve
cover [C].
Remove
the
rear
air suction valve.
•

front air suction valve removal, remove the horn, the
• For
radiator mounting bolt and move the radiator forward.
the hose [A].
• Remove
Unscrew
the mounting bolts [B] and remove the front air
• suction valve
cover [C].
Remove
the
front
air suction valve.
•

Air Suction Valve Installation

the gasket with a new one.
• Replace
Install
each
air suction valve so that its wider side [A] of
• the reed faces
left.

Front Air Suction Valve [B]


the front air suction valve cover installation, set the
• For
lower bolt [A] in the cover [B] and install it.
Torque - Air Suction Valve Cover Bolts: 7.4 N·m (0.75
kgf·m, 65 in·lb)

Air Suction Valve Check

○Refer to Air Suction Valve Check in the Periodic Mainte­
nance Chapter.

5-16 ENGINE TOP END

Clean Air System
Vacuum Switch Valve Removal

• Remove:

Fuel Tank (see Fuel System Chapter)

Pull
• valveoff[B].
the hoses [A] and take out the vacuum switch


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 General Information chap­
• Route
ter).

Vacuum Switch Valve Operation Test

the vacuum switch hose [A] out of the right air cleaner
• Pull
base.
the engine and run it at idle speed.
• Start
Plug
the
switch hose end with your finger and feel
• vacuum 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).
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].

Vacuum Switch Valve Unit Test

the vacuum switch valve (see Vacuum Switch
• Remove
Valve Removal).
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]

ENGINE TOP END 5-17

Clean Air System
raise the vacuum (lower the pressure) applied
• Gradually
to the vacuum switch valve, and check the valve opera­
tion. 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].

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 mm Hg)

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 Ten­
sioner 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 Fuel System
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, 95 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, 14 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

the engine (see Engine Removal/Installation
• Remove
chapter).
the bolts [A] and take off the cover [B] from the
• Remove
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

the engine (see Engine Removal/Installation
• Remove
chapter).
the throttle body assy (see Fuel System (DFI)
• Remove
chapter).
the rocker case covers (see this chapter).
• Remove
Remove
the
• chapter). alternator outer cover (see Electrical System
the timing inspection plug [A] and rotor bolt plug
• Remove
[B].
Special Tool - Driver-Filler Cap: 57001–1454 [C]

Turn the crankshaft counterclockwise [A] and align the “F”
• mark
(TDC mark for front piston) [B] with the middle of the
notch [C].

• Remove:

Oil Hose Banjo Bolt [A]

Oil Hose [B]


the camshaft chain tensioner (see Camshaft
• Remove
Chain Tensioner Removal).
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
Remove
• moval). the lash adjuster if necessary (see HLA Re­

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 rocker arms [A] and retaining springs [B] on
• Install
each rocker shaft as shown. These retaining springs are
the same.
○The rocker arm [C] of the exhaust side [D] 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.
Replace the O-rings [E] with new ones and install them
on the rocker shaft [F].
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): 56019-120

○Do not apply silicone sealant around the camshaft bear­
ing.

molybdenum disulfide oil to the threads and seating
• Apply
surface of 12 mm nuts and both sides of washers.
the rocker case nuts and bolts temporarily follow­
• Tighten
ing the tightening sequence shown, and then tighten them
to the specified torque.
Torque - Rocker Case Nuts 12 mm: 78 N·m (8.0 kgf·m, 58
ft·lb)
Rocker Case Nuts 8 mm: 25 N·m (2.5 kgf·m, 18
ft·lb)

Rocker Case Bolts
 6 mm: 8.8 N·m (0.90 kgf·m,
78 in·lb)

Inlet Side [A]

○The molybdenum disulfide oil is a mixture of engine oil
and molybdenum disulfide grease with a weight ratio (10
: 1).

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, Cylinder Nuts: 25 N·m (2.5
kgf·m, 18 ft·lb)

•

Rocker Cases [C]
Cylinder Heads [D]
Cylinders [E]
Tighten:
Torque - Timing Inspection Plug, Rotor Bolt Plug: 1.5 N·m
(0.15 kgf·m, 13 in·lb)

the engine (see Engine Removal/Installation chap­
• Install
ter).

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 case (see this chapter).
• Remove
Remove
the rocker arms.
• Pull the HLA
(hydraulic lash adjuster) [B] out of the rocker
• arm [A] with your
fingers.

CAUTION
Be careful not to damage or deform an HLA by tap­
ping it during removal or installation.
Do not drop the HLA or hit it sharply. If it is dam­
aged, the plunger will not operate smoothly.

HLA Air Bleeding

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).
• 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

the timing inspection cap [A] and rotor bolt cap
• Remove
[B].
Special Tool - Driver-Filler Cap: 57001–1454 [C]

Turn the crankshaft counterclockwise [A] and align the “F”
• mark
[B] (TDC mark for the front piston) with the middle

•
•

of the notch [C].
Remove the front and rear rocker case covers (see this
chapter).
Remove the front and rear rocker cases (see this chap­
ter).

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 turn­
ing 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].

ENGINE TOP END 5-27

Camshafts
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 to all cam parts, including
• Apply
their journals.

○The molybdenum disulfide oil is a mixture of engine 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).
If necessary, align them.

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 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].

5-28 ENGINE TOP END

Camshafts
the “R” mark [A] (TDC mark for the rear piston) with
• Align
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 ten­
sioner installation.
Install the rocker cases and rocker case covers (see this
chapter).

•
•

Torque - Timing Inspection Cap, Rotor Bolt Cap: 1.5 N·m
(0.15 kgf·m, 13 in·lb)

Camshaft Sprocket Installation

the sprocket marked F for the front camshaft [A] and
• Use
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 be­
tween the journal and camshaft cap.

ENGINE TOP END 5-29

Camshafts
molybdenum disulfide oil to the threads and seating
• Apply
surface of 12 mm nuts and both sides of washers.
the rocker case nuts and bolts temporarily follow­
• Tighten
ing the tightening sequence shown, and then tighten them
to the specified torque.
Torque - Rocker Case Nuts 12 mm: 78 N·m (8.0 kgf·m, 58
ft·lb)
Rocker Case Nuts 8 mm: 25 N·m (2.5 kgf·m, 18
ft·lb)
Rocker Case Bolts 6 mm: 8.8 N·m (0.90 kgf·m,
78 in·lb)

Inlet Side [A]
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 plas­
tigage width.
Camshaft/Rocker Case Clearance
Standard:
( 25) 0.020 ∼ 0.062 mm
(0.000787 ∼ 0.00244 in.)
( 17) 0.016 ∼ 0.055 mm
(0.000630 ∼ 0.00217 in.)
Service Limit:

( 25) 0.15 mm (0.00591 in.)
( 17) 0.14 mm (0.00551 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

(0.982638 ∼ 0.983465 in.)

( 17) 16.966 ∼ 16.984 mm

(0.667953 ∼ 0.668661 in.)

Service Limit:

( 25) 24.93 mm (0.98150 in.)

( 17) 16.93 mm (0.66654 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.

5-30 ENGINE TOP END

Camshafts
Front Camshaft Chain Removal

• Remove:

Front Camshaft [A] (see this chapter)

Spark Plug (left side, see Cylinder Compression Mea­

surement)

Spark Plug Retainer [B] (left side)

Special Tool - Hexagon Wrench, Hex 27 [C]: 57001-1210

• Remove:

Alternator Rotor (see Electrical System chapter)

•

Lower Chain Guide Bolts [A]

Lower Chain Guide [B]

Take out the front camshaft chain [C].

Rear Camshaft Chain Removal

• Remove:

Rear Camshaft (see this chapter)

Spark Plug (left side, see Cylinder Compression Mea­

surement)

Spark Plug Retainer (see Front Chain Removal)

Clutch (see Clutch chapter)

Starter Clutch Gear (see Crankshaft/Transmission chap­

ter)

Primary Gear (see Crankshaft/Transmission chapter)


•

Lower Chain Guide Bolts [A]
Lower Chain Guide [B] (right view)
Take out the rear camshaft chain [C].

ENGINE TOP END 5-31

Camshafts
KACR Inspection

○Due to the simplicity of the KACR (Kawasaki Automatic

Compression Release), no periodic maintenance is
needed. There are only two symptoms of problems with
the KACR mechanism compression is not released dur­
ing 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 po­
sition, 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
Stop
the
• Remove engine.
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: 57001-1024 [A]

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: 57001-221 [A]
Compression Gauge Adapter, M12 × 1.25:
57001-1018 [B] (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 us­
able 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.

Remedy (Action)
Remove the carbon deposits
and replace damaged parts if
necessary.

Replace the gasket with a standard
part.
Damaged or missing compression release cam Replace the spring.
spring.
Replace the compression release
Compression release weights do not move
smoothly.
unit.
Gas leakage around cylinder head
Replace damaged gasket and
check cylinder head warp.
Bad condition of valve seats, valves, and valve
Repair them if necessary.
springs.
HLA seizure.
Replace the HLA.
Incorrect piston/cylinder clearance
Replace the piston and/or cylinder.
Piston seizure.
Inspect the cylinder and liner and
replace/repair the cylinder and/or
piston as necessary.
Bad condition of piston ring and/or piston ring Replace the piston and/or the
piston rings.
grooves.
Replace the compression release
Compression release weights do not move
smoothly.
unit.

Cylinder Head Removal

• Remove:

Engine (see Engine Removal/Installation chapter)

Rocker Cases (see this chapter)

Camshafts (see this chapter)

Spark Plug Retainers (see this chapter)

Special Tool - Hexagon Wrench, Hex 27: 57001-1210

○The camshaft chain comes off.

• Remove:

Air Suction Valve Cover with Valve [A]

Cooling Pipe with Hose [B]


5-34 ENGINE TOP END

Cylinder Head
not remove the coolant drain plug [A] yet.
• Do
Remove
cylinder head nuts [B].
• Take the the
cylinder
head off the cylinder.
•

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)
Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)

• Install:

Camshafts (see this chapter)

•

Rocker Cases (see this chapter)

Tighten:
Torque - Cylinder Head Nuts and Cylinder Nuts: 25 N·m
(2.5 kgf·m, 18 ft·lb)

Cylinder Head Warp

the cylinder head (see this chapter).
• Remove
Lay
a
straightedge
across the lower surface of the cylinder
• head at several positions.
a thickness gauge [A] to measure the space between
• Use
the 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).

ENGINE TOP END 5-35

Cylinder Head
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 this chapter).
• Remove
Swing
open
the rocker arm.
• Using the valve
spring compressor assembly, remove the
• valve.
Special Tools - Valve Spring Compressor Assembly: 57001
-241 [A]
Valve Spring Compressor Adapter, 28.2:
57001-243 [B]

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.
Install
the
springs
so
that the closed coil end faces down­
• 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]


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.

5-36 ENGINE TOP END

Cylinder Head
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 counter­
clockwise or it will be dulled.
○Once the guides are reamed, they must be cleaned thor­
oughly.
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 mea­
suring 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
Service Limit
Exhaust

0.08 ∼ 0.16 mm
(0.0031 ∼ 0.00630 in.)

(0.0118 in.)

Inlet

0.05 ∼ 0.13 mm

0.27 mm

(0.0020 ∼ 0.00512 in.)

(0.0106 in.)

0.30 mm

ENGINE TOP END 5-37

Cylinder Head
Valve Seat Inspection

the valve (see Valve Removal).
• 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 Seat Repair).
Valve Seat Surface Outside Diameter (Seat O.D.)
Standard: Exhaust 31.9 ∼ 32.1 mm (1.256 ∼ 1.264 in.)
Inlet

36.4 ∼ 36.6 mm (1.433 ∼ 1.441 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).
Valve Seat Surface Width (or Seat Width)
Standard: Exhaust: 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)
Inlet:

0.8 ∼ 1.2 mm (0.031∼ 0.047 in.)

Valve Seat Repair

• Repair the valve seat with the valve seat cutters [A].

Special Tools - Valve Seat Cutter Holder, 7: 57001-1126
[B]
Valve Seat Cutter Holder Bar: 57001-1128
[C]

[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° –
Valve Seat Cutter, 55° –

38.5: 57001-1122
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 be­
fore grinding the seat surface. Also wash off ground parti­
cles sticking to the cutter with washing oil.

CAUTION
Do not use a wire brush to remove the metal par­
ticles 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 re­
placed.
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 dis­
tinct 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 pre­
vent 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 mea­
sure 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 assem­
bly.

5-40 ENGINE TOP END

Cylinder Head

ENGINE TOP END 5-41

Cylinders, Piston
Cylinder Removal

the cylinder head (see this chapter).
• Remove
Remove
the coolant drain plug [A] and drain the coolant
• from the cylinder.
out the front camshaft chain guide [B].
• Pull
Remove
nuts [C].
• Tap lightlytheupcylinder
the
cylinder
• from the crankcase. with a plastic mallet to separate
• Remove the cylinder base gasket.

Piston Removal

the cylinder block (see this chapter).
• Remove
Place
a
piece
of clean cloth under the piston and remove
• the piston pin snap
rings [A] from the outside of each pis­
ton.

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]

Arrow mark [E] must be faced toward the engine front.

Opening Positions [G]


the arrow 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 pis­
ton 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 to the outer surface of the
piston pin.
○The molybdenum disulfide oil 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 to the cylinder bore.
Apply molybdenum disulfide oil 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), 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 instal­
lation).

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 ex­
ceeds 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 (4.015748 ∼
4.01622 in.), and less than 0.01 mm
(0.0004 in.) difference between any
two measurements.
Service Limit:	

102.10 mm (4.01969 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 pis­
ton.
Piston Diameter

Standard:

101.942 ∼ 101.957 mm

(4.013457 ∼ 4.014047 in.)

Service Limit:	

101.79 mm (4.00748 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 (0.00169 ∼ 0.00276 in.)

If the piston/cylinder clearance is less than the specified
range, use a smaller piston made within the standard di­
ameter 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 di­
ameter.
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

Before boring a cylinder [A], first measure the exact di­
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 nec­
essary 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 cylin­
der 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 re­
bored 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 mea­
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top
Second

Service Limit:

0.05 ∼ 0.09 mm

0.19 mm

(0.00197 ∼ 0.00354 in.)

(0.00748 in.)

0.03 ∼ 0.07 mm

0.17 mm

(0.0012 ∼ 0.0028 in.)

(0.00669 in.)

If the piston ring groove clearance is greater than the ser­
vice limit, measure the ring thickness and groove width as
follows to decide whether to replace the rings, the piston
or both.

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

Service Limit
1.34 mm

(0.048819 ∼ 0.049606 in.) (0.05276 in.)
Second

1.22 ∼ 1.24 mm

1.32 mm

(0.04803 ∼ 0.04882 in.)

(0.05197 in.)

If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.

5-46 ENGINE TOP END

Cylinders, 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
Second

Service Limit

1.17 ∼ 1.19 mm

1.10 mm

(0.04606 ∼ 0.04685 in.)

(0.0433 in.)

1.17 ∼ 1.19 mm

1.10 mm

(0.04606 ∼ 0.04685 in.)

(0.0433 in.)

If any of the measurements is less than the service limit
on either of the rings, replace all the rings.

NOTE

○When using new rings in a used piston, check for un­

even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.

Piston Ring End Gap

the piston ring [A] inside the cylinder, using the pis­
• Place
ton to locate the ring squarely in place. Set it close to the

•

bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap

Standard
Top
0.25 ∼ 0.35 mm
(0.0098 ∼ 0.0138 in.)
Second 0.40 ∼ 0.55 mm
(0.0157 ∼ 0.0217 in.)
0.3 ∼ 0.9 mm
Oil
(0.012 ∼ 0.035 in.)

Service Limit

0.7 mm

(0.028 in.)

0.8 mm

(0.031 in.)

1.2 mm

(0.0472 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
(For other than U.S.A. and Canadian Models)

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 upper muffler bracket nut [A] for easy removal
• Loosen
or installation of exhaust pipes.
the clamp screw [A].
• Loosen
Detach
the
clamp [B] by sliding it forward.
• Remove thelower
lower
front exhaust pipe cover [C].
• Loosen the clamp screws
• Detach the upper clamps [D].
[E] by sliding them up or for­
• ward.
• Remove the front exhaust pipe cover [F].

the front exhaust pipe clamp bolt [A].
• Loosen
Remove
the front exhaust pipe holder nuts [B].
• Take off the
front exhaust pipe [C].
•

○Next, remove the rear exhaust pipe.

the clamp screws [A] on the rear exhaust pipe
• Loosen
cover [B].
the clamp [C] by sliding it up.
• Detach
Detach
the
[D] by sliding them down or backward.
• Remove theclamps
rear
exhaust
pipe cover by sliding it forward.
•

the right and left chamber bolts [A]
• Loosen
Remove
rear exhaust pipe holder nuts [B].
• Loosen thetherear
pipe clamp bolt [C].
• Pull the upper endexhaust
of
the
exhaust pipe outward and
• twist clockwise a little, andrear
then take off the rear exhaust
pipe [D].

5-48 ENGINE TOP END

Mufflers
Lower Muffler Removal
(For other than U.S.A. and Canadian Models)

• Remove:

Lower Front Exhaust Pipe Cover (see above)

•

Chamber Flange Nuts [A]

Muffler Bracket Bolts [B]

Remove the lower muffler [C].

NOTE

○If the chamber flange nuts are difficult to remove, spray
a penetrating oil on the studs and nuts.

Upper Muffler Removal
(For other than U.S.A. and Canadian Models)

• Remove:

Rear Exhaust Pipe Cover (see above)

•

Lower Muffler (see above)

Muffler Pipe Clamp Bolt [A]

Upper Muffler Bracket Nut [B]

Remove the upper muffler [C].

Muffler, Exhaust Pipe Installation
(For other than U.S.A. and Canadian Models)

the exhaust pipe holder gasket [A] with new
• Replace
ones.
Torque - Muffler Stay Mounting Bolts, 8 (lower): 25 N·m
(2.5 kgf·m, 18 ft·lb)
Upper Muffler Bracket Nut: 29 N·m (3.0 kgf·m, 22
ft·lb)

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.

ENGINE TOP END 5-49

Mufflers
Chamber Removal
(For other than U.S.A. and Canadian Models)

• Remove:

Bolts [A]


Rear Regulator/Rectifier Bracket [B]


• Remove:

Front Exhaust Pipe [A]

•

Rear Exhaust Pipe [B]

Lower and Upper Mufflers [C]

Right and Left Chamber Bolts [D]

Take out the premuffler chamber [E].

Front [F]


Chamber Installation
(For other than U.S.A. and Canadian Models)

the muffler flange gasket with new ones.
• Replace
Install
the
exhaust pipe and muffler pipe clamps [A] with
• its bolt downward.

Front [B]

Torque - Chamber Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb)

Chamber Assembly
(For other than U.S.A. and Canadian Models)

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
(For other than U.S.A. and Canadian Models)

○The this models have a premuffler chamber (Identification
No. KHI M 091) with a honeycomb type catalytic con­
verter 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.

Front Exhaust Pipe Removal
(U.S.A. and Canadian Models)

WARNING
To avoid a serious burn, do not remove the muffler
when the engine is still hot. Wait until the muffler
cools down.
the clamp screws [A].
• Loosen
Detach
the
upper clamps [B] by sliding them up or for­
• ward.
the lower clamp [C] by sliding it forward.
• Detach
Remove
the front exhaust pipe cover [D].
•
the front exhaust pipe clamp bolt [A].
• Loosen
Remove
the front exhaust pipe holder nuts [B].
• Take off the
front exhaust pipe [C].
•

ENGINE TOP END 5-51

Mufflers
Rear Exhaust Pipe Removal
(U.S.A. and Canadian Models)

the clamp screws [A] on the rear exhaust pipe
• Loosen
cover [B].
the upper clamp [C] by sliding it up.
• Detach
Detach
• back. the middle [D] and lower clamp [E] by sliding it
• Remove the rear exhaust pipe cover.
the upper muffler bracket nut [A] and lower muf­
• Remove
fler bracket bolt [B].

the rear exhaust pipe holder nuts [A].
• Remove
Loosen
the
rear exhaust pipe clamp bolt [B].
• Pull the upper
of the rear exhaust pipe outward and
• twist clockwiseend
a little, and then take off the rear exhaust
pipe [C].

Muffler Removal (U.S.A. and Canadian Models)

• Remove:

Rear Exhaust Pipe Covers (see This chapter)

•
•

Rear Exhaust Pipe (see This chapter)

Loosen the front exhaust pipe clamp bolts [A].
Remove the muffler Assembly [B].

Muffler, Exhaust Pipe Installation
(U.S.A. and Canadian Models)

the exhaust pipe holder gasket with new ones.
• Replace
Insert
the
• shown.
 exhaust pipe joint gaskets [A] direction as
Front [B]

Rear [C]

Chamfer Side [D]


5-52 ENGINE TOP END

Mufflers
the front exhaust pipe cover clamp screws [A] with
• Tighten
its head inclined at 50° or less to horizontal as shown.
This prevents the screw from touching ground when bank­
ing.
Front Exhaust Pipe [B]
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
Torque - Muffler Bracket Bolt and Nut: 29 N·m (3.0 kgf·m,
22 ft·lb)

warm up the engine, wait until the engine
• Thoroughly
cools down, and retighten all the clamp bolts.

CLUTCH 6-1


Clutch

Table of Contents
Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools and Sealant ......................................................................................................

Clutch Fluid.............................................................................................................................

Clutch Fluid Level Check ..................................................................................................

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 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


6-13
6-14
6-14

6-16

6-16

6-16

6-17

6-17
6-17

6-17


6







6-2 CLUTCH

Exploded View

CLUTCH 6-3

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Clutch reservoir cap screws

1.5

0.15

13 in·lb

2

Clutch slave cylinder bleed valve

7.8

0.80

69 in·lb

3

Clutch master cylinder clamp bolts

11

1.1

95 in·lb

4

Clutch hose banjo bolt

25

2.5

18

5

Clutch slave cylinder bolts

6.9

0.70

61 in·lb

6

Clutch pipe banjo bolt

25

2.5

18

7

Clutch hub nut

147

15.0

108

8

Clutch cover bolts

11

1.1

95 in·lb

9

Clutch damper cover bolts

9.8

1.0

87 in·lb

L

10 Clutch damper screws

4.9

0.50

43 in·lb

L

11 Clutch lever pivot bolt

1.0

0.10

8.7 in·lb

Si

12 Clutch lever pivot bolt locknut

5.9

0.60

52 in·lb

13 Starter lockout switch screw

1.2

0.12

10 in·lb

14 Clutch damper plate bolts

9.8

1.0

87 in·lb

15. Starter Lockout Switch
16. Clutch Slave Cylinder
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.
R: Replacement Parts
S: Follow the specific tightening sequence.
Si: Apply silicone grease or PBC grease.

S
L

EO

6-4 CLUTCH

Specifications
Item
Clutch Fluid
Grade
Clutch Lever Position
Clutch Lever Free Play
Clutch
Clutch spring free height
Spring plate gap (usable range)
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 (0.235 in)
1.95 ∼ 2.45 mm (0.0768 ∼ 0.0965 in)
3.3 ∼ 3.5 mm (0.130 ∼ 0.138 in)
0.2 mm (0.0079 in) or less

4.0 mm (0.16 in)
– – –
3.1 mm (0.122 in)
0.3 mm (0.012 in)

CLUTCH 6-5

Special Tools and Sealant
Inside Circlip Pliers :
57001–143

Clutch Spring Compressor :
57001–1162

Gear Holder, m2.0 :
57001–1557

6-6 CLUTCH

Clutch Fluid
Clutch Fluid Level Check

○Refer to Clutch Fluid Level Check in the Periodic Mainte­
nance Chapter.

Clutch Fluid Change

○Refer to Clutch Fluid Change in the Periodic Maintenance
Chapter.

Clutch Line Bleeding

• Remove:

Alternator Outer Cover (see 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 reser­

voir. 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 en­
tered the line.

○Repeat this operation until no more air can be seen com­
ing 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 Brake Hoses section in the Brakes chapter for clutch
hose removal or installation.

Clutch Hose and Connection Check

○Refer to Clutch Hose and Connection Check in the Peri­
odic Maintenance Chapter.

CLUTCH 6-7

Clutch Master Cylinder
Clutch Lever Adjustment
The adjuster has 5 positions so that the clutch lever posi­
tion 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
(front view).
○The distance from the grip to the lever is minimum at num­
ber 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 [A] to disconnect the clutch hose
• Remove
from the master cylinder (rear view).
the clamp bolts [B], and take off the master cylin• Unscrew
der [C] 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 (rear
view).
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, 95 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: 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).
that the clutch line has proper fluid pressure and
• Check
no fluid leakage.

Clutch Master Cylinder Disassembly/Assembly

○Refer to Clutch Master Cylinder Cup and Dust Seal Re­
placement in the Periodic Maintenance Chapter.

6-8 CLUTCH

Clutch Master Cylinder
Clutch Master Cylinder Inspection

the clutch master cylinder.
• Disassemble
Check
that
there
no scratches, rust or pitting on the
• inside of the masterarecylinder
[A] and on the outside of the

•

piston [B].
If the master cylinder or piston shows any damage, re­
place 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 as­
sembly 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 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 the bolts [A].

Torque - Clutch Slave Cylinder Bolts: 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 fit­
ting with new ones.
Tighten the banjo bolt [C] to the specified torque.
Torque - Clutch Pipe Banjo Bolt: 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

○Refer to Clutch Slave Cylinder Piston Seal Replacement
in the Periodic Maintenance Chapter.

CLUTCH 6-11

Clutch
Clutch Cover Removal

• Raise the rear wheel off the ground.

Special Tools - Jack: 57001–1238

Attachment Jack: 57001–1398


the engine oil (see Periodic Maintenance chapter).
• Drain
Support
the engine with a suitable stand [A].
•○Put a plank
[B] onto the stand.

• Remove:

Front Exhaust Pipe (see Engine Top End chapter)

Clamps (open) [A]

Downtube [B] (see Frame chapter, but remove the down­

tube with the right footpeg and rear master cylinder left

installed)


the eighteen cover bolts [A].
• Unscrew
Using
the
• crankcase. pry points [B], take the cover

[C] off the

NOTE

○Do not remove the damper cover [D].

Clutch Removal
NOTE

○Use an air impact wrench for removal of the clutch hub
nut.

the clutch cover (see this chapter).
• Remove
Remove
the
ring [A] and take the operating plate
• [B] out of theretaining
clutch assembly.

Screw Driver [C]


• Remove:

Washer [A]

Spring Plate Pusher [B]

Needle Bearing

Washer


6-12 CLUTCH

Clutch
the clutch hub nut [A] by using an air impact
• Unscrew
wrench.
the clutch spring [B], and the clutch spring holder [C]
• Take
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.

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 6-13

Clutch
Clutch Installation
When replacing any one of the following parts, check the
spring plate gap (see Spring Plate Gap Measurement).
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, ap­
ply 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].
the clutch spring [A] on the spring holder [B], noth­
• Install
ing the direction.
grease to the back torque limiter springs [C] and
• Apply
install them on the spring holder as shown.

Clutch Hub Nut [D] (for reference)


• Apply molybdenum disulfide oil to the clutch hub nut.
Molybdenum Disulfide Oil- Threads and Seating
Surface of Clutch Hub Nut

○The molybdenum disulfide oil is a mixture of engine 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: 147 N·m (15.0 kgf·m, 108 ft·lb)
Special Tool - Gear Holder : 57001-1557

6-14 CLUTCH

Clutch
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.

Inner Clutch Hub Disassembly

a press [A], and the clutch spring compressor [B],
• Using
push the damper spring holder [C] to remove the retaining
ring [D].
Special Tool - Clutch Spring Compressor : 57001-1162
Inside Circlip Pliers: 57001-143 [E]

• 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 brak­
ing 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 pul­
sate when pulled.

CLUTCH 6-15

Clutch
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.

[E] : 7 mm (0.276 in.) 

[F] : 4 mm (0.157 in.)


the clutch (see this chapter).
• Remove
Place
the
clutch hub, spring holder assy [A], the
• outer clutchinner
hub [B], and the clutch plates (friction and
steel plates) [C] on blocks [D].

○Do not support the spring holder [E] with the blocks.

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 dam­
age 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 (0.0768 ∼ 0.0965 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.

6-16 CLUTCH

Clutch
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 No.

1.6 mm (0.063 in.)

13089-1080

2.0 mm (0.079 in.)

13089-1075 (standard)

2.3 mm (0.090 in.)

13089-1081

CAUTION
If new friction or steel plates are installed, apply en­
gine oil to the surfaces of each plate to avoid clutch
plate seizure.

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 (0.130 ∼ 0.138 in)

Service Limit:

3.1 mm (0.122 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, re­
place 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 (0.0079 in) or less

Service Limit:

0.3 mm (0.012 in)

CLUTCH 6-17

Clutch
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:
4.3 mm (0.235 in)

Service Limit:

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.

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 Clutch Inner Hub Disassem­
• Disassemble
bly).
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
Engine Oil Flow Chart.............................................................................................................

Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools and Sealant ......................................................................................................

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
7-6

7-7

7-8
7-8

7-8
7-8

7-9
7-9

7-9

7-9

7-10

7-11

7-12

7-14

7-14
7-15

7-15

7-16


7

7-2 ENGINE LUBRICATION SYSTEM

Engine Oil Flow Chart

ENGINE LUBRICATION SYSTEM 7-3

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 Rockercase
26. Rear Rockercase
27. Inside Oil Pipe Fittings
28. Oil Baffle
29. Fitting
30. Left Crankcase
31. Right Air Cleaner Housing (rear view)
32. Crankcase Breather Hose
33. Oil Separating Chambers
34. Right Crankcase
35. Oil Return Pipes

7-4 ENGINE LUBRICATION SYSTEM

Exploded View

ENGINE LUBRICATION SYSTEM 7-5

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Oil pipe holder bolts

11

1.1

95 in·lb

L

2

Oil pipe clamp bolts

11

1.1

95 in·lb

L

3

Oil hose flange bolts

9.8

1.0

87 in·lb

4

Oil hose banjo bolt

9.8

1.0

87 in·lb

5

Relief valve

15

1.5

11

6

Oil pump mounting bolts

11

1.1

95 in·lb

7

Oil pressure switch

15

1.5

11

8

Oil pressure switch terminal screw

1.5

0.15

13 in·lb

9

Oil screen plug

20

2.0

14

L
SS

10 Oil filter

18

1.8

13

11 Oil nozzles

2.9

0.30

26 in·lb

12 Oil nozzle

2.9

0.30

26 in·lb

Lh

13 Oil filter pipe

25

2.5

18

SS

14 Oil drain plug

20

2.0

14

15 Oil baffle bolt

11

1.1

95 in·lb

L

16 Oil return pipe bolts

11

1.1

95 in·lb

L

17. HLA Oil Filters
18. Oil Separator (smaller side goes first.)
19. Oil Return Pipes
20. Oil Screen
21. Crankcase Breather Hose
22. To right air cleaner base
23. Oil Baffle
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 (Kawasaki Bond: 56019-120).

R

7-6 ENGINE LUBRICATION SYSTEM

Specifications
Item
Engine Oil:
Type

Viscosity
Capacity

Standard
API Service Classification : SE, SF or SG class
API Service Classification : SH or SJ class 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

Level (Wait 2 ∼ 3 minutes after idling or
running)
Oil Pressure Measurement:
Oil pressure @2 000 r/min (rpm), Oil temp. 340 ∼ 440 kPa (3.5 ∼ 4.5 kg/cm², 50 ∼ 64 psi)
90°C (194°F)

ENGINE LUBRICATION SYSTEM 7-7

Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm² :
57001–125

Filler Cap Driver :
57001–1454

Oil Pressure Gauge Adapter, PT 1/8 :
57001–1033

Kawasaki Bond (Silicone Sealant) :
56019–120

Oil Filter Wrench :
57001–1249

7-8 ENGINE LUBRICATION SYSTEM

Engine Oil and Oil Filter
WARNING
Motorcycle operation with insufficient, deteri­
orated, or contaminated engine oil will cause
accelerated wear and may result in engine or trans­
mission seizure, accident, and injury.

Oil Level Inspection

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

○Refer to Engine Oil Change in the Periodic Maintenance
Chapter.

Oil Filter Replacement

○Refer to Oil Filter Replacement in the Periodic Mainte­
nance Chapter.

ENGINE LUBRICATION SYSTEM 7-9

Oil Pump and Oil Line
Oil Pump Removal

the engine (see Engine Removal/Installation
• Remove
chapter).
the crankcase (see Crankshaft/Transmission chap­
• Split
ter).
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 dam­
aged.
Be sure to install the dowel pins [D].
Tighten:
Torque - Oil Pump Mounting Bolts: 11 N·m (1.1 kgf·m, 95
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

the fuel tank (see Fuel System (DFI) chapter).
• Remove
Disconnect:

• Water Temperature Sensor Connector [A]

Vacuum Switch Valve Hose [B] (air cleaner side)

Throttle Sensor Connector [C]


7-10 ENGINE LUBRICATION SYSTEM

Oil Pump and Oil Line

• Remove:

Left Air Cleaner Housing (see Fuel System (DFI) chap-

ter)

Oil Hose Flange Bolts [A] on Front and Rear Rocker

Cases

For
○ the front oil hose [B], remove the clamps [C].

• Remove:
Oil Hose Banjo Bolt [A] on Right Crankcase behind Rear
•

Cylinder
Clamp (open) [B]
Pull [C] out the front oil hose [D] forward and the rear oil
hose [E].

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 clamps [C].
• Install
Fit
the
clamp [D] as shown.
•

ENGINE LUBRICATION SYSTEM 7-11

Oil Pump and Oil Line
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 ports.

Inside Oil Pipe Removal

the crankcase (see Crankshaft/Transmission chap­

• Split
ter).

• Remove:

Oil Pipe Clamp Bolts [A]


•

Oil Pipe Holder Bolt [B]

Remove the inside oil pipe [C] from the right crankcase.

• Remove the oil pipe clamp bolt [A], and oil return pipe [B].

• Remove the separator [A].

7-12 ENGINE LUBRICATION SYSTEM

Oil Pump and Oil Line

• Remove:

Oil Pipe Clamp Bolt [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 separator [B].

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]


ENGINE LUBRICATION SYSTEM 7-13

Oil Pump and Oil Line
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.
○Apply a non-permanent locking agent to the oil pipe holder
bolt, oil pipe clamp bolts, and oil baffle bolt.
○If the oil nozzles [G] are removed, install them.
Torque - Oil Pipe Holder Bolt: 11 N·m (1.1 kgf·m, 95 in·lb)
Oil Pipe Clamp Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Oil Baffle Bolt: 11 N·m (1.1 kgf·m, 95 in·lb)
Oil Nozzle: 3.0 N·m (0.30 kgf·m, 26 in·lb)

7-14 ENGINE LUBRICATION SYSTEM

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 in­

side.
○Apply a non-peramanet locking agent to the oil pipe holder
bolt and oil pipe clamp bolts.
○If the oil nozzle [G] is removed, install it.

Torque - Oil Pipe Holder Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Oil Pipe Clamp Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Oil Nozzle: 3.0 N·m (0.30 kgf·m, 26 in·lb)

• Install the removed parts.

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 deteriora­
tion.
○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.

•

•

Breather Drain Cleaning

○Refer to Breather Drain Cleaning in the Periodic Mainte­
nance Chapter.

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 kg/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 im­
mediately.
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 kg/cm², 50 ∼ 64 psi)
@ 2 000 r/min (rpm), oil temp. 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 re­
moved.
installing the oil pressure switch, apply silicone
• When
sealant to the threads of the switch, and tighten it to the
specified torque.
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

7-16 ENGINE LUBRICATION SYSTEM

Oil Pressure
Relief Valve Inspection

the crankcase (see Crankshaft/Transmission chap­
• Split
ter).
the relief valve [A] from the oil pump [B].
• Remove
Check
to
if the valve slides smoothly when pushing
• it in with asee
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 in a well-ventilated area.
○Take care that there is no spark or flame anywhere near
the working area.

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........................................................................................................................
Specifications .........................................................................................................................
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 and nuts
Engine mounting bolts and nuts
Engine mounting bracket bolts

N·m
44
44
25

WL: Apply a soap and water solution or rubber lubricant.

Torque
kgf·m
4.5
4.5
2.5

ft·lb
33
33
18

Remarks

8-4 ENGINE REMOVAL/INSTALLATION

Specifications
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 of the frame into the groove [C] of the attach­
ments.

Squeeze the brake lever slowly and hold it with a band
• [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 Cooling System chapter)

•

Engine Oil (see Engine Lubrication System chapter)

Remove:

Battery Cables

Fuel Tank (see Fuel (DFI) System chapter)

Left and Right Air Cleaner Housings (see Fuel (DFI) Sys-

tem chapter)

Front and Rear Exhaust Pipes (see Engine Top End

chapter)

Shift Pedals (see Crankshaft/Transmission chapter)

Alternator Outer Cover (see Electrical System chapter)

Radiator (see Cooling System chapter)

Thermostat Removal (see Cooling System chapter)

#2 Ignition Coil (right side, see Electrical System chap­

ter)


8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

• Remove:

Spark Plug Caps [A]

Clamp [B]

Throttle Sensor Connector [C]


• Remove:

Injector Connectors [A]

Fuel Hose [B]

Connector [C]

Vacuum Switch Valve [D]

Inlet Air Pressure Sensor Hose


• Remove:

Spark Plug Caps [A]

Horn [B]

Regulator/Rectifier Lead Connectors [C]

Alternator Lead Connectors [D]

Crankshaft Sensor Lead Connector [E]

Side Stand Switch Lead Connector [F]

Speed Sensor Lead Connector

Oil Pressure Switch Connector


• Remove:

Neutral Switch Connector [A]

Bracket Bolts [B]

Clutch Hose Bracket [C]

Clutch Slave Cylinder [D] (see Clutch chapter)


• Remove:

Bracket Bolts [A]

Regulator/Rectifier Bracket [B]

Starter Motor Lead [C]


ENGINE REMOVAL/INSTALLATION 8-7

Engine Removal/Installation

• Remove:

Engine Ground Terminal [A]


• Remove:

Brake Reservoir Cover Bolt [A]

Brake Reservoir Cover [B]


the engine with a commercially available stand

• Support
[A].

the engine mounting nut [B].
• Loosen
Remove:

• Engine Mounting Bracket Bolts [C]


•

Downtube Bolts [D]

Remove the downtube [E] with the right footpeg and rear

master cylinder installed.


• Remove:

Engine Mounting Bolts and Nuts [A]

Engine Mounting Bracket Bolts [B]


• Remove:

Swingarm Cover Bolts [A]

Swingarm Cover [B]


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 pro­
peller 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 and Nuts: 44 N·m (4.5 kgf·m, 33
ft·lb)
Engine Mounting Bolts and 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 General Information
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
throttle cables (see Fuel System chapter).
• Fill the the
engine
• chapter). with engine oil (see Periodic Maintenance
the engine with coolant and bleed the air from the
• Fill
cooling system (see Periodic Maintenance chapter).
the idling (see Periodic Maintenance chapter).
• Adjust
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 appli­
cation 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 Sealants ...............
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 .............

9-2

9-6

9-8

9-9

9-9

9-13

9-20

9-21

9-21

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


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 .......................

9-30
9-30
9-30
9-30
9-31
9-31
9-32
9-32
9-33
9-34
9-34
9-35
9-35
9-35
9-35
9-37
9-37
9-37
9-38

9


9-2 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 9-3

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Connecting rod big end nuts

59

6.0

43

MO

2

Starter clutch bolt

85

8.7

63

MO

3

Left balancer gear bolt

85

8.7

63

MO

4

Camshaft chain guide bolts

11

1.1

95 in·lb

L

5

Starter clutch coupling bolts

15

1.5

11

L

6

Oil nozzle

2.9

0.30

26 in·lb

LH

7

Oil nozzles

2.9

0.30

26 in·lb

8

Cylinder stud

–

–

–

L

9

Bearing retainer bolts

11

1.1

95 in·lb

L

10 Oil baffle bolt
11 Primary gear bolt

11

1.1

95 in·lb

L

147

15.0

108

MO

12 Crankcase bolts,

8

21

2.1

15

S

13 Crankcase bolts,

10

39

4.0

29

S

14 Crankcase bolts,

6

11

1.1

95 in·lb

S

15 Clutch push rod guide bolts

11

1.1

95 in·lb

L

16 Frame ground bracket bolt

11

1.1

95 in·lb

17 Oil pipe clamp bolts

11

1.1

95 in·lb

L

18. Water Pump Drainage Outlet Hose
19. Do not apply any oil.
20. Apply a non-permanent locking agent to the tap end of this stud only.
21. Left Crankcase
22. Right Crankcase
23. Oil Baffle
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 to the threads and the seating surface. The molybdenum disul­
fide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1).
S: Follow the specific tightening sequence.
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

9-4 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 9-5

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Shift shaft return spring pin

39

4.0

29

2

Shift rod locknuts

11

1.1

95 in·lb

3

Rear shift lever clamp bolt

12

1.2

104 in·lb

4

Gear set lever bolt

11

1.1

95 in·lb

L

5

Shift drum cam bolt

15

1.5

11

L

Shift pedal clamp bolts

25

2.5

18

Shift pedal clamp bolts (VN1600–A2 ∼)

30

3.1

22

7

Damper cam nut

195

20

144

8

Idle shaft holder bolts

8.3

0.85

73 in·lb

9

Water pump chain guide spring hook bolt

6

2.9

0.30

26 in·lb

10 Water pump impeller bolt

8.8

0.9

78 in·lb

11 Water pump chain guide bolt

8.3

0.85

73 in·lb

12. Align the punch marks.
13. Align the punch mark with the slit.
14. Drive Shaft
15. Output Shaft
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
MO: Apply molybdenum disulfide oil.
R: Replacement Parts

L

MO

Lh

9-6 CRANKSHAFT/TRANSMISSION

Specifications
Item

Standard

Service Limit

Crankshaft, Connecting Rods:
Connecting rod bend

TIR 0.2/100 mm

– – –

(0.08/3.94 in)
Connecting rod twist

TIR 0.2/100 mm

– – –

(0.08/3.94 in)
Connecting rod big end side clearance

0.16 ∼ 0.46 mm

0.7 mm

(0.0062 ∼ 0.0181 in)

(0.028 in)

Connecting rod big end bearing
insert/crankpin clearance

0.026 ∼ 0.057 mm

0.10 mm

(0.001024 ∼ 0.0022 in)

(0.0039 in)

Crankpin diameter:

54.981 ∼ 55.000 mm

54.97 mm

(2.1646 ∼ 2.1654 in)

(2.1642 in)

Marking

54.981 ∼ 54.991 mm

None

– – –

(2.1646 ∼ 2.16500 in)
54.992 ∼ 55.000 mm

– – –

(2.16504 ∼ 2.1654 in)
Connecting rod big end bore diameter:

58.000 ∼ 58.020 mm

– – –

(2.2835 ∼ 2.2843 in)
Marking

58.000 ∼ 58.010 mm

None

– – –

(2.2835 ∼ 2.28386 in)
58.011 ∼ 58.020 mm

– – –

(2.28390 ∼ 2.2843 in)
Connecting rod big end bearing insert
thickness:

1.483 ∼ 1.487 mm

Brown

– – –

(0.05839 ∼ 0.05854 in)
1.487 ∼ 1.491 mm

Black

– – –

(0.05854 ∼ 0.05870 in)
1.491 ∼ 1.495 mm

Blue

– – –

(0.05870 ∼ 0.05886 in)
Connecting rod big end bearing insert selection:
Con-rod Big End

Crankpin Diameter

Bore Diameter

Marking

Marking
None
None

None
None

Crankshaft side clearance

Bearing Insert
Size Color

Parts Number

Brown

92028-1476

Black

92028-1475

Blue

92028-1474

0.05 ∼ 0.55 mm
(0.00197 ∼ 0.0217 in)

Crankshaft web length

0.75 mm
(0.0295 in)

96.85 ∼ 96.95 mm

96.6 mm

(3.8130 ∼ 3.8169 in)

(3.803 in)

CRANKSHAFT/TRANSMISSION 9-7

Specifications
Item
Crankshaft runout
Crankshaft main bearing/journal clearance

Standard
TIR 0.02 mm

Crankcase main bearing bore diameter

TIR 0.05 mm

(0.0008 in) or less

(0.0020 in)

0.025 ∼ 0.052 mm

0.10 mm

(0.00098 ∼ 0.00205 in)
Crankshaft main journal diameter

Service Limit

(0.00394 in)

54.986 ∼ 55.000 mm

54.96 mm

(2.1648 ∼ 2.1654 in)

(2.1638 in)

55.025 ∼ 55.038 mm

55.07 mm

(2.1663 ∼ 2.1669 in)

(2.1681 in)

Transmission
Shift fork ear thickness

5.9 ∼ 6.0 mm

Gear shift fork groove width

6.05 ∼ 6.15 mm

(0.232 ∼ 0.236 in)
(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)

5.8 mm
(0.228 in)
6.3 mm
(0.248 in)
7.8 mm
(0.307 in)
8.3 mm
(0.327 in)

9-8 CRANKSHAFT/TRANSMISSION

Special Tools and Sealants
Outside Circlip Pliers :
57001–144

Flywheel Holder :
57001–1410

Damper Cam Holder :
57001–1025

Gear Holder, m2.0 :
57001–1557

Bearing Driver Set :
57001–1129

Kawasaki Bond (Silicone Sealant) :
56019–120

Flywheel Holder :
57001–1313

Kawasaki Bond (Liquid Gasket – Black) :
92104–1064

CRANKSHAFT/TRANSMISSION 9-9

Crankcase
Crankcase Disassembly

the engine oil (see Periodic Maintenance chapter).
• Drain
Remove:

• Engine (see Engine Removal/Installation chapter)


•
•

Cylinder Blocks (see Engine Top End chapter)

Pistons (see Engine Top End chapter)

Clutch (see Clutch chapter)

Front Gear Case (see Final Drive chapter)

Remove the shift shaft [A] while pushing [B] the shift

mechanism arm [C] towards the shift shaft.

Unscrew the bolt [D] and remove the gear set lever [E]

and its spring [F].


the retainer [A] and needle bearing [B] from the

• Remove
output shaft.

crankcase bearing upper retainer bolts [C] and

• Remove
retainer [D].


the damper cam nut [A] using the damper cam
• Unscrew
holder [B] and deep socket wrench.
Special Tool - Damper Cam Holder: 57001-1025

the starter clutch gear [A] out of the starter clutch (The
• Pull
starter clutch gear can be removed with the engine in the

•

frame).
Unscrew the starter clutch bolt [B] while holding the pri­
mary gear bolt [C].

Washer [D]


the following from the right end of the balancer
• Remove
shaft.


•

Torque Limit [A]

Needle Bearing [B]

Collar [C]

Copper Washer [D]

Starter Clutch [E]

Unscrew the primary gear bolt [F] while holding the alter­
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

9-10 CRANKSHAFT/TRANSMISSION

Crankcase

• Remove

Alternator Cover (see Electrical System chapter)

•

Alternator Inner Cover (see Electrical System chapter)

Loosen the left balancer gear bolt [A], using the flywheel

holder [B]. The left balancer gear bolt has right-hand

threads.

Special Tool - Flywheel Holder: 57001-1410

Remove the alternator rotor bolt [C] and the alternator rotor
[D].
the balancer drive gear [A].
• Take
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]

Rear Chain Guide Bolts [C]

Rear Chain Guide [D]

Front Camshaft Chain [E]


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.
Take
the
idle
shaft
[E]
of the crankcase.
•○The idle shaft has twoout
pins.

CRANKSHAFT/TRANSMISSION 9-11

Crankcase
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].

the following with the cylinder head removed.

• Remove
Lower Chain Guide Bolts [A]

Lower Chain Guide [B]

Rear Camshaft Chain [C]

Rear Chain Guide Bolts [D]

Rear Chain Guide [E]


the starter motor bolts [A] and the motor [B] from

• Remove
the crankcase.

• Pull the breather tube [C] out of the crankcase.

the water pump sprocket [A] with it’s chain [B] and
• Pull
shaft [C].

• Remove the oil banjo bolt [A] with the hoses [B].

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].

the right crankcase bolts.
• Remove
8 mm Bolts (5) [A]

○Be sure to remove this bolt [B]

all the left crankcase bolts in the order listed.
• Remove
6 mm Bolts (14) [A]
8 mm Bolt (1) [B]
10 mm Bolts (3) [C]

the left crankcase down.
• Turn
Lift
up
the right crankcase.
•○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]

Transmission Gear Assy [B] (see Transmission Re­

moval)

Balancer Shaft [C]


CAUTION
The right and left crankcase halves are machined at
the factory in the assembled state, so the crankcase
halves must be replaced as a set.

Crankcase Assembly

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 dam­
aged.
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

a non-permanent locking agent to the retainer bolts
• Apply
and the oil baffle bolts.
• Install the bearing retainers.
Special Tool - Bearing Driver Set: 57001-1129

Bearings [A]

Bearing Retainers [B]

Left Crankcase [C]

Oil Baffle [D]

Race [E]

Torque - Bearing Retainer Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)

9-14 CRANKSHAFT/TRANSMISSION

Crankcase

○Apply silicone sealant [A] to the step of the oil separating
chamber [B] in the left crankcase [C].

○Install the oil baffle [D] on the chamber.
Front [E]

Torque - Oil Baffle Bolt: 11 N·m (1.1 kgf·m, 95 in·lb)
Sealant - Silicone Sealant: 56019–120

• Install:

Bearings [A]

Bearing Retainer [B]

Right Crankcase [C]

Race [D]

Torque - Bearing Retainer Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)

engine oil to the transmission gears, ball bearings,

• Apply
shift drum, and crankshaft main bearing.

• Install:

Oil Pipe and Oil Return Pipes (see Engine Lubrication

System chapter)


○The left shaft [B] of the crankshaft [A] is longer than the
right shaft [C].

to see that the following parts are in place in the
• Check
left crankcase.

Transmission Assy [A] and Shift Drum [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 [J]

O-ring [K]

Oil Baffle [L]

Oil Pipe [M]

Oil Return Pipe [N]


CRANKSHAFT/TRANSMISSION 9-15

Crankcase

○Install the balancer shaft [A] so that the flanged side [B]
faces downward (toward the left crankcase).

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]


liquid gasket [A] to the mating surface of the right
• Apply
crankcase [B].
Sealant - Kawasaki Bond (Liquid Gasket-Black):
-1064

92104

○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].

NOTE

○Make 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.

9-16 CRANKSHAFT/TRANSMISSION

Crankcase
the crankcase bolts as follows.
•○Tighten
Lightly tighten all the bolts to a snug fit.

○Tighten the 8 mm and 10 mm bolts in the order shown,
and then tighten the 6 mm bolts to the specified torque.

Torque - 8 mm Crankcase Bolts (1 ∼ 6): 21 N·m (2.1 kgf·m,
15 ft·lb)
10 mm Crankcase Bolts (7 ∼ 9): 39 N·m (4.0 kgf·m,
29 ft·lb)
6 mm Crankcase Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)

Front [A]

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.

○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 Ping: 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, 95 in·lb)

CRANKSHAFT/TRANSMISSION 9-17

Crankcase
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.

the camshaft chain [A], lower chain guide [B], re­
• Install
tainer [C] and rear chain guide [D] in the engine left side.

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:

Inside Stator Coil [A] (see Electrical System chapter)

Alternator Rotor [B]

Install
the alternator rotor while fitting the alignment notch
○
[C] of the splines onto the alignment tooth [D].

9-18 CRANKSHAFT/TRANSMISSION

Crankcase

○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 to the threads and the
• Apply
seating surface of the left balancer gear bolt, and alter­

•

nator rotor bolt.
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)

• Install:

Camshaft Chain [A]

Chain Guide [B]

Torque - Camshaft Chain Guide Bolts: 11 N·m (1.1 kgf·m,
95 in·lb)
Camshaft Chain Guide Retainer Bolt: 11 N·m (1.1
kgf·m, 95 in·lb)

• Install:

Water Pump Sprocket [A] with Shaft [B]

Chain [C]


CRANKSHAFT/TRANSMISSION 9-19

Crankcase

• 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.

○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 [B] onto the alignment notch of the balancer shaft.

9-20 CRANKSHAFT/TRANSMISSION

Crankcase
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 starter clutch gear [A] in and turn it clockwise [B]
• Push
and install it.
molybdenum disulfide oil to the threads and seat­
• Apply
ing surface of the starter clutch bolt and tighten it to the
specified torque while holding the primary gear bolt.

○The molybdenum disulfide oil 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 [C] onto the torque limiter.

• Install:

Clutch (see Clutch chapter)

Clutch Cover

Shift Mechanism (see this chapter)

Damper Cam and Front Gear Case (see Final Drive

chapter)

Water Pump (see Cooling System chapter)

Engine Top End (see Engine Top End chapter)

Alternator Inner Cover, Alternator Cover, Alternator

Outer Cover (see Electrical System chapter)

Engine (see Engine Removal/Installation chapter)


Starter Clutch Disassembly

the starter clutch assy (see Crankcase Disas­
• Remove
sembly).
the Allen bolts [A] with the balancer mass [B]
• Remove
held with the flywheel holder [C].
Special Tool - Flywheel Holder: 57001-1313

CRANKSHAFT/TRANSMISSION 9-21

Crankcase
the coupling [A] out of the right balancer [B].
• Pull
Take
• the one-way clutch [C] out of the coupling.

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

9-22 CRANKSHAFT/TRANSMISSION

Crankcase
Starter Torque Limiter Check

the torque limiter (see Crankcase Disassembly)
• Remove
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.
• Remove
Remove
the connecting rod big end nuts, and take off
• 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 crank­
shaft 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 to the inside [A] of the big
• Apply
end bearing inserts.

○The molybdenum disulfide oil is a mixture of engine 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 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 [MO] to the threads, seat­
ing 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,
43 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 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 length to
determine the amount of connecting rod bend.
If connecting rod bend exceeds the service limit, the con­
necting rod must be replaced.
Connecting Rod Bend

Service Limit:
TIR 0.2/100 mm (0.08/3.94 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 length of the arbor to determine the
amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the con­
necting rod must be replaced.
Connecting Rod Twist

Service Limit:
TIR 0.2/100 mm (0.08/3.94 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 (0.0062 ∼ 0.0181 in)

Service Limit:

0.7 mm (0.028 in)

If the clearance exceeds the service limit, replace the con­
necting 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].
the big end nuts to the specified torque to com­
• Tighten
press 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).
Molybdenum Disulfide Oil- Threads and Seating
Surface of Big End Nuts
Torque - Connecting Rod Big End Nuts: 59 N·m (6.0 kgf·m,
43 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 (0.001024 ∼ 0.0022 in)
Service Limit: 0.10 mm (0.0039 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, or 0.0039 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 ser­
vice 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 ∼ 2.16500 in)

:

54.992 ∼ 55.000 mm (2.16504 ∼ 2.1654 in)

Crankpin Diameter Mark: “

” mark or no mark [B]

install the big end cap and tighten the big end
• Temporarily,
nuts to the specified torque.
Molybdenum Disulfide Oil Threads and Seating Surface of Big End Nuts
Torque - Connecting Rod Big End Nuts: 59 N·m (6.0 kgf·m,
43 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 ∼ 2.28386 in)
:

58.011 ∼ 58.020 mm (2.28390 ∼ 2.2843 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 con­
necting rod and crankshaft coding.
Big End Bearing Insert Selection
Con-rod Big End
Bore Diameter
Marking

Crankpin
Diameter
Mark

None
None

None
None

Bearing Insert
Size Color

Part Number

Brown

92028-1476

Black

92028-1475

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 (0.0020 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 (2.1638 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 ∼ 2.1669 in)
Service Limit:

55.07 mm (2.1681 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 (0.00197 ∼ 0.0217 in)
Service Limit:

0.75 mm (0.0295 in)

Crankshaft [A]

Crankcase [B]

Clearance [C]

If the clearance is greater than the service limit, measure
the crankshaft web length [A] to see whether the crank­
shaft or the crankcase is faulty.
Crankshaft Web Length
Standard:
96.85 ∼ 96.95 mm (3.8130 ∼ 3.8169 in)
Service Limit:

96.6 mm (3.803 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 chapter)

•

Starter Clutch Gear (see this chapter)

Using the gear holder [A] to loosen the primary gear bolt

[B].

Special Tool - Gear Holder: 57001–1557

• Install:

Clutch (see 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 chapter).
Torque - Idle Shaft Holder Bolts: 8.3 N·m (0.85 kgf·m, 73
in·lb)

molybdenum disulfide oil to the threads and seat­
• Apply
ing surface, and tighten the primary gear bolt [A], while
holding the primary gear [B] with the gear holder [C].
Special Tool - Gear Holder: 57001–1557
Torque - Primary Gear Bolt: 147 N·m (15.0 kgf·m, 108 ft·lb)

9-30 CRANKSHAFT/TRANSMISSION

Transmission
Shift Pedal Removal

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 pedal is up the 1 serration [B]

•

from the punched mark on the shaft.
Tighten the clamp bolt.
Torque - Shift Pedal Clamp Bolt:
25 N·m (2.5 kgf·m, 18 ft·lb)
30 N·m (3.1 kgf·m, 22 ft·lb) VN1600–A2 ∼

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:
25 N·m (2.5 kgf·m, 18 ft·lb)
30 N·m (3.1 kgf·m, 22 ft·lb) VN1600–A2 ∼

External Shift Mechanism Removal

• Remove:

Shift Pedals (see this chapter)


Alternator Outer Cover [A] (see Electrical System chap­

ter)

Engine (see Engine Removal/Installation chapter)

Front and Rear Shift Levers [B]

Front Gear Case [C] (see 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, 95 in·lb)

the shift mechanism arm assy. Be sure to install
• Install
the washer [D] onto the shift shaft.
the front gear case (see Final Drive chapter).
• Install
Install
the
front shift lever and the rear shift lever.
•

○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 Locknuts: 11 N·m (1.1 kgf·m, 95 in·lb)
Rear Shift Lever Clamp Bolt: 12 N·m (1.2 kgf·m,
104 in·lb)

• Install:

Engine (see Engine Removal/Installation)

Shift Pedal (see this chapter)


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/Installation
• Remove
chapter).
the crankcase (see this chapter).
• Split
Remove
the crankshaft.
• First, remove
pipe [A] (see Engine Lubrication Sys­
• tem chapter),theandoilthen
remove the shift drum bearing

•

holder bolts and holder [B].
Pull out the shift rod [C] and take the shift fork [D] out of
the output shaft 4th gear.

Output Shaft [E]

Drive Shaft [F]

Shift Drum [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 [B] as
• Take
a set.
the drive and output shafts, shift drum, and shift
• Separate
forks.

Transmission Installation

the drive and output shaft assy, shift drum, 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

○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 shift drum
• Apply
bearing holder bolts.
Torque - Shift Drum Bearing Holder Bolts: 11 N·m (1.1
kgf·m, 95 in·lb)

Install:
Shift Drum Bearing Holder [A]
Bolts [B]
Apply engine oil to the shift rod, the shift forks, and gears.

•

• Install:

Shift Fork (No. 293 output shaft, 4th gear) [A]

Shift Rod [B]


Shift Drum Disassembly/Assembly

the shift drum assy [A] (see this chapter).
• Remove
Remove:

• Drive Shaft Shift Fork (No. 292, drive shaft) [B]

Cotter Pin [C]


the shift drum assy as shown.

• Disassemble
Pin Plate [A]


•
•

Pin [B]

Cam [C]

Bearing [D]

Shift Drum [E]

Drive Shaft Shift Fork (No. 292) [F]

Cotter Pin [G]

Be sure to face the number to the right and insert the

cotter pin of the drive shaft shift fork from the right as

shown.

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 in·lb)

9-34 CRANKSHAFT/TRANSMISSION

Transmission
Transmission Disassembly

Remove the transmission shafts (see this chapter).
•Using
the circlip pliers (special tool), remove the circlips,
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

○Refer to the illustration on P.29.

each gear oil hole with the drive shaft oil hole when
• Align
installing the 3rd gear [9] and the 5th gear [6].
each oil hole with the output shaft oil hole, when
• Align
installing the 3rd 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.
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].

CRANKSHAFT/TRANSMISSION 9-35

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 (0.232 ∼ 0.236 in)

Service Limit:

5.8 mm (0.228 in)

If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width

Standard:
6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in)

Service Limit:

6.3 mm (0.248 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:

8.3 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.

9-36 CRANKSHAFT/TRANSMISSION

Transmission

1. Circlip
( 20 × 25.5 × t 1.2)
2. Needle Bearing
3. Thrust Washer
( 22.3 × 35 × t 1.6)
4. Three Circlips ( 28)
5. 2nd Gear
6. 5th (top) Gear
7. Bushing (5th gear)
8. Two Splined Washers
( 28.5 × 34 × t 1.5)
9. 3rd Gear

10. 4th Gear
11. 1st Gear (drive shaft)
12. Output Shaft
13. 2nd Gear
14. Three Splined Washers
( 30.3 × 40 × t 1.5)
15. Three Circlips ( 29)
16. 5th (top) Gear
17. 3rd Gear
18. Bushing (3rd gear)
19. Steel Balls
20. 4th Gear

21. Washer
( 25.5 × 36 × t 1.0)
22. 1st Gear
23. Needle Bearing
24. Circlip ( 25)
25. Align gear or bushing
oil holes with the shaft
holes.
26. Washer
( 25.5 × 38 × t 1.0)

CRANKSHAFT/TRANSMISSION 9-37

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, 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 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. Re­
moval 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 sol­
vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
○Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
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 bear­
ing, replace it.

9-38 CRANKSHAFT/TRANSMISSION

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
10-10
10-11

10-11

10-12
10-12
10-12
10-12

10-13
 10
10-13

10-15

10-15

10-15
10-15
10-15
10-17
10-18
10-18

10-18

10-19

10-19

10-2 WHEELS/TIRES

Exploded View

WHEELS/TIRES 10-3

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

1

Tire air valve stem nuts

1.5

0.15

13 in·lb

2

Air valve cores

0.3

0.03

2.6 in·lb

3

Tire air valve caps

0.15

0.015

1.3 in·lb

4

Front axle clamp bolts

20

2.0

15

5

Front axle

108

11.0

79.6

6

Rear axle nut

108

11.0

79.6

Remarks

G: Apply grease.
R: Replacement Parts
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
WL: Apply soap and water solution or rubber lubricant.

AL

10-4 WHEELS/TIRES

Specifications
Item

Standard

Service Limit

Wheels (Rims):
Rim runout:

Axial

TIR 0.5 mm (0.02 in.)

Radial

TIR 0.8 mm (0.03 in.)

Axle runout/100 mm

TIR 0.05 mm (0.002 in.) or less

Wheel balance

10 g (0.35 oz.) or less

Balance weights

10 g (0.35 oz.), 20 g (0.71 oz.),

TIR 0.2 mm (0.008 in.)
– – –

30 g (1.1 oz.)
Tires:
Air pressure (when cold):
Front

Up to 186 kg (410 lb) load:

Rear

Up to 186 kg (410 lb) load:

– – –

200 kPa (2.0 kg/cm², 28 psi)
250 kPa (2.5 kg/cm², 36 psi)

– – –

Tread depth:
Front

BRIDGESTONE: 4.3 mm (0.17 in.)

1 mm (0.04 in.)
(DE, AT, CH) 1.6 mm (0.063 in.)
Up to 130 km/h (80 mph):

Rear

BRIDGESTONE: 7.2 mm (0.28 in.)

2 mm (0.08 in.)
Over 130 km/h (80 mph):
3 mm (0.1 in.)

Standard tires:

Size

Make, Type
Front

BRIDGESTONE EXEDRA G721

130/90–16 M/C 67H

Rear

BRIDGESTONE EXEDRA G722

170/70B 16 M/C 75H

WARNING
Use the same manufacturer ’s tires on both front and rear wheels.
AT: Republic of Austria
CH: Swiss Confederation
DE: Federal Republic of Germany

WHEELS/TIRES 10-5

Special Tools
Inside Circlip Pliers :
57001–143

Bearing Remover Head,
57001–1293

20 ×

Bearing Driver Set :
57001–1129

Bearing Remover Shaft,
57001–1377

13 :

Jack :
57001–1238

Attachment Jack :
57001–1398

22 :

10-6 WHEELS/TIRES

Wheels (Rims)
Front Wheel Removal

the front brake caliper mounting bolts [A] and
• Unscrew
remove the brake calipers [B] with the hose installed.

the European Model, remove the cap.
• For
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
Ti
ghten
the axle.
•

Torque - Front Axle: 110 N·m (11 kgf·m, 79.6 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: 20 N·m (2.0 kgf·m, 15 ft·lb)

NOTE

○Tighten the two clamp bolts alternately two times to en­
sure even tightening torque.

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.

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.
Special Tools - Jack: 57001-1238

Attachment Jack: 57001-1398


• 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:
Caliper Mounting Bolts [A]
Caliper [B]

• Remove:
Rear Shock Absorbers [A]

WHEELS/TIRES 10-9

Wheels (Rims)

• Remove:
Caliper Holder Bolt [A]
Axle Nut Cotter Pin [B]
Axle Nut [C]
Pu
○ ll the silencer out side and straighten the cotter pin.

ly install the rear shock absorber.
• Temporari
ll
Pu
out
the
and slide the rear wheel [A] toward the
• right [B] to daxle,
isengage 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.
•

the axle [A] from the left side of the rear wheel.
• Insert
Sli
de
the
wheel to the left side, and engage the ring
• gear hub rear
splines with the wheel coupling hub splines.
ll the axle little and install the caliper holder.
• Pu
Tighten:
•

Torque - Rear Axle Nut: 110 N·m (11 kgf·m, 79.6 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.

10-10 WHEELS/TIRES

Wheels (Rims)

• 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].

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.

Wheel Coupling Removal

the rear wheel (see Rear Wheel Removal).
• Remove
Remove
coupling retaining ring [A].
• Remove the
the
• necessary. wheel coupling [B] with a bearing puller if

WHEELS/TIRES 10-11

Wheels (Rims)
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

in [A] the wheel lightly, and check for roughness or
• Sp
binding.

•
•

If roughness or binding is found, replace the hub bearings.
Inspect the front and rear axles for damage (see this
chapter).
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.

Remove the wheel, and support it without the tire by the
• axle.
the rim runout, radiator [A] and axial [B], with a
• Measure
dial 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 condi­
tion.

10-12 WHEELS/TIRES

Wheels (Rims)
Axle Inspection

inspect the front and rear axles for damage.
• IfVisually
the axle is damaged or bent, replace it.
the axle in V blocks that are 100 mm [A] apart, and
• Place
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.
• Remove
Support
the
wheel so that it can be spun freely.
• Spin the wheel
and mark [A] the wheel at the top
• when the wheellightly,
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.

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.

WHEELS/TIRES 10-13

Wheels (Rims)
If proper balance has been achieved, permanently install
the balance weight.
Balance Weight
Part Number
41075–1014
41075-1015
41075–1016

Weight (grams)
10 (0.35 oz.)
20 (0.71 oz.)
30 (1.1 oz.)

NOTE

○Balance weights are available from Kawasaki Dealers

in 10, 20, and 30 gram (0.35, 0.71 and 1.1 ounce) sizes.
An imbalance of less than 10 grams (0.35 ounce) will
not usually affect running stability.
○Do not use four or more balance weights (more than
90 gram, 3.2 ounce). 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 reg­
ular tip screw driver, and slip the weight off the rim flange.
Discard the used balance weight.

(b) When the tire is on the rim.
Pry [A] the balance weight off the rim flange using a reg­
ular 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.


10-14 WHEELS/TIRES

Wheels (Rims)
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 pe­
troleum 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.

required total weight exceeds 20 g, install balance
• When
weight at both sides of rim flange as shown.
Required

Weight Selection

Total Weight

One Side [A]

10 g (0.35 oz.)

10 g (0.35 oz.)

Other Side [B]
–

20 g (0.71 oz.)

10 g (0.35 oz.)

10 g (0.35 oz.)

30 g (1.1 oz.)

20 g (0.71 oz.)

10 g (0.35 oz.)

40 g (1.4 oz.)

20 g (0.71 oz.)

20 g (0.71 oz.)

50 g (1.8 oz.)

30 g (1.1 oz.)

20 g (0.71 oz.)

60 g (2.1 oz.)

30 g (1.1 oz.)

30 g (1.1 oz.)

70 g (2.5 oz.)
80 g (2.8 oz.)
90 g (3.2 oz.)

20 g (0.71 oz.)
+ 20 g (0.71 oz.)
20 g (0.71 oz.)
+ 20 g (0.71 oz.)
20 g (0.71 oz.)
+ 30 g (1.1 oz.)

30 g (1.1 oz.)
20 g (0.71 oz.)
+ 20 g (0.71 oz.)
20 g (0.71 oz.)
+ 20 g (0.71 oz.)

WHEELS/TIRES 10-15

Tires
Air Pressure Inspection/Adjustment

to Tire Inspection in the Periodic Maintenance chap­
• Refer
ter.

Tire Inspection

to Tire Inspection in the Periodic Maintenance chap­
• Refer
ter.

Tire Removal

the following.

• Remove
Wheel (see this chapter)


•

Brake Disc (see 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 distil­
lates 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 stan­
dard 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.

10-16 WHEELS/TIRES

Tires

○Insert the new air valve in the rear wheel rim.
Valve Cap [A]
Valve Body [B]
Valve Nuts [C]
Valve Washer [D]
Rim [E]
Valve Grommet [F]
Coupling Damper Side [G]

○Remove the valve cap, valve nuts, valve washer and in­
sert 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)
Tire Air Valve Cap: 0.15 N·m (0.015 kgf·m, 1.3 in·lb)
Tire Air Valve Core: 0.3 N·m (0.03 kgf·m, 2.6 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 gaso­
line 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 commer­
cially 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 kg/cm², 57 psi). Overinflation can explode
the tire with possibility of injury and loss of life.

WHEELS/TIRES 10-17

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 par­
allel, 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
Inspection).
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 - 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 mi) is necessary to establish nor­
mal tire traction. During break-in, avoid sudden and
maximum braking and acceleration, and hard cor­
nering.

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 under­
stood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.

10-18 WHEELS/TIRES

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 Shaft, 13:

57001-1377 [B]

Bearing Remover Head, 20 × 22:
57001-1293 [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: 57001-1129 [B]

install the following:
• Next,
New Circlip
Distance Collar
Left Bearing

WHEELS/TIRES 10-19

Hub Bearings (Wheel Bearings)

○Replace the circlips with new ones.
Special Tool - Inside Circlip Pliers: 57001-143

the grease seals with new ones.
• Replace
in the grease seals [A] so that the seal surface is
• Press
flush [B] with the end of the hole.

○Apply high temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129 [C]

Hub Bearings Inspection

○Since the hub bearings are made to extremely close tol­
erance, the clearance cannot normally be measured.

NOTE

○Do not remove any bearings for inspection. If any bear­
ings are removed, they will need to be replaced with
new ones.
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 ................

11-2

11-6
11-7
11-8

11-8
11-8

11-8

11-8

11-8

11-10

11-12

11-13

11-14

11-16

11-16

11-17

11-18

11-19

11-21

11-21

11-21

11-21

11-22

11-22


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 .......................

11-23

11-23
11-23
11-23
11-24
11-25

11-26

11-26
11-27
11-27
11-28

11-29

11-30

11-31
11-33

11-33
11-34
 11

11-34
11-34
11-35
11-35
11-35

11-2 FINAL DRIVE

Exploded View

FINAL DRIVE 11-3

Exploded View
Front Gear Case
No.

Fastener

Torque
N·m

kgf·m

ft·lb

1

Oil pipe banjo bolts (front gear)

12

1.2

104 in·lb

2

Front gear case bolts 6 mm

12

1.2

104 in·lb

3

Neutral switch

15

1.5

11

4

Oil nozzle (front gear)

2.9

0.30

26 in·lb

5

Oil nozzle (front gear)

18

1.8

13

6

Speed sensor bolt

9.8

1.0

87 in·lb

Remarks

R

L

7

Bearing retainer bolts (front gear)

8.8

0.9

78 in·lb

L

8

Drive gear nut (front gear)

265

27

195

MO, St

9

Driven gear assy mounting bolts

25

2.5

18

10 Front gear case bolts 8 mm

29

3.0

22

R

11 Driven gear bolt (front gear)

137

14

101

MO, St

12 Damper cam nut (front gear)

195

20

144

MO (threads)

EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil.
R: Replacement Parts

St: Stake the fasteners.


11-4 FINAL DRIVE

Exploded View

FINAL DRIVE 11-5

Exploded View
Final Gear Case
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Final gear case mounting nuts

34

3.5

25

2

Pinion gear nut (final gear)

130

13

94

MO, St

3

Final gear case cover bolts 10 mm

34

3.5

25

L

4

Final gear case cover bolts 8 mm

23

2.3

17

L

5

Bearing retainer bolt

6.9

0.7

61 in·lb

L

6

Final gear case drain plug

8.8

0.9

78 in·lb

7

Final gear case studs

–

–

–

G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdeum disulfide oil.
HO: Apply hypoid gear oil.
R: Replacement Parts

St: Stake the fasteners.


L

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 seal
Propeller Shaft Joint Grease
Front Bevel Gear Backlash
Preload for Front Bevel Gear Bearing:
Torque wrench
Spring scale

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.)
0.06 ∼ 0.09 mm (0.0024 ∼ 0.0035 in.) (at 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 (0.3 ∼ 0.5 kg, 0.7 ∼ 1.1 lb)
20 mL (0.68 US oz.), high-temperature grease
0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) (at gear tooths)
0.5 ∼ 0.9 N·m (0.05 ∼ 0.09 kgf·m, 4.3 ∼ 7.8 in·lb)
3 ∼ 4 N (0.3 ∼ 0.5 kg, 0.6 ∼ 1.0 lb)

FINAL DRIVE 11-7

Special Tools
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

Driven Gear Holder, m2 :
57001–1027

Drive Shaft Holder :
57001–1407

11-8 FINAL DRIVE

Final Gear Case and Oil
Oil Level Inspection

to Oil Level Inspection in Periodic Maintenance
• Refer
chapter.

Oil Change

• Refer to Oil Change in Periodic Maintenance chapter.
Final Gear Case Removal

•
•
•
•

If the final gear case is to be disassembled, drain the final
gear case oil.
Remove the rear wheel (see Wheels/Tires chapter).
Remove the left shock absorber [A] from its studs by tak­
ing off the nuts.
Remove the swingarm cover (see Suspension chapter).
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 Periodic Mainte­
• Lubricate
nance 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.

Final Gear Case Disassembly

the final gear case.
• Remove
Using
6
mm
[A] with 10 mm pitch threads, jack up
• the pinion gearboltsassembly
[B].
Remove
the
pinion
gear
assembly
and shim(s) [C] from
• the final gear case.

FINAL DRIVE 11-9

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

11-10 FINAL DRIVE

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

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 in­
stalled 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.
Apply a thin coat of high temperature grease to the oil seal
lip.
Special Tool - Bearing Driver Set: 57001–1129

a thin coat of high temperature grease to the oil seal
• Apply
lip.

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 DRIVE 11-11

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
a non-permanent locking agent to the bearing re­
• Apply
tainer bolt [C].
• Install the washer [D] and the bearing retainer bolt.
Torque - Bearing Retainer Bolt: 7 N·m (0.7 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 re­
moved.
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 Final Gear Backlash and
Tooth Contact Adjustment).
Apply a non-permanent locking agent to the threads of
the final gear case cover bolts.
Tighten:

•
•
•

Torque - Final Gear Case Cover Bolts:
10: 34 N·m (3.5 kgf·m, 25 ft·lb)
8: 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.

11-12 FINAL DRIVE

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: 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: 57001–1058 [B]

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

FINAL DRIVE 11-13

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 re­
placed as a set.
Check the tapered roller bearing (see 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].

• Replace the pinion gear nut with a new one.
Molybdeum Disulfide Oil -

Threads and Seating Surface of Pinion Gear Nut

○The molybdenum disulfide oil is a mixture of engine 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: 57001-1165
Torque - Pinion Gear Nut: 127 N·m (13 kgf·m, 93 ft·lb)

○Check the pinion gear bearing preload (see this chapter).

• Remove:

Pinion Gear Nut


Washer Shim(s)

Pinion Gear Joint

Pinion Gear Assy


11-14 FINAL DRIVE

Final Gear Case and Oil
the oil seal with a new one.
• Replace
Drive
the
oil seal [A] using the bearing driver set [B].
•
Special Tool - Bearing Driver Set: 57001–1129 [C]

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.

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 instal­
lation 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.

FINAL DRIVE 11-15

Final Gear Case and Oil
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 Spring Scale:

3.0 ∼ 5.0 N (0.30 ∼ 0.50 kg, 0.7 ∼ 1.1 lb)
Using Torque Wrench:
0.6 ∼ 1.0 N·m (0.06 ∼ 0.10 kgf·m, 5.2 ∼ 8.7 in·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 des­
ignated 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: 57001–1165 [C]

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.
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
0.1 (0.004 in.)
0.2 (0.008 in.)
0.3 (0.012 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 (0.040 in.)
1.30 (0.051 in.)
1.32 (0.052 in.)
1.34 (0.053 in.)
1.36 (0.054 in.)
1.38 (0.0543 in.)

*: Standard

Part Number
92025-1219
92025-1220
92025-1221
92025-1222
92025-1223
92025-1224
92025-1225
92025-1226
92025-1227
92025-1214
92025-1215
92025-1216
92025-1217
92025-1218

11-16 FINAL DRIVE

Final Gear Case and Oil

1. Washer
2. Shim(s)
3. Pinion Gear Joint
4. Bearing Housing

5. Tapered Roller Bearing
6. Tapered Roller Bearing
Before Tightening [A]
After Tightening [B]

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 dam­
aged.

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.

Initial Clearance [C]
Under No Preload [D]
No Clearance [E]
Under Preload [F]

FINAL DRIVE 11-17

Final Gear Case and Oil
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 con­
tact 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 posi­
tion more than by ring gear position.

•

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

11-18 FINAL DRIVE

Final Gear Case and Oil
Ring Gear Shims for Backlash Adjustment	
Thickness (mm)
0.15 (0.0059 in.)
0.5 (0.02 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.)

Parts Number
92025-1783
92025-1784
92025-1785
92025-1786
92025-1787
92025-1788
92025-1789
92025-1790

Pinion Gear Shims for Tooth Contact

Adjustment

Parts Number
Thickness (mm)
0.15 (0.0059 in.)
92180-0009
92180-0010
0.5 (0.02 in.)
0.6 (0.023 in.)
92180-0011
0.7 (0.028 in.)
92180-0012
0.8 (0.031 in.)
92180-0013
0.9 (0.035 in.)
92180-0014
92180-0015
1.0 (0.039 in.)
1.2 (0.047 in.)
92180-0016

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 adjust­
ment.
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: 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 dis­
appears. 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]. 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:

•

0.06 ∼ 0.09 mm (0.0024 ∼ 0.0035
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 thick­
ness of the shim(s).
Change the thickness a little at a time.
Recheck the backlash, and readjust as necessary.

FINAL DRIVE 11-19

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.

11-20 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.)

to correct the pattern

shown above.

Heel [A]

Bottom [B]

Top [C]

Toe [D]

FINAL DRIVE 11-21

Propeller Shaft
Propeller Shaft Removal

• Remove:

Final Gear Case (see this chapter)

Swingarm (see 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 [E] on the rear end of the propeller shaft
• Check
for any kind of damage, and replace it if necessary.
the propeller shaft joint (see Periodic Mainte­
• Lubricate
nance chapter).
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.

Propeller Shaft Joint Lubrication

to Propeller Shaft Joint Lubrication in the Periodic
• Refer
Maintenance chapter.

11-22 FINAL DRIVE

Propeller Shaft
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 11-23

Front Bevel Gears
Front Gear Case Removal

• Remove:

Engine (see Engine Removal/Installation chapter)

Rear Shift Lever [A]

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 dam­
aged.

Front Gear Case Installation

• Tighten the front gear case bolts to the specified torque.
Torque - Front Gear Case Bolts:

M8: 29 N·m (3.0 kgf·m, 22 ft·lb)

M6: 12 N·m (1.2 kgf·m, 104 in·lb)


Front Gear Case Disassembly

• Remove:

Front Gear Case (see this chapter)

•

Cam Follower

Damper Spring

Rubber Boot [A]

Remove the driven gear assy mounting bolts [B] and pry

the assy [C] off the case.


○Raise the driven gear, using the following pry points [A].

11-24 FINAL DRIVE

Front Bevel Gears
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

off the drive gear shaft [A], the drive gear [B], and
• Pull
shim(s) [C].
the bearing holder [D] from the gear case.
• Remove
Remove
the drive gear shaft ball bearing [E] using the
• 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: 57001-382
Non-permanent Locking Agent -

Bearing Retainer Bolts

Torque - Bearing Retainer Bolts: 8.8 N·m (0.9 kgf·m, 78
in·lb)

FINAL DRIVE 11-25

Front Bevel Gears
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 Ad­
justment).
After completing all adjustment, reassemble the front gear
case.
○Replace the drive gear nut with a new one.
○Apply molybdenum disulfide oil 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 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.
the driven gear assy mounting bolts to the speci­
• Tighten
fied torque.
Torque - Driven Gear Assy Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)

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: 57001-1027

11-26 FINAL DRIVE

Front Bevel Gears
the driven gear joint [A] with the O-ring [B].
• Remove
Remove
driven gear from the bearing housing.
• Remove the
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

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).
Drive the tapered roller bearing inner race [B] onto the
driven gear shaft [C] using the bearing driver [A].
Special Tool - Bearing Driver: 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

○Apply molybdenum disulfide oil 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: 137 N·m (14 kgf·m, 101 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 this chapter).
• Remove
Remove
• shaft. the retainer and needle bearing of the output
the clutch push rod guide [A] and bolts, and
• Remove
crankcase bearing upper retainer and bolts.
a bolt ( 12 mm, L100 mm, 0.47 in., L3.94 in.) [B]
• Insert
into the engine mounting bolt hole.
the damper cam nut [C] using a damper cam
• Unscrew
holder [D] (special tool) and deep socket wrench.
Special Tool - Damper Cam Holder: 57001-1025

FINAL DRIVE 11-27

Front Bevel Gears
Damper Cam Installation

the damper cam nut with a new one.
• Replace
Remove
clutch push rod guide [A] and bolts, and
• crankcasethebearing
lower retainer and bolts.
Insert
the
bolt
(
12
mm, L100 mm 0.47 in., L3.94 in.)
• [B] into the engine mounting
bolt hole.
Tighten
the
damper
cam
nut
[C]
to the specified torque.
•○Apply oil to the threads and the seating
surface of the nut.
Torque - Damper Cam Nut: 226 N·m (23 kgf·m, 166 ft·lb)
Special Tool - Damper Cam Holder: 57001-1025

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 cor­
rect to prevent the gears from making noise and being dam­
aged.
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.

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

Preload-related Parts
7. Driven Gear
8. Tapered Roller Bearing
9. Driven Gear Shim(s)
10. Driven Gear Bearing
Housing
11. Driven Gear Joint

12. Collar
(Preload Adjustment)
13. Spacer
(Preload Adjustment)
14. Tapered Roller Bearing

11-28 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 con­
tact by replacing shims.

Preload Adjustment

the driven gear assy, and tighten the driven gear
• Install
nut to the specified torque.
Torque - Driven Gear Bolt: 137 N·m (14 kgf·m, 101 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 Spring Scale:
3 ∼ 4 N (0.3 ∼ 0.5 kg, 0.6 ∼ 1.0 lb)
Using Torque Wrench:
0.5 ∼ 0.9 N·m (0.05 ∼ 0.09 kgf·m, 4.3 ∼ 7.8 in·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 des­
ignated by torque (N·m, kgf·m, in·lb).

FINAL DRIVE 11-29

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: 57001-1027

•

If the preload is out of specified range, replace the bear­
ing 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
Part Number
Length (mm)
22.8 (0.898 in.)
92027-1152
92027-1153
22.9 (0.902 in.)
23.0 (0.906 in.)
92027-1154
92027-1155
23.1 (0.909 in.)
23.2 (0.913 in.)
92027-1156
92027-1157
23.3 (0.917 in.)
23.4 (0.921 in.)
92027-1158
92027-1159
23.5 (0.925 in.)
23.6 (0.929 in.)
92027-1160
92027-1161
23.7 (0.933 in.)
23.8 (0.937 in.)
92027-1162
92027-1163
23.9 (0.941 in.)
24.0 (0.945 in.)
92027-1164
92027-1165
24.1 (0.949 in.)

Spacers for Preload Adjustment
Part Number
Thickness (mm)
1.70 (0.0669 in.)
92025-1072
92025-1073
1.72 (0.0677 in.)
1.74 (0.0685 in.)
92025-1074
92025-1075
1.76 (0.0693 in.)
1.78 (0.0701 in.)
92025-1076
92025-1077
1.80 (0.0709 in.)

11-30 FINAL DRIVE

Front Bevel Gears
Bearing Preloading Mechanism

1. Bearing Housing
2. Tapered Roller Bearing
Before Tightening [A]
After Tightening [B]

3. Spacer
4. Collar
Under No Preload [C]
Initial Clearance [D]

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 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 dis­
appears. Then, change the shim to a thicker one.

5. Tapered Roller Bearing
Under Preload [E]
No Clearance [F]

FINAL DRIVE 11-31

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 back-

lash, 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 the gear tooth)
0.10 ∼ 0.15 mm (0.039 ∼ 0.0059 in.)

Shims for Drive Gear
Thickness (mm)
0.15 (0.0059 in.)
0.5 (0.02 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.)

Parts Number
92025-1688

92025-1689

92025-1690

92025-1691

92025-1692

92025-1693

92025-1694

92025-1695

92025-1696


Shims for Driven Gear
Thickness (mm)
0.1 (0.039 in.)
0.15 (0.0059 in.)
0.5 (0.02 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 sup­

ply stores for the purpose of checking differential gear

tooth patterns and contact. Use this for checking the

bevel gears.


Parts Number
92025-1826

92025-1818

92025-1819

92025-1820

92025-1821

92025-1822

92025-1823

92025-1824

92025-1825


11-32 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, follow­
ing the examples shown. Then erase the tooth contact
patterns, and check them again. Also check the back­
lash every time the shims are replaced. Repeat the shim
change procedure as necessary.

NOTE

○If the backlash goes out of standard range after chang­

ing 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 11-33

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 dam­
aged.

Cam Damper Inspection

inspect the spring [A], cam follower [B], damper
• Visually
cam [C], and output shaft [D].
Replace the damaged parts.

11-34 FINAL DRIVE

Bearing and Oil Seal
Ball or Needle Bearing Replacement

the bearing driver set or the oil seal & bearing re­
• Using
mover, 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. Re­
moval 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 sol­
vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
○Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.

FINAL DRIVE 11-35

Bearing and Oil Seal
Tapered Roller Bearing Inspection
CAUTION
Do not remove the tapered roller bearing for inspec­
tion. 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 bear­
ing, 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.........

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

12-13

12-14

12-15

12-15

12-15

12-15

12-16

12-16

12-16


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.

12-16
12-17
12-17
12-18
12-18
12-18
12-19
12-20
12-20
12-21
12-21
12-22
12-23
12-23
12-23
12-23
12-23
12-24 12

12-24
12-24
12-24
12-27

12-27

12-2 BRAKES

Exploded View

BRAKES 12-3

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

1

Brake hose banjo bolts

25

2.5

18

2

Front brake reservoir cap screws

1.5

0.15

13 in·lb

3

Brake lever pivot bolt

1.0

0.10

87 in·lb

4

Brake lever pivot bolt locknut

5.9

0.60

52 in·lb

5

Front master cylinder clamp bolts

8.8

0.9

78 in·lb

6

Front brake light switch screw

1.2

0.12

10 in·lb

7

Caliper bleed valves

7.8

0.8

69 in·lb

8

Front caliper mounting bolts

34

3.5

25

9

Brake disc bolts

27

2.8

20

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.

Remarks

Si
S

L

12-4 BRAKES

Exploded View

BRAKES 12-5

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

1

Rear master cylinder mounting bolts

25

2.5

18

2

Brake hose banjo bolts

25

2.5

18

3

Rear master cylinder push rod locknut

18

1.8

13

4

Brake pedal clamp bolt

25

2.5

18

5

Caliper bleed valves

7.8

0.8

69 in·lb

6

Rear caliper mounting bolts

34

3.5

25

7

Rear caliper holder bolt

64

6.5

47

8

Brake disc bolts

27

2.8

20

B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease or PBC grease.

Remarks

L

12-6 BRAKES

Specifications
Item

Standard

Service Limit

Brake Lever, Brake Pedal:
Brake lever position

No.1

5-way adjustable

Brake lever free play

Non-adjustable

– – –

Pedal free play

Non-adjustable

– – –

Pedal position

About 110 mm (4.33 in.)

– – –

(height from pedal top to footpeg top)
Brake Fluid:
Grade

DOT4

– – –

Brake Pads:
Pad lining
thickness:

Front

4.5 mm (0.2 in.)

1 mm (0.04 in.)

Rear

7.5 mm (0.295 in.)

1 mm (0.04 in.)

Front

4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

4.5 mm (0.18 in.)

Rear

6.8 ∼ 7.2 mm (0.268 ∼ 0.283 in.)

6.0 mm (0.24 in.)

TIR 0.15 mm (0.0059 in.) or less

TIR 0.3 mm (0.01 in.)

Brake Discs:
Thickness:
Runout

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 num­
ber 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 (4.33 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 footpeg [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 - Push Rod Locknut: 18 N·m (1.8 kgf·m, 13 ft·lb)

Brake Pedal Removal

the brake fluid reservoir [A] (see Brake Pedal
• Remove
Position Adjustment).
the rear master cylinder mounting bolts [B].
• Loosen
Remove
footboard bracket bolts [C] and

• footboardtheboltsright[E],front
and turn over the footboard bracket

[D].


• 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
l
Instal
shaft [A] so that the punched mark on the
• shaft isthealipedal
gned [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: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)

the fluid in the reservoir, and bleed the brake
• Replenish
line (see Brake Line Bleeding).
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 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 re­
moval. 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:

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

the fluid level in the brake reservoirs.
• Check
Bleed
the
line (see Brake Line Bleeding).
• Check thebrake
for good braking power, no brake drag,
• and no fluidbrake
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 appli­
cation of the lever or pedal if this is not done.

12-12 BRAKES

Calipers
Front Caliper Disassembly

• Remove:

Caliper (see Front Caliper Removal)

•

Cotter Pin [A]

Pin [B]

Pads [C]

Push the piston in.

• Remove:

Pad Springs [A]

•

Caliper Holder [B]

Using compressed air, remove the piston.

WARNING
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com­
pressed 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)

BRAKES 12-13

Calipers
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.

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.
• Wash the
the
• wipe it off. caliper with water to remove brake fluid and

Rear Caliper Disassembly

the caliper with the hose installed (see Caliper
• Remove
Removal).
• Remove the pads (see Pad Removal).
• Pull out the caliper holder [A].

12-14 BRAKES

Calipers
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.

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 open­
ing 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 com­
pressed air into the caliper, the pistons may crush
your hand or fingers.

CAUTION
Immediately wash away any brake fluid that spills.
the anti rattle spring [A].
• Remove
Remove
the
seals [B] and fluid seals [C].
• Remove the dust
rubber
friction boots [D].
• Remove the bleed valve
[E] and rubber cap [F].
•

Rear Caliper Assembly

• Tighten the bleed valve.

Torque - Caliper Bleed Valve: 7.8 N·m (0.8 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.

BRAKES 12-15

Calipers
the anti-rattle spring [A] in the caliper as shown.
• Install
Apply
brake
the cylinders, pistons, and fluid seals
• (piston seals),fluidandtopush
the pistons into the cylinders by
hand. Take care that neither the cylinder nor the piston
skirt gets scratched.

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 Brake Pad Installation).

Caliper Fluid Seal Damage
The fluid seal (piston seal) [A] is placed around the pis­
ton to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the tem­
perature of the discs or the brake fluid to increase.
Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.

•

Caliper Dust 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 en­
tire caliper assembly.

•

12-16 BRAKES

Brake Pads
Front Brake Pad Removal
NOTE

○The procedure to remove the front caliper is as follows.

The rear caliper pad removal is the same as for the front
caliper.

the caliper with the hose installed (see Caliper
• Remove
Removal).
• 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
l the brake pads.
• Instal
l the pad pin and snap pin [A]. The snap pin must be
• Instal
“outside” of the pads.

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 caliper with the hose installed (see Caliper
• Remove
Removal).
• Remove:
Snap Pin [A]
Pad Pin [B]

BRAKES 12-17

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 Brake Pad Wear Inspection in the Periodic Main­
• Refer
tenance chapter.

12-18 BRAKES

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.
the bolt caps out.
• Pull
Remove
banjo bolt [C] to disconnect the brake hose
• from the the
master cylinder (see Brake Hose Removal/In-

•

stallation).
Unscrew the clamp bolts [B], and take off the master cylin­
der 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.

the upper clamp bolt [B] first, and then the lower
• Tighten
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 (0.9
kgf·m, 78 in·lb)

the bolt caps.
• Install
Use
a
new
• fitting. flat washers [A] on each side of the brake hose
• Tighten the brake hose banjo bolt [B].

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

the fluid in the reservoir, and bleed the brake
• Replenish
line (see Bleeding the Brake Line).
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.

BRAKES 12-19

Master Cylinder
Rear Master Cylinder Removal

the brake fluid reservoir cover (see Brake Pedal
• Remove
Position Adjustment).
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).
the brake hose banjo bolt [A] on the master cylin­
• Unscrew
der.
the master cylinder mounting bolts [B].
• Loosen
Unscrew
• Remove:
the footpeg bracket bolts [C].
• Rear Master Cylinder Mounting Bolts

Brake Pedal Return Spring (see Brake Pedal Removal)

Brake Switch Return Spring [B] (see Brake Pedal Re­

moval)

Brake Lever (see Brake Pedal Removal)


• Remove the cotter pin [A] and joint pin [B].

the reservoir hose lower end clamp [A].
• Slide
Pull
out
reservoir hose lower end [B], and drain the
• brake fluidtheinto
a container.

12-20 BRAKES

Master Cylinder
Rear Master Cylinder Installation

the cotter pin with a new one.
• Replace
Insert
the
pin [A] to the hole of the joint pin [B] and
• separate [cotter
C] the cotter pin ends.
a new flat washer on each side of the brake hose
• Use
fitting.
• Tighten:

Torque - Front Footboard Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

the brake line (see Brake Line Bleeding).
• Bleed
Check
brake for good braking power, no brake drag,
• and nothe
fluid leakage.

WARNING
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.

Front Master Cylinder Disassembly

the front master cylinder.
• Remove
Remove
the
cap, plate and diaphragm.
• Unscrew the reservoir
locknut
and
pivot bolt, and remove the brake
• lever.
the dust cover [A] out of place, and remove the circlip
• Pull
[B].
Special Tool - Inside Circlip Pliers: 57001-143

out the piston assy [C], primary cup [D], and return
• Pull
spring [E].

CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.

BRAKES 12-21

Master Cylinder
Rear Master Cylinder Disassembly
NOTE

○Do not remove the push rod clevis [A] for master cylin­

der disassembly since removal requires brake pedal po­
sition adjustment.

the rear master cylinder (see Rear Master Cylin­
• Remove
der Removal).
the dust cover on the push rod out of place, and
• Slide
remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143

out the push rod with the piston stop.
• Pull
Take
• springoff[D].the piston assy [B], primary cup [C], and return

CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.

Master Cylinder Assembly

assembly, clean all parts including the master
• Before
cylinder with brake fluid or alcohol.

CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi­
cult to wash off completely, and will eventually de­
teriorate the rubber used in the disc brake.
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.
• 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)

12-22 BRAKES

Master Cylinder
Master Cylinder Inspection

the front and rear master cylinders.
• Disassemble
Check
that
there
are no scratches, rust or pitting on the
• inner wall [A] of each
master cylinder and on the outside

•

of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston 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.

Front Master Cylinder [J]


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

BRAKES 12-23

Brake Discs
Brake Disc Removal

the wheel (see Wheels/Tires chapter).
• Remove
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 - 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.
Front Disc Thickness

Standard:
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

Service Limit:

4.5 mm (0.18 in.)

Rear Disk Thickness

Standard:
6.8 ∼ 7.2 mm (0.268 ∼ 0.283 in.)

Service Limit:

6.0 mm (0.24 in.)

Brake Disc Warp

up the motorcycle so that the wheel is off the ground
• Jack
(see 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 mea­
sure 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 (0.0059 in.) or less

TIR 0.3 mm (0.01 in.)

12-24 BRAKES

Brake Fluid
Brake Fluid Level Inspection

to Brake Fluid Level Inspection in Periodic Mainte­
• Refer
nance chapter.

Brake Fluid Change

to Brake Fluid Change in Periodic Maintenance
• Refer
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 when­
ever brake lever or pedal action feels soft or
spongy after the brake fluid is changed, or when­
ever a brake line fitting has been loosened for any
reason.

NOTE

○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
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.
Install the reservoir cap.

BRAKES 12-25

Brake Fluid
the rubber cap from the bleed valve on the
• Remove
caliper.
a clear plastic hose to the bleed valve, and run the
• Attach
other end of the hose into a container.
the brake line and the caliper as follows:
•○Bleed
Repeat this operation until no more air can be seen com­
ing out into the plastic hose.
Pump the brake lever until it becomes hard, and apply
the brake lever and hold it [A].
Quickly open and close [B] the bleed valve while holding
the brake lever applied.
Release the brake lever [C].

NOTE

○The fluid level must be checked often during the bleed­

ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reser­
voir for more complete bleeding.
the clear plastic hose.
• Remove
Tighten:
•

Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)
Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

• Repeat the above steps for other caliper.
NOTE

○For the rear brake caliper [A], bleed the brake line for
two bleed valves [B].

the fluid level.
• Check
After
bleeding
done, check the brake for good braking
• power, no brakeis drag,
and no fluid leakage.

12-26 BRAKES

Brake Fluid
WARNING
When working with the disc brake, observe the pre­
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in
the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off [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 diffi­
cult to wash off completely and will eventually dete­
riorate 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 satisfacto­
rily.
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.

BRAKES 12-27

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.

wash away any brake fluid that spills.
• Immediately
There
are
washers
each side of the brake hose
• fitting. Replace them[B]withonnew
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 General
Information chapter.
Fill the brake line after installing the brake hose (see
Brake Fluid Changing).

SUSPENSION 13-1


Suspension

Table of Contents
Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Front Fork ...............................................................................................................................

Fork Oil Change................................................................................................................

Front Fork Removal ..........................................................................................................

Front Fork Installation .......................................................................................................

Disassembly......................................................................................................................

Assembly ..........................................................................................................................

Inner Tube, Outer Tube Inspection ...................................................................................

Dust Seal Inspection .........................................................................................................

Spring Tension ..................................................................................................................

Rear Shock Absorber .............................................................................................................

Rebound Damping Adjustment .........................................................................................

Spring Preload Adjustment ...............................................................................................

Rear Shock Absorber Removal ........................................................................................

Rear Shock Absorber Installation .....................................................................................

Rear Shock Absorber Inspection ......................................................................................

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
13-13

13-14
13-15
13-15
13-15

13-16

13-16

13-16

13-18
13-18
13-19

13-20 13
13-20
13-20
13-21

13-2 SUSPENSION

Exploded View

SUSPENSION 13-3

Exploded View
No.
1
2
3
4
5

Fastener
Upper front fork clamp bolts
Lower front fork clamp bolts
Front fork top plugs
Front fork bottom allen bolt
Front axle clamp bolts

N·m
20
29
22
30
20

Torque
kgf·m
2.0
3.0
2.2
3.1
2.0

ft·lb
15
21
16
22
15

L: Apply a non-permanent locking agent.
R: Replacement Parts
G: Apply grease.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

Remarks

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
108

G: Apply grease.

WL: Apply a soap and water solution or rubber lubricant.


Torque
kgf·m
3.5
11.0

ft·lb
25
79.6

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 viscosity
Fork oil capacity:

Fork oil level:
Fork spring free length
Rear Shock Absorber:
Rebound damper set
Spring setting position

Standard
43 mm ( 1.7 in.)
Non-adjustable
Atmospheric pressure (Non-adjustable)
Non-adjustable
SAE 10W-20
521 ± 2 mL (17.6 ± 0.068 US oz.) (completely disassembled and
dry)
approx. 445 mL (15.0 US oz.) (when changing oil)
Fully compressed, without fork spring, below from inner tube top
120 mm (4.72 in.)
382.4 mm (15.06 in.) (Service limit: 375 mm (14.8 in.))
No.2 of 4 positions
No.2 of 5 positions

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

the front fork (see Front Fork Removal).
• Remove
Hold
the
• Remove:
outer tube vertically in a vise.
• 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 Viscosity: SAE10W-20
Fork Oil Capacity (when changing oil): Approx. 445
mL (15.0 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:
120 ± 2 mm (4.72 ± 0.08 in.)

the fork spring with the smaller diameter end [A]
• Install
facing down [B].
• Tighten:

Torque - Lower Fork Clamp Bolts: 29 N·m (3.0 kgf·m, 21
ft·lb)
Upper Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15
ft·lb)
Front Axle Clamp Bolt: 20 N·m (2.0 kgf·m, 22 ft·lb)
Front Axle Nut: 110 N·m (11.0 kgf·m, 79.6 ft·lb)
Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m,
25 ft·lb)

SUSPENSION 13-9

Front Fork

• Install:

Fork Spring [A]

Washer [B]

Spacer [C]

Top Plug [D] with O-ring [E] 


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:

Caliper (see Brakes chapter)

Front tire (see Wheels/Tires chapter)

Front fender (see Frame chapter)

Headlight (see Electrical System chapter)


• Remove:

Bolts [A]

Headlight body [B]


13-10 SUSPENSION

Front Fork

• Remove:

Bolts [A] (both side)

Front fork center cover [B]


• Remove:

Front fork clamp bolts [A]

Front fork inner cover

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):
20 N·m (2.0 kgf·m, 15 ft·lb)
Front Fork Top Plug: 22 N·m (2.2 kgf·m, 16 ft·lb)

NOTE

○Tighten the top plug before tightening the upper fork
clamp bolts.

○Tighten the two clamp bolts alternately two times to en­
sure even tightening torque.

• Tighten:

Torque - Front Fork Clamp Bolt (Upper):

20 N·m (2.0 kgf·m, 15 ft·lb)


• Install the removed parts and tighten:

Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
Front Axle Bolt: 110 N·m (11.0 kgf·m, 79.6 ft·lb)
Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m,
25 ft·lb)

NOTE

○Tighten the two clamp bolts alternately two times to en­
sure even tightening torque.

• 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.

SUSPENSION 13-11

Front Fork
Disassembly

the front fork (see Front Fork Removal in this
• Remove
chapter).
the fork oil (see Fork Oil Change in this chapter).
•○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:

57001-183 [D]

Fork Cylinder Holder Adapter:

57001-1057 [E]


• 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.

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.

the inner tube, cylinder unit, and cylinder base as
• Install
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: 57001-183 [D]
Fork Cylinder Holder Adapter: 57001-1057
[E]
Torque - Bottom Allen Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb)

Inner Tube, Outer Tube Inspection

inspect the inner tube [A] and repair any damage.
• ViNisually
ck
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.
ly assemble the inner and outer tubes, and
• Temporari
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 in­
spect the other tube carefully before reusing it.

Dust Seal Inspection
Inspect the dust seal [A] for any signs of deterioration or
damage.
Replace them if necessary.

13-14 SUSPENSION

Front Fork
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 re­
maining 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:
382.4 mm (15.06 in.)

Service Limit:

375 mm (14.8 in.)

SUSPENSION 13-15

Rear Shock Absorber
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.2 for an average-build
rider of 68 kg (150 lb) with no passenger and no acces­
sories.
If the damper setting feels too soft or too stiff, adjust it in
accordance with the following table.

•

Rebound Damping Adjustment
Adjuster
Position
1
2
3
4

Damping
Force
Weak
↑
↓
Strong

Setting

Load

Road

Speed

Soft
↑
↓
Hard

Light
↑
↓
Heavy

Good
↑
↓
Bad

Low
↑
↓
High

Spring Preload Adjustment
The spring preload adjuster on each rear shock absorber
has 5 positions so that the spring tension can be adjusted
for different road and loading conditions.
Using the wrench [A], turn the adjuster [B] to adjust the
spring tension.
○The standard adjuster position for an average-build rider
of 68 kg (150 lb) with no passenger and no accessories
is 2nd step [C] from the weakest position.
If the spring action feels too soft or too stiff, adjust it in
accordance with the following table.

•

Spring Preload Adjustment
Position
1
2
3
4
5

Spring
Force
Stronger
¦
¦
¦
↓

Setting

Load

Road

Speed

Soft
↑
¦
↓
Hard

Light
↑
¦
↓
Heavy

Good
↑
¦
↓
Bad

Low
↑
¦
↓
High

to see that both adjusting sleeves are turned to the
• Check
same relative position.

WARNING
If both adjusters are not adjusted equally, handling
may be impaired and a hazardous condition may
result.

13-16 SUSPENSION

Rear Shock Absorber
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


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 cap nuts [A], lock washers, and flat washers
• Remove
from both ends of the rear shock absorber [B].
• Pull the rear shock absorber off the frame.

Rear Shock Absorber Installation

the sleeve so the flange side faces inside.
• Install
Tighten
• torque. the rear shock absorber nuts to the specified
Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25
ft·lb)

Rear Shock Absorber Inspection

the rear shock absorbers [A].
• Remove
Visually
inspect
following items.

• Smooth Strokethe
[B]


•

Oil Leakage (see 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.

SUSPENSION 13-17

Rear Shock Absorber
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 nee­
dle bearings or sleeves, replace the sleeves, and needle
bearings as a set.

13-18 SUSPENSION

Swingarm
Swingarm Removal

• Remove:
Bolts [A]

Swingarm Cover [B]

the rear exhaust pipe (see Engine Top End chap­
• Remove
ter).
• Loosen:
Right Muffler Chamber Bolt [A]

•

Front Exhaust Pipe Clamp Bolt [B]
Remove:
Swingarm Pivot Cap [C]

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.
Using the jack and attachment jack under the frame pipe
ribs, lift the rear wheel OFF the ground until the front
wheel touches the ground (see Rear Shock Absorber Re­
moval).
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 mo­
torcycle 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.

SUSPENSION 13-19

Swingarm

• Remove:

Rear Wheel (see Wheels/Tires chapter)

•
•
•

Final Gear Case (see Final Drive chapter)

Remove the right rear shock absorber.
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 turn­
ing 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
Apply
• shaft. grease to the threads [A] of the swingarm pivot
Torque - Swingarm Pivot Shaft: 110 N·m (11 kgf·m, 79.6
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.

• Tighten:

Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25
ft·lb)
Rear Caliper Mounting Bolts: 34 N·m (3.5 kgf·m,
25 ft·lb)
Rear Caliper Holder Bolt: 64 N·m (6.5 kgf·m, 47
ft·lb)

• Install:

Final Gear Case (see Final Drive chapter)

•
•

Rear Wheel (see Wheels/Tires chapter)

Tighten:

Silencer Stay Bolt (see Engine Top End chapter)

Right Muffler Chamber Bolt (see Engine Top End chap­

ter)

After installing the swingarm, replenish the brake fluid into

the reservoir and bleed the brake line (see Brake Line

Bleeding in Brakes chapter).


13-20 SUSPENSION

Swingarm
Swingarm Bearing Removal

• Remove:

Swingarm (see this chapter)

Propeller Shaft (see Final Drive chapter)

Right and Left Sleeves [A]

Right and Left Grease Seals [B]


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 bear­
ing driver in the bearing driver set.

Sleeves [B]

Grease Seals [C]

5 mm [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 nee­
dle bearings or sleeve, replace the sleeve, and needle
bearings as a set.

SUSPENSION 13-21

Swingarm
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

14-6
14-6
14-6

14-7

14-7

14-9

14-10

14-11

14-11

14-11

14-12
14-12


14

14-2 STEERING

Exploded View

STEERING 14-3

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

1

Handlebar clamp bolts

34

3.5

25

2

Steering stem head nut

88

9.0

65

3

Steering stem nut

5

0.5

43 in·lb

4

Handlebar holder nuts

34

3.5

25

5

Upper front fork clamp bolts

20

2.0

14

6

Lower front fork clamp bolts

2.9

3.0

21

7

Turn signal light mounting nuts

5.9

0.6

52 in·lb

Remarks

AD: Apply adhesive.
G: Apply grease.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

AL

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, 41.5 :
57001–1345

Head Pipe Outer Race Remover ID > 37 mm :
57001–1107

Attachment Jack :
57001–1398

STEERING 14-5

Handlebar
Handlebar Removal

the straps.
• Cut
Remove:

• Clutch Master Cylinder [A]

Left Handlebar Switch Housing [B]


Front Brake Master Cylinder [A]
Right Handlebar Switch Housing [B]
Throttle Grip [C]

the bolts [A] and remove the handlebar [B] from
• Unscrew
the stem head.

Handlebar Installation

• Tighten the handlebar bolts.

Torque - Handlebar Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)

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 chapter)

Front Brake Master Cylinder (see Brakes chapter)


14-6 STEERING

Steering
Steering Check

to Steering Check in the Periodic Maintenance
• Refer
chapter.

Steering Adjustment

to Steering Adjustment in the Periodic Maintenance
• Refer
chapter.

STEERING 14-7

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

• Remove the front wheel (see Tires/Wheels chapter).
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.
the headlight rim screws and open the headlight
• Unscrew
unit (see Electrical System chapter).
• Remove:
Bolts [A]
Headlight body [B]

• Remove:
Bolts [A] (both side)
Front fork center cover [B]

• Remove:
Bolts [A] (both side)
Front fork rear covers [B]

14-8 STEERING

Steering Stem

• Remove:

Bolts [A]

Turn signal rights bracket [B]


• Remove:

Bolt [A]

Cable bracket [B]


• Remove:

Brake hose banjo bolt [A]

Brake hose [B]


• Remove:

Brake hose joint bolt [A]


• Remove:

Handlebar holder bolts [A]

Handlebar [B]


STEERING 14-9

Steering Stem

• Remove:

Steering stem head nut [A]

Washer [B]


• Remove:

Front fork clamp bolts [A]


• Remove:

Bolts [A]

Front fork inner cover [B]


• 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] (I.D. 34.5 ×
 2 mm) 

Stem Cap [D]

Stem Nut [E]

Claw Washer [F]

Torque - Steering Stem Nut: 4.9 N·m (0.5 kgf·m, 43 in·lb)

14-10 STEERING

Steering Stem
the fork leg [A] and push it up tightly against the
• Install
stem bottom.
tighten the lower fork clamp bolts.
• Temporarily
Install:

• Steering Stem Head [B] with Handlebar


•

O-ring [C]

Washer [D]

Stem Head Nut [E]

Temporarily tighten the upper fork clamp bolts [F].

○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 fork upper clamp bolts and then the stem head
nut, and finally the fork lower clamp bolts.
Torque - Fork Upper Clamp Bolts: 20 N·m (2.0 kgf·m, 14
ft·lb)
Steering Stem Head Nut: 88 N·m (9.0 kgf·m, 65
ft·lb)
Fork Lower Clamp Bolts: 29 N·m (3.0 kgf·m, 21
ft·lb)

NOTE

○Tighten the two clamp bolts alternately two times to en­
sure even tightening torque.

the removed parts.
• Install
Check
and adjust the following items after installation.

• Steering
(see Steering Check)


•

Throttle Cables (see Fuel System chapter)

Headlight Aim

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 14-11

Steering Stem Bearing
Stem Bearing Removal

the steering stem (see this chapter).
• Remove
Drive
out
the bearing outer races from the head pipe.
•
Special Tool - Head Pipe Outer Race Remover:

57001-1107 [A]


NOTE

○If either steering stem bearing is damaged, it is recom­

mended 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:

57001-1075 [A]

Head Pipe Outer Race Drivers:

57001-1077 [B]


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:
57001-1344 [B]
Steering Stem Bearing Driver Adapter:
57001-1345 [C]

• Install the steering stem.

NOTE

○Do not install the O-rings yet.

the bearings in place as follows:
•○Settle
Tighten the stem nut to 49 N·m (0.5 kgf·m, 43 in·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 kg, 99 lb) force in the
direction shown.)
Special Tool - Steering Stem Nut Wrench: 57001-1100 [A]

180 mm [B]

Force [C]


14-12 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 Periodic
Maintenance chapter).
Torque - Steering Stem Nut: 49 N·m (0.5 kgf·m, 43 in·lb)

Stem Bearing Lubrication
In accordance with the Periodic Maintenance Chart, lubricate the steering stem bearings. Refer to the Stem Bearing
Lubrication in Periodic Maintenance chapter.

Stem Cap Deterioration, Damage
Replace the stem cap if its grease seal [A] shows dam­
age.

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/Installation .............................................................................

Fenders ..................................................................................................................................

Front Fender Removal ......................................................................................................

Rear Fender Removal.......................................................................................................

Battery Case/Tool Box ............................................................................................................

Battery Case Removal ......................................................................................................

Tool Box Removal .............................................................................................................

Front Footboard, Sidestand....................................................................................................

Footboard Removal ..........................................................................................................

Footboard Disassembly ....................................................................................................

Sidestand Installation........................................................................................................

Frame .....................................................................................................................................

Downtube Removal...........................................................................................................

Downtube Installation........................................................................................................

Frame Inspection ..............................................................................................................


15-2
15-6
15-7

15-7

15-7

15-7

15-7

15-8
15-8

15-8

15-8

15-9

15-9
15-9
15-10
15-10

15-10

15-11

15-11

15-11

15-11

15-12
15-12

15-12

15-13

15

15-2 FRAME

Exploded View

FRAME 15-3

Exploded View
No.
1
2
3
4

Fastener
Downtube bolts
Footboard bracket bolts
Sidestand bolt
Engine mounting bracket bolts

N·m
44
34
44
25

G: Apply grease.

WL: Apply a soap and water solution or rubber lubricant.


Torque
kgf·m
4.5
3.5
4.5
2.5

ft·lb
33
25
33
18

Remarks

15-4 FRAME

Exploded View

FRAME 15-5

Exploded View
No.
1

Fastener
Footpeg bracket bolts

2. Tool box
3. Battery case
4. Front fender
5. Rear fender
6. Front seat
7. Rear seat
G: Apply grease.
L: Apply a non-permanent locking agent.

N·m
25

Torque
kgf·m
2.5

ft·lb
18

Remarks
L

15-6 FRAME

Special Tools
Jack :
57001–1238

Attachment Jack :
57001–1398

FRAME 15-7

Seats
Rear Seat Removal

the rear seat bolt [A] and move the rear seat
• Remove
backwards [B] and remove it (left view).

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 this section).
• Remove
Remove
the front seat bolt [A].
• 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
• Front [B]the front seat bolt.
• Install the rear seat (see this section).

15-8 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/Installation

• Remove the screw [A].

CAUTION

Be careful not to scratch the right side cover sur­
face 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.
the right side cover off the grommets [C] and remove
• Pull
the cover.


•
•

Front [D]

Put the stoppers into the grommets.
Tighten the screw.

FRAME 15-9

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 (right side view).
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.
the front and rear seats (see this chapter).
• Remove
• Remove the rear fender cover bolts [A] on both sides.

the rear turn signal and taillight lead connector
• Disconnect
[A] and pull off the female connector along with the strap

•
•

[B].
Remove:

Rear Fender Front Bolts [C]

Rear Fender Allen Bolts [D]

Seat Band Stay Bolts [E]

Remove the rear fender [F] rearwards.

15-10 FRAME

Battery Case/Tool Box
Battery Case Removal

(left view):

• Remove
Front and Rear Seats (see this chapter)

Bolts [A] and Battery Holder [B]

Battery [C] (see Electrical System chapter)

ECU [D] (see Fuel System (DFI) chapter)


the following upwards:

• Pull
Oil Pressure Light Delay Unit [A]

DFI Main Relay [B]

Turn Signal Control Unit [C]

Starter Relay [D]

Front [E]


two bottom bolts [A].

• Remove
Front [B]


the rear wheel (see Wheels/Tires chapter).
• Remove
Remove
two rear screws [A] (rear view).
• Remove the
battery case [B] towards the rear [C].
•

Tool Box Removal

the left side cover (see this chapter).
• Remove
For
California,
remove the band [A] and canister [B].
• Unscrew the bolts
[C].
• Pull the tool case [D]
out.
•

FRAME 15-11

Front Footboard, Sidestand
Footboard Removal

the bolts [A] and remove the left front footboard
• Unscrew
[B].

○The right front footboard is removed during brake pedal
removal (see Brakes chapter).

Footboard Disassembly

the front footboard.
• Remove
Remove:

• Footboard Spring [A]

Circlip [B]

Pin [C]


Sidestand Installation

• Tighten:

Torque - Sidestand Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb)

the sidestand spring [A], noting the direction of the
• Install
hooks [B].

15-12 FRAME

Frame
Downtube Removal

the jack and the attachment jack, raise the rear
• Using
wheel off the ground (see Wheels/Tires chapter).
Special Tools - Jack: 57001-1238

Attachment Jack: 57001-1398


the brake reservoir cover [A] and reservoir (see
• Remove
Brakes chapter).
the lead clamps [B]
• Open
Remove
right footboard assembly [C] by taking off the
• bolts [D] the
with the brake pedal and rear master cylinder

•

installed. Place the assembly on a block.
Remove the front exhaust pipe [E] (see Engine Top End
chapter).

• Take off the brake hose [A] from the clamps [B].

the engine with a commercially available stand

• Support
[A].

• Remove:

Right Radiator Cover Bolt [B]

Engine Mounting Bracket Bolts [C]

Downtube Bolts [D]


Downtube Installation

the brake hose inside the downtube and clamp it.
• Run
Put
right
left stoppers [A] of the radiator into the grom­
• mets [B] and
of the downtube.
• Tighten:

Torque - Downtube Bolts: 44 N·m (4.5 kgf·m, 33 ft·lb)
Engine Mounting Bracket Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)

FRAME 15-13

Frame
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
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Wiring Diagram (United States and

Canada) ..........................................
Wiring Diagram (Australia) ................
Wiring Diagram (Other than United

States, Canada and Australia)........
Electrical Parts Location ....................
Servicing Precautions........................
Electrical Wiring.................................
Wiring Inspection .........................
Battery ...............................................
Battery Removal ..........................
Battery Installation .......................
Electrolyte Filling..........................
Initial Charge................................
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 .....
Rectifier Inspection ......................
Regulator Inspection ....................
Ignition System ..................................

16-4

16-12

16-13

16-14

16-16

16-18

16-20

16-22

16-24

16-24

16-25

16-25

16-25

16-26

16-28

16-28

16-29

16-29

16-29

16-31

16-31

16-31

16-31

16-32

16-32

16-33

16-33

16-33

16-34

16-35

16-35

16-36

16-36

16-36

16-38

16-39

16-39

16-40

16-42


Ignition Coil Removal ...................
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 Bulb
Replacement .............................
Automatic Turn Signal Canceling
System............................................
Wiring Inspection .........................
Distance Sensor Inspection .........
Turn Signal Switch Inspection......
Turn Signal Control Relay
Inspection..................................

16-43
16-43
16-44
16-44
16-45
16-45
16-45
16-46
16-46
16-46
16-48
16-49
16-50
16-53
16-53
16-53
16-54
16-55
16-56
16-56
16-56
16-57
16-57
16-57
16-59
16-59
16-59
16-59
16-61
16-61
16-62
16-64
16-64
16-65
16-65
16-65

16

16-2 ELECTRICAL SYSTEM

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...
Speed Sensor Removal ...............
Speed Sensor Installation ............

16-66

16-69

16-69
16-69

16-70
16-70

16-70

16-72
16-72

16-73

16-73

16-74
16-75

16-80
16-81
16-85
16-85

16-86

16-86
16-87
16-87
16-88

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............................

16-88

16-88

16-88

16-88

16-88

16-89

16-89

16-89

16-90

16-90

16-92

16-92

16-92

16-93

16-95

16-95

16-95

16-95

16-95


16-4 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-5

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Spark plugs

18

1.8

13

2

Alternator stator bolts

13

1.3

113 in·lb

L

3

Alternator rotor bolt

78

8.0

58

MO

4

Stator lead holder screw

9.8

1.0

87 in·lb

L

5

Inside stator holder bolts

11

1.1

95 in·lb

L

6

Rotor bolt cap

1.5

0.15

13 in·lb

7

Timing inspection cap

1.5

0.15

13 in·lb

8

Alternator cover bolts

11

1.1

95 in·lb

9

Alternator inner cover bolts

11

1.1

95 in·lb

10 Crankshaft sensor screws

2.9

0.30

26 in·lb

11 Crankshaft sensor lead holder bolt

2.9

0.30

26 in·lb

12 Alternator outer cover bolts

6.9

0.70

61 in·lb

13 Alternator outer cover damper bolts

6.9

0.70

61 in·lb

L

14 Alternator outer cover joint bolts

6.9

0.70

61 in·lb

L

15 Alternator outer cover assembly bolts

6.9

0.70

61 in·lb

16 Speed sensor mounting bolt

9.8

1.0

87 in·lb

17 Neutral switch

15

1.5

11

18 Regulator/Rectifier bolts

6.5

0.66

57 in·lb

19. Regulator/Rectifier (United State and Canada models)
20. Regulator/Rectifier (other than United State and Canada models)
L: Apply a non-permanent locking agent.
G: Apply grease.
EO: Apply engine oil.
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
Si: Apply silicone grease.
WL: Apply a soap and water solution or rubber lubricant.

L

L

16-6 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-7

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Water temperature switch

7.8

0.80

69 in·lb

2

Radiator fan switch

18

1.8

13

3

Radiator fan bolts

8.3

0.85

74 in·lb

4

Water temperature sensor

18

1.8

13

SS

5

Oil pressure switch

15

1.5

11

SS

6

Oil pressure switch terminal screw

1.5

0.15

13 in·lb

G

7. Inlet air temperature sensor
8. Oil pressure light delay unit
9. DFI main relay
10. Turn signal control relay
11. Starter Relay
12. Horn
13. Electronic control unit
14. Junction Box
15. Vehicle-down sensor
16. Atmospheric pressure sensor
17. Inlet air pressure sensor
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

SS

16-8 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-9

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

Remarks

1

Starter lockout switch screw

1.2

0.12

10 in·lb

2

Front brake light switch screw

1.2

0.12

10 in·lb

3

Side stand switch mounting bolt

8.8

0.90

78 in·lb

L

4

Fuel level sensor mounting bolts

6.9

0.70

61 in·lb

L

5

Fuel pump mounting bolts

9.8

1.0

87 in·lb

S

6

Starter motor mounting bolts

11

1.1

95 in·lb

7

Starter motor assembly bolts

4.9

0.50

43 in·lb

8

Starter motor terminal nut

4.9

0.50

43 in·lb

9

Starter motor terminal locknut

11

1.1

95 in·lb

10. Starter relay
L: Apply a non-permanent locking agent.
S: Follow the specific tightening sequence.
R: Replacement Parts
EO: Apply engine oil.

16-10 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-11

Exploded View
No.

Fastener

Torque
N·m

kgf·m

ft·lb

1

Headlight unit bracket screws

1.0

0.10

8.7 in·lb

2

Headlight rim screws

2.9

0.30

26 in·lb

3

Turn signal light lens screws

1.0

0.10

8.7 in·lb

4

Turn signal light mounting screws

6.9

0.70

61 in·lb

5

Tail/brake light mounting nuts

5.9

0.60

52 in·lb

6

Tail/brake light lens screws

1.2

0.12

10 in·lb

7

Tail/brake light assembly screws

1.2

0.12

10 in·lb

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.

Remarks
L

16-12 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
Rear brake light switch timing
Engine oil pressure switch resistance
Radiator fan switch resistance
Rising temperature
Falling temperature

Water temperature switch resistance
Rising temperature
Falling temperature

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 (0.24 in.) or more
1.9 ∼ 2.9 Ω
18 ∼ 28 kΩ
208 V or more
192 V or more
0.8 ∼ 0.9 mm (0.031 ∼ 0.035 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
ON after about 10 mm (0.39 in.) pedal travel
When engine is stopped: ON
When engine is running: OFF
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
From OFF to ON: 113 ∼ 117°C (235 ∼ 243°F)
From ON to OFF: 108°C (226°F) ∼ temperature
less than ON temperature

○Refer to Fuel System chapter for specifications of DFI parts.

ELECTRICAL SYSTEM 16-13

Special Tools
Spark Plug Wrench, Hex 18 :
57001–1024

Attachment Jack :
57001–1398

Jack :
57001–1238

Flywheel Holder :
57001–1410

Timing Light :
57001–1241

Filler Cap Driver :
57001–1454

Hand Tester :
57001–1394

Kawasaki Bond (Silicone Sealant) :
56019–120

16-14 ELECTRICAL SYSTEM

Wiring Diagram (United States and Canada)

ELECTRICAL SYSTEM 16-15

Wiring Diagram (United States and Canada)

16-16 ELECTRICAL SYSTEM

Wiring Diagram (Australia)

ELECTRICAL SYSTEM 16-17

Wiring Diagram (Australia)

16-18 ELECTRICAL SYSTEM

Wiring Diagram (Other than United States, Canada and Australia)

ELECTRICAL SYSTEM 16-19

Wiring Diagram (Other than United States, Canada and Australia)

16-20 ELECTRICAL SYSTEM

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 [E]


Spark Plugs [A]

ISC Valve #2 (Rear Cylinder) [B]

Inlet Air Temperature Sensor [C]

ISC Valve #1 (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]


ELECTRICAL SYSTEM 16-21

Electrical Parts Location
Atmospheric Pressure Sensor [A]

Ignition Coil [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/Rectifier [F]

Regulator/Rectifier [G] (US and Canada Models)

Alternator [H]

Crankshaft Sensors [I]

Sidestand Switch [J]

Speed Sensor [A]

Engine Ground Terminal [B]

Neutral Switch [C]

Oil Pressure Switch [D] 

Regulator/Rectifier [E] (except US and Canada Models)


16-22 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 wind­
ings.
○Take care not to short the leads that are directly con­
nected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they 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 op­
eration.
○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 16-23

Servicing Precautions

○Electrical Connectors

Female Connectors [A]

Male Connectors [B]

16-24 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. Re­
place the wire or the wiring harness [B] if necessary.

ELECTRICAL SYSTEM 16-25

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 Con­
trol Unit).
Never reverse the connections of the battery, this
could damage the ECU.
off the ignition switch.
• Turn
the seats (see Frame chapter).
• Remove
• Disconnect:

Connectors [A]


•

Battery (–) Lead Connector [B]

Remove:

Bolts [C]

Battery Holder [D]


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.
the battery [C] out of the case.
• Pull
Clean
using a solution of baking soda and wa­
• ter. Bethesurebattery
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 connec­
tions, causing damage to electrical and DFI parts.

16-26 ELECTRICAL SYSTEM

Battery
the battery holder [A] on the battery.
• Put
Tighten
• Connect:
the bolts securely.
• Connectors [B]


•

Battery (–) Lead Connector [C]

Install the seats (see Frame chapter).

Electrolyte Filling

sure that the model name [A] of the electrolyte con­
• Make
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name for VN1600-A1 ∼ : FTZ16-BS

CAUTION
Be sure to use the electrolyte container with the
same model name as the battery since the elec­
trolyte volume and specific gravity vary with the
battery type. This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora­
tion of the battery performance.
to see that there is no peeling, tears or holes in the
• Check
seal sheet on the top of the battery.
the battery on a level surface.
• Place
Remove
the seal sheet [A].
•

CAUTION

Do not remove the seal sheet sealing the filler ports
[B] until just before use.

NOTE

○A battery whose seal sheet has any peeling, tears, or
holes, requires a refreshing charge (initial charge).

the electrolyte container out of the plastic bag.
• Take
Detach
the seal cap [A] from the container.
•

NOTE

○Do not discard the seal cap because it is used as the
battery plugs later.

○Do not peel back or pierce the seals [B] on the container.

ELECTRICAL SYSTEM 16-27

Battery
the electrolyte container upside down aligning the
• Place
six seals with the six battery filler ports.
the container down strongly enough to break the
• Push
seals. Now the electrolyte should start to flow into the
battery.

NOTE

○Do not tilt the container as the electrolyte flow may be
interrupted.

sure air bubbles [A] are coming up from all six filler
• Make
ports.

○Leave the container this way for 5 minutes or longer.
NOTE

○If no air bubbles are coming up from a filler port, tap [B]
the bottom of the container two or three times. Never
remove the container from the battery.
CAUTION

Fill the electrolyte into the battery until the con­
tainer is completely emptied.
certain that all the electrolyte has flowed out.
• Be
Tap
the bottom the same way as above if there is any
• electrolyte
left in the container.
Now
pull
the
gently out of the battery.
• Let the batterycontainer
sit
for
20
During this time, the
• electrolyte permeates the minutes.
special separators and the gas

•

generated by chemical reaction is released.
Fit the seal cap [A] tightly into the filler ports until the seal
cap is at the same level as the top of the battery.

NOTE

○Do not hammer. Press down evenly with both hands.
WARNING
Once you installed the seal cap after filling the bat­
tery, never remove it, nor add any water or elec­
trolyte.

16-28 ELECTRICAL SYSTEM

Battery
Initial Charge
While a sealed battery can be used after only filling with electrolyte, a battery may not be able to
sufficiently move a starter motor to start an engine in the cases shown in the table below, where an
initial charge is required before use. However, if a battery shows a terminal voltage of 12.6 V or more,
using a digital volt meter, after 10 minutes of filling, no initial charge is necessary.

NOTE

○To measure battery terminal voltage, use a digital voltmeter which can be read one decimal place
voltage.

Condition requiring initial charge
At low temperature (lower than 0°C)
Battery has been stored under high temperature and humidity.
Seal sheet has been removed, or broken – peeling, tear or hole.
Battery two or more years old from date of manufacture.
Battery manufacturing date is printed on battery top.
Example)
12
10
99
T1
Day
Month Year
Mfg. location

Charging method
1.8 A × 2 ∼ 3 hours

1.8 A × 15 ∼ 20 hours

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 re­
moved. Give a refresh charge once a month during storage.
4) Battery life:
If the battery will not start the engine even after several refresh charges, the battery has ex­
ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob­
lem).

WARNING
Keep the battery away from sparks and open flames during charging, since the battery

gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,

connect the battery to the charger before turning on the charger.

This procedure prevents sparks at the battery terminals which could ignite any battery

gases.

No fire should be drawn near the battery, or no terminals should have the tightening loos­

ened.

The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If

touched, wash it off with liberal amount of water. Get medial attention if severe.


ELECTRICAL SYSTEM 16-29

Battery
Interchange
The sealed battery can fully display its performance only when combined with a proper vehicle elec­
tric 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 voltmeter [A].

the seats (see Frame chapter).
• Remove
Di
sconnect
the battery terminals.
•

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 re­
quired, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
12.6 V or more
Standard:

Refreshing Charge

the battery [A] (see this chapter).
• Remove
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.

16-30 ELECTRICAL SYSTEM

Battery
Terminal Voltage: 11.5 ∼ less than 12.6 V
Standard Charge 1.8 A × 5 ∼ 10 h (see following chart)
9A×1h
Quick Charge

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

Charging Method: 1.8 A × 20 h 


NOTE

○Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min­
utes, 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 16-31

Charging System
Alternator Outer Cover Removal

• Remove:

Left Front Footboard [A] (see Crankshaft/Transmission

chapter)

Rear Shift Pedal [B] (see Crankshaft/Transmission

chapter)

Front Shift Pedal [C] (see 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 Crankshaft/Transmis-

sion chapter)

Left Front Footboad (see Crankshaft/Transmission

chapter)


Alternator Cover Removal/Installation

• Remove:

Left Front
•
•

Footboad (see Crankshaft/Transmission

chapter)

Rear Shift Pedal (see Crankshaft/Transmission chapter)

Front Sift Pedal (see Crankshaft/Transmission chapter)

Remove the alternator outer cover (see Alternator Outer

Cover Removal).

Disconnect the crankshaft sensor lead connector [A] and

alternator lead connector [B].


16-32 ELECTRICAL SYSTEM

Charging System

• Remove:

Alternator Cover Bolts [A]

Bracket [B]

Alternator Cover [C]


and replace the gasket with a new one.
• Discard
Apply
silicone
sealant to the area [A] to the crankshaft
• sensor wire grommet
[B].

Stator Lead Grommet [C]

Sealant - Kawasaki Bond (Silicone Sealant): 56019–120

• Tighten the cover bolts.

Torque - Alternator Cover Bolts: 11 N·m (1.1 kgf·m, 95 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.

Alternator Inner Cover Removal

the engine oil (see Engine Lubrication System
• Drain
chapter).
the jack [A] and the attachment jack [B], raise the
• Using
front and rear wheels just off the ground.
Frame Pipe Rib [C]
Special Tools - Jack: 57001-1238
Attachment Jack: 57001-1398

• Remove:
Fuel Tank (see Fuel System chapter)
•
•

Alternator Outer Cover and Alternator Cover (see this

chapter)

Alternator Lead Connectors

Loosen the front and rear exhaust pipe holder nuts, and
both chamber bolts.
Support the front part of the engine bottom [D], using a
commercially available jack [E].

ELECTRICAL SYSTEM 16-33

Charging System
the front engine mounting bolt [A].
• Remove
Loosen
the
rear engine mounting bolt [B].
•

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.
the bolts [C] and take off the alternator inner
• Unscrew
cover [D].

Alternator Inner Cover Installation

the gasket with a new one.
• Replace
Install
the
alternator inner cover.
•

Torque - Alternator Inner Cover Bolts: 11 N·m (1.1 kgf·m,
95 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.

Alternator Rotor Removal

the alternator cover (see Alternator Cover Re• Remove
moval/Installation).
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

Alternator Rotor Installation

the alternator rotor [A] while fitting the alignment
• Install
notch [B] of the splines onto the alignment tooth [C].

16-34 ELECTRICAL SYSTEM

Charging System
molybdenum disulfide oil to the threads of the alter­
• Apply
nator rotor bolt.

○The molybdenum disulfide oil is a mixture of engine 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)

• Install:

Alternator Cover (see Alternator Cover Removal/Instal-

lation)


Alternator Outside Stator Removal

the alternator cover [A] (see Alternator Cover
• Remove
Removal/Installation).
the crankshaft sensors [B] (see Crankshaft Sen­
• Remove
sor Removal).
the Allen bolts [C] and take the stator [D] off the
• Unscrew
alternator cover.

ELECTRICAL SYSTEM 16-35

Charging System
Alternator Outside Stator Installation

the stator with the BK leads on the alternator cover
• Install
[A].
Non-permanent Locking Agent -

Alternator Stator Bolts

Torque - Alternator Stator Bolts: 13 N·m (1.3 kgf·m, 113
in·lb)

the crankshaft sensors as shown.

• Install
Crankshaft Sensor [B] with shorter leads (BK and BK/Y)

for #1 (front)

Crankshaft Sensor [C] with longer leads (BK/W and

BK/R) for #2 (rear)

Torque - Crankshaft Sensor Screws: 2.9 N·m (0.30 N·m, 26
in·lb)

○Run the shorter crankshaft sensor leads over the alterna­

tor leads, and the longer crankshaft sensor leads over the
shorter crankshaft sensor leads.
Non-permanent Locking Agent -

Stator Lead Holder Screw

Crankshaft Sensor Lead Holder Bolt

Torque - Stator Lead Holder Screw: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Crankshaft Sensor Lead Holder Bolt: 2.9 N·m
(0.30 kgf·m, 26 in·lb)

silicone sealant to all the sides of the grommets as
• Apply
shown, and fit the grommets into the notch of the alterna­

tor cover.
○First, install the grommet [D] of the alternator leads, and
then the grommet [E] of the crankshaft sensor leads with
the round mark [F] up.
Pull [G] the alternator leads [H] and crankshaft sensor
leads [I] outside the alternator cover, and reduce the
slack of leads as possible in the cover in order to pre­
vent contact with the rotor.
Apply silicone sealant to the mating surface [J] of the
grommet.
Connect the outside alternator connector (BK leads) to
the connector (Y leads) of the regulator/rectifire.

•
•
•

Alternator Inside Stator Removal

• Remove:

Alternator Rotor (see Alternator Rotor Removal)

•

Alternator Inner Cover (see Alternator Inner Cover Re­

moval)

Unscrew the inside stator holder bolts [A] and take the

inside stator [B] and holder [C] off the left crankcase.


16-36 ELECTRICAL SYSTEM

Charging System
Alternator Inside Stator Installation

the inside stator with the BK leads on the left
• Install
crankcase.
Non-permanent Locking Agent -

Inside Stator Holder

Bolts

Torque - Inside Stator Holder Bolts: 11 N·m (1.1 kgf·m, 95
in·lb)

silicone sealant to the grommet and fit it into the
• Apply
notch of the alternator inner cover.
the inside alternator connector (BK leads) to the
• Connect
connector (Y/BK leads) of the regulator/rectifier.

Charging Voltage Inspection

the battery condition.
• Check
up the engine to obtain actual alternator operating
• Warm
conditions.
the seats (see Frame chapter).
• Remove
Check
that
the ignition switch is turned off, and connect
• the hand tester
to the battery as shown in the table.
Special Tool - Hand Tester: 57001–1394
Battery Charging Voltage
Tester

Connections

Reading

Range

Tester (+) to

Tester (–) to

@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 head­
light unit). The readings should show nearly battery volt­
age 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 discon­
nect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the output voltage is much higher than the values spec­
ified 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.

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 leav­
ing it near an electromagnetic field, or just by aging, will re­
sult in low output.

ELECTRICAL SYSTEM 16-37

Charging System
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
250 V AC

Connections
Tester (+) to
Tester (–) to
Another black
One black
lead
lead

Reading
@3 000 rpm
60 ∼ 90 V

If the output voltage shows the value in the table, the alter­
nator operates properly and the regulator/rectifier is dam­
aged. 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
Another black
One black
lead
lead

Reading
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.

•

16-38 ELECTRICAL SYSTEM

Charging System
Regulator/Rectifier Removal
US and Canada Models:
Remove:

Alternator Cover (see Alternator Cover Removal)

Regulator/Rectifier Lead Connectors [A]


•

• Remove:

Regulator/Rectifier Bolts [A]

Regulator/Rectifiers [B]


Except US and Canada Models:
Remove:

Alternator Cover (see Alternator Cover Removal)

Regulator/Rectifier Lead Connectors [A]


•

Front Side:
Remove:

Regulator/Rectifier Bolts [A]

Regulator/Rectifier [B]


•

Rear Side:
Remove:

Regulator/Rectifier Cover Bolts [A]

Regulator/Rectifier Cover [B]


•

ELECTRICAL SYSTEM 16-39

Charging System

• Remove:

Regulator/Rectifier Bolts [A]

Regulator/Rectifier [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)

Rectifier Inspection

the alternator outer cover (see Alternator Outer
• Remove
Cover Removal).
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 speak­
ing, the lower reading should be from zero to one half
the scale.

Rectifier Circuit Inspection
No.
1
2
3
4
5
6
7
8
9
10
11
12

Connections
Tester (+) to
Tester (–) to
BK1
BK/BL
BK2
BK3
BK1
BK2
BK3
BK/BL

BK/W

Reading
∞

BK/W
BK1
BK2
BK3
BK1
BK2
BK3

Tester
Range

1/2 scale

∞

• Repeat the test for another regulator/rectifier.

× 10 Ω
or
× 100 Ω

16-40 ELECTRICAL SYSTEM

Charging System
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.
the 1st step regulator circuit test.
•○Do
Connect the test light and the 12 V battery to the regulator/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 dam­
aged. 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 mo­
mentarily to the BK/R terminal, the regurator/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 16-41

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
8. Main Fuse 30 A
9. Starter Relay
10. Load

16-42 ELECTRICAL SYSTEM

Ignition System

ELECTRICAL SYSTEM 16-43

Ignition System
WARNING
The ignition system produces extremely high volt­
age. 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

• Remove:

Fuel Tank (see Fuel System (DFI) chapter)

Clamps [A]

Primary Leads

Ignition Coil Mounting Nuts [B]

Frame Ground Lead [C] (Left Side)

Ignition Coil [D] (Left Side)


• Remove:

Clamps [A]

Primary Leads

Ignition Coil Mounting Nuts [B]

Ignition Coil [C] (Right Side)


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 left ignition coil.

16-44 ELECTRICAL SYSTEM

Ignition System
Ignition Coil Inspection

the ignition coils (see this chapter).
• Remove
Measure
the arcing distance with a commercially avail­
• able coil tester
[A] to check the condition of the ignition

•

coil [B].
Connect the ignition coil (with the spark plug cap left at­
tached at the end of the spark plug terminal) to the tester
in the manner prescribed by the manufacturer and mea­
sure the arcing distance.
3 Needle Arcing Distance
Standard:
6 mm (0.24 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 counter­
clockwise.
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.
Spark Plug Removal

the spark plug caps.
• Remove
Remove
the
• wrench. spark plugs using the 18 mm (0.71 in.) plug
Special Tool - Spark Plug Wrench, Hex 18: 57001-1024

ELECTRICAL SYSTEM 16-45

Ignition System
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

to Spark Plug Cleaning/Inspection in Periodic Main­
• Refer
tenance chapter.

Ignition Coil Primary Peak Voltage
NOTE

○Be sure the battery is fully charged.

the fuel tank (see Fuel System chapter).
• Remove
Remove
all the spark plug caps but do not remove the
• spark plugs.
new spark plugs into all the spark plug caps, and
• Install
ground them onto the engine.
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.
Recommended Tool: Peak Voltage Adapter

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

16-46 ELECTRICAL SYSTEM

Ignition System
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
the ignition switch and the engine stop switch ON.
• Turn
Pushing the starter button, turn the engine 4 ∼ 5 seconds
• with
the transmission in neutral to measure the primary

•

peak voltage.
Repeat the measurements 5 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)
Crankshaft Sensors (see Crankshaft Sensor Inspection)
If the ignition coils and crankshaft sensors are normal,
check the ECU (see Fuel System chapter).

Crankshaft Sensor Removal

the alternator cover [A] (see Alternator Cover
• Remove
Removal).
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 Alternator Stator Installation in this chapter.
Crankshaft Sensor Inspection

the alternator outer cover (see Alternator Outer
• Remove
Cover Removal).
all the spark plug caps but do not remove the
• Remove
spark plugs.
• Disconnect the crankshaft sensor lead connector [A].

ELECTRICAL SYSTEM 16-47

Ignition System
a commercially available peak voltage adapter
• Connect
[A] to the hand tester [B].
Recommended Tool: Peak Voltage Adapter

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

NOTE

○Be sure the battery is fully charged.

•
•
•
•

Hand Tester Range:

DC 10 V

Turn the ignition switch and the engine stop switch ON.
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 crank­
shaft 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 Fuel System
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.

16-48 ELECTRICAL SYSTEM

Ignition System
the hand tester [A] to the × 100 Ω range and wire it to
• Set
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.

Ignition Timing Inspection

the alternator outer cover (see Alternator Outer
• Remove
Cover Removal).
• Remove the timing inspection plug.
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).
If the crankshaft sensor are normal, check the ECU (see
Fuel System chapter).

ELECTRICAL SYSTEM 16-49

Ignition System
Interlock Operation Inspection

• Remove:

Right Side Cover (see Frame chapter)

○Do not disconnect the connectors.

1st Check
Measure the terminal voltage of the R/W lead in the junc­
tion 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

4 V or more 

Standard:

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
Using a stand, raise the rear wheel off the ground.
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 posi­
tion switch, starter lockout switch, side stand switch and
junction box.
If their parts are normality, replace the ECU.

16-50 ELECTRICAL SYSTEM

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 Fuel System chapter for ECU Inspection.
○

ELECTRICAL SYSTEM 16-51

Ignition System

16-52 ELECTRICAL SYSTEM

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
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

ELECTRICAL SYSTEM 16-53

Starter Motor
Starter Motor Removal

the bracket bolts [A] and take off the regula• Unscrew
tor/rectifier [B] with its bracket [C].

• Remove:

Starter Motor Bolts [A]


the starter motor [A] toward the left.
• Pull
Remove:

• Starter Motor Terminal Nut [B] and Cable


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.

16-54 ELECTRICAL SYSTEM

Starter Motor
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,
95 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).
• Remove
Take
off
the
starter motor assembly bolts [A] and remove
• both end covers
[B] and pull the armature out of the yoke.

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].

ELECTRICAL SYSTEM 16-55

Starter Motor
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].

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.
•

16-56 ELECTRICAL SYSTEM

Starter Motor

○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.)

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 commu­
tator 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 resis­
tance 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

ELECTRICAL SYSTEM 16-57

Starter Motor
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 mo­
tor 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.

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 Frame chapter).
• Remove
Remove
the
reserve tank, then the starter relay.
• Connect the coolant
hand
tester
• starter relay [C] as shown.[A] and 12 V battery [B] to the
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

16-58 ELECTRICAL SYSTEM

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

ELECTRICAL SYSTEM 16-59

Lighting System
This model adopts the daylight system and has a head­
light 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

the horizontal adjuster [A] on the headlight with a
• Turn
screwdriver in or out until the beam points straight ahead.

○Turn the adjuster clockwise to face the headlight to the
left.

Headlight Beam Vertical Adjustment

the vertical adjuster [A] in the headlight in or out with
• Turn
a screwdriver to adjust the headlight vertically.

○Turn the adjuster clockwise to face the headlight up.

NOTE

○ON high beam, the brightest points should be slightly

below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an­
gle according to local regulations.
○For US model, the proper angle is 0.4 degrees below
horizontal. This is 50 mm (2 in.) drop at 7.6 m (25
ft.) measured from the center of the headlight with the
motorcycle on its wheels and the rider seated.
50 mm (2 in.) [A]

Center of Brightest Spot [B]

7.6 m (25 ft.) [C] 


Headlight Bulb Replacement

• Remove the headlight rim screws [A] on both sides.

16-60 ELECTRICAL SYSTEM

Lighting System
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.

• 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
Fit
the
dust
[A] with the TOP mark [B] upward onto
• the bulb [C]cover
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 this chap­
• After
ter).

ELECTRICAL SYSTEM 16-61

Lighting System
Headlight Body Removal

the headlight rim screws [A].
• 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].


City Light Bulb Replacement (other than US, CA and
AU)
US: United States model

CA: Canada model

AU: Australia model

the headlight unit (see this chapter).
• Remove
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].

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.

16-62 ELECTRICAL SYSTEM

Lighting System
Tail/Brake Light Bulb Replacement

the screws [A] in the taillight lens.
• Unscrew
Pull
the
lens
[B] off.
•

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 Lense Screws: 1.2 N·m (0.12
kgf·m, 10 in·lb)

ELECTRICAL SYSTEM 16-63

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
13. Joint Connector
14. Dimmer Switch
15. Starter Relay

16. Main Fuse 30A
17. Battery
18. Running Position Lights
(US and Canada Models)
19. City Light (Other than
US, Canada and Aus­
tralia Models)

16-64 ELECTRICAL SYSTEM

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
the
side cover (see Frame chapter).
• Remove the right
coolant
reserve tank bolts and hanging the
• reserve tank.
the turn signal control relay [A].
• Remove
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 ter­
minals.
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

Tester

Connection

Reading

Turn Signal Control Relay

1 – 8

←→ Distance Sensor

3 – 7

Turn Signal Control Relay

2 – 11

←→ Left Handlebar Switch

0 Ω

3 – 9
4 – 10

Turn Signal Control Relay
←→ Battery

6 –

Battery Voltage

Battery (+)

with IG. SW. ON
0 V with IG.SW.
OFF

IG. SW.: Ignition Switch
If any one of the hand tester readings shows an improper
values, check the wiring and connections of the turn sig­
nal switch, distance sensor, and turn signal control relay.
Check the turn signal control relay (see Turn Signal Con­
trol Relay Inspection) if all of them turn out good.

ELECTRICAL SYSTEM 16-65

Automatic Turn Signal Canceling System
Distance Sensor Inspection

the right side cover (see this chapter).
• Remove
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.
•
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 nor­
mal.
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 as­
sembly.

Turn Signal Switch Inspection

the headlight housing.
• Open
Unplug
the 9-pin connectors that leads to the left handle­
• 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 disas­
sembled 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

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.
the right side cover (see Frame chapter).
• Remove
Remove
the coolant reserve tank bolts and hanging the
• reserve tank.

16-66 ELECTRICAL SYSTEM

Automatic Turn Signal Canceling System
one 12 V battery and turn signal lights as indi­
• Connect
cated in the figure, and count how many times the lights
flash for one minute.
Turn Signal Control Relay Connector [A]

Turn Signal Lights [B]

12 V Battery [C]

If the lights do not flash as specified, replace the turn sig­
nal 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 man­
ner especially for automatic turn signal canceling op­
eration not readily detectable with above checks. If all
other checks are good, replace the turn signal control
relay.

Turn Signal Light Bulb Replacement

the turn signal light lens screw [A] and take off
• Remove
the lens [B].

the bulb [A] in the socket and turn the bulb counter• Push
clockwise [B].
• Replace the bulb.

ELECTRICAL SYSTEM 16-67

Automatic Turn Signal Canceling System
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)

16-68 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
14. Joint Connector
15. Main Fuse 30 A
16. Battery

ELECTRICAL SYSTEM 16-69

Radiator Fan System
WARNING
The radiator fan is connected directly to the bat­
tery. 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

Disconnect the leads from the radiator fan switch [A].
• Using
• leads. an auxiliary lead [B], connect the radiator fan switch
If the fan rotates, inspect the fan switch.
If the fan does not rotate, inspect the following.
Leads and Connectors
Main Fuse 30 A and Fan Fuse 10 A
Fan Motor

Fan Motor Inspection

Disconnect the leads [A] from the radiator fan switch [B].
• Using
an auxiliary lead [C], supply battery power to the
• fan motor.
If the fan does not rotate, the fan motor is defective and
must be replaced.
Battery [D]

Radiator Fan Circuit

1. Radiator Fan
2. Radiator Fan Switch

3. Junction Box
4. Fan Fuse 10 A

5. Main Fuse 30 A
6. Battery

16-70 ELECTRICAL SYSTEM

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

Oil Pressure Light Delay Unit Removal

the right side cover (see Frame chapter).
• Remove
Remove
the coolant reserve tank bolts and hanging the
• reserve tank.
the connectors out of the oil pressure light delay unit
• Pull
[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).
If the warning LED light is not lit, check the warning LED
light and wiring (see Meter Unit Inspection).
If the LED light and wiring are good, replace the oil pres­
sure light delay unit [F].

6. Battery
7. Oil Pressure Switch
8. Meter Unit
9. Oil Pressure Warning LED Light

ELECTRICAL SYSTEM 16-71

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.
Measure
this
delay time from grounding of the switch lead
• 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.

16-72 ELECTRICAL SYSTEM

Meter, Gauge
Meter Unit Removal

• Remove:

Bolts [A] and Washers

Nuts [B]

Meter Cover [C]


• 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]


• Pull out the meter unit [A] from the pins [B] on the bracket.
CAUTION

Never drop the meter unit, especially on a hard sur­
face. Such a shock to the unit can damage it. Place
the speedometer so that the face is up. If the me­
ter is left upside down or sideways for any length
of time, it will malfunction.

ELECTRICAL SYSTEM 16-73

Meter, Gauge
Meter Unit Installation

• Install:

Meter Unit [A]


Damper [B] (Outside Diameter: 22 mm (0.87 in.))

Damper [C] (Outside Diameter: 16 mm (0.63 in.))

Bracket [D]

Damper [E] (Outside Diameter: 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).
• Remove
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.

16-74 ELECTRICAL SYSTEM

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.

ELECTRICAL SYSTEM 16-75

Meter, Gauge
Meter Unit Inspection
LCD Segment Inspection:
Remove the meter unit (see Meter Unit Removal).
[A] Meter Unit Lead Connector

•

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.
[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 Illumi­

nation (–)
[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.

16-76 ELECTRICAL SYSTEM

Meter, Gauge
Check 2 :
Using the auxiliary lead, connect the battery positive ter­
minal to terminal [8].
Verify that all the LCD segments (the letters and num­
bers 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 se­
lected.
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 Seg­
ment 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.

ELECTRICAL SYSTEM 16-77

Meter, Gauge
the mode button [A] to CLOCK.
• Push
Push
reset button [B] more than 2 seconds, then the
• displaytheturns
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.

16-78 ELECTRICAL SYSTEM

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 Seg­
ment Inspection, check 2.
Connect the oscillator [A] to the terminal [11]. The vehi­
cle 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.
○Use the jack and the attachment jack to lift the rear wheel.
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 volt­
age are normal, replace the meter unit.

ELECTRICAL SYSTEM 16-79

Meter, Gauge
Speed Sensor Power Supply Voltage Inspection:
Connect the leads in the same circuit as for the LCD Seg­
ment Inspection, Check 2.
Set the hand tester [A] to DC25 V, check the voltage be­
tween 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 seg­
ment 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 re­
sistance value of the variable rheostat.
○When terminal [12] is connected, one segment should ap­
pear 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.

16-80 ELECTRICAL SYSTEM

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 sym­

bol [B] in the LCD should go on.
If the LED light and/or symbol do not go on, replace the
meter unit.

ELECTRICAL SYSTEM 16-81

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
Connections:
Battery Negative Lead (–) to Terminal [4]

LED

Light

○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.

Indicator Light Inspection

the leads in the same circuit as for the LCD Seg­
• Connect
ments Inspection, Check 2.

16-82 ELECTRICAL SYSTEM

Meter, Gauge
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.

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.

ELECTRICAL SYSTEM 16-83

Meter, Gauge
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.

16-84 ELECTRICAL SYSTEM

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

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

ELECTRICAL SYSTEM 16-85

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.
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 Switches and Sen­
sors section). Replace the switch if damaged.
If the warning LED light is not lit, check the warning LED
light and wiring.

16-86 ELECTRICAL SYSTEM

Switch and Sensors
Fuel Level Sensor Inspection

• Remove:

Fuel Tank (see 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 Tool - Hand Tester: 57001-1394

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)

ELECTRICAL SYSTEM 16-87

Switch and Sensors
Fuel Reserve Switch Inspection
the fuel tank with fuel.
• Fill
Close
the fuel tank cap surely.
• Remove:

• Seats (see Frame chapter)


•

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.


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)

Connect
(12 V 3.4 W bulb in a socket with

• leads) andthethetest12light
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 Re­

moval)

Speed Sensor Lead Connector [A]

Band [B]

Bolt [C]

Speed Sensor [D]


16-88 ELECTRICAL SYSTEM

Switch and Sensors
Speed Sensor Installation

grease to the O-ring [A] on the speed sensor.
• Apply
Tighten:
•
Non-permanent Locking Agent -

Speed Sensor Mounting Bolt


Torque - Speed Sensor Mounting Bolt: 9.8 N·m (1.0 kgf·m,
87 in·lb)

Speed Sensor Inspection

• Remove:

Speed Sensor (see Speed Sensor Removal)

Connect
speed sensor connector [A] with a battery

• [B], 10 kΩtheresistor
[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 Front Brake Light Switch Inspection in the
• Refer
Periodic Maintenance chapter.

Rear Brake Light Switch Check/Adjustment

to the Rear Brake Light Switch Check/Adjustment
• Refer
in the Periodic Maintenance chapter.

Radiator Fan Switch Removal
CAUTION
Never drop the fan switch, especially on a hard sur­
face. Such a shock to the part can damage it.
the coolant (see Cooling System chapter).
• Drain
Disconnect
fan switch leads.
• Unscrew thetheradiator
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 Filling in the Cooling System chapter).

ELECTRICAL SYSTEM 16-89

Switch and Sensors
Radiator Fan Switch Inspection

the fan switch from the radiator (see Radiator
• Remove
Fan Switch Removal).
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 con­
tainer 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 tem­
peratures 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 al­
lowed to fall on a hard surface. Such a shock to the
part can damage it.
the coolant (see Cooling System chapter).
• Drain
Disconnect
switch connector.
• Remove thethe
water
temperature switch [A] from the radia­
• tor.

Water Temperature Switch Installation

silicone sealant to the threads of the water temper­
• Apply
ature switch.
Sealant - Kawasaki Bond: 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
• Fill
cooling system (see Coolant Filling in the Cooling System
chapter).

16-90 ELECTRICAL SYSTEM

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 con­
tainer 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 tem­
peratures 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

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
Rear Brake Light Switch Connections

ELECTRICAL SYSTEM 16-91

Switch and Sensors
Side Stand Switch Connections

Neutral Switch Connections

Oil Pressure Switch Connections*

*: Engine lubrication system is in good condition

16-92 ELECTRICAL SYSTEM

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 Frame chapter).
• Remove
Remove
junction box.
• Pull off thetheconnectors
the junction box.
• Make sure all connectorfrom
terminals
• none of them have been bent. are clean and tight, and

•

Clean the dirty terminals, and straighten slightly-bent ter­
minals.
Check conductivity of the numbered terminals with the
hand tester (see Junction Box Internal Circuit).
If the tester does not read as specified, replace the junc­
tion 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).
If the tester does not read as specified, replace the junc­
tion box.

Tester Reading (Ω)
∞
∞
∞
∞
∞
∞

ELECTRICAL SYSTEM 16-93

Junction Box
Relay Circuit Inspection (with the battery disconnected)

Headlight
Relay

Tester
Connection
7 – 8
7 – 13
(+)
(–)
13 – 9

Tester
Reading (Ω)
∞
∞

Starter
Circuit
Relay

Not ∞*

(*): 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)

9 – 13
11 – 12

7 – 8
(+)

(–)

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
Check
conductivity
following pairs of terminals (see
• Junction Box Internalof the
Circuit).
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.

Tester
Connection
9 – 11
12 – 13
(+)
(–)
13 – 11
(+)
(–)
12 – 11

Tester
Reading (Ω)
∞
∞
∞
Not ∞*

16-94 ELECTRICAL SYSTEM

Junction Box
Junction Box Internal Circuit

A. Accessory Fuse 10 A
B. Fan Fuse 10 A
Fan Fuse 15 A (After
Frame No. 010353)
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

ELECTRICAL SYSTEM 16-95

Fuse
Main Fuse Removal

the right side cover (see Frame chapter).
• Remove
Remove
the coolant reserve tank bolts and hanging the
• reserve tank.
the starter relay [A].
• Remove
Pull
out
the
• nose pliers.main fuse [B] from the starter relay with needle

Junction Box Fuse Removal

the right side cover (see Frame chapter).
• Remove
Unlock
the
to lift up the lid [A].
• Pull the fuseshook
[B]
• dle nose pliers. straight out of the junction box with nee­

Fuse Installation

•

If a fuse fails during operation, inspect the electrical sys­
tem to determine the cause, and then replace it with a
new fuse of proper amperage.
Install the junction box fuses on the original position as
specified on the lid.

Fuse Inspection

the fuse (see Fuse Removal).
• Remove
Inspect
the
element.
• If it is downfuse
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 volt­
age 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 rat­
ing will soon blow again.

APPENDIX 17-1


Appendix

Table of Contents
Cable, Wire, and Hose Routing ..............................................................................................
Troubleshooting Guide (except DFI) ......................................................................................

17-2

17-28

17

17-2 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-3

Cable, Wire, and Hose Routing
F: Front
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. -10 ∼ +10 mm (-0.4 ∼ +0.4 in.)
14. Two Way Holders on the black type of hoses [3]
15. Welded Clamps
16. 10 ∼ 30 mm (0.4 ∼ 1.2 in.)
17. Clips
18. Fuel Tank Breather Hose (except California)
19. Marking (Position here.)
20. Run the hose [18] between the bracket and the right frame pipe.
21. Holder
22. Swingarm Pivot
23. Cross Pipe
24. Run the hose in front of [22] and [23].
25. Clamp
26. Coolant Reserve Tank Overflow Hose

17-4 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-5

Cable, Wire, and Hose Routing

F: Front
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 base [9]
11. Throttle Sensor
12. White Marks faced up­
wards
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
21. Clamp
22. Radiator Inlet Hose
23. Rear Coolant Hose (mark
[12])
24. Front Coolant Hose
(mark [12])
25. Reserve Tank Hose
(without mark)
26. Throttle Cables	 (upper:
decelerator, lower: accel­
erator)

27. Plastic Clamp: Align the
clamp with the mark [12].
28. Rear	 Oil Hose into the
cover [36]
29. Canister Purge Hose
(green) for California
30. Air Suction Valve
31. Front Vacuum Switch
Valve Hose
32. Rear Vacuum Switch
Valve Hose
33. Crankcase Breather
Hose over the valve [35]
34. Wire Clamps:	 Face the
tab as shown.
35. Vacuum Switch Valve
36. Rear Rocker Case Cover
37. Vacuum Hose to throttle
body

17-6 APPENDIX

Cable, Wire, and Hose Routing

F: Front
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 (middle)
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. Wire Clamp
14. Clamp
15. Crankcase Breather Hose
16. Wire Clamp
17. Vacuum Switch Valve
18. Front Cylinder Head
19. Elbow Joint

APPENDIX 17-7

Cable, Wire, and Hose Routing

F: Front
20. Front Oil Hose
21. Right Air Cleaner Base
22. Radiator Outlet Hose (right)
23. Rear Cylinder Head
24. Water Temperature Sensor (DFI)
25. Align the mark [26] with the clamp end.
26. White Marks on the hoses [3] and [9]
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 base
[21]
37. Note each position and direction of the
clamp bolts.

17-8 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-9

Cable, Wire, and Hose Routing
F: Front
←: Air Flow
1. Top
2. Locate the glued joint of the gasket [3] within the angle.
3. Gasket
4. Right Air Cleaner Cover Allen Bolt
5. Clamp (lead [6])
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. Blue Mark on Top
16. ISC Valve #2 (rear cylinder)
17. ISC Valve #1 (front cylinder)
18. ISC Valve Hose #2 (red mark)
19. ISC Valve Hose #1 (blue mark)
20. ISC Valve #2 G/Y, W/R Leads
21. ISC Valve #1 G/BL, W/R Leads

17-10 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-11

Cable, Wire, and Hose Routing
F: Front R: 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 [21] inside the rocker case cover.
21. ISC Valve Lead, Inlet Air Temperature Sensor Leads
22. Vacuum Switch Valve Hoes
23. Grommet
24. Right Air Cleaner Base
25. Strap
26. Fuel Pump Outlet Pipe
27. Pressure Regulator
28. Throttle Cables

17-12 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-13

Cable, Wire, and Hose Routing
F: Front
1. Rear View
2. Rear Fender
3. Grommets
4. Five Clamps
5. Rear Fender Harness
6. Plastic Cover
7. Run the harness [5] into the cut of plastic cover [6]
8. Connector for [9] and [10]
9. License Plate Light
10. Tail/Brake Light
11. Snap-on Strap
12. White Mark of [5] (position here.)
13. Rear Left Turn Signal Light
14. Rear Right Turn Signal Light
15. Bracket
16. Connector of [13] (the female plug is fitted into [15].)
17. Connector of [14] (the female plug is fitted into [15].)
18. Press by hands: Clamp the harness [5] with these clamps [4] and press each end of clamps by
hands against the rear fender.

17-14 APPENDIX

Cable, Wire, and Hose Routing

F: Front
Connect the following connectors in the
order numbered and locate them as
shown.
1. Front Regulator/Rectifier Connector
2. Inside Alternator Connector
3. Crankshaft Sensor Connector
4. Oil Pressure Switch/Neutral Switch Con­
nector
5. Speed Sensor Connector
6. 10. Outside Alternator Connector

7. 1. Rear Regulator/Rectifier Connector
8. Sidestand Switch Connector
9. Starter Motor Lead
10. Speed Sensor
11. Strap (speed sensor lead)
12. Insert the	 oil pressure/neutral switch
leads, sidestand switch leads, and regulator/rectifier leads in this order between
the alternator cover and the clutch slave
cylinder.

APPENDIX 17-15

Cable, Wire, and Hose Routing

F: Front T: Top
1. Ignition Switch Connec­
tor: Push the lock to dis­
connect. Join the con­
nector 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 hose [16] be­
tween the pump [5] and
the pipe [3].
7. Fuel Tank Breather Hose
(except California)
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 discon­
nect.

17-16 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 17-17

Cable, Wire, and Hose Routing
F: Front
←→: 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. Decelerator Cable
23. Accelerator Cable
24. Position the white marks here.
25. Cable Clip
26. Stake the cable clip [25] on the holder [14].
27. Rubble Plug (except California)

17-18 APPENDIX

Cable, Wire, and Hose Routing

F: Front
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 [16] as
shown.
12. Clevis

13. Rear Brake Reservoir Cover
14. Downtube
15. Swingarm
16. Cotter Pin
17. Rear Brake Disc

17-20 APPENDIX

Cable, Wire, and Hose Routing

F: Front
1. Throttle Body Assy
2. Decelerator Cable
3. Accelerator Cable
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 harness [13].

APPENDIX 17-21

Cable, Wire, and Hose Routing

F: Front L: Left
1. Left	 Handlebar Switch
Connectors
2. Accessory Lead Connec­
tors
3. Headlight Body
4. Front	 Turn Signal Light
Lead Connectors (left)
5. Front	 Turn Signal Light
Lead Connectors (right)
6. Main Harness
7. Right Handlebar	 Switch
Connectors

8. Clutch Hose
9. Run the throttle cables in­
side the clutch hose [8].
10. Run the throttle cables in­
side the cover [11].
11. Head Pipe Cover
12. Plastic Snap-on Clamps:
Fit them into the frame
pipe.
13. Put the clutch hose	 [8]
into the hole of the cover
[1].
14. Water Baffle Plats

15. Fuel	 Tank Water Drain
Hose
16. Horn Leads
17. Choke Cable
19. Horn
20. Starter Motor
21. Front Regulator/Rectifier
22. White Mark	 (Position it
here.)
23 Clutch Hose Clamp on al­
ternator cover (with white
mark [22] outside)

17-22 APPENDIX

Cable, Wire, and Hose Routing

F: Front
24. Sidestand Switch Leads:
Run the leads through
the front and rear hooks
and hold them with the
clamp [11] a bit tight
behind the sidestand
bracket.
25. Welded Clamp
26. Left Frame Pipe
27. Electric Starter 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 pri­
mary lead connector as
shown.

32. Main Harness
33. Strap (main harness
[32] and California purge
hose-green)
34. Rear Turn Signal/Taillight
Lead Connector
35. Sealed Battery

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 Hoes Joint
8. Run the hose [3] 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

F: Front
1. Main Harness: Run it into the headlight
body and inside the brake hose [3].
2. Throttle Cables
3. Front Brake Hose
4. Rear Brake Light Switch Connector (BR,
BL leads, under the connector [5])
5. Radiator	 Fan Connector (BK/Y, Y/W,
BR/W lead, over the connector [4])
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. Injector #2 Connector (rear)
11. Water Temperature Sensor Connector
(thermostat housing)
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 (+) Terminal
32. White Tape: Align it with the grommet
33. Starter Motor Lead
34. Battery (–) Lead Connector
35. Fuel Pump Connector
36. ECU Connector
37. ECU Main Fuse
38. Fuel Level Sensor Connector
39. Plastic Snap-on Clamp
40. Battery Holder: Fit [35], [37], [38] and [39]
into the holder.
41. Accessory Lead Connectors (female)
42. Rear Turn Signal/Taillight Lead Connec­
tor
43. Self-Diagnossis 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 leads [45] into the holes of the
bracket.
47. Left Handlebar Switch Leads: Connect
them in the headlight body.
48. Straps
49. Right Handlebar Switch Leads

17-26 APPENDIX

Cable, Wire, and Hose Routing

F: Front
T: Top
1. Main Harness
2. Electric Starter Lead
3. Fuel	 Tank Filler Drain
Hose (Except CA.)
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 re­
serve tank)

7. To the inside of the alter­
nator outer cover
8. Through	 the alternator
outer cover to the starter
motor
9. To the engine ground
10. Crank Case
11. To the crankcase back­
ward lower clamp
12. Junction Box Leads
13. DFI Main Relay
14. Turn Signal Control Unit
15. Insert the band attached
main harness

16. Band (Fix the main har­
ness and frame joint part
only. CA 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. Vehcle-down Sensor Connector
22. Vehcle-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. Regulator/Rectifier
29. Rear Brake Light Switch

17-28 APPENDIX

Troubleshooting Guide (except DFI)
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
Difficulty:

Start,

Starting

Starter motor not rotating:
Starter lockout switch or neutral switch trou­
ble
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 (DFI) 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 be­
cause more fuel is supplied automatically
by DFI.)
No spark; spark weak:
Vehicle-down sensor (DFI) coming off
Ignition switch not ON
Engine stop switch turned off
Clutch lever not pulled in and gear not in
neutral whether sidestand up or down
Though clutch lever pulled in, sidestand up
and gear not in neutral

Battery voltage low
Spark plug dirty, broken, or gap malad­
justed
Spark plug cap or high tension wiring trou­
ble
Spark plug cap shorted or not in good con­
tact
Spark plug incorrect
IC igniter in ECU trouble
Neutral, starter lockout, or sidestand switch
trouble
Crankshaft 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 miss­
ing
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 trou­
ble
Spark plug cap shorted or not in good con­
tact

Spark plug incorrect

IC igniter in ECU trouble

Crankshaft sensor trouble

Ignition coil trouble

Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or miss­
ing

Fuel tank air vent obstructed

Throttle body assy loose


APPENDIX 17-29

Troubleshooting Guide (except DFI)
Choke knob left pulled out (DFI)

Throttle body assy O-ring damage

Air cleaner duct loose

Air cleaner O-ring damaged

Fuel pump (DFI) 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 mov­
ing 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 trou­
ble
Spark plug cap shorted or not in good con­
tact

Spark plug incorrect

IC igniter in ECU trouble

Crankshaft sensor trouble

Ignition coil trouble

Fuel/air mixture incorrect:
Choke knob left pulled out (DFI)

Air cleaner clogged, poorly sealed, or miss­

ing

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 (DFI)

Fuel tank air vent obstructed

Fuel line clogged

Fuel pump trouble (DFI)

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 mov­
ing 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 muf­
fler 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 fa­
cility to correct it)
For KLEEN, do not push-start with a dead
battery (Connect another full-charged
battery with jumper cables, and start the
engine, using the electric starter)

17-30 APPENDIX

Troubleshooting Guide (except DFI)
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 igni­
tion 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 sec­
ondary 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 (except DFI)
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 bro­
ken)
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 exces­
sive
Connecting rod big end clearance exces­
sive
Piston ring worn, broken, or stuck
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con­
nection
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 muf­
fler 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 ex­
cessive
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 dam­
aged

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 (DFI)

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 (except DFI)
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade­
quate

Steering stem bent

Tire air pressure too low

Handlebar shakes or excessively vibrates:
Tire worn
Swingarm 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 mas­
ter 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

2003

VN1600-A1

2004

VN1600-A2

Beginning Frame No.
JKBVNKA1□3A000001 or
JKBVNT60AAA000001
JKBVNKA1□4A009001 or
JKBVNT60AAA009001

□:This digit in the frame number changes from one machine to another.

Part No.99924-1309-02

Printed in Japan



---

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