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NHTSA ID Number: 10109087
Manufacturer Communication Number: 99924-1519-01_ZX
Summary
Service Manual
Kawasaki
Z1000SX Ninja 1000
Motorcycle Service Manual
First Edition (0) : Sep. 30, 2016
Quick Reference Guide
General Information – 1
Periodic Maintenance – 2
Fuel System (DFI) – 3
Cooling System – 4
Engine Top End – 5
Clutch – 6
Engine Lubrication System – 7
Engine Removal/Installation – 8
Crankshaft/Transmission – 9
Wheels/Tires – 10
Final Drive – 11
Brakes – 12
Suspension – 13
Steering – 14
Frame – 15
Electrical System – 16
Appendix – 17
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| KAWASAKI | ZX1000 | 2017 |
1 Associated Document
Manufacturer Communications
Z1000SX
Ninja 1000
First Edition (0) : Sep. 30, 2016
99924-1519-01_ZX
MC-10109087-9999.pdf 14025.563KB
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- Formulated with Trizone technology to protect all 3 critical zones: engine, clutch and gearbox
- Race derived technology for maximum engine acceleration
- Extreme high temperature air-cooled performance and water-cooled engine performance
- Excellent shear stability to prevent viscosity breakdown
- Exceeds API SL and JASO MA-2
- 100% Synthetic Ester
- Formulated To Meet The Latest Manufacturers' Specifications
- Improved High Temperature Deposit Protection And Sludge Control
- Ensures Optimum Clutch Performance At Start-Up, Acceleration, And Full Speed
- Standards: Ape Sn, Jasso Ma2
- Optimal lubrication in all operating conditions, ensures low oil consumption
- Very high shear and ageing stability, highest levels of wear protection
- Tested and approved for catalytic converters, optimal engine cleanliness
- Ideally suited for wet clutches
- Specifications and Approvals: API, SM, ACEA A3-04, JASO, MA2
- Full synthetic 5W-40 diesel engine oil with Triple Protection Plus technology protects against wear, deposits, and oil breakdown
- Improved wear performance with significantly increased level of protection against harmful engine wear (compared to previous generation API CJ-4 engine oils)
- Enhanced fuel economy capability of 1.5% without compromising engine protection or durability (compared to 15W-40 oils)
- Multi-functional dispersant additives provide an enhanced level of protection against the effects of soot, dirt, and other contaminants
- Resists breakdown by heat to provide continuous protection throughout the service interval, and also provides improved low-temperature flow compared to conventional 15W-40 oils
- The information below is per-pack only
- ADVANCED PROTECTION IN EUROPEAN VEHICLES agains the four main causes of engine breakdown: wear friction heat and deposits
- EXTRA WEAR PROTECTION vs. industry and OEM standards with advanced anti-wear additives
- SUPERIOR PERFORMANCE FOR EUROPEAN gasoline and diesel engines
- EXCEPTIONAL HIGH/LOW TEMPERATURE PROTECTION defends your engine no matter the climate or driving conditions
- 100% Synthetic Double Ester
- Designed for highly modified engines
- Electrochemical bonding to metal parts
- Up to 5x higher film strength
- 0% shear loss on Bosch ASTM D6278 test
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Z1000SX Ninja 1000 This quick reference guide will assist you in locating a desired topic or procedure. โขBend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. โขRefer to the sectional table of contents for the exact pages to locate the specific topic required. 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 Appendix 17 j Z1000SX Ninja 1000 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. ยฉ 2016 Kawasaki Heavy Industries, Ltd. First Edition (0) : Sep. 30, 2016 LIST OF ABBREVIATIONS A ampere(s) in. inch(es) ABDC after bottom dead center KIBS Kawasaki intelligent anti-lock brake system ABS anti-lock brake system km/h kilometers per hour AC alternating current KTRC Kawasaki traction control Ah ampere hour L liter(s) ATDC after top dead center LCD liquid crystal display BBDC before bottom dead center LED light emitting diode BDC bottom dead center lb pound(s) BTDC before top dead center m meter(s) ยฐC degree(s) Celsius min minute(s) CAN controller area network mmHg millimeters of mercury cmHg centimeters of mercury mph miles per hour CPU central processing unit N newton(s) cu in. cubic inch(es) oz ounce(s) DC direct current Pa pascal(s) DFI digital fuel injection PS horsepower(s) DOHC double overhead camshaft psi pound(s) per square inch DOT department of transportation qt quart(s) ECU electronic control unit r revolution F farad(s) rpm revolution(s) per minute ยฐF degree(s) Fahrenheit s second(s) ft foot, feet TDC top dead center g gram(s) TIR total indicator reading gal gallon(s) V volt(s) h hour(s) W watt(s) HP horsepower(s) โฆ ohm(s) IC integrated circuit COUNTRY AND AREA CODES AT Austria AU Australia CA Canada CAL California CH Switzerland DE Germany EUR Europe GB United Kingdom IN India MY Malaysia PH Philippines SEA-B1 Southeast Asia B1 SEA-B3 Southeast Asia B3 TH Thailand US United States WVTA (FULL) WVTA Model (Full Power) GB WVTA (FULL) GB WVTA Model (Full Power) EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Actโs โtampering provisionsโ. โSec. 203(a) The following acts and the causing thereof are prohibited. (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser.โ NOTE โThe phrase โremove or render inoperative any device or element of designโ has been generally interpreted as follows. 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include. a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below. โข Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. โข Removal of the muffler(s) or any internal portion of the muffler(s). โข Removal of the air box or air box cover. โข Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle. โข Follow the Periodic Maintenance Chart in the Service Manual. โข Be alert for problems and non-scheduled maintenance. โข Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. โข Follow the procedures in this manual carefully. Donโt take shortcuts. โข Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manualโs chapters. The Quick Reference Guide shows you all of the productโs system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want stick coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Stick Coil section. Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury. This manual contains four more symbols which will help you distinguish different types of information. NOTE โNOTE indicates information that may help or guide you in the operation or service of the vehicle. โขIndicates a procedural step or work to be done. โIndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. GENERAL INFORMATION 1-1 1 General Information Table of Contents 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 operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following. Battery Ground Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (โ) 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 (โ) cable to the negative terminal. Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high flash-point solvent when cleaning parts. High flash-point solvent should be used according to directions of the solvent manufacturer. Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle. GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit. Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given. 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. All of the tightening torque values are for use with dry, solvent – cleaned threads unless otherwise indicated. If a fastener which should have dry, clean threads gets contaminated with lubricant, etc., applying even the specified torque could damage it. Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling. Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage. GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage. Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Apply specified grease to the lip of seal before installing the seal. Circlips, Cotter Pins Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation. 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color. Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufactureโs instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments. Handling Electronic Parts Severe impacts to electronic parts such as the ECU, sensor, and relay can damage them. If dropped on a hard surface, replace such parts with new ones. If a high voltage that is created by static electricity is applied to the electric parts, it could cause them to fail. To avoid this, touch a non-painted metal surface to discharge any static electricity that is accumulated on your body before inspecting or replacing electric parts. Be careful not to touch the electrical terminals of the electronic parts. The static electricity discharged from your body could damage them or deform the electrical terminals. GENERAL INFORMATION 1-7 Model Identification ZX1000WH Left Side View ZX1000WH Right Side View Frame Number Engine Number 1-8 GENERAL INFORMATION General Specifications Items ZX1000WH Dimensions Overall Length 2 100 mm (82.68 in.) Overall Width 790 mm (31.10 in.) Overall Height/High Position 1 185 mm (46.65 in.)/1235 mm (48.62 in.) Wheelbase 1 440 mm (56.69 in.) Road Clearance 130 mm (5.12 in.) Seat Height 815 mm (32.1 in.) Curb Mass: 235 kg (518 lb) (US, CA) 234 kg (516 lb) (IN: with Saree Guard equipped model) 239 kg (527 lb) Front 121 kg (267 lb) (US, CA) 120 kg (265 lb) Rear 114 kg (251 lb) (IN: with Saree Guard equipped model) 118 kg (260 lb) Fuel Tank Capacity 19 L (5.0 US gal) Performance Minimum Turning Radius 3.1 m (10.2 ft) Engine Type 4-stroke, DOHC, 4-cylinder Cooling System Liquid-cooled Bore and Stroke 77.0 ร 56.0 mm (3.03 ร 2.20 in.) Displacement 1 043 cmยณ (63.6 cu in.) Compression Ratio 11.8:1 Maximum Horsepower 104.5 kW (142 PS) @10 000 r/min (rpm) (SEA-B1,TH) 100.9 kW (137 PS) @9 800 r/min (rpm) (AU) 105 kW (143 PS) @10 000 r/min (rpm) (US, CA, CAL) — Maximum Torque 111.0 Nยทm (11.3 kgfยทm, 82 ftยทlb) @7 300 r/min (rpm) (SEA-B1,TH) 109.0 Nยทm (11.1 kgfยทm, 80 ftยทlb) @7 300 r/min (rpm) (AU) 111 Nยทm (11.3 kgfยทm, 82 ftยทlb) @7 300 r/min (rpm) (US, CA, CAL) — Fuel System FI (Fuel injection), KEIHIN TTK 38 ร 4 Fuel Type: Minimum Octane Rating: Research Octane number (RON) 95 Antiknock Index (RON + MON)/2 90 Starting System Electric Starter Ignition System Battery and coil (transistorized) Timing Advance Electronically advanced (IC igniter in ECU) Ignition Timing 10ยฐ BTDC @1 100 r/min (rpm) ๏พ 40.2ยฐ BTDC @5 200 r/min (rpm) Spark Plug NGK CR9EIA-9 Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 GENERAL INFORMATION 1-9 General Specifications Items ZX1000WH Valve Timing: Intake: Open 25ยฐ (BTDC) Close 65ยฐ (ABDC) Duration 270ยฐ Exhaust: Open 58ยฐ (BBDC) Close 18ยฐ (ATDC) Duration 256ยฐ Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 4.0 L (4.2 US qt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 1.627 (83/51) Clutch Type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 1st 2.600 (39/15) 2nd 1.950 (39/20) 3rd 1.600 (24/15) 4th 1.389 (25/18) 5th 1.238 (26/21) 6th 1.107 (31/28) Final Drive System: Type Chain drive Reduction Ratio 2.733 (41/15) Overall Drive Ratio 4.925 at Top gear Frame Type Tubular, diamond Caster (Rake Angle) 24.5ยฐ Trail 102 mm (4.02 in.) Front Tire: Type Tubeless Size 120/70 ZR17 M/C (58W) Rim Size J17M/C ร MT3.50 Rear Tire: Type Tubeless Size 190/50 ZR17M/C (73W) Rim Size J17M/C ร MT6.00 1-10 GENERAL INFORMATION General Specifications Items ZX1000WH Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm Wheel Travel 144 mm (5.67 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 Ah (10 HR) Headlight: Type Semi-sealed beam High Beam LED Low Beam LED Brake/Tail Light LED Alternator: Type Three-phase AC Maximum Output 14 V – 24.3 A @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: Prefix Symbol Power mega M ร 1 000 000 kilo k ร 1 000 centi c ร 0.01 milli m ร 0.001 micro ฮผ ร 0.000001 Units of Mass: kg ร 2.205 = lb g ร 0.03527 = oz Units of Volume: L ร 0.2642 = gal (US) L ร 0.2200 = gal (IMP) L ร 1.057 = qt (US) L ร 0.8799 = qt (IMP) L ร 2.113 = pint (US) L ร 1.816 = pint (IMP) mL ร 0.03381 = oz (US) mL ร 0.02816 = oz (IMP) mL ร 0.06102 = cu in. Units of Force: N ร 0.1020 = kg N ร 0.2248 = lb kg ร 9.807 = N kg ร 2.205 = lb Units of Length: km ร 0.6214 = mile m ร 3.281 = ft mm ร 0.03937 = in. Units of Torque: Nยทm ร 0.1020 = kgfยทm Nยทm ร 0.7376 = ftยทlb Nยทm ร 8.851 = inยทlb kgfยทm ร 9.807 = Nยทm kgfยทm ร 7.233 = ftยทlb kgfยทm ร 86.80 = inยทlb Units of Pressure: kPa ร 0.01020 = kgf/cmยฒ kPa ร 0.1450 = psi kPa ร 0.7501 = cmHg kgf/cmยฒ ร 98.07 = kPa kgf/cmยฒ ร 14.22 = psi cmHg ร 1.333 = kPa Units of Speed: km/h ร 0.6214 = mph Units of Power: kW ร 1.360 = PS kW ร 1.341 = HP PS ร 0.7355 = kW PS ร 0.9863 = HP Units of Temperature: PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart . 2-3 Torque and Locking Agent 2-5 Specifications . 2-12 Special Tools 2-14 Periodic Maintenance Procedures 2-15 Fuel System (DFI) 2-15 Air Cleaner Element Replacement 2-15 Idle Speed Inspection . 2-16 Idle Speed Adjustment 2-16 Throttle Control System Inspection. 2-16 Engine Vacuum Synchronization Inspection. 2-17 Fuel System Inspection. 2-20 Fuel Filter Replacement 2-21 Fuel Hose Replacement . 2-23 Evaporative Emission Control System Inspection (Other than US and CA Models) 2-24 Cooling System 2-25 Coolant Level Inspection. 2-25 Cooling System Inspection . 2-26 Coolant Change 2-26 Water Hose and O-ring Replacement. 2-29 Engine Top End . 2-30 Valve Clearance Inspection 2-30 Valve Clearance Adjustment. 2-31 Air Suction System Damage Inspection 2-35 Clutch. 2-36 Clutch Operation Inspection . 2-36 Engine Lubrication System 2-37 Engine Oil Change 2-37 Oil Filter Replacement 2-38 Wheels/Tires 2-38 Air Pressure Inspection. 2-38 Wheels and Tires Inspection. 2-38 Wheel Bearing Damage Inspection 2-39 Final Drive 2-40 Drive Chain Lubrication Condition Inspection. 2-40 Drive Chain Slack Inspection 2-41 Drive Chain Slack Adjustment 2-41 Wheel Alignment Inspection . 2-41 Wheel Alignment Adjustment 2-41 Drive Chain Wear Inspection 2-42 Chain Guide Wear Inspection . 2-42 Brakes 2-43 Brake System Inspection 2-43 Brake Operation Inspection 2-44 Brake Fluid Level Inspection. 2-44 Brake Fluid Change 2-45 Brake Hose and Pipe Replacement 2-46 Master Cylinder Rubber Parts Replacement 2-50 Caliper Rubber Parts Replacement 2-51 Brake Pad Wear Inspection 2-54 2-2 PERIODIC MAINTENANCE Brake Light Switch Operation Inspection 2-55 Suspension 2-56 Suspension System Inspection. 2-56 Steering . 2-57 Steering Play Inspection . 2-57 Steering Play Adjustment 2-57 Steering Stem Bearing Lubrication . 2-59 Electrical System . 2-60 Lights and Switches Operation Inspection 2-60 Headlight Aiming Inspection . 2-62 Side Stand Switch Operation Inspection. 2-63 Engine Stop Switch Operation Inspection. 2-64 Spark Plug Replacement 2-65 Others 2-65 Chassis Parts Lubrication 2-65 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-66 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first. *B: For higher odometer readings, repeat at the frequency interval established here. *C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping. *D: Other than US and CA Models โ: Emission Related Item : Inspection : Change or Replace : Lubrication Odometer Reading (*B) ร 1 000 km (ร 1 000 mile) Items year (*A) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) See Page Fuel System โ Air cleaner element (*C) 2-15 โ Idle speed 2-16 โ Throttle control system (play, smooth return, no drag) :1 2-16 โ Engine vacuum synchronization 2-17 Fuel system :1 2-20 Fuel filter 2-21 Fuel hose :5 2-23 โ Evaporative emission control system (*D) 2-24 Cooling System Coolant level 2-25 Cooling system :1 2-26 Coolant, water hose and O-ring :3 : every 36 000 km (22 500 mile) 2-26, 2-29 Engine Top End โ Valve clearance (US and CA Models) 2-30 Valve clearance (Other than US and CA Models) : every 42 000 km (26 250 mile) 2-30 โ Air suction system 2-35 Clutch Clutch operation (play, engagement, disengagement) 2-36 Engine Lubrication System Engine oil (*C) and oil filter :1 2-37, 2-38 Wheels and Tires Tire air pressure :1 2-38 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) ร 1 000 km (ร 1 000 mile) Items year (*A) 1 (0.6) 6 (3.8) 12 (7.6) 18 (11.4) 24 (15.2) See Page Wheel and tire :1 2-38 Wheel bearing damage :1 2-39 Final Drive Drive chain lubrication condition (*C) : every 600 km (400 mile) 2-40 Drive chain slack (*C) : every 1 000 km (600 mile) 2-41 Drive chain wear (*C) 2-42 Drive chain guide wear 2-42 Brakes Brake system :1 2-43 Brake operation (effectiveness, play, no drag) :1 2-44 Brake fluid level :1 2-44 Brake fluid (front and rear) :2 2-45 Brake hose :4 2-46 Rubber parts of brake master cylinder and caliper :4 : every 48 000 km (30 000 mile) 2-50, 2-51 Brake pad wear (*C) 2-54 Brake light switch operation 2-55 Suspension Suspension system :1 2-56 Steering Steering play :1 2-57 Steering stem bearing :2 2-59 Electrical System Electrical system :1 2-60 โ Spark plug 2-65 Others Chassis parts :1 2-65 Condition of bolts, nuts and fasteners 2-66 PERIODIC MAINTENANCE 2-5 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. All of the values are for use with dry solvent – cleaned threads unless otherwise indicated. Letters used in the โRemarksโ column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. Si: Apply silicone grease. 2T: Apply 2-stroke oil. Torque Fastener Nยทm kgfยทm ftยทlb Remarks Fuel System (DFI) Air Cleaner Housing Assembly Screws 1.1 0.11 10 inยทlb Throttle Body Assy Holder Clamp Bolts 3.0 0.31 27 inยทlb Delivery Pipe Assy Mounting Screws 3.43 0.350 30 inยทlb Air Cleaner Housing Plate Screws 1.1 0.11 10 inยทlb Throttle Case Bolts 3.5 0.36 31 inยทlb Air Cleaner Housing Clamp Bolts 2.0 0.20 18 inยทlb S Oxygen Sensor 45 4.6 33 Water Temperature Sensor 12 1.2 106 inยทlb Vehicle-down Sensor Mounting Bolts 6.0 0.61 53 inยทlb Intake Air Temperature Sensor Screw 1.2 0.12 11 inยทlb Crankshaft Sensor Bolts 6.0 0.61 53 inยทlb Fuel Pump Assembly Screws 0.98 0.10 8.7 inยทlb R Fuel Pump Bolts 10 1.0 89 inยทlb L, S IMU Mounting Bolts 6.5 0.66 58 inยทlb L Cooling System Water Hose Clamp Screws 3.0 0.31 27 inยทlb Fitting Bolt 9.0 0.92 80 inยทlb L Thermostat Housing Bolts 6.0 0.61 53 inยทlb L Heat Insulation Plate Bolts 7.0 0.71 62 inยทlb Oil Cooler Bolts 12 1.2 106 inยทlb L Water Pipe Bolts 12 1.2 106 inยทlb L Water Pump Impeller Bolt 10 1.0 89 inยทlb Water Pump Cover Bolts 11 1.1 97 inยทlb Coolant Drain Bolt 11 1.1 97 inยทlb Engine Top End Air Suction Valve Cover Bolts 10 1.0 89 inยทlb L Spark Plugs 13 1.3 115 inยทlb Cylinder Head Cover Bolts 10 1.0 89 inยทlb S Camshaft Cap Bolts 12 1.2 106 inยทlb S 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nยทm kgfยทm ftยทlb Remarks Upper Camshaft Chain Guide Bolts 12 1.2 106 inยทlb S Cylinder Head Bolts (M10) (First) 30 3.1 22 MO, S Cylinder Head Bolts (M10) (Final) 54 5.5 40 MO, S Cylinder Head Jacket Plugs 19.6 2.00 14.5 L Cylinder Head Bolts (M6) 12 1.2 106 inยทlb S Throttle Body Assy Holder Bolts 12 1.2 106 inยทlb L Throttle Body Assy Holder Clamp Bolts 3.0 0.31 27 inยทlb Camshaft Chain Tensioner Cap Bolt 20 2.0 15 Camshaft Chain Tensioner Mounting Bolts 11 1.1 97 inยทlb Camshaft Sprocket Bolts 15 1.5 11 L Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18 Rear Camshaft Chain Guide Bolt 25 2.5 18 Front Camshaft Chain Guide Bolt (Lower) 12 1.2 106 inยทlb Muffler Body Mounting Bolts 35 3.6 26 Exhaust Pipe Holder Nuts 20 2.0 15 Oxygen Sensor 45 4.6 33 Premuffler Chamber Mounting Bolt 35 3.6 26 Muffler Body Clamp Bolts 21 2.1 15 Premuffler Chamber Cover Bolts 10 1.0 89 inยทlb Clutch Clutch Lever Clamp Bolts 7.8 0.80 69 inยทlb S Clutch Spring Bolts 10 1.0 89 inยทlb Clutch Hub Nut 135 13.8 100 R Clutch Cover Bolts 12 1.2 106 inยทlb S Oil Filler Plug Hand-tighten โ โ Engine Lubrication System Oil Cooler Bolts 12 1.2 106 inยทlb L Oil Filler Plug Hand-tighten – – Oil Passage Plugs 20 2.0 15 L Oil Passage Plug 10 1.0 89 inยทlb Oil Pressure Switch 15 1.5 11 L Oil Pressure Switch Terminal Bolt 2.0 0.20 18 inยทlb G Oil Pressure Relief Valve 15 1.5 11 L Oil Filter 17 1.7 13 G, R Oil Filter Pipe 25 2.5 18 L Engine Oil Drain Bolt 29 3.0 21 Oil Pan Bolts 12 1.2 106 inยทlb S Engine Removal/Installation Upper Engine Bracket Bolts 45 4.6 33 S Lower Engine Bracket Bolts 60 6.1 44 S Upper Adjusting Collar 5.0 0.51 44 inยทlb 2T, S Upper Adjusting Collar Locknut 50 5.1 37 S Upper Engine Mounting Bolt (L = 65 mm) 45 4.6 33 S PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Nยทm kgfยทm ftยทlb Remarks Lower Engine Mounting Nut 45 4.6 33 S Lower Adjusting Collar Locknut 50 5.1 37 S Middle Engine Mounting Nut 45 4.6 33 S Middle Engine Bracket Bolts 25 2.5 18 L, S Lower Adjusting Collar 10 1.0 89 inยทlb S Upper Engine Mounting Bolt (L = 40 mm) 45 4.6 33 S Crankshaft/Transmission Balancer Shaft Clamp Bolt 10 1.0 89 inยทlb Balancer Shaft Clamp Lever Bolt 25 2.5 18 L Connecting Rod Big End Nuts see the text โ โ MO Breather Side Plate Bolt 6.0 0.61 53 inยทlb L Breather Plate Bolts 10 1.0 89 inยทlb L Starter Motor Clutch Bolts 12 1.2 106 inยทlb L Oil Passage Plugs 20 2.0 15 L Oil Passage Plug 10 1.0 89 inยทlb Crankcase Bolts (M6) 12 1.2 106 inยทlb S Crankcase Bolts (M7) 20 2.0 15 S Crankcase Bolts (M8) 27 2.8 20 S Crankcase Bolts (M9) 44 4.5 32 MO, S Gear Positioning Lever Bolt 12 1.2 106 inยทlb Shift Drum Bearing Holder Bolts 12 1.2 106 inยทlb L Shift Drum Cam Holder Bolt 12 1.2 106 inยทlb L Shift Shaft Return Spring Pin 39 4.0 29 L Shift Pedal Mounting Bolt 25 2.5 18 G Shift Lever Clamp Bolt 10 1.0 89 inยทlb L Gear Position Sensor Bolt 10 1.0 89 inยทlb L Wheels/Tires Front Axle Clamp Bolts 20 2.0 15 AL Front Axle 110 11.2 81.1 G Rear Axle Nut 100 10.2 73.8 Final Drive Chain Guide Bolts 10 1.0 89 inยทlb L Engine Sprocket Outer Cover Screws 0.70 0.07 6.2 inยทlb Engine Sprocket Nut 147 15.0 108 MO Rear Sprocket Nuts 60 6.1 44 R, S Mud Guard Bolts 4.0 0.41 35 inยทlb L Chain Cover Bolts 4.0 0.41 35 inยทlb L Chain Adjuster Clamp Bolts 65 6.6 48 Chain Guide Mounting Bolt 4.0 0.41 35 inยทlb Brakes Front Brake Reservoir Bracket Bolt 8.8 0.90 78 inยทlb Front Brake Reservoir Cap Stopper Screw 1.5 0.15 13 inยทlb Brake Lever Pivot Bolt 1.0 0.10 8.9 inยทlb Si 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nยทm kgfยทm ftยทlb Remarks Front Master Cylinder Bleed Valve 5.4 0.55 48 inยทlb Front Master Cylinder Clamp Bolts 11 1.1 97 inยทlb S Brake Lever Pivot Bolt Locknut 5.9 0.60 52 inยทlb Front Brake Light Switch Screw 1.2 0.12 11 inยทlb Front Wheel Rotation Sensor Bolt 25 2.5 18 Brake Hose Banjo Bolts 25 2.5 18 Brake Pipe Joint Nuts 18 1.8 13 Bleed Valves 8.0 0.82 71 inยทlb Front Brake Pad Pins 15 1.5 11 Front Caliper Mounting Bolts 35 3.6 26 Front Brake Disc Mounting Bolts 28 2.9 21 L, S Mud Guard Bolt 4.0 0.41 35 inยทlb L Rear Master Cylinder Mounting Bolts 25 2.5 18 Rear Brake Reservoir Cap Stopper Screw 1.5 0.15 13 inยทlb Brake Pedal Bolt 9.0 0.92 80 inยทlb L Rear Master Cylinder Push Rod Locknut 17 1.7 13 Rear Brake Disc Mounting Bolts 28 2.9 21 L, S Rear Wheel Rotation Sensor Bolt 25 2.5 18 Rear Caliper Mounting Bolts 25 2.5 18 Suspension Upper Front Fork Clamp Bolts 20 2.0 15 Lower Front Fork Clamp Bolts 25 2.5 18 AL Front Fork Top Plugs 34 3.5 25 Piston Rod Nuts 20 2.0 15 Front Axle Clamp Bolts 20 2.0 15 AL Right Front Fork Bottom Allen Bolt 35 3.6 26 Left Front Fork Bottom Allen Bolt 20 2.0 15 Upper Rear Shock Absorber Bolt 35 3.6 26 Swingarm Pivot Shaft Nut 110 11.2 81.1 Swingarm Pivot Shaft 20 2.0 15 Swingarm Pivot Adjusting Collar Locknut 100 10.2 73.8 Tie-rod Nuts 35 3.6 26 R Lower Rear Shock Absorber Nut 35 3.6 26 R Rocker Arm Nut 35 3.6 26 R Torque Link Nuts 35 3.6 26 Steering Right Switch Housing Screws 3.5 0.36 31 inยทlb Throttle Case Bolts 3.5 0.36 31 inยทlb Handlebar Holder Positioning Bolts 10 1.0 89 inยทlb L Handlebar Holder Clamp Bolts 25 2.5 18 Handlebar Bolts 35 3.6 26 L Upper Front Fork Clamp Bolts 20 2.0 15 Steering Stem Head Bolt 110 11.2 81.1 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Nยทm kgfยทm ftยทlb Remarks Left Switch Housing Screws 3.5 0.36 31 inยทlb Steering Stem Nut 30 3.1 22 Lower Front Fork Clamp Bolts 25 2.5 18 AL Frame Windshield Bracket Cover Bolts 0.50 0.05 4.4 inยทlb Lower Fairing Bolts (Front) 0.50 0.05 4.4 inยทlb Meter Cover Bolt (L = 16 mm) 3.0 0.31 27 inยทlb Meter Cover Bolts (L = 20 mm) 0.50 0.05 4.4 inยทlb Socket Cover Screw 1.2 0.12 11 inยทlb Windshield Bolts 0.40 0.04 3.5 inยทlb Stay Assembly Mounting Bolts 6.9 0.70 61 inยทlb Stopper Mounting Bolts 4.2 0.43 37 inยทlb Upper Fairing Bolts 0.50 0.05 4.4 inยทlb Windshield Bracket Assembly Mounting Bolts 25 2.5 18 Front Fender Mounting Bolts 4.0 0.41 35 inยทlb Left Lower Side Fairing Mounting Bolts 3.0 0.31 27 inยทlb Middle Fairing Bolt 0.50 0.05 4.4 inยทlb Lower Fairing Bolts (Rear) 3.0 0.31 27 inยทlb Lower Fairing Assembly Screws 1.2 0.12 11 inยทlb Side Cover Bolts (Front) 0.50 0.05 4.4 inยทlb Side Cover Bolts (Rear) 3.0 0.31 27 inยทlb Rear Frame Bracket Bolts 45 4.6 33 Front Footpeg Bracket Bolts 25 2.5 18 Front Footpeg Sub Bracket Bolts 25 2.5 18 Step Mounting Screws 3.0 0.31 27 inยทlb L Side Stand Switch Bolt 9.0 0.92 80 inยทlb L Side Stand Bracket Bolts 50 5.1 37 L Side Stand Bolt 30 3.1 22 S Side Stand Nut 45 4.6 33 R, S Rear Footpeg Bracket Bolts 25 2.5 18 Rear Frame Bolts 25 2.5 18 L Seat Cover Bolts 0.50 0.05 4.4 inยทlb Battery Case Bolts (Front) 4.0 0.41 35 inยทlb Battery Case Bolts (Rear) 1.0 0.10 8.9 inยทlb Connector Bracket Screw 1.2 0.12 11 inยทlb Grab Rail Mounting Bolts (L = 20 mm) 25 2.5 18 Flap Mounting Screws 1.2 0.12 11 inยทlb Grab Rail Mounting Bolts (L = 60 mm) 25 2.5 18 Mud Guard Bolts 4.0 0.41 35 inยทlb L Chain Cover Bolts 4.0 0.41 35 inยทlb L Flap Screws 1.2 0.12 11 inยทlb License Plate Bracket Mounting Bolts 4.0 0.41 35 inยทlb 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nยทm kgfยทm ftยทlb Remarks Reflector Nut 3.0 0.31 27 inยทlb Electrical System Headlight Screws 1.2 0.12 11 inยทlb Meter Unit Mounting Screws 1.2 0.12 11 inยทlb Tail/Brake Light Mounting Bolts 0.50 0.05 4.4 inยทlb Front Turn Signal Light Screws 1.2 0.12 11 inยทlb License Plate Light Mounting Screws 1.2 0.12 11 inยทlb Turn Signal Light Lens Screw 1.0 0.10 8.9 inยทlb Rear Turn Signal Light Mounting Screws 1.2 0.12 11 inยทlb Left Switch Housing Screws 3.5 0.36 31 inยทlb Right Switch Housing Screws 3.5 0.36 31 inยทlb Front Brake Light Switch Screw 1.2 0.12 11 inยทlb Oil Pressure Switch 15 1.5 11 LG Oil Pressure Switch Terminal Bolt 2.0 0.20 18 inยทlb G Gear Position Sensor Bolt 10 1.0 89 inยทlb L Regulator/Rectifier Bolts 9.8 1.0 87 inยทlb Timing Rotor Bolt 39 4.0 29 Alternator Cover Bolts 12 1.2 106 inยทlb Alternator Lead Holding Plate Bolt 12 1.2 106 inยทlb L Stator Coil Bolts 12 1.2 106 inยทlb L Alternator Rotor Bolt 155 15.8 114 Starter Motor Clutch Bolts 12 1.2 106 inยทlb L Starter Motor Mounting Bolts 10 1.0 89 inยทlb Starter Motor Cable Terminal Nut 6.0 0.61 53 inยทlb Starter Motor Terminal Locknut 11 1.1 97 inยทlb Brush Holder Screw 3.8 0.39 34 inยทlb Starter Motor Through Bolts 5.0 0.51 44 inยทlb Starter Relay Terminal Bolts 5.1 0.52 45 inยทlb Crankshaft Sensor Bolts 6.0 0.61 53 inยทlb Crankshaft Sensor Cover Bolts 12 1.2 106 inยทlb L (1) Water Temperature Sensor 12 1.2 106 inยทlb Oxygen Sensor 45 4.6 33 Engine Ground Cable Terminal Bolt 10 1.0 89 inยทlb ECU Guard Bolts 4.0 0.41 35 inยทlb L, R ECU Guard Bracket Screw 1.2 0.12 11 inยทlb PERIODIC MAINTENANCE 2-11 Torque and Locking Agent The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts, nuts and screws. Use these tables for the bolts, nuts and screws which are not specified the tightening torque particularly on the previous pages. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners For Bolts and Nuts Threads Diameter Torque (mm) Nยทm kgfยทm ftยทlb 5 4.5 0.46 40 inยทlb 6 8.0 0.82 71 inยทlb 8 20 2.0 15 10 35 3.6 26 12 60 6.1 44 For Screws, Plastic Part Tightening Portions and Plastic Washer Tightening Portions Threads Diameter Torque (mm) Nยทm kgfยทm ftยทlb 4 1.2 0.12 11 inยทlb 5 3.0 0.31 27 inยทlb 6 4.0 0.41 35 inยทlb For Self-Tapping Screws Threads Diameter Torque (mm) Nยทm kgfยทm ftยทlb All 1.2 0.12 11 inยทlb For Wellnuts Threads Diameter Torque (mm) Nยทm kgfยทm ftยทlb 4 0.2 0.02 1.8 inยทlb 5 0.5 0.05 4.4 inยทlb 6 1.0 0.10 8.9 inยทlb 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) Throttle Grip Free Play 2 ๏พ 3 mm (0.08 ๏พ 0.12 in.) โโโ Idle Speed 1 100 ยฑ50 r/min (rpm) โโโ Throttle Body Vacuum 40.7 ยฑ1.3 kPa (305 ยฑ10 mmHg) at idle speed โโโ Bypass Screws (Turn Out) 0 ๏พ 2 1/2 (for reference) โโโ Air Cleaner Element Viscous paper element โโโ Cooling System Coolant: Type (Recommended) Permanent type of antifreeze โโโ Color Green โโโ Mixed Ratio Soft water 50%, coolant 50% โโโ Freezing Point โ35ยฐC (โ31ยฐF) โโโ Total Amount 2.9 L (3.1 US qt) โโโ Engine Top End Valve Clearance: Exhaust 0.22 ๏พ 0.31 mm (0.0087 ๏พ 0.0122 in.) โโโ Intake 0.13 ๏พ 0.22 mm (0.0051 ๏พ 0.0087 in.) โโโ Clutch Clutch Lever Free Play 2 ๏พ 3 mm (0.08 ๏พ 0.12 in.) โโโ Engine Lubrication System Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 โโโ Viscosity SAE 10W-40 โโโ Capacity 3.2 L (3.4 US qt) (when filter is not removed) โโโ 3.8 L (4.0 US qt) (when filter is removed) โโโ 4.0 L (4.2 US qt) (when engine is completely dry) โโโ Level Between upper and lower level lines (Wait several minutes after idling or running) โโโ Wheels/Tires Tread Depth: Front 3.6 mm (0.14 in.) 1 mm (0.04 in.), (AT, CH, DE) 1.6 mm (0.06 in.) Rear 5.8 mm (0.23 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.), Over 130 km/h (80 mph): 3 mm (0.12 in.) Air Pressure (when Cold): Front Up to 195 kg (430 lb) load: 250 kPa (2.50 kgf/cmยฒ, 36 psi) โโโ Rear Up to 195 kg (430 lb) load: 290 kPa (2.90 kgf/cmยฒ, 42 psi) โโโ PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive Drive Chain Slack 20 ๏พ 30 mm (0.8 ๏พ 1.2 in.) โโโ Drive Chain Wear (20-link Length) 317.5 ๏พ 318.2 mm (12.50 ๏พ 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA โโโ Type EK525ZX โโโ Link 112 links โโโ Brakes Brake Fluid: Grade DOT4 โโโ Brake Pad Lining Thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.) Rear 5.0 mm (0.20 in.) 1 mm (0.04 in.) Brake Light Timing: Front Pulled ON โโโ Rear ON after about 10 mm (0.39 in.) of pedal travel โโโ Electrical System Spark Plug: Type NGK CR9EIA-9 โโโ Gap 0.8 ๏พ 0.9 mm (0.031 ๏พ 0.035 in.) โโโ 2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: 57001-143 Steering Stem Nut Wrench: 57001-1100 Jack: 57001-1238 Pilot Screw Adjuster, A: 57001-1239 Oil Filter Wrench: 57001-1249 Vacuum Gauge: 57001-1369 Throttle Sensor Setting Adapter: 57001-1538 Extension Tube: 57001-1578 Jack Attachment: 57001-1608 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Replacement NOTE โIn dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Replace the air cleaner element according to the maintenance chart. NOTICE If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. โข Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connector Bracket [A] Air Cleaner Housing Assembly Screws [B] Upper Air Cleaner Housing [C] โข Discard the air cleaner element [A]. โขInstall a new element [A] so that the screen side [B] faces upward. โขInstall: Upper Air Cleaner Housing โข Tighten: Torque – Air Cleaner Housing Assembly Screws: 1.1 Nยทm (0.11 kgfยทm, 10 inยทlb) โขInstall: Fuel Tank (see Fuel Tank Installation in the Fuel System (DFI) chapter) 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection โข Start the engine and warm it up thoroughly. โข With the engine idling, turn the handlebars to both sides [A]. If handlebars movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions before riding (see Throttle Control System Inspection and Cable, Wire, and Hose Routing section in the Appendix chapter). WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to be make sure to correct any of these conditions. โข Check the idle speed. If the idle speed is out of specified range, adjust it. Idle Speed Standard: 1 100 ยฑ50 r/min (rpm) Idle Speed Adjustment โข Start the engine and warm it up thoroughly. โข Turn the adjusting screw [A] until the idle speed is correct. โOpen and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary. Throttle Control System Inspection โข Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and completely by the return spring in all steering positions. If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. โข Check the throttle grip free play [B]. Throttle Grip Free Play Standard: 2 ๏พ 3 mm (0.08 ๏พ 0.12 in.) If the free play is incorrect, adjust the throttle cable as follows. โข Loosen the locknuts [A] [B]. โข Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play. โข Turn the decelerator cable adjuster [C] until there is no play when the throttle grip play completely closed. โข Tighten the locknut [A]. โข Turn the accelerator cable adjuster [D] until 2 ๏พ 3 mm (0.08 ๏พ 0.12 in.) of throttle grip play is obtained. โข Tighten the locknut [B]. If the free play can not be adjusted with the adjusters, replace the cable. PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE โThese procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition. โข Situate the motorcycle so that it is vertical. โข Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Fuel Hose (see Fuel Hose Replacement) โข For the US and CA models, pull off the rubber caps [A] from the fittings of each throttle body. โข For other than the US and CA models, disconnect the vacuum hoses [A]. โข Connect a vacuum gauge and hoses [A] (Special Tool: 57001-1369) to the fittings on the throttle body. Special Tool – Vacuum Gauge: 57001-1369 โข Connect a highly accurate tachometer lead [B] to one of the stick coil primary leads. โข Plug the air switching valve hose end [A] and air cleaner housing fitting [B]. 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures โขInstall the air cleaner housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter). โข Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool – Extension Tube: 57001-1578 โข Start the engine and warm it up thoroughly. โข Check the idle speed, using a highly accurate tachometer [A]. Idle Speed Standard: 1 100 ยฑ50 r/min (rpm) If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment). NOTICE Do not measure the idle speed by the tachometer of the meter unit. โข While idling the engine, inspect the throttle body vacuum, using the vacuum gauge [B]. Throttle Body Vacuum Standard: 40.7 ยฑ1.3 kPa (305 ยฑ10 mmHg) at idle speed If any vacuum is not within specifications, adjust the bypass screws [A]. Special Tool – Pilot Screw Adjuster, A [B]: 57001-1239 NOTE โIn this drawing [C], the throttle body assy has been removed for clarity. โข Adjust the each vacuum (#1 ๏พ #4) to the standard value. โข Open and close the throttle valves after each measurement. NOTE โDo not turn the center adjusting screw [D]. โข Check the vacuums as before. If all vacuums are within the specification range, finish the engine vacuum synchronization. If any vacuum can not be adjusted within the specification, replace the bypass screws #1 ๏พ #4 with new ones, refer to the following procedure. PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures โข Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). โข Turn in the bypass screw [A] with counting the number of turns until it seals fully but not tightly. Record the number of turns. โข Remove: Bypass Screw Spring [B] Washer [C] O-ring [D] โข Check the bypass screw hole in the throttle body for carbon deposits. If any carbons accumulate, wipe the carbons off from the hole, using a cotton pad penetrated with a high flash-point solvent. โข Replace the bypass screw, spring, washer and O-ring as a set. โข Turn in the bypass screw until it seats fully but not tightly. NOTICE Do not over-tighten the bypass screw. The tapered portion [E] of the bypass screw could be damaged. โข Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE โA throttle body assy has different โturns outโ of the bypass screw for each individual unit. On setting the bypass screw, use the โturns outโ determined during disassembly. โข Repeat the same procedure for other bypass screws. โข 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 (+) โ R (sensor Y/W) lead Digital Meter (โ) โ BK (sensor G) lead Standard: DC 1.02 ๏พ 1.06 V at idle throttle opening If the output voltage is out of the standard, check the input voltage of the main throttle sensor (see Main Throttle Sensor Input Voltage Inspection in the Fuel System (DFI) chapter). 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Disconnect the vacuum gauge hoses. โข For the US and CA models, install the rubber caps to each throttle body. โข For other than the US and CA models, connect the vacuum hoses. โRun the vacuum hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. โขInstall the removed parts (see appropriate chapters). Fuel System Inspection Fuel Hose Inspection (fuel leak, damage, installation condition) โIf the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. โข Check that the fuel 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] โข Check that the fuel hose joints are securely connected. โPush and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint. If it does not lock, reinstall the hose joint. PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Fuel Filter Replacement WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (โ) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTICE Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it. โข Remove: Fuel Pump (see Fuel Pump Removal in the Fuel System (DFI) chapter) Fuel Pump Assembly Screws [A] Lead Terminals [B] โข Disconnect: Lead Connector (Yellow) [A] Lead Connector (Light Blue) [B] โข Using the flat tip screwdriver [A], remove the fuel pump case [B] from the fuel pump body [C]. 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Remove the O-ring [A]. โข Remove the fuel pump body [B] from the installation plate [C]. โข Remove the fuel filter [A]. โข Replace the fuel filter [A] with a new one, and install it. โข Replace the following parts with new ones. O-rings [A] Fuel Pump Assembly Screws [B] PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures โขInstall the removed parts in the reverse procedure. โขInstall the cap [A] so that the light blue lead terminal is covered as shown. โข Tighten: Torque – Fuel Pump Assembly Screws: 0.98 Nยทm (0.10 kgfยทm, 8.7 inยทlb) Fuel Hose Replacement โข Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). โข Remove the connector bracket from the air cleaner housing. โข Disconnect the intake air temperature sensor lead connector. โข Be sure to place a piece of cloth around the fuel hose joint. โข Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush. When removing with flat tip screwdriver โขInsert the flat tip screwdriver [A] into slit on the joint lock [B]. โข Turn the driver to disconnect the joint lock. When removing with fingers โข Open and push up [C] the joint lock with your fingers. NOTICE Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing. โข Pull the fuel hose joint [A] out of the delivery pipe [B]. WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage. โข Clean the delivery pipe. โข Cover the delivery pipe with the vinyl bag to keep it clean. 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Remove the vinyl bag on the pipe. โข Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A]. โข Replace the fuel hose with a new one. โข Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInsert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks. โข Push [C] the joint lock [D]. โข 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 Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesnโt leak. If it comes off, reinstall the hose joint. โขInstall the removed parts (see appropriate chapters). โข Start the engine and check the fuel hose for leaks. Evaporative Emission Control System Inspection (Other than US and CA Models) โขInspect the canister as follows. โข Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). โข Slide the clamps [A] and disconnect the hoses [B]. โข Remove the band [C]. โข Remove the canister [D] from the bracket [E]. PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures โข Visually inspect the canister [A] for cracks or other damage. If the canister has any cracks or bad damage, replace it with a new one. NOTE โThe canister is designed to work well through the motorcycleโs life without any maintenance if it is used under normal conditions. โขInspect the purge valve (see Purge Valve Inspection in the Fuel System (DFI) chapter). โCheck that the hoses are securely connected and clips are in position. โReplace any kinked, deteriorated or damaged hoses. โRun the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. โWhen installing the hoses, avoid sharp bending, kinking, flattening or twisting, and run the hoses with a minimum of bending so that the emission flow will not be obstructed. Cooling System Coolant Level Inspection NOTE โCheck the level when the engine is cold (room or ambient temperature). โข 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 โLโ level line [B], unscrew the reserve tank cap and add coolant to the โFโ level line [C]. โLโ: Low โFโ: Full NOTICE For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts. 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Inspection Water Hose and Pipe Inspection (coolant leak, damage, installation condition) โThe high pressure inside the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. โข 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. โข Check that the hoses are securely connected and clamps are tightened correctly. Torque – Water Hose Clamp Screws: 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) Coolant Change WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant. โข Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Radiator Cap [A] โRemove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. โข Place a container under the drain bolt [A] of the water pump cover. โข Drain the coolant from the radiator by removing the drain bolt. PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures โข Remove: Coolant Reserve Tank Cover Bolts [A] Collars โข Pull up the coolant reserve tank [A]. โข Disconnect the radiator overflow hose [B]. โข Remove the cap [C]. โข Pour the coolant into a container. โขInstall: Radiator Overflow Hose Coolant Reserve Tank Collars โข Apply a non-permanent locking agent to the threads of the coolant reserve tank cover bolts and tighten them. โข Tighten the drain bolt with new gasket. Torque – Coolant Drain Bolt: 11 Nยทm (1.1 kgfยทm, 97 inยทlb) โข When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturerโs directions. NOTICE Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Water and Coolant Mixture Ratio (Recommended) Soft Water: 50% Coolant: 50% Freezing Point: โ35ยฐC (โ31ยฐF) Total Amount: 2.9 L (3.1 US qt) โข Fill the radiator up to the filler neck [A] with coolant. NOTE โPour in the coolant slowly so that it can expel the air from the engine and radiator. โข Check the cooling system for leaks. โข Tap the water hoses to force any air bubbles caught inside. 2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Fill the reserve tank up to the โFโ (full) level line [A] with coolant and install the cap [B]. โขInstall the radiator cap. โข Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. โข Check the coolant level in the reserve tank after the engine cools down. If the coolant level is lower than the โLโ (low) level line [C], add coolant to the โFโ level line. NOTICE Do not add more coolant above the โFโ level line. PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Water Hose and O-ring Replacement โข Drain the coolant (see Coolant Change). โข Remove: Oil Cooler [A] (see Oil Cooler Removal in the Engine Lubrication System chapter) Thermostat Housing Cover [B] (see Thermostat Removal in the Cooling System chapter) Water Pump Housing [C] (see Water Pump Removal in the Cooling System chapter) โข Replace the hoses [D] and O-rings [E] with new ones. โข Apply grease or soap and water solution to the new O -rings. โข Run the new hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. โข Tighten: Torque – Water Hose Clamp Screws: 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) โขInstall the removed parts (see appropriate chapters). โข Fill the coolant (see Coolant Change). โข Check the cooling system for leaks. 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE โValve clearance must be checked and adjusted when the engine is cold (at room temperature). โข Remove: Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) โข Using a wrench on the timing rotor bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor is aligned with the mating surface [C] of the crankcase. โข Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter. Valve Clearance Standard: Exhaust 0.22 ๏พ 0.31 mm (0.0087 ๏พ 0.0122 in.) Intake 0.13 ๏พ 0.22 mm (0.0051 ๏พ 0.0087 in.) NOTE โThickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures โWhen positioning #1 piston TDC at the end of the compression stroke: Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] โWhen positioning #4 piston TDC at the end of the compression stroke: Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders Measuring Valve [A] If the valve clearance is not within the specified range, first record the clearance, and then adjust it. Valve Clearance Adjustment โข To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE โMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions. 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures โBesides the standard shims in the valve clearance adjustment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance. Adjustment Shims Thickness 2.675 mm 2.725 mm 2.775 mm 2.825 mm 2.875 mm 2.925 mm 2.975 mm 3.025 mm 3.075 mm 3.125 mm 3.175 mm 3.225 mm 3.275 mm 3.325 mm โข Clean the shim to remove any dust or oil. โข Measure the thickness of the removed shim [A]. PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm Replace 2.95 mm shim with 3.20 mm shim. 5. Remeasure the valve clearance and readjust if necessary. 2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm. Measured clearance is 0.47 mm. Replace 2.95 mm shim with 3.15 mm shim. 5. Remeasure the valve clearance and readjust if necessary. PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. โIf there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance. โข 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. NOTICE Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage. โข Apply engine oil to the valve lifter surface and install the lifter. โขInstall the camshafts (see Camshaft Installation in the Engine Top End chapter). โข Recheck the valve clearance and readjust if necessary. โขInstall the removed parts (see appropriate chapters). Air Suction System Damage Inspection โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clamp [A] (Other than US and CA Models) โข Disconnect: Subthrottle Sensor Connector [B] Air Switching Valve Hose [C] โข Connect the subthrottle sensor connector. โข Start the engine and run it at idle speed. โข Plug the air switching valve hose end [A] 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 System chapter) or air suction valve (see Air Suction Valve Inspection in the Engine Top End chapter). 2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection โข Pull the clutch lever just enough to take up the free play [A]. โข 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 ๏พ 3 mm (0.08 ๏พ 0.12 in.) WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. โข Loosen the locknut [A]. โข Turn the adjuster [B] so that 5 ๏พ 6 mm (0.20 ๏พ 0.24 in.) [C] of threads is visible. โข Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). โข Slide the dust cover [A] at the clutch cable lower end out of place. โข Loosen both adjusting nuts [B] at the clutch cover as far as they will go. โข Pull the clutch outer cable [C] tight and tighten the adjusting nuts against the clutch cover [D]. โข Slip the dust cover back onto place. โข Turn the adjuster at the clutch lever until the free play is correct. โข Push the release lever [A] toward the front of the motorcycle until it becomes hard to turn. โAt this time, the release lever should have the proper angle shown. 60ยฐ [B] If the angle is wrong, check the clutch and release parts for wear. WARNING Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement. โข After the adjustment, start the engine and check that the clutch does not slip and that it releases properly. PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change โข Situate the motorcycle so that it is vertical after warming up the engine. โข Remove the engine oil drain bolt [A] to drain the oil. โThe oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement). โข Replace the drain bolt gasket [B] with a new one. โข Tighten the drain bolt. Torque – Engine Oil Drain Bolt: 29 Nยทm (3.0 kgfยทm, 21 ftยทlb) โข Remove the oil filler plug [A]. โข Pour in the specified type and amount of oil. Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 3.2 L (3.4 US qt) (when filter is not removed) 3.8 L (4.0 US qt) (when filter is removed) 4.0 L (4.2 US qt) (when engine is completely dry) NOTE โDo not add any chemical additive to the oil.Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch. โAlthough 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. โข Replace the O-ring of the oil filler plug with a new one. โข Apply grease to the new O-ring. โขInstall the oil filler plug. Torque – Oil Filler Plug: Hand-tighten โข Check the oil level (see Oil Level Inspection in the Engine Lubrication System chapter). 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement โข Drain the engine oil (see Engine Oil Change). โข Remove the oil filter with the oil filter wrench [A]. Special Tool – Oil Filter Wrench: 57001-1249 โข Replace the filter with a new one. โข Apply grease to the gasket [A] before installation. โข Tighten the filter with the oil filter wrench. Special Tool – Oil Filter Wrench: 57001-1249 Torque – Oil Filter: 17 Nยทm (1.7 kgfยทm, 13 ftยทlb) NOTE โHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque. โข Pour in the specified type and capacity of oil (see Engine Oil Change). Wheels/Tires Air Pressure Inspection โข Remove the air valve cap. โข Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). โขInstall the air valve cap. Adjust the tire air pressure according to the specifications if necessary. Air Pressure (when Cold) Front: Up to 195 kg (430 lb) load: 250 kPa (2.50 kgf/cmยฒ, 36 psi) Rear: Up to 195 kg (430 lb) load: 290 kPa (2.90 kgf/cmยฒ, 42 psi) Wheels and Tires Inspection Wheel/Tire Damage Inspection โข Remove any imbedded stones [A] or other foreign particles [B] from tread. โข Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. โข Visually inspect the wheel for cracks, cuts and dents damage. If any damage is found, replace the wheel if necessary. PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. โข 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 3.6 mm (0.14 in.) Rear 5.8 mm (0.23 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3 mm (0.12 in.) (Over 130 km/h (80 mph)) WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. NOTE โMost countries may have their own regulations a minimum tire tread depth: be sure to follow them. โCheck and balance the wheel when a tire is replaced with a new one. Wheel Bearing Damage Inspection โข Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). Special Tools – Jack: 57001-1238 Jack Attachment: 57001-1608 โข Turn the handlebars all the way to the right or left. โขInspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. โข 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). 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). โขInspect the roughness of the rear wheel bearing by pushing and pulling [A] the wheel. โข 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 Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter). Final Drive Drive Chain Lubrication Condition Inspection Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains following the instructions supplied by the chain cleaner manufacturer. NOTICE The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules. Use only chain cleaner for cleaning of the O-ring of the drive chain. Any other cleaning solution such as gasoline will cause deterioration and swelling of the O-ring. Immediately blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes. โข Apply chain 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. โข Wipe off any excess oil. Oil Applied Areas [A] O-rings [B] โข Wipe off lubricant that gets on the tire surface. PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Drive Chain Slack Inspection NOTE โCheck the slack with the motorcycle setting on its side stand. โClean the chain if it is dirty, and lubricate it if it appears dry. โข Check the wheel alignment (see Wheel Alignment Inspection). โข Rotate the rear wheel to find the position where the chain is tightest. โข Measure the vertical movement (chain slack) [A] midway between the sprockets. If the chain slack exceeds the standard, adjust it. Chain Slack Standard: 20 ๏พ 30 mm (0.8 ๏พ 1.2 in.) Drive Chain Slack Adjustment โข Loosen the chain adjuster clamp bolt [A] (Both Sides). โข Using an Allen wrench [B], turn the adjusters [C] forward or rearward until the drive chain has the correct amount of chain slack. โข Tighten: Torque – Chain Adjuster Clamp Bolts: 65 Nยทm (6.6 kgfยทm, 48 ftยทlb) Wheel Alignment Inspection โข Check that the notch [A] on the swingarm should point to the same marks or positions [B] on the adjuster (Both Sides). If they do not, adjust the chain slack (see Drive Chain Slack Adjustment) and align the wheel alignment. WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned. Wheel Alignment Adjustment โข Remove the right retaining ring [A]. โข Loosen the axle nut [B]. โข Loosen the right chain adjuster clamp bolt [C], and turn the right chain adjuster [D] so that the left and right notches on the swingarm may point to the same marks or positions on the left and right adjusters. โข Tighten: Torque – Chain Adjuster Clamp Bolt: 65 Nยทm (6.6 kgfยทm, 48 ftยทlb) Rear Axle Nut: 100 Nยทm (10.2 kgfยทm, 73.8 ftยทlb) โข Replace the right retaining ring with a new one and install it. 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection โข Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). โข Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. โข Stretch the chain taut by hanging a 10 kg (22 lb) weight [A] on the chain. โข 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 ๏พ 318.2 mm (12.50 ๏พ 12.53 in.) Service Limit: 319 mm (12.6 in.) WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment before each ride. If chain wear exceeds the service limit, replace it with the standard chain. Standard Chain Make: ENUMA Type: EK525ZX Link: 112 links Chain Guide Wear Inspection โข Remove the swingarm (see Swingarm Removal in the Suspension chapter). โข Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Brakes Brake System Inspection Brake Fluid Leak (Brake Hose and Pipe) Inspection โข Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). โข Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes [B] and fittings [C]. If the brake fluid leaked from any position, inspect or replace the problem part. 2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection โข Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). โขInspect the brake hoses, pipe and fittings for deterioration, cracks and signs of leakage. โThe high pressure inside the brake line can cause fluid to leak [A] or the hose, pipe to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose and pipe if any crack [B], bulge [C] or leakage is noticed. Tighten any brake hose banjo bolts and brake pipe joint nuts. Torque – Brake Hose Banjo Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) Brake Pipe Joint Nuts: 18 Nยทm (1.8 kgfยทm, 13 ftยทlb) โขInspect the brake hose and pipe routing. If any brake hose and pipe routing is incorrect, run the brake hose and pipe according to Cable, Wire, and Hose Routing section in the Appendix chapter. Brake Operation Inspection โขInspect the operation of the front and rear brake by running the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. WARNING When test riding the vehicle, be aware of surrounding traffic for your safety. Brake Fluid Level Inspection โข Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE โHold the reservoir horizontal by turning the handlebars 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]. โRemove the stopper [D]. PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures โข 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]. โRemove the stopper [D]. WARNING Mixing brands and types of brake fluid can reduce the brake systemโs effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. Recommended Disc Brake Fluid Grade: DOT4 โข Follow the procedure below to install the rear brake fluid reservoir cap correctly. โFirst, tighten the brake fluid reservoir cap [A] clockwise [B] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body [C], then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body. โขInstall the stopper and tighten the screw. Brake Fluid Change NOTE โThe procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. โข Level the brake fluid reservoir. โข Remove the reservoir cap, diaphragm plate and diaphragm. โข Remove the rubber cap [A] from the bleed valve on the caliper. โข Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. โข Fill the reservoir with fresh specified brake fluid. 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Change the brake fluid. โRepeat 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 โThe fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line. โFront Brake: Repeat the above steps for the other caliper. โข Remove the clear plastic hose. โขInstall the diaphragm, diaphragm plate and reservoir cap. โข Tighten: Torque – Front Brake Reservoir Cap Stopper Screw: 1.5 Nยทm (0.15 kgfยทm, 13 inยทlb) โข Follow the procedure below to install the rear brake fluid reservoir cap correctly. โFirst, tighten the rear brake fluid reservoir cap [A] clockwise [B] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body [C], then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body. โข Tighten the bleed valve, and install the rubber cap. Torque – Bleed Valves: 8.0 Nยทm (0.82 kgfยทm, 71 inยทlb) โข 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. Brake Hose and Pipe Replacement NOTICE Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely washed away immediately. PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures This page intentionally left blank. 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE โWhen removing the brake pipes and hoses on the hydraulic unit, remove them with the flare nut wrench according to each assembly of the exploded view in the Brakes chapter. โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Battery Case (see Battery Case Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Brake Hose Banjo Bolts [B] Bolts [C] Clamps โข There are washers on each side of the brake hose and pipe fitting. Replace them with new ones when installing. โข Before installing the brake pipe, check to see that there is no damage on the threads of the brake pipe joint nut. If there is any damage, replace the damaged parts with new ones. NOTE โTighten the brake pipe joint nut at both ends of the brake pipe temporarily and then tighten them to the specified torque. โขInstall the brake pipes and brake hoses to the specified angle (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Tighten the brake pipe joint nuts with the flare nut wrench. โข Tighten: Torque – Brake Hose Banjo Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) Brake Pipe Joint Nuts: 18 Nยทm (1.8 kgfยทm, 13 ftยทlb) โข Fill the brake line after installing the brake hose and pipe (see Brake Fluid Change). PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly โข Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). โข Remove the seal cover [A], circlip [B], connector [C] and O-ring [D]. Special Tool – Inside Circlip Pliers: 57001-143 โข Unscrew the locknut [E] and pivot bolt [F], and remove the brake lever. โข Remove the bleed valve [G] and rubber cap [H]. โข Remove the piston assembly [I] as follows. โRemove the dust cover and push rod. โRemove the circlip [J]. โPull out the piston (with primary cup and secondary cup). โRemove the return spring and spring guide. โข Replace: Seal Cover [A] Circlip [B] O-ring [D] Rubber Cap [H] Piston Assembly [I] Circlip [J] Diaphragm [K] Rear Master Cylinder Disassembly โข Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter). โข Remove the circlip [A], connector [B] and O-ring [C]. Special Tool – Inside Circlip Pliers: 57001-143 โข Slide the dust cover [D] out of place, and remove the circlip [E]. โข Pull out the push rod assembly [F]. โข Remove the piston assembly [G] and return spring [H]. NOTICE Do not remove the secondary cup from the piston since removal will damage it. โข Replace: Circlip [A] O-ring [C] Circlip [E] Push Rod Assembly [F] Piston Assembly [G] Diaphragm [I] PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Master Cylinder Assembly โข Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake. โข Apply brake fluid to the new parts and to the inner wall of the cylinder. โข Take care not to scratch the piston or the inner wall of the cylinder. โข Apply silicone grease to the followings. Front: Brake Lever Pivot Bolt Rear: Dust Cover of Push Rod Assembly โข For the front master cylinder, tighten the brake lever pivot bolt and the locknut. Torque – Brake Lever Pivot Bolt: 1.0 Nยทm (0.10 kgfยทm, 8.9 inยทlb) Brake Lever Pivot Bolt Locknut: 5.9 Nยทm (0.60 kgfยทm, 52 inยทlb) โข For the front master cylinder, install the bleed valve and rubber cap. Torque – Front Master Cylinder Bleed Valve: 5.4 Nยทm (0.55 kgfยทm, 48 inยทlb) Caliper Rubber Parts Replacement Front Caliper Disassembly โข Loosen the front caliper pad pins [A] and banjo bolt [B] and tighten them loosely. โข Remove: Front Caliper [C] (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) โข Hold the pistons nearest the oil passage [A] with the bands [B]. 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Using compressed air, remove the pistons. โCover the caliper opening with a clean heavy cloth [A]. โLightly apply compressed air [B] to the oil passage. WARNING The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. โPull out the pistons by hand. โข Remove the dust seals [A] and fluid seals [B]. โข Cut the bands. โข Repeat the previous step to remove the pistons from the other side of the caliper body. โข Remove the bleed valve and rubber cap. Front Caliper Assembly โข Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. โขInstall the bleed valve and rubber cap. โข Tighten: Torque – Bleed Valves: 8.0 Nยทm (0.82 kgfยทm, 71 inยทlb) โข Replace the fluid seals [A] with new ones. โApply silicone grease to the fluid seals, and install them into the cylinders by hand. โข Replace the dust seals [B] with new ones if they are damaged. โApply silicone grease to the dust seals, and install them into the cylinders by hand. โข Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. โขInstall the removed parts (see appropriate chapters). โข Wipe up any spilled brake fluid on the caliper with wet cloth. PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Rear Caliper Disassembly โข Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Caliper Holder [A] โข Remove: Dust Boot [A] Friction Boot [B] โข Using compressed air, remove the piston. โCover the caliper opening with a clean heavy cloth [A]. โRemove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper. WARNING The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. โข Remove the pad spring. โข Remove the dust seal and fluid seal. โข Remove the bleed valve and rubber cap. Rear Caliper Assembly โข Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. โขInstall the bleed valve and rubber cap. โข Tighten: Torque – Bleed Valve: 8.0 Nยทm (0.82 kgfยทm, 71 inยทlb) 2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Replace the fluid seal [A] with a new one. โApply silicone grease to the fluid seal, and install it into the cylinder by hand. โข Replace the dust seal [B] with a new one. โApply silicone grease to the dust seal, and install it into the cylinder by hand. โขInstall the pad spring [A] in the caliper as shown. โข Apply brake fluid to the outside of the piston [B], and push it into the cylinder by hand. โข Replace the friction boot [C] and dust boot [D]. โข Apply a silicone grease to the caliper holder shafts [A]. โข Check that the guide [B] is in place on the caliper holder. โข Assemble the caliper and the caliper holder. โขInstall the pads (see Rear Brake Pad Installation in the Brakes chapter). โข Wipe up any spilled brake fluid on the caliper with wet cloth. Brake Pad Wear Inspection โข Remove the brake pads (see Front/Rear Brake Pad Removal in the Brakes chapter). โข 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. Front Brake Pad [C] Rear Brake Pad [D] Pad Lining Thickness Standard: Front 4.0 mm (0.16 in.) Rear 5.0 mm (0.20 in.) Service Limit: 1 mm (0.04 in.) PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Brake Light Switch Operation Inspection โข Turn the ignition switch on. โข The brake light (LED) [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light switch. โข Remove: Rear Lower Fairing (see Rear Lower Fairing Removal in the Frame chapter) Front Footpeg Bracket Bolts [A] โข Pull the right footpeg bracket [B] outward. โข 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] NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. โข Tighten: Torque – Front Footpeg Bracket Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โขInstall: Rear Lower Fairing (see Rear Lower Fairing Installation in the Frame chapter) If it does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Electrical System chapter) Brake Light (LED) (see Tail/Brake Light (LED) Removal/Installation in the Electrical System chapter) Main Fuse 30 A and Brake Light/Horn Fuse 7.5 A (see Fuse Inspection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in the Electrical System chapter) Rear Brake Light Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Suspension System Inspection Front Forks/Rear Shock Absorber Operation Inspection โข 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). โข Pump the rear 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 โข Visually inspect the front forks [A] for oil leakage. Replace any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection โข Visually inspect the rear shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the rear shock absorber with a new one. Rocker Arm Operation Inspection โข Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the rocker arms [A] do not smoothly stroke or noise is found, inspect the fasteners and bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspension chapter). PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Tie-Rod Operation Inspection โข Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rod [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 Suspension chapter). Steering Steering Play Inspection โข Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). Special Tools – Jack: 57001-1238 Jack Attachment: 57001-1608 โข With the front wheel pointing straight ahead, alternately tap each end of the handlebars. 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. โข Feel for steering looseness by pushing and pulling [A] the forks. If you feel looseness, the steering is too loose. NOTE โThe cables and wiring will have some effect on the motion of the fork which must be taken into account. โBe sure the leads and cables are properly routed. โThe bearings must be in good condition and properly lubricated in order for any test to be valid. Steering Play Adjustment โข Remove: Middle Fairing (see Middle Fairing Removal in the Frame chapter) Handlebar Holders (see Handlebar Removal in the Steering chapter) โข Remove the bolt [A], and free the leads from the guide [B] on both side. 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures โข Remove: Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] and Washer โข Loosen the upper front fork clamp bolts [C]. โข Remove the stem head [D]. โข Bend the claws [A] of the claw washer straighten. โข Remove: Steering Stem Locknut [B] Claw Washer โข Adjust the steering using the steering stem nut wrench [A]. Special Tool – Steering Stem Nut Wrench: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn. NOTE โTurn the stem nut 1/8 turn at time maximum. โขInstall the claw washer [A] so that its bent claws [B] faces upward, and engage the bent claws with the grooves of steering stem locknut [C]. โข Hand tighten the steering stem locknut until it contacts against the claw washer. โข Check if the straight claws [D] of the claw washer aligned with the grooves of the steering stem nut [E]. In case of the claws positioned between the grooves: โข Tighten the steering stem locknut [A] until the straight claws aligned with 3rd grooves [B] of the steering stem nut [C]. โCount the number of groove from the first aligned groove [D] as shown. โข Bend the two straight claws downward into the groove of the steering stem nut. PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures In case of the claws aligned with the grooves: โข Tighten the steering stem locknut [A] until the straight claws aligned with 3rd grooves [B] of the steering stem nut [C]. โCount the number of groove from the next aligned groove [D] as shown. โข Bend the two straight claws downward into the groove of the steering stem nut. โขInstall the stem head. โขInstall the washer, and temporary tighten the stem head bolt. NOTE โTighten the upper front fork clamp bolts first, next the stem head bolt. Torque – Upper Front Fork Clamp Bolts: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) Steering Stem Head Bolt: 110 Nยทm (11.2 kgfยทm, 81.1 ftยทlb) WARNING If the handlebars do not turn to the steering stop, they may cause an accident resulting in injury or death. Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Check the steering again. If the steering is still too tight or too loose, repeat the adjustment. โขInstall the removed parts (see appropriate chapters). Steering Stem Bearing Lubrication โข Remove the steering stem (see Stem, Stem Bearing Removal in the Steering chapter). โข Using a high flash-point solvent, wash the upper and lower ball bearings [A] in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. โข Visually check the outer races and the ball bearings. Replace the bearing assemblies if they show wear or damage. โข Pack the upper and lower ball bearings in the cages with grease, and apply a light coat of grease to the upper and lower outer races. โขInstall the steering stem (see Stem, Stem Bearing Installation in the Steering chapter). โข Adjust the steering (see Steering Play Adjustment). 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step โข Set the gear position in the neutral position. โข Turn the ignition switch on. โข The following lights should go on according to below table. City Light (LED) [A] Goes on Taillight (LED) [B] Goes on License Plate Light [C] Goes on Meter Panel Illumination (LED) [D] Goes on Meter Panel LCD [E] Goes on Green Neutral Indicator (LED) [F] Goes on Oil Pressure Warning Indicator [G] and Red Warning Indicator (LED) [H] Goes on Yellow ABS Indicator (LED) [I] Goes on If the light does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Electrical System chapter) Headlight (LED) Assembly (see Headlight (LED) Assembly Removal/Installation in the Electrical System chapter) License Plate Light Bulb (see License Plate Light Bulb Replacement in the Electrical System chapter) Meter Panel LCD (see Meter Unit Inspection in the Electrical System chapter) Green Neutral Indicator (LED) (see Meter Unit Inspection in the Electrical System chapter) Red Warning Indicator (LED) (Oil Pressure Warning) (see Meter Unit Inspection in the Electrical System chapter) Meter Panel Illumination (LED) (see Meter Unit Inspection in the Electrical System chapter) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) Main Fuse 30 A, Meter Fuse 7.5 A and Brake Light/Horn Fuse 7.5 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Oil Pressure Switch (see Switch Inspection in the Electrical System chapter) Gear Position Sensor (see Gear Position Sensor Input Voltage Inspection in the Fuel System (DFI) chapter) Harness (see Wiring Inspection in the Electrical System chapter) Yellow ABS Indicator (LED) (see Yellow ABS Indicator (LED) Inspection in the Brakes chapter) PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures โข Turn the ignition switch off. โข The all lights should go off. โFor models equipped with an immobilizer system, red warning indicator (LED) will blinks. Refer to the Immobilizer System (Equipped Models) section in the Electrical System chapter). If the light does not go off, replace the ignition switch. Second Step โข Turn the ignition switch to hazard position. โข The all lights should go off. If the light goes on, inspect or replace the following item. Ignition Switch (see Switch Inspection in the Electrical System chapter) Third Step โข Turn the ignition switch on. โข Turn on the turn signal switch [A] (left or right position). โข The left or right turn signal lights [B] (front and rear) according to the switch position should blink. โข The green turn signal indicators (LED) [C] in the meter unit should blink. If the each light does not blink, inspect or replace the following parts. Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter) Green Turn Signal Indicator (LED) (see Meter Unit Inspection in the Electrical System chapter) Turn Signal Relay Fuse 7.5 A (see Fuse Inspection in the Electrical System chapter) Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) โข Push the turn signal switch. โข The turn signal lights and green turn signal indicator (LED) should go off. If the light does not go off, inspect or replace the following parts. Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) 2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fourth Step โข Set the dimmer switch [A] to low beam position. โข Start the engine. โข The low beam headlights should go on. If the low beam headlights do not go on, inspect or replace the following parts. Headlight (LED) Assembly (see Headlight (LED) Assembly Removal/Installation in the Electrical System chapter) Headlight Fuse 25 A (see Fuse Inspection in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) Headlight Relay (see Relay Circuit Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) โข Set the dimmer switch to high beam position. โข The low beam [A] and high beam [B] headlights should go on. โข The blue high beam indicator (LED) [C] should goes on. If the high beam headlight and/or blue high beam indicator (LED) does not go on, inspect or replace the following parts. Headlight (LED) Assembly (see Headlight (LED) Assembly Removal/Installation in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) โข Turn the engine stop switch to stop position. โข The low beam and high beam headlights should stay going on. If the headlights and blue high beam indicator (LED) go off, inspect or replace the headlight relay (see Relay Circuit Inspection in the Electrical System chapter). โข Turn the ignition switch off. โข The headlights and blue high beam indicator (LED) should go off. Headlight Aiming Inspection โขInspect the headlight beam for aiming. If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Headlight Beam Horizontal Adjustment โข Turn the horizontal adjuster [A] in both headlights 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 โข Turn the vertical adjuster [B] in both headlights in or out to adjust the headlight vertically. NOTE โOn high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulations. โFor the US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2.0 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated. 50 mm (2.0 in.) [A] Center of Brightest Spot [B] 7.6 m (25 ft) [C] Height of Headlight Center [D] Side Stand Switch Operation Inspection โข Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). โขInspect the side stand switch [A] operation accordance to below table. Side Stand Switch Operation Side Stand Gear Position Clutch Lever Engine Start Engine Run Up Neutral Released Starts Continue running Up Neutral Pulled in Starts Continue running Up In Gear Released Does not start Continue running Up In Gear Pulled in Starts Continue running Down Neutral Released Starts Continue running Down Neutral Pulled in Starts Continue running Down In Gear Released Does not start Stops Down In Gear Pulled in Does not start Stops 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the side stand switch operation does not work, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Electrical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Side Stand Switch (see Switch Inspection in the Electrical System chapter) Engine Stop Switch (see Switch Inspection in the Electrical System chapter) Starter Button (see Switch Inspection in the Electrical System chapter) Gear Position Sensor (see Gear Position Sensor Input Voltage Inspection in the Fuel System (DFI) chapter) Starter Lockout Switch (see Switch Inspection in the Electrical System chapter) Starter Relay (see Starter Relay Inspection in the Electrical System chapter) Relay Box (see Relay Circuit Inspection in the Electrical System chapter) 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) chapter). Engine Stop Switch Operation Inspection First Step โข Turn the ignition switch on. โข Set the gear position in the neutral position. โข Turn the engine stop switch to stop position [A]. โข Push the starter button. โข The engine does not start. If the engine starts, inspect or replace the engine stop switch (see Switch Inspection in the Electrical System chapter). Second Step โข Turn the ignition switch on. โข Set the gear position in the neutral position. โข Turn the engine stop switch to run position [A]. โข Push the starter button and start the engine. โข Turn the engine stop switch to stop position. โขImmediately the engine should be stop. If the engine does not stop, inspect or replace the engine stop switch (see Switch Inspection in the Electrical System chapter). If the engine stop switch is good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter). PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures Spark Plug Replacement โข Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). โข Remove the spark plugs using the 16 mm (0.63 in.) plug wrench [A] vertically. โข Replace the spark plugs with new ones. Standard Spark Plug Type: NGK CR9EIA-9 โขInsert the spark plug vertically into the spark plug hole with the spark plug installed in the plug wrench [A], and finger-tighten it first. NOTICE If tightening the spark plug with the wrench inclined, the insulator of the spark plug may break. โข Tighten: Torque – Spark Plugs: 13 Nยทm (1.3 kgfยทm, 115 inยทlb) โขInstall the stick coils (see Stick Coil Installation in the Electrical System chapter). โข After installation, be sure the stick coils are installed securely by pulling up them lightly. Others Chassis Parts Lubrication โข Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. โข Lubricate the points listed below with indicated lubricant. NOTE โWhenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication. Pivots: Lubricate with Grease. Brake Lever Brake Pedal Clutch Lever Side Stand Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Throttle Inner Cable Upper and Lower Ends 2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables โข Lubricate the cables by seeping the oil between the cable and housing. โThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant. โข With the cable disconnected at both ends, the inner 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. Condition of Bolts, Nuts and Fasteners Tightness Inspection โข 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 โFor the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table. For each fastener, first loosen it by 1/2 turn, then tighten it. If cotter pins are damaged, replace them with new ones. PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Holder Nuts Muffler Body Clamp Bolts Muffler Body Mounting Bolts and Nuts Premuffler Chamber Mounting Bolt Radiator Bolts Wheels: Front Axle Clamp Bolts Front Axle Rear Axle Nut 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 Bolts and Nuts Swingarm Pivot Shaft Nut Tie-rod Nuts Rocker Arm Nut Steering: Handlebar Holder Bolts Steering Stem Head Bolt Others: Footpeg Bracket Bolts Front Fender Mounting Bolts Rear Frame Bolts Side Stand Bolt Side Stand Bracket Bolts FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) Table of Contents Exploded View. 3-4 DFI System 3-10 DFI Components Naming 3-12 DFI Parts Location. 3-17 Specifications 3-21 Special Tools and Sealant . 3-23 DFI Servicing Precautions. 3-25 DFI Servicing Precautions 3-25 Troubleshooting the DFI System . 3-27 Outline 3-27 Inquiries to Rider. 3-31 DFI System Troubleshooting Guide 3-34 Self-Diagnosis . 3-39 Self-Diagnosis Outline . 3-39 Self-Diagnosis Procedures 3-40 Service Code Reading. 3-41 Service Code Erasing 3-42 Backups . 3-44 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) 3-47 Main Throttle Sensor Removal/Adjustment. 3-47 Main Throttle Sensor Input Voltage Inspection. 3-47 Main Throttle Sensor Resistance Inspection 3-48 Main Throttle Sensor Output Voltage Inspection. 3-48 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) 3-51 Intake Air Pressure Sensor #1 Removal 3-51 Intake Air Pressure Sensor #1 Installation. 3-51 Intake Air Pressure Sensor #1 Input Voltage Inspection 3-52 Intake Air Pressure Sensor #1 Output Voltage Inspection. 3-53 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) 3-57 Intake Air Temperature Sensor Removal/Installation 3-57 Intake Air Temperature Sensor Output Voltage Inspection. 3-57 Intake Air Temperature Sensor Resistance Inspection. 3-59 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117). 3-60 Water Temperature Sensor Removal/Installation 3-60 Water Temperature Sensor Output Voltage Inspection. 3-60 Water Temperature Sensor Resistance Inspection. 3-61 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) 3-63 Intake Air Pressure Sensor #2 Removal 3-63 Intake Air Pressure Sensor #2 Installation. 3-63 Intake Air Pressure Sensor #2 Input Voltage Inspection 3-64 Intake Air Pressure Sensor #2 Output Voltage Inspection. 3-65 Crankshaft Sensor (Service Code 21) (DTC P0335). 3-67 Crankshaft Sensor Removal/Installation 3-67 Crankshaft Sensor Resistance Inspection 3-67 Crankshaft Sensor Peak Voltage Inspection 3-67 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158). 3-68 Rear Wheel Rotation Sensor Signal Inspection. 3-68 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0916) 3-70 Gear Position Sensor Removal/Installation 3-70 Gear Position Sensor Input Voltage Inspection. 3-70 Gear Position Sensor Output Voltage Inspection. 3-71 Front Wheel Rotation Sensor (Service Code 27) (DTC P0500). 3-73 Front Wheel Rotation Sensor Signal Inspection. 3-73 Vehicle-down Sensor (Service Code 31) (DTC C0064) 3-75 Vehicle-down Sensor Removal 3-75 Vehicle-down Sensor Installation. 3-76 Vehicle-down Sensor Input Voltage Inspection. 3-76 Vehicle-down Sensor Output Voltage Inspection. 3-77 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) 3-80 Subthrottle Sensor Removal/Adjustment. 3-80 Subthrottle Sensor Input Voltage Inspection 3-80 Subthrottle Sensor Output Voltage Inspection 3-81 Subthrottle Sensor Resistance Inspection 3-83 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) 3-84 Oxygen Sensor Removal/Installation 3-84 Oxygen Sensor Inspection. 3-84 Immobilizer Amplifier (Service Code 35, Equipped Models). 3-87 Antenna Resistance Inspection . 3-87 Amplifier Input Voltage Inspection 3-87 Blank Key Detection (Service Code 36, Equipped Models). 3-88 Ignition Key Inspection. 3-88 ECU Communication Error (Service Code 39) (DTC U0001). 3-89 ECU Communication Line Inspection 3-89 Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) 3-90 Fuel Injector Removal/Installation 3-90 Fuel Injector Audible Inspection. 3-90 Fuel Injector Resistance Inspection 3-90 Fuel Injector Power Source Voltage Inspection. 3-91 Fuel Injector Output Voltage Inspection 3-92 Fuel Injector Fuel Line Inspection 3-93 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) . 3-95 Stick Coil Removal/Installation. 3-95 Stick Coil Primary Winding Resistance Inspection. 3-95 Stick Coil Input Voltage Inspection 3-95 Radiator Fan Relay (Service Code 56) (DTC P0480) 3-97 Radiator Fan Relay Removal/Installation 3-97 Radiator Fan Relay Inspection. 3-97 Subthrottle Valve Actuator (Service Code 62) (DTC P2100). 3-98 Subthrottle Valve Actuator Removal 3-98 Subthrottle Valve Actuator Inspection 3-98 Subthrottle Valve Actuator Resistance Inspection. 3-98 Subthrottle Valve Actuator Input Voltage Inspection. 3-99 Air Switching Valve (Service Code 64) (DTC P0410) 3-101 Air Switching Valve Removal/Installation 3-101 Air Switching Valve Inspection. 3-101 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 3-102 Oxygen Sensor Heater Removal/Installation 3-102 Oxygen Sensor Heater Resistance Inspection. 3-102 Oxygen Sensor Heater Power Source Voltage Inspection 3-103 Fuel Supply System (Service Code 94) (DTC P0170) 3-105 Fuel Supply System Inspection 3-105 Purge Valve (Service Code 3A) (DTC P0443) (Other than US and CA Models). 3-106 Purge Valve Removal/Installation. 3-106 Purge Valve Inspection 3-106 IMU (Inertial Measurement Unit) (Service Code E8E) 3-108 IMU Removal . 3-108 IMU Installation 3-108 IMU Power Supply Inspection 3-108 IMU (Inertial Measurement Unit) Communication Error (Service Code E8F) 3-110 IMU Communication Line Inspection 3-110 Warning Indicator Light (LED) . 3-111 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-111 ECU. 3-112 ECU Identification 3-112 ECU Removal 3-112 ECU Installation . 3-112 ECU Power Supply Inspection. 3-113 CAN Communication Line . 3-116 CAN Communication Line Resistance Inspection. 3-116 CAN Communication Line . 3-117 DFI Power Source . 3-118 ECU Fuse Removal . 3-118 ECU Fuse Installation 3-118 ECU Fuse Inspection. 3-118 ECU Main Relay Removal/Installation 3-118 ECU Main Relay Inspection. 3-118 FUEL SYSTEM (DFI) 3-3 Fuel Line 3-119 Fuel Pressure Inspection . 3-119 Fuel Flow Rate Inspection . 3-120 Fuel Pump . 3-122 Fuel Pump Removal 3-122 Fuel Pump Installation . 3-123 Fuel Pump Operation Inspection . 3-123 Fuel Pump Operating Voltage Inspection 3-124 Pressure Regulator Removal. 3-125 Fuel Pump Relay Removal/Installation 3-125 Fuel Pump Relay Inspection 3-125 Throttle Grip and Cables . 3-127 Free Play Inspection 3-127 Free Play Adjustment. 3-127 Cable Installation . 3-127 Cable Lubrication. 3-127 Throttle Body Assy 3-128 Idle Speed Inspection/Adjustment 3-128 Synchronization Inspection/Adjustment. 3-128 Throttle Body Assy Removal 3-128 Throttle Body Assy Installation. 3-130 Throttle Body Assy Disassembly . 3-131 Throttle Body Assy Assembly 3-132 Air Cleaner. 3-133 Air Cleaner Element Removal/Installation 3-133 Air Cleaner Element Inspection . 3-133 Air Cleaner Oil Draining . 3-133 Air Cleaner Housing Removal 3-133 Air Cleaner Housing Installation. 3-134 Fuel Tank. 3-135 Fuel Tank Removal 3-135 Fuel Tank Installation . 3-137 Fuel Tank and Cap Inspection . 3-139 Fuel Tank Cleaning 3-140 Evaporative Emission Control System (other than US and CA Models) 3-141 Parts Removal/Installation . 3-141 Hose Inspection . 3-141 Purge Valve Inspection 3-141 Canister Inspection . 3-141 3-4 FUEL SYSTEM (DFI) Exploded View FUEL SYSTEM (DFI) 3-5 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Air Cleaner Housing Assembly Screws 1.1 0.11 10 inยทlb 2 Throttle Body Assy Holder Clamp Bolts 3.0 0.31 27 inยทlb 3 Delivery Pipe Assy Mounting Screws 3.43 0.350 30 inยทlb 4 Air Cleaner Housing Plate Screws 1.1 0.11 10 inยทlb 5 Throttle Case Bolts 3.5 0.36 31 inยทlb 6 Air Cleaner Housing Clamp Bolts 2.0 0.20 18 inยทlb S 7. Immobilizer System Equipped Models. 8. US and CA Models. CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. R: Replacement Parts S: Follow the specified tightening sequence. 3-6 FUEL SYSTEM (DFI) Exploded View FUEL SYSTEM (DFI) 3-7 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Oxygen Sensor 45 4.6 33 2 Water Temperature Sensor 12 1.2 106 inยทlb 3 Vehicle-down Sensor Mounting Bolts 6.0 0.61 53 inยทlb 4 Intake Air Temperature Sensor Screw 1.2 0.12 11 inยทlb 5 Crankshaft Sensor Bolts 6.0 0.61 53 inยทlb R: Replacement Parts 3-8 FUEL SYSTEM (DFI) Exploded View FUEL SYSTEM (DFI) 3-9 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Fuel Pump Assembly Screws 0.98 0.10 8.7 inยทlb R 2 Fuel Pump Bolts 10 1.0 89 inยทlb L, S 3 IMU Mounting Bolts 6.5 0.66 58 inยทlb L 4. Fuel Filter 5. Canister 6. Purge Valve 7. Other than US and CA Models. 8. US and CA Models. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. 3-10 FUEL SYSTEM (DFI) DFI System DFI System FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Front Wheel Rotation Sensor 4. Rear Wheel Rotation Sensor 5. ABS Hydraulic Unit 6. Vehicle-down Sensor 7. Pressure Regulator 8. Fuel Pump 9. Fuel Filter 10. Intake Air Temperature Sensor 11. Fuel Injectors 12. Delivery Pipe 13. Stick Coils 14. Water Temperature Sensor 15. Gear Position Sensor 16. Oxygen Sensor 17. Crankshaft Sensor 18. Intake Air Pressure Sensor #1 19. Intake Air Pressure Sensor #2 20. Air Switching Valve 21. Main Throttle Sensor 22. Subthrottle Valve Actuator 23. Subthrottle Sensor 24. IMU 25. Air Flow 26. Fuel Flow 3-12 FUEL SYSTEM (DFI) DFI System DFI Components Naming The terms used in the European regulation for DFI components are sometimes different from those used by Kawasaki. Use this table to cross reference terms which may appear in a generic scan tool whendiagnosing the DFI system. Sensors described in R44/2014 (Description per ISO 15031-6 in the parentheses) Kawasaki Name Barometric pressure sensor (Barometric pressure circuit) Intake air pressure sensor #2 Crankshaft position sensor (Crankshaft position sensor โAโ) Crankshaft sensor Engine coolant temperature sensor (Engine coolant temperature sensor 1) Water temperature sensor Exhaust control valve angle sensor (Exhaust pressure control valve position sensor) Exhaust butterfly valve actuator sensor Gear shift position sensor (Gear Shift Position Circuit) Gear position sensor Intake air temperature sensor (Intake air temperature sensor 1) Intake air temperature sensor Manifold absolute pressure sensor (Manifold absolute pressure/barometric pressure circuit) Intake air pressure sensor #1 O2 sensor (binary/linear) signals (O2 sensor) Oxygen sensor Throttle position sensor (Throttle/Pedal position sensor/switch โAโ) Main throttle sensor Throttle position sensor (Throttle/Pedal position sensor/switch โBโ) Subthrottle sensor Wheel speed sensor (Vehicle speed sensor โAโ) Front wheel rotation sensor Vehicle speed sensor (Vehicle speed sensor โBโ) Rear wheel rotation sensor Actuators described in R44/2014 (Description per ISO 15031-6 in the parentheses) Kawasaki Name Evaporative emission system purge control valve (Evaporative emission system purge control valve) Purge valve Exhaust control valve actuator (motor driven) (Exhaust pressure control valve) Exhaust butterfly valve actuator Fuel injector (Injector – cylinder 1 ๏พ 4) Fuel injector Ignition coil primary control circuits (Ignition coil โA ๏พ Dโ primary/secondary circuit) Stick coil O2 sensor heater (HO2S heater control circuit) Oxygen sensor heater Secondary air injection system (Secondary air injection system) Air switching valve Throttle by wire actuator (Throttle actuator control motor circuit) Subthrottle valve actuator FUEL SYSTEM (DFI) 3-13 DFI System This page intentionally left blank. 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram FUEL SYSTEM (DFI) 3-15 DFI System Part Names 1. ECU 2. Rear Wheel Rotation Sensor 3. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 4. Fuel Pump 5. ABS Hydraulic Unit 6. Frame Ground (5) 7. Frame Ground (4) 8. Frame Ground (2) 9. Frame Ground (1) 10. Engine Ground 11. Battery 12 V 8 Ah 12. Starter Relay 13. Main Fuse 30 A 14. ECU Fuse 15 A 15. Relay Box 16. Fuel Pump Relay 17. ECU Main Relay 18. Radiator Fan Relay 19. Joint Connector B 20. Joint Connector (1) 21. Joint Connector (2) 22. Fuse Box (1) 23. Fan Fuse 15 A 24. Ignition Fuse 15 A 25. Meter Unit 26. Front Wheel Rotation Sensor 27. IMU 28. Immobilizer Antenna (Equipped Models) 29. Immobilizer Amplifier (Equipped Models) 30. Ignition Switch 31. Fan Motor 32. Air Switching Valve 33. Engine Stop Switch 34. Starter Button 35. Spark Plugs and Stick Coils 36. Purge Valve (Other than US and CA Models) 37. Vehicle-down Sensor 38. Intake Air Temperature Sensor 39. Crankshaft Sensor 40. Fuel Injectors 41. Subthrottle Valve Actuator 42. Main Throttle Sensor 43. Subthrottle Sensor 44. Intake Air Pressure Sensor #2 45. Intake Air Pressure Sensor #1 46. Water Temperature Sensor 47. Gear Position Sensor 48. Oxygen Sensor โColor Codes: BK: Black BL: Blue BR: Brown CH: Chocolate DG: Dark Green G: Green GY: Gray LB: Light Blue LG: Light Green O: Orange P: Pink PU: Purple R: Red V: Violet W: White Y: Yellow 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: P/BL 2. Unused 3. Water Temperature Sensor: W/G 4. Power Supply to Sensors: BL 5. Fuel Pump Relay: BR/Y 6. Power Supply to ECU (from Battery): BR/W 7. Power Supply to ECU (from Battery): W/BK 8. Oxygen Sensor: BL/Y 9. CAN Communication Line (High): GY/BL 10. CAN Communication Line (Low): LB 11. Immobilizer Amplifier (Equipped Models): V 12. Subthrottle Valve Actuator: Y/BK 13. Unused 14. Unused 15. Unused 16. Intake Air Temperature Sensor: R/BK 17. Intake Air Pressure Sensor #2: G/W 18. Intake Air Pressure Sensor #1: Y/BL 19. Vehicle-down Sensor: Y/G 20. Rear Wheel Rotation Sensor Output: P 21. Rear Wheel Rotation Sensor Signal: R/Y 22. Immobilizer Amplifier (Equipped Models): P/BK 23. Subthrottle Valve Actuator: BK/O 24. Subthrottle Valve Actuator: G 25. Unused 26. Meter Communication Line: BL/O 27. Main Throttle Sensor: Y/W 28. Subthrottle Sensor: BL/W 29. Unused 30. Front Wheel Rotation Sensor Signal: G/Y 31. Outside Temperature Sensor: BL/R 32. Unused 33. Side Stand Switch: G/BK 34. Upper Button: P/BL 35. Starter Button: R/BK 36. Gear Position Sensor: G/R 37. Crankshaft Sensor (โ): Y/BK 38. Ground for Control System: BK/BL 39. Ground for Fuel System: BK/Y 40. Fuel Injector #3: BL/O 41. Fuel Injector #2: BL/R 42. Fuel Injector #1: BL/BK 43. Stick Coil #4: BK/G 44. Stick Coil #1: BK 45. Lower Button: Y/R 46. Starter Lockout Switch: R/G 47. External Communication Line (Immobilizer System (Equipped Models)/*KDS): LG/BK 48. Crankshaft Sensor (+): Y 49. Ground for Sensors: G 50. Purge Valve (Other than US and CA Models): R/Y 51. Green Neutral Indicator Light: LG 52. Fuel Injector #4: BL/G 53. Yellow KTRC Indicator Light (LED): G/R 54. Unused 55. Stick Coil #2: BK/R 56. SEL Button: G/W 57. Engine Stop Switch: R 58. Ground: BK/BL 59. Oxygen Sensor Ground: G/BK 60. External Communication Line (Immobilizer System (Equipped Models)/*KDS): O 61. Meter Unit (Tachometer): LB 62. Radiator Fan Relay: Y/BL 63. Air Switching Valve: R/BL 64. Oxygen Sensor Heater: P/BK 65. Ground for Ignition System: BK/Y 66. Stick Coil #3: BK/O *: KDS (Kawasaki Diagnostic System) FUEL SYSTEM (DFI) 3-17 DFI Parts Location Subthrottle Valve Actuator [A] Intake Air Pressure Sensor #1 [B] Stick Coils #1, #2, #3, #4 [C] Air Switching Valve [D] Intake Air Pressure Sensor #2 [E] Fuel Injectors #1, #2, #3, #4 [F] Subthrottle Sensor [A] Main Throttle Sensor [B] Water Temperature Sensor [A] Intake Air Temperature Sensor [A] Crankshaft Sensor [A] Oxygen Sensor [B] 3-18 FUEL SYSTEM (DFI) DFI Parts Location Vehicle-down Sensor [A] Battery 12 V 8 Ah [B] Fuse Box (1) [C] Main Fuse 30 A [A] ECU Fuse 15 A [B] ECU [A] Relay Box [B] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [C] Fuel Pump [A] Ignition Key [A] (Transponder, Immobilizer System Equipped Models) Immobilizer Antenna [B] (Equipped Models) Ignition Switch [C] Yellow Engine Warning Indicator Light (LED) [D] FUEL SYSTEM (DFI) 3-19 DFI Parts Location Immobilizer Amplifier [A] (Equipped Models) Front Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor [A] Purge Valve [A] (Other than US and CA Models) Gear Position Sensor [A] 3-20 FUEL SYSTEM (DFI) DFI Parts Location IMU [A] FUEL SYSTEM (DFI) 3-21 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ยฑ50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.5 in.) Throttle Body Vacuum 40.7 ยฑ1.3 kPa (305 ยฑ10 mmHg) at idle speed Bypass Screws (Turn Out) 0 ๏พ 2 1/2 (for reference) ECU: Make DENSO Type Digital memory type, with built in IC igniter, sealed with resin Fuel Pressure (High Pressure Line) 294 kPa (3.0 kgf/cmยฒ, 43 psi) with engine idling Fuel Pump: Type In-tank pump (in fuel pump) Discharge 50 mL (1.7 US oz.) or more for 3 seconds Fuel Injectors: Type EAT289 Nozzle Type Fine atomizing type with 8 holes Resistance About 11.7 ๏พ 12.3 โฆ @20ยฐC (68ยฐF) CAN Communication Line: Resistance About 120 โฆ at ECU Terminals Main Throttle Sensor: Input Voltage DC 4.75 ๏พ 5.25 V Output Voltage DC 1.02 ๏พ 1.06 V at idle throttle opening DC 4.22 ๏พ 4.42 V at full throttle opening (for reference) Resistance 4 ๏พ 6 kโฆ Intake Air Pressure Sensor #1/#2: Input Voltage DC 4.75 ๏พ 5.25 V Output Voltage DC 3.80 ๏พ 4.20 V at standard atmospheric pressure (see this text for details) Intake Air Temperature Sensor: Output Voltage About DC 2.25 ๏พ 2.50 V @20ยฐC (68ยฐF) Resistance 5.4 ๏พ 6.6 kโฆ @0ยฐC (32ยฐF) 0.29 ๏พ 0.39 kโฆ @80ยฐC (176ยฐF) Water Temperature Sensor: Output Voltage About DC 2.80 ๏พ 2.97 V @20ยฐC (68ยฐF) Gear Position Sensor: Input Voltage DC 4.75 ๏พ 5.25 V Output Voltage in the text Vehicle-down Sensor: Input Voltage DC 4.75 ๏พ 5.25 V Output Voltage With sensor tilted 60 ๏พ 70ยฐ or more right or left: DC 0.65 ๏พ 1.35 V With sensor arrow mark pointed up: DC 3.55 ๏พ 4.45 V 3-22 FUEL SYSTEM (DFI) Specifications Item Standard Subthrottle Sensor: Input Voltage DC 4.75 ๏พ 5.25 V Output Voltage DC 1.08 ๏พ 1.12 V at subthrottle valve full close position DC 4.2 ๏พ 4.4 V at subthrottle valve full open position (for reference) Resistance 4 ๏พ 6 kโฆ Immobilizer Antenna (Equipped Models): Resistance About 3.0 ๏พ 4.6 โฆ Subthrottle Valve Actuator: Resistance About 5.2 ๏พ 7.8 โฆ Input Voltage About DC 8.5 ๏พ 10.5 V and then 0 V or About DC 8.5 ๏พ 10.5 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 ๏พ 14.5 โฆ @20ยฐC (68ยฐF) Purge Valve (Other than US and CA Models): Resistance 30 ๏พ 34 โฆ @20ยฐC (68ยฐF) IMU: Input Voltage Battery voltage Throttle Grip and Cables Throttle Grip Free Play 2 ๏พ 3 mm (0.08 ๏พ 0.12 in.) Air Cleaner Air Cleaner Element Viscous paper element FUEL SYSTEM (DFI) 3-23 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cmยฒ: 57001-125 Carburetor Drain Plug Wrench, Hex 3: 57001-1269 Fork Oil Level Gauge: 57001-1290 Vacuum Gauge: 57001-1369 Throttle Sensor Setting Adapter #1: 57001-1400 Peak Voltage Adapter: 57001-1415 Needle Adapter Set: 57001-1457 Throttle Sensor Setting Adapter: 57001-1538 Extension Tube: 57001-1578 Fuel Pressure Gauge Adapter: 57001-1593 3-24 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Hose: 57001-1607 Measuring Adapter: 57001-1700 Liquid Gasket, TB1211: 56019-120 FUEL SYSTEM (DFI) 3-25 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. โThis 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. โDo not reverse the battery cable connections. This will damage the ECU. โTo 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. โTake care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. โWhen charging, remove the battery from the motorcycle. This is to prevent ECU damage by excessive voltage. โWhenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect the battery (โ) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. โConnect these connectors until they click [A]. โDo not turn the ignition switch on while any of the DFI electrical connectors are disconnected. The ECU memorizes service codes. โDo not spray water on the electrical parts, DFI parts, connectors, leads and wiring. โIf 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. โWhen 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. โDo not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure. โBefore removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air. โWhen 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. โWhen installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and run the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed. โRun the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. โTo prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals. 3-26 FUEL SYSTEM (DFI) DFI Servicing Precautions โIf the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A]. Replace the fuel hose if any fraying, cracks or bulges are noticed. โTo maintain the correct fuel/air mixture (F/A), there must be no intake air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Torque – Oil Filler Plug: Hand-tighten FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Outline โข When a problem occurs with DFI system, the yellow engine warning indicator light (LED) [A] goes on to alert the rider. โข When a problem occurs with a electrical control system, the yellow warning indicator light (LED) [B] goes on and following indicator blinking on the LCD to indicate kind of malfunctioning system. Power Mode Indicators [C] KTRC Mode Indicators [D] with โโโ KIBS Indicator [E] IMU Indicator [F] For models equipped with an immobilizer system, the red warning indicator light (LED) [A] and immobilizer warning indicator [B] blink, when a problem occurs in the system. With the engine stopped and turned in the self-diagnosis mode, the service code [A] is displayed on the LCD by the number of two digits. If the problem is with the following parts, the ECU can not recognize these problem. Therefore, the yellow engine warning indicator light (LED) does not go on, and service code is not displayed. Fuel Pump Fuel Pump Relay ECU Main Relay 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the cause [C] of problem. As a pre-diagnosis inspection, check the ECU for ground and power supply, the fuel line for no fuel leaks, and for correct pressure. The pre-diagnosis items are not indicated by the yellow engine warning indicator light (LED). Donโt rely solely on the DFI self-diagnosis function, use common sense. Even when the DFI system is operating normally, the yellow engine warning indicator light (LED) goes on may be displayed under strong electrical interference. Additional measures are not required. Turn the ignition switch off to stop the indicator light. If the yellow engine warning indicator light (LED) of the motorcycle brought in for repair still goes on, check the service code. When the repair has been done, the yellow engine warning indicator light (LED) goes off after the service code erasing procedure (see Service Code Erasing) is done. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel injectors and ignition system. The ignition switch is left on. If the starter button is pushed, the electric starter turns but the engine does not start. 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. FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System โข When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. โThe DFI part connectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C]. Insert the needle adapter inside the seal until the needle adapter reaches the terminal. Special Tool – Needle Adapter Set: 57001-1457 NOTICE Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals. โข Make sure that measuring points are correct in the connector, noting the position of the lock [D] and the lead color before measurement. Do not reverse connections of a digital meter. โข Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters. โข Turn the ignition switch on and measure the voltage with the connector joined. NOTICE Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts. โAfter measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant – Liquid Gasket, TB1211: 56019-120 โข Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. โข 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. โข Measure the coil winding resistance when the DFI part is cold (at room temperature). โข 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. 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System โข 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. โข Check the wiring for continuity. โUse the wiring diagram to find the ends of the lead which is suspected of being a problem. โConnect a tester between the ends of the leads. If the tester does not read about 0 โฆ, the lead is defective. Replace the lead or the main harness or the subharness. โIf both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness is open, repair or replace the harness. โWhen checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or replaced. โข Narrow down suspicious locations by repeating the continuity 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. FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider โEach rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. โTry to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem. โThe 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. 3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather โก fine, โก cloudy, โก rain, โก snow, โก always, โก other: Temperature โก hot, โก warm, โก cold, โก very cold, โก always, โก other: Problem frequency โก chronic, โก often, โกonce Road โก street, โก highway, โก mountain road (โก uphill, โก downhill), โก bumpy, โก pebble Altitude โก normal, โก high (about 1 000 m or more) Motorcycle conditions when problem occurred. โก goes on immediately after turning the ignition switch on, and goes off after about 1 second, and goes off after starting the engine (normal) โก goes on immediately after turning the ignition switch on, goes off after about 1 second, and goes on again after about 10 seconds (ECU communication error) โก goes on immediately after turning the ignition switch on, goes off after about 1 second, and stays on after starting the engine [DFI system or other electrical system problem] Yellow engine warning indicator light (LED) or yellow warning indicator light (LED) โก does not go on after turning the ignition switch on [indicator light (LED), meter unit fault] โก Starts blinking about 1 seconds after ignition switch on, and the immobilizer warning indicator on the LCD starts blinking (immobilizer system problem). โก Does not go on about 1 seconds after ignition switch on (ECU or meter unit fault). Red warning indicator light (LED) โก light up (battery, oil pressure, water temperature, immobilizer or meter unit problem) โก starter motor not rotating. โก starter motor rotating but engine do not turn over. โก starter motor and engine do not turn over. โก no fuel flow (โก no fuel in tank, โก no fuel pump sound). โก no spark. Starting difficulty โก other: โก right after starting. โก when opening throttle grip. โก when closing throttle grip. โก when moving off. โก when stopping the motorcycle. โก when cruising. Engine stalls โก other: FUEL SYSTEM (DFI) 3-33 Troubleshooting the DFI System โก very low idle speed, โก very high idle speed, โก rough idle speed. โก battery voltage is low (charge the battery). โก spark plug loose (tighten it). โก spark plug dirty, broken, or gap maladjusted (remedy it). โก backfiring. โก afterfiring. โก hesitation when acceleration. โก engine oil viscosity too high. โก brake dragging. โก engine overheating. โก clutch slipping. Poor running at low speed โก other: โก spark plug loose (tighten it). โก spark plug dirty, broken, or gap maladjusted (remedy it). โก spark plug incorrect (replace it). โก knocking (fuel poor quality or incorrect, โ use high-octane gasoline). โก brake dragging. โก clutch slipping. โก engine overheating. โก engine oil level too high. โก engine oil viscosity too high. Poor running or no power at high speed โก other: 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE โThis 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. โThe 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 Wonโt Turn Over Symptoms or Possible Causes Actions (chapter) Gear position sensor, starter lockout or side stand switch trouble Inspect each sensor or switch (see chapter 16). Immobilizer system trouble Inspect (see chapter 3). 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 16). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU ground and power supply trouble Inspect (see chapter 3). ECU trouble Inspect (see chapter 3). No or little fuel in tank Supply fuel (see Ownerโs 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 clogged Replace fuel filter (see chapter 2). 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 (chapter) Spark weak: Stick coil shorted or not in good contact Inspect or reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU trouble Inspect (see chapter 3). Fuel/air mixture incorrect: Little fuel in tank Supply fuel (see Ownerโs 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 clogged Replace fuel filter (see chapter 2). FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). 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). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Engine stalls easily: Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Stick coil trouble Inspect (see chapter 16). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake 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 clogged Replace fuel filter (see chapter 2). Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). 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). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake 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 16). Fuel pressure too low Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake 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). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Symptoms or Possible Causes Actions (chapter) Firing incorrect: Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 16). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU trouble Inspect (see chapter 3). Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 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 fuse blows. Fuel pump bearings may wear. Replace the fuel pump (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Cracked or obstructed intake air pressure sensor #1 and #2 vacuum hoses Inspect and repair or replace (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Knocking: Fuel poor quality or incorrect Fuel change (Use the gasoline recommended in the Ownerโs Manual). Spark plug incorrect Replace it with the correct plug (see chapter 2). Stick coil trouble Inspect (see chapter 16). ECU trouble Inspect (see chapter 3). Engine vacuum not synchronizing Inspect and adjust (see chapter 2). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Throttle valves will not fully open Inspect throttle cables and lever linkage (see chapter 3). Engine overheating – Water temperature sensor or crankshaft sensor trouble (see Overheating of Troubleshooting Guide in chapter 17) Air switching valve trouble Inspect and replace (see chapter 16). Air suction valve trouble Inspect and replace (see chapter 5). Exhaust Smokes Excessively: (Black smoke) Air cleaner element clogged Clean element (see chapter 2). Fuel pressure too high Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). (Brown smoke) Air duct loose Reinstall (see chapter 3). Fuel pressure too low Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-Diagnosis Outline The self-diagnosis system is monitoring the following mechanism. DFI System and Ignition System Power Mode System KTRC System IMU KIBS System Immobilizer System (Equipped Models) The following indicator lights (LED) are used for symbols of below table. LED Color Warning Indicators Yellow [A] FI (DFI System and Ignition System) Yellow [B] Power Mode, KTRC, IMU, KIBS Red [C] Oil Pressure, Battery Voltage, Water temperature, Immobilizer (Equipped Models) The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting or blinking the yellow engine warning indicator light (LED) [A], or yellow warning indicator light (LED) [B], power mode indicator [C], KTRC mode indicator [D], and IMU indicator [E] when DFI, ignition, power mode, KTRC or IMU are faulty, and initiates fail-safe function. In case of serious troubles, ECU stops the injection and ignition operation. The ABS hydraulic unit notifies the rider of troubles in this system by lighting or blinking the yellow ABS indicator light (LED) or KIBS indicator [A] when ABS parts are faulty, and initiates fail-safe function. For models equipped with immobilizer system, the ECU notifies the rider of troubles in this system by lighting or blinking the red warning indicator light (LED) [B] and immobilizer indicator [C] when immobilizer system parts are faulty, and initiates fail-safe function. Dealer Mode The LCD displays the service code(s) [A] to show the problem(s) which the above system has at the moment of diagnosis. 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Procedures NOTE โUse a fully charged battery when conducting self-diagnosis. Otherwise, the warning indicator light (LED) and indicator do not light or blink. โข Turn the ignition switch on and start the engine. โWhen a problem occurs with DFI system and ignition system, the yellow engine warning indicator light (LED) [A] stays on after starting the engine to alert the rider. โWhen a problem occurs with immobilizer system (equipped models), the red warning indicator light (LED) [A] and immobilizer warning indicator [B] blink. โข Push the upper meter button [A] to select the odometer mode. โข Push the upper meter button and lower meter button [B] the for more than two seconds. โข The service code [C] is displayed on the LCD by the number or letters of two or three digits. โข Any of the following procedures ends self-diagnosis. โWhen the service code is displayed on the LCD, push the upper and lower meter buttons for more than two seconds. The display will return to the previous display. โWhen the ignition switch is turned off. FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Self-Diagnosis Flow Chart Service Code Reading โThe service code(s) is displayed on the LCD by the numbers or letters of two or three digits. NOTE โThe LCD displays the alphabet of the service code as shown. โThe service code of the IMU adds โEโ at the left side of the code. 3-42 FUEL SYSTEM (DFI) Self-Diagnosis โWhen 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. โThen after completing all codes, the display is repeated until the ignition switch is turned off or upper and lower meter buttons are pushed for more than two seconds. โFor example, if three problems occurred in the order of 56, 16, 33, the service codes are displayed (each two seconds) from the lowest number in the order listed as shown below. (16 โ 33 โ 56) โ (16 โ 33 โ 56) โ ยท ยท ยท (repeated) Service Code Erasing โข The service codes stored in memory of the ECU can be erased using Kawasaki Diagnostic System (KDS Ver.3). If the Kawasaki Diagnostic System (KDS Ver.3) is not available, do the following procedures. 1. Turn on the ignition switch and start the engine. 2. Keep the idling speed more than 30 seconds. 3. Run the vehicle more than 5 minutes at a speed of 40 km/h (25 mph) or more. Be sure to keep the engine running during procedures 2 and 3 for more than 10 minutes in total. 4. Turn the ignition switch off. 5. Repeat the above procedures 3 times. 6. Start the engine and check that the yellow engine warning indicator light (LED) goes off. Service Code Table โThe service codes of the immobilizer system appear to system equipped models. Service Codes DTC (Diagnostic Trouble Code) System Problems P0120 11 P0123 FI Main throttle sensor malfunction, wiring open or short P0105 12 P0107 FI Intake air pressure sensor #1 malfunction, wiring open or short P0110 13 P0112 FI Intake air temperature sensor malfunction, wiring open or short P0115 14 P0117 FI Water temperature sensor malfunction, wiring open or short P2226 16 P2227 P2228 FI Intake air pressure sensor #2 malfunction, wiring open or short 21 P0335 FI Crankshaft sensor malfunction, wiring open or short 24 P2158 FI Rear wheel rotation sensor malfunction, wiring open or short FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Codes DTC (Diagnostic Trouble Code) System Problems P0914 25 P0915 P0916 FI Gear position sensor malfunction, wiring open or short 27 P0500 FI Front wheel rotation sensor malfunction, wiring open or short 31 C0064 FI Vehicle-down sensor malfunction, wiring open or short P0220 32 P0223 FI Subthrottle sensor malfunction, wiring open or short P0130 33 P0132 FI Oxygen sensor malfunction or inactivate, wiring open or short 35 โ Immobilizer Immobilizer amplifier malfunction (Equipped Models) 36 โ Immobilizer Blank key detection (Equipped Models) 39 โ FI ECU communication error 41 P0201 FI Fuel injector #1 malfunction, wiring open or short 42 P0202 FI Fuel injector #2 malfunction, wiring open or short 43 P0203 FI Fuel injector #3 malfunction, wiring open or short 44 P0204 FI Fuel injector #4 malfunction, wiring open or short 51 P0351 FI Stick coil #1 malfunction, wiring open or short 52 P0352 FI Stick coil #2 malfunction, wiring open or short 53 P0353 FI Stick coil #3 malfunction, wiring open or short 54 P0354 FI Stick coil #4 malfunction, wiring open or short 56 P0480 FI Radiator fan relay malfunction, wiring open or short 62 P2100 FI Subthrottle valve actuator malfunction, wiring open or short 64 P0410 FI Air switching valve malfunction, wiring open or short 67 P0030 FI Oxygen sensor heater malfunction, wiring open or short 94 P0170 FI Fuel supply system malfunction 3A P0443 FI Purge valve malfunction, wiring open or short (Other than US and CA Models) E8E โ FI IMU malfunction E8F โ FI IMU communication error or wiring open Notes: โThe 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. โWhen 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. โDTC (Diagnostic Trouble Code) is displayed on the Kawasaki Diagnostic System (KDS Ver.3) and the Generic Scan Tool (GST). 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Backups โThe ECU takes the following measures to prevent engine damage when the DFI, ignition or immobilizer system parts have troubles. Service Codes Parts or Function Output Signal Usable Range or Criteria Backups by ECU 11 Main Throttle Sensor Output Voltage 0.2 ๏พ 4.8 V If the main throttle sensor system fails (the output voltage is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method (1). 12 Intake Air Pressure Sensor #1 Intake Air Pressure (Absolute) Pv = 60 ๏พ 900 mmHg If the intake air pressure sensor #1 system fails (the signal is out of the usable range, wiring short or open), the ECU sets the DFI in the ฮฑ-N method (2). The ECU stops the feedback mode of the oxygen sensor. 13 Intake Air Temperature Sensor Intake Air Temperature Ta = โ30 ๏พ +120ยฐC If the intake air temperature sensor system fails (the signal is out of the usable range, wiring short or open), the ECU sets Ta at 40ยฐC. 14 Water Temperature Sensor Water Temperature Tw = โ30 ๏พ +120ยฐC If the water temperature sensor system fails (the signal is out of the usable range, wiring short or open), the ECU sets Tw at 80ยฐC and the radiator fan operates. 16 Intake Air Pressure Sensor #2 Intake Air Pressure (Absolute) Pv = 60 ๏พ 900 mmHg If the intake air pressure sensor #2 system fails (the signal is out of the usable range, wiring short or open), the ECU sets Pa at 760 mmHg (the standard atmospheric pressure). The ECU stops the feedback mode of the oxygen sensor. 21 Crankshaft Sensor Crankshaft sensor must send 22 signals to the ECU at the one cranking. If the crankshaft sensor fails, the engine stops by itself. 24 Rear Wheel Rotation Sensor Rear wheel rotation sensor must send 45 signals to the ECU at the 1 rotation of the wheel. If the rear wheel rotation sensor system fails (the signal is missing, wiring open), the ECU set the internal gear position value for the top (6th) and stops the KTRC. 25 Gear Position Sensor Output Voltage 0.2 ๏พ 4.8 V If the gear position sensor system fails (no signal, wiring short or open), the ECU set the top (6th) gear position. 27 Front Wheel Rotation Sensor Front wheel rotation sensor must send 48 signals to the ECU at the 1 rotation of the wheel. If the front wheel rotation sensor system fails (the signal is missing, wiring open), the ECU stops the KTRC. 31 Vehicle -down Sensor Output Voltage Vd = 0.10 ๏พ 4.84 V If the vehicle-down sensor system has failures (the output voltage is out of the usable range, wiring short or open), the ECU shuts off the fuel pump relay, the fuel injectors and the ignition system. 32 Subthrottle Sensor Output Voltage 0.15 ๏พ 4.85 V If the subthrottle sensor system fails (the output voltage is out of the usable range, wiring short or open), the ECU drive the subthrottle valve to the full closed position, and it stops the current to the subthrottle valve actuator. FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service Codes Parts or Function Output Signal Usable Range or Criteria Backups by ECU 33 Oxygen Sensor The oxygen sensor is active and sensor must send signals (output voltage) continuously to the ECU. If the oxygen sensor is not activated, the ECU stops the feedback mode of the oxygen sensor. 35 Immobilizer Amplifier (Equipped Models) โ If the immobilizer system fails (no signal, wiring short or open), the vehicle does not start, and does not run. 36 Ignition Key The ignition key must use register key. If the blank key or broken key is used, the vehicle does not start the engine. 39 ECU The communication error between the ECU and meter unit โ 41 Fuel Injector #1* The injector must send signals continuously to the ECU. If the injector #1 fails (no signal, wiring short or open), the ECU shuts off the signal to the injector. Fuel is not supplied to the cylinder #1, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 42 Fuel Injector #2* The injector must send signals continuously to the ECU. If the injector #2 fails (no signal, wiring short or open), the ECU shuts off the signal to the injector. Fuel is not supplied to the cylinder #2, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 43 Fuel Injector #3* The injector must send signals continuously to the ECU. If the injector #3 fails (no signal, wiring short or open), the ECU shuts off the signal to the injector. Fuel is not supplied to the cylinder #3, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 44 Fuel Injector #4* The injector must send signals continuously to the ECU. If the injector #4 fails (no signal, wiring short or open), the ECU shuts off the signal to the injector. Fuel is not supplied to the cylinder #4, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 51 Stick Coil #1* The ECU sends signals (output voltage) continuously to the stick coil. If the stick coil #1 primary winding has failures (no signal, wiring short or open), the ECU shuts off the injector #1 to stop fuel to the cylinder #1, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 52 Stick Coil #2* The ECU sends signals (output voltage) continuously to the stick coil. If the stick coil #2 primary winding has failures (no signal, wiring short or open), the ECU shuts off the injector #2 to stop fuel to the cylinder #2, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 3-46 FUEL SYSTEM (DFI) Self-Diagnosis Service Codes Parts or Function Output Signal Usable Range or Criteria Backups by ECU 53 Stick Coil #3* The ECU sends signals (output voltage) continuously to the stick coil. If the stick coil #3 primary winding has failures (no signal, wiring short or open), the ECU shuts off the injector #3 to stop fuel to the cylinder #3, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 54 Stick Coil #4* The ECU sends signals (output voltage) continuously to the stick coil. If the stick coil #4 primary winding has failures (no signal, wiring short or open), the ECU shuts off the injector #4 to stop fuel to the cylinder #4, though the engine keeps running. The ECU stops the feedback mode of the oxygen sensor. 56 Radiator Fan Relay When the radiator fan relay is OFF, the relay is opened. โ 62 Subthrottle Valve Actuator The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU. If the subthrottle valve actuator fails (the signal is out to the usable range, wiring short or open), the ECU stops the current to the actuator. 64 Air Switching Valve The air switching valve controls the flow of the secondary air by opening and shutting the solenoid valve. โ 67 Oxygen Sensor Heater The oxygen sensor heater raise temperature of the sensor for its earlier activation. If the oxygen sensor heater fails (wiring short or open), the ECU stops the current to the heater. 94 Fuel Supply System Fuel correction value exceeds a threshold. โ 3A Purge Valve (Other than US and CA Models) The purge valve controls the flow of the purge air for the canister and shutting the solenoid valve. If the purge valve fails (wiring short or open), the ECU stops operating purge valve. E8E IMU The IMU sends the data to the ECU and ABS hydraulic unit through the CAN communication line. โ E8F IMU Communication Line The IMU sends the data to the ECU and ABS hydraulic unit through the CAN communication line. โ Note: (1): D-J Method: When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (intake air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method. (2): ฮฑ-N Method: As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle sensor output voltage) and the engine speed. This method is called ฮฑ-N method. *: This depends on the number of stopped cylinders. FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening. Input Terminal [A]: BL Output Terminal [B]: Y/W Ground Terminal [C]: G Main Throttle Sensor Removal/Adjustment NOTICE Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shock to the main throttle sensor can damage it. Main Throttle Sensor Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). โข Disconnect the main throttle sensor connector and connect the setting adapter [A] between these connectors. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 โข Connect a digital meter to the setting adapter leads. Main Throttle Sensor Input Voltage Connections to Adapter: Digital Meter (+) โ W (sensor BL) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: DC 4.75 ๏พ 5.25 V โข Turn the ignition switch off. If the reading is within the standard, check the main throttle sensor resistance (see Main Throttle Sensor Resistance Inspection). 3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Main Throttle Sensor Connector [B] ECU Terminal 4 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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). Main Throttle Sensor Resistance Inspection โข Turn the ignition switch off. โข Disconnect the main throttle sensor connector. โข Connect the setting adapter [A] to the sensor connector only. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 โข Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections to Adapter: W (sensor BL) lead โโ BK (sensor G) lead Standard: 4 ๏พ 6 kโฆ 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 output voltage (see Main Throttle Sensor Output Voltage Inspection). Main Throttle Sensor Output Voltage Inspection โข Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, note the following. โDisconnect the main throttle sensor connector and connect the setting adapter [A] between these connectors. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 Main Throttle Sensor Output Voltage Connections to Adapter: Digital Meter (+) โ R (sensor Y/W) lead Digital Meter (โ) โ BK (sensor G) lead โข Start the engine and warm it up thoroughly. โข Check idle speed to ensure the throttle opening is correct (see Idle Speed Inspection in the Periodic Maintenance chapter). Idle Speed Standard: 1 100 ยฑ50 r/min (rpm) FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) โข Turn the ignition switch off. โข Measure the output voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Output Voltage Standard: DC 1.02 ๏พ 1.06 V at idle throttle opening DC 4.22 ๏พ 4.42 V at full throttle opening (for reference) NOTE โOpen the throttle, confirm the output voltage will be raise. โThe standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. โWhen the input voltage reading shows other than 5 V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V. 1.02 ร 4.75 รท 5.00 = 0.969 V 1.06 ร 4.75 รท 5.00 = 1.007 V Thus, the valid range is 0.969 ๏พ 1.007 V โข Turn the ignition switch off. 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, replace the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Main Throttle Sensor Connector [B] ECU Terminal 27 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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). 3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) Main Throttle Sensor Circuit 1. ECU 2. Subthrottle Sensor 3. Main Throttle Sensor FUEL SYSTEM (DFI) 3-51 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) Intake Air Pressure Sensor #1 Removal NOTICE Never drop the intake air pressure sensor #1 especially on a hard surface. Such a shock to the sensor can damage it. โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) โข Disconnect: Intake Air Pressure Sensor #1 Connector [A] โข Remove the intake air pressure sensor #1 [B] from the bracket [C]. โข Disconnect the vacuum hose [A]. โข Remove the rubber damper [B] from the intake air pressure sensor #1 [C]. Intake Air Pressure Sensor #1 Installation NOTE โThe intake air pressure sensor #1 is the same part as the intake air pressure sensor #2. โขInstallation is the reverse of removal. โข Position the intake air pressure sensor #1 [A] between the projections [B] on the rubber damper. โขInstall the rubber damper [A] on the bracket [B]. 3-52 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) Intake Air Pressure Sensor #1 Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the air cleaner housing (see Air Cleaner Housing Removal). โข Disconnect the intake air pressure sensor #1 connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Intake Air Pressure Sensor #1 [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Intake Air Pressure Sensor #1 Input Voltage Connections to Adapter: Digital Meter (+) โ R (sensor BL) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: DC 4.75 ๏พ 5.25 V โข Turn the ignition switch off. If the reading is within the standard, check the output voltage (see Intake Air Pressure Sensor #1 Output Voltage Inspection). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Intake Air Pressure Sensor #1 Connector [B] ECU Terminal 4 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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) 3-53 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) Intake Air Pressure Sensor #1 Output Voltage Inspection โข Measure the output voltage at the intake air pressure sensor #1 in the same way as input voltage inspection, note the following. โDisconnect the intake air pressure sensor #1 connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Intake Air Pressure Sensor #1 [C] Digital Meter [D] Special Tool – Measuring Adapter: 57001-1700 Intake Air Pressure Sensor #1 Output Voltage Connections to Adapter: Digital Meter (+) โ Y (sensor Y/BL) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the output voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Output Voltage Usable Range: DC 3.80 ๏พ 4.20 V at standard atmospheric pressure (101.32 kPa, 76 cmHg) NOTE โThe output voltage changes according to local atmospheric pressure. โข Turn the ignition switch off. If the reading is out of the usable range, replace the sensor. If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Intake Air Pressure Sensor #1 Connector [B] ECU Terminal 18 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [F] 3-54 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) If the wiring is good, check the sensor for various vacuum. โข Remove the intake air pressure sensor #1 [A] and disconnect the vacuum hose from the sensor. โข Connect an auxiliary hose [B] to the intake air pressure sensor #1. โข Temporarily install the intake air pressure sensor #1. โConnect a digital meter [C], vacuum gauge [D], the fork oil level gauge [E] and the measuring adapter to the intake air pressure sensor #1. Special Tools – Fork Oil Level Gauge: 57001-1290 Vacuum Gauge: 57001-1369 Measuring Adapter: 57001-1700 Intake Air Pressure Sensor #1 Output Voltage Connections to Adapter: Digital Meter (+) โ Y (sensor Y/BL) lead Digital Meter (โ) โ BK (sensor G) lead โTurn the ignition switch on. โMeasure the intake air pressure sensor #1 output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. โCheck the intake air pressure sensor #1 output voltage, using the following formula and chart. Suppose: Pg: Vacuum Pressure (Gauge) of Throttle Body Pl: Local Atmospheric Pressure (Absolute) measured by a barometer Pv: Vacuum Pressure (Absolute) of Throttle Body Vv: Sensor Output Voltage (V) then Pv = Pl + Pg For example, suppose the following data is obtained: Pg = โ8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Barometer Reading) Vv = 3.2 V (Digital Meter Reading) then Pv = 70 + (โ8) = 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 ๏พ 3.48 V Plot Vv (3.2 V) on the vertical line. โ Point [3]. Results: In the chart, Vv is within the usable range and the sensor is normal. If the reading is out of the usable range, replace the sensor. If the reading is within the usable range, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). FUEL SYSTEM (DFI) 3-55 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading) 3-56 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) Intake Air Pressure Sensor #1 Circuit 1. ECU 2. Intake Air Pressure Sensor #1 3. Intake Air Pressure Sensor #2 FUEL SYSTEM (DFI) 3-57 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) Intake Air Temperature Sensor Removal/Installation NOTICE Never drop the intake air temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. โข Remove the fuel tank (see Fuel Tank Removal). โข Disconnect the intake air temperature sensor connector [A]. โข Remove: Intake Air Temperature Sensor Screw [B] Intake Air Temperature Sensor [C] โข Be sure to install the O-ring [A]. โขInstall the intake air temperature sensor. โข Tighten: Torque – Intake Air Temperature Sensor Screw: 1.2 Nยทm (0.12 kgfยทm, 11 inยทlb) โข Connect the intake air temperature sensor connector. โขInstall the fuel tank (see Fuel Tank Installation). Intake Air Temperature Sensor Output Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the fuel tank (see Fuel Tank Removal). โข Disconnect the intake air temperature sensor connector and connect the measuring adapter [A] between these connectors as shown. Main Harness [B] Intake Air Temperature Sensor [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. 3-58 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) Intake Air Temperature Sensor Output Voltage Connections to Adapter: Digital Meter (+) โ R (sensor R/BK) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the output voltage with the engine stopped and the connector joined. โข Turn the ignition switch on. Output Voltage Standard: About DC 2.25 ๏พ 2.50 V @20ยฐC (68ยฐF) NOTE โThe output voltage changes according to the intake air temperature. โข 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 Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Intake Air Temperature Sensor Connector [B] ECU Terminal 16 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [F] If the wiring is good, check the intake air temperature sensor resistance (see Intake Air Temperature Sensor Resistance Inspection). FUEL SYSTEM (DFI) 3-59 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) Intake Air Temperature Sensor Resistance Inspection โข Remove the intake air temperature sensor (see Intake Air Temperature Sensor Removal/Installation). โข Suspend the sensor [A] in a container of water so that the heat-sensitive portion is submerged. โข Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with the sensor. NOTE โThe sensor and thermometer must not touch the container side or bottom. โข Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently for even temperature. โข Using a digital meter, measure the internal resistance of the sensor across the terminals at the temperatures shown in the following. Intake Air Temperature Sensor Resistance Standard: 5.4 ๏พ 6.6 kโฆ @0ยฐC (32ยฐF) 0.29 ๏พ 0.39 kโฆ @80ยฐC (176ยฐF) 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). Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor 3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) Water Temperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. โข Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). โข Disconnect: Water Temperature Sensor Connector [A] โข Remove: Water Temperature Sensor [B] with O-ring โข Replace the O-ring with a new one. โข Tighten: Torque – Water Temperature Sensor: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข Fill the engine with coolant and bleed the air from the cooling system (see Coolant Change in the Periodic Maintenance chapter). Water Temperature Sensor Output Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). โข Disconnect the water temperature sensor connector and connect the measuring adapter [A] between these connectors as shown. Subharness [B] Water Temperature Sensor [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Water Temperature Sensor Output Voltage Connections to Adapter: Digital Meter (+) โ R (sensor W/BL) lead Digital Meter (โ) โ BK (sensor O) lead โข Measure the output voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. FUEL SYSTEM (DFI) 3-61 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) Output Voltage Standard: About DC 2.80 ๏พ 2.97 V @20ยฐC (68ยฐF) NOTE โThe output voltage changes according to the coolant temperature in the engine. โข 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 Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main and subharness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Subharness Connector [B] ECU Terminal 3 [C] โโ Connector Terminal [D] ECU Terminal 49 [E] โโ Connector Terminal [F] Subharness Connector [A] โโ Water Temperature Sensor Connector [B] Connector Terminal [C] โโ Sensor Terminal [D] Connector Terminal [E] โโ Sensor Terminal [F] If the wiring is good, check the water temperature sensor resistance (see Water Temperature Sensor Resistance Inspection). Water Temperature Sensor Resistance Inspection โข 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). 3-62 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) Water Temperature Sensor Circuit 1. ECU 2. Water Temperature Sensor FUEL SYSTEM (DFI) 3-63 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) Intake Air Pressure Sensor #2 Removal NOTICE Never drop the intake air pressure sensor #2 especially on a hard surface. Such a shock to the sensor can damage it. โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) โข Disconnect: Intake Air Pressure Sensor #2 Connector [A] โข Remove the intake air pressure sensor #2 [B] from the bracket [C]. โข Disconnect the vacuum hose [A]. โข Remove the rubber damper [B] from the intake air pressure sensor #2 [C]. Intake Air Pressure Sensor #2 Installation NOTE โThe intake air pressure sensor #2 is the same part as the intake air pressure sensor #1. โขInstallation is the reverse of removal. โข Position the intake air pressure sensor #2 [A] between the projections [B] on the rubber damper. โขInstall the rubber damper [A] on the bracket [B]. 3-64 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) Intake Air Pressure Sensor #2 Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the air cleaner housing (see Air Cleaner Housing Removal). โข Disconnect the intake air pressure sensor #2 connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Intake Air Pressure Sensor #2 [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Intake Air Pressure Sensor #2 Input Voltage Connections to Adapter: Digital Meter (+) โ R (sensor BL) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: DC 4.75 ๏พ 5.25 V โข Turn the ignition switch off. If the reading is within the standard, check the output voltage (see Intake Air Pressure Sensor #2 Output Voltage Inspection). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Intake Air Pressure Sensor #2 Connector [B] ECU Terminal 4 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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) 3-65 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) Intake Air Pressure Sensor #2 Output Voltage Inspection โข Measure the output voltage at the intake air pressure sensor #2 in the same way as input voltage inspection, note the following. โDisconnect the intake air pressure sensor #2 connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Intake Air Pressure Sensor #2 [C] Digital Meter [D] Special Tool – Measuring Adapter: 57001-1700 Intake Air Pressure Sensor #2 Output Voltage Connections to Adapter: Digital Meter (+) โ Y (sensor G/W) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the output voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Output Voltage Usable Range: DC 3.80 ๏พ 4.20 V at standard atmospheric pressure (101.32 kPa, 76 cmHg absolute) NOTE โThe output voltage changes according to the local atmospheric pressure. โข Turn the ignition switch off. If the reading is out of the usable range, replace the sensor. If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Intake Air Pressure Sensor #2 Connector [B] ECU Terminal 17 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [F] If the wiring is good, check the sensor for various vacuum (see Intake Air Pressure Sensor #1 Output Voltage Inspection). 3-66 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) Intake Air Pressure Sensor #2 Circuit 1. ECU 2. Intake Air Pressure Sensor #1 3. Intake Air Pressure Sensor #2 FUEL SYSTEM (DFI) 3-67 Crankshaft Sensor (Service Code 21) (DTC P0335) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no signals. Crankshaft Sensor Removal/Installation โข Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection โข Refer to the Crankshaft Sensor Inspection in the Electrical System chapter. If the reading is within the standard, check the peak voltage (see Crankshaft Sensor Peak Voltage Inspection). Crankshaft Sensor Peak Voltage Inspection โข 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 connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Crankshaft Sensor Connector [B] ECU Terminal 37 [C] โโ Sensor Terminal [D] ECU Terminal 48 [E] โโ Sensor Terminal [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). Crankshaft Sensor Circuit 1. ECU 2. Crankshaft Sensor 3-68 FUEL SYSTEM (DFI) Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158) Rear Wheel Rotation Sensor Signal Inspection โThe rear wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit. โThe ECU uses the rear wheel rotation sensor signal for motorcycle speed. โThe service code 24/DTC P2158 is detected with the ECU. โขInspect the wheel rotation sensor air gap (see Wheel Rotation Sensor Air Gap Inspection in the Brakes chapter). โขInspect the wheel rotation sensor rotor (see Wheel Rotation Sensor Rotor Inspection in the Brakes chapter). โข When service code 24/DTC P2158 is displayed, do the following inspection procedures. โข Disconnect: ECU Connectors (see ECU Removal) Rear Wheel Rotation Sensor Lead Connector (see Rear Wheel Rotation Sensor Removal in the Brakes chapter) ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal in the Brakes chapter) โข Check the wiring for continuity between main harness connectors. Wiring Continuity Inspection ECU Connector [A] โโ ABS Hydraulic Unit Connector [B] ECU Terminal 21 [C] โโ ABS Hydraulic Unit Terminal 16 [D] Wiring Continuity Inspection ABS Hydraulic Unit Connector [A] โโ Rear Wheel Rotation Sensor Connector [B] ABS Hydraulic Unit Connector Terminal 14 [C] โโ Sensor Terminal [D] ABS Hydraulic Unit Connector Terminal 13 [E] โโ Sensor Terminal [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) 3-69 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158) Wheel Rotation Sensor Circuit 1. ECU 2. Rear Wheel Rotation Sensor 3. ABS Hydraulic Unit 4. Front Wheel Rotation Sensor 3-70 FUEL SYSTEM (DFI) Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0916) Gear Position Sensor Removal/Installation โข Refer to the Gear Position Sensor Removal/Installation in the Electrical System chapter. Gear Position Sensor Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Disconnect: Gear Position Sensor Connector [A] โข Connect the measuring adapter [A] between the harness connector and gear position sensor connector. Subharness [B] Gear Position Sensor [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Gear Position Sensor Input Voltage Connections to Adapters: Digital Meter (+) โ R (sensor LG) lead Digital Meter (โ) โ BK (sensor O) lead โข Measure the input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: DC 4.75 ๏พ 5.25 V โข Turn the ignition switch off. If the reading is within standard, check the output voltage (see Gear Position Sensor Output Voltage Inspection). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main and subharness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Subharness Connector [B] ECU Terminal 4 [C] โโ Connector Terminal [D] ECU Terminal 49 [E] โโ Connector Terminal [F] FUEL SYSTEM (DFI) 3-71 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0916) Subharness Connector [A] โโ Gear Position Sensor Connector [B] Connector Terminal [C] โโ Sensor Terminal [D] Connector Terminal [E] โโ Sensor Terminal [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). Gear Position Sensor Output Voltage Inspection โข Measure the output voltage at the gear position sensor in the same way as input voltage inspection, note the following. โDisconnect the gear position sensor connector and connect the measuring adapter [A] between these connectors. Subharness [B] Gear Position Sensor [C] Digital Meter [D] Special Tool – Measuring Adapter: 57001-1700 Gear Position Sensor Output Voltage Connections to Adapters: Digital Meter (+) โ Y (sensor P) lead Digital Meter (โ) โ BK (sensor O) lead โข Measure the output voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. โWhen changing the gear position from lower gear to higher gear, raise the rear wheel off the ground with the stand and rotate the rear wheel by hand. Gear Position Sensor Output Voltage Gear Position Output Voltage 1st 0.195 ๏พ 0.629 V N 0.811 ๏พ 0.976 V 2nd 1.143 ๏พ 1.615 V 3rd 1.860 ๏พ 2.426 V 4th 2.612 ๏พ 3.100 V 5th 3.398 ๏พ 3.998 V 6th 4.272 ๏พ 4.799 V โข Turn the ignition switch off. If the reading is out of the standard, replace the gear position sensor. 3-72 FUEL SYSTEM (DFI) Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0916) If the reading is within standard, remove the ECU and check the wiring for continuity between main and subharness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Subharness Connector [B] ECU Terminal 36 [C] โโ Connector Terminal [D] ECU Terminal 49 [E] โโ Connector Terminal [F] Subharness Connector [A] โโ Gear Position Sensor Connector [B] Connector Terminal [C] โโ Sensor Terminal [D] Connector Terminal [E] โโ Sensor Terminal [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). Gear Position Sensor Circuit 1. ECU 2. Gear Position Sensor FUEL SYSTEM (DFI) 3-73 Front Wheel Rotation Sensor (Service Code 27) (DTC P0500) Front Wheel Rotation Sensor Signal Inspection โThe front wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit. โThe service code 27/DTC P0500 is detected with the ECU. โขInspect the wheel rotation sensor air gap (see Wheel Rotation Sensor Air Gap Inspection in the Brakes chapter). โขInspect the wheel rotation sensor rotor (see Wheel Rotation Sensor Rotor Inspection in the Brakes chapter). โข When service code 27/DTC P0500 is displayed, do the following inspection procedures. โข Disconnect: ECU Connectors (see ECU Removal) Front Wheel Rotation Sensor Lead Connector (see Front Wheel Rotation Sensor Removal in the Brakes chapter) ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal in the Brakes chapter) โข Check the wiring for continuity between harness connectors. Wiring Continuity Inspection ECU Connector [A] โโ ABS Hydraulic Unit Connector [B] ECU Terminal 30 [C] โโ ABS Hydraulic Unit Terminal 8 [D] Wiring Continuity Inspection ABS Hydraulic Unit Connector [A] โโ Front Wheel Rotation Sensor Connector [B] ABS Hydraulic Unit Connector Terminal 12 [C] โโ Sensor Terminal [D] ABS Hydraulic Unit Connector Terminal 3 [E] โโ Sensor Terminal [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). 3-74 FUEL SYSTEM (DFI) Front Wheel Rotation Sensor (Service Code 27) (DTC P0500) Wheel Rotation Sensor Circuit 1. ECU 2. Rear Wheel Rotation Sensor 3. ABS Hydraulic Unit 4. Front Wheel Rotation Sensor FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) (DTC C0064) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ๏พ 70ยฐ or more to either side (in fact falls down), the weight turns and the signal changes. The ECU senses this change, and stops the fuel pump relay, the fuel injectors and the ignition system. Hall IC [B] When the motorcycle is down, the ignition switch is left on. If the starter button is pushed, the electric starter turns but the engine does not start. To start the engine again, raise the motorcycle, turn the ignition switch off, and then turn it on. Vehicle-down Sensor [A] Ground Terminal [B]: G Output Terminal [C]: Y/G Power Source Terminal [D]: BL Vehicle-down Sensor Removal NOTICE Never drop the vehicle-down sensor especially on a hard surface. Such a shock to the sensor can damage it. โข Remove: Fuel Tank (see Fuel Tank Removal) Fuel Tank Bracket Bolts [A] Fuel Tank Bracket [B] Rivet [C] โข Turn up the heat insulation rubber plate [D]. โข Disconnect: Vehicle-down Sensor Connector [A] โข Remove: Vehicle-down Sensor Bolts [B] and Bracket [C] Vehicle-down Sensor [D] 3-76 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) (DTC C0064) Vehicle-down Sensor Installation โข Be sure to install the rubber dampers [A] and collars [B] on the battery case. โข The UP mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situations for an accident resulting in injury or death. Ensure that the vehicle-down sensor is held in place by the battery case. โขInstall the bracket. โข Tighten: Torque – Vehicle-down Sensor Mounting Bolts: 6.0 Nยทm (0.61 kgfยทm, 53 inยทlb) โขInstall the removed parts (see appropriate chapters). Vehicle-down Sensor Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Disconnect the vehicle-down sensor connector and connect the measuring adapter [A] between these connectors as shown. Main Harness [B] Vehicle-down Sensor [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Vehicle-down Sensor Input Voltage Connections to Adapter: Digital Meter (+) โ R (sensor BL) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: DC 4.75 ๏พ 5.25 V โข Turn the ignition switch off. If the reading is within the standard, check the output voltage (see Vehicle-down Sensor Output Voltage Inspection). FUEL SYSTEM (DFI) 3-77 Vehicle-down Sensor (Service Code 31) (DTC C0064) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Vehicle-down Sensor Connector [B] ECU Terminal 4 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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). Vehicle-down Sensor Output Voltage Inspection โข Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). โข Connect the measuring adapter [A] to the vehicle-down sensor connectors as shown. Main Harness [B] Vehicle-down Sensor [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Vehicle-down Sensor Output Voltage Connections to Adapter: Digital Meter (+) โ W (sensor Y/G) lead Digital Meter (โ) โ BK (sensor G) lead 3-78 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) (DTC C0064) โข Hold the sensor vertically. โข Measure the output voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. โข Tilt the sensor 60 ๏พ 70ยฐ or more [A] right or left, then hold the sensor almost vertical with the arrow mark pointed up [B], and measure the output voltage. Output Voltage Standard: With sensor tilted 60 ๏พ 70ยฐ or more right or left: DC 0.65 ๏พ 1.35 V With sensor arrow mark pointed up: DC 3.55 ๏พ 4.45 V โข 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 connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Vehicle-down Sensor Connector [B] ECU Terminal 19 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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) 3-79 Vehicle-down Sensor (Service Code 31) (DTC C0064) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor 3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening. Input Terminal [A]: BL Output Terminal [B]: BL/W Ground Terminal [C]: G Subthrottle Sensor Removal/Adjustment NOTICE Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shock to the subthrottle sensor can damage it. Subthrottle Sensor Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). โข Disconnect the subthrottle sensor connector and connect the setting adapter [A] between these connectors. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 โข Connect a digital meter to the setting adapter leads. Subthrottle Sensor Input Voltage Connections to Adapter: Digital Meter (+) โ W (sensor BL) lead Digital Meter (โ) โ BK (sensor G) lead โข Measure the input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: DC 4.75 ๏พ 5.25 V โข Turn the ignition switch off. If the reading is within the standard, check the output voltage (see Subthrottle Sensor Output Voltage Inspection). FUEL SYSTEM (DFI) 3-81 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Subthrottle Sensor Connector [B] ECU Terminal 4 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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). Subthrottle Sensor Output Voltage Inspection โข Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection, note the following. โDisconnect the subthrottle sensor connector and connect the setting adapter [A] between these connectors. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 Subthrottle Sensor Output Voltage Connections to Adapter: Digital Meter (+) โ R (sensor BL/W) lead Digital Meter (โ) โ BK (sensor G) lead โข Remove the air cleaner housing (see Air Cleaner Housing Removal). โข Disconnect the subthrottle valve actuator connector [A]. 3-82 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) โข Measure the output voltage with the engine stopped with the connector joined. โข Turn the ignition switch on. โข Measure the output voltage when the subthrottle valves [A] are fully opened by hand. Output Voltage Standard: DC 1.08 ๏พ 1.12 V at subthrottle valve full close position DC 4.2 ๏พ 4.4 V at subthrottle valve full open position (for reference) NOTE โOpen the subthrottle valves, confirm the output voltage will be raise. โThe standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. โWhen the input voltage reading shows other than 5 V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V. 1.08 ร 4.75 รท 5.00 = 1.03 V 1.12 ร 4.75 รท 5.00 = 1.06 V Thus, the valid range is 1.03 ๏พ 1.06 V โข Turn the ignition switch off. If the reading is out of the standard, check the subthrottle sensor resistance (see Subthrottle Sensor Resistance Inspection). If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Subthrottle Sensor Connector [B] ECU Terminal 28 [C] โโ Sensor Terminal [D] ECU Terminal 49 [E] โโ Sensor Terminal [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) 3-83 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) Subthrottle Sensor Resistance Inspection โข Turn the ignition switch off. โข Disconnect the subthrottle sensor connector. โข Connect the setting adapter [A] to the sensor connector only. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 โข Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections to Adapter: W (sensor BL) lead โโ BK (sensor G) lead Standard: 4 ๏พ 6 kโฆ 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. Main Throttle Sensor 3-84 FUEL SYSTEM (DFI) Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) Oxygen Sensor Removal/Installation โข Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection โข Turn the ignition switch off. โข Open the clamp [A], and pull out the oxygen sensor lead connector [B]. โข Disconnect the oxygen sensor lead connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Oxygen Sensor [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Oxygen Sensor Output Voltage Connections to Adapter: Digital Meter (+) โ R (sensor BL) lead Digital Meter (โ) โ BK (sensor W) lead โข Remove the air switching valve [A] (see Air Switching Valve Removal in the Engine Top End chapter). โDo not disconnect the air switching valve connector [B]. FUEL SYSTEM (DFI) 3-85 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) โขInstall the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air. โข Remove the fuel hose (see Fuel Hose Replacement in the Periodic Maintenance chapter). โข Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Air Cleaner Housing (see Air Cleaner Housing Installation) Special Tool – Extension Tube: 57001-1578 โข Warm up the engine thoroughly until the radiator fan starts. โข Measure the output voltage with the connector joined. Output Voltage (with Plugs, Rich) Standard: DC 0.7 V or more โข Turn the ignition switch off. โข Remove the air cleaner housing (see Air Cleaner Housing Removal). โข Remove the plugs from the fittings [A]. WARNING The engine gets extremely hot during normal operation and can cause serious burns. Never touch a hot engine. โขInstall the air cleaner housing temporarily (see Air Cleaner Housing Installation). โข Start the engine, and let it idle. โข Measure the output voltage with the connector joined. Output Voltage (without Plugs, Lean) Standard: DC 0.2 V or less โข Turn the ignition switch off. 3-86 FUEL SYSTEM (DFI) Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) If the reading is out of the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connectors [A] โโ Oxygen Sensor Connector [B] ECU Terminal 8 [C] โโ Sensor Terminal [D] ECU Terminal 59 [E] โโ Sensor Terminal [F] If the wiring is good, replace the sensor. If the reading is within the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). Oxygen Sensor Circuit 1. ECU 2. Frame Ground (1) 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6. Main Fuse 30 A 7. ECU Fuse 15 A 8. Relay Box 9. ECU Main Relay 10. Fuse Box (1) 11. Ignition Fuse 15 A 12. Ignition Switch 13. Oxygen Sensor FUEL SYSTEM (DFI) 3-87 Immobilizer Amplifier (Service Code 35, Equipped Models) Antenna Resistance Inspection โข Turn the ignition switch off. โข Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). โข Cut the band [A]. โข Slide the dust cover [B]. โข Disconnect the antenna lead connector [A]. โข Measure the antenna resistance. Antenna Resistance Connections: BK lead โโ BK/W lead Standard: About 3.0 ๏พ 4.6 โฆ If the reading is out of the standard, replace the ignition switch (see Immobilizer System Parts Replacement in the Electrical System chapter). If the reading is within the standard, check the wiring to the amplifier (see Immobilizer System Circuit). If the wiring is good, check the input voltage of the amplifier (see Amplifier Input Voltage Inspection). Amplifier Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). โDo not disconnect the connectors. โข Connect a digital meter to the amplifier connector [A] with needle adapter set. Special Tool – Needle Adapter Set: 57001-1457 Amplifier Input Voltage Connections to Amplifier Connector: Digital Meter (+) โ BR/W lead Digital Meter (โ) โ BK/Y lead โข Measure the input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: Battery Voltage โข Turn the ignition switch off. If the reading is out of the standard, check the wiring (see Immobilizer System Circuit). If the reading is within the standard, check the wiring to ECU (see Immobilizer System Circuit). If the wiring is good, replace the amplifier (see Immobilizer System Parts Replacement in the Electrical System chapter). 3-88 FUEL SYSTEM (DFI) Blank Key Detection (Service Code 36, Equipped Models) โข This code appears in the following conditions. โThe transponder [A] in the ignition key is malfunction. โWhen the spare key of unregistration is used. โWhen the ignition key is registered in the registered ECU. โข Therefore, the service code 36 will disappear when the above issue is solved. Ignition Key Inspection โข Register the ignition key correctly (see Key Registration in the Electrical System chapter). If the service code 36 appears again, the transponder in the key is malfunction, replace it. Immobilizer System Circuit 1. ECU 2. Immobilizer/Kawasaki Diagnostic System Connector 3. Frame Ground (5) 4. Engine Ground 5. Battery 12 V 8 Ah 6. Starter Relay 7. Main Fuse 30 A 8. Joint Connector (1) 9. Joint Connector (2) 10. Fuse Box (1) 11. Ignition Fuse 15 A 12. Meter Unit 13. Immobilizer Antenna 14. Immobilizer Amplifier 15. Ignition Switch FUEL SYSTEM (DFI) 3-89 ECU Communication Error (Service Code 39) (DTC U0001) ECU Communication Line Inspection โWhen the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. โThe service code 39 is detected with meter unit. โข Remove the ECU and meter unit, check the wiring for continuity between main harness connectors. โDisconnect the ECU and meter unit connectors. Wiring Continuity Inspection ECU Connector [A] โโ Meter Unit Connector [B] ECU Terminal 26 [C] โโ Meter Terminal [D] If the wiring is good, check the meter unit (see Meter Unit Inspection in the Electrical System chapter). If the meter unit is normal, replace the ECU (see ECU Removal/Installation). ECU Communication Line Circuit 1. Meter Unit 2. ECU 3. Frame Ground (4) 3-90 FUEL SYSTEM (DFI) Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Inspect the eligible fuel injector according to the following service code or DTC. Service Code 41/DTC P0201 โ Fuel Injector #1 Service Code 42/DTC P0202 โ Fuel Injector #2 Service Code 43/DTC P0203 โ Fuel Injector #3 Service Code 44/DTC P0204 โ Fuel Injector #4 Fuel Injector Removal/Installation โข Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE โBe sure the battery is fully charged. โข Start the engine, and let it idle. โข Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). โข Apply a flat tip screwdriver [A] to the fuel injector [B]. Put the grip end onto your ear, and listen whether the fuel injector is clicking or not. โA sound scope can also be used. โThe click interval becomes shorter as the engine speed rises. โข Do the same for the other fuel injectors. If all the fuel injectors click at a regular intervals, the fuel injectors are normal. โข 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 โข Remove the throttle body assy with the connectors installed (see Throttle Body Assy Removal). โข Disconnect the fuel injector connector. โข Connect a digital meter to the terminals [A] in each fuel injector. โข Measure the fuel injector resistance. Fuel Injector Resistance Standard: About 11.7 ๏พ 12.3 โฆ @20ยฐC (68ยฐF) If the reading is out of the standard, replace the fuel injector. If the reading is within the standard, check the power source voltage (see Fuel Injector Power Source Voltage Inspection). FUEL SYSTEM (DFI) 3-91 Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Fuel Injector Power Source Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the throttle body assy with the connectors installed (see Throttle Body Assy Removal). โข Disconnect the injector connector and connect the measuring adapter [A] between these connectors as shown. Main Harness [B] Fuel Injector #1 [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter lead. Fuel Injector Power Source Voltage Connections to Adapter: For Fuel Injector #1, #2, #3, #4 Digital Meter (+) โ R (injector W/R) lead Digital Meter (โ) โ Battery (โ) Terminal โข Measure the power source voltage with the engine stopped. โข Turn the engine stop switch to run position. โข Turn the ignition switch on. Power Source Voltage Standard: Battery Voltage for 3 seconds, and then 0 V โข 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 fuel 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 fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter). If the fuel pump relay is normal, check the power source wiring (see Fuel Injector Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is in specification, check the output voltage (see Fuel Injector Output Voltage Inspection). 3-92 FUEL SYSTEM (DFI) Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Fuel Injector Output Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the ECU (see ECU Removal). โDo not disconnect the ECU connector. โข 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 (+) โ BL/BK lead (ECU terminal 42) Digital Meter (โ) โ Battery (โ) Terminal For Fuel Injector #2 Digital Meter (+) โ BL/R lead (ECU terminal 41) Digital Meter (โ) โ Battery (โ) Terminal For Fuel Injector #3 Digital Meter (+) โ BL/O lead (ECU terminal 40) Digital Meter (โ) โ Battery (โ) Terminal For Fuel Injector #4 Digital Meter (+) โ BL/G lead (ECU terminal 52) Digital Meter (โ) โ Battery (โ) Terminal โข Measure the output voltage with the engine stopped and with the connector joined. โข Turn the engine stop switch to run position. โข Turn the ignition switch on. Output Voltage Standard: Battery Voltage for 3 seconds, and then 0 V โข Turn the ignition switch off. If the reading is in specification, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). FUEL SYSTEM (DFI) 3-93 Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and injector connector. Wiring Continuity Inspection ECU Connector (Gray) [A] โโ Fuel Injector Connector [B] For Fuel Injector #1 [C] ECU Terminal 42 [D] โโ Fuel Injector Terminal [E] For Fuel Injector #2 ECU Terminal 41 โโ Fuel Injector Terminal For Fuel Injector #3 ECU Terminal 40 โโ Fuel Injector Terminal For Fuel Injector #4 ECU Terminal 52 โโ Fuel Injector Terminal 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 Injector Fuel Line Inspection โข Remove the throttle body assy (see Throttle Body Assy Removal). โข Check the fuel injector fuel line for leakage as follows. โConnect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends with the clamps [D]) as shown. Rear Side View [E] โApply soap and water solution to the areas [F] as shown. โWatching the pressure gauge, squeeze the pump lever [G], and build up the pressure until the pressure reaches the maximum pressure. Fuel Injector Fuel Line Maximum Pressure Standard: 300 kPa (3.06 kgf/cmยฒ, 43 psi) NOTICE During pressure testing, do not exceed the maximum pressure for which the system is designed. โWatch the gauge for at least 6 seconds. If the pressure holds steady, the fuel line is good. If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe, fuel injectors and related parts. โRepeat the leak test, and check the fuel line for no leakage. โขInstall the throttle body assy (see Throttle Body Assy Installation). โข Start the engine and check for fuel leakage. 3-94 FUEL SYSTEM (DFI) Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Fuel Injector Circuit 1. ECU 2. Frame Ground (2) 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6. Main Fuse 30 A 7. ECU Fuse 15 A 8. Relay Box 9. Fuel Pump Relay 10. Ignition Fuse 15 A 11. Fuse Box (1) 12. Ignition Switch 13. Engine Stop Switch 14. Fuel Injector #1 15. Fuel Injector #2 16. Fuel Injector #3 17. Fuel Injector #4 FUEL SYSTEM (DFI) 3-95 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) Inspect the eligible stick coil according to the following service code or DTC. Service Code 51/DTC P0351 โ Stick Coil #1 Service Code 52/DTC P0352 โ Stick Coil #2 Service Code 53/DTC P0353 โ Stick Coil #3 Service Code 54/DTC P0354 โ Stick Coil #4 Stick Coil Removal/Installation โข Refer to the Stick Coil Removal/Installation in the Electrical System chapter. Stick Coil Primary Winding Resistance Inspection โข Refer to the Stick Coil Inspection in the Electrical System chapter. If the reading is within the standard, check the input voltage (see Stick Coil Input Voltage Inspection). Stick Coil Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the ECU (see ECU Removal). โDo not disconnect the ECU connectors. โข 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 (+) โ BK lead (terminal 44) Digital Meter (โ) โ Battery (โ) Terminal For Stick Coil #2 Digital Meter (+) โ BK/R lead (terminal 55) Digital Meter (โ) โ Battery (โ) Terminal For Stick Coil #3 Digital Meter (+) โ BK/O lead (terminal 66) Digital Meter (โ) โ Battery (โ) Terminal For Stick Coil #4 Digital Meter (+) โ BK/G lead (terminal 43) Digital Meter (โ) โ Battery (โ) Terminal โข Measure the input voltage to each primary winding of the stick coils with the engine stopped and with the connectors joined. โข Turn the engine stop switch to run position. โข Turn the ignition switch on. Input Voltage Standard: Battery Voltage 3-96 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) โข Turn the ignition switch off. If the input voltage is out of the standard, check the wiring for continuity (see Stick Coil Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the input voltage is within the standard, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). Stick Coil Circuit 1. ECU 2. Frame Ground (2) 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6. Main Fuse 30 A 7. Ignition Fuse 15 A 8. Fuse Box (1) 9. Ignition Switch 10. Engine Stop Switch 11. Stick Coil #1 12. Stick Coil #2 13. Stick Coil #3 14. Stick Coil #4 FUEL SYSTEM (DFI) 3-97 Radiator Fan Relay (Service Code 56) (DTC P0480) Radiator Fan Relay Removal/Installation โThe radiator fan relay is built in the relay box [A]. โข Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection โข Refer to the Relay Circuit Inspection in the Electrical System chapter. If the radiator fan relay is normal, check the wiring for continuity (see Radiator Fan Relay Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). Radiator Fan Relay Circuit 1. Ignition Switch 2. Fan Motor 3. Fuse Box (1) 4. Ignition Fuse 15 A 5. Fan Fuse 15 A 6. Water Temperature Sensor 7. ECU 8. Frame Ground (5) 9. Frame Ground (1) 10. Engine Ground 11. Battery 12 V 8 Ah 12. Starter Relay 13. Main Fuse 30 A 14. Relay Box 15. Radiator Fan Relay 16. Joint Connector B 3-98 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) (DTC P2100) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shock to the subthrottle valve actuator can damage it. Subthrottle Valve Actuator Inspection NOTE โBe sure the battery is fully charged. โข Remove the air cleaner housing (see Air Cleaner Housing Removal). โข Turn the ignition switch on. โข Check to see that all the subthrottle valves [A] open and close smoothly. โข Turn the ignition switch off. If the subthrottle valves do not operate, check the subthrottle valve actuator resistance (see Subthrottle Valve Actuator Resistance Inspection). Subthrottle Valve Actuator Resistance Inspection โข Turn the ignition switch off. โข Remove the air cleaner housing (see Air Cleaner Housing Removal). โข Disconnect the subthrottle valve actuator connector [A]. โข Connect a digital meter to the subthrottle valve actuator connector [A]. โข Measure the subthrottle valve actuator resistance. Subthrottle Valve Actuator Resistance Connections: Y/BK lead [1] โโ P/BL lead [2] G lead [3] โโ BK/O lead [4] Standard: About 5.2 ๏พ 7.8 โฆ 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 voltage (see Subthrottle Valve Actuator Input Voltage Inspection). FUEL SYSTEM (DFI) 3-99 Subthrottle Valve Actuator (Service Code 62) (DTC P2100) Subthrottle Valve Actuator Input Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the air cleaner housing (see Air Cleaner Housing Removal). โข Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these connectors as shown. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect the peak voltage adapter [D] and a digital meter [E] to the measuring 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 (+) โ R (actuator BK/O) lead Digital Meter (โ) โ BK (actuator G) lead (II) Digital Meter (+) โ W (actuator P/BL) lead Digital Meter (โ) โ Y (actuator Y/BK) lead โข Measure the actuator input voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Input Voltage Standard: About DC 8.5 ๏พ 10.5 V and then 0 V or About DC 8.5 ๏พ 10.5 V โข 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. โDisconnect the ECU and actuator connectors. Wiring Continuity Inspection ECU Connector [A] โโ Subthrottle Valve Actuator Connector [B] ECU Terminal 1 [C] โโ Actuator Terminal [D] ECU Terminal 12 [E] โโ Actuator Terminal [F] ECU Terminal 23 [G] โโ Actuator Terminal [H] ECU terminal 24 [I] โโ Actuator Terminal [J] 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). 3-100 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) (DTC P2100) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator FUEL SYSTEM (DFI) 3-101 Air Switching Valve (Service Code 64) (DTC P0410) Air Switching Valve Removal/Installation โข Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection โข 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 Air Switching Valve Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). Air Switching Valve Circuit 1. ECU 2. Frame Ground (5) 3. Frame Ground (1) 4. Engine Ground 5. Battery 12 V 8 Ah 6. Starter Relay 7. Main Fuse 30 A 8. ECU Fuse 15 A 9. Relay Box 10. ECU Main Relay 11. Ignition Switch 12. Air Switching Valve 13. Fuse Box (1) 14. Ignition Fuse 15 A 3-102 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (DTC P0030) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxygen sensor (see Oxygen Sensor Removal in the Electrical System chapter). Oxygen Sensor Heater Resistance Inspection โข Turn the ignition switch off. โข Open the clamp [A], and pull out the oxygen sensor lead connector [B]. โข Disconnect the oxygen sensor lead connector. โข Connect a digital meter [A] to the oxygen sensor lead connector [B]. โข Measure the oxygen sensor heater resistance. Oxygen Sensor Heater Resistance Connections: BK lead [C] โโ BK lead [D] Standard: 11.7 ๏พ 14.5 โฆ @20ยฐC (68ยฐF) 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). FUEL SYSTEM (DFI) 3-103 Oxygen Sensor Heater (Service Code 67) (DTC P0030) Oxygen Sensor Heater Power Source Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Disconnect the oxygen sensor lead connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Oxygen Sensor [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter lead. Oxygen Sensor Power Source Voltage Connections to Adapter: Digital Meter (+) โ R (main harness BR/W) lead Digital Meter (โ) โ Frame Ground Terminal โข Measure the power source voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Power Source Voltage Standard: Battery Voltage โข Turn the ignition switch off. If the reading is in specification, but the problem still exists, replace the ECU (see ECU Removal/Installation). If the reading is out of the standard, check the following. ECU Fuse 15 A (see Fuse Inspection in the Electrical System chapter) Power Source Wiring (see Oxygen Sensor Circuit) If the fuse and wiring are good, remove the ECU and check the wiring for continuity between main harness connectors. โDisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] โโ Oxygen Sensor Connector [B] ECU Terminal 64 [C] โโ Sensor Terminal [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). 3-104 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (DTC P0030) Oxygen Sensor Circuit 1. ECU 2. Frame Ground (1) 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6. Main Fuse 30 A 7. ECU Fuse 15 A 8. Relay Box 9. ECU Main Relay 10. Fuse Box (1) 11. Ignition Fuse 15 A 12. Ignition Switch 13. Oxygen Sensor FUEL SYSTEM (DFI) 3-105 Fuel Supply System (Service Code 94) (DTC P0170) Fuel Supply System Inspection NOTE โIf the motorcycle has any other service code, first inspect the other service code. โขInspect the General fuel system (throttle body assy, air cleaner, fuel tank etc.). If the General fuel system 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). 3-106 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (DTC P0443) (Other than US and CA Models) Purge Valve Removal/Installation โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) โข Slide the clamps [A]. โข Disconnect: Purge Valve Lead Connector [B] Hoses [C] โข Remove: Nut [D] Purge Valve [E] โขInstallation is the reverse of removal. โข Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Purge Valve Inspection โข Remove the purge valve (see Purge Valve Removal/Installation). โข Connect a digital meter [A] to the purge valve terminals as shown. Purge Valve Resistance Standard: 30 ๏พ 34 โฆ @20ยฐC (68ยฐF) If the resistance reading is out of the specified value, replace it with a new one. โข Connect the 12 V battery [A] to the purge valve terminals as shown. โข Blow the air to the intake air duct [A], and make sure that the air flows from the outlet air duct [B]. FUEL SYSTEM (DFI) 3-107 Purge Valve (Service Code 3A) (DTC P0443) (Other than US and CA Models) โข Disconnect the 12 V battery. โข Blow the air to the intake air duct [A] again, and make sure that the air does not flow from the outlet air duct [B]. If the purge valve dose not operate as described, replace it with a new one. If the purge valve is good, check the wiring for continuity (see Purge Valve Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). Purge Valve Circuit 1. ECU 2. Frame Ground (1) 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6. Main Fuse 30 A 7. ECU Fuse 15 A 8. Relay Box 9. ECU Main Relay 10. Ignition Switch 11. Purge Valve 12. Fuse Box (1) 13. Ignition Fuse 15 A 3-108 FUEL SYSTEM (DFI) IMU (Inertial Measurement Unit) (Service Code E8E) IMU Removal NOTICE Never drop the IMU especially on a hard surface. Such a shock to the IMU can damage it. โข Remove the upper fairing (see Upper Fairing Removal in the Frame chapter). โข Disconnect the IMU connector [A]. โข Remove: IMU Mounting Bolts [B] and Nut Plate [C] IMU [D] IMU Installation โขInstall the grommets [A] and collar [B] if removed. โInstall the collar with flange side outward. โขInstall the IMU. โข Apply a non-permanent locking agent to the threads of the IMU mounting bolts, and tighten them. Torque – IMU Mounting Bolts: 6.5 Nยทm (0.66 kgfยทm, 58 inยทlb) โข Connect the IMU connector. โขInstall the upper fairing (see Upper Fairing Installation in the Frame chapter). IMU Power Supply Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โDo not disconnect the IMU connector [A]. โข Connect a digital meter to the IMU connector with needle adapter set [B]. Special Tool – Needle Adapter Set: 57001-1457 IMU Power Supply Voltage Connections to IMU Connector: Digital Meter (+) โ BR/W [C] lead Digital Meter (โ) โ BK/Y [D] lead โข Measure the power supply voltage with the engine stopped and with the connector joined. โข Turn the ignition switch on. Power Supply Voltage Standard: Battery Voltage โข Turn the ignition switch off. FUEL SYSTEM (DFI) 3-109 IMU (Inertial Measurement Unit) (Service Code E8E) If the reading is out of the specification, check the following. Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter) Power Source and Ground Wirings (see IMU Circuit) If the fuses and wirings are good, replace the IMU (see IMU Installation). If the IMU is normal, check the ECU for its ground and power supply (see ECU Power Supply Inspection in the Fuel System (DFI) chapter). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). IMU Circuit 1. ECU 2. ABS Kawasaki Self-diagnosis System Connector 3. ABS Hydraulic Unit 4. Frame Ground (4) 5. Engine Ground 6. Battery 12 V 8 Ah 7. Starter Relay 8. Main Fuse 30 A 9. Fuse Box (1) 10. Ignition Fuse 15 A 11. Joint Connector (1) 12. Joint Connector (2) 13. IMU 14. Ignition Switch 3-110 FUEL SYSTEM (DFI) IMU (Inertial Measurement Unit) Communication Error (Service Code E8F) IMU Communication Line Inspection โWhen the data (for status of IMU) is not sent from the IMU to the ECU, the service code E8F is displayed. โThe data is sent through the CAN communication line. โThe service code E8F is detected with the ECU. โWhen the service code E8F is detected, the IMU indicator [A] blinks and the yellow warning indicator light (LED) [B] goes on. โข Disconnect the ECU, ABS and IMU connectors, and check the wiring for continuity between main harness connectors. Wiring Continuity Inspection ECU Connector [A] โโ IMU Connector [B] ECU terminal 9 [C] โโ Sensor Terminal [D] ECU terminal 10 [E] โโ Sensor Terminal [F] If the wiring is good, check the ECU for CAN communication line resistance (see CAN Communication Line Resistance Inspection). If the CAN communication line resistance is good, replace the IMU (see IMU Installation). If the IMU is normal, check the ECU for its ground and power supply (see ECU Power Supply Inspection in the Fuel System (DFI) chapter). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter). FUEL SYSTEM (DFI) 3-111 Warning Indicator Light (LED) Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection Yellow Engine Warning Indicator Light (LED) [A] Yellow Warning Indicator Light (LED) [B] Red Warning Indicator Light (LED) [C] โIn this model, the above mentioned warning indicator lights (LED) go on or blink by the data sent from the ECU. โข Refer to the Meter Unit Inspection in the Electrical System chapter. Warning Indicator Light (LED) Circuit 1. ECU 2. Frame Ground (5) 3. Frame Ground (4) 4. Meter Unit 3-112 FUEL SYSTEM (DFI) ECU ECU Identification โMost countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Otherwise, the motorcycle cannot clear the regulation. ECU Identification Part Number [A] Specification 21175-1247 AU, IN and WVTA (FULL), with Immobilizer 21175-1248 US and CA without Immobilizer 21175-1249 CAL, without Immobilizer 21175-1250 ID, PH, SEA-B3 and IN (with saree guard equipped model) 21175-1251 SEA-B1 and TH with Immobilizer 21175-1254 MY with Immobilizer ECU Removal NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. NOTE โRefer to the Immobilizer System Parts Replacement in the Electrical System chapter for the models with the ECU guard. โข Remove the rear fender from the battery case and rear frame (see Flap and Rear Fender Removal in the Frame chapter). โข Remove the relay box [A] from the rubber protector. โข Disconnect the ECU connectors [B]. โข Remove: ECU [C] (with Rubber Protector [D]) โLift up the ECU with rubber protector to clear the projections [E]. ECU Installation โขInstall: ECU [A] (in Rubber Protector [B]) โขInsert the slits of the rubber protector to the projections [C] of the rear fender. โข Connect the ECU connectors [D]. โขInstall the removed parts (see appropriate chapters). FUEL SYSTEM (DFI) 3-113 ECU ECU Power Supply Inspection โข Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. โข Remove the ECU (see ECU Removal). โข Visually inspect the terminals [A] of the ECU and main harness connectors. If the terminals of the main harness connectors are damaged, replace the main harness. If the terminals of the ECU connectors are damaged, replace the ECU. โข Turn the ignition switch off. โข Disconnect the ECU connectors. Gray Connector [A] โข Set a digital tester [B] and check the following wiring for continuity. ECU Grounding Inspection Connections: (I) ECU Terminal 38, 39 or 65 โโ Battery (โ) Terminal (II) Engine Ground โโ Battery (โ) Terminal Criteria: Both: 0 โฆ If no continuity, check the connectors, the engine ground lead, or main harness, and repair or replace them if necessary. 3-114 FUEL SYSTEM (DFI) ECU If the wiring is good, check the power source voltage of the ECU. NOTE โBe sure the battery is fully charged. โข Connect the ECU connectors. โข Connect a digital meter [A] to the connector (black) [B] with the needle adapter set. Special Tool – Needle Adapter Set: 57001-1457 ECU Power Supply Inspection Connections: (I) Digital Meter (+) โ BR/W lead (terminal 6) Digital Meter (โ) โ Battery (โ) Terminal (II) Digital Meter (+) โ W/BK lead (terminal 7) Digital Meter (โ) โ Battery (โ) Terminal Ignition Switch off: BR/W lead (terminal 6): 0 V W/BK lead (terminal 7): Battery Voltage Ignition Switch on: Both: Battery Voltage If the reading is out of the specification, check the following. Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) 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 ECU Power Source Circuit) If the fuse, wiring and relay are good, replace the ECU (see ECU Removal/Installation). FUEL SYSTEM (DFI) 3-115 ECU ECU Power Source Circuit 1. ECU 2. Frame Ground (5) 3. Frame Ground (1) 4. Frame Ground (2) 5. Engine Ground 6. Battery 12 V 8 Ah 7. Starter Relay 8. Main Fuse 30 A 9. ECU Fuse 15 A 10. Relay Box 11. ECU Main Relay 12. Ignition Switch 13. Fuse Box (1) 14. Ignition Fuse 15 A 3-116 FUEL SYSTEM (DFI) CAN Communication Line CAN Communication Line Resistance Inspection โIn this model, resistors for CAN communication line are built in the ECU [A] and ABS hydraulic unit. โข Refer to the ABS Hydraulic Unit Inspection in the Brackes chapter for the resistor in the ABS hydraulic unit. โข Turn the ignition switch off. โข Remove: ECU [A] (see ECU Removal) โข Connect a digital meter [A] to the ECU connector (black) [B]. โข Measure the resistance between the CAN communication terminals. CAN Communication Line Resistance (at ECU Terminals) Connections: Terminal 9 โโ Terminal 10 Standard: about 120 โฆ If the reading is out of the standard, replace the ECU with new one. If the reading is within the standard, resistor of the ECU for CAN communication line is normal. โข Check the wiring for continuity of the CAN communication line (see wiring diagram in this section). If there is a open or short circuit, repair or replace the main harness. FUEL SYSTEM (DFI) 3-117 CAN Communication Line CAN Communication Line Circuit 1. ECU 2. Kawasaki Diagnostic System Connector 3. ABS Hydraulic Unit 4. Joint Connector (1) 5. Joint Connector (2) 6. IMU 3-118 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal โข Refer to the 30 A Main/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. โข Refer to the Fuse Installation in the Electrical System chapter. ECU Fuse Inspection โข Refer to the Fuse Inspection in the Electrical System chapter. ECU Main Relay Removal/Installation โThe ECU main relay is built in the relay box [A]. โข Refer to the Relay Box Removal in the Electrical System chapter. ECU Main Relay Inspection โข Refer to the Relay Circuit Inspection in the Electrical System chapter. FUEL SYSTEM (DFI) 3-119 Fuel Line Fuel Pressure Inspection NOTE โBe sure the battery is fully charged. โข Remove: Side Covers (see Side Cover Removal in the Frame chapter) Fuel Tank Bolts [A] Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) โBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy. WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. โขInstall the fuel pressure gauge adapter [A] and fuel hoses (Special Tool: 57001-1607) [B] between the fuel outlet pipe and delivery pipe. โข Secure the fuel hoses with the clamps. โข Connect the pressure gauge [C] to the fuel pressure gauge adapter. Special Tools – Oil Pressure Gauge, 5 kgf/cmยฒ: 57001-125 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607 WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death. Do not try to start the engine with the fuel hoses disconnected. โข Turn the engine stop switch to run position. โข Turn the ignition switch on. โThe fuel pump should operate for 3 seconds, and then should stop. NOTE โAfter turning on the engine stop switch and ignition switch, inspect the fuel leakage from the connected portion of the special tools. NOTICE Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged. 3-120 FUEL SYSTEM (DFI) Fuel Line โข Start the engine, and let it idle. โข Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cmยฒ, 43 psi) NOTE โThe gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. โข 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 Inspection) Amount of Fuel Flow (see Fuel Flow Rate Inspection) โข After above checks, measure the fuel pressure again. โข Remove the fuel pressure gauge, hoses and adapter. โขInstall: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Installation) โข Start the engine and check for fuel leakage. Fuel Flow Rate Inspection WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Wait until the engine cools down. โข Prepare a fuel hose (Special Tool: 57001-1607) and a measuring cylinder. Special Tool – Fuel Hose: 57001-1607 โข Remove: Seat Covers (see Seat Cover Removal in the Frame chapter) Fuel Tank Bolts [A] FUEL SYSTEM (DFI) 3-121 Fuel Line โข Open the fuel tank cap [A] to lower the pressure in the tank. โข Disconnect the fuel hose from the fuel pump (see Fuel Tank Removal). โBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. โข Connect the prepared fuel hose [A] to the fuel outlet pipe. โข Secure the fuel hose with a clamp. โขInsert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. โข Close the fuel tank cap. โข Turn the engine stop switch to run position. โข Turn the ignition switch on. โThe fuel pump should operate for 3 seconds, and then should stop. NOTICE Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged. โข Measure the discharge for 3 seconds. โRepeat this operation several times. Amount of Fuel Flow Standard: 50 mL (1.7 US oz.) or more for 3 seconds โข Turn the ignition switch off. If the fuel flow is much less than the specified, replace the fuel pump (see Fuel Pump Removal/Installation). โขInstall the fuel tank (see Fuel Tank Installation). โข Start the engine and check for fuel leakage. 3-122 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (โ) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTICE Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it. โข Draw the fuel out from the fuel tank with a commercially available electric pump. โข Remove the fuel tank (see Fuel Tank Removal). โBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. Plug the fuel pipe of the fuel tank. โข Turn the fuel tank upside down. โข Remove the fuel pump bolts [A], and take out the fuel pump [B]. NOTICE Do not pull the leads of the fuel pump. If they are pulled, the lead terminals may be damaged. โข Discard the fuel pump gasket [A]. FUEL SYSTEM (DFI) 3-123 Fuel Pump Fuel Pump Installation โข Remove dirt or dust from the fuel pump [A] by lightly applying compressed air. โข Replace the fuel pump gasket with a new one. โข Apply grease to the fuel pump gasket. NOTE โBe careful not to bend the fuel level sensor arm. โข Check that the fuel pump terminal [A] and band [B] are in place. โข Apply a non-permanent locking agent to the threads of the fuel pump bolts. โข Tighten the fuel pump bolts [C] to a snug fit. โข Tighten the fuel pump bolts alternating diagonally. Torque – Fuel Pump Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โข Tighten the pump bolts again to check the tightness. Fuel Pump Operation Inspection NOTE โBe sure the battery is fully charged. โข Turn the engine stop switch to run position. โข Turn the ignition switch on and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops. โข Turn the ignition switch off. If the pump does not operate as described above, check the operating voltage (see Fuel Pump Operating Voltage Inspection). 3-124 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection NOTE โBe sure the battery is fully charged. โข Turn the ignition switch off. โข Remove the front seat (see Front Seat Removal in the Frame chapter). โข Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown. Main Harness [B] Fuel Pump [C] Special Tool – Measuring Adapter: 57001-1700 โข Connect a digital meter [D] to the measuring adapter leads. Fuel Pump Operating Voltage Connections to Adapter: Digital Meter (+) โ R (pump BK/Y) lead Digital Meter (โ) โ BK (pump BK/W) lead โข Measure the operating voltage with engine stopped and with the connector joined. โข Turn the engine stop switch to run position. โข Turn the ignition switch on. Operating Voltage Standard: Battery Voltage for 3 seconds, and then 0 V โข 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 fuel 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 fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter). If the fuel pump relay is normal, check the wiring for continuity (see Fuel Pump Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is in specification, but the pump does not operate, replace the fuel pump (see Fuel Pump Removal/Installation). FUEL SYSTEM (DFI) 3-125 Fuel Pump Pressure Regulator Removal โThe pressure regulator [A] is built into the fuel pump [B] and can not be removed. Fuel Pump Relay Removal/Installation โThe fuel pump relay is built in the relay box [A]. โข Refer to the Relay Box Removal in the Electrical System chapter. Fuel Pump Relay Inspection โข Refer to the Relay Circuit Inspection in the Electrical System chapter. 3-126 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Ignition Fuse 15 A 4. Fuse Box (1) 5. ECU 6. Fuel Pump 7. Frame Ground (2) 8. Engine Ground 9. Battery 12 V 8 Ah 10. Starter Relay 11. Main Fuse 30 A 12. ECU Fuse 15 A 13. Relay Box 14. Fuel Pump Relay FUEL SYSTEM (DFI) 3-127 Throttle Grip and Cables Free Play Inspection โข Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Free Play Adjustment โข Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Cable Installation โขInstall the throttle cables in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. โขInstall 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. โข After installation, adjust each cable properly (see Throttle Control System Inspection in the Periodic Maintenance chapter). WARNING Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition. Be sure the cables are routed correctly and properly adjusted. Cable Lubrication โข Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter. 3-128 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection/Adjustment โข Refer to the Idle Speed Inspection/Adjustment in the Periodic Maintenance chapter. Synchronization Inspection/Adjustment โข Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTICE Never drop the throttle body assy especially on a hard surface. Such a shock to the body assy can damage it. โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) โข Disconnect: Intake Air Pressure Sensor #1 Connector [A] Intake Air Pressure Sensor #2 Connector [B] Subthrottle Valve Actuator Connector [C] Main Throttle Sensor Connector [D] Subthrottle Sensor Connector [E] โข Open the clamp [F]. โข Disconnect the vacuum hose [G] (Other than US and CA models). โข Loosen the locknuts [A]. โข Turn the adjusters [B] to give the more free play. FUEL SYSTEM (DFI) 3-129 Throttle Body Assy โข Remove: Bolts [A] Throttle Pulley Cover [B] โข Remove: Throttle Cable Holder Clamp [A] Throttle Cable Lower Ends [B] โข Loosen the throttle body assy holder clamp bolts [A]. Special Tool – Carburetor Drain Plug Wrench, Hex 3: 57001-1269 โข Disconnect the adjusting screw [A] from the bracket. 3-130 FUEL SYSTEM (DFI) Throttle Body Assy โข Remove the throttle body assy [A] from the throttle body assy holders. โข Disconnect the fuel injector connectors [B]. โข Remove the clamps [C]. โข After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders. NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage will occur. Throttle Body Assy Installation โข Be sure to position the throttle body assy holder clamp in original position (see Throttle Body Assy Holder Installation in the Engine Top End chapter). โข Connect the fuel injector connectors [A]. โขInstall the throttle body assy to the throttle body assy holders. โข Tighten: Torque – Throttle Body Assy Holder Clamp Bolts: 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) Special Tool – Carburetor Drain Plug Wrench, Hex 3: 57001-1269 โข Apply a thin coat of grease to the throttle cable lower ends. โข Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. โThe accelerator cable has a clamp [C]. โขInstall the clamp securely. โข Turn the throttle grip and make sure that the throttle pulley moves smoothly and return by spring force. โข Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). โข Adjust: Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter) Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter) FUEL SYSTEM (DFI) 3-131 Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 2. Subthrottle Valve Actuator 3. Main Throttle Sensor 4. Subthrottle Sensor 5. Fuel Injectors 6. Delivery Pipe Assy 7. Intake Air Pressure Sensor #1 8. Intake Air Pressure Sensor #2 NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy. โข Remove the throttle body assy (see Throttle Body Assy Removal). โข Remove the delivery pipe assy mounting screws [A] to pull out the fuel injectors [B] from the throttle body assy together with the delivery pipe assy [C]. NOTE โDo not damage the insertion portions of the injectors when they are pulled out from the throttle body. 3-132 FUEL SYSTEM (DFI) Throttle Body Assy โข Remove the fuel injectors [A] from the delivery pipe assy [B]. NOTE โDo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the fuel injector especially on a hard surface. Such a shock to the injector can damage it. Throttle Body Assy Assembly โข Before assembling, blow away dirt or dust from the throttle body and delivery pipe assy by applying compressed air. โข Replace the O-rings [A] of the joint pipe [B] with new ones. โข Apply engine oil to the new O-rings, and insert it to the delivery pipes [C]. โInsert the joint pipe so that the short side [D] faces right side. โLeft and right delivery pipes are identical. โข Replace the O-rings [A] of each fuel injector [B] with new ones. โข 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. โข Replace the dust seals [A] with new ones. โข Apply engine oil to the new dust seals. โขInstall the fuel injectors along with the delivery pipe assy to the throttle body. โข Tighten: Torque – Delivery Pipe Assy Mounting Screws: 3.43 Nยทm (0.350 kgfยทm, 30 inยทlb) โขInstall the throttle body assy (see Throttle Body Assy Installation). FUEL SYSTEM (DFI) 3-133 Air Cleaner Air Cleaner Element Removal/Installation โข Refer to the Air Cleaner Element Replacement in the Periodic Maintenance chapter. Air Cleaner Element Inspection โข Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). โข Visually check the element [A] for tears or breaks. If the element has any tears or breaks, replace the element. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. โข Visually check the catch tank [A] of the drain hose, if the water or oil accumulates in the tank. If any water or oil accumulates in the catch tank, remove the catch tank from the drain hose and drain it. WARNING Oil on tires will make them slippery and can cause an accident and injury. Be sure to reinstall the catch tank after draining. Air Cleaner Housing Removal โข Remove: Fuel Tank (see Fuel Tank Removal) Connector Bracket [A] โข Slide the clamp [B]. โข Disconnect: Breather Hose [C] Intake Air Temperature Sensor Connector [D] โข Remove: Bolt [A] 3-134 FUEL SYSTEM (DFI) Air Cleaner โข Loosen the air cleaner housing clamp bolt [A] on both sides. โข Lift up the air cleaner housing, and disconnect the air switching valve hose [A]. โข After removing the air cleaner housing, cover the clean cloth on the throttle body assy. Air Cleaner Housing Installation โขInstall the clamp bolt heads [A] outside as shown. โขInstall the air switching valve hose [B] to the air cleaner housing. โขInstall the air cleaner housing on the throttle body assy. โPush in the ducts touch the stopper of the throttle body assy. โข Tighten the air cleaner housing clamp bolt (left) first, and then air cleaner housing bolt (right). Torque – Air Cleaner Housing Clamp Bolts: 2.0 Nยทm (0.20 kgfยทm, 18 inยทlb) โข Tighten the bolt [C] securely. โข Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). FUEL SYSTEM (DFI) 3-135 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (โ) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. โข Turn the ignition switch off. โข Wait until the engine cools down. โข Disconnect the battery (โ) terminal (see Battery Removal in the Electrical System chapter). โข Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter) Fuel Tank Bolts [A] โข Disconnect the fuel pump lead connector [A]. โข Clear the fuel pump lead from the clamp [B]. โข Open the fuel tank cap [A] to lower the pressure in the tank. โDuring tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. 3-136 FUEL SYSTEM (DFI) Fuel Tank โข Draw the fuel out from the fuel tank with a commercially available pump [A]. โUse a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly. โPut the hose through the fill opening [C] into the tank and draw the fuel out. WARNING Spilled fuel is flammable and can be explosive under certain conditions. The fuel can not be removed completely from the fuel tank. Be careful for remained fuel spillage. โข Slide the clamp [A]. โข Disconnect the drain hose [B], and free the drain hose from the clamps [C]. โข Be sure to place a piece of cloth around the fuel hose joint. โข Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush. When removing with flat tip screwdriver โขInsert the flat tip screwdriver [A] into slit on the joint lock [B]. โข Turn the driver to disconnect the joint lock. When removing with fingers โข Open and push up [C] the joint lock with your fingers. NOTICE Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing. FUEL SYSTEM (DFI) 3-137 Fuel Tank โข Pull [A] the fuel hose joint [B] out of the outlet pipe. WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. โข Slide the clamp [A]. โข Disconnect: Fuel Tank Breather Hose [B] โข Remove: Fuel Tank Bolt [C] โข Close the fuel tank cap. โข Remove the fuel tank, and place it on a flat surface. โDo not apply the load to the fuel pipe of the fuel pump. โข Clean the pipe [A]. โข Cover the pipe and the hose joint [B] with the vinyl bags [C] to keep it clean. Fuel Tank Installation โข Note the above WARNING (see Fuel Tank Removal). โข Check that the dampers [A], pads [B] and trim [C] are in place on the frame and the fuel tank. If the dampers, pads and trim are damaged or deteriorated, replace them. โข Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). 3-138 FUEL SYSTEM (DFI) Fuel Tank โข When assembling the fuel tank, note the followings. โWhen attaching the pads [A], align its corner with the rounded edge of the tank. โWhen attaching the pads [B] align its center with the fuel pump cover on the fuel tank. Dampers [C] View X [D] View Y [E] Dampers [F] (Both Side) โWhen installing the dampers [G], position it at center of left and right. โWhen installing the grommets [H], position the large diameter side toward the outside. โข Remove the vinyl bags on the pipe and fuel hose joint. โข Check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose with a new one. โข Check that there are no flaws, burrs, and adhesion of foreign materials on the pipe [A]. โข Apply engine oil to the pipe. FUEL SYSTEM (DFI) 3-139 Fuel Tank โขInsert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. โข Push [B] the joint lock [C] until the hose joint clicks. โข 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 Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is installed correctly on the delivery pipe. If it comes off, reinstall the hose joint. โข Connect the drain hose [A]. โข Bend the clamps [B] to hold the drain hose. โข Connect the fuel pump lead connector and the battery (โ) terminal (see Battery Installation in the Electrical System chapter). โขInstall the removed parts (see appropriate chapters). Fuel Tank and Cap Inspection โข Open the tank cap. โข Visually inspect the gasket [A] on the tank cap for any damage. Replace the tank cap if gasket is damaged. โข Check to see if the water drain pipe hole [B] and fuel breather pipe hole [C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air. NOTICE Do not apply compressed air to the air vent holes [D] in the tank cap. This could cause damage and clogging of the labyrinth in the cap. 3-140 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low flash-point solvents to clean the tank. โข Remove: Fuel Tank (see Fuel Tank Removal) Fuel Pump (see Fuel Pump Removal) โข Pour some high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. โข Draw the solvent out of the fuel tank. โข Dry the tank with compressed air. โขInstall: Fuel Pump (see Fuel Pump Installation) Fuel Tank (see Fuel Tank Installation) FUEL SYSTEM (DFI) 3-141 Evaporative Emission Control System (other than US and CA Models) The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart. Parts Removal/Installation WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. NOTICE If gasoline, solvent, water or any other liquid enters the canister, the canisterโs vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one. โข Connect the hoses according to the diagram of the system (see Cable, Wire, and Hose Routing section in the Appendix chapter). Make sure they do not get pinched or kinked. Hose Inspection โข Refer to the Evaporative Emission Control System Inspection (Other than US and CA Models) in the Periodic Maintenance chapter. Purge Valve Inspection โข Refer to the Purge Valve Inspection. Canister Inspection โข Refer to the Evaporative Emission Control System Inspection (Other than US and CA Models) in the Periodic Maintenance chapter. COOLING SYSTEM 4-1 4 Cooling System Table of Contents Exploded View 4-2 Coolant Flow Chart. 4-4 Specifications . 4-6 Special Tools . 4-7 Coolant . 4-8 Coolant Deterioration Inspection. 4-8 Coolant Level Inspection. 4-8 Coolant Draining . 4-8 Coolant Filling . 4-8 Pressure Testing . 4-8 Cooling System Flushing 4-9 Coolant Reserve Tank Removal/Installation . 4-9 Water Pump 4-10 Water Pump Removal. 4-10 Water Pump Installation 4-10 Water Pump Inspection. 4-12 Water Pump Impeller Disassembly/Assembly 4-12 Water Pump Impeller Inspection. 4-12 Water Pump Housing Disassembly 4-12 Water Pump Housing Assembly . 4-13 Mechanical Seal Inspection 4-13 Radiator 4-14 Radiator and Radiator Fan Removal 4-14 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection. 4-16 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection. 4-17 Thermostat . 4-18 Thermostat Removal. 4-18 Thermostat Installation 4-18 Thermostat Inspection 4-18 Hose and Pipes 4-20 Hose Installation . 4-20 Hose Inspection 4-20 Water Temperature Sensor 4-21 Water Temperature Sensor Removal/Installation . 4-21 Water Temperature Sensor Inspection . 4-21 4-2 COOLING SYSTEM Exploded View COOLING SYSTEM 4-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Water Hose Clamp Screws 3.0 0.31 27 inยทlb 2 Fitting Bolt 9.0 0.92 80 inยทlb L 3 Thermostat Housing Bolts 6.0 0.61 53 inยทlb L 4 Heat Insulation Plate Bolts 7.0 0.71 62 inยทlb 5 Oil Cooler Bolts 12 1.2 106 inยทlb L 6 Water Pipe Bolts 12 1.2 106 inยทlb L 7 Water Pump Impeller Bolt 10 1.0 89 inยทlb 8 Water Pump Cover Bolts 11 1.1 97 inยทlb 9 Coolant Drain Bolt 11 1.1 97 inยทlb G: Apply grease. HG: Apply high-temperature grease. L: Apply a non-permanent locking agent. R: Replacement Parts W: Apply water. WL: Apply soap and water solution or rubber lubricant. 4-4 COOLING SYSTEM Coolant Flow Chart 1. Radiator 2. Radiator Fan 3. Water Temperature Sensor 4. Air Bleeder Hose 5. Radiator Overflow Hose 6. Radiator Cap 7. Thermostat Housing 8. Outlet Pipe 9. Reserve Tank Overflow Hose 10. Reserve Tank 11. Water Pump 12. Intake Pipe 13. Cylinder Jacket 14. Oil Cooler 15. Cylinder Head Jacket 16. Hot Coolant 17. Cold Coolant COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is less than 55ยฐC (131ยฐF), the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant temperature is more than 58 ๏พ 62ยฐC (136 ๏พ 144ยฐF), the thermostat opens and the coolant flows. When the coolant temperature goes up beyond 100ยฐC (212ยฐF), the radiator fan relay conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the coolant temperature is below 97.5ยฐC (208ยฐF), the fan relay opens and the radiator fan stops. In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies. The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank. The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 93.3 ๏พ 122.7 kPa (0.95 ๏พ 1.25 kgf/cmยฒ, 13.5 ๏พ 17.8 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 93.3 ๏พ 122.7 kPa (0.95 ๏พ 1.25 kgf/cmยฒ, 13.5 ๏พ 17.8 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to 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 โ35ยฐC (โ31ยฐF) Total Amount 2.9 L (3.1 US qt) (reserve tank full level, including radiator and engine) Radiator Cap Relief Pressure 93.3 ๏พ 122.7 kPa (0.95 ๏พ 1.25 kgf/cmยฒ, 13.5 ๏พ 17.8 psi) Thermostat Valve Opening Temperature 58 ๏พ 62ยฐC (136 ๏พ 144ยฐF) Valve Full Opening Lift 8 mm (0.31 in.) or more at 75ยฐC (167ยฐF) COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: 57001-1129 Oil Seal Driver 37.5: 57001-1660 4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection โข Visually inspect the coolant in the reserve tank [A]. 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 โข Refer to the Coolant Level Inspection in the Periodic Maintenance chapter. Coolant Draining โข Refer to the Coolant Change in the Periodic Maintenance chapter. Coolant Filling โข Refer to the Coolant Change in the Periodic Maintenance chapter. Pressure Testing โข Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). โข Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck. NOTE โWet the cap sealing surfaces with water or coolant to prevent pressure leaks. โข Build up pressure in the system carefully until the pressure reaches 122.7 kPa (1.25 kgf/cmยฒ, 17.8 psi). NOTICE During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 122.7 kPa (1.25 kgf/cmยฒ, 17.8 psi). โข 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. โข Remove the pressure tester, replenish the coolant, and install the radiator cap. โขInstall the right lower fairing (see Lower Fairing Installation in the Frame chapter). COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the efficiency of the cooling system. โข Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter). โข Fill the cooling system with fresh water mixed with a flushing compound. NOTICE Do not use a flushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer of the cleaning product. โข Warm up the engine, and run it at normal operating temperature for about ten minutes. โข Stop the engine, and drain the cooling system. โข Fill the system with fresh water. โข Warm up the engine and drain the system. โข Repeat the previous two steps once more. โข Fill the system with a permanent type coolant and bleed the air from the system (see Coolant Change in the Periodic Maintenance chapter). Coolant Reserve Tank Removal/Installation โข The coolant reserve tank is removed and installed during coolant change (see Coolant Change in the Periodic Maintenance chapter). 4-10 COOLING SYSTEM Water Pump Water Pump Removal โข Drain: Coolant (see Coolant Change in the Periodic Maintenance chapter) Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) โข Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). โข Remove the water pipe bolts [A], and disconnect the water pipes [B]. โข Slide the water hose clamp [C]. โข Disconnect the water hose [D]. โข Remove: Water Pump Cover Bolts [A] Clamp [B] Water Pump Cover [C] โข Remove: Water Pump Impeller Bolt [A] and Washer Water Pump Impeller [B] Water Pump Housing [C] Water Pump Installation โข Replace the O-ring [A] with a new one, and install it. COOLING SYSTEM 4-11 Water Pump โข Be sure to install the dowel pins [A]. โขInstall: Water Pump Housing [A] Water Pump Impeller [B] โข Replace the washer with a new one, and install it. โข Tighten: Torque – Water Pump Impeller Bolt [C]: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โข Be sure to install the dowel pins [D]. โข Replace the O-ring [A] with a new one, and install it. โขInstall: Water Pump Cover [A] Clamp [B] โข Tighten: Torque – Water Pump Cover Bolts [C]: 11 Nยทm (1.1 kgfยทm, 97 inยทlb) โข Replace the O-rings [D] with new ones. โข Apply soap and water solution to the O-rings. โขInstall the water pipes [A] to the water pump cover. โข Apply a non-permanent locking agent to the threads of the water pipe bolts [B], and tighten them. Torque – Water Pipe Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โขInstall the water hose [C] and clamp [D] (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). 4-12 COOLING SYSTEM Water Pump Water Pump Inspection โข Check the drainage outlet passage [A] at the bottom of the water pump housing for coolant leaks. โขIf a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously. โWhen coolant does not continuously leak, it is normal. If the mechanical seal is damaged, the coolant continuously leaks through the drainage outlet passage. Replace the mechanical seal unit (see Water Pump Housing Disassembly/Assembly). If the oil seal is damaged, engine oil leaks through the drainage outlet passage. Replace the oil seal. Water Pump Impeller Disassembly/Assembly โข Remove the water pump impeller (see Water Pump Removal). โข The sealing seat [A] and rubber seal [B] may be removed easily by hand. โข Apply water or coolant around the surfaces of the rubber seal and sealing seat. โขInstall the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole. โขInstall the water pump impeller (see Water Pump Installation). Water Pump Impeller Inspection โข Remove the water pump cover (see Water Pump Removal). โข Visually inspect the water pump impeller [A]. If the surface is corroded or if the blades are damaged, replace the water pump impeller. Water Pump Housing Disassembly NOTICE Do not damage the hole wall of the water pump housing. โขInsert a bar [A] into the pump housing [B], and hammer evenly around the circumference of the mechanical seal bottom [C]. COOLING SYSTEM 4-13 Water Pump โข Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly NOTICE Do not reuse the mechanical seal and oil seal. โข Apply high-temperature grease to the oil seal lips [A]. โข Press the new oil seal into the housing with a bearing driver [B] until it stops at the bottom surface [C] of the housing. Special Tool – Bearing Driver Set: 57001-1129 NOTICE Be careful not to damage the sealing surface of the mechanical seal. โข Press the new mechanical seal into the housing with the oil seal driver [A] until its flange [B] touches the surface [C] of the housing. Special Tool – Oil Seal Driver 37.5: 57001-1660 Mechanical Seal Inspection โข Remove the water pump impeller (see Water Pump Removal). โข Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechanical seal as a unit. Impeller Sealing Seat Surface [A] Rubber Seal [B] Mechanical Seal [C] 4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal โข Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). โข Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). โข Cut the band [A]. โข Slide the dust cover [A]. โข Open the clamp [B]. โข Disconnect the radiator fan motor lead connector [C]. โข Remove the bolt [A] and collar. โข Loosen the water hose clamp screw [B]. โข Disconnect the water hose [C]. โข Loosen the water hose clamp screw [A]. โข Disconnect the water hose [B]. โข Remove the radiator lower bolt [C]. โข Remove the radiator upper bolt [A]. COOLING SYSTEM 4-15 Radiator โข Move the radiator leftward [A] to clear the frame projection [B]. โข Remove the radiator [C]. NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency. โข Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] Radiator and Radiator Fan Installation โขInstallation is the reverse of removal. โขInstall the rubber dampers [A] and radiator bracket collars [B] as shown. Larger [C] Smaller [D] Frame Projection [E] โข When installing the pads [F], install it so that the corners [G] align. 4-16 COOLING SYSTEM Radiator โข Fit the slits [A] of the heat insulation rubber plate to the upper mounting brackets [B] and fan bracket [C] as shown. โข Run the radiator fan motor lead [D] into the slit. โขInsert the upper right mounting bracket [A] to the frame projection [B]. โข Run the radiator fan motor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the water hoses and clamps (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Tighten: Torque – Water Hose Clamp Screws: 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) โขInstall the removed parts (see appropriate chapters). Radiator Inspection โข Remove the radiator (see Radiator and Radiator Fan Removal). โข 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 deformed fins, replace the radiator with a new one. NOTICE When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface. Run the steam gun, following the core fin direction. Radiator Cap Inspection โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Radiator Cap โข 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 4-17 Radiator โขInstall the cap [A] on a cooling system pressure tester [B]. NOTE โWet the cap sealing surfaces with water or coolant to prevent pressure leaks. โข 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 measure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds. Radiator Cap Relief Pressure Standard: 93.3 ๏พ 122.7 kPa (0.95 ๏พ 1.25 kgf/cmยฒ, 13.5 ๏พ 17.8 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 โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Radiator Cap โข Check the radiator filler neck for signs of damage. โข 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. 4-18 COOLING SYSTEM Thermostat Thermostat Removal โข Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). โข Remove: Thermostat Housing Bolts [A] Thermostat Housing Cover [B] Thermostat Thermostat Installation โขInstall the thermostat [A] in the housing so that the air bleeder hole [B] is on top. โข Replace the O-ring [A] with a new one, and install it. โDo not apply grease to the O-ring. โขInstall the thermostat housing cover. NOTE โNote that the thermostat does not move at the place when installing the thermostat housing cover. โข Apply a non-permanent locking agent to the threads of the thermostat housing bolts. โข Tighten: Torque – Thermostat Housing Bolts: 6.0 Nยทm (0.61 kgfยทm, 53 inยทlb) โข Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Fill the radiator with coolant (see Coolant Change in the Periodic Maintenance chapter). โขInstall the removed parts (see appropriate chapters). Thermostat Inspection โข Remove the thermostat (see Thermostat Removal). โขInspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. COOLING SYSTEM 4-19 Thermostat โข To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of the water. โThe thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth. It must not touch the container, either. If the measurement is out of the specified range, replace the thermostat with a new one. Thermostat Valve Opening Temperature 58 ๏พ 62ยฐC (136 ๏พ 144ยฐF) 4-20 COOLING SYSTEM Hose and Pipes Hose Installation โขInstall the hoses and pipes, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. โข Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall 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. โThe clamp screws should be positioned correctly to prevent the clamps from contacting the other parts. Torque – Water Hose Clamp Screws: 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) Hose Inspection โข Refer to the Water Hose and Pipe Inspection in the Periodic Maintenance chapter. COOLING SYSTEM 4-21 Water Temperature Sensor NOTICE The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation โข Refer to the Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection โข Refer to the Water Temperature Sensor Inspection in the Electrical System chapter. ENGINE TOP END 5-1 5 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-9 Special Tools and Sealants . 5-11 Clean Air System. 5-14 Air Suction Valve Removal. 5-14 Air Suction Valve Installation 5-16 Air Suction Valve Inspection 5-16 Air Switching Valve Removal . 5-16 Air Switching Valve Installation 5-17 Air Switching Valve Operation Test 5-17 Air Switching Valve Unit Test . 5-17 Clean Air System Hose Inspection 5-17 Cylinder Head Cover . 5-18 Cylinder Head Cover Removal 5-18 Cylinder Head Cover Installation . 5-18 Camshaft Chain Tensioner 5-20 Camshaft Chain Tensioner Removal 5-20 Camshaft Chain Tensioner Installation. 5-20 Camshaft, Camshaft Chain . 5-21 Camshaft Removal 5-21 Camshaft Installation . 5-22 Camshaft, Camshaft Cap Wear Inspection 5-25 Camshaft Runout Inspection 5-25 Cam Wear Inspection 5-26 Camshaft Chain Removal 5-26 Cylinder Head 5-27 Cylinder Compression Measurement 5-27 Cylinder Head Removal. 5-28 Cylinder Head Installation 5-29 Cylinder Head Warp Inspection . 5-30 Valves 5-31 Valve Clearance Inspection . 5-31 Valve Clearance Adjustment 5-31 Valve Removal. 5-31 Valve Installation 5-31 Valve Guide Removal 5-31 Valve Guide Installation . 5-32 Valve-to-Guide Clearance Measurement (Wobble Method). 5-33 Valve Seat Inspection 5-33 Valve Seat Repair 5-34 Cylinder, Pistons 5-39 Cylinder Removal. 5-39 Cylinder Installation 5-39 Piston Removal 5-40 Piston Installation. 5-41 Cylinder Wear Inspection. 5-42 Piston Wear Inspection 5-42 Piston Ring, Piston Ring Groove Wear Inspection 5-42 Piston Ring Groove Width Inspection 5-42 Piston Ring Thickness Inspection 5-43 Piston Ring End Gap Inspection 5-43 Throttle Body Assy Holder. 5-44 Throttle Body Assy Holder Removal 5-44 Throttle Body Assy Holder Installation. 5-44 Muffler 5-46 Muffler Body Removal 5-46 Muffler Body Installation. 5-46 Exhaust Pipe Removal. 5-48 Exhaust Pipe Installation 5-49 5-2 ENGINE TOP END Exploded View ENGINE TOP END 5-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Air Suction Valve Cover Bolts 10 1.0 89 inยทlb L 2 Spark Plugs 13 1.3 115 inยทlb 3 Cylinder Head Cover Bolts 10 1.0 89 inยทlb S 4 Camshaft Cap Bolts 12 1.2 106 inยทlb S 5 Upper Camshaft Chain Guide Bolts 12 1.2 106 inยทlb S Cylinder Head Bolts (M10) (First) 30 3.1 22 MO, S 6 Cylinder Head Bolts (M10) (Final) 54 5.5 40 MO, S 7 Cylinder Head Jacket Plugs 19.6 2.00 14.5 L 8 Cylinder Head Bolts (M6) 12 1.2 106 inยทlb S 9 Throttle Body Assy Holder Bolts 12 1.2 106 inยทlb L 10 Throttle Body Assy Holder Clamp Bolts 3.0 0.31 27 inยทlb 11 Camshaft Chain Tensioner Cap Bolt 20 2.0 15 12 Camshaft Chain Tensioner Mounting Bolts 11 1.1 97 inยทlb 13 Camshaft Sprocket Bolts 15 1.5 11 L 14 Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18 15 Rear Camshaft Chain Guide Bolt 25 2.5 18 16 Front Camshaft Chain Guide Bolt (Lower) 12 1.2 106 inยทlb 17. Face the round end outward. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. 5-4 ENGINE TOP END Exploded View ENGINE TOP END 5-5 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Muffler Body Mounting Bolts 35 3.6 26 2 Exhaust Pipe Holder Nuts 20 2.0 15 3 Oxygen Sensor 45 4.6 33 4 Premuffler Chamber Mounting Bolt 35 3.6 26 5 Muffler Body Clamp Bolts 21 2.1 15 6 Premuffler Chamber Cover Bolts 10 1.0 89 inยทlb G: Apply grease. R: Replacement Parts S: Follow the specified tightening sequence. 5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] ENGINE TOP END 5-7 Exhaust System Identification Left Muffler Body Mark Position [A] Right Muffler Body Mark Position [A] Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] 5-8 ENGINE TOP END Exhaust System Identification Honeycomb Type Catalyst Positions [A] ENGINE TOP END 5-9 Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 33.743 ๏พ 33.857 mm (1.3285 ๏พ 1.3330 in.) 33.64 mm (1.324 in.) Intake 34.443 ๏พ 34.557 mm (1.3560 ๏พ 1.3605 in.) 34.34 mm (1.352 in.) Camshaft Journal, Camshaft Cap Clearance 0.038 ๏พ 0.081 mm (0.0015 ๏พ 0.0032 in.) 0.17 mm (0.0067 in.) Camshaft Journal Diameter 23.940 ๏พ 23.962 mm (0.94252 ๏พ 0.94338 in.) 23.91 mm (0.9413 in.) Camshaft Bearing Inside Diameter 24.000 ๏พ 24.021 mm (0.94488 ๏พ 0.94571 in.) 24.08 mm (0.9480 in.) Camshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.004 in.) Cylinder Head Cylinder Compression (Usable Range) 966 ๏พ 1 478 kPa (9.85 ๏พ 15.1 kgf/cmยฒ, 140 ๏พ 214 psi) @280 r/min (rpm) โโโ Cylinder Head Warp โโโ 0.05 mm (0.002 in.) Valves Valve Clearance: Exhaust 0.22 ๏พ 0.31 mm (0.0087 ๏พ 0.0122 in.) โโโ Intake 0.13 ๏พ 0.22 mm (0.0051 ๏พ 0.0087 in.) โโโ Valve Head Thickness: Exhaust 0.8 mm (0.031 in.) 0.6 mm (0.024 in.) Intake 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 ๏พ 4.470 mm (0.1754 ๏พ 0.1760 in.) 4.44 mm (0.175 in.) Intake 4.475 ๏พ 4.490 mm (0.1762 ๏พ 0.1768 in.) 4.46 mm (0.176 in.) Valve Guide Inside Diameter: Exhaust 4.500 ๏พ 4.512 mm (0.1772 ๏พ 0.1776 in.) 4.58 mm (0.180 in.) Intake 4.500 ๏พ 4.512 mm (0.1772 ๏พ 0.1776 in.) 4.58 mm (0.180 in.) Valve/Valve Guide Clearance (Wobble Method): Exhaust 0.08 ๏พ 0.16 mm (0.0031 ๏พ 0.0063 in.) 0.35 mm (0.014 in.) Intake 0.03 ๏พ 0.10 mm (0.0012 ๏พ 0.0039 in.) 0.30 mm (0.012 in.) Valve Seat Cutting Angle 32ยฐ, 45ยฐ, 60ยฐ โโโ Valve Seating Surface: Outside Diameter: Exhaust 24.7 ๏พ 24.9 mm (0.972 ๏พ 0.980 in.) โโโ Intake 28.9 ๏พ 29.1 mm (1.138 ๏พ 1.146 in.) โโโ Width: Exhaust 0.8 ๏พ 1.2 mm (0.031 ๏พ 0.047 in.) โโโ Intake 0.5 ๏พ 1.0 mm (0.020 ๏พ 0.039 in.) โโโ Valve Spring Free Length: Exhaust 36.62 mm (1.442 in.) 35.2 mm (1.39 in.) Intake 36.62 mm (1.442 in.) 35.2 mm (1.39 in.) 5-10 ENGINE TOP END Specifications Item Standard Service Limit Cylinder, Pistons Cylinder Inside Diameter 76.994 ๏พ 77.006 mm (3.0313 ๏พ 3.0317 in.) 77.09 mm (3.035 in.) Piston Diameter 76.974 ๏พ 76.984 mm (3.0305 ๏พ 3.0309 in.) 76.82 mm (3.024 in.) Piston/Cylinder Clearance 0.010 ๏พ 0.032 mm (0.0004 ๏พ 0.0013 in.) โโโ Piston Ring/Groove Clearance: Top 0.03 ๏พ 0.07 mm (0.0012 ๏พ 0.0028 in.) 0.17 mm (0.0067 in.) Second 0.02 ๏พ 0.06 mm (0.0008 ๏พ 0.0024 in.) 0.16 mm (0.0063 in.) Piston Ring Groove Width: Top 0.82 ๏พ 0.84 mm (0.0323 ๏พ 0.0331 in.) 0.92 mm (0.0362 in.) Second 0.81 ๏พ 0.83 mm (0.0319 ๏พ 0.0327 in.) 0.91 mm (0.0358 in.) Piston Ring Thickness: Top 0.77 ๏พ 0.79 mm (0.0303 ๏พ 0.0311 in.) 0.70 mm (0.028 in.) Second 0.77 ๏พ 0.79 mm (0.0303 ๏พ 0.0311 in.) 0.70 mm (0.028 in.) Piston Ring End Gap: Top 0.20 ๏พ 0.30 mm (0.0079 ๏พ 0.0118 in.) 0.6 mm (0.024 in.) Second 0.38 ๏พ 0.48 mm (0.0150 ๏พ 0.0189 in.) 0.8 mm (0.031 in.) ENGINE TOP END 5-11 Special Tools and Sealants Compression Gauge, 20 kgf/cmยฒ: 57001-221 Valve Spring Compressor Assembly: 57001-241 Piston Pin Puller Assembly: 57001-910 Valve Seat Cutter, 45ยฐ – 27.5: 57001-1114 Valve Seat Cutter, 45ยฐ – 32: 57001-1115 Valve Seat Cutter, 32ยฐ – 28: 57001-1119 Valve Seat Cutter Holder Bar: 57001-1128 Valve Seat Cutter, 32ยฐ – 33: 57001-1199 Valve Seat Cutter Holder, 4.5: 57001-1330 Valve Guide Arbor, 4.5: 57001-1331 5-12 ENGINE TOP END Special Tools and Sealants Valve Guide Reamer, 4.5: 57001-1333 Valve Seat Cutter, 60ยฐ – 33: 57001-1334 Valve Seat Cutter, 60ยฐ – 27: 57001-1409 Engine Mount Nut Wrench: 57001-1450 Valve Guide Driver: 57001-1564 Valve Spring Compressor Adapter, 24: 57001-1586 Compression Gauge Adapter, M10 ร 1.0: 57001-1601 L-Shape Hose: 57001-1606 Washer: 57001-1612 Liquid Gasket, TB1211F: 92104-0004 ENGINE TOP END 5-13 Special Tools and Sealants Liquid Gasket, TB1216B: 92104-1064 5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal โข Remove: Air Switching Valve (see Air Switching Valve Removal) Quick Rivets [A] โข Cut the band [A]. โข Slide the dust cover [A]. โข Open the clamp [B]. โข Disconnect the radiator fan motor lead connector [C]. โข Remove the quick rivet [D]. โข Remove the radiator lower bolt [A]. โข Remove the radiator upper bolt [A]. ENGINE TOP END 5-15 Clean Air System โข Remove the radiator cap mounting bolt [A] and collar. โข Move the radiator leftward [A] to clear the frame projection [B]. โข Remove the quick rivets [A]. โข Turn up the heat insulation rubber plate. โขInstall the radiator temporarily to prevent damage the radiator core. โข Remove the connector [A] from the bracket. โข Remove: Air Suction Valve Cover Bolts [B] (Both Sides) Bracket with Heat Insulation Plate Air Suction Valve Cover [C] (Both Sides) โข Remove the air suction valve [A] on both sides. 5-16 ENGINE TOP END Clean Air System Air Suction Valve Installation โขInstall the air suction valve so that opening [A] of the reed faces the front and downward. โขInstall: Air Suction Valve Covers [A] Bracket with Heat Insulation Plate โข Apply a non-permanent locking agent to the threads of the air suction valve cover bolts [B], and tighten them. Torque – Air Suction Valve Cover Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โขInstall the removed parts (see appropriate chapters). Air Suction Valve Inspection โข Remove the air suction valve (see Air Suction Valve Removal). โข Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, replace the air suction valve as an assembly. โข Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage. If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly. If any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly clean with a high flash-point solvent. NOTICE Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly. Air Switching Valve Removal NOTICE Never drop the air switching valve especially on a hard surface. Such a shock to the air switching valve can damaged it. โข Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). โข Disconnect the connector [A]. โข Clear the right turn signal light lead [B] from the clamp [C] on the air switching valve. โข Disconnect the hoses [D] from the air suction valve covers, and remove the air switching valve. ENGINE TOP END 5-17 Clean Air System Air Switching Valve Installation โขInstall the air switching valve [A] with hoses as shown. Left Side View [B] About 40ยฐ [C] โขInstall the removed parts (see appropriate chapters). Air Switching Valve Operation Test โข Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test โข Refer to the Air Switching Valve Unit Test in the Electrical System chapter. Clean Air System Hose Inspection โข Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers. If they are not, correct them. Replace them if they are damaged. 5-18 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical System chapter) Air Suction Valves (see Air Suction Valve Removal) Bracket Bolts [A] (Both Sides) Bracket [B] (Both Sides) โข Remove: Cylinder Head Cover Bolts [A] with Washers Cylinder Head Cover Gasket Cylinder Head Cover Installation โข Replace the plug hole gaskets with new ones. โขInstall: Dowel Pins [A] Plug Hole Gaskets [B] โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket [A] to the cylinder head as shown. Sealant – Liquid Gasket, TB1216B: 92104-1064 NOTE โMake the application finish within 20 minutes with the liquid gasket (TB1216B) to the mating surface of the cylinder head cover is applied. ENGINE TOP END 5-19 Cylinder Head Cover โข Replace the head cover gasket with a new one. โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket around the groove [A] on the sealing surface to retain the gasket in the cylinder head cover. Sealant – Liquid Gasket, TB1211F: 92104-0004 โขInstall the gasket to the cylinder head cover. โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket [A] to the cylinder head cover [B] as shown. Sealant – Liquid Gasket, TB1211F: 92104-0004 โข Replace the washers with new ones. โขInstall the washers with the metal side [A] faces upward. โข Tighten the cylinder head cover bolts following the specified tightening sequence [1 ๏พ 6]. Torque – Cylinder Head Cover Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โขInstall: Bracket โข Tighten the bracket bolts. โขInstall the removed parts (see appropriate chapters). 5-20 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below. When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in โCamshaft Chain Tensioner Installation.โ Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Cap Bolt [A] Washer [B] Spring [C] Rod [D] Camshaft Chain Tensioner Mounting Bolts [E] Bracket [F] Camshaft Chain Tensioner Body [G] Camshaft Chain Tensioner Installation โข Replace the O-ring [A] with a new one. โข Apply grease to the new O-ring. โข Release the stopper [B] and push the push rod [C] into the interior of the tensioner body [D]. โขInstall the tensioner body so that the stopper faces upward. โขInstall the bracket [A]. โข Tighten: Torque – Camshaft Chain Tensioner Mounting Bolts [B]: 11 Nยทm (1.1 kgfยทm, 97 inยทlb) โขInstall the rod, spring and washer. โข Tighten: Torque – Camshaft Chain Tensioner Cap Bolt [C]: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) โข Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing. โขInstall: Right Lower Fairing (see Lower Fairing Installation in the Frame chapter) ENGINE TOP END 5-21 Camshaft, Camshaft Chain Camshaft Removal โข Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) โข Using a wrench on the timing rotor bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1, 4 pistons) on the timing rotor is aligned with the mating surface [C] of the crankcase. โข Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). โข Loosen the upper camshaft chain guide bolts and camshaft cap bolts gradually and evenly as shown sequence [1 ๏พ 20], and remove them. โข Remove: Upper Camshaft Chain Guide [A] Camshaft Caps [B] Camshafts [C] โข Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase. โข Remove: Camshaft Sprocket Mounting Bolts [A] Camshaft Sprockets [B] NOTICE The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket. 5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Installation โข Be sure to install the following parts. Plug Hole Gaskets [A] Dowel Pins [B] NOTE โThe exhaust camshaft has a 8943 EX mark [A] and the intake camshaft has a 8943 IN mark [B]. Be careful not to mix up these shafts. โขInstall the camshaft sprockets so that position the timing marks [A] outside. โThe intake camshaft sprocket and exhaust camshaft sprocket are identical. โข Apply a non-permanent locking agent to the threads of the camshaft sprocket bolts and tighten them. Torque – Camshaft Sprocket Bolts: 15 Nยทm (1.5 kgfยทm, 11 ftยทlb) โข Apply molybdenum disulfide oil solution to all cam parts and journals. โข Using a wrench on the timing rotor bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor is aligned with the mating surface [C] of the crankcase. NOTICE The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket. ENGINE TOP END 5-23 Camshaft, Camshaft Chain โข Pull the tension side (exhaust side) [A] of the chain taut to install the chain. โข Engage the camshaft chain with the sprockets so that timing marks on the sprockets are positioned as shown. โThe timing marks must be aligned with the cylinder head upper surface [B]. EX mark [C] IN mark [D] #1 pin [E] #2 pin [F] #30 pin [G] #31 pin [H] 5-24 ENGINE TOP END Camshaft, Camshaft Chain โข Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body temporarily (see Camshaft Chain Tensioner Installation). โขInstall the camshaft caps and upper camshaft chain guide [A] as shown. Identification No. 1 ๏พ 4 (Camshaft Cap) [B] โข First tighten the all camshaft cap bolts and upper camshaft chain guide bolts evenly to seat the camshaft in place, then tighten all bolts following the specified tightening sequence. Torque – Camshaft Cap Bolts [1 ๏พ 18]: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) Upper Camshaft Chain Guide Bolts [19, 20]: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โขInstall the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). โข Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing. โขInstall the removed parts (see appropriate chapters). ENGINE TOP END 5-25 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection โข Remove: Camshaft Caps (see Camshaft Removal) โข Cut the strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. โข Tighten the camshaft cap bolts and upper camshaft chain guide bolts to the specified torque (see Camshaft Installation). NOTE โDo not turn the camshaft when the plastigage is between the journal and camshaft cap. โข Remove the camshaft cap again, measure each clearance between the camshaft journal and the camshaft cap using plastigage [A]. Camshaft Journal, Camshaft Cap Clearance Standard: 0.038 ๏พ 0.081 mm (0.0015 ๏พ 0.0032 in.) Service Limit: 0.17 mm (0.0067 in.) If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.940 ๏พ 23.962 mm (0.94252 ๏พ 0.94338 in.) Service Limit: 23.91 mm (0.9413 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again. If the clearance still remains out of the service limit, replace the cylinder head unit. Camshaft Runout Inspection โข Remove the camshafts (see Camshaft Removal). โข Set the camshaft in a camshaft alignment jig or on V blocks. โข Measure the runout with a dial gauge [A] at the specified place as shown. 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.) 5-26 ENGINE TOP END Camshaft, Camshaft Chain Cam Wear Inspection โข Remove the camshafts (see Camshaft Removal). โข Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: Exhaust 33.743 ๏พ 33.857 mm (1.3285 ๏พ 1.3330 in.) Intake 34.443 ๏พ 34.557 mm (1.3560 ๏พ 1.3605 in.) Service Limit: Exhaust 33.64 mm (1.324 in.) Intake 34.34 mm (1.352 in.) Camshaft Chain Removal โข Split the crankcase (see Crankcase Splitting in the Crankshaft/Transmission chapter). โข Remove the camshaft chain [A] from the crankshaft sprocket. ENGINE TOP END 5-27 Cylinder Head Cylinder Compression Measurement NOTE โUse the battery which is fully charged. โข Warm up the engine thoroughly. โข Stop the engine. โข Remove: Spark Plugs (see Spark Plug Replacement in the Periodic Maintenance chapter) โข Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole. โข Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. Special Tools – Compression Gauge, 20 kgf/cmยฒ: 57001-221 Compression Gauge Adapter, M10 ร 1.0: 57001-1601 L-Shape Hose: 57001-1606 Cylinder Compression Usable Range: 966 ๏พ 1 478 kPa (9.85 ๏พ 15.1 kgf/cmยฒ, 140 ๏พ 214 psi) @280 r/min (rpm) โข Repeat the measurement for the other cylinders. โขInstall the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). โThe following table should be consulted if the obtainable compression reading is not within the usable range. Problem Diagnosis Remedy (Action) Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke). Remove the carbon deposits and replace damaged parts if necessary. Cylinder compression is higher than usable range. Incorrect cylinder head gasket thickness Replace the gasket with a standard part. Gas leakage around cylinder head Replace damaged gasket and check cylinder head warp. 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. Cylinder compression is lower than usable range. Bad condition of piston ring and/or piston ring grooves Replace the piston and/or the piston rings. 5-28 ENGINE TOP END Cylinder Head Cylinder Head Removal โข Drain: Coolant (see Coolant Change in the Periodic Maintenance chapter) โข Remove: Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) โข Slide the clamps [A]. โข Disconnect: Air Bleeder Hose [B] Water Hose [C] Water Temperature Sensor Connector [D] โข Remove: Timing Rotor (see Timing Rotor Removal in the Electrical System chapter) Front Camshaft Chain Guide Bolts [A] Collar Front Camshaft Chain Guide [B] Rear Camshaft Chain Guide Bolt [C] Rear Camshaft Chain Guide [D] โข Loosen: Lower Engine Bracket Bolts (Both Sides) [A] Upper Engine Mounting Bolts (Left) โข Remove: Upper Engine Mounting Bolts (Right) [B] โข Loosen: Upper Adjusting Collar Locknut [C] Special Tool – Engine Mount Nut Wrench: 57001-1450 โข Loosen: Upper Adjusting Collar [D] โข Remove the M6 cylinder head bolts [A]. โข Loosen the M10 cylinder head bolts as shown sequence [1 ๏พ 10], and remove them with washers. โข Remove the cylinder head. ENGINE TOP END 5-29 Cylinder Head Cylinder Head Installation NOTE โThe 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. โข Replace the cylinder head gasket [A] with a new one. โขInstall the dowel pins [B] and cylinder head gasket. โข Replace the cylinder head bolt washers [A] with new ones. โข Apply molybdenum disulfide oil solution to the followings. Both Side [B] of Cylinder Head Bolt Washers Threads [C] of Cylinder Head Bolts โข Tighten the M10 cylinder head bolts following the tightening sequence [1 ๏พ 10]. Torque – Cylinder Head Bolts (M10): First 30 Nยทm (3.1 kgfยทm, 22 ftยทlb) Final: 54 Nยทm (5.5 kgfยทm, 40 ftยทlb) โข Tighten the M6 cylinder head bolts [A]. Torque – Cylinder Head Bolts (M6): 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข Tighten the following parts (see Engine Installation in the Engine Removal/Installation chapter). Upper Adjusting Collar Upper Adjusting Collar Locknut: Upper Engine Mounting Bolts Lower Engine Bracket Bolts 5-30 ENGINE TOP END Cylinder Head โขInstall: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide [B] New O-rings [C] Collar [D] โข Tighten: Torque – Front Camshaft Chain Guide Bolt (Upper) [E]: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) Rear Camshaft Chain Guide Bolt [G]: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โขInstall the removed parts (see appropriate chapters). Cylinder Head Warp Inspection โข Clean the cylinder head. โข Lay a straightedge across the lower surface of the cylinder head at several positions. โข Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp Standard: โโโ 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). ENGINE TOP END 5-31 Valves Valve Clearance Inspection โข Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment โข Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal โข Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim NOTE โMark and record the valve lifter and shim locations so they can be installed in their original positions. โข Using the valve spring compressor assembly, remove the valve. Special Tools – Valve Spring Compressor Assembly [A]: 57001-241 Valve Spring Compressor Adapter, 24 [B]: 57001-1586 Valve Installation โข Replace the oil seal with a new one. โข Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation. โขInstall the springs so that the closed coil end faces downwards. Valve Stem [A] Oil Seal [B] Spring Seat [C] Closed Coil End [D] Valve Spring [E] Retainer [F] Split Keepers [G] Valve Guide Removal โข Remove: Valve (see Valve Removal) Oil Seal Spring Seat โข Heat the area around the valve guide to 120 ๏พ 150ยฐC (248 ๏พ 302ยฐF), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head in oil and heat the oil. Special Tool – Valve Guide Arbor, 4.5: 57001-1331 5-32 ENGINE TOP END Valves Valve Guide Installation โข Apply oil to the valve guide outer surface before installation. โข Heat the area around the valve guide hole to about 120 ๏พ 150ยฐC (248 ๏พ 302ยฐF). NOTICE Do not heat the cylinder head with a torch. This Will warp the cylinder head. Soak the cylinder head and heat the oil. โข Using the valve guide driver [A] and two washers [B], press and insert the valve guide in until the valve guide driver surface touches the head surface [C]. 12.8 ๏พ 13.0 mm (0.504 ๏พ 0.512 in.) [D] Special Tools – Valve Guide Driver: 57001-1564 Washer: 57001-1612 โข Ream the valve guide with valve guide reamer [A], even if the old guide is reused. Special Tool – Valve Guide Reamer, 4.5: 57001-1333 ENGINE TOP END 5-33 Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. โขInsert 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. โข Move the stem back and forth [C] to measure valve/valve guide clearance. โข Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide. NOTE โThe reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: Exhaust 0.08 ๏พ 0.16 mm (0.0031 ๏พ 0.0063 in.) Intake 0.03 ๏พ 0.10 mm (0.0012 ๏พ 0.0039 in.) Service Limit: Exhaust 0.35 mm (0.014 in.) Intake 0.30 mm (0.012 in.) Valve Seat Inspection โข Remove the valve (see Valve Removal). โข Check the valve seating surface [A] between the valve [B] and valve seat [C]. โMeasure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat (see Seat Repair). Valve Seating Surface Outside Diameter Standard: Exhaust 24.7 ๏พ 24.9 mm (0.972 ๏พ 0.980 in.) Intake 28.9 ๏พ 29.1 mm (1.138 ๏พ 1.146 in.) โMeasure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper. Good [F] If the width is too wide [G], too narrow [H] or uneven [J], repair the seat (see Valve Seat Repair). Valve Seating Surface Width Standard: Exhaust 0.8 ๏พ 1.2 mm (0.031 ๏พ 0.047 in.) Intake 0.5 ๏พ 1.0 mm (0.020 ๏พ 0.039 in.) 5-34 ENGINE TOP END Valves Valve Seat Repair โข 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, 45ยฐ – 27.5: 57001-1114 Valve Seat Cutter, 32ยฐ – 28: 57001-1119 Valve Seat Cutter, 60ยฐ – 27: 57001-1409 [For Intake Valve Seat] Valve Seat Cutter, 45ยฐ – 32: 57001-1115 Valve Seat Cutter, 32ยฐ – 33: 57001-1199 Valve Seat Cutter, 60ยฐ – 33: 57001-1334 If the manufacturerโs instructions are not available, use the following procedure. Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil. NOTICE 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 โPrior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil. 5. After use, wash it with washing oil and apply thin layer of engine oil before storing. Marks Stamped on the Cutter The marks stamped on the back of the cutter [A] represent the following. 60ยฐ . Cutter angle [B] 37.5 . Outer diameter of cutter [C] ENGINE TOP END 5-35 Valves Operating Procedures โข Clean the seat area carefully. โข Coat the seat with machinistโs dye. โข Fit a 45ยฐ cutter into the holder and slide it into the valve guide. โข Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth. NOTICE Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. โข 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 45ยฐ grind until the diameter is within the specified range. Widened Width [A] of engagement by machining with 45ยฐ cutter Ground Volume [B] by 32ยฐ cutter 32ยฐ [C] Correct Width [D] Ground Volume [E] by 60ยฐ cutter 60ยฐ [F] โข 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 45ยฐ [A] grind until the diameter is within the specified range. Original Seating Surface [B] NOTE โRemove all pittings of flaws from 45ยฐ ground surface. โAfter grinding with 45ยฐ cutter, apply thin coat of machinistโs dye to seating surface. This makes seating surface distinct and 32ยฐ and 60ยฐ grinding operation easier. โWhen the valve guide is replaced, be sure to grind with 45ยฐ cutter for centering and good contact. 5-36 ENGINE TOP END Valves If the outside diameter [A] of the seating surface is too large, make the 32ยฐ [B] grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. โข Grind the seat at a 32ยฐ angle until the seat outside diameter is within the specified range. โTo make the 32ยฐ grind, fit a 32ยฐ cutter into the holder, and slide it into the valve guide. โTurn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. NOTICE The 32ยฐ cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. โAfter making the 32ยฐ grind, return to the seat outside diameter measurement step above. โข To measure the seat width, use a vernier caliper to measure the width of the 45ยฐ angle portion of the seat at several places around the seat. If the seat width is too narrow, repeat the 45ยฐ grind until the seat is slightly too wide, and then return to the seat outside diameter measurement step above. If the seat width is too wide, make the 60ยฐ [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. โข Grind the seat at a 60ยฐ angle until the seat width is within the specified range. โTo make the 60ยฐ grind, fit 60ยฐ cutter into the holder, and slide it into the valve guide. โTurn the holder, while pressing down lightly. โAfter making the 60ยฐ grind, return to the seat width measurement step above. Correct Width [B] ENGINE TOP END 5-37 Valves โข Lap the valve to the valve seat, once the seat width and outside diameter are within the ranges specified above. โPut a little coarse grinding compound on the face of the valve in a number of places around the valve head. โSpin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. โRepeat the process with a fine grinding compound. Lapper [A] Valve Seat [B] Valve [C] โข 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. โข Be sure to remove all grinding compound before assembly. โข When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter). 5-38 ENGINE TOP END Valves ENGINE TOP END 5-39 Cylinder, Pistons Cylinder Removal โข Remove: Cylinder Head (see Cylinder Head Removal) Engine Brackets (see Engine Removal in the Engine Removal/Installation chapter) Radiator Bracket Bolt [A] Radiator Bracket [B] โข Slide the water hose clamp [A]. โข Disconnect the water hose [B]. โข Remove: Upper Engine Mounting Bolts (Left) [A] โข Remove: Cylinder [A] NOTE โIf it is hard to remove it, tap lightly using a plastic-faced mallet [B]. Cylinder Installation NOTE โIf a new cylinder is used, use new piston ring. โข Replace the cylinder gasket [A] with a new one. โขInstall the dowel pins [B] and new cylinder gasket. โข Apply molybdenum disulfide oil solution to the cylinder bore. 5-40 ENGINE TOP END Cylinder, Pistons โข The piston ring openings must be positioned as shown. The openings of the oil ring steel rails must be about 30 ๏พ 40ยฐ of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Upper Oil Ring Steel Rail [C] Oil Ring Expander [D] Lower Oil Ring Steel Rail [E] Dent [F] 30 ๏พ 40ยฐ [G] โข Position the crankshaft at #2, 3 piston TDC. โข Prepare two auxiliary head bolts with their head cut. โInstall the two cylinder head bolts [A] diagonally in the crankcase. โขInstall the cylinder block [B]. Pistons [C] โFirst insert the #2, 3 pistons, and then rotate the crankshaft at 90ยฐ angle. โInsert the piston rings with your thumbs or the standard tip screwdriver. โข Tighten the upper engine mounting bolts and engine bracket bolts after cylinder head bolts tightend. โขInstall the removed parts (see appropriate chapters). Piston Removal โข Remove the cylinder (see Cylinder Removal). โข Place a clean cloth under the pistons and remove the piston pin snap ring [A] from the outside of each piston. โข Using the piston pin puller assembly [A], remove the piston pins. Special Tool – Piston Pin Puller Assembly: 57001-910 โข Remove the pistons. ENGINE TOP END 5-41 Cylinder, Pistons โข Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it. โข Remove the 3-piece oil ring with your thumbs in the same manner. Piston Installation NOTE โIf a new piston is used, use new piston ring. โข Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. โข Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it. โSpread the rail with your thumbs, but only enough to fit the rail over the piston. โRelease the rail into the bottom piston ring groove. NOTE โThe oil ring rails have no โtopโ or โbottom.โ โข Apply molybdenum disulfide oil solution to the piston rings. NOTE โDo not mix up the top and second ring. โขInstall the top ring [A] so that the โ1Tโ mark [B] faces up. โขInstall the second ring [C] so that the โ2Tโ mark [D] faces up. โขInstall the piston with its dent mark facing forward. โข Apply molybdenum disulfide oil solution to the piston pins and piston journals. โข Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. โWhen installing the piston pin snap ring, compress it only enough to install it and no more. NOTICE Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. โขInstall the cylinder (see Cylinder Installation). 5-42 ENGINE TOP END Cylinder, Pistons Cylinder Wear Inspection โข Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) as shown. If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. 10 mm (0.39 in.) [A] 60 mm (2.36 in.) [B] Cylinder Inside Diameter Standard: 76.994 ๏พ 77.006 mm (3.0313 ๏พ 3.0317 in.) Service Limit: 77.09 mm (3.035 in.) Piston Wear Inspection โข Measure the outside diameter [A] of each piston 11 mm (0.43 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the piston. Piston Diameter Standard: 76.974 ๏พ 76.984 mm (3.0305 ๏พ 3.0309 in.) Service Limit: 76.82 mm (3.024 in.) Piston Ring, Piston Ring Groove Wear Inspection โข Check for uneven groove wear by inspecting the ring seating. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. โข With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance. Piston Ring/Groove Clearance Standard: Top 0.03 ๏พ 0.07 mm (0.0012 ๏พ 0.0028 in.) Second 0.02 ๏พ 0.06 mm (0.0008 ๏พ 0.0024 in.) Service Limit: Top 0.17 mm (0.0067 in.) Second 0.16 mm (0.0063 in.) Piston Ring Groove Width Inspection โข Measure the piston ring groove width. โUse a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.82 ๏พ 0.84 mm (0.0323 ๏พ 0.0331 in.) Second [B] 0.81 ๏พ 0.83 mm (0.0319 ๏พ 0.0327 in.) Service Limit: Top [A] 0.92 mm (0.0362 in.) Second [B] 0.91 mm (0.0358 in.) If the width of any of the two grooves are wider than the service limit at any point, replace the piston. ENGINE TOP END 5-43 Cylinder, Pistons Piston Ring Thickness Inspection โข Measure the piston ring thickness. โUse the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top [A] 0.77 ๏พ 0.79 mm (0.0303 ๏พ 0.0311 in.) Second [B] 0.77 ๏พ 0.79 mm (0.0303 ๏พ 0.0311 in.) Service Limit: Top [A] 0.70 mm (0.028 in.) Second [B] 0.70 mm (0.028 in.) If any of the measurements is less than the service limit on either of the rings, replace all the rings. NOTE โWhen using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Piston Ring End Gap Inspection โข Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. โข Measure the gap [B] between the ends of the ring with a thickness gauge. Piston Ring End Gap Standard: Top 0.20 ๏พ 0.30 mm (0.0079 ๏พ 0.0118 in.) Second 0.38 ๏พ 0.48 mm (0.0150 ๏พ 0.0189 in.) Service Limit: Top 0.6 mm (0.024 in.) Second 0.8 mm (0.031 in.) If the end gap of either ring is greater than the service limit, replace all the rings. 5-44 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal โข Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] Throttle Body Assy Holder Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation โข Replace the O-rings [A] with new ones. โข Apply grease to the O-rings, and install them. โข Apply a non-permanent locking agent to the threads of the throttle body assy holder bolts. โข Tighten: Torque – Throttle Body Assy Holder Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข Fit the hole of the clamp [A] to the projection [B] of the holder [C]. โBe sure that the clamp bolt heads [D] face as shown. โขInstall: Throttle Body Assy (see Throttle Body Assy Installation in the Fuel System (DFI) chapter) ENGINE TOP END 5-45 Throttle Body Assy Holder This page intentionally left blank. 5-46 ENGINE TOP END Muffler WARNING The exhaust pipe or muffler body can become extremely hot during normal operation and cause severe burns. Do not remove the exhaust pipe or muffler body while it is hot. Muffler Body Removal โข Remove the rear lower fairing (see Rear Lower Fairing Removal in the Frame chapter). โข Loosen the muffler body clamp bolt [A] on both sides. โข Remove: Muffler Body Mounting Bolt [B] and Nut (Both Sides) Muffler Body [C] (Both Sides) Muffler Body Installation โข Replace the muffler body gaskets [A] with new ones. โขInstall the muffler body gaskets until it is bottomed so that the inside chamfer side faces rear [B]. โขInstall the muffler body clamps [C] so that the projection [D] fits into the clamp slit [E]. Downside [F] Inside [G] Viewed from Rear [H] โขInstall the muffler bodies until it stops at the bottom surface of the exhaust pipe. โข Replace the muffler body mounting nuts [I] with new ones. โขInstall the muffler body mounting bolts and nuts. โข Tighten: Torque – Muffler Body Mounting Bolts [J]: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) โข Turn the muffler body clamps outward until it stops at the slit ends. โข Tighten the muffler body clamp bolt while pulling the muffler body outward (both sides). Torque – Muffler Body Clamp Bolts [K]: 21 Nยทm (2.1 kgfยทm, 15 ftยทlb) ENGINE TOP END 5-47 Muffler โข Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. 5-48 ENGINE TOP END Muffler โข When installing the muffler covers, note the following. โขInstall the pads [A] to the right muffler cover as shown. โFit one pad on top of the other without any gap. โขInstall the dampers [A], collars [B] and pads [C] as shown. โข Tighten the muffler cover bolts temporarily. โข Tighten the two muffler cover bolts [D]. โข Push the muffler body covers outward. โข Tighten the two muffler cover bolts [E]. โข Make sure the gap between the muffler body and muffler cover. โขInstall the removed parts (see appropriate chapters). Exhaust Pipe Removal โข Remove: Muffler Bodies (see Muffler Body Removal) Oxygen Sensor (see Oxygen Sensor Removal in the Electrical System chapter) โข Support the premuffler chamber with the suitable stand [A]. โข Remove the premuffler chamber mounting bolt [B]. ENGINE TOP END 5-49 Muffler โข Remove: Exhaust Pipe Holder Nuts [A] Exhaust Pipe (Premuffler Chamber) [B] โIn this photo, the radiator has been removed for clarity. Exhaust Pipe Installation โข Replace the exhaust pipe gaskets [A] with new ones. โข Apply grease to the exhaust pipe gaskets and install them. โขInstall the exhaust pipe. โข Tighten the exhaust pipe holder nuts [B] and premuffler chamber mounting bolt [C]. Torque – Exhaust Pipe Nuts: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) Premuffler Chamber Mounting Bolt: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) โขInstall the removed parts (see appropriate chapters). โข Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. CLUTCH 6-1 6 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 Assembly Installation. 6-6 Clutch Lever and Cable 6-7 Clutch Lever Installation 6-7 Clutch Lever Position Adjustment. 6-8 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation. 6-9 Release Shaft Removal 6-10 Release Shaft Installation . 6-10 Clutch Cover Disassembly 6-10 Clutch Cover Assembly. 6-11 Clutch . 6-12 Clutch Removal. 6-12 Clutch Installation 6-13 Clutch Plate Assembly Length Inspection. 6-16 Clutch Plate Assembly Length Adjustment. 6-16 Clutch Plate, Wear, Damage Inspection . 6-17 Clutch Plate Warp Inspection 6-17 Clutch Housing Finger Inspection. 6-17 Clutch Housing Spline Inspection . 6-17 Clutch Pressure Plate and Clutch Hub Inspection 6-18 Clutch Spring Inspection. 6-18 6-2 CLUTCH Exploded View CLUTCH 6-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Clutch Lever Clamp Bolts 7.8 0.80 69 inยทlb S 2 Clutch Spring Bolts 10 1.0 89 inยทlb 3 Clutch Hub Nut 135 13.8 100 R 4 Clutch Cover Bolts 12 1.2 106 inยทlb S 5 Oil Filler Plug Hand -tighten โ โ CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement Parts S: Follow the specified tightening sequence. WL: Apply soap and water solution or rubber lubricant. 6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever and Cable Clutch Lever Free Play 2 ๏พ 3 mm (0.08 ๏พ 0.12 in.) โโโ Clutch Lever Clutch Lever Position 5-way adjustable (to suit rider) โโโ Clutch Clutch Plate Assembly Length 45.6 ๏พ 46.4 mm (1.80 ๏พ 1.83 in.) โโโ Friction Plate Thickness 2.72 ๏พ 2.88 mm (0.107 ๏พ 0.113 in.) 2.5 mm (0.098 in.) Friction and Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.) CLUTCH 6-5 Special Tool and Sealant Clutch Holder: 57001-1243 Liquid Gasket, TB1211F: 92104-0004 6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection โข Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment โข Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal โข Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). โข Slide the dust cover [A] at the clutch cable lower end out of place. โข Loosen the nuts [B], and slide the lower end of the clutch cable to give the cable plenty of play. โข Loosen the locknut [A] and screw in the adjuster [B]. โข Line up the slots [C] in the clutch lever, locknut and adjuster, and then free the cable from the lever. โข Free the clutch inner cable tip from the clutch release lever. โข Remove the clutch cable out of the frame. Clutch Cable Installation โข Run the clutch cable correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Adjust the clutch cable (see Clutch Operation Inspection in the Periodic Maintenance chapter). โขInstall the removed parts (see appropriate chapters). Clutch Cable Lubrication โข Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter. Clutch Lever Assembly Installation โขInstall the clutch lever so that the mating surface [A] of the clutch lever clamp is aligned with the punch mark [B]. โข Tighten the upper clamp bolt first, and then the lower clamp bolt. There will be a gap at the lower part of the clamp after tightening. Torque – Clutch Lever Clamp Bolts: 7.8 Nยทm (0.80 kgfยทm, 69 inยทlb) CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation WARNING If the starter lockout switch pin has been damaged the starter lockout system will not work properly. This allows the motorcycle to be started in gear with the clutch lever released (clutch engaged), creating sudden forward movement that can result in an accident or injury. Check that the starter lockout switch operates properly when installing the clutch lever. โข Replace the locknut with a new one. โข Apply grease to the clutch lever collar. โขInstall the clutch lever [A] from frame left side [B] so that it may not damage a pin [C] of the starter lockout switch. NOTICE Do not install the clutch lever [A] from the front side [B]. The pin [C] of the starter lockout switch may be damaged in the projection [D] of a clutch lever. โข Tighten the bolt [A] and locknut [B]. โขInstall the upper end of the clutch cable (see Clutch Cable Installation). โข Adjust the clutch cable (see Clutch Operation Inspection in the Periodic Maintenance chapter). โข Check that the pin [C] of the starter lockout switch moves smoothly. WARNING Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement. 6-8 CLUTCH Clutch Lever and Cable Clutch Lever Position Adjustment The adjuster has 5 positions so that the clutch lever position can be adjusted to suit the operatorโs hand. โข Push the lever forward and turn the adjuster [A] to align the number with the mark [B] on the lever holder. โThe distance from the grip to the lever is minimum at number 5 and maximum at number 1. CLUTCH 6-9 Clutch Cover Clutch Cover Removal โข Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). โข Disconnect the clutch cable lower end (see Clutch Cable Removal). โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Rear Lower Fairing (see Rear Lower Fairing Removal in the Frame chapter) Clutch Cover Bolts [A] Brackets [B] โข Turn the release lever [A] counterclockwise as shown, and remove the clutch cover [B]. About 90ยฐ [C] Clutch Cover Installation โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant – Liquid Gasket, TB1211F: 92104-0004 โข Be sure to dowel pins [B] are in position. โข Replace the clutch cover gasket with a new one and install it. โขInstall: Clutch Cover [A] Brackets [B] โข Tighten the clutch cover bolts following the specified tightening sequence [1 ๏พ 13]. Torque – Clutch Cover Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โขInstall the removed parts (see appropriate chapters). 6-10 CLUTCH Clutch Cover Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required. โข Remove the clutch cover (see Clutch Cover Removal). โข Pull the release lever and shaft assembly [A] straight out of the clutch cover. Release Shaft Installation โข Apply grease to the oil seal lips on the upper ridge of the clutch cover. โข Apply engine oil to the needle bearings in the hole of the clutch cover. โข Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft. โขInstall the washer [B] and spring [C]. โขInsert the release shaft straight into the upper hole of the clutch cover. NOTICE When inserting the release shaft, be careful not to remove the spring of the oil seal. โข Fit the spring [A] as shown. Viewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly โข Remove: Release Lever and Shaft Assembly (see Release Shaft Removal) Oil Filler Plug [A] Oil Seal [B] Needle Bearing [C] CLUTCH 6-11 Clutch Cover โข Remove: Needle Bearing [A] Oil Level Inspection Window [B] Clutch Cover Assembly โข Replace the needle bearings and oil seal with new ones. NOTE โInstall the needle bearings so that the manufactureโs mark face out. โข Apply soap and water solution to the oil seal. โขInstall the needle bearings [A] and oil seal [B] position as shown. โPress the needle bearing until the bottom [C]. โPress the needle bearing so that the bearing surface [D] is flush with the housing end of clutch cover [E]. โPress the oil seal until the bottom. โข Apply grease to the oil seal lips. โข Apply soap and water solution to the rubber portion [A] of the oil level inspection window. โข Press the oil level inspection window until the bottom so that its projection [B] faces inside of the clutch cover [C]. โข Replace the O-ring [A] of the oil filler plug [B] with a new one. โข Apply grease to the new O-ring. โข Tighten: Torque – Oil Filler Plug: Hand-tighten 6-12 CLUTCH Clutch Clutch Removal โข Remove the clutch cover (see Clutch Cover Removal). โข Loosen the three clutch spring bolts [A] alternately with little by little (1/4 turn at a time) to prevent tilting the clutch stopper plate [B]. NOTICE Do not loosen the one or two clutch stopper bolt at once to prevent clutch stopper plate from warpage by the spring force. โข Remove: Clutch Spring Bolts [A] Clutch Stopper Plate [B] Clutch Springs [C] โข Visually inspect the clutch stopper plate. If the clutch stopper plate is warped, replace it with a new one. โข Remove: Spring Seats [A] Clutch Pressure Plate [B] (with Shim, Bearing and Pusher [C]) Friction Plates and Steel Plates โข Hold the sub clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C] and washers. Special Tool – Clutch Holder: 57001-1243 โUse the clutch holder with sharpened hook nose by grinding. Special Tool – Clutch Holder: 57001-1243 โGrind the hook nose by 0.5 mm (0.02 in.) as shown. CLUTCH 6-13 Clutch โข Remove: Clutch Hub [A] Spacer [B] โข Using the two 4 mm (0.16 in.) bolts [A], pull out the sleeve [B], needle bearing [C] and clutch housing [D]. โข Remove the spacer. Clutch Installation โขInstall the spacer [A] so that the tapered side [B] faces inward. โข Engage the clutch housing gear [A] and oil pump drive gear [B] with the crankshaft primary gear [C] and oil pump drive gear [D]. โข Apply engine oil to the sleeve [A] and needle bearing [B]. โขInstall: Needle Bearing Sleeve Spacer [C] 6-14 CLUTCH Clutch โขInstall: Clutch Hub [A] Washer [B] โขInstall the washer [C] so that the โOUT SIDEโ mark faces outward. โข Replace the clutch hub nut [A] with a new one. โข Hold the sub clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut. Special Tool – Clutch Holder: 57001-1243 Torque – Clutch Hub Nut: 135 Nยทm (13.8 kgfยทm, 100 ftยทlb) โขInstall the friction plates [A] and steel plates [B] alternately as shown. Thick Steel Plate [C] NOTICE If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. โInstall the last friction plate and steel plate later with the clutch pressure plate. โข Apply molybdenum disulfide grease to the pusher end [A]. โขInstall the bearing [B] and shim [C] to the pusher. โขInstall the pusher to the drive shaft [D] direction as shown. CLUTCH 6-15 Clutch โข Put the last friction plate [A] and steel plate [B] on the clutch pressure plate [C] and install them. โขInstall the last friction plate so that the tangs [A] fit into the grooves in the housing as shown. NOTE โMake sure that the clutch pressure plate is installed without a gap. โข Be sure to install the spring seats [A] on the clutch pressure plate. โขInstall: Clutch Springs [A] Clutch Stopper Plate [B] โข Tighten the three clutch spring bolts [C] by hand until they just begin to press each clutch spring. โHold the clutch pressure plate by hand while tightening the clutch stopper bolts. โข Tighten the three clutch spring bolts [A] alternately with little by little (1/4 turn at a time) to prevent tilting the clutch stopper plate [B]. NOTICE Do not tighten the one or two clutch stopper bolt at once to prevent the clutch stopper plate from warpage by the spring force. โข Tighten: Torque – Clutch Spring Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โขInstall the clutch cover (see Clutch Cover Installation). 6-16 CLUTCH Clutch Clutch Plate Assembly Length Inspection โข Assemble the following parts. Clutch Hub [A] Friction Plates [B] Steel Plates [C] Clutch Pressure Plate [D] Spring Seats [E] Clutch Springs [F] Clutch Stopper Plate [G] Clutch Spring Bolts [H] Torque – Clutch Spring Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โข Measure the clutch plate assembly length [I]. Clutch Plate Assembly Length 45.6 ๏พ 46.4 mm (1.80 ๏พ 1.83 in.) If the length is not within the specified range, adjust the length (see Clutch Plate Assembly Adjustment). Clutch Plate Assembly Length Adjustment โขInspect the clutch plate assembly length, and then replace the steel plate(s) which brings the length within the specified range. โข Remove: Clutch Spring Bolts Clutch Stopper Plates Clutch Springs Clutch Pressure Plate Spring Seats โข Replace the following steel plate(s). Thickness Part Number 2.0 mm (0.079 in.) 13089-1073 2.3 mm (0.091 in.) (STD) 13089-1084 2.6 mm (0.102 in.) 13089-1115 NOTE โDo not use the steel plate of 2.0 mm (0.079 in.) and 2.6 mm (0.102 in.) thickness at the same time. โWhen adjusting the clutch plate assembly, install the steel plate of 2.0 mm (0.079 in.) or 2.6 mm (0.102 in.) thickness to the second or third from the clutch pressure plate. โขInstall the removed parts, and inspect the clutch plate assembly length. Torque – Clutch Spring Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) CLUTCH 6-17 Clutch Clutch Plate, Wear, Damage Inspection โข Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. โข Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones. Friction Plate Thickness Standard: 2.72 ๏พ 2.88 mm (0.107 ๏พ 0.113 in.) Service Limit: 2.5 mm (0.098 in.) Clutch Plate Warp Inspection โข 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 (0.01 in.) Clutch Housing Finger Inspection โข Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged. Clutch Housing Spline Inspection โข Visually inspect where the teeth [A] on the steel plates wear against the sub clutch hub splines [B]. If there are notches worn into the splines, replace the sub clutch hub. Also, replace the steel plates if their teeth are damaged. 6-18 CLUTCH Clutch Clutch Pressure Plate and Clutch Hub Inspection โข Visually inspect the contact areas [A] of the clutch pressure plate [B] and clutch hub [C] for damage. If the contact areas are damaged replace them with new ones. Clutch Spring Inspection If all the components are good, but the problem still exists, replace the clutch springs (see Clutch Removal and Clutch Installation). ENGINE LUBRICATION SYSTEM 7-1 7 Engine Lubrication System Table of Contents Exploded View 7-2 Engine Oil Flow Chart. 7-4 Specifications . 7-5 Special Tools and Sealants 7-6 Engine Oil and Oil Filter 7-7 Oil Level Inspection. 7-7 Engine Oil Change 7-7 Oil Filter Replacement 7-7 Oil Pan 7-8 Oil Pan Removal. 7-8 Oil Pan Installation 7-8 Oil Screen. 7-10 Oil Screen Removal 7-10 Oil Screen Installation. 7-10 Oil Screen Cleaning 7-10 Oil Pressure Relief Valve 7-11 Oil Pressure Relief Valve Removal. 7-11 Oil Pressure Relief Valve Installation 7-11 Oil Pressure Relief Valve Inspection. 7-11 Oil Pump. 7-12 Oil Pump Removal 7-12 Oil Pump Installation. 7-12 Oil Pump Drive Gear Removal 7-13 Oil Pump Drive Gear Installation. 7-13 Oil Cooler 7-14 Oil Cooler Removal. 7-14 Oil Cooler Installation 7-14 Oil Pressure Measurement. 7-15 Oil Pressure Measurement . 7-15 Oil Pressure Switch 7-16 Oil Pressure Switch Removal . 7-16 Oil Pressure Switch Installation 7-16 Oil Pipe. 7-17 Oil Pipe Removal 7-17 Oil Pipe Installation . 7-17 7-2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Oil Cooler Bolts 12 1.2 106 inยทlb L 2 Oil Filler Plug Hand -tighten – – 3 Oil Passage Plugs 20 2.0 15 L 4 Oil Passage Plug 10 1.0 89 inยทlb 5 Oil Pressure Switch 15 1.5 11 L 6 Oil Pressure Switch Terminal Bolt 2.0 0.20 18 inยทlb G 7 Oil Pressure Relief Valve 15 1.5 11 L 8 Oil Filter 17 1.7 13 G, R 9 Oil Filter Pipe 25 2.5 18 L 10 Engine Oil Drain Bolt 29 3.0 21 11 Oil Pan Bolts 12 1.2 106 inยทlb S EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. 7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Balancer Oil Passage 2. Camshaft Oil Passages 3. Crankshaft Oil Passage 4. Drive Shaft Oil Passage 5. Output Shaft Oil Passage 6. Oil Pump 7. Oil Pipe 8. Oil Screen 9. Oil Pressure Relief Valve 10. Oil Cooler 11. Oil Filter 12. Main Oil Passage 13. Oil Pressure Switch 14. Engine Oil 15. Blowby Gas ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 3.2 L (3.4 US gt) (when filter is not removed) 3.8 L (4.0 US gt) (when filter is removed) 4.0 L (4.2 US gt) (when engine is completely dry) Level Between upper and lower level lines (Wait several minutes after idling or running) Oil Pressure Measurement Oil Pressure 255 ๏พ 304 kPa (2.60 ๏พ 3.10 kgf/cmยฒ, 37.0 ๏พ 44.1 psi) @4 000 r/min (rpm), Oil Temperature 50ยฐC (122ยฐF) 7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealants Outside Circlip Pliers: 57001-144 Oil Pressure Gauge, 10 kgf/cmยฒ: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001-1233 Liquid Gasket, TB1211: 56019-120 Liquid Gasket, TB1207B: 92104-2068 ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart. Oil Level Inspection โข Check that the engine oil level is between the upper [A] and lower [B] levels in the oil level inspection window. NOTE โSituate the motorcycle so that it is perpendicular to the ground. โIf the motorcycle has just been used, wait several minutes for all the oil to drain down. โIf the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles. NOTICE Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the red warning indicator (LED) and oil pressure warning indicator will light. If it stays on when the engine is running above idle speed, stop the engine immediately and find the cause. If the oil level is too high, remove the excess oil, using a syringe or some other suitable device. If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine. NOTE โIf 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 โข Refer to the Engine Oil Change in the Periodic Maintenance chapter. Oil Filter Replacement โข Refer to the Oil Filter Replacement in the Periodic Maintenance chapter. 7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal โข Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Pan Bolts [A] Oil Pan [B] โข Remove the following parts if necessary. Oil Screen (see Oil Screen Removal) Oil Pipe (see Oil Pipe Removal) Oil Pressure Relief Valve (see Oil Pressure Relief Valve Removal) Oil Pan Installation โขInstall the following parts if removed. Oil Pressure Relief Valve (see Oil Pressure Relief Valve Installation) Oil Pipe (see Oil Pipe Installation) Oil Screen (see Oil Screen Installation) โข Replace the O-rings [A] with new ones. โข Apply grease to the O-rings, and install them. โขInstall the dowel pins [B]. โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket [A] to the mating surface of the oil pan. Sealant – Liquid Gasket, TB1207B: 92104-2068 NOTE โEspecially, apply liquid gasket so that it shall be filled up on the grooves [B]. ENGINE LUBRICATION SYSTEM 7-9 Oil Pan NOTE โMake the application finish within 7 minutes when the liquid gasket to the mating surface of the oil pan is applied. โMoreover fit the oil pan and tighten the bolts just after application of the liquid gasket. โข Tighten the oil pan bolts following sequence [1 ๏พ 22]. Torque – Oil Pan Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โขInstall the removed parts (see appropriate chapters). 7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal โข Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] Oil Screen Installation โข Clean the oil screen (see Oil Screen Cleaning). โข Replace the O-ring [A] with a new one, and install it. โข Apply grease to the O-ring. โขInstall the rubber damper [B] to the oil pressure relief valve. โขInstall: Oil Screen Oil Pan (see Oil Pan Installation) Oil Screen Cleaning โข Remove the oil screen (see Oil Screen Removal). โข Clean the oil screen with a high flash-point solvent and remove the particles stuck. โข Blow away the particles by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side). WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the screen in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the screen. NOTE โWhile cleaning the screen, check for any metal particles that might indicate internal engine damage. โข Check the screens carefully for any damage. If the screen is damaged, replace the oil screen. ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal โข Remove: Oil Screen (see Oil Screen Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation โข Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it. Torque – Oil Pressure Relief Valve: 15 Nยทm (1.5 kgfยทm, 11 ftยทlb) Oil Pressure Relief Valve Inspection โข Check to see if the valve [A] slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE โInspect the valve in its assembled state. Disassembly and assembly may change the valve performance. If any rough spots are found during above inspection, wash the valve clean with a high flash-point solvent and blow out any foreign particles that may be in the valve with compressed air. WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the oil pressure relief valve in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the oil pressure relief valve. If cleaning does not solve the problem, replace the oil pressure relief valve as an assembly. The oil pressure relief valve is precision made with no allowance for replacement of individual parts. 7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal โข Remove: Water Pump (see Water Pump Removal in the Cooling System chapter) Oil Pump Cover [A] โข Remove: Oil (Water) Pump Shaft [A] with Inner Rotor [B] Outer Rotor [C] Oil Pump Installation โขInstall the outer rotor [A] into the crankcase. โข Apply grease to the pin [A]. โข Assemble the pin, inner rotor [B] and oil (water) pump shaft [C]. โข Turn the pump shaft so that the slot [A] in its shaft fits onto the projection [B] of the pump drive gear shaft. ENGINE LUBRICATION SYSTEM 7-13 Oil Pump โข Pack grease into the cavity [A] between the inner rotor and outer rotor for improve the oil pump initial priming. โขInstall the dowel pin [B]. โขInstall the oil pump cover [C] so that the dowel pin fits into the hole [D] of the oil pump cover. โขInstall the water pump (see Water Pump Installation in the Cooling System chapter). Oil Pump Drive Gear Removal โข Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pan (see Oil Pan Removal) Circlip [A] and Washer [B] Special Tool – Outside Circlip Pliers: 57001-144 โข Remove: Oil Pump Drive Gear [A] Washer [B] Oil Pump Drive Gear Installation โข Apply molybdenum disulfide oil solution to the hole of the oil pump drive gear shaft in the crankcase. โข Apply molybdenum grease to the journal portion [A] on the oil pump drive gear shaft [B]. โขInstall the washer [C] to the shaft. โข Replace the circlip [A] with a new one. โขInsert the oil pump drive gear to the lower crankcase. โขInstall the washer [B] and circlip. Special Tool – Outside Circlip Pliers: 57001-144 โข Fit the projection on the shaft and oil (water) pump shaft slot. โข Set the circlip to the original position. 7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal โข Drain: Coolant (see Coolant Change in the Periodic Maintenance chapter) Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) โข Slide the water hose clamps [A]. โข Disconnect the water hoses [B]. โข Remove: Oil Cooler Bolts [C] Oil Cooler [D] Oil Cooler Installation โข Replace the O-ring [A] with a new one. โข Apply grease to the O-ring and install it. โขInstall the oil cooler. โข Apply a non-permanent locking agent to the threads of the oil cooler bolts. โข Tighten: Torque – Oil Cooler Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โขInstall the water hoses [A] and clamps [B] as shown. โข Pour: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Coolant (see Coolant Change in the Periodic Maintenance chapter) ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] โข Attach the adapter [A] and gauge [B] to the plug hole. Special Tools – Oil Pressure Gauge, 10 kgf/cmยฒ: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 โข Start the engine and warm up the engine. โข Run the engine at the specified speed, and read the oil pressure gauge. Oil Pressure Standard: 255 ๏พ 304 kPa (2.60 ๏พ 3.10 kgf/cmยฒ, 37.0 ๏พ 44.1 psi) @4 000 r/min (rpm), oil temperature 50ยฐC (122ยฐF) If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately. If the reading is much higher than the standard, check the oil passages for clogging. โข Stop the engine. โข Remove the oil pressure gauge and adapter. WARNING Hot oil can cause severe burns. Beware of hot engine oil that will drain through the oil passage when the gauge adapter is removed. โข Apply a non-permanent locking agent to the oil passage plug, and tighten it. Torque – Oil Passage Plug: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) 7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal โข Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). โข Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). โข Slide the switch cover. โข Remove: Switch Terminal Bolt [A] Oil Pressure Switch [B] Oil Pressure Switch Installation โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket to the threads of the oil pressure switch and tighten it. Sealant – Liquid Gasket, TB1211: 56019-120 Torque – Oil Pressure Switch: 15 Nยทm (1.5 kgfยทm, 11 ftยทlb) โขInstall the switch lead (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Tighten: Torque – Oil Pressure Switch Terminal Bolt: 2.0 Nยทm (0.20 kgfยทm, 18 inยทlb) โข Apply grease to the terminal. NOTE โApply a small amount grease to the terminal so that grease should not close two breather holes [A] for switch diaphragm. โขInstall the switch cover. โขInstall the removed parts (see appropriate chapters). ENGINE LUBRICATION SYSTEM 7-17 Oil Pipe Oil Pipe Removal โข Remove: Oil Pan (see Oil Pan Removal) Oil Pipe [A] Oil Pipe Installation โข Replace the O-rings [A] with new ones. โข Apply grease to the O-rings, and install them. โขInstall: Oil Pipe Oil Pan (see Oil Pan Installation) ENGINE REMOVAL/INSTALLATION 8-1 8 Engine Removal/Installation Table of Contents Exploded View 8-2 Special Tool 8-4 Engine Removal/Installation. 8-5 Engine Removal 8-5 Engine Installation. 8-9 8-2 ENGINE REMOVAL/INSTALLATION Exploded View ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Upper Engine Bracket Bolts 45 4.6 33 S 2 Lower Engine Bracket Bolts 60 6.1 44 S 3 Upper Adjusting Collar 5.0 0.51 44 inยทlb 2T, S 4 Upper Adjusting Collar Locknut 50 5.1 37 S 5 Upper Engine Mounting Bolt (L = 65 mm) 45 4.6 33 S 6 Lower Engine Mounting Nut 45 4.6 33 S 7 Lower Adjusting Collar Locknut 50 5.1 37 S 8 Middle Engine Mounting Nut 45 4.6 33 S 9 Middle Engine Bracket Bolts 25 2.5 18 L, S 10 Lower Adjusting Collar 10 1.0 89 inยทlb S 11 Upper Engine Mounting Bolt (L = 40 mm) 45 4.6 33 S L: Apply a non-permanent locking agent. S: Follow the specified tightening sequence. 2T: Apply 2-stroke oil. 8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal โข Support the rear part of the swingarm with a stand. โข Squeeze the brake lever slowly and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine. NOTICE Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged. โข Drain: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Coolant (see Coolant Change in the Periodic Maintenance chapter) โข Remove: Clutch Cable Lower End (see Clutch Cable Removal in the Clutch chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Air Switching Valve (see Air Switching Valve Removal in the Engine Top End chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) โข Disconnect: Stick Coil Connectors (see Stick Coil Removal in the Electrical System chapter) Alternator Lead Connector (see Alternator Cover Removal in the Electrical System chapter) Crankshaft Sensor Lead Connector (see Crankshaft Senor Removal in the Electrical System chapter) Starter Motor Cable (see Starter Motor Removal in the Electrical System chapter) Water Temperature Sensor Connector (see Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter) 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation โข Remove: Quick Rivets [A] โข Remove the quick rivets [A]. Left Side [B] Right Side [C] โข Slide the clamp [A]. โข Disconnect the air bleeder hose [B]. โข Remove the heat insulation rubber plate. โข Slide the water hose clamp [A]. โข Disconnect the water hose [B]. โข Disconnect the connector [A] from bracket. ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation โข Open the clamp [A]. โข Disconnect: Gear Position Sensor Connector [B] Oil Pressure Switch Lead [C] โข Remove: Engine Ground Cable Terminal Bolt [A] Clamps [B] โข Remove the drive chain [A] from the output shaft [B]. โข Remove: Bracket Bolts [A] (Both Sides) Bracket [B] (Both Sides) โข Disconnect the regulator/rectifier connector [A]. โข Remove: Immobilizer Amplifier [B] (Equipped Models) Left Upper Engine Bracket Bolts [C] Regulator/Rectifier with Bracket [D] 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation โข Remove: Canister Bracket Bolts [A] (Other than US and CA Models) Right Upper Engine Bracket Bolts [B] โข Remove: Lower Engine Bracket Bolt [A] and Washer (Both Sides) Engine Bracket [B] (Both Sides) โข Support the engine with a suitable stand [A]. โPut a plank [B] onto the suitable stand for engine balance. โข Remove: Upper Engine Mounting Bolt [A] (Both Sides) Middle Engine Mounting Nut [B] and Bolt Lower Engine Mounting Nut [C] โข Using the nut wrench [A], loosen the upper adjusting collar locknut [B]. Special Tool – Engine Mount Nut Wrench: 57001-1450 โข Using the hexagon wrench, turn the adjusting collar [C] counterclockwise to make the gap between the engine and adjusting collar. ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation โข Using the nut wrench [A], loosen the lower adjusting collar locknut [B]. Special Tool – Engine Mount Nut Wrench: 57001-1450 โข Remove the lower engine mounting bolt [C]. โข Using the hexagon wrench, turn the adjusting collar [D] counterclockwise to make the gap between the engine and adjusting collar. โข Using the suitable stand, take out the engine. Engine Installation โข Support the engine with a suitable stand. โPut a plank onto the suitable stand for engine balance. โข Apply 2-stroke oil to the upper adjusting collar [A]. โข Screw the upper adjusting collar and lower adjusting collar [B] to the frame. 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation โขInstall the engine mounting bolts and nuts, following the specified installing sequence. โFirst, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. โSecond, apply a non-permanent locking agent to the threads of the middle engine bracket bolts [A]. Install the middle engine bracket [B] and clamp [C], tighten the middle engine bracket bolts. Torque – Middle Engine Bracket Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โThird, insert the lower engine mounting bolt [D]. โForth, install the collar [E], and insert the middle engine mounting bolt [F]. โFifth, tighten the left upper engine mounting bolt [G]. Torque – Upper Engine Mounting Bolt (L = 40 mm): 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) โSixth, tighten the upper adjusting collar locknut [H] and right upper engine mounting bolt [I] temporarily. โSeventh, tighten the lower adjusting collar [J]. Torque – Lower Adjusting Collar: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โEighth, tighten the lower adjusting collar locknut [K] and lower engine mounting nut [L]. Torque – Lower Adjusting Collar Locknut: 50 Nยทm (5.1 kgfยทm, 37 ftยทlb) Lower Engine Mounting Nut: 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) Special Tool – Engine Mount Nut Wrench: 57001-1450 โNinth, tighten the middle engine mounting nut [M]. Torque – Middle Engine Mounting Nut: 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) โTenth, install the left engine bracket [N], and tighten the mounting bolts temporarily. โEleventh, install the bracket [O], and tighten the mounting bolts [P]. โTwelfth, tighten the engine bracket bolts and bracket mounting bolts evenly. Torque – Upper Engine Bracket Bolts [Q]: 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) Lower Engine Bracket Bolts [R]: 60 Nยทm (6.1 kgfยทm, 44 ftยทlb) โThirteenth, install the right engine bracket [S] just like the left engine bracket. โFourteenth, remove the right upper engine mounting bolt. โFifteenth, tighten the upper adjusting collar [T]. Torque – Upper Adjusting Collar: 5.0 Nยทm (0.51 kgfยทm, 44 inยทlb) โSixteenth, tighten the upper adjusting collar locknut [H]. Torque – Upper Adjusting Collar Locknut: 50 Nยทm (5.1 kgfยทm, 37 ftยทlb) Special Tool – Engine Mount Nut Wrench: 57001-1450 โLastly, tighten the right upper engine mounting bolt [I]. Torque – Upper Engine Mounting Bolt (L = 65 mm): 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation โข Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). โข Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Clutch Cable (see Clutch Operation Inspection in the Periodic Maintenance chapter) Drive Chain (see Drive Chain Slack Inspection in the Periodic Maintenance chapter) โข Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter). โข Fill the engine with coolant (see Coolant Change in the Periodic Maintenance chapter). CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-8 Crankcase Splitting 9-9 Crankcase Splitting 9-9 Crankcase Assembly . 9-10 Crankshaft and Connecting Rods 9-15 Crankshaft Removal 9-15 Crankshaft Installation . 9-15 Connecting Rod Removal 9-15 Connecting Rod Installation. 9-16 Crankshaft/Connecting Rod Cleaning 9-19 Connecting Rod Bend Inspection 9-20 Connecting Rod Twist Inspection. 9-20 Connecting Rod Big End Side Clearance Inspection 9-20 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-21 Crankshaft Side Clearance Inspection 9-22 Crankshaft Runout Inspection 9-23 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-23 Balancer 9-26 Balancer Removal 9-26 Balancer Installation. 9-26 Balancer Adjustment 9-27 Balancer Damper Inspection 9-27 Starter Motor Clutch 9-28 Starter Motor Clutch Removal/Installation 9-28 Starter Motor Clutch Disassembly 9-28 Starter Motor Clutch Assembly 9-28 Starter Motor Clutch Inspection . 9-28 External Shift Mechanism 9-29 Shift Pedal Removal 9-29 Shift Pedal Installation . 9-29 External Shift Mechanism Removal 9-30 External Shift Mechanism Installation. 9-30 External Shift Mechanism Inspection 9-31 Transmission . 9-33 Transmission Shaft Removal . 9-33 Transmission Shaft Installation 9-33 Transmission Shaft Disassembly. 9-33 Transmission Shaft Assembly 9-34 Shift Drum and Fork Removal 9-38 Shift Drum and Fork Installation. 9-38 Shift Drum Disassembly. 9-38 Shift Drum Assembly . 9-39 Shift Fork Bending Inspection 9-39 Shift Fork/Gear Groove Wear Inspection 9-39 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-39 Gear Dog and Gear Dog Hole Damage Inspection . 9-40 Ball Bearing, Needle Bearing, and Oil Seal. 9-41 Ball and Needle Bearing Replacement. 9-41 Ball and Needle Bearing Wear Inspection 9-41 Oil Seal Inspection. 9-41 9-2 CRANKSHAFT/TRANSMISSION Exploded View CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Balancer Shaft Clamp Bolt 10 1.0 89 inยทlb 2 Balancer Shaft Clamp Lever Bolt 25 2.5 18 L 3 Connecting Rod Big End Nuts see the text โ โ MO 4 Breather Side Plate Bolt 6.0 0.61 53 inยทlb L 5 Breather Plate Bolts 10 1.0 89 inยทlb L 6 Starter Motor Clutch Bolts 12 1.2 106 inยทlb L 7 Oil Passage Plugs 20 2.0 15 L 8 Oil Passage Plug 10 1.0 89 inยทlb 9 Crankcase Bolts (M6) 12 1.2 106 inยทlb S 10 Crankcase Bolts (M7) 20 2.0 15 S 11 Crankcase Bolts (M8) 27 2.8 20 S 12 Crankcase Bolts (M9) 44 4.5 32 MO, S 13. Do not apply any grease or oil. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. WL: Apply soap and water solution or rubber lubricant. 9-4 CRANKSHAFT/TRANSMISSION Exploded View CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Gear Positioning Lever Bolt 12 1.2 106 inยทlb 2 Shift Drum Bearing Holder Bolts 12 1.2 106 inยทlb L 3 Shift Drum Cam Holder Bolt 12 1.2 106 inยทlb L 4 Shift Shaft Return Spring Pin 39 4.0 29 L 5 Shift Pedal Mounting Bolt 25 2.5 18 G 6 Shift Lever Clamp Bolt 10 1.0 89 inยทlb L 7 Gear Position Sensor Bolt 10 1.0 89 inยทlb L EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. Lh: Left-hand threads MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts 9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend โโโ TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist โโโ TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.13 ๏พ 0.38 mm (0.0051 ๏พ 0.0150 in.) 0.6 mm (0.024 in.) Connecting Rod Big End Bearing Insert/Crankpin Clearance 0.030 ๏พ 0.060 mm (0.0012 ๏พ 0.0024 in.) 0.10 mm (0.0039 in.) Crankpin Diameter: 34.484 ๏พ 34.500 mm (1.3576 ๏พ 1.3583 in.) 34.47 mm (1.357 in.) Marking: None 34.484 ๏พ 34.492 mm (1.3576 ๏พ 1.3579 in.) โโโ โ 34.493 ๏พ 34.500 mm (1.3580 ๏พ 1.3583 in.) โโโ Connecting Rod Big End Inside Diameter: 37.500 ๏พ 37.516 mm (1.4764 ๏พ 1.4770 in.) โโโ Marking: None 37.500 ๏พ 37.508 mm (1.4764 ๏พ 1.4766 in.) โโโ โ 37.509 ๏พ 37.516 mm (1.4767 ๏พ 1.4770 in.) โโโ Connecting Rod Big End Bearing Insert Thickness: Brown 1.478 ๏พ 1.483 mm (0.05819 ๏พ 0.05839 in.) โโโ Black 1.483 ๏พ 1.488 mm (0.05839 ๏พ 0.05858 in.) โโโ Blue 1.488 ๏พ 1.493 mm (0.05858 ๏พ 0.05878 in.) โโโ Connecting Rod Bolt Stretch (Usable Range) 0.20 ๏พ 0.32 mm (0.0079 ๏พ 0.0126 in.) โโโ Crankshaft Side Clearance 0.09 ๏พ 0.19 mm (0.0035 ๏พ 0.0075 in.) 0.39 mm (0.0154 in.) Crankshaft #3 Main Journal Width 23.49 ๏พ 23.54 mm (0.9248 ๏พ 0.9268 in.) โโโ Crankshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Clearance 0.010 ๏พ 0.034 mm (0.0004 ๏พ 0.0013 in.) 0.06 mm (0.0024 in.) Crankshaft Main Journal Diameter: 34.984 ๏พ 35.000 mm (1.3773 ๏พ 1.3780 in.) 34.96 mm (1.376 in.) Marking: None 34.984 ๏พ 34.992 mm (1.3773 ๏พ 1.3776 in.) โโโ 1 34.993 ๏พ 35.000 mm (1.3777 ๏พ 1.3780 in.) โโโ Crankcase Main Bearing Inside Diameter: 38.000 ๏พ 38.016 mm (1.4961 ๏พ 1.4967 in.) โโโ Marking: โ 38.000 ๏พ 38.008 mm (1.4961 ๏พ 1.4963 in.) โโโ None 38.009 ๏พ 38.016 mm (1.4964 ๏พ 1.4967 in.) โโโ CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: Brown 1.491 ๏พ 1.495 mm (0.05870 ๏พ 0.05886 in.) โโโ Black 1.495 ๏พ 1.499 mm (0.05886 ๏พ 0.05902 in.) โโโ Blue 1.499 ๏พ 1.503 mm (0.05902 ๏พ 0.05917 in.) โโโ Transmission Shift Fork Ear Thickness 5.9 ๏พ 6.0 mm (0.232 ๏พ 0.236 in.) 5.8 mm (0.23 in.) Gear Groove Width 6.05 ๏พ 6.15 mm (0.238 ๏พ 0.242 in.) 6.3 mm (0.25 in.) Shift Fork Guide Pin Diameter 6.9 ๏พ 7.0 mm (0.272 ๏พ 0.276 in.) 6.8 mm (0.27 in.) Shift Drum Groove Width 7.05 ๏พ 7.20 mm (0.278 ๏พ 0.283 in.) 7.3 mm (0.29 in.) Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bearing Insert Inside Diameter Marking Crankpin Diameter Marking Size Color Part Number None โ Brown 92139-0124 None None โ โ Black 92139-0123 โ None Blue 92139-0122 Crankshaft Main Bearing Insert Selection Crankcase Main Bearing Insert* Bearing Inside Diameter Marking Crankshaft Main Journal Diameter Marking Size Color Part Number Journal Nos. 92139-0034 2, 4 โ 1 Brown 92139-0219 1, 3, 5 None 1 92139-0033 2, 4 โ None Black 92139-0218 1, 3, 5 92139-0032 2, 4 None None Blue 92139-0217 1, 3, 5 *: The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively. 9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Bearing Puller: 57001-135 Outside Circlip Pliers: 57001-144 Bearing Puller Adapter: 57001-317 Bearing Driver, 32: 57001-382 Bearing Driver Set: 57001-1129 Flywheel Holder: 57001-1313 Liquid Gasket, TB1216B: 92104-1064 Liquid Gasket, TB1207B: 92104-2068 CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting โข Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). โข Set the engine on a clean surface and hold the engine steady while parts are being removed. โข Remove: Cylinder (see Cylinder Removal in the Engine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mechanism Removal) Starter Motor (see Starter Motor Removal in the Electrical System chapter) Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Cooler (see Oil Cooler Removal in the Engine Lubrication System chapter) Oil Pipe (see Oil Pipe Removal in the Engine Lubrication System chapter) Oil Pressure Relief Valve (see Oil Pressure Relief Valve Removal in the Engine Lubrication System chapter) If the crankshaft is to be removed, remove the pistons (see Piston Removal in the Engine Top End chapter). โข Loosen the balancer shaft clamp bolt [A]. โข Remove: Balancer Shaft Clamp Lever Bolt [B] Balancer Shaft Clamp Lever [C] โข Remove the upper crankcase bolts, following the specified sequence. โFirstly, loosen the M6 bolts [A]. โSecondly, loosen the M7 bolts [B]. โLastly, loosen the M8 bolts [C]. 9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting โข Remove the lower crankcase bolts, following the specified sequence. โFirstly, loosen the M7 bolts [A]. โLastly, loosen the M9 bolts as shown sequence [1 ๏พ 10]. โข Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. โTake care not to damage the crankcase. Crankcase Assembly NOTICE The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. โข With a high flash-point solvent, clean off the mating surfaces of the crankcase halves and wipe dry. โข Using compressed air, blow out the oil passages in the crankcase halves. โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket to the breather plate mating surface [A] 1 mm (0.04 in.) or more thick, and then install the breather plate. โApply liquid gasket start from the corner area [B] as shown. Sealant – Liquid Gasket, TB1207B: 92104-2068 NOTE โMake the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied. โMoreover fit the plate and tighten the bolts just after application of the liquid gasket. CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting โข Apply a non-permanent locking agent to the threads of the breather plate bolts [A] and tighten them. Torque – Breather Plate Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โขInstall the breather side plate [A] so that the plate hole [B] fit the projection [C] of the upper crankcase. โข Apply a non-permanent locking agent to the threads of the breather side plate bolt [D] and tighten it. Torque – Breather Side Plate Bolt: 6.0 Nยทm (0.61 kgfยทm, 53 inยทlb) โข Press the fitting [A] in the upper crankcase [B] until it is bottomed. Special Tool – Bearing Driver Set: 57001-1129 โข Press the plug [C] in the upper crankcase so that the plug is deeper than crankcase surface. โข Press the new needle bearing [A] for the shift shaft so that its marked side faces outside and its surface [B] is flush with the end of the hole. โขInstall the new oil seal [C] so that its surface [D] is flush with the end of the hole. โข Apply grease to the oil seal lips. โข Apply a non-permanent locking agent to the oil passage plugs [A], and tighten them. Torque – Oil Passage Plugs: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) โขInstall the oil passage plug [B] in the lower crankcase, and tighten it. Torque – Oil Passage Plug: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting โขInstall: Crankshaft (see Crankshaft Installation) Connecting Rods (see Connecting Rod Installation) Balancer (see Balancer Installation) Transmission Shafts (see Transmission Shaft Installation) Dowel Pins [A] Shift Drum (see Shift Drum and Fork Installation) Shift Forks and Shift Rods (see Shift Drum and Fork Installation) โข Before fitting the lower case on the upper case, check the following. โBe sure to hang the camshaft chain on the crankshaft. โCheck to see that the shift drum and transmission gears are in the neutral position. โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant – Liquid Gasket, TB1216B: 92104-1064 NOTE โEspecially, apply a liquid gasket so that it shall be filled up on the grooves [B]. โDo not apply liquid gasket to the inside of the groove [C]. NOTICE Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes. CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting โข Fit the lower crankcase to the upper crankcase. NOTE โMake the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied. โMoreover fit the case and tighten the bolts just after application of the liquid gasket. โข The M9 bolts [A] have copper plated washers [B], replace them with new ones. โข Apply molybdenum disulfide oil solution to both sides [C] of the copper plated washer and threads [D] of the M9 bolts. โข Tighten the lower crankcase bolts using the following steps. โFollowing the sequence numbers on the lower crankcase half, tighten the M9 bolts [1 ๏พ 10] with copper plated washers. Torque – Crankcase Bolts (M9): 44 Nยทm (4.5 kgfยทm, 32 ftยทlb) โReplace the washer [A] with a new one. โTighten the M7 bolts. Torque – Crankcase Bolts (M7): 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) L = 60 mm (2.36 in.) [B] L = 50 mm (1.97 in.) [C] L = 45 mm (1.77 in.) [D] 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting โข Tighten the upper crankcase bolts using the following steps. โTighten the M8 bolts [A]. Torque – Crankcase Bolts (M8): 27 Nยทm (2.8 kgfยทm, 20 ftยทlb) โReplace the washer [B] with a new one. โTighten the M7 bolts. L = 85 mm (3.35 in.) [C] L = 50 mm (1.97 in.) [D] Torque – Crankcase Bolts (M7): 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) โTighten the M6 bolts. L = 68 mm (2.69 in.) [E] L = 40 mm (1.57 in.) [F] Torque – Crankcase Bolts (M6): 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข After tightening all crankcase bolts, check the following items. โWipe up the liquid gasket that seeps out around the crankcase mating surface. โCrankshaft and transmission shafts turn freely. โWhile spinning the output shaft, gears shift smoothly from the 1st to 6th gear, and 6th to 1st. โWhen the output shaft stays still, the gear can not be shifted to 2nd gear or other higher gear positions. โขInstall the removed parts (see appropriate chapters). CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods Crankshaft Removal โข Split the crankcase (see Crankcase Splitting). โข Remove: Connecting Rods (see Connecting Rod Removal) Balancer (see Balancer Removal) Crankshaft [A] Crankshaft Installation NOTICE If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed. โข Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts. โขInstall the crankshaft with the camshaft chain [A] hanging on it. โขInstall the removed parts (see appropriate chapters). Connecting Rod Removal โข Split the crankcase (see Crankcase Splitting). โข Remove: Connecting Rod Big End Nuts [A] Connecting Rod Big End Caps [B] NOTE โMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions. โข Remove the connecting rods from the crankshaft. NOTICE Discard the connecting rod bolts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins. 9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Installation NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D]: โโโ or no mark NOTICE If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed. โข Apply molybdenum disulfide oil solution [A] to the inner surfaces of upper and lower bearing inserts. โข Apply molybdenum disulfide grease to the connecting rod big end inside surface [B]. โข Do not apply any grease or oil to the cap inside and cap insert outside [C]. โขInstall the inserts so that their nails [D] are on the same side and fit them into the recess of the connecting rod and cap. NOTICE Wrong application of oil and grease could cause bearing damage. โWhen 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] โข Remove debris and clean the surface of inserts. โขInstall the cap on the connecting rod, aligning the weight and diameter marks. โข Apply molybdenum disulfide oil solution [MO] to the threads and seating surfaces of the big end nuts and bolts. CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods โขInstall each connecting rod on its original crankpin. โThe connecting rod big end is bolted using the โplastic region fastening method.โ โThis method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight. โThere are two types of the plastic region fastening. One is a bolt length measurement method and other is a rotation angle method. Observe one of the following two, but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts. NOTICE The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage. NOTICE Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase. (1) Bolt Length Measurement Method โข Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high flash-point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the bolts, nuts, and connecting rods in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean them. NOTICE Immediately dry the bolts and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely. 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods โขInstall new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. โข Apply a small amount of molybdenum disulfide oil solution to the following portions. Threads [A] of Bolts and Nuts Seating Surfaces [B] of Nuts and Connecting Rod Caps โข Dent both bolt head and bolt tip with a punch as shown. โข Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch. Connecting Rod [A] Dent here with a punch [B]. Nuts [C] Fit micrometer pins into dents [D]. โข Tighten the big end nuts until the bolt elongation reaches the length specified as follows. Bolt Length after tightening โ Bolt Length before tightening = Bolt Stretch Connecting Rod Bolt Stretch Usable Range: 0.20 ๏พ 0.32 mm (0.0079 ๏พ 0.0126 in.) โข Check the length of the connecting rod bolts. If the stretch is more than the usable range, the bolt has stretched too much. An overelongated bolt may break in use. (2) Rotation Angle Method If you do not have a point micrometer, you may tighten the nuts using the โRotation Angle Method.โ โข Be sure to clean the bolts, nuts and connecting rods thoroughly with a high flash-point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution. WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the bolts, nuts, and connecting rods in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean them. NOTICE Immediately dry the bolts and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely. CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods โขInstall new bolts and nuts in reused connecting rods. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. โข Apply a small amount of molybdenum disulfide oil solution to the following portions. Threads [A] of Bolts and Nuts Seating Surfaces [B] of Nuts and Connecting Rod Caps โข First, tighten the nuts to the specified torque. See the table below. โข Next, tighten the nuts 120ยฐ ยฑ5ยฐ . โMark [A] the connecting rod big end caps and nuts so that nuts can be turned 120ยฐ [B] properly. โTighten the hexagon nut by 2 corners. Connecting Torque + Angle Rod Assy Bolt Nut Nยทm (kgfยทm, ftยทlb) Attached to 22 (2.2, 16) new con-rod + 120ยฐ 20 (2.0, 15) New Use the bolts attached to new con-rod. New + 120ยฐ 26 (2.7, 19) Used + 120ยฐ 26 (2.7, 19) Used Replace the bolts with new ones. New + 120ยฐ โThe nuts can be tightened by using a torque angle gauge [A]. Crankshaft/Connecting Rod Cleaning โข After removing the connecting rods from the crankshaft, clean them with a high flash-point solvent. โข Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages. 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend Inspection โข Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. โข Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. โข 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. โข On a surface plate, set the big-end arbor on V block [C]. โข 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 โข 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 determine 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 โข Measure connecting rod big end side clearance. โInsert a thickness gauge [A] between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.13 ๏พ 0.38 mm (0.0051 ๏พ 0.0150 in.) Service Limit: 0.6 mm (0.024 in.) If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again. If the clearance is too large after connecting rod replacement, the crankshaft also must be replaced. CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection โข Remove the connecting rod big end (see Connecting Rod Removal). โข Cut strips of plastigage (press gauge) to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position. โข Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE โDo not move the connecting rod and crankshaft during clearance measurement. โข Remove the connecting rod big end again, measure each clearance between the bearing insert and crankpin [A] using plastigage (press gauge) [B]. NOTICE After measurement, replace the connecting rod bolts. Connecting Rod Big End Bearing Insert/Crankpin Clearance Standard: 0.030 ๏พ 0.060 mm (0.0012 ๏พ 0.0024 in.) Service Limit: 0.10 mm (0.0039 in.) If the clearance is within the standard, no bearing replacement is required. If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the crankpins. Crankpin Diameter Standard: 34.484 ๏พ 34.500 mm (1.3576 ๏พ 1.3583 in.) Service Limit: 34.47 mm (1.357 in.) If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters [A] are not less than the service limit, but do not coincide with the original diameter markings [B] on the crankshaft, make new marks on it. Crankpin Diameter Marks None 34.484 ๏พ 34.492 mm (1.3576 ๏พ 1.3579 in.) โ 34.493 ๏พ 34.500 mm (1.3580 ๏พ 1.3583 in.) : Crankpin Diameter Marks, โโโ or no mark. 9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods โข Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. โข Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE โThe mark already on the big end should almost coincide with the measurement. Connecting Rod Big End Inside Diameter Marks None 37.500 ๏พ 37.508 mm (1.4764 ๏พ 1.4766 in.) โ 37.509 ๏พ 37.516 mm (1.4767 ๏พ 1.4770 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: โโโ or no mark โข Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Bearing Insert Con-rod Big End Inside Diameter Marking Crankpin Diameter Marking Size Color Part Number None โ Brown 92139-0124 None None โ โ Black 92139-0123 โ None Blue 92139-0122 โขInstall the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage. Crankshaft Side Clearance Inspection โขInsert a thickness gauge [A] between the crankcase main bearing and the crank web at the #3 journal to determine clearance. If the clearance exceeds the service limit, replace the crankcase halves as a set. NOTE โThe upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. Crankshaft Side Clearance Standard: 0.09 ๏พ 0.19 mm (0.0035 ๏พ 0.0075 in.) Service Limit: 0.39 mm (0.0154 in.) CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Crankshaft Runout Inspection โข 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 โข Split the crankcase (see Crankcase Splitting). โข Cut strips of plastigage (press gauge) to journal width. โข Place a strip on each journal parallel to the crankshaft installed in the correct position. โข Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE โDo not turn the crankshaft during clearance measurement. โJournal clearance less than 0.025 mm (0.00098 in.) can not be measured by plastigage [A], however, using genuine parts maintains the minimum standard clearance. โข Split the crankcase again, measure each clearance between the bearing insert and journal [B] using plastigage (press gauge). Crankshaft Main Bearing Insert/Journal Clearance Standard: 0.010 ๏พ 0.034 mm (0.0004 ๏พ 0.0013 in.) Service Limit: 0.06 mm (0.0024 in.) If the clearance is within the standard, no bearing replacement is required. If the clearance is between 0.035 mm (0.0014 in.) and the service limit (0.06 mm, 0.0024 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the crankshaft main journal. 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter Standard: 34.984 ๏พ 35.000 mm (1.3773 ๏พ 1.3780 in.) Service Limit: 34.96 mm (1.376 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters [A] are not less than the service limit, but do not coincide with the original diameter markings [B] on the crankshaft, make new marks on it. Crankshaft Main Journal Diameter Marks None 34.984 ๏พ 34.992 mm (1.3773 ๏พ 1.3776 in.) 1 34.993 ๏พ 35.000 mm (1.3777 ๏พ 1.3780 in.) โก: Crankshaft Main Journal Diameter Marks, โ1โ or no mark. โข Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diameter. Crankcase Main Bearing Inside Diameter Marks: โโโ or no mark. โข Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE โThe mark already on the upper crankcase half should almost coincide with the measurement. Crankcase Main Bearing Inside Diameter Marks โ 38.000 ๏พ 38.008 mm (1.4961 ๏พ 1.4963 in.) None 38.009 ๏พ 38.016 mm (1.4964 ๏พ 1.4967 in.) โข Select the proper bearing insert [A] in accordance with the combination of the crankcase and crankshaft coding. Size Color [B] CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Bearing Insert* Crankcase Main Bearing Inside Diameter Marking Crankshaft Main Journal Diameter Marking Size Color Part Number Journal Nos. 92139-0034 2, 4 โ 1 Brown 92139-0219 1, 3, 5 None 1 92139-0033 2, 4 โ None Black 92139-0218 1, 3, 5 92139-0032 2, 4 None None Blue 92139-0217 1, 3, 5 * The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively. โขInstall the new inserts in the crankcase halves and check insert/journal clearance with the plastigage. 9-26 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal โข Split the crankcase (see Crankcase Splitting). โข Remove: Oil Seal [A] Balancer [B] Balancer Installation โข Check that the rubber dampers [A] are in place as shown. โข Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight [A]. โขInstall the balancer weight into the gear [B]. โAlign the punch mark [C] of the balancer weight with the groove [D] of the gear. โข Apply molybdenum disulfide oil solution to the needle bearings. Insert the needle bearings. โข Fit the washers [A] on both ends of the weight and gear assembly. The projected sides [B] face inward. โขInsert the pin [A] as shown. โข Set the balancer on the upper crankcase half. โAlign the punch mark [B] on the balancer gear [C] with the mark [D] on the balancer drive gear [E] of crankshaft. CRANKSHAFT/TRANSMISSION 9-27 Balancer โข Assemble the crankcase (see Crankcase Assembly). โข Fill the oil seal lips with grease. โขInstall the new oil seal [A] so that its surface is flush with the surface of the crankcase. โขInstall the balancer shaft clamp lever [B]. โข Apply a non-permanent locking agent to the threads of the balancer shaft clamp lever bolt [C]. โข Tighten: Torque – Balancer Shaft Clamp Lever Bolt: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โข Turn the balancer shaft so that its mark [D] faces downward. โข Check that the balancer shaft clamp lever is in contact with the oil seal. โข Tighten: Torque – Balancer Shaft Clamp Bolt [E]: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) Balancer Adjustment โข Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). โข Start the engine and warm it up thoroughly. โข Adjust the balancer gear backlash with the engine idling. The amount of backlash can be changed by turning the balancer shaft which has eccentric journals. โStart the engine and let it idle. โLoosen the clamp bolt [A] and turn the balancer shaft [B] clockwise [C] until the balancer gear makes a whining sound. โTurn the shaft counterclockwise [D] until the balancer gear whining sound disappears and tighten the clamp bolt. Torque – Balancer Shaft Clamp Bolt: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) Balancer Damper Inspection โข Remove the balancer and disassemble the weight and gear assembly. โข Visually inspect the rubber dampers [A]. If they appear damaged or deteriorated, replace them. 9-28 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation โข Refer to the Starter Motor Clutch Disassembly/Assembly. Starter Motor Clutch Disassembly โข Remove the alternator rotor (see Alternator Rotor Removal in the Electrical System chapter). โข Hold the alternator rotor with the flywheel holder [A]. Special Tool – Flywheel Holder: 57001-1313 โข Remove the starter motor clutch bolts [B]. โข Remove: Starter Motor Clutch Housing [A] Starter Motor Clutch [B] Starter Motor Clutch Assembly โขInstall the starter motor clutch to the housing so that the flange [A] fit to the housing groove [B]. โข Hold the alternator rotor with the flywheel holder. Special Tool – Flywheel Holder: 57001-1313 โข Apply a non-permanent locking agent to the threads of the starter motor clutch bolts and tighten them. Torque – Starter Motor Clutch Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) Starter Motor Clutch Inspection โข Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Shaft โข 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. โข Disassemble the starter motor clutch, and visually inspect the clutch parts. If there is any worn or damaged part, replace it. NOTE โExamine the starter motor clutch gear as well. Replace it if it worn or damaged. CRANKSHAFT/TRANSMISSION 9-29 External Shift Mechanism Shift Pedal Removal โข Remove: Shift Lever Clamp Bolt [A] Shift Lever [B] If the tie-rod is removed from the shift pedal and shift lever, note the following. โThe following portions have left-hand threads. Locknut [C] of Shift Lever Side Ball Joint [D] of Shift Lever โข Remove: Shift Pedal Mounting Bolt [E] Shift Pedal [F] with Tie-Rod [G] Washer Shift Pedal Installation โข Apply grease to the sliding surface [A] on the shift pedal mounting bolt [B]. โขInstall: Washer [C] Tie-Rod [D] and Shift Pedal [E] โข Tighten: Torque – Shift Pedal Mounting Bolt: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โข Align the punch mark [A] on the shift shaft with the slit [B] of the shift lever. โข Apply a non-permanent locking agent to the threads of the shift lever clamp bolt [C] and tighten it. Torque – Shift Lever Clamp Bolt: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โข After installation, confirm that the shift pedal [A] is positioned as shown. About 90ยฐ [B] If the pedal position is different, adjust it as follows. โTo adjust the pedal position, loosen the front locknut [C] (left-hand threads) and rear locknut [D], and then turn the tie-rod [E]. โTighten the locknuts securely. 9-30 CRANKSHAFT/TRANSMISSION External Shift Mechanism External Shift Mechanism Removal โข Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Shift Lever (see Shift Pedal Removal) Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Washer [B] Special Tool – Outside Circlip Pliers: 57001-144 โข Remove the shift shaft assembly [A]. โข Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar and Spring [C] External Shift Mechanism Installation โข Assemble the following parts as shown. Gear Positioning Lever [A] Spring [B] Collar [C] Gear Positioning Lever Bolt [D] โHang the spring end [E] to the gear positioning lever. โข While prying the gear positioning lever [A], tighten the gear positioning lever bolt [B]. Torque – Gear Positioning Lever Bolt: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) CRANKSHAFT/TRANSMISSION 9-31 External Shift Mechanism โข Apply grease to the lips of the oil seal [A]. โขInstall the shift shaft [A] so that the return spring pin [B] fits between the spring [C]. โขInstall the washer [A]. โข Replace the circlip [B] with a new one, and install it. Special Tool – Outside Circlip Pliers: 57001-144 โFit the circlip into the groove of the shift shaft securely. โขInstall the removed parts (see appropriate chapters). External Shift Mechanism Inspection โข Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the springs [C] are damaged in any way, replace them. If the shift mechanism arm [D] is damaged in any way, replace the shift shaft. โข 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: 39 Nยทm (4.0 kgfยทm, 29 ftยทlb) 9-32 CRANKSHAFT/TRANSMISSION External Shift Mechanism โข Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. โข Visually inspect the shift drum cam [B]. If it is badly worn or shows any damage, replace it. CRANKSHAFT/TRANSMISSION 9-33 Transmission Transmission Shaft Removal โข Split the crankcase (see Crankcase Splitting). โข Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation โข Check to see that the set pins [A] and set rings [B] are in place. โข Apply molybdenum disulfide oil solution to the transmission gears. โขInstall the drive shaft and output shaft into the upper crankcase half. โข Apply engine oil to the bearings. โThe bearing set pins and rings must match properly with the holes or grooves in the bearing outer races or bearings. When they are properly matched, there is no clearance [A] between the crankcase and the bearing outer races or bearings. โข Assemble the crankcase (see Crankcase Assembly). โข Replace the oil seal [A] with a new one. โข Apply grease to the oil seal lips. โข Apply soap and water solution to the outer circumference of the oil seal so that it will go into place smoothly. โข Press in the oil seal into the crankcase so that the surface of the oil seal is flush with the surface [B] of the crankcase. Transmission Shaft Disassembly โข Remove the transmission shafts (see Transmission Shaft Removal). โข Remove the circlips, and disassemble the transmission shafts. Special Tool – Outside Circlip Pliers: 57001-144 โข The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mechanism. Remove the 5th gear. โSet the output shaft in a vertical position holding the 3rd gear [B]. โSpin the 5th gear quickly [C] and pull it off upward. 9-34 CRANKSHAFT/TRANSMISSION Transmission โข Remove the ball bearing [A] from each shafts and collar [B] from output shaft. Special Tools – Bearing Puller [C]: 57001-135 Bearing Puller Adapter [D]: 57001-317 โข Discard the bearing and collar (output shaft). Transmission Shaft Assembly โขInstall the new ball bearing [A] on the each shaft, using the bearing driver. Spacial Tool – Bearing Driver, 32: 57001-382 โขInstall the collar [A] on the output shaft, using the bearing driver. Special Tool – Bearing Driver, 32: 57001-382 โข Apply engine oil to the bushings, ball bearings and shafts. โขInstall the gear bushings [A] on the shaft with their holes [B] aligned. โข Replace any circlips removed with new ones. โขInstall the circlips [A] so that the opening [B] is aligned with a spline groove [C]. CRANKSHAFT/TRANSMISSION 9-35 Transmission โข 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 correct sequence and all circlips and washers are properly in place. โขInstall the 3rd/4th gear onto the drive shaft with their oil holes aligned. โขInstall the 5th and 6th gear bushings onto the drive shaft with their oil holes aligned. โข The output shaft gears can be recognized by size: the gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place. โขInstall the 6th gear onto the output shaft with their oil holes aligned. โขInstall the 2nd and 3rd/4th gear bushings onto the output shaft with their oil holes aligned. NOTE โWhen the toothed washers are assembled onto the each shaft, note the following. โAlign the punch marks [A] of the toothed washers (only on drive shaft). โWhen the tangs [B] of the toothed washer shall be assembled, they should be installed into the notch [C] of the toothed washer (see Page 9-36). โข Fit the steel balls into the 5th gear holes in the output shaft, aligning the holes as shown. 5th Gear [A] Output Shaft [B] Steel Balls [C] NOTICE Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction. โAfter assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear doesnโt come out of the output shaft when moving it up and down by hand. โข Check that each gear spins or slides freely on the transmission shafts without binding after assembly. 9-36 CRANKSHAFT/TRANSMISSION Transmission CRANKSHAFT/TRANSMISSION 9-37 Transmission 1. Output Shaft 2. Collar 3. Ball Bearings 4. Bushing 5. 2nd Gear (39 T) 6. Washer ( 34 ร 28.1) 7. Circlips ( 33 ร 25.9) 8. Top Gear (31 T) 9. Toothed Washer ( 34) 10. 4th Gear (25 T) 11. Bushings 12. Toothed Washer ( 40.5) 13. Toothed Washer ( 37) 14. 3rd Gear (24 T) 15. Steel Balls 16. 5th Gear (26 T) 17. Low Gear (39 T) 18. Washers ( 31 ร 20.5) 19. Races 20. Needle Bearings 21. Circlips ( 22.2 ร 18.7) 22. Needle Bearing 23. Low Gear (15 T) (Drive Shaft) 24. Bushing 25. 5th Gear (21 T) 26. Toothed Washers ( 31) 27. Circlips ( 29 ร 22.6) 28. 3rd/4th Gear (15 T/18 T) 29. Bushing 30. Top Gear (28 T) 31. Toothed Washer ( 34.2) 32. Toothed Washer ( 32) 33. 2nd Gear (20 T) 34. Washer ( 30 ร 20.5) 9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal NOTICE Never drop the shift drum, especially on a hard surface. Such a shock to the shift drum can damage it. โข Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts (see Transmission Shaft Removal) Gear Positioning Lever (see External Shift Mechanism Removal) Shift Drum Bearing Holder Bolts [A] Shift Drum Bearing Holder [B] โข Pull out the shift rods [C], and remove the shift forks. โข Pull out the shift drum [D]. Shift Drum and Fork Installation โข Apply engine oil to the shift drum, forks and rods. โขInstall the shift drum [A]. โTake care not to damage the magnet part [B] of the shift drum. โขInstall the shift rods [C] and shift forks, note the following. โThe rods are identical. โPosition the one with shortest ears [D] on the drive shaft and place the pin in the center groove in the shift drum. โThe two forks [E] on the output shaft are identical. โInstall the forks so that its โ0061โ and โ0062โ side faces engine left side. โข Apply a non-permanent locking agent to the threads of the shift drum bearing holder bolts, and tighten them. Torque – Shift Drum Bearing Holder Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โขInstall the removed parts (see appropriate chapters). Shift Drum Disassembly โข Remove the shift drum (see Shift Drum and Fork Removal). โข While holding the shift drum with a vise, remove the shift drum cam holder bolt [A]. โข Remove: Shift Drum Cam [B] Dowel Pin [C] Ball Bearing [D] CRANKSHAFT/TRANSMISSION 9-39 Transmission Shift Drum Assembly โขInstall: Ball Bearing [A] Dowel Pin [B] and Shift Drum Cam [C] โAlign the pin with the groove in the shift drum cam. โข Apply a non-permanent locking agent to the threads of the shift drum cam holder bolt [D] and tighten it. Torque – Shift Drum Cam Holder Bolt: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) Shift Fork Bending Inspection โข 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. 90ยฐ [A] Shift Fork/Gear Groove Wear Inspection โข Measure the thickness of the shift fork ears [A], and measure the width of the gear grooves [B]. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness Standard: 5.9 ๏พ 6.0 mm (0.232 ๏พ 0.236 in.) Service Limit: 5.8 mm (0.23 in.) If the gear groove is worn over the service limit, the gear must be replaced. Gear Groove Width Standard: 6.05 ๏พ 6.15 mm (0.238 ๏พ 0.242 in.) Service Limit: 6.3 mm (0.25 in.) Shift Fork Guide Pin/Drum Groove Wear Inspection โข Measure the diameter of each shift fork guide pin [A], and measure the width of each shift drum groove [B]. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift Fork Guide Pin Diameter Standard: 6.9 ๏พ 7.0 mm (0.272 ๏พ 0.276 in.) Service Limit: 6.8 mm (0.27 in.) If any shift drum groove is worn over the service limit, the drum must be replaced. Shift Drum Groove Width Standard: 7.05 ๏พ 7.20 mm (0.278 ๏พ 0.283 in.) Service Limit: 7.3 mm (0.29 in.) If the shift drum has been replaced, replace the gear position sensor as a set. 9-40 CRANKSHAFT/TRANSMISSION Transmission Gear Dog and Gear Dog Hole Damage Inspection โข Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes. CRANKSHAFT/TRANSMISSION 9-41 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. โข Using a press or puller, remove the ball bearing and/or needle bearings. NOTE โIn the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93ยฐC (200ยฐF) max., and tapping the bearing in or out. NOTICE Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil. โข Using a press and the bearing driver set [A], install the new ball bearing until it stops at the bottom of its housing. โThe new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole. Special Tool – Bearing Driver Set: 57001-1129 Ball and Needle Bearing Wear Inspection NOTICE Do not remove the bearings for inspection. Removal may damage them. โข Check the ball bearings. โSince the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. โSpin [A] the bearing by hand to check its condition. If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it. โข Check the needle bearings. โThe rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a needle bearing, replace it. Oil Seal Inspection โขInspect the oil seals. Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged. WHEELS/TIRES 10-1 10 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. 10-9 Wheel Inspection 10-10 Axle Inspection 10-11 Balance Inspection 10-11 Balance Adjustment 10-11 Balance Weight Removal 10-12 Balance Weight Installation. 10-12 Tires 10-14 Air Pressure Inspection/Adjustment 10-14 Tire Inspection 10-14 Tire Removal. 10-14 Tire Installation 10-14 Tire Repair 10-16 Hub Bearing 10-17 Hub Bearing Removal. 10-17 Hub Bearing Installation 10-17 Hub Bearing Inspection. 10-18 Hub Bearing Lubrication . 10-18 10-2 WHEELS/TIRES Exploded View WHEELS/TIRES 10-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Front Axle Clamp Bolts 20 2.0 15 AL 2 Front Axle 110 11.2 81.1 G 3 Rear Axle Nut 100 10.2 73.8 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. 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.): Front TIR 0.03 mm (0.001 in.) or less TIR 0.2 mm (0.008 in.) Rear 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 โโโ Balance Weights 10 g (0.35 oz.), 20 g (0.71 oz.), 30 g (1.06 oz.) โโโ Rim Size: Front J17M/C ร MT3.50 โโโ Rear J17M/C ร MT6.00 โโโ Tires Air Pressure (when Cold): Front Up to 195 kg (430 lb) load: 250 kPa (2.50 kgf/cmยฒ, 36 psi) โโโ Rear Up to 195 kg (430 lb) load: 290 kPa (2.90 kgf/cmยฒ, 42 psi) โโโ Tread Depth: Front 3.6 mm (0.14 in.) 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 5.8 mm (0.23 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.) Over 130 km/h (80 mph): 3 mm (0.12 in.) Standard Tires: Front: Make BRIDESTONE โโโ Type BATTLAX, S20F N โโโ Size 120/70ZR17M/C (58W) โโโ Rear: Make BRIDESTONE โโโ Type BATTLAX, S20R N โโโ Size 190/50ZR17M/C (73W) โโโ WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Head, 20 ร 22: 57001-1293 Bearing Remover Shaft, 13: 57001-1377 Jack Attachment: 57001-1608 10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal โข Remove: Front Wheel Rotation Sensor Bolt [A] Front Wheel Rotation Sensor [B] Front Caliper Mounting Bolts [C] (Both Sides) Front Caliper [D] (Both Sides) โข Loosen: Front Axle Clamp Bolts [A] Front Axle [B] โข Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Oxygen Sensor (see Oxygen Sensor Removal in the Electrical System chapter) โข Raise the front wheel off the ground. Special Tools – Jack [A]: 57001-1238 Jack Attachment [B]: 57001-1608 โข Pull out the front axle to the right and drop the front wheel out of the front forks. NOTICE Do not lay the wheel down on one of the discs. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Front Wheel Installation NOTE โThe direction of the wheel rotation [A] is shown by an arrow [B] on the wheel spoke. โข Check the wheel rotation mark on the front wheel and install it. WHEELS/TIRES 10-7 Wheels (Rims) โข Apply high-temperature grease to the grease seal lips. โข Fit the collar [A] on the both sides of the hub. โThe collars are identical. โข Apply a thin coat of grease [A] to the front axle [B]. About 10 mm (0.4 in.) [C] About 30 mm (1.2 in.) [D] NOTE โDo not apply grease to the threads of the axle. โขInsert the front axle from the right side. โข Tighten: Torque – Front Axle: 110 Nยทm (11.2 kgfยทm, 81.1 ftยทlb) โข Before tightening the front axle clamp bolts [A] on the right front fork leg, pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle. NOTE โPut a block in front of the front wheel to stop moving. โข Tighten: Torque – Front Axle Clamp Bolts: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) NOTE โTighten the two clamp bolts alternately two times to ensure even tightening torque. โขInstall the removed parts (see appropriate chapters). โข Check the front brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc. 10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal โข Raise the rear wheel off the ground with the stand [A]. โข Loosen the torque link nuts [A] lightly to turn the chain adjuster easily. โข Remove: Rear Wheel Rotation Sensor Bolt [A] Guide [B] Rear Wheel Rotation Sensor [C] Rear Caliper Mounting Bolts [D] Rear Caliper [E] โข Loosen the chain adjuster clamp bolt [A] on both sides. โข Turn the chain adjuster [B] to make the chain slack. โข Remove: Retaining Ring [C] (Both Sides) Rear Axle Nut [D] Washer โข Remove: Rear Axle [A] (from Left Side) WHEELS/TIRES 10-9 Wheels (Rims) โข Remove the drive chain [A] from the rear sprocket toward the left. โข Move the rear wheel back and remove it. NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Rear Wheel Installation โข Apply high-temperature grease to the grease seal lips. โข Fit the collars on the both sides of the hub. Left Side Collar [A] ( 40 ร 35) Right Side Collar [B] ( 41 ร 28) โข Engage the drive chain with the rear sprocket. โข Apply a thin coat of grease [A] to the rear axle [B]. About 10 mm (0.4 in.) [C] About 70 mm (2.8 in.) [D] NOTE โDo not apply grease to the thread portion of the axle. If the rear axle nut adhere, wipe off any grease. โขInsert the rear axle from the left side of the wheel. โข Align the hole of the brake holder with hole of the rear wheel. โขInstall: Washer Rear Axle Nut [A] โข Before tightening the rear axle nut, check that the scale on the left and right adjusters set the same position. โข Tighten: Torque – Rear Axle Nut: 100 Nยทm (10.2 kgfยทm, 73.8 ftยทlb) โข Replace the retaining rings [B] with new ones, and install them. 10-10 WHEELS/TIRES Wheels (Rims) โข Adjust the drive chain slack after installation (see Drive Chain Slack Inspection in the Periodic Maintenance chapter). โขInstall the removed parts (see appropriate chapters). โข Check the rear brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). WARNING After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc. Wheel Inspection โข Raise the front/rear wheel off the ground. Special Tools – Jack: 57001-1238 Jack Attachment: 57001-1608 โข 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). โขInspect the wheel for small cracks, dents, bending, or warp. If there is any damage to the wheel, replace the wheel. โข Remove the wheel, and support it with the tire by the axle. โข Measure the rim runout, axial [A] and radial [B], with a dial gauge. If rim runout exceeds the service limit, check the hub bearings (see Hub Bearing Inspection). If the problem is not due to the bearings, replace the wheel. Rim Runout (with tire installed) Standard: Axial TIR 0.5 mm (0.02 in.) or less Radial TIR 0.8 mm (0.03 in.) or less Service Limit: Axial TIR 1.0 mm (0.04 in.) Radial TIR 1.0 mm (0.04 in.) WARNING Damaged wheel parts may fail and cause an accident resulting in serious injury or death. Never attempt to repair a damaged wheel part. If the wheel part is damaged, it must be replaced with a new one. WHEELS/TIRES 10-11 Wheels (Rims) Axle Inspection โข Remove the front and rear axles (see Front/Rear Wheel Removal). โข Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. โข 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 measure the runout. The difference between the highest and lowest dial readings is the amount of runout. If axle runout exceeds the service limit, replace the axle. Axle Runout/100 mm (3.94 in.) Standard: Front TIR 0.03 mm (0.001 in.) or less Rear TIR 0.1 mm (0.004 in.) or less Service Limit: TIR 0.2 mm (0.008 in.) Balance Inspection โข Remove the front and rear wheels (see Front/Rear Wheel Removal). โข Support the wheel so that it can be spun freely. โข Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops. โRepeat 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 โขIf the wheel always stops in one position, provisionally attach a balance weight [A] on the rim at the marking using adhesive tape. โข 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. โข Rotate the wheel another 1/4 turn and then another 1/4 turn to see if the wheel is correctly balanced. โข Repeat the entire procedure as many times as necessary to achieve correct wheel balance. โข Permanently install the balance weight. 10-12 WHEELS/TIRES Wheels (Rims) Balance Weight Removal โขInsert a flat tip screwdrivers [A] [B] between the rib [C] and weight [D] as shown. โข Pry the balance weight with two screwdrivers and remove the balance weight. โข Discard the used balance weight. NOTICE Do not tap the screwdrivers. The rim could be damaged. Balance Weight Installation โข Check if the weight portion has any play on the blade [A] and clip [B]. If it does, discard it. WARNING Unbalanced wheels can create an unsafe riding condition. If the balance weight has any play on the rib of the rim, the blade and/or clip have been stretched. Replace the loose balance weight. Do not reuse used balance weight. 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 โBalance 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. โDo not use four or more balance weight (more than 90 gram, 3.2 oz.). If the wheel requires an excess balance weight, disassemble the wheel to find the cause. โข Slip the balance weight [A] onto the rib [B] by pushing or lightly hammering [C] the clip [D]. Left Side [E] Right Side [F] WHEELS/TIRES 10-13 Wheels (Rims) โข Be sure to install the balance weight. โCheck 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] 10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment โข Refer to the Air Pressure Inspection in the Periodic Maintenance chapter. Tire Inspection โข Refer to the Wheel/Tire Damage Inspection in the Periodic Maintenance chapter. Tire Removal โข Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) โข To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position. Chalk Mark or Yellow Mark [A] Valve Stem [B] Align [C] โข 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. NOTICE Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire. โข Remove the tire from the rim using a suitable commercially available tire changer. NOTE โThe tires cannot be removed with hand tools because they fit the rims too tightly. Tire Installation WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. โขInspect the rim and tire, and replace them if necessary. โข Clean the sealing surfaces of the rim and tire, and smooth the sealing surfaces of the rim with a fine emery cloth if necessary. โข Remove the air valve and discard it. NOTICE Replace the air valve whenever the tire is replaced. Do not reuse the air valve. WHEELS/TIRES 10-15 Tires โขInstall a new valve in the rim. โRemove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place. NOTICE Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber. โThe air valve is as shown. Valve Cap [A] Valve Core [B] Stem Seal [C] Valve Stem [D] Valve Seat [E] Valve Opened [F] โข 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] โข Position the tire on the rim so that the valve [A] align with the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire). โขInstall the tire bead over the rim flange using a suitable commercially available tire changer. โข 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. โข Center the rim in the tire beads, and inflate the tire with compressed air until the tire beads seat in the sealing surfaces. WARNING Overinflating a tire can cause it to explode, causing serious injury or death. Be sure to install the valve core whenever inflating the tire, and do not inflate the tire to more than 400 kPa (4.0 kgf/cmยฒ, 57 psi). 10-16 WHEELS/TIRES Tires โข 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. โข Lubricate the rim flanges and tire beads. โขInstall the valve core and inflate the tire again. โข After the tire beads seat in the rim flanges, check for air leakage. โInflate the tire slightly above standard inflation. โUse a soap and water solution or submerge the tire, and check for bubbles that would indicate leakage. โข Adjust the air pressure to the specified pressure (see Air Pressure Inspection in the Periodic Maintenance chapter). โขInstall the air valve cap. โข Adjust the wheel balance (see Balance Adjustment). Tire Repair Currently two types of repair for tubeless tires have come into wide use. One type is called a temporary (external) repair which can be carried out without removing the tire from the rim, and the other type is called permanent (internal) repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones. Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make. Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained. WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Removal โข Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars [A] Coupling [B] (Out of rear hub) Grease Seals [C] โข Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Special Tools – Bearing Remover Head, 20 ร 22 [B]: 57001-1293 Bearing Remover Shaft, 13 [C]: 57001 -1377 Hub Bearing Installation โข Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. โข Replace the bearings with new ones. โขInstall the bearings by using the bearing driver set which does not contact the bearing inner race. NOTE โInstall the bearings so that the marked side faces out. โข Press in each right the bearing [A] until they are bottomed. Special Tool – Bearing Driver Set [B]: 57001-1129 10-18 WHEELS/TIRES Hub Bearing โข Replace the grease seals with new ones. โข Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole. โApply high-temperature grease to the grease seal lips. Special Tool – Bearing Driver Set [C]: 57001-1129 โขInstall the removed parts (see appropriate chapters). Hub Bearing Inspection Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured. NOTE โDo not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with new ones. โข 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. โข Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing. Hub Bearing Lubrication NOTE โSince the hub bearings are packed with grease and sealed, lubrication is not required. FINAL DRIVE 11-1 11 Final Drive Table of Contents Exploded View 11-2 Specifications . 11-4 Special Tools 11-5 Drive Chain. 11-6 Drive Chain Slack Inspection 11-6 Drive Chain Slack Adjustment 11-6 Wheel Alignment Inspection/Adjustment 11-6 Drive Chain Wear Inspection 11-6 Drive Chain Lubrication. 11-6 Drive Chain Removal 11-6 Drive Chain Installation. 11-7 Drive Chain Replacement. 11-7 Sprocket, Coupling . 11-11 Engine Sprocket Removal 11-11 Engine Sprocket Installation . 11-11 Engine Sprocket Cover Disassembly 11-12 Engine Sprocket Cover Assembly 11-12 Rear Sprocket Removal 11-13 Rear Sprocket Installation. 11-13 Coupling Installation 11-13 Coupling Bearing Removal . 11-14 Coupling Bearing Installation 11-14 Coupling Bearing Inspection. 11-15 Coupling Bearing Lubrication 11-15 Coupling Damper Inspection. 11-15 Sprocket Wear Inspection. 11-15 Rear Sprocket Warp Inspection 11-16 11-2 FINAL DRIVE Exploded View FINAL DRIVE 11-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Chain Guide Bolts 10 1.0 89 inยทlb L 2 Engine Sprocket Outer Cover Screws 0.70 0.07 6.2 inยทlb 3 Engine Sprocket Nut 147 15.0 108 MO 4 Rear Sprocket Nuts 60 6.1 44 R, S 5 Mud Guard Bolts 4.0 0.41 35 inยทlb L 6 Chain Cover Bolts 4.0 0.41 35 inยทlb L 7 Chain Adjuster Clamp Bolts 65 6.6 48 8 Chain Guide Mounting Bolt 4.0 0.41 35 inยทlb 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 S: Follow the specified tightening sequence. 11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 20 ๏พ 30 mm (0.8 ๏พ 1.2 in.) โโโ Drive Chain Wear (20-link Length) 317.5 ๏พ 318.2 mm (12.50 ๏พ 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA โโโ Type EK525ZX โโโ Link 112 links โโโ Link Pin Outside Diameter (When drive chain replacing) 5.6 ๏พ 6.0 mm (0.22 ๏พ 0.24 in.) โโโ Link Plates Outside Width (When drive chain replacing) 20.35 ๏พ 20.55 mm (0.8012 ๏พ 0.8091 in.) โโโ 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 Tools Inside Circlip Pliers: 57001-143 Bearing Driver Set: 57001-1129 11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection โข Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment โข Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment โข Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter. Drive Chain Wear Inspection โข Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter. Drive Chain Lubrication โข Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter. Drive Chain Removal โข Remove: Mud Guard (see Mud Guard Removal in the Frame chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Chain Cover Bolt [A] โข Remove: Clamp [A] Chain Cover [B] Swingarm (see Swingarm Removal in the Suspension chapter) โข Remove the engine sprocket cover (see Engine Sprocket Removal). โข Remove the drive chain [A] from the engine sprocket [B], and take it off the chassis. FINAL DRIVE 11-7 Drive Chain Drive Chain Installation โขInstall the drive chain to the engine sprocket. โขInstall: Swingarm (see Swingarm Installation in the Suspension chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) Engine Sprocket Cover (see Engine Sprocket Installation) โขInsert the projection [A] on the chain cover into the swingarm hole [B]. โขInstall the clamp [A] as shown. โข Apply a non-permanent locking agent to the threads of the chain cover bolt and tighten it. โข Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). Drive Chain Replacement โข Remove: Engine Sprocket Cover (see Engine Sprocket Removal) Mud Guard (see Mud Guard Removal in the Frame chapter) Chain Cover (see Drive Chain Removal) NOTICE For safety, if the drive chain shall be replaced, replace it using a recommended tool. Recommended Tool – Type: EK Joint Tool #50 Brand: ENUMA Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] 11-8 FINAL DRIVE Drive Chain โข Grind [A] the pin head to make it flat. โข Set the cutting and riveting pin [B] as shown. โข Screw the pin holder until it touches the chain pin. โข Be sure that the cutting pin hits center of the chain pin. โข Screw the handlebar [A] into the body. โข Turn the pin holder with the wrench [B] clockwise to extract the chain pin. โข Replace the link pin, link plate and grease seals. โข Apply grease to the link pins [A] and grease seals [B] [C]. โข Engage the drive chain on the engine and rear sprockets. โขInsert the link pins in the drive chain ends. โขInstall the grease seals. โขInstall the link plate [D] so that the mark faces out. โข Push the link plate by hand or plier to fix it. โข Be sure to set the grease seals correctly. โข Set the plate holder (A) [A] and plate holder (B) [B] on the body. FINAL DRIVE 11-9 Drive Chain โข Fit the plate holder (A) [A] to the link plate. โข Turn the pin holder by hand until the plate holder (B) [B] touches the other link plate. โข Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder (A). โข Take off the plate holder. โข Set the plate holder (B) [A] and cutting and riveting pin [B] as shown. โข Turn the pin holder until the riveting pin touches the link pin. โข Turn the wrench clockwise until the tip of riveting pin hits to the link pin. โข Rivet it. โข Same work for the other link pin. 11-10 FINAL DRIVE Drive Chain โข After staking, check the staked area of the link pin for cracks. โข Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter Standard: 5.6 ๏พ 6.0 mm (0.22 ๏พ 0.24 in.) Link Plates Outside Width Standard: 20.35 ๏พ 20.55 mm (0.8012 ๏พ 0.8091 in.) If the reading exceeds the specified length, cut and rejoin the chain again. โข Check: Movement of the Rollers โข Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). โขInstall the removed parts (see appropriate chapters). FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Removal โข Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] โข Flatten out the bended washer [A]. โข Remove the engine sprocket nut [B] and washer. NOTE โWhen loosening the engine sprocket nut, hold the rear brake on. โข Raise the rear wheel off the ground with the stand. โข Loosen the drive chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). โข Remove the drive chain from the rear sprocket toward the right. โข Disengage the drive chain [A] from the engine sprocket [B]. โข Pull the engine sprocket off the output shaft [C]. Engine Sprocket Installation โข Replace the sprocket washer. โขInstall the engine sprocket so that โOUT SIDEโ letters [A] face outward. โข Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut. โข Tighten: Torque – Engine Sprocket Nut : 147 Nยทm (15.0 kgfยทm, 108 ftยทlb) NOTE โTighten the engine sprocket nut while applying the rear brake. โข After torquing the engine sprocket nut, bend the one side of the washer over the nut. โข Adjust the drive chain slack after installing the engine sprocket (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). 11-12 FINAL DRIVE Sprocket, Coupling โขInstall: Dowel Pins [A] โขInstall: Engine Sprocket Cover [A] โข Tighten the engine sprocket cover bolts. โFirst tighten the two bolts [B] at the dowel pin positions. Engine Sprocket Cover Disassembly โข Remove: Engine Sprocket Cover (see Engine Sprocket Removal) Chain Guide Bolts [A] Chain Guide [B] Engine Sprocket Outer Cover Screws [C] โข Separate the engine sprocket outer cover and inner cover. Engine Sprocket Cover Assembly โขInstall the engine sprocket outer cover [A] to the inner cover [B]. โข Tighten: Torque – Engine Sprocket Outer Cover Screws [C]: 0.70 Nยทm (0.07 kgfยทm, 6.2 inยทlb) โขInstall the chain guide [D]. โข Apply a non-permanent locking agent to the threads of the chain guide bolts [E], and tighten them. Torque – Chain Guide Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โขInstall: Engine Sprocket Cover (see Engine Sprocket Installation) FINAL DRIVE 11-13 Sprocket, Coupling Rear Sprocket Removal โข Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. โข Remove: Rear Sprocket Nuts [A] Rear Sprocket [B] Rear Sprocket Installation โขInstall the sprocket facing the tooth number marking [A] outward. โข Replace the rear sprocket nuts with new ones. โข Tighten the rear sprocket nuts following the specified tightening sequence [1 ๏พ 7]. Torque – Rear Sprocket Nuts: 60 Nยทm (6.1 kgfยทm, 44 ftยทlb) โขInstall the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter). Coupling Installation โข Apply high-temperature grease to the following. Coupling Grease Seal Lips [A] Coupling Internal Surface [B] 11-14 FINAL DRIVE Sprocket, Coupling โขInstall: Collar [A] Coupling [B] Coupling Bearing Removal โข Remove: Coupling Grease Seal Circlip [A] Special Tool – Inside Circlip Pliers: 57001-143 โข Remove the bearing [A] by tapping from the wheel side. Special Tool – Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation โข Replace the bearing with a new one. โข Press in the bearing [A] until it is bottomed. Special Tool – Bearing Driver Set [B]: 57001-1129 โข Replace the circlip with a new one. Special Tool – Inside Circlip Pliers: 57001-143 โข Replace the grease seal with a new one. โข Press in the grease seal so that the seal surface is flush with the end of the hole. โApply high-temperature grease to the grease seal lip. Special Tool – Bearing Driver Set: 57001-1129 FINAL DRIVE 11-15 Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE โIt 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. โข 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. โข Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing. Coupling Bearing Lubrication NOTE โSince the coupling bearing is packed with grease and sealed, lubrication is not required. Coupling Damper Inspection โข Remove the rear wheel coupling, and inspect the rubber dampers [A]. โข Replace the damper if it appears damaged or deteriorated. Sprocket Wear Inspection โข 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 โIf a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the chain. 11-16 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection โข Raise the rear wheel off the ground with the stand so that it will turn freely. โข Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, 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 12 Brakes Table of Contents Exploded View 12-3 Specifications . 12-8 Special Tools 12-9 Brake Lever, Brake Pedal. 12-10 Brake Lever Position Adjustment 12-10 Brake Pedal Position Inspection . 12-10 Brake Pedal Position Adjustment 12-10 Brake Pedal Removal . 12-10 Brake Pedal Installation 12-11 Calipers 12-12 Front Caliper Removal 12-12 Rear Caliper Removal. 12-12 Caliper Installation 12-12 Front Caliper Disassembly 12-12 Front Caliper Assembly. 12-13 Rear Caliper Disassembly 12-13 Rear Caliper Assembly . 12-13 Caliper Fluid Seal Damage Inspection 12-13 Caliper Dust Seal Damage Inspection 12-13 Rear Caliper Dust Boot and Friction Boot Damage Inspection. 12-14 Caliper Piston and Cylinder Damage Inspection 12-14 Rear Caliper Holder Shaft Wear Inspection 12-14 Brake Pads. 12-15 Front Brake Pad Removal. 12-15 Front Brake Pad Installation 12-15 Rear Brake Pad Removal 12-15 Rear Brake Pad Installation 12-16 Brake Pad Wear Inspection 12-16 Master Cylinder 12-17 Front Master Cylinder Removal 12-17 Front Master Cylinder Installation . 12-17 Rear Master Cylinder Removal. 12-17 Rear Master Cylinder Installation 12-18 Front Master Cylinder Disassembly 12-18 Rear Master Cylinder Disassembly. 12-18 Master Cylinder Assembly 12-18 Master Cylinder Inspection (Visual Inspection). 12-19 Brake Disc 12-20 Brake Disc Removal . 12-20 Brake Disc Installation 12-20 Brake Disc Wear Inspection 12-20 Brake Disc Warp Inspection 12-21 Brake Fluid . 12-22 Brake Fluid Level Inspection. 12-22 Brake Fluid Change 12-22 Brake Line Bleeding 12-22 Brake Hose. 12-26 Brake Hose Removal/Installation 12-26 Brake Hose and Pipe Inspection. 12-26 Anti-Lock Brake System . 12-27 12-2 BRAKES Parts Location. 12-27 ABS Servicing Precautions. 12-31 ABS Troubleshooting Outline 12-33 Inquiries to Rider. 12-36 Self-diagnosis Outline. 12-40 Self-diagnosis Procedures 12-40 Service Code Clearing Procedures. 12-41 How to Read Service Codes. 12-44 How to Erase Service Codes 12-44 Yellow ABS and Yellow Warning Indicator Lights (LED) Inspection 12-47 Solenoid Valve Inspection (Service Code 13, 14, 17, 18). 12-47 ABS Solenoid Valve Relay Inspection (Service Code 19) 12-48 Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) 12-48 ABS Motor Relay Inspection (Service Code 35). 12-49 Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) 12-49 Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) 12-50 Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44). 12-51 Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 12-51 Power Supply Voltage Abnormal (Low-Voltage) (Service Code 52) . 12-52 Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) 12-52 ABS Solenoid Valve Relay Supply Voltage Inspection (Low-Voltage) (Service Code 54) 12-52 ECU Inspection (Service Code 55). 12-53 CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code 57) 12-53 ECU Communication Line Inspection (Service Code 62) . 12-54 IMU Communication Line Inspection (Service Code 63) 12-55 Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83) 12-55 Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code 84) . 12-56 Fluid Pressure Sensor Supply Voltage Inspection (Service Code 89) 12-56 IMU Inspection (Service Code 94) 12-56 ABS Hydraulic Unit Removal 12-56 ABS Hydraulic Unit Installation . 12-58 ABS Hydraulic Unit Inspection 12-58 Front Wheel Rotation Sensor Removal 12-59 Front Wheel Rotation Sensor Installation . 12-60 Rear Wheel Rotation Sensor Removal. 12-60 Rear Wheel Rotation Sensor Installation 12-61 Wheel Rotation Sensor Inspection 12-61 Wheel Rotation Sensor Air Gap Inspection 12-61 Wheel Rotation Sensor Rotor Inspection 12-62 ABS Solenoid Valve Relay Fuse (15 A) Removal. 12-62 ABS Motor Relay Fuse (25 A) Removal . 12-62 Fuse Installation 12-62 Fuse Inspection. 12-62 BRAKES 12-3 Exploded View This page intentionally left blank. 12-4 BRAKES Exploded View BRAKES 12-5 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Front Brake Reservoir Bracket Bolt 8.8 0.90 78 inยทlb 2 Front Brake Reservoir Cap Stopper Screw 1.5 0.15 13 inยทlb 3 Brake Lever Pivot Bolt 1.0 0.10 8.9 inยทlb Si 4 Front Master Cylinder Bleed Valve 5.4 0.55 48 inยทlb 5 Front Master Cylinder Clamp Bolts 11 1.1 97 inยทlb S 6 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 inยทlb 7 Front Brake Light Switch Screw 1.2 0.12 11 inยทlb 8 Front Wheel Rotation Sensor Bolt 25 2.5 18 9 Brake Hose Banjo Bolts 25 2.5 18 10 Brake Pipe Joint Nuts 18 1.8 13 11 Bleed Valves 8.0 0.82 71 inยทlb 12 Front Brake Pad Pins 15 1.5 11 13 Front Caliper Mounting Bolts 35 3.6 26 14 Front Brake Disc Mounting Bolts 28 2.9 21 L, 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. 12-6 BRAKES Exploded View BRAKES 12-7 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Brake Pipe Joint Nuts 18 1.8 13 2 Mud Guard Bolt 4.0 0.41 35 inยทlb L 3 Brake Hose Banjo Bolts 25 2.5 18 4 Rear Master Cylinder Mounting Bolts 25 2.5 18 5 Rear Brake Reservoir Cap Stopper Screw 1.5 0.15 13 inยทlb 6 Brake Pedal Bolt 9.0 0.92 80 inยทlb L 7 Rear Master Cylinder Push Rod Locknut 17 1.7 13 8 Rear Brake Disc Mounting Bolts 28 2.9 21 L, S 9 Rear Wheel Rotation Sensor Bolt 25 2.5 18 10 Bleed Valve 8.0 0.82 71 inยทlb 11 Rear Caliper Mounting Bolts 25 2.5 18 B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. Si: Apply silicone grease. 12-8 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) โโโ Brake Lever Free Play Non-adjustable โโโ Pedal Free Play Non-adjustable โโโ Pedal Position About 62 mm (2.4 in.) below footpeg top โโโ Brake Pads Lining Thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.) Rear 5.0 mm (0.20 in.) 1 mm (0.04 in.) Brake Discs Thickness: Front 5.3 ๏พ 5.7 mm (0.21 ๏พ 0.22 in.) 5.0 mm (0.20 in.) Rear 5.8 ๏พ 6.2 mm (0.23 ๏พ 0.24 in.) 5.5 mm (0.22 in.) Runout: Front โโโ TIR 0.3 mm (0.01 in.) Rear โโโ TIR 0.2 mm (0.008 in.) Brake Fluid Grade DOT4 โโโ ABS ABS Hydraulic Unit: Make BOSCH โโโ Wheel Rotation Sensor Air Gap: Front 0.1 ๏พ 2.1 mm (0.004 ๏พ 0.083 in.) โโโ Rear 0.1 ๏พ 1.7 mm (0.004 ๏พ 0.067 in.) โโโ CAN Communication Line Resistance 30 ๏พ 70 โฆ โโโ CAN Communication Line/Ground Resistance 4 ๏พ 30 kโฆ โโโ BRAKES 12-9 Special Tools Jack: 57001-1238 Jack Attachment: 57001-1608 12-10 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operatorโs hand. โข Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever. โThe distance from the grip to the lever is minimum at number 6 and maximum at number 1. Brake Pedal Position Inspection โข Check that the brake pedal [A] is in the correct position. Footpeg [B] Pedal Position Standard: About 62 mm (2.4 in.) [C] below top of footpeg If it is incorrect, adjust the brake pedal position. Brake Pedal Position Adjustment NOTE โUsually it is not necessary to adjust the pedal position, but always adjust it when the push rod locknut has been loosened. โข 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 70 ยฑ1 mm (2.76 ยฑ0.04 in.), the pedal position will be within the standard range. โข Tighten: Torque – Rear Master Cylinder Push Rod Locknut: 17 Nยทm (1.7 kgfยทm, 13 ftยทlb) โข Check the brake light switch operation (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter). Brake Pedal Removal โข Remove: Rear Lower Fairing (see Rear Lower Fairing Removal in the Frame chapter) Rear Master Cylinder Mounting Bolts [A] Right Front Footpeg Bracket Bolts [B] BRAKES 12-11 Brake Lever, Brake Pedal โข Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] Brake Pedal [F] Brake Pedal Installation โข Apply grease to the footpeg pivot shaft [A]. โขInstall: Washer [B] Brake Pedal [C] Washer [D] โข Apply a non-permanent locking agent to the threads of the brake pedal bolt [E], and tighten it. Torque – Brake Pedal Bolt: 9.0 Nยทm (0.92 kgfยทm, 80 inยทlb) โข Hook the shorter end of the rear brake light switch spring [A] on the brake light switch. โข Hook the upper end of the return spring [B] on the footpeg bracket hook. โFace the both lower spring ends forward. โข Replace the cotter pin [A] with a new one. โขInsert the cotter pin and bend the pin ends [B]. โขInstall the front footpeg bracket. โข Tighten: Torque – Front Footpeg Bracket Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โข Check that the rear brake light switch spring is installed correctly. โข Check the brake pedal position (see Brake Pedal Position Inspection). 12-12 BRAKES Calipers Front Caliper Removal โข Remove: Bolt [A] Front Wheel Rotation Sensor [B] โข Loosen the banjo bolt [C] at the brake hose lower end, and tighten it loosely. โข Remove the caliper mounting bolts [D], and detach the caliper [E] from the disc. โข Remove the banjo bolt and disconnect the brake hose from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). NOTICE Immediately wash away any brake fluid that spills. Rear Caliper Removal โข Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. โข Remove the caliper mounting bolts [B], and detach the caliper [C] from the disc. โข Remove the banjo bolt and disconnect the brake hose [D] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). NOTICE Immediately wash away any brake fluid that spills. Caliper Installation โขInstall the caliper and brake hose lower end. โFor the front caliper, be sure to install the collars [A] on the fork leg and fit the holes of the front caliper to the collars. โReplace the washers on each side of hose fitting with new ones. โTouch the brake hoses to the stopper of the caliper. โข Tighten: Torque – Caliper Mounting Bolts Front: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) Rear: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) Brake Hose Banjo Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โข Check the fluid level in the brake reservoirs. โข Bleed the brake line (see Brake Line Bleeding). โข Check the brake for good braking power, no brake drag, and no fluid leakage. WARNING After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc. Front Caliper Disassembly โข Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. BRAKES 12-13 Calipers Front Caliper Assembly โข Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Caliper Disassembly โข Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Caliper Assembly โข Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase. โข Replace the fluid seal if it exhibits any of the conditions listed below. โBrake fluid leakage around the pad. โBrakes overheat. โConsiderable difference in inner and outer pad wear. โSeal and piston are stuck together. If the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed. Caliper Dust Seal Damage Inspection โข 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] 12-14 BRAKES Calipers Rear Caliper Dust Boot and Friction Boot Damage Inspection โข 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. Caliper Piston and Cylinder Damage Inspection โข Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Rear 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 constant drag on the disc will raise brake and brake fluid temperature. โข Check to see that the caliper holder shafts are not badly worn or stepped, and that the rubber friction boots are not damaged. If the rubber friction boot is damaged, replace the rubber friction boot. To replace the friction boot, remove the pads and the caliper bracket. If the caliper holder shaft is damaged, replace the caliper holder. BRAKES 12-15 Brake Pads Front Brake Pad Removal โข Loosen the pad pins [A]. โข Remove the front caliper with the hose installed (see Front Caliper Removal). โข Remove: Pad Pins Brake Pads Front Brake Pad Installation โข Check that the pad spring [A] is in place on the caliper. โข Push the caliper pistons in by hand as far as they will go. โขInstall the brake pads [A] on the pad spring correctly. โFit the pad into the groove of the caliper as shown. โขInstall the pad pins while pushing the brake pads lightly. โข Tighten the pad pins temporarily. โขInstall the front caliper (see Caliper Installation). โข Tighten: Torque – Front Brake Pad Pins: 15 Nยทm (1.5 kgfยทm, 11 ftยทlb) WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc. Rear Brake Pad Removal โข Remove the rear caliper with the hose installed (see Rear Caliper Removal). โข Remove: Clip [A] Pad Pin [B] โข Remove the brake pad [C] of the jaw side from the holder shaft [D], then remove the other pad [E]. 12-16 BRAKES Brake Pads Rear Brake Pad Installation โข Check that the pad spring [A], guide [B] and insulator [C] are in place on the caliper and holder. โข Push the caliper piston in by hand as far as it will go. โขInstall the brake pad [A] on the piston side first, then install the other pad on the holder shaft. โFit the projections [B] of the piston side pad into the recesses [C] of the caliper holder. โขInstall the pad pin while pushing the brake pad of the jaw side lightly. โขInstall a new clip. โThe clip must be โoutsideโ of the pad. โขInstall the rear caliper (see Rear Caliper Installation). WARNING After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc. Brake Pad Wear Inspection โข Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter. BRAKES 12-17 Master Cylinder Front Master Cylinder Removal โข Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). โข Unscrew the clamp bolts [B], and take off the master cylinder [C] as an assembly with the reservoir, brake lever, and brake light switch installed. โข Disconnect the front brake light switch connector [D]. NOTICE Immediately wash away any brake fluid that spills. Front Master Cylinder Installation โขInstall the master cylinder clamp so that the arrow mark [A] faces upward. โข Set the front master cylinder to match its mating surface [B] to the punch mark [C] of the handlebar. โข Tighten the upper clamp bolt first, and then the lower clamp bolt. Torque – Front Master Cylinder Clamp Bolts: 11 Nยทm (1.1 kgfยทm, 97 inยทlb) โข Connect the front brake light switch connector. โข Replace the washers that are on each side of the hose fitting with new ones. โขInstall the brake hose. โTouch the brake hose to the stopper of the front master cylinder. โข Tighten: Torque – Brake Hose Banjo Bolt: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โข Bleed the brake line (see Brake Line Bleeding). โข Check the brake for good braking power, no brake drag, and no fluid leakage. Rear Master Cylinder Removal โข Remove the brake hose banjo bolt [A] and disconnect the brake hose (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). NOTICE Immediately wash away any brake fluid that spills. โข Remove: Rear Lower Fairing (see Rear Lower Fairing Removal in the Frame chapter) Rear Master Cylinder Mounting Bolts [B] Front Footpeg Bracket Bolts [C] 12-18 BRAKES Master Cylinder โข Remove: Cotter Pin [A] Joint Pin [B] โข Slide the clamp [C]. โข Disconnect the reservoir hose lower end, and drain the brake fluid into a container. Rear Master Cylinder Installation โข Replace the cotter pin [A] with a new one. โขInsert the cotter pin and bend the pin ends [B]. โข Tighten: Torque – Front Footpeg Bracket Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) Rear Master Cylinder Mounting Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) NOTE โDepress the brake pedal [A] and then align the holes of the master cylinder [B]. โAfter installation, check that the rear brake light switch spring is hooked on the brake pedal. โข Replace the washers that are on each side of hose fitting with new ones. โขInstall the brake hose. โTouch the brake hose to the stopper of the rear master cylinder. โข Tighten: Torque – Brake Hose Banjo Bolt: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โข Bleed the brake line (see Brake Line Bleeding). โข Check the brake for good braking power, no brake drag, and no fluid leakage. โขInstall: Rear Lower Fairing (see Rear Lower Fairing Installation in the Frame chapter) Front Master Cylinder Disassembly โข Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Master Cylinder Disassembly โข Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Assembly โข Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. BRAKES 12-19 Master Cylinder Master Cylinder Inspection (Visual Inspection) โข Remove the master cylinders (see Front/Rear Master Cylinder Removal). โข Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter). โข 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. โขInspect the primary cup [C] and secondary cup [D]. If a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups. If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups. โข Check the dust covers [E] for damage. If they are damaged, replace them. โข Check the piston return springs [F] for any damage. If the springs are damaged, replace them. โข 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 [I] Rear Master Cylinder [J] 12-20 BRAKES Brake Disc Brake Disc Removal โข Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). โข Remove the brake disc mounting bolts [A], and take off the disc [B]. โข Remove the wheel rotation sensor rotor [C]. Brake Disc Installation โข Replace the gaskets with new ones. โขInstall the brake disc on the wheel so that the marked side [A] faces out. โขInstall the wheel rotation sensor rotor on the brake disc so that the marked side faces out. โข Apply a non-permanent locking agent to the threads of the front and rear brake disc mounting bolts. โข Tighten the front and rear brake disc mounting bolts following the specified tightening sequence. Front Brake Discs [B] Rear Brake Disc [C] Torque – Brake Disc Mounting Bolts: 28 Nยทm (2.9 kgfยทm, 21 ftยทlb) Brake Disc Wear Inspection โข 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 5.3 ๏พ 5.7 mm (0.21 ๏พ 0.22 in.) Rear 5.8 ๏พ 6.2 mm (0.23 ๏พ 0.24 in.) Service Limit: Front 5.0 mm (0.20 in.) Rear 5.5 mm (0.22 in.) BRAKES 12-21 Brake Disc Brake Disc Warp Inspection โข Raise the front/rear wheel off the ground. Special Tools – Jack: 57001-1238 Jack Attachment: 57001-1608 โFor front disc inspection, turn the handlebars fully to one side. โข Set up a dial gauge against the disc [A] as shown and measure disc runout, while turning [B] the wheel by hand. If runout exceeds the service limit, replace the disc. Disc Runout Standard: โโโ Service Limit: Front TIR 0.3 mm (0.01 in.) Rear TIR 0.2 mm (0.008 in.) 12-22 BRAKES Brake Fluid Brake Fluid Level Inspection โข Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change โข Refer to the Brake Fluid Change in the Periodic Maintenance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake lever or pedal has a soft or “spongy” feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately. NOTE โThe procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake. โข Remove: Front Brake Reservoir Cap Stopper Screw [A] Stopper [B] Front Brake Reservoir Cap [C] Diaphragm Plate Diaphragm โข Fill the reservoir with fresh brake fluid to the upper level line in the reservoir. โข 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. โข Remove the rubber cap from the bleed valve on the front master cylinder. โข Attach a clear plastic hose [A] to the bleed valve, and run the other end of the hose into a container. BRAKES 12-23 Brake Fluid โข Bleed the brake line and the master cylinder. โRepeat this operation until no more air can be seen coming out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release the brake [C]. NOTICE After pumping the brake lever several times, releasing it without opening and closing of the bleed valve may cause brake fluid to be blown back from the master cylinder reservoir. Brake fluid spilt on painted surfaces and plastic parts will quickly damage them. Be sure to open and close the bleed valve. NOTE โThe fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. โข Remove the clear plastic hose. โข Tighten the bleed valve, and install the rubber cap. Torque – Front Master Cylinder Bleed Valve: 5.4 Nยทm (0.55 kgfยทm, 48 inยทlb) โข Remove the rubber cap [A] from the bleed valve on the caliper. โข Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. 12-24 BRAKES Brake Fluid โข Bleed the brake line and the caliper. โRepeat this operation until no more air can be seen coming out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release the brake [C]. NOTE โThe fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. โTap the brake hose lightly from the caliper to the reservoir for more complete bleeding. โFront Brake: Repeat the above steps for the other caliper. โข Remove the clear plastic hose. โขInstall: Diaphragm Diaphragm Plate Front Brake Reservoir Cap โข Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. โFirst, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A]. โข Tighten: Torque – Front Brake Reservoir Cap Stopper Screw: 1.5 Nยทm (0.15 kgfยทm, 13 inยทlb) โข Tighten the bleed valve, and install the rubber cap. Torque – Bleed Valves: 8.0 Nยทm (0.82 kgfยทm, 71 inยทlb) โข Check the fluid level (see Brake Fluid Level Inspection in the Periodic Maintenance chapter). โข After bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage. BRAKES 12-25 Brake Fluid WARNING When working with the disc brake, observe the precautions listed below. โข Never reuse old brake fluid. โข Do not use fluid from a container that has been left unsealed or that has been open for a long time. โข 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. โข Do not leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. โข Do not change the fluid in the rain or when a strong wind is blowing. โข Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake. โข When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash-point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily. โข Brake fluid quickly damages painted surfaces; any spilled fluid should be completely wiped up immediately. โขIf any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE. 12-26 BRAKES Brake Hose Brake Hose Removal/Installation โข Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection โข Refer to the Brake Hose and Pipe Damage and Installation Condition Inspection in the Periodic Maintenance chapter. BRAKES 12-27 Anti-Lock Brake System Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator (LED) [A] Yellow Warning Indicator Light (LED) [B] KIBS Indicator [C] ABS Hydraulic Unit [A] Fuse Box (2) [A] 12-28 BRAKES Anti-Lock Brake System ABS Kawasaki Diagnosis System Connector [A] ABS Self-diagnosis Terminal [B] BRAKES 12-29 Anti-Lock Brake System ABS System Wiring Diagram 1. Ignition Switch 2. Front Brake Light Switch 3. ECU 4. Rear Wheel Rotation Sensor 5. Rear Brake Light Switch 6. ABS Hydraulic Unit 7. ABS Self-diagnosis Terminal 8. ABS Kawasaki Diagnosis System Connector 9. Frame Ground (4) 10. Frame Ground (3) 11. Engine Ground 12. Battery 12 V 8 Ah 13. Starter Relay 14. Main Fuse 30 A 15. Joint Connector (1) 16. Joint Connector (2) 17. Meter Unit 18. Yellow ABS Indicator (LED) 19. Front Wheel Rotation Sensor 20. IMU 21. Fuse Box (1) 22. Ignition Fuse 15 A 23. Brake Light/Horn Fuse 7.5 A 24. Fuse Box (2) 25. ABS Motor Relay Fuse 25 A 26. ABS Solenoid Valve Relay Fuse 15 A โColor Codes: BK: Black BL: Blue BR: Brown CH: Chocolate DG: Dark Green G: Green GY: Gray LB: Light Blue LG: Light Green O: Orange P: Pink PU: Purple R: Red V: Violet W: White Y: Yellow 12-30 BRAKES Anti-Lock Brake System ABS Hydraulic Unit Terminal Names 1. Ground: BK/BL 2. CAN Communication Line (High): GY/BL 3. Front Wheel Rotation Sensor Signal Input: BK/W 4. Power Supply: BR/W 5. ABS Kawasaki Diagnosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7. ABS Self-diagnosis Terminal: GY 8. Front Wheel Rotation Sensor Signal Output: G/Y 9. Power Supply to ABS Solenoid Valve Relay: R/BK 10. Ground to Motor: BK 11. CAN Communication Line (Low): LB 12. Power Supply to Front Wheel Rotation Sensor: W/BK 13. Power Supply to Rear Wheel Rotation Sensor: W/G 14. Rear Wheel Rotation Sensor Signal Input: BK/O 15. KIBS Indicator: Y/G 16. Rear Wheel Rotation Sensor Signal Output: R/Y 17. Yellow ABS Indicator (LED): BL/Y 18. Power Supply to ABS Motor Relay: R/W BRAKES 12-31 Anti-Lock Brake System ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. โThis ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. โDo not reverse the battery cable connections. This will damage the ABS hydraulic unit. โTo prevent damage to the ABS parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running. โTake care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. โDo not turn the ignition switch on while any of the ABS electrical connectors are disconnected. The ABS hydraulic unit memorizes service codes. โDo not spray water on the electrical parts, ABS parts, connectors, leads and wiring. โIf a transceiver is installed on the motorcycle, make sure that the operation of the ABS system is not influenced by electric wave radiated from the antenna. Locate the antenna as far as possible away from the ABS hydraulic unit. โWhenever the ABS electrical connections are to be disconnected, first turn off the ignition switch. โThe ABS parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. โThe ABS parts cannot be disassembled. Even if a fault is found, do not try to disassemble and repair the ABS parts, replace it. โThe ABS has many brake lines, pipes, and leads. And the ABS cannot detect problems with the conventional braking system (brake disc wear, unevenly worn brake pad, and other mechanical faults). To prevent trouble, check the brake lines and pipes for correct routing and connection, the wiring for correct routing, and the brakes for proper braking power. Be sure to check for fluid leakage, and bleed the brake line thoroughly. 12-32 BRAKES Anti-Lock Brake System WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line. If the brake lever has a soft or “spongy” feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately. NOTICE Do not ride the motorcycle with air in the brake line, or the ABS could malfunction. โThe yellow ABS indicator (LED) [A], yellow warning indicator light (LED) [B] and KIBS indicator [C] may light if the tire pressure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. WARNING Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended braking distance resulting in an accident causing serious injury or death. Always use recommended standard tires for this motorcycle. BRAKES 12-33 Anti-Lock Brake System โThe yellow ABS indicator (LED) may come on if the engine is run with the motorcycle on its stand and the transmission in gear. If the indicator comes on, just turn the ignition switch off, then clear service code 42, which indicates a โFaulty front wheel rotation sensor.โ โWhen the ABS operates, the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal. This is a normal condition. It informs the rider that the ABS is operating normally. โService codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit. Therefore, after maintenance work is finished, be sure to erase the service codes. Do not erase the service codes during troubleshooting. Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work. โBefore delivering the motorcycle to the customer, be sure to erase any service codes which might be stored in the ABS hydraulic unit. Using the self-diagnosis feature, make sure that the yellow ABS indicator (LED) lights. A fully charged battery is a must for conducting reliable self-diagnosis. Test run the motorcycle at a speed of more than 20 km/h (12 mph) to see that the yellow ABS indicator (LED), yellow warning indicator light (LED) and KIBS indicator do not come on. Finally, test run the motorcycle at a speed of more than 30 km/h (20 mph) and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally (The reaction force generated is felt in the brake lever and pedal.). This completes the final inspection. ABS Troubleshooting Outline When an abnormality in the system occurs, the yellow ABS indicator (LED) and yellow warning indicator light (LED) light up and the KIBS indicator are displayed on the LCD to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the service code [A] is indicated by the number of times the yellow ABS indicator (LED) blinks. The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected. Therefore, after correcting the problem, always erase the service codes and then run the self-diagnosis program to confirm normal signal output. When, due to a malfunction, the yellow ABS indicator (LED), yellow warning indicator light (LED) and KIBS indicator remains lit, get a thorough understanding of the background before starting the repair work. Ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C]. Do not rely solely on the ABS self-diagnosis function, use common sense; check the brakes for proper braking power, and brake fluid level, search for leaks, etc. 12-34 BRAKES Anti-Lock Brake System Even when the ABS is operating normally, the yellow ABS indicator (LED) and yellow warning indicator light (LED) may light up and the KIBS indicator are displayed on the LCD under the conditions listed below. Turn the ignition switch off to go off the indicator light and the KIBS indicator. If the motorcycle runs without erasing the service code, the indicator and yellow warning indicator light (LED) may light up and the KIBS indicator are displayed on the LCD again. โAfter continuous riding on a rough road. โWhen the engine is started with the stand raised and the transmission engaged, and the rear wheel turns. โWhen accelerating so abruptly that the front wheel leaves the ground. โWhen the ABS has been subjected to strong electrical interference. โWhen tire pressure is abnormal. Adjust tire pressure. โWhen a tire different in size from the standard size is being used. Replace with standard size. โWhen the wheel is deformed. Replace the wheel. Much of the ABS troubleshooting work consists of confirming continuity of the wiring. The ABS parts are assembled and adjusted by the manufacturer, so there is no need to disassemble or repair them. Replace the ABS hydraulic unit. The basic troubleshooting procedures are listed below. โข Carry out pre-diagnosis inspections as a preliminary inspection. โข Determine the fault using the self-diagnosis function. โข Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part, using a tester. โข Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. โข Pull each connector 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. โข Check the wiring for continuity. โUse the wiring diagram to find the ends of the lead which is suspected of being a problem. โConnect a tester between the ends of the leads. If the tester does not read about 0 โฆ, the lead is defective. Replace the main harness [A] if necessary. โข Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests. If no abnormality is found in the wiring or connectors, the ABS parts are the next likely suspects. Check each part one by one. If an abnormality is found, replace the affected ABS part. BRAKES 12-35 Anti-Lock Brake System ABS Diagnosis Flow Chart 12-36 BRAKES Anti-Lock Brake System Inquiries to Rider BRAKES 12-37 Anti-Lock Brake System 12-38 BRAKES Anti-Lock Brake System BRAKES 12-39 Anti-Lock Brake System Pre-Diagnosis Inspection 1 12-40 BRAKES Anti-Lock Brake System Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the yellow ABS indicator light (LED) has blinked or goes on, the ABS hydraulic unit memorizes and stores the service code (23 codes including โNormal Codeโ) for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch. The ABS hydraulic unit can memorize up to 6 service codes. Further service codes are memorized after erasing the preceding 6 service codes. If there is no fault, only the start code 12 is shown, indicating that โThe ABS is normalโ. Self-diagnosis Procedures โWhen a problem occurs with the ABS system, the yellow ABS indicator (LED) [A] lights. โWhen a problem occurs with the KIBS system, the yellow warning indicator (LED) [B] lights and KIBS indicator [C] blinks. NOTE โUse a fully charged battery when conducting self-diagnosis. Otherwise, the indicator blinks very slowly or doesnโt blink. โThe motorcycle is stopped. โKeep the self-diagnosis terminal grounded during self -diagnosis, with an auxiliary lead. BRAKES 12-41 Anti-Lock Brake System โข Remove the front seat (see Front Seat Removal in the Frame chapter). โข Ground the self-diagnosis terminal [A] (Gray) to the battery (โ) terminal, using a suitable lead. โข Turn the ignition switch on. โCount the blinks of the yellow ABS indicator light (LED) to read the service code. Keep the auxiliary lead ground until you finish reading the service code. Service Code Clearing Procedures โข Start the service code erase mode with the following procedure. โThe erase mode starts when the ABS self-diagnosis terminal is disconnected from the battery (โ) terminal after starting the self-diagnosis mode. โThe service code can be erased by grounding and ungrounding (each time for at least one second) the ABS self-diagnosis terminal three times within about 12.5 seconds after starting the erase mode. โThe yellow ABS indicator (LED) remains lit during the erase mode. โAfter erasing, the yellow ABS indicator (LED) blinks and lights. โOnce erasing is finished, enter the self-diagnosis mode again to confirm that the service codes have been erased. If the ABS has been reset and all codes have been erased, only start code 12 will be shown. 12-42 BRAKES Anti-Lock Brake System BRAKES 12-43 Anti-Lock Brake System Self-diagnosis Flow Chart 12-44 BRAKES Anti-Lock Brake System How to Read Service Codes โService codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED) as shown below. โRead 10th digit and unit digit as the yellow ABS indicator light (LED) blinks. โWhen there are a number of faults, a maximum of 6 service codes can be stored and the display will begin starting from the last service code entered. โFor the display pattern, first, start code 12 is shown, next up to 6 service codes, then the display is repeated from the start code once again. โIf there is no fault, the yellow ABS indicator (LED) lights as shown. How to Erase Service Codes โEven if the ignition switch is turned to OFF, the battery or the ABS hydraulic unit are disconnected, all service codes remain in the ABS hydraulic unit. โRefer to the Service Code Clearing Procedure for the service code erasure. BRAKES 12-45 Anti-Lock Brake System Service Code Table Service Code Yellow ABS Indicator Light (LED) Problems 12 Start code (not fault) 13 Rear inlet solenoid valve trouble (shorted or open, stuck valve) 14 Rear outlet solenoid valve trouble (shorted or open, stuck valve) 17 Front inlet solenoid valve trouble (shorted or open, stuck valve) 18 Front outlet solenoid valve trouble (shorted or open, stuck valve) 19 ABS solenoid valve relay trouble (wiring shorted or open, stuck relay) 25 Front, rear tire abnormal (substandard tire, deformation wheel, sensor rotor teeth number wrong) 35 ABS motor relay trouble (wiring shorted, open or lock, stuck relay) 42 Front wheel rotation sensor signal abnormal (sensor or rotor missing, too large clearance, rotor tooth worn or missing) 43 Front wheel rotation sensor wiring abnormal (wiring shorted or open) 44 Rear wheel rotation sensor signal abnormal (sensor or rotor missing, too large clearance, rotor tooth worn or missing) 45 Rear wheel rotation sensor wiring abnormal (wiring shorted or open) 52 Power supply voltage abnormal (low-voltage) 53 Power supply voltage abnormal (over-voltage) 54 ABS solenoid valve relay supply voltage (low voltage) 55 ECU trouble (ECU operation abnormal) 57 CAN communication (transmission)/CAN bus monitor malfunction 62 ABS hydraulic unit – FI ECU communication error 12-46 BRAKES Anti-Lock Brake System Service Code Yellow ABS Indicator Light (LED) Problems 63 ABS hydraulic unit – IMU communication error 83 Output fluid pressure sensor (front brake) trouble (voltage abnormal, wiring shorted or open) 84 Output fluid pressure sensor (front brake) trouble (offset abnormal) 89 Power supply voltage for fluid pressure sensor abnormal (voltage abnormal, wiring shorted or open) 94 IMU malfunction BRAKES 12-47 Anti-Lock Brake System Yellow ABS and Yellow Warning Indicator Lights (LED) Inspection โIn this model, the yellow ABS indicator light (LED) [A], yellow warning indicator light (LED) [B] and KIBS indicator [C] go on or blink by the data sent from the ABS hydraulic unit. โข Refer to the Meter Unit Inspection in the Electrical System chapter. Yellow ABS Indicator Light (LED), Yellow Warning Indicator Light (LED) and KIBS Indicator Function Status Brake Condition Yellow ABS Indicator Light (LED) Yellow Warning Indicator Light (LED) KIBS Indicator Normal KIBS Goes off Goes off Goes off IMU error*1 KIBS Goes off Goes on Blinks Engine information communication error ABS Goes off Goes off Blinks Battery voltage decreases Low voltage ABS*2 Blinks Goes on Goes off ABS error Normal brake Goes on Goes off Goes off *1: When the IMU is malfunctioned, the IMU indicator blinks. *2: The mode of โLow voltage ABSโ controls ABS while reducing the load to the battery. NOTE โWhen the yellow ABS indicator light (LED) is blinking, the ABS has been in the low voltage mode (insufficient battery voltage). When it is in the low voltage mode, the KIBS system does not function, but the ABS functions. To recover the KIBS system, charge the battery. (see Refreshing Charge in the Electrical System chapter). Solenoid Valve Inspection (Service Code 13, 14, 17, 18) โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] light, the solenoid valve in the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). 12-48 BRAKES Anti-Lock Brake System ABS Solenoid Valve Relay Inspection (Service Code 19) โข Remove: Front Seat (see Front Seat Removal in the Frame chapter) โข Check the ABS solenoid valve relay fuse (15 A) [A] (see Fuse Inspection in the Electrical System chapter). If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and terminal 9 [B] in the ABS hydraulic unit lead connector [C]. If there is not the continuity in the lead, replace or repair the main harness. If there is the continuity in the lead, go to next stemp. โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) โข Check the following and correct the faulty part. Incorrect Tire Pressure Tires not recommended for the motorcycle were installed (incorrect tire size). Deformation of Wheel or Tire Missing Teeth and Clogging with Foreign Matter of Sensor Rotor (see Wheel Rotation Sensor Inspection) If the all parts correct, recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. BRAKES 12-49 Anti-Lock Brake System If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). ABS Motor Relay Inspection (Service Code 35) โข Remove: Front Seat (see Front Seat Removal in the Frame chapter) โข Check the ABS motor relay fuse (25 A) [A] (see Fuse Inspection in the Electrical System chapter). If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and terminal 18 [B] in the ABS hydraulic unit lead connector [C]. If there is not the continuity in the lead, replace or repair the main harness. If there is the continuity in the lead, go to next step. โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) โข Measure the air gap between the front wheel rotation sensor and sensor rotor (see Wheel Rotation Sensor Air Gap Inspection). โข Check the front wheel rotation sensor (see Wheel Rotation Sensor Inspection). If both inspections are good, go to next step. 12-50 BRAKES Anti-Lock Brake System โข Check that there is iron or other magnetic deposits between the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. โข Check the installation condition of the sensor for looseness. โข Check the sensor rotor tip for deformation or damage (e.g., chipped sensor rotor teeth). If the sensor rotor in bad condition, remove the any deposits. Install the proper part or replace faulty part. If the all items are good, go to next step. โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) โข Disconnect: ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal) Front Wheel Rotation Sensor Connector (see Front Wheel Rotation Sensor Removal) โข Check the wiring continuity between main harness connectors. Wiring Continuity Inspection ABS Hydraulic Unit Connector [A] โโ Front Wheel Rotation Sensor Connector [B] ABS Hydraulic Unit Terminal 3 [C] โโ Sensor Terminal [D] ABS Hydraulic Unit Terminal 12 [E] โโ Sensor Terminal [F] If there is not the continuity in the lead, replace or repair the main harness. If the wiring is good, go to next step. โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, replace the front wheel rotation sensor (see Front Wheel Rotation Sensor Removal). Still, when it is not good, replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). BRAKES 12-51 Anti-Lock Brake System Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44) โข Measure the air gap between the rear wheel rotation sensor and sensor rotor (see Wheel Rotation Sensor Air Gap Inspection). โข Check the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Inspection). If both inspections are good, go to next step. โข Check that there is iron or other magnetic deposits between the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. โข Check the installation condition of the sensor for looseness. โข Check the sensor rotor tip for deformation or damage (e.g., chipped sensor rotor teeth). If the sensor rotor in bad condition, remove the any deposits. Install the proper part or replace faulty part. If the all items are good, go to next step. โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) โข Disconnect: ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal) Rear Wheel Rotation Sensor Connector (see Rear Wheel Rotation Sensor Removal) โข Check the wiring continuity between main harness connectors. Wiring Continuity Inspection ABS Hydraulic Unit Connector [A] โโ Rear Wheel Rotation Sensor Connector [B] ABS Hydraulic Unit Terminal 14 [C] โโ Sensor Terminal [D] ABS Hydraulic Unit Terminal 13 [E] โโ Sensor Terminal [F] If there is not the continuity in the lead, replace or repair the main harness. If the wiring is good, go to next step. 12-52 BRAKES Anti-Lock Brake System โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, replace the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Removal). Still, when it is not good, replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). Power Supply Voltage Abnormal (Low-Voltage) (Service Code 52) โข Check the battery condition (see Charging Condition Inspection in the Electrical System chapter) If the battery is good condition, go to next step. โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) โข Check the charging voltage (see Charging Voltage Inspection in the Electrical System chapter). If the charging voltage is good, go to next step. โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). ABS Solenoid Valve Relay Supply Voltage Inspection (Low-Voltage) (Service Code 54) โข Check the charging voltage (see Charging Voltage Inspection in the Electrical System chapter). If the charging voltage is good, go to next step. BRAKES 12-53 Anti-Lock Brake System โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not light, ABS system is normal (service code is not stored; temporary failure.). ECU Inspection (Service Code 55) โข Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not lgiht, ABS system is normal (service code is not stored; temporary failure.). CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code 57) โข Remove: Front Seat (see Front Seat Removal in the Frame chapter) Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector Cap [A] โข Measure the CAN communication line resistance. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [A] GY/BL Terminal [B] LB Terminal [C] CAN Communication Line Resistance Standard: 30 ๏พ 70 โฆ If the reading is out of the standard, go to Check 1. If the reading is the standard, go to Check 2. Check 1 โข Check the CAN communication line resistance of following parts. Meter Unit (see Meter Unit Inspection in the Electrical System chapter) ECU (see CAN Communication Line Resistance Inspection in the Fuel System (DFI) chapter) 12-54 BRAKES Anti-Lock Brake System Check 2 โข Measure the resistance between the GY/BL [A] or LB [B] terminal and ground [C]. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [D] CAN Communication Line/Ground Resistance Standard: 4 ๏พ 30 kโฆ If the reading is out of the standard, replace or repair the main harness. If the reading is the standard, go to next step. โข Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If the yellow warning indicator (LED) [A] and KIBS indicator [B] go on or blink even if all checks are ended, replace the ABS hydraulic unit. If the yellow warning indicator (LED) and KIBS indicator go off, the KIBS system normal (temporary failure). ECU Communication Line Inspection (Service Code 62) โข Check the wiring continuity between the main harness connectors. โข Disconnect: ECU Connector (see ECU Removal in the Fuel System (DFI) chapter) ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal in the Brakes chapter) Wiring Continuity Inspection ECU Connector [A] โโ ABS Hydraulic Unit Connector [B] ECU Terminal 10 [C] โโ ABS Hydraulic Unit Terminal 11 [D] ECU Terminal 9 [E] โโ ABS Hydraulic Unit Terminal 2 [F] If the wiring is open, replace or repair the harness (see ABS System Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection in the Fuel System (DFI) chapter). If the ground and power supply are good, go to next step. BRAKES 12-55 Anti-Lock Brake System โข Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If the yellow warning indicator (LED) [A] and KIBS indicator [B] go on or blink even if all checks are ended, replace the ABS hydraulic unit. If the yellow warning indicator (LED) and KIBS indicator go off, the KIBS system normal (temporary failure). IMU Communication Line Inspection (Service Code 63) โข Check the wiring continuity between the main harness connectors. โข Disconnect: IMU Connector (see IMU Removal in the Fuel System (DFI) chapter) ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal in the Brakes chapter) Wiring Continuity Inspection ABS Hydraulic Unit Connector [A] โโ IMU Connector [B] ABS Hydraulic Unit Terminal 11 [C] โโ Sensor Connector [D] ABS Hydraulic Unit Terminal 2 [E] โโ Sensor Connector [F] If the wiring is open, replace or repair the harness (see ABS System Circuit). If the wiring is good, go to next step. โข Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If the yellow warning indicator (LED) [A] and KIBS indicator [B] go on or blink even if all checks are ended, replace the ABS hydraulic unit. If the yellow warning indicator (LED) and KIBS indicator go off, the KIBS system normal (temporary failure). Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83) โข Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not lgiht, ABS system is normal (service code is not stored; temporary failure.). 12-56 BRAKES Anti-Lock Brake System Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code 84) โข Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not lgiht, ABS system is normal (service code is not stored; temporary failure.). Fluid Pressure Sensor Supply Voltage Inspection (Service Code 89) โข Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If the yellow ABS indicator (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator (LED) does not lgiht, ABS system is normal (service code is not stored; temporary failure.). IMU Inspection (Service Code 94) โข Check the IMU power supply voltage (see IMU Power Supply Inspection). If the IMU is good, perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If the yellow warning indicator (LED) [A] and KIBS indicator [B] go on or blink even if all checks are ended, replace the ABS hydraulic unit. If the yellow warning indicator (LED) and KIBS indicator go off, the KIBS system normal (temporary failure). ABS Hydraulic Unit Removal NOTICE The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface. Be careful not to get water or mud on the ABS hydraulic unit. โข Drain the brake fluid from the front and rear brake lines. โDrain the brake fluid through the bleed valve by pumping the brake lever and pedal. BRAKES 12-57 Anti-Lock Brake System โข Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery Case (see Battery Case Removal in the Frame chapter) โข Clean the ABS hydraulic unit. NOTICE Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation. Spread over a shop towel around the ABS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts. โข Pull the lever [A] backward to disconnect the ABS hydraulic unit connector [B]. โข Loosen the brake pipe joint nuts [A] with the flare nut wrench. โข Disconnect the brake pipe from the ABS hydraulic unit. NOTICE Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely washed away immediately. โข Remove: Bolts [A] 12-58 BRAKES Anti-Lock Brake System โข Remove: Bolts [A] Bracket [B] โข Pull up the ABS hydraulic unit [A]. โข Remove: Bolts [B] ABS Hydraulic Unit NOTICE The ABS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disassemble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation NOTICE Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely washed away immediately. โขInstallation is the reverse of removal. โข Be sure to install the dampers [A] and collars [B] on the bracket [C]. โขInstall the brake pipes (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Tighten the brake pipe joint nuts with the flare nut wrench. Torque – Brake Pipe Joint Nuts: 18 Nยทm (1.8 kgfยทm, 13 ftยทlb) โข Pull the lever forward to connect the ABS hydraulic unit connector [A]. โข Bleed the brake line (see Brake Line Bleeding). โข Check the brake for good braking power, no brake drag, and no fluid leakage. ABS Hydraulic Unit Inspection โข Remove the ABS hydraulic unit (see ABS Hydraulic Unit Removal). โข Visually inspect the ABS hydraulic unit. Replace the ABS hydraulic unit if any of them are cracked, or otherwise damaged. BRAKES 12-59 Anti-Lock Brake System โข Visually inspect the connector terminals [A]. Replace the ABS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air. Front Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to get water or mud on the wheel rotation sensor. Do not try to disassemble or repair the wheel rotation sensor. โข Disconnect the front wheel rotation sensor lead connector [A]. โข Remove the front wheel rotation sensor from the windshield bracket assembly [B]. โข Clear the sensor lead from the clamps [A]. โข Clear the sensor lead from the clamps [A]. โข Remove: Bolt [B] Front Wheel Rotation Sensor [C] 12-60 BRAKES Anti-Lock Brake System Front Wheel Rotation Sensor Installation โขInstallation is the reverse of removal. โข When installing the sensor which is fastened by bolt, tighten the bolt after placing the sensor on the bottom surface completely. Torque – Front Wheel Rotation Sensor Bolt: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โRun the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to get water or mud on the wheel rotation sensor. Do not try to disassemble or repair the wheel rotation sensor. โข Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) โข Disconnect the rear wheel rotation sensor lead connector [A]. โข Remove the rear wheel rotation sensor from the connector bracket [B]. โข Clear the sensor lead from the clamp [C]. โข Clear the sensor lead from the clamps [A]. โข Clear the sensor lead from the clamps [A]. โข Remove: Bolt [B] Clamp [C] Rear Wheel Rotation Sensor [D] BRAKES 12-61 Anti-Lock Brake System Rear Wheel Rotation Sensor Installation โขInstallation is the reverse of removal. โข When installing the sensor which is fastened by bolt, tighten the bolt after placing the sensor on the bottom surface completely. Torque – Rear Wheel Rotation Sensor Bolt: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โRun the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Wheel Rotation Sensor Inspection โข Remove the front wheel rotation sensor [A] from the front fork. โข Remove the rear wheel rotation sensor [B] from the caliper bracket. โข Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged. Wheel Rotation Sensor Air Gap Inspection โข Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). โข Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly. Thickness Gauge [A] Air Gap Standard: Front 0.1 ๏พ 2.1 mm (0.004 ๏พ 0.083 in.) Rear 0.1 ๏พ 1.7 mm (0.004 ๏พ 0.067 in.) NOTE โThe sensor air gap cannot be adjusted. If the air gap is not within the specification, inspect the hub bearing (see Hub Bearing Inspection in the Wheels/Tires chapter), sensor installation condition and sensor (see Wheel Rotation Sensor Inspection). 12-62 BRAKES Anti-Lock Brake System Wheel Rotation Sensor Rotor Inspection โข Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one. If there is iron or other magnetic deposits [B], remove the deposits. ABS Solenoid Valve Relay Fuse (15 A) Removal โข Refer to the Fuse Box Fuse Removal in the Electrical System chapter. ABS Motor Relay Fuse (25 A) Removal โข Refer to the Fuse Box Fuse Removal in the Electrical System chapter. Fuse Installation โขIf a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage (see Fuse Installation in the Electrical System chapter). Fuse Inspection โข Remove the fuses (see ABS Solenoid Valve Relay Fuse (15 A)/ABS Motor Relay Fuse (25 A) Removal). โข Refer to the Fuse Inspection in the Electrical System chapter. SUSPENSION 13-1 13 Suspension Table of Contents Exploded View 13-2 Specifications . 13-6 Special Tools 13-7 Front Fork. 13-9 Rebound Damping Force Adjustment 13-9 Spring Preload Adjustment . 13-9 Compression Damping Force Adjustment (Right Side Only) 13-10 Front Fork Removal (Each Fork Leg) . 13-10 Front Fork Installation . 13-11 Fork Oil Change 13-11 Front Fork Disassembly 13-21 Front Fork Assembly. 13-22 Inner Tube, Outer Tube Inspection . 13-23 Dust Seal Inspection. 13-24 Spring Tension Inspection. 13-24 Rear Shock Absorber . 13-25 Rebound Damping Force Adjustment. 13-25 Spring Preload Adjustment . 13-25 Rear Shock Absorber Removal 13-25 Rear Shock Absorber Installation . 13-26 Rear Shock Absorber Inspection 13-27 Rear Shock Absorber Scrapping 13-27 Rear Shock Absorber Bearing Removal. 13-27 Rear Shock Absorber Bearing Installation 13-27 Swingarm 13-28 Swingarm Removal. 13-28 Swingarm Installation 13-29 Swingarm Bearing Removal . 13-30 Swingarm Bearing Installation 13-30 Swingarm Bearing, Sleeve Inspection 13-31 Swingarm Bearing Lubrication 13-31 Chain Guide Inspection. 13-31 Tie-Rod, Rocker Arm 13-32 Tie-Rod Removal 13-32 Tie-Rod Installation . 13-32 Rocker Arm Removal 13-32 Rocker Arm Installation. 13-33 Tie-Rod and Rocker Arm Bearing Removal 13-34 Tie-Rod and Rocker Arm Bearing Installation. 13-34 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-35 Rocker Arm/Tie-Rod Bearing Lubrication . 13-35 13-2 SUSPENSION Exploded View SUSPENSION 13-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Upper Front Fork Clamp Bolts 20 2.0 15 2 Lower Front Fork Clamp Bolts 25 2.5 18 AL 3 Front Fork Top Plugs 34 3.5 25 4 Piston Rod Nuts 20 2.0 15 5 Front Axle Clamp Bolts 20 2.0 15 AL 6 Right Front Fork Bottom Allen Bolt 35 3.6 26 7 Left Front Fork Bottom Allen Bolt 20 2.0 15 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. R: Replacement Parts 13-4 SUSPENSION Exploded View SUSPENSION 13-5 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Upper Rear Shock Absorber Bolt 35 3.6 26 2 Swingarm Pivot Shaft Nut 110 11.2 81.1 3 Swingarm Pivot Shaft 20 2.0 15 4 Swingarm Pivot Adjusting Collar Locknut 100 10.2 73.8 5 Tie-rod Nuts 35 3.6 26 R 6 Lower Rear Shock Absorber Nut 35 3.6 26 R 7 Rocker Arm Nut 35 3.6 26 R 8 Torque Link Nuts 35 3.6 26 G: Apply grease. R: Replacement Parts 13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting 2 3/4 turns out from the fully clockwise position (Usable Range: 0 โโ 3 1/2 turns out) Compression Damper Setting (Right Side Only) 1 3/4 turns out from the fully clockwise position (Usable Range: 0 โโ 3 turns out) Fork Spring Preload Setting 5 turns in from the fully counterclockwise position (Usable Range: 0 โโ 15 turns in) Suspension Oil Kawasaki SS-47 or equivalent Amount: When Changing Oil Approx. 415 mL (14.0 US oz.) After Disassembly and Completely Dry 487 ยฑ2.5 mL (16.5 ยฑ0.085 US oz.) Fork Oil Level 96 ยฑ2 mm (3.8 ยฑ0.08 in.) (fully compressed, below from the top of outer tube) Fork Spring Free Length 313 mm (12.3 in.) (Service Limit: 307 mm (12.1 in.)) Rear Shock Absorber Rebound Damper Setting 2 1/2 turns out from the fully clockwise position (Usable Range: 0 โโ 2 1/2 turns out) Spring Preload Setting Position 8 clicks from the fully counterclockwise position (Usable Range: 0 โโ 40 clicks) Gas Pressure 980 ๏พ 1 280 kPa (10.00 ๏พ 13.05 kgf/cmยฒ, 142.1 ๏พ 185.6 psi, non-adjustable) SUSPENSION 13-7 Special Tools Inside Circlip Pliers: 57001-143 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 Jack: 57001-1238 Fork Oil Seal Driver, 41: 57001-1288 Fork Oil Level Gauge: 57001-1290 Fork Piston Rod Puller, M10 ร 1.0: 57001-1298 Fork Spring Stopper: 57001-1374 Fork Spring Compressor: 57001-1587 Swingarm Pivot Nut Wrench: 57001-1597 13-8 SUSPENSION Special Tools Jack Attachment: 57001-1608 Needle Bearing Driver, 17/ 18: 57001-1609 Needle Bearing Driver, 28: 57001-1610 Clamp: 57001-1693 Bar: 57001-1751 Fork Spring Compressor: 57001-1771 Fork Oil Seal Driver Weight, 26 ๏พ 46: 57001-1795 Fork Oil Seal Driver Attachment, 36 ๏พ 46: 57001-1798 SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment โข To adjust the rebound damping force, turn the rebound damping adjuster [A]. โThe standard adjuster setting is the 2 3/4 turns out from the fully clockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. Be sure the adjusters are set equally. โThe damping force can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger. If the damping feels too soft or too stiff, adjust it in accordance with the following table. Rebound Damping Force Adjustment Adjuster Position Damping Force Setting Load Road Speed 3 1/2 turns out Weak Soft Light Good Low โ โ โ โ โ โ โ โ โ โ โ โ 0 Strong Hard Heavy Bad High Spring Preload Adjustment โข To adjust the spring preload, turn the spring preload adjuster [A]. โThe standard adjuster setting is the 5 turns in from the fully counterclockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. Be sure the adjusters are set equally. โThe spring preload can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger. If the spring action feels too soft or too stiff, adjust it in accordance with the following table. Spring Action Adjuster Position Damping Force Setting Load Road Speed 0 Weak Soft Light Good Low โ โ โ โ โ โ โ โ โ โ โ โ 15 turns in Strong Hard Heavy Bad High 13-10 SUSPENSION Front Fork Compression Damping Force Adjustment (Right Side Only) โข To adjust the compression damping force, turn the compression damping adjuster [A]. โThe standard adjuster setting is the 1 3/4 turns out from the fully clockwise position. โThe damping force can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger. If the damping feels too soft or too stiff, adjust it in accordance with the following table. Compression Damping Force Adjustment Adjuster Position Damping Force Setting Load Road Speed 3 turns out Weak Soft Light Good Low โ โ โ โ โ โ โ โ โ โ โ โ 0 Strong Hard Heavy Bad High Front Fork Removal (Each Fork Leg) โข 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) โข Loosen the handlebar holder clamp bolt [A]. โข Remove: Handlebar Holder Positioning Bolt [B] Handlebar Holder [C] โข Loosen the upper front fork clamp bolt [D] and lower front fork clamp bolts [E]. SUSPENSION 13-11 Front Fork If fork leg is to be disassembled, loosen the upper front clamp bolt [A] and front fork top plug [B]. NOTE โLoosen the front fork top plug after loosening the upper front fork clamp bolt. โLoosen the lower front fork clamp bolts. โข With a twisting motion, work the fork leg down and out. Front Fork Installation โขInstall the fork so that the top end [A] of the outer tube as shown. 27.9 mm (1.10 in.) [B] โข Tighten: Torque – Lower Front Fork Clamp Bolts : 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) Front Fork Top Plugs: 34 Nยทm (3.5 kgfยทm, 25 ftยทlb) Upper Front Fork Clamp Bolts: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) NOTE โTighten the top plug before tightening the upper front fork clamp bolt. โTighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. โขInstall the removed parts (see appropriate chapters). โข Adjust: Spring Preload (see Spring Preload Adjustment) Rebound Damping Force (see Rebound Damping Force Adjustment) Compression Damping Force (see Compression Damping Force Adjustment) Fork Oil Change โข Remove the front fork (see Front Fork Removal). โข Hold the inner tube lower end in a vice. โข Place a plastic bag [A] over the top plug [B] to protect the top plug. โข Unscrew the top plug out of the outer tube. 13-12 SUSPENSION Front Fork โข Holding the top plug [A] with a wrench [B], tighten the spring preload adjuster [C]. NOTE โAfter tightening, lift the top plug to make the space. โข Slide down the damper [D]. โขInstall the clamps [A] as shown. NOTE โSet the cutout [B] of the clamp to the slider [C], pull up the outer tube [D] to hold it by the clamps, and then tighten the two bolts [E]. The outer tube is used as a guide. Special Tool – Clamp: 57001-1693 โข Set the fork spring compressor [A] and a suitable jack [B] as shown. Special Tool – Fork Spring Compressor: 57001-1771 โขInsert the projection of the protector [A] into the front fork bottom hole [B]. SUSPENSION 13-13 Front Fork โข Set the front fork [A] under the holder [B]. โข Lift up the suitable jack, and hold the front fork. โข Lift up the suitable jack until the piston rod nut [A] comes out. โขInsert the fork spring stopper [B] between the piston rod nut and the holder [C] while holding up the top plug [D]. Special Tool – Fork Spring Stopper: 57001-1374 โข Holding the spring preload adjuster [A] with a wrench [B], loosen the piston rod nut [C]. โข Remove: Top Plug with Rebound Damping Adjuster Rod โข Remove the front fork from the fork spring compressor. โข Remove: Damper [A] Slider [B] Collar [C] Fork Spring [D] โข Drain the fork oil into a suitable container. โUsing the piston rod puller [A], pump the piston rod [B] up and down at least ten times to expel the oil from the fork. Special Tool – Fork Piston Rod Puller, M10 ร 1.0: 57001 -1298 13-14 SUSPENSION Front Fork โข Hold the fork tube upright, press the outer tube [A] and the piston rod all the way down. โข Pour in the type and amount of fork oil specified. Suspension Oil – SS-47 (1 L): 44091-0010 Amount (Per Side): When changing oil: Approx. 415 mL (14.0 US oz.) After disassembly and completely dry: 487 ยฑ2.5 mL (16.5 ยฑ0.085 US oz.) If necessary, measure the oil level as follows. โHold the inner tube vertically in a vise. โUsing the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil. Special Tool – Fork Piston Rod Puller, M10 ร 1.0: 57001 -1298 โRemove the piston rod puller. โWait until the oil level settles. โWith the fork fully compressed and the piston rod fully pushed in, insert a tape measure or rod into the inner tube, and measure the distance from the top of the outer tube to the oil. Oil Level (fully compressed, without spring) Standard: 96 ยฑ2 mm (3.8 ยฑ0.08 in.) (from the top of the outer tube) NOTE โFork oil lever may also be measured using the fork oil level gauge. Special Tool – Fork Oil Level Gauge [A]: 57001-1290 โWith the fork fully compressed and without fork spring, insert the gauge tube into the inner tube [B] and position the stopper across the top end [C] of the outer tube [D]. โSet the gauge stopper [E] so that its lower side shows the oil level distance specified [F]. โPull the handle slowly to pump out the excess oil until the oil no longer comes out. If no oil is pumped out, there is insufficient oil in the inner tube. Pour in enough oil, then pump out the excess oil as shown above. SUSPENSION 13-15 Front Fork โข Screw on the piston rod nut [A] fully to the piston rod [B]. โข Screw the fork piston rod puller onto the end of the piston rod. Special Tool – Fork Piston Rod Puller, M10 ร 1.0: 57001 -1298 โข Pull the puller up above the outer tube top. โขInstall the fork spring [A] with the smaller end [B] facing upward. โขInstall: Collar [A] Damper [B] Slider [C] โขInstall the clamps [A] as shown. Special Tool – Clamp: 57001-1693 NOTE โSet the cutout [B] of the clamp to the slider [C], pull up the outer tube [D] to hold it by the clamps, and then tighten the two bolts [E]. The outer tube is used as a guide. 13-16 SUSPENSION Front Fork โข Set the fork spring compressor [A], front fork [B], protector and suitable jack. โข Lift up the suitable jack until the piston rod nut comes out. Special Tool – Fork Spring Compressor: 57001-1771 โข Hold up the fork piston rod puller. โขInsert the fork spring stopper between the piston rod nut and the holder while holding up the fork piston rod puller. Special Tool – Fork Spring Stopper: 57001-1374 โข Remove the fork piston rod puller. โข Check the distance between the upper end [A] of the spring preload adjuster [B] and rebound damping adjuster [C] with a pair of vernier caliper. 1.5 mm (0.059 in.) [D] โขInsert the rebound damping adjuster rod into the hole of the piston rod. โข Screw in the top plug until it stops onto the piston rod. โข Replace the O-ring [A] on the top plug with a new one. โข Holding the spring preload adjuster [B] with a wrench [C], tighten the piston rod nut [D] against the top plug. Torque – Piston Rod Nuts: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) โข Remove the fork spring stopper. โข Remove the front fork from the fork spring compressor. โข Raise the outer tube and screw the top plug into it. โขInstall the front fork (see Front Fork Installation). โข Adjust the spring preload (see Spring Preload Adjustment). โข Adjust the rebound damping force (see Rebound Damping Force Adjustment). SUSPENSION 13-17 Front Fork If using the fork spring compressor (57001-1587). โขInstall the clamps [A] as shown. NOTE โSet the cutout [B] of the clamp to the slider [C], pull up the outer tube [D] to hold it by the clamps, and then tighten the two bolts [E]. The outer tube is used as a guide. Special Tools – Fork Spring Compressor: 57001-1587 Clamp : 57001-1693 โขInsert the holder bar [A] into the axle hole of the front fork [B]. Special Tool – Bar: 57001-1751 (For Left Fork Leg) โPosition the bar left and right and evenly. โขInsert the compression shaft and install the nut. โขInsert the lower end of the compression shaft [A] into the hole [B] of the holder bar. โข Screw the adjust nut [A] onto the compression shaft as shown. โข Screw the locknut [B]. โข Set the other side compression shaft same process. 13-18 SUSPENSION Front Fork โข Set the holder bar [A] and compression shafts [B]. โข Screw in the nuts [A] until the piston rod nut comes out. โข While holding up the top plug [A], insert the fork spring stopper [B] between the piston rod nut [C] and the slider. Special Tool – Fork Spring Stopper: 57001-1374 โข Holding the spring preload adjuster [A] with a wrench [B], loosen the piston rod nut [C]. โข Remove: Top Plug with Rebound Damping Adjuster Rod Damper [A] Slider [B] Collar [C] Fork Spring [D] SUSPENSION 13-19 Front Fork โข Drain the fork oil into a suitable container. โUsing the piston rod puller [A], pump the piston rod [B] up and down at least ten times to expel the oil from the fork. Special Tool – Fork Piston Rod Puller, M10 ร 1.0: 57001 -1298 โข Hold the fork tube upright, press the outer tube [A] and the piston rod all the way down. โข Pour in the type and amount of fork oil specified. Suspension Oil – SS-47 (1 L): 44091-0010 Amount (Per Side): When changing oil: Approx. 415 mL (14.0 US oz.) After disassembly and completely dry: 487 ยฑ2.5 mL (16.5 ยฑ0.085 US oz.) If necessary, measure the oil level as follows. โHold the inner tube vertically in a vise. โUsing the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil. Special Tool – Fork Piston Rod Puller, M10 ร 1.0 [A]: 57001 -1298 โRemove the piston rod puller. โWait until the oil level settles. โWith the fork fully compressed and the piston rod fully pushed in, insert a tape measure or rod into the inner tube, and measure the distance from the top of the outer tube to the oil. 13-20 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: 96 ยฑ2 mm (3.8 ยฑ0.08 in.) (from the top of the outer tube) NOTE โFork oil level may also be measured using the fork oil level gauge. Special Tool – Fork Oil Level Gauge [A]: 57001-1290 โWith the fork fully compressed and without fork spring, insert the gauge tube into the inner tube [B] and position the stopper across the top end [C] of the outer tube [D]. โSet the gauge stopper [E] so that its lower side shows the oil level distance specified [F]. โPull the handle slowly to pump out the excess oil until the oil no longer comes out. If no oil is pumped out, there is insufficient oil in the inner tube. Pour in enough oil, then pump out the excess oil as shown above. โข Screw on the piston rod nut [A] fully to the piston rod [B]. โข Screw the fork piston rod puller onto the end of the piston rod. Special Tool – Fork Piston Rod Puller, M10 ร 1.0: 57001 -1298 โข Pull the puller up above the outer tube top. โขInstall the fork spring [A] with the smaller end [B] facing upward. โขInstall: Collar [A] Damper [B] Slider [C] SUSPENSION 13-21 Front Fork โข Set the fork spring compressor on the slider [A] using the outer tube as a guide. Special Tools – Fork Spring Compressor: 57001-1587 Clamp: 57001-1693 NOTE โSet the cutout of the clamp to the slider. โข While holding up the piston rod puller, insert the fork spring stopper between the piston rod nut and the slider. Special Tool – Fork Spring Stopper: 57001-1374 โข Remove the piston rod puller. โข Check the distance between the upper end [A] of the spring preload adjuster [B] and rebound damping adjuster [C] with a pair of vernier caliper. 1.5 mm (0.059 in.) [D] โขInsert the rebound damping adjuster rod into the hole of the piston rod. โข Screw in the top plug until it stops onto the piston rod. โข Replace the O-ring [A] on the top plug with a new one. โข Holding the spring preload adjuster [B] with a wrench [C], tighten the piston rod nut [D] against the top plug. Torque – Piston Rod Nuts: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) โข While holding up the top plug [A], pull out the fork spring stopper [B]. โข Remove the fork spring compressor. โข Raise the outer tube and screw the top plug into it. โขInstall the front fork (see Front Fork Installation). โข Adjust the spring preload (see Spring Preload Adjustment). โข Adjust the rebound damping force (see Rebound Damping Force Adjustment). Front Fork Disassembly โข Remove the front fork (see Front Fork Removal). โข Drain the fork oil (see Fork Oil Change). โขInstall the suitable pipe ( 26 ๏พ 32) [A] into the cylinder unit. โข Set the fork leg inverted. โข While pushing down [B] the fork leg, loosen the bottom Allen bolt. โข Remove the Allen bolt and gasket. 13-22 SUSPENSION Front Fork โข Take the cylinder unit [A] and center ring plate [B] out of the inner tube. โDo not disassemble the cylinder unit. โข Separate the inner tube from the outer tube as follows. โSlide up the dust seal [A]. โRemove the retaining ring [B] from the outer tube. โHolding the outer tube [A] by hand, pull the inner tube [B] several times to pull out the outer tube. โข Remove the following parts from the inner tube. Inner Tube Guide Busing [A] Outer Tube Guide Busing [B] Washer [C] Oil Seal [D] Retaining Ring [E] Dust Seal [F] Front Fork Assembly โข Replace the following parts with new ones. Oil Seal [A] Outer Tube Guide Bushing [B] Inner Tube Guide Bushing [C] Dust Seal [D] Retaining Ring [E] Bottom Allen Bolt Gasket โขInstall the following parts onto the inner tube. Dust Seal Retaining Ring Oil Seal Washer [F] Outer Tube Guide Bushing Inner Tube Guide Bushing SUSPENSION 13-23 Front Fork โขInsert the inner tube to the outer tube. โข Fit the new outer tube guide bushing [A] into the outer tube. NOTE โWhen assembling the new outer tube guide bushing, hold the washer against the new outer tube guide bushing and tap the washer with the fork oil seal driver [B] until it stops. Special Tools – Fork Oil Seal Driver, 41: 57001-1288 or Fork Oil Seal Driver Weight, 26 ๏พ 46: 57001-1795 Fork Oil Seal Driver Attachment, 36 ๏พ 46: 57001-1798 โขInstall the oil seal by using the fork oil seal driver. Special Tools – Fork Oil Seal Driver, 41: 57001-1288 or Fork Oil Seal Driver Weight, 26 ๏พ 46: 57001-1795 Fork Oil Seal Driver Attachment, 36 ๏พ 46: 57001-1798 โขInstall the retaining ring and dust seal into the outer tube. โขInstall the center ring plate [A] on the cylinder unit. โขInsert the center ring plate and cylinder unit as a set into the inner tube. โขInsert the suitable pipe into the cylinder unit. โข While pushing down [A] the fork leg, tighten the front fork bottom Allen bolt [B]. โข Tighten: Torque – Right Front Fork Bottom Allen Bolt: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) Left Front Fork Bottom Allen Bolt: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) โข Pour in the specified type of oil (see Fork Oil Change). Inner Tube, Outer Tube Inspection โข Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced. NOTICE If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube. 13-24 SUSPENSION Front Fork โข Temporarily assemble the inner tube [A] and outer tube [B], and pump [C] them back and forth manually to check for smooth operation. If you feel binding or catching, the inner and outer tubes must be replaced. WARNING A straightened inner or outer fork tube may fall in use, possibly causing an accident resulting in serious injury or death. Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it. Dust Seal Inspection โขInspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension Inspection โข 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: 313 mm (12.3 in.) Service Limit: 307 mm (12.1 in.) SUSPENSION 13-25 Rear Shock Absorber Rebound Damping Force Adjustment โข To adjust the rebound damping force, turn the rebound damping adjuster [A] to the desired position. โThe standard adjuster setting is the 2 1/2 turns out from the fully clockwise position. Rebound Damping Force Adjustment Adjuster Position Damping Force Setting Load Road Speed 2 1/2 turns out Weak Soft Light Good Low โ โ โ โ โ โ โ โ โ โ โ โ 0 Strong Hard Heavy Bad High Spring Preload Adjustment โข To adjust the spring preload, turn in the adjuster [A] until you feel a click to the desired position. โThe standard adjuster setting is the 8 clicks from the fully counterclockwise position. If the spring action feels too soft, adjust it. Spring Preload Adjustment Adjuster Position Damping Force Setting Load Road Speed 0 clicks Weak Soft Light Good Low โ โ โ โ โ โ โ โ โ โ โ โ 40 clicks Strong Hard Heavy Bad High Rear Shock Absorber Removal โข Support the motorcycle with the stand. โข Remove: Side Stand Bracket Bolts [A] Side Stand Bracket [B] with Side Stand 13-26 SUSPENSION Rear Shock Absorber โข Squeeze the brake lever slowly and hold it with a band [A]. โข Remove the rear lower fairing (see Rear Lower Fairing Removal in the Frame chapter). โข Raise the rear wheel off the ground with the jack. Special Tools – Jack [A]: 57001-1238 Jack Attachment [B]: 57001-1608 WARNING When raising the rear wheel off the ground with the jack and removing part(s) from the motorcycle, be sure to hold the front brake, or the motorcycle may fall over. It could cause an accident and injury. โข Remove: Spring Preload Adjuster Bolts [A] Bracket โข Remove: Lower Rear Shock Absorber Nut and Bolt [A] Upper Rear Shock Absorber Bolt [B] โข Clear the spring preload adjustor hose from the guide [C]. โข Remove the rear shock absorber [D] rearward. Rear Shock Absorber Installation โข Replace the rear shock absorber nuts with new ones. โข Tighten: Torque – Upper Rear Shock Absorber Bolt: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) Lower Rear Shock Absorber Nut: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) SUSPENSION 13-27 Rear Shock Absorber โข Run the spring preload adjuster hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Be sure to install the dampers [A] and collars [B] on the right rear footpeg bracket. โWhen installing the dampers, face the small diameter side outward. โขInstall the bracket. โข Tighten the spring preload adjuster bolts. โขInstall the removed parts (see appropriate chapters). Rear Shock Absorber Inspection โข Remove the rear shock absorber (see Rear Shock Absorber Removal). โข Visually inspect the following items. Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace it. โข Visually inspect the rubber bushing. If it show any signs of damage, replace it. Rear Shock Absorber Scrapping WARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber without first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [A] shown to release the nitrogen gas completely. Wear safety glasses when drilling the hole, as the gas may blow out bits of drilled metal when the hole opens. Rear Shock Absorber Bearing Removal โข Remove: Rear Shock Absorber (see Rear Shock Absorber Removal) Sleeve [A] Grease Seals [B] โข Remove the needle bearing, using a suitable tool. Rear Shock Absorber Bearing Installation โข Replace the needle bearing [A] and grease seals [B] with new ones. โขInstall the needle bearing position as shown. 7.5 mm (0.30 in.) [C] โข Apply plenty of grease to the lips of the grease seals. โขInstall the grease seals and sleeve [D]. 13-28 SUSPENSION Swingarm Swingarm Removal โข Remove: Rear Brake Hose Lower End (see Rear Caliper Removal in the Brakes chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Mud Guard (see Mad Guard Removal in the Frame chapter) Chain Cover (see Drive Chain Replacement in the Final Drive chapter) Rocker Arm (see Rocker Arm Removal) โข Remove: Cotter Pin [A] Torque Link Bolt and Nut [B] Torque Link [C] โข Remove: Brake Hose Clamp Bolt [A] โข Clear the brake hose [B] from the guide [C] on the swingarm. โข Remove the swingarm pivot shaft nut [A]. โข Using the swingarm pivot nut wrench [A], loosen the swingarm pivot adjusting collar locknut [B]. Special Tool – Swingarm Pivot Nut Wrench: 57001-1597 SUSPENSION 13-29 Swingarm โข Turn the swingarm pivot shaft [A] counterclockwise to free the adjusting collar from the swingarm. โMake the gap between the adjusting collar and swingarm. โข Pull out the pivot shaft to the right side and remove the swingarm. Swingarm Installation โข Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. โข Apply grease to the lips of the grease seals [A]. โข Be sure to install the grease seals and sleeve [B] to the swingarm. โข Fit the collar [C] on the grease seal of the left side. โข Screw the adjusting collar [A] into the frame [B] so that the collar does not project the swingarm mating surface [C]. โขInstall the swingarm and insert the swingarm pivot shaft [A] into the adjusting collar [B] from the right side, and tighten the pivot shaft. NOTE โTighten the swingarm pivot shaft until the clearance [C] between the ball bearing [D] and collar comes to 0 mm (0 in.). Torque – Swingarm Pivot Shaft: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) โข Using the swingarm pivot nut wrench, tighten the swingarm pivot adjusting collar locknut [E]. Special Tool – Swingarm Pivot Nut Wrench: 57001-1597 Torque – Swingarm Pivot Adjusting Collar Locknut: 100 Nยทm (10.2 kgfยทm, 73.8 ftยทlb) 13-30 SUSPENSION Swingarm โข Tighten the swingarm pivot shaft nut. Torque – Swingarm Pivot Shaft Nut: 110 Nยทm (11.2 kgfยทm, 81.1 ftยทlb) โข Move the swingarm up and down to check for abnormal friction. โขInstall the removed parts (see appropriate chapters). Swingarm Bearing Removal โข Remove: Swingarm (see Swingarm Removal) Collar [A] Grease Seals [B] Sleeve [C] Circlip (Right Side) [D] Special Tool – Inside Circlip Pliers: 57001-143 โข Remove the ball bearing and needle bearings. Special Tool – Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation โข Replace the needle bearings [A], ball bearing [B], grease seals [C] and circlip [D] with new ones. โขInstall the needle bearings, ball bearing, grease seals and circlip as shown. Left Side [E] Right Side [F] 9.5 mm (0.37 in.) [G] 29.5 mm (1.16 in.) [H] NOTE โInstall the needle and ball bearings so that the marked side faces out. Special Tool – Needle Bearing Driver, 28: 57001-1610 โPress in the ball bearing until it bottomed. Special Tool – Bearing Driver Set: 57001-1129 โInstall the circlip. Special Tool – Inside Circlip Pliers: 57001-143 โPress in the grease seals so that seal surface is flushed with the end of housing. Special Tool – Bearing Driver Set: 57001-1129 SUSPENSION 13-31 Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Removal may damage them. โขInspect the needle bearings [A] and ball bearing [B] installed in the swingarm. โThe rollers and ball in a bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually inspect the bearing for abrasion, discoloration, or other damage. If the needle bearing and sleeve [C] show any sings of abnormal wear, discoloration, or damage, replace them as a set. โข Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. โข Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing. Swingarm Bearing Lubrication NOTE โSince the bearings are packed with grease and sealed, lubrication is not required. Chain Guide Inspection โข Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter. 13-32 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal โข Remove: Mud Guard (see Mud Guard Removal in the Frame chapter) โข Squeeze the brake lever slowly and hold it with a band [A]. โข Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal). Special Tools – Jack: 57001-1238 Jack Attachment: 57001-1608 WARNING When raising the rear wheel off the ground with the jack and removing part(s) from the motorcycle, be sure to hold the front brake, or the motorcycle may fall over. It could cause an accident and injury. โข Remove: Upper Tie-Rod Bolt and Nut [A] Lower Tie-Rod Bolt and Nut [B] Tie-Rod [C] Tie-Rod Installation โข Apply grease to the inside of the grease seals. โขInstall the tie-rod. โข Replace the tie-rod nuts with new ones. โข Tighten: Torque – Tie-rod Nuts: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) โขInstall the removed parts (see appropriate chapters). Rocker Arm Removal โข Remove: Mud Guard (see Mud Guard Removal in the Frame chapter) โข Squeeze the brake lever slowly and hold it with a band [A]. SUSPENSION 13-33 Tie-Rod, Rocker Arm โข Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal). Special Tools – Jack: 57001-1238 Jack Attachment: 57001-1608 WARNING When raising the rear wheel off the ground with the jack and removing part(s) from the motorcycle, be sure to hold the front brake, or the motorcycle may fall over. It could cause an accident and injury. โข Remove: Lower Rear Shock Absorber Bolt and Nut [A] Upper Tie-Rod Bolt and Nut [B] Rocker Arm Bolt and Nut [C] Rocker Arms [D] Rocker Arm Installation โข Apply grease to the inside of the oil seals. โข Replace the following nuts with new ones. Rocker Arm Nut Upper Tie-Rod Nut Lower Rear Shock Absorber Nut โขInstall the rocker arms so that the marked side faces left side. โข Tighten: Torque – Rocker Arm Nut: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) Tie-Rod Nut: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) Lower Rear Shock Absorber Nut: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) โขInstall the removed parts (see appropriate chapters). 13-34 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal โข Remove: Tie-Rod (see Tie-Rod Removal) Rocker Arms (see Rocker Arm Removal) Swingarm [A] (see Swingarm Removal) Sleeves [B] Grease Seals [C] โข Remove the needle bearings [D], using a suitable tool. Tie-Rod and Rocker Arm Bearing Installation โข Replace the needle bearing [A] and grease seals with new ones. โขInstall the needle bearings position as shown. โScrew the needle bearing driver into the driver holder. โInsert the needle bearing driver into the needle bearing and press the needle bearing. 7.5 mm (0.30 in.) [B] NOTE โFor a bearing of inner diameter 17, select the pressing side of the needle bearing driver according to its pressing depth. Special Tools – Bearing Driver Set: 57001-1129 Needle Bearing Driver, 17/ 18: 57001 -1609 โข Apply plenty of grease to the lips of the grease seals. โขInstall the grease seals. SUSPENSION 13-35 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Removal may damage them. โข Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. โข The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of any of the needle bearings or sleeve, replace the sleeve and needle bearings as a set. Rocker Arm/Tie-Rod Bearing Lubrication NOTE โSince the bearings are packed with grease, lubrication is not required. STEERING 14-1 14 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 Stem Cap Deterioration, Damage Inspection . 14-10 Handlebar. 14-11 Handlebar Removal 14-11 Handlebar Installation . 14-11 14-2 STEERING Exploded View STEERING 14-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Right Switch Housing Screws 3.5 0.36 31 inยทlb 2 Throttle Case Bolts 3.5 0.36 31 inยทlb 3 Handlebar Holder Positioning Bolts 10 1.0 89 inยทlb L 4 Handlebar Holder Clamp Bolts 25 2.5 18 5 Handlebar Bolts 35 3.6 26 L 6 Upper Front Fork Clamp Bolts 20 2.0 15 7 Steering Stem Head Bolt 110 11.2 81.1 8 Left Switch Housing Screws 3.5 0.36 31 inยทlb 9 Steering Stem Nut 30 3.1 22 10 Lower Front Fork Clamp Bolts 25 2.5 18 AL AD: Apply adhesive. AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. 14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver, 54.5: 57001-1077 Steering Stem Nut Wrench: 57001-1100 Steering Stem Bearing Driver, 42.5: 57001-1344 Steering Stem Bearing Driver Adapter, 41.5: 57001-1345 Head Pipe Outer Race Driver, 55: 57001-1446 STEERING 14-5 Steering Steering Inspection โข Refer to the Steering Play Inspection in the Periodic Maintenance chapter. Steering Adjustment โข Refer to the Steering Play Adjustment in the Periodic Maintenance chapter. 14-6 STEERING Steering Stem Stem, Stem Bearing Removal โข Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Handlebar Holders (see Handlebar Removal) Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] and Washer โข Remove: Front Forks (see Front Fork Removal in the Suspension chapter) Brake Hose Fitting Bolt [A] โข Remove the bolt [A]. โข Free the lead [B], throttle cables [C] and brake hose [D] from the guide [E]. โข Remove: Bolts [A] Guide [B] Steering Stem Head โข Bend the claws [A] of claw washer straighten. โข Remove the steering stem locknut [B]. Special Tool – Steering Stem Nut Wrench: 57001-1100 โข Remove the claw washer. STEERING 14-7 Steering Stem โข Pushing up the stem base, and remove the steering stem nut [A]. Special Tool – Steering Stem Nut Wrench [B]: 57001-1100 โข Remove: Steering Stem Stem Cap [C] Upper Ball Bearing Inner Race and Ball Bearing โข To remove the ball bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE โIf either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones. โข Remove the lower ball bearing from the steering stem. โข Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation โข Replace the bearing outer races with new ones. โข Drive them into the head pipe at the same time. Special Tools – Head Pipe Outer Race Press Shaft [A]: 57001-1075 Head Pipe Outer Race Driver, 54.5: 57001 -1077 Head Pipe Outer Race Driver, 55 [B]: 57001 -1446 โข Apply grease to the outer races. โข Replace the bearing inner races and oil seal with new ones. โข Apply grease to the oil seal. โขInstall the oil seal [A] on the steering stem. โข Apply grease to the stem and hammer the lower ball bearing inner race [B]. Special Tools – Steering Stem Bearing Driver, 42.5 [C]: 57001-1344 Steering Stem Bearing Driver Adapter, 41.5 [D]: 57001-1345 14-8 STEERING Steering Stem โข Apply grease to the lower ball bearing [A], and install it onto the steering stem. โThe lower and upper ball bearings are identical. โข Apply grease to the upper ball bearing [B] and inner race [C]. โขInstall the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it. โขInstall: Stem Cap [D] Steering Stem Nut [E] โข Settle the bearings in place as follows. โTighten the steering stem nut with 65 Nยทm (6.6 kgfยทm, 48 ftยทlb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [A]. Special Tool – Steering Stem Nut Wrench: 57001-1100 Torque – Steering Stem Nut: 30 Nยทm (3.1 kgfยทm, 22 ftยทlb) โขInstall the claw washer [A] so that its bent claws [B] faces upward, and engage the bent claws with the grooves of steering stem locknut [C]. โข Hand tighten the steering stem locknut until it contacts against the claw washer. โข Check if the straight claws [D] of the claw washer aligned with the grooves of the steering stem nut [E]. In case of the claws positioned between the grooves: โข Tighten the steering stem locknut [A] until the straight claws aligned with 3rd grooves [B] of the steering stem nut [C]. โCount the number of groove from the first aligned groove [D] as shown. โข Bend the two straight claws downward into the groove of the steering stem nut. STEERING 14-9 Steering Stem In case of the claws aligned with the grooves: โข Tighten the steering stem locknut [A] until the straight claws aligned with 3rd grooves [B] of the steering stem nut [C]. โCount the number of groove from the next aligned groove [D] as shown. โข Bend the two straight claws downward into the groove of the steering stem nut. โขInstall the stem head. โขInstall the washer, and temporary tighten the steering stem head bolt. โขInstall the front forks (see Front Fork Installation in the Suspension chapter). NOTE โTighten the upper front fork clamp bolts first, next the stem head bolt, last the lower front fork clamp bolts. โTighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. Torque – Upper Front Fork Clamp Bolts: 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) Steering Stem Head Bolt: 110 Nยทm (11.2 kgfยทm, 81.1 ftยทlb) Lower Front Fork Clamp Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) WARNING If the handlebars do not turn to the steering stop, they may cause an accident resulting in injury or death. Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). Steering Stem Bearing Lubrication โข Refer to the Steering Stem Bearing Lubrication in the Periodic Maintenance chapter. Steering Stem Warp Inspection โข Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem. 14-10 STEERING Steering Stem Stem Cap Deterioration, Damage Inspection Replace the stem cap if its oil seal [A] shows damage. STEERING 14-11 Handlebar Handlebar Removal โข Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] Left Handlebar Grip [E] โข Remove: Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter) Right Switch Housing [B] Throttle Case [C] Handlebar Weight [D] Throttle Grip [E] โข Remove: Handlebar Bolt [A] Handlebar โข Loosen the handlebar holder clamp bolt [A]. โข Remove: Handlebar Holder Positioning Bolt [B] Handlebar Holder [C] Handlebar Installation โขInstall the handlebar holder [A] on the steering stem head. โข Apply a non-permanent locking agent to the threads of the handlebar holder positioning bolt [B]. โข Tighten: Torque – Handlebar Holder Positioning Bolt: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) Handlebar Holder Clamp Bolt [C]: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) 14-12 STEERING Handlebar โข Fit the pin [A] of the handlebar to the recess [B] of the handlebar holder. โข Apply a non-permanent locking agent to the threads of the handlebar bolt. โข Tighten: Torque – Handlebar Bolt: 35 Nยทm (3.6 kgfยทm, 26 ftยทlb) โข Using a high flash-point solvent, clean off any oil or dirt that may be on the adhesive coating area. Dry them with a clean cloth. โข Apply adhesive to the inside of the left handlebar grip. โขInstall the left handlebar grip, throttle grip and left/right handlebar weight. โWipe off any protruding abhesive cement. โข Apply a non-permanent locking agent to the threads of the handlebar weight screws, and tighten them. โขInstall the throttle cable tips [A]. โขInstall the throttle case. โFit the projection [B] into a hole [C] in the handlebar. โข Tighten: Torque – Throttle Case Bolts: 3.5 Nยทm (0.36 kgfยทm, 31 inยทlb) โขInstall the left and right switch housings. โFit the projection [A] into a hole [B] in the handlebar. โข Tighten: Torque – Switch Housing Screws: 3.5 Nยทm (0.36 kgfยทm, 31 inยทlb) โขInstall: Clutch Lever Assembly (see Clutch Lever Assembly Installation in the Clutch chapter) Front Master Cylinder (see Front Master Cylinder Installation in the Brakes chapter) โข Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). FRAME 15-1 15 Frame Table of Contents Exploded View. 15-2 Seats . 15-10 Rear Seat Removal 15-10 Rear Seat Installation. 15-10 Front Seat Removal. 15-10 Front Seat Installation 15-10 Fairings 15-11 Middle Fairing Removal . 15-11 Middle Fairing Installation 15-12 Lower Fairing Removal 15-13 Lower Fairing Installation. 15-14 Lower Fairing Disassembly 15-15 Lower Fairing Assembly. 15-16 Rear Lower Fairing Removal . 15-16 Rear Lower Fairing Installation 15-16 Windshield Removal 15-17 Windshield Installation . 15-17 Upper Fairing Removal 15-17 Upper Fairing Installation. 15-17 Upper Fairing Disassembly 15-18 Upper Fairing Assembly. 15-18 Windshield Bracket Disassembly. 15-18 Windshield Bracket Assembly 15-19 Windshield Bracket Assembly Removal 15-21 Windshield Bracket Assembly Installation. 15-21 Covers . 15-22 Side Cover Removal 15-22 Side Cover Installation. 15-22 Left Lower Side Fairing Removal. 15-22 Left Lower Side Fairing Installation. 15-22 Seat Cover Removal 15-23 Seat Cover Installation. 15-23 Meter Cover Removal 15-23 Meter Cover Installation 15-24 Fenders . 15-26 Front Fender Removal. 15-26 Front Fender Installation 15-26 Flap and Rear Fender Removal. 15-26 Flap and Rear Fender Installation 15-27 Frame 15-29 Frame Inspection . 15-29 Rear Frame Removal. 15-29 Rear Frame Installation 15-29 Rear Frame Bracket Removal . 15-29 Rear Frame Bracket Installation 15-29 Battery Case 15-30 Battery Case Removal. 15-30 Battery Case Installation 15-30 Guard. 15-31 Mud Guard Removal 15-31 Mud Guard Installation. 15-31 Side Stand. 15-32 Side Stand Removal 15-32 Side Stand Installation . 15-32 15-2 FRAME Exploded View FRAME 15-3 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Windshield Bracket Cover Bolts 0.50 0.05 4.4 inยทlb 2 Lower Fairing Bolts (Front) 0.50 0.05 4.4 inยทlb 3 Meter Cover Bolt (L = 16 mm) 3.0 0.31 27 inยทlb 4 Meter Cover Bolts (L = 20 mm) 0.50 0.05 4.4 inยทlb 5 Socket Cover Screw 1.2 0.12 11 inยทlb 6 Windshield Bolts 0.40 0.04 3.5 inยทlb 7 Stay Assembly Mounting Bolts 6.9 0.70 61 inยทlb 8 Stopper Mounting Bolts 4.2 0.43 37 inยทlb 9 Upper Fairing Bolts 0.50 0.05 4.4 inยทlb 10 Windshield Bracket Assembly Mounting Bolts 25 2.5 18 11 Front Fender Mounting Bolts 4.0 0.41 35 inยทlb 12 Left Lower Side Fairing Mounting Bolts 3.0 0.31 27 inยทlb 13. Other than PH and TH models G. Apply grease. L: Apply a non-permanent locking agent. 15-4 FRAME Exploded View FRAME 15-5 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Middle Fairing Bolt 0.50 0.05 4.4 inยทlb 2 Lower Fairing Bolts (Rear) 3.0 0.31 27 inยทlb 3 Lower Fairing Assembly Screws 1.2 0.12 11 inยทlb 15-6 FRAME Exploded View FRAME 15-7 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Side Cover Bolts (Front) 0.50 0.05 4.4 inยทlb 2 Side Cover Bolts (Rear) 3.0 0.31 27 inยทlb 3 Rear Frame Bracket Bolts 45 4.6 33 4 Front Footpeg Bracket Bolts 25 2.5 18 5 Front Footpeg Sub Bracket Bolts 25 2.5 18 6 Step Mounting Screws 3.0 0.31 27 inยทlb L 7 Side Stand Switch Bolt 9.0 0.92 80 inยทlb L 8 Side Stand Bracket Bolts 50 5.1 37 L 9 Side Stand Bolt 30 3.1 22 S 10 Side Stand Nut 45 4.6 33 R, S 11 Rear Footpeg Bracket Bolts 25 2.5 18 12 Rear Frame Bolts 25 2.5 18 L G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. 15-8 FRAME Exploded View FRAME 15-9 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Seat Cover Bolts 0.50 0.05 4.4 inยทlb 2 Battery Case Bolts (Front) 4.0 0.41 35 inยทlb 3 Battery Case Bolts (Rear) 1.0 0.10 8.9 inยทlb 4 Connector Bracket Screw 1.2 0.12 11 inยทlb 5 Grab Rail Mounting Bolts (L = 20 mm) 25 2.5 18 6 Flap Mounting Screws 1.2 0.12 11 inยทlb 7 Grab Rail Mounting Bolts (L = 60 mm) 25 2.5 18 8 Mud Guard Bolts 4.0 0.41 35 inยทlb L 9 Chain Cover Bolts 4.0 0.41 35 inยทlb L 10 Flap Screws 1.2 0.12 11 inยทlb 11 License Plate Bracket Mounting Bolts 4.0 0.41 35 inยทlb 12 Reflector Nut 3.0 0.31 27 inยทlb 13. US, CA, and CAL Models L: Apply a non-permanent locking agent. 15-10 FRAME Seats Rear Seat Removal โขInsert the ignition switch key [A] into the seat lock. โข Pull up the front part of the seat [B] while turning the key clockwise, and remove it forward. Rear Seat Installation โขInsert the rear seat hook [A] under the rear frame [B]. โขInsert the seat hook [C] into the latch hole [D]. โข Push down the front part of the seat until the lock clicks. Front Seat Removal โข Remove: Rear Seat (see Rear Seat Removal) Bolts [A] โข Remove the front seat [B] by pulling the rear of it up and backward. Front Seat Installation โขInsert the front seat hooks [A] under the fuel tank bracket [B]. โข Tighten the bolts. FRAME 15-11 Fairings Middle Fairing Removal Projections [A] Tab [B] Hooks [C] โข Remove: Middle Fairing Bolt [A] Quick Rivet [B] 15-12 FRAME Fairings โข Clear the projections [A] of the middle fairing [B] from the grommets. โข Pull the middle fairing forward to clear the hooks [C] from the upper fairing. โข Remove the middle fairing. Middle Fairing Installation โข Check that the grommets [A] and damper [B] are in place. โขInsert the hooks [A] of the middle fairing into the holes [B]. โข Slide the middle fairing rearward to fit the hooks [C]. โขInsert the projections [A] of the middle fairing into the grommets [B]. โขInsert the meter cover [A] between middle fairing [B] and tab [C]. โขInstall the quick rivet [D]. โข Tighten: Torque – Middle Fairing Bolt [E]: 0.50 Nยทm (0.05 kgfยทm, 4.4 inยทlb) FRAME 15-13 Fairings Lower Fairing Removal โข Remove: Middle Fairing (see Middle Fairing Removal) Side Cover (see Side Cover Removal) Rear Lower Fairing (see Rear Lower Fairing Removal) Quick Rivets [A] โข Remove: Quick Rivets [A] (Both Sides) โข Remove the bolts [A]. Left Side [B] Right Side [C] โข Disconnect: Turn Signal Light Lead Connector [A] Outside Temperature Sensor Connector [B] (Left Side only) โข Remove the turn signal light lead connector from lower fairing [C]. โข Remove: Lower Fairing Bolts (Front) [D] Lower Fairing Bolt (Rear) [E] 15-14 FRAME Fairings โข Pulling out the lower fairing [A] to clear the projection [B]. โข Remove the hook [C] from the frame. โข Pull the lower fairing rearward to clear the hooks [D]. โข Remove the lower fairing. Lower Fairing Installation โขInstallation is the reverse of removal. โข Check that the following parts are in place on the lower fairing. Pads [A] Dampers [B] Grommets [C] Left Side [D] Right Side [E] โขInsert the hooks [A] of the lower fairing into the hooks [B] of the upper fairing. FRAME 15-15 Fairings โข Hang the hook [A] to the frame. โขInsert the projection into the grommet. โข Tighten: Torque – Lower Fairing Bolts (Front): 0.50 Nยทm (0.05 kgfยทm, 4.4 inยทlb) Lower Fairing Bolt (Rear): 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) โขInstall the removed parts (see appropriate chapters). Lower Fairing Disassembly โข Remove: Lower Fairing (see Lower Fairing Removal) Lower Fairing Assembly Screws [A] Lower Fairing Lower [B] โข Remove: Quick Rivet [A] Lower Fairing Assembly Screws [B] Inner Fairing [C] โข Remove: Front Turn Signal Light Mounting Screws [A] Front Turn Signal Light [B] โข Remove: Lower Fairing Assembly Screws [A] Slat Fairing [B] Lower Fairing Upper [C] โClear the hooks [D] of the slot fairing from the lower fairing upper. 15-16 FRAME Fairings Lower Fairing Assembly โข Assembly is the reverse of disassembly. โขInsert the hooks [A] into the slots [B]. โข Hang the hook [C] to the hook [D]. โข Tighten: Torque – Lower Fairing Assembly Screws: 1.2 Nยทm (0.12 kgfยทm, 11 inยทlb) โขInsert the inner fairing [A] washer the tab [B] of slot fairing. โข Tighten: Torque – Lower Fairing Assembly Screws: 1.2 Nยทm (0.12 kgfยทm, 11 inยทlb) โขInsert the tab [A] into the slot [B]. โข Tighten: Torque – Lower Fairing Assembly Screws: 1.2 Nยทm (0.12 kgfยทm, 11 inยทlb) Rear Lower Fairing Removal โข Remove the bolt [A]. โข Pull the rear lower fairing [B] outward to clear the projection [C]. โข Pull the rear lower fairing downward to clear the projection [D]. Rear Lower Fairing Installation โข Check that the grommets [A] are in place. โขInsert the projections [B] into the grommets. โข Tighten the bolt. FRAME 15-17 Fairings Windshield Removal โข Remove: Windshield Bolts [A] with Washers Windshield [B] Windshield Installation โขInstallation is the reverse of removal. โข Tighten: Torque – Windshield Bolts: 0.40 Nยทm (0.04 kgfยทm, 3.5 inยทlb) Upper Fairing Removal โข Remove: Lower Fairing (see Lower Fairing Removal) Meter Cover (see Meter Cover Removal) โข Disconnect the headlight lead connector [A]. โข Open the clamps [B], free the main harness [C] and headlight lead [D]. โข Remove: Nuts [A] (Both Sides) Rear View Mirror [B] (Both Sides) Upper Fairing Bolt [C] (Both Sides) โข Remove: Bolts [A] and Nuts โข Remove the upper fairing [B] with the headlight. Upper Fairing Installation โขInstallation is the reverse of removal. โข Run the leads and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). 15-18 FRAME Fairings Upper Fairing Disassembly โข Remove: Upper Fairing (see Upper Fairing Removal) Quick Rivets [A] Headlight Screws [B] Clamp [C] Headlight [D] Upper Fairing [E] Upper Inner Fairing [F] Upper Fairing Assembly โข Assembly is the reverse of disassembly. โข Check that the damper [A] is in place on the upper fairing. โขInsert the tabs [A] of the upper inner fairing into the inside of the upper fairing. โขInsert the tabs [B] of the upper fairing into the inside of the upper inner fairing. โข Tighten: Torque – Headlight Screws: 1.2 Nยทm (0.12 kgfยทm, 11 inยทlb) Windshield Bracket Disassembly โข Remove: Upper Fairing (see Upper Fairing Removal) Springs [A] with Dampers [B] โข Remove: Stay Assembly Mounting Bolt [A] and Collars (Both Sides) Stay Assembly [B] Adjust Knob Assembly Bolt [C], Collar, Damper and Washers (Both Sides) Adjust Knob Assembly [D] FRAME 15-19 Fairings โข Remove: Bolts [A] Adjust Knob [B] Adjust Knob Bracket [C] โข Remove: Stopper Mounting Bolts [A] Stay Shaft Bolts [B] Stay Shaft [C] Stoppers [D] Stays [E] Windshield Bracket Assembly โข Confirm that the upper fairing bracket has been firmly installed by the windshield bracket assembly mounting bolts [A]. โข Assemble the adjust knob assembly as shown. Adjust Knob Bracket [A] Adjust Knob [B] Bolts [C] โข Apply a non-permanent locking agent to the threads of the stay shaft bolts [A]. โข Assemble the stay assembly as shown. Stays [B] Stoppers [C] Stay Shaft [D] Stay Shaft Bolts Stopper Mounting Bolts [E] โDo not tighten firmly the stopper mounting bolts at this time. 15-20 FRAME Fairings โข Apply grease to the dampers [A] and washers [B]. โข Apply a non-permanent locking agent to the threads of the adjust knob assembly bolts [C]. โขInstall: Adjust Knob Assembly [D] Washers Dampers Collars [E] โข Tighten the adjust knob assembly bolts. โขInstall the stay assembly [A]. โFit the pin [B] of the adjust knob assembly into the groove [C] of the stopper (Both Sides). โขInstall: Stay Assembly Mounting Bolts [A] and Collars โข Tighten the following bolts while the pins fit in the stoppers. Torque – Stay Assembly Mounting Bolts: 6.9 Nยทm (0.70 kgfยทm, 61 inยทlb) Stopper Mounting Bolts [B]: 4.2 Nยทm (0.43 kgfยทm, 37 inยทlb) โขInstall: Springs [A] with Dampers โข Confirm that the position of the windshield stoppers [B] change smoothly and surely (Both Sides). โPush the adjust knob [C] and change the positions of the windshield stoppers. If the windshield stoppers do not move smoothly reassemble the windshield bracket. FRAME 15-21 Fairings Windshield Bracket Assembly Removal โข Remove: Upper Fairing (see Upper Fairing Assembly Removal) Canister (see Evaporative Emission Control System Inspection in the Periodic Maintenance chapter) โข Open the clamps [A]. โข Remove the front wheel rotation sensor lead connector [B] from the wind shield bracket assembly. โข Disconnect: Horn Lead Connectors [C] โข Remove: IMU [A] (see IMU Removal in the Fuel System chapter) Turn Signal Relay [B] โข Open the clamp [C]. โข Remove: Windshield Bracket Assembly Bolts [A] Windshield Bracket Assembly [B] Windshield Bracket Assembly Installation โขInstallation is the reverse of removal. Torque – Windshield Bracket Assembly Mounting Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โข Run the leads and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). 15-22 FRAME Covers Side Cover Removal โข Remove: Middle Fairing (see Middle Fairing Removal) Side Cover Bolt (Front) [A] with Washer Side Cover Bolt (Rear) [B] with Washer โข Pull the side cover [C] outward to clear the projections [D]. Side Cover Installation โข Check that the pads [A] are in place on the side cover [B]. โขInsert the projections [A] into the grommets [B] and hole [C]. โข Tighten the bolts with washers. Torque – Side Cover Bolt (Front): 0.50 Nยทm (0.05 kgfยทm, 4.4 inยทlb) Side Cover Bolt (Rear): 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) Left Lower Side Fairing Removal โข Remove: Left Lower Fairing (see Lower Fairing Removal) Bolts [A] with Washers Left Lower Side Fairing [B] Left Lower Side Fairing Installation โขInstallation is the reverse of removal. โข Be sure to install the damper [A]. FRAME 15-23 Covers Seat Cover Removal โข Remove: Seats (see Rear/Front Seat Removal) Grab Rail Mounting Bolt (L = 60 mm) [A] and Washer (Both Sides) โข Remove: Grab Rail Mounting Bolt (L = 20 mm) [A] (Both Sides) Grab Rail [B] (Both Sides) โข Remove: Bolts [A] with Washers โข Pull the seat cover [B] rearward to clear the hooks [C]. Seat Cover Installation โขInstallation is the reverse of removal. โขInsert the hooks [A] into the slots [B] and damper [C] on both sides. โข Tighten: Torque – Grab Rail Mounting Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) Meter Cover Removal โข Remove: Middle Fairing (see Middle Fairing Removal in the Frame chapter) Windshield (see Windshield Removal) Windshield Bracket Cover Bolts [A] with Washers 15-24 FRAME Covers โข Remove: Windshield Bracket Cover Bolts [A] with Washers Quick Rivets [B] โข Pull the windshield bracket cover [C] downward to clear the hook [D] from the upper fairing. โข Slide the dust cover [A]. โข Disconnect the meter connector [B]. โข Remove: Meter Cover Bolt (L = 16 mm) [C] โข Remove: Meter Cover Bolt (L = 20 mm) [A] (Both Sides) โข Pull the meter cover [B] rearward to clear the hooks [C] of the upper fairing on both sides. Meter Cover Installation โขInstallation id the reverse of removal. โขInsert the meter cover [A] between upper fairing [B] and hooks [C]. โข Tighten: Torque – Meter Cover Bolts (L = 20 mm): 0.50 Nยทm (0.05 kgfยทm, 4.4 inยทlb) Meter Cover Bolt (L = 16 mm): 3.0 Nยทm (0.31 kgfยทm, 27 inยทlb) โข Hang the hook [A] of windshield bracket cover to tab [B] of the upper fairing. FRAME 15-25 Covers โขInsert the tabs [A] into the inside of meter cover [B]. โข Tighten: Torque – Windshield Bracket Cover Bolts: 0.50 Nยทm (0.05 kgfยทm, 4.4 inยทlb) 15-26 FRAME Fenders Front Fender Removal โข Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) โข Clear the brake hoses and front wheel rotation sensor lead from the clamps [A]. โข Remove: Reflector [B] with Washer (Both Sides, other than PH and TH models) Front Fender Mounting Bolts [C] with Washers (Both Sides) Front Fender [D] Front Fender Installation โขInstallation is the reverse of removal. โข Tighten: Torque – Front Fender Mounting Bolts: 4.0 Nยทm (0.41 kgfยทm, 35 inยทlb) โข Run the brake hoses and front wheel rotation sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Flap and Rear Fender Removal โข Remove: Seats (see Front/Rear Seat Removal) Seat Cover (see Seat Cover Removal) Ownerโs Tool Rear Fender Mounting Bolts [A] โข Remove: Battery Case Bolts (Rear) [A] Bracket [B] โข Pull the rear fender [A] outward to clear the projections [B]. FRAME 15-27 Fenders โข Push the rear fender [A] downward. โข Remove: ECU [B] with Relay Box [C] โข Disconnect: License Plate Light Lead Connector [D] Turn Signal Light Lead Connectors [E] โข Free the leads from the clamps [A]. โข Disconnect: Tail/Brake Light Lead Connector [B] โข Remove: Flap Mounting Screws [C] Flap [D] Rear Fender [E] Flap and Rear Fender Installation โขInstallation is the reverse of removal. โข When installing the pads [A], install them as shown. [B] 3 mm (0.12 in.) [C] Align the edge of the pad with the lines of the rear fender. [D] View A [E] View B 15-28 FRAME Fenders โข Run the cables, leads, harness and hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Apply a non-permanent locking agent to the threads of the rear fender mounting bolts [A], and tighten them securely. FRAME 15-29 Frame Frame Inspection โข Visually inspect the frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it. Rear Frame Removal โข Remove: Rear Fender (see Flap and Rear Fender Removal) Rear Frame Bolts [A] (Both Sides) Rear Frame [B] Rear Frame Installation โข Apply a non-permanent locking agent to the threads of the rear frame bolts. โข Tighten: Torque – Rear Frame Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โขInstall the removed parts (see appropriate chapters). Rear Frame Bracket Removal โข Remove: Side Covers (see Side Cover Removal) Battery Case (see Battery Case Removal) Rear Frame (see Rear Frame Removal) Bolts [A] Clamp [B] (Left Side only) โข Remove: Rear Footpeg Bracket Bolts [A] (Both Sides) Rear Frame Bracket Bolts [B] (Both Sides) Rear Frame Brackets [C] Rear Frame Bracket Installation โข Tighten: Torque – Rear Frame Bracket Bolts: 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) Rear Footpeg Bracket Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) โขInstall the removed parts (see appropriate chapters). 15-30 FRAME Battery Case Battery Case Removal โข Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Bolts [A] Bracket [B] Fuel Tank Bracket [C] โข Remove: Screw Rivets [A] Clamp [B] โข Disconnect: Vehicle-down Sensor Lead Connector [A] โข Cut the bands [B]. โข Remove: Fuse Box (1) [C] Fuse Box (2) [D] Starter Relay [E] Battery Case Bolts (Front) [F] Battery Case Bolts (Rear) [G] Connector Bracket Screw [H] Brackets Battery Case [I] Battery Case Installation โขInstallation is the reverse of removal. โข Run the cables, leads, harness and hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Tighten: Torque – Connector Bracket Screw: 1.2 Nยทm (0.12 kgfยทm, 11 inยทlb) Battery Case Bolts (Front): 4.0 Nยทm (0.41 kgfยทm, 3.5 inยทlb) Battery Case Bolts (Rear): 1.0 Nยทm (0.10 kgfยทm, 8.9 inยทlb) โขInstall the removed parts (see appropriate chapters). FRAME 15-31 Guard Mud Guard Removal โข Remove: Muffler Bodies (see Muffler Body Removal in the Engine Top End chapter) Mud Guard Mounting Bolts [A] โข Remove: Right Front Footpeg Bracket Bolts [A] โข Remove: Quick Rivets [A] Mud Guard Mounting Bolt [B] Bracket [C] Mud Guard [D] Mud Guard Installation โขInstallation is the reverse of removal. โข Apply a non-permanent locking agent to the threads of the mud guard mounting bolts, and tighten them securely. โข Tighten: Torque – Front Footpeg Bracket Bolts: 25 Nยทm (2.5 kgfยทm, 18 ftยทlb) 15-32 FRAME Side Stand Side Stand Removal โข Raise the rear wheel off the ground with a stand. โข Remove: Side Stand Switch Bolt [A] Side Stand Switch [B] โข Remove: Spring [A] Side Stand Nut [B] Side Stand Bolt [C] Collar Side Stand [D] Side Stand Installation โข Apply grease to the sliding area [A] of the side stand [B]. โข Replace the side stand nut [C] with a new one. โขInstall: Side Stand Collar [D] โข Tighten the side stand bolt [E] first, and then the side stand nut. Torque – Side Stand Bolt: 30 Nยทm (3.1 kgfยทm, 22 ftยทlb) Side Stand Nut: 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) โข Hook the spring [F] so that the long spring end faces upward. โInstall the spring hook direction as shown. โขInstall the side stand switch. โข Apply a non-permanent locking agent to the thread of the side stand switch bolt, and tighten it. Torque – Side Stand Switch Bolt: 9.0 Nยทm (0.92 kgfยทm, 80 inยทlb) ELECTRICAL SYSTEM 16-1 16 Electrical System Table of Contents Exploded View 16-4 Specifications . 16-10 Special Tools and Sealant 16-11 Parts Location. 16-13 Wiring Diagram (US, CA and CAL Models) 16-16 Wiring Diagram (Other than US, CA and CAL Models) 16-18 Precautions. 16-20 Electrical Wiring 16-21 Wiring Inspection 16-21 Battery 16-22 Battery Removal . 16-22 Battery Installation 16-22 Battery Activation 16-22 Precautions. 16-25 Interchange. 16-26 Charging Condition Inspection 16-26 Refreshing Charge 16-26 Charging System 16-28 Alternator Cover Removal. 16-28 Alternator Cover Installation 16-28 Stator Coil Removal 16-28 Stator Coil Installation. 16-29 Alternator Rotor Removal . 16-29 Alternator Rotor Installation 16-30 Charging Voltage Inspection. 16-32 Alternator Inspection. 16-32 Regulator/Rectifier Removal. 16-34 Regulator/Rectifier Installation 16-34 Regulator/Rectifier Inspection. 16-34 Ignition System. 16-37 Crankshaft Sensor Removal. 16-37 Crankshaft Sensor Installation 16-38 Crankshaft Sensor Inspection. 16-39 Crankshaft Sensor Peak Voltage Inspection. 16-40 Timing Rotor Removal 16-40 Timing Rotor Installation . 16-40 Stick Coil Removal 16-41 Stick Coil Installation. 16-41 Stick Coil Inspection 16-41 Stick Coil Primary Peak Voltage Inspection 16-41 Spark Plug Removal . 16-42 Spark Plug Installation 16-42 Spark Plug Condition Inspection. 16-43 Interlock Operation Inspection 16-43 IC Igniter Inspection 16-44 Electric Starter System. 16-47 Starter Motor Removal 16-47 Starter Motor Installation. 16-47 Starter Motor Disassembly 16-47 Starter Motor Assembly 16-48 16-2 ELECTRICAL SYSTEM Brush Inspection . 16-50 Commutator Cleaning and Inspection. 16-50 Armature Inspection 16-51 Brush Lead Inspection 16-51 Right-hand End Cover Inspection. 16-51 Starter Relay Inspection 16-51 Lighting System 16-54 Headlight Beam Horizontal Adjustment 16-54 Headlight Beam Vertical Adjustment. 16-54 Headlight (LED) Assembly Removal/Installation 16-54 Headlight Harness Circuit Inspection 16-54 City Light Input Voltage Inspection 16-55 Headlight Lo Beam Input Voltage Inspection 16-55 City Light (LED) Removal/Installation . 16-55 Tail/Brake Light (LED) Removal 16-56 Tail/Brake Light (LED) Installation. 16-56 License Plate Light Bulb Replacement . 16-56 Turn Signal Light Bulb Replacement 16-58 Turn Signal Relay Inspection 16-59 Air Switching Valve. 16-62 Air Switching Valve Operation Test . 16-62 Air Switching Valve Unit Test 16-62 Radiator Fan System 16-64 Fan Motor Inspection 16-64 Meter, Gauge, Indicator Unit. 16-66 Meter Unit Removal 16-66 Meter Unit Installation . 16-66 Meter Unit Disassembly/Assembly . 16-66 Meter Operation Inspection. 16-66 Meter System Inspection 16-70 Meter Unit Inspection 16-71 Fuel Level Sensor Line Self-Diagnosis Mode Inspection 16-79 Immobilizer System (Equipped Models). 16-81 Operational Cautions 16-81 Key Registration 16-81 Immobilizer System Parts Replacement. 16-99 Immobilizer System Inspection . 16-101 Immobilizer System Circuit . 16-102 Switches and Sensors 16-103 Brake Light Timing Inspection. 16-103 Brake Light Timing Adjustment . 16-103 Switch Inspection 16-103 Water Temperature Sensor Inspection . 16-104 Oxygen Sensor Removal 16-104 Oxygen Sensor Installation. 16-105 Oxygen Sensor Inspection 16-105 Fuel Level Sensor Inspection 16-105 Gear Position Sensor Removal. 16-105 Gear Position Sensor Installation 16-106 Gear Position Sensor Inspection 16-106 Outside Temperature Sensor Removal. 16-106 Outside Temperature Sensor Installation 16-107 Relay Box . 16-108 Relay Box Removal/Installation 16-108 Relay Circuit Inspection 16-108 Diode Circuit Inspection 16-109 Fuse 16-111 ELECTRICAL SYSTEM 16-3 30 A Main/15 A ECU Fuse Removal. 16-111 Fuse Box Fuse Removal. 16-111 Fuse Installation 16-111 Fuse Inspection. 16-111 16-4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16-5 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Headlight Screws 1.2 0.12 11 inยทlb 2 Meter Unit Mounting Screws 1.2 0.12 11 inยทlb 3 Tail/Brake Light Mounting Bolts 0.50 0.05 4.4 inยทlb 4 Front Turn Signal Light Screws 1.2 0.12 11 inยทlb 5 License Plate Light Mounting Screws 1.2 0.12 11 inยทlb 6 Turn Signal Light Lens Screw 1.0 0.10 8.9 inยทlb 7 Rear Turn Signal Light Mounting Screws 1.2 0.12 11 inยทlb 16-6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16-7 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Left Switch Housing Screws 3.5 0.36 31 inยทlb 2 Right Switch Housing Screws 3.5 0.36 31 inยทlb 3 Front Brake Light Switch Screw 1.2 0.12 11 inยทlb 4 Oil Pressure Switch 15 1.5 11 LG 5 Oil Pressure Switch Terminal Bolt 2.0 0.20 18 inยทlb G 6 Gear Position Sensor Bolt 10 1.0 89 inยทlb L 7 Regulator/Rectifier Bolts 9.8 1.0 87 inยทlb 8 Timing Rotor Bolt 39 4.0 29 9 Alternator Cover Bolts 12 1.2 106 inยทlb 10 Alternator Lead Holding Plate Bolt 12 1.2 106 inยทlb L 11 Stator Coil Bolts 12 1.2 106 inยทlb L 12 Alternator Rotor Bolt 155 15.8 114 13 Starter Motor Clutch Bolts 12 1.2 106 inยทlb L 14 Starter Motor Mounting Bolts 10 1.0 89 inยทlb 15 Starter Motor Cable Terminal Nut 6.0 0.61 53 inยทlb 16 Starter Motor Terminal Locknut 11 1.1 97 inยทlb 17 Brush Holder Screw 3.8 0.39 34 inยทlb 18 Starter Motor Through Bolts 5.0 0.51 44 inยทlb 19 Starter Relay Terminal Bolts 5.1 0.52 45 inยทlb 20 Crankshaft Sensor Bolts 6.0 0.61 53 inยทlb 21 Crankshaft Sensor Cover Bolts 12 1.2 106 inยทlb L (1) 22. Immobilizer System Equipped Models G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. M: Apply molybdenum disulfide grease. R: Replacement Parts 16-8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16-9 Exploded View Torque No. Fastener Nยทm kgfยทm ftยทlb Remarks 1 Water Temperature Sensor 12 1.2 106 inยทlb 2 Oxygen Sensor 45 4.6 33 3 Engine Ground Cable Terminal Bolt 10 1.0 89 inยทlb 4 ECU Guard Bolts 4.0 0.41 35 inยทlb L, R 5 ECU Guard Bracket Screw 1.2 0.12 11 inยทlb 6. EUR Model G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts 16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX9-BS Capacity 12 V 8 Ah (10 HR) Voltage 12.8 V or more Gross Weight 2.9 kg (6.4 lb) Electrolyte Volume 0.40 L (24 cu in.) Charging System Type Three-phase AC Charging Voltage (Regulator/Rectifier Output Voltage) DC 14.3 ๏พ 14.7 V @25ยฐC (77ยฐF) Alternator Output Voltage AC 42 V or more @4 000 r/min (rpm) Stator Coil Resistance 0.18 ๏พ 0.27 โฆ @20ยฐC (68ยฐF) Ignition System Spark Plug: Type NGK CR9EIA-9 Gap 0.8 ๏พ 0.9 mm (0.031 ๏พ 0.035 in.) Stick Coil: Primary Winding Resistance 1.1 ๏พ 1.5 โฆ @20ยฐC (68ยฐF) Secondary Winding Resistance 6.4 ๏พ 9.6 kโฆ @20ยฐC (68ยฐF) Primary Peak Voltage 100 V or more Crankshaft Sensor: Resistance 376 ๏พ 564 โฆ @20ยฐC (68ยฐF) Peak Voltage 2.0 V or more Electric Starter System Starter Motor: Brush Length 12 mm (0.47 in.) [Service Limit: 6.5 mm (0.26 in.)] Air Switching Valve Resistance 20 ๏พ 24 โฆ @20ยฐC (68ยฐF) Switches and Sensors Rear Brake Light Switch Timing ON after about 10 mm (0.39 in.) pedal travel Engine Oil Pressure Switch Connections When engine is stopped: ON When engine is running: OFF Water Temperature Sensor Resistance in the text Fuel Level Sensor Resistance: Full Position 9.6 ๏พ 12.4 โฆ Empty Position 222 ๏พ 228 โฆ ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Peak Voltage Adapter: 57001-1415 Lead Wire – Peak Voltage Adapter: 57001-1449 Needle Adapter Set: 57001-1457 Key Registration Unit: 57001-1582 Grip: 57001-1591 Flywheel & Pulley Holder: 57001-1605 Flywheel Puller Assembly, M38 ร 1.5/M35 ร 1.5: 57001-1615 Stopper: 57001-1679 Rotor Holder: 57001-1690 Measuring Adapter: 57001-1700 16-12 ELECTRICAL SYSTEM Special Tools and Sealant Key Registration Adapter: 57001-1746 Rotor Holder: 57001-1757 Liquid Gasket, TB1211F: 92104-0004 ELECTRICAL SYSTEM 16-13 Parts Location Timing Rotor [A] Crankshaft Sensor [B] Oxygen Sensor [C] Turn Signal Relay [A] Regulator/Rectifier [B] Immobilizer Amplifier (Immobilizer Equipped Models) [C] Relay Box [A] ECU [B] Immobilizer/Kawasaki Diagnostic System Connector [C] Rear Brake Light Switch [A] Water Temperature Sensor [A] Radiator Fan Motor [B] Stater Motor [C] 16-14 ELECTRICAL SYSTEM Parts Location Alternator [A] Oil Pressure Switch [B] Gear Position Sensor [C] Side Stand Switch [D] Battery 12 V 8 Ah [A] Starter Relay [B] Fuse Box (1) [C] Fuse Box (2) [D] Air Switching Valve [A] Stick Coils [B] Spark Plugs [C] Starter Lockout Switch [A] Ignition Switch [B] (Immobilizer Equipped Models: Including Immobilizer Antenna) Meter Unit [C] Front Brake Light Switch [D] ELECTRICAL SYSTEM 16-15 Parts Location This page intentionally left blank. 16-16 ELECTRICAL SYSTEM Wiring Diagram (US, CA and CAL Models) ELECTRICAL SYSTEM 16-17 Wiring Diagram (US, CA and CAL Models) 16-18 ELECTRICAL SYSTEM Wiring Diagram (Other than US, CA and CAL Models) ELECTRICAL SYSTEM 16-19 Wiring Diagram (Other than US, CA and CAL Models) 16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. โDo not reverse the battery cable connections. This will burn out the diodes on the electrical parts. โAlways check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests. โThe 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. โTo 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. โBecause of the large amount of current, never keep the starter button pushed when the starter motor will not turn over, or the current may burn out the starter motor windings. โTake care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis ground. โTroubles 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. โMake sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation. โMeasure coil and winding resistance when the part is cold (at room temperature). ELECTRICAL SYSTEM 16-21 Electrical Wiring Wiring Inspection โข Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. โข 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. โข Check the wiring for continuity. โUse the wiring diagram to find the ends of the lead which is suspected of being a problem. โConnect a tester between the ends of the leads. If the tester does not read about 0 โฆ, the lead is defective. Replace the lead or the wiring harness [B] if necessary. 16-22 ELECTRICAL SYSTEM Battery Battery Removal โข Turn the ignition switch off. โข Remove: Front Seat (see Front Seat Removal in the Frame chapter) โข Disconnect the negative (โ) cable [A]. NOTICE Be sure to disconnect the negative (โ) cable first. โข Slide out the positive (+) terminal cap [B] and disconnect the positive (+) cable [C]. โข Remove the battery. Battery Installation โข Turn the ignition switch off. โข Put the battery into the battery case. โข Connect the positive (+) cable [A] first. โข Connect the negative (โ) cable [B]. โข Apply a light coat of grease on the terminals to prevent corrosion. โข Cover the positive (+) terminal with the cap [C]. โขInstall the front seat (see Front Seat Installation in the Frame chapter). Battery Activation Electrolyte Filling โข Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These names must be the same. Battery Model Name ZX1000W: YTX9-BS NOTICE Each battery comes with its own specific electrolyte container; using the wrong container may overfill the battery with incorrect electrolyte, which can shorten battery life and deteriorate battery performance. Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type. ELECTRICAL SYSTEM 16-23 Battery NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns. To prevent burns, wear protective clothing and safety glasses when handling electrolyte. If the electrolyte comes in contact with your skin or eyes, wash the area with liberal amounts of water and seek medical attention for more severe burns. โข Place the battery on a level surface. โข Check to see that the sealing sheet has no peeling, tears, or holes in it. โข Remove the sealing sheet. NOTE โThe battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge. โข Remove the electrolyte container from the vinyl bag. โข Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE โDo not pierce or otherwise open the sealed cells [B] of the electrolyte container. Do not attempt to separate individual cells. โข 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 โDo not tilt the electrolyte container. 16-24 ELECTRICAL SYSTEM Battery โข 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. NOTE โBe careful not to have the battery fall down. โข Keep the container in place. Donโt remove the container from the battery, the battery requires all the electrolyte from the container for proper operation. NOTICE Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the container until it is completely empty. โข After filling, let the battery sit for 20 ๏พ 60 minutes with the electrolyte container kept in place, which is required for the electrolyte to fully permeate into the plates. โข Make sure that the container cells have emptied completely, and remove the container from the battery. โข Place the strip of caps [A] loosely over the filler ports, press down firmly with both hands to seat the strip of caps into the battery (donโt pound or hammer). When properly installed, the strip of caps will be level with the top of the battery. NOTICE Once the strip of caps is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery. NOTE โCharging the battery immediately after filling can shorten service life. ELECTRICAL SYSTEM 16-25 Battery Initial Charge โข Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 A ร 5 ๏พ 10 hours If using a recommended battery charger, follow the chargerโs instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060 Christie C10122S If the above chargers are not available, use equivalent one. โข Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. (Voltage immediately after charging becomes temporarily high. For accurate measuring, let the battery sit for given time.) NOTE โCharging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. If voltage is not at least 12.8 V, repeat charging cycle. โTo ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test. If still below 12.8 V the battery is defective. Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge. If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see Refreshing Charge). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery. NOTICE This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the batteryโs performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap during refresh charge. If by chance an excessive amount of gas is generated due to overcharging, the relief valve releases the gas to keep the battery normal. 3) When you do not use the motorcycle for months. Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage. 4) Battery life. If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicleโs starting system has no problem). 16-26 ELECTRICAL SYSTEM Battery DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water and seek medical attention for more severe burns. Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed batteryโs life will be shortened. Charging Condition Inspection โBattery charging condition can be checked by measuring battery terminal voltage with a digital meter [A]. โข Remove: Battery (see Battery Removal) โข Measure the battery terminal voltage. NOTE โMeasure with a digital voltmeter which can be read one decimal place voltage. If the reading is 12.8 V or more, no refresh charge is required, however, if the read is below the specified, refresh charge is required. Battery Terminal Voltage Standard: 12.8 V or more Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Good [C] Refresh charge is required [D] Refreshing Charge โข Remove the battery [A] (see Battery Removal). โข Do refresh charge by following method according to the battery terminal voltage. WARNING This battery is sealed type. Never remove sealing cap [B] even at charging. Never add water. Charge with current and time as stated below. ELECTRICAL SYSTEM 16-27 Battery Terminal Voltage: 11.5 ๏พ less than 12.8 V Standard Charge: 0.9 A ร 5 ๏พ 10 h (see following chart) Quick Charge: 4Aร1h NOTICE If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal Voltage: less than 11.5 V Charging Method: 0.9 A ร 20 h NOTE โIncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery. Battery [A] Battery Charger [B] Standard Value [C] Current starts to flow [D] โข Determine the battery condition after refresh charge. โDetermine 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 ๏พ lower than 12.8 V Charge insufficient โ Recharge lower than 12.0 V Unserviceable โ Replace 16-28 ELECTRICAL SYSTEM Charging System Alternator Cover Removal โข Drain: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) โข Disconnect the alternator lead connector [A]. โข Clear the alternator lead from the clamp [B]. โข Place a suitable container under the alternator cover [A]. โข Open the clamp [B]. โข Remove: Alternator Cover Bolts [C] Bracket [D] Alternator Cover Alternator Cover Installation โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant – Liquid Gasket, TB1211F: 92104-0004 โข Check that dowel pins [B] are in place on the crankcase. โข Replace the alternator cover gasket with a new one. โข Tighten: Torque – Alternator Cover Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข Run the alternator lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). Stator Coil Removal โข Remove: Alternator Cover (see Alternator Cover Removal) Alternator Lead Holding Plate Bolt [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] โข Remove the stator coil [D] from the alternator cover. ELECTRICAL SYSTEM 16-29 Charging System Stator Coil Installation โข Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them. Torque – Stator Coil Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข Secure the alternator lead with a holding plate. โข Apply a non-permanent locking agent to the threads of the plate bolt and tighten it. Torque – Alternator Lead Holding Plate Bolt: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket to the circumference of the alternator lead grommet [A], and fit the grommet into the notch of the cover securely. Sealant – Liquid Gasket, TB1211F: 92104-0004 โขInstall the alternator cover (see Alternator Cover Installation). Alternator Rotor Removal โข Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear [A] and Shaft [B] โข Hold the alternator rotor steady with the rotor holder [A] and stopper [B]. โข Remove the rotor bolt [C] and washer. Special Tools – Grip [D]: 57001-1591 Stopper: 57001-1679 Rotor Holder: 57001-1690 If using the rotor holder (57001-1757). โข Hold the alternator rotor steady with the rotor holder [A]. โข Remove the rotor bolt [B] and washer. Special Tool – Rotor Holder: 57001-1757 16-30 ELECTRICAL SYSTEM Charging System โข Using the flywheel puller [A], remove the alternator rotor [B] from the crankshaft. Special Tool – Flywheel Puller Assembly, M38 ร 1.5/M35 ร 1.5: 57001-1615 NOTICE Do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism. Alternator Rotor Installation โข Apply a thin coat of molybdenum disulfide grease to the crankshaft [A] and the outer surface [B] of the starter clutch gear [C]. โขInstall the starter clutch gear [A]. โข Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth. Crankshaft Tapered Portion [B] Alternator Rotor Tapered Portion [C] โข Fit the woodruff key [D] securely in the slot in the crankshaft before installing the alternator rotor. โขInstall the alternator rotor [A] while turning [B] the starter clutch gear [C] clockwise. โข Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry it with a clean cloth. โขInstall the washer. NOTE โConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. โขInstall the rotor bolt [B] and tighten it with 70 Nยทm (7.0 kgfยทm, 52 ftยทlb) of torque. ELECTRICAL SYSTEM 16-31 Charging System โข Remove the rotor bolt and washer. โข Check the tightening torque with flywheel puller [A]. Special Tool – Flywheel Puller Assembly, M38 ร 1.5/M35 ร 1.5: 57001-1615 If the rotor is not pulled out with 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) of drawing torque, it is installed correctly. If the rotor is pulled out with under 20 Nยทm (2.0 kgfยทm, 15 ftยทlb) 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. โขInstall the washer and rotor bolt. โข Tighten the alternator rotor bolt [A] while holding the alternator rotor steadily with the holder [B]. Special Tools – Grip [C]: 57001-1591 Stopper [D]: 57001-1679 Rotor Holder: 57001-1690 Torque – Alternator Rotor Bolt: 155 Nยทm (15.8 kgfยทm, 114 ftยทlb) If using rotor holder (57001-1757). โขInstall the washer and rotor bolt. โข Tighten the alternator rotor bolt [A] while holding the alternator rotor steadily with the holder [B]. Special Tool – Rotor Holder: 57001-1757 Torque – Alternator Rotor Bolt: 155 Nยทm (15.8 kgfยทm, 114 ftยทlb) โข Using a thickness gauge, make sure the clearance [A] between the starter clutch gear [B] and the starter clutch race [C] is 0.4 mm (0.02 in.) or more. If the clearance is less than 0.4 mm (0.02 in.), remove the rotor and starter clutch race, and then clean them thoroughly and reinstall them. 16-32 ELECTRICAL SYSTEM Charging System โข Apply a thin coat of molybdenum disulfide grease to the shaft [A], and install it with the starter idle gear [B]. โขInstall the alternator cover (see Alternator Cover Installation). Charging Voltage Inspection โข Check the battery condition (see Charging Condition Inspection). โข Warm up the engine to obtain actual alternator operating conditions. โข Remove the front seat (see Front Seat Removal in the Frame chapter). โข Check that the ignition switch is turned off, and connect a tester [A] to the battery terminals [B]. โข Start the engine, and note the voltage readings at various engine speeds (except idling engine speed) 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 @25ยฐC (77ยฐF) Connections Tester (+) to Tester (โ) to Reading Battery (+) Battery (โ) DC 14.3 ๏พ 14.7 V โข Turn off the ignition switch to stop the engine, and disconnect the 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 16-33 Charging System โข To check the alternator output voltage, do the following procedures. โTurn the ignition switch off. โRemove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). โDisconnect the alternator lead connector [A]. โConnect a tester as shown in the table 1. โInstall the fuel tank temporary (see Fuel Tank Installation in the Fuel System (DFI) chapter). โStart the engine. โRun it at the rpm given in the table 1. โNote the voltage readings (total 3 measurements). Table 1 Alternator Output Voltage @4 000 r/min (rpm) Connections Tester (+) to Tester (โ) to Reading One Black lead Another Black lead AC 42 V or more If the output voltage shows the value in the table, the alternator operates properly. If the output voltage shows a much lower reading than that given in the table, stop the engine and inspect the stator coil resistance. โข Check the stator coil resistance as follows. โStop the engine. โConnect the tester as shown in the table 2. โNote the readings (total 3 measurement). Table 2 Stator Coil Resistance @20ยฐC (68ยฐF) Connections Tester (+) to Tester (โ) to Reading One Black lead Another Black lead 0.18 ๏พ 0.27 โฆ โข When measuring the resistance, use a tester that can measure the standard value. If there is more resistance than shown in the table, or no tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. โข Measure the resistance between each of the black leads and chassis ground. Any tester reading less than infinity (โ) 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. 16-34 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal โข Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) โข Disconnect the connector [A]. โข Remove: Regulator/Rectifier Bolts and Nuts [B] Regulator/Rectifier [C] Regulator/Rectifier Installation โขInstall the grommets [A] to the bracket [B] with its large diameter side [C] facing outward [D]. โขInsert the collars [E] into the grommets from the inside. โขInstall: Regulator/Rectifier [A] Regulator/Rectifier Bolts and Nuts [B] โInstall the regulator/rectifier bolts from inside. Torque – Regulator/Rectifier Bolts: 9.8 Nยทm (1.0 kgfยทm, 87 inยทlb) โข Connect the connector [C] to the regulatory/rectifier. Regulator/Rectifier Inspection โข Refer to the Charging System Troubleshooting for the Regulator/Rectifier Inspection. Charging System Troubleshooting โข Before inspection, remove all accessories that consume electrical power. NOTE โEven when the charging system is working properly, the battery may discharge if the motorcycle is equipped with too many accessories. โข Pay attention to riding conditions and the customerโs riding habits which could affect the charging system such as: Frequent use at low engine speed Frequent and unnecessary brake pedal dragging โ Battery Discharged โข Recharge the battery if it is discharged. ELECTRICAL SYSTEM 16-35 Charging System 16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Frame Ground (4) 4. Engine Ground 5. Battery 12 V 8 Ah 6. Starter Relay 7. Main Fuse 30 A 8. Regulator/Rectifier 9. Alternator ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plug, stick coil or stick coil lead while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent ECU damage. Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the ECU. Crankshaft Sensor Removal NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) โข Disconnect the crankshaft sensor lead connector [A]. โข Turn up the heat insulation rubber plate [B] and free the clamp. โข Clear the crankshaft sensor lead from the clamps [A]. โข Remove: Crankshaft Sensor Cover Bolts [A] Crankshaft Sensor Cover Bolts [B] (with a Dent on the Bolt Head) Crankshaft Sensor Cover [C] 16-38 ELECTRICAL SYSTEM Ignition System โข Remove: Crankshaft Sensor Bolts [A] Crankshaft Sensor [B] Crankshaft Sensor Installation โขInstall the crankshaft sensor. โWhen installing the sensor which is fastened by bolts, tighten the bolts after placing the sensor on the bottom surface completely. โข Tighten: Torque – Crankshaft Sensor Bolts: 6.0 Nยทm (0.61 kgfยทm, 53 inยทlb) โข Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. โข Apply liquid gasket [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant – Liquid Gasket, TB1211F: 92104-0004 โข Replace the O-ring [A] with a new one. ELECTRICAL SYSTEM 16-39 Ignition System โขInstall: Crankshaft Sensor Cover [A] โข Apply a non-permanent locking agent to the threads of the crankshaft sensor cover bolt [B] which has a dent on the bolt head. โข Tighten the crankshaft sensor cover bolts [B] [C]. Torque – Crankshaft Sensor Cover Bolts: 12 Nยทm (1.2 kgfยทm, 106 inยทlb) โข Run the crankshaft sensor lead and clutch cable correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). Crankshaft Sensor Inspection โข Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor Removal). โข Set a tester [A], and connect it to the crankshaft sensor lead connector [B]. Special Tool – Needle Adapter Set [C]: 57001-1457 Crankshaft Sensor Resistance Connections: Tester (+) โ Y lead Tester (โ) โ BK lead Standard: 376 ๏พ 564 โฆ @20ยฐC (68ยฐF) 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. โข Measure the resistance between the crankshaft sensor leads and chassis ground. Any tester reading less than infinity (โ) indicates a short, necessitating replacement of the crankshaft sensor. 16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE โBe sure the battery is fully charged. โUsing the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. โข Disconnect the crankshaft sensor lead connector [B] (see Alternator Cover Removal). โข Set a tester [C], and connect it peak voltage adapter. Special Tools – Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Needle Adapter Set [D]: 57001-1457 โข Connect the adapter to the terminals of the crankshaft sensor lead connector. Connections: Crankshaft Sensor Lead Peak Voltage Adapter Tester Y lead โ R lead โ (+) BK lead โ BK lead โ (โ) โข Turn the engine stop switch to run position. โข Turn the ignition switch on. โข Pushing the starter button, turn the engine 4 ๏พ 5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. โข Repeat the measurement 5 or more times. Crankshaft Sensor Peak Voltage Standard: 2.0 V or more If the reading is less than the standard, inspect the crankshaft sensor (see Crankshaft Sensor Inspection). Timing Rotor Removal โข Remove the crankshaft sensor (see Crankshaft Sensor Removal). โข Holding the timing rotor with the flywheel & pulley holder [A] and remove the timing rotor bolt [B]. Special Tool – Flywheel & Pulley Holder: 57001-1605 โข Remove the timing rotor [C]. Timing Rotor Installation โขInstall the timing rotor [A] on the crankshaft [B] with their teeth [C] aligned. โข Holding the timing rotor with the flywheel & pulley holder and tighten the timing rotor bolt. Torque – Timing Rotor Bolt: 39 Nยทm (4.0 kgfยทm, 29 ftยทlb) Special Tool – Flywheel & Pulley Holder: 57001-1605 โขInstall the crankshaft sensor (see Crankshaft Sensor Installation). ELECTRICAL SYSTEM 16-41 Ignition System Stick Coil Removal NOTICE Never drop the stick coils, especially on a hard surface. Such a shock to the stick coils can damage it. โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) โข To ease the #1 stick coil removal, pull the main harness [A] to inward [B] and release the clamp [C] from the frame. โข Disconnect the connectors from the stick coils [D] and pull out the stick coils. NOTICE Do not pry the connector part of the coil while removing the coil. Stick Coil Installation โขInsert the stick coils [A] so that the coil heads align with the lines [B] on the cylinder head cover. NOTICE Do not tap the coil head while installing the coil. โข After installation, be sure the stick coils are installed securely by pulling up them lightly. โข Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed parts (see appropriate chapters). Stick Coil Inspection โข Remove the stick coils (see Stick Coil Removal). โข Measure the primary winding resistance [A] as follows. โConnect a tester between the coil terminals. โข Measure the secondary winding resistance [B] as follows. โConnect the tester between the plug terminal and (โ) coil terminal. Stick Coil Winding Resistance Primary Windings: 1.1 ๏พ 1.5 โฆ @20ยฐC (68ยฐF) Secondary Windings: 6.4 ๏พ 9.6 kโฆ @20ยฐC (68ยฐF) If the tester does not read as specified, replace the coil. Stick Coil Primary Peak Voltage Inspection NOTE โBe sure the battery is fully charged. 16-42 ELECTRICAL SYSTEM Ignition System โข Remove the stick coils (see Stick Coil Removal), but do not remove the spark plugs. โข Measure the primary peak voltage as follows. โInstall the new spark plug [A] into each stick coil [B], and ground them onto the engine. โConnect the peak voltage adapter [C] into a tester [D]. โConnect 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 – 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 (W) Adapter (BK, โ) to lead wire-peak voltage adapter (R) WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. โข Turn the engine stop switch to run position. โข Turn the ignition switch on. โข Pushing the starter button, turn the engine 4 ๏พ 5 seconds with the transmission in neutral to measure the primary peak voltage. โข Repeat the measurements 5 times for one stick coil. Stick Coil Primary Peak Voltage Standard: 100 V or more โข 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 System (DFI) chapter) Spark Plug Removal โข Refer to the Spark Plug Replacement in the Periodic Maintenance chapter. Spark Plug Installation โข Refer to the Spark Plug Replacement in the Periodic Maintenance chapter. ELECTRICAL SYSTEM 16-43 Ignition System Spark Plug Condition Inspection โข Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). โข Visually inspect the spark plugs. If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug. If the spark plug is dirtied or the carbon is accumulated, replace the spark plug. โข Measure the gap [D] with a wire-type thickness gauge. If the gap is incorrect, replace the spark plug. Spark Plug Gap: 0.8 ๏พ 0.9 mm (0.031 ๏พ 0.035 in.) โข Use the standard spark plug or its equivalent. Spark Plug: NGK CR9EIA-9 Interlock Operation Inspection โข Raise the rear wheel off the ground with the stand. โข Turn the engine stop switch on (run position). 1st Check โข Start the engine to the following conditions. Condition: Transmission Gear โ 1st Position Clutch Lever โ Release Side Stand โ Down or Up โTurn the ignition switch on and push the starter button. โThen the starter motor should not turn when the starter system circuit is normality. If the engine is start, inspect the starter lockout switch, gear position sensor and relay box. 2nd Check โข Start the engine to the following conditions. Condition: Transmission Gear โ 1st Position Clutch Lever โ Pulled in Side Stand โ Up โTurn the ignition switch on and push the starter button. โThen the starter motor should turn when the starter system circuit is normality. If the starter motor is not turn, inspect the starter lockout switch, side stand switch, relay box, and starter relay. 16-44 ELECTRICAL SYSTEM Ignition System 3rd Check โขInspect the engine for its secure stop after the following operations are completed. โข Run the engine to the following conditions. Condition: Transmission Gear โ 1st Position Clutch Lever โ Release Side Stand โ Up โข Set the side stand on the ground, then the engine will stop. If the engine does not stop, inspect the gear position sensor, side stand switch and relay box. If their parts are normality, replace the ECU. IC Igniter Inspection โThe IC igniter is built in the ECU [A]. โข 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 16-45 Ignition System 16-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Engine Stop Switch 2. Spark Plugs 3. Stick Coils 4. Vehicle-down Sensor 5. Crankshaft Sensor 6. Main Throttle Sensor 7. Subthrottle Sensor 8. Water Temperature Sensor 9. Gear Position Sensor 10. Side Stand Switch 11. ECU 12. Frame Ground (5) 13. Frame Ground (1) 14. Engine Ground 15. Battery 12 V 8 Ah 16. Starter Relay 17. Main Fuse 30 A 18. ECU Fuse 15 A 19. Relay Box 20. ECU Main Relay 21. Starter Lockout Switch 22. Ignition Switch 23. Fuse Box (1) 24. Ignition Fuse 15 A ELECTRICAL SYSTEM 16-47 Electric Starter System Starter Motor Removal โข Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). โข Slide out the rubber cap [A]. โข Remove: Starter Motor Cable Terminal Nut [B] Starter Motor Mounting Bolts [C] Starter Motor [D] Starter Motor Installation NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. โข Clean the starter motor legs [A] and crankcase [B] where the starter motor is ground. โข Replace the O-ring [A] with a new one. โข Apply grease to the O-ring. โขInstall the starter motor on the crankcase. โข Tighten the starter motor mounting bolts [A]. Torque – Starter Motor Mounting Bolts: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โข Connect the starter motor cable [B] to the terminal and position it vertically [C] as shown. โข Tighten the starter motor cable terminal nut [D]. Torque – Starter Motor Cable Terminal Nut: 6.0 Nยทm(0.61 kgfยทm, 53 inยทlb) โข Slide back the rubber cap [E] to the original position. โขInstall the removed parts (see appropriate chapters). Starter Motor Disassembly โข Remove: Starter Motor (see Starter Motor Removal) Starter Motor Through Bolts [A] End Covers [B] 16-48 ELECTRICAL SYSTEM Electric Starter System โข Remove the armature [A] from the commutator side. NOTE โDo not remove the circlip [B] from the shaft. โข Remove: Starter Motor Terminal Locknut [A] Washer [B] Collar [C] O-ring [D] โข Pull out the brushes from the brush holder [A]. โข Remove: Brush Springs [B] Starter Motor Terminal [C] Positive Brush Assy [D] Brush Holder Screw [E] Negative Brush Assy [F] Brush Holder Starter Motor Assembly โข Align the hole [A] of the brush holder [B] to the boss [C] of the right-hand end cover [D]. โข Align the stoppers [A] of the negative brush assy [B] to the grooves [C] of the brush holder [D]. โข Tighten: Torque – Brush Holder Screw: 3.8 Nยทm (0.39 kgfยทm, 34 inยทlb) ELECTRICAL SYSTEM 16-49 Electric Starter System โข Align the hole [A] of the positive brush assy [B] with the hole [C] of the brush holder [D]. โขInsert the starter motor terminal through the holes. โข Replace the O-ring [A] with a new one. โขInstall the following parts to the starter motor terminal [B]. New O-ring Collar [C] Washer [D] Starter Motor Terminal Locknut [E] โInstall the collar so that stepped side faces outward. โข Tighten: Torque – Starter Motor Terminal Locknut: 11 Nยทm (1.1 kgfยทm, 97 inยทlb) โขInstall the brush springs [A] and insert the brushes [B]. โข Apply thin coat of grease to the oil seal [A]. โข Replace the O-rings [A] with new ones. โขInsert the armature [B] so that commutator side [C] faces hollow side [D] of the yoke [E]. 16-50 ELECTRICAL SYSTEM Electric Starter System โขInstall the end cover [A] so that the stopper [B] is aligned with the hollow [C] of the yoke. โข Align the marks [A] to assembly the yoke and the end covers [B]. โข Tighten the through bolts. Torque – Starter Motor Through Bolts: 5.0 Nยทm (0.51 kgfยทm, 44 inยทlb) Brush Inspection โข Measure the length of each brush [A]. If any is worn down to the service limit, replace the brush assy. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit: 6.5 mm (0.26 in.) Commutator Cleaning and Inspection โข Clean the metallic debris off the between commutator segments [A]. NOTE โDo not use emery or sand paper on the commutator. โข Check the commutator for damage or abnormal wear. Replace the starter motor with a new one if there is any damage or wear. โข Visually inspect the commutator segments for discoloration. Replace the starter motor with a new one if discoloration is noticed. ELECTRICAL SYSTEM 16-51 Electric Starter System Armature Inspection โข Using a tester, measure the resistance between any two commutator segments [A]. If there is a high resistance or no reading (โ) between any two segments, a winding is open and the starter motor must be replaced. โข Using the tester, measure the resistance between the segments and the shaft [B]. If there is any reading at all, the armature has a short and the starter motor must be replaced. NOTE โEven if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the 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 โข Using a tester, measure the resistance as shown. Terminal Bolt and Positive Brushes [A] Right-hand End Cover and Negative Brushes [B] If there is not close to zero ohms, the brush lead has an open. Replace the brush plate assy. Right-hand End Cover Inspection โข Using a tester, measure the resistance as shown. Terminal Bolt and Right-hand End Cover [A] Terminal Bolt and Negative Brushes [B] If there is any reading, the brush assy and/or terminal bolt assy have a short. Replace the starter motor. Starter Relay Inspection โข Remove: Front Seat (see Front Seat Removal in the Frame chapter) Battery Negative (โ) Cable (see Battery Removal) Starter Relay Cover [A] 16-52 ELECTRICAL SYSTEM Electric Starter System โข Disconnect: Connector [A] โข Remove: Cable Terminal Bolts [B] Starter Relay [C] โข Connect a tester [A] and 12 V battery [B] to the starter relay [C] as shown. If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Criteria: When battery is connected โ 0 โฆ When battery is disconnected โโโฆ ELECTRICAL SYSTEM 16-53 Electric Starter System Electric Starter Circuit 1. Engine Stop Switch 2. Starter Button 3. Gear Position Sensor 4. Side Stand Switch 5. ECU 6. Frame Ground (5) 7. Frame Ground (1) 8. Engine Ground 9. Battery 12 V 8 Ah 10. Starter Relay 11. Main Fuse 30 A 12. Starter Motor 13. Relay Box 14. Starter Circuit Relay 15. Starter Lockout Switch 16. Ignition Switch 17. Fuse Box (1) 18. Ignition Fuse 15 A 16-54 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released. Headlight Beam Horizontal Adjustment โข Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Beam Vertical Adjustment โข Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight (LED) Assembly Removal/Installation โข Refer to the Upper Fairing Disassembly/Assembly in the Frame chapter. Headlight Harness Circuit Inspection NOTE โIf one of the LED in the headlight unit does not turn on, replace the headlight unit as an assembly. โข Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) โข Disconnect the headlight lead connector [A]. โข Connect the measuring adapter [B] to the main harness connector [C] for the headlight unit. Special Tool – Measuring Adapter: 57001-1700 โข Check the headlight wiring for continuity Wiring Continuity Inspection BK/Y Lead [D] โ โ Ground [E] If there is no continuity, the harness has an open circuit, and it must be repaired or replaced. ELECTRICAL SYSTEM 16-55 Lighting System City Light Input Voltage Inspection โข Connect the measuring adapter [A] to the main harness connector [B] for the headlight unit. โข Connect a tester between the terminals as shown. BR/Y Lead (+) [C] โ โ Ground (โ) [D] โข The battery voltage should appear after the ignition switch is turned on. Headlight Lo Beam Input Voltage Inspection โข Connect a tester between the terminals as shown. R/Y Lead (+) [A] โ โ Ground (โ) [B] โข Turn the ignition switch on. โข Push the starter button momentarily to turn the headlight relay on. โข The battery voltage should appear when the headlight relay turned on. Headlight Hi Beam Input Voltage Inspection โข Connect a tester between the terminals as shown. R/BK Lead (+) [C] โ โ Ground (โ) โข The battery voltage should appear after the dimmer switch [D] turned to high beam position. โข Turn the ignition switch off. If the headlight input voltage is out of the standard, check the followings: Head light Fuse (see Fuse Inspection) Brake/Horn Fuse (see Fuse Inspection) Headlight Relay (see Relay Circuit Inspection) If the headlight relay and the fuses are good, check the headlight wiring for open or short circuit. If all measurements are within the standard, replace the headlight (LED) assembly (see Headlight (LED) Assembly Removal/Installation). City Light (LED) Removal/Installation โข The city lights are integrated into the headlight unit. Refer to the headlight removal and installation. 16-56 ELECTRICAL SYSTEM Lighting System Tail/Brake Light (LED) Removal โข Remove: Seat Covers (see Seat Cover Removal in the Frame chapter) โข Loosen the rear fender mounting bolts [A]. โข Remove the bolts [A] and pull the tail/brake light (LED) unit [B] rearward with the clamp [C]. โข Disconnect the tail/brake light lead connector [A]. โข Remove: Tail/brake Light (LED) [B] Clamp [C] Washers [D] and Collars Tail/Brake Light (LED) Installation โขInstallation is the reverse of removal. โข Make sure that the pads [A] and [B] are in place as shown. โขIf removed, install the grommets [C] with its large diameter [D] side facing upward. โขInstall: Collars [E] Washers [F] Clamp [G] โข Run the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). License Plate Light Bulb Replacement โข Remove: License Plate Light Cover Screws [A] License Plate Light Cover [B] and Lens ELECTRICAL SYSTEM 16-57 Lighting System โข Pull out the bulb [A] straight from the socket. NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. โข Replace the bulb with a new one. โขInsert the new bulb into the socket. โขInstall the license plate light cover. โข Tighten the license plate light cover screws. Headlight/Tail Light Circuit 1. Ignition Switch 2. Fuse Box (1) 3. Headlight Relay Fuse 15 A 4. Brake Light/Horn Fuse 7.5 A 5. Joint Connector C 6. Tail/Brake Light (LED) 7. License Plate Light 12 V 5 W 8. Frame Ground (4) 9. Frame Ground (1) 10. Engine Ground 11. Battery 12 V 8 Ah 12. Starter Relay 13. Main Fuse 30 A 14. Alternator 15. Relay Box 16. Headlight Circuit Relay 17. Dimmer Switch 18. Passing Button 19. Headlight Unit 20. Headlights (LED) 21. City Lights (LED) 22. Joint Connector A 23. Meter Unit 16-58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Bulb Replacement Front Turn Signal Light โข Remove: Meter Cover (see Upper Fairing Removal in the Frame chapter) โข Turn the socket [A] counterclockwise and pull out the socket together with the bulb. โข Push and turn the bulb [A] counterclockwise and remove it. โขInsert the new bulb [A] by aligning its pins [B] with the grooves [C] in the socket, and turn the bulb clockwise. โTurn the bulb about 15ยฐ. โข Fit the projections [A] of the socket into the grooves [B] of the turn signal light. โAlign the size of the projections with the grooves. โข Turn the socket clockwise until it stops. โขInstall the removed parts (see appropriate chapters). Rear Turn Signal Light โข Remove: Turn Signal Light Lens Screw [A] Turn Signal Light Lens Housing [B] ELECTRICAL SYSTEM 16-59 Lighting System โข Turn the socket [A] counterclockwise and remove the lens housing [B]. โข Pull out the bulb [C] straight from the socket. NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. โข Replace the bulb [A] with a new one. โข Push the new bulb into the socket. โขInsert the socket by aligning its tabs [B] with the cutouts [C] of the lens. โข Turn the socket clockwise until it stops. โข Fit the lens housing [A] to the light case [B] by inserting the projection [C] on the lens housing to the inside of the light case. โข Tighten the turn signal light lens screw. Torque – Tern Signal Light Lens Screw: 1.0 Nยทm (0.10 kgfยทm, 8.9 inยทlb) Turn Signal Relay Inspection โข Remove: Meter Cover (see Upper Fairing Removal in the Frame chapter) โข Remove the turn signal relay [A]. โข Disconnect the turn signal relay connector [B]. 16-60 ELECTRICAL SYSTEM Lighting System โข Connect one 12 V battery and turn signal lights as indicated, and count how many times the lights blink for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not blink as specified, replace the turn signal relay. Testing Turn Signal Relay Load The Number of Turn Signal Lights Wattage (W) Blinking Times (c/m*) 1** 10 140 ๏พ 250 2 20 75 ๏พ 95 (*): Cycle(s) per minute (**): Correspond to โone light burned out.โ ELECTRICAL SYSTEM 16-61 Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Fuse Box (2) 3. Turn Signal Relay Fuse 7.5 A 4. Joint Connector C 5. Rear Right Turn Signal Light 12 V 10 W 6. Rear Left Turn Signal Light 12 V 10 W 7. Frame Ground (1) 8. Engine Ground 9. Battery 12 V 8 Ah 10. Starter Relay 11. Main Fuse 30 A 12. Turn Signal Switch 13. Hazard Switch 14. Turn Signal Relay 15. Front Left Turn Signal Light 12 V 10 W 16. Front Right Turn Signal Light 12 V 10 W 17. Joint Connector A 18. Meter Unit 16-62 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test โข Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test โข Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter). โข Connect a tester [A] to the air switching valve terminals as shown. Air Switching Valve Resistance Standard: 20 ๏พ 24 โฆ @20ยฐC (68ยฐF) If the resistance reading is out of the specified value, replace it with a new one. โข Connect the 12 V battery [A] to the air switching valve terminals as shown. โข Blow the air to the intake air duct [A], and make sure does not flow the blown air from the outlet air ducts [B]. โข Disconnect the 12 V battery. โข Blow the air to the intake air duct [A] again, and make sure flow the blown air from the outlet air ducts [B]. If the air switching valve does not operate as described, replace it with a new one. NOTE โTo check air flow through the air switching valve, just blow through the air switching valve hose (intake side) [C]. ELECTRICAL SYSTEM 16-63 Air Switching Valve Air Switching Valve Circuit 1. ECU 2. Frame Ground (5) 3. Frame Ground (1) 4. Engine Ground 5. Battery 12 V 8 Ah 6. Starter Relay 7. Main Fuse 30 A 8. ECU Fuse 15 A 9. Relay Box 10. ECU Main Relay 11. Ignition Switch 12. Air Switching Valve 13. Fuse Box (1) 14. Ignition Fuse 15 A 16-64 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection โข Remove the left lower fairing (see lower Fairing Removal in the Frame chapter). โข Cut the band [A]. โข Slide the dust cover [B]. โข Disconnect the fan motor lead connector [A]. โข Using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. ELECTRICAL SYSTEM 16-65 Radiator Fan System Radiator Fan Circuit 1. Ignition Switch 2. Fan Motor 3. Fuse Box (1) 4. Ignition Fuse 15 A 5. Fan Fuse 15 A 6. Water Temperature Sensor 7. ECU 8. Frame Ground (5) 9. Frame Ground (1) 10. Engine Ground 11. Battery 12 V 8 Ah 12. Starter Relay 13. Main Fuse 30 A 14. Relay Box 15. Radiator Fan Relay 16. Joint Connector B 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal โข Remove: Meter Cover [A] (see Upper Fairing Removal in the Frame chapter) Screw [B] and washer Meter Unit [C] Meter Unit Installation โขInsert the projections [A] into the grommets [B] to install the meter unit [C]. Meter Unit Disassembly/Assembly โข Remove: Meter Unit (see Meter Unit Removal) Screws [A] Lower Meter Cover [B] โข Separate the meter assembly [A] and upper meter cover [B]. โข Apply is the reverse of disassembly. Meter Operation Inspection Check 1: Meter Unit Switching Inspection Display Mode Setting โข Turn the ignition switch on and check the following. โข By pushing the upper meter button [A] or upper button [B] each time, check that the display [C] changes as follows. โThis display is ordinary indication. ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit Unit Setting โข Set the ODO mode by pushing the upper meter button or upper button. โข By pushing the lower meter button or lower button each time while the upper button pushed in, check that the display changes as shown. NOTE โMile/Km Display can alternate between English and metric modes (mile and km) in the digital meter. Make sure that km or mile according to local regulations is correctly displayed before riding. If the display function does not work, replace the meter unit. Clock Setting โข Push the upper meter button [A] and lower meter button [B] for more than two seconds. โThe clock setting menu (hour and minute) should blink [C]. โข Push the lower meter button and hold it. โโ12hโ or โ24hโ display is appeared. โข Push the upper meter button to select โ12hโ or โ24hโ [A]. โข Push the lower meter button. โThe hour display [A] starts blinking. โข By pushing the upper meter button each time, check that the hour display changes. 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit โข By pushing the lower meter button, check that the hour display decides and minute display [A] starts blinking. โข By pushing the upper meter button each time, check that the minute display changes. โข By pushing the lower meter button, check that the hour and minute display start blinking. โข By pushing the upper meter button, check that the hour and minute display decide. โข When both hour and minute display is blinking, by pushing the lower meter button, check that the hour display start blinking. The clock returns the hour setting display. If the display function does not work, replace the meter unit. Check 1-2: Left Switch Housing Switching Inspection โข Turn the ignition switch on. โข By pushing the โSELโ button [A] each time, check that the display selects POWER mode [B] or KTRC mode [C]. The selected mode will blinks. If the modes does not slected, check the following parts. SEL Button (see Switch Inspection) Wiring (see Meter Unit Circuit) If the above parts is good, replace the meter unit and/or ECU. ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit โข Select the POWER mode. โข By pushing the upper button [A] or lower button [B] each time, check that the POWER mode indicator changes to going on. If the POWER mode indicator function does not work or blinks, check the following parts. Upper Button or Lower Button (see Switch Inspection) Wiring (see Meter Unit Circuit) If the above parts is good, replace the meter unit. โข Select the KTRC mode. โข By pushing the upper button [A] or lower button [B] each time, check that the KTRC mode indicator changes to going on. If the KTRC mode indicator function does not work or โโโ blinks, check the following parts. Upper Button or Lower Button (see Switch Inspection) Wiring (see Meter Unit Circuit) If the above parts is good, replace the meter unit. 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter System Inspection Check 2-1: Water Temperature Inspection โข Disconnect the water temperature sensor connector [A] (see Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter). โข Connect the variable rheostat [B] to the W/BL lead [C] and O lead [D] terminals. LCD Display Resistance (kโฆ) โโโ 1.231 or more 40ยฐC (104ยฐF) 1.136 ยฑ0.095 100ยฐC (212ยฐF) 0.1553 ยฑ0.0070 HI 0.1483 or less โข Turn the ignition switch on. โข Read the temperature in the display. โThe display range is 40 ๏พ 119ยฐC (104 ๏พ 247ยฐF). If the temperature is out of the range, check the wiring (see Meter Circuit). If the wiring is good, replace the meter unit. Check 2-2: Battery Warning Indicator Inspection โข When the battery condition is low voltage (10.8 ๏พ 11.2 V or less) or high voltage (15.5 ๏พ 16.5 V or more), the battery warning indicator [A] and red warning indicator (LED) [B] go on. If the battery warning indicator and red warning indicator (LED) go on, inspect the charging voltage (see Charging Voltage Inspection). If the charging voltage is good, replace the meter unit. Check 2-3: Gear Position Indication Inspection โข Turn the ignition switch on and shift the transmission gear into neutral position. โThe green neutral indicator light (LED) [A] goes on, and the gear position indicator [B] should display โNโ. โข Set the gear to the low position, and check that the display changes to โ1โ mark [A] and the green neutral indicator light (LED) [B] goes off. โข Using the rear stand, raise the rear wheel off the ground. โข Rotate the rear wheel by hand and change the gear position. โข Check that the display corresponding to each gear position (1, N, 2, 3, 4, 5 or 6) appears. If the display function does not work, check the following parts. Gear Position Sensor (see Gear Position Sensor Input Voltage Inspection in the Fuel System (DFI) chapter) Wiring (see Meter Unit Circuit) If the above parts are good, replace the meter unit and/or ECU. ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit Meter Unit Inspection โข Remove the meter unit [A] (see Meter Unit Removal). [1] Unused [2] Unused [3] Left Switch Housing Upper Button (โ) [4] Left Switch Housing Lower Button (โ) [5] KIBS Indicator (โ) [6] Red Warning Indicator (LED) (โ) [7] Green Neutral Indicator (LED) (โ) [8] Yellow ABS Indicator (LED) (โ) [Equipped Models] [9] Ground (โ) [10] Ignition (+) [11] Fuel Level Sensor [12] Rear Wheel Rotation Sensor Pulse [13] ECU Communication Line [14] Unused [15] Tachometer Pulse [16] Green Right Turn Signal Indicator (LED) (+) [17] Blue High Beam Indicator (LED) (+) [18] Yellow KTRC Indicator (LED) (โ) [19] Green Left Turn Signal Indicator (LED) (+) [20] Battery (+) NOTICE Do not drop the meter unit. Do not short each terminal. Check 3-1: Meter Unit Primary Operation Check โข Using the auxiliary leads, connect the 12 V battery to the meter unit connector as follows. โConnect the battery positive (+) terminal to the terminal [20]. โConnect the battery negative (โ) terminal to the terminal [9]. โข Connect the terminal [10] to the battery (+) terminal. 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit โข Check the following items. โThe LCD display and meter illuminations should turn on. โAll the LCD segments [A] appear for few seconds. โFollowing indicators are goes on for few seconds. Yellow KTRC Indicator (LED) [B] Yellow Shift-up Indicator (LED) [C] Red Warning Indicator (LED) [D] โFollowing indicators are remains on. Yellow Engine Warning Indicator (LED) [E] Yellow Warning Indicator (LED) [F] Yellow ABS Warning Indicator (LED) [G] (if equipped) If the meter unit does not work properly, replace the meter assembly. โMake sure that the following indicators on the LCD start blinking approx. 5 seconds after turning on the meter unit. Fuel Level Gauge segments [A] and Indicator KIBS Indicator [B] If the meter unit does not work properly, replace the meter assembly. โข Make sure that the following indicators on the LCD start blinking approx. 10 seconds after turning on the meter unit. Gear Position Indicator with “- -” Message [A] IMU Indicator [B] All Segments of Water Temperature Gauge [C] and Indicator Power Mode Indicator [D] KTRC Mode Indicator [E] Multifunction Display with “- -.-” Message [F] If the meter unit does not work properly, replace the meter assembly. โข Disconnect the terminal [10]. โAll the LCD segments disappear. โThe red warning indicator (LED) [A] starts blinking (see Abstract section in the Immobilizer System). If the segments do not disappear, replace the meter unit. ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Check 3-2: Meter Communication Line (Service Code 39) Check โข Connect the leads in the same circuit as Check 3-1. โข After 10 seconds, the gear position indicator starts blinking. โข Set the ODO mode [A] by pushing the upper meter button [B]. โข Push the upper meter button and lower meter button [C] for more than 2 seconds. โข Check the following items. โThe number โ39โ [A] in the display appears. โข Push the upper meter button and lower meter button again for more than 2 seconds. โข Check the following items. โThe display returns ODO mode from number โ39.โ If the meter unit does not work, replace the meter unit. NOTE โThe number โ39โ is service code of Self-Diagnosis (see Fuel System (DFI) chapter). It is the service code of the meter communication line error. โThe number โ39โ in the display disappear when the meter unit is connected to main harness of the normal motorcycle. Check 3-3: Immobilizer Blinking Mode Inspection โข Connect the leads in the same circuit as Check 3-1. โข Disconnect the terminal [10]. 16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit โข Check that the red warning indicator (LED) [A] starts blinking (Immobilizer Warning Indicator Blinking Mode). โข Push the upper meter button [B] and lower meter button [C] more than 2 seconds, within 20 seconds after the terminal [6] disconnected. โข Check that the red warning indicator (LED) goes on 1 second, and then the indicator goes off (Immobilizer No Blinking Mode). NOTE โFor this inspection, be sure the battery is 12.2 V or more. Immobilizer Blinking Mode does not work, when the battery voltage is less than 12 ยฑ0.2 V. โข Connect the terminal [10] to the battery (+) terminal. โข And then, disconnect the terminal [10]. โข Push the upper meter button [A] and lower meter button [B] more than 2 seconds, within 20 seconds after the terminal [10] disconnected. โข Check that the red warning indicator (LED) [C] goes on 1 second, and then the indicator starts blinking (Immobilizer Warning Indicator Blinking Mode). If the meter function does not work, replace the meter unit. Check 3-4: Blue High Beam Indicator (LED) Inspection โข Connect the leads in the same circuit as Check 3-1. โข Connect the terminal [17] to the battery (+) terminal. ELECTRICAL SYSTEM 16-75 Meter, Gauge, Indicator Unit โข Check that the blue high beam indicator (LED) [A] goes on. If the indicator (LED) does not go on, replace the meter unit. Check 3-5: Green Left Turn Signal Indicator (LED) Inspection โข Connect the leads in the same circuit as Check 3-1. โข Connect the terminal [19] to the battery (+) terminal. โข Check that the green left turn signal indicator (LED) [A] goes on. If the indicator (LED) does not go on, replace the meter unit. Check 3-6: Green Right Turn Signal Indicator (LED) Inspection โข Connect the leads in the same circuit as Check 3-1. โข Connect the terminal [16] to the battery (+) terminal. โข Check that the green right turn signal indicator (LED) [A] goes on. If the indicator (LED) does not go on, replace the meter unit. 16-76 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3-7: Green Neutral Indicator (LED) Inspection โข Connect the leads in the same circuit as Check 3-1. โข Connect the terminal [7] to the battery (โ) terminal. โข Check that the green neutral indicator (LED) [A] goes on. If the indicator (LED) does not go on, replace the meter unit. Check 3-8: Yellow ABS Indicator (LED) Inspection (Equipped Model) โข Connect the leads in the same circuit as Check 3-1. โThe yellow ABS indicator (LED) goes on. โข Connect the terminal [8] to the battery (โ) terminal. โข Check that the yellow ABS indicator (LED) [A] goes off. If the indicator (LED) does not go off, replace the meter unit. Check 3-9: Red Warning Indicator (LED) Inspection (Oil Pressure Warning) โข Connect the leads in the same circuit as Check 3-1. โข Connect the terminal [6] to the battery (โ) terminal. ELECTRICAL SYSTEM 16-77 Meter, Gauge, Indicator Unit โข Check that the oil pressure warning indicator [A] and red warning indicator (LED) [B] go on. If the oil pressure warning indicator and indicator (LED) do not go on, replace the meter unit. Check 3-10: Fuel Gauge Inspection โข Connect the leads in the same circuit as Check 3-1. โThe all segments of the fuel gauge in the display will blink. โข Connect the variable rheostat [A] to the terminal [11] and the battery (โ) terminal. โข Check that the number of segments on the fuel level gauge [A] matches the resistance value of the variable rheostat. โWhen the terminal [11] is connected, 1 segment in the fuel level gauge should appear about every 15 seconds. Variable Rheostat Resistance (โฆ) Display Segments 20 6 segments go on 40 5 segments go on 60 4 segments go on 80 3 segments go on 110 2 segments go on 170 1 segment goes on 210 1 segment blinks If the display function does not work, replace the meter assembly. 16-78 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3-11: Speedometer Inspection โข Connect the leads in the same circuit as Check 3-1. โข The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [12]. โIndicates approximately 60 km/h if the input frequency is approximately 370 Hz. โIndicates approximately 60 mph if the input frequency is approximately 600 Hz. If the meter function does not work, replace the meter unit. NOTE โThe input frequency of the oscillator adds the integrated value of the odometer. โThe integrated value of the odometer cannot be reset. Check 3-12: Odometer Check โข Check the odometer with the speedometer check in the same way. If value indicated in the odometer is not added, replace the meter unit. NOTE โThe data is maintained even if the battery is disconnected. โWhen the figures come to 999999, they are stopped and locked. โThe integrated value of the odometer cannot be reset. Check 3-13: Trip A/B Meter Check โข Check the trip meter with the speedometer in the same way. If value indicated in the trip meter is not added, replace the meter unit. โข Check that when the lower meter button is pushed for more than two seconds, the figure display turns to 0.0. If the figure display does not indicate 0.0, replace the meter unit. ELECTRICAL SYSTEM 16-79 Meter, Gauge, Indicator Unit Check 3-14: Tachometer Inspection โข Connect the leads in the same circuit as Check 3-1. โข The engine speed (rpm) equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [15]. โIndicates approximately 4 000 rpm if the input frequency is approximately 133 Hz. If the meter function does not work, replace the meter unit. Check 3-15: Other Inspection โThe following items are displayed while running. AVERAGE CURRENT RANGE ECO Mark โข When the above item is faulty indication check the following items. Wiring (see Wiring Inspection) ECU Communication Line (see ECU Communication Line Inspection in the Fuel System (DFI) chapter) Fuel Injectors (see Fuel Injectors section in the Fuel System (DFI) chapter) Rear Wheel Rotation Sensor (see Rear Wheel Rotation Sensor Signal (Service Code 24) section in the Fuel System (DFI) chapter) Crankshaft Sensor (see Crankshaft Sensor Inspection) If the above items are good, replace the meter unit and/or ECU. Fuel Level Sensor Line Self-Diagnosis Mode Inspection NOTE โUsually when the open or short of the fuel level sensor circuit is detected, it becomes the Fuel Level Sensor Line Self-Diagnosis Mode. โThe all segments of the fuel level gauge [A] and fuel level warning indicator [B] in the display will blink. (This function is Fuel Level Sensor Line Self-Diagnosis Mode.) If the meter enters the self-diagnosis mode when the meter is installed in the motorcycle, check the fuel level sensor (see Fuel Level Sensor Inspection) and wiring. If the fuel level sensor and wiring are good, replace the meter unit. 16-80 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 2. Water Temperature Sensor 3. Gear Position Sensor 4. Oil Pressure Switch 5. ECU 6. Rear Wheel Rotation Sensor 7. Fuel Level Sensor 8. ABS Hydraulic Unit 9. Frame Ground (4) 10. Frame Ground (2) 11. Engine Ground 12. Battery 12 V 8 Ah 13. Starter Relay 14. Main Fuse 30 A 15. Upper and Lower Button 16. SEL Button 17. to Turn Signal Switch (Right) 18. to Dimmer Switch and Passing Button 19. to Turn Signal Switch (Left) 20. Meter Unit 21. Fuse Box (1) 22. Ignition Fuse 15 A 23. Meter Fuse 7.5 A ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU. If the code does not match, ignition system, injectors, subthrottle valve actuator and exhaust butterfly valve actuator will not operate and the engine will not start. Abstract โข Do not keep more than one immobilizer key of any system on a key ring. Jamming of the key code signal may occur and the operation of the system may be affected. โข The red warning indicator (LED) will blink for a period of 24 hours once the ignition switch has been switched off and the key removed. This blinking can be set to on or off as desired by holding the upper and lower meter buttons down for 2 seconds within 20 seconds of switching the ignition off. โขIf all coded keys are lost the ECU and ignition switch will have to be replaced. โข The immobilizer system can not function until the ignition key code is registered in the ECU. โข A total of five keys can be registered in the ECU at any one time. Operational Cautions 1. Do not put two keys of any immobilizer system on the same key ring. 2. Do not submerge any key in water. 3. Do not expose any key to excessively high temperature. 4. Do not place any key close to magnet. 5. Do not place a heavy item on any key. 6. Do not grind any key or alter its shape. 7. Do not disassemble the plastic part of any key. 8. Do not drop the key and/or apply any shocks to the key. 9. When a ignition key is lost, the user should go to his dealer to invalidate the lost key registration in the ECU. 10.When the all ignition keys are lost, the user should go to his dealer and have a new ECU installed and register the ignition keys. NOTE โNo.9 and 10 are strongly recommended to the customer to ensure security of the motorcycle. Key Registration Case 1: When additional spare ignition key is required. โข Prepare a new spare ignition key. โข Cut the key in accordance with the shape of the current ignition key. โข Remove the front seat (see Front Seat Removal in the Frame chapter). โข Remove the immobilizer/Kawasaki diagnostic system connector cap [A]. โข Connect the key registration unit [A] and key registration adapter [B] as shown. Special Tools – Key Registration Unit: 57001-1582 Key Registration Adapter: 57001-1746 16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) โขInsert the registered ignition key to the ignition switch and turn it to โON.โ Verified โThe red warning indicator (LED) and immobilizer warning indicator [A] blink to display the registration mode (go to the next step). Not Verified โThe red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error (refer to the following failure illustrations). Immobilizer Amplifier Failure Registered Ignition Key Collation Error โข Turn the registered ignition key to โOFFโ and remove the registered ignition key. If there are other registered ignition keys, they should all do the procedure above. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink continuously to display that the ECU is in the registration mode for 15 seconds. NOTE โInsert next key and turn it to โONโ within 15 seconds after previous key is turned to โOFFโ and removed otherwise registration mode will be ended and the red warning indicator (LED) and immobilizer warning indicator stops blinking. โTo return to the registration mode start the registered ignition key(s) verification procedure. This applies to all ignition key registration. โขInsert the ignition key 1 to the ignition switch and turn it to โON.โ NOTE โKeep the other ignition key away from the immobilizer antenna. ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted. Ignition Key Collation Error โข The ignition key 1 is successfully registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 3 times and stops for 1 second and then repeats this cycle. 16-84 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) โข Turn the ignition key 1 to โOFFโ and remove the ignition key 1. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink to display the registration mode. NOTE โTurn to โOFFโ the ignition switch and wait for the period of 15 seconds or more. The registration mode automatically finishes and the red warning indicator (LED) and immobilizer warning indicator will switch off. โThis procedure registered the registered ignition key and one ignition key. โContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed. โขInsert the ignition key 2 to the ignition switch and turn it to โON.โ โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted. Ignition Key Collation Error ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) โข The ignition key 2 is registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 4 times and stops for 1 second and then repeats this cycle. โThis procedure has registered the 2 ignition keys. โข Continue with the procedure to register an additional one ignition key. NOTE โThe ECU can store up the five key codes. Red Warning Indicator (LED) and Immobilizer Warning Indicator Blink Indicators Blinks Indicators Stop Remarks Ignition Key 3 5 times 1 second Repeat โข Turn to โOFFโ the ignition switch and wait for period of more than 15 seconds. โข The registration mode automatically ends. โข The red warning indicator (LED) [A] goes off. โข Remove the key registration unit, key registration adapter and install the immobilizer/Kawasaki diagnostic system connector cap. NOTE โTurn the ignition switch to โONโ with the registered ignition key. โCheck that the engine can be started using all registered ignition keys. 16-86 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Spare Ignition Key Registration Flow Chart ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) Case 2: When the ignition switch is faulty and to be replaced. โข Prepare a new ignition switch [A] and two new ignition keys [B]. โThese parts are available as a set. Prepare the current registered ignition key [C]. โข Remove: Ignition Switch (see Immobilizer System Parts Replacement) Front Seat (see Front Seat Removal in the Frame chapter) โข Remove the immobilizer/Kawasaki diagnostic system connector cap [A]. โข Connect the key registration unit [A] and key registration adapter [B] as shown. Special Tools – Key Registration Unit: 57001-1582 Key Registration Adapter: 57001-1746 โข Connect: New Ignition Switch Lead Connector [A] Current Immobilizer Antenna Lead Connector [B] NOTE โKeep the ignition switches more than 15 cm (5.9 in.). New Ignition Switch [C] Current Ignition Switch [D] โขInsert the current registered ignition key [A] at the current ignition switch [B]. โขInsert the new ignition key 1 [C] to the new ignition switch [D] and turn it to โON.โ 16-88 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 1 time and stops for 1 second and repeats this cycle. Not Verified โThe red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure Registered Ignition Key Collation Error โข Turn to โOFFโ and remove the new ignition key 1. NOTE โInsert the next key and turn it to โONโ within 15 seconds after previous key is turned to โOFFโ and removed otherwise registration mode will be ended and the red warning indicator (LED) and immobilizer warning indicator stops blinking. Verified โThe red warning indicator (LED) and immobilizer warning indicator [A] blink to display the ECU is in the registration mode (go to the next step). ELECTRICAL SYSTEM 16-89 Immobilizer System (Equipped Models) โข Disconnect the immobilizer antenna lead connector, then connect the antenna lead connector of the new ignition switch. โขInsert the ignition key 1 [A] again into the new ignition switch and turn it to โON.โ NOTE โInsert the next key and turn it to โONโ within 15 seconds after previous key is turned to โOFFโ and removed otherwise registration mode will be ended and the red warning indicator (LED) and immobilizer warning indicator stops blinking. โTo return to the registration mode start the registered ignition key verification procedure. This applies to all ignition key registration. โKeep other ignition keys away from the ignition switch. โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted. Ignition Key Collation Error 16-90 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) โข The ignition key 1 is successfully registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of ignition key 1. โข Turn to โOFFโ and remove ignition key 1. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink to display the registration mode. NOTE โTurn to โOFFโ the ignition switch and wait for the period more than 15 seconds. The registration mode automatically ends and red warning indicator (LED) and immobilizer warning indicator go off. โThis procedure has , registered the registered ignition key and one ignition key. โContinue the procedure to program the second and later keys. โขInsert the ignition key 2 to the ignition switch and turn it to โON.โ โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted. ELECTRICAL SYSTEM 16-91 Immobilizer System (Equipped Models) Ignition Key Collation Error โข The ignition key 2 is successfully registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 3 times and stops for 1 second and then repeat this cycle to indicate successful programming of ignition key 2. โข Turn to โOFFโ the ignition switch and wait for period more than 15 seconds. โข The registration mode automatically ends. โข The red warning indicator (LED) [A] goes off. โข Remove the key registration unit, key registration adapter and install the immobilizer/Kawasaki diagnostic system connector cap. NOTE โTurn the ignition switch to โONโ with the registered ignition key. โCheck that the engine can be started using all registered ignition keys. โขInstall the new ignition switch (see Immobilizer System Parts Replacement). Case 3: When the ECU is faulty and has to be replaced. โข Prepare a new ECU [A] and current registered ignition key(s) [B]. NOTE โThe key registration unit is not required. โAfter replacing the ECU, be sure to register the 2 ignition keys. If the 2 keys are not registered, the engine can not be started. 16-92 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) โข Replace the ECU [A] (see ECU Removal/Installation in the Fuel System (DFI) chapter). โขInsert the current registered ignition key into the ignition switch and turn it to โON.โ โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure Registered Ignition Key Collation Error โข The registered ignition key is registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the registered ignition key. ELECTRICAL SYSTEM 16-93 Immobilizer System (Equipped Models) โข Turn to โOFFโ the registered ignition key and remove it. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink to display the registration mode. NOTE โInsert next key and turn it to โONโ within 15 seconds after previous key is turned to โOFFโ and removed otherwise registration mode will be ended and the red warning indicator (LED) and immobilizer warning indicator go off. โTo return to the registration mode start the registered ignition key verification procedure. This applies to all ignition key registration. โขInsert the other remaining registered ignition key to the ignition switch and turn it to โON.โ NOTE โKeep the other ignition keys away from the immobilizer antenna. โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted. Ignition Key Collation Error 16-94 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) โข The other remaining ignition key is registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of ignition key. โข Turn to โOFFโ the ignition switch and wait for period more than 15 seconds. โข The registration mode automatically ends. โข The red warning indicator (LED) [A] goes off . NOTE โTurn the ignition switch to โONโ with the registered ignition key. โCheck that the engine can be started using all registered ignition keys. Case 4: When all registered ignition keys are faulty or lost. The all registered ignition keys replacement is considered very rare case. However if it is required, the following is necessary. NOTE โThe ECU must be replaced with a new one because the registered ignition key code that is registered in the current ECU can not be rewritten. โข Prepare a new ECU [A] and 2 new ignition keys [B]. NOTE โThe key registration unit is not required. โAfter replacing the ECU, be sure to register the 2 ignition keys. If the 2 keys are not registered, the engine can not be started. โขInsert the first ignition key into the ignition switch and turn it to โON.โ ELECTRICAL SYSTEM 16-95 Immobilizer System (Equipped Models) โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure Ignition Key Collation Error โข The first ignition key is registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the first ignition key. โข Turn to โOFFโ the first ignition key and remove it. โข The red warning indicator (LED) and immobilizer warning indicator [A] blink to display the registration mode. NOTE โInsert next key and turn it to โONโ within 15 seconds after previous key is turned to โOFFโ and removed otherwise registration mode will be ended and the red warning indicator (LED) and immobilizer warning indicator go off. โTo return to the registration mode start the registered ignition key verification procedure. This applies to all ignition key registration. โขInsert the second ignition key to the ignition switch and turn it to โON.โ NOTE โKeep the other ignition keys away from the immobilizer antenna. 16-96 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) โIf there is any problem in the registration, the red warning indicator (LED) and immobilizer warning indicator [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error โข The second ignition key is registered in the ECU. โThe red warning indicator (LED) and immobilizer warning indicator [A] blink 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of second ignition key. โข Turn to โOFFโ the ignition switch and wait for period more than 15 seconds. โข The registration mode automatically ends. โข The red warning indicator (LED) [A] goes off. ELECTRICAL SYSTEM 16-97 Immobilizer System (Equipped Models) NOTE โTurn the ignition switch to โONโ with the registered ignition key. โCheck that the engine can be started using all registered ignition keys. 16-98 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) All Keys Initial Registration Flow Chart ELECTRICAL SYSTEM 16-99 Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Ignition Switch Replacement โข Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) โข Slide the dust cover [A]. โข Disconnect the lead connectors [B]. โข Using a punch mark the punch mark at the center of broken Torx bolt head [A]. NOTE โMake the punch mark at center of the bolt head surely. โข Extend the punch mark with the 2 mm drill. โขIn addition, extend the punch mark with the 3.5 mm drill. โข Lastly, shave off the Torx bolt head with the 6.5 mm drill. NOTE โBe sure to do not damage the lead wires and component parts with a drill. โข Remove the guide [B] and ignition switch. โข Replace the ignition switch [A] with a new one. โข Hold the ignition switch lead [B] with the guide [C] as shown. Install the dampers and washers [D]. โข Tighten a new Torx bolt [A] until the bolt head [B] is broken [C]. โข Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โข Register the more than two ignition keys (see Key Registration). 16-100 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer Amplifier Replacement โข Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). โข Remove the immobilizer amplifier [A] from the bracket. โข Disconnect the connector [B]. โขInstallation is the reverse of removal. ECU Replacement (EUR Model) NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. NOTE โReplace the ECU according to the following procedure for the models with the ECU guard. โRefer to the ECU Removal/Installation in the Fuel System (DFI) chapter for the models without the ECU guard. โข Remove: Front Seat (see Front Seat Removal in the Frame chapter) โข Using a small chisel or other suitable tool, remove the ECU guard bolts [A] and ECU guard [B]. โข Remove: Relay Box (see Relay Box Removal) โข Disconnect ECU connectors [A]. โข Remove the ECU [B]. โข Connect the connectors to the ECU. โขInstall the ECU guard [A]. NOTICE Do not pinch the leads. โข Tighten the new ECU guard bolts [B] using the Kawasaki genuine screws of which threads are coated with locking agent. ELECTRICAL SYSTEM 16-101 Immobilizer System (Equipped Models) Registered Immobilizer Relational Parts Replacement Chart Failed or Lost Part Ignition Keys Ignition Switch Amplifier ECU Ignition Key โข โ Ignition Switch โข Amplifier โข * ECU โ โข * Replacement Part โข Main Replacement Part โ Additional Replacement Part Immobilizer System Inspection โข Refer to the Immobilizer Amplifier and Blank Key Detection section in the Fuel System (DFI) chapter. 16-102 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Circuit 1. Ignition Switch 2. ECU 3. Immobilizer/Kawasaki Diagnostic System Connector 4. Frame Ground (5) 5. Frame Ground (4) 6. Engine Ground 7. Battery 12 V 8 Ah 8. Starter Relay 9. Main Fuse 30 A 10. Joint Connector (1) 11. Joint Connector (2) 12. Meter Unit 13. Fuse Box (1) 14. Ignition Fuse 15 A 15. Immobilizer Antenna 16. Immobilizer Amplifier ELECTRICAL SYSTEM 16-103 Switches and Sensors Brake Light Timing Inspection โข Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment โข Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection โข Using a tester, check to see that only the connections shown in the table have continuity (about zero ohms). โFor 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. Rear Brake Light Switch Connections Side Stand Switch Connections Oil Pressure Switch Connections* *: Engine lubrication system is in good condition. 16-104 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection โข Remove the water temperature sensor (see Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter). โข Suspend the sensor [A] in a container of coolant so that the threaded portion is submerged. โข Suspend an accurate thermometer [B] with temperature sensing portions [C] located in almost the same depth. NOTE โThe sensor and thermometer must not touch the container side or bottom. โข Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently. โข Using a digital meter, measure the internal resistance of the sensor. If the digital meter does not show the specified values, replace the sensor. Water Temperature Sensor Resistance Temperature Resistance (kโฆ) โ20ยฐC (โ4ยฐF) *18.80 ยฑ2.37 0ยฐC (32ยฐF) *(about 6.544) 40ยฐC (104ยฐF) 1.136 ยฑ0.095 100ยฐC (212ยฐF) 0.1553 ยฑ0.0070 *: Reference Information Oxygen Sensor Removal NOTICE Never drop the sensor especially on a hard surface. Such a shock to the sensor can damage it. NOTICE Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open. โข Clear the oxygen sensor lead from the clamp [A]. โข Disconnect the oxygen sensor lead connector [B]. โข Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Exhaust Pipe Cover (see Muffler Body Removal in the Engine Top chapter) โข Clear the oxygen sensor lead from the clamp [A]. โข Remove the oxygen sensor [B]. ELECTRICAL SYSTEM 16-105 Switches and Sensors Oxygen Sensor Installation NOTICE Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] and filter holes [C] of the sensor to prevent oil contact. Oil contamination from hands can reduce sensor performance. โข Tighten: Torque – Oxygen Sensor: 45 Nยทm (4.6 kgfยทm, 33 ftยทlb) โข Run the oxygen sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). โขInstall the removed (see appropriate chapters). Oxygen Sensor Inspection โข Refer to the Oxygen Sensor Inspection in the Fuel System (DFI) chapter. Fuel Level Sensor Inspection โข Remove: Fuel Pump (see Fuel Pump Removal in the Fuel System (DFI) chapter) โข Check that the float moves up and down smoothly without binding. It should go down under its own weight. If the float does not move smoothly, replace the fuel pump. Float in Full Position [A] Float in Empty Position [B] โข Using a tester [A], measure the resistance across the terminals in the fuel level sensor lead connector [B]. Special Tool – Needle Adapter Set: 57001-1457 If the tester readings are not as specified, or do not change smoothly according as the float moves up and down, replace the fuel pump. Fuel Level Sensor Resistance Standard: Full position: 9.6 ๏พ 12.4 โฆ Empty position: 222 ๏พ 228 โฆ Gear Position Sensor Removal โข Drain: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) โข Disconnect the connector [A] to remove the gear position sensor. โข Remove the gear position sensor bolt [B] and pull out the gear position sensor [C]. 16-106 ELECTRICAL SYSTEM Switches and Sensors Gear Position Sensor Installation If replace the gear position sensor, select new sensor which has same mark with the current one. Mark [A] Parts Number H 21176-0845 M 21176-0825 L 21176-0846 โข Replace the O-ring [A] with a new one. โข Apply grease to the O-ring. โข Apply a non-permanent locking agent to the threads of the gear position sensor bolt [A]. โขInstall the gear position sensor [B] to the crankcase. โWhen installing the sensor which is fastened by bolt, tighten the bolt after placing the sensor on the bottom surface completely. Torque – Gear Position Sensor Bolt: 10 Nยทm (1.0 kgfยทm, 89 inยทlb) โข Connect the connector [C] to the gear position sensor. โข Fill the engine with recommended engine oil (see Engine Oil Change in the Periodic Maintenance chapter). Gear Position Sensor Inspection โข Refer to the Gear Position Sensor Input Voltage Inspection in the Fuel System (DFI) chapter. Outside Temperature Sensor Removal โข Remove the meter cover (see Upper Fairing Removal in the Frame chapter). โข Disconnect the connector [A]. โข Remove: Outside Temperature Sensor Screw [B] Outside Temperature Sensor [C] ELECTRICAL SYSTEM 16-107 Switches and Sensors Outside Temperature Sensor Installation โข Check that the O-ring [A] is in place on the outside temperature sensor [B]. โขInstall the outside temperature sensor. โข Tighten: Torque – Outside Temperature Sensor Screw: 0.50 Nยทm (0.05 kgfยทm, 4.4 inยทlb) โข Connect the connector. โขInstall the removed parts (see appropriate chapters). 16-108 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal/Installation NOTICE Never drop the relay box especially on a hard surface. Such a shock to the relay box can damage it. โข Remove the rear fender from the battery case and rear frame (see Flap and Rear Fender Removal in the Frame chapter). โข Disconnect: Connectors [A] โข Remove: Relay Box [B] โขInstallation is the reverse of removal. Relay Circuit Inspection โข Remove the relay box (see Relay Box Removal). โข Check conductivity of the following numbered terminals by connecting a tester and one 12 V battery to the relay box as shown (see Relay Box Internal Circuit in this section). If the tester does not read as specified, replace the relay box. Relay Circuit Inspection (with the battery disconnected) Tester Connection Tester Reading (โฆ) Headlight Circuit Relay 1-3 โ 7-6 โ ECU Main Relay 4-5 Not โ* 7-8 โ Fuel Pump Relay 9-10 Not โ* 11-16 โ Starter Circuit Relay 11-12 โ 17-20 โ Fan Relay 18-19 Not โ* *: The actual reading varies with the tester used. ELECTRICAL SYSTEM 16-109 Relay Box Relay Circuit Inspection (with the battery connected) Battery Connection (+) (โ) Tester Connection Tester Reading (โฆ) Headlight Relay 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 Connection (+) (โ) Tester Connection (+) (โ) Tester Reading (V) Starter Circuit Relay 16-12 11-12 Battery Voltage (+): Apply positive lead. (โ): Apply negative lead. Diode Circuit Inspection โข Remove the relay box (see Relay Box Removal). โข Check conductivity of the following pairs of terminals (see Relay Box Internal Circuit in this section). Diode Circuit Inspection Tester Connection 1-11, 2-11, 12-13, 12-15, 12-16, 13-14, 13-15 The resistance should be low in one direction and more than 10 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 โThe actual meter reading varies with the meter or tester used and the individual diodes, but generally speaking, the lower reading should be from zero to one half the scale. 16-110 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A. Headlight Circuit Relay B. ECU Main Relay C. Fuel Pump Relay D. Starter Circuit Relay E. Fan Relay ELECTRICAL SYSTEM 16-111 Fuse 30 A Main/15 A ECU Fuse Removal โข Remove: Starter Relay Cover (see Starter Relay Inspection) โข Pull out the fuses [A] from the starter relay with needle nose pliers. Fuse Box Fuse Removal โข Remove: Front Seat (see Front Seat Removal in the Frame chapter) โข Unlock the hook [A] to lift up the lid. Fuse Box (1) [B] Fuse Box (2) [C] โข Pull the fuses [A] straight out of the fuse box with needle nose pliers. Fuse Installation If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. โขInstall the fuse box fuses on the original position as specified on the lid. Fuse Inspection โข Remove the fuse (see 30 A Main/15 A ECU/Fuse Box Fuse Removal). โขInspect 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] NOTICE When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components. APPENDIX 17-1 17 Appendix Table of Contents Cable, Wire, and Hose Routing 17-2 Troubleshooting Guide . 17-44 17-2 APPENDIX Cable, Wire, and Hose Routing 1. Clamp (Hold the main harness.) 2. Clamp (Hold the left front turn signal light lead to the left upper fairing.) 3. Left Front Turn Signal Light Lead 4. Clamp (Hold the right front turn signal light lead to the right upper fairing.) 5. Right Front Turn Signal Light Lead 6. Run the left front turn signal light lead into the hole of the left upper fairing. 7. Run the right front turn signal light lead into the hole of the right upper fairing. APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Clamp (Hold the right front turn signal light lead to the meter bracket.) 2. Meter Lead 3. Clamp (Hold the main harness to the meter bracket.) 4. Turn Signal Relay 5. Horn 6. Install the horn connectors to the horn as shown. 17-4 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clamp (Run the clutch cable and left switch housing lead in order from the inside of the motorcycle.) 2. Clutch Cable 3. Left Switch Housing Lead 4. Clamp (Hold the clutch cable and left switch housing lead.) 5. Run the ignition switch lead, immobilizer antenna lead (equipped models), left switch housing lead and clutch cable to the inside of the front fork. 6. Ignition Switch Lead 7. Immobilizer Antenna Lead (Equipped Models) 8. Run the ignition switch lead and immobilizer antenna lead (equipped models) through the clamp. 9. Run the ignition switch lead, immobilizer antenna lead (equipped models) and left switch housing lead to the inside of the clamp. 10. Run the clutch cable to the inside of the radiator mounting position. Run the clutch cable under the other leads. 17-6 APPENDIX Cable, Wire, and Hose Routing 1. Throttle Cable (Decelerator) 2. Throttle Cable (Accelerator) 3. Clamp (Run the brake hose, throttle cable (decelerator), throttle cable (accelerator) and right switch housing lead in order from the outside of the motorcycle.) 4. Clutch Cable 5. Run the brake hose to the front side of the right switch housing lead and throttle cables. Run the right switch housing lead to the rear side of the brake hose and throttle cables. 6. Run the throttle cables, clutch cable, right switch housing lead and purge valve lead (equipped models) through this point to the inside of the frame. 7. Purge Valve Lead (Equipped Models) 8. Right Switch Housing Lead 9. Brake Hose APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Canister (Equipped Models) 2. Install the front wheel rotation sensor to the windshield bracket assembly. 3. Right Front Turn Signal Light Lead 4. Clutch Cable 5. Clamp (Hold the clutch cable.) 6. Quick Rivet (Hold the front heat insulation rubber plate to the bracket.) 7. Front Heat Insulation Rubber Plate 8. Viewed from A 17-8 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Run the purge hose (equipped models) to left side of the stick coil #2 lead. 2. Air Switching Valve 3. Run the purge hose (equipped models) under the air switching valve hose. 4. Air Switching Valve Hose 5. Run the purge hose (equipped models) above the bracket. 6. Stick Coil Lead 7. Hold the breather hose (equipped models) and the water hose with the clamp. Run the breather hose (equipped models) inside of the water hose. 8. Run the air switching valve hose to the upside of the stick coil lead. 9. Breather Hose (Equipped Models) 10. Run the breather hose (equipped models) under the crankshaft sensor lead, wheel rotation sensor lead and alternator lead. 11. Crankshaft Sensor Lead 12. Alternator Lead 13. Rear Wheel Rotation Sensor Lead 14. Intake Air Temperature Sensor Lead 15. Run the intake air temperature sensor lead under the crankshaft senor lead, rear wheel rotation sensor lead and alternator lead. 16. Clamps (Hold the fuel injector lead.) 17. Fuel Tank Breather Hose 18. Run the fuel injector lead in front of the fuel tank breather hose. 19. Run the subharness between the throttle body assy holder #1 and #2. Do not pinch the subharness with the throttle body assy. 20. Subharness 21. Run the right switch housing lead under the other leads and cables. 22. Clamp (Hold the vacuum hose and main harness at the white tape position of the main harness.) 23. Vacuum Hose 24. Main Harness 17-10 APPENDIX Cable, Wire, and Hose Routing 1. Run the ignition switch lead and immobilizer antenna lead (equipped models) under the left switch housing lead. 2. Left Switch Housing Lead 3. Ignition Switch Lead 4. Immobilizer Antenna Lead (Equipped Models) 5. Main Harness 6. Run the main harness between the bracket and frame. 7. Install the clamps to the frame as shown. 8. 5 mm (0.20 in.) 9. 3 mm (0.12 in.) APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Crankshaft Sensor Lead Connector (Install it to the connector bracket.) 2. Connector Bracket (Install it to the air cleaner housing.) 3. Rear Wheel Rotation Sensor Lead Connector (Install it to the connector bracket.) 4. Alternator Lead Connector (Install it to the connector bracket.) 5. Run the radiator overflow hose between the main throttle sensor and subthrottle sensor. 6. Radiator Overflow Hose 7. Battery Negative (โ) Cable 8. Run the starter motor cable to the outside of the battery negative (โ) cable. 9. Starter Motor Cable 10. Clamp (Face the open side of the clamp upward and install it to the frame. Then hold the breather hose (equipped models) at the blue paint position of the breather hose (equipped models).) 11. Side Stand Switch Lead 12. Run the side stand switch lead to the rear side of the fuel tank breather hose. Run the alternator lead and crankshaft sensor lead to the front side of the fuel tank breather hose. 17-12 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Regulator/Rectifier 2. Immobilizer Amplifier (Equipped Models) 3. Regulator/Rectifier Lead Connector 4. Run the regulator/rectifier lead to the inside of the main harness. 5. Main Harness 6. Cover the right switch housing lead connector, ignition switch lead connector, radiator fan motor lead connector and immobilizer antenna lead connector (equipped models) with the dust cover. 7. Band (Hold the dust cover. Cut the band excess length after holding the dust cover.) 8. Clamp (Hold the right switch housing lead, ignition switch lead, radiator fan motor lead and immobilizer antenna lead (equipped models).) 9. Radiator Fan Motor Lead 10. Ignition Switch Lead 11. Right Switch Housing Lead 12. Run the subharness under the bracket, cables and other leads. 13. Install the clamp to the bracket as shown. 14. Immobilizer Antenna Lead (Equipped Models) 17-14 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Air Cleaner Drain Hose 2. Alternator Lead 3. Side Stand Switch Lead 4. Run the starter motor cable to the inside of the other hoses, alternator lead and side stand switch lead. 5. Clamp (Hold the reserve tank overflow hose, side stand switch lead, alternator lead, fuel tank chain hose and subharness.) 6. Reserve Tank Overflow Hose 7. Clamp (Hold the side stand switch lead and subharness.) 8. Fuel Tank Drain Hose 9. Run the alternator lead to the inside of the subharness. 10. Starter Motor Cable 11. Subharness 17-16 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Idle Adjusting Cable 2. Clamp (Hold the alternator lead and side stand switch lead, and face the open side of the clamp forward.) 3. Fuel Hose 4. Run the fuel hose, battery negative (โ) cable, starter motor cable and fuel tank drain hose in order from the inside of the frame. 5. Battery Negative (โ) Cable 6. Side Stand Switch Lead 7. Alternator Lead 8. Fuel Tank Drain Hose 9. Reserve Tank Overflow Hose 10. Run the reserve tank overflow hose and side stand switch lead to the inside of the engine sprocket cover. 11. Air Cleaner Drain Hose 12. Starter Motor Cable 13. Run the idle adjusting cable to the under of the air cleaner drain hose. Run the idle adjusting cable to the front side of the side stand switch lead and alternator lead. Run the idle adjusting cable to the outside of the air cleaner drain hose. 17-18 APPENDIX Cable, Wire, and Hose Routing 1. Radiator Overflow Hose 2. Breather Hose (Equipped Models) 3. Run the water hose, breather hose (equipped models), radiator overflow hose and air bleeder hose in order from the outside of the frame. 4. Water Hose 5. Air Bleeder Hose 6. Clutch Cable 7. Run the clutch cable through the clamp of the crankshaft sensor cover. 8. Crankshaft Sensor Lead 9. Oxygen Sensor Lead 10. Clamp (Hold the oxygen sensor lead and crankshaft sensor lead.) APPENDIX 17-19 Cable, Wire, and Hose Routing This page intentionally left blank. 17-20 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Run the alternator lead and crankshaft sensor lead through this point. 2. Rear Wheel Rotation Sensor Lead 3. Run the rear wheel rotation sensor lead through this point. 4. Clamp (Hold the main harness and heat insulation rubber plate, and face the open side of the clamp to the right side.) 5. Main Harness 6. Rivets (Hold the heat insulation rubber plate to the battery case.) 7. Crankshaft Sensor Lead 8. Alternator Lead 9. Battery Negative (โ) Cable 10. Run the breather hose (equipped models) to right side of the battery negative (โ) cable. 11. Run the breather hose (equipped models) under the battery negative (โ) cable. 12. Clamp (Face the open side of the clamp upward and install it to the frame. Then hold the breather hose (equipped models) at the blue paint position of the breather hose.) 13. Fuel Tank Drain Hose 14. Run the breather hose (equipped models) under the fuel tank drain hose. 15. Run the fuel tank drain hose into the hole of the heat insulation rubber plate. 16. Breather Hose (Equipped Models) (Run it above the heat insulation rubber plate.) 17. Run the fuel hose into the hole of the heat insulation rubber plate. 18. Fuel Hose 19. Run the fuel tank breather hose (US and CA models) and battery negative (โ) cable into the hole of the heat insulation rubber plate. 17-22 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Main Harness 2. Crankshaft Sensor Lead 3. Run the oxygen sensor lead, crankshaft sensor lead and rear brake light switch lead to the outside of the main harness. 4. Clamp (Hold the rear wheel rotation sensor lead.) 5. Rear Wheel Rotation Sensor Lead 6. Oxygen Sensor Lead 7. Clamp (Hold the oxygen sensor lead, crankshaft sensor lead and rear brake light switch lead.) 8. Rear Brake Light Switch Lead 9. Run the oxygen sensor lead and crankshaft sensor lead between the clamp and frame. 10. Clamp (Hold the reserve tank overflow hose.) 11. Reserve Tank Overflow Hose 12. Radiator Overflow Hose 13. Run the radiator overflow hose through the clamps. 14. Run the radiator overflow hose to the inside of the reserve tank overflow hose. 17-24 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Spring Preload Adjuster Hose 2. Rear Wheel Rotation Sensor Lead 3. Run the rear wheel rotation sensor lead to the outside of the brake pipes. 4. Run the rear brake light switch lead to the inside of the brake pipes. 5. Brake Pipes 6. Run the spring preload adjuster hose to the inside of the brake pipes. 7. Run the spring preload adjuster hose between the frame and clamp. 8. Rear Brake Light Switch Lead 9. Run the rear brake light switch lead and rear wheel rotation sensor lead to the outside of the spring preload adjuster hose. 10. Clamp (Hold the rear brake light switch lead and rear wheel rotation sensor lead.) 11. Run the brake pipe to the inside of the rear brake light switch lead. 12. Crankshaft Sensor Lead 13. Oxygen Sensor Lead 14. Bend the clamp rearward to hold the crankshaft sensor and oxygen sensor lead. 17-26 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Fuel Pump Lead 2. Main Harness 3. Install the clamp to the battery case as shown. 4. Run the fuel pump lead to the upside of the main harness. 5. Run the fuel pump lead and main harness to the outside of the fuse boxes. 6. Clamp (Hold the fuel pump lead and main harness.) 7. Install the fuel pump lead connector to the bracket. 8. Battery Positive (+) Cable 9. Run the starter motor cable to the inside of the battery positive (+) cable. 10. Starter Relay 11. Starter Motor Cable 12. Run the starter motor cable between the starter relay and battery. 13. Run the starter motor cable to the upside of the main harness. 14. Battery 15. Fuse Boxes 16. Install the clamp to the frame as shown. 17-28 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Hold the right rear turn signal light lead connector and left rear turn signal light lead connector to the bracket. 2. Left Rear Turn Signal Light Lead Connector 3. Main Harness 4. Run the main harness to the right side of the rear turn signal light lead connectors. 5. Right Rear Turn Signal Light Lead Connector 6. License Plate Light Lead 7. Relay Box 8. Clamp (Hold the license plate light lead, tail/brake light lead and rear turn signal light leads. When installing the clamp, bended portion of the clamp faces to inside.) 9. Seat Lock Cable 10. Run the seat lock cable to the front side of the rib. Run the seat lock cable to the upside of the license plate light lead, tail/brake light lead and rear turn signal light leads. 11. Left Rear Turn Signal Light Lead 12. Right Rear Turn Signal Light Lead 13. Clamp (Hold the rear turn signal light leads, and face the open side of the clamp rearward.) 14. Tail/Brake Light Lead 15. Run the license plate light lead through this point. 16. Put the tail/brake light lead connector in this position. Do not pinch the tail/brake light lead with the rear fender. 17. Bend the clamp upward to hold the tail/brake light lead. 18. Run the rear turn signal light leads through this point. 19. ECU 20. Run the ECU leads to the front side of the rib. 21. ECU Leads 22. ABS Kawasaki Diagnosis System Connector 23. Kawasaki Diagnostic System Connector 17-30 APPENDIX Cable, Wire, and Hose Routing 1. Right Rear Turn Signal Light Lead 2. Run the license plate light lead, left rear turn signal light lead and right rear turn signal light lead to the upside of the flap. 3. Clamp (Hold the license plate light lead, left rear turn signal light lead and right rear turn signal light lead.) 4. License Plate Light Lead 5. Left Rear Turn Signal Light Lead APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Water Temperature Sensor Lead 2. Subharness 3. Clamp (Hold the gear position sensor/oil pressure switch lead. Attach the clamp to the upside of the water pipe branch.) 4. Run the gear position sensor/oil pressure switch lead to the rear side of the water pipe branch. 5. Connect the gear position sensor lead to the gear position sensor. Do not stretch the lead after connected. 6. Run the oil pressure switch lead to the inside of the water hose. 7. Cover the oil pressure switch with the switch cover. 8. Water Pipe 9. Viewed from A 17-32 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Front Heat Insulation Rubber Plate 2. Stick Coil Connectors 3. Throttle Body Assy Holder #3 and #4 4. Fuel Hose 5. Rear Heat Insulation Rubber Plate (Install the rear heat insulation rubber plate to the throttle body assy holder #2 and #3.) 6. Breather Hose 17-34 APPENDIX Cable, Wire, and Hose Routing 1. Install the clamps as shown. 2. Water Hoses 3. Air Bleeder Hose 4. Radiator Overflow Hose 5. Reserve Tank Overflow Hose 6. Coolant Reserve Tank APPENDIX 17-35 Cable, Wire, and Hose Routing This page intentionally left blank. 17-36 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Water Hoses 2. Install the clamps as shown. 3. Install the water hose so that the white paint mark faces upward. 4. Install the water hose so that the white paint mark faces outward. 5. Align the yellow paint mark of the water hose with the projection on the water pipe. 6. Install the water hose until the rised portion of the water pipe. 7. Install the water hose until the half of the punch mark is hidden. 8. Air Bleeder Hose 9. Install the air bleeder hose above the thermostat cover bolt. 10. Viewed from A 11. Viewed from B 12. Viewed from C 13. Install the clamp so that the tab of the clamp faces rearward. 14. Breather Hose 15. Install the breather hose so that the white paint mark faces rearward. 17-38 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-39 Cable, Wire, and Hose Routing 1. Front Brake Hose 2. Front Wheel Rotation Sensor Lead 3. Clamp (Hold the front wheel rotation sensor lead.) 4. Clamp (Hold the front wheel rotation sensor lead.) 5. Clamps (Hold the front brake hose.) 6. Clamps (Hold the front brake hose and front wheel rotation sensor lead.) 7. Clamps (Hold the brake pipes.) 8. Front Wheel Rotation Sensor 9. About 90ยฐ 10. About 50ยฐ 17-40 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Rear Brake Hose 2. Run the rear wheel rotation sensor lead through the clamp. 3. Rear Wheel Rotation Sensor Lead 4. Clamp (Hold the rear wheel rotation sensor lead.) 5. Clamp (Hold the rear brake hose.) 6. Clamp (Hold the rear brake hose.) 7. Clamps (Hold the rear brake hose and rear wheel rotation sensor lead.) 8. Clamp (Hold the rear wheel rotation sensor lead.) 9. Clamp (Hold the rear wheel rotation sensor lead.) 10. Rear Wheel Rotation Sensor 11. About 9ยฐ 12. About 3ยฐ 17-42 APPENDIX Cable, Wire, and Hose Routing 1. Brake Pipes 2. Clamp (Hold the brake pipes.) 3. Clamp (Hold the brake pipe.) 4. Run the brake hoses under the other leads. 5. Brake Hoses APPENDIX 17-43 Cable, Wire, and Hose Routing Other than US and CA Models 1. Breather Hose 2. Purge Hose (to Canister) 3. Install the clamps so that their tabs face outward of the motorcycle. 4. Canister 5. Purge Valve 6. Purge Hose 7. Purge Valve Lead 8. Run the purge hose to the inside of the purge valve lead and the radiator overflow hose. 9. Radiator Overflow Hose 10. Run the purge hose above the radiator cap housing mounting bolt. 11. Clamp (Hold the purge hose (to canister).) 17-44 APPENDIX Troubleshooting Guide NOTE โRefer to the Fuel System chapter for most of DFI trouble shooting guide. โThis is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesnโt Start, Starting Difficulty: Starter motor not rotating: Ignition and engine stop switch not on Starter lockout switch or gear position sensor trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesnโt turn over: Vehicle-down sensor (DFI) coming off Immobilizer system trouble (Equipped Models) Starter clutch trouble Starter idle gear trouble Engine wonโt turn over: Valve seizure Valve lifter seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure Balancer bearing seizure No fuel flow: No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark; spark weak: Vehicle-down sensor (DFI) coming off Ignition switch not on Engine stop switch turned to stop position Clutch lever not pulled in or gear not in neutral Battery voltage low Immobilizer system trouble (Equipped Models) Spark plug dirty, broken, or gap maladjusted Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble Gear position sensor, starter lockout, or side stand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Fuel/air mixture incorrect: Bypass screw maladjusted Air passage clogged Air cleaner clogged, poorly sealed, or missing Leak from oil filler cap, crankcase breather hose or air cleaner drain hose. Compression Low: Spark plug loose Cylinder head not sufficiently tightened down Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Poor Running at Low Speed: Spark weak: Battery voltage low Immobilizer system trouble (Equipped Models) Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Crankshaft sensor trouble Fuel/air mixture incorrect: Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged, poorly sealed, or missing Fuel tank air vent obstructed Fuel pump trouble Fuel to injector insufficient APPENDIX 17-45 Troubleshooting Guide Fuel line clogged Throttle body assy holder loose Air cleaner housing holder loose Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Camshaft cam worm Run-on (dieseling): Ignition switch trouble Engine stop switch trouble Fuel injector trouble Carbon accumulating on valve seating surface Engine overheating Other: ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Air cleaner housing holder loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.) Knocking: Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous: Throttle valve wonโt fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worm Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating (KLEEN) Overheating: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Muffler overheating: For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running (Request the nearest service facility to correct it) For KLEEN, do not push-start with a dead battery (Connect another full-charged battery with jumper cables, and start the engine using the electric starter) For KLEEN, do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN, do not coast the motorcycle with the ignition switch off (Turn the ignition switch on and run the engine) ECU trouble Fuel/air mixture incorrect: Throttle body assy holder loose 17-46 APPENDIX Troubleshooting Guide Air cleaner housing holder loose Air cleaner poorly sealed, or missing Air cleaner clogged Compression high: Carbon built up in combustion chamber Engine load faulty: Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect: Oil cooler clogged Gauge incorrect: Water temperature gauge broken Water temperature sensor broken Coolant incorrect: Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect: Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling: Gauge incorrect: Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect: Thermostat trouble Clutch Operation Faulty: Clutch slipping: Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly: Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble Gear Shifting Faulty: Doesnโt go into gear; shift pedal doesnโt return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear: Shift fork ear worn, bent Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Gear positioning lever spring weak or broken Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts: Gear positioning lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise: Knocking: ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise: Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring/groove clearance excessive Piston ring worn, broken, or stuck APPENDIX 17-47 Troubleshooting Guide Piston ring groove worn Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating (KLEEN) Balancer gear worn or chipped Balancer shaft position maladjusted Balancer bearing worn Balancer rubber damper damaged Abnormal Drive Train Noise: Clutch noise: Clutch damper weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise: Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise: Drive chain adjusted improperly Drive chain worn Rear and/or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise: Front fork noise: Oil insufficient or too thin Spring weak or broken Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise: Bracket, nut, bolt, etc. not properly mounted or tightened Warning Indicator (LED) (Oil Pressure Warning) Doesnโt Go OFF: Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O-ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively: White smoke: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner clogged Brown smoke: Air cleaner housing holder loose Air cleaner poorly sealed or missing Handling and/or Stability Unsatisfactory: Handlebars hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Tire air pressure too low Handlebars shakes or excessively vibrates: Tire worn Swingarm pivot bearing worn Rim warped, or not balanced Wheel bearing worn Handlebar holder clamp bolt loose Steering stem nut loose Front, rear axle runout excessive Engine mounting bolt loose Handlebars pulls to one side: Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent 17-48 APPENDIX Troubleshooting Guide Right and left front fork oil level uneven Shock absorption unsatisfactory: (Too hard) Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent (Too soft) Tire air pressure too low Front fork oil insufficient and/or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesnโt 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 Part No.99924-1519-01 MODEL APPLICATION Year Model Beginning Frame No. 2017 ZX1000WH JKAZXCW1โกHA000001 JKAZXT00WWA000001 โก:This digit in the frame number changes from one machine to another.
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SEOCONTENT-START
General Information Table of Contents Before Servicing . 1-2 Model Identification. 1-7 General Specifications 1-8 Unit Conversion Table 1-11 Periodic Maintenance Table of Contents Periodic Maintenance Chart . 2-3 Torque and Locking Agent 2-5 Specifications . 2-12 Special Tools 2-14 Periodic Maintenance Procedures 2-15 Fuel System (DFI) 2-15 Air Cleaner Element Replacement 2-15 Idle Speed Inspection . 2-16 Idle Speed Adjustment 2-16 Throttle Control System Inspection. 2-16 Engine Vacuum Synchronization Inspection. 2-17 Fuel System Inspection. 2-20 Fuel Filter Replacement 2-21 Fuel Hose Replacement . 2-23 Evaporative Emission Control System Inspection (Other than US and CA Models) 2-24 Cooling System 2-25 Coolant Level Inspection. 2-25 Cooling System Inspection . 2-26 Coolant Change 2-26 Water Hose and O-ring Replacement. 2-29 Engine Top End . 2-30 Valve Clearance Inspection 2-30 Valve Clearance Adjustment. 2-31 Air Suction System Damage Inspection 2-35 Clutch. 2-36 Clutch Operation Inspection . 2-36 Engine Lubrication System 2-37 Engine Oil Change 2-37 Oil Filter Replacement 2-38 Wheels/Tires 2-38 Air Pressure Inspection. 2-38 Wheels and Tires Inspection. 2-38 Wheel Bearing Damage Inspection 2-39 Final Drive 2-40 Drive Chain Lubrication Condition Inspection . 2-40 Drive Chain Slack Inspection 2-41 Drive Chain Slack Adjustment 2-41 Wheel Alignment Inspection . 2-41 Wheel Alignment Adjustment 2-41 Drive Chain Wear Inspection 2-42 Chain Guide Wear Inspection . 2-42 Brakes 2-43 Brake System Inspection 2-43 Brake Operation Inspection 2-44 Brake Fluid Level Inspection. 2-44 Brake Fluid Change 2-45 Brake Hose and Pipe Replacement 2-46 Master Cylinder Rubber Parts Replacement 2-50 Caliper Rubber Parts Replacement 2-51 Brake Pad Wear Inspection 2-54 Brake Light Switch Operation Inspection 2-55 Suspension 2-56 Suspension System Inspection. 2-56 Steering . 2-57 Steering Play Inspection . 2-57 Steering Play Adjustment 2-57 Steering Stem Bearing Lubrication . 2-59 Electrical System . 2-60 Lights and Switches Operation Inspection 2-60 Headlight Aiming Inspection . 2-62 Side Stand Switch Operation Inspection. 2-63 Engine Stop Switch Operation Inspection. 2-64 Spark Plug Replacement 2-65 Others 2-65 Chassis Parts Lubrication 2-65 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-66 Fuel System (DFI) Table of Contents Exploded View. 3-4 DFI System 3-10 DFI Components Naming 3-12 DFI Parts Location. 3-17 Specifications 3-21 Special Tools and Sealant . 3-23 DFI Servicing Precautions. 3-25 DFI Servicing Precautions 3-25 Troubleshooting the DFI System . 3-27 Outline 3-27 Inquiries to Rider. 3-31 DFI System Troubleshooting Guide 3-34 Self-Diagnosis . 3-39 Self-Diagnosis Outline . 3-39 Self-Diagnosis Procedures 3-40 Service Code Reading . 3-41 Service Code Erasing 3-42 Backups . 3-44 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) 3-47 Main Throttle Sensor Removal/Adjustment. 3-47 Main Throttle Sensor Input Voltage Inspection. 3-47 Main Throttle Sensor Resistance Inspection 3-48 Main Throttle Sensor Output Voltage Inspection. 3-48 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) 3-51 Intake Air Pressure Sensor #1 Removal 3-51 Intake Air Pressure Sensor #1 Installation . 3-51 Intake Air Pressure Sensor #1 Input Voltage Inspection 3-52 Intake Air Pressure Sensor #1 Output Voltage Inspection . 3-53 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) 3-57 Intake Air Temperature Sensor Removal/Installation 3-57 Intake Air Temperature Sensor Output Voltage Inspection . 3-57 Intake Air Temperature Sensor Resistance Inspection . 3-59 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117). 3-60 Water Temperature Sensor Removal/Installation 3-60 Water Temperature Sensor Output Voltage Inspection . 3-60 Water Temperature Sensor Resistance Inspection . 3-61 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) 3-63 Intake Air Pressure Sensor #2 Removal 3-63 Intake Air Pressure Sensor #2 Installation . 3-63 Intake Air Pressure Sensor #2 Input Voltage Inspection 3-64 Intake Air Pressure Sensor #2 Output Voltage Inspection . 3-65 Crankshaft Sensor (Service Code 21) (DTC P0335). 3-67 Crankshaft Sensor Removal/Installation 3-67 Crankshaft Sensor Resistance Inspection 3-67 Crankshaft Sensor Peak Voltage Inspection 3-67 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158). 3-68 Rear Wheel Rotation Sensor Signal Inspection. 3-68 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0916) 3-70 Gear Position Sensor Removal/Installation 3-70 Gear Position Sensor Input Voltage Inspection. 3-70 Gear Position Sensor Output Voltage Inspection. 3-71 Front Wheel Rotation Sensor (Service Code 27) (DTC P0500). 3-73 Front Wheel Rotation Sensor Signal Inspection. 3-73 Vehicle-down Sensor (Service Code 31) (DTC C0064) 3-75 Vehicle-down Sensor Removal 3-75 Vehicle-down Sensor Installation . 3-76 Vehicle-down Sensor Input Voltage Inspection. 3-76 Vehicle-down Sensor Output Voltage Inspection. 3-77 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) 3-80 Subthrottle Sensor Removal/Adjustment. 3-80 Subthrottle Sensor Input Voltage Inspection 3-80 Subthrottle Sensor Output Voltage Inspection 3-81 Subthrottle Sensor Resistance Inspection 3-83 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) 3-84 Oxygen Sensor Removal/Installation 3-84 Oxygen Sensor Inspection. 3-84 Immobilizer Amplifier (Service Code 35, Equipped Models). 3-87 Antenna Resistance Inspection . 3-87 Amplifier Input Voltage Inspection 3-87 Blank Key Detection (Service Code 36, Equipped Models). 3-88 Ignition Key Inspection. 3-88 ECU Communication Error (Service Code 39) (DTC U0001). 3-89 ECU Communication Line Inspection 3-89 Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) 3-90 Fuel Injector Removal/Installation 3-90 Fuel Injector Audible Inspection. 3-90 Fuel Injector Resistance Inspection 3-90 Fuel Injector Power Source Voltage Inspection. 3-91 Fuel Injector Output Voltage Inspection 3-92 Fuel Injector Fuel Line Inspection 3-93 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) . 3-95 Stick Coil Removal/Installation. 3-95 Stick Coil Primary Winding Resistance Inspection . 3-95 Stick Coil Input Voltage Inspection 3-95 Radiator Fan Relay (Service Code 56) (DTC P0480) 3-97 Radiator Fan Relay Removal/Installation 3-97 Radiator Fan Relay Inspection. 3-97 Subthrottle Valve Actuator (Service Code 62) (DTC P2100). 3-98 Subthrottle Valve Actuator Removal 3-98 Subthrottle Valve Actuator Inspection 3-98 Subthrottle Valve Actuator Resistance Inspection . 3-98 Subthrottle Valve Actuator Input Voltage Inspection. 3-99 Air Switching Valve (Service Code 64) (DTC P0410) 3-101 Air Switching Valve Removal/Installation 3-101 Air Switching Valve Inspection . 3-101 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 3-102 Oxygen Sensor Heater Removal/Installation 3-102 Oxygen Sensor Heater Resistance Inspection . 3-102 Oxygen Sensor Heater Power Source Voltage Inspection 3-103 Fuel Supply System (Service Code 94) (DTC P0170) 3-105 Fuel Supply System Inspection 3-105 Purge Valve (Service Code 3A) (DTC P0443) (Other than US and CA Models). 3-106 Purge Valve Removal/Installation . 3-106 Purge Valve Inspection 3-106 IMU (Inertial Measurement Unit) (Service Code E8E) 3-108 IMU Removal . 3-108 IMU Installation 3-108 IMU Power Supply Inspection 3-108 IMU (Inertial Measurement Unit) Communication Error (Service Code E8F) 3-110 IMU Communication Line Inspection 3-110 Warning Indicator Light (LED) . 3-111 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-111 ECU. 3-112 ECU Identification 3-112 ECU Removal 3-112 ECU Installation . 3-112 ECU Power Supply Inspection. 3-113 CAN Communication Line . 3-116 CAN Communication Line Resistance Inspection . 3-116 CAN Communication Line . 3-117 DFI Power Source . 3-118 ECU Fuse Removal . 3-118 ECU Fuse Installation 3-118 ECU Fuse Inspection . 3-118 ECU Main Relay Removal/Installation 3-118 ECU Main Relay Inspection . 3-118 Fuel Line 3-119 Fuel Pressure Inspection . 3-119 Fuel Flow Rate Inspection . 3-120 Fuel Pump . 3-122 Fuel Pump Removal 3-122 Fuel Pump Installation . 3-123 Fuel Pump Operation Inspection . 3-123 Fuel Pump Operating Voltage Inspection 3-124 Pressure Regulator Removal. 3-125 Fuel Pump Relay Removal/Installation 3-125 Fuel Pump Relay Inspection 3-125 Throttle Grip and Cables . 3-127 Free Play Inspection 3-127 Free Play Adjustment. 3-127 Cable Installation . 3-127 Cable Lubrication. 3-127 Throttle Body Assy 3-128 Idle Speed Inspection/Adjustment 3-128 Synchronization Inspection/Adjustment. 3-128 Throttle Body Assy Removal 3-128 Throttle Body Assy Installation. 3-130 Throttle Body Assy Disassembly . 3-131 Throttle Body Assy Assembly 3-132 Air Cleaner. 3-133 Air Cleaner Element Removal/Installation 3-133 Air Cleaner Element Inspection . 3-133 Air Cleaner Oil Draining . 3-133 Air Cleaner Housing Removal 3-133 Air Cleaner Housing Installation. 3-134 Fuel Tank. 3-135 Fuel Tank Removal 3-135 Fuel Tank Installation . 3-137 Fuel Tank and Cap Inspection . 3-139 Fuel Tank Cleaning 3-140 Evaporative Emission Control System (other than US and CA Models) 3-141 Parts Removal/Installation . 3-141 Hose Inspection . 3-141 Purge Valve Inspection 3-141 Canister Inspection . 3-141 Cooling System Table of Contents Exploded View 4-2 Coolant Flow Chart. 4-4 Specifications . 4-6 Special Tools . 4-7 Coolant . 4-8 Coolant Deterioration Inspection. 4-8 Coolant Level Inspection. 4-8 Coolant Draining . 4-8 Coolant Filling . 4-8 Pressure Testing . 4-8 Cooling System Flushing 4-9 Coolant Reserve Tank Removal/Installation . 4-9 Water Pump 4-10 Water Pump Removal. 4-10 Water Pump Installation 4-10 Water Pump Inspection. 4-12 Water Pump Impeller Disassembly/Assembly 4-12 Water Pump Impeller Inspection. 4-12 Water Pump Housing Disassembly 4-12 Water Pump Housing Assembly . 4-13 Mechanical Seal Inspection 4-13 Radiator 4-14 Radiator and Radiator Fan Removal 4-14 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection . 4-16 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection . 4-17 Thermostat . 4-18 Thermostat Removal. 4-18 Thermostat Installation 4-18 Thermostat Inspection 4-18 Hose and Pipes 4-20 Hose Installation . 4-20 Hose Inspection 4-20 Water Temperature Sensor 4-21 Water Temperature Sensor Removal/Installation . 4-21 Water Temperature Sensor Inspection . 4-21 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-9 Special Tools and Sealants . 5-11 Clean Air System. 5-14 Air Suction Valve Removal. 5-14 Air Suction Valve Installation 5-16 Air Suction Valve Inspection 5-16 Air Switching Valve Removal . 5-16 Air Switching Valve Installation 5-17 Air Switching Valve Operation Test 5-17 Air Switching Valve Unit Test . 5-17 Clean Air System Hose Inspection 5-17 Cylinder Head Cover . 5-18 Cylinder Head Cover Removal 5-18 Cylinder Head Cover Installation . 5-18 Camshaft Chain Tensioner 5-20 Camshaft Chain Tensioner Removal 5-20 Camshaft Chain Tensioner Installation . 5-20 Camshaft, Camshaft Chain . 5-21 Camshaft Removal 5-21 Camshaft Installation . 5-22 Camshaft, Camshaft Cap Wear Inspection 5-25 Camshaft Runout Inspection 5-25 Cam Wear Inspection 5-26 Camshaft Chain Removal 5-26 Cylinder Head 5-27 Cylinder Compression Measurement 5-27 Cylinder Head Removal. 5-28 Cylinder Head Installation 5-29 Cylinder Head Warp Inspection . 5-30 Valves 5-31 Valve Clearance Inspection . 5-31 Valve Clearance Adjustment 5-31 Valve Removal . 5-31 Valve Installation 5-31 Valve Guide Removal 5-31 Valve Guide Installation . 5-32 Valve-to-Guide Clearance Measurement (Wobble Method). 5-33 Valve Seat Inspection 5-33 Valve Seat Repair 5-34 Cylinder, Pistons 5-39 Cylinder Removal. 5-39 Cylinder Installation 5-39 Piston Removal 5-40 Piston Installation. 5-41 Cylinder Wear Inspection. 5-42 Piston Wear Inspection 5-42 Piston Ring, Piston Ring Groove Wear Inspection 5-42 Piston Ring Groove Width Inspection 5-42 Piston Ring Thickness Inspection 5-43 Piston Ring End Gap Inspection 5-43 Throttle Body Assy Holder. 5-44 Throttle Body Assy Holder Removal 5-44 Throttle Body Assy Holder Installation . 5-44 Muffler 5-46 Muffler Body Removal 5-46 Muffler Body Installation. 5-46 Exhaust Pipe Removal. 5-48 Exhaust Pipe Installation 5-49 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 Assembly Installation . 6-6 Clutch Lever and Cable 6-7 Clutch Lever Installation 6-7 Clutch Lever Position Adjustment. 6-8 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation . 6-9 Release Shaft Removal 6-10 Release Shaft Installation . 6-10 Clutch Cover Disassembly 6-10 Clutch Cover Assembly. 6-11 Clutch . 6-12 Clutch Removal. 6-12 Clutch Installation 6-13 Clutch Plate Assembly Length Inspection. 6-16 Clutch Plate Assembly Length Adjustment . 6-16 Clutch Plate, Wear, Damage Inspection . 6-17 Clutch Plate Warp Inspection 6-17 Clutch Housing Finger Inspection. 6-17 Clutch Housing Spline Inspection . 6-17 Clutch Pressure Plate and Clutch Hub Inspection 6-18 Clutch Spring Inspection . 6-18 Engine Lubrication System Table of Contents Exploded View 7-2 Engine Oil Flow Chart. 7-4 Specifications . 7-5 Special Tools and Sealants 7-6 Engine Oil and Oil Filter 7-7 Oil Level Inspection. 7-7 Engine Oil Change 7-7 Oil Filter Replacement 7-7 Oil Pan 7-8 Oil Pan Removal. 7-8 Oil Pan Installation 7-8 Oil Screen. 7-10 Oil Screen Removal 7-10 Oil Screen Installation . 7-10 Oil Screen Cleaning 7-10 Oil Pressure Relief Valve 7-11 Oil Pressure Relief Valve Removal . 7-11 Oil Pressure Relief Valve Installation 7-11 Oil Pressure Relief Valve Inspection. 7-11 Oil Pump. 7-12 Oil Pump Removal 7-12 Oil Pump Installation . 7-12 Oil Pump Drive Gear Removal 7-13 Oil Pump Drive Gear Installation. 7-13 Oil Cooler 7-14 Oil Cooler Removal. 7-14 Oil Cooler Installation 7-14 Oil Pressure Measurement. 7-15 Oil Pressure Measurement . 7-15 Oil Pressure Switch 7-16 Oil Pressure Switch Removal . 7-16 Oil Pressure Switch Installation 7-16 Oil Pipe . 7-17 Oil Pipe Removal 7-17 Oil Pipe Installation . 7-17 Engine Removal/Installation Table of Contents Exploded View 8-2 Special Tool 8-4 Engine Removal/Installation . 8-5 Engine Removal 8-5 Engine Installation. 8-9 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-8 Crankcase Splitting 9-9 Crankcase Splitting 9-9 Crankcase Assembly . 9-10 Crankshaft and Connecting Rods 9-15 Crankshaft Removal 9-15 Crankshaft Installation . 9-15 Connecting Rod Removal 9-15 Connecting Rod Installation . 9-16 Crankshaft/Connecting Rod Cleaning 9-19 Connecting Rod Bend Inspection 9-20 Connecting Rod Twist Inspection. 9-20 Connecting Rod Big End Side Clearance Inspection 9-20 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-21 Crankshaft Side Clearance Inspection 9-22 Crankshaft Runout Inspection 9-23 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-23 Balancer 9-26 Balancer Removal 9-26 Balancer Installation. 9-26 Balancer Adjustment 9-27 Balancer Damper Inspection 9-27 Starter Motor Clutch 9-28 Starter Motor Clutch Removal/Installation 9-28 Starter Motor Clutch Disassembly 9-28 Starter Motor Clutch Assembly 9-28 Starter Motor Clutch Inspection . 9-28 External Shift Mechanism 9-29 Shift Pedal Removal 9-29 Shift Pedal Installation . 9-29 External Shift Mechanism Removal 9-30 External Shift Mechanism Installation . 9-30 External Shift Mechanism Inspection 9-31 Transmission . 9-33 Transmission Shaft Removal . 9-33 Transmission Shaft Installation 9-33 Transmission Shaft Disassembly. 9-33 Transmission Shaft Assembly 9-34 Shift Drum and Fork Removal 9-38 Shift Drum and Fork Installation. 9-38 Shift Drum Disassembly. 9-38 Shift Drum Assembly . 9-39 Shift Fork Bending Inspection 9-39 Shift Fork/Gear Groove Wear Inspection 9-39 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-39 Gear Dog and Gear Dog Hole Damage Inspection . 9-40 Ball Bearing, Needle Bearing, and Oil Seal. 9-41 Ball and Needle Bearing Replacement. 9-41 Ball and Needle Bearing Wear Inspection 9-41 Oil Seal Inspection . 9-41 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. 10-9 Wheel Inspection 10-10 Axle Inspection 10-11 Balance Inspection 10-11 Balance Adjustment 10-11 Balance Weight Removal 10-12 Balance Weight Installation. 10-12 Tires 10-14 Air Pressure Inspection/Adjustment 10-14 Tire Inspection 10-14 Tire Removal. 10-14 Tire Installation 10-14 Tire Repair 10-16 Hub Bearing 10-17 Hub Bearing Removal. 10-17 Hub Bearing Installation 10-17 Hub Bearing Inspection. 10-18 Hub Bearing Lubrication . 10-18 Final Drive Table of Contents Exploded View 11-2 Specifications . 11-4 Special Tools 11-5 Drive Chain. 11-6 Drive Chain Slack Inspection 11-6 Drive Chain Slack Adjustment 11-6 Wheel Alignment Inspection/Adjustment 11-6 Drive Chain Wear Inspection 11-6 Drive Chain Lubrication. 11-6 Drive Chain Removal 11-6 Drive Chain Installation . 11-7 Drive Chain Replacement . 11-7 Sprocket, Coupling . 11-11 Engine Sprocket Removal 11-11 Engine Sprocket Installation . 11-11 Engine Sprocket Cover Disassembly 11-12 Engine Sprocket Cover Assembly 11-12 Rear Sprocket Removal 11-13 Rear Sprocket Installation. 11-13 Coupling Installation 11-13 Coupling Bearing Removal . 11-14 Coupling Bearing Installation 11-14 Coupling Bearing Inspection . 11-15 Coupling Bearing Lubrication 11-15 Coupling Damper Inspection. 11-15 Sprocket Wear Inspection. 11-15 Rear Sprocket Warp Inspection 11-16 Brakes Table of Contents Exploded View 12-3 Specifications . 12-8 Special Tools 12-9 Brake Lever, Brake Pedal. 12-10 Brake Lever Position Adjustment 12-10 Brake Pedal Position Inspection . 12-10 Brake Pedal Position Adjustment 12-10 Brake Pedal Removal . 12-10 Brake Pedal Installation 12-11 Calipers 12-12 Front Caliper Removal 12-12 Rear Caliper Removal. 12-12 Caliper Installation 12-12 Front Caliper Disassembly 12-12 Front Caliper Assembly. 12-13 Rear Caliper Disassembly 12-13 Rear Caliper Assembly . 12-13 Caliper Fluid Seal Damage Inspection 12-13 Caliper Dust Seal Damage Inspection 12-13 Rear Caliper Dust Boot and Friction Boot Damage Inspection. 12-14 Caliper Piston and Cylinder Damage Inspection 12-14 Rear Caliper Holder Shaft Wear Inspection 12-14 Brake Pads. 12-15 Front Brake Pad Removal. 12-15 Front Brake Pad Installation 12-15 Rear Brake Pad Removal 12-15 Rear Brake Pad Installation 12-16 Brake Pad Wear Inspection 12-16 Master Cylinder 12-17 Front Master Cylinder Removal 12-17 Front Master Cylinder Installation . 12-17 Rear Master Cylinder Removal. 12-17 Rear Master Cylinder Installation 12-18 Front Master Cylinder Disassembly 12-18 Rear Master Cylinder Disassembly. 12-18 Master Cylinder Assembly 12-18 Master Cylinder Inspection (Visual Inspection). 12-19 Brake Disc 12-20 Brake Disc Removal . 12-20 Brake Disc Installation 12-20 Brake Disc Wear Inspection 12-20 Brake Disc Warp Inspection 12-21 Brake Fluid . 12-22 Brake Fluid Level Inspection. 12-22 Brake Fluid Change 12-22 Brake Line Bleeding 12-22 Brake Hose. 12-26 Brake Hose Removal/Installation 12-26 Brake Hose and Pipe Inspection. 12-26 Anti-Lock Brake System . 12-27 Parts Location . 12-27 ABS Servicing Precautions . 12-31 ABS Troubleshooting Outline 12-33 Inquiries to Rider. 12-36 Self-diagnosis Outline . 12-40 Self-diagnosis Procedures 12-40 Service Code Clearing Procedures. 12-41 How to Read Service Codes. 12-44 How to Erase Service Codes 12-44 Yellow ABS and Yellow Warning Indicator Lights (LED) Inspection 12-47 Solenoid Valve Inspection (Service Code 13, 14, 17, 18). 12-47 ABS Solenoid Valve Relay Inspection (Service Code 19) 12-48 Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) 12-48 ABS Motor Relay Inspection (Service Code 35) . 12-49 Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) 12-49 Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) 12-50 Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44). 12-51 Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 12-51 Power Supply Voltage Abnormal (Low-Voltage) (Service Code 52) . 12-52 Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) 12-52 ABS Solenoid Valve Relay Supply Voltage Inspection (Low-Voltage) (Service Code 54) 12-52 ECU Inspection (Service Code 55) . 12-53 CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code 57) 12-53 ECU Communication Line Inspection (Service Code 62) . 12-54 IMU Communication Line Inspection (Service Code 63) 12-55 Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83) 12-55 Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code 84) . 12-56 Fluid Pressure Sensor Supply Voltage Inspection (Service Code 89) 12-56 IMU Inspection (Service Code 94) 12-56 ABS Hydraulic Unit Removal 12-56 ABS Hydraulic Unit Installation . 12-58 ABS Hydraulic Unit Inspection 12-58 Front Wheel Rotation Sensor Removal 12-59 Front Wheel Rotation Sensor Installation . 12-60 Rear Wheel Rotation Sensor Removal. 12-60 Rear Wheel Rotation Sensor Installation 12-61 Wheel Rotation Sensor Inspection 12-61 Wheel Rotation Sensor Air Gap Inspection 12-61 Wheel Rotation Sensor Rotor Inspection 12-62 ABS Solenoid Valve Relay Fuse (15 A) Removal. 12-62 ABS Motor Relay Fuse (25 A) Removal . 12-62 Fuse Installation 12-62 Fuse Inspection. 12-62 Suspension Table of Contents Exploded View 13-2 Specifications . 13-6 Special Tools 13-7 Front Fork. 13-9 Rebound Damping Force Adjustment 13-9 Spring Preload Adjustment . 13-9 Compression Damping Force Adjustment (Right Side Only) 13-10 Front Fork Removal (Each Fork Leg) . 13-10 Front Fork Installation . 13-11 Fork Oil Change 13-11 Front Fork Disassembly 13-21 Front Fork Assembly. 13-22 Inner Tube, Outer Tube Inspection . 13-23 Dust Seal Inspection . 13-24 Spring Tension Inspection. 13-24 Rear Shock Absorber . 13-25 Rebound Damping Force Adjustment. 13-25 Spring Preload Adjustment . 13-25 Rear Shock Absorber Removal 13-25 Rear Shock Absorber Installation . 13-26 Rear Shock Absorber Inspection 13-27 Rear Shock Absorber Scrapping 13-27 Rear Shock Absorber Bearing Removal. 13-27 Rear Shock Absorber Bearing Installation 13-27 Swingarm 13-28 Swingarm Removal. 13-28 Swingarm Installation 13-29 Swingarm Bearing Removal . 13-30 Swingarm Bearing Installation 13-30 Swingarm Bearing, Sleeve Inspection 13-31 Swingarm Bearing Lubrication 13-31 Chain Guide Inspection. 13-31 Tie-Rod, Rocker Arm 13-32 Tie-Rod Removal 13-32 Tie-Rod Installation . 13-32 Rocker Arm Removal 13-32 Rocker Arm Installation. 13-33 Tie-Rod and Rocker Arm Bearing Removal 13-34 Tie-Rod and Rocker Arm Bearing Installation. 13-34 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-35 Rocker Arm/Tie-Rod Bearing Lubrication . 13-35 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 Stem Cap Deterioration, Damage Inspection . 14-10 Handlebar. 14-11 Handlebar Removal 14-11 Handlebar Installation . 14-11 Frame Table of Contents Exploded View. 15-2 Seats . 15-10 Rear Seat Removal 15-10 Rear Seat Installation. 15-10 Front Seat Removal. 15-10 Front Seat Installation 15-10 Fairings 15-11 Middle Fairing Removal . 15-11 Middle Fairing Installation 15-12 Lower Fairing Removal 15-13 Lower Fairing Installation . 15-14 Lower Fairing Disassembly 15-15 Lower Fairing Assembly. 15-16 Rear Lower Fairing Removal . 15-16 Rear Lower Fairing Installation 15-16 Windshield Removal 15-17 Windshield Installation . 15-17 Upper Fairing Removal 15-17 Upper Fairing Installation . 15-17 Upper Fairing Disassembly 15-18 Upper Fairing Assembly. 15-18 Windshield Bracket Disassembly. 15-18 Windshield Bracket Assembly 15-19 Windshield Bracket Assembly Removal 15-21 Windshield Bracket Assembly Installation . 15-21 Covers . 15-22 Side Cover Removal 15-22 Side Cover Installation . 15-22 Left Lower Side Fairing Removal. 15-22 Left Lower Side Fairing Installation . 15-22 Seat Cover Removal 15-23 Seat Cover Installation. 15-23 Meter Cover Removal 15-23 Meter Cover Installation 15-24 Fenders . 15-26 Front Fender Removal. 15-26 Front Fender Installation 15-26 Flap and Rear Fender Removal. 15-26 Flap and Rear Fender Installation 15-27 Frame 15-29 Frame Inspection . 15-29 Rear Frame Removal. 15-29 Rear Frame Installation 15-29 Rear Frame Bracket Removal . 15-29 Rear Frame Bracket Installation 15-29 Battery Case 15-30 Battery Case Removal. 15-30 Battery Case Installation 15-30 Guard. 15-31 Mud Guard Removal 15-31 Mud Guard Installation. 15-31 Side Stand. 15-32 Side Stand Removal 15-32 Side Stand Installation . 15-32 Electrical System Table of Contents Exploded View 16-4 Specifications . 16-10 Special Tools and Sealant 16-11 Parts Location. 16-13 Wiring Diagram (US, CA and CAL Models) 16-16 Wiring Diagram (Other than US, CA and CAL Models) 16-18 Precautions. 16-20 Electrical Wiring 16-21 Wiring Inspection 16-21 Battery 16-22 Battery Removal . 16-22 Battery Installation 16-22 Battery Activation 16-22 Precautions . 16-25 Interchange . 16-26 Charging Condition Inspection 16-26 Refreshing Charge 16-26 Charging System 16-28 Alternator Cover Removal. 16-28 Alternator Cover Installation 16-28 Stator Coil Removal 16-28 Stator Coil Installation . 16-29 Alternator Rotor Removal . 16-29 Alternator Rotor Installation 16-30 Charging Voltage Inspection. 16-32 Alternator Inspection . 16-32 Regulator/Rectifier Removal. 16-34 Regulator/Rectifier Installation 16-34 Regulator/Rectifier Inspection. 16-34 Ignition System. 16-37 Crankshaft Sensor Removal. 16-37 Crankshaft Sensor Installation 16-38 Crankshaft Sensor Inspection. 16-39 Crankshaft Sensor Peak Voltage Inspection. 16-40 Timing Rotor Removal 16-40 Timing Rotor Installation . 16-40 Stick Coil Removal 16-41 Stick Coil Installation. 16-41 Stick Coil Inspection 16-41 Stick Coil Primary Peak Voltage Inspection 16-41 Spark Plug Removal . 16-42 Spark Plug Installation 16-42 Spark Plug Condition Inspection. 16-43 Interlock Operation Inspection 16-43 IC Igniter Inspection 16-44 Electric Starter System. 16-47 Starter Motor Removal 16-47 Starter Motor Installation. 16-47 Starter Motor Disassembly 16-47 Starter Motor Assembly 16-48 Brush Inspection . 16-50 Commutator Cleaning and Inspection. 16-50 Armature Inspection 16-51 Brush Lead Inspection 16-51 Right-hand End Cover Inspection. 16-51 Starter Relay Inspection 16-51 Lighting System 16-54 Headlight Beam Horizontal Adjustment 16-54 Headlight Beam Vertical Adjustment. 16-54 Headlight (LED) Assembly Removal/Installation 16-54 Headlight Harness Circuit Inspection 16-54 City Light Input Voltage Inspection 16-55 Headlight Lo Beam Input Voltage Inspection 16-55 City Light (LED) Removal/Installation . 16-55 Tail/Brake Light (LED) Removal 16-56 Tail/Brake Light (LED) Installation. 16-56 License Plate Light Bulb Replacement . 16-56 Turn Signal Light Bulb Replacement 16-58 Turn Signal Relay Inspection 16-59 Air Switching Valve . 16-62 Air Switching Valve Operation Test . 16-62 Air Switching Valve Unit Test 16-62 Radiator Fan System 16-64 Fan Motor Inspection 16-64 Meter, Gauge, Indicator Unit. 16-66 Meter Unit Removal 16-66 Meter Unit Installation . 16-66 Meter Unit Disassembly/Assembly . 16-66 Meter Operation Inspection. 16-66 Meter System Inspection 16-70 Meter Unit Inspection 16-71 Fuel Level Sensor Line Self-Diagnosis Mode Inspection 16-79 Immobilizer System (Equipped Models) . 16-81 Operational Cautions 16-81 Key Registration 16-81 Immobilizer System Parts Replacement. 16-99 Immobilizer System Inspection . 16-101 Immobilizer System Circuit . 16-102 Switches and Sensors 16-103 Brake Light Timing Inspection. 16-103 Brake Light Timing Adjustment . 16-103 Switch Inspection 16-103 Water Temperature Sensor Inspection . 16-104 Oxygen Sensor Removal 16-104 Oxygen Sensor Installation . 16-105 Oxygen Sensor Inspection 16-105 Fuel Level Sensor Inspection 16-105 Gear Position Sensor Removal. 16-105 Gear Position Sensor Installation 16-106 Gear Position Sensor Inspection 16-106 Outside Temperature Sensor Removal. 16-106 Outside Temperature Sensor Installation 16-107 Relay Box . 16-108 Relay Box Removal/Installation 16-108 Relay Circuit Inspection 16-108 Diode Circuit Inspection 16-109 Fuse 16-111 30 A Main/15 A ECU Fuse Removal. 16-111 Fuse Box Fuse Removal. 16-111 Fuse Installation 16-111 Fuse Inspection. 16-111
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Last update on 2025-04-17 / Affiliate links / Images from Amazon Product Advertising API
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