Ninja 250R

Motorcycle
Service Manual
 Quick Reference Guide

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

This quick reference guide will assist

Appendix 17 j
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.
 Ninja 250R

Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/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.

© 2008 Kawasaki Heavy Industries, Ltd. First Edition (1) : Feb. 20, 2008 (K)
 LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)

COUNTRY AND AREA CODES

AT Austria WVTA WVTA Model (Full Power)
(FULL N)
CH Switzerland GB WVTA WVTA Model (Left Side Traffic Full
(FULL N) Power)
DE Germany
 Foreword
This manual is designed primarily for use by Guide shows you all of the product’s system
trained mechanics in a properly equipped shop. and assists in locating their chapters. Each
However, it contains enough detail and basic in- chapter in turn has its own comprehensive Ta-
formation to make it useful to the owner who de- ble of Contents.
sires to perform his own basic maintenance and For example, if you want ignition coil informa-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Electrical System chapter. Then, use the
dures must be understood in order to carry out Table of Contents on the first page of the chap-
maintenance and repair satisfactorily. When- ter to find the Ignition Coil section.
ever the owner has insufficient experience or Whenever you see these WARNING and
doubts his ability to do the work, all adjust- CAUTION symbols, heed their instructions!
ments, maintenance, and repair should be car- Always follow safe operating and maintenance
ried out only by qualified mechanics. practices.
In order to perform the work efficiently and
WARNING
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures This warning symbol identifies special
before starting work, and then do the work care- instructions or procedures which, if not
fully in a clean area. Whenever special tools or correctly followed, could result in per-
equipment are specified, do not use makeshift sonal injury, or loss of life.
tools or equipment. Precision measurements
can only be made if the proper instruments are CAUTION
used, and the use of substitute tools may ad-
This caution symbol identifies special
versely affect safe operation.
instructions or procedures which, if not
For the duration of the warranty period,
strictly observed, could result in dam-
we recommend that all repairs and scheduled
age to or destruction of equipment.
maintenance be performed in accordance with
this service manual. Any owner maintenance or This manual contains four more symbols (in
repair procedure not performed in accordance addition to WARNING and CAUTION) which will
with this manual may void the warranty. help you distinguish different types of informa-
To get the longest life out of your vehicle. tion.
• Follow the Periodic Maintenance Chart in the
Service Manual. NOTE
• Be alert for problems and non-scheduled ○This note symbol indicates points of par-
maintenance. ticular interest for more efficient and con-
• Use proper tools and genuine Kawasaki Mo- venient operation.
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing • Indicates
done.
a procedural step or work to be
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
spare parts are listed in the Parts Catalog. also precedes the text of a NOTE.
• Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
• Remember to keep complete records of main-
tenance and repair with dates and any new
tion in the procedural step or sub-step it fol-
lows.
parts installed. In most chapters an exploded view illustration
of the system components follows the Table of
How to Use This Manual Contents. In these illustrations you will find the
In this manual, the product is divided into instructions indicating which parts require spec-
its major systems and these systems make up ified tightening torque, oil, grease or a locking
the manual’s chapters. The Quick Reference agent during assembly.
 GENERAL INFORMATION 1-1

General Information
Table of Contents
1
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Unit Conversion Table ............................................................................................................ 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, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca-
ble to the negative terminal.

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
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.

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

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thor-
oughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
 GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the 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.

Apply specified grease to the lip of seal before installing

the seal.

Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Engine Rotation

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

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

Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
 GENERAL INFORMATION 1-7
Model Identification
EX250K8F Left Side View

EX250K8F Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION
General Specifications

Items EX250K8F
Dimensions
Overall Length 2 085 mm (82.09 in.)
Overall Width 715 mm (28.15 in.)
Overall Height 1 115 mm (43.90 in.)
Wheelbase 1 400 mm (55.12 in.)
Road Clearance 130 mm (5.12 in.)
Seat Height 775 mm (30.51 in.)
Dry Mass 152 kg (335.2 lb)
Curb Mass:
Front 82 kg (180.8 lb)
Rear 87 kg (191.8 lb)
Fuel Tank Capacity 17.8 L (4.7 US gal.)
Performance
Minimum Turning Radius 2.7 m (8.9 ft)
Engine
Type 4-stroke, DOHC, 2-cylinder
Cooling System Liquid-cooled
Bore and Stroke 62.0 × 41.2 mm (2.44 × 1.62 in.)
Displacement 249 cm³ (15.19 cu in.)
Compression Ratio 11.6 : 1
Maximum Horsepower 24 kW (33 PS) @11 000 r/min (rpm)
Maximum Torque 22 N·m (2.2 kgf·m, 16 ft·lb) @8 200 r/min (rpm)
Carburetion System FI (Fuel Injection) KEIHIN TTK28 × 2
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter in ECU)
Ignition Timing From 10° BTDC @1 300 r/min (rpm)
38° BTDC @6 000 r/min (rpm)
Spark Plug NGK CR8E
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
Valve Timing:
Inlet:
Open 36° BTDC
Close 56° ABDC
Duration 272°
Exhaust:
Open 61° BBDC
Close 31° ATDC
Duration 272°
 GENERAL INFORMATION 1-9
General Specifications

Items EX250K8F
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Type API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity SAE 10W-40
Capacity 1.7 L (1.8 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 3.087 (71/23)
Clutch Type Wet multi disc
Transmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.600 (39/15)
2nd 1.789 (34/19)
3rd 1.409 (31/22)
4th 1.160 (29/25)
5th 1.000 (27/27)
6th 0.893 (25/28)
Final Drive System:
Type Chain drive
Reduction Ratio 3.071 (43/14)
Overall Drive Ratio 8.466 @Top gear
Frame
Type Tubular, diamond
Caster (Rake Angle) 26°
Trail 82 mm (3.23 in.)
Front Tire:
Type Tubeless
Size 110/70 17 M/C (54S)
Rim Size 17 × 2.75
Rear Tire:
Type Tubeless
Size 130/70 17 M/C (62S)
Rim Size 17 × 3.50
Front Suspension:
Type Telescopic fork
Wheel Travel 120 mm (4.72 in.)
Rear Suspension:
Type Swingarm (uni-trak)
Wheel Travel 130 mm (5.12 in.)
1-10 GENERAL INFORMATION
General Specifications

Items EX250K8F
Brake Type:
Front Single disc
Rear Single disc
Electrical Equipment
Battery 12 V 8 Ah
Headlight:
Type Semi-sealed beam
Bulb:
High 12 V 55 W (quartz-halogen) × 2
Low 12 V 55 W (quartz-halogen)
Tail/Brake Light 12 V 5/21 W
Alternator:
Type Three-phase AC
Rated Output 23.0 A/14.0 V @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
 GENERAL INFORMATION 1-11
Unit Conversion Table
Prefixes for Units: Units of Length:
km × 0.6214 = mile
Prefix Symbol Power
m × 3.281 = ft
mega M × 1 000 000
mm × 0.03937 = in
kilo k × 1 000
centi c × 0.01
milli m × 0.001 Units of Torque:
micro µ × 0.000001 N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
Units of Mass: kgf·m × 9.807 = N·m
kg × 2.205 = lb kgf·m × 7.233 = ft·lb
g × 0.03527 = oz kgf·m × 86.80 = in·lb

Units of Volume: Units of Pressure:

L × 0.2642 = gal (US) kPa × 0.01020 = kgf/cm²
L × 0.2200 = gal (imp) kPa × 0.1450 = psi
L × 1.057 = qt (US) kPa × 0.7501 = cmHg
L × 0.8799 = qt (imp) kgf/cm² × 98.07 = kPa
L × 2.113 = pint (US) kgf/cm² × 14.22 = psi
L × 1.816 = pint (imp) cmHg × 1.333 = kPa
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp) Units of Speed:
mL × 0.06102 = cu in km/h × 0.6214 = mph

Units of Force: Units of Power:

N × 0.1020 = kg kW × 1.360 = PS
N × 0.2248 = lb kW × 1.341 = HP
kg × 9.807 = N PS × 0.7355 = kW
kg × 2.205 = lb PS × 0.9863 = HP

Units of Temperature:
 PERIODIC MAINTENANCE 2-1

Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-3
Torque and Locking Agent...................................................................................................... 2-6 2
Specifications ......................................................................................................................... 2-11
Special Tools .......................................................................................................................... 2-13
Periodic Maintenance Procedures.......................................................................................... 2-14
Fuel System (DFI)................................................................................................................ 2-14
Air Cleaner Element Cleaning........................................................................................... 2-14
Throttle Control System Inspection................................................................................... 2-14
Engine Vacuum Synchronization Inspection..................................................................... 2-15
Idle Speed Inspection ....................................................................................................... 2-18
Idle Speed Adjustment...................................................................................................... 2-18
Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-18
Cooling System.................................................................................................................... 2-19
Coolant Level Inspection................................................................................................... 2-19
Water Hose and Pipe Inspection (coolant leak, damage, installation condition) .............. 2-20
Engine Top End ................................................................................................................... 2-20
Valve Clearance Inspection .............................................................................................. 2-20
Valve Clearance Adjustment............................................................................................. 2-21
Air Suction System Damage Inspection............................................................................ 2-23
Clutch................................................................................................................................... 2-23
Clutch Operation Inspection.............................................................................................. 2-23
Wheels/Tires ........................................................................................................................ 2-24
Air Pressure Inspection..................................................................................................... 2-24
Wheel/Tire Damage Inspection......................................................................................... 2-25
Tire Tread Wear Inspection............................................................................................... 2-25
Wheel Bearing Damage Inspection .................................................................................. 2-26
Final Drive............................................................................................................................ 2-26
Drive Chain Lubrication Condition Inspection ................................................................... 2-26
Drive Chain Slack Inspection ............................................................................................ 2-27
Drive Chain Slack Adjustment .......................................................................................... 2-27
Wheel Alignment Inspection ............................................................................................. 2-28
Drive Chain Wear Inspection ............................................................................................ 2-29
Chain Guide Wear Inspection ........................................................................................... 2-29
Brakes.................................................................................................................................. 2-30
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-30
Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-30
Brake Fluid Level Inspection............................................................................................. 2-30
Brake Pad Wear Inspection .............................................................................................. 2-31
Brake Operation Inspection .............................................................................................. 2-31
Brake Light Switch Operation Inspection .......................................................................... 2-32
Suspension .......................................................................................................................... 2-32
Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-32
Front Fork Oil Leak Inspection.......................................................................................... 2-33
Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-33
Rocker Arm Operation Inspection..................................................................................... 2-33
Tie-Rod Operation Inspection ........................................................................................... 2-33
Swingarm Pivot Lubrication .............................................................................................. 2-34
Steering ............................................................................................................................... 2-34
Steering Play Inspection ................................................................................................... 2-34
Steering Play Adjustment.................................................................................................. 2-35
2-2 PERIODIC MAINTENANCE

Steering Stem Bearing Lubrication ................................................................................... 2-35

Electrical System ................................................................................................................. 2-36
Lights and Switches Operation Inspection........................................................................ 2-36
Headlight Aiming Inspection ............................................................................................. 2-38
Sidestand Switch Operation Inspection ............................................................................ 2-39
Engine Stop Switch Operation Inspection......................................................................... 2-40
Others .................................................................................................................................. 2-40
Chassis Parts Lubrication ................................................................................................. 2-40
Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-42
Replacement Parts .............................................................................................................. 2-43
Air Cleaner Element Replacement.................................................................................... 2-43
Fuel Hose Replacement ................................................................................................... 2-44
Coolant Change ................................................................................................................ 2-45
Radiator Hose and O-ring Replacement........................................................................... 2-48
Engine Oil Change............................................................................................................ 2-48
Oil Filter Replacement ...................................................................................................... 2-49
Brake Hose and Pipe Replacement.................................................................................. 2-50
Brake Fluid Change .......................................................................................................... 2-50
Master Cylinder Rubber Parts Replacement .................................................................... 2-51
Caliper Rubber Parts Replacement .................................................................................. 2-53
Spark Plug Replacement .................................................................................................. 2-54
 PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
FREQUENCY Whichever * ODOMETER READING
comes × 1 000 km
first (× 1 000 mile) See
Page
1 6 12 18 24 30 36
ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24)
Fuel System
Air cleaner element - clean • • • 2-14
Throttle control system (play, smooth return,
no drag) - inspect
year • • • • 2-14

Engine vacuum synchronization - inspect • • • 2-15

Idle speed - inspect • • • • 2-18
Fuel leak (fuel hose and pipe) - inspect year • • • • 2-18
Fuel hose and pipe damage - inspect year • • • • 2-18
Fuel hose and pipe installation condition -
inspect
year • • • • 2-18

Cooling System
Coolant level - inspect • • • • 2-19
Coolant leak (water hose and pipe) - inspect year • • • • 2-20
Water hose damage - inspect year • • • • 2-20
Water hose installation condition - inspect year • • • • 2-20
Engine Top End
Valve clearance - inspect • • • 2-20
Air suction system damage - inspect • • • 2-23
Clutch
Clutch operation (play, disengagement,
engagement) - inspect • • • • 2-23

Wheels and Tires

Tire air pressure - inspect year • • • 2-24
Wheel/tire damage - inspect • • • 2-25
Tire tread wear, abnormal wear - inspect • • • 2-25
Wheel bearing damage - inspect year • • • 2-26
Final Drive
Drive chain lubrication condition - inspect # Every 600 km (400 mile) 2-26
Drive chain slack - inspect # Every 1 000 km (600 mile) 2-27
Drive chain wear - inspect # • • • 2-29
Chain guide wear - inspect • • • 2-29
Brakes
Brake fluid leak (brake hose and pipe) -
inspect
year • • • • • • • 2-30

Brake hose and pipe damage - inspect year • • • • • • • 2-30

Brake hose installation condition - inspect year • • • • • • • 2-30
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart

FREQUENCY Whichever * ODOMETER READING

comes × 1 000 km
first (× 1 000 mile) See
Page
1 6 12 18 24 30 36
ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24)
6
Brake fluid level - inspect
months • • • • • • • 2-30

Brake pad wear - inspect # • • • • • • 2-31

Brake operation (effectiveness, play, no
drag) - inspect
year • • • • • • • 2-31

Brake light switch operation - inspect • • • • • • • 2-32

Suspension
Front forks/rear shock absorber operation
(damping and smooth stroke) - inspect • • • 2-32

Front forks/rear shock absorber oil leak -

inspect
year • • • 2-33

Rocker arm operation - inspect • • • 2-33

Tie-rods operation - inspect • • • 2-33
Swingarm pivot - lubricate • 2-34
Steering
Steering play - inspect year • • • • 2-34
Steering stem bearings - lubricate 2 years • 2-35
Electrical System
Lights and switches operation - inspect year • • • 2-36
Headlight aiming - inspect year • • • 2-38
Sidestand switch operation - inspect year • • • 2-39
Engine stop switch operation - inspect year • • • 2-40
Others
Chassis parts - lubricate year • • • 2-40
Bolts and nuts tightness - inspect • • • • 2-42
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
 PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever * ODOMETER READING
comes × 1 000 km
first (× 1 000 mile) See
Page
1 12 24 36 48
ITEM Every (0.6) (7.5) (15) (24) (30)
Air cleaner element # - replace 2 years 2-43
Fuel hose - replace 4 years • 2-44
Coolant - change 3 years • 2-45
Radiator hose and O-ring - replace 3 years • 2-48
Engine oil # - change year • • • • • 2-48
Oil filter - replace year • • • • • 2-49
Brake hose and pipe - replace 4 years • 2-50
Brake fluid - change 2 years • • 2-50
Rubber parts of master cylinder and caliper - 2-51,
replace
4 years • 2-53
Spark plug - replace • • • • 2-54
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or silicone sealant etc.

Letters used in the "Remarks" column mean:

G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide grease oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
SS: Apply silicone sealant.

Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System (DFI)
Air Cleaner Housing Cap Bolts 2.5 0.25 22 in·lb
Air Cleaner Housing Mounting Bolts 9.8 1.0 87 in·lb
Air Cleaner Housing Screws 1.15 0.12 10 in·lb
Air Duct Clamp Screws 2.0 0.20 18 in·lb
Crankshaft Sensor Screws 3.0 0.31 27 in·lb
Delivery Pipe Assy Mounting Screws 3.4 0.35 30 in·lb
Fuel Pump Bolts 9.8 1.0 87 in·lb L
Inlet Air Temperature Sensor Screw 1.2 0.12 11 in·lb
Oxygen Sensor 44.1 4.50 32.5
Speed Sensor Bolt 7.8 0.80 69 in·lb L
Throttle Body Assy Holder Clamp Screws 2.0 0.20 18 in·lb
Water Temperature Sensor 25 2.5 18
Cooling System
Coolant Drain Bolt (Cylinder) 5.9 0.60 52 in·lb
Coolant Drain Bolt (Water Pump) 9.8 1.0 87 in·lb
Radiator Bolts 9.8 1.0 87 in·lb
Radiator Cap Bracket Bolt 9.8 1.0 87 in·lb
Radiator (Water) Hose Clamp Screws 1.5 0.15 13 in·lb
Reserve Tank Bolts 9.8 1.0 87 in·lb
Reserve Tank Bracket Bolts 9.8 1.0 87 in·lb
Reserve Tank Cap – – – Hand
-Tighten
Resistor Bolt 7.8 0.80 69 in·lb
Thermostat Cover Bolts 9.8 1.0 87 in·lb
Thermostat Housing Mounting Bolts 9.8 1.0 87 in·lb
Water Hose Fitting Bolts 9.8 1.0 87 in·lb
Water Pipe Bolts 9.8 1.0 87 in·lb
Water Pump Bolts 9.8 1.0 87 in·lb
Water Pump Cover Bolts 9.8 1.0 87 in·lb
Water Temperature Sensor 25 2.5 18
Engine Top End
Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb
 PERIODIC MAINTENANCE 2-7
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Air Switching Valve Bracket Bolts 9.8 1.0 87 in·lb
Camshaft Cap Bolts 12 1.2 106 in·lb S
Camshaft Chain Tensioner Cap Bolt 5.0 0.51 44 in·lb
Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb
Camshaft Sprocket Bolts 15 1.5 11 L
Coolant Drain Bolt (Cylinder) 5.9 0.60 52 in·lb
Cylinder Head Bolts (M8) 31.4 3.2 23.2 MO, S
Cylinder Head Bolt (M6) 12 1.2 106 in·lb S
Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
Cylinder Head Jacket Plugs 20 2.0 15 L
Exhaust Pipe Holder Nuts 12 1.2 106 in·lb
Exhaust Pipe Mounting Bolt 9.8 1.0 87 in·lb
Muffler Body Clamp Bolt 17 1.7 13
Muffler Body Mounting Bolt 30 3.1 22
Muffler Body Rear Cover Bolts 9.8 1.0 87 in·lb L
Muffler Cover Bolts 9.8 1.0 87 in·lb
Muffler Cover Clamp Bolt 9.8 1.0 87 in·lb
Muffler Cover Clamp Screw 6.9 0.70 61 in·lb
Rear Camshaft Chain Guide Bolt 17 1.7 13
Spark Plugs 13 1.3 115 in·lb
Throttle Body Assy Holder Clamp Screws 2.0 0.20 18 in·lb
Clutch
Clutch Cover Bolts 9.8 1.0 87 in·lb
Clutch Hub Nut 132 13.5 97.4
Clutch Lever Clamp Bolt 8.8 0.90 78 in·lb
Clutch Spring Bolts 8.8 0.90 78 in·lb
Oil Filler Plug – – – Hand
-Tighten
Engine Lubrication System
Crankcase Oil Passage Plug 15 1.5 11
Engine Oil Drain Bolt (Crankcase) 19.6 2.0 14.5
Engine Oil Drain Bolt (Oil Screen Cover) 19.6 2.0 14.5
Oil Breather Mounting Bolts 9.8 1.0 87 in·lb L
Oil Filter Mounting Bolt 19.6 2.0 14.5
Oil Hose Banjo Bolts 19.6 2.0 14.5
Oil Passage Plugs 20 2.0 15 L
Oil Pipe Banjo Bolt 12 1.2 106 in·lb
Oil Pressure Relief Valve 15 1.5 11 L
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb G
Oil Pump Mounting Bolts 9.8 1.0 87 in·lb L
Oil Screen Cover Bolts 9.8 1.0 87 in·lb
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Engine Removal/Installation
Engine Mounting Bracket Bolts and Nuts 69 7.0 51
Engine Mounting Nuts 69 7.0 51
Crankshaft/Transmission
Connecting Rod Big End Nuts 27.5 2.8 20 MO
Crankcase Bolts (M8, L = 90 mm) 24 2.4 18 MO, S
Crankcase Bolts (M8, L = 73 mm) 19 1.9 14 MO, S
Crankcase Bolts (M6) 12 1.2 106 in·lb
Neutral Switch 15 1.5 11
Oil Breather Mounting Bolts 9.8 1.0 87 in·lb L
Shift Drum Bearing Holder Bolts 12 1.2 106 in·lb L
Shift Drum Pin Plate Bolt 9.0 0.92 80 in·lb L
Shift Drum Positioning Bolt 24.5 2.5 18
Shift Lever Bolt 12 1.2 106 in·lb
Shift Pedal Mounting Bolt 25 2.5 18
Shift Shaft Return Spring Pin 19.6 2.0 14.5 L
Starter Motor Clutch Bolts 34.3 3.5 25 L
Tie-Rod Locknuts 7.0 0.71 62 in·lb
Wheels/Tires
Front Axle Nut 88 9.0 65
Rear Axle Nut 98 10.0 72.3
Final Drive
Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb
Engine Sprocket Nut 127 13.0 93.7 MO
Rear Axle Nut 98 10.0 72.3
Rear Sprocket Nuts 59 6.0 44
Speed Sensor Mounting Bracket Bolts 9.8 1.0 87 in·lb L
Brakes
Bleed Valves 5.5 0.56 49 in·lb L
Brake Hose Banjo Bolts 25 2.5 18
Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si
Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
Brake Pedal Bolt 8.8 0.90 78 in·lb
Front Brake Disc Mounting Bolts 27 2.8 20 L
Front Brake Light Switch Screw 1.2 0.12 11 in·lb
Front Brake Pad Pins 17.2 1.8 13
Front Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
Front Caliper Holder Pin Bolt 17.2 1.8 13 Si
Front Caliper Mounting Bolts 25 2.5 18
Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Rear Brake Disc Mounting Bolts 27 2.8 20 L
Rear Brake Pad Pins 17.2 1.8 13
Rear Caliper Holder Pin Bolt 17.2 1.8 13 Si
 PERIODIC MAINTENANCE 2-9
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Rear Caliper Mounting Bolts 25 2.5 18
Rear Master Cylinder Mounting Bolts 25 2.5 18
Rear Master Cylinder Push Rod Locknut 17.2 1.8 13
Suspension
Front Fork Bottom Allen Bolts 20 2.0 15 L
Lower Front Fork Clamp Bolts 30 3.1 22
Rear Shock Absorber Nuts 59 6.0 44
Swingarm Pivot Shaft Nut 98 10.0 72.3
Tie-Rod Nuts 59 6.0 44
Uni-Trak Rocker Arm Nut 59 6.0 44
Upper Front Fork Clamp Bolts 20 2.0 15
Steering
Handlebar Mounting Bolts 25 2.5 18
Lower Front Fork Clamp Bolts 30 3.1 22
Steering Stem Head Bolt 44 4.5 32
Steering Stem Nut 4.9 0.50 43 in·lb
Switch Housing Screws 3.5 0.36 31 in·lb
Upper Front Fork Clamp Bolts 20 2.0 15
Frame
Front Footpeg Bracket Bolts 25 2.5 18
Rear Footpeg Bracket Bolts 25 2.5 18
Sidestand Nut 39 4.0 29
Sidestand Switch Bolt 8.8 0.90 78 in·lb L
Windshield Mounting Bolts 0.42 0.043 3.7 in·lb
Electrical System
Alternator Cover Bolts 9.8 1.0 87 in·lb
Alternator Rotor Bolt 88.2 9.0 65 S
Crankshaft Sensor Screws 3.0 0.31 27 in·lb
Front Brake Light Switch Screw 1.2 0.12 11 in·lb
Fuel Pump Bolts 9.8 1.0 87 in·lb L
License Plate Light Cover Screws 0.90 0.092 8.0 in·lb
License Plate Light Mounting Screws 1.2 0.12 11 in·lb
Neutral Switch 15 1.5 11
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb G
Oxygen Sensor 44.1 4.50 32.5
Plugs (Alternator Cover) – – – Hand
-Tighten
Regulator/Rectifier Bolts 9.8 1.0 87 in·lb
Resistor Bolt 7.8 0.80 69 in·lb
Sidestand Switch Bolt 8.8 0.90 78 in·lb L
Spark Plugs 13 1.3 115 in·lb
Speed Sensor Bolt 7.8 0.80 69 in·lb L
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent

Torque
Fastener Remarks
N·m kgf·m ft·lb
Starter Motor Cable Terminal Nut 9.8 1.0 87 in·lb
Starter Motor Clutch Bolts 34.3 3.5 25 L
Starter Motor Mounting Bolts 9.8 1.0 87 in·lb
Starter Motor Terminal Locknut 6.9 0.70 61 in·lb
Starter Motor Through Bolts 3.4 0.35 30 in·lb
Starter Relay Cable Terminal Nuts 5.0 0.51 44 in·lb
Stator Coil Bolts 12 1.2 106 in·lb
Switch Housing Screws 3.5 0.36 31 in·lb
Tail/Brake Light Mounting Bolts 5.9 0.60 52 in·lb
Water Temperature Sensor 25 2.5 18

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads Diameter Torque
(mm) N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240
 PERIODIC MAINTENANCE 2-11
Specifications

Item Standard Service Limit

Fuel System (DFI)
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –
Idle Speed 1 300 ±50 r/min (rpm) – – –
Throttle Body Vacuum 24.0 ±1.33 kPa (180 ±10 mmHg) at idle
– – –
speed
Bypass Screws (Turn Out) 0 ∼ 2 1/2 (for reference) – – –
Air Cleaner Element Polyurethane foam – – –
Cooling System
Coolant:
Type (Recommended) Permanent type of antifreeze – – –
Color Green – – –
Mixed Ratio Soft water 50%, Coolant 50% – – –
Freezing Point –35°C (–31°F) – – –
Total Amount 1.5 L (1.6 US qt) – – –
Engine Top End
Valve Clearance:
Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.) – – –
Inlet 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) – – –
Clutch
Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –
Engine Lubrication System
Engine Oil:
Type API SE, SF or SG – – –
API SH, SJ or SL with JASO MA
Viscosity SAE 10W-40 – – –
Capacity 1.3 L (1.4 US qt) (when filter is not – – –
removed)
1.6 L (1.7 US qt) (when filter is removed) – – –
1.7 L (1.8 US qt) (when engine is – – –
completely dry)
Level Between upper and lower level lines – – –
(Wait 2 ∼ 3 minutes after idling or running)
Wheels/Tires
Tread Depth:
Front:
IRC 4.2 mm (0.17 in.) 1 mm (0.04 in.),
BRIDGESTONE 4.6 mm (0.18 in.) (AT, CH, DE)
1.6 mm (0.06 in.)
DUNLOP 4.5 mm (0.18 in.)
Rear:
IRC 6.5 mm (0.26 in.) Up to 130 km/h (80 mph):
BRIDGESTONE 7.0 mm (0.28 in.) 2 mm (0.08 in.),
Over 130 km/h (80 mph):
DUNLOP 7.4 mm (0.29 in.)
3 mm (0.12 in.)
2-12 PERIODIC MAINTENANCE
Specifications

Item Standard Service Limit

Air Pressure (when Cold):
Front Up to 170 kg (375 lb) load: – – –
200 kPa (2.00 kgf/cm², 28 psi)
Rear Up to 170 kg (375 lb) load: – – –
225 kPa (2.25 kgf/cm², 32 psi)
Final Drive
Drive Chain Slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – –
Drive Chain Wear (20-link 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)
Length)
Standard Chain:
Make ENUMA – – –
Type EK520SR-O2 – – –
Link 106 links – – –
Brakes
Brake Fluid:
Grade DOT4 – – –
Brake Pad Lining
Thickness:
Front 4.5 mm (0.18 in.) 1 mm (0.04 in.)
Rear 4.5 mm (0.18 in.) 1 mm (0.04 in.)
Brake Light Timing:
Front Pulled ON – – –
Rear ON after about 10 mm (0.39 in.) of pedal – – –
travel
Electrical System
Spark Plug:
Type NGK CR8E – – –
Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) – – –
 PERIODIC MAINTENANCE 2-13
Special Tools
Inside Circlip Pliers: Filler Cap Driver:
57001-143 57001-1454

Steering Stem Nut Wrench: Throttle Sensor Setting Adapter:

57001-1100 57001-1538

Jack: Extension Tube:

57001-1238 57001-1578

Vacuum Gauge: Jack Attachment:

57001-1369 57001-1608
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System (DFI)
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 muddily roads, the ele-
ment should be cleaned immediately.

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.

• Remove the element [A] (see Air Cleaner Element Re-

placement).
WARNING
Clean the element in a well-ventilated area, and
make sure that there are no sparks or flame any-
where near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or a low-flash point solvent to
clean the element.

• Clean the element in a bath of high-flash point solvent,

and then dry it with compressed air or by shaking it.
• After cleaning, saturate a clean, lint-free towel with SE,
SF, or SG class SAE 30 oil and apply the oil to the element
by tapping the element outside with the towel.
• Visually check the element for tears or breaks.
• If the element has any tears or breaks, replace the ele-
ment.
Throttle Control System Inspection
• Check that the throttle grip [A] moves smoothly from full
open to close, and the throttle closes quickly and com-
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
• Check the throttle grip free play [B].
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
 PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
If the free play is incorrect, adjust the throttle cable as
follows.
• Loosen the locknut [A].
• Turn the adjuster [B] until the proper amount of free play
can be obtained.
• Tighten the locknut against the adjuster securely.

If the throttle grip free play can not be adjusted with the
adjuster, use the adjusters in the lower ends of the throttle
cables.
• Remove:
Left Side Cover (see Side Cover Removal in the Frame
chapter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Turn out both upper nuts [A] and turn in both lower nuts [B]
as far as they will go so as to give the throttle grip plenty
of play.
• With the throttle grip completely closed, turn out the lower
nut and turn in the upper nut of the decelerator cable [C]
until the inner cable just becomes tight.
• Turn out the lower nut and turn in the upper nut of the
accelerator cable [D] until the correct free play is obtained.

• Check that the throttle linkage lever [A] stops against the
adjusting screw [B] with the throttle grip closed.

Engine Vacuum Synchronization Inspection

NOTE
○These procedures are explained on the assumption that
the inlet and exhaust systems of the engine are in good
condition.

• Situate the motorcycle so that it is vertical.

• System (DFI)
Remove the fuel tank (see Fuel Tank Removal in the Fuel
chapter).
• Pull
body.
off the rubber caps [A] from the fittings of each throttle
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• Pull off the air switching valve hose [A] from the air cleaner
housing.
• Plug the air switching valve hose end and air cleaner
housing fitting.

• Connect a vacuum gauge (special tool) and hoses [A] to

the fittings on the throttle body.
Special Tool - Vacuum Gauge: 57001-1369
• Connect a highly accurate tachometer [B] to one of the
stick coil primary leads.

• Remove the fuel hose (see Fuel Hose Replacement).

• Fuel Pump
Connect the following parts temporary.
Lead Connector [A]
Extension Tube [B]
Special Tool - Extension Tube: 57001-1578

• Start the engine and warm it up thoroughly.

• [A]. the idle speed, using a highly accurate tachometer
Check

Idle Speed
Standard: 1 300 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it with
the adjusting screw (see Idle Speed Adjustment).
CAUTION
Do not measure the idle speed by the tachometer of
the meter unit.

• While idling the engine, inspect the throttle body vacuum,

using the vacuum gauge [B].
Throttle Body Vacuum
Standard: 24.0 ±1.33 kPa (180 ±10 mmHg) at idle speed

If any one vacuum is not within the specification, turn in

the bypass screws until it seats fully but not tightly.
CAUTION
Do not over tighten them. They could be damaged,
requiring replacement.
 PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures

• Turn out the bypass screw of the higher vacuum between

#1 [A] and #2 [B] to the lower vacuum.
• Open and close the throttle valves after each measure-
ment and adjust the idle speed as necessary.
• Inspect the vacuums as before.
If both vacuums are within the specification, finish the en-
gine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
remove the bypass screws #1, #2 and clean them.

• Remove:
Bypass Screw [A]
Spring [B]
Washer [C]
O-ring [D]
• Check the bypass screw and its hole for carbon deposits.
If any carbons accumulate, wipe the carbons off from the
bypass screw and the hole, using a cotton pad penetrated
with a high-flash point solvent.
• Replace the O-ring with a new one.
• Check the tapered portion [E] of the bypass screw for
wear or damage.
If the bypass screw is worn or damaged, replace it.
• Turn in the bypass screw until it seats fully but not tightly.

• Repeat the same procedure for other bypass screw.

• Repeat the synchronization.
If the vacuums are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:
Digital Meter (+) → R (sensor Y/W) lead
Digital Meter (–) → W (sensor BR/BK) lead

Standard: DC 1.020 ∼ 1.050 V at idle throttle opening

If the output voltage is out of the standard, check the in-
put voltage of the main throttle sensor (see Main Throttle
Sensor Input Voltage Inspection in the Fuel System (DFI)
chapter).
• Remove the vacuum gauge hoses and install the rubber
caps on the original position.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• [A]. engine idling, turn the handlebar to both sides
With the

If handlebar movement changes the idle speed, the

throttle cables may be improperly adjusted or incorrectly
routed or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition.

• Check the idle speed.

Idle Speed
Standard: 1 300 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it.
Idle Speed Adjustment
• Start the engine and warm it up thoroughly.
•○Open andadjusting
Turn the screw [A] until the idle speed is correct.
close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

Fuel Hose Inspection (fuel leak, damage,

installation condition)
○If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re-
moval in the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.

• Check that the hose is routed according to Cable, Wire,

and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Hose Joints [A]
Fuel Hose [B]
 PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures

•○Check that the hose joints are securely connected.

Push and pull [A] the hose joint [B] back and forth more
than two times, and make sure it is locked and does not
come off.
Fuel Pump Side [C]
Throttle Body Assy Side [D]
WARNING
Make sure the hose joint is installed correctly on the
fuel supply pipe or the fuel could leak.
If it comes off, reinstall the hose joint.

Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambi-
ent temperature).

• Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the side-
stand.).
If the coolant level is lower than the "L" level line [B], un-
screw the reserve tank cap and add coolant to the "F"
level line [C].
"L": low
"F": full
CAUTION
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the 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.
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Water Hose and Pipe Inspection (coolant leak,
damage, installation condition)
○The high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.
• Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
• Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator (Water) Hose Clamp Screws: 1.5 N·m
(0.15 kgf·m, 13 in·lb)

Engine Top End

Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).

• Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Plugs [A] [B]
Special Tool - Filler Cap Driver: 57001-1454

•○Check the valve clearance when the pistons are at TDC.

The pistons are numbered beginning with the engine left
side.
• Using a wrench on the alternator rotor bolt, turn the crank-
shaft counterclockwise until the "2T" mark [A] on the al-
ternator rotor is aligned with the projection [B] in the in-
spection window on the alternator cover.

○Measure the valve clearance of the valves for which the

cam [A] are turned away from each other.
 PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures

• Using the thickness gauge [A], measure the valve clear-

ance between the cam and the valve lifter.
Valve Clearance
Standard:
Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)
Inlet 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

○Each piston has two inlet and two exhaust valves. Mea-
sure these two inlet or exhaust valves at the same crank-
shaft position.
Valve Clearance Measuring Position
#1 Piston TDC at End of Compression Stroke:
Inlet Valve Clearances of #1 Piston
Exhaust Valve Clearances of #1 Piston

NOTE
○Check the valve clearance using this method only.
Checking the clearance at any other cam position may
result in improper valve clearance.

Valve Clearance Measuring Position

#2 Piston TDC at End of Compression Stroke:
Inlet Valve Clearances of #2 Piston
Exhaust Valve Clearances of #2 Piston
If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.
Valve Clearance Adjustment
• To change the valve clearance, remove the camshaft
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.
NOTE
○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.

• Clean the shim to remove any dust or oil.

• Select a new
Measure the thickness of the removed shim [A].
• a + b – c = dshim thickness calculation as follows.
[a] Present Shim Thickness
[b] Measured Valve Clearance
[c] Specified Valve Clearance (Mean Value = 0.255 mm
(Exhaust), 0.195 mm (Inlet))
[d] Replace Shim Thickness
Example (Inlet):
2.90 + 0.45 – 0.195 = 3.155 mm
○Exchange the shim for the 3.175 size shim.
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Adjustment Shims
Thickness Part Number Mark
2.50 92180-1014 50
2.55 92180-1016 55
2.60 92180-1018 60
2.65 92180-1020 65
2.675 92180-1174 68
2.70 92180-1022 70
2.725 92180-1175 73
2.75 92180-1024 75
2.775 92180-1176 78
2.80 92180-1026 80
2.825 92180-1177 83
2.85 92180-1028 85
2.875 92180-1178 88
2.90 92180-1030 90
2.925 92180-1179 93
2.95 92180-1032 95
2.975 92180-1180 98
3.00 92180-1034 00
3.025 92180-1181 03
3.05 92180-1036 05
3.075 92180-1182 08
3.10 92180-1038 10
3.125 92180-1183 13
3.15 92180-1040 15
3.175 92180-1184 18
3.20 92180-1042 20
3.25 92180-1044 25
3.30 92180-1046 30
3.35 92180-1048 35
3.40 92180-1050 40
3.45 92180-1052 45
3.50 92180-1054 50
 PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
CAUTION
Be sure to remeasure the clearance after selecting a
shim. If the clearance is out of the specified range,
use the additional shim.
○If there is no valve clearance, use a shim that is a few
sizes smaller, and remeasure the valve clearance.
• When installing the shim, face the marked side toward the
valve lifter. At this time, apply engine oil to the shim or
the valve lifter to keep the shim in place during camshaft
installation.
CAUTION
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex-
tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.

• Apply molybdenum disulfide oil solution to the valve lifter

surface and install the lifter.
• Install the camshaft (see Camshaft Installation in the En-
gine Top End chapter).
• Recheck the valve clearance and readjust if necessary.
• Install the removed parts (see appropriate chapters).
Air Suction System Damage Inspection
• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank Bolts (see Fuel Tank Removal in the Fuel Sys-
tem (DFI) chapter)
• Pull the air switching valve hose [A] out of the air cleaner
housing.
• Start the engine and run it at idle speed.
• Plug the air switching valve hose end with your finger and
feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical Sys-
tem chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).

Clutch
Clutch Operation Inspection
• Pull
[A].
the clutch lever just enough to take up the free play

• Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.

• Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B]

of threads are visible.

• Remove the right lower fairing (see Lower Fairing Re-

moval in the Frame chapter).
• Slide the dust cover [A] at the clutch cable lower end out
of place.
• Loosen both adjusting nuts [B] at the clutch cover as far
as they will go.
• Pull the clutch outer cable [C] tight and tighten the adjust-
ing nuts against the cable holder [D].
• Slip the dust cover back onto place.
• correct.
Turn the adjuster at the clutch lever until the free play is

WARNING
Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into place later, creating enough cable
play to prevent clutch disengagement.

• After the adjustment, start the engine and check that the
clutch does not slip and that it releases properly.

Wheels/Tires
Air Pressure Inspection
• Remove the air valve cap.
• [A] when the
Measure tire air pressure with an air pressure gauge
the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
• Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front: Up to 170 kg (375 lb) load:
200 kPa (2.00 kgf/cm², 28 psi)
Rear: Up to 170 kg (375 lb) load:
225 kPa (2.25 kgf/cm², 32 psi)
 PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
Wheel/Tire Damage Inspection
• Remove any imbedded stones [A] or other foreign parti-
cles [B] from tread.
• Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate inter-
nal damage, requiring tire replacement.
• Visually inspect the wheel for cracks, cuts and dents dam-
age.
If any damage is found, replace the wheel if necessary.

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more sus-
ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
• Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).

Tread Depth
Standard:
Front:
IRC 4.2 mm (0.17 in.)
BRIDGESTONE 4.6 mm (0.18 in.)
DUNLOP 4.5 mm (0.18 in.)
Rear:
IRC 6.5 mm (0.26 in.)
BRIDGESTONE 7.0 mm (0.28 in.)
DUNLOP 7.4 mm (0.29 in.)
Service Limit:
Front 1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)
Rear 2 mm (0.08 in.)
(Up to 130 km/h (80 mph))
3 mm (0.12 in.)
(Over 130 km/h (80 mph))

WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, in-
flated to the standard pressure.

NOTE
○Most countries may have their own regulations a mini-
mum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wheel Bearing Damage Inspection
• Raise the front wheel off the ground with the jack (see
Front Wheel Removal in the Wheels/Tires chapter).
• Turn the handlebar all the way to the right or left.
• ing and the
Inspect roughness of the front wheel bearing by push-
pulling [A] the wheel.
• Spin [B] the front wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).

• Raise the rear wheel off the ground with the stand (see
Rear Wheel Removal in the Wheels/Tires chapter).
• Inspect the roughness of the rear wheel bearing by push-
ing and pulling [A] the wheel.
• Spin [B] the rear wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Re-
moval, Hub Bearing Inspection in the Wheels/Tires chap-
ter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).

Final Drive
Drive Chain Lubrication Condition Inspection
• IfSAE
a special lubricant is not available, a heavy oil such as
90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
• If the chain appears especially dirty, clean it before lubri-
cation.
CAUTION
The O-rings between the side plates seal in the lu-
bricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubri-
cant, observe the following rules.
Use only kerosene or diesel oil for cleaning of the O
-ring of the drive chain. Any other cleaning solution
such as gasoline or trichloroethylene will cause de-
terioration and swelling of the O-ring. Immediately
blow the chain dry with compressed air after clean-
ing. Complete cleaning and drying the chain within
10 minutes.
 PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures

• Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings. Apply the oil to the O-rings so
that the O-rings will be coated with oil.
• Wipe off any excess oil.
Oil Applied Areas [A]
O-rings [B]

Drive Chain Slack Inspection

NOTE
○Check the slack with the motorcycle setting on its side-
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.

• Check
tion).
the wheel alignment (see Wheel Alignment Inspec-

• Rotate the rear wheel to find the position where the chain
is tightest.
• Measure the vertical movement (chain slack) [A] midway
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard: 20 ∼ 30 mm (0.8 ∼ 1.2 in.)

Drive Chain Slack Adjustment

• Remove the cotter pin [A], and loosen the axle nut [B].
• If the chain both
Loosen the chain adjuster locknuts [C].
is too loose, turn out the left and right chain
adjusters [D] evenly.
If the chain is too tight, turn in the left and right chain
adjusters evenly, and kick the wheel forward.
• Turn both chain adjusters evenly until the drive chain has
the correct amount of slack. To keep the chain and wheel
properly aligned, the notch [E] on the right wheel align-
ment indicator [F] should align with the same swingarm
mark or position [G] that the left indicator notch aligns
with.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.

• Tighten both chain adjuster locknuts securely.

• Tighten:
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
• Turn the wheel, measure the chain slack again at the tight-
est position, and readjust if necessary.
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• 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°.
○Loosen once and tighten again when the slot goes past
the nearest hole.

• Bend the cotter pin [A] over the nut.

WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.

Wheel Alignment Inspection

• Check that the notch [A] on the left alignment indicator [B]
aligns with the same swingarm mark or position [C] that
the right alignment indicator notch aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).
NOTE
○Wheel alignment can be also checked using the
straightedge or string method.

WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
 PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
Drive Chain Wear Inspection
• Remove the chain cover (see Drive Chain Removal in the
Final Drive chapter).
• Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.
• Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit: 323 mm (12.7 in.)

WARNING
If the drive chain wear exceeds the service limit, re-
place the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprock-
ets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
For safely, use only the standard chain. It is an end-
less type and should not be cut for installation.

Standard Chain
Make: ENUMA
Type: EK520SR-O2
Link: 106 links

Chain Guide Wear Inspection

• Remove the swingarm (see Swingarm Removal in the
Suspension chapter).
• Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brakes
Brake Fluid Leak (Brake Hose and Pipe) Inspection
• Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A] and fittings [B].
If the brake fluid leaked from any position, inspect or re-
place the problem part.

Brake Hose and Pipe Damage and Installation

Condition Inspection
• Inspect the brake hoses and fittings for deterioration,
cracks and signs of leakage.
○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 crack [B], bulge [C] or leakage is
noticed.
Tighten any brake hose banjo bolts.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Inspect the brake hose routing.
If any brake hose routing is incorrect, run the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.
Brake Fluid Level Inspection
• Check that the brake fluid level in the front brake reservoir
[A] is above the lower level line [B].
NOTE
○Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C] in the reservoir.
 PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures

• Check that the brake fluid level in the rear brake reservoir
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
WARNING
Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that is already in the reser-
voir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

• Follow procedure below to install the rear brake fluid

reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].

Brake Pad Wear Inspection

• Remove the brake pads (see Brake Pad Removal in the
Brakes chapter).
• Check the lining thickness [A] of the pads in each caliper.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
Front 4.5 mm (0.18 in.)
Rear 4.5 mm (0.18 in.)
Service Limit: 1 mm (0.04 in.)

Brake Operation Inspection

• Inspect the operation of the front and rear brake by run-
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
WARNING
When inspecting by running the vehicle, note a
surrounding traffic situation enough in the place of
safety.
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Light Switch Operation Inspection
• Turn on the ignition switch.
• applied or light
The brake [A] should go on when the brake lever is
after the brake pedal is depressed about 10
mm (0.39 in.).

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.

If it does not go on, inspect or replace the following items.

Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Brake Light (see Tail/Brake Light Removal in the Electri-
cal System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-
spection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Suspension
Front Forks/Rear Shock Absorber Operation
Inspection
• Pump the forks down and up [A] 4 or 5 times, and inspect
the smooth stroke.
If the forks do not smoothly or noise is found, inspect the
fork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).
 PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures

• Pump the seat down and up [A] 4 or 5 times, and inspect

the smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection).

Front Fork Oil Leak Inspection

• Visually inspect the front forks [A] for oil leakage.
Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

• Visually inspect the shock absorber [A] for oil leakage.
If the oil leakage is found on it, replace the shock absorber
with a new one.

Rocker Arm Operation Inspection

• Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the rocker arm [A] does not smoothly stroke or noise
is found, inspect the fasteners and bearings (see Rocker
Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen-
sion chapter).

Tie-Rod Operation Inspection

• Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the tie-rods [A] do not smoothly stroke or noise is found,
inspect the fasteners and tie-rod bearings (see Rocker
Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen-
sion chapter).
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Swingarm Pivot Lubrication
• Remove:
Swingarm (see Swingarm Removal in the Suspension
chapter)
Sleeve [A]
• Using a high-flash point solvent, clean the old grease out
of the needle bearings [B].
• Apply plenty of grease to the inner surface of the needle
bearings.
• Apply thin coat of grease to the lips of the oil seals.
• Install the swingarm (see Swingarm Installation in the
Suspension chapter).

Steering
Steering Play Inspection
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Raise the front wheel off the ground with the jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• With the front wheel pointing straight ahead, alternately
tap each end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
• Feel for steering looseness by pushing and pulling the
forks.
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 leads and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
 PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
Steering Play Adjustment
• Loosen:
Lower Front Fork Clamp Bolts (Both Sides)
Stem Head Bolt [A]
• Adjust the steering.
Special Tool - Steering Stem Nut Wrench [B]: 57001-1100
If the steering is too tight, loosen the stem nut a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
○Turn the stem nut 1/8 turn at time maximum.
• Tighten:
Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)
Lower Front Fork Clamp Bolts: 30 N·m (3.1 kgf·m,
22 ft·lb)
• Check the steering again.
If the steering is still too tight or too loose, repeat the ad-
justment.
Steering Stem Bearing Lubrication
• Remove the steering stem (see Stem, Stem Bearing Re-
moval in the Steering chapter).
• Using a high-flash point solvent, wash the upper and
lower [A] ball bearings, and wipe the upper and lower
outer races, which are press-fitted into the frame head
pipe, clean off grease and dirt.
• Visually check the outer races and the ball bearings.
Replace them if they show wear or damage.
• Apply a light coat of grease to the upper and lower ball
bearings and outer races.
• Install the steering stem (see Stem, Stem Bearing Instal-
lation in the Steering chapter).
• Adjust the steering (see Steering Play Adjustment).
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Electrical System
Lights and Switches Operation Inspection
First Step
• Turn on the ignition switch.
• The following lights should go on according to below table.
Taillight [A] goes on
License Plate Light [B] goes on
Meter Panel Lights [C] go on
Neutral Indicator Light [D] goes on
Oil Pressure Warning Indicator Light [E] goes on
goes on
FI Indicator Light [F]
(about 2 seconds)
City Light [G] goes on
If the light does not go on, inspect or replace the following
item.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-
spection in the Electrical System chapter)
Applicable Bulb (see Wiring Diagram in the Electrical
System chapter)
Taillight Bulb (see Tail/Brake Light Bulb Replacement in
the Electrical System chapter)
License Plate Light Bulb (see License Plate Light Bulb
Replacement in the Electrical System chapter)
Meter Unit for Meter Lights (see Meter, Indicator Light
Replacement in the Electrical System chapter)
Meter Unit for Neutral Indicator Light (see Meter, Indica-
tor Light Replacement in the Electrical System chapter)
Meter Unit for Oil Pressure Warning Indicator Light (see
Meter, Indicator Light Replacement in the Electrical Sys-
tem chapter)
FI Indicator Light (see Meter, Indicator Light Replace-
ment in the Electrical System chapter)
City Light Bulb (see City Light Bulb Replacement in the
Electrical System chapter)
Oil Pressure Switch (see Switch Inspection in the Elec-
trical System chapter)
ECU (see ECU Power Supply Inspection in the Fuel Sys-
tem (DFI) chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

• Turn off the ignition switch.

• If the light
The all lights should go off.
does not go off, replace the ignition switch.
 PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
Second Step
•Turn on the turn signal switch [A] (left or right position).
•The left or right turn signal lights [B] (front and rear) ac-
cording to the switch position should flash.
•The turn signal indicator light [C] in the meter unit should
flash.
If the each light does not flash, inspect or replace the
following item.
Turn Signal Light Bulb (see Turn Signal Light Bulb Re-
placement in the Electrical System chapter)
Meter Unit for Turn Signal Indicator Light (see Meter, In-
dicator Light Replacement in the Electrical System chap-
ter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in the
Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
•Push the turn signal switch.
•The turn signal lights and indicator light should go off.
If the light does not go off, inspect or replace the following
item.
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)

Third Step
•Set the dimmer switch [A] to low beam position.
•Start the engine.
•The low beam headlight should go on.
If the low beam headlight does not go on, inspect or re-
place the following item.
Headlight Low Beam Bulb (see Headlight Bulb Replace-
ment in the Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electri-
cal System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay in Relay Box (see Relay Circuit Inspec-
tion in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• Set the dimmer switch to high beam position.

• go on.low beam [A] and high beam [B] headlights should
The

• The high beam indicator light [C] should go on.

If the high beam headlight and/or high beam indicator light
does not go on, inspect or replace the following item.
Headlight High Beam Bulb (see Headlight Bulb Replace-
ment in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
• Turn off the engine stop switch.
• The low beam and high beam headlights should stay go-
ing on.
If the headlights and high beam indicator light does go off,
inspect or replace the following item.
Headlight Relay in Relay Box (see Relay Circuit Inspec-
tion in the Electrical System chapter)
• Turn off the ignition switch.
• The headlights and high beam indicator light should go
off.

Headlight Aiming Inspection

• Inspect the headlight beam for aiming.
If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.
Headlight Beam Horizontal Adjustment
•Turn the horizontal adjuster [A] on the headlight in or out
until the beam points straight ahead.
If the headlight beam points too low or high, adjust the
vertical beam.

Headlight Beam Vertical Adjustment

•Turn the vertical adjuster [A] on the headlight in or out to
adjust the headlight vertically.

NOTE
○ON high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an-
gle according to local regulations.
 PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
Sidestand Switch Operation Inspection
• Inspect the sidestand switch [A] operation accordance to
the following table.
Sidestand Switch Operation
Gear Clutch Engine Engine
Sidestand
Position Lever Start Run
Continue
Up Neutral Released Starts
running
Continue
Up Neutral Pulled in Starts
running
Doesn’t
Up In Gear Released Stops
start
Continue
Up In Gear Pulled in Starts
running
Continue
Down Neutral Released Starts
running
Continue
Down Neutral Pulled in Starts
running
Doesn’t
Down In Gear Released Stops
start
Doesn’t
Down In Gear Pulled in Stops
start

If the sidestand switch operation does not work, inspect

or replace the following item.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the Electrical
System chapter)
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Elec-
trical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
If the all parts are good condition, replace the ECU (see
ECU Removal/Installation in the Fuel System (DFI) chap-
ter).
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Engine Stop Switch Operation Inspection
First Step
• Turn on the ignition switch.
• Set the neutral position.
• Turn the engine stop switch to stop position [A].
• Push the starter button.
• The engine does not start.
If the engine starts, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)

Second Step
•Turn on the ignition switch.
•Set the neutral position.
•Turn the engine stop switch to run position [A].
•Push the starter button and run the engine.
•Turn the engine stop switch to stop position.
•Immediately the engine should be stop.
If the engine does not stop, inspect or replace the follow-
ing item.
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
If the engine stop switch is good condition, replace the
ECU (see ECU Removal/Installation in the Fuel System
(DFI) chapter).

Others
Chassis Parts Lubrication
• Before lubricating each part, clean off any rusty spots with
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 Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
 PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cables
•Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.

• With the cable disconnected at both ends, the cable

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.
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Bolts, Nuts and Fasteners Tightness Inspection
• Check the tightness of the bolts and nuts listed here. Also,
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. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Bolt Locknut
Engine Mounting Bracket Bolts and Nuts
Engine Mounting Nuts
Exhaust Pipe Holder Nuts
Exhaust Pipe Mounting Bolt
Muffler Body Clamp Bolt
Muffler Body Mounting Bolt
Radiator Bolts
Wheels:
Front Axle Nut
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Brake Lever Pivot Bolt Locknut
Brake Pedal Bolt
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Nuts
Swingarm Pivot Shaft Nut
Tie-Rod Nuts
Uni-Trak Rocker Arm Nut
Steering:
Handlebar Mounting Bolts
Steering Stem Head Bolt
Others:
Footpeg Bracket Bolts
Sidestand Nut
 PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Replacement Parts
Air Cleaner Element Replacement
NOTE
○In dusty areas, the element should be replaced more
frequently than the recommended interval.
○After riding through rain or on muddily roads, the ele-
ment should be replaced immediately.

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.

• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Air Cleaner Housing Cap Bolts [A]
Air Cleaner Housing Cap [B]

• Pull out the air cleaner element [A].

• Separate the plastic holders [A].

• Install a new element and air cleaner housing cap.

• Tighten:
Torque - Air Cleaner Housing Cap Bolts: 2.5 N·m (0.25
kgf·m, 22 in·lb)
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel Hose Replacement
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.

• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
• Be sure to place a piece of cloth [A] around the fuel hose
joint.
• Push the joint lock claws [B].

• Pull the joint lock [A] as shown in the figure.

• Pull the fuel hose joint [B] out of the fuel supply pipe.

• Replace the fuel hose with a new one.

• Pull [A] the joint lock [B] fully as shown in the figure.

• Install a new fuel hose so that the white mark side faces
fuel supply pipe of the fuel pump.
• Insert the fuel hose joint [A] straight onto the fuel supply
pipe until the hose joint clicks.
• Push [B] the joint lock [C] until the hose joint clicks.
 PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures

• Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked and does
not come off.
WARNING
Make sure the fuel hose joint is installed correctly
on the fuel supply pipe or the fuel could leak.
If it comes off, reinstall the hose joint.
• Run the fuel hose correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
• Install the fuel tank (see Fuel Tank Installation in the Fuel
System (DFI) chapter).
• Start the engine and check the fuel hose for leaks.
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. Immediately wipe up or wash away any
coolant that spills on the frame, engine, or other
painted parts.
Since coolant is harmful to the human body, do not
use for drinking.

• Remove the lower fairings (see Lower Fairing Removal in

the Frame chapter).
• 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.
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• Place a container under the coolant drain bolts [A], then

remove the drain bolts.
○The coolant will drain from the radiator and engine.

• Remove the hose [A].

• Install thecoolant
Pour the into a suitable container.
• Tighten the drain bolts with the gasket.
hose.
•○Replace the drain bolt gaskets with new ones.
Torque - Coolant Drain Bolt (Water Pump): 9.8 N·m (1.0
kgf·m, 87 in·lb)
Coolant Drain Bolt (Cylinder): 5.9 N·m (0.60 kgf·m,
52 in·lb)

• 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 in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and consider-
ably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%
Coolant: 50%
Freezing Point: –35°C (–31°F)
Total Amount: 1.5 L (1.6 US qt)
 PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures

• Fill the radiator up to the filler neck [A] with coolant.

NOTE
○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.

• Check the cooling system for leaks.

• inside. radiator hoses to force any air bubbles caught
Tap the

• Fill the radiator up to the filler neck with coolant.

• Fill the reserve tank up to the "F" (full) level line [A] with
coolant and install the cap [B].
• Install the radiator cap.
• fan turns engine,
Start the warm it up thoroughly until the radiator
on and then stop the engine.
• gine cools down.
Check the coolant level in the reserve tank after the en-

If the coolant level is lower than the "L" (low) level line [C],
add coolant to the "F" level line.
CAUTION
Do not add more coolant above the "F" level line.
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Radiator Hose and O-ring Replacement
• Drain the coolant (see Coolant Change).
• Thermostat Housing [A] (see Thermostat Housing Re-
Remove:

moval in the Cooling System chapter)

Water Pump Cover [B] (see Water Pump Cover Removal
in the Cooling System chapter)
O-rings [C]
Hoses [D]
• Apply grease to the new O-rings and install them.
• Install the new hoses and tighten the clamps securely.
Torque - Radiator (Water) Hose Clamp Screws: 1.5 N·m
(0.15 kgf·m, 13 in·lb)
• Fill the coolant (see Coolant Change).
• Check the cooling system for leaks.

Engine Oil Change

• Situate the motorcycle so that it is vertical after warming
up the engine.
•○Remove the engine oil drain bolt [A] to drain the oil.
The oil in the oil filter can be drained by removing the filter
(see Oil Filter Replacement).
• Replace the drain bolt gasket [B] with a new one.
• Tighten the drain bolt.
Torque - Engine Oil Drain Bolt (Oil Screen Cover): 19.6 N·m
(2.0 kgf·m, 14.5 ft·lb)
• Pour in the specified type and amount of oil.
 PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures
Recommended Engine Oil
Type: API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity: SAE 10W-40
Capacity: 1.3 L (1.4 US qt) (when filter is not
removed)
1.6 L (1.7 US qt) (when filter is removed)
1.7 L (1.8 US qt) (when engine is
completely dry)

NOTE
○Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.

• Check the oil level (see Oil Level Inspection in the Engine
Lubrication System chapter).
Oil Filter Replacement
• Drain the engine oil (see Engine Oil Change).
• Remove the oil filter mounting bolt [A].

• Replace the oil filter with a new one.

• Install the oil filter,
Apply engine oil to a new O-rings [A] before installation.
• and tighten the mounting bolt [B].
Torque - Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5
ft·lb)
• Pour in the specified type and amount of oil (see Engine
Oil Change).
2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose and Pipe Replacement
CAUTION
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.

• Remove the brake hose banjo bolts [A].

• When removing the brake hose, take care not to spill the
brake fluid on the painted or plastic parts.
• When removing the brake hoses [B], temporarily secure
the end of the brake hose to some high place to keep fluid
loss to a minimum.
• Immediately wash away any brake fluid that spills.
• There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• When installing the hoses, avoid sharp bending, kinking,
flatting or twisting, and run the hoses according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
• Fill the brake line after installing the brake hose (see
Brake Fluid Change).

Brake Fluid Change

NOTE
○The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for
the front brake.

• Level the brake fluid reservoir.

• Remove the
Remove reservoir cap and diaphragm.
• caliper. the rubber cap [A] from the bleed valve on the
• Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
 PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures

•○Change the brake fluid.

Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].
NOTE
○The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.

• Remove the clear plastic hose.

• Tighten: diaphragm and reservoir cap.
Install the
•
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

• Follow the procedure below to install the rear brake fluid

reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].

• Apply a non-permanent locking agent to the threads of

the bleed valve.
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)
• 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.
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
• Remove the front master cylinder (see Front Master Cylin-
der Removal in the Brakes chapter).
• Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
• Unscrew the locknut and pivot bolt, and remove the brake
lever.
• Pull the dust cover out of place, and remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the piston [A], secondary cup [B], primary cup [C]
and return spring [D].
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Rear Master Cylinder Disassembly
NOTE
○Do not remove the push rod clevis for master cylinder
disassembly since removal requires brake position ad-
justment.

• Remove the rear master cylinder (see Rear Master Cylin-

der Removal in the Brakes chapter).
• Remove the circlip [A].
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the push rod with the piston stop.
• Take off the piston [B], secondary cup [C], primary cup [D]
and return spring [E].
• Remove the circlip [F] and pull out the brake hose con-
nector [G] and O-ring [H].
Special Tool - Inside Circlip Pliers: 57001-143

CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.

Master Cylinder Assembly

•Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi-
cult to wash off completely, and will eventually de-
teriorate the rubber used in the disc brake.

• Apply brake fluid to the new parts and to the inner wall of
the cylinder.
• Take care not to scratch the piston or the inner wall of the
cylinder.
• Apply silicone grease to the brake lever pivot bolt and
push rod.
• Tighten:
Torque - Brake Lever Pivot Bolt: 5.9 N·m (0.60 kgf·m, 52
in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
 PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
Caliper Rubber Parts Replacement
NOTE
○The procedure to assembly/disassembly the front
caliper is as follows. Assembling/disassembling the
rear caliper is the same as for the front caliper.
Caliper Disassembly
•Remove:
Front/Rear Caliper (see Front/Rear Caliper Removal in
the Brakes chapter)
Brake Pads (see Brake Pad Removal in the Brakes
chapter)
Pad Spring

•○Using compressed air, remove the pistons.

Cover the piston area with a clean, thick cloth [A].
○Blow compressed air [B] into the hole for the banjo bolt to
remove the piston.

WARNING
To avoid serious injury, never place your fingers or
palm in front of the piston. If you apply compressed
air into the caliper, the piston may crush your hand
or fingers.

• Pull out the pistons by hand.

• Caliper Holder
Remove:

Dust Seals
Fluid Seals
Bleed Valve
Rubber Cap

NOTE
○If compressed air is not available, do as follows with the
brake hose connected to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the pads (see Brake Pad Removal in the
Brakes chapter).
○Pump the brake lever until the pistons come out of the
cylinders, and then disassemble the caliper.
2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Caliper Assembly
•Clean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.

• Apply a non-permanent locking agent to the threads of

the bleed valve.
• Install the bleed valve and rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)

• Apply brake fluid to the cylinder bores.

•○Apply silicone
Replace the fluid seals [A] with new ones.
grease to the fluid seals, and install them
into the cylinders by hand.
• Replace the dust seals [B] with new ones.

• Apply brake fluid to the outside of the pistons, and push

them into each cylinder by hand.
• Check the dust cover [A] and the friction boot [B] replace
them with new ones if they are damaged.
• Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to
the caliper holder shaft [C] and pin bolt [D] (PBC is a spe-
cial high-temperature, water-resistance grease).
• Install the caliper holder and pad spring.

• Install the pads (see Brake Pad Installation in the Brakes

chapter).
• Wipe
cloth.
up any spilled brake fluid on the caliper with wet

Spark Plug Replacement

• Remove the stick coils (see Stick Coil Removal in the
Electrical System chapter).
• Remove the spark plugs using the 16 mm (0.63 in.) plug
wrench [A] vertically.
 PERIODIC MAINTENANCE 2-55
Periodic Maintenance Procedures

• Replace the spark plug with a new one.

Standard Spark Plug
Type: NGK CR8E

• Insert the new spark plug in the plug hole, and finger
-tighten it first.
• Using the plug wrench [A] vertically, tighten the plug.
CAUTION
The insulator of the spark plug may break if when
the wrench is inclined during tightening.

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)

•○Install the stick coils securely.
Be sure the stick coils are installed by pulling up it lightly.
 FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents
Exploded View........................................................................................................................ 3-4
DFI System............................................................................................................................. 3-8
DFI Parts Location.................................................................................................................. 3-14
Specifications ......................................................................................................................... 3-17 3
Special Tools and Sealant ...................................................................................................... 3-19
DFI Servicing Precautions ...................................................................................................... 3-21
DFI Servicing Precautions ................................................................................................... 3-21
Troubleshooting the DFI System ............................................................................................ 3-23
Outline ................................................................................................................................. 3-23
Inquiries to Rider.................................................................................................................. 3-26
DFI System Troubleshooting Guide ....................................................................................... 3-29
Self-Diagnosis ........................................................................................................................ 3-34
Self-diagnosis Outline ....................................................................................................... 3-34
Self-diagnosis Procedures ................................................................................................ 3-34
Service Code Clearing Procedures................................................................................... 3-35
How to Read Service Codes............................................................................................. 3-37
How to Erase Service Codes ............................................................................................ 3-37
Service Code Table........................................................................................................... 3-38
Backups ............................................................................................................................ 3-39
Main Throttle Sensor (Service Code 11) ................................................................................ 3-41
Main Throttle Sensor Removal/Adjustment ...................................................................... 3-41
Main Throttle Sensor Input Voltage Inspection ................................................................. 3-41
Main Throttle Sensor Output Voltage Inspection .............................................................. 3-42
Main Throttle Sensor Resistance Inspection .................................................................... 3-43
Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-44
Inlet Air Pressure Sensor Removal................................................................................... 3-44
Inlet Air Pressure Sensor Installation................................................................................ 3-44
Inlet Air Pressure Sensor Input Voltage Inspection........................................................... 3-44
Inlet Air Pressure Sensor Output Voltage Inspection........................................................ 3-45
Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-50
Inlet Air Temperature Sensor Removal/Installation........................................................... 3-50
Inlet Air Temperature Sensor Output Voltage Inspection .................................................. 3-50
Inlet Air Temperature Sensor Resistance Inspection ........................................................ 3-51
Water Temperature Sensor (Service Code 14) ...................................................................... 3-53
Water Temperature Sensor Removal/Installation ............................................................. 3-53
Water Temperature Sensor Output Voltage Inspection..................................................... 3-53
Water Temperature Sensor Resistance Inspection........................................................... 3-54
Crankshaft Sensor (Service Code 21).................................................................................... 3-55
Crankshaft Sensor Removal/Installation........................................................................... 3-55
Crankshaft Sensor Resistance Inspection ........................................................................ 3-55
Crankshaft Sensor Peak Voltage Inspection..................................................................... 3-55
Speed Sensor (Service Code 24, 25)..................................................................................... 3-56
Speed Sensor Removal/Installation.................................................................................. 3-56
Speed Sensor Inspection.................................................................................................. 3-56
Speed Sensor Input Voltage Inspection............................................................................ 3-56
Speed Sensor Output Voltage Inspection ......................................................................... 3-57
Vehicle-down Sensor (Service Code 31)................................................................................ 3-59
Vehicle-down Sensor Removal ......................................................................................... 3-59
Vehicle-down Sensor Installation ...................................................................................... 3-59
Vehicle-down Sensor Input Voltage Inspection................................................................. 3-59
3-2 FUEL SYSTEM (DFI)

Vehicle-down Sensor Output Voltage Inspection .............................................................. 3-60

Subthrottle Sensor (Service Code 32).................................................................................... 3-63
Subthrottle Sensor Removal/Adjustment .......................................................................... 3-63
Subthrottle Sensor Input Voltage Inspection..................................................................... 3-63
Subthrottle Sensor Output Voltage Inspection .................................................................. 3-64
Subthrottle Sensor Resistance Inspection ........................................................................ 3-65
Oxygen Sensor - not activated (Service Code 33) ................................................................. 3-66
Oxygen Sensor Removal/Installation................................................................................ 3-66
Oxygen Sensor Inspection................................................................................................ 3-66
Stick Coils #1, #2 (Service Code 51, 52)................................................................................ 3-69
Stick Coil Removal/Installation.......................................................................................... 3-69
Stick Coil Primary Winding Resistance Inspection ........................................................... 3-69
Stick Coil Input Voltage Inspection.................................................................................... 3-69
Radiator Fan Relay (Service Code 56)................................................................................... 3-71
Radiator Fan Relay Removal/Installation.......................................................................... 3-71
Radiator Fan Relay Inspection.......................................................................................... 3-71
Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-73
Subthrottle Valve Actuator Removal ................................................................................. 3-73
Subthrottle Valve Actuator Inspection ............................................................................... 3-73
Subthrottle Valve Actuator Resistance Inspection ............................................................ 3-73
Subthrottle Valve Actuator Input Voltage Inspection ......................................................... 3-74
Air Switching Valve (Service Code 64) ................................................................................... 3-76
Air Switching Valve Removal/Installation .......................................................................... 3-76
Air Switching Valve Inspection .......................................................................................... 3-76
Oxygen Sensor Heater (Service Code 67) ............................................................................. 3-77
Oxygen Sensor Heater Removal/Installation .................................................................... 3-77
Oxygen Sensor Heater Resistance Inspection ................................................................. 3-77
Oxygen Sensor Heater Power Source Voltage Inspection ............................................... 3-77
Oxygen Sensor - Incorrect Output Voltage (Service Code 94)............................................... 3-79
Oxygen Sensor Removal/Installation................................................................................ 3-79
Oxygen Sensor Inspection................................................................................................ 3-79
FI Indicator Light..................................................................................................................... 3-82
Light Inspection................................................................................................................. 3-82
ECU ........................................................................................................................................ 3-83
ECU Identification ............................................................................................................. 3-83
ECU Removal ................................................................................................................... 3-83
ECU Installation ................................................................................................................ 3-83
ECU Power Supply Inspection.......................................................................................... 3-84
DFI Power Source .................................................................................................................. 3-87
ECU Fuse Removal .......................................................................................................... 3-87
ECU Fuse Installation ....................................................................................................... 3-87
ECU Fuse Inspection ........................................................................................................ 3-87
ECU Main Relay Removal/Installation .............................................................................. 3-87
ECU Main Relay Inspection .............................................................................................. 3-87
Fuel Line................................................................................................................................. 3-88
Fuel Pressure Inspection .................................................................................................. 3-88
Fuel Flow Rate Inspection ................................................................................................ 3-89
Fuel Pump .............................................................................................................................. 3-91
Fuel Pump Removal ......................................................................................................... 3-91
Fuel Pump Installation ...................................................................................................... 3-92
Fuel Pump Operation Inspection ...................................................................................... 3-92
Fuel Pump Operating Voltage Inspection ......................................................................... 3-93
Pressure Regulator Removal............................................................................................ 3-94
Fuel Filter Cleaning........................................................................................................... 3-94
Fuel Pump Relay Removal/Installation ............................................................................. 3-94
Fuel Pump Relay Inspection ............................................................................................. 3-94
Fuel Injectors .......................................................................................................................... 3-96
 FUEL SYSTEM (DFI) 3-3

Fuel Injector Removal/Installation..................................................................................... 3-96

Fuel Injector Audible Inspection........................................................................................ 3-96
Fuel Injector Resistance Inspection .................................................................................. 3-96
Fuel Injector Power Source Voltage Inspection ................................................................ 3-97
Fuel Injector Output Voltage Inspection ............................................................................ 3-98
Fuel Injector Fuel Line Inspection ..................................................................................... 3-99
Throttle Grip and Cables ........................................................................................................ 3-101
Free Play Inspection ......................................................................................................... 3-101
Free Play Adjustment........................................................................................................ 3-101
Cable Installation .............................................................................................................. 3-101
Cable Lubrication .............................................................................................................. 3-101
Throttle Body Assy ................................................................................................................. 3-102
Idle Speed Inspection/Adjustment .................................................................................... 3-102
Synchronization Inspection/Adjustment ............................................................................ 3-102
Throttle Body Assy Removal............................................................................................. 3-102
Throttle Body Assy Installation.......................................................................................... 3-104
Throttle Body Assy Disassembly ...................................................................................... 3-105
Throttle Body Assy Assembly ........................................................................................... 3-106
Air Cleaner.............................................................................................................................. 3-107
Air Cleaner Element Removal/Installation ........................................................................ 3-107
Air Cleaner Element Inspection ........................................................................................ 3-107
Air Cleaner Oil Draining .................................................................................................... 3-107
Air Cleaner Housing Removal........................................................................................... 3-107
Air Cleaner Housing Installation........................................................................................ 3-108
Air Cleaner Housing Disassembly .................................................................................... 3-108
Air Cleaner Housing Assembly ......................................................................................... 3-109
Fuel Tank ................................................................................................................................ 3-110
Fuel Tank Removal ........................................................................................................... 3-110
Fuel Tank Installation ........................................................................................................ 3-112
Fuel Tank Inspection ......................................................................................................... 3-113
Fuel Tank Cleaning ........................................................................................................... 3-113
3-4 FUEL SYSTEM (DFI)
Exploded View
 FUEL SYSTEM (DFI) 3-5
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Crankshaft Sensor Screws 3.0 0.31 27 in·lb
2 Delivery Pipe Assy Mounting Screws 3.4 0.35 30 in·lb
3 Inlet Air Temperature Sensor Screw 1.2 0.12 11 in·lb
4 Oxygen Sensor 44.1 4.50 32.5
5 Speed Sensor Bolt 7.8 0.80 69 in·lb L
6 Throttle Body Assy Holder Clamp Screws 2.0 0.20 18 in·lb
7 Water Temperature Sensor 25 2.5 18
8. Throttle Cable (Accelerator)
9. Throttle Cable (Decelerator)
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant.
3-6 FUEL SYSTEM (DFI)
Exploded View
 FUEL SYSTEM (DFI) 3-7
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Air Cleaner Housing Cap Bolts 2.5 0.25 22 in·lb
2 Air Cleaner Housing Mounting Bolts 9.8 1.0 87 in·lb
3 Air Cleaner Housing Screws 1.15 0.12 10 in·lb
4 Air Duct Clamp Screws 2.0 0.20 18 in·lb
5 Fuel Pump Bolts 9.8 1.0 87 in·lb L
AD: Apply adhesive.
AO: Apply high-quality-form-air-filter oil.
L: Apply a non-permanent locking agent.
R: Replacement Parts
3-8 FUEL SYSTEM (DFI)
DFI System
DFI System
 FUEL SYSTEM (DFI) 3-9
DFI System
1. ECU
2. Battery 12 V 8 Ah
3. Neutral Switch
4. Inlet Air Pressure Sensor
5. Air Switching Valve
6. Water Temperature Sensor
7. Speed Sensor
8. Vehicle-down Sensor
9. Oxygen Sensor
10. Crankshaft Sensor
11. Main Throttle Sensor
12. Fuel Injectors
13. Subthrottle Valve Actuator
14. Subthrottle Sensor
15. Inlet Air Temperature Sensor
16. Fuel Pump
3-10 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram
 FUEL SYSTEM (DFI) 3-11
DFI System
Part Names
1. Oxygen Sensor
2. ECU
3. Joint Connector 2
4. Kawasaki Diagnostic System Connector
5. Self-diagnosis Terminal
6. Fuel Pump
7. Battery 12 V 8 Ah
8. Frame Ground
9. Starter Relay
10. Main Fuse 30 A
11. Relay Box
12. Fuel Pump Relay
13. ECU Main Relay
14. Fan Relay
15. Ignition Fuse 10 A
16. ECU Fuse 15 A
17. Fan Fuse 10 A
18. Oxygen Sensor Heater Fuse 10 A
19. Fuse Box
20. Joint Connector 1
21. FI Indicator Light
22. Tachometer
23. Water Temperature Gauge
24. Ignition Switch
25. Engine Stop Switch
26. Starter Button
27. Fan Motor
28. Resistor
29. Stick Coil #1, #2
30. Water-proof Joint 3
31. Air Switching Valve
32. Speed Sensor
33. Subthrottle Valve Actuator
34. Subthrottle Sensor
35. Main Throttle Sensor
36. Inlet Air Pressure Sensor
37. Water-proof Joint 2
38. Vehicle-down Sensor
39. Fuel Injector #1, #2
40. Water-proof Joint 1
41. Water Temperature Sensor
42. Inlet Air Temperature Sensor
43. Crankshaft Sensor
○Color Codes:
BK: Black GY: Gray PU: Purple
BL: Blue LB: Light Blue R: Red
BR: Brown LG: Light Green V: Violet
CH: Chocolate O: Orange W: White
DG: Dark Green P: Pink Y: Yellow
G: Green
3-12 FUEL SYSTEM (DFI)
DFI System
Terminal Numbers of ECU Connectors

Terminal Names
1. Subthrottle Valve Actuator: W/BL
2. Subthrottle Valve Actuator: P
3. Fuel Level Warning Indicator Light: GY
4. Oxygen Sensor: BL/Y
5. Speed Sensor: LG/R
6. Main Throttle Sensor: Y/W
7. Inlet Air Pressure Sensor: Y/BL
8. Power Supply to Sensors: BL
9. Vehicle-down Sensor: Y/G
10. Neutral Switch: LG
11. Crankshaft Sensor (+): R/BK
12. Power Supply to ECU (from ECU Main Relay): BR/W
13. External Communication Line: LG/BK
14. Subthrottle Valve Actuator: G/Y
15. Subthrottle Valve Actuator: BK/BL
16. Unused
17. Water Temperature Sensor: O
18. Self-diagnosis Terminal: Y/BK
19. Subthrottle Sensor: BL/W
20. Inlet Air Temperature Sensor: Y
21. Unused
22. Ground for Sensors: BR/BK
23. Oxygen Sensor Heater: P/BK
24. Crankshaft Sensor (–): Y/BK
25. Unused
26. Ground for ECU: BK/Y
27. Power Supply to ECU (from Battery): W/BK
28. Engine Stop Switch: R
29. Starter Lockout Switch: R/G
30. Starter Button: BK/R
31. Fuel Pump Relay: BR/Y
32. Air Switching Valve: R/BL
33. Injector #2: BL/G
34. Injector #1: BL/R
 FUEL SYSTEM (DFI) 3-13
DFI System
35. Stick Coil #1: BK
36. Sidestand Switch: G/BK
37. Fan Relay: P/W
38. Unused
39. Meter Unit (Tachometer): LB
40. FI Indicator Light: R/Y
41. Unused
42. Ground for Fuel System: BK/Y
43. Ground for Ignition System: BK/Y
44. Stick Coil #2: BK/G
3-14 FUEL SYSTEM (DFI)
DFI Parts Location
Main Throttle Sensor [A]
Subthrottle Sensor [B]

Fuel Injectors #1, #2 [A]

Crankshaft Sensor [A]

Oxygen Sensor [A]

Ignition Switch [A]

FI Indicator Light [B]
 FUEL SYSTEM (DFI) 3-15
DFI Parts Location
Stick Coils #1, #2 [A]
Air Switching Valve [B]
Inlet Air Pressure Sensor [C]

Subthrottle Valve Actuator [A]

Speed Sensor [A]

Water Temperature Sensor [A]

Vehicle-down Sensor [B]

Inlet Air Temperature Sensor [A]

3-16 FUEL SYSTEM (DFI)
DFI Parts Location
Fuse Box (Oxygen Sensor Heater Fuse 10 A, ECU Fuse
15 A, Ignition Fuse 10 A, Fan Fuse 10 A ) [A]
Battery 12 V 8 Ah [B]
Relay Box (ECU Main Relay, Fan Relay, Fuel Pump Re-
lay) [C]
ECU [D]
Kawasaki Diagnostic System Connector [E]
Self-diagnosis Terminal [F]

Fuel Pump [A]

 FUEL SYSTEM (DFI) 3-17
Specifications

Item Standard
Digital Fuel Injection System
Idle Speed 1 300 ±50 r/min (rpm)
Throttle Body Assy:
Type Two barrel type
Bore 28 mm (1.10 in.)
Throttle Body Vacuum 24.0 ±1.33 kPa (180 ±10 mmHg)
Bypass Screws (Turn Out) 0 ∼ 2 1/2 (for reference)
ECU:
Make DENSO
Fuel Pressure (High Pressure Line) 294 kPa (3.0 kgf/cm², 43 psi) with engine idling
Fuel Pump:
Discharge 17 mL (0.57 US oz.) or more for 3 seconds
Fuel Injectors:
Type INP-288
Nozzle Type Fine atomizing type with 8 holes
Resistance About 11.7 ∼ 12.3 Ω at 20°C (68°F)
Main Throttle Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 1.020 ∼ 1.050 V at idle throttle opening
DC 4.185 ∼ 4.385 V at full throttle opening (for
reference)
Resistance 4 ∼ 6 kΩ
Inlet Air Pressure Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 3.80 ∼ 4.20 V at standard atmospheric pressure
(see this text for details)
Inlet Air Temperature Sensor:
Output Voltage About DC 2.25 ∼ 2.50 V at inlet air temperature 20°C
(68°F)
Resistance 5.4 ∼ 6.6 kΩ at 0°C (32°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
Water Temperature Sensor:
Output Voltage About DC 2.80 ∼ 2.97 V at 20°C (68°F)
Speed Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage About DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.9 V at ignition
switch ON and 0 km/h
Vehicle-down Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage With sensor tilted 55 ∼ 75° or more right or left: DC
3.7 ∼ 4.4 V
With sensor arrow mark pointed up: DC 0.4 ∼ 1.4 V
3-18 FUEL SYSTEM (DFI)
Specifications

Item Standard
Subthrottle Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 0.78 ∼ 0.82 V at subthrottle valve full close
position
DC 3.9 ∼ 4.1 V at subthrottle valve full open position
(for reference)
Resistance 4 ∼ 6 kΩ
Subthrottle Valve Actuator:
Resistance About 5.2 ∼ 7.8 Ω
Input Voltage About DC 11.5 ∼ 13.5 V
Oxygen Sensor:
Output Voltage (Rich) DC 0.7 V or more
Output Voltage (Lean) DC 0.2 V or less
Heater Resistance 11.7 ∼ 15.5 Ω at 20°C (68°F)
Throttle Grip and Cables
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Air Cleaner
Element Polyurethane foam
 FUEL SYSTEM (DFI) 3-19
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter:
57001-125 57001-1415

Fork Oil Level Gauge: Needle Adapter Set:

57001-1290 57001-1457

Vacuum Gauge: Throttle Sensor Setting Adapter:

57001-1369 57001-1538

Hand Tester: Sensor Harness Adapter:

57001-1394 57001-1561

Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter:

57001-1400 57001-1593
3-20 FUEL SYSTEM (DFI)
Special Tools and Sealant
Fuel Hose: Measuring Adapter:
57001-1607 57001-1700

Oxygen Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant):

57001-1682 56019-120
 FUEL SYSTEM (DFI) 3-21
DFI Servicing Precautions
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.

○This DFI system is designed to be used with a 12 V sealed

battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
○Do not reverse the battery cable connections. This will
damage the ECU.
○To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is ON, or while the engine is running.
○Take care not to short the leads that are directly 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 dis-

connected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the con-
nector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the en-
gine.
○Connect these connectors until they click [A].

○Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memo-
rizes service codes.
○Do not spray water on the electrical parts, DFI parts, con-
nectors, leads and wiring.
○If a transceiver is installed on the motorcycle, make sure
that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.
○When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
○Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer 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.
○When installing the fuel hoses, avoid sharp bending, kink-
ing, flattening or twisting, and run the fuel hoses with a
minimum of bending so that the fuel flow will not be ob-
structed.
○Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.
○To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.
3-22 FUEL SYSTEM (DFI)
DFI Servicing Precautions
○If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak or the hose
to burst. Remove the fuel tank (see Fuel Tank Removal)
and check the fuel hose [A].
Replace the fuel hose if any fraying, cracks or bulges are
noticed.

○To maintain the correct fuel/air mixture (F/A), there must

be no inlet air leaks in the DFI system. Be sure to install
the oil filler plug [A] after filling the engine oil.
Torque - Oil Filler Plug: Hand-Tighten
 FUEL SYSTEM (DFI) 3-23
Troubleshooting the DFI System
Outline
When an abnormality in the system occurs, the FI indi-
cator light goes on to alert the rider on the meter panel. In
addition, the condition of the problem is stored in the mem-
ory 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
light blinks.
When due to a malfunction, the FI indicator light remains
lit, ask the rider about the conditions [B] under which the
problem occurred and try to determine the cause [C].
Don’t rely solely on the DFI self-diagnosis function, use
common sense.

Even when the DFI system is operating normally, the FI

indicator light [A] may light up under strong electrical inter-
ference. No remedy needed. Turn the ignition switch OFF
to stop the indicator light.
When the FI indicator light goes on and the motorcycle is
brought in for repair, check the service codes.
When the repair has been done, the light doesn’t go on.
But the service codes stored in memory are not erased to
preserve the problem history, and the light can display the
codes in the self-diagnosis mode. The problem history is
referred when solving unstable problems.
When the motorcycle is down, the vehicle-down sensor
operates and the ECU shuts off the fuel pump relay, fuel in-
jectors and ignition system. The ignition switch is left ON. If
the starter button is pushed, the electric starter turns but the
engine does not start. When the starter button is pushed,
the FI indicator light blinks but the service code is not dis-
played. To start the engine again, raise the motorcycle, turn
the ignition switch OFF, and then ON.
Much of the DFI system troubleshooting work consists
of confirming continuity of the wiring. The DFI parts are
assembled and adjusted with precision, and it is impossible
to disassemble or repair them.
3-24 FUEL SYSTEM (DFI)
Troubleshooting the DFI System

• When checking the DFI parts, use a digital meter which

can be read two decimal place voltage or resistance.
○The DFI part connectors [A] have seals [B], including the
ECU. When measuring the input or output voltage with the
connector joined, use the needle adapter set [C]. Insert
the needle adapter inside the seal until the needle adapter
reaches the terminal.
Special Tool - Needle Adapter Set: 57001-1457

CAUTION
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.

• Make sure that measuring points are correct in the con-

nector, noting the position of the lock [D] and the lead
color before measurement. Do not reverse connections
of a digital meter.
• Be careful not to short-circuit the leads of the DFI or elec-
trical system parts by contact between adapters.
• Turn the ignition switch ON and measure the voltage with
the connector joined.
CAUTION
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.

○After measurement, remove the needle adapters and ap-

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

• Always check battery condition before replacing the DFI

parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.
• Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
• Measure coil winding resistance when the DFI part is cold
(at room temperature).
• Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, short,
etc. Deteriorated leads and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.
 FUEL SYSTEM (DFI) 3-25
Troubleshooting the DFI System

• 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.
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 lead or the main harness or the subharness.

○If both ends of a harness [A] are far apart, ground [B] the
one end [C], using a jumper lead [D] and check the con-
tinuity between the end [E] and the ground [F]. This en-
ables 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.

• Narrow down suspicious locations by repeating the con-

tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.
3-26 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
DFI Diagnosis Flow Chart

Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.
○Try to find out exactly what problem occurred under exactly what conditions by asking the rider;
knowing this information may help you reproduce the problem.
○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.
 FUEL SYSTEM (DFI) 3-27
Troubleshooting the DFI System
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.): Year of initial registration:
Model: Engine No.: Frame No.:
Date problem occurred: Mileage:
Environment when problem occurred.
Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other:
Temperature □ hot, □ warm, □ cold, □ very cold, □ always, □ other:
Problem □ chronic, □ often, □once
frequency
Road □ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble
Altitude □ normal, □ high (about 1 000 m or more)
Motorcycle conditions when problem occurred.
FI indicator □ lights up immediately after ignition switch ON, and goes off after 1 ∼ 2 seconds
light (normal).
□ lights up immediately after ignition switch ON, and stays on (DFI problem).
□ unlights (light, ECU or its wiring fault).
□ sometimes lights up (probably wiring fault).
Starting □ starter motor not rotating.
difficulty □ starter motor rotating but engine do not turn over.
□ starter motor and engine do not turn over.
□ no fuel flow (□ no fuel in tank, □ no fuel pump sound).
□ no spark.
□ other:
Engine stalls □ right after starting.
□ when opening throttle grip.
□ when closing throttle grip.
□ when moving off.
□ when stopping the motorcycle.
□ when cruising.
□ other:
Poor running □ very low idle speed, □ very high idle speed, □ rough idle speed.
at low speed □ battery voltage is low (charge the battery).
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ backfiring.
□ afterfiring.
□ hesitation when acceleration.
□ engine oil viscosity too high.
□ brake dragging.
□ engine overheating.
□ clutch slipping.
□ other:
3-28 FUEL SYSTEM (DFI)
Troubleshooting the DFI System

Poor running □ spark plug loose (tighten it).

or no power at □ spark plug dirty, broken, or gap maladjusted (remedy it).
high speed
□ spark plug incorrect (replace it).
□ knocking (fuel poor quality or incorrect).
□ brake dragging.
□ clutch slipping.
□ engine overheating.
□ engine oil level too high.
□ engine oil viscosity too high.
□ other:
 FUEL SYSTEM (DFI) 3-29
DFI System Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed.It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties in
DFI system.
○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits are checked out good, be sure to check the ECU for ground and power supply. If the
ground and power supply are checked good, replace the ECU.

Engine Won’t Turn Over

Symptoms or Possible Causes Actions
Neutral, starter lockout or sidestand switch Inspect each switch (see chapter 16).
trouble
Vehicle-down sensor operated Turn ignition switch OFF (see chapter 3).
Vehicle-down sensor trouble Inspect (see chapter 3).
Crankshaft sensor trouble Inspect (see chapter 16).
Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
ECU ground and power supply trouble Inspect (see chapter 3).
ECU trouble Inspect (see chapter 3).
No or little fuel in tank Supply fuel (see Owner’s Manual).
Fuel injector trouble Inspect and replace (see chapter 3).
Fuel pump not operating Inspect (see chapter 3).
Fuel pump relay trouble Inspect and replace (see chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).

Poor Running at Low Speed

Symptoms or Possible Causes Actions
Spark weak:
Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
ECU trouble Inspect (see chapter 3).
Fuel/air mixture incorrect:
Little fuel in tank Supply fuel (see Owner’s Manual).
Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 2).
Air duct loose Reinstall (see chapter 3).
Throttle body assy holder loose Reinstall (see chapter 3).
Throttle body assy dust seal damage Replace (see chapter 3).
Fuel injector O-ring damage Replace (see chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
3-30 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions

Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Unstable (rough) idling:
Fuel pressure too low or too high Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Engine vacuum not synchronizing Inspect and adjust (see chapter 2).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Engine stalls easily:
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Stick coil trouble Inspect (see chapter 16).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Fuel pressure too low or too high Inspect (see chapter 3).
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Poor acceleration:
Fuel pressure too low Inspect (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
 FUEL SYSTEM (DFI) 3-31
DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions

Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Stick coil trouble Inspect (see chapter 16).
Stumble:
Fuel pressure too low Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Surge:
Unstable fuel pressure Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and replace fuel pump) (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Backfiring when deceleration:
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Fuel pressure too low Inspect (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Air switching valve trouble Inspect and replace (see chapter 16).
Air suction valve trouble Inspect and replace (see chapter 5).
After fire:
Spark plug burned or gap maladjusted Replace (see chapter 2).
Fuel injector trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Other:
Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight,
and examine leads for signs of burning or fraying
(see chapter 3).
3-32 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Poor Running or No Power at High Speed
Symptoms or Possible Causes Actions
Firing incorrect:
Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16).
Stick coil trouble Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
ECU trouble Inspect (see chapter 3).
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 2).
Air duct loose Reinstall (see chapter 3).
Throttle body assy holder loose Reinstall (see chapter 3).
Throttle body assy dust seal damage Replace (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel injector O-ring damage Replace (see chapter 3).
Fuel injector clogged Inspect and repair (see chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Fuel pump operates intermittently and often DFI Fuel pump bearings may wear. Replace the fuel
fuse blows. pump (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Cracked or obstructed inlet air pressure sensor Inspect and repair or replace (see chapter 3).
vacuum hose
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Knocking:
Fuel poor quality or incorrect Fuel change (Use the gasoline recommended in
the Owner’s Manual).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
Stick coil trouble Inspect (see chapter 16).
ECU trouble Inspect (see chapter 3).
Engine vacuum not synchronizing Inspect and adjust (see chapter 2).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Miscellaneous:
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Speed sensor trouble Inspect (see chapter 3).
Throttle valves will not fully open Inspect throttle cables and lever linkage (see
chapter 3).
 FUEL SYSTEM (DFI) 3-33
DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions

Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in
crankshaft sensor or speed sensor trouble chapter 17)
Air switching valve trouble Inspect and replace (see chapter 16).
Air suction valve trouble Inspect and replace (see chapter 5).
Exhaust Smokes Excessively:
(Black smoke)
Air cleaner element clogged Clean element (see chapter 2).
Fuel pressure too high Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
(Brown smoke)
Air duct loose Reinstall (see chapter 3).
Fuel pressure too low Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
3-34 FUEL SYSTEM (DFI)
Self-Diagnosis
Self-diagnosis Outline
The self-diagnosis system has three modes and can be
switched to another mode by grounding the self-diagnosis
terminal.
User Mode
The ECU notifies the rider of troubles in DFI system and
ignition system by lighting the FI indicator light when DFI
system and ignition system parts are faulty, and initiates
fail-safe function. In case of serious troubles, the ECU stops
the injection/ignition/starter motor operation.
Dealer Mode 1
The FI indicator light emits service code(s) to show the
problem(s) which the DFI system, and ignition system has
at the moment of diagnosis.
Dealer Mode 2
The FI indicator light emits service code(s) to show the
problem(s) which the DFI system, and ignition system had
in the past.
Self-diagnosis Procedures
○When a problem occurs with the DFI system and ignition
system, the FI indicator light [A] goes on.
NOTE
○Use a fully charged battery when conducting
self-diagnosis. Otherwise, the FI indicator light blinks
very slowly or doesn’t blink.
○Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.

• Remove the front seat (see Front Seat Removal in the

Frame chapter).
• Ground the self-diagnosis terminal [A] (Yellow lead) to the
battery (–) terminal, using a wire.

• Turn on the ignition switch.

• [B] for grounding.
Connect an auxiliary lead [A] to the self-diagnosis terminal

• To enter the self-diagnosis dealer mode 1, ground [C] the

self-diagnosis indicator terminal to the battery (–) terminal
for more than 2 seconds [D], and then keep it grounded
continuously [E].
○Count the blinks of the FI indicator light to read the ser-
vice code. Keep the auxiliary lead ground until you finish
reading the service code.
 FUEL SYSTEM (DFI) 3-35
Self-Diagnosis

• To enter the self-diagnosis dealer mode 2, open [A] and

ground [B] the lead more than five times [C] within 2 sec-
onds [D] after the lead is first grounded, and then keep it
grounded continuously [E] for more than 2 seconds.
○Count the blinks of the FI indicator light to read the ser-
vice code. Keep the auxiliary lead ground until you finish
reading the service code.
Auxiliary Lead [F]
Self-diagnosis Terminal [G]
NOTE
○To enter the dealer mode 2 from the dealer mode 1, turn
off the ignition switch once.
Service Code Clearing Procedures
• Enter the self-diagnosis
-diagnosis Procedures).
dealer mode 2 (see Self

NOTE
○Make sure to keep the grounding until the following
opening and grounding starts.

• Pull the clutch lever in more than 5 seconds, and then

release it.
• Repeat opening [A] and grounding [B] the lead
(self-diagnosis terminal) more than five times [C] within 2
seconds [D] after the lead is grounded, and then keep it
grounded continuously [E] for more than 2 seconds.
Auxiliary Lead [F]
Self-diagnosis Terminal [G]
3-36 FUEL SYSTEM (DFI)
Self-Diagnosis
 FUEL SYSTEM (DFI) 3-37
Self-Diagnosis
How to Read Service Codes
○Service codes are shown by a series of long and short blinks of the FI indicator light as shown below.
○Read 10th digit and unit digit as the FI indicator light blinks.
○When there are a number of problems, all the service codes can be stored and the display will
begin starting from the lowest number service code in the numerical order. Then after completing
all codes, the display is repeated until the self-diagnosis indicator terminal is open.
○If there is no problem, no code and unlight.
○For example, if two problems occurred in the order of 21, 12, the service codes are displayed from
the lowest number in the order listed.
(12 → 21) → (12 → 21) → · · · (repeated)

○If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator
light doesn’t go on, and no service codes can be displayed.
FI Indicator Light
Fuel Pump
Fuel Pump Relay
ECU Main Relay
ECU Power Source Wiring and Ground Wiring (see ECU Power Supply Inspection)
Fuel Injectors
How to Erase Service Codes
○Even if the ignition switch is turned OFF, the battery or the ECU are disconnected or the problem is
solved, all service codes remain in the ECU.
○Refer to the Service Code Clearing Procedure for the service code erasure.
3-38 FUEL SYSTEM (DFI)
Self-Diagnosis
Service Code Table
Service
FI Indicator Light Problems
Code
Main throttle sensor malfunction,
11
wiring open or short
Inlet air pressure sensor malfunction,
12
wiring open or short
Inlet air temperature sensor
13
malfunction, wiring open or short
Water temperature sensor
14
malfunction, wiring open or short
Crankshaft sensor malfunction, wiring
21
open or short

Speed sensor malfunction, wiring

24
open or short
and +
First 24 is displayed and then 25,
25
repeatedly

Vehicle-down sensor, malfunction,

31
wiring open or short
Subthrottle sensor malfunction, wiring
32
open or short
Oxygen sensor inactivation, wiring
33
open or short
Stick coil #1 malfunction, wiring open
51
or short
Stick coil #2 malfunction, wiring open
52
or short
Radiator fan relay malfunction, wiring
56
open or short
Subthrottle valve actuator
62
malfunction, wiring open or short
Air switching valve malfunction, wiring
64
open or short

Oxygen sensor heater malfunction,

67
wiring open or short

Oxygen sensor malfunction, wiring

94
open or short
Notes:
○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to check the ECU for ground and power supply. If the ground and power supply are checked good,
replace the ECU.
○When no service code is displayed, the electrical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.
 FUEL SYSTEM (DFI) 3-39
Self-Diagnosis
Backups
○The ECU takes the following measures to prevent engine damage when the DFI or the ignition
system parts have troubles.
Service Output Signal Usable
Parts Backups by ECU
Codes Range or Criteria
If the main throttle sensor system fails (the
output voltage is out of the usable range,
wiring short or open), the ECU locks ignition
timing into the ignition timing at closed throttle
Main Throttle Output Voltage
11 position and sets the DFI in the D-J method.
Sensor 0.2 ∼ 4.8 V
Also, the main throttle sensor system and
inlet air pressure fails, the ECU locks ignition
timing into the ignition timing at closed throttle
position and sets the DFI in the α-N method.
If the inlet air pressure sensor system fails
Inlet Air Inlet Air Pressure
(the signal is out of the usable range, wiring
12 Pressure (Absolute)
short or open), the ECU sets the DFI in the
Sensor Pv = 150 ∼ 800 mmHg
α-N method.
Inlet Air If the inlet air temperature sensor fails (the
Inlet Air Temperature
13 Temperature signal is out of the usable range, wiring short
Ta = –30 ∼ +120°C
Sensor or open), the ECU sets Ta at 40°C.
Water If the water temperature sensor system fails
Water Temperature
14 Temperature (the signal is out of the usable range, wiring
Tw = –30 ∼ +120°C
Sensor short or open), the ECU sets Tw at 80°C.
Crankshaft sensor must
Crankshaft send 22 signals to If the crankshaft sensor generates other than
21
Sensor the ECU at the one 22 signals, the engine stops by itself.
cranking.
Speed sensor must
send 4 signals to the
24 ECU at the one rotation If the speed sensor system fails (no signal,
and Speed Sensor of the engine sprocket. wiring short or open), the speedometer shows
25 The gear position is 0, and the ECU sets the top (6) gear position.
decided by the signal of
the speed sensor.
If the vehicle-down sensor system has failures
Vehicle-down Output Voltage (the output voltage is more than usable range,
31
Sensor 0.4 ∼ 4.4 V wiring open), the ECU shuts off the fuel pump
relay, the fuel injectors and the ignition system.
If the subthrottle sensor system fails (the
output voltage is out of the usable range, wiring
Subthrottle Output Voltage
32 short or open), the ECU drive the subthrottle
Sensor 0.15 ∼ 4.85 V
valve to the full closed position, and it stops
the current to the subthrottle valve actuator.
The oxygen sensor is
active and sensor must If the oxygen sensor is not activated, the
33 Oxygen Sensor send signals (output ECU stops the feedback mode of the oxygen
voltage) continuously to sensor.
the ECU.
The stick coil primary If the stick coil #1 primary winding has failures
winding must send (no signal, wiring short or open), the ECU
51 Stick Coil #1*
signals continuously to shuts off the injector #1 to stop fuel to the
the ECU. cylinder #1, though the engine keeps running.
3-40 FUEL SYSTEM (DFI)
Self-Diagnosis

Service Output Signal Usable

Parts Backups by ECU
Codes Range or Criteria
The stick coil primary If the stick coil #2 primary winding has failures
winding must send (no signal, wiring short or open), the ECU
52 Stick Coil #2*
signals continuously to shuts off the injector #2 to stop fuel to the
the ECU. cylinder #2, though the engine keeps running.
When the relay OFF
Radiator Fan
56 condition, the fan relay –
Relay
is open.
The actuator operates
If the subthrottle valve actuator fails (the
open and close of the
Subthrottle signal is out of the usable range, wiring short
62 subthrottle valve by the
Valve Actuator or open), the ECU stops the current to the
pulse signal from the
actuator.
ECU.
The air switching valve
controls the flow of
Air Switching
64 the secondary air by –
Valve
opening and shutting
the solenoid valve.
The oxygen sensor
heater raise
If the oxygen sensor heater fails (wiring short
Oxygen Sensor temperature of the
67 or open), the ECU stops the current to the
Heater sensor for its earlier
heater.
activation. 12 V - 6.6
W, 0.55 A
The oxygen sensor
If the oxygen sensor output voltage is incorrect,
must send signals
94 Oxygen Sensor the ECU stops the feedback mode of the
continuously to the
oxygen sensor.
ECU

Note:
(1) α-N Method: the DFI control method from medium to heavy engine load. When the engine load
is light like at idling or low speed, the ECU determines the injection quantity by calculating from the
throttle vacuum (inlet air pressure sensor output voltage) and engine speed (crankshaft sensor output
voltage). This method is called D-J method. As the engine speed increases, and the engine load turns
middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening
(main throttle sensor output voltage) and the engine speed. This method is called α-N method.
*: This depends on the number of stopped cylinders.
 FUEL SYSTEM (DFI) 3-41
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Removal/Adjustment
CAUTION
Do not remove or adjust the main throttle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the main throttle sen-
sor can damage it.

Main Throttle Sensor Input Voltage Inspection

NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• moval in the
Remove the right lower fairing (see Lower Fairing Re-
Frame chapter).
• nect the harnessmain
Disconnect the throttle sensor connector and con-
adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
• Connect a digital meter to the harness adapter leads.
Main Throttle Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → BK (sensor BL) lead
Digital Meter (–) → W (sensor BR/BK) lead

• Measure the input voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V

• Turn the ignition switch OFF.

If the reading is within the standard, check the output volt-
age (see Main Throttle Sensor Output Voltage Inspec-
tion).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
BL lead (ECU terminal 8) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-42 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Output Voltage Inspection
• Measure the output voltage at the main throttle sensor in
the same way as input voltage inspection, note the follow-
ing.
○Disconnect the main throttle sensor connector and con-
nect the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:
Digital Meter (+) → R (sensor Y/W) lead
Digital Meter (–) → W (sensor BR/BK) lead

• Start the engine and warm it up thoroughly.

• Check idle speed to ensure the throttle opening is correct.
Idle Speed
Standard: 1 300 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it
(see Idle Speed Adjustment in the Periodic Maintenance
chapter).

• Turn the ignition switch OFF.

• with the connector
Measure the output voltage with the engine stopped and
joined.
• Turn the ignition switch ON.
Output Voltage
Standard: DC 1.020 ∼ 1.050 V at idle throttle opening
DC 4.185 ∼ 4.385 V at full throttle opening
(for reference)

NOTE
○Open the throttle, confirm the output voltage will be
raise.
○The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.020 × 4.75 ÷ 5.00 = 0.969 V
1.050 × 4.75 ÷ 5.00 = 0.998 V
Thus, the valid range is 0.969 ∼ 0.998 V

• Turn the ignition switch OFF.

If the reading is out of the standard, check the main throt-
tle sensor resistance (see Main Throttle Sensor Resis-
tance Inspection).
 FUEL SYSTEM (DFI) 3-43
Main Throttle Sensor (Service Code 11)
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
Y/W lead (ECU terminal 6) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Main Throttle Sensor Resistance Inspection
• Turn the ignition switch OFF.
• Connect a digital
Disconnect the main throttle sensor connector.
• connector [B]. meter [A] to the main throttle sensor
• Measure the main throttle sensor resistance.
Main Throttle Sensor Resistance
Connections: BL lead [C] ←→ BR/BK lead [D]
Standard: 4 ∼ 6 kΩ
If the reading is out of the standard, replace the throttle
body assy (see Throttle Body Assy Removal/Installation).
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Main Throttle Sensor Circuit

1. ECU
2. Main Throttle Sensor
3. Water-proof Joint 2
4. Water-proof Joint 1
3-44 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
Inlet Air Pressure Sensor Removal
CAUTION
Never drop the inlet air pressure sensor especially
on a hard surface. Such a shock to the sensor can
damage it.

• Remove:
Fuel Tank (see Fuel Tank Removal)
Inlet Air Pressure Sensor Connector [A] (Disconnect)

• Remove the inlet air pressure sensor [A] from the rubber
damper of the air switching valve and separate the vac-
uum hose [B].

Inlet Air Pressure Sensor Installation

• Installation is the reverse of removal.
Inlet Air Pressure Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Disconnectthethe
Remove fuel tank (see Fuel Tank Removal).
• connect the harness
inlet air pressure sensor connector and
adapter [A] between these connec-
tors.
Special Tool - Sensor Harness Adapter: 57001-1561
• Connect a digital meter to the harness adapter leads.
Inlet Air Pressure Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → G (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead

• Measure the input voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V

• Turn the ignition switch OFF.

If the reading is within the standard, check the output volt-
age (see Inlet Air Pressure Sensor Output Voltage Inspec-
tion).
 FUEL SYSTEM (DFI) 3-45
Inlet Air Pressure Sensor (Service Code 12)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Inlet Air Pressure Sensor Connector [B]
BL lead (ECU terminal 8) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Inlet Air Pressure Sensor Output Voltage
Inspection
• Measure the output voltage at the inlet air pressure sen-
sor in the same way as input voltage inspection, note the
following.
○Disconnect the inlet air pressure sensor connector and
connect the harness adapter [A] between these connec-
tors.
Special Tool - Sensor Harness Adapter: 57001-1561

Inlet Air Pressure Sensor Output Voltage

Connections to Adapter:
Digital Meter (+) → G/W (sensor Y/BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead

• Measure the output voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Usable Range: DC 3.80 ∼ 4.20 V at standard
atmospheric pressure (101.32 kPa,
76 cmHg)

NOTE
○The output voltage changes according to local atmo-
spheric pressure.

• Turn the ignition switch OFF.

If the reading is out of the usable range, replace the sen-
sor.
3-46 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connector.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Inlet Air Pressure Sensor Connector [B]
Y/BL lead (ECU terminal 7) [C]
BR/BK lead (ECU terminal 22) [D]

If the wiring is good, check the sensor for various vacuum.

•Remove the inlet air pressure sensor [A] and disconnect
the vacuum hose from the sensor.
•Connect an auxiliary hose [B] to the inlet air pressure sen-
sor.
•Temporarily install the inlet air pressure sensor.
○Connect a digital meter [C], vacuum gauge [D], the fork
oil level gauge [E] and the harness adapter to the inlet air
pressure sensor.
Special Tools - Fork Oil Level Gauge: 57001-1290
Vacuum Gauge: 57001-1369
Sensor Harness Adapter: 57001-1561

Inlet Air Pressure Sensor Output Voltage

Connections to Adapter:
Digital Meter (+) → G/W (sensor Y/BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead
○Turn the ignition switch ON.
○Measure the inlet air pressure sensor output voltage from
various vacuum readings, while pulling the handle of the
fork oil level gauge.
○Check the inlet air pressure sensor output voltage, using
the following formula and chart.
Suppose:
Pg: Vacuum Pressure (Gauge) of Throttle Body
Pl: Local Atmospheric Pressure (Absolute) measured by
a barometer
Pv: Vacuum Pressure (Absolute) of Throttle Body
Vv: Sensor Output Voltage (V)
 FUEL SYSTEM (DFI) 3-47
Inlet Air Pressure Sensor (Service Code 12)
then
Pv = Pl – Pg
For example, suppose the following data is obtained:
Pg = 8 cmHg (Vacuum Gauge Reading)
Pl = 70 cmHg (Barometer Reading)
Vv = 3.2 V (Digital Meter Reading)
then
Pv = 70 – 8 = 62 cmHg (Absolute)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.
Usable range = 3.08 ∼ 3.48 V
Plot Vv (3.2 V) on the vertical line. → Point [3].
Results: In the chart, Vv is within the usable range and
the sensor is normal.
If the reading is out of the usable range, replace the sen-
sor.
If the reading is within the usable range, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-48 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)

ID: Idling
Ps: Standard Atmospheric Pressure (Absolute)
Pv: Throttle Vacuum Pressure (Absolute)
ST: Standard of Sensor Output Voltage (V)
TO: Throttle Full Open
UR: Usable Range of Sensor Output Voltage (V)
Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
 FUEL SYSTEM (DFI) 3-49
Inlet Air Pressure Sensor (Service Code 12)
Inlet Air Pressure Sensor Circuit

1. ECU
2. Water-proof Joint 2
3. Inlet Air Pressure Sensor
4. Water-proof Joint 1
3-50 FUEL SYSTEM (DFI)
Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Removal/Installation
CAUTION
Never drop the inlet air temperature sensor espe-
cially on a hard surface. Such a shock to the sensor
can damage it.

• Remove:
Fuel Tank (see Fuel Tank Removal)
Inlet Air Temperature Sensor Connector [A] (Disconnect)
Inlet Air Temperature Sensor Screw [B]
Inlet Air Temperature Sensor [C]

• Put the inlet air temperature sensor [A] into the air cleaner
housing [B].
• Tighten:
Torque - Inlet Air Temperature Sensor Screw: 1.2 N·m (0.12
kgf·m, 11 in·lb)

Inlet Air Temperature Sensor Output Voltage

Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Disconnectthethe
Remove fuel tank (see Fuel Tank Removal).
• and connect theinletharness
air temperature sensor connector
adapter [A] between these
connectors as shown in the figure.
Main Harness [B]
Inlet Air Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Inlet Air Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor Y) lead
Digital Meter (–) → BK (sensor BR/BK) lead

• Measure the output voltage with the engine stopped and

the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 2.25 ∼ 2.50 V at inlet air
temperature 20°C (68°F)

NOTE
○The output voltage changes according to the inlet air
temperature.
 FUEL SYSTEM (DFI) 3-51
Inlet Air Temperature Sensor (Service Code 13)

• Turn the ignition switch OFF.

If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU and
check the wiring for continuity between main harness side
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Inlet Air Temperature Sensor Connector [B]
Y lead (ECU terminal 20) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the inlet air temperature sensor
resistance (see Inlet Air Temperature Sensor Resistance
Inspection).
Inlet Air Temperature Sensor Resistance
Inspection
• Remove the inlet air temperature sensor (see Inlet Air
Temperature Sensor Removal/Installation).
• Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion is 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.

• Place the container over a source of heat and gradually

raise the temperature of the oil while stirring the oil gently
for even temperature.
• Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the following.
Inlet Air Temperature Sensor Resistance
Standard: 5.4 ∼ 6.6 kΩ at 0°C (32°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
3-52 FUEL SYSTEM (DFI)
Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Circuit

1. ECU
2. Water-proof Joint 1
3. Inlet Air Temperature Sensor
 FUEL SYSTEM (DFI) 3-53
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
CAUTION
Never drop the water temperature sensor especially
on a hard surface. Such a shock to the sensor can
damage it.

• Remove:
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Connector [A] (Disconnect)
Water Temperature Sensor [B]
• Replace the gasket with a new one, and tighten the water
temperature sensor.
Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Fill the engine with coolant and bleed the air from the cool-
ing system (see Coolant Change in the Periodic Mainte-
nance chapter).
Water Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Disconnectthethefuelwater
Remove tank (see Fuel Tank Removal).
• connect the harness adapter
temperature sensor connector and
[A] between these connec-
tors as shown in the figure.
Main Harness [B]
Water Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Water Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor O) lead
Digital Meter (–) → BK (sensor BR/BK) lead

• Measure the output voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 2.80 ∼ 2.97 V at 20°C (68°F)

NOTE
○The output voltage changes according to the coolant
temperature in the engine.

• Turn the ignition switch OFF.

If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-54 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Water Temperature Sensor Connector [B]
O lead (ECU terminal 17) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).
Water Temperature Sensor Resistance Inspection
• Refer to the Water Temperature Sensor Inspection in the
Electrical System chapter.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Water Temperature Sensor Circuit

1. ECU
2. Water-proof Joint 1
3. Water Temperature Sensor
 FUEL SYSTEM (DFI) 3-55
Crankshaft Sensor (Service Code 21)
The crankshaft sensor has no power source, and when
the engine stops, the crankshaft sensor generates no sig-
nals.
Crankshaft Sensor Removal/Installation
• Refer to the Crankshaft Sensor Removal/Installation in
the Electrical System chapter.
Crankshaft Sensor Resistance Inspection
• Refer to the Crankshaft Sensor Inspection in the Electrical
System chapter.
If the reading is within the standard, check the peak volt-
age (see Crankshaft Sensor Peak Voltage Inspection).
Crankshaft Sensor Peak Voltage Inspection
• Refer to the Crankshaft Sensor Peak Voltage Inspection
in the Electrical System chapter.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Crankshaft Sensor Connector [B]
R/BK lead (ECU terminal 11) [C]
Y/BK lead (ECU terminal 24) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Crankshaft Sensor Circuit

1. ECU
2. Crankshaft Sensor
3-56 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24, 25)
Speed Sensor Removal/Installation
• Refer to the Speed Sensor Removal/Installation in the
Electrical System chapter.
Speed Sensor Inspection
• Refer to the Speed Sensor Inspection in the Electrical
System chapter.
Speed Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• the Framethechapter).
Remove left side cover (see Side Cover Removal in

• Disconnect the speed sensor connector and connect the

harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400
• Connect a digital meter to the harness adapter leads.
Speed Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → BL (sensor P) lead
Digital Meter (–) → BK/W (sensor BK) lead

• Measure the input voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V

• Turn the ignition switch OFF.

If the reading is within the standard, check the output volt-
age (see Speed Sensor Output Voltage Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Speed Sensor Connector [B]
BL lead (ECU terminal 8) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
 FUEL SYSTEM (DFI) 3-57
Speed Sensor (Service Code 24, 25)
Speed Sensor Output Voltage Inspection
• Raise the rear wheel off the ground with the stand.
• same waythe
Measure output voltage at the speed sensor in the
as input voltage inspection, note the following.
○Disconnect the speed sensor connector and connect the
harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001
-1400

Speed Sensor Output Voltage

Connections to Adapter:
Digital Meter (+) → Y/W (sensor Y) lead
Digital Meter (–) → BK/W (sensor BK) lead

• Measure the output voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.9 V at
ignition switch ON and 0 km/h

NOTE
○Rotate the rear wheel by hand, confirm the output volt-
age will be raise or lower.

• Turn the ignition switch OFF.

If the reading is out of the standard, replace the sensor.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Speed Sensor Connector [B]
LG/R lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-58 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24, 25)
Speed Sensor Circuit

1. ECU
2. Speed Sensor
3. Water-proof Joint 2
4. Water-proof Joint 1
 FUEL SYSTEM (DFI) 3-59
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Removal
CAUTION
Never drop the vehicle-down sensor especially on
a hard surface. Such a shock to the sensor can
damage it.

• Remove:
Fuel Tank (see Fuel Tank Removal)
Connector [A] (Disconnect)
Vehicle-down Sensor [B]
Vehicle-down Sensor Installation
• The UPPER mark [A] of the sensor should face upward.
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situ-
ations, like leaning over in a turn, with the potential
for an accident resulting in injury or death. Ensure
that the vehicle-down sensor is held in place by the
sensor bracket.
Vehicle-down Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Remove the fuel tank (see Fuel Tank Removal).
• nect the harness
Disconnect the vehicle-down sensor connector and con-
adapter [A] between these connectors
as shown in the figure.
Main Harness [B]
Vehicle-down Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Vehicle-down Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor BR/BK) lead

• Measure the input voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V

• Turn the ignition switch OFF.

If the reading is within the standard, check the output volt-
age (see Vehicle-down Sensor Output Voltage Inspec-
tion).
3-60 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
BL lead (ECU terminal 8) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Vehicle-down Sensor Output Voltage Inspection
• Remove the vehicle-down sensor (see Vehicle-down
Sensor Removal).
• Connect the harness adapter [A] to the vehicle-down sen-
sor connectors as shown in the figure.
Special Tool - Measuring Adapter: 57001-1700
Main Harness [B]
Vehicle-down Sensor [C]
• Connect a digital meter [D] to the harness adapter leads.
Vehicle-down Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (sensor Y/G) lead
Digital Meter (–) → BK (sensor BR/BK) lead
 FUEL SYSTEM (DFI) 3-61
Vehicle-down Sensor (Service Code 31)

• Hold the sensor vertically.

• with the connector
Measure the output voltage with the engine stopped and
joined.
• Turn the ignition switch ON.
• the sensor
Tilt the sensor 55 ∼ 75° or more [A] right or left, then hold
almost vertical with the arrow mark pointed up
[B], and measure the output voltage.
Output Voltage
Standard: With sensor tilted 55 ∼ 75° or more right
or left: DC 3.7 ∼ 4.4 V
With sensor arrow mark pointed up: DC
0.4 ∼ 1.4 V

NOTE
○If you need to test again, turn the ignition switch OFF,
and then ON.

• Turn the ignition switch OFF.

If the reading is out of the standard, replace the sensor.

If the reading is within the standard, remove the ECU and

check the wiring for continuity between main harness con-
nectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
Y/G lead (ECU terminal 9) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-62 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Circuit

1. ECU
2. Water-proof Joint 2
3. Vehicle-down Sensor
4. Water-proof Joint 1
 FUEL SYSTEM (DFI) 3-63
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Removal/Adjustment
CAUTION
Do not remove or adjust the subthrottle sensor [A]
since it has been adjusted and set with precision at
the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the subthrottle sen-
sor can damage it.

Subthrottle Sensor Input Voltage Inspection

NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• ness adapterthe[A]subthrottle
Disconnect sensor and connect the har-
between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
• Connect a digital meter to the harness adapter leads.
Subthrottle Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → BK (sensor BL) lead
Digital Meter (–) → W (sensor BR/BK) lead

• Measure the input voltage with the engine stopped and

with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V

• Turn the ignition switch OFF.

If the reading is within the standard, check the output volt-
age (see Subthrottle Sensor Output Voltage Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subthrottle Sensor Connector [B]
BL lead (ECU terminal 8) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-64 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Output Voltage Inspection
• Measure the output voltage at the subthrottle sensor in
the same way as input voltage inspection, note the fol-
lowing.
○Disconnect the subthrottle sensor connector and connect
the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538

Subthrottle Sensor Output Voltage

Connections to Adapter:
Digital Meter (+) → R (sensor BL/W) lead
Digital Meter (–) → W (sensor BR/BK) lead

• Remove the fuel tank (see Fuel Tank Removal).

• nector [A]. the subthrottle valve actuator harness con-
Disconnect

• Measure the output voltage with the engine stopped with

the connector joined.
• Turn the ignition switch ON.
• completelytheclosed
Measure output voltage when the subthrottle valve is
by turning the lever [A] fully clockwise
[B].
Output Voltage
Standard: DC 0.78 ∼ 0.82 V at subthrottle valve full
close position
DC 3.9 ∼ 4.1 V at subthrottle valve full open
position (for reference)

NOTE
○Turn the lever counterclockwise, confirm the output volt-
age will be raise.
○The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
0.78 × 4.75 ÷ 5.00 = 0.741 V
0.82 × 4.75 ÷ 5.00 = 0.779 V
Thus, the valid range is 0.741 ∼ 0.779 V

• Turn the ignition switch OFF.

If the reading is out of the standard, check the subthrot-
tle sensor resistance (see Subthrottle Sensor Resistance
Inspection).
 FUEL SYSTEM (DFI) 3-65
Subthrottle Sensor (Service Code 32)
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subthrottle Sensor Connector [B]
BL/W lead (ECU terminal 19) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Subthrottle Sensor Resistance Inspection
• Turn the ignition switch OFF.
• Disconnect the subthrottle sensor connector.
• nector [B].
Connect a digital meter [A] to the subthrottle sensor con-

• Measure the subthrottle sensor resistance.

Subthrottle Sensor Resistance
Connections: BL lead [C] ←→ BR/BK lead [D]
Standard: 4 ∼ 6 kΩ
If the reading is out of the standard, replace the throttle
body assy (see Throttle Body Assy Removal/Installation).
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Subthrottle Sensor Circuit

1. ECU
2. Subthrottle Sensor
3. Water-proof Joint 2
4. Water-proof Joint 1
3-66 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33)
Oxygen Sensor Removal/Installation
• Refer to the Oxygen Sensor Removal/Installation in the
Electrical System chapter.
Oxygen Sensor Inspection
• Warm
starts.
up the engine thoroughly until the radiator fan

• Turn the ignition switch OFF.

• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Disconnect the oxygen sensor lead connector and con-
nect the harness adapter [A] between these connectors.
Special Tool - Oxygen Sensor Measuring Adapter: 57001
-1682
• Connect a digital meter to the harness adapter leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → BL/W (sensor BL) lead
Digital Meter (−) → BR/BK (sensor W) lead

• Remove the fuel tank (see Fuel Tank Removal).

• Separate the hose [A] from the air cleaner housing.

• Separate the hose [A] from the air suction valve cover.

○Do not disconnect the air switching valve connector [A].

 FUEL SYSTEM (DFI) 3-67
Oxygen Sensor - not activated (Service Code 33)

• Install the suitable plug [A] on the fitting of the air suction
valve cover, and shut off the secondary air.
• Install the fuel tank (see Fuel Tank Installation).

• Start the engine, and let it idle.

• Measure the output voltage with the connector joined.
Output Voltage (with Plug)
Standard: DC 0.7 V or more

• Next, remove the plug from the fitting [A] with idling.
• Measure the output voltage with the connector joined.
Output Voltage (without Plug)
Standard: DC 0.2 V or less

• Turn the ignition switch OFF.

If the reading is out of the standard (with plug: DC 0.7 V

or more, without plug: DC 0.2 V or less), remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Oxygen Sensor Connector [B]
BL/Y lead (ECU terminal 4) [C]
BR/BK lead (ECU terminal 22) [D]
If the wiring is good, replace the sensor.
If the reading is within the standard (with plug: DC 0.7 V
or more, without plugs: DC 0.2 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-68 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33)
Oxygen Sensor Circuit

1. Ignition Switch
2. Water-proof Joint 3
3. Water-proof Joint 1
4. Oxygen Sensor
5. ECU
6. Joint Connector 2
7. Battery 12 V 8 Ah
8. Frame Ground
9. Main Fuse 30 A
10. Oxygen Sensor Heater Fuse 10 A
11. Fuse Box
 FUEL SYSTEM (DFI) 3-69
Stick Coils #1, #2 (Service Code 51, 52)
Stick Coil #1: Service Code 51
Stick Coil #2: Service Code 52
Stick Coil Removal/Installation
• Refer to the Stick Coil Removal/Installation in the Electri-
cal System chapter.
Stick Coil Primary Winding Resistance Inspection
• Refer to the Stick Coil Inspection in the Electrical System
chapter.
If the reading is within the standard, check the input volt-
age (see Stick Coil Input Voltage Inspection).
Stick Coil Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
•○Remove the ECU (see ECU Removal).
Do not disconnect the ECU connectors.
• Connect a digital meter [A] to the connector [B] with the
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457

Stick Coil Input Voltage

Connections to ECU Connector:
For Stick Coil #1
Digital Meter (+) → BK lead (terminal 35)
Digital Meter (–) → BK/Y lead (terminal 43)
For Stick Coil #2
Digital Meter (+) → BK/G lead (terminal 44)
Digital Meter (–) → BK/Y lead (terminal 43)

• Measure the input voltage to each primary winding of the

stick coils with the engine stopped and with the connec-
tors joined.
• Turn the engine stop switch to run position.
• Turn the ignition switch ON.
Input Voltage
Standard: Battery Voltage

• Turn the ignition switch OFF.

If the input voltage is out of the standard, check the wiring
for continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the input voltage is within the standard, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-70 FUEL SYSTEM (DFI)
Stick Coils #1, #2 (Service Code 51, 52)
Stick Coil Circuit

1. Engine Stop Switch

2. Stick Coil #1, #2
3. Water-proof Joint 3
4. ECU
5. Joint Connector 2
6. Battery 12 V 8 Ah
7. Frame Ground
8. Main Fuse 30 A
9. Ignition Fuse 10 A
10. Fuse Box
11. Ignition Switch
 FUEL SYSTEM (DFI) 3-71
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation
○The radiator fan relay is built in the relay box [A].
• Refer to the Relay Box Removal in the Electrical System
chapter.

Radiator Fan Relay Inspection

• Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.
If the radiator fan relay is normal, check the wiring for
continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-72 FUEL SYSTEM (DFI)
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Circuit

1. ECU
2. Joint Connector 2
3. Battery 12 V 8 Ah
4. Frame Ground
5. Main Fuse 30 A
6. Joint Connector 1
7. Relay Box
8. Fan Relay
9. ECU Fuse 15 A
10. Fan Fuse 10 A
11. Fuse Box
12. Resistor
13. Fan Motor
14. Water-proof Joint 3
15. Water-proof Joint 1
16. Water Temperature Sensor
 FUEL SYSTEM (DFI) 3-73
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Removal
CAUTION
Do not remove the subthrottle valve actuator [A]
since it has been adjusted and set with precision
at the factory.
Never drop the throttle body assy especially on a
hard surface. Such a shock to the subthrottle valve
actuator can damage it.

Subthrottle Valve Actuator Inspection

NOTE
○Be sure the battery is fully charged.
• Remove the throttle body assy (see Throttle Body Assy
Removal).
• Connect the following parts temporary.
Main Throttle Sensor Connector [A]
Subthrottle Sensor Connector [B]
Subthrottle Valve Actuator Connector [C]
• Turn the ignition switch ON.
• Check to see that all the subthrottle valves [D] open and
close smoothly.
• Turn the ignition switch OFF.
If the subthrottle valves do not operate, check the sub-
throttle valve actuator resistance (see Subthrottle Valve
Actuator Resistance Inspection).
Subthrottle Valve Actuator Resistance Inspection
• Turn the ignition switch OFF.
• Disconnectthethefuelsubthrottle
Remove tank (see Fuel Tank Removal).
• valve actuator connector [A].

• Connect a digital meter to the subthrottle valve actuator

connector [A].
• Measure the subthrottle valve actuator resistance.
Subthrottle Valve Actuator Resistance
Connections: BK lead [1] ←→ P lead [2]
G lead [3] ←→ W/BL lead [4]
Standard: About 5.2 ∼ 7.8 Ω
If the reading is out of the standard, replace the throttle
body assy (see Throttle Body Assy Removal/Installation).
If the reading is within the standard, check the input volt-
age (see Subthrottle Valve Actuator Input Voltage Inspec-
tion).
3-74 FUEL SYSTEM (DFI)
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• connect the the
Disconnect subthrottle valve actuator connector and
harness adapter [A] between these connec-
tors as shown in the figure.
Main Harness [B]
Subthrottle Valve Actuator [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect the peak voltage adapter [D] and a digital meter
[E] to the harness adapter leads.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

Subthrottle Valve Actuator Input Voltage

Connections to Adapter:
(I) Digital Meter (+) → R (actuator P) lead
Digital Meter (–) → BK (actuator BK) lead
(II) Digital Meter (+) → W (actuator W/BL) lead
Digital Meter (–) → Y (actuator G) lead

• Measure the actuator input voltage with

stopped and with the connector joined.
the engine

• Turn the ignition switch ON.

Input Voltage
Standard: About DC 11.5 ∼ 13.5 V

• Turn the ignition switch OFF.

If the reading is in specification, but the actuator does not
operate, replace the throttle body assy (see Throttle Body
Assy Removal/Installation).
If the reading is out of the specification, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and actuator connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subthrottle Valve Actuator Connector [B]
W/BL lead (ECU terminal 1) [C]
P lead (ECU terminal 2) [D]
G/Y lead (ECU terminal 14) [E]
BK/BL lead (ECU terminal 15) [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
 FUEL SYSTEM (DFI) 3-75
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Circuit

1. ECU
2. Subthrottle Valve Actuator
3-76 FUEL SYSTEM (DFI)
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation
• Refer to the Air Switching Valve Removal/Installation in
the Engine Top End chapter.
Air Switching Valve Inspection
• Refer to the Air Switching Valve Unit Test in the Electrical
System chapter.
If the air switching valve is normal, check the wiring for
continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Air Switching Valve Circuit

1. ECU 7. ECU Main Relay

2. Joint Connector 2 8. ECU Fuse 15 A
3. Battery 12 V 8 Ah 9. Fuse Box
4. Frame Ground 10. Ignition Switch
5. Main Fuse 30 A 11. Water-proof Joint 3
6. Relay Box 12. Air Switching Valve
 FUEL SYSTEM (DFI) 3-77
Oxygen Sensor Heater (Service Code 67)
Oxygen Sensor Heater Removal/Installation
The oxygen sensor heater is built in the oxygen sensor.
So, the heater itself can not be removed. Remove the oxy-
gen sensor (see Oxygen Sensor Removal in the Electrical
System chapter).
Oxygen Sensor Heater Resistance Inspection
• Turn the ignition switch OFF.
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Disconnect the oxygen sensor lead connector [A].

• Connect a digital meter [A] to the oxygen sensor lead con-

nector [B].
• Measure the oxygen sensor heater resistance.
Oxygen Sensor Heater Resistance
Connections: BK lead [C] ←→ BK lead [D]
Standard: 11.7 ∼ 15.5 Ω at 20°C (68°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, check the power
source voltage (see Oxygen Sensor Heater Power
Source Voltage Inspection).
Oxygen Sensor Heater Power Source Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• nect the harness
Disconnect the oxygen sensor lead connector and con-
adapter [A] between these connectors.
Special Tool - Oxygen Sensor Measuring Adapter: 57001
-1682
• Connect a digital meter to the harness adapter lead.
Oxygen Sensor Power Source Voltage
Connections to Adapter:
Digital Meter (+) → P/Y (sensor BK) lead
Digital Meter (–) → Battery (–) terminal

• Measure the power source voltage with

stopped and with the connector joined.
the engine

• Turn the ignition switch ON.

Power Source Voltage
Standard: Battery Voltage

• Turn the ignition switch OFF.

If the reading is in specification, but the problem still ex-
ists, replace the ECU (see ECU Removal/Installation).
If the reading is out of the standard, check the following.
Oxygen Sensor Heater Fuse 10 A (see Fuse Inspection
in the Electrical System chapter)
Power Source Wiring (see wiring diagram in this section)
3-78 FUEL SYSTEM (DFI)
Oxygen Sensor Heater (Service Code 67)
If the fuse and wiring are good, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Oxygen Sensor Connector [B]
P/BK lead (ECU terminal 23) [C]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Oxygen Sensor Circuit

1. Ignition Switch
2. Water-proof Joint 3
3. Water-proof Joint 1
4. Oxygen Sensor
5. ECU
6. Joint Connector 2
7. Battery 12 V 8 Ah
8. Frame Ground
9. Main Fuse 30 A
10. Oxygen Sensor Heater Fuse 10 A
11. Fuse Box
 FUEL SYSTEM (DFI) 3-79
Oxygen Sensor - Incorrect Output Voltage (Service Code 94)
Oxygen Sensor Removal/Installation
• Refer to the Oxygen Sensor Removal/Installation in the
Electrical System chapter.
Oxygen Sensor Inspection
• Warm
starts.
up the engine thoroughly until the radiator fan

• Turn the ignition switch OFF.

• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Disconnect the oxygen sensor lead connector and con-
nect the harness adapter [A] between these connectors.
Special Tool - Oxygen Sensor Measuring Adapter: 57001
-1682
• Connect a digital meter to the harness adapter leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → BL/W (sensor BL) lead
Digital Meter (−) → BR/BK (sensor W) lead

• Remove the fuel tank (see Fuel Tank Removal).

• Separate the hose [A] from the air cleaner housing.

• Separate the hose [A] from the air suction valve cover.

○Do not disconnect the air switching valve connector [A].

3-80 FUEL SYSTEM (DFI)
Oxygen Sensor - Incorrect Output Voltage (Service Code 94)

• Install the suitable plug [A] on the fitting of the air suction
valve cover, and shut off the secondary air.
• Install the fuel tank (see Fuel Tank Installation).

• Start the engine, and let it idle.

• Measure the output voltage with the connector joined.
Output Voltage (with Plug)
Standard: DC 0.7 V or more

• Next, remove the plug from the fitting [A] with idling.
• Measure the output voltage with the connector joined.
Output Voltage (without Plug)
Standard: DC 0.2 V or less

• Turn the ignition switch OFF.

If the reading is out of the standard (with plug: DC 0.7 V or
more, without plug: DC 0.2 V or less), check the following.
Fuel Pressure (see Fuel Pressure Inspection)
Fuel Injector (see Fuel Injectors section)
If the fuel pressure and fuel injectors are good, replace
the sensor.
If the reading is within the standard (with plug: DC 0.7 V
or more, without plug: DC 0.2 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
 FUEL SYSTEM (DFI) 3-81
Oxygen Sensor - Incorrect Output Voltage (Service Code 94)
Oxygen Sensor Circuit

1. Ignition Switch
2. Water-proof Joint 3
3. Water-proof Joint 1
4. Oxygen Sensor
5. ECU
6. Joint Connector 2
7. Battery 12 V 8 Ah
8. Frame Ground
9. Main Fuse 30 A
10. Oxygen Sensor Heater Fuse 10 A
11. Fuse Box
3-82 FUEL SYSTEM (DFI)
FI Indicator Light
Light Inspection
• Refer to the Lights and Switches Operation Inspection in
the Periodic Maintenance chapter.
FI Indicator Light Circuit

1. Ignition Switch
2. Water-proof Joint 3
3. ECU
4. Joint Connector 2
5. Battery 12 V 8 Ah
6. Frame Ground
7. Main Fuse 30 A
8. Ignition Fuse 10 A
9. Fuse Box
10. FI Indicator Light
 FUEL SYSTEM (DFI) 3-83
ECU
ECU Identification
○Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with
each other and use only the ECU for your model. Other-
wise, the motorcycle cannot clear the regulation.
ECU Identification
Part Number [A] Specification
WVTA (FULL N)
21175-0199
GB WVTA (FULL N)

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

• Remove:
Seat Covers (see Seat Cover Removal in the Frame
chapter)
Bolts [A]
Brackets [B]

• Lift up the ECU [A] with rubber protector [B].

• Remove:
ECU Connectors [A] (Disconnect)
ECU [B]

ECU Installation
• Install:
ECU [A] (In Rubber Protector [B])
ECU Connectors [C] (Connect)
3-84 FUEL SYSTEM (DFI)
ECU

• Insert the slits of the rubber protector to the projections

[A] of the rear fender.

ECU Power Supply Inspection

• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Visually inspect the ECU connectors.
If the connector is clogged with mud or dust, blow it off
with compressed air.
• Remove the ECU (see ECU Removal).
• Visually inspect the terminals [A] of the ECU connectors.
If the terminals of the main harness connectors are dam-
aged, replace the main harness.
If the terminals of the ECU connectors are damaged, re-
place the ECU.

• Turn the ignition switch OFF.

• Set the handthetester
Disconnect ECU connectors [A].
• following wiring for continuity.
[B] to the × 1 Ω range and check the

Special Tool - Hand Tester: 57001-1394

ECU Grounding Continuity Inspection

Connections:
(I) BK/Y leads (ECU
←→ Battery (–) Terminal
terminal 26, 42 or 43)
(II) Engine Ground ←→ Battery (–) Terminal
Criteria:
Both: 0 Ω
If no continuity, check the connectors, the engine ground
lead, or main harness, and repair or replace them if nec-
essary.
 FUEL SYSTEM (DFI) 3-85
ECU
If the wiring is good, check the power source voltage of
the ECU.
NOTE
○Be sure the battery is fully charged.
• Connect the ECU connectors.
• needle adapter
Connect a digital meter [A] to the connector [B] with the
set.
Special Tool - Needle Adapter Set: 57001-1457

ECU Power Supply Inspection

Connections:
(I) Digital Meter (+) → Terminal 12 (BR/W)
Digital Meter (–) → Battery (–) terminal
(II) Digital Meter (+) → Terminal 27 (W/BK)
Digital Meter (–) → Battery (–) terminal
Ignition Switch OFF:
Terminal 12 (BR/W): 0 V
Terminal 27 (W/BK): Battery Voltage
Ignition Switch ON:
Both: Battery Voltage
If the reading is out of the specification, check the follow-
ing.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
ECU Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
ECU Main Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Power Source Wiring (see wiring diagram in this sec-
tion )
If the fuse, wiring and relay are good, replace the ECU
(see ECU Removal/Installation).
3-86 FUEL SYSTEM (DFI)
ECU
ECU Power Source Circuit

1. Ignition Switch
2. Water-proof Joint 3
3. ECU
4. Joint Connector 2
5. Battery 12 V 8 Ah
6. Frame Ground
7. Main Fuse 30 A
8. Relay Box
9. ECU Main Relay
10. ECU Fuse 15 A
11. Fuse Box
 FUEL SYSTEM (DFI) 3-87
DFI Power Source
ECU Fuse Removal
• Refer to the 15 A ECU Fuse Removal in the Electrical
System chapter.
ECU Fuse Installation
If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.
• Refer to the Fuse Installation in the Electrical System
chapter.
ECU Fuse Inspection
• Refer to the Fuse Inspection in the Electrical System
chapter.
ECU Main Relay Removal/Installation
○The ECU main relay is built in the relay box [A].
• Refer to the Relay Box Removal in the Electrical System
chapter.

ECU Main Relay Inspection

• Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.
3-88 FUEL SYSTEM (DFI)
Fuel Line
Fuel Pressure Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
○ sure to place a piece of cloth around the fuel supply
Be
pipes of the fuel pump and the throttle body assy.
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.

• Install the fuel pressure gauge adapter [A] and fuel hoses
(Special Tool: 57001-1607) [B] between the fuel supply
pipes of the fuel pump and throttle body assy.
• Secure the fuel hoses with the clamps.
• Connect the pressure gauge [C] to the fuel pressure
gauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607
WARNING
Do not try to start the engine with the fuel hoses
disconnected.

• Connect the fuel pump lead connector.

• Turn the ignition stop
Turn the engine switch run position.
•○The fuel pump should
switch ON.
operate for 3 seconds, and then
should stop.
NOTE
○After turning on the engine stop switch and ignition
switch, inspect the fuel leakage from the connected
portion of the special tools.

CAUTION
Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.

• Start the engine, and let it idle.

• Measure the fuel pressure with the engine idling.
Fuel Pressure (with Engine Idling)
Standard: 294 kPa (3.0 kgf/cm², 43 psi)
 FUEL SYSTEM (DFI) 3-89
Fuel Line
NOTE
○The gauge needle will fluctuate.
Read the pressure at
the average of the maximum and minimum indications.

• Turn the ignition switch OFF.

If the fuel pressure is much higher than specified, replace
the fuel pump because the fuel pressure regulator in the
fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check
the following.
Fuel Line Leakage (see Fuel Injector Fuel Line Inspec-
tion)
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
• After above checks, measure the fuel pressure again.
• Remove the fuel pressure gauge, hoses and adapter.
• Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)
• Start the engine and check for fuel leakage.
Fuel Flow Rate Inspection
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.

NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Wait until the engine cools down.
• measuringa fuel
Prepare hose (Special Tool:
cylinder.
57001-1607) and a

Special Tool - Fuel Hose: 57001-1607

• Remove the fuel tank bolts (see Fuel Tank Removal).
• Open
tank.
the fuel tank cap [A] to lower the pressure in the

• Remove
Removal).
the fuel hose from the fuel pump (see Fuel Tank

○Be sure to place a piece of cloth around the fuel supply

pipe of the fuel pump.
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.
3-90 FUEL SYSTEM (DFI)
Fuel Line

• Connect the prepared fuel hose [A] to the fuel supply pipe
of the fuel pump.
• Secure the fuel hose with a clamp.
• Insert the fuel hose into the measuring cylinder [B].
WARNING
Wipe off spilled out fuel immediately. Be sure to
hold the measuring cylinder vertical.

• Close the fuel tank cap.

• Turn the engine
Turn the stop switch to run position.
•○The fuel ignition switch ON.
pump should operate for 3 seconds, and then
should stop.

CAUTION
Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.

•○Measure the discharge for 3 seconds.

Repeat this operation several times.
Amount of Fuel Flow
Standard: 17 mL (0.57 US oz.) or more for 3 seconds

• Turn the ignition switch OFF.

If the fuel flow is much less than the specified, replace the
fuel pump (see Fuel Pump Removal/Installation).
• Install the fuel tank (see Fuel Tank Installation).
• Start the engine and check for fuel leakage.
 FUEL SYSTEM (DFI) 3-91
Fuel Pump
Fuel Pump 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
and 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.

CAUTION
Never drop the fuel pump especially on a hard sur-
face. Such a shock to the pump can damage it.

• Draw the fuel out from the fuel tank with a commercially
available electric pump.
•○Remove the fuel tank (see Fuel Tank Removal).
Be careful of fuel spillage from the fuel tank since fuel
still remains in the fuel tank and fuel pump. Plug the fuel
supply pipe of the fuel pump.

• Turn the fuel tank upside down.

• Unscrew
Free the lead from the clamp [A].
• pump [C].the fuel pump bolts [B], and take out the fuel
CAUTION
Do not pull the lead of the fuel pump. If they are
pulled, the lead terminals may be damaged.

• Discard the fuel pump gasket [A].

3-92 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Installation
• Remove dirt or dust from the fuel pump [A] by lightly ap-
plying compressed air.
• Replace the fuel pump gasket with a new one.

• Apply a non-permanent locking agent to the threads of

the fuel pump bolts.
• Tighten the fuel pump bolts to a snug fit, tighten them
alternating diagonally.
Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Tighten the pump bolts again alternating diagonally to
check the tightness.
• Hold the lead [A] with the clamp [B].
Fuel Pump Operation Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the engine stop switch to run position.
• Turn the ignition switch ON and make sure that the fuel
pump operates (make light sounds) for 3 seconds, and
then stops.
• Turn the ignition switch OFF.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).
 FUEL SYSTEM (DFI) 3-93
Fuel Pump
Fuel Pump Operating Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Remove the fuel tank bolts (see Fuel Tank Removal).
• harness adapter
Disconnect the fuel pump lead connector and connect the
[A] between these connectors as shown
in the figure.
Main Harness [B]
Fuel Pump [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Fuel Pump Operating Voltage
Connections to Adapter:
Digital Meter (+) → R (pump R) lead
Digital Meter (–) → BK (pump BK) lead

• Measure the operating voltage with engine stopped and

with the connector joined.
• Turn the engine stop switch run position.
• Turn the ignition switch ON.
Operating Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V

• Turn the ignition switch OFF.

If the reading stays on battery voltage and never shows 0
V, check the fuel pump relay (see Relay Circuit Inspection
in the Electrical System chapter).
If the pump relay is normal, check the ECU for its ground
and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If there is still no battery voltage, check the ECU main
relay and fuel pump relay (see Relay Circuit Inspection in
the Electrical System chapter).
If the main relay and pump relay are normal, check the
wiring for continuity (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is in specification, but the pump does not op-
erate, replace the fuel pump (see Fuel Pump Removal/In-
stallation).
3-94 FUEL SYSTEM (DFI)
Fuel Pump
Pressure Regulator Removal
○The pressure regulator [A] is built into the fuel pump [B]
and can not be removed.

Fuel Filter Cleaning

○The fuel filter [A] are built into the pump and can not be
cleaned or checked.
If the fuel filter is suspected of clogging or being damaged,
replace it with the fuel pump as a set.

Fuel Pump Relay Removal/Installation

○The fuel pump relay is built in the relay box [A].
• Refer to the Relay Box Removal in the Electrical System
chapter.

Fuel Pump Relay Inspection

• Refer to the Relay Circuit Inspection in the Electrical Sys-
tem chapter.
 FUEL SYSTEM (DFI) 3-95
Fuel Pump
Fuel Pump Circuit

1. Ignition Switch
2. Engine Stop Switch
3. Water-proof Joint 3
4. ECU
5. Joint Connector 2
6. Fuel Pump
7. Battery 12 V 8 Ah
8. Frame Ground
9. Main Fuse 30 A
10. Fuel Pump Relay
11. Relay Box
12. ECU Main Relay
13. Ignition Fuse 10 A
14. ECU Fuse 15 A
15. Fuse Box
3-96 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Removal/Installation
• Refer to the Throttle Body Assy Disassembly/Assembly.
Fuel Injector Audible Inspection
NOTE
○Be sure the battery is fully charged.
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Start the engine, and let it idle.
• Put thethegriptipend
Apply of a screwdriver [A] to the fuel injector [B].
onto your ear, and listen whether the fuel
injector is clicking or not.
○A sound scope can also be used.
○The click interval becomes shorter as the engine speed
rises.
•Do the same for the other fuel injector.
If all the fuel injectors click at a regular intervals, the fuel
injectors are normal.
•Turn the ignition switch OFF.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).
Fuel Injector Resistance Inspection
• Remove the fuel tank (see Fuel Tank Removal).
• Connect a digital
Disconnect the injector connector [A].
• Measure the fuel meter to the terminals of the injector [B].
• injector resistance.
Fuel Injector Resistance
Connections:
For Fuel Injector #1
W/R ←→ BL/R terminal
For Fuel Injector #2
W/R ←→ BL/G terminal

Standard: About 11.7 ∼ 12.3 Ω at 20°C (68°F)

If the reading is out of the standard, replace the injector.
If the reading is within the standard, check the power
source voltage (see Fuel Injector Power Source Voltage
Inspection).
 FUEL SYSTEM (DFI) 3-97
Fuel Injectors
Fuel Injector Power Source Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Disconnect the injector connector and connect the har-
ness adapter [A] between these connectors as shown in
the figure.
Main Harness [B]
Fuel Injector #1 [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Fuel Injector Power Source Voltage
Connections to Adapter:
For Fuel Injector #1, #2
Digital Meter (+) → R (injector W/R) lead
Digital Meter (–) → Battery (–) terminal

• Measure
stopped.
the power source voltage with the engine

• Turn the engine stop switch to run position.

• the ignition switch ON.
Turn
Power Source Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V

• Turn the ignition switch OFF.

If the reading stays on battery voltage and never shows 0
V, check the fuel pump relay (see Relay Circuit Inspection
in the Electrical System chapter).
If the pump relay is normal, check the ECU for its ground
and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If there is still no battery voltage, check the ECU main
relay and pump relay (see Relay Circuit Inspection in the
Electrical System chapter).
If the main relay and pump relay are normal, check the
power source wiring (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is in specification, check the output voltage
(see Fuel Injector Output Voltage Inspection).
3-98 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Output Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
•○Remove the ECU (see ECU Removal).
Do not disconnect the ECU connector.
• Connect a digital meter [A] to the connector [B] with the
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457

Fuel Injector Output Voltage

Connections to ECU Connector:
For Fuel Injector #1
Digital Meter (+) → BL/R lead (ECU terminal 34)
Digital Meter (–) → Battery (–) terminal
For Fuel Injector #2
Digital Meter (+) → BL/G lead (ECU terminal 33)
Digital Meter (–) → Battery (–) terminal

• Measure the output voltage with the engine stopped and

with the connector joined.
• Turn the engine stop switch to run position.
• the ignition switch ON.
Turn
Output Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V

• Turn the ignition switch OFF.

If the reading is in specification, check the ECU for its
ground and power supply (see ECU Power Supply In-
spection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the specification, remove the ECU
and check the wiring for continuity between main harness
connector.
Special Tool - Hand Tster: 57001-1394
○Disconnect the ECU and injector connector.
Wiring Continuity Inspection
ECU Connector [A] ←→ Fuel Injector Connector [B]
For Fuel Injector #1 [C]
BL/R lead (ECU terminal 34) [D]
For Fuel Injector #2
BL/G lead (ECU terminal 33)
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
 FUEL SYSTEM (DFI) 3-99
Fuel Injectors
Fuel Injector Fuel Line Inspection
• Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
○Be sure to place a piece of cloth around the fuel supply
pipes of the fuel pump and the throttle body assy.
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.

•○Check the injector fuel line for leakage as follows.

Connect a commercially available vacuum/pressure
pump [A] to the nipple of the fuel supply pipe [B] with the
fuel hose [C] (both ends with the clamps [D]) as shown
in the figure.
Right Side View [E]
○Apply soap and water solution to the areas [F] as shown
in the figure.
○Watching the pressure gauge, squeeze the pump lever
[G], and build up the pressure until the pressure reaches
the maximum pressure.
Injector Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm², 43 psi)

CAUTION
During pressure testing, do not exceed the maxi-
mum pressure for which the system is designed.

○Watch the gauge for at least 6 seconds.

If the pressure holds steady, the fuel line is good.
If the pressure drops at once or if bubbles are found in the
area, the fuel line is leaking. Replace the fuel supply pipe
assy, injectors and related parts.
○Repeat the leak test, and check the fuel line for no leak-
age.
•Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)
•Start the engine and check for fuel leakage.
3-100 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Circuit

1. Ignition Switch
2. Engine Stop Switch
3. Water-proof Joint 3
4. Fuel Injector #1, #2
5. ECU
6. Joint Connector 2
7. Fuel Pump
8. Battery 12 V 8 Ah
9. Frame Ground
10. Main Fuse 30 A
11. Fuel Pump Relay
12. Relay Box
13. ECU Main Relay
14. Ignition Fuse 10 A
15. ECU Fuse 15 A
16. Fuse Box
 FUEL SYSTEM (DFI) 3-101
Throttle Grip and Cables
Free Play Inspection
• Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.
Free Play Adjustment
• Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.
Cable Installation
• Install the throttle cables in accordance with the Cable,
Wire, and Hose Routing section in the Appendix chapter.
• Install the lower ends of the throttle cables in the throttle
pulley on the throttle body assy after installing the upper
ends of the throttle cables in the grip.
• After installation, adjust each cable properly (see Throttle
Control System Inspection in the Periodic Maintenance
chapter).
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition.

Cable Lubrication
• Refer to the Chassis Parts Lubrication in the Periodic
Maintenance chapter.
3-102 FUEL SYSTEM (DFI)
Throttle Body Assy
Idle Speed Inspection/Adjustment
• Refer to the Idle Speed Inspection/Adjustment in the Pe-
riodic Maintenance chapter.
Synchronization Inspection/Adjustment
• Refer to the Engine Vacuum Synchronization Inspection
in the Periodic Maintenance chapter.
Throttle Body Assy 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.
Be prepared for fuel spillage: any spilled fuel must
be completely wiped up immediately.

CAUTION
Never drop the throttle body assy especially on a
hard surface. Such a shock to the body assy can
damage it.

• Remove:
Fuel Tank (see Fuel Tank Removal)
Vacuum Hose [A]
Fuel Injector Connectors [B]
Subthrottle Valve Actuator Connector [C]

• Disconnect:
Main Throttle Sensor Connector [A]
Subthrottle Sensor Connector [B]
 FUEL SYSTEM (DFI) 3-103
Throttle Body Assy

• Loosen the nuts [A], and remove the throttle cable lower
ends [B].

• Remove:
Bolts [A]
Idle Adjusting Cable [B] (from Bracket)

• Remove:
Air Switching Valve Hose [A]
Bracket Bolts [B]
Right Air Cleaner Housing Mounting Bolt [C]

• Remove the left air cleaner housing mounting bolt [A].

• Move [C] theairairduct
Loosen the clamp screws [B].
• out the air ducts from thehousing
cleaner [D] backward, and pull
throttle body assy.

• Loosen the throttle body assy holder clamp screws [A],

and pull out the throttle body assy [B] backward.
• Remove the throttle body assy to left side of motorcycle.
• After removing the throttle body assy, stuff pieces of lint-
free, clean cloth into the throttle body assy holders.
CAUTION
If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.
3-104 FUEL SYSTEM (DFI)
Throttle Body Assy
Throttle Body Assy Installation
• Install the throttle body assy holder clamp screws in the
direction as shown in the figure.
Screw Heads [A]
• Install the throttle body assy to the throttle body assy hold-
ers.
• Tighten:
Torque - Throttle Body Assy Holder Clamp Screws: 2.0
N·m (0.20 kgf·m, 18 in·lb)

• Install the air duct clamp screws in the direction as shown

in the figure.
Screw Heads [A]
About 21° [B]
• Install the air ducts to the throttle body assy.
• Tighten:
Torque - Air Duct Clamp Screws: 2.0 N·m (0.20 kgf·m, 18
in·lb)
Air Cleaner Housing Mounting Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)

• Apply
ends.
a thin coating of grease to the throttle cable lower

• Fit the accelerator cable end and the decelerator cable

end into the throttle pulley.
• Turn the throttle grip and make sure that the throttle valves
move smoothly and return by spring force.
• Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
• Adjust:
Throttle Grip Free Play (see Throttle Control System In-
spection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
 FUEL SYSTEM (DFI) 3-105
Throttle Body Assy
Throttle Body Assy Disassembly

1. Subthrottle Valve Actuator

2. Subthrottle Sensor
3. Main Throttle Sensor
4. Throttle Body Assy
5. Fuel Injectors
6. Delivery Pipe Assy
CAUTION
Do not remove, disassemble or adjust the main
throttle sensor, subthrottle sensor, subthrottle
valve actuator, throttle link mechanism and throttle
body assy, because they are adjust or set surely at
the manufacturer. Adjustment of these parts could
result in poor performance, requiring replacement
of the throttle body assy.

• Remove
Removal).
the throttle body assy (see Throttle Body Assy

• Cut the band [A].

• throttle body
Remove the screws [B] to pull out the injectors from the
assy together with the delivery pipe assy [C].
NOTE
○Do not damage the insertion portions of the injectors
when they are pulled out from the throttle body.
3-106 FUEL SYSTEM (DFI)
Throttle Body Assy

• Pull out the injectors [A] from the delivery pipe assy [B].
NOTE
○Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.

CAUTION
Never drop the fuel injector especially on a hard
surface. Such a shock to the injector can damage
it.

Throttle Body Assy Assembly

• Before assembling, blow away dirt or dust from the throttle
body and delivery pipe by applying compressed air.
• Replace the O-rings [A] of each injector [B] with new ones.
• Apply engine oil to the new O-rings, insert them to the
delivery pipe assy [C] and confirm whether the injectors
turn smoothly or not.

• Replace the dust seals [A] with new ones.

• Install the injectors
Apply engine oil to the new dust seals.
• the throttle body. along with the delivery pipe assy to
• Tighten:
Torque - Delivery Pipe Assy Mounting Screws: 3.4 N·m
(0.35 kgf·m, 30 in·lb)
• Bind the lead with band.
• stallation).
Install the throttle body assy (see Throttle Body Assy In-
 FUEL SYSTEM (DFI) 3-107
Air Cleaner
Air Cleaner Element Removal/Installation
• Refer to the Air Cleaner Element Replacement in the Pe-
riodic Maintenance chapter.
Air Cleaner Element Inspection
• Remove the air cleaner element (see Air Cleaner Element
Replacement in the Periodic Maintenance chapter).
• Visually check the element [A] for tears or breaks.
If the element has any tears or breaks, replace the ele-
ment.

Air Cleaner Oil Draining

• Visually
mulates.
check the drain cap [A] if the water or oil accu-

If any water or oil accumulates in the cap, remove the cap

and drain it.
WARNING
Be sure to reinstall the cap after draining. Oil on
tires will make them slippery and can cause an ac-
cident and injury.

Air Cleaner Housing Removal

• Remove:
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Fuel Tank (see Fuel Tank Removal)
Air Switching Valve Hose [A]
Bracket Bolts [B]
Right Air Cleaner Housing Mounting Bolt [C]
Rear Fender (see Flap and Rear Fender Removal in the
Frame chapter)

• Remove:
Left Air Cleaner Housing Mounting Bolt [A]
Breather Hose [B]
3-108 FUEL SYSTEM (DFI)
Air Cleaner

• Loosen the air duct clamp screws [A].

• portion [C]thefrom
Remove air cleaner housing [B], pulling out the duct
the grommet.

• After removing the air cleaner housing, stuff pieces of lint-

free, clean cloth into the throttle body assy.
CAUTION
If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.

Air Cleaner Housing Installation

•○Install is the reverse of removal.
Install the air duct clamp screws in the direction as shown
in the figure.
Screw Heads [A]
About 21° [B]

○Insert the duct portion [A] into the grommet [B].

○Tighten:
Torque - Air Duct Clamp Screws: 2.0 N·m (0.20 kgf·m, 18
in·lb)
Air Cleaner Housing Mounting Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters).

Air Cleaner Housing Disassembly

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Air Cleaner Element (see Air Cleaner Element Replace-
ment in the Periodic Maintenance chapter)
Screws [A]
Right Cover [B]
Flame Arrester
 FUEL SYSTEM (DFI) 3-109
Air Cleaner
Air Cleaner Housing Assembly
• Install the flame arrester [A].
• Be sure the O-ring [B] is in position.

• Apply a adhesive cement to the slash portion [A] of the air

cleaner housing.
• Install the right cover.
• Tighten:
Torque - Air Cleaner Housing Screws: 1.15 N·m (0.12
kgf·m, 10 in·lb)
3-110 FUEL SYSTEM (DFI)
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
and 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 when the engine is cold.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.

• Turn the ignition switch OFF.

• Disconnectthetheengine
Wait until cools down.
• in the Electrical System(–)chapter).
battery terminal (see Battery Removal

• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank Bolts [A]

• Pull off the fuel tank drain hose [A] from the fuel tank.

• Open
tank.
the fuel tank cap [A] to lower the pressure in the
 FUEL SYSTEM (DFI) 3-111
Fuel Tank

• Draw the fuel out from the fuel tank with a commercially
available pump [A].
○Use a soft plastic hose [B] as a pump inlet hose in order
to insert the hose smoothly.
○Put the hose through the fill opening [C] into the tank and
draw the fuel out.
Front [D]
WARNING
The fuel could not be removed completely from the
fuel tank. Be careful for remained fuel spillage.

• Disconnect the fuel pump lead connector [A].

• Be sure to place a piece of cloth [A] around the fuel hose

joint [B].
• Push the joint lock claws [C].

• Pull the joint lock [A] as shown in the figure.

• Pull [B] the fuel hose joint [C] out of the fuel supply pipe.
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.

• Close the fuel tank cap.

• Remove the fuel tank, and place a it on a flat surface.
3-112 FUEL SYSTEM (DFI)
Fuel Tank
Fuel Tank Installation
• Note the above WARNING (see Fuel Tank Removal).
• ing section
Run the hoses correctly (see Cable, Wire, and Hose Rout-
in the Appendix chapter).
• the fuel tank. dampers [A] are in place on the frame and
Check that the

If the dampers are damaged or deteriorated, replace

them.

• Pull the joint lock [A] as shown in the figure.

• Insert the fuel hose joint [A] straight onto the fuel supply
pipe until the hose joint clicks.
• Push the joint lock [B] until the hose joint clicks.

• Push and pull [A] the hose joint [B] back and forth more
than two times, and make sure it is locked and does not
come off.
WARNING
Make sure the hose joint is installed correctly on the
supply pipe or the fuel could leak.
If it comes off, reinstall the hose joint.
• Connect the fuel pump lead connector and the battery (–)
terminal (see Battery Installation in the Electrical System
chapter).
 FUEL SYSTEM (DFI) 3-113
Fuel Tank
Fuel Tank Inspection
• Open the tank cap.
• damage.inspect the gasket [A] on the tank cap for any
Visually

Replace the gasket if it is damaged.

• Check to see if the water drain pipe [B] in the tank are not
clogged. Check the tank cap breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.
CAUTION
Do not apply compressed air to the air vent holes
[C] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.

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 or
highly flammable liquids, do not use gasoline or
low-flash point solvents to clean the tank.

• Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Pump (see Fuel Pump Removal)
• Pour some high-flash point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
• Draw the solvent out of the fuel tank.
• Dry the tank with compressed air.
• Install:
Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)
 COOLING SYSTEM 4-1

Cooling System
Table of Contents
Exploded View........................................................................................................................ 4-2
Coolant Flow Chart................................................................................................................. 4-4
Specifications ......................................................................................................................... 4-6
Coolant ................................................................................................................................... 4-7
Coolant Deterioration Inspection....................................................................................... 4-7
Coolant Level Inspection................................................................................................... 4-7 4
Coolant Draining ............................................................................................................... 4-7
Coolant Filling ................................................................................................................... 4-7
Pressure Testing ............................................................................................................... 4-7
Cooling System Flushing .................................................................................................. 4-8
Coolant Reserve Tank Removal ....................................................................................... 4-8
Coolant Reserve Tank Installation .................................................................................... 4-8
Water Pump............................................................................................................................ 4-9
Water Pump Cover Removal ............................................................................................ 4-9
Water Pump Cover Installation ......................................................................................... 4-9
Water Pump Removal ....................................................................................................... 4-9
Water Pump Installation .................................................................................................... 4-9
Water Pump Impeller Inspection ....................................................................................... 4-10
Radiator .................................................................................................................................. 4-11
Radiator and Radiator Fan Removal ................................................................................ 4-11
Radiator and Radiator Fan Installation ............................................................................. 4-12
Radiator Inspection ........................................................................................................... 4-12
Radiator Cap Inspection ................................................................................................... 4-12
Radiator Filler Neck Inspection ......................................................................................... 4-13
Thermostat ............................................................................................................................. 4-14
Thermostat Removal......................................................................................................... 4-14
Thermostat Installation...................................................................................................... 4-14
Thermostat Housing Removal .......................................................................................... 4-14
Thermostat Housing Installation ....................................................................................... 4-14
Thermostat Inspection ...................................................................................................... 4-15
Hoses and Pipes .................................................................................................................... 4-16
Hose Installation ............................................................................................................... 4-16
Hose Inspection ................................................................................................................ 4-16
Water Temperature Sensor .................................................................................................... 4-17
Water Temperature Sensor Removal/Installation ............................................................. 4-17
Water Temperature Sensor Inspection ............................................................................. 4-17
4-2 COOLING SYSTEM
Exploded View
 COOLING SYSTEM 4-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Coolant Drain Bolt (Cylinder) 5.9 0.60 52 in·lb
2 Coolant Drain Bolt (Water Pump) 9.8 1.0 87 in·lb
3 Radiator Bolts 9.8 1.0 87 in·lb
4 Radiator Cap Bracket Bolt 9.8 1.0 87 in·lb
5 Radiator (Water) Hose Clamp Screws 1.5 0.15 13 in·lb
6 Reserve Tank Bolts 9.8 1.0 87 in·lb
7 Reserve Tank Bracket Bolts 9.8 1.0 87 in·lb
8 Reserve Tank Cap – – – Hand-Tighten
9 Resistor Bolt 7.8 0.80 69 in·lb
10 Thermostat Cover Bolts 9.8 1.0 87 in·lb
11 Thermostat Housing Mounting Bolts 9.8 1.0 87 in·lb
12 Water Hose Fitting Bolts 9.8 1.0 87 in·lb
13 Water Pipe Bolts 9.8 1.0 87 in·lb
14 Water Pump Bolts 9.8 1.0 87 in·lb
15 Water Pump Cover Bolts 9.8 1.0 87 in·lb
16 Water Temperature Sensor 25 2.5 18
G: Apply grease.
R: Replacement Parts
4-4 COOLING SYSTEM
Coolant Flow Chart
 COOLING SYSTEM 4-5
Coolant Flow Chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The
thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is less than 63.5 ∼ 66.5°C (146 ∼ 152°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 63.5 ∼ 66.5°C (146 ∼ 152°F), the thermostat opens and the
coolant flows.
When the coolant temperature goes up beyond 103°C (217°F), the radiator fan relay conducts to
operate the radiator fan. The radiator fan draws air through the radiator core when there is not suffi-
cient air flow such as at low speeds. This increases up the cooling action of the radiator. When the
coolant temperature is below 98°C (208°F), the fan relay opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine 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 ∼ 18
psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure
escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi).
When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the
coolant from the reserve tank to enter the radiator.
4-6 COOLING SYSTEM
Specifications

Item Standard
Coolant Provided when Shipping
Type (Recommended) Permanent type of antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
Color Green
Mixed Ratio Soft water 50%, coolant 50%
Freezing Point −35°C (−31°F)
Total Amount 1.5 L (1.6 US qt) (reserve tank full level, including radiator
and engine)
Radiator Cap
Relief Pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
Thermostat
Valve Opening Temperature 63.5 ∼ 66.5°C (146 ∼ 152°F)
Valve Full Opening Lift 6 mm (0.24 in.) or more at 80°C (176°F)
 COOLING SYSTEM 4-7
Coolant
Coolant Deterioration Inspection
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• 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, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
• Refer to the Coolant Level Inspection in the Periodic Main-
tenance chapter.
Coolant Draining
• Refer to the Coolant Change in the Periodic Maintenance
chapter.
Coolant Filling
• Refer to the Coolant Change in the Periodic Maintenance
chapter.
Pressure Testing
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Remove the radiator cap, and install a cooling system
pressure tester [A] on the filler neck.
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.

• Build up pressure in the system carefully until the pres-

sure reaches 123 kPa (1.25 kgf/cm², 18 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 kgf/cm², 18 psi).

• Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is all right.
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
water pump.
• Remove the pressure tester, replenish the coolant, and
install the radiator cap.
4-8 COOLING SYSTEM
Coolant
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool-
ing system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the effi-
ciency of the cooling system.
• 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.

• Warm up the engine, and run it at normal operating tem-

perature for about ten minutes.
• Stop the engine, and drain the cooling system.
• Warm upsystem
Fill the with fresh water.
• Repeat the previous two
the engine and drain the system.
• Fill the system with a permanent
steps once more.
• the air from the system (see Coolant type coolant and bleed
Change in the Peri-
odic Maintenance chapter).
Coolant Reserve Tank Removal
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Coolant [A] (from Reserve Tank) (Drain, see Coolant
Change in the Periodic Maintenance chapter)
Bolts [B]
Hoses [C]
Clutch Cable [D] (see Clutch Cable Removal in the
Clutch chapter)
Coolant Reserve Tank [E]
Coolant Reserve Tank Installation
• Installation is the reverse of removal.
• Hose Routing section
Run the cable and hoses correctly (see Cable, Wire, and
in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
Torque - Reserve Tank Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
 COOLING SYSTEM 4-9
Water Pump
Water Pump Cover Removal
• Remove:
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
Bolts [A] and Water Pipes [B]

• Remove:
Water Pump Cover Bolts [A]
Water Pump Cover [B]

Water Pump Cover Installation

• Apply grease to a new O-ring [A].
• Install the
Fit the O-ring into the groove of the water pump cover [B].
• the bolts. water pump cover and water pipes, and tighten
Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Water Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters).
Water Pump Removal
• Remove:
Water Pump Cover (see Water Pump Cover Removal)
Water Pump Bolts [A]
Water Pump [B]

Water Pump Installation

• Apply grease to a new O-ring [A].
• pump shaft
Install the water pump aligning the slot [B] of the water
with the oil pump shaft.
• Tighten:
Torque - Water Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
4-10 COOLING SYSTEM
Water Pump
Water Pump Impeller Inspection
• Remove the water pump (see Water Pump Removal).
• If the surface is the
Visually inspect impeller [A].
corroded or if the blades are damaged,
replace the water pump unit.
 COOLING SYSTEM 4-11
Radiator
Radiator and Radiator Fan Removal
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 MOTOR LEAD CON-
NECTOR IS DISCONNECTED. TOUCHING THE FAN
BEFORE THE CONNECTOR IS DISCONNECTED
COULD CAUSE INJURY FROM THE FAN BLADES.

• Remove:
Inner Fairing (see Inner Fairing Removal in the Frame
chapter)
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Resistor (see Resistor Inspection in the Electrical Sys-
tem chapter)
Radiator Hose Clamp Screw [A] (Loosen)
Radiator Bolts [B]

• Remove:
Radiator Hose Clamp Screw [A] (Loosen)
Radiator Bolts [B]

• Remove:
Radiator Fan Motor Lead Connector [A] (Disconnect)
Radiator [B]
CAUTION
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.

• Remove:
Radiator Fan Mounting Bolts [A]
Radiator Fan [B]
4-12 COOLING SYSTEM
Radiator
Radiator and Radiator Fan Installation
• Installation is the reverse of removal.
• ing section in the
Run the leads correctly (see Cable, Wire, and Hose Rout-
Appendix chapter).
• (see Engine Installation in the
Cover the heat insulation rubber plate on the radiator
Engine Removal/Installa-
tion chapter).
• Install the removed parts (see appropriate chapters).
Torque - Radiator Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Radiator (Water) Hose Clamp Screws: 1.5 N·m
(0.15 kgf·m, 13 in·lb)
Resistor Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Radiator Inspection
• Check the radiator core.
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.
Run the steam gun, following the core fin direction.

Radiator Cap Inspection

• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Radiator Cap
• Check the condition of the bottom [A] and top [B] valve
seals and valve spring [C].
If any one of them shows visible damage, replace the cap
with a new one.
 COOLING SYSTEM 4-13
Radiator

• Install the cap [A] on a cooling system pressure tester [B].

NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.

• Watching the pressure gauge, pump the pressure tester

to build up the pressure until the relief valve opens: the
gauge needle flicks downward. Stop pumping and mea-
sure leak time at once. The relief valve must open within
the specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi)
If the cap can not hold the specified pressure or if it holds
too much pressure, replace it with a new one.
Radiator Filler Neck Inspection
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Radiator Cap
• Check the radiator filler neck for signs of damage.
• Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
4-14 COOLING SYSTEM
Thermostat
Thermostat Removal
• Remove:
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Thermostat Cover Bolts [A]

• Move the thermostat cover [A] outwards and remove the

thermostat [B].

Thermostat Installation
• Install the thermostat [A] in the housing so that the air
bleeder hole [B] as shown in the figure.
• Tighten:
Torque - Thermostat Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
• Install the removed parts (see appropriate chapters).

Thermostat Housing Removal

• Remove:
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Water Temperature Sensor Connector [A] (Disconnect)
Hose Clamp Screws [B] (Loosen)
Hoses [C]
Bolts [D]
Thermostat Housing [E]
Thermostat Housing Installation
• Be sure to install the ground lead on the thermostat hous-
ing mounting bolt.
• Tighten:
Torque - Thermostat Housing Mounting Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Radiator (Water) Hose Clamp Screws: 1.5 N·m
(0.15 kgf·m, 13 in·lb)
• Install the removed parts (see appropriate chapters).
 COOLING SYSTEM 4-15
Thermostat
Thermostat Inspection
• Remove the thermostat (see Thermostat Removal), and
inspect the thermostat valve [A] at room temperature.
If the valve is open, replace the thermostat with a new
one.

• To check valve opening temperature, suspend the ther-

mostat [A] in a container of water and raise the tempera-
ture of the water.
○The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an ac-
curate thermometer [B] in the water so that the heat sen-
sitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
63.5 ∼ 66.5°C (146 ∼ 152°F)
4-16 COOLING SYSTEM
Hoses and Pipes
Hose Installation
• Install the hoses and pipes, being careful to follow bend-
ing direction. Avoid sharp bending, kinking, flattening or
twisting.
•Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
•Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to pre-
vent the clamps from contacting the other parts.
Torque - Radiator (Water) Hose Clamp Screws: 1.5 N·m
(0.15 kgf·m, 13 in·lb)

Hose Inspection
• Refer to the Water Hose and Pipe Inspection in the Peri-
odic Maintenance chapter.
 COOLING SYSTEM 4-17
Water Temperature Sensor
CAUTION
The water temperature sensor should never be al-
lowed to fall on a hard surface. Such a shock to the
water temperature sensor can damage it.

Water Temperature Sensor Removal/Installation

• Refer to the Water Temperature Sensor Removal/Instal-
lation in the Fuel System (DFI) chapter.
Water Temperature Sensor Inspection
• Refer to the Water Temperature Sensor Inspection in the
Electrical System chapter.
 ENGINE TOP END 5-1

Engine Top End

Table of Contents
Exploded View................................... 5-2 Cylinder Head Warp Inspection ... 5-25
Exhaust System................................. 5-6 Valves ................................................ 5-26
Specifications .................................... 5-7 Valve Clearance Inspection ......... 5-26
Special Tools and Sealant ................. 5-9 Valve Clearance Adjustment ....... 5-26
Clean Air System............................... 5-11 Valve Removal ............................. 5-26
Air Suction Valve Removal........... 5-11 Valve Installation .......................... 5-26
Air Suction Valve Installation........ 5-11 Valve Guide Removal .................. 5-26
Air Suction Valve Inspection ........
Air Switching Valve Removal .......
5-11
5-12
Valve Guide Installation ...............
Valve-to-Guide Clearance
5-27 5
Air Switching Valve Installation .... 5-12 Measurement (Wobble
Air Switching Valve Operation Method) ..................................... 5-27
Test............................................ 5-12 Valve Seat Inspection .................. 5-28
Air Switching Valve Unit Test ....... 5-12 Valve Seat Repair ........................ 5-28
Clean Air System Hose Cylinder, Pistons................................ 5-33
Inspection.................................. 5-12 Cylinder Removal......................... 5-33
Cylinder Head Cover ......................... 5-13 Cylinder Installation...................... 5-33
Cylinder Head Cover Removal .... 5-13 Piston Removal............................ 5-33
Cylinder Head Cover Installation . 5-13 Piston Installation......................... 5-34
Camshaft Chain Tensioner ................ 5-15 Cylinder Wear Inspection............. 5-35
Camshaft Chain Tensioner Piston Wear Inspection ................ 5-35
Removal .................................... 5-15 Piston Ring, Piston Ring Groove
Camshaft Chain Tensioner Wear Inspection ........................ 5-36
Installation ................................. 5-15 Piston Ring Groove Width
Camshaft, Camshaft Chain ............... 5-17 Inspection.................................. 5-36
Camshaft Removal ...................... 5-17 Piston Ring Thickness Inspection 5-36
Camshaft Installation ................... 5-18 Piston Ring End Gap Inspection .. 5-37
Camshaft, Camshaft Cap Wear Boring, Honing Performance ....... 5-37
Inspection.................................. 5-20 Throttle Body Assy Holder................. 5-38
Camshaft Runout Inspection........ 5-20 Throttle Body Assy Holder
Cam Wear Inspection .................. 5-21 Installation ................................. 5-38
Camshaft Chain Removal ............ 5-21 Muffler................................................ 5-39
Cylinder Head.................................... 5-22 Muffler Body Removal.................. 5-39
Cylinder Compression Muffler Body Installation............... 5-39
Measurement ............................ 5-22 Exhaust Pipe Removal................. 5-40
Cylinder Head Removal ............... 5-23 Exhaust Pipe Installation.............. 5-41
Cylinder Head Installation ............ 5-24
5-2 ENGINE TOP END
Exploded View
 ENGINE TOP END 5-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb
2 Air Switching Valve Bracket Bolts 9.8 1.0 87 in·lb
3 Camshaft Cap Bolts 12 1.2 106 in·lb S
4 Camshaft Chain Tensioner Cap Bolt 5.0 0.51 44 in·lb
5 Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb
6 Camshaft Sprocket Bolts 15 1.5 11 L
7 Coolant Drain Bolt (Cylinder) 5.9 0.60 52 in·lb
8 Cylinder Head Bolts (M8) 31.4 3.2 23.2 MO, S
9 Cylinder Head Bolt (M6) 12 1.2 106 in·lb S
10 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
11 Cylinder Head Jacket Plugs 20 2.0 15 L
12 Rear Camshaft Chain Guide Bolt 17 1.7 13
13 Spark Plugs 13 1.3 115 in·lb
14 Throttle Body Assy Holder Clamp Screws 2.0 0.20 18 in·lb
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
5-4 ENGINE TOP END
Exploded View
 ENGINE TOP END 5-5
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Exhaust Pipe Holder Nuts 12 1.2 106 in·lb
2 Exhaust Pipe Mounting Bolt 9.8 1.0 87 in·lb
3 Muffler Body Clamp Bolt 17 1.7 13
4 Muffler Body Mounting Bolt 30 3.1 22
5 Muffler Body Rear Cover Bolts 9.8 1.0 87 in·lb L
6 Muffler Cover Bolts 9.8 1.0 87 in·lb
7 Muffler Cover Clamp Bolt 9.8 1.0 87 in·lb
8 Muffler Cover Clamp Screw 6.9 0.70 61 in·lb
L: Apply a non-permanent locking agent.
R: Replacement Parts
5-6 ENGINE TOP END
Exhaust System
Exhaust System

Manifold Mark Position [A] Muffler Body Mark Position [B] Honeycomb Type Catalyst
Position [C]

Honeycomb Type Catalyst Manifold with Hole [E] for

Position [D] Oxygen Sensor [F].
 ENGINE TOP END 5-7
Specifications

Item Standard Service Limit

Camshafts
Cam Height:
Exhaust 32.843 ∼ 32.957 mm (1.2930 ∼ 1.2975 in.) 32.74 mm (1.289 in.)
Inlet 33.843 ∼ 33.957 mm (1.3324 ∼ 1.3369 in.) 33.74 mm (1.328 in.)
Camshaft Journal, Camshaft 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) 0.16 mm (0.0063 in.)
Cap Clearance
Camshaft Journal Diameter 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) 23.92 mm (0.942 in.)
Camshaft Bearing Inside 24.000 ∼ 24.021 mm (0.9449 ∼ 0.9457 in.) 24.08 mm (0.948 in.)
Diameter
Camshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.004 in.)
Cylinder Head
Cylinder Compression (Usable Range)
1 050 ∼ 1 500 kPa (10.7 ∼ 15.3 kgf/cm², – – –
152 ∼ 218 psi) at 500 r/min (rpm)
Cylinder Head Warp ––– 0.05 mm (0.002 in.)
Valves
Valve Clearance:
Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.) – – –
Inlet 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) – – –
Valve Head Thickness:
Exhaust 0.8 mm (0.032 in.) 0.5 mm (0.020 in.)
Inlet 0.5 mm (0.020 in.) 0.3 mm (0.012 in.)
Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm (0.002 in.)
Valve Stem Diameter:
Exhaust 4.455 ∼ 4.470 mm (0.1754 ∼ 0.1760 in.) 4.44 mm (0.175 in.)
Inlet 4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.) 4.46 mm (0.176 in.)
Valve Guide Inside Diameter:
Exhaust 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.) 4.58 mm (0.180 in.)
Inlet 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.) 4.58 mm (0.180 in.)
Valve/Valve Guide
Clearance (Wobble Method):
Exhaust 0.07 ∼ 0.12 mm (0.0028 ∼ 0.0047 in.) 0.27 mm (0.011 in.)
Inlet 0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.) 0.23 mm (0.010 in.)
Valve Seat Cutting Angle 32°, 45°, 67.5° – – –
Valve Seating Surface:
Width:
Exhaust 0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.) – – –
Inlet 0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.) – – –
Outside Diameter:
Exhaust 19.3 ∼ 19.5 mm (0.7598 ∼ 0.7677 in.) – – –
Inlet 21.9 ∼ 22.1 mm (0.8622 ∼ 0.8701 in.) – – –
Valve Spring Free Length:
Exhaust 39.5 mm (1.555 in.) 38.0 mm (1.50 in.)
Inlet 39.5 mm (1.555 in.) 38.0 mm (1.50 in.)
5-8 ENGINE TOP END
Specifications

Item Standard Service Limit

Cylinder, Pistons
Cylinder Inside Diameter 62.000 ∼ 62.012 mm (2.4409 ∼ 2.4414 in.) 62.10 mm (2.4449 in.)
Piston Diameter 61.942 ∼ 61.957 mm (2.4387 ∼ 2.4392 in.) 61.79 mm (2.4327 in.)
Piston/Cylinder Clearance 0.043 ∼ 0.070 mm (0.0017 ∼ 0.0028 in.) – – –
Oversize Pistons and Rings +0.5 mm (0.020 in.) – – –
Piston Ring/Groove
Clearance:
Top 0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.) 0.17 mm (0.0067 in.)
Second 0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.) 0.16 mm (0.0063 in.)
Piston Ring Groove Width:
Top 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) 0.92 mm (0.0362 in.)
Second 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.) 0.91 mm (0.0358 in.)
Piston Ring Thickness:
Top 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.028 in.)
Second 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.028 in.)
Piston Ring End Gap:
Top 0.15 ∼ 0.30 mm (0.0059 ∼ 0.0118 in.) 0.6 mm (0.024 in.)
Second 0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.) 0.9 mm (0.035 in.)
Oil 0.20 ∼ 0.80 mm (0.0079 ∼ 0.0315 in.) 1.1 mm (0.043 in.)
 ENGINE TOP END 5-9
Special Tools and Sealant
Compression Gauge, 20 kgf/cm²: Valve Seat Cutter Holder Bar:
57001-221 57001-1128

Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 22:

57001-241 57001-1206

Piston Pin Puller Assembly: Valve Seat Cutter, 67.5° - 22:

57001-910 57001-1207

Valve Seat Cutter, 45° - 24.5: Valve Spring Compressor Adapter, 16:
57001-1113 57001-1305

Valve Seat Cutter, 32° - 25: Compression Gauge Adapter, M10 × 1.0:
57001-1118 57001-1317
5-10 ENGINE TOP END
Special Tools and Sealant
Valve Seat Cutter Holder, 4.5: Valve Guide Driver:
57001-1330 57001-1564

Valve Guide Arbor, 4.5: Washer:

57001-1331 57001-1720

Valve Guide Reamer, 4.5: Kawasaki Bond (Silicone Sealant):

57001-1333 92104-0004

Piston Base, 2.3:

57001-1336
 ENGINE TOP END 5-11
Clean Air System
Air Suction Valve Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Switching Valve (see Air Switching Valve Removal)
• Free the heat insulation rubber plate [A] from the air suc-
tion valve cover [B].

• Remove:
Air Suction Valve Cover Bolts [A]
Air Suction Valve Cover [B]
Air Suction Valve

Air Suction Valve Installation

• Install the air suction valve [A] so that its wider side [B] of
the reed valve case faces the front.
• Tighten:
Torque - Air Suction Valve Cover Bolts : 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Install the removed parts (see appropriate chapters).

Air Suction Valve Inspection

• Remove
moval).
the air suction valve (see Air Suction Valve Re-

• Visually inspect the reeds for cracks, folds, warps, heat

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.
• If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
• If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high-flash point solvent.
CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
5-12 ENGINE TOP END
Clean Air System
Air Switching Valve Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Connector [A] (Disconnect)
• Separate the hoses [B] from the air suction valve cover
and air cleaner housing fitting, and remove the air switch-
ing valve [C].
CAUTION
Never drop the air switching valve especially on
a hardsurface. Such a shock to the air switching
valve can damaged it.

Air Switching Valve Installation

• Installation is the reverse of removal.
• Hose Routingand
Run the lead hoses correctly (see Cable, Wire, and
section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
Air Switching Valve Operation Test
• Refer to the Air Suction System Damage Inspection in the
Periodic Maintenance chapter.
Air Switching Valve Unit Test
• Refer to the Air Switching Valve Unit Test in the Electrical
System chapter.
Clean Air System Hose Inspection
• Be certain that all the hoses are routed without being flat-
tened or kinked, and are connected correctly to the air
cleaner housing, air switching valve and air suction valve
cover.
If they are not, correct them. Replace them if they are
damaged.
 ENGINE TOP END 5-13
Cylinder Head Cover
Cylinder Head Cover Removal
• Remove:
Air Switching Valve (see Air Switching Valve Removal)
Stick Coils (see Stick Coil Removal in the Electrical Sys-
tem chapter)
Coolant Reserve Tank Bolts (see Coolant Reserve Tank
Removal in the Cooling System chapter)
Thermostat Housing (see Thermostat Housing Removal
in the Cooling System chapter)
Water Hose [A]
Bolt [B] and Bracket [C]

• Free the heat insulation rubber plate [A] from the cylinder
head cover.

• Remove:
Air Suction Valve Cover [A] (see Air Suction Valve Re-
moval)
Cylinder Head Cover Bolts [B]
Cylinder Head Cover [C]

Cylinder Head Cover Installation

• Replace the head cover gasket with a new one.
• shown in the figure.
Apply silicone sealant [A] to the head cover gasket as

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Install the new head cover gasket.

• Install:
Dowel Pins [A]
Plug Hole Gaskets [B]
5-14 ENGINE TOP END
Cylinder Head Cover

• Insert the hook [A] of the water pipe [B] in the groove of
the damper [C] as shown in the figure.
Damper [D]
• Install the head cover [E], and tighten the bolts.
Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
• Install the removed parts (see appropriate chapters).
 ENGINE TOP END 5-15
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
CAUTION
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below.
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in "Camshaft Chain Ten-
sioner Installation".
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing and damage the valves.

• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Cap Bolt [A] (Loosen)
Mounting Bolts [B]
Chain Tensioner [C]

Camshaft Chain Tensioner Installation

• Remove the tensioner cap bolt and O-ring.
• a suitable screwdriver
While compressing the push rod [A], turn it clockwise with
until the rod stopped.
CAUTION
Do not turn the rod counterclockwise at installation.
This could detach the rod and the tensioner cannot
be reinstalled.

• Replace the chain tensioner gasket with a new one.

• While holding the rod in position with a suitable push rod
holder plate [A] install the tensioner on the cylinder block.
3.5 mm (0.14 in.) [B]
7 mm (0.28 in.) [C]
12 mm (0.47 in.) [D]
8.5 mm (0.33 in.) [E]
5-16 ENGINE TOP END
Camshaft Chain Tensioner

• Tighten:
Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 9.8
N·m (1.0 kgf·m, 87 in·lb)
• Take out the holder plate [B].
• Install the O-ring and tighten the cap bolt.
Torque - Camshaft Chain Tensioner Cap Bolt: 5.0 N·m (0.51
kgf·m, 44 in·lb)
 ENGINE TOP END 5-17
Camshaft, Camshaft Chain
Camshaft Removal
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Plugs
•Position the crankshaft at #2 piston TDC.
○Using a wrench on the alternator rotor bolt, turn the crank-
shaft counterclockwise until the "2T" mark [A] on the al-
ternator rotor is aligned with the projection [B] in the in-
spection window on the alternator cover.

• Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Camshaft Cap Bolts [A]
Plates
Upper Chain Guide [B]
Camshaft Caps [C]
Camshafts [D]
○Loosen the camshaft cap bolts as shown sequence [1 ∼
12] in the figure.
•Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.

• Remove:
Camshaft Sprocket Bolts [A]
Camshaft Sprockets [B]
CAUTION
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turn-
ing the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.
5-18 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Installation
• Install the camshaft sprockets as shown in the figure.
Inlet Camshaft Sprocket [A]
Exhaust Camshaft Sprocket [B]
○The exhaust camshaft has the groove [C].
• Apply a non-permanent locking agent to the threads of
the camshaft sprocket bolts and tighten them.
Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11
ft·lb)
• Apply molybdenum disulfide oil solution to all cam parts
and journals.
If a new camshaft is to be used, apply a thin coat of molyb-
denum disulfide grease to the cam surfaces.

NOTE
○Be sure to operate from the engine left side.
• Position
Removal).
the crankshaft at #2 piston TDC (see Camshaft

CAUTION
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turn-
ing the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.

• Engage
ets.
the camshaft chain [A] with the camshaft sprock-

• Pull the tension side (exhaust side) of the chain taut to

install the chain on the sprockets.
○Timing marks [B] align with the cylinder head upper sur-
face.
Exhaust Camshaft Sprocket [C]
Inlet Camshaft Sprocket [D]
○Count the camshaft chain link pins as shown to verify that
the sprocket are positioned correctly.
 ENGINE TOP END 5-19
Camshaft, Camshaft Chain

• Install the six dowel pins on the marks [A].

• the "EX"the[B]camshaft
Install caps as shown in the figure, noting
and "IN" [C] marks.
CAUTION
The camshaft caps are machined with the cylinder
head. So, if a cap is installed in a wrong location,
the camshaft may seize because of improper oil
clearance in the bearings.

•○Install the plates on the camshaft caps.

The exhaust side plates [A] is longer the inlet side plates
[B].

• Install the upper chain guide [A].

• camshaft in place,
First tighten the all camshaft cap bolts evenly to seat the
then tighten all bolts following the spec-
ified tightening sequence.
Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
Plates (EX) [B]
Plates (IN) [C]
• Install the camshaft chain tensioner (see Camshaft Chain
Tensioner Installation).

• Finally, inject [A] the engine oil into 8 places on the cylin-
der head as shown in the figure.
• Install the cylinder head cover (see Cylinder Head Cover
Installation).
5-20 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft, Camshaft Cap Wear Inspection
• Remove:
Upper Chain Guide (see Camshaft Removal)
Camshaft Caps (see Camshaft Removal)
• Cut the strips of plastigauge to journal width. Place a strip
on each journal parallel to the camshaft installed in the
correct position.
• Measure each clearance between the camshaft journal
and the camshaft cap using the plastigauge (press gauge)
[A].
• Tighten the camshaft cap bolts (see Camshaft Installa-
tion).
NOTE
○Do not turn the camshaft when the plastigauge is be-
tween the journal and camshaft cap.

Camshaft Journal, Camshaft Cap Clearance

Standard: 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)
Service Limit: 0.16 mm (0.0063 in.)
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard: 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.)
Service Limit: 23.92 mm (0.942 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 service limit, re-
place the cylinder head unit.
Camshaft Runout Inspection
• Remove the camshafts (see Camshaft Removal).
• blocks.
Set the camshaft in a camshaft alignment jig or on V

• Measure the runout with a dial gauge at the specified

place as shown in the figure.
If the runout exceeds the service limit, replace the
camshaft.
Camshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.1 mm (0.004 in.)
 ENGINE TOP END 5-21
Camshaft, Camshaft Chain
Cam Wear Inspection
• Remove the camshafts (see Camshaft Removal).
• If the camstheareheight
Measure [A] of each cam with a micrometer.
worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust 32.843 ∼ 32.957 mm (1.2930 ∼ 1.2975 in.)
Inlet 33.843 ∼ 33.957 mm (1.3324 ∼ 1.3369 in.)
Service Limit:
Exhaust 32.74 mm (1.289 in.)
Inlet 33.74 mm (1.328 in.)

Camshaft Chain Removal

• Split the crankcase (see Crankcase Splitting in the Crank-
shaft/Transmission chapter).
• Remove
sprocket.
the camshaft chain [A] from the crankshaft
5-22 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
NOTE
○Use the battery which is fully charged.
• Warm up the engine thoroughly.
• Stop the engine.
• Fuel Tank (see Fuel Tank Removal in the Fuel System
Remove:

(DFI) chapter)
Stick Coils (see Stick Coil Removal in the Electrical Sys-
tem chapter)
Spark Plugs (see Spark Plug Replacement in the Peri-
odic Maintenance chapter)

• Attach the compression gauge [A] and adapter [B] firmly

into the spark plug hole.
• Using the starter motor, turn the engine over with the throt-
tle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1317

Cylinder Compression
Usable Range: 1 050 ∼ 1 500 kPa (10.7 ∼ 15.3 kgf/cm²,
152 ∼ 218 psi) at 500 r/min (rpm)

• Repeat the measurement for the other cylinder.

• Install the spark plugs.
Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)

○The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem Diagnosis Remedy (Action)
Cylinder compression Carbon accumulation on piston and in Remove the carbon deposits
is higher than usable combustion chamber possibly due to and replace damaged parts if
range damaged valve stem oil seal and/or necessary.
damaged piston oil rings (This may be
indicated by white exhaust smoke).
Incorrect cylinder head gasket Replace the gasket with a standard
thickness part.
Cylinder compression Gas leakage around cylinder head Replace damaged check gasket
is lower than usable and cylinder head warp.
range Bad condition of valve seating Repair if necessary.
Incorrect valve clearance Adjust the valve clearance.
Incorrect piston/cylinder clearance Replace the piston and/or cylinder.
Piston seizure Inspect the cylinder and
replace/repair the cylinder and/or
piston as necessary.
Bad condition of piston ring and/or Replace the piston and/or the
piston ring grooves. piston rings.
 ENGINE TOP END 5-23
Cylinder Head
Cylinder Head Removal
• Remove:
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Camshafts (see Camshaft Removal)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Exhaust Pipe (see Exhaust Pipe Removal)

• Remove the water pipe [A].

• Remove:
Front Camshaft Chain Guide [A]
Rear Camshaft Chain Guide Bolt [B]
Rear Camshaft Chain Guide [C]

• Remove:
Engine Mounting Bracket Nuts and Bolts [A] (Both Sides)
Engine Mounting Nut [B] and Bolt
Engine Mounting Brackets [C] (Both Sides)
Oil Hose Banjo Bolt [D]
5-24 ENGINE TOP END
Cylinder Head

• Remove:
M6 Cylinder Head Bolt [A]
M8 Cylinder Head Bolts [B]
Cylinder Head

Cylinder Head Installation

NOTE
○The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.

• Install a new cylinder head gasket and dowel pins.

• Apply molybdenum
Replace the cylinder head bolt washers with new ones.
• of the cylinder headdisulfide oil solution to both sides [A]
bolt washers [B] and the threads of
the head bolts [C].

• Tighten the M8 cylinder head bolts following the tightening

sequence [1 ∼ 7].
146 mm (5.75 in.) [1 ∼ 6]
115 mm (4.53 in.) [7]
Torque - Cylinder Head Bolts (M8): 31.4 N·m (3.2 kgf·m,
23.2 ft·lb)
• Tighten the M6 cylinder head bolt following the tightening
sequence [8].
Torque - Cylinder Head Bolt (M6): 12 N·m (1.2 kgf·m, 106
in·lb)
 ENGINE TOP END 5-25
Cylinder Head

• Install:
Front Camshaft Chain Guide [A]
Rear Camshaft Chain Guide [B]
• Tighten:
Torque - Rear Camshaft Chain Guide Bolt [C]: 17 N·m (1.7
kgf·m, 13 ft·lb)
• Install the removed parts (see appropriate chapters).

Cylinder Head Warp Inspection

• Clean the cylinder head.
• head at several positions.
Lay a straightedge across the lower surface of the cylinder

• Use a thickness gauge [A] to measure the space between

the straightedge [B] and the head.
Cylinder Head Warp
Standard: –––
Service Limit: 0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).
5-26 ENGINE TOP END
Valves
Valve Clearance Inspection
• Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.
Valve Clearance Adjustment
• Refer to the Valve Clearance Adjustment in the Periodic
Maintenance chapter.
Valve Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Valve Lifter and Shim
○Mark and record the valve lifter and shim locations so they
can be installed in their original positions.
•Using the valve spring compressor assembly, remove the
valve.
Special Tools - Valve Spring Compressor Assembly [A]:
57001-241
Valve Spring Compressor Adapter, 16 [B]:
57001-1305

Valve Installation
• Replace the oil seal with a new one.
• Apply a thin coat
Apply engine oil to the lip of the oil seal.
• valve stem beforeofvalve
molybdenum disulfide grease to the
installation.
• Install
wards.
the spring so that the closed coil end faces down-

Valve Stem [A]

Spring Seat [B]
Valve Spring (White) [C]
Oil Seal [D]
Retainer [E]
Split Keepers [F]
Closed Coil End [G]
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
Oil Seal
Spring Seat
• Heat the area around the valve guide to 120 ∼ 150°C (248
∼ 302°F), and hammer lightly on the valve guide arbor [A]
to remove the guide from the top of the head.
CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Special Tool - Valve Guide Arbor, 4.5: 57001-1331
 ENGINE TOP END 5-27
Valves
Valve Guide Installation
• Apply engine oil to the valve guide outer surface before
installation.
• Heat the area around the valve guide hole to about 120 ∼
150°C (248 ∼ 302°F).
CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head and
heat the oil.

• Using the valve guide driver [A] and washer [B], press
and insert the valve guide in until the washer surface [C]
touches the head surface [D].
15.3 ∼ 15.5 mm (0.60 ∼ 0.61 in.) [E]
Special Tools - Valve Guide Driver: 57001-1564
Washer: 57001-1720

• Wait until the cylinder head cools down and then ream the
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, 4.5: 57001-1333

Valve-to-Guide Clearance Measurement (Wobble

Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
• Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
• Move the stem back and forth [C] to measure valve/valve
guide clearance.
• Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
5-28 ENGINE TOP END
Valves
NOTE
○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard:
Exhaust 0.07 ∼ 0.12 mm (0.0028 ∼ 0.0047 in.)
Inlet 0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.)
Service Limit:
Exhaust 0.27 mm (0.011 in.)
Inlet 0.23 mm (0.010 in.)

Valve Seat Inspection

• Remove the valve (see Valve Removal).
• and valve seat
Check the valve seating surface [A] between the valve [B]
[C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust 19.3 ∼ 19.5 mm (0.7598 ∼ 0.7677 in.)
Inlet 21.9 ∼ 22.1 mm (0.8622 ∼ 0.8701 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust 0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.)
Inlet 0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.)

Valve Seat Repair

• Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder Bar [B]: 57001
-1128
Valve Seat Cutter Holder, 4.5 [C]: 57001
-1330

[For Exhaust Valve Seat]

Valve Seat Cutter, 45° - 24.5: 57001-1113
Valve Seat Cutter, 32° - 22: 57001-1206
Valve Seat Cutter, 67.5° - 22: 57001-1207
[For Inlet Valve Seat]
Valve Seat Cutter, 45° - 24.5: 57001-1113
Valve Seat Cutter, 32° - 25: 57001-1118
Valve Seat Cutter, 67.5° - 22: 57001-1207
If the manufacturer’s instructions are not available, use
the following procedure.
 ENGINE TOP END 5-29
Valves
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
37.5 ....................... Outer diameter of cutter [C]

Operating Procedures
•Clean the seat area carefully.
•Coat the seat with machinist’s dye.
•Fit a 45° cutter into the holder and slide it into the valve
guide.
•Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.
5-30 ENGINE TOP END
Valves

• Measure the outside diameter of the seating surface with

a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the spec-
ified range.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 67.5° cutter
67.5° [F]

• Measure the outside diameter of the seating surface with

a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 67.5° grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter [A] of the seating surface is too
large, make the 32° grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described be-
low.
•Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat outside di-
ameter measurement step above.
• To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.
 ENGINE TOP END 5-31
Valves
If the seat width is too wide, make the 67.5° [A] grind
described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
•Grind the seat at a 67.5° angle until the seat width is within
the specified range.
○To make the 67.5° grind, fit 67.5° cutter into the holder,
and slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 67.5° grind, return to the seat width mea-
surement step above.
Correct Width [B]

• Lap the valve to the seat, once the seat width and outside
diameter are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding 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]
•The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
•Be sure to remove all grinding compound before assem-
bly.
•When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Inspection in the Periodic
Maintenance chapter).
5-32 ENGINE TOP END
Valves
 ENGINE TOP END 5-33
Cylinder, Pistons
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Bolt [A]
Water Pipe [B]
Water Hose Fitting [C]
Cylinder [D]

Cylinder Installation
NOTE
○If a new cylinder is used, use a new piston ring.
• Install the dowel pins [A] and new cylinder gasket [B].
• bore. molybdenum disulfide oil solution to the cylinder
Apply

• The piston ring openings must be positioned as shown in

the figure. The openings of the oil ring steel rails must be
about 30 ∼ 40° of angle from the opening of the top ring.
Top Ring [A]
Second Ring [B]
Upper Oil Ring Steel Rail [C]
Lower Oil Ring Steel Rail [D]
Oil Ring Expander [E]
Hollow [F]
30 ∼ 40° [G]

• Slip the piston base [A] to hold piston level as shown in

the figure, and install the cylinder.
Special Tool - Piston Base, 2.3: 57001-1336

Piston Removal
• Remove the cylinder (see Cylinder Removal).
• ton pin snap ring
Place a clean cloth under the pistons and remove the pis-
[A] from the outside of each piston.
5-34 ENGINE TOP END
Cylinder, Pistons

• Remove the piston pins.

Special Tool - Piston Pin Puller Assembly [A]: 57001-910
• Remove the pistons.

• Carefully spread the ring opening with your thumbs and

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.

Piston Installation
• Apply molybdenum disulfide oil solution to the oil ring ex-
pander, and install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] not butt together.
•Apply molybdenum disulfide oil solution to the oil ring steel
rails, and install the oil ring steel rails, one above the ex-
pander and one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
NOTE
○The oil ring rails have no "top" or "bottom".
• Do not mix up the top and second ring.
• Install the top ring [A] so that the "R" mark [B] faces up.
• up.
Install the second ring [C] so that the "RN" mark [D] faces

○Apply molybdenum disulfide oil solution to the piston

rings.
 ENGINE TOP END 5-35
Cylinder, Pistons
NOTE
○If a new piston is used, use new piston ring.
• Install the piston with its marking hollow facing forward.
• so that thepiston
Fit a new pin snap ring into the side of the piston
ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○Apply molybdenum disulfide oil solution to the piston pins
and piston journals.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.

• Install the cylinder (see Cylinder Installation).

Cylinder Wear Inspection
• Since there is a difference in cylinder wear in different di-
rections, take a side-to-side and a front-to-back measure-
ment at each of the two locations (total of four measure-
ments) 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]
60 mm (2.36 in.) [B]
Cylinder Inside Diameter
Standard: 62.000 ∼ 62.012 mm (2.4409 ∼ 2.4414 in.)
Service Limit: 62.10 mm (2.4449 in.)

Piston Wear Inspection

• Measure the outside diameter [A] of each piston 5 mm
(0.20 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the pis-
ton.
Piston Diameter
Standard: 61.942 ∼ 61.957 mm (2.4387 ∼ 2.4392 in.)
Service Limit: 61.79 mm (2.4327 in.)
5-36 ENGINE TOP END
Cylinder, Pistons
Piston Ring, Piston Ring Groove Wear Inspection
• Check
ing.
for uneven groove wear by inspecting the ring seat-

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 0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
Second 0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
Service Limit:
Top 0.17 mm (0.0067 in.)
Second 0.16 mm (0.0063 in.)

Piston Ring Groove Width Inspection

•○Measure the piston ring groove width.
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard:
Top [A] 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.)
Second [B] 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
Service Limit:
Top 0.92 mm (0.0362 in.)
Second 0.91 mm (0.0358 in.)
If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.
Piston Ring Thickness Inspection
•○Measure the piston ring thickness.
Use the micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top [A] 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Second [B] 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Service Limit:
Top 0.70 mm (0.028 in.)
Second 0.70 mm (0.028 in.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
○When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
 ENGINE TOP END 5-37
Cylinder, Pistons
Piston Ring End Gap Inspection
• Place the piston ring [A] inside the cylinder, using the pis-
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 0.15 ∼ 0.30 mm (0.0059 ∼ 0.0118 in.)
Second 0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)
Oil 0.20 ∼ 0.80 mm (0.0079 ∼ 0.0315 in.)
Service Limit:
Top 0.6 mm (0.024 in.)
Second 0.9 mm (0.035 in.)
Oil 1.1 mm (0.043 in.)
If the end gap of either ring is greater than the service
limit, replace all the rings.
Boring, Honing Performance
When boring and honing a cylinder, note the following:
○There is one size of oversize piston available. Oversize
piston require oversize rings.
Oversize Pistons and Rings
+ 0.5 mm (0.020 in.)
○Before boring a cylinder, first measure the exact diameter
of the oversize piston, and then, according to the stan-
dard clearance in the Specifications section, determine
the rebore diameter. However, if the amount of boring
necessary would make the inside diameter greater than
0.5 mm (0.020 in.) oversize, 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 a 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.
○Never separate the liner from the cylinder, because the
top surface of cylinder and liner is machined at the factory
as an assembly.
5-38 ENGINE TOP END
Throttle Body Assy Holder
Throttle Body Assy Holder Installation
• Fit the groove [A] of the throttle body holder to the projec-
tion [B] of the cylinder head.
• Install the clamps [C] as shown in the figure.
• Tighten:
Torque - Throttle Body Assy Holder Clamp Screws: 2.0
N·m (0.20 kgf·m, 18 in·lb)
 ENGINE TOP END 5-39
Muffler
WARNING
To avoid a serious burn, do not remove the muffler
when the engine is still hot. Wait until the muffler
cool down.

Muffler Body Removal

• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Muffler Cover Clamp Bolt [A] and Clamp
Muffler Cover Clamp Screw [B]
Muffler Cover Bolts [C]
Muffler Cover [D]

• Remove:
Clamp Bolt [A] (Loosen)
Mounting Nut and Bolt [B]
Muffler Body [C]

Muffler Body Installation

• Replace the muffler body gasket [A] with a new one.
• Install the muffler body gasket so that its chamfer side [B]
faces front [C].
Rear [D]

• Install the muffler body and mounting bolt.

• figure. the muffler body clamp bolt [A] as shown in the
Install

74 ∼ 84° [B]
More than 15 mm (0.59 in.) [C]
Swingarm [D]
• Tighten:
Torque - Muffler Body Mounting Bolt: 30 N·m (3.1 kgf·m, 22
ft·lb)
Muffler Body Clamp Bolt: 17 N·m (1.7 kgf·m, 13
ft·lb)
5-40 ENGINE TOP END
Muffler
If the pad [A] was removed, install it as shown in the figure.
Muffler Cover [B]
1 ∼ 5 mm (0.04 ∼ 0.20 in.) [C]

• Insert the claw [A] into the cover clamp [B] and tighten the
clamp screw [C] as shown in the figure.
About 15° [D]
Torque - Muffler Cover Clamp Screw: 6.9 N·m (0.70 kgf·m,
61 in·lb)

• Tighten:
Torque - Muffler Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Fit the hole [A] of the clamp [B] to the hook [C] of the
muffler cover [D].
• Tighten:
Torque - Muffler Cover Clamp Bolt [E]: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Thoroughly warm up the engine, wait until the engine
cools down, retighten all the bolts and screw.
• Install the removed parts (see appropriate chapters).
Exhaust Pipe Removal
• Remove:
Muffler Body (see Muffler Body Removal)
Oxygen Sensor (see Oxygen Sensor Removal in the
Electrical System chapter)
Mounting Bolt [A]
 ENGINE TOP END 5-41
Muffler

• Remove:
Exhaust Pipe Holder Nuts [A]
Exhaust Pipe [B]

Exhaust Pipe Installation

• Replace the exhaust pipe gaskets with new ones.
• Tighten: exhaust pipe.
Install the
•
Torque - Exhaust Pipe Holder Nuts: 12 N·m (1.2 kgf·m, 106
in·lb)
Exhaust Pipe Mounting Bolt: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Install the removed parts (see appropriate chapters).
 CLUTCH 6-1

Clutch
Table of Contents
Exploded View........................................................................................................................ 6-2
Specifications ......................................................................................................................... 6-4
Special Tool and Sealant ........................................................................................................ 6-5
Clutch Lever and Cable .......................................................................................................... 6-6
Clutch Lever Free Play Inspection .................................................................................... 6-6
Clutch Lever Free Play Adjustment .................................................................................. 6-6
Clutch Cable Removal ...................................................................................................... 6-6
Clutch Cable Installation ................................................................................................... 6-6
Clutch Cable Lubrication................................................................................................... 6-6
Clutch Lever Installation.................................................................................................... 6-6
Clutch Cover........................................................................................................................... 6-7 6
Clutch Cover Removal ...................................................................................................... 6-7
Clutch Cover Installation ................................................................................................... 6-7
Release Shaft Removal .................................................................................................... 6-7
Release Shaft Installation ................................................................................................. 6-7
Clutch Cover Disassembly................................................................................................ 6-8
Clutch Cover Assembly..................................................................................................... 6-8
Clutch ..................................................................................................................................... 6-9
Clutch Removal................................................................................................................. 6-9
Clutch Installation.............................................................................................................. 6-9
Clutch Plate Wear and Damage Inspection ...................................................................... 6-11
Clutch Plate Warp Inspection............................................................................................ 6-11
Clutch Spring Free Length Inspection............................................................................... 6-11
6-2 CLUTCH
Exploded View
 CLUTCH 6-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Clutch Cover Bolts 9.8 1.0 87 in·lb
2 Clutch Hub Nut 132 13.5 97.4
3 Clutch Lever Clamp Bolt 8.8 0.90 78 in·lb
4 Clutch Spring Bolts 8.8 0.90 78 in·lb
5 Oil Filler Plug – – – Hand-Tighten
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
Si: Apply silicone grease.
W: Apply water.
6-4 CLUTCH
Specifications

Item Standard Service Limit

Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –
Clutch
Friction Plate Thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.6 mm (0.10 in.)
Friction and Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
Clutch Spring Free Length 39.4 mm (1.55 in.) 37.6 mm (1.48 in.)

Clutch Housing Gear Selection when Replacing Clutch Housing Gear

Crankshaft Clutch Housing
Primary Gear
Color Gear Marking Color Part Number
Marking
A White A White 13095-0095
A White B Red 13095-0096
A White C None 13095-0097
A White D Yellow 13095-0098
B Red A White 13095-0095
B Red B Red 13095-0096
B Red C None 13095-0097
B Red D Yellow 13095-0098
C None B Red 13095-0096
C None C None 13095-0097
C None D Yellow 13095-0098
D Yellow C None 13095-0097
D Yellow D Yellow 13095-0098
 CLUTCH 6-5
Special Tool and Sealant
Clutch Holder: Kawasaki Bond (Silicone Sealant):
57001-1243 92104-0004
6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection
• Refer to the Clutch Operation Inspection in the Periodic
Maintenance chapter.
Clutch Lever Free Play Adjustment
• Refer to the Clutch Operation Inspection in the Periodic
Maintenance chapter.
Clutch Cable Removal
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Loosen the locknut [A] at the clutch lever, and screw in
the adjuster [B].
• Line up the slots [C] in the clutch lever, locknut and ad-
juster, and then free the cable from the lever.

• Slide the dust cover [A] at the clutch cable lower end out
of place.
• Remove the clutch cable lower from the cable holder [B]
loosening the locknuts [C].
• Free
lever.
the clutch inner cable tip from the clutch release

• Pull the clutch cable out of the frame.

Clutch Cable Installation

• Run the clutch cable correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
• Adjust the clutch cable (see Clutch Operation Inspection
in the Periodic Maintenance chapter).
Clutch Cable Lubrication
• Refer to the Chassis Parts Lubrication in the Periodic
Maintenance chapter.
Clutch Lever Installation
• Install the clutch lever so that the mating surface [A] of the
clutch lever is aligned with the punch mark [B].
• Tighten:
Torque - Clutch Lever Clamp Bolt: 8.8 N·m (0.90 kgf·m, 78
in·lb)
 CLUTCH 6-7
Clutch Cover
Clutch Cover Removal
• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Clutch Cable Lower End [A]
Clutch Cover Bolts [B]

• Turn the release lever [A] toward the rear as shown in the
figure, and remove the clutch cover [B].
About 90° [C]

Clutch Cover Installation

• Apply silicone sealant to the area [A] where the mating
surface of the crankcase touches the clutch cover gasket.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Replace the clutch cover gasket with a new one.
• Tighten the clutch cover bolts.
Torque - Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Release Shaft Removal

CAUTION
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If re-
moved, the oil seal replacement may be required.

• Remove the clutch cover (see Clutch Cover Removal).

• Pull the lever and shaft assembly straight out of the clutch
cover.
Release Shaft Installation
• Apply grease to the oil seal lips on the upper ridge of the
clutch cover.
• Apply engine oil to the needle bearing in the hole of the
clutch cover.
• Apply molybdenum disulfide grease to the pusher-holding
portion on the release shaft.
• Insert the release shaft straight into the upper hole of the
clutch cover.
CAUTION
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
6-8 CLUTCH
Clutch Cover
Clutch Cover Disassembly
• Remove:
Oil Seal [A]
Needle Bearing [B]
Oil Level Gauge

Clutch Cover Assembly

• Replace the needle bearing and oil seal with new ones.
NOTE
○Installthe needle bearing so that the manufacture’s
mark face out.

• Install the needle bearing [A] and oil seal [B] position as
shown in the figure.
Press the needle bearing so that the bearing surface [C]
is flush with the housing end of clutch cover [D].
Press the oil seal until the bottom [E].
• Install the oil level gauge until the bottom.
 CLUTCH 6-9
Clutch
Clutch Removal
• Remove:
Clutch Cover (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs
Clutch Spring Plate [B] (with Bearing and Pusher [C])

• Remove:
Friction Plates and Steel Plates
Clutch Hub Nut [A]
○Holding the clutch hub [B], remove the nut and washer.
Special Tool - Clutch Holder [C]: 57001-1243
• Remove:
Clutch Hub
Spacer
Needle Bearing
Bushing
Clutch Housing
Thrust Spacer
Clutch Installation
• Install the thrust spacer [A] so that the chamfer side [B]
faces inward.

•○Install the bushing [A] and needle bearing [B].

Install the snap ring [C] on the bushing so that it faces
inward.

• Install the clutch housing, spacer, clutch hub, washer and

clutch hub nut.
○Holding the clutch hub, tighten the clutch hub nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 97.4 ft·lb)
6-10 CLUTCH
Clutch

• Ifproper
the clutch housing is replaced with a new one, select the
clutch housing in accordance with the combination
of the clutch housing gear and crankshaft primary gear
markings with colors.
Crankshaft Primary Gear [A]
Clutch Housing Gear [B]
• Be sure to confirm the marking and color on the clutch
housing gear.

Clutch Housing Gear Selection when Replacing Clutch Housing Gear

Crankshaft Clutch Housing
Primary Gear
Color [D] Gear Marking [E] Color [F] Part Number
Marking [C]
A White A White 13095-0095
A White B Red 13095-0096
A White C None 13095-0097
A White D Yellow 13095-0098
B Red A White 13095-0095
B Red B Red 13095-0096
B Red C None 13095-0097
B Red D Yellow 13095-0098
C None B Red 13095-0096
C None C None 13095-0097
C None D Yellow 13095-0098
D Yellow C None 13095-0097
D Yellow D Yellow 13095-0098

• Install the friction plate first and steel plate, and afterward
install them alternately.
○The inner-end [A] and outer-end [B] friction plate blocks
are wider than the others.
Wider [C]
Narrower [D]
 CLUTCH 6-11
Clutch

• Apply engine oil to the bearing, and install it.

• Install the clutch spring
Apply molybdenum disulfide grease to the pusher ends.
• plate [A] with the pusher [B].

• Install the springs and tighten the clutch spring bolts.

Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Install the clutch cover (see Clutch Cover Installation).
Clutch Plate Wear and Damage Inspection
• Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.
• Measure
points.
the thickness of each friction plate [A] at several

If any plates show signs of damage, or if they have worn

past the service limit, replace them with new ones.
Friction Plate Thickness
Standard: 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.)
Service Limit: 2.6 mm (0.10 in.)

Clutch Plate Warp Inspection

• Place each friction plate or steel plate on a surface plate
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
Standard: 0.15 mm (0.0059 in.) or less
Service Limit: 0.3 mm (0.012 in.)

Clutch Spring Free Length Inspection

• Measure the free length of the clutch springs [A].
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard: 39.4 mm (1.55 in.)
Service Limit: 37.6 mm (1.48 in.)
 ENGINE LUBRICATION SYSTEM 7-1

Engine Lubrication System

Table of Contents
Exploded View........................................................................................................................ 7-2
Engine Oil Flow Chart............................................................................................................. 7-4
Specifications ......................................................................................................................... 7-5
Special Tools and Sealant ...................................................................................................... 7-6
Engine Oil and Oil Filter.......................................................................................................... 7-7
Oil Level Inspection........................................................................................................... 7-7
Engine Oil Change............................................................................................................ 7-7
Oil Filter Replacement ...................................................................................................... 7-7
Bypass Valve Disassembly ............................................................................................... 7-8
Bypass Valve Assembly.................................................................................................... 7-8
Bypass Valve Cleaning and Inspection............................................................................. 7-8
Oil Screen Cleaning and Inspection.................................................................................. 7-8
Oil Pressure Relief Valve........................................................................................................ 7-9 7
Oil Pressure Relief Valve Removal ................................................................................... 7-9
Oil Pressure Relief Valve Installation ................................................................................ 7-9
Oil Pressure Relief Valve Inspection................................................................................. 7-9
Oil Pump................................................................................................................................. 7-10
Oil Pump Removal ............................................................................................................ 7-10
Oil Pump Installation ......................................................................................................... 7-10
Oil Pump Inspection.......................................................................................................... 7-10
Oil Pressure Measurement..................................................................................................... 7-11
Oil Pressure Measurement ............................................................................................... 7-11
Oil Pressure Switch ................................................................................................................ 7-12
Oil Pressure Switch Removal ........................................................................................... 7-12
Oil Pressure Switch Installation ........................................................................................ 7-12
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
 ENGINE LUBRICATION SYSTEM 7-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Crankcase Oil Passage Plug 15 1.5 11
2 Engine Oil Drain Bolt (Crankcase) 19.6 2.0 14.5
3 Engine Oil Drain Bolt (Oil Screen Cover) 19.6 2.0 14.5
4 Oil Breather Mounting Bolts 9.8 1.0 87 in·lb L
5 Oil Filter Mounting Bolt 19.6 2.0 14.5
6 Oil Hose Banjo Bolts 19.6 2.0 14.5
7 Oil Passage Plugs 20 2.0 15 L
8 Oil Pipe Banjo Bolt 12 1.2 106 in·lb
9 Oil Pressure Relief Valve 15 1.5 11 L
10 Oil Pressure Switch 15 1.5 11 SS
11 Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb G
12 Oil Pump Mounting Bolts 9.8 1.0 87 in·lb L
13 Oil Screen Cover Bolts 9.8 1.0 87 in·lb
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant.
7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
 ENGINE LUBRICATION SYSTEM 7-5
Specifications

Item Standard
Engine Oil
Type API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity SAE 10W-40
Capacity 1.3 L (1.4 US qt) (when filter is not removed)
1.6 L (1.7 US qt) (when filter is removed)
1.7 L (1.8 US qt) (when engine is completely dry)
Level Between upper and lower level lines (Wait 2 ∼ 3 minutes
after idling or running)
Oil Pressure Measurement
Oil Pressure 98 ∼ 147 kPa (1.0 ∼ 1.5 kgf/cm², 14 ∼ 21 psi) at 4 000
r/min (rpm), Oil Temperature 90°C (194°F)
7-6 ENGINE LUBRICATION SYSTEM
Special Tools and Sealant
Outside Circlip Pliers: Oil Pressure Gauge Adapter, M18 × 1.5:
57001-144 57001-1278

Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant):

57001-164 56019-120
 ENGINE LUBRICATION SYSTEM 7-7
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

• Check that the engine oil level is between the upper [A]
and lower [B] levels in the gauge.
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground.
○If the motorcycle has just been used, wait several min-
utes for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.

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 indicator light
will light. If this light stays on when the engine is
running above idle speed, stop the engine immedi-
ately 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 the Engine Oil Change in the Periodic Mainte-
nance chapter.
Oil Filter Replacement
• Refer to the Oil Filter Replacement in the Periodic Main-
tenance chapter.
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
Bypass Valve Disassembly
• Remove the oil filter (see Oil Filter Replacement in the
Periodic Maintenance chapter).
NOTE
○Oil draining is not necessary, but place the oil pan un-
der the oil filter because oil drain a little at the oil filter
removal.

• Drive
[B].
the retaining pin [A] out of the oil filter mounting bolt

• Drop out the spring [C] and the bypass valve steel ball [D].
Bypass Valve Assembly
• Drop
bolt.
the bypass valve steel ball into the oil filter mounting

• Put the spring into the oil filter mounting bolt and com-
press it beyond the small hole.
• Drive
spring.
the retaining pin into the small hole to hold the

• Install the oil filter (see Oil Filter Replacement in the Pe-
riodic Maintenance chapter).
Bypass Valve Cleaning and Inspection
• Disassemble
sembly).
the bypass valve (see Bypass Valve Disas-

• Clean the bypass valve parts in a high-flash point solvent.

WARNING
Clean the parts in a well-ventilated area, and take
care that there is no spark or flame anywhere near
the working area. Because of the danger of highly
flammable liquids, do not use gasoline or low-flash
point solvent.

• Visually inspect the bypass valve parts.

If there is any damaged part, replace it.
Oil Screen Cleaning and Inspection
• Remove the bolts [A] and oil screen cover [B].
• remove anyoilparticles
Clean the screen [C] with high-flash point solvent and
stuck to it.
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 solvent.

NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.

• Check the screen carefully for any damage; holes and

broken wires.
If the screen is damaged, replace the oil screen.
 ENGINE LUBRICATION SYSTEM 7-9
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
• Remove the clutch cover (see Clutch Cover Removal in
the Clutch chapter).
• Unscrew
crankcase.
the oil pressure relief valve [A] from the

Oil Pressure Relief Valve Installation

• Apply a non-permanent locking agent to the threads of
the relief valve, and tighten it.
CAUTION
Do not apply too much non-permanent locking
agent to the threads. This may block the oil pas-
sage.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11

ft·lb)

Oil Pressure Relief Valve Inspection

• Check to see if the valve [A] slides smoothly when push-
ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] pressure.
NOTE
○Inspect the valve in its assembled state. Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high-flash point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Clean the oil pressure relief valve in a well
-ventilated area, and take care that there is no
spark or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low-flash point solvent.
If cleaning does not solve the problem, replace the oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for re-
placement of individual parts.
7-10 ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Oil Pump Mounting Bolts [A]
Oil Pump [B]

Oil Pump Installation

• Fill the oil pump with engine oil for initial lubrication.
• fits into
Turn the oil pump shaft so that the projection [A] in its shaft
the slot [B] of the water pump shaft.
• Apply a non-permanent locking agent to the threads of
the oil pump mounting bolts, and tighten them.
Torque - Oil Pump Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)

Oil Pump Inspection

• Visually inspect the oil pump body, inner and outer rotors
and cover.
If there is any damage or uneven wear, replace the oil
pump as an assembly.
 ENGINE LUBRICATION SYSTEM 7-11
Oil Pressure Measurement
Oil Pressure Measurement
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Remove the oil passage plug, and attach the adapter [A]
and gauge [B] to the plug hole.
Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164
Oil Pressure Gauge Adapter, M18 × 1.5:
57001-1278

• Start the engine and warm up the engine.

• pressureengine
Run the
gauge.
at the specified speed, and read the oil

If the reading is much lower than the standard, check

the oil pump, relief valve, and/or crankshaft bearing in-
sert wear immediately.
If the reading is much higher than the standard, check the
oil passages for clogging.
Oil Pressure
Standard: 98 ∼ 147 kPa (1.0 ∼ 1.5 kgf/cm², 14 ∼ 21 psi)
at 4 000 r/min (rpm), Oil Temperature 90°C
(194°F)

• Stop the engine.

• Remove the oil pressure gauge and adapter.
WARNING
Take care against burns form hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.

• Tighten:
Torque - Crankcase Oil Passage Plug: 15 N·m (1.5 kgf·m,
11 ft·lb)
7-12 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Switch Cover [A]
Switch Terminal Bolt [B]
Oil Pressure Switch [C]

Oil Pressure Switch Installation

• Apply silicone sealant to the threads of the oil pressure
switch, and tighten it.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
• Install
45° [B]
the switch lead [A] as shown in the figure.

Front [C]
• Apply grease to the terminal.
• Tighten the terminal bolt.
Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Cover the switch.
• in the Frame
Install the left lower fairing (see Lower Fairing Installation
chapter).
 ENGINE REMOVAL/INSTALLATION 8-1

Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................ 8-2
Engine Removal/Installation ................................................................................................... 8-4
Engine Removal................................................................................................................ 8-4
Engine Installation............................................................................................................. 8-5

8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
 ENGINE REMOVAL/INSTALLATION 8-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Engine Mounting Bracket Bolts and Nuts 69 7.0 51
2 Engine Mounting Nuts 69 7.0 51
8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal
• Support the rear part of the swingarm with a stand.
• [A]. the brake lever slowly and hold it with a band
Squeeze

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.

• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Clutch Cable Lower End (see Clutch Cable Removal in
the Clutch chapter)
Coolant Reserve Tank (see Coolant Reserve Tank Re-
moval in the Cooling System chapter)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Air Switching Valve (see Air Switching Valve Removal in
the Engine Top End chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Shift Lever (see Shift Pedal Removal in the Crank-
shaft/Transmission chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
Regulator/Rectifier (see Regulator/Rectifier Inspection
in the Electrical System chapter)

• Remove:
Oil Pressure Switch Lead [A]
Neutral Switch Lead Connector [B]
Breather Hose End [C]
 ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation

• Remove:
Starter Motor Cable [A]
Engine Ground Cable Terminal Bolt [B]
Alternator and Crankshaft Sensor Lead Connectors (see
Alternator Cover Removal in the Electrical System chap-
ter)
Stick Coil Lead Connectors (see Stick Coil Removal in
the Electrical System chapter)

•○Support the engine with a suitable stand [A].

Put a plank [B] onto the suitable stand for engine balance.

• Remove:
Engine Mounting Bracket Nuts and Bolts [A] (Both Sides)
Engine Mounting Nut [B] and Bolt
Engine Mounting Brackets [C] (Both Sides)

• Remove:
Engine Mounting Nuts [A] and Bolts
Engine [B]

Engine Installation
•○Support the engine with a suitable stand.
Put a plank onto the suitable stand for engine balance.
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation

• Install
figure.
the heat insulation rubber plate as shown in the

A: After installation, set the projection in the hole.

B: To Radiator
C: To Fan Motor Lead
D: To Air Suction Valve Cover
E: To Stick Coils
F: To Water Pipe
G: To Throttle Body Assy Holders
H: To Breather Hose

• Insert the lower engine mounting bolt [A] first while sup-
porting the engine. Then insert the upper engine mount-
ing bolt [B], and tighten the nuts lightly.
 ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation

• Before tightening the mounting nuts, install the engine

mounting brackets. When inserting the front engine
mounting bolt, use the suitable stand under the engine
to lift it.
• Tighten:
Torque - Engine Mounting Bracket Bolts and Nuts: 69 N·m
(7.0 kgf·m, 51 ft·lb)
Engine Mounting Nuts: 69 N·m (7.0 kgf·m, 51 ft·lb)
• Run the leads, cables and hoses correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
• Throttle Cables (see Throttle Control System Inspection
Adjust:

in the Periodic Maintenance chapter)

Clutch Cable (see Clutch Operation Inspection in the Pe-
riodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Inspection in the
Periodic Maintenance chapter)
• Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).
• Fill the engine with coolant (see Coolant Change in the
Periodic Maintenance chapter).
 CRANKSHAFT/TRANSMISSION 9-1

Crankshaft/Transmission
Table of Contents
Exploded View................................... 9-2 Starter Motor Clutch Assembly .... 9-22
Specifications .................................... 9-6 Balancer ............................................ 9-23
Special Tools and Sealant ................. 9-9 Balancer Removal........................ 9-23
Crankcase ........................................ 9-10 Balancer Installation..................... 9-23
Crankcase Splitting ...................... 9-10 Balancer Shaft Bearing
Crankcase Assembly ................... 9-11 Insert/Journal Wear Inspection . 9-23
Crankshaft and Connecting Rods...... 9-14 Transmission ..................................... 9-25
Crankshaft Removal .................... 9-14 Shift Pedal Removal .................... 9-25
Crankshaft Installation ................. 9-14 Shift Pedal Installation ................. 9-25
Connecting Rod Removal ............ 9-15 External Shift Mechanism
Connecting Rod Installation ......... 9-15 Removal .................................... 9-26
Crankshaft/Connecting Rod External Shift Mechanism
Cleaning .................................... 9-16 Installation ................................. 9-26
Connecting Rod Bend Inspection 9-17 External Shift Mechanism
Connecting Rod Twist Inspection. 9-17 Inspection.................................. 9-26
Connecting Rod Big End Side Transmission Shaft Removal ....... 9-27
Clearance Inspection ................ 9-17 Transmission Shaft Installation .... 9-27
Connecting Rod Big End Transmission Shaft Disassembly . 9-28
9
Bearing Insert/Crankpin Wear Transmission Shaft Assembly...... 9-28
Inspection.................................. 9-18 Shift Drum and Fork Removal...... 9-31
Crankshaft Side Clearance Shift Drum and Fork Installation... 9-31
Inspection.................................. 9-19 Shift Drum Disassembly............... 9-32
Crankshaft Runout Inspection...... 9-20 Shift Drum Assembly ................... 9-32
Crankshaft Main Bearing Shift Fork Bending Inspection ...... 9-32
Insert/Journal Wear Inspection . 9-20 Shift Fork/Gear Groove Wear
Starter Motor Clutch .......................... 9-22 Inspection.................................. 9-33
Starter Motor Clutch Shift Fork Guide Pin/Drum
Removal/Installation.................. 9-22 Groove Wear Inspection ........... 9-33
Starter Motor Clutch Inspection ... 9-22 Gear Dog and Gear Dog Hole
Starter Motor Clutch Disassembly 9-22 Damage Inspection ................... 9-33
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
 CRANKSHAFT/TRANSMISSION 9-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Connecting Rod Big End Nuts 27.5 2.8 20 MO
2 Crankcase Bolts (M8, L = 90 mm) 24 2.4 18 MO, S
3 Crankcase Bolts (M8, L = 73 mm) 19 1.9 14 MO, S
4 Crankcase Bolts (M6) 12 1.2 106 in·lb
5 Oil Breather Mounting Bolts 9.8 1.0 87 in·lb L
6 Shift Drum Bearing Holder Bolts 12 1.2 106 in·lb L
7 Starter Motor Clutch Bolts 34.3 3.5 25 L
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
 CRANKSHAFT/TRANSMISSION 9-5
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Neutral Switch 15 1.5 11
2 Shift Drum Pin Plate Bolt 9.0 0.92 80 in·lb L
3 Shift Drum Positioning Bolt 24.5 2.5 18
4 Shift Lever Bolt 12 1.2 106 in·lb
5 Shift Pedal Mounting Bolt 25 2.5 18
6 Shift Shaft Return Spring Pin 19.6 2.0 14.5 L
7 Tie-Rod Locknuts 7.0 0.71 62 in·lb
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
9-6 CRANKSHAFT/TRANSMISSION
Specifications

Item Standard Service Limit

Crankshaft, Connecting Rods
Connecting Rod Bend ––– TIR 0.2/100 mm
(0.008/3.94 in.)
Connecting Rod Twist ––– TIR 0.2/100 mm
(0.008/3.94 in.)
Connecting Rod Big End Side Clearance 0.13 ∼ 0.38 mm 0.58 mm
(0.0051 ∼ 0.0150 in.) (0.023 in.)
Connecting Rod Big End Bearing 0.031 ∼ 0.059 mm 0.10 mm
Insert/Crankpin Clearance (0.0012 ∼ 0.0023 in.) (0.004 in.)
Crankpin Diameter: 29.984 ∼ 30.000 mm 29.97 mm
(1.1805 ∼ 1.1811 in.) (1.1799 in.)
Marking
None 29.984 ∼ 29.994 mm – – –
(1.1805 ∼ 1.1809 in.)
○ 29.995 ∼ 30.000 mm – – –
(1.1809 ∼ 1.1811 in.)
Connecting Rod Big End Inside Diameter: 33.000 ∼ 33.016 mm – – –
(1.2992 ∼ 1.2998 in.)
Marking
None 33.000 ∼ 33.008 mm – – –
(1.2992 ∼ 1.2995 in.)
○ 33.009 ∼ 33.016 mm – – –
(1.2996 ∼ 1.2998 in.)
Connecting Rod Big End Bearing Insert
Thickness:
Brown 1.480 ∼ 1.485 mm – – –
(0.05827 ∼ 0.05846 in.)
Black 1.485 ∼ 1.490 mm – – –
(0.05846 ∼ 0.05866 in.)
Blue 1.489 ∼ 1.494 mm – – –
(0.05862 ∼ 0.05882 in.)
Crankshaft Side Clearance 0.05 ∼ 0.20 mm 0.40 mm
(0.0020 ∼ 0.0079 in.) (0.0157 in.)
Crankshaft Runout TIR 0.02 mm (0.0008 in.) or TIR 0.05 mm
less (0.0020 in.)
Crankshaft Main Bearing Insert/Journal 0.014 ∼ 0.038 mm 0.07 mm
Clearance (0.0006 ∼ 0.0015 in.) (0.0028 in.)
Crankshaft Main Journal Diameter: 27.984 ∼ 28.000 mm 27.96 mm
(1.1017 ∼ 1.1024 in.) (1.101 in.)
Marking
None 27.984 ∼ 27.992 mm – – –
(1.1017 ∼ 1.1020 in.)
1 27.993 ∼ 28.000 mm – – –
(1.1021 ∼ 1.1024 in.)
Crankcase Main Bearing Inside Diameter: 31.000 ∼ 31.016 mm – – –
(1.2205 ∼ 1.2211 in.)
 CRANKSHAFT/TRANSMISSION 9-7
Specifications

Item Standard Service Limit

Marking
○ 31.000 ∼ 31.008 mm – – –
(1.2205 ∼ 1.2208 in.)
None 31.009 ∼ 31.016 mm – – –
(1.2208 ∼ 1.2211 in.)
Crankshaft Main Bearing Insert Thickness:
Black 1.495 ∼ 1.499 mm – – –
(0.05885 ∼ 0.05902 in.)
Blue 1.499 ∼ 1.503 mm – – –
(0.05902 ∼ 0.05917 in.)
Yellow 1.503 ∼ 1.507 mm – – –
(0.05917 ∼ 0.05933 in.)
Balancer
Balancer Shaft Bearing Insert/Journal 0.020 ∼ 0.044 mm 0.07 mm
Clearance (0.0008 ∼ 0.0017 in.) (0.0028 in.)
Balancer Shaft Journal Diameter: 25.984 ∼ 26.000 mm 25.96 mm
(1.0230 ∼ 1.0236 in.) (1.022 in.)
Marking
None 25.984 ∼ 25.994 mm – – –
(1.0230 ∼ 1.0234 in.)
○ 25.995 ∼ 26.000 mm – – –
(1.0234 ∼ 1.0236 in.)
Crankcase Main Bearing Inside Diameter: 29.000 ∼ 29.016 mm – – –
(1.1417 ∼ 1.1424 in.)
Marking
○ 29.000 ∼ 29.008 mm – – –
(1.1417 ∼ 1.1420 in.)
None 29.009 ∼ 29.016 mm – – –
(1.1421 ∼ 1.1424 in.)
Balancer Shaft Bearing Insert Thickness:
Brown 1.495 ∼ 1.499 mm – – –
(0.05885 ∼ 0.05902 in.)
Black 1.499 ∼ 1.503 mm – – –
(0.05902 ∼ 0.05917 in.)
Blue 1.503 ∼ 1.507 mm – – –
(0.05917 ∼ 0.05933 in.)
Transmission
Shift Fork Ear Thickness 4.9 ∼ 5.0 mm 4.8 mm
(0.193 ∼ 0.197 in.) (0.189 in.)
Gear Groove Width 5.05 ∼ 5.15 mm 5.3 mm
(0.199 ∼ 0.203 in.) (0.209 in.)
Shift Fork Guide Pin Diameter 5.9 ∼ 6.0 mm 5.8 mm
(0.232 ∼ 0.236 in.) (0.228 in.)
Shift Drum Groove Width 6.05 ∼ 6.20 mm 6.3 mm
(0.238 ∼ 0.244 in.) (0.248 in.)
9-8 CRANKSHAFT/TRANSMISSION
Specifications
Connecting Rod Big End Bearing Insert Selection
Con-rod Big End Bearing Insert
Crankpin Diameter
Inside Diameter
Marking Size Color Part Number
Marking
None ○ Brown 92028-1494
None None
Black 92028-1493
○ ○
○ None Blue 92028-1492

Crankshaft Main Bearing Insert Selection

Crankcase Main Crankpin Main Bearing Insert*
Bearing Inside Journal Diameter
Diameter Marking Marking Size Color Part Number Journal Nos.
92028-1487 1, 3
○ 1 Black
92028-1490 2
○ None
Blue
92028-1486 1, 3
None 1 92028-1489 2
92028-1582 1, 3
None None Yellow
92028-1586 2
*: The bearing insert for Nos. 2 journal have an oil groove.

Balancer Shaft Bearing Insert Selection

Crankcase Main Balancer Shaft Bearing Insert
Bearing Inside Journal Diameter
Diameter Marking Marking Size Color Part Number

○ ○ Brown 92028-1424
○ None
Black 92028-1423
None ○
None None Blue 92028-1422

Crankshaft Selection when Replacing Crankshaft

Clutch Housing Crankshaft
Primary Gear
Gear Marking Color Color Part Number
Marking
A White A White 13031-0111
A White B Red 13031-0112
B Red A White 13031-0111
B Red B Red 13031-0112
B Red C None 13031-0113
C None A White 13031-0111
C None B Red 13031-0112
C None C None 13031-0113
C None D Yellow 13031-0114
D Yellow A White 13031-0111
D Yellow B Red 13031-0112
D Yellow C None 13031-0113
D Yellow D Yellow 13031-0114
 CRANKSHAFT/TRANSMISSION 9-9
Special Tools and Sealant
Bearing Puller: Bearing Puller Adapter:
57001-135 57001-317

Outside Circlip Pliers: Kawasaki Bond(Liquid Gasket - Black):

57001-144 92104-1064
9-10 CRANKSHAFT/TRANSMISSION
Crankcase
Crankcase Splitting
• Remove the engine (see Engine Removal in the Engine
Removal/Installation chapter).
• Set the engine on a clean surface and hold the engine
steady while parts are being removed.
• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
External Shift Mechanism (see External Shift Mecha-
nism Removal)
Oil Pump (see Oil Pump Removal in the Engine Lubri-
cation System chapter)
Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Water Pump (see Water Pump Removal in the Cooling
System chapter)
Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)
Oil Screen (see Oil Screen Cleaning and Inspection in
the Engine Lubrication System chapter)
Cylinder Head (see Cylinder Head Removal in the En-
gine Top End chapter)
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
If the crankshaft is to be removed, remove the pistons
(see Piston Removal in the Engine Top End chapter).

• Remove the upper crankcase bolts [A].

•○Remove the lower crankcase bolts.

First loosen the M6 bolts [A].
M8 Bolts [B]
• Tap lightly around the crankcase mating surface with a
plastic mallet, and split the crankcase. Take care not to
damage the crankcase.
 CRANKSHAFT/TRANSMISSION 9-11
Crankcase
Crankcase Assembly
CAUTION
The upper and lower crankcase halves are ma-
chined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.

• With a high-flash point solvent, clean off the mating sur-

faces of the crankcase halves and wipe dry.
• Using compressed air, blow out the oil passages in the
crankcase halves.

• Apply engine oil to the new O-ring [A].

• Apply a non-permanent locking agent to the threads of
the oil breather mounting bolts [B] and tighten them.
Torque - Oil Breather Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Install the breather hose [C] as shown in the figure.
About 34.5 mm (1.36 in.) [D]

• Replace the O-rings [A] with new ones.

• Apply grease to the new O-rings.
• Slit (Horizontal)
Install the oil passage pipe [B] as shown in the figure.
[C]
70° [D] (1 mm (0.04 in.) Hole direction)
Lower Crankcase [E]
9-12 CRANKSHAFT/TRANSMISSION
Crankcase

• Install:
Shift Drum (see Shift Drum and Fork Installation)
Shift Forks and Shift Rods (see Shift Drum and Fork In-
stallation)
Crankshaft (see Crankshaft Installation)
Balancer Shaft (see Balancer Installation)
Connecting Rods (see Connecting Rod Installation)
Camshaft Chain
Transmission Shafts and Gears (see Transmission Shaft
Installation)
Dowel Pins [A]
•Before fitting the lower case on the upper case, check the
following.
○Be sure to hang the camshaft chain on the crankshaft.
○Check to see that the shift drum and transmission gears
are in the neutral position.

• Apply liquid gasket [A] to the mating surface of the lower

crankcase half.
Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104
-1064

CAUTION
Do not apply liquid gasket around the crankshaft
main bearing inserts, and oil passage holes.

• Fit the lower crankcase to the upper crankcase.

• Apply molybdenum disulfide oil solution to the seating sur-

face [A] and threads [B] of the M8 bolts.
 CRANKSHAFT/TRANSMISSION 9-13
Crankcase

• Tighten
steps.
the lower crankcase bolts using the following

○Following the sequence numbers on the lower crankcase

half, tighten the M8 bolts [1 ∼ 7] L= 90 mm (3.54 in.).
Torque - Crankcase Bolts (M8): 24 N·m (2.4 kgf·m, 18 ft·lb)
○Tighten the M8 bolts [8 ∼ 9] L= 73 mm (2.87 in.).
Torque - Crankcase Bolts (M8): 19 N·m (1.9 kgf·m, 14 ft·lb)
○Tighten the M6 bolts.
Torque - Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

L = 135 mm (5.31 in.) [A]

L = 85 mm (3.35 in.) [B] (with New Copper
Washer)
L = 60 mm (2.36 in.) [C]
L = 38 mm (1.50 in.) [D]

• Tighten the upper crankcase bolts in the order listed.

Torque - Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)
L= 85 mm (3.35 in.) [A]
L= 60 mm (2.36 in.) [B] (with New Copper
Washer)

• After
items.
tightening all crankcase bolts, check the following

○Wipe up the liquid gasket that seeps out around the

crankcase mating surface.
○Crankshaft and transmission shafts turn freely.
○While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
○When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.
•Install the removed parts (see appropriate chapters).
9-14 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Removal
• Split the crankcase (see Crankcase Splitting).
• Removal the crankshaft [A].

Crankshaft Installation
• Ifproper
the crankshaft is replaced with a new one, select the
crankshaft in accordance with the combination
of the crankshaft primary gear and clutch housing gear
markings with colors.
Crankshaft Primary Gear [A]
Clutch Housing Gear [B]
• Be sure to confirm the marking and color on the crank-
shaft primary gear.

Crankshaft Selection when Replacing Crankshaft

Clutch Housing Crankshaft
Primary Gear
Gear Marking [E] Color [F] Color [D] Part Number
Marking [C]
A White A White 13031-0111
A White B Red 13031-0112
B Red A White 13031-0111
B Red B Red 13031-0112
B Red C None 13031-0113
C None A White 13031-0111
C None B Red 13031-0112
C None C None 13031-0113
C None D Yellow 13031-0114
D Yellow A White 13031-0111
D Yellow B Red 13031-0112
D Yellow C None 13031-0113
D Yellow D Yellow 13031-0114
 CRANKSHAFT/TRANSMISSION 9-15
Crankshaft and Connecting Rods
NOTE
○If the crankshaft is replaced with a new one, refer to the
Connecting Rod Big End Bearing Insert Selection in the
Specifications.

CAUTION
If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with a plastigage
(press gauge) before assembling engine to be sure
the correct bearing inserts are installed.

•○Install the crankshaft.

Align the timing mark [A] on the balancer drive gear [B]
with the timing mark [C] on the balancer gear [D].
• Apply molybdenum disulfide oil solution to the crankshaft
main bearing inserts.

Connecting Rod Removal

• Split the crankcase (see Crankcase Splitting).
• Connecting Rod Big End Nuts [A]
Remove:

Crankshaft
NOTE
○Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.

• Remove the connecting rods from the crankshaft.

CAUTION
Discard the connecting rod bolts. To prevent dam-
age to the crankpin surfaces, do not allow the con-
necting rod bolts to bump against the crankpins.

Connecting Rod Installation

CAUTION
To minimize vibration, the connecting rods should
have the same weight mark.
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: "○" or no
mark
9-16 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
CAUTION
If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select the
bearing insert and check clearance with a plasti-
gage (press gauge) before assembling engine to be
sure the correct bearing inserts are installed.

CAUTION
The connecting rod bolts are designed to stretch
when tightened. Never reuse them.

• Replace the connecting rod big end bolts and nuts with
new ones.

• Apply molybdenum disulfide oil solution to the inner sur-

faces of upper and lower bearing inserts [A].
• Do not apply any grease or oil to the cap inside and cap
insert outside [B].
• Install the inserts so that their nails [C] are on the same
side and fit them into the recess of the connecting rod and
cap.
CAUTION
Wrong application of oil and grease could cause
bearing damage.

○When installing the inserts [A], be careful not to damage

the insert surface with the edge of the connecting rod [B]
or the cap [C]. One way to install inserts is as follows.
Installation [D] to Cap
Installation [E] to Connecting Rod
Push [F]
Spare Dowel Pin [G]
Connecting Rod Bolts [H]
• Install the cap on the connecting rod, aligning the weight
and diameter marks.
• Remove debris and clean the surface of inserts.
• Apply molybdenum disulfide oil solution [MO] to the
threads and seating surfaces of the big end nuts and
bolts.

• Install the crankshaft (see Crankshaft Installation).

• Tighten: connecting rod on its original crankpin.
Install each
•
Torque - Connecting Rod Big End Nuts: 27.5 N·m (2.8
kgf·m, 20 ft·lb)

Crankshaft/Connecting Rod Cleaning

• After removing the connecting rods from the crankshaft,
clean them with a high-flash point solvent.
• Blow the crankshaft oil passages with compressed air to
remove any foreign particles or residue that may have
accumulated in the passages.
 CRANKSHAFT/TRANSMISSION 9-17
Crankshaft and Connecting Rods
Connecting Rod Bend Inspection
• Remove the connecting rod big end bearing inserts, and
reinstall the connecting rod big end cap.
• Select an arbor [A] of the same diameter as the connect-
ing rod big end, and insert the arbor through the connect-
ing rod big end.
• Select an arbor of the same diameter as the piston pin
and at least 100 mm (3.94 in.) long, and insert the arbor
[B] through the connecting rod small end.
• On a surface plate, set the big-end arbor on V block [C].
• With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If the connecting rod bend exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Bend
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist Inspection

• With the big-end arbor [A] still on V block [C], hold the
connecting rod horizontally and measure the amount that
the arbor [B] varies from being paralleled with the surface
plate over a 100 mm (3.94 in.) length of the arbor to de-
termine the amount of connecting rod twist.
If the connecting rod twist exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance

Inspection
•○Measure the connecting rod big end side clearance.
Insert a thickness gauge [A] between the big end and ei-
ther crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard: 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.)
Service Limit: 0.58 mm (0.023 in.)
If the clearance exceeds the service limit, replace the con-
necting rod with new one and then check the clearance
again. If the clearance is too large after connecting rod
replacement, the crankshaft also must be replaced.
9-18 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Big End Bearing Insert/Crankpin
Wear Inspection
• Measure the bearing insert/crankpin [A] clearance with
plastigage [B].
• Tighten the big end nuts to the specified torque (see Con-
necting Rod Installation).
NOTE
○Do not move the connecting rod and crankshaft during
clearance measurement.

Connecting Rod Big End Bearing Insert/Crankpin

Clearance
Standard: 0.031 ∼ 0.059 mm (0.0012 ∼ 0.0023 in.)
Service Limit: 0.10 mm (0.004 in.)

If the clearance is within the standard, no bearing replace-

ment is required.
If the clearance is between 0.059 mm (0.0023 in.) and
the service limit 0.10 mm (0.004 in.), replace the bear-
ing inserts [A] with inserts painted blue [B]. Check the in-
sert/crankpin clearance with the plastigage. The clear-
ance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard: 29.984 ∼ 30.000 mm (1.1805 ∼ 1.1811 in.)
Service Limit: 29.97 mm (1.1799 in.)

If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankpin Diameter Marks
None: 29.984 ∼ 29.994 mm (1.1805 ∼ 1.1809 in.)
○: 29.995 ∼ 30.000 mm (1.1809 ∼ 1.1811 in.)
◊: Crankpin Diameter Marks, "○" or no mark.
 CRANKSHAFT/TRANSMISSION 9-19
Crankshaft and Connecting Rods

• Measure the connecting rod big end inside diameter, and

mark each connecting rod big end in accordance with the
inside diameter.
• Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).
NOTE
○The mark already on the big end should almost coincide
with the measurement.

Connecting Rod Big End Inside Diameter Marks

None: 33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.)
○: 33.009 ∼ 33.016 mm (1.2996 ∼ 1.2998 in.)
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: "○" or no
mark

• Select the proper bearing insert [A] in accordance with the

combination of the connecting rod and crankshaft coding.
Size Color [B]
Con-rod Big Bearing Insert
Crankpin
End Inside
Diameter
Diameter Size Color Part Number
Marking
Marking
None ○ Brown 92028-1494
None None
Black 92028-1493
○ ○
○ None Blue 92028-1492

• Install the new inserts in the connecting rod and check

insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance Inspection
• Insert a thickness gauge [A] between the crankcase main
bearing and the crank web at the No. 2 journal [B] to
determine clearance.
If the clearance exceeds the service limit, replace the
crankcase halves as a set.
NOTE
○The upper and lower crankcase halves are machined
at the factory in the assembled state, so the crankcase
halves must be replaced as a set.

Crankshaft Side Clearance

Standard: 0.05 ∼ 0.20 mm (0.0020 ∼ 0.0079 in.)
Service Limit: 0.40 mm (0.0157 in.)
9-20 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Runout Inspection
• Measure the crankshaft runout.
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.05 mm (0.0020 in.)

Crankshaft Main Bearing Insert/Journal Wear

Inspection
• Using a plastigage (press gauge), measure the bearing
insert/journal [B] clearance [A].
NOTE
○Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
○Do not turn the crankshaft during clearance measure-
ment.
○Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.

Crankshaft Main Bearing Insert/Journal Clearance

Standard: 0.014 ∼ 0.038 mm (0.0006 ∼ 0.0015 in.)
Service Limit: 0.07 mm (0.0028 in.)

If the clearance is within the standard, no bearing replace-

ment is required.
If the clearance is between 0.038 mm (0.0015 in.) and the
service limit 0.07 mm (0.0028 in.), replace the bearing in-
serts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.

Crankshaft Main Journal Diameter

Standard: 27.984 ∼ 28.000 mm (1.1017 ∼ 1.1024 in.)
Service Limit: 27.96 mm (1.101 in.)
If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None: 27.984 ∼ 27.992 mm (1.1017 ∼ 1.1020 in.)
1: 27.993 ∼ 28.000 mm (1.1021 ∼ 1.1024 in.)
□: Crankshaft Main Journal Diameter Marks, "1" or no
mark.
 CRANKSHAFT/TRANSMISSION 9-21
Crankshaft and Connecting Rods

• Measure the main bearing inside diameter, and mark the

upper crankcase half in accordance with the inside diam-
eter.
A: Crankcase Main Bearing Inside Diameter Marks, "○"
or no mark.
NOTE
○Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
○The mark already on the upper crankcase half should
almost coincide with the measurement.

Crankcase Main Bearing Inside Diameter Marks

○ : 31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.)
None: 31.009 ∼ 31.016 mm (1.2208 ∼ 1.2211 in.)

• Select the proper bearing insert [A] in accordance with the

combination of the crankcase and crankshaft coding.
Size Color [B]

Crankcase Main Crankpin Main Bearing Insert*

Bearing Inside Journal Diameter
Diameter Marking Marking Size Color Part Number Journal Nos.
92028-1487 1, 3
○ 1 Black
92028-1490 2
○ None
Blue
92028-1486 1, 3
None 1 92028-1489 2
92028-1582 1, 3
None None Yellow
92028-1586 2
*: The bearing insert for Nos. 2 journal have an oil groove.

• Install the new inserts in the crankcase halves and check

insert/journal clearance with the plastigage.
9-22 CRANKSHAFT/TRANSMISSION
Starter Motor Clutch
Starter Motor Clutch Removal/Installation
• Refer to the Alternator Rotor Removal/Installation in the
Electrical System chapter.
Starter Motor Clutch Inspection
• Remove:
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Starter Idle Gear and shaft
• Turn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, but
should not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
• Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.
NOTE
○Examine the starter motor clutch gear as well. Replace
it if it worn or damaged.
Starter Motor Clutch Disassembly
• Remove:
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Starter Motor Clutch Bolts [A]
Starter Motor Clutch [B]

Starter Motor Clutch Assembly

• Apply a non-permanent locking agent to the threads of
the starter motor clutch bolts and tighten them.
Torque - Starter Motor Clutch Bolts: 34.3 N·m (3.5 kgf·m,
25 ft·lb)
 CRANKSHAFT/TRANSMISSION 9-23
Balancer
Balancer Removal
• Split the crankcase (see Crankcase Splitting).
• Remove the balancer shaft [A] with the balancer gear.

Balancer Installation
•○Install the balancer shaft.
Align the timing mark [A] on the balancer gear [B] with the
timing mark [C] on the balancer drive gear [D].
• Apply molybdenum disulfide oil solution to the balancer
shaft bearing inserts.

Balancer Shaft Bearing Insert/Journal Wear

Inspection
• Measure the bearing insert/journal [A] clearance with
plastigage [B].
NOTE
○Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
○Do not turn the balancer shaft during clearance mea-
surement.
○Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.

Balancer Shaft Bearing Insert/Journal Clearance

Standard: 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.)
Service Limit: 0.07 mm (0.0028 in.)

If the clearance is within the standard, no bearing replace-

ment is required.
If the clearance is between 0.044 mm (0.0017 in.) and the
service limit 0.07 mm (0.0028 in.), replace the bearing in-
serts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the balancer shaft journal.
Balancer Shaft Journal Diameter
Standard: 25.984 ∼ 26.000 mm (1.0230 ∼ 1.0236 in.)
Service Limit: 25.96 mm (1.022 in.)
9-24 CRANKSHAFT/TRANSMISSION
Balancer
If any journal has worn past the service limit, replace the
balancer shaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings [A] on the balancer shaft, make new marks on
it.
Balancer Shaft Journal Diameter Marks
None: 25.984 ∼ 25.994 mm (1.0230 ∼ 1.0234 in.)
○: 25.995 ∼ 26.000 mm (1.0234 ∼ 1.0236 in.)
: Balancer Shaft Journal Diameter Marks, "○" or no
mark.

• Measure the main bearing inside diameter, and mark the

upper crankcase half in accordance with the inside diam-
eter.
A: Crankcase Main Bearing Inside Diameter Marks, "○"
or no mark.
NOTE
○Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
○The mark already on the upper crankcase half should
almost coincide with the measurement.

Crankcase Main Bearing Inside Diameter Marks

○ : 29.000 ∼ 29.008 mm (1.1417 ∼ 1.1420 in.)
None: 29.009 ∼ 29.016 mm (1.1421 ∼ 1.1424 in.)

• Select the proper bearing insert [A] in accordance with the

combination of the crankcase and balancer shaft coding.
Size Color [B]
Crankcase Bearing Insert
Balancer
Main Bearing
Shaft Journal
Inside
Diameter Size Color Part Number
Diameter
Marking
Marking
○ ○ Brown 92028-1424
○ None
Black 92028-1423
None ○
None None Blue 92028-1422

• Install the new inserts in the crankcase and check in-

sert/journal clearance with the plastigage.
 CRANKSHAFT/TRANSMISSION 9-25
Transmission
Shift Pedal Removal
• Remove:
Shift Pedal Mounting Bolt [A]
Shift Lever Bolt [B]
Shift Pedal [C] with Shift Lever

Shift Pedal Installation

• Apply grease to the shift pedal [A].
• Tighten:the washers [B] and shift pedal.
Install
•
Torque - Shift Pedal Mounting Bolt [C]: 25 N·m (2.5 kgf·m,
18 ft·lb)

• Align the mark [A] on the shift shaft with the mark [B] on
the shift lever.
• Tighten:
Torque - Shift Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
• Install the shift pedal [C] as shown in the figure.
About 16° [D]
○To adjust the pedal position, loosen the front locknut [E]
(left-hand threads) and rear locknut [F] and then turn the
tie-rod [G].
• Tighten:
Torque - Tie-Rod Locknuts: 7.0 N·m (0.71 kgf·m, 62 in·lb)
9-26 CRANKSHAFT/TRANSMISSION
Transmission

• Be sure the sealing lip of the rubber boots [A] fits into the
groove of the ball joint after installing the shift lever link.
Correctly Boot Fitting Position [B]
Incorrectly Boot Fitting Position [C]

External Shift Mechanism Removal

• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Shift Lever (see Shift Pedal Removal)
Clutch (see Clutch Removal in the Clutch chapter)
• Spread the shift mechanism arm [A] and over shift limiter
[B] out of the shift drum [C], and pull out the shift shaft
assembly [D].

External Shift Mechanism Installation

• Check that the return spring [A] and pawl spring [B] are
properly fitted on the mechanism.
• Install the shift shaft assembly.
• [D] on the shift
Place the mechanism arm [C] and over shift limiter
shift drum pins.
• Install the removed parts (see appropriate chapters).

External Shift Mechanism Inspection

• Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the return spring [C] or pawl spring [D] is damaged in
any way, replace them.
If the shift mechanism arm [E] or over shift limiter [F] is
damaged in any way, replace the shaft.
 CRANKSHAFT/TRANSMISSION 9-27
Transmission

• Check the return spring pin [A] is not loose.

If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 19.6 N·m (2.0 kgf·m,
14.5 ft·lb)

• Visually inspect the shift drum pins [A], pin holder [B] and
pin plate [C].
If they are badly worn or if they show any damage, replace
them.

Transmission Shaft Removal

• Split the crankcase (see Crankcase Splitting).
• Remove the drive shaft [A] and output shaft [B].

Transmission Shaft Installation

• Check
place.
to see that the set pins [A] and set rings [B] are in

• Install the drive shaft and output shaft into the upper
crankcase half.
•○Apply engine oil to the bearings.
The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When
they are properly matched, there is no clearance [A] be-
tween the crankcase and the bearing outer races.
9-28 CRANKSHAFT/TRANSMISSION
Transmission

• Assemble the crankcase (see Crankcase Assembly).

• of the oil sealoilis seal
Press in the [A] onto collar [B] so that the surface
flush with the counterbore bottom surface
[C] of the crankcase.
○Apply grease to the oil seal lips.

Transmission Shaft Disassembly

• Remove the transmission shafts (see Transmission Shaft
Removal).
• Remove
shafts.
the circlips, disassemble the transmission

Special Tool - Outside Circlip Pliers: 57001-144

• The 5th gear [A] on the output shaft has three steel balls
assembled into it for the positive neutral finder mecha-
nism. Remove the 5th gear.
○Set the output shaft in a vertical position holding the 3rd
gear [B].
○Spin the 5th gear quickly [C] and pull it off upward.
• Remove the ball bearing [A] from each shafts.
Special Tools - Bearing Puller [B]: 57001-135
Bearing Puller Adapter [C]: 57001-317
• Discard the bearing.

Transmission Shaft Assembly

• Apply engine oil to the bushings, ball bearings and shafts.
• ward the
Install the ball bearings on the shafts with the groove to-
clutch side.
• [B] aligned.gear bushings [A] on the shaft with their holes
Install the
 CRANKSHAFT/TRANSMISSION 9-29
Transmission

• Replace any circlips removed with new ones.

• with a splinecirclips
Install the [A] so that the opening [B] is aligned
groove [C].

• The drive shaft gears can be recognized by size: the gear

with the smallest diameter is 1st gear, and the largest one
is 6th gear. Be sure that all parts are put back in the cor-
rect sequence and all circlips and washers are properly in
place.
• Install the 6th gear bushing onto the drive shaft with their
oil holes aligned.
• The output shaft gears can be recognized by size: the
gear with the largest diameter is 1st gear, and the small-
est one is 6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and washers are
properly in place.
• Install the 5th and 6th gears onto the output shaft with
their oil holes aligned.
• Install the 2nd and 3rd/4th gear bushings onto the output
shaft with their oil holes aligned.

• Fit the steel balls into the 5th gear holes in the output
shaft, aligning three oil holes [A].
5th Gear [B]
Output Shaft [C]
Steel Balls [D]
CAUTION
Do not apply grease to the balls to hold them in
place. This will cause the positive neutral finder
mechanism to malfunction.
○After assembling the 5th gear with steel balls in place on
the output shaft, check the ball-locking effect that the 5th
gear doesn’t come out of the output shaft when moving it
up and down by hand.
• Check that each gear spins or slides freely on the trans-
mission shafts without binding after assembly.
9-30 CRANKSHAFT/TRANSMISSION
Transmission

1. Circlip, 29 mm (1.14 in.) 15. Ball Bearing

2. Circlip 16. Drive Shaft
3. Thrust Washer, 30 mm (1.18 in.) (Inside Diameter: 17. Nut
25.3 mm (0.996 in.)) 18. Washer
4. Toothed Washer, 30 mm (1.18 in.) 19. Collar
5. Thrust Washer, 30 mm (1.18 in.) (Inside Diameter: 20. Oil Seal
20.5 mm (0.807 in.)) 21. Bushing
6. Needle Bearing 22. 2nd Gear
7. Bearing Outer Race 23. 6th (Top) Gear
8. 2nd Gear 24. 3rd Gear
9. Bushing 25. Bushing
10. 6th (Top) Gear 26. 4th Gear
11. 3rd Gear 27. 5th Gear
12. 4th Gear 28. 1st Gear
13. 5th Gear 29. Output Shaft
14. 1st Gear
 CRANKSHAFT/TRANSMISSION 9-31
Transmission
Shift Drum and Fork Removal
• Remove:
Lower Crankcase Half (see Crankcase Splitting)
Transmission Shafts (see Transmission Shaft Removal)
Shift Drum Positioning Bolt [A]
Washer [B]
Spring [C]
Pin [D]

• Remove:
Shift Drum Bearing Holder Bolts [A]
Shift Drum Bearing Holder [B]
Shift Rods [C]
Shift Forks

• Pull out the shift drum [A] about half of it, and remove the
circlip [B] and the operating plate [C].
• Pull out the shift drum fully from the upper crankcase.

Shift Drum and Fork Installation

• Apply engine oil to the shift drum, forks and rods.
• install the
Insert the shift drum into the upper crankcase half, and
operating plate pin [A], operating plate [B] and
new circlip [C].
NOTE
○When installing the operating plate, the projection [D] of
the operating plate faces toward the outside.

•○Install the shift rods [E], noting the groove position.

Position the one with shorter ears [F] on the drive shaft
and place the pin in the center groove in the shift drum
[G].
○The two forks [H] on the output shaft are identical.
9-32 CRANKSHAFT/TRANSMISSION
Transmission

• Install the shift drum bearing holder [A].

• the shift drum
Apply a non-permanent locking agent to the threads of
bearing holder bolts [B], and tighten them.
Torque - Shift Drum Bearing Holder Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)

• Install the pin, spring, washer and, tighten the shift drum
positioning bolt to the upper crankcase.
Torque - Shift Drum Positioning Bolt: 24.5 N·m (2.5 kgf·m,
18 ft·lb)

Shift Drum Disassembly

• Remove
moval).
the shift drum (see Shift Drum and Fork Re-

• While holding the shift drum with a vise, remove the shift
drum pin plate bolt.
Shift Drum Assembly
• Be sure to install the dowel pin [A].
• Applyshift
The drum pins [B] are identical.
• the shift drum pin plate bolt
a non-permanent locking agent to the threads of
[C], and tighten it.
Torque - Shift Drum Pin Plate Bolt: 9.0 N·m (0.92 kgf·m, 80
in·lb)
Shift Drum Pin Plate [D]
Shift Drum Pin Holder [E]
Shift Drum Bearing [F]
Shift Drum [G]
Operating Plate Pin [H]
Operating Plate [I]
Circlip [J]
Shift Fork Bending Inspection
• Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
 CRANKSHAFT/TRANSMISSION 9-33
Transmission
Shift Fork/Gear Groove Wear Inspection
• Measure the thickness of the shift fork ears [A], and mea-
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: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)
Service Limit: 4.8 mm (0.189 in.)
If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard: 5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.)
Service Limit: 5.3 mm (0.209 in.)

Shift Fork Guide Pin/Drum Groove Wear

Inspection
• Measure the diameter of each shift fork guide pin [A], and
measure the width [B] 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: 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Service Limit: 5.8 mm (0.228 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard: 6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)
Service Limit: 6.3 mm (0.248 in.)

Gear Dog and Gear Dog Hole Damage Inspection

• Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
 WHEELS/TIRES 10-1

Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 10-2
Specifications ......................................................................................................................... 10-4
Special Tools ......................................................................................................................... 10-5
Wheels (Rims) ........................................................................................................................ 10-6
Front Wheel Removal ....................................................................................................... 10-6
Front Wheel Installation .................................................................................................... 10-6
Rear Wheel Removal........................................................................................................ 10-8
Rear Wheel Installation..................................................................................................... 10-8
Wheel Inspection .............................................................................................................. 10-10
Axle Inspection.................................................................................................................. 10-10
Balance Inspection............................................................................................................ 10-11
Balance Adjustment .......................................................................................................... 10-11
Balance Weight Removal.................................................................................................. 10-11
Balance Weight Installation............................................................................................... 10-11
Tires........................................................................................................................................ 10-13
Air Pressure Inspection/Adjustment.................................................................................. 10-13
Tire Inspection .................................................................................................................. 10-13
Tire Removal..................................................................................................................... 10-13
Tire Installation.................................................................................................................. 10-14
Tire Repair ........................................................................................................................ 10-16 10
Hub Bearing............................................................................................................................ 10-17
Hub Bearing Removal....................................................................................................... 10-17
Hub Bearing Installation.................................................................................................... 10-17
Hub Bearing Inspection..................................................................................................... 10-18
Hub Bearing Lubrication ................................................................................................... 10-18
Speedometer Gear Housing................................................................................................... 10-19
Speedometer Gear Housing Disassembly........................................................................ 10-19
Speedometer Gear Housing Assembly............................................................................. 10-19
Speedometer Gear Housing Lubrication........................................................................... 10-20
10-2 WHEELS/TIRES
Exploded View
 WHEELS/TIRES 10-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Front Axle Nut 88 9.0 65
2 Rear Axle Nut 98 10.0 72.3
HG: Apply high-temperature grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES
Specifications

Item Standard Service Limit

Wheels (Rims)
Rim Runout:
Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.)
Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.)
Axle Runout/100 mm (3.94 in.) TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.)
Wheel Balance 10 g (0.35 oz.) or less – – –
Balance Weights 10 g (0.35 oz.), 20 g (0.71 oz.), – – –
30 g (1.06 oz.)
Rim Size:
Front 17 × 2.75 – – –
Rear 17 × 3.50 – – –
Tires
Air Pressure (when Cold):
Front Up to 170 kg (375 lb) load:
– – –
200 kPa (2.00 kgf/cm², 28 psi)
Rear Up to 170 kg (375 lb) load: – – –
225 kPa (2.25 kgf/cm², 32 psi)
Tread Depth:
Front:
IRC 4.2 mm (0.17 in.) 1 mm (0.04 in.),
BRIDGESTONE 4.6 mm (0.18 in.) (AT, CH, DE)
1.6 mm (0.06 in.)
DUNLOP 4.5 mm (0.18 in.)
Rear:
IRC 6.5 mm (0.26 in.) Up to 130 km/h (80 mph):
BRIDGESTONE 7.0 mm (0.28 in.) 2 mm (0.08 in.),
Over 130 km/h (80 mph):
DUNLOP 7.4 mm (0.29 in.)
3 mm (0.12 in.)
Standard Tires: Make, Type Size
Front IRC RX-01F 110/70 17 M/C (54S)
BRIDGESTONE BATTLAX BT45F 110/70 17 M/C (54H)
DUNLOP GT501F
Rear IRC RX-01R 130/70 17 M/C (62S)
BRIDGESTONE BATTLAX BT45R 130/70 17 M/C (62H)
DUNLOP GT501

WARNING
Use the same manufacturer’s tires on both front and rear wheels.
 WHEELS/TIRES 10-5
Special Tools
Inside Circlip Pliers: Jack:
57001-143 57001-1238

Rim Protector: Bearing Remover Shaft, 9:

57001-1063 57001-1265

Bead Breaker Assembly: Bearing Remover Head, 15 × 17:

57001-1072 57001-1267

Bearing Driver Set: Jack Attachment:

57001-1129 57001-1608
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Remove:
Speedometer Cable Lower End [A]
Cotter Pin [B]
Axle Nut [C] and Washer
Front Caliper Mounting Bolts [D]
Front Caliper [E]

• Remove the lower fairings (see Lower Fairing Removal in

the Frame chapter).
• Raise the front wheel off the ground with the jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Pull out the axle to the left and drop the front wheel out of
the forks.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

Front Wheel Installation

• Apply high-temperature grease to the grease seal lips.
• Fit the speedometer
Fit the collar on the right of the hub.
• projections [B]. gear projections [A] to the wheel hub
 WHEELS/TIRES 10-7
Wheels (Rims)

• Install the front wheel so that the speedometer gear hous-

ing stop [A] fit into the fork leg projection [B].

• Insert the front axle, and install the washer.

• Tighten:
Torque - Front Axle Nut: 88 N·m (9.0 kgf·m, 65 ft·lb)

• 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°.
○Loosen once and tighten again when the slot goes past
the nearest hole.

• Bend the cotter pin [A] over the nut.

WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.

• Install the speedometer cable so that the drive notch [A]

of it fits into the projection [B] of the speedometer pinion
in the housing.

• Install the removed parts (see appropriate chapters).

• Check the front brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).
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.
10-8 WHEELS/TIRES
Wheels (Rims)
Rear Wheel Removal
• Raise the rear wheel off the ground with the stand [A].

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

• Remove:
Cotter Pin [A]
Axle Nut [B]
Washer [C]
Axle [D] (from Left Side)

• Remove
the left.
the drive chain [A] from the rear sprocket toward

• Move the rear wheel back and remove it.

CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

Rear Wheel Installation

• Apply high-temperature grease to the grease seal lips.
• Left Side
Fit the collars on the both sides of the hub.
Collar [A]
Right Side Collar [B] (with Flange)
 WHEELS/TIRES 10-9
Wheels (Rims)

• Engage the drive chain with the rear sprocket.

• Insert the axle
Install the caliper bracket [A] onto the swingarm stop [B].
• the axle nut. from the left side of the wheel, and tighten
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72.3 ft·lb)

• 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°.
○Loosen once and tighten again when the slot goes past
the nearest hole.

• Bend the cotter pin [A] over the nut.

WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.

• Adjust the drive chain slack after installation (see Drive

Chain Slack Inspection in the Periodic Maintenance chap-
ter).
• Install the rear caliper (see Caliper Installation in the
Brakes chapter).
• Check the rear brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.
10-10 WHEELS/TIRES
Wheels (Rims)
Wheel Inspection
• Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Spin the wheel lightly, and check for roughness or binding.
If roughness or binding is found, replace the hub bearings
(see Hub Bearing Removal/Installation).
• Inspect the wheel for small cracks, dents, bending, or
warp.
If there is any damage to the wheel, replace the wheel.
• Remove the wheel, and support it with the tire by the axle.
• Measure the rim runout, axial [A] and radial [B], with a dial
gauge.
If rim runout exceeds the service limit, check the hub bear-
ings (see Hub Bearing Inspection).
If the problem is not due to the bearings, replace the
wheel.
Rim Runout (with tire installed)
Standard:
Axial TIR 0.5 mm (0.02 in.) or less
Radial TIR 0.8 mm (0.03 in.) or less
Service Limit:
Axial TIR 1.0 mm (0.04 in.)
Radial TIR 1.0 mm (0.04 in.)

WARNING
Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condi-
tion.
Axle Inspection
• Remove
Removal).
the front and rear axles (see Front/Rear Wheel

• Visually inspect the front and rear axle for damages.

If the axle is damaged or bent, replace it.
• Place the axle in V blocks that are 100 mm (3.94 in.) [A]
apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to mea-
sure the runout. The difference between the highest and
lowest dial readings is the amount of runout.
If axle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)
Standard: TIR 0.1 mm (0.004 in.) or less
Service Limit: TIR 0.2 mm (0.008 in.)
 WHEELS/TIRES 10-11
Wheels (Rims)
Balance Inspection
• Remove
Removal).
the front and rear wheels (see Front/Rear Wheel

• Support the wheel so that it can be spun freely.

• when thewheel
Spin the lightly, and mark [A] the wheel at the top
wheel stops.
○Repeat this procedure several times. If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance (see Balance Adjustment).

Balance Adjustment
• Ifattach
the wheel always stops in one position, provisionally
a balance weight [A] on the rim at the marking using
adhesive tape.
• Rotate the wheel 1/4 turn [B], and see whether or not the
wheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size. If the wheel rotates and
the weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.
• Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.
• Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
• Permanently install the balance weight.
Balance Weight Removal
• Insert a regular tip screwdrivers [A] [B] between the rib [C]
and the weight [D] as shown in the figure.
• Pry the balance weight with two screwdrivers and remove
the balance weight.
• Discard the used balance weight.
CAUTION
Do not tap the screwdrivers. The rim could be dam-
aged.

Balance Weight Installation

• Check if the weight portion has any play on the blade [A]
and clip [B].
If it does, discard it.
WARNING
If the balance weight has any play on the rib of the
rim, the blade and/or clip have been stretched. Re-
place the loose balance weight. Do not reuse used
balance weight. Unbalanced wheels can create an
unsafe riding condition.
10-12 WHEELS/TIRES
Wheels (Rims)
Balance Weight
Part Number Weight
41075-0007 10 g (0.35 oz.)
41075-0008 20 g (0.71 oz.)
41075-0009 30 g (1.06 oz.)

NOTE
○Balance weights are available from Kawasaki dealers in
10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes.
An imbalance of less than 10 grams (0.35 oz.) will not
usually affect running stability.
○Do not use four or more balance weight (more than 90
gram, 3.17 oz.). If the wheel requires an excess bal-
ance weight, disassemble the wheel to find the cause.

• Slip the balance weight [A] onto the rib [B] by pushing or
lightly hammering [C] the clip [D].
Left Side [E]
Right Side [F]

•○Be sure to install the balance weight.

Check that the blade [A] and clip [B] are fully seated on
the rim [C] and that the clip is hooked over the rib [D].
Left Side [E]
Right Side [F]
 WHEELS/TIRES 10-13
Tires
Air Pressure Inspection/Adjustment
• Refer to the Air Pressure Inspection in the Periodic Main-
tenance chapter.
Tire Inspection
• Refer to the Wheel/Tire Damage Inspection in the Peri-
odic Maintenance chapter.
Tire Removal
• Remove:
Wheels (see Front/Rear Wheel Removal)
Valve Core (Let out the air)
• To maintain wheel balance, mark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]

• Lubricate the tire beads and rim flanges on both sides with
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.

• Break the beads away from both sides of the rim with the
bead breaker [A].
Special Tool - Bead Breaker Assembly: 57001-1072

• Step on the side of the tire opposite the valve stem and
start prying the tire off the rim near the air valve with tire
irons [A].
Special Tools - Rim Protector [B]: 57001-1063
Bead Breaker Assembly: 57001-1072
10-14 WHEELS/TIRES
Tires
NOTE
○For easier removal, always position the tire bead oppo-
site the valve stem in the rim well, and pry the tire bead
a little at a time.

CAUTION
Be careful not to scratch the inner liner [A] and air
sealing surfaces [B] of the rim and tire with the tire
irons. A scratched inner liner or sealing surface
may allow air to leak.

• After removing the bead on one side, remove the other

bead from the same manner.
• Remove the tire from the rim.
Tire Installation
WARNING
Use the same manufacturer’s tires on both front and
rear wheels.

• Inspect the rim and tire, and replace them if necessary.

• the sealingsealing
Clean the surfaces of the rim and tire, and smooth
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.

•○Install a new valve in the rim.

Remove the valve cap, lubricate the stem seal [A] with a
soap and water solution or rubber lubricant, and pull [B]
the valve stem through the rim from the inside out until it
snaps into place.
CAUTION
Do not use engine oil or petroleum distillates to lu-
bricate the stem because they will deteriorate the
rubber.

○The air valve is shown in the figure.

Valve Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
 WHEELS/TIRES 10-15
Tires

• Check the tire rotation mark on the front and rear tires and
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotating Direction [B]

• Position the tire on the rim so that the air valve [A] align
with the tire balance mark [B] (the chalk mark made during
removal, or the yellow paint mark on a new tire).

• By hand, slide as much as possible of the lower side of the

tire bead over the rim flange, starting at the side opposite
the valve stem.
• Fit the rim protectors and tire irons to install the remaining
part of the tire bead which cannot be installed by hand.
For easy tire installation, position the parts of the bead
which is already over the rim flange in the rim well.
NOTE
○To prevent rim damage, be sure to place the rim protec-
tors at any place the tire irons are applied.

• Install the other side of the tire bead onto the rim in the
same manner.
• Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
• Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.
WARNING
Be sure to install the valve core whenever inflating
the tire, and do not inflate the tire to more than 400
kPa (4.0 kgf/cm², 57 psi). Overinflation can explode
the tire with possibility of injury and loss of life.
10-16 WHEELS/TIRES
Tires

• Check to see that the rim lines [A] on both sides of the tire
sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall rim lines are not parallel,
remove the valve core.
•Lubricate the rim flanges and tire beads.
•Install the valve core and inflate the tire again.
•After the tire beads seat in the rim flanges, check for air
leakage.
○Inflate the tire slightly above standard inflation.
○Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
•Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chap-
ter).
•Install the air valve cap.
•Adjust the wheel balance (see Balance Adjustment).
Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) re-
pair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally under-
stood that higher running durability is obtained by perma-
nent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (exter-
nal) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.
 WHEELS/TIRES 10-17
Hub Bearing
Hub Bearing Removal
• Remove the wheels (see Front/Rear Wheel Removal),
and take out the following.
Collars
Speedometer Gear (Out of front hub)
Coupling (Out of rear hub)
Grease Seals
Circlips [A]
Special Tool - Inside Circlip Pliers: 57001-143

• Use the bearing remover to remove the hub bearings [A].

CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

Special Tools - Bearing Remover Shaft, 9 [B]: 57001-1265

Bearing Remover Head, 15 × 17 [C]:
57001-1267

Hub Bearing Installation

• Before installing the hub bearings, blow any dirt or foreign
particles out of the hub with compressed air to prevent
contamination of the bearings.
• Replace the bearings with new ones.
• Install the bearings by using the bearing driver set which
does not contact the bearing inner race.
NOTE
○Install the bearings so that the marked side faces out.
• Press in each bearing [A] right until they are bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129

• Replace the circlips with new ones.

Special Tool - Inside Circlip Pliers: 57001-143
• Replace the grease seals with new ones.
• Press in the grease seals [A] so that the seal surface is
flush [B] with the end of the hole.
○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set [C]: 57001-1129
10-18 WHEELS/TIRES
Hub Bearing
Hub Bearing Inspection
Since the hub bearings are made to extremely close tol-
erances, the clearance can not 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.

• Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding.
If bearing play, roughness, or binding is found, replace
the bearing.
• Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication
NOTE
○Since the hub bearings are packed with grease and
sealed, lubrication is not required.
 WHEELS/TIRES 10-19
Speedometer Gear Housing
Speedometer Gear Housing Disassembly
• Pull the speedometer gear housing [A] off the front wheel.
• Pull out the
Remove the grease seal [B] and snap ring [C].
• If the speedometer
speedometer gear [D].
• ion [F] needs to be removed,
cable bushing [E] or speedometer pin-
work in accordance with fol-
lowing procedures.

• First drill the housing [A] through the pin [B] using a 1.0 ∼
1.5 mm (0.04 ∼ 0.06 in.) drill bit [C].

• Drill the housing from the outside to the pin end [A] using
a 3.0 ∼ 3.5 mm (0.12 ∼ 0.14 in.) drill bit [B].

• Using a 3 mm (0.12 in.) rod [A], tap out the pin [B],
and then pull out the speedometer cable bushing and
speedometer pinion.
NOTE
○It is recommended that the assembly be replaced rather
than attempting to repair the components.

Speedometer Gear Housing Assembly

• When assembling the speedometer gear housing,
careful of the following items.
be

○After inserting a new pin, stake the housing hole to secure

the pin in place.
○Apply high-temperature grease to the speedometer gear.
○Replace the grease seal with a new one. Apply a little high
-temperature grease to the seal. Install it using a press or
a suitable driver so that the face of the seal is level with
the surface of the housing.
10-20 WHEELS/TIRES
Speedometer Gear Housing
Speedometer Gear Housing Lubrication
• Clean and grease [A] the speedometer gear housing [B].
 FINAL DRIVE 11-1

Final Drive
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Special Tool and Sealant ........................................................................................................ 11-5
Drive Chain............................................................................................................................. 11-6
Drive Chain Slack Inspection ............................................................................................ 11-6
Drive Chain Slack Adjustment .......................................................................................... 11-6
Wheel Alignment Inspection/Adjustment .......................................................................... 11-6
Drive Chain Wear Inspection ............................................................................................ 11-6
Drive Chain Lubrication..................................................................................................... 11-6
Drive Chain Guide Wear Inspection.................................................................................. 11-6
Drive Chain Removal ........................................................................................................ 11-6
Drive Chain Installation ..................................................................................................... 11-6
Drive Chain Replacement ................................................................................................. 11-7
Sprocket, Coupling ................................................................................................................. 11-10
Engine Sprocket Removal ................................................................................................ 11-10
Engine Sprocket Installation ............................................................................................. 11-10
Rear Sprocket Removal.................................................................................................... 11-11
Rear Sprocket Installation................................................................................................. 11-11
Coupling Installation.......................................................................................................... 11-11
Coupling Bearing Removal ............................................................................................... 11-12
Coupling Bearing Installation ............................................................................................ 11-12
Coupling Bearing Inspection ............................................................................................. 11-12 11
Coupling Bearing Lubrication............................................................................................ 11-13
Coupling Damper Inspection............................................................................................. 11-13
Sprocket Wear Inspection................................................................................................. 11-13
Rear Sprocket Warp Inspection ........................................................................................ 11-13
11-2 FINAL DRIVE
Exploded View
 FINAL DRIVE 11-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb
2 Engine Sprocket Nut 127 13.0 93.7 MO
3 Rear Axle Nut 98 10.0 72.3
4 Rear Sprocket Nuts 59 6.0 44
5 Speed Sensor Mounting Bracket Bolts 9.8 1.0 87 in·lb L
HG: Apply high-temperature grease.
HO: Apply heavy oil.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
SS: Apply silicone sealant.
11-4 FINAL DRIVE
Specifications

Item Standard Service Limit

Drive Chain
Drive Chain Slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) – – –
Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)
Standard Chain:
Make ENUMA – – –
Type EK520SR-O2 – – –
Link 106 links – – –
Sprockets
Rear Sprocket Warp TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm (0.020 in.)
 FINAL DRIVE 11-5
Special Tool and Sealant
Bearing Driver Set: Kawasaki Bond (Silicone Sealant):
57001-1129 92104-0004
11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
• Refer to the Drive Chain Slack Inspection in the Periodic
Maintenance chapter.
Drive Chain Slack Adjustment
• Refer to the Drive Chain Slack Adjustment in the Periodic
Maintenance chapter.
Wheel Alignment Inspection/Adjustment
• Refer to the Wheel Alignment Inspection in the Periodic
Maintenance chapter.
Drive Chain Wear Inspection
• Refer to the Drive Chain Wear Inspection in the Periodic
Maintenance chapter.
Drive Chain Lubrication
• Refer to the Drive Chain Lubrication Condition in the Pe-
riodic Maintenance chapter.
Drive Chain Guide Wear Inspection
• Refer to the Chain Guide Wear Inspection in the Periodic
Maintenance chapter.
Drive Chain Removal
• Remove:
Chain Cover Bolts [A] and Chain Cover [B]
Engine Sprocket (see Engine Sprocket Removal)
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Swingarm (see Swingarm Removal in the Suspension
chapter)

• Remove the drive chain [A] from the output shaft [B], and
take it off the chassis.

Drive Chain Installation

• Install the drive chain to the output shaft.
• Swingarm (see Swingarm Installation in the Suspension
Install:

chapter)
Rear Wheel (see Rear Wheel Installation in the
Wheels/Tires chapter)
Engine Sprocket (see Engine Sprocket Installation)
Chain Cover
• Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Adjustment in the Periodic Mainte-
nance chapter).
 FINAL DRIVE 11-7
Drive Chain
Drive Chain Replacement
• Remove:
Chain Cover (see Drive Chain Removal)
Engine Sprocket Cover (see Engine Sprocket Removal)

CAUTION
For safety, if the drive chain shall be replaced, re-
place it using a recommended tool.

Recommended Tool - Type: EK Joint Tool #50

Brand: ENUMA

Body [A]
Handlebar [B]
Cutting and Riveting Pin [C]
For Cutting [D]
For Riveting [E]
Plate Holder (A) [F]
Plate Holder (B) [G]
Gauge [H]

• Grind [A] the pin head to make it flat.

• Set the cutting and riveting pin [B] as shown in the figure.

• Screw the pin holder until it touches the link pin.

• Be sure that the cutting pin hits center of the link pin.
11-8 FINAL DRIVE
Drive Chain

• Screw the handlebar [A] into the body.

• tract the link
Turn the pin holder with the wrench [B] clockwise to ex-
pin.

• Replace the link pin, link plate and grease seals.

• Engage the drive
Apply grease to the link pins [A] and grease seals [B] [C].
• Insert the link pinschain on the engine and rear sprockets.
• Install the grease seals. drive chain ends.
in the
• Install the link plate so that the mark [D] faces out.
• Push the link plate by hand or plier to fix it.
• Be sure to set the grease seals correctly.
•

• Set the plate holder (A) [A] and plate holder (B) [B] on the
body.

• Fit the plate holder (A) to the link plate.

• touches
Turn the pin holder by hand until the plate holder (B)
the other link plate.

• Turn the pin holder by a wrench clockwise until two pins

of link come into groove of the plate holder (A).
• Take off the plate holder.
 FINAL DRIVE 11-9
Drive Chain

• Set the plate holder (B) [A] and cutting and riveting pin [B]
as shown in the figure.

• Turn
pin.
the pin holder until the riveting pin touches the link

• Turn the wrench clockwise until the tip of riveting pin hits
of the link pin.
• Rivet it.
• Same work for the other link pin.

• After staking, check the staked area of the link pin for
cracks.
• Measure the outside diameter [A] of the link pin and link
plates width [B].
Link Pin Outside Diameter
Standard: 5.3 ∼ 5.7 mm (0.21 ∼ 0.22 in.)

Link Plates Outside Width

Standard: 17.35 ∼ 17.50 mm (0.683 ∼ 0.689 in.)
If the reading exceeds the specified length, cut and rejoin
the chain again.
• Check:
Movement of the Rollers
• Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Adjustment in the Periodic Mainte-
nance chapter).
• Install the removed parts (see appropriate chapters).
11-10 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Removal
• Remove:
Shift Lever [A] (see Shift Pedal Removal in the Crank-
shaft/Transmission chapter)
Engine Sprocket Cover Bolts [B]
Engine Sprocket Cover [C]

• Remove the bolts [A].

• Flatten out the bended washer [A].

• Remove the engine sprocket nut [B] and washer.
NOTE
○When loosening the engine sprocket nut, hold the rear
brake on.

• Raise the rear wheel off the ground with the stand.
• ment in the
Loosen the drive chain (see Drive Chain Slack Adjust-
Periodic Maintenance chapter).
• Remove
right.
the drive chain from the rear sprocket toward the

• Pull the engine sprocket [A] with drive chain [B] off the
output shaft [C].
• Disengage the drive chain from the engine sprocket.
Engine Sprocket Installation
• Replace the sprocket washer and axle cotter pin.
• faces inside.engine sprocket so that protruding side [A]
Install the

• Apply molybdenum disulfide oil solution to the threads

and the seating surface of the engine sprocket nut.
• Tighten:
Torque - Engine Sprocket Nut: 127 N·m (13.0 kgf·m, 93.7
ft·lb)

NOTE
○Tighten the nut while applying the rear brake.
• After torquing the engine sprocket nut, bend the one side
of the washer over the nut.
 FINAL DRIVE 11-11
Sprocket, Coupling

• Apply silicone sealant [A] to the crankcase as shown in

the figure.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Install the speed sensor mounting bracket.
• Tighten:
Torque - Speed Sensor Mounting Bracket Bolts: 9.8 N·m
(1.0 kgf·m, 87 in·lb)
• Run the speed sensor lead correctly (see Cable, Wire,
and Hose Routing section in the Appendix chapter).
• Install the engine sprocket cover.
• Tighten:
Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Adjust the drive chain slack after installing the engine
sprocket (see Drive Chain Slack Adjustment in the Pe-
riodic Maintenance chapter).
• Install the removed parts (see appropriate chapters).
Rear Sprocket Removal
• Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

• Remove:
Rear Sprocket Nuts [A]
Rear Sprocket [B]
Rear Sprocket Installation
• Install
outward.
the sprocket facing the tooth number marking [A]

• Tighten:
Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the rear wheel (see Rear Wheel Installation in the
Wheels/Tires chapter).

Coupling Installation
• Apply high-temperature grease to the following.
Coupling Grease Seal Lips [A]
Coupling Internal Surface [A]
Ball Bearing [A]
11-12 FINAL DRIVE
Sprocket, Coupling

• Apply high-temperature grease to the following.

Wheel Flange Portion [A]
O-ring [B]
• Install the collar [C].

Coupling Bearing Removal

• Remove:
Coupling
Grease Seal

• Remove the bearing [A] by tapping from the wheel side.

Special Tool - Bearing Driver Set [B]: 57001-1129

Coupling Bearing Installation

• Replace the bearing with a new one.
• Press in the bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129
○Pack the bearing with high-temperature grease.

• Replace the grease seal with a new one.

• with the end grease
Press in the seal so that the seal surface is flush
of the hole.
○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129

Coupling Bearing Inspection

Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
○It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.

• Turn the bearing in the coupling back and forth [A] while
checking for plays, roughness or binding.
If the bearing play, roughness or binding is found, replace
the bearing.
 FINAL DRIVE 11-13
Sprocket, Coupling
Coupling Bearing Lubrication
• Pack the bearing with high-temperature grease. Turn the
bearing around by hand a few times to make sure the
grease is distributed uniformly inside the bearing.
Coupling Damper Inspection
• Remove the rear wheel coupling, and inspect the rubber
dampers [A].
• Replace
rated.
the damper if it appears damaged or deterio-

Sprocket Wear Inspection

• Visually inspect the engine and rear sprocket teeth for
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
NOTE
○If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.
Rear Sprocket Warp Inspection
• Raise the rear wheel off the ground with the stand so that
it will turn freely.
• Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown in the figure, and rotate [C] the rear wheel
to measure the sprocket runout (warp). The difference
between the highest and lowest dial gauge readings is
the amount of runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard: TIR 0.4 mm (0.016 in.) or less
Service Limit: TIR 0.5 mm (0.020 in.)
 BRAKES 12-1

Brakes
Table of Contents
Exploded View ....................................................................................................................... 12-2
Specifications ........................................................................................................................ 12-6
Special Tools .......................................................................................................................... 12-7
Brake Lever, Brake Pedal....................................................................................................... 12-8
Brake Pedal Position Inspection ...................................................................................... 12-8
Brake Pedal Position Adjustment ..................................................................................... 12-8
Brake Pedal Removal ....................................................................................................... 12-8
Brake Pedal Installation .................................................................................................... 12-8
Calipers .................................................................................................................................. 12-9
Front Caliper Removal ...................................................................................................... 12-9
Rear Caliper Removal....................................................................................................... 12-9
Caliper Installation ............................................................................................................ 12-9
Front Caliper Disassembly................................................................................................ 12-10
Front Caliper Assembly..................................................................................................... 12-10
Rear Caliper Disassembly ................................................................................................ 12-10
Rear Caliper Assembly ..................................................................................................... 12-10
Caliper Fluid Seal Damage Inspection.............................................................................. 12-10
Caliper Dust Seal Damage Inspection .............................................................................. 12-11
Caliper Dust Boot and Friction Boot Damage Inspection.................................................. 12-11
Caliper Piston and Cylinder Damage Inspection .............................................................. 12-12
Caliper Holder Shaft Wear Inspection............................................................................... 12-12
Brake Pads ............................................................................................................................. 12-13
Brake Pad Removal .......................................................................................................... 12-13
Brake Pad Installation ....................................................................................................... 12-13 12
Brake Pad Wear Inspection .............................................................................................. 12-13
Master Cylinder ...................................................................................................................... 12-14
Front Master Cylinder Removal ........................................................................................ 12-14
Front Master Cylinder Installation ..................................................................................... 12-14
Rear Master Cylinder Removal......................................................................................... 12-14
Rear Master Cylinder Installation...................................................................................... 12-14
Front Master Cylinder Disassembly .................................................................................. 12-15
Rear Master Cylinder Disassembly................................................................................... 12-15
Master Cylinder Assembly ................................................................................................ 12-15
Master Cylinder Inspection (Visual Inspection)................................................................. 12-15
Brake Disc .............................................................................................................................. 12-16
Brake Disc Removal ......................................................................................................... 12-16
Brake Disc Installation ...................................................................................................... 12-16
Brake Disc Wear Inspection.............................................................................................. 12-16
Brake Disc Warp Inspection.............................................................................................. 12-16
Brake Fluid ............................................................................................................................. 12-17
Brake Fluid Level Inspection............................................................................................. 12-17
Brake Fluid Change .......................................................................................................... 12-17
Brake Line Bleeding.......................................................................................................... 12-17
Brake Hose............................................................................................................................. 12-20
Brake Hose Removal/Installation...................................................................................... 12-20
Brake Hose Inspection...................................................................................................... 12-20
12-2 BRAKES
Exploded View
 BRAKES 12-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Bleed Valve 5.5 0.56 49 in·lb L
2 Brake Hose Banjo Bolts 25 2.5 18
3 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si
4 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
5 Front Brake Disc Mounting Bolts 27 2.8 20 L
6 Front Brake Light Switch Screw 1.2 0.12 11 in·lb
7 Front Brake Pad Pins 17.2 1.8 13
8 Front Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
9 Front Caliper Holder Pin Bolt 17.2 1.8 13 Si
10 Front Caliper Mounting Bolts 25 2.5 18
11 Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
12-4 BRAKES
Exploded View
 BRAKES 12-5
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Bleed Valve 5.5 0.56 49 in·lb L
2 Brake Hose Banjo Bolts 25 2.5 18
3 Brake Pedal Bolt 8.8 0.90 78 in·lb
4 Rear Brake Disc Mounting Bolts 27 2.8 20 L
5 Rear Brake Pad Pins 17.2 1.8 13
6 Rear Caliper Holder Pin Bolt 17.2 1.8 13 Si
7 Rear Caliper Mounting Bolts 25 2.5 18
8 Rear Master Cylinder Mounting Bolts 25 2.5 18
9 Rear Master Cylinder Push Rod Locknut 17.2 1.8 13
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).
12-6 BRAKES
Specifications

Item Standard Service Limit

Brake Lever, Brake Pedal
Brake Lever Position Non-adjustable – – –
Brake Lever Free Play Non-adjustable – – –
Pedal Free Play Non-adjustable – – –
Pedal Position About 40 mm (1.57 in.) below top of footpeg – – –
Brake Pads
Lining Thickness:
Front 4.5 mm (0.18 in.) 1 mm (0.04 in.)
Rear 4.5 mm (0.18 in.) 1 mm (0.04 in.)
Brake Discs
Thickness:
Front 4.3 ∼ 4.7 mm (0.17 ∼ 0.19 in.) 4.0 mm (0.16 in.)
Rear 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.) 4.5 mm (0.18 in.)
Runout TIR 0.15 mm (0.006 in.) or less TIR 0.3 mm (0.01 in.)
Brake Fluid
Grade DOT4 – – –
 BRAKES 12-7
Special Tools
Inside Circlip Pliers: Jack Attachment:
57001-143 57001-1608

Jack:
57001-1238
12-8 BRAKES
Brake Lever, Brake Pedal
Brake Pedal Position Inspection
• Check that the brake pedal [A] is in the correct position.
Footpeg [B]
Pedal Position
Standard: About 40 mm (1.57 in.) [C] below top of
footpeg
If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment

NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when push rod locknut has been
loosened.

• Loosen the locknut [A] and turn the push rod with the hex
head [B] to achieve the correct pedal position.
If the length [C] shown is 80 ±1 mm (3.15 ±0.04 in.), the
pedal position will be within the standard range.
• Tighten:
Torque - Rear Master Cylinder Push Rod Locknut: 17.2 N·m
(1.8 kgf·m, 13 ft·lb)
• Check the brake light switch operation (see Brake Light
Switch Operation Inspection in the Periodic Maintenance
chapter).
Brake Pedal Removal
• Remove:
Right Front Footpeg Bracket Bolts [A]
Cotter Pin [B]
Joint Pin [C]
Rear Brake Light Switch Spring
Return Spring
• Remove the brake pedal bolt and take out the brake pedal
[D].

Brake Pedal Installation

• Apply
[B].
grease to the pivot shaft [A] and install the washer

• Install:
Brake Pedal [C]
Washer [D]
• Tighten:
Torque - Brake Pedal Bolt [E]: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Hook:
Rear Brake Light Switch Spring
Return Spring [F]
• Replace the cotter pin with a new one.
• Insert the cotter pin and bend the pin ends.
• Install the right front footpeg bracket, and tighten the bolts.
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
• Check the brake pedal position (see Brake Pedal Position
Inspection).
 BRAKES 12-9
Calipers
Front Caliper Removal
• Loosen the banjo bolt [A] at the brake hose lower end,
and tighten it loosely.
• Unscrew the caliper mounting bolts [B], and detach the
caliper [C] from the disc.
• Unscrew the banjo bolt and remove the brake hose [D]
from the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.

NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Front Caliper
Disassembly).
Rear Caliper Removal
• Loosen the banjo bolt [A] at the brake hose lower end,
and tighten it loosely.
• Unscrew the caliper mounting bolts [B], and detach the
caliper [C] from the disc.
• Unscrew the banjo bolt and remove the brake hose [D]
from the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.

NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Rear Caliper
Disassembly).
Caliper Installation
•○Install the caliper and brake hose lower end.
Replace the washers on each side of hose fitting with new
ones.
• Tighten:
Torque - Caliper Mounting Bolts:
Front: 25 N·m (2.5 kgf·m, 18 ft·lb)
Rear: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

• Check the fluid level in the brake reservoirs.

• Bleed the brake line (see Brake Line Bleeding).
• and nothe
Check brake for good braking power, no brake drag,
fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal and 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.
12-10 BRAKES
Calipers
Front Caliper Disassembly
• Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
Front Caliper Assembly
• Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
Rear Caliper Disassembly
• Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
Rear Caliper Assembly
• Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.
Caliper Fluid Seal Damage Inspection
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.
 BRAKES 12-11
Calipers
Caliper Dust Seal Damage Inspection
• Check that the dust seals [A] are not cracked, worn,
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.
Pistons [B]
Fluid Seals [C]

Caliper Dust Boot and Friction Boot Damage

Inspection
• Check that the dust boot [A] and friction boot [B] are not
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
12-12 BRAKES
Calipers
Caliper Piston and Cylinder Damage Inspection
• Visually inspect the pistons [A] and cylinder surfaces [B].
Replace the caliper if the cylinder and piston are badly
scores or rusty.

Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
perature.
• Check to see that the caliper holder shafts are not badly
worn or stepped, and that the friction boots [B] are not
damaged.
If the friction boot is damaged, replace the friction boot. To
replace the friction boot, remove the pads and the caliper
holder.
If the caliper holder shaft is damage, replace the caliper
holder.
 BRAKES 12-13
Brake Pads
Brake Pad Removal
NOTE
○The procedure to remove the front brake pad is as fol-
lows. Removing the rear brake pad is the same as for
the front brake pad.

• Loosen the pad pins [A].

• Remove the
Unscrew the bolts [B].
• caliper with the hose installed.

• Remove:
Pad Pins
Brake Pads [A]

Brake Pad Installation

• Push the caliper pistons in by hand as far as they will go.
• Install the pad spring [A] in its correct position.
• Insert the pad
Install the outside pad first, then install the inside pad.
• pins.

• Install the caliper (see Caliper Installation).

• Tighten:
Torque - Brake Pad Pins: 17.2 N·m (1.8 kgf·m, 13 ft·lb)

WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
and the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.

Brake Pad Wear Inspection

• Refer to the Brake Pad Wear Inspection in the Periodic
Maintenance chapter.
12-14 BRAKES
Master Cylinder
Front Master Cylinder Removal
• Remove the banjo bolt [A] to disconnect the brake hose
from the master cylinder (see Brake Hose Removal/In-
stallation).
• Unscrew the clamp bolts [B], and take off the master cylin-
der [C] as an assembly with the reservoir, brake lever, and
brake switch installed.
• Disconnect the front brake light switch connector [D].
CAUTION
Immediately wash away any brake fluid that spills.

Front Master Cylinder Installation

• Set the front master cylinder to match its mating surface
[A] to the punch mark [B] of the handlebar.
• The master cylinder clamp must be installed with the ar-
row mark [C] upward.
• Tighten the upper clamp bolt first, and then the lower
clamp bolt.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90
kgf·m, 78 in·lb)
• Replace the washers that are on each side of the hose
fitting with new ones.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Bleed the brake line (see Brake Line Bleeding).
• and nothe
Check brake for good braking power, no brake drag,
fluid leakage.
Rear Master Cylinder Removal
• Remove:
Brake Hose Banjo Bolt [A]
Brake Hose [B]
Cotter Pin [C]
Joint Pin [D]
Bolts [E]
Rear Master Cylinder [F]
• Slide out the clamp [G].
• Pull off the reservoir hose lower end, and drain the brake
fluid into a container.
Rear Master Cylinder Installation
• Replace the cotter pin with a new one.
• with new ones.
Replace the washers that are on each side of hose fitting

• Tighten:
Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Bleed the brake line (see Brake Line Bleeding).
• and nothe
Check brake for good braking power, no brake drag,
fluid leakage.
 BRAKES 12-15
Master Cylinder
Front Master Cylinder Disassembly
• Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
• Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.
Master Cylinder Assembly
• Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.
Master Cylinder Inspection (Visual Inspection)
• Remove the master cylinders (see Front/Rear Master
Cylinder Removal).
• Disassemble the front and rear master cylinders (see
Master Cylinder Rubber Parts Replacement in the Peri-
odic Maintenance chapter).
• Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
• Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cups.
• Check the dust covers [E] for damage.
If they are damaged, replace them.
• Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
• Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Front Master Cylinder [J]
Rear Master Cylinder [K]
12-16 BRAKES
Brake Disc
Brake Disc Removal
• Remove the wheels (see Front/Rear Wheel Removal in
the Wheels/Tires chapter).
• Unscrew the mounting bolts, and take off the disc.
Brake Disc Installation
• Install the brake disc on the wheel so that the marked side
[A] faces out.
• Apply a non-permanent locking agent to the threads of the
front and rear brake disc mounting bolts [B], and tighten
them.
Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20
ft·lb)

Brake Disc Wear Inspection

• Measure the thickness of each disc [A] at the point where
it has worn the most.
If the disc has worn past the service limit, replace it.
Measuring Area [B]
Brake Discs Thickness
Standard:
Front 4.3 ∼ 4.7 mm (0.17 ∼ 0.19 in.)
Rear 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
Service Limit:
Front 4.0 mm (0.16 in.)
Rear 4.5 mm (0.18 in.)

Brake Disc Warp Inspection

• Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
○For front disc inspection, turn the handlebar fully to one
side.
• Set up a dial gauge against the disc [A] as shown in
the figure and measure disc runout, while turning [B] the
wheel by hand.
If runout exceeds the service limit, replace the disc.
Disc Runout
Standard: TIR 0.15 mm (0.006 in.) or less
Service Limit: TIR 0.3 mm (0.01 in.)
 BRAKES 12-17
Brake Fluid
Brake Fluid Level Inspection
• Refer to the Brake Fluid Level Inspection in the Periodic
Maintenance chapter.
Brake Fluid Change
• Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.
Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
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 the same as for the front
brake.

• Remove the reservoir cap [A] and diaphragm.

• line in the reservoir.
Fill the reservoir with fresh brake fluid to the upper level

• Slowly pump the brake lever several times until no air

bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.
○Bleed the air completely from the master cylinder by this
operation.

• Remove
caliper.
the rubber cap [A] from the bleed valve on the

• Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.
12-18 BRAKES
Brake Fluid

•○Bleed the brake line and the caliper.

Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while hold-
ing the brake applied.
3. Release the brake [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.

• Remove the clear plastic hose.

• Tighten: diaphragm and reservoir cap.
Install the
•
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

• Follow the procedure below to install the rear brake fluid

reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].

• Apply a non-permanent locking agent to the threads of

the bleed valve.
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)
• Check the fluid level (see Brake Fluid Level Inspection in
the Periodic Maintenance chapter).
• After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.
 BRAKES 12-19
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 for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine oil,
or any other petroleum distillate will cause deterio-
ration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads or
disc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfacto-
rily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme-
diately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
12-20 BRAKES
Brake Hose
Brake Hose Removal/Installation
• Refer to the Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter.
Brake Hose Inspection
• Refer to the Brake Hose and Pipe Damage and Instal-
lation Condition Inspection in the Periodic Maintenance
chapter.
 SUSPENSION 13-1

Suspension
Table of Contents
Exploded View........................................................................................................................ 13-2
Specifications ......................................................................................................................... 13-6
Special Tools .......................................................................................................................... 13-7
Front Fork ............................................................................................................................... 13-8
Front Fork Removal (Each Fork Leg) ............................................................................... 13-8
Front Fork Installation (Each Fork Leg) ............................................................................ 13-8
Front Fork Oil Change ...................................................................................................... 13-9
Front Fork Disassembly .................................................................................................... 13-10
Front Fork Assembly......................................................................................................... 13-11
Inner Tube, Outer Tube Inspection ................................................................................... 13-13
Dust Seal Inspection ......................................................................................................... 13-13
Spring Tension Inspection................................................................................................. 13-13
Rear Shock Absorber ............................................................................................................. 13-14
Spring Preload Adjustment ............................................................................................... 13-14
Rear Shock Absorber Removal ........................................................................................ 13-14
Rear Shock Absorber Installation ..................................................................................... 13-15
Rear Shock Absorber Inspection ...................................................................................... 13-15
Rear Shock Absorber Scrapping ...................................................................................... 13-15
Swingarm................................................................................................................................ 13-16
Swingarm Removal........................................................................................................... 13-16
Swingarm Installation........................................................................................................ 13-17
Swingarm Bearing Removal ............................................................................................. 13-17
Swingarm Bearing Installation .......................................................................................... 13-17
Swingarm Bearing, Sleeve Inspection .............................................................................. 13-17
Swingarm Bearing Lubrication .......................................................................................... 13-17
Tie-Rod, Rocker Arm .............................................................................................................. 13-18 13
Tie-Rod Removal .............................................................................................................. 13-18
Tie-Rod Installation ........................................................................................................... 13-18
Rocker Arm Removal........................................................................................................ 13-18
Rocker Arm Installation..................................................................................................... 13-18
Tie-Rod, Rocker Arm Bushing Inspection ......................................................................... 13-18
Tie-Rod, Rocker Arm Sleeve Inspection ........................................................................... 13-19
13-2 SUSPENSION
Exploded View
 SUSPENSION 13-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Front Fork Bottom Allen Bolts 20 2.0 15 L
2 Lower Front Fork Clamp Bolts 30 3.1 22
3 Upper Front Fork Clamp Bolts 20 2.0 15
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
13-4 SUSPENSION
Exploded View
 SUSPENSION 13-5
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Rear Shock Absorber Nuts 59 6.0 44
2 Swingarm Pivot Shaft Nut 98 10.0 72.3
3 Tie-Rod Nuts 59 6.0 44
4 Uni-Trak Rocker Arm Nut 59 6.0 44
G: Apply grease.
R: Replacement Parts
13-6 SUSPENSION
Specifications

Item Standard
Front Fork (Per One Unit)
Fork Inner Tube Diameter 37 mm (1.5 in.)
Air Pressure Atmospheric pressure (Non-adjustable)
Rebound Damper Setting Non-adjustable
Fork Spring Preload Setting Non-adjustable
Fork Oil:
Viscosity SHOWA SS08 or equivalent SAE 10W
Amount Approx. 310 mL (10.5 US oz.) (when changing oil)
360 ±2.5 mL (12.2 ±0.085 US oz.) (after disassembly and
completely dry)
Fork Oil Level 108 ±2 mm (4.25 ±0.08 in.) (fully compressed, without fork
spring, below from the top of the inner tube)
Fork Spring Free Length 420.5 mm (16.56 in.) (Service Limit: 412 mm (16.22 in.))
Rear Shock Absorber
Rebound Damper Setting Non-adjustable
Spring Preload Setting 2nd position (Adjustable range: 1st ∼ 5th position)
Gas Pressure 980 kPa (10 kgf/cm², 142 psi, Non-adjustable)
 SUSPENSION 13-7
Special Tools
Fork Cylinder Holder Handle: Fork Outer Tube Weight:
57001-183 57001-1218

Fork Cylinder Holder Adapter: Front Fork Oil Seal Driver:

57001-1057 57001-1219

Oil Seal & Bearing Remover: Jack:

57001-1058 57001-1238

Steering Stem Nut Wrench: Fork Oil Level Gauge:

57001-1100 57001-1290

Bearing Driver Set: Jack Attachment:

57001-1129 57001-1608
13-8 SUSPENSION
Front Fork
Front Fork Removal (Each Fork Leg)
• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Bolts [A] (Both Sides)
Bracket [B]

Remove the handlebar and remove the fork top plug [A]
beforehand if the fork leg is to be disassembled.
NOTE
○To remove the top plug, remove the snap ring [B] push-
ing down the top plug with the screwdriver.

• Loosen the upper [A] and lower [B] front fork clamp bolts.
• With a twisting motion, remove the fork leg down and out.

Front Fork Installation (Each Fork Leg)

• Insert the fork leg until the inner tube top hit the handlebar
lightly, that is, the distance between the inner tube top [A]
and steering stem head surface [B] is approximate 12 mm
(0.47 in.) [C].
• Tighten:
Torque - Lower Front Fork Clamp Bolts: 30 N·m (3.1 kgf·m,
22 ft·lb)
Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
• Install the removed parts (see appropriate chapters).
 SUSPENSION 13-9
Front Fork
Front Fork Oil Change
• Remove:
Front Fork (see Front Fork Removal)
Snap Ring [A] (see Front Fork Removal)
Top Plug [B] with O-ring [C]
Collar [D]
Fork Spring Seat [E]
Fork Spring [F]

• Compress [A] the fork [B] upside down to draw out the oil
into the suitable container [C].

• Hold the fork tube upright, pour in the type and amount of
fork oil specified.
Fork Oil
Viscosity:
SHOWA SS08 or equivalent SAE 10W
Amount (Per Side):
When changing oil:
Approx. 310 mL (10.5 US oz.)
After disassembly and completely dry:
360 ±2.5 mL (12.2 ±0.085 US oz.)

NOTE
○Move the outer tube up and down a few times to remove
the air that is trapped in the fork oil in order to stabilize
the oil level.
13-10 SUSPENSION
Front Fork

• Hold the outer tube vertically in a vise and compress the

fork completely.
• Wait until the oil level stabilizes.
• Use the fork oil level gauge [A] to measure the distance
between the top of the inner tube to the oil level.
Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the oil level gauge stopper [B] so that the distance [C]
from the bottom of the stopper to the lower end of the pipe
is the standard oil level distance.
○A correct measurement can not be obtained unless the
level gauge pipe is placed in the center of the inner tube.
Oil Level (fully compressed, without spring)
Standard: 108 ±2 mm (4.25 ±0.08 in.)
○Place the stopper of the level gauge at the top [D] of the
inner tube [E] and pull the handle slowly to draw out the
excess oil from fork into the gauge, thus attaining the stan-
dard level.
If not oil is drawn out, there is not enough oil in the fork.
Pour in some more oil and measure again.

• Install:
Fork Spring [A]
Fork Spring Seat [B]
Collar [C]
• Replace the top plug O-ring and snap ring with new ones.
• Install:
Top Plug
Snap Ring
Front Fork (see Front Fork Installation)

Front Fork Disassembly

• Drain the fork oil (see Front Fork Oil Change).
• Stop the cylinder
Hold the fork leg horizontally in a vise [A].
• tools. unit [B] from turning by using the special

Special Tools - Fork Cylinder Holder Handle [C]: 57001-183

Fork Cylinder Holder Adapter [D]: 57001
-1057
• Unscrew the Allen bolt [E], then take the bolt and gasket
out of the bottom of the outer tube.
• Take the cylinder unit out of the inner tube.
 SUSPENSION 13-11
Front Fork

• Remove the following from the top of the outer tube.

Dust Seal [A]
Retaining Ring [B]

• Use the fork outer tube weight [A] to separate the inner
tube from the outer tube. Holding the inner tube by hand
in a vertical position, pull down the outer tube several
times to pull out the inner tube.
Special Tool - Fork Outer Tube Weight: 57001-1218
• Take out the cylinder base from the outer tube bottom.

• Remove the inner guide bushing from the inner tube.

Front Fork Assembly
• Replace the following parts with a new one.
Inner Guide Bushing [A]
Oil Seal [B]
Outer Guide Bushing [C]
Bottom Allen Bolt Gasket [D]

• Put the cylinder unit [A] with the spring into the inner tube
[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] facing
upward.
• Install the inner tube, cylinder unit, and cylinder base as
a set into the outer tube.
13-12 SUSPENSION
Front Fork

• Install the new guide bushing [A] with a use one [B] on it
by tapping the use one with the fork oil seal driver [C].
○The split [D] of the bushing should face toward the side of
the motorcycle.
Special Tool - Front Fork Oil Seal Driver: 57001-1219

• Apply molybdenum disulfide grease to the oil seal lips,

and install the washer and the oil seal [A] into the outer
tube.
Special Tool - Front Fork Oil Seal Driver [B]: 57001-1219
• Install the retaining ring on the outer tube.

• Install a new bottom Allen bolt gasket.

• the bottomnon-permanent
Apply a locking agent to the threads of
Allen bolt, and tighten it.
• Hold the outer tube in a vise [A], stop the cylinder unit [B]
with the special tools, then tighten the Allen bolt [C].
Special Tools - Fork Cylinder Holder Handle [D]: 57001-183
Fork Cylinder Holder Adapter [E]: 57001
-1057
Torque - Front Fork Bottom Allen Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
• Install the dust seal.
• Change).the specified type of oil (see Front Fork Oil
Pour in
 SUSPENSION 13-13
Front Fork
Inner Tube, Outer Tube Inspection
• Visually
age.
inspect the inner tube [A], and repair any dam-

• Nicks or rust damage can sometimes be repaired by using

a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
CAUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.

• Temporarily assemble the inner and outer [B] tubes, and

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 may fail in
use, possibly causing an accident. Replace a badly
bent or damaged inner or outer tube and inspect the
other tube carefully before reusing it.

Dust Seal Inspection

• Inspect
damage.
the dust seal [A] for any signs of deterioration or

Replace it if necessary.

Spring Tension Inspection

• Since a spring becomes shorter as it weakens, check its
free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Spring Free Length
Standard: 420.5 mm (16.56 in.)
Service Limit: 412 mm (16.22 in.)
13-14 SUSPENSION
Rear Shock Absorber
Spring Preload Adjustment
• Remove the bolts [A], chain cover [B] and left front footpeg
bracket [C] for turning the wrench easily.

• Using the steering stem nut wrench [A], turn the adjusting
nut to adjust the spring preload.
Special Tool - Steering Stem Nut Wrench: 57001-1100
○The standard adjuster setting for average-build rider of 68
kg (150 Ib) with no passenger and no accessories is 2nd
position.
Spring Preload Setting
Standard Position: 2nd position
Adjustable Range: 1st ∼ 5th position

• Iferating
the compression of the spring is not suited to the op-
conditions, adjust it to an appropriate position by
referring to the table below.
Spring Preload Adjustment
Shock
Adjuster Damping Road Driving
Absorber Load
Position Force Conditions Speed
Hardness
1st Weak Soft Light Good Low
↑ ↑ ↑ ↑ ↑ ↑
↓ ↓ ↓ ↓ ↓ ↓
5th Strong Hard Heavy Bad Highway

Rear Shock Absorber Removal

• Squeeze
[A].
the brake lever slowly and hold it with a band

WARNING
Be sure to hold the front brake when removing the
shock absorber, or the motorcycle may fall over. It
could cause an accident and injury.

• Remove the lower fairings (see Lower Fairing in the

Frame chapter).
• Raise the rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
 SUSPENSION 13-15
Rear Shock Absorber

• Remove the caps [A] (both sides).

• Remove:
Lower Tie-Rod Nut and Bolt [A]
Rear Shock Absorber Nuts and Bolts [B]
• Remove the shock absorber [C] from downside.

Rear Shock Absorber Installation

• Install the rear shock absorber.
• Tighten:
Torque - Rear Shock Absorber Nuts: 59 N·m (6.0 kgf·m, 44
ft·lb)
Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the removed parts (see appropriate chapters).
Rear Shock Absorber Inspection
• Remove the rear shock absorber (see Rear Shock Ab-
sorber Removal).
• Visually inspect the following items.
Smooth Stroke
Oil Leakage
Crack or Dent
If there is any damage to the rear shock absorber, replace
it.
• Visually inspect the rubber bushing.
If it show any signs of damage, replace it.
Rear Shock Absorber Scrapping
WARNING
Since the rear shock absorber contains nitrogen
gas, do not incinerate the rear shock absorber with-
out first releasing the gas or it may explode.
Before a rear shock absorber is scrapped, drill a
hole at the point [A] shown to release the nitrogen
gas completely. Wear safety glasses when drilling
the hole, as the gas may below out bits of drilled
metal when the hole opens.

• Remove the rear shock absorber (see Rear Shock Ab-

sorber Removal).
• Drill the cylinder of the shock absorber using about 2 mm
(0.08 in.) drillbit.
13-16 SUSPENSION
Swingarm
Swingarm Removal
• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Chain Cover (see Drive Chain Removal in the Final Drive
chapter)
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Caps [A] (Both Sides)

• Remove:
Bolt [A]
Clamp [B]

• Raise the rear wheel off the ground with jack.

Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove:
Lower Rear Shock Absorber Nut and Bolt [A]
Upper Tie-Rod Nut and Bolt [B]

• Unscrew the swingarm pivot shaft nut [A].

• Pull out the pivot shaft [A] and remove the swingarm [B].
 SUSPENSION 13-17
Swingarm
Swingarm Installation
•○Installation is the reverse of removal.
Apply grease to the lips of the oil seals.
○Tighten:
Torque - Swingarm Pivot Shaft Nut: 98 N·m (10.0 kgf·m,
72.3 ft·lb)
• Install the removed parts (see appropriate chapters).
Swingarm Bearing Removal
• Remove:
Swingarm (see Swingarm Removal)
Oil Seals [A]
Sleeve [B]

• Remove the needle bearings.

Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058

Swingarm Bearing Installation

• Apply plenty of grease to the needle bearings.
• marks face
Install the needle bearings so that the manufacturer’s
out.
Special Tool - Bearing Driver Set [A]: 57001-1129

Swingarm Bearing, Sleeve Inspection

CAUTION
Do not remove the bearings for inspection. Re-
moval may damage them.

•○Inspect the needle bearings [A] installed in the swingarm.

The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
visually inspect the bearing for abrasion, discoloration, or
other damage.
If the needle bearing and sleeve [B] show any signs of
abnormal wear, discoloration, or damage, replace them
as a set.
Swingarm Bearing Lubrication
• Refer to the Swingarm Pivot Lubrication in the Periodic
Maintenance chapter.
13-18 SUSPENSION
Tie-Rod, Rocker Arm
Tie-Rod Removal
• Squeeze
[A].
the brake lever slowly and hold it with a band

• Remove the lower fairings (see Lower Fairing Removal in

the Frame chapter).
• Raise the rear wheel off the ground with the jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove:
Upper Tie-Rod Nut and Bolt [A]
Lower Tie-Rod Nut and Bolt [B]
Tie-Rods [C]

Tie-Rod Installation
• Apply grease to the inside of the oil seals and O-rings.
• Tighten:
Torque - Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the removed parts (see appropriate chapters).
Rocker Arm Removal
• Squeeze the brake lever slowly and hold it with a band.
• the Frame chapter).
Remove the lower fairings (see Lower Fairing Removal in

• Raise the rear wheel off the ground with the jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove:
Lower Rear Shock Absorber Nut and Bolt [A]
Lower Tie-Rod Nut and Bolt [B]
Rocker Arm Nut and Bolt [C]
Rocker Arm [D]
Rocker Arm Installation
• Apply grease to the inside of the oil seals and O-rings.
• Tighten:
Torque - Uni-Trak Rocker Arm Nut: 59 N·m (6.0 kgf·m, 44
ft·lb)
Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
Rear Shock Absorber Nuts: 59 N·m (6.0 kgf·m, 44
ft·lb)
• Install the removed parts (see appropriate chapters).
Tie-Rod, Rocker Arm Bushing Inspection
• The bushings wear so little that the wear is difficult to mea-
sure. Instead, inspect the bushings for abrasion, color
change, or other damage.
If there is any doubt as to the condition of either bushings,
replace the bushing with a new one.
 SUSPENSION 13-19
Tie-Rod, Rocker Arm
Tie-Rod, Rocker Arm Sleeve Inspection
• Visually inspect the sleeves.
If there is visible damage, replace the sleeve with a new
one.
 STEERING 14-1

Steering
Table of Contents
Exploded View........................................................................................................................ 14-2
Special Tools .......................................................................................................................... 14-4
Steering .................................................................................................................................. 14-5
Steering Inspection ........................................................................................................... 14-5
Steering Adjustment.......................................................................................................... 14-5
Steering Stem......................................................................................................................... 14-6
Stem, Stem Bearing Removal........................................................................................... 14-6
Stem, Stem Bearing Installation........................................................................................ 14-7
Steering Stem Bearing Lubrication ................................................................................... 14-9
Steering Stem Warp Inspection ........................................................................................ 14-9
Oil Seal Deterioration, Damage Inspection....................................................................... 14-9
Handlebar ............................................................................................................................... 14-10
Handlebar Removal .......................................................................................................... 14-10
Handlebar Installation ....................................................................................................... 14-10

14
14-2 STEERING
Exploded View
 STEERING 14-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Handlebar Mounting Bolts 25 2.5 18
2 Lower Front Fork Clamp Bolts 30 3.1 22
3 Steering Stem Head Bolt 44 4.5 32
4 Steering Stem Nut 4.9 0.50 43 in·lb
5 Switch Housing Screws 3.5 0.36 31 in·lb
6 Upper Front Fork Clamp Bolts 20 2.0 15
AD: Apply adhesive.
G: Apply grease.
L: Apply a non-permanent locking agent.
14-4 STEERING
Special Tools
Steering Stem Bearing Driver: Head Pipe Outer Race Press Shaft:
57001-137 57001-1075

Bearing Puller: Head Pipe Outer Race Driver, 51.5:

57001-158 57001-1076

Bearing Puller Adapter: Steering Stem Nut Wrench:

57001-317 57001-1100

Oil Seal & Bearing Remover: Head Pipe Outer Race Driver, 47:
57001-1058 57001-1447

Steering Stem Bearing Driver Adapter, 34.5:

57001-1074
 STEERING 14-5
Steering
Steering Inspection
• Refer to the Steering Play Inspection in the Periodic Main-
tenance chapter.
Steering Adjustment
• Refer to the Steering Play Adjustment in the Periodic
Maintenance chapter.
14-6 STEERING
Steering Stem
Stem, Stem Bearing Removal
• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Handlebars (see Handlebar Removal)
Front Forks (see Front Fork Removal in the Suspension
chapter)
Steering Stem Head Bolt [A]
Steering Stem Head [B]

• Remove the bolts [A].

• Pushing up the stem base, and remove the steering stem

nut [A] and stem cap [B].
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100
• Remove:
Steering Stem [D]
Upper Ball Bearing Inner Race and Ball Bearings
NOTE
○Be aware of removing the steering stem so that the stem
bearing steel balls are not lost.

• Remove the upper and lower outer races using the re-
mover [A].
Special Tool - Oil Seal & Bearing Remover: 57001-1058

NOTE
○If either steering stem bearing is damaged, it is recom-
mended that both the upper and lower bearings (includ-
ing outer races) should be replaced with new ones.
 STEERING 14-7
Steering Stem

• Remove the lower ball bearing inner race (with its oil seal)
[A] which is pressed onto the steering stem using the
bearing puller [B] and adapter [C].
Special Tools - Bearing Puller: 57001-158
Bearing Puller Adapter: 57001-317

Stem, Stem Bearing Installation

• Replace the bearing outer races with new ones.
• Drive them into the head pipe at the same time.
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver, 51.5 [B]:
57001-1076
Head Pipe Outer Race Driver, 47 [C]: 57001
-1447
• Apply grease to the outer races.
• Replace
ones.
the bearing inner races and oil seal with new

• Apply grease to the oil seal.

• and drive
Install the washer [A] and oil seal [B] on the steering stem,
the ball bearing inner race [C] applied grease
onto the stem.
Special Tools - Steering Stem Bearing Driver [D]: 57001
-137
Steering Stem Bearing Driver Adapter,
34.5 [E]: 57001-1074

• Apply grease to the lower ball bearings (20) [A] and inner
race [B], and install the ball bearings onto the inner race.

• Apply grease to the upper ball bearings (19) [A] and outer
race [B], and install the ball bearings onto the outer race.
14-8 STEERING
Steering Stem

• Install the steering stem [A] carefully through the head

pipe so that the steel balls on the steering stem does not
fall.
• Install the stem cap [B] and steering stem nut [C], and
tighten it by hand.

• Install the stem head [A].

• Tighten the stem head bolt [B] lightly.

•○Settle the bearings in place as follows.

Tighten the steering stem nut with 15 N·m (1.5 kgf·m, 11
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly (To tighten the stem nut to the specified
torque, hook the wrench on the stem nut, and pull the
wrench at the hole by 84 N (8.6 kgf, 19 lb) [A] force in the
direction shown.). Afterward tighten it again with specified
torque using a steering stem nut wrench [B].
Special Tool - Steering Stem Nut Wrench: 57001-1100
Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)

• Adjust the steering (see Steering Play Inspection in the

Periodic Maintenance chapter).
• Install the front forks (see Front Fork Installation in the
Suspension chapter).
NOTE
○Tighten the upper front fork clamp bolts first, next the
stem head bolt, last the lower front fork clamp bolts.
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)
Lower Front Fork Clamp Bolts: 30 N·m (3.1 kgf·m,
22 ft·lb)

WARNING
Do not impede the handlebar turning by routing the
cables, harnesses and hoses improperly (see Ca-
ble, Wire and Hose Routing section in the Appendix
chapter).

• Install the removed parts (see appropriate chapters).

 STEERING 14-9
Steering Stem
Steering Stem Bearing Lubrication
• Refer to the Steering Stem Bearing Lubrication in the Pe-
riodic Maintenance chapter.
Steering Stem Warp Inspection
• Whenever the steering stem [A] is removed, or if the
steering can not be adjusted for smooth action, check
the steering stem for straightness.
If the steering stem is bent, replace the steering stem.

Oil Seal Deterioration, Damage Inspection

• Inspect
age.
the oil seal for any sign of deterioration or dam-

If the oil seal is deterioration or damage, replace it with a

new one.
14-10 STEERING
Handlebar
Handlebar Removal
• Remove:
Left Switch Housing [A]
Handlebar Weight [B]
Left Handlebar Grip [C]
Clutch Lever Clamp Bolt [D]
Clutch Lever Assembly [E]
Bolts [F]
Left Handlebar [G]

• Remove:
Front Master Cylinder [A] (see Front Master Cylinder Re-
moval in the Brakes chapter)
Right Switch Housing [B]
Handlebar Weight [C]
Throttle Grip [D]
Bolts [E]
Right Handlebar [F]

Handlebar Installation
• Tighten:
Torque - Handlebar Mounting Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

• Install the clutch lever (see Clutch Lever Installation in the

Clutch chapter).
• Apply adhesive cement to the inside of the left handlebar
grip, and install it.
• Apply a non-permanent locking agent to the left handlebar
weight screw, and tighten it.
•○Install the left switch housing.
Fit the projection [A] into a hole [B] in the handlebar.
• Tighten:
Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31
in·lb)

• Install:
Throttle Grip
Throttle Cable Tips [A]
Right Switch Housing
○Fit the projection [B] into a hole [C] in the handlebar.
•Tighten:
Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31
in·lb)
• Apply a non-permanent locking agent to the right handle-
bar weight screw, and tighten it.
• Install the front brake master cylinder (see Front Master
Cylinder Installation in the Brakes chapter).
 FRAME 15-1

Frame
Table of Contents
Exploded View........................................................................................................................ 15-2
Seats ...................................................................................................................................... 15-7
Rear Seat Removal........................................................................................................... 15-7
Rear Seat Installation........................................................................................................ 15-7
Front Seat Removal .......................................................................................................... 15-7
Front Seat Installation ....................................................................................................... 15-7
Fairings................................................................................................................................... 15-8
Lower Fairing Removal ..................................................................................................... 15-8
Lower Fairing Installation .................................................................................................. 15-8
Windshield Removal ......................................................................................................... 15-8
Windshield Installation ...................................................................................................... 15-9
Upper Fairing Removal ..................................................................................................... 15-9
Upper Fairing Disassembly............................................................................................... 15-9
Upper Fairing Assembly.................................................................................................... 15-9
Upper Fairing Installation .................................................................................................. 15-9
Inner Cover Removal ........................................................................................................ 15-9
Inner Cover Installation ..................................................................................................... 15-9
Upper Fairing Bracket Removal........................................................................................ 15-10
Upper Fairing Bracket Installation..................................................................................... 15-10
Inner Fairing Removal....................................................................................................... 15-10
Inner Fairing Installation.................................................................................................... 15-10
Side Cover.............................................................................................................................. 15-11
Side Cover Removal ......................................................................................................... 15-11
Side Cover Installation ...................................................................................................... 15-11
Seat Covers............................................................................................................................ 15-12
Seat Cover Removal......................................................................................................... 15-12
Seat Cover Installation...................................................................................................... 15-12
Fenders .................................................................................................................................. 15-14
Front Fender Removal ...................................................................................................... 15-14
Front Fender Installation ................................................................................................... 15-14
Flap and Rear Fender Removal........................................................................................ 15-14
15
Flap and Rear Fender Installation..................................................................................... 15-15
Frame ..................................................................................................................................... 15-16
Frame Inspection .............................................................................................................. 15-16
Sidestand................................................................................................................................ 15-17
Sidestand Removal........................................................................................................... 15-17
Sidestand Installation........................................................................................................ 15-17
15-2 FRAME
Exploded View
 FRAME 15-3
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Front Footpeg Bracket Bolts 25 2.5 18
2 Rear Footpeg Bracket Bolts 25 2.5 18
3 Sidestand Nut 39 4.0 29
4 Sidestand Switch Bolt 8.8 0.90 78 in·lb L
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
15-4 FRAME
Exploded View
 FRAME 15-5
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Windshield Mounting Bolts 0.42 0.043 3.7 in·lb
15-6 FRAME
Exploded View
 FRAME 15-7
Seats
Rear Seat Removal
• Insert the ignition switch key [A] into the seat lock, turning
the key clockwise, pulling the front part of the seat [B] up,
and pull the seat forward.

Rear Seat Installation

• Insert the rear seat slot [A] to the bracket [B] of the frame.
• Push down
Insert the seat hook [C] into the latch hole [D].
• the front part of the seat until the lock clicks.

Front Seat Removal

• Remove:
Side Covers (see Side Cover Removal)
Bolts [A] (Both Sides)
• Pull the front seat [B] backward.

Front Seat Installation

• Insert
bracket.
the front seat hooks [A] into the braces [B] of the

• Tighten the bolts.

• Install the side covers (see Side Cover Installation).
15-8 FRAME
Fairings
Lower Fairing Removal
• Remove:
Side Covers (see Side Cover Removal)
Rivets [A]
Bolts [B]
Front Turn Signal Light Lead Connectors (Disconnect)
Lower Fairings [C]

Lower Fairing Installation

•○Installation is the reverse of removal.
Run the front turn signal light lead [A] to the hooks [B].

○Fit [A] the front portion of the lower fairing in the rear por-
tion of the upper fairing.
○Install the tabs [B] of the lower fairing into the slots [C] of
the inner cover.

Windshield Removal
• Remove:
Bolts [A] with Washer
Windshield [B]
 FRAME 15-9
Fairings
Windshield Installation
• Put the bottom end [A] to the projection [B].
• Tighten:
Torque - Windshield Mounting Bolts: 0.42 N·m (0.043
kgf·m, 3.7 in·lb)

Upper Fairing Removal

• Remove:
Windshield (see Windshield Removal)
Lower Fairings (see Lower Fairing Removal)
Inner Fairing (see Inner Fairing Removal)
Bolts [A] (Both Sides)
• Pull out the upper fairing [B] forward.

• Disconnect:
Headlight Lead Connectors [A]
City Light Lead Connector [B]
• Remove the upper fairing [C].

Upper Fairing Disassembly

• Remove:
Upper Fairing (see Upper Fairing Removal)
Bolts [A]
Headlight [B]
Brackets [C]
Nuts [D] and Rear View Mirrors

Upper Fairing Assembly

• Assembly is the reverse of disassembly.
Upper Fairing Installation
• Installation is the reverse of removal.
Inner Cover Removal
• Refer to the Meter Unit Removal/Installation in the Elec-
trical System chapter.
Inner Cover Installation
• Refer to the Meter Unit Removal/Installation in the Elec-
trical System chapter.
15-10 FRAME
Fairings
Upper Fairing Bracket Removal
• Remove:
Upper Fairing (see Upper Fairing Removal)
Meter Unit (see Meter Unit Removal/Installation in the
Electrical System chapter)
Fuel Tank [A] (see Fuel Tank Removal in the Fuel Sys-
tem (DFI) chapter)
Clutch Cable [B]
Throttle Cables [C]
Left and Right Switch Housing Lead Connectors
Ignition Switch Lead Connector
Bands [D]
Bolt [E]
Nuts [F] and Bolts
Upper Fairing Bracket [G]
Upper Fairing Bracket Installation
• Installation is the reverse of removal.
• Hose Routing section
Run the cables and leads correctly (see Cable, Wire, and
in the Appendix chapter).
Inner Fairing Removal
• Remove:
Lower Fairings (see Lower Fairing Removal)
Rivets [A] (Both Sides)
Screws [B] (Both Sides)
Inner Fairing [C]

Inner Fairing Installation

• Fit the front portions [A] of the inner fairing into the lower
portions [B] of the upper fairing.
 FRAME 15-11
Side Cover
Side Cover Removal
• Remove the screw [A].
• pers [C]. cover [B] evenly outward to clear the stop-
Pull the side

Side Cover Installation

• Fit the groove [A] to the projection [B].
• Tightenthetheprojections
Insert [C] into the holes [D].
• screw.
15-12 FRAME
Seat Covers
Seat Cover Removal
• Remove:
Side Covers (see Side Cover Removal)
Seats (see Rear/Front Seat Removal)
Bolts [A]
• Pull the left and right seat covers [B] to clear the stoppers
[C].

• Remove the projections [A] from the holes [B], and pull
out the center seat cover [C] forward.

Seat Cover Installation

•○Installation is the reverse of removal.
Install the damper to the center seat cover so that its flat-
ten side [A] faces downward.

○Put the projection [A] into the hole [B] of the tail/brake light.
○Put the holes [C] to the projections [D] of the rear fender.

○Be sure that the damper [A] is in position.

 FRAME 15-13
Seat Covers

○Put the projections [A] into the holes [B].

• Install the removed parts (see appropriate chapters).
15-14 FRAME
Fenders
Front Fender Removal
• Remove:
Bolts [A] with Collar (Both Sides)
Front Fender [B]

Front Fender Installation

• Installation is the reverse of removal.
Flap and Rear Fender Removal
• Remove:
Seat Covers (see Seat Cover Removal)
Bolts [A] (Both Sides)
Rear Footpeg Brackets [B] (Both Sides)

• Remove:
Relay Box [A] (see Relay Box Removal in the Electrical
System chapter)
Battery Case [B] (see Battery Removal in the Electrical
System chapter)
ECU [C] (see ECU Removal in the Fuel System (DFI)
chapter)

• Remove:
Fuse Box [A]
Clamp [B]
Connectors [C]
 FRAME 15-15
Fenders

• Remove:
Tail/Brake Light (see Tail/Brake Light Removal in the
Electrical System chapter)
Owner’s Tool [A]
Connector [B]
Bolts [C]
Flap (with Turn Signal and License Plate Lights)

• Remove the screws [A] (both sides).

• Pull out the rear fender backward.

Flap and Rear Fender Installation

• Installation is the reverse of removal.
• Install the removed parts (see appropriate chapters).
Torque - Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Run the cable, leads and harness correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
15-16 FRAME
Frame
Frame Inspection
• Visually
warp.
inspect the frame for cracks, dents, bending, or

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.
 FRAME 15-17
Sidestand
Sidestand Removal
• Raise the rear wheel off the ground with the stand.
• Sidestand Switch Bolt [A]
Remove:

Sidestand Switch [B]

Spring [C]
Sidestand Bolt [D]
Sidestand [E]

Sidestand Installation
• Apply grease to the sliding area [A] of the sidestand [B].
• Tighten the bolt and lock them with the nut.
Torque - Sidestand Nut: 39 N·m (4.0 kgf·m, 29 ft·lb)
• Hook
ward.
the spring [C] so that face the long spring end up-

○Install the spring hook direction as shown in the figure.

• Install the sidestand switch.
• the switchnon-permanent
Apply a locking agent to the threads of
bolt, and tighten it.
Torque - Sidestand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78
in·lb)
 ELECTRICAL SYSTEM 16-1

Electrical System
Table of Contents
Exploded View........................................................................................................................ 16-4
Specifications ......................................................................................................................... 16-10
Special Tools and Sealant ...................................................................................................... 16-11
Parts Location......................................................................................................................... 16-12
Wiring Diagram....................................................................................................................... 16-14
Precautions............................................................................................................................. 16-16
Electrical Wiring...................................................................................................................... 16-17
Wiring Inspection .............................................................................................................. 16-17
Battery .................................................................................................................................... 16-18
Battery Removal ............................................................................................................... 16-18
Battery Installation ............................................................................................................ 16-18
Battery Activation .............................................................................................................. 16-19
Precautions ....................................................................................................................... 16-22
Interchange ....................................................................................................................... 16-22
Charging Condition Inspection.......................................................................................... 16-22
Refreshing Charge............................................................................................................ 16-23
Charging System .................................................................................................................... 16-24
Alternator Cover Removal................................................................................................. 16-24
Alternator Cover Installation.............................................................................................. 16-24
Stator Coil Removal .......................................................................................................... 16-25
Stator Coil Installation ....................................................................................................... 16-25
Alternator Rotor Removal ................................................................................................. 16-25
Alternator Rotor Installation .............................................................................................. 16-26
Charging Voltage Inspection ............................................................................................. 16-28
Alternator Inspection ......................................................................................................... 16-28
Regulator/Rectifier Inspection........................................................................................... 16-30
Ignition System ....................................................................................................................... 16-33
Crankshaft Sensor Removal ............................................................................................. 16-33
Crankshaft Sensor Installation .......................................................................................... 16-33
Crankshaft Sensor Inspection........................................................................................... 16-33
Crankshaft Sensor Peak Voltage Inspection..................................................................... 16-34
Stick Coil Removal............................................................................................................
Stick Coil Installation.........................................................................................................
16-34
16-35
16
Stick Coil Inspection.......................................................................................................... 16-35
Stick Coil Primary Peak Voltage ....................................................................................... 16-36
Spark Plug Removal ......................................................................................................... 16-36
Spark Plug Installation ...................................................................................................... 16-36
Spark Plug Condition Inspection....................................................................................... 16-37
Interlock Operation Inspection .......................................................................................... 16-37
IC Igniter Inspection .......................................................................................................... 16-38
Electric Starter System ........................................................................................................... 16-41
Starter Motor Removal...................................................................................................... 16-41
Starter Motor Installation................................................................................................... 16-41
Starter Motor Disassembly................................................................................................ 16-42
Starter Motor Assembly .................................................................................................... 16-42
Brush Inspection ............................................................................................................... 16-43
Commutator Cleaning and Inspection............................................................................... 16-43
Armature Inspection.......................................................................................................... 16-44
Brush Lead Inspection ...................................................................................................... 16-44
Brush Plate and Terminal Bolt Inspection ......................................................................... 16-44
16-2 ELECTRICAL SYSTEM

Starter Relay Inspection.................................................................................................... 16-44

Lighting System ...................................................................................................................... 16-47
Headlight Beam Horizontal Adjustment ............................................................................ 16-47
Headlight Beam Vertical Adjustment................................................................................. 16-47
Headlight Bulb Replacement ............................................................................................ 16-47
Headlight Removal/Installation ......................................................................................... 16-48
City Light Bulb Replacement............................................................................................. 16-48
Tail/Brake Light Bulb Replacement ................................................................................... 16-49
Tail/Brake Light Removal .................................................................................................. 16-50
Tail/Brake Light Installation ............................................................................................... 16-50
License Plate Light Bulb Replacement ............................................................................. 16-50
Turn Signal Light Bulb Replacement ................................................................................ 16-51
Turn Signal Relay Inspection ............................................................................................ 16-52
Air Switching Valve ................................................................................................................. 16-54
Air Switching Valve Operation Test ................................................................................... 16-54
Air Switching Valve Unit Test ............................................................................................ 16-54
Radiator Fan System.............................................................................................................. 16-56
Fan Motor Inspection ........................................................................................................ 16-56
Resistor Inspection ........................................................................................................... 16-56
Meter, Gauge, Indicator Unit................................................................................................... 16-58
Meter Unit Removal/Installation ........................................................................................ 16-58
Meter Unit Disassembly .................................................................................................... 16-58
Meter, Indicator Light Bulb Replacement .......................................................................... 16-59
Tachometer Inspection...................................................................................................... 16-59
Water Temperature Gauge Inspection .............................................................................. 16-60
Switches and Sensors ............................................................................................................ 16-62
Brake Light Timing Inspection........................................................................................... 16-62
Brake Light Timing Adjustment ......................................................................................... 16-62
Switch Inspection .............................................................................................................. 16-62
Water Temperature Sensor Inspection ............................................................................. 16-63
Speed Sensor Removal .................................................................................................... 16-63
Speed Sensor Installation ................................................................................................. 16-64
Speed Sensor Inspection.................................................................................................. 16-64
Oxygen Sensor Removal ................................................................................................. 16-64
Oxygen Sensor Installation .............................................................................................. 16-65
Oxygen Sensor Inspection ............................................................................................... 16-65
Fuel Reserve Switch Inspection........................................................................................ 16-65
Relay Box ............................................................................................................................... 16-66
Relay Box Removal .......................................................................................................... 16-66
Relay Circuit Inspection .................................................................................................... 16-66
Diode Circuit Inspection .................................................................................................... 16-67
Fuse........................................................................................................................................ 16-69
30 A Main Fuse Removal.................................................................................................. 16-69
Fuse Box Fuse Removal................................................................................................... 16-69
15 A ECU Fuse Removal.................................................................................................. 16-69
Fuse Installation................................................................................................................ 16-70
Fuse Inspection................................................................................................................. 16-70
 ELECTRICAL SYSTEM 16-3

Dummy Page
16-4 ELECTRICAL SYSTEM
Exploded View
 ELECTRICAL SYSTEM 16-5
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Front Brake Light Switch Screw 1.2 0.12 11 in·lb
2 License Plate Light Cover Screws 0.90 0.092 8.0 in·lb
3 License Plate Light Mounting Screws 1.2 0.12 11 in·lb
4 Switch Housing Screws 3.5 0.36 31 in·lb
5 Tail/Brake Light Mounting Bolts 5.9 0.60 52 in·lb
16-6 ELECTRICAL SYSTEM
Exploded View
 ELECTRICAL SYSTEM 16-7
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Alternator Cover Bolts 9.8 1.0 87 in·lb
2 Alternator Rotor Bolt 88.2 9.0 65 S
3 Crankshaft Sensor Screws 3.0 0.31 27 in·lb
Hand
4 Plugs (Alternator Cover) – – –
-Tighten
5 Regulator/Rectifier Bolts 9.8 1.0 87 in·lb
6 Spark Plugs 13 1.3 115 in·lb
7 Speed Sensor Bolt 7.8 0.80 69 in·lb L
8 Starter Motor Cable Terminal Nut 9.8 1.0 87 in·lb
9 Starter Motor Clutch Bolts 34.3 3.5 25 L
10 Starter Motor Mounting Bolts 9.8 1.0 87 in·lb
11 Starter Motor Terminal Locknut 6.9 0.70 61 in·lb
12 Starter Motor Through Bolts 3.4 0.35 30 in·lb
13 Starter Relay Cable Terminal Nuts 5.0 0.51 44 in·lb
14 Stator Coil Bolts 12 1.2 106 in·lb
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
16-8 ELECTRICAL SYSTEM
Exploded View
 ELECTRICAL SYSTEM 16-9
Exploded View

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Fuel Pump Bolts 9.8 1.0 87 in·lb L
2 Neutral Switch 15 1.5 11
3 Oil Pressure Switch 15 1.5 11 SS
4 Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb G
5 Oxygen Sensor 44.1 4.50 32.5
6 Resistor Bolt 7.8 0.80 69 in·lb
7 Sidestand Switch Bolt 8.8 0.90 78 in·lb L
8 Water Temperature Sensor 25 2.5 18
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant.
16-10 ELECTRICAL SYSTEM
Specifications

Item Standard
Battery
Type Sealed Battery
Model Name YTX9-BS
Capacity 12 V 8 Ah
Voltage 12.8 V or more
Charging System
Type Three-phase AC
Alternator Output Voltage 40 V or more at 4 000 r/min (rpm)
Stator Coil Resistance 0.05 ∼ 0.6 Ω at 20°C (68°F)
Charging Voltage 13.9 ∼ 14.9 V
(Regulator/Rectifier Output Voltage)
Ignition System
Crankshaft Sensor Resistance 100 ∼ 150 Ω
Crankshaft Sensor Peak Voltage 4.5 V or more
Stick Coil:
Primary Winding Resistance 1.0 ∼ 1.6 Ω
Secondary Winding Resistance 10.8 ∼ 16.2 kΩ
Primary Peak Voltage 90 V or more
Spark Plug:
Type NGK CR8E
Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
Electric Starter System
Starter Motor:
Brush Length 10 mm (0.39 in.) (Service Limit: 5.0 mm (0.20 in.))
Commutator Diameter 28 mm (1.10 in.) (Service Limit: 27 mm (1.06 in.))
Air Switching Valve
Resistance 20 ∼ 24 Ω at 20°C (68°F)
Switches and Sensors
Rear Brake Light Switch Timing ON after about 10 mm (0.39 in.) of pedal travel
Engine Oil Pressure Switch Connections When engine is stopped: ON
When engine is running: OFF
Water Temperature Sensor Resistance In the text
 ELECTRICAL SYSTEM 16-11
Special Tools and Sealant
Flywheel Holder: Peak Voltage Adapter:
57001-1313 57001-1415

Hand Tester: Lead Wire - Peak Voltage Adapter:

57001-1394 57001-1449

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Kawasaki Bond (Silicone Sealant):
57001-1405 92104-0004
16-12 ELECTRICAL SYSTEM
Parts Location
 ELECTRICAL SYSTEM 16-13
Parts Location
1. Meter Unit
2. Ignition Switch
3. Starter Lockout Switch
4. Air Switching Valve
5. Stick Coils
6. Spark Plugs
7. Starter Relay
8. Relay Box
9. ECU
10. Turn Signal Relay
11. Fuse Box
12. Battery 12 V 8 Ah
13. Speed Sensor
14. Sidestand Switch
15. Neutral Switch
16. Starter Motor
17. Alternator
18. Crankshaft Sensor
19. Oil Pressure Switch
20. Regulator/Rectifier
21. Front Brake Light Switch
22. Resistor
23. Fan Motor
24. Water Temperature Sensor
25. Oxygen Sensor
26. Engine Ground
27. Rear Brake Light Switch
16-14 ELECTRICAL SYSTEM
Wiring Diagram
 ELECTRICAL SYSTEM 16-15
Wiring Diagram
16-16 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
○Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is ON, or while the engine is
running.
○Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor wind-
ings.
○Take care not to short the cables 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 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).
 ELECTRICAL SYSTEM 16-17
Electrical Wiring
Wiring Inspection
• Visually
etc.
inspect the wiring for signs of burning, fraying,

If any wiring is poor, replace the damaged wiring.

•Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
•Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Re-
place the lead or the wiring harness [B] if necessary.
16-18 ELECTRICAL SYSTEM
Battery
Battery Removal
• Turn off the ignition switch.
• Front Seat (see Front Seat Removal in the Frame chap-
Remove:

ter)
Relay Box (see Relay Box Removal)
Screw [A] and Battery Cover [B]

• Disconnect the negative (–) cable [A].

CAUTION
Be sure to disconnect the negative (–) cable first.

• Slide out the positive (+) terminal cap [B] and disconnect
the positive (+) cable.
• Remove the battery [C].

• Remove the screws [A] and battery case [B] as necessary.

Battery Installation
• Turn off the ignition switch.
• Connectbattery
Put the into the battery case.
• Connect the positive (+) cable [A] first.
• Apply a light negative
the (–) cable [B].
• corrosion. coat of grease on the terminals to prevent

• Cover the (+) terminal with red cap [C].

• Insert the projections [A] into the holes [B].

• Install the removed parts (see appropriate chapters).
 ELECTRICAL SYSTEM 16-19
Battery
Battery Activation
Electrolyte Filling
• Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name for EX250K: YTX9-BS

CAUTION
Be sure to use the electrolyte container with the
same model name as the battery since the elec-
trolyte volume and specific gravity vary with the
battery type. This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora-
tion of the battery performance.

CAUTION
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.

• Place the battery on a level surface.

• or holestoinseeit. that the sealing sheet has no peeling, tears,
Check

• Remove the sealing sheet.

NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.

• Remove the electrolyte container from the vinyl bag.

• Detach the strip of caps [A] from the container and set
aside, these will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.

• Place the electrolyte container upside down with the six

sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container.
16-20 ELECTRICAL SYSTEM
Battery

• Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.
• Keep the container in place for 20 minutes or more. Don’t
remove the container from the battery until it’s empty, the
battery requires all the electrolyte from the container for
proper operation.
CAUTION
Removal of the container before it is completely
empty can shorten the service life of the battery. Do
not remove the electrolyte container until it is com-
pletely empty and 20 minutes have elapsed.

• Gently remove the container from the battery.

• the electrolyte
Let the battery sit for 30 minutes prior to charging to allow
to permeate into the plates for optimum
performance.
NOTE
○Charging the battery immediately after filling can
shorten service life. Let the battery sit for at least 30
minutes after filling.

Initial Charge
• Place the strip [A] of caps loosely over the filler ports.
• Newly activated sealed batteries require an initial charge.
Standard Charge: 0.9 A × 5 ∼ 10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers:
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9
If the above chargers are not available, use equivalent
one.
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. Let battery sit 30 minutes after initial
charge, then check voltage using a voltmeter. If it is
not at least 12.8 V, repeat charging cycle.
 ELECTRICAL SYSTEM 16-21
Battery

• After charging is completed, press down firmly with both

hands to seat the strip of caps [A] into the battery (don’t
pound or hammer). When properly installed, the strip of
the caps will be level with the top of the battery.
CAUTION
Once the strip of the caps is installed onto the bat-
tery, never remove the caps, nor add water or elec-
trolyte to the battery.

NOTE
○To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V the
battery is defective.
16-22 ELECTRICAL SYSTEM
Battery
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying
off the seal cap to add water is very dangerous. Never do that.
2) Refreshing charge
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable re-
moved. Give a refresh charge once a month during storage.
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.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.

Charging Condition Inspection

○Battery charging condition can be checked by measuring
battery terminal voltage with a digital voltmeter [A].
• Remove the battery (see Battery Removal).
• Measure the battery terminal voltage.
NOTE
○Measure with a digital voltmeter which can be read one
decimal place voltage.
 ELECTRICAL SYSTEM 16-23
Battery
If the reading is 12.8 V or more, no refresh charge is re-
quired, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
Standard: 12.8 V or more
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]

Refreshing Charge
• Remove the battery [A] (see Battery Removal).
• battery terminal
Do refresh charge by following method according to the
voltage.
WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.

Terminal Voltage: 11.5 ∼ less than 12.8 V

Standard Charge 0.9 A × 5 ∼ 10 h (see following chart)
Quick Charge 4A×1h

CAUTION
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method: 0.9 A × 20 h

NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]

•○Determine the battery condition after refresh charge.

Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria Judgement
12.8 V or higher Good
12.0 ∼ lower than 12.8 V Charge insufficient → Recharge
lower than 12.0 V Unserviceable → Replace
16-24 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Coolant (Drain, see Coolant Change in the Periodic
Maintenance chapter)
Water Pipes (see Water Pump Cover Removal in the
Cooling System chapter)

• Disconnect
nectors [A].
the alternator and crankshaft sensor lead con-

• Place a suitable container under the alternator cover [A].

• Remove: the leads from the clamps [B].
Take out
• Alternator Cover Bolts [C]
Alternator Cover

Alternator Cover Installation

• Apply silicone sealant to the crankshaft sensor lead grom-
met and crankcase halves mating surface [A] on the front
and rear sides of the cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Check that dowel pins [B] are in place on the crankcase.
• Install a new gasket [C] and the alternator cover.
• Tighten:
Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
• Run the leads correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
 ELECTRICAL SYSTEM 16-25
Charging System
Stator Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Screws [A] and Clamp [B]
Crankshaft Sensor [C]
Lead Grommets [D]
Stator Coil Bolts [E]
Stator Coil [F]

Stator Coil Installation

• Install the stator coil [A] and tighten the bolts.
Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
• Install the alternator [B] and crankshaft sensor [C] leads
into the alternator cover as shown in the figure.
Crankshaft Sensor [D]
Damper [E]
Clamp [F]
Grommets [G]
Silicone Sealant Applied Areas [H]
○Apply silicone sealant to the grommets, and fit them into
the notch of the cover securely.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Install the crankshaft sensor and clamp.
• Tighten:
Torque - Crankshaft Sensor Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
• Install
tion).
the alternator cover (see Alternator Cover Installa-

Alternator Rotor Removal

• Remove:
Alternator Cover (see Alternator Cover Removal)
Shaft [A]
Starter Idle Gear [B]

• Hold
[A].
the alternator rotor steady with the flywheel holder

• Remove the rotor bolt [B] and washer [C].

Special Tool - Flywheel Holder: 57001-1313

CAUTION
Do not hold the projections [D].
16-26 ELECTRICAL SYSTEM
Charging System

• Using the flywheel puller [A], remove the alternator rotor

[B] from the crankshaft.
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1405

CAUTION
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.

Alternator Rotor Installation

• Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions and dry them with a clean cloth.
Crankshaft Tapered Portion [A]
Alternator Rotor Tapered Portion [B]
• Apply a thin coat of molybdenum disulfide grease to the
crankshaft [C].

• Install the starter clutch gear [A] and washer [B].

• there. clean the crankshaft tapered portion [C] and dry
Again,

• Fit the woodruff key [D] securely in the slot in the crank-
shaft before installing the alternator rotor.

• Install the alternator rotor [A] while turning [B] the starter
clutch gear [C].
 ELECTRICAL SYSTEM 16-27
Charging System

• Install the washer and alternator rotor bolt [A].

NOTE
○Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.

• Install the rotor bolt and tighten it with 55 N·m (5.6 kgf·m,
41 ft·lb) of torque.
Special Tool - Flywheel Holder [B]: 57001-1313

CAUTION
Do not hold the projections [C].

• Remove the rotor bolt and washer.

• Check the tightening torque with flywheel puller.
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1405
If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them with
a clean cloth. Then, confirm that it is not pulled out with
above torque.
• Tighten the alternator rotor bolt while holding the alterna-
tor rotor steady with the flywheel holder.
Special Tool - Flywheel Holder: 57001-1313

CAUTION
Do not hold the projections.

Torque - Alternator Rotor Bolt: 88.2 N·m (9.0 kgf·m, 65 ft·lb)

• Apply a thin coat of molybdenum disulfide grease to the

shaft [A], and install it and starter idle gear [B].
• Install
tion).
the alternator cover (see Alternator Cover Installa-
16-28 ELECTRICAL SYSTEM
Charging System
Charging Voltage Inspection
• Check the battery condition (see Charging Condition In-
spection).
• Warm up the engine to obtain actual alternator operating
conditions.
• Remove the battery cover (see Battery Removal).
• the hand tester
Check that the ignition switch is turned off, and connect
[A] to the battery terminals [B].
Special Tool - Hand Tester: 57001-1394
• Start the engine, and note the voltage readings at var-
ious engine speeds with the headlight turned on and
then turned off (To turn off the headlight, disconnect
the headlight connector on the headlight unit.). The
readings should show nearly battery voltage when the
engine speed is low, and, as the engine speed rises, the
readings should also rise. But they must be kept under
the specified voltage.
Charging Voltage
Connections
Tester Range Reading
Tester (+) to Tester (–) to
25 V DC Battery (+) Battery (–) 13.9 ∼ 14.9 V

• 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 charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
 ELECTRICAL SYSTEM 16-29
Charging System

• To check the alternator output voltage, do the following

procedures.
○Turn off the ignition switch.
○Remove the right side cover (see Side Cover Removal in
the Frame chapter).
○Disconnect the alternator lead connector [A].
○Connect the hand tester as shown in the table 1.
Special Tool - Hand Tester: 57001-1394
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage at 4 000 r/min (rpm)
Tester Connections
Reading
Range Tester (+) to Tester (–) to
One Yellow Another Yellow
250 V AC 40 V or more
Lead Lead
If the output voltage shows the value in the table, the al-
ternator operates properly. The regulator/rectifier is dam-
aged.
If the output voltage shows a much lower reading than
that given in the table, stop the engine and inspect the
stator coil resistance.
•Check the stator coil resistance as follows.
○Stop the engine.
○Connect the hand tester as shown in the table 2.
Special Tool - Hand Tester: 57001-1394
○Note the readings (total 3 measurements).
Table 2 Stator Coil Resistance at 20°C (68°F)
Tester Connections
Reading
Range Tester (+) to Tester (–) to
× 1 Ω One Yellow Lead Another Yellow Lead 0.05 ∼ 0.6 Ω
If there is more resistance than shown in the table, or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
• Using the highest resistance range of the hand tester,
measure the resistance between each of the yellow leads
and chassis ground.
Any hand tester reading less than infinity (∞) indicates a
short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
16-30 ELECTRICAL SYSTEM
Charging System
Regulator/Rectifier Inspection
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Bolts [A]
Connector [B] (Disconnect)
Regulator/Rectifier [C]

Rectifier Circuit Check

•Check conductivity of the following pair of terminals.
Rectifier Circuit Inspection
W-Y1, W-Y2, W-Y3
Tester connection
BK/Y-Y1, BK/Y-Y2, BK/Y-Y3
The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
terminals are low or high in both directions, the rectifier is
defective and the regulator/rectifier must be replaced.
NOTE
○The actual meter reading varies with the meter used
and the individual rectifier, but, generally speaking the
lower reading should be from zero to one half the scale.
Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 ∼ 6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a cur-
rent limiter to protect the regulator/rectifier from ex-
cessive current. Do not use an ammeter instead of
a test light.

• Check to be sure the rectifier circuit is normal before con-

tinuing.

•○Do the 1st step regulator circuit test.

Connect the test light and the 12 V battery to the regula-
tor/rectifier as shown in the figure.
○Check the Y1, Y2 and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
 ELECTRICAL SYSTEM 16-31
Charging System

•○Do the 2nd step regulator circuit test.

Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1st
Step".
○Apply 12 V to the BR terminal.
○Check the Y1, Y2 and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.

•○Do the 3rd step regulator circuit test.

Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1st
Step".
○Momentarily apply 24 V to the BR terminal by adding a 12
V battery.
○Check the Y1, Y2 and Y3 terminals respectively.
CAUTION
Do not apply more than 24 V. If more than 24 V is ap-
plied, the regulator/rectifier may be damaged. Do
not apply 24 V more than a few seconds. If 24 V
is applied for more than a few seconds, the regula-
tor/rectifier may be damaged.
If the test light did not light when the 24 V was applied
momentarily to the voltage monitoring terminal, the regu-
lator/rectifier is defective. Replace it.
If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
16-32 ELECTRICAL SYSTEM
Charging System
Charging System Circuit

1. Alternator
2. Battery 12 V 8 Ah
3. Frame Ground
4. Main Fuse 30 A
5. Joint Connector 1
6. Load
7. Water-proof Joint 3
8. Ignition Switch
9. Regulator/Rectifier
 ELECTRICAL SYSTEM 16-33
Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plugs or stick coils
while the engine is running, or you could receive
a severe electrical shock.

CAUTION
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
ON, or while the engine is running. This is to pre-
vent ECU damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
ECU.

Crankshaft Sensor Removal

• Refer to the Stator Coil Removal.
Crankshaft Sensor Installation
• Refer to the Stator Coil Installation.
Crankshaft Sensor Inspection
• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Crankshaft Sensor Lead Connector [A] (Disconnect)
• Set the hand tester [B] to the × 1 Ω range and connect (+)
lead to the yellow lead and (–) lead to the black lead in
the connector.
Special Tool - Hand Tester: 57001-1394

Crankshaft Sensor Resistance: 100 ∼ 150 Ω

If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
• Using the highest resistance range of the tester, measure
the resistance between the crankshaft sensor leads and
chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the crankshaft sensor as-
sembly.
16-34 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Peak Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Crankshaft Sensor Lead Connector [A] (Disconnect)
• Set the hand tester [B] to the DC 25 V range.
• Connect the peak voltage adapter [C] to the hand tester
and crankshaft sensor leads in the connector.
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

Connections:
Crankshaft Peak Voltage
Hand Tester
Sensor Lead Adapter
Yellow ← Red → (+)
Black ← Black → (–)

• Turn the ignition switch and engine stop switch ON.

• onds withthe
Pushing starter button, turn the engine 4 ∼ 5 sec-
the transmission gear in neutral to measure the
crankshaft sensor peak voltage.
• Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
Standard: 4.5 V or more
If the tester reading is not specified one, inspect the crank-
shaft sensor (see Crankshaft Sensor Inspection).
Stick Coil Removal
CAUTION
Never drop the stick coils especially on a hard sur-
face. Such a shock to the stick coils can damage it.

• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

• Disconnect the stick coil connectors [A].

• Pull the stick coils [B] off the spark plugs.
CAUTION
Do not pry the connector part of the coil while re-
moving the coil.
 ELECTRICAL SYSTEM 16-35
Ignition System
Stick Coil Installation
• Insert the coil as shown being careful of the coil heads [A]
direction.
• Be sure the stick coils are installed by pulling up it lightly.
• Connect the connectors.
CAUTION
Do not tap the coil head while installing the coil.

• Run the leads correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
Stick Coil Inspection
• Remove the stick coils (see Stick Coil Removal).
•○Connect the
Measure the primary winding resistance [A] as follows.
hand tester between the coil terminals.
○Set the tester to the × 1 Ω range, and read the tester.
•○Measure the secondary winding resistance [B] as follows.
Connect the tester between the plug terminal and (–) coil
terminal.
○Set the tester to the × 1 kΩ range and read the tester.
Stick Coil Winding Resistance
Primary Windings: 1.0 ∼ 1.6 Ω
Secondary Windings: 10.8 ∼ 16.2 kΩ
If the tester does not read as specified, replace the coil.
16-36 ELECTRICAL SYSTEM
Ignition System
Stick Coil Primary Peak Voltage
NOTE
○Be sure the battery is fully charged.
• Remove the stick coils (see Stick Coil Removal), but do
not remove the spark plugs.
•○Measure the primary peak voltage as follows.
Install the new spark plug [A] into each stick coil [B], and
ground them onto the engine.
○Connect the peak voltage adapter [C] into the hand tester
[D] which is set to the DC 250 V range.
○Connect the adapter to the lead wire-peak voltage
adapter [E] which is connected between the stick coil
connector and stick coil.
ECU [F]
Battery [G]

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Lead Wire - Peak Voltage Adapter: 57001
-1449

Primary Lead Connection

Adapter (R, +) to lead wire-peak voltage adapter (R)
Adapter (BK, –) to lead wire-peak voltage adapter (W)

WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.

• 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 primary
peak voltage.
• Repeat the measurements 5 times for one stick coil.
Stick Coil Primary Peak Voltage
Standard: 90 V or more

• Repeat the test for the other stick coil.

If the reading is less than the specified value, check the
following.
Stick Coils (see Stick Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
ECU (see ECU Power Supply Inspection in the Fuel Sys-
tem (DFI) chapter)
Spark Plug Removal
• Refer to the Spark Plug Replacement in the Periodic
Maintenance chapter.
Spark Plug Installation
• Refer to the Spark Plug Replacement in the Periodic
Maintenance chapter.
 ELECTRICAL SYSTEM 16-37
Ignition System
Spark Plug Condition Inspection
• Remove the spark plugs (see Spark Plug Replacement in
the Periodic Maintenance chapter).
• Visually inspect the spark plugs.
If the spark plug center electrode [A] and/or side elec-
trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.
• Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

• Use the standard spark plug or its equivalent.

Spark Plug: NGK CR8E

Interlock Operation Inspection

• Raise the rear wheel off the ground with stand.
•1st Check engine stop switch ON (run position).
Turn the

• Start the engine to the following conditions.

Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Sidestand → Down or Up
○Turn the ignition switch ON and push the starter button.
○Then the starter motor should not turn when the starter
system circuit is normality.
If the engine is start, inspect the starter lockout switch,
neutral switch and relay box.
If their parts are normality, replace the ECU.
2nd Check
•Start the engine to the following conditions.
Condition:
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Sidestand → Up
○Turn the ignition switch ON and push the starter button.
○Then the starter motor should turn when the starter sys-
tem circuit is normality.
If the starter motor is not turn, inspect the starter lockout
switch, neutral switch, sidestand switch and relay box.
If their parts are normality, replace the ECU.
16-38 ELECTRICAL SYSTEM
Ignition System
3rd Check
• Inspect the engine for its secure stop after the following
operations are completed.
• Run the engine to the following conditions.
Condition:
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Sidestand → Up

• Set the sidestand on the ground, then the engine will stop.
If the engine does not stop, inspect the neutral switch,
sidestand switch and relay box.
If their parts are normality, replace the ECU.
IC Igniter Inspection
○The IC igniter is built in the ECU [A].
• Refer to the following items.
Interlock Operation Inspection (see Interlock Operation
Inspection)
Ignition System Troubleshooting (see Ignition System
section)
ECU Power Supply Inspection (see ECU Power Supply
Inspection in the Fuel System (DFI) chapter)
 ELECTRICAL SYSTEM 16-39
Ignition System
16-40 ELECTRICAL SYSTEM
Ignition System
Ignition System Circuit

1. ECU 11. ECU Fuse 15 A 19. Speed Sensor

2. Joint Connector 2 12. Oxygen Sensor Heater 20. Subthrottle Sensor
3. Sidestand Switch Fuse 10 A 21. Main Throttle Sensor
4. Battery 12 V 8 Ah 13. Fuse Box 22. Water-proof Joint 2
5. Frame Ground 14. Ignition Switch 23. Vehicle-down Sensor
6. Main Fuse 30 A 15. Engine Stop Switch 24. Water-proof Joint 1
7. ECU Main Relay 16. Spark Plugs 25. Neutral Switch
8. Relay Box 17. Stick Coils 26. Crankshaft Sensor
9. Starter Lockout Switch 18. Water-proof Joint 3 27. Oxygen Sensor
10. Ignition Fuse 10 A
 ELECTRICAL SYSTEM 16-41
Electric Starter System
Starter Motor Removal
CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.

• Remove the lower fairings (see Lower Fairings Removal

in the Frame chapter).
• Slide back the rubber cap [A].
• Starter Motor Cable Terminal Nut [B]
Remove:

Mounting Bolts [C]

• Pull out the starter motor [A] toward the left side.

Starter Motor Installation

CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.

• When installing the starter motor, clean the starter mo-

tor legs [A] and crankcase [B] where the starter motor is
grounded.

• Replace the O-ring [A] with a new one.

• Tighten: to the O-ring.
Apply grease
•
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Install the starter motor cable, and tighten the nut.
Torque - Starter Motor Cable Terminal Nut: 9.8 N·m (1.0
kgf·m, 87 in·lb)
• Slide the rubber cap to the original position.
• Install the removed parts (see appropriate chapters).
16-42 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Disassembly
• Remove the starter motor (see Starter Motor Removal).
• the both endstarter
Take off the motor through bolts [A] and remove
covers [B] and pull the armature out of the
yoke.

• Remove the terminal locknut [A], washer and insulators,

and then remove the brushes and terminal bolt [B] with
the brush plate [C] from the end cover.

Starter Motor Assembly

• Replace the O-rings with new ones.
• [A] and needle
Apply a thin coat of high-temperature grease to the oil seal
bearing [B].
• Fit the toothed washer [C] into the end cover.

• Install:
Brush Plate [A]
New O-ring
Insulators
Washer
• Tighten:
Torque - Starter Motor Terminal Locknut [B]: 6.9 N·m (0.70
kgf·m, 61 in·lb)
○Fit the tongue [C] of the brush plate into the groove of the
end cover.

• Install the steel washer [A] and resin washer [B] on the
armature shaft.
• Install the armature [C] among the brushes.
 ELECTRICAL SYSTEM 16-43
Electric Starter System

• Align the end covers [A] with the marks [C] of the yoke [B].

• Replace the O-rings on the through bolts with new ones

and tighten them.
Torque - Starter Motor Through Bolts: 3.4 N·m (0.35 kgf·m,
30 in·lb)

Brush Inspection
• Measure the length of each brush [A].
If any is worn down to the service limit, replace the brush
plate assembly [B].
Starter Motor Brush Length [C]
Standard: 10 mm (0.39 in.)
Service Limit: 5.0 mm (0.20 in.)

Commutator Cleaning and Inspection

• Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.

• Measure the diameter [A] of the commutator [B].

If the commutator diameter is less than the service limit,
replace the starter motor with a new one.
Commutator Diameter
Standard: 28 mm (1.10 in.)
Service Limit: 27 mm (1.06 in.)
16-44 ELECTRICAL SYSTEM
Electric Starter System
Armature Inspection
• tance
Using the × 1 Ω hand tester range, measure the resis-
between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
• Using the highest hand tester range, measure the 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.

NOTE
○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.

Brush Lead Inspection

• tance
Using the × 1 Ω hand tester range, measure the resis-
as shown in the figure.
Terminal Bolt and Positive Brush [A]
Brush Plate and Negative Brush [B]
Special Tool - Hand Tester: 57001-1394
If there is not close to zero ohms, the brush lead has an
open. Replace the brush plate assembly.

Brush Plate and Terminal Bolt Inspection

• Using the highest hand tester range, measure the resis-
tance as shown in the figure.
Terminal Bolt and Brush Plate [A]
Terminal Bolt and Negative Brush Holder [B]
Terminal Bolt and End Cover [C]
Special Tool - Hand Tester: 57001-1394
If there is any reading, the brush holder and/or terminal
bolt have a short. Replace the brush plate assembly.

Starter Relay Inspection

• Remove:
Battery Negative (–) Cable (see Battery Removal)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Bracket Bolts [A]
Bracket [B]
 ELECTRICAL SYSTEM 16-45
Electric Starter System

• Remove:
Cable Terminals [A] and Connector [B] (Disconnect)
Starter Relay [C]

• Connect the hand tester [A] and 12 V battery [B] to the

starter relay [C] as shown in the figure.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Tester Range: × 1 Ω range
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
16-46 ELECTRICAL SYSTEM
Electric Starter System
Electric Starter Circuit

1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
4. Water-proof Joint 3
5. Neutral Switch
6. Joint Connector 2
7. Sidestand Switch
8. Battery 12 V 8 Ah
9. Frame Ground
10. Starter Relay
11. Main Fuse 30 A
12. Starter Motor
13. Relay Box
14. Starter Circuit Relay
15. Starter Lockout Switch
16. Fuse Box
17. Ignition Fuse 10 A
 ELECTRICAL SYSTEM 16-47
Lighting System
This motorcycle adopt the daylight system and have a
headlight relay in the relay box. The headlight does not
go on when the ignition switch and the engine stop switch
are first turned on. The headlight comes on after the starter
button is released and stays on until the ignition switch is
turned off. The headlight will go out momentarily whenever
the starter button is pressed and come back on when the
button is released.
Headlight Beam Horizontal Adjustment
• Refer to the Headlight Aiming Inspection in the Periodic
Maintenance chapter.
Headlight Beam Vertical Adjustment
• Refer to the Headlight Aiming Inspection in the Periodic
Maintenance chapter.
Headlight Bulb Replacement
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Headlight Bulb Dust Cover [A]

• Remove:
Hook [A]
Headlight Bulb [B]
CAUTION
When handling the quartz-halogen bulb, never
touch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands or
dirty rags can reduce bulb life or cause the bulb to
explode.

NOTE
○Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.

• Replace the headlight bulb.

• headlight.
Fit the projection [A] of the bulb in the hollow [B] of the
16-48 ELECTRICAL SYSTEM
Lighting System

• Install the hook [A].

• Fit the dust cover [A] onto the bulb [B] firmly as shown in
the figure.
Good [C]
Bad [D]
• After installation, adjust the headlight aim (see Headlight
Aiming Inspection in the Periodic Maintenance chapter).

Headlight Removal/Installation
• Refer to the Upper Fairing Disassembly/Assembly in the
Frame chapter.
• After installing, confirm the damper [A] between the head-
light [B] and upper fairing [C] as shown in the figure.

City Light Bulb Replacement

• Remove the upper fairing (see Upper Fairing Removal in
the Frame chapter).
• Pull out the socket [A] together with the bulb.
 ELECTRICAL SYSTEM 16-49
Lighting System

• Pull out the bulb [A] straight from the socket.

CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage then the specified value.

• Replace the bulb with a new one.

Tail/Brake Light Bulb Replacement

• Remove the rear seat (see Rear Seat Removal in the
Frame chapter).
• Turn the socket [A] counterclockwise [B].

• Push the bulb [A] in the socket, turn it counterclockwise

[B], and pull it out.

• Insert the new bulb [A] by aligning its upper and lower pins
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
○Turn the bulb about 15°.

• Fit the projections [A] of the socket into the grooves [B] of
the tail/brake light.
• Turn the socket clockwise.
16-50 ELECTRICAL SYSTEM
Lighting System
Tail/Brake Light Removal
• Remove:
Seat Covers (see Seat Cover Removal in the Frame
chapter)
Connector [A] (Disconnect)
Tail/Brake Light Mounting Bolts [B]
Tail/Brake Light [C]

Tail/Brake Light Installation

• Tighten:
Torque - Tail/Brake Light Mounting Bolts: 5.9 N·m (0.60
kgf·m, 52 in·lb)
• Run the lead correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
License Plate Light Bulb Replacement
• Remove:
Screws [A]
License Plate Light Cover [B]

• Push
it.
and turn the bulb [A] counterclockwise and remove

• Replace the bulb with a new one.

• Insert the new bulb [A] by aligning its upper and lower pins
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
○Turn the bulb about 15°.
•Tighten:
Torque - License Plate Light Cover Screws: 0.90 N·m
(0.092 kgf·m, 8.0 in·lb)
 ELECTRICAL SYSTEM 16-51
Lighting System
Headlight/Tail Light Circuit

1. High Beam Indicator 7. Tail/Brake Light 12 V 21/5 W 15. Headlight Fuse 10 A

Light 12 V 3.4 W 8. Battery 12 V 8 Ah 16. Fuse Box
2. Ignition Switch 9. Frame Ground 17. Dimmer Switch
3. Alternator 10. Starter Relay 18. Headlight (Low) 12 V 55 W
4. Water-proof Joint 3 11. Main Fuse 30 A 19. Headlight (High) 12 V 55 W
5. Joint Connector 2 12. Headlight Circuit Relay 20. City Light 12 V 5 W
6. License Plate Light 12 13. Relay Box 21. Joint Connector 1
V5W 14. Taillight Fuse 10 A

Turn Signal Light Bulb Replacement

• Unscrew the screw [A] and remove the lens [B].
16-52 ELECTRICAL SYSTEM
Lighting System

• Push
it.
and turn the bulb [A] counterclockwise and remove

• Insert the new bulb [A] by aligning its upper and lower pins
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
○Turn the bulb about 15°.

Turn Signal Relay Inspection

• Remove:
Left Seat Cover (see Seat Cover Removal in the Frame
chapter)
Turn Signal Relay [A]
Connector [B] (Disconnect)

• Connect one 12 V battery and turn signal lights as indi-

cated in the figure, and count how may times the lights
flash for one minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not flash as specified, replace the turn sig-
nal relay.
Testing Turn Signal Relay
Load
Flashing Times
The Number of Turn (c/m*)
Wattage (W)
Signal Lights
1** 10 Lights stays on
2 20 75 ∼ 95
(*): Cycle(s) per minute
(**): Corrected to "one light burned out".
 ELECTRICAL SYSTEM 16-53
Lighting System
Turn Signal Light Circuit

1. Ignition Switch
2. Water-proof Joint 3
3. Joint Connector 2
4. Rear Right Turn Signal Light 12 V 10 W
5. Rear Left Turn Signal Light 12 V 10 W
6. Battery 12 V 8 Ah
7. Frame Ground
8. Main Fuse 30 A
9. Turn Signal Relay Fuse 10 A
10. Fuse Box
11. Turn Signal Switch
12. Turn Signal Relay
13. Front Left Turn Signal Light 12 V 10 W
14. Front Right Turn Signal Light 12 V 10 W
15. Joint Connector 1
16. Turn Signal Indicator Light 12 V 3.4 W
16-54 ELECTRICAL SYSTEM
Air Switching Valve
Air Switching Valve Operation Test
• Refer to the Air Suction System Damage Inspection in the
Periodic Maintenance chapter.
Air Switching Valve Unit Test
• Remove the air switching valve (see Air Switching Valve
Removal in the Engine Top End chapter).
• toSetthetheairhand tester [A] to the × 1 Ω range and connect it
switching valve terminals as shown in the figure.
Special Tool - Hand Tester: 57001-1394

Air Switching Valve Resistance

Standard: 20 ∼ 24 Ω at 20°C (68°F)
If the tester does not read as specified value, replace it
with a new one.

• Connect the 12 V battery [A] to the air switching valve

terminals as shown in the figure.

• Blow the air to the inlet air duct [A], and make sure does
not flow the blown air from the outlet air duct [B].

• Disconnect the 12 V battery.

• Blow the air to the inlet air duct [A] again, and make sure
flow the blown air from the outlet air duct [B].
If the air switching valve does not operate as described,
replace it with a new one.
NOTE
○To check air flow through the air switching valve, just
blow through the air switching valve hose (inlet side).
 ELECTRICAL SYSTEM 16-55
Air Switching Valve
Air Switching Valve Circuit

1. ECU
2. Joint Connector 2
3. Battery 12 V 8 Ah
4. Frame Ground
5. Main Fuse 30 A
6. Relay Box
7. ECU Main Relay
8. ECU Fuse 15 A
9. Fuse Box
10. Ignition Switch
11. Water-proof Joint 3
12. Air Switching Valve
16-56 ELECTRICAL SYSTEM
Radiator Fan System
Fan Motor Inspection
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
• Disconnect the connector [A].
• motor.
Using an auxiliary leads, supply battery power to the fan

If the fan does not rotate, the fan motor is defective and
must be replaced.

Resistor Inspection
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Bolt [A]
Clamp [B]
Connectors [C]
Resistor [D]

• Set the hand tester to the × 1 Ω range, and check the

continuity as shown in the figure.
Special Tools - Hand Tester: 57001-1394

Connections: BL lead [A] ←→ BL lead [B]

BK lead [C] ←→ BK lead [D]
Standard About 0 Ω
If the resistor has an open or short, replace it with a new
one.
 ELECTRICAL SYSTEM 16-57
Radiator Fan System
Radiator Fan Circuit

1. ECU
2. Joint Connector 2
3. Battery 12 V 8 Ah
4. Frame Ground
5. Main Fuse 30 A
6. Joint Connector 1
7. Relay Box
8. Fan Relay
9. ECU Fuse 15 A
10. Fan Fuse 10 A
11. Fuse Box
12. Resistor
13. Fan Motor
14. Water-proof Joint 3
15. Water-proof Joint 1
16. Water Temperature Sensor
16-58 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Unit Removal/Installation
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Speedometer Cable Upper End [A]
Connectors [B]

• Remove the inner cover [A] with meter unit [B].

• Remove:
Bolts [A]
Meter Unit [B]
CAUTION
Place the meter unit so that the face is up. If a meter
unit is left upside down or sideways for any length
of time, it will malfunction.

•○Installation is the reverse of removal.

Fit the projections [A] into the grommets [B].
• Run the leads and cable correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

Meter Unit Disassembly

• Remove:
Meter Unit (Meter Unit Removal/Installation)
Screws [A]
Meter Cover [B]
 ELECTRICAL SYSTEM 16-59
Meter, Gauge, Indicator Unit

• Remove the speedometer [A], tachometer [B] and water

temperature gauge [C] by removing screws [D].
CAUTION
Do not remove a meter pointer unless the meter is
to be replace. The pointers cannot be reinstalled.
The pointer mounting is different from replacement
meters.

Meter, Indicator Light Bulb Replacement

• Remove the meter unit (Meter Unit Removal/Installation).
• Pull the bulbsocket
Pull out the [A] together with the bulb.
• [B] out of the socket.
CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage then the specified value.

•○Replace the bulb with a new one.

Repeat the same procedure for other bulbs.
Tachometer Inspection
• Remove
tion).
the meter unit (see Meter Unit Removal/Installa-

• Using the insulated auxiliary leads, connect the 12 V bat-

tery to the meter unit connector (9 pins connector) as fol-
lows.
○Connect the battery positive terminal to the BR lead ter-
minal [A].
○Connect the battery negative terminal to the BK/Y lead
terminal [B].
CAUTION
Do not short each terminals.

• Using the insulated auxiliary leads, open and connect the

BK lead terminal [A] to the battery positive terminal re-
peatedly.
16-60 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit

• Then the tachometer needle [A] should flick [B].

If the needle does not flick, check the meter unit harness
for continuity (see wiring diagram in this section).
Special Tool - Hand Tester: 57001-1394
If the harness is normal, replace the tachometer.

Water Temperature Gauge Inspection

• Remove
tion).
the meter unit (see Meter Unit Removal/Installa-

• Using the insulated auxiliary leads, connect the 12 V bat-

tery to the meter unit connector (9 pins connector) as fol-
lows.
○Connect the battery positive terminal to the BR lead ter-
minal [A].
○Connect the battery negative terminal to the BK/Y lead
terminal [B].
CAUTION
Do not short each terminals.

• Connect the variable rheostat [A] to the W/Y lead terminal

[B] as shown in the figure.
• Adjust the resistance value to the approximately 20 Ω.

• The water temperature gauge [A] indicate the position [B]

of the about 125°C.
If the water temperature gauge does not work, check the
meter unit harness for continuity (see wiring diagram in
this section).
Special Tool - Hand Tester: 57001-1394
If the harness is normal, replace the water temperature
gauge.
 ELECTRICAL SYSTEM 16-61
Meter, Gauge, Indicator Unit
Meter Unit Circuit

1. Fuel Level Warning Indicator Light 12 V 3.4 13. Ignition Fuse 10 A

W 14. Joint Connector 1
2. Ignition Switch 15. FI Indicator Light 12 V 3.4 W
3. Water-proof Joint 3 16. Oil Pressure Warning Indicator Light 12 V
4. Water Temperature Sensor 3.4 W
5. Neutral Switch 17. Neutral Indicator Light 12 V 3.4 W
6. Oil Pressure Switch 18. Turn Signal Indicator Light 12 V 3.4 W
7. ECU 19. High Beam Indicator Light 12 V 3.4 W
8. Fuel Reserve Switch 20. Tachometer
9. Battery 12 V 8 Ah 21. Speedometer
10. Frame Ground 22. Water Temperature Gauge
11. Main Fuse 30 A 23. Meter Lights 12 V 3.4 W
12. Fuse Box
16-62 ELECTRICAL SYSTEM
Switches and Sensors
Brake Light Timing Inspection
• Refer to the Brake Light Switch Operation Inspection in
the Periodic Maintenance chapter.
Brake Light Timing Adjustment
• Refer to the Brake Light Switch Operation Inspection in
the Periodic Maintenance chapter.
Switch Inspection
• Using a hand tester, check to see that only the connec-
tions shown in the table have continuity.
○For the switch housings and the ignition switch, refer to
the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Special Tool - Hand Tester: 57001-1394
Rear Brake Light Switch Connections

Sidestand Switch Connections

Neutral Switch Connections

Oil Pressure Switch Connections*

*: Engine lubrication system is in good condition.

 ELECTRICAL SYSTEM 16-63
Switches and Sensors
Water Temperature Sensor Inspection
• Remove the water temperature sensor (see Water Tem-
perature Sensor Removal/Installation in the Fuel System
(DFI) chapter).
• Suspend the sensor [A] in a container of coolant so that
the threaded portion is submerged.
• Suspend an accurate thermometer [B] with temperature
sensing portions [C] located in almost the same depth.
NOTE
○The sensor and thermometer must not touch the con-
tainer side or bottom.

• Place the container over a source of heat and gradu-

ally raise the temperature of the coolant while stirring the
coolant gently.
•Using the hand tester, measure the internal resistance of
the sensor.
○The sensor sends electric signals to the ECU and water
temperature gauge in the meter unit.
○Measure the resistance across the terminals and the body
(for the gauge) at the temperatures shown in the table.
If the hand tester does not show the specified values, re-
place the sensor.
Water Temperature Sensor
Resistance for ECU [D]
Resistance (kΩ)
Temperature
(Terminal [1]-[3])
+ 0.155
20°C (68°F) 2.46
– 0.143
80°C (176°F) 0.32 ±0.011
110°C (230°F) 0.1426 ±0.0041

Resistance for Water Temperature Gauge [E]

Resistance (Ω)
Temperature
(Terminal [2]-Body)
50°C (122°F) 210 ±40
120°C (248°F) 21.2 ±1.5

Speed Sensor Removal

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

• Remove:
Left Side Cover (see Side Cover Removal in the Frame
chapter)
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
Connector [A] (Disconnect)
16-64 ELECTRICAL SYSTEM
Switches and Sensors

• Remove:
Speed Sensor Bolt [A]
Speed Sensor [B]

Speed Sensor Installation

• Installation is the reverse of removal.
• ing section in correctly
Run the lead (see Cable, Wire, and Hose Rout-
the Appendix chapter).
• Apply a non-permanent locking agent to the threads of
the speed sensor bolt, and tighten it.
Torque - Speed Sensor Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Install the removed parts (see appropriate chapters).
Speed Sensor Inspection
• Remove the speed sensor (see Speed Sensor Removal).
• Connect the speed sensor connector [A] with the battery
[B], 10 kΩ resistor [C] and hand tester [D] as shown in the
figure.
• Set the tester to the DC 25 V range.
Special Tool - Hand Tester: 57001-1394

• Trace [A] each side of the speed sensor surface with the
screwdriver.
○Then the tester indicator should flick [B].
If the tester indicator does not flick, replace the speed
sensor.

Oxygen Sensor Removal

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

• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Oxygen Sensor Lead Connector [A] (Disconnect)
• Free the lead from the clamps [B].
• Remove the oxygen sensor [C].
 ELECTRICAL SYSTEM 16-65
Switches and Sensors
Oxygen Sensor Installation
CAUTION
Never drop the oxygen sensor [A] especially on a
hard surface. Such a shock to the unit can damage
it. Do not touch the sensing part [B] and filter holes
[C] of the sensor to prevent oil contact. Oil contami-
nation from hands can reduce sensor performance.

• Tighten:
Torque - Oxygen Sensor: 44.1 N·m (4.50 kgf·m, 32.5 ft·lb)
• Run the oxygen sensor lead correctly (see Cable, Wire,
and Hose Routing section in the Appendix chapter).
Oxygen Sensor Inspection
• Refer to the Oxygen Sensor Inspection in the Fuel System
(DFI) chapter.
Fuel Reserve Switch Inspection
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
• Fill the fuel tank with fuel.
• Connectthethefueltesttank
Close cap surely.
• leads) and the 12 V battery
light [A] (12 V 3.4 W bulb in a socket with
[B] to the fuel pump connector.
Connections:
Battery (+) → 12 V 3.4 W Bulb (One Side)
12 V 3.4 W Bulb (Other Side) → BL Lead Terminal
Battery (–) → BK Lead Terminal
If the test light turn on, the reserve switch is defective.
Replace the fuel pump.

• Remove the fuel pump (see Fuel Pump Removal in the

Fuel System (DFI) chapter).
• Connect the test light (12 V 3.4 W bulb in a socket with
leads) and the 12 V battery to the fuel pump connector as
shown in the figure.
12 V Battery [A]
Test Light [B]
Fuel Pump Connector [C]
Fuel Reserve Switch [D]
If the test light doesn’t light, replace the fuel pump.
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 pump is removed. Leave the fuel reserve switch
with leads for inspection connected for few minutes.
16-66 ELECTRICAL SYSTEM
Relay Box
The relay box [A] has relays and diodes. The relays and
diodes can not be removed.

Relay Box Removal

CAUTION
Never drop the relay box especially on a hard sur-
face. Such a shock to the relay box can damage it.

• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Connectors [A] (Disconnect)
Relay Box [B]
Relay Circuit Inspection
• Remove the relay box (see Relay Box Removal).
• by connecting the hand
Check conductivity of the following numbered terminals
tester and one 12 V battery to the
relay box as shown in the figure (see Relay Box Internal
Circuit in this section).
If the tester does not read as specified, replace the relay
box.

Relay Circuit Inspection (with the battery disconnected)

Tester Connection Tester Reading (Ω)
Headlight Circuit
1-3 ∞
Relay
7-6 ∞
ECU Main Relay
4-5 Not ∞*
7-8 ∞
Fuel Pump Relay
9-10 Not ∞*
11-16 ∞
Starter Circuit Relay
11-12 ∞
17-20 ∞
Fan Relay
18-19 Not ∞*
*: The actual reading varies with the hand tester used.
 ELECTRICAL SYSTEM 16-67
Relay Box
Relay Circuit Inspection (with the battery connected)
Battery
Tester Tester
Connection
Connection Reading (Ω)
(+) (–)
2-11 1-3 0
ECU Main Relay
4-5 7-6 0
Fuel Pump Relay 9-10 7-8 0
Fan Relay 18-19 17-20 0

Battery Tester Connection

Tester
Connection DC 25 V Range
Reading (V)
(+) (–) (+) (–)
Starter Battery
16-12 11-12
Circuit Relay Voltage
(+): Apply positive lead.
(–): Apply negative lead.

Diode Circuit Inspection

• Remove the relay box (see Relay Box Removal).
• Check conductivity of the following pairs of terminals (see
Relay Box Internal Circuit in this section).
Diode Circuit Inspection
1-11, 2-11, 12-13, 12-15, 12-16, 13-14,
Tester Connection
13-15
The resistance should be low in one direction and more
than ten times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the relay box must be replaced.
NOTE
○The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking,
the lower reading should be from zero to one half the
scale.
16-68 ELECTRICAL SYSTEM
Relay Box
Relay Box Internal Circuit

A: Headlight Circuit Relay

B: ECU Main Relay
C: Fuel Pump Relay
D: Starter Circuit Relay
E: Fan Relay
 ELECTRICAL SYSTEM 16-69
Fuse
30 A Main Fuse Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
30 A Main Fuse Connector [A] (Disconnect)

• Pull out the main fuse [A] from the starter relay with a
needle nose pliers.

Fuse Box Fuse Removal

• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Unlock the hook [A] to lift up the lid [B].

• Pull the fuses [A] straight out of the fuse box with needle
nose pliers.

15 A ECU Fuse Removal

• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Unlock the hook [A] to lift up the lid [B].
16-70 ELECTRICAL SYSTEM
Fuse

• Pull out the ECU fuse [A] from the fuse box.

Fuse Installation
• Iftema fuse fails during operation, inspect the electrical sys-
to determine the cause, and then replace it with a
new fuse of proper amperage.
• Install the fuse box fuses on the original position as spec-
ified on the lid.
Fuse Inspection
• Remove the fuse (see 30 A Main/Fuse Box/15 A ECU
Fuse Removal).
• Inspect the fuse element.
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
CAUTION
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
 APPENDIX 17-1

Appendix
Table of Contents
Cable, Wire, and Hose Routing .............................................................................................. 17-2
Troubleshooting Guide ........................................................................................................... 17-32

17
17-2 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Headlight (High) Connector
2. Headlight (Low) Connector
3. Bands
4. Meter Lead Connectors
5. City Light Lead Connector
6. Horn Lead Connectors
7. Regulator/Rectifier Lead Connector
8. Oil Pressure Switch Lead Connector
9. Left Switch Housing Lead Connectors
10. Inlet Air Pressure Sensor Lead Connector
11. Stick Coil #1 Lead Connector
12. Front Left Turn Signal Light Lead Connector
13. Fuel Injector #1 Lead Connector
14. Subthrottle Valve Actuator Lead Connector
15. Neutral Switch Lead Connector
16. Sidestand Switch Lead Connector
17. Speed Sensor Lead Connector
18. Inlet Air Temperature Sensor Lead Connector
19. Fuel Pump Lead Connector
20. Starter Relay Lead Connector
21. Relay Box Lead Connectors
22. Turn Signal Relay Lead Connector
23. Clamp
24. Fuse Box
25. Clamp
26. Band
17-4 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-5
Cable, Wire, and Hose Routing
1. License Plate Light Lead Connector
2. Tail/Brake Light Lead Connector
3. ECU Lead Connectors
4. Rear Brake Light Switch Lead Connector
5. Rear Right Turn Signal Light Lead Connector
6. Rear Left Turn Signal Light Lead Connector
7. Kawasaki Diagnostic System Connector
8. Bands
9. Battery Negative Cable
10. Alternator Lead Connector
11. Crankshaft Sensor Lead Connector
12. Fuel Injector #2 Lead Connector
13. Front Right Turn Signal Light Lead Connector
14. Subthrottle Sensor Lead Connector
15. Main Throttle Sensor Lead Connector
16. Oxygen Sensor Lead Connector
17. Stick Coil #1 Lead Connector
18. Ignition Switch Lead Connector
19. Air Switching Valve Lead Connector
20. Frame Ground Terminal
21. Vehicle-down Sensor Lead Connector
22. Right Switch Housing Lead Connector
23. Resistor Lead Connector
17-6 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Right Switch Housing Lead
2. Guide (Run the left switch housing lead through into the guide.)
3. Guide (Run the right switch housing lead through into the guide.)
4. Clutch Cable
5. Left Switch Housing Lead
6. Guide (Run the clutch cable and left switch housing lead through into the guide.)
7. Guide (Run the throttle cables, right switch housing and ignition switch leads through into the
guide.)
8. Brake Hose
9. Throttle Cable (Accelerator)
10. Throttle Cable (Decelerator)
11. Ignition Switch Lead
12. Speedometer Cable
13. Guide (Run the speedometer cable through into the guide.)
14. Guide (Run the speedometer cable through into the guide.)
15. Guides (Run the main harness through into the guides.)
16. Regulator/Rectifier Lead Connector
17. Left Switch Housing Lead Connector
18. Guide (Run the throttle cables and inlet air pressure sensor lead through into the guide.)
19. Guides (Run the main harness through inside the guides.)
20. Inlet Air Pressure Sensor Lead Connector
21. Guide (Run the horn lead through into the guide.)
22. Horn Lead Connectors
23. Guide (Run the main harness through inside the guide.)
24. Band (Hold the main harness together with the frame pipe.)
25. Clamp (Hold the main harness and insert the clamp into the frame.)
17-8 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Speedometer Cable
2. Guide (Run the headlight (high) lead through into the guide.)
3. Headlight (High) Connector
4. Band (Hold the headlight (high) lead and insert the band into the upper fairing bracket.)
5. Guide (Run the meter unit harness and main harness through into the guide.)
6. Band (Hold the meter unit harness and main harness, and insert the band into the upper fairing
bracket.)
7. Starter Lockout Switch Lead
8. Meter Connectors
9. Left Switch Housing Lead
10. Headlight (Low) Connector
11. Fuel Tank Breather Hose
12. Guide (Run the fuel tank breather hose through into the guide.)
13. Guide (Run the fuel tank breather hose through into the guide.)
14. Guide (Run the fuel tank breather and reserve tank overflow hoses through into the guide.)
15. Guide (Run the fuel tank breather and reserve tank overflow hoses through into the guide.)
16. Run the fuel tank breather and reserve tank overflow hoses through the inside of the swingarm.
17. Reserve Tank Overflow Hose
18. Sidestand Switch Lead Connector
19. Clamp (Run the sidestand switch lead through the inside of the clamp.)
20. Sidestand Switch
17-10 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Ignition Switch Lead Connector
2. Vehicle-down Sensor Lead Connector
3. Throttle Cable (Accelerator)
4. Throttle Cable (Decelerator)
5. Guide (Run the throttle cables, right switch housing and ignition switch leads through into the
guide.)
6. Right Switch Housing Lead
7. Brake Hose
8. Clamp
9. Clutch Cable
10. Air Switching Valve Lead Connector
11. Band (Hold the main harness and insert the band into the frame.)
12. Resistor Lead Connector (Main Harness Side)
13. Right Switch Housing Lead Connector
14. Clamp (Hold the right switch housing and resistor leads, and insert the clamp into the frame.)
15. Resistor Lead Connector (Radiator Fan Side)
16. Water Temperature Sensor Lead Connector
17. Resistor
18. Bracket
17-12 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Subthrottle Sensor Lead Connector
2. Main Throttle Sensor Lead Connector
3. Front Right Turn Signal Light Lead Connector
4. Oxygen Sensor
5. Clutch Cable
6. Subthrottle Sensor
7. Main Throttle Sensor
8. Fuel Injector #2
9. Subthrottle Valve Actuator Lead Connector
10. Fuel Injector #1
11. Throttle Body Assy
12. Fuel Injector #2 Lead Connector
13. Fuel Injector #1 Lead Connector
17-14 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Stick Coil #1 Lead Connector
2. Front Left Turn Signal Light Lead Connector
3. Throttle Cable (Decelerator)
4. Throttle Cable (Accelerator)
5. Guide (Run the oil pressure switch lead through into the guide.)
6. Oil Pressure Switch Lead Connector
7. Stick Coil #2 Lead Connector
8. Inlet Air Temperature Sensor Lead Connector
9. To Fuel Tank
10. Fuel Pump Lead Connector
17-16 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Clamp (Hold the neutral switch and speed sensor leads.)
2. Speed Sensor Lead
3. Neutral Switch Lead Connector
4. Insert the speed sensor lead into the groove of the speed sensor mounting bracket.
5. Clutch Cable
6. Clamps (Hold the oxygen sensor lead.)
7. Oxygen Sensor Lead Connector
17-18 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Alternator Lead Connector
2. Crankshaft Sensor Lead Connector
3. Alternator Lead
4. Crankshaft Sensor Lead
5. Brackets
6. Clutch Cable
7. Run the clutch cable and reserve tank hose into the hole of the reserve tank.
8. Reserve Tank Overflow Hose
9. Reserve Tank Hose
10. Battery Negative Cable (Set the direction of the cable as shown in the figure.)
17-20 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-21
Cable, Wire, and Hose Routing
1. Starter Relay
2. Relay Box Lead Connectors
3. Clamp (Hold the main harness and insert the clamp into the frame.)
4. ECU Lead Connectors
5. Battery Positive Cable
6. Clamp (Hold the main harness and insert the clamp into the frame.)
7. Turn Signal Relay Lead Connector
8. Clamp (Hold the rear turn signal light and turn signal relay leads, and insert the clamp into the
rear fender.)
9. Rear Turn Signal Light Lead Connectors
10. Rear Brake Light Switch
11. Clamp (Hold the rear brake light switch lead.)
12. Rear Brake Light Switch Lead Connector
13. Battery Negative Cable
14. Starter Motor Cable
17-22 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-23
Cable, Wire, and Hose Routing
1. Tail/Brake Light Lead Connector
2. License Plate Light Lead Connector
3. Clamp (Hold the license plate light lead.)
4. Clamp (Hold the license plate light and tail/brake light leads.)
5. Rear Right Turn Signal Light Lead
6. Rear Left Turn Signal Light Lead
7. License Plate Light Lead
8. Clamp
9. Kawasaki Diagnostic System Connector
10. Self-diagnosis Terminal
17-24 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-25
Cable, Wire, and Hose Routing
1. Thermostat
2. Radiator Cap
3. Install the hose so that its white paint mark side faces the radiator.
4. Radiator
5. Clamp Screw
6. 45°
7. Cylinder Head
8. 45 ∼ 55°
9. Align the white paint mark on the hose with the projection mark on the fitting.
10. Install the hose so that its end covers the white paint mark on the pipe.
11. Cylinder
12. Install the hose so that its white paint mark side faces the pipe.
13. Align the white paint mark on the hose with the projection mark on the fitting.
14. Upper
15. Viewed A
16. Section B-B
17. Viewed C
18. Viewed D
17-26 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-27
Cable, Wire, and Hose Routing
1. Run the reserve tank overflow hose into the guides.
2. Reserve Tank Overflow Hose
3. Bracket
4. Run the clutch cable and reserve tank hose into the hole of the reserve tank.
5. Clutch Cable
6. Reserve Tank Hose
7. Radiator Cap
8. Reserve Tank
9. Clamps
10. Hose Curve Side
11. Run the only reserve tank overflow hose into the bracket guide.
17-28 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-29
Cable, Wire, and Hose Routing
1. Vehicle-down Sensor
2. Clamps
3. Air Switching Valve
4. Install the hose so that its white mark side faces the air switching valve.
5. Damper
6. Inlet Air Pressure Sensor
7. Vacuum Hose
8. Air Switching Valve Hose
9. Clamp
17-30 APPENDIX
Cable, Wire, and Hose Routing
 APPENDIX 17-31
Cable, Wire, and Hose Routing
1. Front Master Cylinder
2. Front Brake Hose
3. Bracket
4. Guide
5. Front Brake Caliper
6. Rear Brake Reservoir Tank
7. Rear Brake Caliper
8. Clamp
9. Rear Master Cylinder
17-32 APPENDIX
Troubleshooting Guide
NOTE Neutral, starter lockout, or sidestand switch
○Refer to the Fuel System chapter for most trouble
of DFI trouble shooting guide. Crankshaft sensor trouble
○This is not an exhaustive list, giving every Ignition switch or engine stop switch
possible cause for each problem listed. It shorted
is meant simply as a rough guide to assist Starter system wiring shorted or open
the troubleshooting for some of the more Main 30 A or ignition fuse blown
common difficulties. Fuel/air mixture incorrect:
Bypass screw and/or idle adjusting screw
Engine Doesn’t Start, Starting
maladjusted
Difficulty:
Air passage clogged
Starter motor not rotating:
Air cleaner clogged, poorly sealed, or miss-
Ignition and engine stop switch not ON
ing
Starter lockout switch or neutral switch trou-
Leak from oil filler cap, crankcase breather
ble
hose or air cleaner drain cap.
Starter motor trouble
Compression Low:
Battery voltage low
Spark plug loose
Starter relay not contacting or operating
Cylinder head not sufficiently tightened
Starter button not contacting
down
Starter system wiring shorted or open
Cylinder, piston worn
Ignition switch trouble
Piston ring bad (worn, weak, broken, or
Engine stop switch trouble
sticking)
Main 30 A or ignition fuse blown
Piston ring/groove clearance excessive
Starter motor rotating but engine doesn’t
Cylinder head gasket damaged
turn over:
Cylinder head warped
Vehicle-down sensor (DFI) coming off
Valve spring broken or weak
Starter clutch trouble
No valve clearance
Starter idle gear trouble
Valve not seating properly (valve bent,
Engine won’t turn over:
worn, or carbon accumulation on the
Valve seizure
seating surface)
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure Poor Running at Low Speed:
Connecting rod small end seizure Spark weak:
Connecting rod big end seizure Battery voltage low
Transmission gear or bearing seizure Stick coil trouble
Camshaft seizure Stick coil shorted or not in good contact
Starter idle gear seizure Spark plug dirty, broken, or maladjusted
No fuel flow: Spark plug incorrect
No fuel in tank ECU trouble
Fuel pump trouble Crankshaft sensor trouble
Fuel tank air vent obstructed Fuel/air mixture incorrect:
Fuel filter clogged Bypass screw maladjusted
Fuel line clogged Air passage clogged
No spark; spark weak: Air bleed pipe bleed holes clogged
Vehicle-down sensor (DFI) coming off Pilot passage clogged
Ignition switch not ON Air cleaner clogged, poorly sealed, or miss-
Engine stop switch turned OFF ing
Clutch lever not pulled in or gear not in neu- Fuel tank air vent obstructed
tral Fuel pump trouble
Battery voltage low Throttle body assy holder loose
Spark plug dirty, broken, or gap malad- Air cleaner duct loose
justed Compression low:
Spark plug incorrect Spark plug loose
Stick coil shorted or not in good contact Cylinder head not sufficiently tightened
Stick coil trouble down
ECU trouble No valve clearance
Cylinder, piston worn
 APPENDIX 17-33
Troubleshooting Guide
Piston ring bad (worn, weak, broken, or Piston ring/groove clearance excessive
sticking) Cylinder head gasket damaged
Piston ring/groove clearance excessive Cylinder head warped
Cylinder head gasket damaged Valve spring broken or weak
Cylinder head warped Valve not seating properly (valve bent,
Valve spring broken or weak worn, or carbon accumulation on the
Valve not seating properly (valve bent, seating surface)
worn, or carbon accumulation on the Knocking:
seating surface) Carbon built up in combustion chamber
Camshaft cam worn Fuel poor quality or incorrect
Run-on (dieseling): Spark plug incorrect
Ignition switch trouble ECU trouble
Engine stop switch trouble Miscellaneous:
Fuel injector trouble Throttle valve won’t fully open
Loosen terminal of battery (–) cable or ECU Brake dragging
ground lead Clutch slipping
Carbon accumulating on valve seating sur- Engine overheating
face Engine oil level too high
Engine overheating Engine oil viscosity too high
Other: Drive train trouble
ECU trouble Camshaft cam worn
Throttle body assy not synchronizing Air suction valve trouble
Engine oil viscosity too high Air switching valve trouble
Drive train trouble Catalytic converter melt down due to muffler
Brake dragging overheating (KLEEN)
Clutch slipping
Engine overheating Overheating:
Air suction valve trouble Firing incorrect:
Air switching valve trouble Spark plug dirty, broken, or maladjusted
Spark plug incorrect
Poor Running or No Power at High ECU trouble
Speed: Muffler overheating:
Firing incorrect: For KLEEN, do not run the engine even if
Spark plug dirty, broken, or maladjusted with only one cylinder misfiring or poor
Spark plug incorrect running (Request the nearest service fa-
Stick coil shorted or not in good contact cility to correct it)
trouble For KLEEN, do not push-start with a dead
Stick coil trouble battery (Connect another full-charged
ECU trouble battery with jumper cables, and start the
Fuel/air mixture incorrect: engine using the electric starter)
Air cleaner clogged, poorly sealed, or miss- For KLEEN, do not start the engine under
ing misfire due to spark plug fouling or poor
Air cleaner duct loose connection of the stick coil
Water or foreign matter in fuel For KLEEN, do not coast the motorcycle
Throttle body assy holder loose with the ignition switch off (Turn the igni-
Fuel to injector insufficient tion switch ON and run the engine)
Fuel tank air vent obstructed ECU trouble
Fuel line clogged Fuel/air mixture incorrect:
Fuel pump trouble Throttle body assy holder loose
Compression low: Air cleaner duct loose
Spark plug loose Air cleaner clogged, poorly sealed, or miss-
Cylinder head not sufficiently tightened ing
down Compression high:
No valve clearance Carbon built up in combustion chamber
Cylinder, piston worn Engine load faulty:
Piston ring bad (worn, weak, broken, or Clutch slipping
sticking) Engine oil level too high
17-34 APPENDIX
Troubleshooting Guide
Engine oil viscosity too high Gear Shifting Faulty:
Drive train trouble Doesn’t go into gear; shift pedal doesn’t
Brake dragging return:
Lubrication inadequate: Clutch not disengaging
Engine oil level too low Shift fork bent or seized
Engine oil poor quality or incorrect Gear stuck on the shaft
Gauge incorrect: Shift return spring weak or broken
Water temperature gauge broken Shift return spring pin loose
Water temperature sensor broken Shift mechanism arm broken
Coolant incorrect: Shift pawl broken
Coolant level too low Pawl spring broken
Coolant deteriorated Jumps out of gear:
Wrong coolant mixed ratio Shift fork ear worn, bent
Cooling system component incorrect: Gear groove worn
Radiator fin damaged Gear dogs and/or dog holes worn
Radiator clogged Shift drum groove worn
Thermostat trouble Shift fork guide pin worn
Radiator cap trouble Drive shaft, output shaft, and/or gear
Radiator fan relay trouble splines worn
Fan motor broken Overshifts:
Fan blade damaged Neutral positioning pin spring weak or bro-
Water pump not turning ken
Water pump impeller damaged Pawl spring broken

Over Cooling: Abnormal Engine Noise:

Gauge incorrect: Knocking:
Water temperature gauge broken ECU trouble
Water temperature sensor broken Carbon built up in combustion chamber
Cooling system component incorrect: Fuel poor quality or incorrect
Thermostat trouble Spark plug incorrect
Overheating
Clutch Operation Faulty: Piston slap:
Clutch slipping: Cylinder/piston clearance excessive
Friction plate worn or warped Cylinder, piston worn
Steel plate worn or warped Connecting rod bent
Clutch spring broken or weak Piston pin, piston pin hole worn
Clutch hub or housing unevenly worn Valve noise:
No clutch lever play Valve clearance incorrect
Clutch inner cable trouble Valve spring broken or weak
Clutch release mechanism trouble Camshaft bearing worn
Clutch not disengaging properly: Valve lifter worn
Clutch plate warped or too rough Other noise:
Clutch spring compression uneven Connecting rod small end clearance exces-
Engine oil deteriorated sive
Engine oil viscosity too high Connecting rod big end clearance exces-
Engine oil level too high sive
Clutch housing frozen on drive shaft Piston ring/groove clearance excessive
Clutch hub nut loose Piston ring worn, broken, or stuck
Clutch hub spline damaged Piston ring groove worn
Clutch friction plate installed wrong Piston seizure, damage
Clutch lever play excessive Cylinder head gasket leaking
Clutch release mechanism trouble Exhaust pipe leaking at cylinder head con-
nection
Crankshaft runout excessive
Engine mount loose
Crankshaft bearing worn
Primary gear worn or chipped
 APPENDIX 17-35
Troubleshooting Guide
Camshaft chain tensioner trouble Exhaust Smokes Excessively:
Camshaft chain, sprocket, guide worn White smoke:
Air suction valve damaged Piston oil ring worn
Air switching valve damaged Cylinder worn
Alternator rotor loose Valve oil seal damaged
Catalytic converter melt down due to muffler Valve guide worn
overheating (KLEEN) Engine oil level too high
Black smoke:
Abnormal Drive Train Noise: Air cleaner clogged
Clutch noise: Brown smoke:
Clutch damper weak or damaged Air cleaner duct loose
Clutch housing/friction plate clearance ex- Air cleaner poorly sealed or missing
cessive
Clutch housing gear worn Handling and/or Stability
Transmission noise: Unsatisfactory:
Bearings worn Handlebar hard to turn:
Transmission gear worn or chipped Cable routing incorrect
Metal chips jammed in gear teeth Hose routing incorrect
Engine oil insufficient Wiring routing incorrect
Drive line noise: Steering stem nut too tight
Drive chain adjusted improperly Steering stem bearing damaged
Drive chain worn Steering stem bearing lubrication inade-
Rear and/or engine sprocket worn quate
Chain lubrication insufficient Steering stem bent
Rear wheel misaligned Tire air pressure too low
Handlebar shakes or excessively vibrates:
Abnormal Frame Noise: Tire worn
Front fork noise: Swingarm pivot bearing worn
Oil insufficient or too thin Rim warped, or not balanced
Spring weak or broken Wheel bearing worn
Rear shock absorber noise: Handlebar mounting bolt loose
Shock absorber damaged Steering stem nut loose
Disc brake noise: Front, rear axle runout excessive
Pad installed incorrectly Engine mounting nut loose
Pad surface glazed Handlebar pulls to one side:
Disc warped Frame bent
Caliper trouble Wheel misalignment
Other noise: Swingarm bent or twisted
Bracket, nut, bolt, etc. not properly Swingarm pivot shaft runout excessive
mounted or tightened Steering maladjusted
Front fork bent
Oil Pressure Warning Indicator Light Right and left front fork oil level uneven
Goes On: Shock absorption unsatisfactory:
Engine oil pump damaged (Too hard)
Engine oil screen clogged Front fork oil excessive
Engine oil filter clogged Front fork oil viscosity too high
Engine oil level too low Rear shock absorber adjustment too hard
Engine oil viscosity too low Tire air pressure too high
Camshaft bearing worn Front fork bent
Crankshaft bearing worn (Too soft)
Oil pressure switch damaged Tire air pressure too low
Wiring faulty Front fork oil insufficient and/or leaking
Relief valve stuck open Front fork oil viscosity too low
O-ring at the oil passage in the crankcase Rear shock adjustment too soft
damaged Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
17-36 APPENDIX
Troubleshooting Guide
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
cylinder
Master cylinder scratched inside

Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery cable making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty
 MODEL APPLICATION
Year Model Beginning Frame No.
2008 EX250K8F JKAEX250KKDA00052

□:This digit in the frame number changes from one machine to another.

Part No.99924-1399-01 Printed in Japan