2017 Kawasaki Ninja 650 & Ninja 650 ABS Motorcycle Service Manual

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NHTSA ID Number: 10089685

Manufacturer Communication Number: 99924-1517-01

Summary

SERVICE MANUAL

Motorcycle Service Manual

Kawasaki

Ninja 650
Ninja 650 ABS

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

1 Associated Document

Manufacturer Communications

99924-1517-01

https://www.nhtsa.gov/recalls?nhtsaId=10089685

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Bestseller No. 1

Motorcycle Diagnostic Tool OBD2 Motorcycle Fault Code Readers Scan Tool Motorcycle Code Reader Scaner Compatible with Yamaha 2/3/4P, Kawasaki 4-6P, Honda 4P, OBDII（Not Applicable to Bike）

Comprehensive System Diagnosis: The M3 Motorcycle Scanner Tool supports engine, ABS, tire pressure, anti-theft, and other systems. It allows you to quickly read and clear diagnostic trouble codes, view freeze frame data, perform active tests, and access vehicle information. With this tool, you can perform thorough and complete diagnostics for your motorcycles, saving you time and money on unnecessary trips to the repair shop.
Wide Compatibility: The M3 Motorcycle Scanner Tool is compatible with a wide range of motorcycle brands, including Asian, European, and American models. It can compatible with Yamaha 2/3/4P, with Honda 4P, with Kawasaki 4-6P, and OBD2 motorcycles. (Note: The M3 motorcycle scanning tool is not compatible with bike. The plug we provide is not suitable for 2023 Kawasaki KLR 650. If your motorcycle is 2023 Kawasaki KLR 650, you will need to purchase a dedicated G4 plug.)
Portable and Convenient: With its lightweight and handheld design, the M3 Motorcycle Scanner Tool is highly portable and convenient to use. It does not require an internet connection or any complicated setup. You can take it anywhere and perform diagnostics on your motorcycles effortlessly, whether you're in your garage or on the go.
Multi-Language Support: Our Motorcycle Scanner has a clear interface and is easy to operate. It supports Turkish, Spanish, Portuguese, Vietnamese, Khmer, Thai, English, French, Chinese, Indonesian, Traditional Chinese, and many other languages for you to choose from, which can help you read the diagnostic data from the motorcycle scanner and repair faster.
Free Software Upgrades: The M3 Motorcycle Scanner Tool offers free software upgrades to ensure you have the latest diagnostic capabilities. Simply connect the device to your computer, replace the "DIAGNOSE" folder with the downloaded upgrade folder, and power it on. If you need assistance with the updated files, our customer service team is readily available to help.

Bestseller No. 2

Motorcycle Diagnostic Scan Tool, Full System Scanner OBD2 Diagnostic Tool Fault Code Reader with 104 Service Functions & Quick Test Compatible for BMW, Honda, Yamaha, Kawasaki, Suzuki

【Kind Reminder】（1）After choosing our M6 motorcycle diagnostic tool, please be sure to pick up our Upgraded M6 Main Cable. Our Upgraded M6 Main Cable is compatible with more motorcycle models.（2）We are constantly upgrading and improving our motorcycle diagnostic tools, please keep an eye out and download our latest software packages to get the latest version and more product features.（3）If you encounter any problems during use, please do not hesitate to tell us and our professional technical team will help you solve the problem.
【Full System Diagnostics】The motorcycle obd2 scanner supports a wide range of systems including engine, ABS, tyre pressure and anti-theft systems. It can quickly read and clear diagnostic trouble codes, view freeze frames, display data streams, perform active tests, print data, view images, record and playback data, retrieve vehicle information.Especially suitable for DIY enthusiasts and professionals.
【Supports 70+ Motorcycle Makes and Models】Our motorcycle diagnostic tool is compatible with multi-brand motorbikes from Asia, Europe and the United States. It compatible with BMW, Yamaha Honda Kawasaki Suzuki and so on. For more models, please check the details page. It is easy to operate and has a clear interface, providing functions such as voltage detection, multi-language selection and theme switching.
【104 Service Functions Support】Motorcycle obd2 scan tool with live data supports up to 104 service functions, such as ECU reset, idle control, HEGO sensor, oil service light reset, speedometer test, throttle balance, fan control, etc. Provide you with a comprehensive and professional motorcycle maintenance solution.
【5-inch RGB Display Screen & Information Printing】The motorcycle diagnostic scanner is equipped with a 5-inch RGB display (800*480 resolution) offers light and dark themes for easy viewing. With fast processing and smooth interface refresh, it ensures a seamless experience. It supports printing diagnostic reports, module info, trouble codes, and data streams , etc., helping you to view performance and troubleshoot problems efficiently. Keep your motorcycle in top condition with accurate diagnostics.

Bestseller No. 3

Motorcycle Scan Tool TOPDON TopScan, Wireless Motorcycle Scanner Fits for Harley, Ducati, BMW & Japan Brands, All Systems Motorbike Scanner Tool with Reset Functioan, Data Stream, AutoVIN

Diagnose Wirelessly, Operate On-The-Go: Carry this motocycle OBD2 scanner in your pocket. TopScan Moto, a combo of “dongle + app”, can turn your Android & iOS smartphone into a motorcycle OBD2 scanner with a long list of pro features. You’ll have an easy time diagnosing via Blue tooth 5.0 wireless connection, instead of using a short cable. And the dongle is mini-sized. Slip it in pocket and you’re ready to solve motor issues anytime, anywhere
All Systems Diagnostics, Compatible with Harley/BM.W/Du cati: This motorcycle scanner scan tool scans pretty much every system on your motorcycle: Engine, ABS, BCM, Smart Ke.y, Instrument, Blutooth, Headlights, Radar, Radio, TPMS, Entertainment, Handlebar Left/Right, Suspension, Speedo, Safety and more. You can read/clear DTCs, view graphic live data, locate system faults, and pull ECU info. (*The system you can scan may vary across different models)
Bi-directional Control, Ease Your Work Load: Feel difficult to locate trouble area? This Motoscan BMW scanner TopScan Moto allows you to directly control and test motor lamps, relays, fans, brake lights, tachometer, fuel pump, and more. This helps you quickly determine whether a specific system, subsystem, or component is functioning properly. It's a great time-saver for mechanics and DIYers. (The available active tests vary by the model)
Essential Special Functions, Make Easy Maintenance: This Bluetooth motorcycle Harley scan tool offers the most common services available for Harley/BM.W/Du cati/Kawasaki/Suzuki/Yamaha/Honda: 1) Reset various indicators like oil maintenance, DESMO, and annual inspection at correct intervals. 2) Calibrate TPMS, parking brake, odometer, and air purifier intake valve. 3) Tweak idle speed for a smoother ride. If you’re into DIY, TopScan Moto motorcycle OBD2 scanner can save you 1,000+ bucks in maintenance costs. (*The services you can do depend on model)
Instant Scan with Only One Tap: This motor scanner can automatically read and store your motorcycle's VIN number, allowing for swift scanning of all system modules. A single touch quickly identifies most motorcycle models, clears DTCs, and removes warning lights. The software is updated monthly, or even weekly, adding new features and support for more Motorcycles. Updating your motorcycle diagnostic scan tool TopScan Moto is a breeze, easily done online via a Wi-Fi connection

Bestseller No. 4

Motorcycle Diagnostic Tool,M6 Full System Motorcycle OBDII Engine Code Reader Scanner,Read/Clear Fault Code With Data Stream,Printer,104 Service Functions Compatible For Harley,BMW,Honda,Yamaha,Suzuki

🏍️【Easy To Use】M6 Motorcycle Diagnostic Tool is a handheld motorcycle diagnostic tool for mainstream motorcycle brands and can help technicians diagnose problems faster and make repairs. This tool has functions such as voltage detection, multi-language selection, and unit switching. It has a clear interface and is easy to operate. It is a good helper for motorcycle maintenance.
🏍️【104 Service Functions Supported】M6 Motorcycle Diagnostic Tool supports up to 104 service functions that allow technicians to perform factory service procedures such as Oil maintenance lamp reset, ECU reset, making injection adjustments (CO Trimmer), adjusting the throttle valve position sensor (TPS), re-setting auto adaptive parameters, and re-setting the service light, and making idling adjustments.
🏍️【Wide Compatibility】Support the diagnosis of Asian, European and American multi-brand motorcycles, Supports 12 languages, M6 Motocycle diagnostic tool Support Turkic,Spanish,Chinese,Thai,French,Khmer,English,Vietnamese,Portuguese,Traditional Chinese, Bahasa,Indonesia,German.
🏍️【System Diagnosis Features】The Motocycle diagnostic tool Support engine / ABS / Tire pressure / Anti-theft and other systems, It can quickly read and clear diagnostic trouble codes, view freeze frame, display data stream and do active tests, get vehicle information, You are allowed to perform a complete and deep detection for your motorcycles, rather than send it directly to repair shop, very suitable for diyers.
🏍️【Read Data Steam】The data stream waveform graph automatically adapts to the data without the need for manual adjustment of amplitude and allows for viewing of specific data streams rather than displaying all data streams at once. It comes equipped with features such as a printer, image viewer, data logging and playback, battery testing, charge detection, error reporting and feedback, and more.

SaleBestseller No. 5

Motorcycle Scan Tool TOPDON TopScan Moto, All System Bidirectional Motorcycle Scanner for Harley, Duca ti, BMW & Japan Brands, Reset Services Motorcycle Diagnostic Scanner, AutoVIN Diagnostic Tool

Bi-Directional Control, Target The Problems Easily: Motocycle OBD2 scanner TopScan Moto's bi-directional feature allows you to send commands directly from your smartphone to your vehicle's ECU for active testing. Helps you differentiate between software and hardware issues, quickly narrowing down the problem and reducing diagnostic time for mechanics and can help DIY users locate faults more easily
Wireless Diagnostics, Pack light anytime, anywhere: Designed for use on the go, transforming your smartphone into a diagnostic tool. the Bluetooth OBD2 scanner TOPDON TopScan Moto's compact size and Bluetooth 5.0 compatibility provide seamless wireless diagnostics. Easily carry it with you and solve problems on the go
Full System Diagnosis: Motoscan BMW scanner TOPDON TopScan Moto Covering engine, ABS, smart key, entertainment systems and more, it ensures a thorough analysis for overhauling 20 internal systems. It can quickly read and clear troubleshooting codes, view freeze frames, display data streams and perform active tests, get vehicle information, and know the condition of your vehicle anytime, anywhere
Moto Reset Function, Better Care of Your Car: Dive into maintenance functions, including oil maintenance resets, service indicator adjustments, and idle speed tweaks. Comprehensive diagnostics, maintenance insights, and on-the-go convenience so you can work on your motorcycle, anytime, anywhere
Rider Full Vehicle Pass: Whether you are an off-road rider, a cruiser, a superbike rider or an adventure rider, it has your back. This amazing motorcycle Harley scan tool supports Ducati, BMW, Harley, Kawasaki, Suzuki, Yamaha and Honda. Supports 12 languages, You can switch the language you need anytime

Bestseller No. 6

OBDPROG Moto 100 Motorcycle Diagnostic Tool, Full System Motorcycle OBD2 Scanner for Harley Honda Yamaha Victory Indian Polaris Brp, 30+ Services Reset, 5.0 Touch Screen

💸【One-Click Upgrades–Simple & Always Up-to-Date】MOTO100 motorcycle scan tool offers one-click WIFI upgrades, so you can easily enjoy the latest features and improvements without any hassle. The first year of upgrades is free, ensuring you can get the best performance without worry. After the first year, you can choose to renew your $80 annual upgrade for continuous updates, fixes, and new features. If you decide not to upgrade, don’t worry—the current version will still work perfectly with all core functions intact, and will continue to meet your everyday needs
🏍️【 The Ultimate Tool for HARLEY 】The harley davidson scan tool is a powerful tool designed specifically for all Harley-Davidson models from 2022 and earlier. Whether you're cruising the streets or seeking the ultimate riding experience, MOTO 100 is your all-in-one solution for optimizing and enhancing your motorcycle's performance. It offers comprehensive diagnostics, but also adjusts and optimizes with additional special features-Idle speed adjustment, Servomotor Exhaust flap, Cruise control, EITMS, Automatic Compression Release, Side Stand Switch, Module Replacement, AFV reset, Vehicle Speed Sensor Calibration, Air Cleaner Intake Valve, Oil Cooler Fan, Chassis fan cooler,Odometer unit
🏍️【 Boost Your BRP Motorcyce’s Performance 】If you're looking for a smart device that can enhance your BRP motorcycle’s performance, simplify vehicle management, and make your rides more enjoyable, the MOTO100 motorcycle diagnostic tool is the perfect choice. It’s compatible with over 100 BRP models (including DS, Defender, etc.). The MOTO100 also supports over 20 specialized features for BRP motorcycles, such as TPS reset, Reset Trip Hours and more, all designed to improve your riding experience and ensure the long-term reliability of your motorcyle. Unsure of compatibility? Provide your model, year, and VIN, and we'll confirm compatibility for you, so you can purchase with confidence
🏍️【 Fit for POLARIS & VICTORY 】For POLARIS ( RANGER, ATV, Snow, RZR, Slingshot, Commercial, LEV, ACE, General, and Generic and more)--can supports TPS Set Procedure, ECU Replacement, PTO Enable/Disable Procedure & Speed Key Options. --The special functions corresponding to different models are different, and they need to be carefully confirmed with us. For VICTORY motorcycles (Vision, High-Ball, Cross Country, Cross Roads, and more)--No special function
🏍️【 Fit for YAMAHA, HONDA & INDIAN】For YAMAHA (Byson, Cygnus X, WR 125R, YZF R15, and more ) --can supports CO volume adjustment, Writing Frame number & Idle speed learning. For HONDA ( CB1300A, ADV150, ADV750, CB1300A, and more)-- can supports Crank Pulse Intialize Learning, Start Mode History Information Reset & Drive-Driven Ratio Error Detection History Information Reset. For INDIAN motorcycles (Chieftain, Scout, Scout Sixty, Scout Bobber, Springfield, and more)--Only 17 models can support Ride Command Odometer Maintenance

Bestseller No. 7

Motorcycle System Diagnostic Test Measurement Tools M3-B Motorcycle Fault Code Readers Scan Tools Moto Diagnostic Test Measurement Tools Compatible for Yamaha 2/3/4P,KYMCO,SYM,OBDII 16P

🚴【System Diagnosis Features】The Motocycle diagnostic tool Support engine / ABS / Tire pressure / Anti-theft and other systems, It can quickly read and clear diagnostic trouble codes, view freeze frame, display data stream and do active tests, get vehicle information, You are allowed to perform a complete and deep detection for your motorcycles, rather than send it directly to repair shop, very suitable for diyers.
🚴【Easy To Use】 M3 is a handheld motorcycle diagnostic tool for mainstream motorcycle brands and can help technicians diagnose problems faster and make repairs. This tool has functions such as voltage detection, multi-language selection, and unit switching. It has a clear interface and is easy to operate. It is a good helper for motorcycle maintenance.
🚴【Wide Compatibility】support the diagnosis of Asian, European and American multi-brand motorcycles, M3-B is suitable for motorcycles of Yamaha, Honda, Kawasaki and OBD2, Supports 11 languages, You can switch the language you need anytime.
🚴【Portable and Convenient】The motorcycle diagnostic requires no Internet connection or setup, and with a lightweight body that can be operated with one hand, you can take it anywhere and use it very conveniently.
🚴【Free Software Upgrade】Connect the device to the computer and wait for the device to be recognized by the computer. After the recognition is successful, a new drive symbol will appear on the computer. Open this and replace the “DIAGNOSE" folder in the drive with the downloaded “DIAGNOSE" upgrade folder, and then power on again. The updated files can be obtained by contacting the customer service.

SaleBestseller No. 8

lydesor Obd2 Cable for Harley 4pin+6pin 2 in 1 Motorcycle OBD Scanner Adapter,OBD Connector Work with Many Motorcycle Diagnostic Tool 16 Pin to 4 Pin 6 Pin Fits for Harley Davidson Scan Tool

【Wide Compatibility】This obd2 cable 16 pin to 4 pin 6 pin fits for harley davidson are compatible with a wide range of motorcycles. You only pay for one cable, got 2 connectors both for Harley 4pin and 6pin.
【Feature】This obd2 cable 16 pin to 4 pin 6 pin can read and erase error codes. Support both J1850 and Can-bus protocols Scanner Diagnostics.This 4pin+6pin for harley davidson diagnostic adapter cable are supports many obd code scanners and obdii code readers such as ELM327 and M100pro or other diagnostic scanner tools.
【3 Seconds To Connect and Easy To Use】This harley obd2 adapter are easy to use, even for those who are not familiar with motorcycle diagnostics. Simply plug them in and follow the instructions. This motorbike OBD cable works with various programs / apps and with standard OBD2 readers, convert OBD2 16 pin connector to required 4pin/6pin connector.Use the RPMitUP app to easily view real-time data, such as engine speed, temperature, gear, fuel consumption, etc.
【High-Quality Materials】This obd2 scanner adapter for harley davidson are made from high-quality materials that ensure durability and longevity. The motorbike diagnostic cable not easy to aging and abrasion resistant.
【Cost-Effective】 This obd2 adapter 6 and 4 pin are an affordable alternative to expensive diagnostic tools, making them a cost-effective solution for motorcycle owners and mechanics alike.

Bestseller No. 9

Motorcycle Diagnostic Tool,M4 Motorcycle Diagnostic Scan Tool,Multi-System Diagnostics Code Readers & Scan Tools Compatible for BMW-10P Special with Oil Service Reset,ECM,ABS,BCM,IM-MO,17 Languages

🚴【MULTI-SYSTEM DIAGNOSTICS】 M4 Motorcycle Code Reader Scanner ONLY Supports compatible BMW diagnostics and troubleshooting for systems such as engine ABS, tire pressure, and lMMO, enabling comprehensive testing and one-click fault code clearing.
🚴【CORE DIAGNOSTIC FUNCTIONS】 Read data ECU codes stream,Read fault codes,Clear fault codes,ECU reset,Co idle speed regulation,Read system information,Freeze frame data,Learning value reset,Maintenance information reset,Throttle position reset,Actuator test,Throttle test,ABS bleed.
🚴【17 LANGUAGES SELECTION】 M4 Motorcycle Diagnostic Tool Supports Turkish, Vietnamese, English, Spanish, Portuguese, Italian, Khmer, Indonesian, Korean, Japanese, French, Chinese, Thai, Russian, Cerman, Traditional, Chinese, Polish.
🚴【VOLTAGE TEST 】Through the diagnostic interface or battery clamps,the motorcycle battery status is monitored in real-time and the current voltage value is displayed in digital form.
🚴【QUICKTEST】 M4 Moto Diagnostic Test Measurement Tool Through the OBD (On-Board Diagnostics)interface, automatic scanning and matching quickly display all vehicle fault information.

SaleBestseller No. 10

ANCEL MT500 PRO Motorcycle Diagnostic Tool, Motorcycle Scanner Fits for Harley Yamaha Honda Kawasaki Suzuki Indian Polaris BRP Victory Motorbike OBD2 Scanner, 30+ Reset, Android 5'' Touch Screen

👍[[100% SATISFIED AFTER-SALE SERVICE] We promise offer the professional technical support for lifetime, 1 Years f-ree warranty, 90 Days Refund & Replacement and 24/7/365 after-sale service. After 1-Years FREE UPDATE, you can continue to upgrade by paying the annual fee, or not to upgrade, which will not affect its normal use.🚩Please send your VIN to check the compatibility before the purchase
👍【Multifunctional Motorcycle Diagnostic Tool】MT500 PRO is an advanced motorcycle diagnostic tablet developed by ANCEL specifically for motorcycle enthusiasts. Bright 5" touchscreen & Android 5.1.1 OS & 8 Languages; Auto VIN & Scan; Online remote assistance and solve problems, One-click WIFI update; Full systems diagnosis for most popular motorcycle models; 30+ Resets like oil service reset, abs bleeding, etc
✅【Wider Motorcycle Coverage Than Others】 Compare with other similar motorcycle scan tools, MT500PRO added more popular motorcycle brands, it' not only compatible with Harley Yamaha Honda Indian Polaris BRP Victory diagnosis.Newly upgraded in 2023 with the addition of two more popular brands fit for Kawasaki Suzuki diagnosis. Plug and play, easy to use
✅ [Manufacturer-level Diagnostic] MT500 PRO is a all-system motorcycle diagnostic scanner. It can read and clear trouble codes and turn off the CEL when a check engine light comes on. Besides, it can also scan all the available electronic control modules of your motorcycle including Engine, ABS, TPMS, Suspensions, Ignition, EPS, Service system, Meter system, etc. to read/clear fault codes, and view live data.You can quickly and accurately find existing or potential problems, saving time and money
✅ [Excluisive Advance Functions, Save Costs For You] MT500 PRO obd2 scanner with almost all daily maintenance services that necessary advanced functions for most motorcycle to meet the market trends and needs. Auto scan, auto VIN recognition, ECU setting, maintenance light reset, CO adjustment, idle speed adjustment, A/F value reset, ABS control unit setting etc. Help you solve all kinds of complex maintenance problems easily

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Ninja 650 Ninja 650 ABS This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required. 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 Ninja 650 Ninja 650 ABS Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2016 Kawasaki Heavy Industries, Ltd. First Edition (0) : Oct. 14, 2016 LIST OF ABBREVIATIONS A ampere(s) IC integrated circuit ABDC after bottom dead center in. inch(es) ABS anti-lock brake system km/h kilometers per hour AC alternating current L liter(s) Ah ampere hour LCD liquid crystal display ATDC after top dead center LED light emitting diode BBDC before bottom dead center lb pound(s) BDC bottom dead center m meter(s) BTDC before top dead center min minute(s) °C degree(s) Celsius 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 °F 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) Ω ohm(s) COUNTRY AND AREA CODES AT Austria ID Indonesia AU Australia IN India AU LAMS Australia Learner Approved Motorcycle Scheme MY Malaysia CA Canada PH Philippines CAL California SEA-B1 Southeast Asia B1 CH Switzerland SEA-B3 Southeast Asia B3 CN China TH Thailand DE Germany US United States EUR Europe WVTA (FULL) 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 Act’s “tampering provisions”. “Sec. 203(a) The following acts and the causing thereof are prohibited. (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser.” NOTE ○The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows. 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include. a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below. •Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. •Removal of the muffler(s) or any internal portion of the muffler(s). •Removal of the air box or air box cover. •Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle. • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don’t take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want 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. A DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. AWARNING 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 ONO TE indicates information that may help or guide you in the operation or service of the vehicle. • Indicates a procedural step or work to be done. Olndicates 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 (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal. Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high 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. 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. GENERAL INFORMATION 1-5 Grease G8020468S I C 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color. Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments. 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. V/ R G8020628S1 C GENERAL INFORMATION 1-7 Model Identification EX650JH/KH Left Side View EX650JH/KH Right Side View Frame Number Engine Number 1-8 GENERAL INFORMATION General Specifications Items EX650JH/KH Dimensions Overall Length 2 055 mm (80.91 in.) (CN, TH, ID, IN, MY, PH) 2 115 mm (83.27 in.) Overall Width 740 mm (29.1 in.) Overall Height 1 135 mm (44.68 in.) Wheel Base 1 410 mm (55.51 in.) Ground Clearance 130 mm (5.12 in.) Seat Height 790 mm (31.1 in.) Curb Mass: EX650J 190 kg (419 lb) (CAL, MY, PH) 191 kg (421 lb) EX650K 193 kg (426 lb) (US, CA, AU, AU LAMS) 192 kg (423 lb) (IN) 196 kg (432 lb) Front: EX650J 99 kg (218 lb) (CAL, MY, PH) 100 kg (221 lb) EX650K 101 kg (223 lb) (US, CA, AU, AU LAMS) 100 kg (221 lb) Rear: EX650J 91 kg (201 lb) EX650K 92 kg (203 lb) (IN) 95 kg (209 lb) Fuel Tank Capacity 15 L (4.0 US gal) Performance Minimum Turning Radius 2.8 m (9.2 ft.) Engine Type 4-stroke, DOHC, 2-cylinder Cooling System Liquid-cooled Bore and Stroke 83.0 × 60.0 mm (3.27 × 2.36 in.) Displacement 649 cm3 (39.6 cu in.) Compression Ratio 10.8:1 Maximum Horsepower 50.2 kW (68 PS) @8 000 r/min (rpm) (AU) 50 kW (68 PS) @8 000 r/min (rpm) (AU LAMS) 37.8 kW (51 PS) @8 000 r/min (rpm) (US, CA, CAL) – – – Maximum Torque 65.7 N·m (6.7 kgf·m, 48 ft·lb) @6 500 r/min (rpm) (AU) 66 N·m (6.7 kgf·m, 49 ft·lb) @6 500 r/min (rpm) (AU LAMS) 59 N·m (6.0 kgf·m, 44 ft·lb) @6 500 r/min (rpm) (US, CA, CAL) – – – Fuel System FI (Fuel injection) KEIHIN TTK36 × 2 Fuel Type: Minimum Octane Rating: Research Octane number (RON) 91 Antiknock Index (RON + MON)/2 87 GENERAL INFORMATION 1-9 General Specifications Items EX650JH/KH Starting System Electric Starter Ignition System Battery and coil (transistorized) Timing Advance Electronically advanced (IC igniter in ECU) Ignition Timing From 10° BTDC @1 300 r/min (rpm) to 47° BTDC @6 000 r/min (rpm) Spark Plug NGK CR9EIA-9 Cylinder Numbering Method Left to right, 1-2 Firing Order 1-2 Valve Timing: Intake: Open 26° BTDC Close 48° ABDC Duration 254° Exhaust: Open 47° BBDC Close 19° ATDC Duration 246° Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.3 L (2.4 US qt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 2.095 (88/42) Clutch Type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 1st 2.438 (39/16) 2nd 1.714 (36/21) 3rd 1.333 (32/24) 4th 1.111 (30/27) 5th 0.966 (28/29) 6th 0.852 (23/27) Final Drive System: Type Chain drive Reduction Ratio 3.067 (46/15) Overall Drive Ratio 5.473 @Top gear Frame Type Tubular, diamond Caster (Rake Angle) 24° Trail 100 mm (3.94 in.) 1-10 GENERAL INFORMATION General Specifications Items EX650JH/KH Front Tire: Type Tubeless Size 120/70ZR17 M/C (58W) Rim Size J17M/C × MT3.50 Rear Tire: Type Tubeless Size 160/60ZR17 M/C (69W) Rim Size J17M/C × MT4.50 Front Suspension: Type Telescopic fork Wheel Travel 125 mm (4.92 in.) Rear Suspension: Type Swingarm (horizontal back-link) Wheel Travel 130 mm (5.12 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8.6 Ah (10 HR) (ID) 12 V 10 Ah (10 HR) Headlight: High Beam 12 V 55 W Low Beam 12 V 55 W Brake/Tail Light LED Alternator: Type Three-phase AC Maximum Output 14 V – 24 A @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country. Unit Conversion Table Prefixes for Units: Prefix Symbol Power mega M X 1 000 000 kilo k X 1 000 centi C X 0.01 milli m X 0.001 micro μ X 0.000001 Units of Mass: kg X 2.205 = lb g X 0.03527 = oz Units of Volume: l X 0.2642 = gal (US) l X 0.2200 = gal (IMP) l X 1.057 = qt (US) l X 0.8799 = qt (IMP) l X 2.1 13 = pint (US) l X 1.816 = pint (IMP) ml X 0.03381 = oz (US) ml X 0.02816 = oz (IMP) ml X 0.061 02 = cu in. Units of Force: N X 0.1020 = kg N X 0.2248 = lb kg X 9.807 = N kg X 2.205 = lb Units of Temperature: 9 ( °C+40) —- – 40 = °F OF -40 -20 I II -40 oc 5 -4 iO j ! -20: -17.8 32 20 : 40 I : I I I ; I I 0 : 4.4 68 104 60 : 80 100! 120 I I’ I: != I I I ,1 20 ! 40 : 26.7 48.9 GENERAL INFORMATION 1-11 Units of Length: km X 0.6214 m X 3.281 mm X 0.03937 Units of Torque: N·m X 0.1020 N·m X 0.7376 N·m X 8.851 kgf·m X 9.807 kgf·m X 7.233 kgf·m X 86.80 Units of Pressure: kPa X 0.01020 kPa X 0.1450 kPa X 0.7501 kgf/cm2 X 98.07 kgf/cm2 X 14.22 cmHg X 1.333 Units of Speed: km/h X 0.6214 Units of Power: kW X 1.360 kW X 1.341 PS X 0.7355 PS X 0.9863 5 ( °F+ 40) —- – 40 = °C 9 = = = = = = = = = = = = = = = = = = = = 176 212 248 284 mile ft in. kgf·m ft·lb in·lb N·m ft·lb in·lb kgf/cm2 psi cmHg kPa psi kPa mph PS HP kW HP OF 140 160 :180 200 ! 220 240 i 260 280! 300 320 I I : I I : I I : I I : I I Ii I I : I I : I I : I I 60 : 80 : 100 : 120 : 140 160 71.1 93.3 116 138 oc PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart . 2-3 Torque and Locking Agent 2-5 Specifications . 2-11 Special Tools 2-13 Periodic Maintenance Procedures 2-14 Fuel System (DFI) 2-14 Air Cleaner Element Replacement 2-14 Idle Speed Inspection . 2-15 Idle Speed Adjustment 2-15 Throttle Control System Inspection. 2-16 Engine Vacuum Synchronization Inspection. 2-16 Fuel System Inspection. 2-20 Fuel Filter Replacement 2-20 Fuel Hose Replacement . 2-22 Evaporative Emission Control System Inspection (Equipped Models) . 2-24 Cooling System 2-25 Coolant Level Inspection. 2-25 Cooling System Inspection . 2-25 Coolant Change 2-25 Water Hose and O-ring Replacement. 2-28 Engine Top End . 2-28 Valve Clearance Inspection 2-28 Valve Clearance Adjustment. 2-30 Air Suction System Damage Inspection 2-33 Clutch. 2-34 Clutch Operation Inspection . 2-34 Engine Lubrication System 2-35 Engine Oil Change 2-35 Oil Filter Replacement 2-36 Wheels/Tires 2-36 Air Pressure Inspection. 2-36 Wheels and Tires Inspection. 2-36 Wheel Bearing Damage Inspection 2-37 Final Drive 2-38 Drive Chain Lubrication Condition Inspection . 2-38 Drive Chain Slack Inspection 2-39 Drive Chain Slack Adjustment 2-39 Wheel Alignment Inspection . 2-40 Drive Chain Wear Inspection 2-41 Chain Guide Wear Inspection . 2-41 Brakes 2-42 Brake System Inspection 2-42 Brake Operation Inspection 2-43 Brake Fluid Level Inspection. 2-43 Brake Fluid Change 2-44 Brake Hose and Pipe Replacement 2-46 Master Cylinder Rubber Parts Replacement 2-50 Caliper Rubber Parts Replacement 2-51 Brake Pad Wear Inspection 2-55 Brake Light Switch Operation Inspection 2-55 2-2 PERIODIC MAINTENANCE Suspension 2-56 Suspension System Inspection. 2-56 Steering . 2-58 Steering Play Inspection . 2-58 Steering Play Adjustment 2-58 Steering Stem Bearing Lubrication . 2-60 Electrical System . 2-61 Lights and Switches Operation Inspection 2-61 Headlight Aiming Inspection . 2-63 Side Stand Switch Operation Inspection. 2-64 Engine Stop Switch Operation Inspection. 2-65 Spark Plug Replacement 2-66 Others 2-66 Chassis Parts Lubrication 2-66 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-67 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. ○: Emission Related Item : Inspection : Change or Replace : Lubrication Odometer Reading (*B) × 1 000 km (× 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 ○ Air cleaner element (*C) 2-14 ○ Idle speed 2-15 ○ Throttle control system (play, smooth return, no drag) :1 2-16 ○ Engine vacuum synchronization 2-16 Fuel system :1 2-20 Fuel filter 2-20 Fuel hose :5 2-22 ○ Evaporative emission control system (Equipped Models) 2-24 Cooling System Coolant level 2-25 Cooling system :1 2-25 Coolant, water hose and O-ring :3 : every 36 000 km (22 500 mile) 2-25, 2-28 Engine Top End ○ Valve clearance (US and CA Models) 2-28 Valve clearance (Other than US and CA Models) : every 42 000 km (26 250 mile) 2-28 ○ Air suction system 2-33 Clutch Clutch operation (play, engagement, disengagement) 2-34 Engine Lubrication System Engine oil (*C) and oil filter :1 2-35, 2-36 Wheels and Tires Tire air pressure :1 2-36 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 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 2-36 Wheel bearing damage :1 2-37 Final Drive Drive chain lubrication condition (*C) : every 600 km (400 mile) 2-38 Drive chain slack (*C) : every 1 000 km (600 mile) 2-39 Drive chain wear (*C) 2-41 Drive chain guide wear 2-41 Brakes Brake system :1 2-42 Brake operation (effectiveness, play, no drag) :1 2-43 Brake fluid level :1 2-43 Brake fluid (front and rear) :2 2-44 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) 2-55 Brake light switch operation 2-55 Suspension Suspension system :1 2-56 Lubrication of rear suspension 2-57 Steering Steering play :1 2-58 Steering stem bearings :2 2-60 Electrical System Electrical system :1 2-61 ○ Spark plugs 2-66 Others Chassis parts :1 2-66 Condition of bolts, nuts and fasteners 2-67 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 “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. 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 S: Follow the specified tightening sequence. Si: Apply silicone grease. Torque Fastener N·m kgf·m ft·lb Remarks Fuel System (DFI) Spark Plugs 15 1.5 11 Water Temperature Sensor 12 1.2 106 in·lb Crankshaft Sensor Bolts 6.0 0.61 53 in·lb Intake Air Temperature Sensor Screw 1.2 0.12 11 in·lb Air Cleaner Housing Assembly Screws 1.2 0.12 11 in·lb Air Cleaner Element Screw 1.2 0.12 11 in·lb Oxygen Sensor 25 2.5 18 Gear Position Sensor Bolt 9.8 1.0 87 in·lb Air Cleaner Housing Clamp Bolt 2.0 0.20 18 in·lb Switch Housing Screws 3.5 0.36 31 in·lb Fuel Pump Assembly Screws 0.98 0.10 8.7 in·lb R Fuel Pump Bolts 9.8 1.0 87 in·lb L, S Delivery Pipe Assy Mounting Screws 3.4 0.35 30 in·lb Purge Valve Mounting Nut 7.0 0.71 62 in·lb Cooling System Coolant Reserve Tank Bolts 7.9 0.81 70 in·lb Radiator Mounting Bolt 7.9 0.81 70 in·lb Radiator Fan Bolts 8.4 0.86 74 in·lb Thermostat Housing Bolts 12 1.2 106 in·lb Water Temperature Sensor 12 1.2 106 in·lb Water Pump Impeller Bolt 9.8 1.0 87 in·lb Water Pump Cover Bolts, L = 30 mm (1.2 in.) 12 1.2 106 in·lb Water Pump Cover Bolts, L = 40 mm (1.6 in.) 12 1.2 106 in·lb Coolant Drain Bolt 12 1.2 106 in·lb Engine Top End Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb Cylinder Head Cover Bolts 9.8 1.0 87 in·lb Camshaft Sprocket Bolts 15 1.5 11 L Camshaft Cap Bolts 12 1.2 106 in·lb S 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Rear Camshaft Chain Guide Bolt 20 2.0 15 L Cylinder Head Plugs 19.6 2.00 14.5 L Camshaft Chain Tensioner Cap Bolt 20 2.0 15 Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb L Throttle Body Assy Holder Bolts 12 1.2 106 in·lb L Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in·lb Cylinder Head Bolt (M10), L = 176 mm (6.9 in.) see text – – MO, R, S Cylinder Head Bolts (M6) 12 1.2 106 in·lb L, S Cylinder Head Bolts (M10), L = 158 mm (6.2 in.) see text – – MO, R, S Cylinder Head Bolts (M10), L = 100 mm (3.9 in.) see text – – MO, R, S Cylinder Bolt (M8) 27.5 2.80 20.3 MO, S Cylinder Bolts (M6) 12 1.2 106 in·lb L, S Cylinder Nut 49 5.0 36 MO, S Exhaust Pipe Holder Nuts 17 1.7 13 S Muffler Body Mounting Bolt 20 2.0 15 Muffler Cover Bolts 7.0 0.71 62 in·lb Oxygen Sensor 25 2.5 18 Clutch Clutch Lever Holder Clamp Bolts 8.8 0.90 78 in·lb S Timing Inspection Cap 3.9 0.40 35 in·lb Clutch Cover Bolts 12 1.2 106 in·lb S Timing Rotor Bolt Cap 4.9 0.50 43 in·lb Oil Pump Chain Guide Bolt, L = 12 mm (0.47 in.) 12 1.2 106 in·lb L Oil Pump Chain Guide Bolt, L = 11 mm (0.43 in.) 12 1.2 106 in·lb Oil Pump Sprocket Bolt 12 1.2 106 in·lb L, Lh Clutch Hub Nut 200 20.4 148 R Clutch Stopper Bolts 9.8 1.0 87 in·lb Engine Lubrication System Oil Filter 17.5 1.78 12.9 G Oil Filter Pipe 25 2.5 18 L Oil Passage Plug (PT3/8) 20 2.0 15 L Oil Pressure Switch 15 1.5 11 LG Oil Pressure Relief Valve 15 1.5 11 L Oil Pump Cover Bolts 9.8 1.0 87 in·lb L, S Oil Pump Chain Guide Bolt, L = 12 mm (0.47 in.) 12 1.2 106 in·lb L Oil Pump Chain Guide Bolt, L = 11 mm (0.43 in.) 12 1.2 106 in·lb Oil Pump Sprocket Bolt 12 1.2 106 in·lb L, Lh Oil Pipe Retaining Plate Bolt 9.8 1.0 87 in·lb L Oil Strainer Holder Bolts 9.8 1.0 87 in·lb L Oil Pan Bracket Bolts 12 1.2 106 in·lb L, S(2) Engine Oil Drain Bolt 30 3.1 22 Oil Pan Bolts 12 1.2 106 in·lb S PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Engine Removal/Installation Adjusting Collar Locknut 49 5.0 36 S Right Front Engine Mounting Bolt 44 4.5 32 S Left Front Engine Mounting Bolt 44 4.5 32 S Adjusting Collar 1.5 0.15 13 in·lb S Upper Engine Mounting Bolt 44 4.5 32 S Lower Engine Mounting Bolt 44 4.5 32 S Crankshaft/Transmission Connecting Rod Big End Nuts see the text – – MO Side Oil Plate Bolts 9.8 1.0 87 in·lb L Oil Pipe Bolts 9.8 1.0 87 in·lb L Middle Oil Plate Bolts 9.8 1.0 87 in·lb L Breather Plate Bolts 9.8 1.0 87 in·lb L Oil Passage Plug (M6) 3.5 0.36 31 in·lb Oil Passage Plug (PT3/8) 20 2.0 15 L Starter Motor Clutch Bolts 34 3.5 25 L Shift Shaft Return Spring Pin 29 3.0 21 L Bottom Oil Plate Bolts 9.8 1.0 87 in·lb L Crankcase Bolts (M8), L = 60 mm (2.4 in.) see text – – MO, S Crankcase Bolts (M8), L = 73 mm (2.9 in.) see text – – MO, S Crankcase Bolts (M9), L = 113 mm (4.45 in.) see text – – MO, S Crankcase Bolt (M8), L = 110 mm (4.33 in.) 27.4 2.79 20.2 S Crankcase Bolt (M8, Rear), L = 60 mm (2.4 in.) 27.4 2.79 20.2 S Crankcase Bolts (M6), L = 45 mm (1.8 in.) 19.6 2.00 14.5 S Crankcase Bolts (M6), L = 38 mm (1.5 in.) 19.6 2.00 14.5 S Crankcase Bolt (M8), L = 50 mm (2.0 in.) 27.4 2.79 20.2 S Crankcase Bolt (M6), L = 32 mm (1.3 in.) 19.6 2.00 14.5 S Crankcase Bolts (M9), L = 83 mm (3.3 in.) see text – – MO, S Upper Crankcase Bolt (M8), L = 120 mm (4.72 in.) 27.5 2.80 20.3 S Upper Crankcase Bolts (M8), L = 110 mm (4.33 in.) 27.5 2.80 20.3 S Shift Drum Cam Holder Bolt 12 1.2 106 in·lb L Shift Drum Holder Bolt 12 1.2 106 in·lb L Shift Rod Retaining Plate Bolt 9.8 1.0 87 in·lb L Shift Drum Bearing Holder Screws 4.9 0.50 43 in·lb L Nozzle 2.9 0.30 26 in·lb L Transmission Case Bolts, L = 30 mm (1.2 in.) 20 2.0 15 S Transmission Case Bolts, L = 26 mm (1.0 in.) 20 2.0 15 S Gear Positioning Lever Bolt 12 1.2 106 in·lb L Race Holder Screw 4.9 0.50 43 in·lb L Drive Shaft Bearing Holder Screw 4.9 0.50 43 in·lb L Shift Shaft Cover Bolts, L = 30 mm (1.2 in.) 9.8 1.0 87 in·lb L (1), S Shift Shaft Cover Bolts, L = 40 mm (1.6 in.) 12 1.2 106 in·lb S 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Shift Shaft Cover Screw 4.9 0.50 43 in·lb L, S Shift Lever Bolt 12 1.2 106 in·lb Shift Lever Tie-rod Locknuts 9.8 1.0 87 in·lb Lh(1) Shift Pedal Bolt 25 2.5 18 Wheels/Tires Front Axle Clamp Bolt 20 2.0 15 Front Axle 108 11.0 79.7 Rear Axle Nut 108 11.0 79.7 Final Drive Engine Sprocket Cover Bolt, L = 30 mm (1.2 in.) 9.8 1.0 87 in·lb Engine Sprocket Cover Bolt, L = 20 mm (0.8 in.) 9.8 1.0 87 in·lb Engine Sprocket Nut 165 16.8 122 MO Rear Sprocket Nuts 59 6.0 44 R, S Brakes Brake Hose Banjo Bolts 25 2.5 18 Front Brake Fluid Reservoir Cap Screws 1.5 0.15 13 in·lb Brake Lever Pivot Bolt 1.0 0.10 8.9 in·lb Si Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb Front Master Cylinder Clamp Bolts 11 1.1 97 in·lb S Front Brake Light Switch Screw 1.2 0.12 11 in·lb Front Caliper Mounting Bolts 25 2.5 18 Front Caliper Holder Shaft 22 2.2 16 L, Si Bleed Valve 7.8 0.80 69 in·lb Front Brake Pad Pin 17 1.7 13 Front Brake Disc Mounting Bolts 27 2.8 20 L, S Rear Caliper Holder Pin Bolt 27 2.8 20 Si Rear Brake Pad Pin 17 1.7 13 Rear Caliper Holder Bolt 22 2.2 16 Rear Master Cylinder Mounting Bolts 25 2.5 18 Rear Master Cylinder Push Rod Locknut 17 1.7 13 Rear Wheel Rotation Sensor Bolt 22 2.2 16 Brake Pedal Bolt 8.8 0.90 78 in·lb Rear Brake Disc Mounting Bolts 27 2.8 20 L, S Brake Pipe Joint Nuts 18 1.8 13 Front Wheel Rotation Sensor Rotor Bolts 4.2 0.43 37 in·lb Front Wheel Rotation Sensor Bolt 8.0 0.82 71 in·lb L Suspension Upper Front Fork Clamp Bolts 20 2.0 15 Front Fork Top Plugs 22 2.2 16 Lower Front Fork Clamp Bolts 20 2.0 15 AL Front Fork Bottom Allen Bolts 30 3.1 22 L Upper Rear Shock Absorber Nut 34 3.5 25 R, S Swingarm Bracket Bolts 25 2.5 18 S PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Tie-Rod Bolt (Lower) 44 4.5 32 S Side Stand Bracket Bolts 49 5.0 36 L, S Swingarm Pivot Shaft Nut 108 11.0 79.7 S Tie-Rod Bolt (Upper) 44 4.5 32 S Rocker Arm Bolt 59 6.0 44 S Lower Rear Shock Absorber Bolt 34 3.5 25 S Steering Handlebar Bolts 34 3.5 25 L Steering Stem Head Bolt 108 11.0 79.7 Upper Front Fork Clamp Bolts 20 2.0 15 Handlebar Holder Mounting Nuts 34 3.5 25 R Switch Housing Screws 3.5 0.36 31 in·lb Steering Stem Nut 20 2.0 15 Lower Front Fork Clamp Bolts 20 2.0 15 AL Frame Windshield Bolts 0.50 0.05 4.4 in·lb Meter Cover Bolts 0.50 0.05 4.4 in·lb Upper Fairing Bolts 0.50 0.05 4.4 in·lb Upper Inner Fairing Bolts 0.50 0.05 4.4 in·lb Fairing Bracket Nuts 35 3.6 26 Fairing Cover Bolts 0.50 0.05 4.4 in·lb Oil Pan Bracket Bolts 12 1.2 106 in·lb L, S(2) Seat Cover Bolts 3.0 0.31 27 in·lb Battery Holder Bolts, L = 18 mm (0.71 in.) 1.0 0.10 8.9 in·lb Rear Reflector Nuts 3.0 0.31 27 in·lb Rear Reflector Nuts (CN Model) 4.0 0.41 35 in·lb Grab Rail Mounting Bolts 17 1.7 13 Saree Guard Mounting Bolt 17 1.7 13 Swingarm Bracket Bolts 25 2.5 18 S Rear Footpeg Bracket Bolts 25 2.5 18 Side Stand Switch Bolt 8.8 0.90 78 in·lb L Side Stand Bracket Bolts 49 5.0 36 L, S Side Stand Bolt 29 3.0 21 Side Stand Nut 44 4.5 32 R Electrical System Tail/Brake Light Bolts 0.50 0.05 4.4 in·lb Turn Signal Light Lens Screw 1.0 0.10 8.9 in·lb License Plate Light Screws 1.2 0.12 11 in·lb Switch Housing Screws 3.5 0.36 31 in·lb Front Brake Light Switch Screw 1.2 0.12 11 in·lb Starter Motor Cable Terminal Nut 6.0 0.61 53 in·lb Starter Relay Terminal Bolts 3.6 0.37 32 in·lb Starter Motor Through Bolts 5.0 0.51 44 in·lb 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Brush Holder Screw 3.8 0.39 34 in·lb Starter Motor Mounting Bolts 9.8 1.0 87 in·lb L Starter Motor Terminal Locknut 11 1.1 97 in·lb Timing Rotor Bolt 40 4.1 30 Crankshaft Sensor Bolts 6.0 0.61 53 in·lb Alternator Cover Bolts, L = 35 mm (1.4 in.) 12 1.2 106 in·lb S Alternator Cover Bolts, L = 25 mm (1.0 in.) 12 1.2 106 in·lb S Alternator Cover Bolts, L = 70 mm (2.8 in.) 12 1.2 106 in·lb S Stator Coil Bolts 12 1.2 106 in·lb L Alternator Lead Holding Plate Bolt 9.8 1.0 87 in·lb L Alternator Rotor Bolt 200 20.4 148 MO Starter Motor Clutch Bolts 34 3.5 25 L Oil Pressure Switch 15 1.5 11 LG Engine Ground Terminal Bolt 9.8 1.0 87 in·lb Gear Position Sensor Bolt 9.8 1.0 87 in·lb Side Stand Switch Bolt 8.8 0.90 78 in·lb L Battery Holder Bolts, L = 18 mm (0.71 in.) 1.0 0.10 8.9 in·lb Fuel Pump Bolts 9.8 1.0 87 in·lb L, S Regulator/Rectifier Bolts 9.8 1.0 87 in·lb Regulator/Rectifier Bracket Bolt 9.8 1.0 87 in·lb Spark Plugs 15 1.5 11 Oxygen Sensor 25 2.5 18 Water Temperature Sensor 12 1.2 106 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Threads Diameter Torque (mm) N·m kgf·m ft·lb 5 3.4  4.9 0.35  0.50 30  43 in·lb 6 5.9  7.8 0.60  0.80 52  69 in·lb 8 14  19 1.4  1.9 10  13.5 10 25  34 2.6  3.5 19  25 12 44  61 4.5  6.2 33  45 14 73  98 7.4  10.0 54  72 16 115  155 11.5  16.0 83  115 18 165  225 17.0  23.0 125  165 20 225  325 23.0  33.0 165  240 PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) Throttle Grip Free Play 2  3 mm (0.08  0.12 in.) – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 35.3 ±1.3 kPa (265 ±10 mmHg) at idle speed – – – Bypass Screws (Turn Out) 0  2 1/2 (for reference) – – – Air Cleaner Element Viscous paper element – – – Cooling System Coolant: Type (Recommended) Permanent type of antifreeze – – – Color Green – – – Mixed Ratio Soft water 50%, coolant 50% – – – Freezing Point –35°C (–31°F) – – – Total Amount 1.2 L (1.3 US qt) – – – Engine Top End Valve Clearance: Exhaust 0.22  0.31 mm (0.0087  0.0122 in.) – – – Intake 0.15  0.21 mm (0.0059  0.0083 in.) – – – Clutch Clutch Lever Free Play 2  3 mm (0.08  0.12 in.) – – – Engine Lubrication System Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 – – – Viscosity SAE 10W-40 – – – Capacity 1.6 L (1.7 US qt) (When filter is not removed.) – – – 1.8 L (1.9 US qt) (When filter is removed.) – – – 2.3 L (2.4 US qt) (When engine is completely dry.) – – – Level Between upper and lower level lines (Wait several minutes after idling or running) – – – Wheels/Tires Tread Depth: Front 4 mm (0.16 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.) Tire Air Pressure (when cold): Front Up to 200 kg (441 lb) load: 225 kPa (2.25 kgf/cm², 32 psi) – – – Rear Up to 200 kg (441 lb) load: 250 kPa (2.50 kgf/cm², 36 psi) – – – 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Chain Slack 20  30 mm (0.8  1.2 in.) – – – Drive Chain Wear (20-link Length) 317.5  318.2 mm (12.50  12.53 in.) 319 mm (12.6 in.) Standard Chain: Make DAIDO – – – Type DID520VE – – – Link 114 links – – – Brakes Brake Fluid: Grade DOT4 – – – Brake Pad Lining Thickness: Front 4 mm (0.16 in.) 1 mm (0.04 in.) Rear 5 mm (0.20 in.) 1 mm (0.04 in.) Brake Light Timing: Front Pulled ON – – – Rear ON after about 10 mm (0.39 in.) of pedal travel – – – Electrical System Spark Plug: Type NGK CR9EIA-9 – – – Gap 0.8  0.9 mm (0.031  0.035 in.) – – – Special Tools Inside Circlip Pliers: 57001-143 Steering Stem Nut Wrench: 57001-1100 Oil Filter Wrench: 57001-1249 Vacuum Gauge: 57001-1369 Filler Cap Driver: 57001-1454 ST570143ST C ST571100ST C ST571249ST C ST571369ST C ST571454ST C PERIODIC MAINTENANCE 2-13 Throttle Sensor Setting Adapter: 57001-1538 Extension Tube: 57001-1578 Pilot Screw Adjuster, D: 57001-1588 ST571578ST C ST571588ST C Brake Caliper Piston Pliers (4>16 – 4>26): 57001-1861 ST571861ST C Brake Caliper Piston Pliers (4>26 – 4>36): 57001-1862 ST571862ST C 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Replacement NOTE ○In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Replace the air cleaner element according to the maintenance chart. NOTICE If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. •Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Bolts [A] Clamps [B] •Take out the ECU with the harness connected from the upper air cleaner housing. •Remove: Air Cleaner Housing Assembly Screws [A] •Take out the upper air cleaner housing [B] with the intake air temperature sensor connector and clamps connected. •Remove the air cleaner element screw [A]. •Discard the air cleaner element [B]. PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Make sure the seals [A] are installed • Install a new element [B] so that the screen side faces upward. • Tighten: Torque -Air Cleaner Element Screw [C]: 1.2 N·m (0.12 kgf·m, 11 in·lb) • Install: Upper Air Cleaner Housing [D] • Tighten: Torque • Air Cleaner Housing Assembly Screws [E]: 1.2 N·m (0.12 kgf·m, 11 in·lb) • Run the harness and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the clamps, and tighten the bolts. • Install the removed parts (see appropriate chapters). Idle Speed Inspection • Start the engine and warm it up thoroughly. • 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). AWARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to be make sure to correct any of these conditions. • Check the idle speed. * If the idle speed is out of specified range, adjust it. Idle Speed Standard: 1 300 ±50 r/min (rpm) Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. OOpen and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary. D GS053568SZ C 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Control System Inspection •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. •Check the throttle grip free play [B]. Throttle Grip Free Play Standard: 2  3 mm (0.08  0.12 in.) If the free play is incorrect, adjust the throttle cable as follows. •Loosen the locknut [A] at the upper end of the accelerator cable. •Turn the adjuster [B] in completely so as to give the throttle grip plenty of play. •Loosen the locknut [A] at the middle of the decelerator cable. •Turn the adjuster [B] until there is no play when the throttle grip is completely closed. •Tighten the locknut. •Turn the accelerator cable adjuster until 2  3 mm (0.08  0.12 in.) of throttle grip free play is obtained. •Tighten the locknut. If the free play can not be adjusted with the adjusters, replace the cable. Engine Vacuum Synchronization Inspection NOTE ○These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition. •Situate the motorcycle so that it is vertical. •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) PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures •Pull off the rubber caps or vacuum hoses [A] from the fittings of each throttle body. ○The evaporative emission control system equipped models are equipped the vacuum hoses. NOTE ○Do not disconnect the intake air pressure sensor hose [B] on the left side of the throttle body assy. •Connect a vacuum gauge and hoses [A] (Special Tool: 57001-1369) to the fittings on the throttle body. Special Tool – Vacuum Gauge: 57001-1369 •Connect a highly accurate tachometer lead [B] to one of the stick coil primary leads. •Plug the air switching valve hose end [A] and air cleaner housing fitting [B]. •Install the air cleaner housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter). •Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool – Extension Tube: 57001-1578 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • Check the idle speed using a highly accurate tachometer. Idle Speed Standard: 1 300 ±50 r/min (rpm) * If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment). NOTE ODo not measure the idle speed by the tachometer of the meter unit. • While idling the engine, inspect the throttle body vacuum, using the vacuum gauge. Throttle Body Vacuum Standard: 35.3 ±1.3 kPa (265 ±10 mmHg) at idle speed * If any vacuum is not within specifications, turn the bypass screws [A]. Special Tool· Pilot Screw Adjuster, D [B]: 57001-1588 NOTICE Do not over-tighten the bypass screw. The tapered portion of the bypass screw could be damaged. • Adjust the each vacuum (#1, #2) to the standard value. • Open and close the throttle valves after each measurement. • 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 and #2 with new ones, refer to the following procedure. NOTE Oln this photo, the air cleaner housing have been removed for clarity. GS053248S1 C PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). • Turn in the bypass screw [A] with counting the number of turns until it seals fully but not tightly. Record the number of turns. • Remove: Bypass Screw Spring [B] Washer [C] 0-ring [D] • 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. • Replace the bypass screw, spring, washer and 0 -ring as a set. • 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. • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE OA throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, use the “turns out” determined during disassembly. • Repeat the same procedure for the other bypass screw. • Repeat the synchronization. * If the vacuums are correct, check the output voltage of the main throttle sensor (see Main Throttle Sensor Output Voltage Inspection in the Fuel System (DFI) chapter). Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 Main Throttle Sensor Output Voltage Connections to Adapter: Digital Meter (+) -. R (sensor Y/R) lead Digital Meter (-) -. W (sensor BR/BK) lead Standard: DC 0.99 – 1.05 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). • Remove the vacuum gauge hoses and install the rubber caps or vacuum hoses to the original position. OThe evaporative emission control system equipped models are equipped the vacuum hoses. ORun the vacuum hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. • Install the removed parts (see appropriate chapters). GS050 I S8S I C 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Inspection Fuel Hose Inspection (fuel leak, damage, installation condition) Olf the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose. * Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. • Check that the 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] • Check that the fuel hose joints are securely connected. OPush and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked. NOTICE When pushing and pulling the fuel hose joint, do not apply strong force to the delivery pipe on the nozzle assy and the pipe on the fuel pump. The pipe made from resin could be damaged. AWARNING 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 locked, reinstall the hose joint. Fuel Filter Replacement AWARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery(-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTICE Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it. GSOS32SBS 1 C GS053268S1 C PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures •Remove: Fuel Pump (see Fuel Pump Removal in the Fuel System (DFI) chapter) Fuel Pump Assembly Screw [A] Lead Terminal [B] Plate Nut [C] •Disconnect: Lead Terminal (Red) [D] Lead Terminal (Light Blue) [E] •Remove: Fuel Pump Assembly Screw [A] Lead Terminal [B] Plate Nut [C] •Using the flat tip screwdriver [A], clear the tabs [B] and remove the fuel pump fitting [C] from the case [D]. •Remove the fuel pump body [A] with fuel filter [B] from the fitting. •Wrap the fuel filter [A] with the clean cloth [B], and remove the fuel filter. 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fuel filter [A] with a new one. • Replace the following parts with new ones and install the removed parts in the reverse procedure. 0 -rings [A] Fuel Pump Assembly Screws [B] • Tighten: Torque · Fuel Pump Assembly Screws: 0.98 N·m (0.10 kgf·m, 8.7 in·lb) • Run the lead [A] into the guide [B]. Fuel Hose Replacement • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Be sure to place a piece of cloth around the fuel hose joint. • Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush. B_.-f GS052 70 8S I C PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures When removing with flat tip screwdriver • Insert the flat tip screwdriver [A] into slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. When removing with fingers • 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. • Pull the fuel hose joint out of the delivery pipe. AWARNING 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. • Clean the delivery pipe. • Cover the delivery pipe with the vinyl bag to keep it clean. • Remove the vinyl bag on the pipe. • Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A]. • Replace the fuel hose with a new one. • Install the new fuel hose. • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. • Push [B] the joint lock [C]. B GS0 5 3008S I C ® ~ [ 0—3 GSOS2 658S I 0 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures •Push and pull the fuel hose joint [A] back and forth [B] more than two times and make sure it is locked and does not come off. WARNING Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak. If it comes off, reinstall the hose joint. •Install the removed parts (see appropriate chapters). •Start the engine and check the fuel hose for leaks. Evaporative Emission Control System Inspection (Equipped Models) •Inspect the canister as follows. ○Remove: Front Seat (see Front Seat Removal in the Frame chapter) Battery Holder (see Battery Removal in the Electrical System chapter) Screws [A] ○Remove: Cover [A] ○Pull out the canister [A]. ○Slide the clamps [B]. ○Disconnect the hoses [C]. ○Visually inspect the canister for cracks or other damage. If the canister has any cracks or bad damage, replace it with a new one. NOTE ○The canister is designed to work well through themotorcycle’s life without any maintenance if it is used under normal conditions. •Inspect the purge valve (see Purge Valve Inspection in the Fuel System (DFI) chapter). ○Check that the hoses are securely connected and clamps are in position. ○Replace any kinked, deteriorated or damaged hoses. ○Run the hoses according to the Cable, Wire, and Hose Routing section in the Appendix chapter. ○When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and run the hoses with aminimum of bending so that the emission flow will not be obstructed. PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold (room or ambient temperature). • Check the coolant level in the coolant reserve tank with the motorcycle held perpendicular (Do not use the side stand). * If the coolant level is lower than the “L” level line [A], unscrew the reserve tank cap and add coolant to the “F” level line [B]. “L”: Low “F”: Full NOTICE For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often or the coolant reserve tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Coolant damages painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts. Cooling System Inspection Water Hose and Pipe Inspection (coolant leak, damage, installation condition) OThe high pressure inside the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. • Remove the middle fairing (see Middle Fairing Removal in the Frame chapter). • Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. * Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. • Check that the hoses are securely connected. Coolant Change AWARNING 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. A 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures •Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Coolant Reserve Tank Bolts [A] •Disconnect the coolant reserve tank overflow hose [A]. •Remove the cap [B]. •Drain the coolant into a container from the coolant reserve tank. •Remove the right middle fairing (see Middle Fairing Removal in the Frame chapter). •Remove: Radiator Cap [A] •Place a container under the drain bolt [A] of the water pump cover. •Drain the coolant from the radiator by removing the drain bolt. PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures •Connect the coolant reserve tank overflow hose. •Replace the drain bolt gasket with a new one. •Tighten: Torque – Coolant Drain Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) Coolant Reserve Tank Bolts: 7.9 N·m (0.81 kgf·m, 70 in·lb) •When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. NOTICE Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Water and Coolant Mixture Ratio (Recommended) Soft Water: 50% Coolant: 50% Freezing Point: –35°C (–31°F) Total Amount: 1.2 L (1.3 US qt) •Fill the radiator up to the filler neck [A] with coolant. NOTE ○Pour in the coolant slowly so that it can expel the air from the engine and radiator. •Check the cooling system for leaks. •Tap the water hoses to force any air bubbles caught inside. •Fill the radiator up to the filler neck with coolant. •Install the radiator cap. •Fill the reserve tank up to the “F” (full) level line [A] with coolant and install the cap. •Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. •Check the coolant level in the reserve tank after the engine cools down. If the coolant level is lower than the “L” (low) level line [B], add coolant to the “F” level line. NOTICE Do not add more coolant above the “F” level line. •Install the removed parts (see appropriate chapters). 2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and 0 -ring Replacement • Drain the coolant (see Coolant Change). • Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Right Fuel Tank Side Cover (see Fuel Tank Side Cover Removal in the Frame chapter) Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Removal in the Cooling System chapter) • Replace the hoses [C] and 0-rings [D] with new ones. • Apply grease to the new 0-rings. • Run the new hoses according to the Cable, Wire, and Hose Routing section in the Appendix chapter. • Install the removed parts (see appropriate chapters). • Fill the coolant (see Coolant Change). • Check the cooling system for leaks. Engine Top End Valve Clearance Inspection NOTE o Valve clearance must be checked and adjusted when the engine is cold (room temperature). • Remove: Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Special Tool – Filler Cap Driver: 57001-1454 • Check the valve clearance when the pistons are at TDC. OThe pistons are numbered beginning with the engine left side. • Using a wrench, turn the timing rotor clockwise until the “1/T” or “2/T” [A] mark line aligns with the notch [B] on the timing inspection hole [C]. For #1 Cylinder: “1/T” Mark Line For #2 Cylinder: “2/T” Mark Line GS081 138S2 C OE1 l4388 S I C PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures OMeasure the valve clearance of the valves for which the cams [A] are turned away from each other. • Using the thickness gauge [A], measure the valve clearance between cam and valve lifter. Valve Clearance Standard: Exhaust 0.22 – 0.31 mm (0.0087 – 0.0122 in.) Intake 0.15 – 0.21 mm (0.0059 – 0.0083 in.) NOTE o Thickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] OEach piston has two intake and two exhaust valves. Measure these two intake or exhaust valves at the same crankshaft position. NOTE OCheck the valve clearance using this method only. Checking the clearance at any other cam position may result in improper valve clearance. Valve Clearance Measuring Position #1 Piston TDC at End of Compression Stroke: Intake Valve Clearances of #1 Piston Exhaust Valve Clearances of #1 Piston #2 Piston TDC at End of Compression Stroke: Intake Valve Clearances of #2 Piston Exhaust Valve Clearances of #2 Piston * If the valve clearance is not within the specified range, first record the clearance, and then adjust it. GS070728S 1 0 ® GS0702•BS 1 C 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions. 0 Besides the standard shims in the valve clearance adjustment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance. Adjustment Shims Thickness 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 • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. GS010738SI C PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE PRESENT SHIM .-Ex amp I e PART No. (92 180- ) 1014 1016 1018 1020 1022 1024 1026 102, 103( 1032 1034 1036 1038 1040 1042 1044 1046 1048 1050 1052 1054 MARK 50 55 60 65 70 75 80 85 9( 95 00 05 10 15 20 25 30 35 40 45 50 TH I CKNESS (11111) 2.50 2.55 2. 6C 2.65 2. 70 2. 75 2.80 2. 85 2. 9( 2. 95 3. 0( 3. 05 3. 10 3. 15 3. 2C 3.25 3.30 3.35 3. 40 3. 45 3.50 0.00″-0. 01 – – – – 2. 50 2. 55 2. 60 2. 65 2. 7( 2. 75 2. 8( 2. 85 2.90 2.95 3. oc 3. 05 3. 10 3. 15 3.20 3. 25 3. 30 0. 02″-0. 06 – – – 2. 50 2. 55 2. 6( 2.65 2. 7( 2. H 2. 80 2. 85 2. 90 2. 95 3.00 3. 05 3. 10 3. 15 3. 20 3. 25 3. 3( 3. 35 0. 07″-0. 11 – – 2. 50 2.55 2. 60 2. 65 2. 70 2. 75 2. 8( 2. 85 2. 9( 2. 95 3. 00 3. 05 3. 1 C 3. 15 3.20 3.25 3. 30 3. 35 3.40 0. 12′-0.14 – 2. 50 2. 55 2.60 2.65 2. 7( 2. 75 2. SC 2. 8! 2. 90 2. 95 3.00 3. 05 3. 10 3. 15 3. 20 3.25 3.30 3. 35 3. 4( 3. 45 0. 15″-0. 21 SPEC I FIED CLEARANCE/ NO CHANGE REOU I RED G> 0. 22″-0. 24 2.55 2.60 2. 65 2. 70 2. 75 2. 8( 2.85 2. 9( 2. 9! 3. 00 3. 05 3. 10 3. 15 3.20 3. 25 3.30 3. 35 3.40 3. 45 3. 5~ – 0.25″-0. 29 2.60 2. 65 2. 7C 2. 75 2. 80 2. 85 2. 90 2. 95 3. 0( 3. 05 3. 1( a. 3. 15 3. 20 3. 25 3. 3C 3. 35 3.40 3.45 3. 5~ E “‘ 0. 30′-0. 34 2. 65 2. 70 2. 75 2.80 2.85 2. 9( 2. 95 3. 0( 3. O! 3. 10 3. 15 3.20 3. 25 3. 30 3. 35 3. 40 3.45 3.50 X t 0.35″-0. 39 2. 70 2. 75 2.80 2. 85 2. 90 2. 95 3. 00 3.05 3. l( 3. 1 • 3. 2( 3. 25 3.30 3.35 3. 4C 3. 45 3. 50 0. 40′-0. 44 2. 75 2. 80 2. 85 2. 90 2. 95 3. 0( 3. 05 3. 1 C 3. 15 3. 20 3. 25 3. 30 3. 35 3. 40 3. 45 3. 50 0.45″-0.49 2.80 2.85 2. 9C 2.95 3. 00 3.05 3. 10 3. 15 3. 20 3. 25 3. 3( 3. 35 3. 40 3. 45 3. SC Iz: 0. 50′-0. 54 2. 85 2. 90 2. 95 3.00 3.05 3. 1C 3. 15 3. 2( 3. 25 3. 30 3. 35 3.40 3. 45 3. 50 w ::z 0. 55′-0. 59 2.90 2. 95 3.0C 3.05 3. 10 3. 15 3. 20 3. 25 3. 30 3. 35 3. 4( 3. 45 3. 50 w a: 0. 60′-0. 64 2. 95 3. 00 3. 05 3. 10 3. 15 3. 2( 3. 25 3. 3( 3. 35 3. 40 3.45 3.50 ::, en 0. 65′-0. 69 3.00 3. 05 3. 10 3. 15 3. 20 3. 25 3. 30 3. 35 3. 40 3. 45 3. 5( < w 0. 70′-0. 74 3.05 3. 10 3. 15 3. 20 3. 25 3. 3( 3.35 3. 4( 3.45 3. 50 ~ 0. 75′-0. 79 3. 10 3. 15 3.2C 3.25 3. 30 3. 35 3. 40 3. 45 3. 50 w c., 0. 80′-0. 84 3. 15 3. 20 3. 25 3. 30 3. 3• 3. 4( 3. 45 3. 5( z < 0.85–.0.89 3. 20 3.25 3. 3C 3. 35 3. 40 3.45 3. 50 0:: < 0.90′-0.94 3.25 3.30 3. 35 3.40 3.45 3. 5( w .J 0. 95–.0. 99 3.30 3.35 3. 40 3.45 3. 50 c., 1. 00′-1. 04 3. 35 3. 40 3. 45 3.50 w > 1. 05′-1. 09 3. 40 3. 45 3.5C .J < 1. 10″-I. 14 3. 45 3. 50 INSTALL THE SH IM OF TH IS TH I CK NESS (mm) > 1.15′-1.19 3.50 SS07 1196W3 C 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. 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE PRESENT SHIM .-Ex amp I e PART No. (92180-) 1014 1016 10H 1020 1022 1024 1026 1028 103( 1032 1034 1036 1038 1040 1041 1044 104E 1048 1050 1052 1054 MARK 50 55 6C 65 70 75 80 85 9( 95 00 05 10 15 2( 25 30 35 40 45 50 TH ICKN ESS(01m) 2.50 2. 55 2. 6( 2.65 2. 10 2. 75 2.80 2.85 2. 9( 2. 9• 3. 00 3.05 3. 10 3. 15 3. 2( 3. 25 3. 3C 3. 35 3.40 3.45 3.50 0. 00″-0 . 04 – – – – – 2. 5( 2. 55 2. 60 2. 6! 2. 7C 2. 75 2.80 2.85 2. 90 2. 9! 3. 00 3.0’ 3. 10 3. 15 3. 2( 3. 25 0. 05″-0 . 09 – – – – 2. 50 2. 55 2. 60 2. 65 2. 7( 2. 75 2. 80 2. 85 2. 90 2.95 3. 0( 3. 05 3. 1 C 3. 15 3. 20 3. 25 3. 30 0. 10″-0. 14 – – – 2.50 2.55 2 6( 2. 65 2. 70 2. 7! 2. SC 2.85 2. 90 2. 95 3. 00 3. O! 3. 10 3. 15 3. 20 3. 25 3. 3( 3.35 0. 15″-0. 19 – – 2. 5( 2. 55 2. 60 2. 65 2. 70 2. 75 2. 8( 2. 85 2.90 2. 95 3. 00 3.05 3. 1( 3. 15 3. 2C 3. 25 3. 30 3. 35 3. 40 0. 20″-0 . 21 – 2. 50 2. 5! 2. 60 2. 65 2. 7( 2. 75 2. 80 2. 8! 2. 9C 2. 95 3. 00 3. 05 3. 10 3. 1 ! 3. 20 3. 25 3. 30 3. 35 3. 4 ( 3. 45 G> 0. 22”-0 . 31 SPEC IFI ED CLEARANCE/ NO CHANGE REOU I RED a. 0. 32–0. 34 2.55 2. 60 2. 65 2. 70 2. 75 2.8( 2. 85 2.90 2. 9! 3. oc 3. 05 3. lC 3. 15 3. 20 3. 25 3. 30 3. 35 3. 40 3. 45 3. 5~ e “‘ 0. 35–0 . 39 2.60 2. 65 2. 7( 2. 75 2.80 2. 85 2. 90 2.95 3. 0( 3. o• 3. 10 3. 15 3.20 3.25 3. 3( 3. 35 3. 4C 3.45 3. 5~ >< t 0. 40–0 . 44 2.65 2. 70 2. 75 2.80 2.85 2. 9( 2. 95 3.00 3. O! 3. lC 3. 15 3. 20 3.25 3. 30 3. 3′ 3. 40 3.45 3. 50 0.45–0.49 2. 70 2. 75 2. SC 2.85 2.90 2.95 3.00 3.05 3. 10 3. 15 3. 20 3.25 3.30 3.35 3. 4( 3. 45 3. 5C 0. 50–0.54 2. 75 2. 80 2. 85 2. 90 2. 95 3. oc 3.05 3. 10 3. 15 3. 2C 3. 25 3.3C 3.35 3.40 3. 4! 3.50 0. 55–0 . 59 2. 80 2.85 2. 9( 2. 95 3. 00 3. 05 3. 10 3. 15 3.20 3. 25 3.30 3. 35 3. 40 3. 45 3. 5( I- z 0. 60–0 . 64 2. 85 2. 90 2. 9! 3. 00 3. o• 3. 1( 3. 15 3.20 3.25 3. 3C 3. 35 3. 4C 3. 45 3. 50 w ::E 0. 65–0 . 69 2.90 2. 95 3. oc 3.05 3. 10 3. 15 3. 20 3.25 3.30 3. 35 3. 40 3. 45 3.50 w e:::: 0. 70–0 . 74 2.95 3. 00 3. O! 3. I 0 3. 15 3. 2( 3. 25 3.30 3.35 3. 4C 3. 45 3. 50 ::, (/) 0. 75–0 . 79 3.00 3. 05 3. IC 3. 15 3. 20 3. 25 3. 30 3. 35 3. 40 3. 4′ 3.50 < w 0. 80–0.84 3. 05 3. 10 3. 15 3. 20 3.25 3. 3( 3. 35 3. 40 3. 45 3. SC :::E 0. 85–0 . 89 3. 10 3. 15 3. 2( 3.25 3.30 3. 35 3. 40 3. 45 3.50 w 0 0. 90–0 . 94 3. 15 3. 20 3. 25 3. 30 3.35 3. 4( 3. 45 3.50 z < 0. 95–0. 99 3.20 3. 25 3. 3( 3. 35 3. 40 3. 45 3.50 e:::: < 1. 00″-l . 04 3. 25 3. 30 3. 35 3. 40 3. 45 3. 5( w_. 1. 05″-1. 09 3. 30 3. 35 3. 4 ( 3.45 3.50 0 1.10”-1.14 3. 35 3. 40 3. 4! 3. 50 w >_. 1. 15 “-1. 19 3.40 3. 45 3. 5( I NS TA LL TH E SHI M OF THIS TH ICKNESS (mm) < 1. 20”-l , 24 3.45 3.50 > 1. 25’-1. 29 3. 50 GS07120813 C 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 2-33 Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance. •When installing the shim, face the marked side toward the valve lifter. At this time, apply molybdenum disulfide oil solution 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. •Apply molybdenum disulfide oil solution to the valve lifter surface and install the lifter. •Install the camshafts (see Camshaft Installation in the Engine Top End chapter). •Recheck the valve clearance and readjust if necessary. •Install the removed parts (see appropriate chapters). Air Suction System Damage Inspection •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) •Bring the air switching valve hose end [A] to the outside of the frame. •Reinstall: Air Cleaner Housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter) Fuel Tank (see Fuel Tank Installation in the Fuel System (DFI) chapter) •Start the engine and run it at idle speed. •Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve Inspection in the Engine Top End chapter). 2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection •Pull the clutch lever just enough to take up the free play [A]. •Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it. Clutch Lever Free Play Standard: 2  3 mm (0.08  0.12 in.) 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. •Turn the adjuster [A] so that 5  6 mm (0.20  0.24 in.) [B] of threads is visible. •Remove the right fairing cover (see Fairing Cover Removal in the Frame chapter). •Slide the dust cover [A] at the clutch cable lower end out of place. •Loosen both adjusting nuts [B] at the clutch cover as far as they will go. •Pull the clutch outer cable [C] and tighten the adjusting nuts against the clutch cover. •Slip the dust cover back onto place. •Turn the adjuster at the clutch lever until the free play is correct. 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. •After the adjustment, start the engine and check that the clutch does not slip and that it releases properly. PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. OThe oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement). • Replace the drain bolt gasket [B] with a new one. • Tighten the drain bolt. Torque · Engine Oil Drain Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb) • Remove the oil filler plug [A]. • 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 1 OW-40 Capacity: 1.6 L (1.7 US qt) (When filter is not removed.) 1.8 L (1.9 US qt) (When filter is removed.) 2.3 L (2.4 US qt) (When engine is completely dry.) NOTE ODo 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. OAlthough 1 OW-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. • Replace the 0-ring of the oil filler plug with a new one. • Apply grease to the new 0-ring. • Install the oil filler plug. • Check the oil level (see Oil Level Inspection in the Engine Lubrication System chapter). • 20 • 10 0 10 20 30 40(°C) – 4 14 32 50 68 86 104( “F ) GS0 90 10 8 SI C 2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove the oil filter with the oil filter wrench [A]. Special Tool· Oil Filter Wrench: 57001-1249 • Replace the filter with a new one. • Apply grease to the gasket [A] before installation. • Tighten the filter with the oil filter wrench. Special Tool· Oil Filter Wrench: 57001-1249 Torque· Oil Filter: 17.5 N·m (1.78 kgf·m, 12.9 ft-lb) NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque. • Pour in the specified type and capacity of oil (see Engine Oil Change). Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • 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). • Install the air valve cap. * Adjust the tire air pressure according to the specifications if necessary. Tire Air Pressure (when cold): Front: Up to 200 kg (441 lb) load: 225 kPa (2.25 kgflcm2 , 32 psi) Rear: Up to 200 kg (441 lb) load: 250 kPa (2.50 kgflcm2 , 36 psi) Wheels and Tires Inspection Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign particles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. • Visually inspect the wheel for cracks, cuts and dents damage. *If any damage is found, replace the wheel if necessary. GG050’402S1 C OJOSOC7BSI C OSI 1022.BSI C PERIODIC MAINTENANCE 2-37 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. • 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 4 mm (0.16 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)) AWARNING 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 OMost countries may have their own regulations a minimum tire tread depth: be sure to follow them. OCheck and balance the wheel when a tire is replaced with a new one. Wheel Bearing Damage Inspection • Raise the front wheel off the ground with a suitable stand. • Turn the handlebars all the way to the right or left. • Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. • Spin [BJ 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). 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the rear wheel off the ground with a stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the roughness of the rear wheel bearing by pushing and pulling [A] the wheel. • Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise. * If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see 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 0-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid damaging the 0-rings and resultant loss of lubricant, observe the following rules. Use only chain cleaner for cleaning of the 0-ring of the drive chain. Any other cleaning solution such as gasoline will cause deterioration and swelling of the 0-ring. Immediately blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes. • Apply chain oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the 0 -rings so that the 0-rings will be coated with oil. • Wipe off any excess oil. Oil Applied Areas [A] 0-rings [B] • Wipe off lubricant that gets on the tire surface. GK0 40607S1 C PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on ;ts side stand. OClean the chain if it is dirty, and lubricate ;t if it appears dry. • Check the wheel alignment (see Wheel Alignment Inspection). • Rotate the rear wheel to find the position where the chain is tightest. • Measure the vertical movement (chain slack) [AJ midway between the sprockets. Measuring Point [BJ About 115 mm (4.53 in.) [CJ * If the chain slack exceeds the standard, adjust it. Chain Slack Standard: 20 – 30 mm (0.8 – 1.2 in.) Drive Chain Slack Adjustment • Remove the rubber cap [AJ. • Remove the cotter pin [A], and loosen the axle nut [BJ. • Loosen the both chain adjuster locknuts [C]. * If the chain is too loose, turn in the right and left chain adjusters [DJ evenly. * If the chain is too tight, turn out the right and left chain adjusters evenly, and kick the wheel forward. • Turn both chain adjusters evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the left wheel alignment indicator [EJ should align with the same swingarm mark [FJ that the right wheel alignment indicator aligns with. AWARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned. • Tighten both chain adjuster locknuts securely. • Tighten: Torque· Rear Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft-lb) • Turn the wheel, measure the chain slack again at the tightest position, and readjust if necessary. 00 00000 n . GS 1202 18S I C GS 1206 18S I C 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE OWhen inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [BJ up to next alignment. Oft should be within 30 degrees. OLoosen once and tighten again when the slot goes past the nearest hole. • Bend the cotter pin [A] along the nut [B]. AWARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. • Install the rubber cap. Wheel Alignment Inspection • Remove the rubber cap [A]. • Check that the left alignment indicator [A] aligns with the same swingarm mark [B] that the right alignment indicator aligns with. * If they are not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment). NOTE OWheel alignment can be also checked using the straightedge or string method. AWARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned. • Install the rubber cap. ® A GJ 0 42498S I C PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the mud guard and chain cover (see Mud Guard Removal in the Frame chapter). • 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. • Stretch the chain taut by hanging a 10 kg (22 lb) weight [A] on the chain. • Measure the length of 20 links [B] on the straight part [CJ of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. * If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced. Drive Chain 20-link Length Standard: 317.5 – 318.2 mm (12.50 – 12.53 in.) Service Limit: 319 mm (12.6 in.) AWARNING 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: DAIDO Type: DID520VE Link: 114 links • Install the mud guard and chain cover (see Mud Guard Installation in the Frame chapter). Chain Guide Wear Inspection • Remove the swingarm (see Swingarm Removal in the Suspension chapter). • Visually inspect the chain guide [A]. * Replace the chain guide if it shows any signs of abnormal wear or damage. ~ 1st 2 1 s t GK0 40606S I C 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake System Inspection Brake Fluid Leak (Brake Hose and Pipe) Inspection • Remove the right side cover (see Side Cover Removal in the Frame chapter). • For ABS equipped models, remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], fittings [B] and pipes [C] (ABS equipped models). * If the brake fluid leaked from any position, inspect or replace the problem part. GS 134088W2 C PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • Remove the right side cover (see Side Cover Removal in the Frame chapter). • For ABS equipped models, remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Inspect the brake hoses, pipes and fittings for deterioration, cracks and signs of leakage. OThe high pressure inside the brake line can cause fluid to leak [A] or the hose, pipe (ABS equipped models) to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. • Replace the hose and pipe (ABS equipped models) if any crack [B], bulge [C] or leakage is noticed. * Tighten any brake hose banjo bolts and brake pipe joint nuts. Torque – Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft-lb) Brake Pipe Joint Nuts (ABS Equipped Models): 18 N·m (1.8 kgf·m, 13 ft·lb) • Inspect 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 • Inspect 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. AWARNING When test riding the vehicle, be aware of surrounding traffic for your safety. Brake Fluid Level Inspection • Check that the brake fluid level in the front brake fluid reservoir [A] is above the lower level line [B]. NOTE OHold the reservoir horizontal by turning the handlebars when checking brake fluid level. GL1 00201SI C @ 2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures * If the fluid level is lower than the lower level line, remove the reservoir cap and fill the reservoir to the upper level line [A]. • Tighten: Torque • Front Brake Fluid Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) • Check that the brake fluid level in the rear brake fluid reservoir [A] is above the lower level line [B]. * If the fluid level is lower than the lower level line, remove the right side cover (see Side Cover Removal in the Frame chapter) fill the reservoir to the upper level line [C]. AWARNING Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. Recommended Disc Brake Fluid Grade: D0T4 • Follow the procedure below to install the rear brake fluid reservoir cap correctly. OFirst, 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. • Install the stopper and tighten the screw. Brake Fluid Change NOTE o The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Level the brake flu id reservoir. • Remove the reservoir cap, diaphragm plate and diaphragm. • Remove the rubber cap [A] from the bleed valve on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. • Fill the reservoir with fresh specified brake fluid. • Change the brake fluid. ORepeat 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 o The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line. • Remove the clear plastic hose. • Install the diaphragm, diaphragm plate and reservoir cap. • Tighten: Torque – Front Brake Fluid Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) • Follow the procedure below to install the rear brake fluid reservoir cap correctly. OFirst, 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. • Tighten the bleed valve, and install the rubber cap. Torque – Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) • After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage. * If necessary, bleed the air from the lines. 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely washed away immediately. •Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Mud Guard (see Mud Guard Removal in the Frame chapter) •Release the brake hoses from the clamps [A]. •Remove the brake hose banjo bolts [B]. •When removing the brake hoses [C], note the following. ○Take care not to spill the brake fluid on the painted or plastic parts. ○Temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum. ○Immediately wash away any brake fluid that spills. •When installing the brake hoses, note the following. ○Avoid sharp bending, kinking, flatting or twisting, and run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. ○There are washers on each side of the brake hose fitting. Replace them with new ones. ○Tighten: Torque – Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •Fill the brake line after installing the brake hose (see Brake Fluid Change). PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures •For ABS equipped models; note the following. NOTE ○When 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. •Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Mud Guard (see Mud Guard Removal in the Frame chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Brake Pipe Joint Nuts [A] Brake Hose Banjo Bolts [B] Bolts Brackets Dampers Clamps •There are washers on each side of the brake hose and pipe fitting. Replace them with new ones when installing. •Before installing the brake pipe, check to see that there is no damage on the threads of the brake pipe joint nut. If there is any damage, replace the damaged parts with new ones. NOTE ○Tighten the brake pipe joint nut at both ends of the brake pipe temporarily and then tighten them to the specified torque. •Install the brake pipes and brake hoses to the specified angle (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Tighten the brake pipe joint nuts with the flare nut wrench. •Tighten: Torque – Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb) •Fill the brake line after installing the brake hose and pipe (see Brake Fluid Change). 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures B GS13419Bfl’3 C PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures GSI 3420815 C 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). • Remove: Front Brake Reservoir Cap Screws [A] Reservoir Cap [B] Diaphragm Plate [C] Diaphragm [D] • Unscrew the locknut [E] and pivot bolt [F], and remove the brake lever. • Remove the dust cover [G] and circlip [H]. Special Tool – Inside Circlip Pliers: 57001-143 • Pull out the piston assembly [I]. NOTICE Do not remove the secondary cup from the piston since removal will damage it. • Replace: Diaphragm [D] Dust Cover [G] Circlip [H] Piston Assembly [I] Rear Master Cylinder Disassembly • Remove: Rear Master Cylinder (see Rear Master Cylinder Removal in the Brakes chapter) • Remove the circlip [A], connector [B] and 0-ring [C]. Special Tool – Inside Circlip Pliers: 57001-143 • Slide the dust cover [D] out of place, and remove the circlip [E]. • Pull out the push rod assembly [F]. • Remove the piston assembly [G]. NOTICE Do not remove the secondary cup from the piston since removal will damage it. • Replace: Circlip [A] 0-ring [C] Circlip [E] Push Rod Assembly [F] Piston Assembly [G] Diaphragm [H] GS 13421BS2 C GS 134 12BS2 C PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Master Cylinder Assembly •Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake. •Apply brake fluid to the new parts and to the inner wall of the cylinder. •Take care not to scratch the piston or the inner wall of the cylinder. •Apply silicone grease to the followings. Front: Brake Lever Pivot Bolt Rear: Dust Cover of Push Rod Assembly •For the front master cylinder, tighten the brake lever pivot bolt and the locknut. Torque – Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9 in·lb) Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb) Caliper Rubber Parts Replacement Front Caliper Disassembly •Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) Front Caliper Holder [A] Pad Spring [B] •Using compressed air, remove the pistons. ○Cover the piston area with a clean, thick cloth [A]. ○Blow compressed air [B] into the hole for the banjo bolt to remove the piston. WARNING The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. ○Pull out the pistons by hand. 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When compressed air is not used, using the brake caliper piston pliers [A] remove the pistons [B]. Special Tool – Brake Caliper Piston Pliers (q,16 – 4>26): 57001-1 861 • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed valve [C] and rubber cap [D]. Front Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque – Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Replace the fluid seals [A] with new ones. OApply silicone grease to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are damaged. OApply silicone grease to the dust seals, and install them into the cylinders by hand. • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • Check the shaft rubber friction boot [A] and the dust cover [B] replace them with new ones if they are damaged. • Apply a silicone grease to the caliper holder shafts [C] and the holes [D]. A GLOSO.t02S 1 C PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures •Install the pad spring [A]. •Install the removed parts (see appropriate chapters). •Wipe up any spilled brake fluid on the caliper with wet cloth. Rear Caliper Disassembly •Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pad (see Rear Brake Pad Removal in the Brakes chapter) •Remove: Pad Spring [A] Sleeve [B] Friction Boot [C] •Using compressed air, remove the piston. ○Cover the caliper opening with a clean heavy cloth [A]. ○Remove 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. •When compressed air is not used, using the brake caliper piston pliers [A] remove the piston [B]. Special Tool – Brake Caliper Piston Pliers ( 26  36): 57001-1862 •Remove the dust seal and fluid seal. •Remove the bleed valve and rubber cap. 2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque · Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Replace the fluid seal [A] with a new one. OApply silicone grease to the fluid seal, and install it into the cylinder by hand. • Replace the dust seal [B] with a new one. OApply silicone grease to the dust seal, and install it into the cylinder by hand. • Replace the friction boot [A] with a new one and install it. • Install the sleeve [B]. OApply a silicone grease to the sleeve. • Apply brake fluid to the outside of the piston [A], and push it into the cylinder by hand. • Install the pad spring [B] in the caliper as shown. • Apply silicone grease to the caliper holder shaft [C]. • Install the removed parts (see appropriate chapters). • Wipe up any spilled brake fluid on the caliper with wet cloth. A GLOSO.t02S 1 C PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Brake Pad Wear Inspection •Remove the brake pads (see Front/Rear Brake Pad Removal in the Brakes chapter). •Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Front Brake Pad [C] Rear Brake Pad [D] Pad Lining Thickness Standard: Front 4 mm (0.16 in.) Rear 5 mm (0.20 in.) Service Limit: 1 mm (0.04 in.) Brake Light Switch Operation Inspection •Turn the ignition switch on. •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. •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. 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 10 A (see Fuse Inspection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in the Electrical System chapter) Rear Brake Light Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) Suspension Suspension System Inspection Front Forks/Rear Shock Absorber Operation Inspection •Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter). •Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection). Front Fork Oil Leak Inspection •Visually inspect the front forks [A] for oil leakage. Replace any defective parts, if necessary. PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Rear Shock Absorber Oil Leak Inspection •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 •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). Tie-Rod Operation Inspection •Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rod [A] does not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspension chapter). Swingarm Pivot Lubrication •Remove the swingarm (see Swingarm Removal in the Suspension chapter). •Remove the sleeve [A]. •Using a high flash-point solvent, clean the old grease out of the left needle bearing [A]. •Apply plenty of grease to the inner surface of the left needle bearing. NOTE ○Since the right needle bearing [B] is packed with grease and sealed, lubrication is not required. •Apply thin coat of grease to the lips of the grease seals [C]. •Install the swingarm (see Swingarm Installation in the Suspension chapter). 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection •Raise the front wheel off the ground with a suitable stand. •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. •Feel for steering looseness by pushing and pulling [A] the forks. If you feel looseness, the steering is too loose. NOTE ○The cables and wiring will have some effect on the motion of the fork which must be taken into account. ○Be sure the leads and cables are properly routed. ○The bearings must be in good condition and properly lubricated in order for any test to be valid. Steering Play Adjustment •Remove: Handlebars (see Handlebar Removal in the Steering chapter) Ignition Switch Cover (see Ignition Switch Cover Removal in the Frame chapter) •Remove: Upper Harness Bracket Bolts [A] Upper Harness Bracket [B] •Raise the front wheel off the ground with a suitable stand. •Remove: Plug Steering Stem Head Bolt [A] and Washer •Loosen: Upper Front Fork Clamp Bolts [B] •Remove: Steering Stem Head [C] PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Straighten the claws [AJ of the washer. • Remove: Steering Stem Locknut [BJ Claw Washer • Adjust the steering using the steering stem nut wrench [AJ. Special Tool· Steering Stem Nut Wrench: 57001-1100 * If the steering is too tight, loosen the stem nut [BJ a fraction of a turn. * If the steering is too loose, tighten the stem nut a fraction of a turn. NOTE o Turn the stem nut 118 turn at time maximum. • Install the claw washer [AJ so that its bent side [BJ faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer. • Hand tighten the stem locknut clockwise until the claws are aligned with the second groove of stem nut [DJ, and bend the 2 claws downward [EJ. • Install the steering stem head. • Install the washer, and temporary tighten the stem head bolt. NOTE o Tighten the upper front fork clamp bolts first, next the stem head bolt. Torque· Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 79.7 ft·lb) AWARNING 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). • Check the steering again. * If the steering is still too tight or too loose, repeat the adjustment. • Install the removed parts (see appropriate chapters). GS l50648S2 C 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication •Remove the steering stem (see Steering Stem, Stem Bearing Removal in the Steering chapter). •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. •Visually check the outer races and the ball bearings. Replace the bearing assemblies if they show wear or damage. •Pack the upper and lower ball bearings in the cages with grease, and apply a light coat of grease to the upper and lower outer races. •Install the steering stem (see Steering Stem, Stem Bearing Installation in the Steering chapter). •Adjust the steering (see Steering Play Adjustment). PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step •Set the gear position in the neutral position. •Turn the ignition switch on. •The following lights should go on according to below table. City Lights [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 Light (LED) [F] Goes on Oil Pressure Warning Indicator [G] and Red Warning Indicator (LED) [H] Goes on Yellow Engine Warning Indicator Light (LED) [I] Goes on Yellow ABS Indicator Light (LED) [J] (ABS Equipped Models) 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) City Light (see City Light 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) Indicator Lights (LED) (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 10 A and Brake Light/Horn Fuse 10 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) •Turn the ignition switch off. •The all lights should go off. If the light does not go off, replace the ignition switch. 2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step •Turn the ignition switch to hazard position. •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 •Turn the ignition switch on. •Turn on the turn signal switch [A] (left or right position). •The left or right turn signal lights [B] (front and rear) according to the switch position should blink. •The green turn signal indicator lights (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 Light (LED) (see Meter Unit Inspection in the Electrical System chapter) Turn Signal Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) •Push the turn signal switch. •The turn signal lights and green turn signal indicator light (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) Fourth Step •Set the dimmer switch [A] to low beam position. •Start the engine. •The low beam headlight should go on. If the low beam headlight does not go on, inspect or replace the following parts. Headlight Bulb (see Headlight Blub Replacement in the Electrical System chapter) Headlight Fuse 15 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) PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures •Set the dimmer switch to high beam position. •The low beam [A] and high beam [B] headlights should go on. •The blue high beam indicator light (LED) [C] should go on. If the high beam headlight and/or blue high beam indicator light (LED) does not go on, inspect or replace the following item. Headlight High Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) •Turn the engine stop switch to stop position. •The low beam and high beam headlights should stay going on. If the headlights and/or the blue high beam indicator light (LED) goes off, inspect or replace the following item. Headlight Circuit Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) •Turn the ignition switch off. •The headlights and the blue high beam indicator light (LED) should go off. Headlight Aiming Inspection •Inspect the headlight beam for aiming. If the headlight beam is off the point, adjust the headlight aiming as following. Headlight Beam Horizontal Adjustment •Turn the horizontal adjuster [A] on the headlight in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam. Headlight Beam Vertical Adjustment •Turn the vertical adjuster [B] on the headlight in or out to adjust the headlight vertically. NOTE ○For 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] 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Side Stand Switch Operation Inspection •Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). •Inspect 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 PERIODIC MAINTENANCE 2-65 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 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Side Stand Switch (see Switch Inspection in the Electrical System chapter) Engine Stop Switch (see Switch Inspection in the Electrical System chapter) Starter Button (see Switch Inspection in the Electrical System chapter) 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 •Turn the ignition switch on. •Set the gear position in the neutral position. •Turn the engine stop switch to stop position [A]. •Push the starter button [B]. •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 •Turn the ignition switch on. •Set the gear position in the neutral position. •Turn the engine stop switch to run position [A]. •Push the starter button [B] and start the engine. •Turn the engine stop switch to stop position. •Immediately the engine should be stop. If the engine does not stop, inspect or replace the 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). 2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spark Plug Replacement • Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). • Remove the spark plugs using the 16 mm (0.63 in.) plug wrench [A] vertically. • Replace the spark plugs with new ones. Standard Spark Plug Type: NGK CR9EIA-9 • Insert 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. • Tighten: Torque -Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft-lb) • Install the stick coils (see Stick Coil Installation in the Electrical System chapter). • After installation, be sure the stick coils are installed securely by pulling up them lightly. Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE OWhenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication. Pivots: Lubricate with Grease. Brake Lever Brake Pedal Clutch Lever Rear Master Cylinder Push Rod Joint Pin Side Stand Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Throttle Inner Cable Upper and Lower Ends PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant. • With the cable disconnected at both ends, the 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 • 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 OFor 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. GC04011 4SI C 2-68 PERIODIC MAINTENANCE 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 Mounting Bolts Wheels: Front Axle Clamp Bolt 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 Steering: Handlebar Holder Bolts Steering Stem Head Bolt Others: Footpeg Bracket Bolts Front Fender Mounting Bolts Side Stand Bolt 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 3-19 Specifications . 3-22 Special Tools and Sealant 3-24 DFI Servicing Precautions 3-26 DFI Servicing Precautions . 3-26 Troubleshooting the DFI System 3-28 Outline . 3-28 Inquiries to Rider 3-31 DFI System Troubleshooting Guide . 3-34 Self-Diagnosis 3-39 Self-Diagnosis Outline 3-39 Self-Diagnosis Procedures . 3-39 Service Code Reading 3-42 Service Code Erasing . 3-42 Backups 3-43 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) 3-46 Main Throttle Sensor Removal/Adjustment 3-46 Main Throttle Sensor Input Voltage Inspection . 3-46 Main Throttle Sensor Resistance Inspection 3-47 Main Throttle Sensor Output Voltage Inspection 3-47 Intake Air Pressure Sensor (Service Code 12) (DTC P0105, P0106, P0107) 3-50 Intake Air Pressure Sensor Removal 3-50 Intake Air Pressure Sensor Installation. 3-50 Intake Air Pressure Sensor Input Voltage Inspection 3-51 Intake Air Pressure Sensor Output Voltage Inspection. 3-52 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112). 3-56 Intake Air Temperature Sensor Removal/Installation 3-56 Intake Air Temperature Sensor Output Voltage Inspection . 3-56 Intake Air Temperature Sensor Resistance Inspection . 3-57 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) 3-59 Water Temperature Sensor Removal/Installation . 3-59 Water Temperature Sensor Output Voltage Inspection. 3-59 Water Temperature Sensor Resistance Inspection. 3-60 Crankshaft Sensor (Service Code 21) (DTC P0335) 3-62 Crankshaft Sensor Removal/Installation. 3-62 Crankshaft Sensor Resistance Inspection 3-62 Crankshaft Sensor Peak Voltage Inspection. 3-62 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158) 3-63 Rear Wheel Rotation Sensor Signal Inspection 3-63 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0917) 3-66 Gear Position Sensor Removal/Installation 3-66 Gear Position Sensor Input Voltage Inspection 3-66 Gear Position Sensor Output Voltage Inspection 3-67 Vehicle-down Sensor (Service Code 31) (DTC C0064) . 3-69 Vehicle-down Sensor Removal. 3-69 Vehicle-down Sensor Installation 3-69 Vehicle-down Sensor Input Voltage Inspection. 3-70 3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Output Voltage Inspection 3-71 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) . 3-73 Subthrottle Sensor Removal/Adjustment 3-73 Subthrottle Sensor Input Voltage Inspection. 3-73 Subthrottle Sensor Output Voltage Inspection 3-74 Subthrottle Sensor Resistance Inspection 3-76 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132). 3-77 Oxygen Sensor Removal/Installation 3-77 Oxygen Sensor Inspection 3-77 ECU Communication Error (Service Code 39). 3-80 ECU Communication Line Inspection . 3-80 Fuel Injectors (Service Code 41, 42) (DTC P0201, P0202) . 3-81 Fuel Injector Removal/Installation. 3-81 Fuel Injector Audible Inspection 3-81 Fuel Injector Resistance Inspection 3-81 Fuel Injector Power Source Voltage Inspection 3-82 Fuel Injector Output Voltage Inspection 3-83 Fuel Injector Fuel Line Inspection. 3-84 Stick Coils #1, #2 (Service Code 51, 52) (DTC P0351, P0352) . 3-86 Stick Coil Removal/Installation 3-86 Stick Coil Primary Winding Resistance Inspection . 3-86 Stick Coil Input Voltage Inspection 3-86 Radiator Fan Relay (Service Code 56) (DTC P0480) 3-88 Radiator Fan Relay Removal/Installation 3-88 Radiator Fan Relay Inspection 3-88 Subthrottle Valve Actuator (Service Code 62) (DTC P2100) 3-89 Subthrottle Valve Actuator Removal . 3-89 Subthrottle Valve Actuator Inspection . 3-89 Subthrottle Valve Actuator Resistance Inspection 3-89 Subthrottle Valve Actuator Input Voltage Inspection . 3-90 Air Switching Valve (Service Code 64) (DTC P0410). 3-92 Air Switching Valve Removal/Installation 3-92 Air Switching Valve Inspection 3-92 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 3-93 Oxygen Sensor Heater Removal/Installation 3-93 Oxygen Sensor Heater Resistance Inspection . 3-93 Oxygen Sensor Heater Power Source Voltage Inspection . 3-94 Fuel Supply System (Service Code 94) (DTC P0170) . 3-96 Fuel Supply System Inspection. 3-96 Purge Valve (Service Code 3A) (DTC P0443) (Equipped Models) 3-97 Purge Valve Removal/Installation . 3-97 Purge Valve Inspection . 3-97 Warning Indicator Light (LED) 3-99 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-99 ECU 3-100 ECU Identification . 3-100 ECU Removal . 3-100 ECU Installation 3-100 ECU Power Supply Inspection 3-101 DFI Power Source 3-104 ECU Fuse Removal 3-104 ECU Fuse Installation . 3-104 ECU Fuse Inspection 3-104 ECU Main Relay Removal/Installation 3-104 ECU Main Relay Inspection 3-104 Fuel Line. 3-105 Fuel Pressure Inspection 3-105 FUEL SYSTEM (DFI) 3-3 Fuel Flow Rate Inspection 3-106 Fuel Pump 3-108 Fuel Pump Removal . 3-108 Fuel Pump Installation 3-109 Fuel Pump Operation Inspection 3-109 Fuel Pump Operating Voltage Inspection . 3-109 Pressure Regulator Removal 3-111 Fuel Pump Relay Removal/Installation. 3-111 Fuel Pump Relay Inspection . 3-111 Throttle Grip and Cables 3-113 Throttle Grip Free Play Inspection 3-113 Throttle Grip Free Play Adjustment. 3-113 Throttle Cable Installation . 3-113 Throttle Cable Lubrication. 3-113 Throttle Body Assy . 3-114 Idle Speed Inspection/Adjustment 3-114 Throttle Bore Cleaning 3-114 Synchronization Inspection/Adjustment 3-114 Throttle Body Assy Removal. 3-114 Throttle Body Assy Installation 3-116 Throttle Body Assy Disassembly 3-117 Throttle Body Assy Assembly . 3-118 Air Cleaner 3-120 Air Cleaner Element Removal/Installation 3-120 Air Cleaner Element Inspection 3-120 Air Cleaner Oil Draining 3-120 Air Cleaner Housing Removal. 3-120 Air Cleaner Housing Installation 3-121 Fuel Tank 3-122 Fuel Tank Removal . 3-122 Fuel Tank Installation 3-125 Fuel Tank and Cap Inspection 3-127 Fuel Tank Cleaning . 3-127 Evaporative Emission Control System (Equipped Models) 3-128 Parts Removal/Installation 3-128 Hose Inspection 3-128 Purge Valve Inspection . 3-128 Canister Inspection 3-128 34 FUEL SYSTEM (DFI) Exploded View GC02799BW5 C FUEL SYSTEM (DFI) 3-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Spark Plugs 15 1.5 11 2 Water Temperature Sensor 12 1.2 106 in·lb 3 Crankshaft Sensor Bolts 6.0 0.61 53 in·lb 4 Intake Air Temperature Sensor Screw 1.2 0.12 11 in·lb 5 Air Cleaner Housing Assembly Screws 1.2 0.12 11 in·lb 6 Air Cleaner Element Screw 1.2 0.12 11 in·lb 7 Oxygen Sensor 25 2.5 18 8 Gear Position Sensor Bolt 9.8 1.0 87 in·lb 9 Air Cleaner Housing Clamp Bolt 2.0 0.20 18 in·lb G: Apply grease. R: Replacement Parts 3-6 FUEL SYSTEM Exploded v·1 ew (DFI) • ‘ FUEL SYSTEM (DFI) 3-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Switch Housing Screws 3.5 0.36 31 in·lb 2 Fuel Pump Assembly Screws 0.98 0.10 8.7 in·lb R 3 Fuel Pump Bolts 9.8 1.0 87 in·lb L, S 4 Delivery Pipe Assy Mounting Screws 3.4 0.35 30 in·lb 5. US, CA, AU, ID, PH and MY Models CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. 3-8 FUEL SYSTEM (DFI) Exploded View Evaporative Emission Control System Equipped Models GC02803BW5 C FUEL SYSTEM (DFI) 3-9 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Purge Valve Mounting Nut 7.0 0.71 62 in·lb 2. Purge Valve 3. Canister 3-10 FUEL SYSTEM (DFI) DFI System DFI System CD ® 20 GC 179920W5 C FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 3. Fuel Tank 4. Fuel Filter 5. Pressure Regulator 6. Fuel Pump 7. Fuel Injectors 8. Intake Air Temperature Sensor 9. Subthrottle Sensor 10. Air Flow 11. Subthrottle Valve Actuator 12. Air Switching Valve 13. Gear Position Sensor 14. Intake Air Pressure Sensor 15. Vehicle-down Sensor 16. Rear Wheel Rotation Sensor 17. Fuel Flow 18. Main Throttle Sensor 19. Water Temperature Sensor 20. Purge Valve (Equipped Models) 21. Crankshaft Sensor 22. Oxygen Sensor 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 Crankshaft position sensor (Crankshaft position sensor “A”) Crankshaft sensor Engine coolant temperature sensor (Engine coolant temperature sensor 1) Water (Engine) temperature 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 O2 sensor (binary/linear) signals (O2 sensor) Oxygen sensor Throttle position sensor (Throttle/Pedal position sensor/switch “A”) Main throttle sensor Throttle position sensor (Throttle/Pedal position sensor/switch “B”) Subthrottle sensor Vehicle speed sensor (Vehicle speed sensor “B”) 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 Fuel injector (Injector – cylinder 1  2) Fuel injector Ignition coil primary control circuits (Ignition coil “A  B” primary/secondary circuit) Ignition coil (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 (ETV actuator) FUEL SYSTEM (DFI) 3-13 DFI System This page intentionally left blank. 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram @!IDJ: @O©~=rn= @[fil;l[g ”””‘ ,.,,._ ‘”‘ .H,.ff ~ @)l§D: ~ “”‘ ;r:= a.10- . @O=ITE @l§D: @[)IE :;, – @[)IE UllK- – TIIL 81/H.- – J_ @® @~ ~ M:Lu=r a:::,. n- @(:UTfil @!IDJ: @!IDJ: @!IDJ: ‘” . =~~ ll/ f “‘ ‘.”,,’ .,. – ~-:~:- @ ·- @ *’~ “” ‘”‘ @8J::~:(Il: :~:- ~.- 8~, :1r , ~~ . ;:~:, -~ ii ., • . ~-~· ~~ ~ ~;: . l I I I I ~ t @~ ,– —, ; @: @ : . L———‘ •• ti li .,.w~ – Kl’!’ ‘I © CI~] ® •• 7 © 0 ‘”~ 8 ‘” 9 ~ ‘” 10 ‘”” 1 1 ® ~ @ ‘”~ (1j} 2) ! ! r- :e @ @ L: S5 . r iEJ@ ~ – ,'”v’ “, >- >-, •<n l rt= – •”11{11 1 ~ , -,:;131 ~, .,1 l,- ~ GC I 8003BW5 C FUEL SYSTEM (DFI) 3-15 DFI System Part Names 1. ECU 2. Kawasaki Diagnostic System Connector 3. Rear Wheel Rotation Sensor 4. Fuel Pump 5. Engine Ground 6. Battery 7. Main Fuse 30 A 8. Frame Ground (6) 9. Frame Ground (5) 10. Frame Ground (4) 11. Frame Ground (3) 12. Frame Ground (1) 13. Fuse Box (1) 14. ECU Fuse 15 A 15. Fan Fuse 15 A 16. Ignition Fuse 10 A 17. Relay Box 18. Fuel Pump Relay 19. ECU Main Relay 20. Radiator Fan Relay 21. Yellow Engine Warning Indicator Light (LED) 22. Meter Unit 23. Ignition Switch 24. Engine Stop Switch 25. Starter Button 26. Fan Motor 27. Spark Plugs 28. Stick Coils 29. Air Switching Valve 30. Fuel Injector #1 31. Fuel Injector #2 32. Subthrottle Valve Actuator 33. Main Throttle Sensor 34. Subthrottle Sensor 35. Intake Air Pressure Sensor 36. Vehicle-down Sensor 37. Intake Air Temperature Sensor 38. Gear Position Sensor 39. Water Temperature Sensor 40. Oxygen Sensor 41. Crankshaft Sensor 42. Purge Vale (Equipped Models) 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ABS Equipped Models) @!IDJ: @O©~=rn= @[fil;l[g ”””‘ ,.,,._ ‘”‘ .H,.ff ~ @l§D: ~ “”‘ @O=ITE ;r:= @l§D: a.10 – . :;, – UllKTIIL @[)IE @[)IE 81/H.- J_ @® @~ ~ M:Lu=r a:::,. n- @(:UTfil @!IDJ: @!IDJ: @!IDJ: ‘” . =~~ ll/ f “‘ ‘.”,,’ .,. – — – ~-:~:- @ ·- @ *’~ “” ‘”‘ @8J::~:(Il: :~:- ~.- 8~, . . r . ;:~:, -~ ·’j .• . ~-~· ~ ~ ~;: . l I I I ~ t @~ ,– —, ; @: @ : . L ———‘ •• ti – ~ . .,.w~ – Kl’!’ ‘I © CI~] ® •• 7 © 0 ‘”~ 8 ‘” 9 ~ ‘” 10 ‘”” 1 1 ® ~ @ ‘”~ (1j} 2) ! ! r- :e @ @ L: S5 . r iEJ@ – ,'”v’ “, >- >-, •<n l rt= – •”1{1111 ~ , -,:;131 ~, .,1 l,- ~ _ ,”.,.’, – •!• GC I 8002BW5 C FUEL SYSTEM (DFI) 3-17 DFI System Part Names 1. ECU 2. Kawasaki Diagnostic System Connector 3. Rear Wheel Rotation Sensor 4. Fuel Pump 5. Engine Ground 6. Battery 7. Main Fuse 30 A 8. Frame Ground (6) 9. Frame Ground (5) 10. Frame Ground (4) 11. Frame Ground (3) 12. Frame Ground (1) 13. Fuse Box (1) 14. ECU Fuse 15 A 15. Fan Fuse 15 A 16. Ignition Fuse 10 A 17. Relay Box 18. Fuel Pump Relay 19. ECU Main Relay 20. Radiator Fan Relay 21. ABS Hydraulic Unit 22. Yellow Engine Warning Indicator Light (LED) 23. Meter Unit 24. Ignition Switch 25. Engine Stop Switch 26. Starter Button 27. Fan Motor 28. Spark Plugs 29. Stick Coils 30. Air Switching Valve 31. Fuel Injector #1 32. Fuel Injector #2 33. Subthrottle Valve Actuator 34. Main Throttle Sensor 35. Subthrottle Sensor 36. Intake Air Pressure Sensor 37. Vehicle-down Sensor 38. Intake Air Temperature Sensor 39. Gear Position Sensor 40. Water Temperature Sensor 41. Oxygen Sensor 42. Crankshaft Sensor 43. Purge Vale (Equipped Models) ○Color Codes: BK: Black BL: Blue BR: Brown CH: Chocolate DG: Dark Green G: Green GY: Gray LB: Light Blue LG: Light Green O: Orange P: Pink PU: Purple R: Red V: Violet W: White Y: Yellow 3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 Terminal Names 1. Subthrottle Valve Actuator: BK/0 2. Subthrottle Valve Actuator: G/Y 3. Unused 4. Green Neutral Indicator Light (LED): LG 5. Oxygen Sensor: BL/Y 6. Unused 7. Main Throttle Sensor: Y/R 8. Intake Air Pressure Sensor: Y/BL 9. Unused 10. Power Supply to Sensors: BL 11. Vehicle-down Sensor: Y /G 12. Gear Position Sensor: LG/R 13. Crankshaft Sensor ( + ): R/BK 14. Power Supply to Rear Wheel Rotation Sensor (EX650J): WIG 15. Rear Wheel Rotation Sensor Signal (from ABS Hydraulic Unit, EX650K): G/R 16. Power Supply to ECU (from ECU Main Relay): BR/W 17. External Communication Line (*KOS): P/BL 18. Subthrottle Valve Actuator: G 19. Subthrottle Valve Actuator: W/BL 20. Unused 21. Unused 22. Water Temperature Sensor: O 23. Unused 24. Subthrottle Sensor: BR 25. Oxygen Sensor: G/BK 26. Intake Air Temperature Sensor: R 27. Unused GC 177750W2 C 28. Ground for Sensors: BR/BK 29. Oxygen Sensor Heater: P/BK 30. Crankshaft Sensor (- ): Y/BK 31 . Rear Wheel Rotation Sensor Signal: P 32. Rear Wheel Rotation Sensor (EX650J): BK/0 33. Purge Valve (Equipped Models): R/Y 34. Ground for Control System: BK 35. Power Supply to ECU (from Battery): W/BK 36. Engine Stop Switch: R 37. Starter Lockout Switch: RIG 38. Starter Button: BK/R 39. Fuel Pump Relay: BR/Y 40. Air Switching Valve: R/BL 41 . Fuel Injector #2: BL/Y 42. Fuel Injector #1: BL/R 43. Stick Coil #1: BK 44. Side Stand Switch: G/BK 45. Radiator Fan Relay: P/BL 46. External Communication Line (*KOS): LG/BK 47. Meter Unit (Tachometer): LB 48. Meter Communication Line: BUO 49. Unused 50. Ground for Oxygen Sensor Heater: BK/Y 51 . Ground for Ignition System: BK/Y 52. Stick Coil #2: BK/0 *: KOS (Kawasaki Diagnostic System) FUEL SYSTEM (DFI) 3-19 DFI Parts Location Battery [A] Kawasaki Diagnostic System Connector [B] Gear Position Sensor [A] Oxygen Sensor [B] Water Temperature Sensor [A] Subthrottle Valve Actuator [A] Main Throttle Sensor [B] Subthrottle Sensor [C] Intake Air Pressure Sensor [A] Vehicle-down Sensor [B] ECU [C] Intake Air Temperature Sensor [D] 3-20 FUEL SYSTEM (DFI) DFI Parts Location Yellow Engine Warning Indicator Light (LED) [A] Ignition Switch [B] Fuel Injectors #1, #2 [A] Air Switching Valve [A] Stick Coils #1, #2 [B] Purge Valve [A] (Equipped Models) Crankshaft Sensor [A] FUEL SYSTEM (DFI) 3-21 DFI Parts Location Fuel Pump [A] Rear Wheel Rotation Sensor [A] Fuse Box (1) [A] 3-22 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valves Bore 36 mm (1.4 in.) Throttle Body Vacuum 35.3 ±1.3 kPa (265 ±10 mmHg) at idle speed Bypass Screws 0  2 1/2 (for reference) ECU (Electronic Control Unit): Make Denso Type Digital memory type, with built in IC igniter, sealed with resin Fuel Pressure (High Pressure Line) 294 kPa (3.0 kgf/cm², 43 psi) with engine idling Fuel Pump: Type In-tank pump (in fuel tank) Discharge 50 mL (1.7 US oz.) or more for 3 seconds Fuel Injectors: Type EAT828 Nozzle Type Fine atomizing type with 12 holes Resistance About 11.5  12.5 Ω @20°C (68°F) Main Throttle Sensor: Input Voltage DC 4.75  5.25 V Output Voltage DC 0.99  1.05 V at idle throttle opening DC 4.11  4.50 V at full throttle opening (for reference) Resistance 4  6 kΩ Intake Air Pressure Sensor: Input Voltage DC 4.75  5.25 V Output Voltage DC 3.80  4.20 V at standard atmospheric pressure (101.32 kPa, 76 cmHg) Intake Air Temperature Sensor: Output Voltage About DC 2.25  2.50 V @20°C (68°F) Resistance 5.4  6.6 kΩ @0°C (32°F) 0.29  0.39 kΩ @80°C (176°F) Water Temperature Sensor: Output Voltage About DC 2.80  2.97 V @20°C (68°F) Gear Position Sensor: Input Voltage DC 4.75  5.25 V Output Voltage in the text Vehicle-down Sensor: Input Voltage DC 4.75  5.25 V Output Voltage with sensor tilted 60  70° or more right or left: DC 0.65  1.35 V with sensor arrow mark pointed up: DC 3.55  4.45 V FUEL SYSTEM (DFI) 3-23 Specifications Item Standard Subthrottle Sensor: Input Voltage DC 4.75  5.25 V Output Voltage DC 0.49  0.91 V at subthrottle valve full close position (for reference) DC 3.88  4.32 V at subthrottle valve full open position Resistance 4  6 kΩ Subthrottle Valve Actuator: Input Voltage About DC 8.5  10.5 V and then 0 V or About DC 8.5  10.5 V Resistance About 5.2  7.8 Ω @20°C (68°F) Oxygen Sensor: Output Voltage (Rich) DC 0.5 V or more Output Voltage (Lean) DC 0.2 V or less Heater Resistance 5.49  6.91 kΩ @20°C (68°F) Purge Valve (Equipped Models): Resistance 30  34 Ω @20°C (68°F) Throttle Grip and Cables Throttle Grip Free Play 2  3 mm (0.08  0.12 in.) Air Cleaner Air Cleaner Element Viscous paper element 3-24 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm2 : 57001-125 Fork Oil Level Gauge: 57001-1290 Vacuum Gauge: 57001-1369 Peak Voltage Adapter: 57001-1415 Needle Adapter Set: 57001-1457 ST570125ST C ST571369ST C ST5 71 457ST C Throttle Sensor Setting Adapter: 57001-1538 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607 Oxygen Sensor Measuring Adapter: 57001-1682 Measuring Adapter: 57001-1700 ST571593ST C ST571607ST C Special Tools and Sealant Liquid Gasket, TB1211: 56019-120 FUEL SYSTEM (DFI) 3-25 ST560120ST C 3-26 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. OThis 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. ODo not reverse the battery cable connections. This will damage the ECU. OTo 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. OTake care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. OWhen charging, remove the battery from the motorcycle. This is to prevent ECU damage by excessive voltage. OWhenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect the battery (- ) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. OConnect these connectors until they click [A]. ODo not turn the ignition switch on while any of the DFI electrical connectors are disconnected. The ECU memorizes service codes. ODo not spray water on the electrical parts, DFI parts, connectors, leads and wiring. Olf 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. OWhen 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. ODo not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure. OBefore removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air. OWhen 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. OWhen 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. ORun the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. OTo prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals. GC1 70368S1 C FUEL SYSTEM (DFI) 3-27 DFI Servicing Precautions ○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A]. Replace the fuel hose if any fraying, cracks or bulges are noticed. ○To maintain the correct fuel/air mixture (F/A), there must be no intake air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow engine warning indicator light (LED) [A] stays on after starting the engine to alert the rider. 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 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). Don’t 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. Troubleshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. OThe 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. • 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. • Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters. • Turn the ignition switch on and measure the voltage with the connector joined. NOTICE Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts. OAfter 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 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. • Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem. If the problem was caused by some other item or items, they too must be repaired or replaced, or the new replacement part will soon fail again. • Measure the coil winding resistance when the DFI part is cold (at room temperature). • Make sure all connectors in the circuit are clean and tight, and examine leads for signs of burning, fraying, short, etc. Deteriorated leads and bad connections can cause reappearance of problems and unstable operation of the DFI system. *If any wiring is deteriorated, replace the wiring. FUEL SYSTEM (DFI) 3-29 GC11572CS1 0 GC110313S 1 C 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. * If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • Check the wiring for continuity. OUse the wiring diagram to find the ends of the lead which is suspected of being a problem. OConnect a tester between the ends of the leads. * If the tester does not read about On, the lead is defective. Replace the lead or the main harness. Olf 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 continu ity. If the harness is open, repair or replace the harness. OWhen 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. • 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. GC1’120HS1 C E D IC15195BS1 C C D D ICHl19HS1 C Troubleshooting the DFI System DFI Diagnosis Flow Chart Yellow engine warning indicator light (LED) does not go on. Conduct non-self-diagnosis inspection. Conduct general fuel system inspection. General fuel system: throttle body assy, air cleaner, fuel tank etc. Inquiries to Rider Problem occurs. Confirm problems. Gather information from rider. Turn the ignition switch on. Start the engine. End. FUEL SYSTEM (DFI) 3-31 Yellow engine warning indicator light (LED) goes on. Conduct self-diagnosis inspection. GCl7634G F OEach rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. OTry to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem. OThe 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 □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Temperature □ hot, □ warm, □ cold, □ very cold, □ always, □ other: Problem frequency □ chronic, □ often, □once Road □ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble Altitude □ normal, □ high (about 1 000 m or more) Motorcycle conditions when problem occurred. □ goes on immediately after turning the ignition switch on, and goes off after starting the engine (normal) □ goes on immediately after turning the ignition switch on, and stays on after starting the engine (DFI problem) Yellow engine warning indicator light (LED) □ does not go on after turning the ignition switch on (indicator light (LED), meter unit fault) □ Does not Red warning go on about 1 second after ignition switch on (ECU or meter unit fault). indicator light (LED) □ light up (battery, oil pressure, water temperature or meter unit problem) □ starter motor not rotating. □ starter motor rotating but engine do not turn over. □ starter motor and engine do not turn over. □ no fuel flow (□ no fuel in tank, □ no fuel pump sound). □ no spark. Starting difficulty □ other: □ right after starting. □ when opening throttle grip. □ when closing throttle grip. □ when moving off. □ when stopping the motorcycle. □ when cruising. Engine stalls □ other: □ very low idle speed, □ very high idle speed, □ rough idle speed. □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty or broken. □ backfiring. □ afterfiring. □ hesitation when acceleration. □ engine oil viscosity too high. □ brake dragging. □ engine overheating. □ clutch slipping. Poor running at low speed □ other: FUEL SYSTEM (DFI) 3-33 Troubleshooting the DFI System □ spark plug loose (tighten it). □ spark plug dirty or broken. □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect). □ brake dragging. □ clutch slipping. □ engine overheating. □ engine oil level too high. □ engine oil viscosity too high. Poor running or no power at high speed □ other: 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system. ○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and circuits are checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU. Engine Won’t Turn Over Symptoms or Possible Causes Actions (chapter) Gear position sensor, starter lockout or side stand switch trouble Inspect each sensor or switch (see chapter 3 or 16). 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 Owner’s Manual). Fuel injector trouble Inspect and replace (see chapter 3). Fuel pump not operating Inspect (see chapter 3). Fuel pump relay trouble Inspect and replace (see chapter 16). 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 Owner’s Manual). Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 2). Air duct loose Reinstall (see chapter 3). Throttle body assy holder loose Reinstall (see chapter 3). Throttle body assy dust seal damage Replace (see chapter 3). Fuel injector O-ring damage Replace (see chapter 3). Fuel filter 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 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 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 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). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 3). 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) 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 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 line) (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 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 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide 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 trouble Inspect (see chapter 3). Cracked or obstructed intake air pressure sensor vacuum hose 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 Owner’s Manual). Spark plug incorrect Replace it with the correct plug (see chapter 2). Stick coil trouble Inspect (see chapter 16). ECU trouble Inspect (see chapter 3). Engine vacuum not synchronizing Inspect and adjust (see chapter 2). Intake air pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). 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) 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) 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 mechanisms. DFI System and Ignition System The following warning indicator lights (LED) are used for warning indicators of below table. LED Color Warning Indicators Red [A] Oil Pressure Battery Water Temperature Yellow [B] FI 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] when DFI and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, ECU stops the injection and ignition operations. 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. Self-Diagnosis Procedures NOTE ○Use a fully charged battery when conducting self-diagnosis. Otherwise, the warning indicator light (LED) and indicator do not light or blink. •Turn the ignition switch on and start the engine. ○When 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. 3-40 FUEL SYSTEM (DFI) Self-Diagnosis •Push the upper meter button [A] to display the odometer. •Push the upper [A] and lower [B] meter buttons for more than two seconds. •The service code [C] is displayed on the LCD by the number of two digits. •Any of the following procedures ends self-diagnosis. ○When the service code is displayed on the LCD, push the left and right meter buttons for more than two seconds. The display will return to the previous display. ○When the ignition switch is turned off. FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Self-Diagnosis Flow Chart Turn the ignition switch off. ~ . i I Turn the ignition switch on. I J Display the odometer and push the left and right meter buttons for more than two seconds. Then self-diagnosis mode starts. t The service code(s) is displayed on the LCD. t I Turn the ignition switch off. I J Locate the problem with the service code table and inspect and repair DFI and/or ignition system according to inspection procedure on all the service codes. t Erase the service codes stored in memory of the ECU (see Service Code Erasing). 1 Start the engine. t Make sure the yellow engine warning indicator light (LED) goes off. NG, /’ t OK Run the engine for several minutes at idling and run the motorcycle NG at 30 km/h (18 mph) or above in order to confirm no problem. toK (__E_ ND_) GCl7839G F 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○The service code(s) is displayed on the LCD by the number of two digits. ○When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. ○Then after completing all codes, the display is repeated until the ignition switch is turned off or upper and lower meter buttons are pushed for more than two seconds. ○For example, if three problems occurred in the order of 56, 11, 24, the service codes are displayed (each two seconds) from the lowest number in the order listed as shown. (11→24→56)→(11→24→56)→· · ·(repeated) Service Code Erasing •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 Service Codes DTC (Diagnostic Trouble Code) Problems P0120 11 P0123 Main throttle sensor malfunction, wiring open or short P0105 12 P0106 P0107 Intake air pressure sensor malfunction, wiring open or short P0110 13 P0112 Intake air temperature sensor malfunction, wiring open or short P0115 14 P0117 Water temperature sensor malfunction, wiring open or short 21 P0335 Crankshaft sensor malfunction, wiring open or short 24 P2158 Rear wheel rotation sensor malfunction, wiring open or short P0914 25 P0915 P0917 Gear position sensor malfunction, wiring open or short 31 C0064 Vehicle-down sensor malfunction, wiring open or short FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Codes DTC (Diagnostic Trouble Code) Problems P0220 32 P0223 Subthrottle sensor malfunction, wiring open or short P0130 33 P0132 Oxygen sensor malfunction or inactivate, wiring open or short 39 – ECU communication error 41 P0201 Fuel injector #1 malfunction, wiring open or short 42 P0202 Fuel injector #2 malfunction, wiring open or short 51 P0351 Stick coil #1 malfunction, wiring open or short 52 P0352 Stick coil #2 malfunction, wiring open or short 56 P0480 Radiator fan relay malfunction, wiring open or short 62 P2100 Subthrottle valve actuator malfunction, wiring open or short 64 P0410 Air switching valve malfunction, wiring open or short 67 P0030 Oxygen sensor heater malfunction, wiring open or short 94 P0170 Fuel supply system malfunction 3A P0443 Purge valve malfunction, wiring open or short (Equipped Models) Notes: ○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU. ○When no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical parts of the DFI system and the engine are suspect. ○DTC (Diagnostic Trouble Code) is displayed on the Kawasaki Diagnostic System (KDS Ver.3) and the Generic Scan Tool (GST). Backups ○The ECU takes the following measures to prevent engine damage when the DFI or ignition 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  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). Also, the main throttle sensor system and intake air pressure fails, the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the α-N method (2). 12 Intake Air Pressure Sensor Intake Air Pressure (absolute) Pv = 150  800 mmHg If the intake air pressure sensor system fails (the signal is out of the usable range, wiring short or open), the ECU sets the DFI in the α-N method. 13 Intake Air Temperature Sensor Intake Air Temperature Ta = –30  +120°C If the intake air temperature sensor fails (the signal is out of the usable range, wiring short or open), the ECU sets Ta at 40°C. 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Codes Parts or Function Output Signal Usable Range or Criteria Backups by ECU 14 Water Temperature Sensor Water Temperature Tw = –30  +120°C If the water temperature sensor system fails (the signal is out of the usable range, wiring short or open), the ECU sets Tw at 80°C. 21 Crankshaft Sensor Crankshaft sensor must send 22 signals to the ECU at the one cranking. If the crankshaft sensor generates other than 22 signals, the engine stops by itself. 24 Rear Wheel Rotation Sensor Rear wheel rotation sensor must send 50 signals to the ECU at the 1 rotation of the wheel. – 25 Gear Position Sensor Output Voltage 0.2  4.8 V If the gear position sensor system fails (no signal, wiring short or open), the ECU set the top (6th) gear position. 31 Vehicle -down Sensor Output Voltage Vd = 0.1  4.8 V If the vehicle-down sensor system has failures (the output voltage Vd is more than usable range, wiring open), the ECU shuts off the fuel pump relay, the fuel injectors and the ignition system. 32 Subthrottle Sensor Output Voltage 0.15  4.85 V If the subthrottle sensor system fails (the signal 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 actuator. 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 oxygen sensor feedback mode. 39 ECU The ECU sends the data (for service code) to the meter unit. – 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. 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. 51 Stick Coil #1* The ECU must send signals continuously to the stick coil primary winding. 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. 52 Stick Coil #2* The ECU must send signals continuously to the stick coil primary winding. 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. 56 Radiator Fan Relay When the radiator fan relay is OFF, the relay is opened. – FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service Codes Parts or Function Output Signal Usable Range or Criteria Backups by ECU 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 of 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. – 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. – 3A Purge Valve (Equipped Models) The purge valve controls the flow of the purge air for the canister and shutting the solenoid valve. – 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). Thismethod is called D-J method (low-speed mode). (2): α-N Method: As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (main throttle sensor output voltage) and the engine speed. This method is called α-N method (high-speed mode). (*): This depends on the number of stopped cylinders. 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (OTC 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/R Ground Terminal [C]: BR/BK 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 OBe sure the battery is fully charged. • Remove the left fairing cover (Fairing Cover Removal in the Frame chapter). • Turn the ignition switch off. • Disconnect the main throttle sensor connector and connect the setting adapter [A] between these connectors. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 • Connect a digital meter to the setting adapter leads. Main Throttle Sensor Input Voltage Connections to Adapter: Digital Meter(+) -. BK (sensor BL) lead Digital Meter (-) -. W (sensor BR/BK) lead • Measure the input voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Input Voltage Standard: DC 4.75 – 5.25 V • Turn the ignition switch off. •If the reading is within the standard, check the main throttle sensor resistance (see Main Throttle Sensor Resistance Inspection). ©®® FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) (OTC P0120, P0123) * If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Main Throttle Sensor Connector [BJ ECU Terminal 10 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). •If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). Main Throttle Sensor Resistance Inspection • Turn the ignition switch off. • Disconnect the main throttle sensor connector. • Connect the setting adapter [A] to the sensor connector only. Special Tool • Throttle Sensor Setting Adapter: 57001 -1538 • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections to Adapter: BK (sensor BL) lead .–. W (sensor BR/BK) lead Standard: 4 – 6 kO •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 • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, note the following. ODisconnect 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 (+) -. R (sensor Y/R) lead Digital Meter (-) -. W (sensor BR/BK) lead • Start the engine and warm it up thoroughly. • Check idle speed to ensure the throttle opening is correct (see Idle Speed Inspection in the Periodic Maintenance chapter). Idle Speed Standard: 1 300 ±50 r/min (rpm) GC 17 l84GS1 C 3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (OTC P0120, P0123) • Turn the ignition switch off. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Output Voltage Standard: DC 0.99 – 1.05 V at idle throttle opening DC 4.11 – 4.50 Vat full throttle opening (for reference) NOTE OOpen the throttle, confirm the output voltage will be raise. o The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. o When the input voltage reading shows other than 5 \I, derive a voltage range as follows. Example: In the case of a input voltage of 4. 75 V. 0.99 x 4. 75 + 5.00 = 0.941 V 1.05 x 4. 75 + 5.00 = 0.998 V Thus, the valid range is 0.941 – 0.998 V • 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. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Main Throttle Sensor Connector [BJ ECU Terminal 7 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * 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). 0C1’18 S6SI C FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) (OTC P0120, P0123) Main Throttle Sensor Circuit CD ~ ~ – BR iR/ H BL – rt• 81t / 8l BL – 1. ECU 2. Main Throttle Sensor 3. Subthrottle Sensor I I I ; ~ GC11849Glt C 3-50 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) (DTC P0105, P0106, P0107) Intake Air Pressure Sensor Removal NOTICE Never drop the intake air pressure sensor especially on a hard surface. Such a shock to the sensor can damage it. •Remove: Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter) •Disconnect: Intake Air Pressure Sensor Connector [A] •Remove the intake air pressure sensor [B] from the bracket [C]. •Disconnect the vacuum hose [D]. •Remove the rubber damper [E] from the intake air pressure sensor. Intake Air Pressure Sensor Installation •Installation is the reverse of removal. •Position the intake air pressure sensor [A] between the projections [B] on the rubber damper. •Install the rubber damper [A] on the bracket [B]. FUEL SYSTEM (DFI) 3-51 Intake Air Pressure Sensor (Service Code 12) (OTC P0105, P0106, P0107) Intake Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter). • Disconnect the intake air pressure sensor connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Intake Air Pressure Sensor [C] Special Tool • Measuring Adapter: 57001-1700 • Connect a digital meter [D] to the measuring adapter leads. Intake Air Pressure Sensor Input Voltage Connections to Adapter: Digital Meter (+) -. R (sensor BL) lead Digital Meter (-) -. BK (sensor BR/BK) lead • Measure the input voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Input Voltage Standard: DC 4.75 – 5.25 V • Turn the ignition switch off. * If the reading is within the standard, check the output voltage (see Intake Air Pressure Sensor Output Voltage Inspection). * If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Intake Air Pressure Sensor Connector [BJ ECU Terminal 10 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ *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). BR/BK~ Y/BL B BL GC 1708 1GS1 C B GC 17l86GS1 C 3-52 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) (OTC P0105, P0106, P0107) Intake Air Pressure Sensor Output Voltage Inspection • Measure the output voltage at the intake air pressure sensor in the same way as input voltage inspection, note the following. ODisconnect the intake air pressure sensor connector and connect the measuring adapter [A] between these connectors. Main Harness [B] Intake Air Pressure Sensor [C] Digital Meter [D] Special Tool – Measuring Adapter: 57001-1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter: Digital Meter (+) -. Y (sensor Y/BL) lead Digital Meter (-) -. BK (sensor BR/BK) lead • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Output Voltage Usable Range: DC 3.80 – 4.20 V at standard atmospheric pressure (101.32 kPa, 76 cmHg) NOTE o The output voltage changes according to the local atmospheric pressure. • Turn the ignition switch off. * If the reading is out of the usable range, replace the sensor (see Intake Air Pressure Sensor Removal/Installation). * If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Intake Air Pressure Sensor Connector [BJ ECU Terminal 8 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ BR/BK3@ y /BL B BL GC170886S1 C GC 171’176S1 C FUEL SYSTEM (DFI) 3-53 Intake Air Pressure Sensor (Service Code 12) (OTC P0105, P0106, P0107) * If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor [AJ and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [BJ to the intake air pressure sensor. • Temporarily install the intake air pressure sensor. OConnect a digital meter [C], vacuum gauge [DJ, the fork oil level gauge [EJ and the measuring adapter to the intake air pressure sensor. Special Tools • Fork Oil Level Gauge: 57001-1290 Vacuum Gauge: 57001-1369 Measuring Adapter: 57001-1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter: Digital Meter(+) -. Y (sensor Y/BL) lead Digital Meter (-) -. BK (sensor BR/BK) lead OTurn the ignition switch on. OMeasure the intake air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. OCheck the intake air pressure sensor output voltage, using the following formula and chart. Suppose: Pg: Vacuum Pressure (Gauge) of Throttle Body Pl: Local Atmospheric Pressure (Absolute) measured by a barometer Pv: Vacuum Pressure (Absolute) of Throttle Body Vv: Sensor Output Voltage (V) then Pv =Pl + Pg For example, suppose the following data is obtained: Pg= -8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Barometer Reading) Vv = 3.2 V (Digital Meter Reading) then Pv = 70 + (-8) = 62 cmHg (Absolute) Plot this Pv (62 cmHg) at a point [1J on the chart and draw a vertical line through the point. Then, you can get the usable range [2J of the sensor output voltage. Usable range= 3.08 – 3.48 V Plot Vv (3.2 V) on the vertical line. – Point [3J. Results: In the chart, Vv is within the usable range and the sensor is normal. * If the read ing is out of the usable range, replace the sensor (see Intake Air Pressure Sensor Removal/Installation). * If the read ing 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). ® BK y R BR /BK-< Y/BL -l BL -l GC l7089GS2 C 3-54 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) (OTC P0105, P0106, P0107) (V) V V 4. 5————————-~~/ / / / / / / / 2 3 UR ST 1. 01——+—–r—–r————-l—–+—— / / / / / / / 0. 51–~~~—————–l—–+—— / / / / / / , / / / / / / 10 20 30 I 40 50 20 40 60 I D -<—-> T 0 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) 6,0 ‘ 80 70 76 80 (P s) I 101 . 32 (P s) 90 (cmHg) I 12o(kPa) ~~~~~-P v(ab s) GC17120814 C Vv: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) FUEL SYSTEM (DFI) 3-55 Intake Air Pressure Sensor (Service Code 12) (OTC P0105, P0106, P0107) Intake Air Pressure Sensor Circuit CD I I 0 []E:~.l·——-‘ GC11850Glt C 1. ECU 2. Intake Air Pressure Sensor 3-56 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) (OTC 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. • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the connector [AJ from the intake air temperature sensor [BJ. • Remove: Intake Air Temperature Sensor Screw [CJ Intake Air Temperature Sensor • Be sure to install the 0-ring [AJ. • Install the intake air temperature sensor. • Tighten: Torque – Intake Air Temperature Sensor Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb) • Connect the intake air temperature sensor connector. • Install the removed parts (see appropriate chapters). Intake Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU with the ECU connectors connected (see ECU Removal). • Disconnect the intake air temperature sensor connector and connect the measuring adapter [AJ between these connectors as shown. Main Harness [BJ Intake Air Temperature Sensor [CJ Special Tool – Measuring Adapter: 57001-1700 [filJ= R C BK • Connect a digital meter [DJ to the measuring adapter leads. Intake Air Temperature Sensor Output Voltage Connections to Adapter: Digital Meter (+) -. R (sensor R) lead Digital Meter (-) -. BK (sensor BR/BK) lead • Measure the output voltage with the engine stopped and the connector joined. • Turn the ignition switch on. Output Voltage Standard: About DC 2.25 – 2.50 V @20°C (68°F) NOTE o The output voltage changes according to the intake air temperature. ICl ‘IIIJQS , GC 179()3f S1 C FUEL SYSTEM (DFI) 3-57 Intake Air Temperature Sensor (Service Code 13) (OTC P0110, P0112) • 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. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Intake Air Temperature Sensor Connector [BJ ECU Terminal 26 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * If the wiring is good, check the intake air temperature sensor resistance (see Intake Air Temperature Sensor Resistance Inspection). Intake Air Temperature Sensor Resistance Inspection • Remove the intake air temperature sensor (see Intake Air Temperature Sensor Removal/Installation). • Suspend the sensor [A] in a container of water so that the heat-sensitive portion is submerged. • Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with the sensor. NOTE o The sensor and thermometer must not touch the container side or bottom. • Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently for even temperature. • Using a digital meter, measure the internal resistance of the sensor across the terminals at the temperatures shown in the following. Intake Air Temperature Sensor Resistance Standard: 5.4 – 6.6 kQ @0°C (32°F) 0.29 – 0.39 kO @80°C (176°F) • If the reading is out of the standard, replace the sensor (see Intake Air Temperature Sensor Removal/ Installation). • If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation). A B D GC 17 l88GS1 C D 6Cl7686FS2 C 3-58 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) (OTC P0110, P0112) Intake Air Temperature Sensor Circuit CD ® [§D:··, _______ __, GC178510W2 C 1. ECU 2. Intake Air Temperature Sensor FUEL SYSTEM (DFI) 3-59 Water Temperature Sensor (Service Code 14) (OTC 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. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left Fairing Cover (see Fairing Cover Removal in the Frame chapter) • Disconnect: Water Temperature Sensor Connector [AJ • Remove: Water Temperature Sensor [BJ with 0-ring • Replace the 0-ring with a new one. • Tighten: Torque – Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106 in·lb) • 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 OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove: Left Fairing Cover (see Fairing Cover Removal in the chapter) • Disconnect the water temperature sensor connector and connect the measuring adapter [AJ between these connectors as shown. Main Harness [BJ ~ Water Temperature Sensor [CJ ~ eRK Special Tool – Measuring Adapter: 57001-1700 • Connect a digital meter [DJ to the measuring adapter leads. Water Temperature Sensor Output Voltage Connections to Adapter: Digital Meter (+) -. R (sensor 0) lead Digital Meter (-) -. BK (sensor BR/BK) lead GC l7906FS1 C 3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) (OTC P0115, P0117) • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Output Voltage Standard: About DC 2.80 – 2.97 V @20°C (68°F) NOTE o The output voltage changes according to the coolant temperature in the engine. • Turn the ignition switch off. * If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply 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. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Water Temperature Sensor Connector [BJ ECU Terminal 22 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * If the wiring is good, check the water temperature sensor resistance (see Water Temperature Sensor Resistance Inspection). Water Temperature Sensor Resistance Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter. • If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation). A GCl 778HS1 C FUEL SYSTEM (DFI) 3-61 Water Temperature Sensor (Service Code 14) (OTC P0115, P0117) Water Temperature Sensor Circuit CD I 0 [§]: ~ —–‘ GC118S2Cl2 C 1. ECU 2. Water Temperature Sensor 3-62 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) (OTC P0335) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no signals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection • Refer to the Crankshaft Sensor Inspection in the Electrical System chapter. * If the reading is within the standard, check the peak voltage (see Crankshaft Sensor Peak Voltage Inspection). Crankshaft Sensor Peak Voltage Inspection • Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter. • If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Crankshaft Sensor Connector [BJ ECU Terminal 13 [CJ .–. Sensor Terminal [DJ ECU Terminal 30 [EJ .–. Sensor Terminal [FJ * 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 CD A .I ;;, ® 0© ·: =m=~~=:——–‘ 1. ECU 2. Crankshaft Sensor OC 1’1906SI C GC 178530W2 C FUEL SYSTEM (DFI) 3-63 Rear Wheel Rotation Sensor (Service Code 24) (OTC P2158) Rear Wheel Rotation Sensor Signal Inspection OThe rear wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit (ABS equipped models). For other than ABS equipped models, the signal is sent directly to the ECU. OThe ECU uses the rear wheel rotation sensor signal for motorcycle speed. OThe service code 24/DTC P2158 is detected with the ECU. • Inspect the wheel rotation sensor air gap (see Wheel Rotation Sensor Air Gap Inspection in the Brakes chapter). • Inspect the wheel rotation sensor rotor (see Wheel Rotation Sensor Rotor Inspection in the Brakes chapter). • When service code 24/DTC P2158 is displayed, do the following inspection procedures. • 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) • For ABS equipped models, check the wiring for continuity between main harness connectors. Wiring Continuity Inspection ECU Connector [AJ .- -. ABS Hydraulic Unit Connector [BJ ECU Terminal 15 [CJ .–. ABS Hydraulic Unit Terminal 16 [DJ Wiring Continuity Inspection ABS Hydraulic Unit Connector [AJ .- -. Rear Wheel Rotation Sensor Connector [BJ ABS Hydraulic Unit Connector Terminal 13 [CJ .–. Sensor Terminal [DJ ABS Hydraulic Unit Connector Terminal 14 [EJ .–. Sensor Terminal [FJ D GC 17 l 9 1GS1 C D GC 17 l 92G S1 C 3-64 FUEL SYSTEM (DFI) Rear Wheel Rotation Sensor (Service Code 24) (OTC P2158) • For other than ABS equipped models, check the wiring for continuity between main harness connectors. Wiring Continuity Inspection ECU Connector [AJ .- -. Rear Wheel Rotation Sensor Connector [BJ ECU Terminal 14 [CJ .–. Sensor Terminal [DJ ECU Terminal 32 [EJ .–. Sensor Terminal [FJ * 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). Rear Wheel Rotation Sensor Circuit (ABS Equipped Models) CD I ~~ 5 11 I 0 1. ECU 2. Rear Wheel Rotation Sensor 3. ABS Hydraulic Unit GC 177936S1 C GC 17854 0W2 C FUEL SYSTEM (DFI) 3-65 Rear Wheel Rotation Sensor (Service Code 24) (OTC P2158) Rear Wheel Rotation Sensor Circuit (other than ABS Equipped Models) G) 1. ECU 2. Rear Wheel Rotation Sensor I 0 .’ I 0 GC118S6Cl2 C 3-66 FUEL SYSTEM (DFI) Gear Position Sensor (Service Code 25) (OTC P0914, P0915, P0917) Gear Position Sensor Removal/Installation • Refer to the Gear Position Sensor Removal/Installation in the Electrical System chapter. Gear Position Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) • Disconnect: Gear Position Sensor Connector [A] • Connect the measuring adapter [A] between the main harness connector and gear position sensor connector. Main Harness [B] Gear Position Sensor [C] Special Tool • Measuring Adapter: 57001-1700 • Connect a digital meter [D] to the measuring adapter leads. Gear Position Sensor Input Voltage Connections to Adapter: Digital Meter (+) -. R (sensor BL) lead Digital Meter (-) -. BK (sensor BR/BK) lead • Measure the input voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Input Voltage Standard: DC 4.75 – 5.25 V • Turn the ignition switch off. * If the reading is within the standard, check the output 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 harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .- -. Gear Position Sensor Connector [BJ ECU Terminal 10 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * 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). A BL 3® LG/R B BR/BK GC 177946S1 C GC 1779S6S1 C FUEL SYSTEM (DFI) 3-67 Gear Position Sensor (Service Code 25) (OTC P0914, P0915, P0917) Gear Position Sensor Output Voltage Inspection • Remove the gear position sensor (see Gear Position Sensor Removal in the Electrical System chapter). • Measure the output voltage at the gear position sensor in the same way as input voltage inspection, note the following. OConnect the measuring adapter [A] between these connectors. Main Harness [B] Gear Position Sensor [C] Digital Meter [D] Special Tool – Measuring Adapter: 57001-1700 Gear Position Sensor Output Voltage Connections to Adapter: Digital Meter (+) -. Y (sensor LG/R) lead Digital Meter (-) -. BK (sensor BR/BK) lead • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Output Voltage Angle Output Voltage (V) -240° 0.40 – 0.60 – 185° 1.03 – 1.23 +55° 3.82 – 3.92 +110° 4.40 – 4.60 NOTE o This figure shows 55°. ORotate the gear position sensor, confirm the output voltage will be raise or lower. • Turn the ignition switch off. * If the reading is out of the standard, replace the gear position sensor (see Gear Position Sensor Removal/Installation 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. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .- -. Gear Position Sensor Connector [BJ ECU Terminal 12 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * 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). BL 3® LG/R B BR/BK GC17 l 96G S1 C GT04J76B S GC17 l 98GS1 C 3-68 FUEL SYSTEM (DFI) Gear Position Sensor (Service Code 25) (OTC P0914, P0915, P0917) Gear Position Sensor Circuit CD .I I ‘ J ~ . ® []f[E”·t·: ___________ __, 1. ECU 2. Gear Position Sensor GC 178560W2 C FUEL SYSTEM (DFI) 3-69 Vehicle-down Sensor (Service Code 31) (OTC C0064) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 – 70° or more to either side (in fact falls down), the weight turns and the signal changes. The ECU senses this change, and stops the fuel pump relay, the fuel injectors and the ignition system. Hall IC [B] When the motorcycle is down, the ignition switch is left on. If the starter button is pushed, the electric starter turns but the engine does not start. To start the engine again, raise the motorcycle, turn the ignition switch off, and then turn it on. Vehicle-down Sensor [A] Ground Terminal [B]: BR/BK 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. • Remove: Fuel Tank (see Fuel Tank Removal) • Disconnect: Vehicle-down Sensor Connector [A] • Remove the vehicle-down sensor with the rubber damper upward. Vehicle-down Sensor Installation • The UP mark [A] of the sensor should face upward. AWARNING 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 sensor bracket. GCl7982FS I C A GCl7983FS 1 C GSOS2S38S I 0 3-70 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) (OTC C0064) • Install the vehicle-down sensor [A] so that the rubber damper hole [B] fits the bracket projection [C]. • Install the removed parts (see appropriate chapters). Vehicle-down Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the fuel tank (see Fuel Tank Removal). • 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 • Connect a digital meter [D] to the measuring adapter leads. Vehicle-down Sensor Input Voltage Connections to Adapter: Digital Meter (+) -. R (sensor BL) lead Digital Meter (-) -. BK (sensor BR/BK) lead • Measure the input voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Input Voltage Standard: DC 4.75 – 5.25 V • Turn the ignition switch off. * If the reading is within the standard, check the output voltage (see Vehicle-down Sensor Output Voltage Inspection). * If the read ing is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Vehicle-down Sensor Connector [BJ ECU Terminal 10 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * 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). l@l= : ~ BK YB/LG ~B BR / BK GC1 70906S 1 C GC 177996S1 C FUEL SYSTEM (DFI) 3-71 Vehicle-down Sensor (Service Code 31) (OTC C0064) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). • Connect the measuring adapter [AJ to the vehicle-down sensor connectors as shown. Main Harness [BJ Vehicle-down Sensor [C] Special Tool – Measuring Adapter: 57001-1700 • Connect a digital meter [DJ to the measuring adapter leads. Vehicle-down Sensor Output Voltage Connections to Adapter: Digital Meter (+) -. W (sensor Y/G) lead Digital Meter (-) -. BK (sensor BR/BK) lead • Hold the sensor vertically. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. • Tilt the sensor 60 – 70° or more [AJ right or left, then hold the sensor almost vertical with the arrow mark pointed up [BJ, and measure the output voltage. Output Voltage Standard: With sensor tilted 60 – 70° or more right or left: DC 0.65 – 1.35 V With sensor arrow mark pointed up: DC 3.55 – 4.45 V • Turn the ignition switch off. *If the reading is out of the standard, replace the sensor (see Vehicle-down Sensor Removal/Installation). YB/ G L~B BR/ BK f@c : ~BK GC 17092G S1 C 6C l7981FS2 C 3-72 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) (OTC C0064) *If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Vehicle-down Sensor Connector [BJ ECU Terminal 11 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * 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 Circuit CD I I 0 []tf:.———+——–‘ 1. ECU 2. Vehicle-down Sensor GC1 7a()06S 1 C GC 178570W2 C FUEL SYSTEM (DFI) 3-73 Subthrottle Sensor (Service Code 32) (OTC 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]: BR Ground Terminal [C]: BR/BK 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 OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove: Left Fuel Tank Side Cover (see Fuel Tank Side Cover Removal in the Frame chapter) • Disconnect the subthrottle sensor connector and connect the setting adapter [A] between these connectors. Special Tool – Throttle Sensor Setting Adapter: 57001 -1538 • Connect a digital meter to the setting adapter leads. Subthrottle Sensor Input Voltage Connections to Adapter: Digital Meter(+) -. BK (sensor BL) lead Digital Meter (-) -. W (sensor BR/BK) lead • Measure the input voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Input Voltage Standard: DC 4.75 – 5.25 V • Turn the ignition switch off. * If the reading is within the standard, check the output voltage (see Subthrottle Sensor Output Voltage Inspection). ©®© 3-74 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (OTC P0220, P0223) * If the read ing is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Subthrottle Sensor Connector [BJ ECU Terminal 10 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * 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 • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection, note the following. ODisconnect the subthrottle sensor connector and connect the setting adapter [A] between these connectors. Special Tool – Throttle Sensor Setting Adapter: 57001 -1 538 Subthrottle Sensor Output Voltage Connections to Adapter: Digital Meter (+) -. R (sensor BR) lead Digital Meter (-) -. W (sensor BR/BK) lead • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the subthrottle valve actuator connector [A]. GC 17’1146S1 C FUEL SYSTEM (DFI) 3-75 Subthrottle Sensor (Service Code 32) (OTC P0220, P0223) • Measure the output voltage with the engine stopped with the connector joined. • Turn the ignition switch on. • Measure the output voltage when the subthrottle valves [A] are fully opened by hand. Output Voltage Standard: DC 0.49 – 0.91 Vat subthrottle valve full close position (for reference) DC 3.88 – 4.32 Vat subthrottle valve full open position NOTE OOpen the subthrottle valves, confirm the output voltage will be raise. o The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. o When the input voltage reading shows other than 5 \I, derive a voltage range as follows. Example: In the case of a input voltage of 4. 75 V. 0.49 x 4.75 + 5.00 = 0.466 V 0.91 x 4. 75 + 5.00 = 0.865 V Thus, the valid range is 0. 466 – 0. 865 V • 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. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Subthrottle Sensor Connector [BJ ECU Terminal 24 [CJ .–. Sensor Terminal [DJ ECU Terminal 28 [EJ .–. Sensor Terminal [FJ * 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). GC17 60 1GS1 C 3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (OTC P0220, P0223) Subthrottle Sensor Resistance Inspection • Turn the ignition switch off. • Disconnect the subthrottle sensor connector. • Connect the setting adapter [A] to the sensor connector only. Special Tool • Throttle Sensor Setting Adapter: 57001 -1 538 • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections to Adapter: BK (sensor BL) lead .–. W (sensor BR/BK) lead Standard: 4-6 kQ * 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 CD I ~ ~ “-== 81.•t /.•U – Y/i It/ BK o, – 1. ECU 2. Main Throttle Sensor 3. Subthrottle Sensor I I GC 178490W2 C FUEL SYSTEM (DFI) 3-77 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) Oxygen Sensor Removal/Installation •Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection •Turn the ignition switch off. •Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). •Disconnect the oxygen sensor lead connector and connect the measuring adapter [A] between these connectors. Special Tool – Oxygen Sensor Measuring Adapter: 57001 -1682 •Connect a digital meter to the measuring adapter leads. Oxygen Sensor Output Voltage Connections to Adapter: Digital Meter (+) → BL (sensor BL) lead Digital Meter (−) → BR (sensor W) lead •Remove the air cleaner housing (see Air Cleaner Housing Removal). •Slide the clamp [A]. •Disconnect the air switching valve hose [B]. •Install the suitable plug [A] on the fitting of the air suction valve cover, and shut off the secondary air. •Install the following parts temporarily. Air Cleaner Housing (see Air Cleaner Housing Installation) Fuel Tank (see Fuel Tank Removal) •Warm up the engine thoroughly until the radiator fan starts. •Measure the output voltage with the connector joined. Output Voltage (with Plug, Rich) Standard: DC 0.5 V or more 3-78 FUEL SYSTEM (DFI) Oxygen Sensor – not activated (Service Code 33) (OTC P0130, P0132) • Turn the ignition switch off. • Remove air cleaner housing (see Air Cleaner Housing Removal) • Remove the plug from the fitting [A]. AWARNING The engine gets extremely hot during normal operation and can cause serious burns. Never touch a hot engine. • Install the following parts temporarily. Air Cleaner Housing (see Air Cleaner Housing Installation) Fuel Tank (see Fuel Tank Removal) • Start the engine, and let it idle. • Measure the output voltage with the connector joined. Output Voltage (without Plug, Lean) Standard: DC 0.2 V or less • Turn the ignition switch off. * If the reading is out of the standard (with plug: DC O .5 V or more, without plug: DC 0.2 Vor less), remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Oxygen Sensor Connector [BJ ECU Terminal 5 [CJ .–. Sensor Terminal [DJ ECU Terminal 25 [EJ .–. Sensor Terminal [FJ * If the wiring is good, replace the sensor (see Oxygen Sensor Removal/ Installation in the Electrical System chapter). * If the reading is within the standard (with plug: DC 0.5 V or more, without plug: DC 0.2 V or less), check the ECU for its ground and power supply (see ECU Power Supply Inspection). * If the ground and power supply are good, replace the ECU (see ECU Removal/ Installation). GC1 7a()26S 1 C FUEL SYSTEM (DFI) 3-79 Oxygen Sensor – not activated (Service Code 33) (OTC P0130, P0132) Oxygen Sensor Circuit “~ 0 0 1 I ~I]® ‘El =======31:~;:=::=======~I _. © j~,,,~ ® 11 I i T I l. ‘-of–U/T ® GC1 18 S9Cl2 C 1. ECU 2. Engine Ground 3. Battery 4. Main Fuse 30 A 5. Frame Ground (4) 6. Fuse Box (1) 7. ECU Fuse 15 A 8. Ignition Fuse 1 O A 9. Relay Box 10. ECU Main Relay 11. Ignition Switch 12. Oxygen Sensor 3-80 FUEL SYSTEM (DFI) ECU Communication Error (Service Code 39) ECU Communication Line Inspection OWhen the data is not sent from the ECU to the meter unit for more than about 1 O seconds, the service code 39 is displayed. OThe service code 39 is detected with meter unit. • Remove the ECU and meter unit, check the wiring for continuity between main harness connectors. ODisconnect the ECU and meter unit connectors. Wiring Continuity Inspection ECU Connector [A] –Meter Unit Connector [B] ECU Terminal 48 [C] –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 CD I ~ l i , — –, : ~0 :© L ___________ _J 1. ECU 2. Meter Unit 3. Yellow Engine Warning Indicator Light (LED) GC1 7a()36S 1 C GC 178600W2 C FUEL SYSTEM (DFI) 3-81 Fuel Injectors (Service Code 41, 42) (DTC P0201, P0202) Inspect the eligible fuel injector according to the following service code or DTC. Service Code 41/DTC P0201 → Fuel Injector #1 Service Code 42/DTC P0202 → Fuel Injector #2 Fuel Injector Removal/Installation •Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○Be sure the battery is fully charged. •Remove the left fairing cover (see Fairing Cover Removal in the Frame chapter). •Start the engine, and let it idle. •Apply the 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. ○A sound scope can also be used. ○The click interval becomes shorter as the engine speed rises. •Do the same for the other fuel injectors. If all the fuel injectors click at a regular intervals, the fuel injectors are normal. •Turn the ignition switch off. If any fuel injector does not click, check the fuel injector resistance (see Fuel Injector Resistance Inspection). Fuel Injector Resistance Inspection •Remove the air cleaner housing (see Air Cleaner Housing Removal). •Disconnect the fuel injector connector. •Connect a digital meter to the terminals [A] in each fuel injector. •Measure the fuel injector resistance. Fuel Injector Resistance Standard: About 11.5  12.5 Ω @20°C (68°F) If the reading is out of the standard, replace the fuel injector (see Throttle Body Assy Disassembly/Assembly). If the reading is within the standard, check the power source voltage (see Fuel Injector Power Source Voltage Inspection). 3-82 FUEL SYSTEM (DFI) Fuel Injectors (Service Code 41 , 42) (OTC P0201 , P0202) Fuel Injector Power Source Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the fuel injector connector and connect the measuring adapter [A] between these connectors as shown. Main Harness [B] Fuel Injector [C] Special Tool • Measuring Adapter: 57001-1700 • Connect a digital meter [D] to the measuring adapter lead. Fuel Injector Power Source Voltage Connections to Adapter: For Fuel Injector #1, #2 Digital Meter (+) – R (injector W/R) lead Digital Meter (-) – Battery (- ) Terminal • Measure the power source voltage with the engine stopped and with the connector joined. • Turn the engine stop switch to run position. • Turn the ignition switch on. Power Source Voltage Standard: Battery Voltage for 3 seconds, and then O V • Turn the ignition switch off. * If the reading stays on battery voltage and never shows 0 V, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter). * If the 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). @D GC1730US1 C FUEL SYSTEM (DFI) 3-83 Fuel Injectors (Service Code 41, 42) (OTC P0201, P0202) Fuel Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ODo not disconnect the ECU connector. • Connect a digital meter [A] to the connector [B] with the needle adapter set. Special Tool· Needle Adapter Set: 57001-1457 Fuel Injector Output Voltage Connections to ECU Connector: For Fuel Injector #1 Digital Meter(+) -. BL/R lead (ECU terminal 42) Digital Meter (-) -. Battery (-) Terminal For Fuel Injector #2 Digital Meter(+) -. BUY lead (ECU terminal 41) Digital Meter (-) -. Battery (-) Terminal • Measure the output voltage with the engine stopped and with the connector joined. • Turn the engine stop switch to run position. • Turn the ignition switch on. Output Voltage Standard: Battery Voltage for 3 seconds, and then O V • Turn the ignition switch off. *If the reading is in specification, check the ECU for its ground and power supply (see ECU Power Supply Inspection). *If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). * If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and injector connector. Wiring Continuity Inspection ECU Connector [A] .–. For Fuel Injector #1 [C] Fuel Injector Connector [B] ECU Terminal 42 [D] .–. Fuel Injector Terminal [E] For Fuel Injector #2 ECU Terminal 41 .–. 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). 42 41 © E GC 17 605GS1 C 3-84 FUEL SYSTEM (DFI) Fuel Injectors (Service Code 41 , 42) (OTC P0201 , P0202) Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) OBe 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. AWARNING Fuel is flammable and explosive under certain condit ions 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. • Check the fuel injector fuel line for leakage as follows. OConnect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [BJ with the fuel hose [CJ (both ends with the clamps [DJ) as shown. OApply soap and water solution to the areas [E] as shown. OWatching the pressure gauge, squeeze the pump lever [F], and build up the pressure until the pressure reaches the maximum pressure. Injector Fuel Line Maximum Pressure Standard: 300 kPa (3.06 kgf/cm2 , 43 psi) NOTICE During pressure testing, do not exceed the maximum pressure for which the system is designed. OWatch 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 (see Throttle Body Assy Disassembly/Assembly). ORepeat the leak test, and check the fuel line for no leakage. • Install: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Installation) • Start the engine and check for fuel leakage. FUEL SYSTEM (DFI) 3-85 Fuel Injectors (Service Code 41 , 42) (OTC P0201 , P0202) Fuel Injector Circuit -~ ® 01 I [l]® I Ii I 11I I -~© ~i i • I “~ ® I ! U)@:I=·::: rel®~© @@:I=·::: _ _J @~-·+ ! s i r–+-:::: _. I . ,n @) “~l ® ‘” – @ mS? 1:.r”111=·:=or- ij GC11861Cl2 C 1. ECU 2. Engine Ground 3. Battery 4. Main Fuse 30 A 5. Frame Ground (3) 6. Fuse Box (1) 7. ECU Fuse 15 A 8. Ignition Fuse 1 O A 9. Relay Box 10. Fuel Pump Relay 11. Ignition Switch 12. Engine Stop Switch 13. Fuel Injector #1 14. Fuel Injector #2 3-86 FUEL SYSTEM (DFI) Stick Coils #1 , #2 (Service Code 51 , 52) (OTC P0351 , P0352) Inspect the eligible stick coil according to the following service code or OTC. Service Code 51/DTC P0351 – Stick Coil #1 Service Code 52/DTC P0352 – Stick Coil #2 Stick Coil Removal/Installation • Refer to the Stick Coil Removal/Installation in the Electrical System chapter. Stick Coil Primary Winding Resistance Inspection • Refer to the Stick Coil Inspection in the Electrical System chapter. * If the reading is within the standard, check the input voltage (see Stick Coil Input Voltage Inspection). Stick Coil Input Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ODo not disconnect the ECU connectors. • Connect a digital meter [A] to the connector [B] with the needle adapter set. Special Tool – Needle Adapter Set: 57001-1457 Stick Coil Input Voltage Connections to ECU Connector: For Stick Coil #1 Digital Meter(+) – BK lead (terminal 43) Digital Meter (-) – Battery (-) Terminal For Stick Coil #2 Digital Meter(+) – BK/0 lead (terminal 52) Digital Meter (-) – Battery (-) Terminal • Measure the input voltage to each primary winding of the stick coils with the engine stopped and with the connectors joined. • Turn the engine stop switch to run position. • Turn the ignition switch on. Input Voltage Standard: Battery Voltage • Turn the ignition switch off. * If the input voltage is out of the standard, check the wiring for continuity (see 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). 4 3 FUEL SYSTEM (DFI) 3-87 Stick Coils #1 , #2 (Service Code 51 , 52) (OTC P0351 , P0352) Stick Coil Circuit ,_J @ ~•~ @~~· ,._ ·. – – ,’ ,_ 1. ECU 2. Engine Ground 3. Battery 4. Main Fuse 30 A 5. Frame Ground (3) 6. Fuse Box (1) 7. Ignition Fuse 10 A 8. Ignition Switch 9. Engine Stop Switch 10. Stick Coil #1 11. Stick Coil #2 ” ~ ! i I I 0 f GC11862Glt C 3-88 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) (OTC P0480) Radiator Fan Relay Removal/Installation OThe radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection • Refer to the Relay Circuit Inspection in the Electrical System chapter. * If the radiator fan relay is normal, check the wiring for continu ity (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 01 I II I I ! I , = i . I I (8) §D: ; _ @ ~:~:):: I [ ”.~ 0 I r.JJ® .~© “~ffi ‘”~ 6 w! ! 0-, :® ® : _ _J . ~ @ t:ffil? 1!12’11~·:=m=-: ~ @ -~3 -==~I 1. ECU 8. Fan Fuse 15 A 2. Engine Ground 9. Ignition Fuse 10 A 3. Battery 10. Relay Box 4. Main Fuse 30 A 11. Radiator Fan Relay 5. Frame Ground (3) 12. Ignition Switch 6. Frame Ground (1) 13. Fan Motor 7. Fuse Box (1) 14. Water Temperature Sensor @ GC 178630W2 C FUEL SYSTEM (DFI) 3-89 Subthrottle Valve Actuator (Service Code 62) (OTC 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 OBe sure the battery is fully charged. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Turn the ignition switch on. • Check to see that all the subthrottle valves [A] open and close smoothly. • 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 • Turn the ignition switch off. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the subthrottle valve actuator connector [A]. • Connect a digital meter to the subthrottle valve actuator connector [A]. • Measure the subthrottle valve actuator resistance. Subthrottle Valve Actuator Resistance Connections: BK lead [1] — P lead [2] G lead [3] — W/BL lead [4] Standard: About 5.2 – 7.8 Q @20°C (68°F) * 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). GC 171598S I C 3-90 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) (OTC P2100) Subthrottle Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Open the clamp. • 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 • 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(+) -. R (actuator P) lead Digital Meter(-) -. BK (actuator BK) lead (II) Digital Meter(+) -. Y (actuator W/BL) lead Digital Meter (-) -. W (actuator G) lead • Measure the actuator input voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Input Voltage Standard: About DC 8.5 – 10.5 V and then O V or About DC 8.5 – 10.5 V • Turn the ignition switch off. * If the reading is in specification, but the actuator does not operate, replace the throttle body assy (see Throttle Body Assy Removal/ Installation). * If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. ODisconnect the ECU and actuator connectors. Wiring Continuity Inspection ECU Connector [AJ .–. Subthrottle Valve Actuator Connector [BJ ECU Terminal 1 [CJ .–. Actuator Terminal [DJ ECU Terminal 2 [EJ .–. Actuator Terminal [FJ ECU Terminal 18 [GJ .–. Actuator Terminal [HJ ECU Terminal 19 [IJ .–. Actuator Terminal [JJ * 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). GC1 7864fiS1 C OC 1’8C86SI C FUEL SYSTEM (DFI) 3-91 Subthrottle Valve Actuator (Service Code 62) (OTC P2100) Subthrottle Valve Actuator Circuit G) I I 0 81•1:’fil ·~’ M G 1/81.——–‘ H BK/0 ————-‘ GC11865Glt C 1. ECU 2. Subthrottle Valve Actuator 3-92 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) (OTC P0410) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter. * If the air switching valve is normal, check the wiring for continuity (see 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 ® ‘i$ I CD e 1:n11=·:=rrr: 11 @l 1 “” I l . ·- =~ ~=· _, Q, ._ L __ J ® a ~ il ©0 . 1. Ignition Switch 8. Frame Ground (3) 2. Air Switching Valve 9. Fuse Box (1) 3. ECU 10. ECU Fuse 15 A 4. Engine Ground 11. Ignition Fuse 1 O A 5. Battery 12. Relay Box 6. Main Fuse 30 A 13. ECU Main Relay 7. Frame Ground (4) ® u 1r – ,.-. GC 17083HW2 C FUEL SYSTEM (DFI) 3-93 Oxygen Sensor Heater (Service Code 67) (OTC 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/Installation in the Electrical System chapter). Oxygen Sensor Heater Resistance Inspection • Turn the ignition switch off. • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Disconnect the oxygen sensor lead connector [A]. • Connect a digital meter [A] to the oxygen sensor lead connector [B]. • Measure the oxygen sensor heater resistance. Oxygen Sensor Heaters Resistance Connections: BK lead [C] .–. BK lead [D] Standard: 5.49 – 6.91 0 @20° C (68°F) * If the reading is out of the standard, replace the sensor (see Oxygen Sensor Removal/ Installation in the Electrical System chapter). * If the reading is within the standard, check the power source voltage (see Oxygen Sensor Heater Power Source Voltage Inspection). D GC171IOFS 1 C 3-94 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (OTC P0030) Oxygen Sensor Heater Power Source Voltage Inspection NOTE OBe sure the battery is fully charged. • Turn the ignition switch off. • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Disconnect the oxygen sensor lead connector and connect the measuring adapter [A] between these connectors. Special Tool – Oxygen Sensor Measuring Adapter: 57001 -1682 • Connect a digital meter to the measuring adapter lead. Oxygen Sensor Power Source Voltage Connections to Adapter: Digital Meter(+) -. W (main harness BR/W) lead Digital Meter (-) -. Frame Ground Terminal • Measure the power source voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Power Source Voltage Standard: Battery Voltage • Turn the ignition switch off. * If the reading is in specification, but the problem still 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. ODisconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] — Oxygen Sensor Connector [B] ECU Terminal 29 [C] — 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). D OC 1’8C96SI C FUEL SYSTEM (DFI) 3-95 Oxygen Sensor Heater (Service Code 67) (OTC P0030) Oxygen Sensor Circuit “~ 0 0 1 I ~I]® ‘El =======31:~;:=::=======~I _. © j~,,,~ ® 11 I i T I l. ‘-of–U/T ® GC118S9Cl2 C 1. ECU 2. Engine Ground 3. Battery 4. Main Fuse 30 A 5. Frame Ground (4) 6. Fuse Box (1) 7. ECU Fuse 15 A 8. Ignition Fuse 1 O A 9. Relay Box 10. ECU Main Relay 11. Ignition Switch 12. Oxygen Sensor 3-96 FUEL SYSTEM (DFI) Fuel Supply System (Service Code 94) (DTC P0170) Fuel Supply System Inspection NOTE ○If the motorcycle has any other service code, first inspect the other service code. •Inspect 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). FUEL SYSTEM (DFI) 3-97 Purge Valve (Service Code 3A) (OTC P0443) (Equipped Models) Purge Valve Removal/Installation • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Purge Valve Mounting Nut [A] • Pull out the purge valve [A] from the left side of the frame. • Disconnect the purge valve connector [B]. • Slide the clamps [C], and disconnect the hoses [D]. • Installation is the reverse of removal. • Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Tighten: Torque – Purge Valve Mounting Nut: 7.0 N·m (0.71 kgf·m, 62 in·lb) Purge Valve Inspection • Remove the purge valve (see Purge Valve Removal/Installation). • Connect a digital meter [A] to the purge valve terminals as shown. Purge Valve Resistance Standard: 30 – 34 0 @20°C (68°F) *If the resistance reading is out of the specified value, replace it with a new one. • Connect the 12 V battery [A] to the purge valve terminals as shown. GC11 193f$1 0 e e © GC11 194f$1 0 3-98 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (OTC P0443) (Equipped Models) • Blow the air to the intake air duct [A], and make sure that the air flows from the outlet air duct [B]. • Disconnect the 12 V battery. • 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 normal, 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. Engine Ground 3. Battery 4. Main Fuse 30 A 5. Frame Ground (4) 6. Fuse Box (1) 7. ECU Fuse 15 A 8. Ignition Fuse 1 O A 9. Relay Box 10. ECU Main Relay 11. Ignition Switch 12. Purge Valve B GC11195FS I C GC17196FS1 C ® GC 178680W2 C FUEL SYSTEM (DFI) 3-99 Warning Indicator Light (LED) Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection Red Warning Indicator Light (LED) [A] Yellow Engine Warning Indicator Light (LED) [B] Oln this model, the above mentioned warning indicator lights (LED) go on or blink by the data sent from the ECU. • Refer to the Meter Unit Inspection in the Electrical System chapter. Warning Indicator (LED) Circuit CD I 0 m I © ~ ~0 ,– –, : :0 L ___________ _J 1. ECU 2. Meter Unit 3. Red Warning Indicator Light (LED) 4. Yellow Engine Warning Indicator Light (LED) GC11869GW2 C 3-100 FUEL SYSTEM (DFI) ECU ECU Identification OMost 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 21175-1176 SEA-B1 WVTA (FULL) 21175-1187 us CA 21175-1188 ID PH 21175-1191 IN SEA-B3 21175-1192 CN 21175-1193 TH 21175-1194 CAL AU 21175-1195 AU LAMS MY ECU Removal NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) • Disconnect the ECU connectors [A]. • Remove: ECU [B] ECU Installation • Installation is the reverse of removal. GC 1’A106S1 C ECU ECU Power Supply Inspection • Remove the fuel tank (see Fuel Tank Removal). • Visually inspect the ECU connectors. * If the connector is clogged with mud or dust, blow it off with compressed air. • Remove the ECU (see ECU Removal). • Visually inspect the terminals [A] of the ECU 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. • Turn the ignition switch off. • Disconnect the ECU connectors [A]. • Set a tester [B] and check the following wiring for continuity. ECU Grounding Inspection Connections: (I) ECU Terminal 34, 50 or 51 (II) Engine Ground Criteria: Both: 0 0 .–. Battery (-) Terminal .–. Battery (-) Terminal * If no continuity, check the connectors, the engine ground lead, or main harness, and repair or replace them if necessary. FUEL SYSTEM (DFI) 3-101 3-102 FUEL SYSTEM (DFI) ECU * If the wiring is good, check the power source voltage of the ECU. NOTE OBe sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connectors [BJ with the needle adapter set. Special Tool – Needle Adapter Set: 57001-1457 ECU Power Supply Inspection Connections: (I) Digital Meter(+) -. BR/W lead (terminal 16) Digital Meter(-) -. Battery (-) Terminal (II) Digital Meter(+) -. W/BK lead (terminal 35) Digital Meter(-) -. Battery (-) Terminal Ignition Switch off: BR/W (terminal 16): 0 V W/BK (terminal 35): 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). 35 1 6 FUEL SYSTEM (DFI) 3-103 ECU ECU Power Source Circuit ii ! • i I .,::,~ (©D ,:®- ®~: L _ ~~ 3 L 0 ~–~ =or- I GC11870Glt C 1. ECU 2. Engine Ground 3. Battery 4. Main Fuse 30 A 5. Frame Ground (2) 6. Frame Ground (5) 7. Fuse Box (1) 8. ECU Fuse 15 A 9. Ignition Fuse 1 O A 10. Relay Box 11. ECU Main Relay 12. Ignition Switch 3-104 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal •Refer to the Fuse Box Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. •Refer to the Fuse Installation in the Electrical System chapter. ECU Fuse Inspection •Refer to the Fuse Inspection in the Electrical System chapter. ECU Main Relay Removal/Installation ○The ECU main relay is built in the relay box [A]. •Refer to the Relay Box Removal in the Electrical System chapter. ECU Main Relay Inspection •Refer to the Relay Circuit Inspection in the Electrical System chapter. FUEL SYSTEM (DFI) 3-105 Fuel Line Fuel Pressure Inspection NOTE ○Be sure the battery is fully charged. •Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy. WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. •Install the fuel pressure gauge adapter [A] and fuel hoses (Special Tool: 57001-1607) [B] between the fuel outlet pipe and delivery pipe. •Secure the fuel hoses with the clamps. •Connect the pressure gauge [C] to the fuel pressure gauge adapter. Special Tools – Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607 WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death. Do not try to start the engine with the fuel hoses disconnected. •Connect the fuel pump lead connector. •Turn the engine stop switch to run position. •Turn the ignition switch on. ○The fuel pump should operate for 3 seconds, and then should stop. NOTE ○After turning on the engine stop switch and ignition switch, inspect the fuel leakage from the connected portion of the special tools. 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. 3-106 FUEL SYSTEM (DFI) Fuel Line •Start the engine, and let it idle. •Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. •Turn the ignition switch off. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck. If the fuel pressure is much lower than specified, check the following. Fuel Line Leakage (see Fuel Injector Fuel Line Inspection) Amount of Fuel Flow (see Fuel Flow Rate Inspection) •After above checks, measure the fuel pressure again. •Remove the fuel pressure gauge, hoses and adapter. •Install: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Installation) •Start the engine and check for fuel leakage. Fuel Flow Rate Inspection WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTE ○Be sure the battery is fully charged. •Turn the ignition switch off. •Wait until the engine cools down. •Prepare a fuel hose (Special Tool: 57001-1607) and a measuring cylinder. Special Tool – Fuel Hose: 57001-1607 •Remove: Fuel Tank Bolts (see Fuel Tank Removal) FUEL SYSTEM (DFI) 3-107 Fuel Line •Open the fuel tank cap [A] to lower the pressure in the tank. •Disconnect the fuel hose from the fuel pump (see Fuel Tank Removal). ○Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. •Connect the prepared fuel hose [A] to the fuel outlet pipe. •Secure the fuel hose with a clamp. •Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. •Close the fuel tank cap. •Turn the engine stop switch to run position. •Turn the ignition switch on. ○The fuel pump should operate for 3 seconds, and then should stop. NOTICE Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged. •Measure the discharge for 3 seconds. ○Repeat this operation several times. Amount of Fuel Flow Standard: 50 mL (1.7 US oz.) or more for 3 seconds •Turn the ignition switch off. If the fuel flow is much less than the specified, replace the fuel pump (see Fuel Pump Removal/Installation). •Install the fuel tank (see Fuel Tank Installation). •Start the engine and check for fuel leakage. 3-108 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (–) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTICE Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it. •Draw the fuel out from the fuel tank with a commercially available electric pump. •Remove the fuel tank (see Fuel Tank Removal). ○Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. Plug the fuel pipe of the fuel tank. •Remove: Rubber Cover [A] •Turn the fuel tank upside down. •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. FUEL SYSTEM (DFI) 3-109 Fuel Pump •Discard the fuel pump gasket [A]. Fuel Pump Installation •Remove dirt or dust from the fuel pump [A] by lightly applying compressed air. •Replace the fuel pump gasket with a new one. NOTE ○Be careful not to bend the fuel level sensor arm. •Check that the fuel pump terminal [A] and clamp [B] are in place. •Apply a non-permanent locking agent to the threads of the fuel pump bolts. •Tighten the fuel pump bolts following the specified tightening sequence [1  6] temporarily. •Tighten the fuel pump bolts with the specified torque by the same sequence. Torque – Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •Tighten the pump bolts again to check the tightness. •Install the rubber cover. Fuel Pump Operation Inspection NOTE ○Be sure the battery is fully charged. •Turn the engine stop switch to run position. •Turn the ignition switch on and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops. •Turn the ignition switch off. If the pump does not operate as described above, check the operating voltage (see Fuel Pump Operating Voltage Inspection). Fuel Pump Operating Voltage Inspection NOTE ○Be sure the battery is fully charged. •Turn the ignition switch off. 3-110 FUEL SYSTEM (DFI) Fuel Pump •Remove the left side cover (see Side Cover Removal in the Frame chapter). •Disconnect the fuel pump lead connector [A]. •Connect the measuring adapter [A] between fuel pump lead connectors. Special Tool – Oxygen Sensor Measuring Adapter: 57001 -1682 •Connect a digital meter to the measuring adapter leads. Fuel Pump Operating Voltage Connections to Adapter: Digital Meter (+) → BR (pump BK/Y) lead Digital Meter (–) → W (pump BK/W) lead •Measure the operating voltage with engine stopped and with the connector joined. •Turn the engine stop switch to run position. •Turn the ignition switch on. Operating Voltage Standard: Battery Voltage for 3 seconds, and then 0 V •Turn the ignition switch off. If the reading stays on battery voltage and never shows 0 V, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter). If the 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) 3-111 Fuel Pump Pressure Regulator Removal ○The pressure regulator [A] is built into the fuel pump [B] and can not be removed. Fuel Pump Relay Removal/Installation ○The fuel pump relay is built in the relay box [A]. •Refer to the Relay Box Removal in the Electrical System chapter. Fuel Pump Relay Inspection •Refer to the Relay Circuit Inspection in the Electrical System chapter. 3-112 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit CD ~t:F’lil=” .= ar. ! ==::::!l 11 ·~ @1 1. Ignition Switch 2. Engine Stop Switch 3. ECU 4. Fuel Pump 5. Engine Ground 6. Battery 7. Main Fuse 30 A 8. Frame Ground (5) 9. Frame Ground (4) 10. Fuse Box (1) 11. ECU Fuse 15 A 12. Ignition Fuse 1 O A 13. Relay Box 14. Fuel Pump Relay 0 u , –, 1@ 1 I I I . !. _ ,I., D@ ~~ il f., n ~ – _ _J ~ tj. @ ®®0 ~ ©® 4 GC1 01018W2 C FUEL SYSTEM (DFI) 3-113 Throttle Grip and Cables Throttle Grip Free Play Inspection •Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Throttle Grip Free Play Adjustment •Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Throttle Cable Installation •Install the throttle cables in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. •Install the lower ends of the throttle cables in the throttle pulley on the throttle body assy after installing the upper ends of the throttle cables in the grip. •After installation, adjust each cable properly (see Throttle Control System Inspection in the Periodic Maintenance chapter). WARNING Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition. Be sure the cables are routed correctly and properly adjusted. Throttle Cable Lubrication •Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter. 3-114 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection/Adjustment •Refer to the Idle Speed Inspection/Adjustment in the Periodic Maintenance chapter. Throttle Bore Cleaning •Check the throttle bore for cleanliness as follows. ○Remove the throttle body assy (see Throttle Body Assy Removal). ○Check the main throttle valves and throttle bores for carbon deposits by opening the main throttle valves. If any carbon accumulates, wipe the carbon off the throttle bores around the throttle bores and the throttle valves, using a cotton pad penetrated with a high flash-point solvent. Synchronization Inspection/Adjustment •Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTICE Never drop the throttle body assy especially on a hard surface. Such a shock to the body assy can damage it. •Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) •Disconnect: Main Throttle Sensor Connector [A] Subthrottle Sensor Connector [B] FUEL SYSTEM (DFI) 3-115 Throttle Body Assy •Open the clamp [A]. •Disconnect: Subthrottle Valve Actuator Connector [B] Fuel Injector Connectors [C] •Disconnect the vacuum hose [A]. •Disconnect the vacuum hoses [B] (evaporative emission control system equipped models). •Loosen the locknuts [A]. •Turn the adjusters [B] to give the more free play. •Remove the clamp [A] and the throttle cables from the throttle cable holder [B]. 3-116 FUEL SYSTEM (DFI) Throttle Body Assy •Disconnect the throttle cable lower ends [A]. •Loosen the throttle body assy holder clamp bolts [A]. •Remove the throttle body assy from the throttle body assy holders. •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 •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). •Install the throttle body assy to the throttle body assy holders. •Tighten: Torque – Throttle Body Assy Holder Clamp Bolts: 2.0 N·m (0.20 kgf·m, 18 in·lb) •Apply a thin coat of grease to the throttle cable lower ends. •Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. Throttle Body Assy • Install the clamp [A] securely. • Turn the throttle grip and make sure that the throttle pulley moves smoothly and return by spring force. • Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). • 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) Throttle Body Assy Disassembly NOTICE Do not remove, disassemble or adjust the main throttle sensor [AJ, subthrottle sensor [BJ, subthrottle valve actuator [CJ, throttle link mechanism [DJ and throttle body assy [EJ, because they are adjusted or set at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy. NOTICE Never drop the throttle body assy especially on a hard surface. Such a shock to the body assy can damage it. • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Quick Rivet [A] Clamp [B] FUEL SYSTEM (DFI) 3-117 GC 1712 1HS 1 C 3-118 FUEL SYSTEM (DFI) Throttle Body Assy •Cut the band [A]. •Remove the delivery pipe assy mounting screws [B]. •Pull out the fuel injectors [C] from the throttle body assy together with the delivery pipe [D]. NOTE ○Do not damage the insertion portions of the fuel injectors when they are pulled out from the throttle body assy. •Remove the fuel injectors [A] from the delivery pipe [B]. NOTE ○Do not damage the insertion portions of the fuel injectors when they are pulled out from the delivery pipe. NOTICE Never drop the fuel injector especially on a hard surface. Such a shock to the fuel injector can damage it. Throttle Body Assy Assembly •Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air. •Replace the O-rings [A] of each fuel injector [B] with new ones. •Apply engine oil to the new O-rings, insert them to the delivery pipe [C] and confirm whether the fuel injectors turn smoothly or not. •Replace the dust seals [A] with new ones. •Apply engine oil to the new dust seals. •Install the fuel injectors along with the delivery pipe to the throttle body assy. •Tighten: Torque – Delivery Pipe Assy Mounting Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb) FUEL SYSTEM (DFI) 3-119 Throttle Body Assy •Replace the band [A] with a new one. •Hold the lead [B] with the band. •Install: Clamp [A] Quick Rivet [B] Throttle Body Assy (see Throttle Body Assy Installation) 3-120 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation •Refer to the Air Cleaner Element Replacement in the Periodic Maintenance chapter. Air Cleaner Element Inspection •Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •Visually check the element [A] for tears or breaks. If the element has any tears or breaks, replace the element. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. •Visually check the drain hose [A], if the water or oil accumulates in the hose. If any water or oil accumulates in the drain hose, slide the clamp [B] and remove the plug [C] 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 plug in the drain hose after draining. Air Cleaner Housing Removal •Remove: Bolts [A] Clamps [B] •Disconnect the intake air temperature sensor connector [A]. •Open the clamps [B]. FUEL SYSTEM (DFI) 3-121 Air Cleaner •Loosen the air cleaner housing clamp bolt [A]. •Lift up the air cleaner housing, and disconnect the air switching valve hose [A]. •Disconnect the breather hose [A]. •After removing the air cleaner housing, cover the clean cloth on the throttle body assy. Air Cleaner Housing Installation •Installation is the reverse of removal. •Install the air cleaner housing on the throttle body assy. ○Push in the ducts touch the stopper of the throttle body assy. •Tighten: Torque – Air Cleaner Housing Clamp Bolt: 2.0 N·m (0.20 kgf·m, 18 in·lb) •Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Install the removed parts (see appropriate chapters). 3-122 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (–) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. •Turn the ignition switch off. •Wait until the engine cools down. •Disconnect the battery (–) terminal (see Battery Removal in the Electrical System chapter). •Remove: Fuel Tank Side Covers (see Fuel Tank Side Cover Removal in the Frame chapter) Left Side Cover (see Side Cover Removal in the Frame chapter) •Remove: Fuel Tank Bolts [A] and Washers •Remove: Seat Bracket Bolts [A] Clamps [B] Seat Bracket [C] Fuel Tank • Remove: Fuel Tank Bolts [A] • Slide the clamp [B] and disconnect the fuel tank breather hose [C]. • Open the fuel tank cap [A] to lower the pressure in the tank. ODuring tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. • Draw the fuel out from the fuel tank with a commercially available pump [A]. OUse a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly. OPut the hose through the fill opening [C] into the tank and draw the fuel out. AWARNING Spilled fuel is flammable and can be explosive under certain condit ions. The fuel can not be removed completely f rom the fuel tank. Be careful for remained fuel spillage. • Close the fuel tank cap. • Disconnect the fuel pump lead connector [A]. FUEL SYSTEM (DFI) 3-123 !lCt”/Glll , GC091008$1 0 3-124 FUEL SYSTEM (DFI) Fuel Tank • Slide the clamps [A] and disconnect the fuel drain hose [B]. • Pull up the rear of the fuel tank. • Be sure to place a piece of cloth around the fuel hose joint. • Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush. When removing with flat tip screwdriver • Insert the flat tip screwdriver [A] into slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. When removing with fingers • 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. • Pull [A] the fuel hose joint [B] out of the outlet pipe. AWARNING 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. GS0 5270 8S1 C GS0:1 3()0BS 1 C Fuel Tank • Remove the fuel tank, and place it on a flat surface. ODo not apply the load to the fuel pipe of the fuel pump. • Clean the pipe [A]. • Cover the pipe and the hose joint [B] with the vinyl bags [C] to keep it clean. Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Check that the dampers [A], collars [B], pads [C] and trims [D] are in place on the fuel tank. * If the dampers, pads and trims are damaged or deteriorated, replace them. Viewed from Bottom [E] Viewed from Rear [F] OWhen installing the dampers, face the big thickness side downward. Olnstall the pads and trims as shown. 38 mm (1.5 in.) [G] © ® FUEL SYSTEM (DFI) 3-125 GSOS272BS 1 0 GC091’8Bl2 C 3-126 FUEL SYSTEM (DFI) Fuel Tank • Check that the dampers [A] are in place on the frame. * If the dampers are damaged or deteriorated, replace them. • Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Remove the vinyl bag on the pipe and fuel hose joint. • Check the joint lock for deformation and wear. * If the joint lock is deformed, replace the fuel hose with a new one. • Check that there are no flaws, burrs, and adhesion of foreign materials on the fuel outlet pipe [A]. • Apply engine oil to the fuel outlet pipe. • Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked and does not come off. AWARNING 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. • Connect the fuel drain hose and fuel tank breather hose (see Cable, Wire, and Horse Routing section in the Appendix chapter). • Connect the fuel pump lead connector and the battery (- ) terminal (see Battery Installation in the Electrical System chapter). • Install the removed parts (see appropriate chapters). GS0 5265 8S1 C FUEL SYSTEM (DFI) 3-127 Fuel Tank Fuel Tank and Cap Inspection •Open the tank cap. •Visually inspect the gasket [A] on the tank cap for any damage. Replace the tank cap if gasket is damaged. •Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air. NOTICE Do not apply compressed air to the air vent holes [D] in the tank cap. This could cause damage and clogging of the labyrinth in the cap. Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low flash-point solvents to clean the tank. •Remove: Fuel Tank (see Fuel Tank Removal) Fuel Pump (see Fuel Pump Removal) •Pour some high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. •Draw the solvent out of the fuel tank. •Dry the tank with compressed air. •Install: Fuel Pump (see Fuel Pump Installation) Fuel Tank (see Fuel Tank Installation) 3-128 FUEL SYSTEM (DFI) Evaporative Emission Control System (Equipped Models) The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart. Parts Removal/Installation WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. NOTICE If gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one. •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 •Refer to the Evaporative Emission Control System Inspection (Equipped Models) in the Periodic Maintenance chapter. Purge Valve Inspection •Refer to the Purge Valve Inspection. Canister Inspection •Refer to the Evaporative Emission Control System Inspection (Equipped 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 . 4-9 Coolant Reserve Tank Installation 4-10 Water Pump 4-11 Water Pump Removal. 4-11 Water Pump Installation 4-11 Water Pump Inspection. 4-12 Mechanical Seal Inspection 4-12 Water Pump Housing Disassembly 4-13 Water Pump Housing Assembly . 4-13 Impeller Assembly. 4-13 Pump Impeller Inspection . 4-13 Radiator 4-14 Radiator and Radiator Fan Removal 4-14 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection . 4-15 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection . 4-16 Thermostat . 4-17 Thermostat Removal. 4-17 Thermostat Installation 4-17 Thermostat Inspection 4-18 Water Hose and Pipes 4-19 Water Hose Installation. 4-19 Water Hose Inspection 4-19 Water Hose and O-ring Replacement. 4-19 Water Temperature Sensor 4-20 Water Temperature Sensor Removal/Installation . 4-20 Water Temperature Sensor Inspection . 4-20 4-2 COOLING SYSTEM Exploded View COOLING SYSTEM 4-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Coolant Reserve Tank Bolts 7.9 0.81 70 in·lb 2 Radiator Mounting Bolt 7.9 0.81 70 in·lb 3 Radiator Fan Bolts 8.4 0.86 74 in·lb 4 Thermostat Housing Bolts 12 1.2 106 in·lb 5 Water Temperature Sensor 12 1.2 106 in·lb 6 Water Pump Impeller Bolt 9.8 1.0 87 in·lb 7 Water Pump Cover Bolts, L = 30 mm (1.2 in.) 12 1.2 106 in·lb 8 Water Pump Cover Bolts, L = 40 mm (1.6 in.) 12 1.2 106 in·lb 9 Coolant Drain Bolt 12 1.2 106 in·lb G: Apply grease. R: Replacement Parts W: Apply water. 4-4 COOLING SYSTEM Coolant Flow Chart C ~ —.: 0004203B S 1. Hot Coolant 2. Cold Coolant 3. Reserve Tank Overflow Hose 4. Radiator Cap 5. Reserve Tank 6. Reserve Tank Hose 7. Radiator 8. Radiator Fan 9. Thermostat 10. Cylinder/Cylinder Head Jacket 11. Water Pump 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 below 80.5  83.5°C (177  182°F), the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant temperature is more than 80.5  83.5°C (177  182°F), the thermostat opens and the coolant flows. When the coolant temperature goes up beyond 104°C (219°F), the radiator fan relay conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the temperature is below 99°C (210°F)  temperature less than ON temperature, 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 108  137.4 kPa (1.10  1.40 kgf/cm², 15.7  19.9 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 108  137.4 kPa (1.10  1.40 kgf/cm², 15.7  19.9 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator. 4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount 1.2 L (1.3 US qt) (Reserve tank full level, including radiator and engine) Radiator Cap Relief Pressure 108  137.4 kPa (1.10  1.40 kgf/cm², 15.7  19.9 psi) Thermostat Valve Opening Temperature 80.5  83.5°C (177  182°F) Valve Full Opening Lift 8 mm (0.31 in.) or more @95°C (203°F) Special Tools Bearing Driver Set: 57001-1129 ST571 129ST C COOLING SYSTEM 4-7 Oil Seal Driver <f>37.5: 57001-1660 ST5716&0ST C 4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection •Remove the right side cover (see Side Cover Removal in the Frame chapter). •Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system. Coolant Level Inspection •Refer to the Coolant Level Inspection in the PeriodicMaintenance chapter. Coolant Draining •Refer to the Coolant Change in the Periodic Maintenance chapter. Coolant Filling •Refer to the Coolant Change in the Periodic Maintenance chapter. Pressure Testing •Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) •Remove the radiator cap (see Coolant Change in the Periodic Maintenance chapter), and install a cooling system pressure tester [A] on the filler neck [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. •Build up pressure in the system carefully until the pressure reaches 137.4 kPa (1.40 kgf/cm², 19.9 psi). NOTICE During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 137.4 kPa (1.40 kgf/cm², 19.9 psi). •Watch the gauge for at least 6 seconds. If the pressure holds steady, the system is all right. If the pressure drops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump. •Remove the pressure tester, replenish the coolant, and install the radiator cap. COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the efficiency of the cooling system. •Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter). •Fill the cooling system with fresh water mixed with a flushing compound. NOTICE Do not use a flushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer of the cleaning product. •Warm up the engine, and run it at normal operating temperature for about ten minutes. •Stop the engine, and drain the cooling system. •Fill the system with fresh water. •Warm up the engine and drain the system. •Repeat the previous two steps once more. •Fill the system with a permanent type coolant and bleed the air from the system (see Coolant Change in the Periodic Maintenance chapter). Coolant Reserve Tank Removal •Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Coolant Reserve Tank Bolts [A] •Disconnect the coolant reserve tank overflow hose [A]. 4-10 COOLING SYSTEM Coolant •Remove the coolant reserve tank cap. •Pour the coolant into a container. •Slide the clamp [A] and disconnect the reserve tank hose [B]. •Remove the coolant reserve tank [C]. Coolant Reserve Tank Installation •Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Install the removed parts (see appropriate chapters). •Tighten: Torque – Coolant Reserve Tank Bolts: 7.9 N·m (0.81 kgf·m, 70 in·lb) •Fill the coolant reserve tank with the coolant (see Coolant Change in the Periodic Maintenance chapter). COOLING SYSTEM 4-11 Water Pump Water Pump Removal •Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). •Slide the clamp [A]. •Disconnect the water hose [B]. •Remove: Water Pump Cover Bolts [C] Water Pump Cover [D] •Remove: Water Pump Impeller Bolt [A] Impeller [B] Water Pump Housing [C] Water Pump Installation •Replace the O-rings [A] on the water pump housing with new ones and apply grease to them. •Replace the water pump housing oil seal [B] with a new one and apply grease to the lips of the oil seal (seeWater Pump Housing Disassembly/Assembly). •Be sure that the dowel pin [A] is in position. •Install the water pump housing. •Apply water to the mechanical seal, and install the impeller. •Tighten: Torque – Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •Replace the O-ring [A] on the water pump cover with a new one and apply grease to it. 4-12 COOLING SYSTEM Water Pump •Be sure that the dowel pins [A] are in position. •Install the water pump cover. •Tighten: Torque – Water Pump Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •Align the line [A] of the water pump cover with the white mark [B] of the water hose [C]. •Install the water hose clamp [D] as shown. •Fill the radiator with the coolant (see Coolant Change in the Periodic Maintenance chapter). •Install the removed parts (see appropriate chapters). Water Pump Inspection •Remove the right middle fairing (see Middle Fairing Removal in the Frame chapter). •Check the drainage outlet passage [A] at the bottom of the water pump housing for coolant leaks. •If a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously. ○When 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. If the oil seal is damaged, engine oil leaks through the drainage outlet passage. Replace the oil seal. Mechanical Seal Inspection •Remove the impeller (see Water Pump Removal). •Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechanical seal as a unit. ○The sealing seat and rubber seal may be removed easily by hand. Impeller Sealing Seat Surface [A] Rubber Seal [B] Mechanical Seal Diaphragm [C] Water Pump Water Pump Housing Disassembly NOTICE Be careful not to damage the sealing surface of the mechanical seal. • Remove the water pump housing (see Water Pump Removal). • Take the oil seal [A] out of the housing [B] with a hook [C]. • Press the mechanical seal [A] out of the housing with a bearing driver [B]. Special Tool – Bearing Driver Set: 57001 -1129 Water Pump Housing Assembly • Apply grease [A] to the new oil seal [B]. • Press the oil seal into the housing as shown. O – 0.5 mm (0 – 0.02 in.) [C] OApply a soap and water solution or rubber lubricant to the outer circumference [D] of the oil seal so that it will go into place smoothly. Special Tool – Bearing Driver Set: 57001-1129 • Press the new mechanical seal into the housing with the oil seal driver [E] until its flange [F] touches the surface [G] of the housing. Special Tool – Oil Seal Driver ¢ 37.5: 57001-1660 Impeller Assembly • Clean the sliding surface of the mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication. • Apply water to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole. Pump Impeller Inspection • Remove the water pump cover (see Water Pump Removal). • Visually check the impeller [A]. * If the surface is corroded, or if the blades are damaged, replace the impeller (see Water Pump Removal). COOLING SYSTEM 4-13 60060618$1 0 A 60060638$1 0 60050328$1 C 4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal •Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). •Remove the middle fairings (see Middle Fairing Removal in the Frame chapter). •Slide the clamps [A]. •Disconnect: Radiator Overflow Hose [B] Water Hose [C] •Disconnect the regulator/rectifier connector [A]. •Slide the dust cover [B]. •Disconnect the radiator fan lead connector [C]. •Slide the clamp [A]. •Disconnect the water hose [B]. •Remove the radiator mounting bolt [C]. •Pull [D] the radiator [E] toward the left. NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency. •Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Radiator and Radiator Fan Installation • Install: Clip Nuts [A] Radiator Fan [B] • Tighten: Torque· Radiator Fan Bolts [CJ: 8.4 N·m (0.86 kgf·m, 74 in·lb) • Install the rubber dampers [D] and collar [E]. • Align the projections on the frame with the holes on the dampers. • Run the rad iator fan lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Tighten: Torque· Radiator Mounting Bolt [F]: 7.9 N·m (0.81 kgf·m, 70 in·lb) • Install the removed parts (see appropriate chapters). • Fill the radiator with the coolant (see Coolant Change in the Periodic Maintenance chapter). Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Removal). • 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. COOLING SYSTEM 4-15 G0011478W2 C 4-16 COOLING SYSTEM Radiator NOTICE When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [AJ away more than 0.5 m (1.6 ft) [BJ from the radiator core. Hold the steam gun perpendicular [CJ (not oblique [DJ) to the core surface. Run the steam gun, following the core fin direction. Radiator Cap Inspection • Remove the radiator cap (see Coolant Change in the Periodic Maintenance chapter). • Check the condition of the bottom [AJ and top [BJ valve seals. * If any one of them shows visible damage, replace the cap with a new one. • Install the cap [AJ on a cooling system pressure tester [BJ. NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and 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: 108 – 137.4 kPa (1.10 – 1.40 kgf/cm2 , 15.7 – 19.9 psi) * If the cap can not hold the specified pressure or if it holds too much pressure, replace it with a new one. Radiator Filler Neck Inspection • Remove the radiator cap (see Coolant Change in the Periodic Maintenance chapter). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [AJ in the filler neck. They must be smooth and clean for the radiator cap to function properly. OK D ® 000’70201 S 1 C COOLING SYSTEM 4-17 Thermostat Thermostat Removal •Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). •Remove: Radiator (see Radiator and Radiator Fan Removal) Thermostat Housing Bolts [A] Thermostat Housing [B] •Pull the thermostat [A] out of the cylinder head. Thermostat Installation •Install the thermostat [A] in the cylinder head so that the air bleeder hole [B] is on top. •Replace the O-ring [A] with a new one and apply grease to it. •When installing the water hose [A], align the mark [B] of the water hose with the line [C] of thermostat housing. •Install the water hose clamp [D] as shown. •Install the thermostat housing. •Tighten: Torque – Thermostat Housing Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •Install the removed parts (see appropriate chapters). •Fill the radiator with coolant (see Coolant Change in the Periodic Maintenance chapter). 4-18 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. * If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of the water. OThe 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 Standard: 80.5 – 83.5°C (177 – 182°F) A A G009020 2S2 C Water Hose and Pipes Water Hose Installation • Install the hoses and pipes, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting. This will prevent the hoses from working loose. OThe clamp should be positioned correctly to prevent the clamps from contacting the other parts. Water Hose Inspection • Refer to the Cooling System Inspection in the Periodic Maintenance chapter. Water Hose and 0 -ring Replacement • Refer to the Water Hose and 0-ring Replacement in the Periodic Maintenance chapter. COOLING SYSTEM 4-19 A GO I 00 201SI C 4-20 COOLING SYSTEM Water Temperature Sensor NOTICE The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation •Refer to the Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection •Refer to the Water Temperature Sensor Inspection in the Fuel System (DFI) chapter. ENGINE TOP END 5-1 5 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-8 Special Tools and Sealant . 5-10 Clean Air System. 5-12 Air Suction Valve Removal. 5-12 Air Suction Valve Installation 5-12 Air Suction Valve Inspection 5-13 Air Switching Valve Removal . 5-13 Air Switching Valve Installation 5-13 Air Switching Valve Operation Test 5-13 Air Switching Valve Unit Test . 5-13 Clean Air System Hose Inspection 5-14 Cylinder Head Cover . 5-15 Cylinder Head Cover Removal 5-15 Cylinder Head Cover Installation . 5-15 Camshaft Chain Tensioner 5-17 Camshaft Chain Tensioner Removal 5-17 Camshaft Chain Tensioner Installation . 5-17 Camshaft, Camshaft Chain . 5-19 Camshaft Removal 5-19 Camshaft Installation . 5-21 Camshaft, Camshaft Cap Wear Inspection 5-24 Camshaft Runout Inspection 5-24 Cam Wear Inspection 5-25 Camshaft Chain Removal 5-25 Cylinder Head 5-26 Cylinder Compression Measurement 5-26 Cylinder Head Removal. 5-27 Cylinder Head Installation 5-28 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). 5-32 Valve Seat Inspection 5-33 Valve Seat Repair 5-33 Cylinder, Pistons 5-38 Cylinder Removal. 5-38 Cylinder Installation 5-38 Piston Removal 5-39 Piston Installation. 5-39 Cylinder Wear Inspection. 5-40 Piston Wear Inspection 5-41 Piston Ring, Piston Ring Groove Wear Inspection 5-41 Piston Ring Groove Width Inspection 5-41 Piston Ring Thickness Inspection 5-42 Piston Ring End Gap Inspection 5-42 Throttle Body Assy Holder. 5-43 Throttle Body Assy Holder Removal 5-43 Throttle Body Assy Holder Installation . 5-43 Muffler 5-44 Muffler Removal. 5-44 Muffler Installation 5-45 5-2 ENGINE TOP END Exploded v· 1ew ENGINE TOP END 5-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb 2 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb 3 Camshaft Sprocket Bolts 15 1.5 11 L 4 Camshaft Cap Bolts 12 1.2 106 in·lb S 5 Rear Camshaft Chain Guide Bolt 20 2.0 15 L 6 Cylinder Head Plugs 19.6 2.00 14.5 L 7 Camshaft Chain Tensioner Cap Bolt 20 2.0 15 8 Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb L 9 Throttle Body Assy Holder Bolts 12 1.2 106 in·lb L 10 Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in·lb 11 Cylinder Head Bolt (M10), L = 176 mm (6.9 in.) see text – – MO, R, S 12 Cylinder Head Bolts (M6) 12 1.2 106 in·lb L, S 13 Cylinder Head Bolts (M10), L = 158 mm (6.2 in.) see text – – MO, R, S 14 Cylinder Head Bolts (M10), L = 100 mm (3.9 in.) see text – – MO, R, 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. 5-4 ENGINE TOP END Exploded View GE02688BW5 C ENGINE TOP END 5-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Cylinder Bolt (M8) 27.5 2.80 20.3 MO, S 2 Cylinder Bolts (M6) 12 1.2 106 in·lb L, S 3 Cylinder Nut 49 5.0 36 MO, S 4 Exhaust Pipe Holder Nuts 17 1.7 13 S 5 Muffler Body Mounting Bolt 20 2.0 15 6 Muffler Cover Bolts 7.0 0.71 62 in·lb 7 Oxygen Sensor 25 2.5 18 G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. 5-6 ENGINE TOP END Exhaust System Identification Exhaust System MUFFLER Honeycomb Type Catalyst With Oxygen Sensor ——————–~ P/No. 49069-0821 Mark: KH I K 669 Honeycomb Type Catalyst With Oxygen Sensor ·——————– P/No. 49069-0819 – Mark: KHI K 668 EPA Noise Emission Control Information Honeycomb Type Catalyst With Oxygen Sensor ——————— P/No. 49069-0816 Mark: KHI K 657 SPECIFICATION AU AU LAMS ID MY PH TH CA CAL CN us IN SEA-B1 SEA-B3 WVTA MODEL EX650KH EX650KH EX650KH EX650JH/KH EX650JH/KH EX650KH EX650KH EX650JH/KH EX650KH EX650JH/KH EX650KH EX650KH EX650KH EX650KH GE245S8C F Exhaust System Identification Muffler Mark Position [A] GE24595CS 1 0 Muffler Body with Hole [A] for Oxygen Sensor [BJ GE24597CS 1 0 ENGINE TOP END 5-7 Honeycomb Type Catalyst Position [A] GE24596CS I 0 5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 35.343  35.457 mm (1.3915  1.3959 in.) 35.24 mm (1.387 in.) Intake 35.843  35.957 mm (1.4111  1.4156 in.) 35.74 mm (1.407 in.) Camshaft Journal/Cap Clearance 0.028  0.071 mm (0.0011  0.0028 in.) 0.16 mm (0.0063 in.) Camshaft Journal Diameter 23.950  23.972 mm (0.94291  0.94378 in.) 23.92 mm (0.9417 in.) Camshaft Bearing Inside Diameter 24.000  24.021 mm (0.94488  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) 1 120  1 698 kPa (11.42  17.32 kgf/cm², 162.4  246.2 psi) @400 r/min (rpm) – – – Cylinder Head Warp – – – 0.05 mm (0.002 in.) Valves Valve Clearance: Exhaust 0.22  0.31 mm (0.0087  0.0122 in.) – – – Intake 0.15  0.21 mm (0.0059  0.0083 in.) – – – Valve Head Thickness: Exhaust 0.8 mm (0.031 in.) 0.7 mm (0.03 in.) Intake 0.5 mm (0.020 in.) 0.3 mm (0.01 in.) Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm (0.002 in.) Valve Stem Diameter: Exhaust 4.455  4.470 mm (0.1754  0.1760 in.) 4.44 mm (0.175 in.) Intake 4.475  4.490 mm (0.1762  0.1768 in.) 4.46 mm (0.176 in.) Valve Guide Inside Diameter: Exhaust 4.500  4.512 mm (0.1772  0.1776 in.) 4.58 mm (0.180 in.) Intake 4.500  4.512 mm (0.1772  0.1776 in.) 4.58 mm (0.180 in.) Valve/Valve Guide Clearance (Wobble Method): Exhaust 0.08  0.16 mm (0.0031  0.0063 in.) 0.35 mm (0.014 in.) Intake 0.03  0.10 mm (0.0012  0.0039 in.) 0.29 mm (0.011 in.) Valve Seat Cutting Angle 45°, 32°, 55°, 60° – – – Valve Seating Surface: Outside Diameter: Exhaust 27.6  27.8 mm (1.087  1.094 in.) – – – Intake 32.6  32.8 mm (1.28  1.29 in.) – – – Width: Exhaust 0.8  1.2 mm (0.031  0.047 in.) – – – Intake 0.5  1.0 mm (0.020  0.039 in.) – – – ENGINE TOP END 5-9 Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 41.9 mm (1.65 in.) 40.3 mm (1.59 in.) Intake 41.9 mm (1.65 in.) 40.3 mm (1.59 in.) Cylinder, Pistons Cylinder Inside Diameter 82.994  83.006 mm (3.2675  3.2679 in.) 83.09 mm (3.271 in.) Piston Diameter 82.969  82.984 mm (3.2665  3.2671 in.) 82.82 mm (3.261 in.) Piston/Cylinder Clearance 0.010  0.037 mm (0.0004  0.0015 in.) – – – Piston Ring/Groove Clearance: Top 0.030  0.070 mm (0.00118  0.00276 in.) 0.17 mm (0.0067 in.) Second 0.020  0.060 mm (0.00079  0.00236 in.) 0.16 mm (0.0063 in.) Piston Ring Groove Width: Top 0.92  0.94 mm (0.0362  0.0370 in.) 1.02 mm (0.0402 in.) Second 1.01  1.03 mm (0.0398  0.0406 in.) 1.11 mm (0.0437 in.) Piston Ring Thickness: Top 0.870  0.890 mm (0.0343  0.0350 in.) 0.80 mm (0.031 in.) Second 0.970  0.990 mm (0.0382  0.0390 in.) 0.90 mm (0.035 in.) Piston Ring End Gap: Top 0.25  0.40 mm (0.0098  0.0157 in.) 0.7 mm (0.03 in.) Second 0.40  0.55 mm (0.0157  0.0217 in.) 0.9 mm (0.04 in.) 5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm2 : 57001-221 Valve Spring Compressor Assembly: 57001-241 Valve Seat Cutter, 45° • <f,35: 57001-1116 0 Valve Seat Cutter, 32° • <f,30: 57001-1120 Valve Seat Cutter, 32° • <f,35: 57001-1121 ST570221ST C ST570241ST C ST571 11 6ST C ST571 120ST C ST571 12 1ST C Valve Seat Cutter, 60° • <f,30: 57001-1123 @ . . . Valve Seat Cutter Holder Bar: 57001-1128 Valve Seat Cutter, 45° • <f,30: 57001-1187 Valve Seat Cutter, 55° • <f,35: 57001-1247 ST571 123ST C ST571 128ST C ST571 187ST C ST571247ST C Valve Spring Compressor Adapter, <f,21: 57001-1272 ST571272ST C Special Tools and Sealant Compression Gauge Adapter, M10 x 1.0: 57001-1317 Valve Seat Cutter Holder, 4>4.5: 57001-1330 Valve Guide Arbor, 4>4.5: 57001-1331 Valve Guide Reamer, 4>4.5: 57001-1333 Engine Mount Nut Wrench: 57001-1450 ST571317ST C ST571330ST C ST571331ST C ST571333ST C ST571450ST C ENGINE TOP END 5-11 Filler Cap Driver: 57001-1454 Piston Pin Puller: 57001-1568 Piston Pin Puller Adapter, 4>12: 57001-1657 Liquid Gasket, TB1216B: 92104-1064 ST571 454ST C ST571 568ST C ST571657ST C ST921064ST C 5-12 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] Clamp [B] • Remove the air suction valve [A]. Air Suction Valve Installation • Install the air suction valve [A] so that its side where stopper is fixed with the screws [B] faces the front [C]. • Install the clamp [A] as shown. • Tighten: Torque -Air Suction Valve Cover Bolts [BJ: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the damper [C] as shown if removed. A GE.0 40488S I C Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Removal). • Visually inspect the reeds [AJ 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. • Check the reed contact areas [BJ 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 • 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) • Disconnect the connector [AJ. • Slide the clamp [BJ. • Disconnect the air switching valve hose [CJ from the air suction valve cover, and remove the air switching valve [DJ. NOTICE Never drop the air switching valve, especially on a hard surface. Such a shock to the valve can damage it. Air Switching Valve Installation • Install the air switching valve [AJ with hoses [BJ as shown. White Paint Marks [CJ • Connect the air switching valve lead connector. Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter. ENGINE TOP END 5-13 ~Ill. 5-14 ENGINE TOP END Clean Air System Clean Air System Hose Inspection •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 cover. If they are not, correct them. Replace them if they are damaged. ENGINE TOP END 5-15 Cylinder Head Cover Cylinder Head Cover Removal •Remove: 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) Air Switching Valve (see Air Switching Valve Removal) Stick Coils (see Stick Coil Removal in the Electrical System chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) •Remove the cylinder head cover bolts [A] and washers. •Remove the cylinder head cover [B] backward. Cylinder Head Cover Installation •Replace the plug hole gaskets [A] with new ones. •Install: Dowel Pins [B] Plug Hole Gaskets •Replace the head cover gasket with a new one. •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. •Apply liquid gasket [A] to the cylinder head as shown. Sealant – Liquid Gasket, TB1216B: 92104-1064 NOTE ○Make the application finish within 20 minutes with the liquid gasket (TB1216B) to the mating surface of the cylinder head cover is applied. •Install: Head Cover Gasket Cylinder Head Cover 5-16 ENGINE TOP END Cylinder Head Cover • Replace the washers [A] with new ones. • Install the washers with metal side faces upward. • Tighten: Torque • Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the removed parts (see appropriate chapters). GE.09033 8S I C ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in “Camshaft Chain Tensioner Installation.” Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. •Remove: Right Fuel Tank Side Cover (see Fuel Tank Side Cover Removal in the Frame chapter) Camshaft Chain Tensioner Cap Bolt [A] Washer Spring Camshaft Chain Tensioner Mounting Bolts [B] Camshaft Chain Tensioner Body [C] Camshaft Chain Tensioner Installation •Replace the O-ring [A] with a new one. •Apply grease to the new O-ring. •Release the stopper [B] and push the push rod [C] into the tensioner body [D]. •Install the tensioner body so that the stopper [A] faces upward. •Apply a non-permanent locking agent to the camshaft chain tensioner mounting bolts, and tighten them. Torque – Camshaft Chain Tensioner Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) 5-18 ENGINE TOP END Camshaft Chain Tensioner •Install: Spring [A] Washer [B] •Tighten: Torque – Camshaft Chain Tensioner Cap Bolt [C]: 20 N·m (2.0 kgf·m, 15 ft·lb) •Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing. Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Special Tool – Filler Cap Driver: 57001-1454 • Using a wrench on the timing rotor bolt, turn the crankshaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of the timing inspection hole [C] in the clutch cover as shown. •If the clutch cover is removed, perform the next procedure. OUsing a wrench on the timing rotor bolt, turn the crankshaft clockwise until the 1/T mark line [A] on the timing rotor is aligned with the mating surface [B] of the crankcase front side. ENGINE TOP END 5-19 GE 11 4368$ I C 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the camshaft cap bolts gradually and evenly as shown sequence [1 – 12), and remove them. • Remove: Camshaft Caps [A] Camshafts [BJ 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. • Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase. • Remove the camshaft sprocket bolts [A]. • Remove the camshaft sprocket. OE 11204812 C GE. I 120S8S1 C Camshaft, Camshaft Chain Camshaft Installation • Be sure to install the following parts. Plug Hole Gaskets [A] Dowel Pins [B] • Install the camshaft sprockets so that the marked (“IN” and “EX”) side faces to the outward. OThe intake [A] and exhaust [B] camshaft sprockets are identical. NOTICE Intake camshaft sprocket must use “IN” marked bolt holes [CJ. Exhaust camshaft sprocket must use “EX” marked bolt holes [DJ. • Apply a non-permanent locking agent to the camshaft sprocket bolts and tighten them. Torque – Camshaft Sprocket Bolts: 15 N ·m (1.5 kgf·m, 11 ft·lb) • Apply molybdenum disulfide oil solution to all cams [A], journals [B] and thrust blocks [C] with x marks. * If a new camshaft is to be used, apply a thin coat of molybdenum disulfide grease to the cam surfaces. NOTE o The exhaust camshaft has a 3478 EX mark [DJ and the intake camshaft has a 3478 IN mark [E]. Be careful not to mix up these shafts. ENGINE TOP END 5-21 GEi 1436812 C 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Using a wrench on the timing rotor bolt, turn the crankshaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of the timing inspection hole [C] in the clutch cover. 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. *If the clutch cover is removed, perform the next procedure. OUsing a wrench on the bolt, turn the crankshaft clockwise until the 1/T mark line [A] on the timing rotor is aligned with the mating surface [B] of the crankcase front side. • Pull the tension side ( exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown. OThe timing marks must be aligned with the cylinder head upper surface [B]. EX Mark [C] (Between #1 Pin and #2 Pin) IN Mark [D] (Between #31 Pin and #32 Pin) #1 Pin [E] #2 Pin [F] #31 Pin [G] #32 Pin [H] GE1 143HS1 C Camshaft, Camshaft Chain • Install the camshaft caps as shown. NOTE o The exhaust cap has a “EX” mark [A] and the intake cap has a “IN” mark [BJ. Be careful not to mix up these caps. • First tighten the all camshaft cap bolts evenly to seat the camshaft in place, then tighten all bolts following the specified tightening sequence [1 – 12]. Torque· Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). • Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing. • Replace the 0-ring of the timing inspection cap and timing rotor bolt cap with new ones. • Apply grease to the new 0-rings. • Install the timing inspection cap and timing rotor bolt cap. • Tighten: Torque· Timing Inspection Cap: 3.9 N·m (0.40 kgf·m, 35 in·lb) Timing Rotor Bolt Cap: 4.9 N ·m (0.50 kgf·m, 43 in·lb) Special Tool • Filler Cap Driver: 57001-1454 • Install the cylinder head cover (see Cylinder Head Cover Installation). ENGINE TOP END 5-23 SE112096W2 C 5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove the camshaft caps (see Camshaft Removal). • 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. • Tighten the camshaft cap bolts to the specified torque (see Camshaft Installation). NOTE ODo not turn the camshaft when the plastigage is between the j ournal and camshaft cap. • Remove the camshaft cap again, measure each clearance between the camshaft journal and the camshaft cap using plastigage [A]. Camshaft Journal/Cap Clearance Standard: 0.028 – 0.071 mm (0.0011 – 0.0028 in.) Service Limit: 0.16 mm (0.0063 in.) * If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.950 – 23.972 mm (0.94291 – 0.94378 in.) Service Limit: 23.92 mm (0.9417 in.) * If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again. * If the clearance still remains out of the limit, replace the cylinder head unit. Camshaft Runout Inspection • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown. * If the runout exceeds the service limit, replace the shaft. Camshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.1 mm (0.004 in.) GE1 1012BS1 C GE. 11 15 78S I C Camshaft, Camshaft Chain Cam Wear Inspection • Remove the camshaft (see Camshaft Removal). • 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 Intake Service Limit: 35.343 – 35.457 mm (1.3915 – 1.3959 in.) 35.843- 35.957 mm (1.4111 – 1.4156 in.) Exhaust 35.24 mm (1.387 in.) Intake 35.74 mm (1.407 in.) Camshaft Chain Removal • Split the crankcase (see Crankcase Splitting in the Crankshaft/ Transmission chapter). • Remove the camshaft chain [A] from the crankshaft sprocket. ENGINE TOP END 5-25 I -+- A GE 1101 22S I C 5-26 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○Use the battery which is fully charged. •Warm up the engine thoroughly. •Stop the engine. •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) Stick Coils (see Stick Coil Removal in the Electrical System chapter) Spark Plugs (see Spark Plug Replacement in the Periodic Maintenance chapter) •Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole. ○Using the startermotor, turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. Special Tools – Compression Gauge, 20 kgf/cm²: 57001-221 Compression Gauge Adapter, M10 × 1.0: 57001-1317 Cylinder Compression Usable Range: 1 120  1 698 kPa (11.42  17.32 kgf/cm², 162.4  246.2 psi) @400 r/min (rpm) •Repeat the measurement for the other cylinders. •Install the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). ○The 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. ENGINE TOP END 5-27 Cylinder Head Cylinder Head Removal •Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). •Remove: Muffler (see Muffler Removal) Cylinder Head Cover (see Cylinder Head Cover Removal) Camshafts (see Camshaft Removal) Throttle Body Assy Holders (see Throttle Body Assy Holder Removal) •Slide the clamp [A]. •Disconnect the water hose [B]. •Disconnect the water temperature sensor connector [A]. •Remove the front camshaft chain guide [A]. •Open the clamp [A]. 5-28 ENGINE TOP END Cylinder Head • Remove the cylinder head and cylinder bolts, following the specified sequence. OFirstly remove the cylinder head bolts (MG) [AJ and cylinder bolts (MG) [BJ. 0 Secondly, remove the cylinder bolts (M8) [C]. OThirdly, remove the cylinder nut [DJ. OLastly, remove the cylinder head bolts (M10) [EJ. ORemove the cylinder head. Cylinder Head Installation NOTE o The camshaft cap is machined w;th the cylinder head. So if a new cylinder head is installed, use the cap that is supplied w;th the new head. • Install a new cylinder head gasket [AJ and dowel pins [BJ. • Replace the cylinder head bolts [1 – 6J and washers with new ones. • Apply molybdenum disulfide oil solution [AJ to both sides of washers and the threads of bolts and nut. Cylinder Head Bolts (M10) [BJ Cylinder Nut [CJ Cylinder Bolt (M8) [DJ Cylinder Head • Tighten the cylinder head bolts and nut following the tightening sequence [1 – 8]. • Tighten: Cylinder Head Bolts (M1 0) [1, 3, 5] L = 176 mm (6.9 in.) Cylinder Head Bolts (M10) [2, 4] L = 158 mm (6.2 in.) Cylinder Head Bolt (M10) [6] L = 100 mm (3.9 in.) Torque – Cylinder Head Bolts (M10): 35 N·m (3.6 kgf·m, 26 ft-lb) • Tighten the cylinder head bolts (M1 0) [1 – 6] with the specified angle. Angle – Cylinder Head Bolt (M10) [1]: 220° Cylinder Head Bolts (M10) [2 – 4): 210° Cylinder Head Bolt (M10) [5]: 240° Cylinder Head Bolt (M10) [6]: 210° • Tighten: Torque – Cylinder Nut [7]: 49 N·m (5.0 kgf·m, 36 ft·lb) Cylinder Bolt (MS) [8]: 27.5 N·m (2.80 kgf·m, 20.3 ft·lb) NOTE o The tightening sequence No.1 – No. 5 are the cylinder head bolts that are tightened between the cylinder head and the crankcase. OThe No.6 is the cylinder head bolt that is tightened between the cylinder head and the cylinder. o The No. 7 and No. 8 are the cylinder nut and cylinder bolt that are tightened between the cylinder and the crankcase. OUsing a torque angle [E], tighten the bolts specified angle. HHG, m u t:111-1– —– ,:+.e.-~ ENGINE TOP END 5-29 B GE163528W2 C 5-30 ENGINE TOP END Cylinder Head • Apply a non-permanent locking agent to the threads of cylinder head bolts (MG) [A] and cylinder bolts (MG) [B]. • Tighten: Torque · Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) • Install the front camshaft chain guide [A]. Olnsert the end [B] of front camshaft chain guide into the hollow on the lower crankcase half. • Install the removed parts (see appropriate chapters). Cylinder Head Warp Inspection • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp Standard: Service Limit: 0.05 mm (0.002 in.) * If the cylinder head is warped more than the service limit, replace it. * If the cylinder head is warped less than the service limit, repair the head by rubbing the lower surface on emery paper secured to a surface plate (first No. 200, then No. 400). GE1407ISBS2. C Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim OMark and record the valve lifter and shim locations so they can be installed in their original positions. • Using the valve spring compressor assembly, remove the valve. Special Tools· Valve Spring Compressor Assembly [A]: 57001-241 Valve Spring Compressor Adapter, </>21 [B]: 57001-1272 Valve Installation • Replace the oil seal with a new one. OApply engine oil to the oil seal lip. • Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation. • Install the springs so that the closed coil end faces downwards (the side painted in red faces upwards). Valve Stem [A] Oil Seal [B] Spring Seat [C] Closed Coil End [D] Valve Spring [E] Side Painted in Red [F] Retainer [G] Split Keepers [H] Valve Guide Removal • Remove: Valve (see Valve Removal) Oil Seal Spring Seat • Heat the area around the valve guide to 120 – 150°C (248 – 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head in oil and heat the oil. Special Tool • Valve Guide Arbor, 4>4.5: 57001-1331 ENGINE TOP END 5-31 GE1S11 S8S1 0 A GE 1S04 S8S 1 C 5-32 ENGINE TOP END Valves Valve Guide Installation • Replace the snap ring of valve guide with a new one. • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 – 150°C (248 – 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor. The snap ring stops the guide from going in too far. Special Tool – Valve Guide Arbor, 4>4.5: 57001-1331 • Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer [A] even if the old guide is reused. OTurn the reamer in a clockwise direction until the reamer turns freely in the guide. Never turn the reamer counterclockwise or it will be dulled. OOnce the guides are reamed they must be cleaned thoroughly. Special Tool – Valve Guide Reamer, 4>4.5: 57001-1333 Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [BJ and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. • Move the stem back and forth [CJ to measure valve/valve guide clearance. • Repeat the measurement in a direction at a right angle to the first. * If the reading exceeds the service limit, replace the guide. NOTE o The reading is not actual valve/valve guide clearance because the measuring point is above the guide. ValveNalve Guide Clearance (Wobble Method) Standard: Exhaust 0.08 – 0.16 mm (0.0031 – 0.0063 in.) Intake 0.03 – 0.10 mm (0.0012 – 0.0039 in.) Service Limit: Exhaust 0.35 mm (0.014 in.) Intake 0.29 mm (0.011 in.) GEH IO.UBS 1 C GE 150078S2 C Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [AJ between the valve [BJ and valve seat [C]. OMeasure the outside diameter [DJ of the seating pattern on the valve seat. * If the outside diameter is too large or too small, repair the seat (see Valve Seat Repair). Valve Seating Surface Outside Diameter Standard: Exhaust Intake 27.6 – 27.8 mm (1.087 – 1.094 in.) 32.6 – 32.8 mm (1.28 – 1.29 in.) OMeasure the seat width [EJ of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper. Good [FJ * If the width is too wide [G], too narrow [HJ or uneven [JJ, repair the seat (see Valve Seat Repair). Valve Seating Surface Width Standard: Exhaust Intake 0.8 – 1.2 mm (0.031 – 0.047 in.) 0.5 – 1.0 mm (0.020 – 0.039 in.) Valve Seat Repair • Repair the valve seat with the valve seat cutters [AJ. Special Tools -Valve Seat Cutter Holder Bar [BJ: 57001 -1128 Valve Seat Cutter Holder, q,4.5 [CJ: 57001 -1330 For Exhaust Valve Seat Valve Seat Cutter, 45° – q,30: 57001-1187 Valve Seat Cutter, 32° – q,30: 57001-1120 Valve Seat Cutter, 60° – q,30: 57001-1123 For Intake Valve Seat Valve Seat Cutter, 45° – q,35: 57001-1116 Valve Seat Cutter, 32° – q,35: 57001-1121 Valve Seat Cutter, 55° – q,35: 57001-1247 •If the manufacturer’s instructions are not available, use the following procedure. ENGINE TOP END 5-33 ® I I 80 0 0 GEISOl17SZ C 5-34 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the 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 OPrior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter w;th washing oil. 5. After use, wash it with washing oil and apply thin layer of engine oil before storing. Marks Stamped on the Cutter The marks stamped on the back of the cutter [A] represent the following. 60° . . . Cutter angle [B] ¢37.5 . Outer diameter of cutter [C] Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter into the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth. 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. GEHIO I US 1 C Valves • Measure the outside diameter of the seating surface with a vernier caliper. * If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range. Widened Width [A] of engagement by machining with 45° cutter Ground Volume [B] by 32° cutter 32° [C] Correct Width [D] Ground Volume [E] by 60° or 55° cutter 60° or 55° [F] • Measure the outside diameter of the seating surface with a vernier caliper. * If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range. Original Seating Surface [B] NOTE ORemove all pittings of flaws from 45° ground surface. OAfter grinding w;th 45° cutter, apply thin coat of machinist’s dye to seating surface. This makes seating surface distinct and 32° and 60° (or 55°) grinding operation easier. OWhen the valve guide is replaced, be sure to grind with 45° cutter for centering and good contact. * If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. * If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. • Grind the seat at a 32° angle [B] until the seat outside diameter is within the specified range. OTo make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. OTurn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. NOTICE The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. OAfter making the 32° grind, return to the seat outside diameter measurement step above. • To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat. * If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat outside diameter measurement step above. ENGINE TOP END 5-35 ® GE 150121SI C © GE 150122S I C 5-36 ENGINE TOP END Valves * If the seat width is too wide, make the 60° or 55° [AJ grind described below. * If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° or 55° angle until the seat width is within the specified range. OTo make the 60° or 55° grind, fit 60° or 55° cutter into the holder, and slide it into the valve guide. OTurn the holder, while pressing down lightly. OAfter making the 60° or 55° grind, return to the seat width measurement step above. Correct Width [BJ • Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head. 0 Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. ORepeat the process with a fine grinding compound. Lapper [AJ Valve Seat [BJ Valve [CJ • The seating area should be marked about in the middle of the valve face. * If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. • Be sure to remove all grinding compound before assembly. • When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter). GEHIO l 23S 1 C GEHIO l 20S 1 C Valves Valve Seat Repair C START ) I 45° Grind Tool : 45° Cutter Purpose : increase outside diameter of seat area to s ecification. 45° Grind Tool : 45° Cutter Machinist’s dye on seat 45° Grind Tool : 45° Cutter Purpose : make seating area smooth and round. Measure Seating Area Outside Diameter Tool : Vernier Caliper Purpose : check seat outside diameter against s ecification. Results OK Measure Seating Width Tool : Vernier Caliper Purpose : check seat width against s ecification. Results OK Purpose : increase width of seat area beyond specification to increase outside diameter. Lap Valve Tools : Valve Lapper, Grinding Compound Purpose : perfectly match valve and valve seat area; check valve head for damage. ENGINE TOP END 5-37 Tool: ~ Machinist’s dye on seat 32° Grind 32° Cutter Purpose : reduce outside diameter of seat area to s ecification. 9 Machinist’s dye on seat 60° or 55° Grind Tool : 60° or 55° Cutter Purpose : reduce seat width to s ecification. C FINISHED ) GE1527~8 F 5-38 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Engine Mounting Bolt [A] (Both Sides) • Using the engine mount nut wrench [A], loosen the locknut [B]. Special Tool· Engine Mount Nut Wrench: 57001-1450 • Using the hexagon wrench, turn the adjusting collar [A] counterclockwise to make the gap. • Remove: Collar (Both Sides) Cylinder Cylinder Installation NOTE Off a new cylinder is used, use new piston ring. • Replace the cylinder gasket [A] with a new one. • Install the dowel pins [B] and new cylinder gasket. • The piston ring openings must be positioned as shown. The openings of the oil ring steel rails must be about 30 – 40° of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Oil Ring Steel Rails [C] Oil Ring Expander [D] Dent [E] 30 – 40° [F] ©–Q ~ () <p ®-Q CQ~©~~ ~In\”– ~/ ~~ 0 11 ®® GE.1 151428S I C Cylinder, Pistons • Apply molybdenum disulfide oil solution to the cylinder bore, piston rings and piston skirt. • Prepare two auxiliary head bolts with their head cut. Olnstall the two bolts [AJ diagonally in the crankcase. • Position the crankshaft so that all the piston heads are almost level. • Install the cylinder block. Olnsert the piston rings with your thumbs. • Install the removed parts (see appropriate chapters). Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the pistons and remove the piston pin snap ring [AJ from the outside of each piston. • Remove the piston pins with the piston pin puller [AJ. Center Bolt [BJ Shell of Piston [CJ Special Tools • Piston Pin Puller: 57001-1568 Piston Pin Puller Adapter, 4>12 [DJ: 57001 -1657 • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [AJ to remove it. • Remove the 3-piece oil ring with your thumbs in the same manner. Piston Installation NOTE Off a new piston is used, use new piston ring. • Apply molybdenum disulfide oil solution to the oil ring expander, install the oil ring expander [AJ in the bottom piston ring groove so the ends [BJ butt together. • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it. 0 Spread the rail with your thumbs, but only enough to fit the rail over the piston. ORelease the rail into the bottom piston ring groove. NOTE o The oil ring rails have no “top” or “bottom.” ENGINE TOP END 5-39 SIK250M5S 1 C GE 160598$ I C B GE160H8S 1 C 5-40 ENGINE TOP END Cylinder, Pistons • Apply molybdenum disulfide oil solution to the top and second rings. • Do not mix up the top and second ring. • Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces up. • Install the piston with its dent mark [A] facing forward. • Apply molybdenum disulfide oil solution to the piston pins and piston journals. • 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. OWhen installing the piston pin snap ring, compress it only enough to install it and no more. NOTICE Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. • Install the cylinder (see Cylinder Installation). Cylinder Wear Inspection • 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) shown. * If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. 1 O mm (0.39 in.) [A] 60 mm (2.36 in.) [B] Cylinder Inside Diameter Standard: 82.994 – 83.006 mm (3.2675 – 3.2679 in.) Service Limit: 83.09 mm (3.271 in.) , 7 T ( ~ . 1 ) GE.1151028S I C GE.1151 768$1 C GE.1151448 S I C ® A GE.1151458 S I C Cylinder, Pistons Piston Wear Inspection • Measure the outside diameter [A] of each piston 14 mm (0.55 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: 82.969 – 82.984 mm (3.2665 – 3.2671 in.) Service Limit: 82.82 mm (3.261 in.) Piston Ring, Piston Ring Groove Wear Inspection • 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. • 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 0.030 – 0.070 mm (0.00118 – 0.00276 in.) Second 0.020 – 0.060 mm (0.00079 – 0.00236 in.) Service Limit: Top 0.17 mm (0.0067 in.) Second 0.16 mm (0.0063 in.) Piston Ring Groove Width Inspection • Measure the piston ring groove width. OUse a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.92 – 0.94 mm (0.0362 – 0.0370 in.) Second [BJ 1.01 – 1.03 mm (0.0398 – 0.0406 in.) Service Limit: Top 1.02 mm (0.0402 in.) Second 1.11 mm (0.0437 in.) * If the width of any of the two grooves is wider than the service limit at any point, replace the piston. ENGINE TOP END 5-41 ® © GE161H8$1 0 GE161• JB$1 0 GE 160107$1 C 5-42 ENGINE TOP END Cylinder, Pistons Piston Ring Thickness Inspection • Measure the piston ring thickness. OUse the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top [A] 0.870 – 0.890 mm (0.0343 – 0.0350 in.) Second [BJ Service Limit: Top Second 0.970 – 0.990 mm (0.0382 – 0.0390 in.) 0.80 mm (0.031 in.) 0.90 mm (0.035 in.) * If any of the measurements is less than the service limit on either of the rings, replace all the rings. NOTE OWhen 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 • 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. • Measure the gap [BJ between the ends of the ring with a thickness gauge. Piston Ring End Gap Standard: Top 0.25 – 0.40 mm (0.0098 – 0.0157 in.) Second Service Limit: Top Second 0.40 – 0.55 mm (0.0157 – 0.0217 in.) 0.7 mm (0.03 in.) 0.9 mm (0.04 in.) * If the end gap of either ring is greater than the service limit, replace all the rings. <-)J.—::::::::-~~< -‘—–r1- © S-_____._________’—–+j- @ GE.1 15 1038SI C GE.1151488SI C Throttle Body Assy Holder Throttle Body Assy Holder Removal • 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) 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 • Be sure to install the new 0 -rings [A]. • Apply grease to the new 0-rings. • Apply a non-permanent locking agent to the threads of throttle body assy holder bolts. • Tighten: Torque · Throttle Body Assy Holder Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the clamps [B] so that their projections [C] fit on the holes of the holders. OBe sure that the clamp bolt heads [D] face outward. Upside View [E] • Install the removed parts (see appropriate chapters). ENGINE TOP END 5-43 GE170118$2 C 5-44 ENGINE TOP END Muffler Muffler Removal WARNING The muffler can become extremely hot during normal operation and cause severe burns. Do not remove the muffler while it is hot. •Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) •Disconnect the oxygen sensor lead connector [A]. •Open the clamps [B]. •Remove the exhaust pipe holder nuts [A]. •Remove: Shift Pedal (see Shift Pedal Removal in the Crankshaft/ Transmission chapter) Muffler Body Mounting Bolt [A] and Nut Muffler with Oxygen Sensor Muffler Muffler Installation • Install the muffler cover in the following procedure if removed. 0 Be sure to install the dampers [A] on the muffler cover [B]. OBe sure to install the damper [C] of tab on the muffler. Olnsert the hook to the slot [D] of the muffler cover. Olnstall the collars [E]. OTighten: Torque – Muffler Cover Bolts [F]: 7.0 N·m (0.71 kgf·m, 62 in·lb) ENGINE TOP END 5-45 GE 182598S2 S 5-46 ENGINE TOP END Muffler • Install: Dampers [A] Collars [B] • Replace the exhaust pipe gaskets [C] with new ones and install them. • Install the muffler [D]. • Temporarily tighten the exhaust pipe holder nut [E] following the specified tightening sequence [1 – 3]. • Tighten the exhaust pipe holder nuts following the specified tightening sequence [1 – 3]. Torque – Exhaust Pipe Holder Nuts: 17 N·m (1.7 kgf·m, 13 ft·lb) • Tighten: Torque – Muffler Body Mounting Bolt [F]: 20 N·m (2.0 kgf·m, 15 ft·lb) • Install the removed parts (see appropriate chapters). • Thoroughly warm up the engine, wait until the engine cools down, and retighten all the bolts and nuts. GE182658W2 C 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 . 6-7 Clutch Lever Removal. 6-7 Clutch Lever Installation 6-8 Clutch Lever Position Adjustment. 6-8 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation . 6-9 Release Shaft Removal 6-9 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 Measurement. 6-16 Clutch Plate Assembly 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 GF02292BW5 C CLUTCH 6-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Clutch Lever Holder Clamp Bolts 8.8 0.90 78 in·lb S 2 Timing Inspection Cap 3.9 0.40 35 in·lb 3 Clutch Cover Bolts 12 1.2 106 in·lb S 4 Timing Rotor Bolt Cap 4.9 0.50 43 in·lb 5 Oil Pump Chain Guide Bolt, L = 12 mm (0.47 in.) 12 1.2 106 in·lb L 6 Oil Pump Chain Guide Bolt, L = 11 mm (0.43 in.) 12 1.2 106 in·lb 7 Oil Pump Sprocket Bolt 12 1.2 106 in·lb L, Lh 8 Clutch Hub Nut 200 20.4 148 R 9 Clutch Stopper Bolts 9.8 1.0 87 in·lb CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. Lh: Left-hand Threads 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. Si: Apply silicone grease. W: Apply water. 6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever and Cable Clutch Lever Free Play 2  3 mm (0.08  0.12 in.) – – – Clutch Clutch Plate Assembly Length (Reference) 32.36  33.36 mm (1.27  1.31 in.) – – – Friction Plate Thickness 2.92  3.08 mm (0.115  0.121 in.) 2.6 mm (0.10 in.) Friction Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.) Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.) Special Tool and Sealant Clutch Holder: 57001-1243 Liquid Gasket, TB1211F: 92104-0004 CLUTCH 6-5 ST920004ST C 6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection •Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment •Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •Remove the right middle fairing (see Middle Fairing Removal in the Frame chapter). •Open the clamp [A]. •Slide the dust cover [A] at the clutch cable lower end out of place. •Loosen the nuts [B], and slide the lower end of the clutch cable to give the cable plenty of play. •Loosen the locknut [A]. •Screw in the adjuster [B]. •Line up the slots [C] in the clutch lever and adjuster, and then free the cable from the lever. •Push the release lever toward the front of the motorcycle. •Free the clutch inner cable tip from the clutch release lever. •Pull the clutch cable out of the frame. Clutch Cable Installation •Run the clutch cable correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Adjust the clutch cable (see Clutch Operation Inspection in the Periodic Maintenance chapter). •Install the removed parts (see appropriate chapters). Clutch Cable Lubrication •Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter. CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Assembly Installation •Install the clutch lever holder so that the mating surface [A] of the clutch lever holder clamp is aligned with the punch mark [B]. •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 Holder Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Clutch Lever Removal •Remove the upper end of the clutch cable (see Clutch Cable Removal). •Remove: Starter Lockout Switch Screws [A] Starter Lockout Switch [B] Clutch Lever Pivot Locknut [C] Clutch Lever Pivot Bolt Clutch Lever [D] 6-8 CLUTCH 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 themotorcycle 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. •Apply silicone grease to the clutch lever collar. •Replace the clutch lever pivot locknut [A] with a new one. •Install the clutch lever [B] and clutch lever pivot bolt. •Tighten the clutch lever locknut securely. •Apply a non-permanent locking agent to the starter lockout switch screws [C]. •Install the starter lockout switch [D]. ○Take care not to damage a pin [E] when installing the starter lockout switch. •Tighten the starter lockout switch screws securely. •Install the upper end of the clutch cable (see Clutch Cable Installation). •Adjust the clutch cable (see Clutch Operation Inspection in the Periodic Maintenance chapter). •Check that the pin 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. Clutch Lever Position Adjustment The adjuster has 5 positions so that the clutch lever position can be adjusted to suit the operator’s hand. •Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder. ○The distance from the grip to the lever is minimum at number 5 and maximum at number 1. Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Clutch Cable Removal) Clutch Cover Bolts [A] Bracket [B] • Turn the release lever [A] toward the rear as shown, and remove the clutch cover [B]. About 90° [C] Clutch Cover Installation • Apply liquid gasket to the areas [A] where the mating surface of the crankcase touches the clutch cover gasket and to the crankshaft sensor lead grommet [B]. Sealant· Liquid Gasket, TB1211F: 92104-0004 • Be sure that the dowel pins [C] are in position. • Replace the clutch cover gasket with a new one. • Install the bracket [A]. • Tighten the clutch cover bolts following the specified tightening sequence [1 – 14]. Torque· Clutch Cover Bolts: 12 N·m (1 .2 kgf·m, 106 in·lb) • Install the clutch cable lower end (see Clutch Cable Installation). 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. • Remove the clutch cover (see Clutch Cover Removal). • Pull the lever and shaft assembly [A] straight out of the clutch cover. CLUTCH 6-9 CF051114A P 6-10 CLUTCH Clutch Cover Release Shaft Installation • Apply grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft. • Install the washer [B] and spring [C]. • Insert the release shaft straight into the upper hole of the clutch cover. NOTICE When inserting the release shaft, be careful not to remove the spring of the oil seal. • Fit the spring [A] as shown. Viewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly • Remove: Clutch Cover (see Clutch Cover Removal) Release Lever and Shaft Assembly (see Release Shaft Removal) Oil Seal [A] Needle Bearings [B] • Remove: Oil Level Inspection Window [A] Timing Inspection Cap [B] Timing Rotor Bolt Cap [C] Oil Filler Plug [D] GF050308S I C ® GF05059 8S I C @ Clutch Cover Clutch Cover Assembly • Replace the needle bearings [A] and oil seal [B] with new ones. • Apply grease to the oil seal rips. NOTE Olnsta/1 the needle bearings so that the manufacture’s mark face out. • Install the needle bearings and oil seal position as shown. OPress [C] the bearing so that the bearing surface [D] is flushwith the housing end of clutch cover [E]. OPress the oil seal until it is bottomed. • Apply water to the rubber of the oil level inspection window [A] and press [B] it so that the glass surface [C] faces outside. • Replace the 0-rings of the following parts with new ones and apply grease to them. Timing Inspection Cap Timing Rotor Bolt Cap Oil Filler Plug • Tighten: Torque – Timing Inspection Cap: 3.9 N·m (0.40 kgf·m, 35 in·lb) Timing Rotor Bolt Cap: 4.9 N ·m (0.50 kgf·m, 43 in·lb) CLUTCH 6-11 GFOS0328$1 0 ® 0 C GFOS0318$1 0 6-12 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) • Loosen the three clutch stopper 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. • Remove: Clutch Stopper Bolts [A] Clutch Stopper Plate [B] Clutch Springs [C] • Visually inspect the clutch stopper plate. * If the clutch stopper plate is warped, replace it with a new one. • Remove: Spring Seats [A] Clutch Pressure Plate [B] (with Shim, Bearing and Pusher [C]) Friction Plates and Steel Plates Spring and Spring Seat • Hold the sub clutch hub [A] steady with the clutch holder [B], and remove the nut [C] and washers. Special Tool • Clutch Holder: 57001-1243 OUse the clutch holder with sharpened hook nose by grinding. Special Tool • Clutch Holder: 57001-1243 OGrind the hook nose by 0.5 mm (0.02 in.) as shown. S I ZXT0 40S1 C Clutch • Remove: Clutch Hub [A] Spacer [B] • Remove the oil pump sprocket bolt [A] and washer. NOTE o The oil pump sprocket bolt has a left-hand threads. • Using the holes [B], pull out the sleeve [C]. • Remove the following as a set. Clutch Housing [D] Oil Pump Sprocket [E] Oil Pump Chain [F] • Remove: Spacer [A] Clutch Installation • Install the spacer on the drive shaft. • Engage the oil pump chain [A] to the clutch housing gear [B] and the oil pump sprocket [C]. CLUTCH 6-13 GF062318$1 0 6-14 CLUTCH Clutch • Install the following on the drive shaft as a set. Clutch Housing [AJ Oil Pump Chain [BJ Oil Pump Sprocket [CJ • Apply molybdenum disulfide oil solution to the sleeve [DJ. • Install the sleeve so that the holes [EJ face outward. • Align the hole on the oil pump sprocket with the oil pump shaft. • Apply a non-permanent locking agent to the oil pump sprocket bolt [FJ and install the washer. • Tighten: Torque – Oil Pump Sprocket Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) NOTE o The oil pump sprocket bolt has a left-hand threads. • Install: Spacer [AJ Clutch Hub [BJ Washer [CJ • Install the washer [DJ so that the “OUT SIDE” mark faces outward. • Replace the clutch hub nut [AJ with a new one. • Hold the sub clutch hub [BJ steady with the clutch holder [CJ, and tighten the clutch hub nut. Special Tool – Clutch Holder: 57001-1243 Torque – Clutch Hub Nut: 200 N·m (20.4 kgf·m, 148 ft·lb) • Install the following as shown. Friction Plates [AJ [BJ Spring Seat [CJ Spring [DJ Steel Plates [EJ [FJ 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. Olnstall the last friction plate and steel plate later with the clutch pressure plate. B \ GF062848S1 C GF06262BS1 S CLUTCH 6-15 Clutch •Applymolybdenum disulfide grease to the pusher end [A]. •Install the pusher [B] to the drive shaft direction as shown. •Apply engine oil to the sliding surfaces of the bearing [A]. •Put the last friction plate [B] and steel plate [C] on the clutch pressure plate [D] and install them. •Install the last friction plate so that the tangs [A] fit into the grooves in the housing as shown. NOTE ○Make sure that the clutch pressure plate is installed without a gap. •Be sure to install the spring seats [A] on the clutch pressure plate. •Install: Clutch Springs Clutch Stopper Plate •Tighten the three clutch stopper 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. •Tighten: Torque – Clutch Stopper Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) 6-16 CLUTCH Clutch • Install: Clutch Cover (see Clutch Cover Installation) Clutch Plate Assembly Length Measurement • Assemble the following parts. Clutch Hub [A] Spring Seat [B] Spring [C] Friction Plates [D] Steel Plates [E] Clutch Pressure Plate [F] Spring Seats [G] Clutch Springs [H] Clutch Stopper Plate [I] Clutch Stopper Bolts [J] Torque • Clutch Stopper Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Measure the clutch plate assembly length [K]. Clutch Plate Assembly Length (Reference) 32.36 – 33.36 mm (1.27 – 1.31 in.) * If the length is not within the specified range, adjust the length (see Clutch Plate Assembly Adjustment). Clutch Plate Assembly Adjustment • Inspect the clutch plate assembly length, and then replace the steel plate(s) which brings the length within the specified range. • Remove: Clutch Stopper Bolts Clutch Stopper Plates Clutch Springs Clutch Pressure Plate • Replace the following steel plate(s). Thickness 1.6 mm (0.063 in .) 2.0 mm (0.079 in.) (STD) 2.3 mm (0.091 in .) NOTE Part Number 13089-0038 13089-0021 13089-0039 ODo not use the steel plate of 1.6 mm (0.063 in.) and 2.3 mm (0.091 in.) thickness at the same time. OWhen adjusting the clutch plate assembly, install the steel plate of 1.6 mm (0.063 in.) or 2.3 mm (0.091 in.) thickness to the second or third from the clutch pressure plate. • Install the removed parts, and inspect the clutch plate assembly length. Torque • Clutch Stopper Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) ® GF06263BS2 S Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • 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: 2.92 – 3.08 mm (0.115 – 0.121 in.) Service Limit: 2.6 mm (0.10 in.) Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. * If any plate is warped over the service limit, replace it with a new one. Friction and Steel Plate Warp Standard: 0.15 mm (0.0059 in.) or less Service Limit: 0.3 mm (0.01 in.) Clutch Housing Finger Inspection • 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 • 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. CLUTCH 6-17 A GF060602S I C B GF 130107S I C 6-18 CLUTCH Clutch Clutch Pressure Plate and Clutch Hub Inspection •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 . 7-6 Special Tools and Sealant 7-7 Engine Oil and Oil Filter 7-8 Oil Level Inspection. 7-8 Engine Oil Change 7-8 Oil Filter Replacement 7-8 Oil Pan 7-9 Oil Pan Removal. 7-9 Oil Pan Installation 7-10 Oil Screen. 7-12 Oil Screen Removal 7-12 Oil Screen Installation . 7-12 Oil Screen Cleaning 7-12 Oil Pressure Relief Valve 7-13 Oil Pressure Relief Valve Removal . 7-13 Oil Pressure Relief Valve Installation 7-13 Oil Pressure Relief Valve Inspection. 7-13 Oil Pumps. 7-14 Oil Pump Chain and Sprocket Removal . 7-14 Oil Pump Chain and Sprocket Installation 7-14 Oil Pump Removal 7-14 Oil Pump Installation . 7-16 Oil Pressure Measurement. 7-18 Oil Pressure Measurement . 7-18 Oil Pressure Switch 7-19 Oil Pressure Switch Removal . 7-19 Oil Pressure Switch Installation 7-19 Oil Pipes . 7-20 Oil Pipe Removal 7-20 Oil Pipe Installation . 7-20 7-2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Oil Filter 17.5 1.78 12.9 G 2 Oil Filter Pipe 25 2.5 18 L 3 Oil Passage Plug (PT3/8) 20 2.0 15 L 4 Oil Pressure Switch 15 1.5 11 LG 5 Oil Pressure Relief Valve 15 1.5 11 L 6 Oil Pump Cover Bolts 9.8 1.0 87 in·lb L, S 7 Oil Pump Chain Guide Bolt, L = 12 mm (0.47 in.) 12 1.2 106 in·lb L 8 Oil Pump Chain Guide Bolt, L = 11 mm (0.43 in.) 12 1.2 106 in·lb 9 Oil Pump Sprocket Bolt 12 1.2 106 in·lb L, Lh 10 Oil Pipe Retaining Plate Bolt 9.8 1.0 87 in·lb L 11 Oil Strainer Holder Bolts 9.8 1.0 87 in·lb L 12 Oil Pan Bracket Bolts 12 1.2 106 in·lb L, S(2) 13 Engine Oil Drain Bolt 30 3.1 22 14 Oil Pan Bolts 12 1.2 106 in·lb S EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. 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 S: Follow the specified tightening sequence. 7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 1.6 L (1.7 US qt)(When filter is not removed.) 1.8 L (1.9 US qt)(When filter is removed.) 2.3 L (2.4 US qt)(When engine is completely dry.) Level Between upper and lower level lines (Wait several minutes after idling or running) Oil Pressure Measurement Oil Pressure 216  294 kPa (2.20  3.00 kgf/cm², 31.3  42.6 psi) at 4 000 r/min (rpm), Oil Temperature 90°C (194°F) Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm2 : 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001-1233 ST570 164ST C STS71233ST C ENGINE LUBRICATION SYSTEM 7-7 Liquid Gasket, TB1211: 56019-120 STS60120ST C 7-8 ENGINE LUBRICATION SYSTEM 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 •Check that the engine oil level is between the upper [A] and lower [B] levels in the oil level inspection window. NOTE ○Situate the motorcycle so that it is perpendicular to the ground. ○If the motorcycle has just been used, wait several minutes for all the oil to drain down. ○If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles. NOTICE Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the 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 filter opening. Use the same type and make of oil that is already in the engine. NOTE ○If the engine oil type and make are unknown, use any brand of the specified oil to top off the level in preference to running the engine with the oil level low. Then at your earliest convenience, change the oil completely. Engine Oil Change •Refer to the Engine Oil Change in the Periodic Maintenance chapter. Oil Filter Replacement •Refer to the Oil Filter Replacement in the Periodic Maintenance chapter. ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Remove: Muffler (see Muffler Removal in the Engine Top End chapter) Oil Pan Bracket Bolts [AJ Oil Pan Brackets [BJ • Open the clamps [CJ. • Remove: Oil Pan Bolts [AJ Clamp [BJ Oil Pan [CJ • Remove the following from the oil pan as necessary. Oil Strainer Holder Bolts [AJ Oil Strainer Holder [BJ Oil Strainer [CJ 8 GG060838S I C 7-10 ENGINE LUBRICATION SYSTEM Oil Pan • Remove the following from the lower crankcase half as necessary. Oil Screen [A] (see Oil Screen Removal) Oil Pipes [B] (see Oil Pipe Removal) Oil Pressure Relief Valve [C] (see Oil Pressure Relief Valve Removal) Oil Pan Installation • Install the following parts if remove. Oil Pressure Relief Valve (see Oil Pressure Relief Valve Installation) Oil Pipes (see Oil Pipe Installation) Oil Screen (see Oil Screen Installation) • Replace the oil pan gasket with a new one. • When installing the oil pan, fit the damper [A] on the breather pipe into the hollow [B] of the oil pan. • Install the clamp [A]. • Tighten the oil pan bolts following the specified tightening sequence [1 – 12]. Torque· Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) • Apply a non-permanent locking agent to the threads of the oil pan bracket bolts. • Install the right oil pan bracket [A]. • Tighten the right oil pan bracket bolts following the specified tightening sequence [1 – 2]. Torque· Oil Pan Bracket Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) 7 1 ® Jr @ ® @) GGO&OS SBS 1 C ENGINE LUBRICATION SYSTEM 7-11 Oil Pan •Install: Left Oil Pan Bracket [A] •Tighten: Torque – Oil Pan Bracket Bolts [B]: 12 N·m (1.2 kgf·m, 106 in·lb) •Install the removed parts (see appropriate chapters). 7-12 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal •Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] Oil Screen Installation •Clean the oil screen [A] (see Oil Screen Cleaning). •Replace the O-ring [B] with a new one, and install it. •Apply grease to the O-ring. •Install the oil screen so that its guide portion [C] fits to the crankcase rib [D]. •Install: Oil Pan (see Oil Pan Installation) Oil Screen Cleaning •Remove the oil screen (see Oil Screen Removal). •Clean the oil screen with a high flash-point solvent and remove the particles stuck. •Blow away the particles by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side). WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the screen in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the screen. NOTE ○While cleaning the screen, check for any metal particles that might indicate internal engine damage. •Check the screens carefully for any damage. If the screen is damaged, replace the oil screen. ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it. NOTICE Do not apply too much non-permanent locking agent to the threads. This may block the oil passage. Torque · Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the oil pan (see Oil Pan Installation). Oil Pressure Relief Valve Inspection • Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). • 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 0 /nspect 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. AWARNING 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. GG080602S I C 7-14 ENGINE LUBRICATION SYSTEM Oil Pumps Oil Pump Chain and Sprocket Removal •Refer to the Clutch Removal in the Clutch chapter. Oil Pump Chain and Sprocket Installation •Refer to the Clutch Installation in the Clutch chapter. Oil Pump Removal •Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Chain Guide Bolts [A] Oil Pump Chain Guide [B] •Remove: Oil Pump Cover Bolts [A] •Temporarily install the oil pump sprocket bolt [A]. NOTE ○The oil pump sprocket bolt has a left-hand threads. •Using the oil pump sprocket bolt, pull out the oil pump as a assembly. •Remove the outer rotor [A] for feed pump. ENGINE LUBRICATION SYSTEM 7-15 Oil Pumps •Remove the oil pump cover [A]. •Remove: Inner Rotor [A] for Scavenge Pump Outer Rotor [B] for Scavenge Pump •Remove the pin [A]. •Remove: Pin [A] Inner Rotor for Feed Pump [B] Oil Pump Shaft [C] 7-16 ENGINE LUBRICATION SYSTEM Oil Pumps Oil Pump Installation • Apply engine oil to the rotors. • Apply molybdenum disulfide oil solution to the portion [A] of the oil pump shaft as shown. • Assemble the following parts. Oil Pump Shaft [B] Pin [C] Inner Rotor [D] for Feed Pump Oil Pump Body [E] Pin [F] Inner Rotor [G] for Scavenge Pump Outer Rotor [H] for Scavenge Pump NOTE o The scavenge pump rotors are wider than the feed pump rotors. • Install: Dowel Pin [A] Outer Rotor [B] for Feed Pump • Fit the pin of the crankcase into the hole [C] in the oil pump body. OTurn the oil pump shaft so that the inner rotor [D] fits into the outer rotor. • Fit the pin [A] into the hole [B] on the oil pump cover [C]. • Apply a non-permanent locking agent to the oil pump cover bolts [1 – 3] and tighten them temporarily (Do not seated). • Push [A] the arrow portion of the oil pump cover to left until it stopped. • Tighten the oil pump cover bolts following the specified tightening sequence [1 – 3]. Torque · Oil Pump Cover Bolts: 9.8 N·m (1 .0 kgf·m, 87 in·lb) • Check whether the oil pump turns smoothly. ENGINE LUBRICATION SYSTEM 7-17 Oil Pumps •Apply a non-permanent locking agent to the oil pump chain guide bolt, L = 12 mm (0.47 in.) [A]. •Install the oil pump chain guide [B]. •Tighten: Torque – Oil Pump Chain Guide Bolt, L = 12 mm (0.47 in.): 12 N·m (1.2 kgf·m, 106 in·lb) Oil Pump Chain Guide Bolt, L = 11 mm (0.43 in.) [C]: 12 N·m (1.2 kgf·m, 106 in·lb) •Install the clutch (see Clutch Installation in the Clutch chapter). 7-18 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement •Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Oil Passage Plug (PT318) [A] •Attach the adapter [A] and gauge [B] to the plug hole. Special Tools – Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •Start the engine and warm up the engine. •Run the engine at the specified speed, and read the oil pressure gauge [A]. If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately. If the reading is much higher than the standard, check the oil passages for clogging. Oil Pressure Standard: 216  294 kPa (2.20  3.00 kgf/cm², 31.3  42.6 psi) at 4 000 r/min (rpm), Oil Temperature 90°C (194°F) •Stop the engine. •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. •Apply a non-permanent locking agent to the oil passage plug, and install it. Torque – Oil Passage Plug (PT3/8): 20 N·m (2.0 kgf·m, 15 ft·lb) ENGINE LUBRICATION SYSTEM 7-19 Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation • 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. • 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 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead so that its direction is downward [A]. • Apply grease to the terminal, and tighten the terminal bolt securely. NOTE OApply a small amount grease to the terminal so that grease should not close two breather holes [A] for switch diaphragm. GG130208S I C G6 13 00 <8SI 0 7-20 ENGINE LUBRICATION SYSTEM Oil Pipes Oil Pipe Removal •Remove: Oil Pan (see Oil Pan Removal) Oil Screen (see Oil Screen Removal) Oil Pipe Retaining Plate Bolt [A] Oil Pipe Retaining Plate [B] Oil Pipes [C] Oil Pipe Installation •Replace the O-rings with new ones. •Apply grease to the O-rings on the oil pipes [A]. •Apply a non-permanent locking agent to the oil pipe retaining plate bolt [B]. •Install: Oil Pipes Oil Pipe Retaining Plate [C] •Tighten: Torque – Oil Pipe Retaining Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •Install the removed parts (see appropriate chapters). 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. 8-8 8-2 ENGINE REMOVAL/INSTALLATION Exploded View ~f’ dxD J II • GH02234BW5 C ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Adjusting Collar Locknut 49 5.0 36 S 2 Right Front Engine Mounting Bolt 44 4.5 32 S 3 Left Front Engine Mounting Bolt 44 4.5 32 S 4 Adjusting Collar 1.5 0.15 13 in·lb S 5 Upper Engine Mounting Bolt 44 4.5 32 S 6 Lower Engine Mounting Bolt 44 4.5 32 S R: Replacement Parts S: Follow the specified tightening sequence. 8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450 ST571 450ST C ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal •Support the rear part of the swingarm with a stand. •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. •Drain: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Coolant (see Coolant Change in the Periodic Maintenance chapter) •Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Air Switching Valve (see Air Switching Valve Removal in the Fuel System (DFI) chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Shift Pedal (see Shift Pedal Removal in the Crankshaft/ Transmission chapter) Muffler (see Muffler Removal in the Engine Top End chapter) Clutch Cable Lower End (see Clutch Cable Removal in the Clutch chapter) •Disconnect the stick coil lead connectors [A]. •Open the clamp [B]. 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation •Disconnect the crankshaft sensor/oil pressure switch lead connector [A]. •Open the clamp [B]. •Remove the engine ground terminal bolt [A]. •Slide the dust cover [B]. •Remove the starter motor cable terminal nut [C]. •Disconnect the water temperature sensor lead connector [D]. •Disconnect: Alternator Lead Connector [A] Gear Position Sensor Lead Connector [B] •Clear the drive chain [A] from the output shaft [B]. •Remove the clamp [C]. •Open the clamps [D]. ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Oil pan Bracket Bolts [A] Oil Pan Bracket [B] • Open the clamp [C]. • Support the engine with a suitable stand [A]. OPut a plank [B] onto the suitable stand for engine balance. • Remove the left front engine mounting bolt [A] and nut. • Using the engine mount nut wrench [A], loosen the adjusting collar locknut [B]. Special Tool· Engine Mount Nut Wrench: 57001-1450 8 GH 042298S I C 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation •Using the Allen wrench, turn the adjusting collar [A] counterclockwise. •Remove the collar [B]. •Remove: Right Front Engine Mounting Bolt [A] and Nut Collar •Remove the upper engine mounting bolt and nut [A]. •Remove the lower engine mounting bolt and nut [A]. •Using the suitable stand, take out the engine. Engine Installation •Replace the engine mounting nuts with new ones. •Install the adjusting collar to the frame until end of the threads. •Support the engine with a suitable stand. ○Put a plank onto the suitable stand for engine balance. ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation This page intentionally left blank. 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation •Install the engine mounting bolts and nuts, following the specified installing sequence. ○First, install the engine to the frame by inserting the engine mounting bolts [A]. ○Second, temporarily tighten the lower engine mounting nut [B]. ○Third, temporarily tighten the upper engine mounting nut [C]. ○Fourth, temporary install the left front engine mounting bolt [D], collar [E] and nut [F]. ○Fifth, temporarily install the right front engine mounting bolt [G] and collar [H]. ○Sixth, by the following specified sequence, tighten the bolts. Torque – Lower Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) Upper Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) Left Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) ○Seventh, remove the right front engine mounting bolt. ○Eighth, tighten the adjusting collar [I]. Torque – Adjusting Collar: 1.5 N·m (0.15 kgf·m, 13 in·lb) ○Ninth, tighten the adjusting collar locknut [J]. Special Tool – Engine Mount Nut Wrench: 57001-1450 Torque – Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb) ○Tenth, install the nut [K] and tighten the bolt. Torque – Right Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) ENGINE REMOVAUINSTALLATION 8-11 Engine Removal/Installation • Run the leads, cables, and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). • 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 Adjustment in the Periodic Maintenance chapter) • Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Fill the engine with coolant and bleed the air from the cooling system (see Coolant Change in the Periodic Maintenance chapter). • Adjust the idling (see Idle Speed Adjustment in the Periodic Maintenance chapter). GH042218W3 C CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-9 Crankcase Splitting 9-10 Crankcase Splitting 9-10 Crankcase Assembly . 9-12 Crankshaft and Connecting Rods 9-21 Crankshaft Removal 9-21 Crankshaft Installation . 9-21 Connecting Rod Removal 9-21 Connecting Rod Installation . 9-22 Crankshaft/Connecting Rod Cleaning 9-25 Connecting Rod Bend Inspection 9-26 Connecting Rod Twist Inspection. 9-26 Connecting Rod Big End Side Clearance Inspection 9-26 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-27 Crankshaft Side Clearance Inspection 9-28 Crankshaft Runout Inspection 9-29 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-29 Balancer 9-31 Balancer Removal 9-31 Balancer Installation. 9-31 Balancer Shaft Bearing Insert/Journal Wear Inspection . 9-31 Starter Motor Clutch 9-34 Starter Motor Clutch Removal/Installation 9-34 Starter Motor Clutch Inspection . 9-34 Starter Motor Clutch Disassembly 9-34 Starter Motor Clutch Assembly 9-34 External Shift Mechanism 9-35 Shift Pedal Removal 9-35 Shift Pedal Installation . 9-35 External Shift Mechanism Removal 9-36 External Shift Mechanism Installation . 9-37 External Shift Mechanism Inspection 9-38 Transmission . 9-40 Transmission Assy Removal 9-40 Transmission Assy Installation. 9-41 Transmission Assy Disassembly . 9-42 Transmission Assy Assembly 9-42 Transmission Shaft Removal . 9-44 Transmission Shaft Installation 9-44 Transmission Shaft Disassembly. 9-45 Transmission Shaft Assembly 9-45 Shift Drum and Fork Removal 9-48 Shift Drum and Fork Installation. 9-48 Shift Drum Disassembly. 9-48 Shift Drum Assembly . 9-48 Shift Fork Bending Inspection 9-48 Shift Fork/Gear Groove Wear Inspection 9-48 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-48 Gear Dog and Gear Dog Hole Damage Inspection . 9-49 Ball Bearing, Needle Bearing, and Oil Seal. 9-50 Ball and Needle Bearing Replacement. 9-50 Ball and Needle Bearing Wear Inspection 9-50 Oil Seal Inspection . 9-50 9-2 CRANKSHAFT/TRANSMISSION Exploded View 81 02480BW5 C CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Connecting Rod Big End Nuts see the text – – MO 2 Side Oil Plate Bolts 9.8 1.0 87 in·lb L 3 Oil Pipe Bolts 9.8 1.0 87 in·lb L 4 Middle Oil Plate Bolts 9.8 1.0 87 in·lb L 5 Breather Plate Bolts 9.8 1.0 87 in·lb L 6 Oil Passage Plug (M6) 3.5 0.36 31 in·lb 7 Oil Passage Plug (PT3/8) 20 2.0 15 L 8 Starter Motor Clutch Bolts 34 3.5 25 L 9 Shift Shaft Return Spring Pin 29 3.0 21 L 10 Bottom Oil Plate Bolts 9.8 1.0 87 in·lb L 11 Crankcase Bolts (M8), L = 60 mm (2.4 in.) see text – – MO, S 12 Crankcase Bolts (M8), L = 73 mm (2.9 in.) see text – – MO, S 13 Crankcase Bolts (M9), L = 113 mm (4.45 in.) see text – – MO, S 14 Crankcase Bolt (M8), L = 110 mm (4.33 in.) 27.4 2.79 20.2 S 15 Crankcase Bolt (M8, Rear), L = 60 mm (2.4 in.) 27.4 2.79 20.2 S 16 Crankcase Bolts (M6), L = 45 mm (1.8 in.) 19.6 2.00 14.5 S 17 Crankcase Bolts (M6), L = 38 mm (1.5 in.) 19.6 2.00 14.5 S 18 Crankcase Bolt (M8), L = 50 mm (2.0 in.) 27.4 2.79 20.2 S 19 Crankcase Bolt (M6), L = 32 mm (1.3 in.) 19.6 2.00 14.5 S 20 Crankcase Bolts (M9), L = 83 mm (3.3 in.) see text – – MO, S 21 Upper Crankcase Bolt (M8), L = 120 mm (4.72 in.) 27.5 2.80 20.3 S 22 Upper Crankcase Bolts (M8), L = 110 mm (4.33 in.) 27.5 2.80 20.3 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. 9-4 CRANKSHAFT/TRANSMISSION Exploded View CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Shift Drum Cam Holder Bolt 12 1.2 106 in·lb L 2 Shift Drum Holder Bolt 12 1.2 106 in·lb L 3 Shift Rod Retaining Plate Bolt 9.8 1.0 87 in·lb L 4 Shift Drum Bearing Holder Screws 4.9 0.50 43 in·lb L 5 Nozzle 2.9 0.30 26 in·lb L 6 Transmission Case Bolts, L = 30 mm (1.2 in.) 20 2.0 15 S 7 Transmission Case Bolts, L = 26 mm (1.0 in.) 20 2.0 15 S 8 Gear Positioning Lever Bolt 12 1.2 106 in·lb L 9 Race Holder Screw 4.9 0.50 43 in·lb L 10 Drive Shaft Bearing Holder Screw 4.9 0.50 43 in·lb L 11 Shift Shaft Cover Bolts, L = 30 mm (1.2 in.) 9.8 1.0 87 in·lb L, S 12 Shift Shaft Cover Bolts, L = 30 mm (1.2 in.) 12 1.2 106 in·lb S 13 Shift Shaft Cover Bolts, L = 40 mm (1.6 in.) 12 1.2 106 in·lb S 14 Shift Shaft Cover Screw 4.9 0.50 43 in·lb L, S 15 Shift Lever Bolt 12 1.2 106 in·lb 16 Shift Lever Tie-rod Locknuts 9.8 1.0 87 in·lb Lh(1) 17 Shift Pedal Bolt 25 2.5 18 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 S: Follow the specified tightening sequence. W: Apply water. 9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft/Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.13  0.38 mm (0.0051  0.0150 in.) 0.6 mm (0.02 in.) Connecting Rod Big End Bearing Insert/Crankpin Clearance 0.017  0.041 mm (0.0007  0.0016 in.) 0.08 mm (0.003 in.) Crankpin Diameter: 37.984  38.000 mm (1.4954  1.4961 in.) 37.97 mm (1.495 in.) Marking: None 37.984  37.992 mm (1.4954  1.4958 in.) – – – ○ 37.993  38.000 mm (1.49578  1.4961 in.) – – – Connecting Rod Big End Inside Diameter: 41.000  41.016 mm (1.6142  1.6148 in.) – – – Marking: None 41.000  41.008 mm (1.6142  1.61448 in.) – – – ○ 41.009  41.016 mm (1.61452  1.6148 in.) – – – Connecting Rod Big End Bearing Insert Thickness: Brown 1.475  1.480 mm (0.05807  0.05827 in.) – – – Black 1.480  1.485 mm (0.05827  0.05846 in.) – – – Blue 1.485  1.490 mm (0.05846  0.05866 in.) – – – Connecting Rod Bolt Stretch: New Connecting Rod 0.20  0.32 mm (0.0079  0.0126 in.) – – – Used Connecting Rod 0.24  0.36 mm (0.0094  0.0142 in.) – – – Crankshaft Side Clearance 0.05  0.20 mm (0.0020  0.0079 in.) 0.40 mm (0.0157 in.) Crankshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.05 mm (0.002 in.) Crankshaft Main Bearing Insert/Journal Clearance 0.016  0.040 mm (0.0006  0.0016 in.) 0.07 mm (0.0028 in.) Crankshaft Main Journal Diameter: 37.984  38.000 mm (1.4954  1.4961 in.) 37.96 mm (1.4945 in.) Marking: None 37.984  37.992 mm (1.4954  1.49575 in.) – – – 1 37.993  38.000 mm (1.49578  1.4961 in.) – – – CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankcase Main Bearing Inside Diameter: 41.000  41.016 mm (1.6142  1.6148 in.) – – – Marking: ○ 41.000  41.008 mm (1.6142  1.61448 in.) – – – None 41.009  41.016 mm (1.61452  1.6148 in.) – – – Crankshaft Main Bearing Insert Thickness: Brown 1.490  1.494 mm (0.05866  0.05882 in.) – – – Black 1.494  1.498 mm (0.05882  0.05898 in.) – – – Blue 1.498  1.502 mm (0.05898  0.05913 in.) – – – Balancer Shaft Balancer Shaft Bearing Insert/Journal Clearance 0.011  0.033 mm (0.0004  0.0013 in.) 0.06 mm (0.002 in.) Balancer Shaft Journal Diameter: 27.987  28.000 mm (1.1018  1.1024 in.) 27.96 mm (1.1008 in.) Marking: None 27.987  27.993 mm (1.1018  1.10208 in.) – – – ○ 27.994  28.000 mm (1.10212  1.1024 in.) – – – Balancer Shaft Bearing Inside Diameter: 31.000  31.016 mm (1.2205  1.2211 in.) – – – Marking: ○ 31.000  31.008 mm (1.2205  1.22078 in.) – – – None 31.009  31.016 mm (1.22082  1.2211 in.) – – – Crankshaft Main Bearing Insert Thickness: Brown 1.490  1.494 mm (0.05866  0.05882 in.) – – – Black 1.494  1.498 mm (0.05882  0.05898 in.) – – – Blue 1.498  1.502 mm (0.05898  0.05913 in.) – – – Transmission Shift Fork Ear Thickness 5.9  6.0 mm (0.23  0.24 in.) 5.8 mm (0.23 in.) Transmission Gear Groove Width 6.05  6.15 mm (0.238  0.242 in.) 6.3 mm (0.25 in.) Shift Fork Guide Pin Diameter 6.9  7.0 mm (0.27  0.28 in.) 6.8 mm (0.27 in.) Shift Drum Groove Width 7.05  7.20 mm (0.278  0.283 in.) 7.3 mm (0.29 in.) 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Connecting Rod Big Bearing Insert End Inside Diameter Marking Crankpin Diameter Marking Size Color Part Number None ○ Brown 92139-0116 ○ ○ None None Black 92139-0115 ○ None Blue 92139-0114 Crankshaft Main Bearing Insert Selection Crankcase Main Bearing Insert* Bearing Inside Diameter Marking Crankshaft Main Journal Diameter Marking Size Color Part Number ○ 1 Brown 92028-1905 ○ None None 1 Black 92028-1904 None None Blue 92028-1903 *: The crankshaft main bearing inserts have an oil groove. Balancer Shaft Bearing Insert Selection Balancer Shaft Bearing Insert* Bearing Inside Diameter Marking Balancer Shaft Journal Diameter Marking Size Color Part Number ○ ○ Brown 92139-0119 ○ None None ○ Black 92139-0118 None None Blue 92139-0117 *: The balancer shaft bearing inserts have an oil groove. Special Tools and Sealants Outside Circlip Pliers: 57001-144 Bearing Driver Set: 57001-1129 Flywheel Holder: 57001-1313 ST5 7014 4ST C ST5 71129ST C ST5 71313ST C CRANKSHAFT/TRANSMISSION 9-9 Liquid Gasket, TB1211F: 92104-0004 Liquid Gasket, TB1216B: 92104-1064 Liquid Gasket, TB1207B: 92104-2068 ST920004ST C ST9210& 4ST C ST9220&8ST C 9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting •Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). •Set the engine on a clean surface and hold the engine steady while parts are being removed. •Remove: Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter) Cylinder (see Cylinder Removal in the Engine Top End chapter) Pistons (see Piston Removal in the Engine Top End chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Starter Motor (see Starter Motor Removal in the Electrical System chapter) Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter) Timing Rotor (see Timing Rotor Removal in the Electrical System chapter) Clutch (see Clutch Removal in the Clutch chapter) Water Pump (see Water Pump Removal in the Cooling System chapter) Transmission Assy (see Transmission Assy Removal) If the rear camshaft chain guide is to be removed, follow the next procedure. •Remove: Rear Camshaft Chain Guide Bolt [A] Rear Camshaft Chain Guide [B] and Collars CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Remove the upper crankcase bolts [A] and the washers. • Remove: Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Oil Screen (see Oil Screen Removal in the Engine Lubrication System chapter) Oil Pipes (see Oil Pipe Removal in the Engine Lubrication System chapter) • Remove the lower crankcase bolts, following the specified sequence. OFirstly, loosen the MG bolts [A]. OSecondly, loosen the M8 bolts [B]. OLastly, loosen the M9 bolts [C]. • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. OTake care not to damage the crankcase. * If the oil pipe is to be removed, follow the next procedures. • Remove: Oil Pipe Bolts [A] Clamp [B] Oil Pipe [C] 0 -rings [D] GI 0’3528$2 C GI 0’3538$2 C 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Prepare a ¢5 mm rod [A], and insert it to the hole of the upper crankcase half. • Remove the oil pipe [B] by tapping [C] the rod as shown. * If the breather plate [A] is to be removed, follow the next procedures. • Remove the oil pipe (see above). • Cut the gasket [B] around the plate. • Remove: Breather Plate Bolts [C] Breather Plate with Pipe [D] * If the side oil plate [A] is to be removed, follow the next procedure. • Remove: Side Oil Plate Bolts [B] Side Oil Plate * If the middle oil plate [A] is to be removed, follow the next procedure. • Remove: Middle Oil Plate Bolts [B] Middle Oil Plate 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. • With a high flash-point solvent, clean off the mating surfaces of the crankcase halves and wipe dry. • Using compressed air, blow out the oil passages in the crankcase halves. I I ~ GI 0 43548SI C CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting * If the side oil plate [A] on the upper crankcase half was removed, install it as shown. • Apply a non-permanent locking agent to the side oil plate bolts and tighten them. Torque – Side Oil Plate Bolts [BJ: 9.8 N·m (1.0 kgf·m, 87 in·lb) * If the middle oil plate [A] on the lower crankcase half was removed, install it. • Apply a non-permanent locking agent to the middle oil plate bolts [B] and tighten them. Torque – Middle Oil Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) * If the bottom oil plate [A] on the lower crankcase half was removed, install it. • Apply a non-permanent locking agent to the bottom oil plate bolts [B] and tighten them. Torque – Bottom Oil Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • When the new needle bearing [A] for the shift drum is installed in the lower crankcase half [B], press and insert [C] the needle bearing until it is bottomed. Special Tool – Bearing Driver Set: 57001-1129 • When the new needle bearing [D] for the shift shaft is installed in the lower crankcase half, press and insert [E] the needle bearing so that the bearing surface is flush with the end of hole. OThe marked side of the needle bearing faces outside of the crankcase. Special Tool – Bearing Driver Set: 57001-1129 I I ~ GI 043S<8$1 0 6 1042 118$1 0 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • 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. • When the oil plug [A] and new race [B] for drive shaft is installed in the upper crankcase half [C], install them using the following procedures. • Apply grease to the 0-rings [D]. • Apply liquid gasket to the portions [E] on the upper crankcase half, and insert [F] the oil plug until it is bottomed. Sealant – Liquid Gasket, TB1211F: 92104-0004 • Press and insert the race until it is bottomed. Special Tool – Bearing Driver Set: 57001-1129 NOTE 0 /nstall the race so that the stepped side [GJ faces inside of the crankcase. ODo not apply liquid gasket to the 0-ring and the oil line. • Install the race holder [H] as shown. • Apply a non-permanent locking agent to the threads of the race holder screw [I] and tighten it. Torque – Race Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb) • 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. • Apply liquid gasket to the breather plate mating surface [A] 1 mm (0.04 in.) or more thick, and then install the breather plate. Sealant – Liquid Gasket, TB1207B: 92104-2068 NOTE OMake the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied. OMoreover fit the plate and tighten the bolts just after application of the liquid gasket. • Apply a non-permanent locking agent to the threads and tighten the bolts [A] and tighten them. Torque – Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) ® (l Gl 043 S78S2 C 0 10 42 538SI C CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • When installing the breather pipe [A], follow the next procedures. • Align the white mark [B] on the pipe with the white mark [C] on the breather fitting. • Install the clamps [D] so that the pinch heads [E] face the white marks. • When installing the oil pipes, follow the next procedures. • Apply molybdenum disulfide oil solution to the edge [A] of the oil pipe. • Install the oil pipe [B] so that its flange [C] touches to the surface [D] of the upper crankcase half. • Replace the 0-ring [E] with a new one. • Apply grease to the 0 -ring on the oil pipe. • Replace the 0-rings [A] with new ones. • Apply grease to the 0-rings. • Apply a non-permanent locking agent to the threads of the oil pipe bolts and tighten them. Olnstall the clamp with the upper oil pipe bolt. Torque – Oil Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Apply molybdenum disulfide oil solution to the following items. Crankshaft Main Bearing Insert Balancer Shaft Bearing Insert • Install the crankshaft and the balancer shaft on the upper crankcase half. OAlign the timing mark [A] on the balancer gear [B] with the timing mark [C] on the balancer drive gear [D] of the crankshaft. GI 04 2S<BS 1 0 GI 0 449l8S1 C GI 0 44988SZ C 9-16 CRANKSHAFT/TRANSMISSION Crankcase Splitting •Be sure to hang the camshaft chain [A] on the crankshaft. •Be sure that the dowel pins [A] are in position. •Set the bearing groove [A] on the positioning ring [B] as shown. CRANKSHAFT/TRANSMISSION 9-17 Crankcase Splitting • 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. • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant· Liquid Gasket, TB12168: 92104-1 064 NOTE OEspecially, apply a liquid gasket carefully so that it shall be filled up on the grooves. NOTICE Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. ODo not apply liquid gasket to the oil passage [B]. 9-18 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. Olnsert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half. NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied. OMoreover t;t the case and tighten the case bolts Just after finishing the application of the liquid gasket. Gl 0 42S78S2 C CRANKSHAFT/TRANSMISSION 9-19 Crankcase Splitting • Tighten the lower crankcase bolts following the sequence numbers on the lower crankcase half. • The crankcase bolts (M9) [1 – 6] have copper plated washers, replace them with new ones. • Apply molybdenum disulfide oil solution to both sides of the copper plated washers and the threads of the crankcase bolts (M9). • Tighten: Crankcase Bolts (M9) [1 , 2] L = 113 mm (4.45 in.) with Copper Plated Washers Crankcase Bolts (M9) [3, 4] L = 83 mm (3.3 in.) with Copper Plated Washers Crankcase Bolts (M9) [5, 6] L = 113 mm (4.45 in.) with Copper Plated Washers Torque· Crankcase Bolts (M9): 20 N·m (2.0 kgf·m, 15 ft·lb) • Tighten the crankcase bolts (M9) [1 – 6] with the specified angle. Angle· Crankcase Bolts (M9) [1 – 2]: S5° Crankcase Bolts (M9) [3 – 4]: 70° Crankcase Bolts (M9) [5 – 6]: S5° • Apply molybdenum disulfide oil solution to flange and the threads of the crankcase bolts (M8) [7 – 1 O]. • Tighten: Crankcase Bolts (M8) [7, 9] L = 73 mm (2.9 in.) Crankcase Bolts (M8) [8, 1 O] L = 60 mm (2.4 in.) Torque· Crankcase Bolts (MS): 20 N·m (2.0 kgf·m, 15 ft·lb) • Tighten the crankcase bolts (M8) [7 – 1 O] with the specified angle. Angle· Crankcase Bolts (MS) [7 -10]: 35° • Do not apply molybdenum disulfide oil solution to the crankcase bolts (M8) [A] [B] [C]. • Tighten: Crankcase Bolt (M8) [A] L = 110 mm (4.33 in.) Crankcase Bolt (M8, Rear) [B] L = 60 mm (2.4 in.) Crankcase Bolt (M8) [C] L = 50 mm (2.0 in.) Crankcase Bolts (MG) [D] L = 38 mm (1.5 in.) Crankcase Bolts (MG) [E] L = 45 mm (1.8 in.) Crankcase Bolt (MG) [F] L = 32 mm (1.3 in.) Torque· Crankcase Bolts (MS): 27.4 N·m (2.79 kgf·m, 20.2 ft·lb) Crankcase Bolts (M6): 19.6 N·m (2.00 kgf·m, 14.5 ft·lb) OUsing a torque angle [A], tighten the bolts specified angle. 9-20 CRANKSHAFT/TRANSMISSION Crankcase Splitting • The upper crankcase bolts have copper plated washers, replace them with new ones. • Tighten the upper crankcase bolts with washers. Upper Crankcase Bolts (M8) [A] L = 11 O mm (4.33 in.) Upper Crankcase Bolt (M8) [B] L = 120 mm (4.72 in.) Torque· Upper Crankcase Bolts (MS): 27.5 N·m (2.80 kgf·m, 20.3 ft·lb) • After tightening all crankcase bolts, check the following items. OWipe up the liquid gasket that seeps out around the crankcase mating surface. OCrankshaft and balancer shaft turn freely. * If the rear camshaft chain guide was removed, install it. • Installation the rear camshaft chain guide [A] and collars. • Apply a non-permanent locking agent to the threads of the rear camshaft chain guide bolt [B]. • Tighten: Torque· Rear Camshaft Chain Guide Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb) • Install the removed parts (see appropriate chapters). G l04SC08S2 C CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Camshaft Chain [A] Crankshaft [B] Crankshaft Installation NOTE Off the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications. 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. • Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts. • Align the timing mark [A] on the balancer gear [B] with the timing mark [C] on the balancer drive gear [D] of the crankshaft. • Install the crankshaft with the camshaft chain [A] hanging on it. Connecting Rod Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A]. NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions. • Remove the connecting rods from the crankshaft. NOTICE Discard the connecting rod bolts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins. GI 0 44988SZ C 9-22 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]: “O” 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. • Apply molybdenum disulfide oil solution [A] to the inner surfaces of upper and lower bearing inserts. ODo not apply any grease or oil to the cap inside and cap insert outside [B]. Olnstall the inserts so that their nails [C] 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. OWhen 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] • Remove debris and clean the surface of inserts. • Apply molybdenum disulfide oil solution to the threads and seating surfaces of the big end nuts and bolts. • Install each connecting rod on its original crankpin. NOTE Olnsta/1 each connecting rod so that its oil Jet [A] faces the exhaust side (the front [BJ) (see Engine Oil Flow Chart in the Engine Lubrication System chapter). • Install the cap on the connecting rod, aligning the weight and diameter marks. GIO:i0601S1 C Gl 052228S1 C 0 105 1478SI C CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods ○The connecting rod big end is bolted using the “plastic region fastening method.” ○This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight. ○There are two types of the plastic region fastening. One is a bolt length measurement method and other is a rotation angle method. Observe one of the following two, but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts. NOTICE The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage. NOTICE Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase. (1) Bolt Length Measurement Method •Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high flash-point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. WARNING 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. 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • 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] Mark here with a punch [B]. Nuts [C] Fit micrometer pins into punch marks [D]. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Connecting Rods • Tighten the big end nuts until the bolt elongation reaches the length specified in the table. • 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. Bolt Length after tightening Connecting Rod Assy Bolt Length before tightening Bolt = Bolt Stretch Nut A Use the bolts attached Attached to new New connecting rod to new connecting rod. New Used Replace the bolts with Used new ones. New (2) Rotation Angle Method * If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method.” • Be sure to clean the bolts and nuts thoroughly with a high flash-point solvent, because the new bolts and nuts are treated with an anti-rust solution. AWARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the bolts and nuts 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 bolts and nuts. NOTICE Immediately dry the bolts and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely. D GIO:IO.t03S1 C G 105040 4 S1 C Usable Range of Connecting Rod Bolt Stretch 0.20 – 0.32 mm (0.0079 – 0.0126 in.) 0.24 – 0.36 mm (0.0094 – 0.0142 in.) CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [AJ of Nuts and Bolts Seating Surfaces [BJ of Nuts and Connecting Rods • First, tighten the nuts to the specified torque. See the table below. • Next, tighten the nuts 120° ±5° . OMark [AJ the connecting rod big end caps and nuts so that nuts can be turned 120° [BJ properly. Connecting Rod Assy Bolt ® A Nut Use the bolts attached Attached to new New to new connecting rod. connecting rod Used Replace the bolts with new ones. OUsing a torque angle [AJ, tighten the nuts specified angle. Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high flash-point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages. New Used New A GI05040 4 SI C GI050405S I C Torque + Angle N·m (kgf·m, ft·lb) 18 (1.8, 13.0) + 120° 20 (2.0, 15) + 120° 24 (2.4, 17.4) + 120° 25 (2.6, 18.8) + 120° 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend Inspection • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [AJ of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. • Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [BJ through the connecting rod small end. • Ona surface plate, set the big-end arbor on V block [C]. • With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend. * If connecting rod bend exceeds the service limit, the connecting rod must be replaced. Connecting Rod Bend Service Limit: TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist Inspection • With the big-end arbor [AJ still on V block [BJ, hold the connecting rod horizontally and measure the amount that the arbor [CJ varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist. * If connecting rod twist exceeds the service limit, the connecting rod must be replaced. Connecting Rod Twist Service Limit: TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance Inspection • Measure connecting rod big end side clearance. Olnsert a thickness gauge [AJ between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.13 – 0.38 mm (0.0051 – 0.0150 in.) Service Limit: 0.6 mm (0.02 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. GI0 :10 .tOUl C CRANKSHAFT/TRANSMISSION 9-27 Crankshaft and Connecting Rods Connecting Rod Big End Bearing lnserVCrankpin Wear Inspection • Measure the bearing insert/crankpin [A] clearance with plastigage [B]. • Tighten the big end nuts to the specified torque (see Connecting Rod Installation). NOTE ODo not move the connecting rod and crankshaft during clearance measurement. NOTICE After measurement, replace the connecting rod bolts and nuts. Connecting Rod Big End Bearing lnsert/Crankpin Clearance Standard: 0.017 – 0.041 mm (0.0007 – 0.0016 in.) Service Limit: 0.08 mm (0.003 in.) * If the clearance is within the standard, no bearing replacement is required. •If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.003 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: 37.984 – 38.000 mm (1.4954 – 1.4961 in.) Service Limit: 37.97 mm (1.495 in.) * If any crankpin has worn past the service limit, replace the crankshaft with a new one. * If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankpin Diameter Marks None 37.984- 37.992 mm (1.4954 – 1.49575 in.) O 37.993 – 38.000 mm (1.49578 – 1.4961 in.) !:).: Crankpin Diameter Marks, “O” or no mark. • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE o The mark already on the big end should almost coincide with the measurement. A GI0504 17S I C NO. 1 NO. 2 GIOS1398SI 0 9-28 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 41.000- 41.008 mm (1.61 42-1.61448 in.) O 41.009 – 41.016 mm (1.61 452- 1.6148 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: “O” or no mark • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Connecting Rod Big End Crankpin Diameter Inside Diameter Marking Marking None 0 0 0 None None 0 None • Install the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage. Crankshaft Side Clearance Inspection • Insert a thickness gauge [A] between the crankshaft main bearing and the crank web at the No. 2 journal [B] to determine clearance. * If the clearance exceeds the service limit, replace the crankcase halves as a set. NOTE o The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. Crankshaft Side Clearance Standard: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) Service Limit: 0.40 mm (0.0157 in.) GIO:i0601S1 C A Gl050.f llS1 C Bearing Insert Size Color Part Number Brown 92139-01 16 Black 92139-01 15 Blue 92139-01 14 Gl 050198S1 C CRANKSHAFT/TRANSMISSION 9-29 Crankshaft and Connecting Rods Crankshaft Runout Inspection • Measure the crankshaft runout. * If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.002 in.) Crankshaft Main Bearing lnserVJournal Wear Inspection • Using a plastigage (press gauge) [A], measure the bearing insert/journal [B] clearance. NOTE o Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ODo not turn the crankshaft during clearance measurement. OJournal clearance less than 0.025 mm (0.00098 in.) can not be measured by plastigage, however, using genuine parts maintains the minimum standard clearance. Crankshaft Main Bearing Insert/Journal Clearance Standard: 0.016 – 0.040 mm (0.0006 – 0.0016 in.) Service Limit: 0.07 mm (0.0028 in.) * If the clearance is within the standard, no bearing replacement is required. •If the clearance is between 0.041 mm (0.0015 in.) and the service limit (0.07 mm, 0.003 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. * If the clearance exceeds the service limit, measure the diameter of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 37.984 – 38.000 mm (1.4954 – 1.4961 in.) Service Limit: 37.96 mm (1.4945 in.) * If any journal has worn past the service limit, replace the crankshaft with a new one. * If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankshaft Main Journal Diameter Marks None 37 .984 – 37 .992 mm (1.4954 – 1.4958 in.) 1 37 .993 – 38.000 mm (1.49578 – 1.4961 in.) o: Crankshaft Main Journal Diameter Marks, “1” or no mark. GI OS 1•oes1 0 GI050304 S A GI0504l 7S 1 C NO. 1 NO. 2 NO. 3 GI OS 1•1BS1 0 9-30 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diameter. Crankshaft Main Bearing Inside Diameter Marks: “O” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE o The mark already on the upper crankcase half should almost coincide with the measurement. Crankshaft Main Bearing Inside Diameter Marks O 41.000 – 41.008 mm (1.6142-1.61448 in.) None 41.009 – 41.016 mm (1.61452-1.6148 in.) ooo: Crankshaft Main Bearing Inside Diameter Marks, “O” mark or no mark No.1 Journal [A] No.2 Journal [B] No.3 Journal [C] • Select the proper bearing insert [A] in accordance with the combination of the crankcase and crankshaft coding. Size Color [B] Crankcase Main Bearing Crankshaft Main Inside Diameter Marking Journal Diameter Marking 0 1 0 None None 1 None None Gl 0S1428S2 C A 0 10:10.tllSl C Bearing Insert* Size Color Part Number Brown 92028-1905 Black 92028-1904 Blue 92028-1903 * The crankshaft main bearing inserts have an oil groove. • Install the new inserts in the crankcase halves and check insert/journal clearance with the plastigage. CRANKSHAFT/TRANSMISSION 9-31 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft [A] with the balancer gear out of the crankcase. Balancer Installation • Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. • Align the timing mark [A] on the balancer gear [B] with the timing mark [C] on the balancer drive gear [D] of the crankshaft. • Assemble the crankcase (see Crankcase Assembly). Balancer Shaft Bearing lnserVJournal Wear Inspection • Measure the bearing insert/journal clearance using a plastigage. OSplit the crankcase and wipe each bearing insert and journal surface clean of oil. OCut strips of plastigage to bearing insert width, and place a strip on each journal parallel to the balancer shaft so that the plastigage will be compressed between the journal and the bearing insert. Olnstall the lower crankcase half, and tighten the case bolts to the specified torque (see Crankcase Assembly). GI 0 44988SZ C 9-32 CRANKSHAFT/TRANSMISSION Balancer NOTE ODo not turn the balancer shaft during clearance measurement. ORemove the lower crankcase half and measure the plastigage width [A] to determine the bearing insert/journal [B] clearance. Balancer Shaft Bearing Insert/Journal Clearance Standard: 0.011 – 0.033 mm (0.0004 – 0.0013 in.) Service Limit: 0.06 mm (0.002 in.) * If the clearance is within the standard, no bearing insert replacement is required. *If the clearance is between 0.034 mm (0.00134 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 a 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 balancer shaft journal. Balancer Shaft Journal Diameter Standard: 27.987 – 28.000 mm (1.1018 -1.1024 in.) Service Limit: 27.96 mm (1.1008 in.) * If either journal has worn past the service limit, replace the balancer shaft with a new one. *If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it. Balancer Shaft Diameter Marks None 27.987 – 27.993 mm (1.1018 -1.10208 in.) O 27.994 – 28.000 mm (1.10212 -1.1024 in.) ti: Balancer Shaft Journal Diameter Marks, “O” mark or no mark. A G 1060302S1 C $d- IA·~ N0 . 1 N0.2 0 105 1438SI C CRANKSHAFT/TRANSMISSION 9-33 Balancer • Put the lower crankcase half on the upper crankcase half without bearing inserts, and tighten the case bolts to the specified torque and sequence (see Crankcase Assembly). • Measure the balancer shaft bearing inside diameter, and mark the upper crankcase half in accordance with the inside diameter. NOTE o The mark already on the upper crankcase half should almost coincide with the measurement. Balancer Shaft Bearing Inside Diameter Marks O 31.000 – 31.008 mm (1.2205 – 1.22078 in.) None 31.009 – 31.016mm(1.22082 – 1.2211 in.) DD: Balancer Shaft Bearing Inside Diameter Marking, “O” mark or no mark. No.1 Journal [A] No.2 Journal [B] • Select the proper bearing insert in accordance with the combination of the crankcase and the balancer shaft coding. • Install the new inserts in the crankcase and check insert/ journal clearance with a plastigage. Balancer Shaft Balancer Shaft Journal Diameter GI 060188$2 C Bearing Insert* Bearing Inside Diameter Marking Marking Size Color Part Number 0 0 Brown 92139-0119 0 None Black 92139-0118 None 0 None None Blue 92139-0117 *The balancer shaft bearing inserts have an oil groove. 9-34 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation •Refer to the Alternator Rotor Removal/Installation in the Electrical System chapter. Starter Motor Clutch Inspection •Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Torque Limiter (see Alternator Removal in the Electrical System chapter) •Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C]. If the starter motor clutch does not operate as it should or if it makes noise, go to the next step. •Disassemble the starter motor clutch, and visually inspect the clutch parts (see Starter Motor Clutch Disassembly). If there is any worn or damaged part, replace it. NOTE ○Examine the starter motor clutch gear as well. Replace it if it worn or damaged. Starter Motor Clutch Disassembly •Remove: Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Starter Motor Clutch Bolts [A] Special Tool – Flywheel Holder [B]: 57001-1313 •Remove the starter motor clutch [A]. Starter Motor Clutch Assembly •Install the starter motor clutch to the housing so that the flange [A] fit to the housing groove [B]. •Apply a non-permanent locking agent to the threads of the starter motor clutch bolts and tighten them. Special Tool – Flywheel Holder: 57001-1313 Torque – Starter Motor Clutch Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [AJ Shift Lever [BJ CRANKSHAFT/TRANSMISSION 9-35 * If the tie-rod is removed from the shift pedal and shift lever, note the following. OThe following portions have left-hand threads. Locknut [CJ of Shift Lever Side Ball Joint [DJ of Shift Lever • Remove: Shift Pedal Bolt [EJ Shift Pedal [FJ with Tie-Rod Shift Pedal Installation • Apply grease to the sliding surface [AJ on the shift pedal bolt [BJ. • Install: Washer [CJ Tie-Rod [DJ and Shift Pedal [EJ • Tighten: Torque · Shift Pedal Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) • Align the punch mark [AJ on the shift shaft with the punch mark [BJ on the shift lever. • Tighten: Torque -Shift Lever Bolt [CJ: 12 N·m (1.2 kgf·m, 106 in·lb) • After installation, confirm that the shift pedal [AJ is positioned as shown. About 138.5 mm (5.453 in.) [BJ Pedal top is the same height as sown bolt [CJ. * If the pedal position is different, adjust it as follows. OTo adjust the pedal position, loosen the front locknut [DJ (left-hand threads) and rear locknut [EJ, and then turn the tie-rod. OTighten: Torque • Shift Lever Tie-rod Locknuts: 9.8 N·m (1 .0 kgf·m, 87 in·lb) 9-36 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Be sure the sealing lip of the rubber boot fits into the groove of the ball joint. Incorrectly Boot Fitting Position [A] Correctly Boot Fitting Position [B] External Shift Mechanism Removal • Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Gear Position Sensor [A] (see Gear Position Sensor Removal in the Electrical System chapter) Shift Lever Bolt [B] Shift Lever [C] * Loosen the alternator cover bolt [D] and then slide the clamp [E], if necessary. • Remove: Shift Shaft Cover Bolts [A] Shift Shaft Cover Screw [B] Shift Shaft Cover [C] • Remove the shift shaft assembly [A]. CRANKSHAFT/TRANSMISSION 9-37 External Shift Mechanism • Remove: Clutch (see Clutch Removal in the Clutch chapter) Gear Positioning Lever Bolt [AJ Spacer [BJ Gear Positioning Lever [CJ Washer and Spring External Shift Mechanism Installation • Install the gear positioning lever [AJ as shown. Spring [BJ Washer [CJ Spacer [DJ Bolt [EJ OHook the spring at gear position ing lever, pushing up [FJ the hook portion, as shown. • Apply a non-permanent locking agent to the gear positioning lever bolt and tighten it. • Tighten: Torque · Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) • Apply grease to the rubbing surface [AJ between the lever [BJ and pawl [CJ, and move them 5 – 10 times up and down to lubricate them. OApply grease more than 3 mm [DJ around the hole of pawl. • Be sure that the collar [EJ is on the shaft. • Be sure that the spring hook portions are as shown. • Install the shift shaft assembly [AJ. • Be sure that the washer [BJ is on the shaft. • Be sure that the dowel pins [CJ are in position. GI 132418$1 0 ® GI 136088$1 C 9-38 CRANKSHAFT/TRANSMISSION External Shift Mechanism • When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing so that its surface is flush with the end of the hole. Special Tool· Bearing Driver Set: 57001-1129 • When the new oil seal [C] is installed in the shift cover, press and insert the new oil seal until it is bottomed. • Apply a water to the outer circumference of the oil seal so that it will go in to place smoothly. Special Tool· Bearing Driver Set: 57001-1129 • Apply engine oil to the needle bearing. • Apply grease to the oil seal lips. • Replace the shift shaft cover gasket with a new one. • Install the shift shaft cover. • Apply a non-permanent locking agent to the shift shaft cover screw [A] and bolts [B]. ODo not apply a non-permanent locking agent to the shift shaft cover bolts [C, D]. • First tighten the cover bolts, then tighten the cover screw. L = 30 mm (1.2 in.) [B, C] L = 40 mm (1.6 in.) [D] Torque • Shift Shaft Cover Bolts [B]: 9.8 N ·m (1.0 kgf·m, 87 in·lb) Shift Shaft Cover Bolts [C, D]: 12 N·m (1.2 kgf·m, 106 in·lb) Shift Shaft Cover Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb) * Be sure to the position the clamp [E] in the original position, if the necessary. • Tighten: Torque -Alternator Cover Bolt [F]: 12 N·m (1.2 kgf·m, 106 in·lb) • Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. * If the shaft is bent, straighten or replace it. * If the serration [B] is 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 shaft. C GI UI IHSl C 0 1 1325 18SI C CRANKSHAFT/TRANSMISSION 9-39 External Shift Mechanism •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: 29 N·m (3.0 kgf·m, 21 ft·lb) •Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring is damaged in any way, replace them. •Visually inspect the shift drum cam [B]. If they are badly worn or if they show any damage, replace it. 9-40 CRANKSHAFT/TRANSMISSION Transmission Transmission Assy Removal • Remove: Shift Shaft Assembly (see External Shift Mechanism Removal) Gear Position Sensor Shaft [AJ • Remove: Shift Drum Holder Bolt [AJ Shift Drum Holder [BJ and Pin • Remove the collar [AJ and the 0-ring [BJ from the output shaft [C]. • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Chain Guide Bolts [AJ Oil Pump Chain Guide [BJ • Remove the transmission case bolts [AJ. * If the transmission assy [BJ is to be disassembled, remove the following. Shift Rod Retaining Plate Bolt [CJ and Plate Gear Positioning Lever [DJ (see External Shift Mechanism Removal) • Pull the transmission assy out of the crankcase. CRANKSHAFT/TRANSMISSION 9-41 Transmission Transmission Assy Installation • Replace the 0-ring [A] on the oil pipe [B] with a new one. • Apply grease to the 0 -ring. • Be sure that the dowel pins [C] are in position. • Install the transmission assy on the crankcase. • Tighten the transmission case bolts following the specified tightening sequence [1 – 11 ]. L = 30 mm (1.2 in.) [1, 5, 7 – 10] L = 26 mm (1.0 in.) [2 – 4] Torque· Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15 ft-lb) * If the gear positioning lever [A] was removed, install it (see External Shift Mechanism Installation). * If the shift rod plate [B] was removed, install it. OApply a non-permanent locking agent to the shift rod retaining plate bolt [C], and tighten it. • Tighten: Torque • Shift Rod Retaining Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Set the gear position ing lever to the neutral position [D]. • Check that the drive and output shaft turn freely. • Apply a non-permanent locking agent to the oil pump chain guide bolt, L = 12 mm (0.47 in.) [E]. • Install the oil pump chain guide [F]. • Tighten: Torque· Oil Pump Chain Guide Bolt, L = 12 mm (0.47 in.): 12 N·m (1.2 kgf·m, 106 in·lb) • Install: Pin [A] Oil Pump Chain Guide Bolt, L = 11 mm (0.43 in.) [G]: 12 N·m (1.2 kgf·m, 106 in·lb) Shift Drum Holder [B] • Apply a non-permanent locking agent to the shift drum holder bolt [C] and tighten it. • Tighten: Torque • Shift Drum Holder Bolt: 12 N ·m (1.2 kgf·m, 106 in·lb) • Fit the tab [D] to the slot of the gear position sensor shaft [E]. 9-42 CRANKSHAFT/TRANSMISSION Transmission • Apply grease to the new 0-ring [AJ, and install its position on the output shaft. • Apply grease to the oil seal lips. • Install the collar [BJ. • When the new oil seal [CJ is installed, press in it onto the oil seal so that the surface of the oil seal is flush with the surface [DJ of the crankcase. OUsing a high flash-point solvent, clean the outer circumference [EJ of the oil seal. Transmission Assy Disassembly • Remove the transmission assy (see Transmission Assy Removal). • Remove the following from the transmission case [AJ. Shift Rods [BJ Shift Forks [CJ Drive Shaft [DJ Output Shaft [EJ • Remove: Shift Drum Cam Holder Bolt [AJ Shift Drum Cam [BJ and Pin Shift Drum [CJ Transmission Assy Assembly • When the new ball bearing [AJ and new race [BJ are installed in the transmission case [CJ, press and insert them until they are bottomed. Special Tool – Bearing Driver Set: 57001-1129 NOTE Olnsta/1 the new ball bearing and new race so that the stepped side [DJ faces inside of the transmission case. • When the ball bearing [EJ for shift drum is installed in the transmission case, insert the ball bearing until it is bottomed. A B D G 1133 20 8S 2 C Gl 133 218SI C CRANKSHAFT/TRANSMISSION 9-43 Transmission • Install the shift drum bearing holder [A]. • Apply a non-permanent locking agent to the threads of the shift drum bearing holder screws [B], and tighten them. Torque – Shift Drum Bearing Holder Screws: 4.9 N·m (0.50 kgf·m, 43 in·lb) • Install the drive shaft bearing holder [A]. • Apply a non-permanent locking agent to the threads of the drive shaft bearing holder screw [B] and tighten it. Torque – Drive Shaft Bearing Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb) GI 133228$1 0 GI 133388$1 0 9-44 CRANKSHAFT/TRANSMISSION Transmission • Apply engine oil to the shift drum groove. • Install the following on the transmission case [AJ. Shift Drum [BJ Pin [C] Shift Drum Cam [DJ OAlign the pin with the hole on the shift drum cam. • Apply a non-permanent locking agent to the shift drum cam holder bolt [EJ and tighten it. Torque -Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the following as a set. Drive Shaft [F] Output Shaft [GJ • Install the shift forks as shown. OPosition the one [HJ with shortest ears on the drive shaft and place the pin in the center groove in the shift drum. OThe two forks [JJ on the output shaft are identical. • Install the shift rods. OThe rod [K] length of the output shaft side is shorter than the rod [LJ length of the drive shaft side. • Apply molybdenum disulfide oil solution to the transmission gears shown with X marks [MJ. • Be sure that the spacer [NJ is on the output shaft. • Install the transmission assy (see Transmission Assy Installation). Transmission Shaft Removal • Refer to the Transmission Assy Disassembly. Transmission Shaft Installation • Refer to the Transmission Assy Assembly. GI 13457812 C CRANKSHAFT/TRANSMISSION 9-45 Transmission Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Assy Disassembly). • Remove the circlips, disassemble the transmission shafts. Special Tool· Outside Circl ip Pliers: 57001-144 • 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. 0 Set the output shaft in a vertical position holding the 3rd gear [B]. 0 Spin the 5th gear quickly [C] and pull it off upward. Transmission Shaft Assembly • Apply engine oil to the bushings, needle bearings and shafts. • Install the gear bushings [A] on the shaft with their holes [B] aligned. • Replace any circlips removed with new ones. • Install the circlips [A] so that the opening [B] is aligned with a spline groove [C]. • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place. • Install the 3rd/4th gear onto the drive shaft with their oil holes aligned. • Install the 6th gear bushing onto the drive shaft with their oil holes aligned. • The output shaft gears can be recognized by size: the gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place. • Install the 5th and 6th gears onto the output shaft with their oil holes aligned. • Install the 3rd/4th gear bushings onto the output shaft with their oil holes aligned. Gl130408S I C Gl130102S I C 9-46 CRANKSHAFT/TRANSMISSION Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning oil hole as shown. 5th Gear [A] Output Shaft [B] Steel Balls [C] Oil Hole [D] NOTICE Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction. OAfter assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear doesn’t come out of the output shaft when moving it up and down by hand. • Check that each gear spins or slides freely on the transmission shafts without binding after assembly. Gl 134478SI C CRANKSHAFT/TRANSMISSION 9-47 Transmission 1 4 ©-Q ©–(g ®-0 ©–Q@@ @{)@-0@-0 @—{Q) @-{) 1. Circlip 2. Needle Bearing 3. Thrust Washer, ¢30 mm (1.18 in.) 4. 2nd Gear 5. Bushing 6. 6th (Top) Gear 7. Toothed Washer, ¢34 mm (1.34 in.) 8. Circlip 9. 4th Gear 10. 3rd Gear 11. 5th Gear 12. Bushing 13. 1stGear 14. Drive Shaft 15. Output Shaft 16. Spacer, ¢39 mm (1.54 in.) 17. Washer, ¢40 mm (1.57 in.) 18. Toothed Washer, ¢38 mm (1.50 in.) 19. Circlip, ¢32.2 mm (1.268 in.) 20. Shim, ¢28 mm (1.10 in.) 21. Thrust Washer, ¢25 mm (0.98 in.) 22. Steel Ball 23. Bushing GI 138 238W3 C 9-48 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Refer to the Transmission Assy Disassembly. Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly. Shift Drum Disassembly • Refer to the Transmission Assy Disassembly. Shift Drum Assembly • Refer to the Transmission Assy Assembly. Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] Shift Fork/Gear Groove Wear Inspection • Measure the thickness [A] of the shift fork ears, and measure the width [B] of the gear grooves. * If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness Standard: 5.9 – 6.0 mm (0.23 – 0.24 in.) Service Limit: 5.8 mm (0.23 in.) * If the transmission gear groove is worn over the service limit, the gear must be replaced. Transmission Gear Groove Width Standard: 6.05 – 6.15 mm (0.238 – 0.242 in.) Service Limit: 6.3 mm (0.25 in.) Shift Fork Guide Pin/Drum Groove Wear Inspection • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. * If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift Fork Guide Pin Diameter Standard: 6.9 – 7.0 mm (0.27 – 0.28 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 – 7.20 mm (0.278 – 0.283 in.) Service Limit: 7.3 mm (0.29 in.) ® Gl 130 145S1 C ® 0 1135 138$1 C Gl 13134BS1 C CRANKSHAFT/TRANSMISSION 9-49 Transmission Gear Dog and Gear Dog Hole Damage Inspection • Visually inspect the gear dogs [A] and gear dog holes [BJ. * Replace any damaged gears or gears with excessively worn dogs or dog holes. Gl13 13S8S1 C 9-50 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings. NOTE Oln the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out. NOTICE Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil. • Using a press and the bearing driver set [A], install the new ball bearing until it stops at the bottom of its housing. OThe 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. • Check the ball bearings. 0 Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. OSpin [A] the bearing by hand to check its condition. * If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it. • Check the needle bearings. OThe 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 • Inspect the oil seals. * Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged. 0 I 14080SSI C Gl 140008S1 C 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 10-7 Rear Wheel Installation. 10-8 Wheel Inspection 10-11 Axle Inspection 10-11 Balance Inspection 10-12 Balance Adjustment 10-12 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 v· 1ew ~,A) ®@ ~~ ~~ ~ 7 ~!A~~ ___ o~ WHEELS/TIRES 10-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Axle Clamp Bolt 20 2.0 15 2 Front Axle 108 11.0 79.7 3 Rear Axle Nut 108 11.0 79.7 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: Front TIR 0.5 mm (0.02 in.) or less TIR 2.0 mm (0.08 in.) Rear TIR 0.5 mm (0.02 in.) or less TIR 2.0 mm (0.08 in.) Radial: Front TIR 0.8 mm (0.03 in.) or less TIR 2.0 mm (0.08 in.) Rear TIR 0.8 mm (0.03 in.) or less TIR 2.0 mm (0.08 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 0.03 mm (0.001 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less – – – Balance Weights 10 g (0.35 oz.), 20 g (0.71 oz.), 30 g (1.06 oz.) – – – Rim Size: Front J17M/C × MT3.50 – – – Rear J17M/C × MT4.50 – – – Tires Air Pressure (when cold): Front 225 kPa (2.25 kgf/cm², 32 psi) – – – Rear 250 kPa (2.50 kgf/cm², 36 psi) – – – Tread Depth: Front 4 mm (0.16 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 DUNLOP – – – Type SPORTMAX , D214F W – – – Size 120/70ZR17 MC (58W) – – – Rear: Make DUNLOP – – – Type SPORTMAX , D214 W – – – Size 160/60ZR17 MC (69W) – – – 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. Special Tools Bearing Driver Set: 57001-1129 Bearing Remover Head, ¢20 x ¢ 22: 57001-1293 ST571 129ST C ST571293ST C WHEELS/TIRES 10-5 Bearing Remover Shaft, ¢ 13: 57001-1377 ST571377ST C 10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • For the ABS equipped models, remove the bolt [AJ and front wheel rotation sensor [BJ, and clear the front wheel rotation sensor lead from the clamp [C]. • Remove: Front Caliper Mounting Bolts [DJ (Both Sides) Front Calipers [EJ (Both Sides) • Loosen: Front Axle Clamp Bolt [AJ Front Axle [BJ • Raise the front wheel off the ground with a suitable stand. • 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 • Apply high-temperature grease to the grease seal lips. • Fit the collar [AJ on the both sides of the hub. OThe collars are identical. • Apply a thin coat of grease [AJ to the front axle [BJ for rust prevention. About 10 mm (0.4 in.) [CJ About 30 mm (1.2 in.) [DJ NOTE ODo not apply grease to the threads of the axle. ®© GJ0433HS1 C WHEELS/TIRES 10-7 Wheels (Rims) •Check the wheel rotation mark on the front wheel and install it. NOTE ○The wheel rotation direction [A] is shown by an arrow [B] on the wheel spoke. •Insert the front axle from the right side. •Wipe off excess grease if necessary. •Install the front axle temporarily and remove the jack. •Tighten: Torque – Front Axle: 108 N·m (11.0 kgf·m, 79.7 ft·lb) •Before tightening the front axle clamp bolt [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 ○Put a block in front of the front wheel to stop moving. •Tighten: Torque – Front Axle Clamp Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb) •Install the removed parts (see appropriate chapters). •Check the front brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc. Rear Wheel Removal •Raise the rear wheel off the ground with the stand [A]. 10-8 WHEELS/TIRES Wheels (Rims) • Remove the bolt [A] and rear wheel rotation sensor [B], and clear the rear wheel rotation sensor lead from clamp [C]. • Remove the rear caliper [D] together with the brake hose (see Rear Caliper Removal in the Brake chapter). • Remove the cap [A]. • Remove: Cotter Pin [A] Rear Axle Nut [B] Washer [C] Wheel Alignment Indicator [D] (Both Sides) Rear Axle [E] (from Right Side) • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove it. NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Rear Wheel Installation *If the chain adjuster assembly is removed, install the next procedure. • Install the chain adjusters [A] to the swingarm as shown. Left Side [B] Right Side [C] Wheels (Rims) • Install the caps [A] so that the stepped side [B] faces inside of the swingarm. Left Side [C] Right Side [D] • Apply high-temperature grease to the grease seal lips. • Fit the collars on the both sides of the hub. Left Side Collar [A] Right Side Collar [B] (with Flange) • Install the caliper bracket [A] onto the stopper [B] of the swingarm. • Engage the drive chain with the rear sprocket. • Apply a thin coat of grease [A] to the rear axle [B] for rust prevention. About 10 mm (0.4 in.) [C] About 70 mm (2.8 in.) [D] NOTE ODo not apply grease to the threads of the axle. • Insert the axle from the right side of the wheel. • Wipe off any excess grease if necessary. • Adjust the drive chain slack before tightening the axle nut (see Drive Chain Slack Inspection in the Periodic Maintenance chapter). • Tighten: Torque – Rear Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb) WHEELS/TIRES 10-9 ® © GJ 043428S I C 10-10 WHEELS/TIRES Wheels (Rims) • Insert a new cotter pin [A]. NOTE OWhen inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [BJ up to next alignment. Oft should be within 30 degrees. OLoosen once and tighten again when the slot goes past the nearest hole. • Bend the cotter pin ends [A] along the nut [B]. AWARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. • Install the cap. • Install the rear caliper (see Rear Caliper Installation in the Brakes chapter). • For the ABS equipped models, install the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Installation in the Brakes chapter). • Check the rear brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). AWARNING 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. ® A GJ 0 42498S I C Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground with a suitable stand. • Spin the wheel lightly, and check for roughness or binding. * If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation). • Inspect the wheel for small cracks, dents, bending, or warp. * If there is any damage to the wheel, replace the wheel. • Remove the wheel, and support it with the tire by the axle. • Measure the rim runout, axial [A] and radial [B], with a dial gauge. * If rim runout exceeds the service limit, check the hub 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 2.0 mm (0.08 in.) Radial TIR 2.0 mm (0.08 in.) AWARNING Damaged wheel parts may fail and cause an accident resulting in serious injury or death. Never attempt to repair a damaged wheel part. If the wheel part is damaged, it must be replaced with a new one. Axle Inspection • Remove the front and rear axles (see Front/Rear Wheel Removal). • Visually inspect the front and rear axle for damages. * If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and lowest dial readings is the amount of runout. •If axle runout exceeds the service limit, replace the axle. Axle Runout/100 mm (3.94 in.) Standard: TIR 0.03 mm (0.001 in.) or less Service Limit: TIR 0.2 mm (0.008 in.) WHEELS/TIRES 10-11 GJ 041 308$1 0 GJ 042SS8$1 0 10-12 WHEELS/TIRES Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see FronURear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [AJ the wheel at the top when the wheel stops. ORepeat 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 • If the wheel always stops in one position, provisionally attach a balance weight [AJ on the rim at the marking using adhesive tape. • Rotate the wheel 1/4 turn [BJ, and see whether or not the wheel stops in this position. If it does, the correct balance weight is being used. * If the wheel rotates and the weight goes up, replace the weight with the next heavier size. If the wheel rotates and the weight goes down, replace the weight with the next lighter size. Repeat these steps until the wheel remains at rest after being rotated 1/4 turn. • Rotate the wheel another 1/4 turn and then another 1/4 turn to see if the wheel is correctly balanced. • Repeat the entire procedure as many times as necessary to achieve correct wheel balance. • Permanently install the balance weight. Balance Weight Removal • Insert a flat tip screwdrivers [AJ [BJ between the rib [CJ and weight [DJ as shown. • Pry the balance weight with two screwdrivers and remove the balance weight. • Discard the used balance weight. NOTICE Do not tap the screwdrivers. The rim could be damaged. Balance Weight Installation • Check if the weight portion has any play on the blade [AJ and clip [BJ. * If it does, discard it. AWARNING Unbalanced wheels can create an unsafe riding condit ion. 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. GJ044() 4BS 1 C GJ040l3BS 1 C GJ040 11 8BS 1 C Wheels (Rims) Balance Weight Part Number Weight 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0009 30 g (1.06 oz.) NOTE OBalance 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. ODo not use four or more balance weight (more than 90 grams, 3.2 oz.). If the wheel requires an excess balance weight, disassemble the wheel to find the cause. • Slip the balance weight [A] onto the rib [B] by pushing or lightly hammering [C] the clip [D]. Left Side [E] Right Side [F] • Be sure to install the balance weight. OCheck that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. Left Side [E] Right Side [F] WHEELS/TIRES 10-13 ® – –® A D GJ 040148S I C ® — –® B GJ 040898S I C 10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Maintenance chapter. Tire Inspection • Refer to the Wheelm re Damage Inspection in the Periodic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) • To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position. Chalk Mark or Yellow Mark [A] Valve Stem [BJ Align [C] • Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant. This helps the tire beads slip off the rim flanges. NOTICE Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire. • Remove the tire from the rim using a suitable commercially available tire changer. NOTE o The tires cannot be removed with hand tools because they fit the rims too tightly. Tire Installation AWARNING 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. • Inspect the rim and tire, and replace them if necessary. • Clean the sealing surfaces of the rim and tire, and smooth the sealing surfaces of the rim with a fine emery cloth if necessary. • Remove the air valve and discard it. NOTICE Replace the air valve whenever the tire is replaced. Do not reuse the air valve. GJ 050’40 8 S1 C Tires • Install a new valve in the rim. ORemove 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. OThe air valve is as shown. Valve Cap [A] Valve Core [B] Stem Seal [C] Valve Stem [D] Valve Seat [E] Valve Opened [F] • Check the tire rotation mark on the front and rear tires and install them on the rim accordingly. Tire Rotation Mark [A] Wheel Rotation Mark [B] (Front Wheel) Rotating Direction [C] • 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). • Install the tire bead over the rim flange using a suitable commercially available tire changer. • Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire. • Center the rim in the tire beads, and inflate the tire with compressed air until the tire beads seat in the sealing surfaces. AWARNING Overinflating a tire can cause it to explode, causing serious injury or death. Be sure to install the valve core whenever inflating the tire, and do not inflate the tire to more than 400 kPa (4.0 kgf/cm2 , 57 psi). WHEELS/TIRES 10-15 GJOS0418S1 0 GJ 050307$ I C GJ 044068S I C GJ 050H8S1 C 10-16 WHEELS/TIRES Tires • Check to see that the rim lines [A] on both sides of the tire sidewalls are parallel with the rim flanges. * If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. • Lubricate the rim flanges and tire beads. • Install the valve core and inflate the tire again. • After the tire beads seat in the rim flanges, check for air leakage. Olnflate the tire slightly above standard inflation. OUse a soap and water solution or submerge the tire, and check for bubbles that would indicate leakage. • Adjust the air pressure to the specified pressure (see Air Pressure Inspection in the Periodic Maintenance chapter). • Install the air valve cap. • Adjust the wheel balance (see Balance Adjustment). Tire Repair Currently two types of repair for tubeless tires have come into wide use. One type is called a temporary (external) repair which can be carried out without removing the tire from the rim, and the other type is called permanent (internal) repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones. Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make. Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained. GJO:i0 4 2BS 1 C Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars [A] Coupling [B] (Out of rear hub) Grease Seals [C] • 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 x </>22 [B]: 57001-1293 Bearing Remover Shaft, </>13 [C]: 57001 -1377 Hub Bearing Installation • Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. • Replace the bearings with new ones. • Install the bearings by using the bearing driver set which does not contact the bearing inner race. NOTE Olnsta/1 the bearings so that the marked side faces out. WHEELS/TIRES 10-17 GJ 0& 1 siesz c GJ060’38$1 0 10-18 WHEELS/TIRES Hub Bearing • Press in each right bearing [A] until it is bottomed. Special Tool· Bearing Driver Set [BJ: 57001 -1129 • Install the collar [C]. • Press in each left bearing until it is bottomed. Special Tool· Bearing Driver Set: 57001-1129 • Confirm that the axle can be inserted smoothly. • Confirm that the each bearing inner race can be turned smoothly. Then visually inspect that the inner race of the opposite side turns. * If they do not turn smoothly, remove the bearings and sleeve and visually inspect the wheel and sleeve. • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole. Special Tool· Bearing Driver Set [CJ: 57001 -1129 • Apply high-temperature grease to the grease seal lips. • Install 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 ODo not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with new ones. • Turn each bearing in the hub back and forth [A] while checking for plays, roughness, or binding. * If bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. * If the seal is torn or is leaking, replace the bearing. Hub Bearing Lubrication NOTE 0 Since the hub bearings are packed with grease and sealed, lubrication is not required. GJ OISOHBSI C B GJ0&0()2BS 1 C 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 Drive Chain Installation . 11-8 Sprocket, Coupling . 11-11 Engine Sprocket Removal 11-11 Engine Sprocket Installation . 11-11 Rear Sprocket Removal 11-12 Rear Sprocket Installation. 11-12 Coupling Installation 11-13 Coupling Bearing Removal . 11-13 Coupling Bearing Installation 11-14 Coupling Bearing Inspection . 11-14 Coupling Bearing Lubrication 11-14 Coupling Damper Inspection. 11-15 Sprocket Wear Inspection. 11-15 Rear Sprocket Warp Inspection 11-15 11-2 FINAL DRIVE Exploded View ~~J l @~ ~’~ GK02 312BW5 C FINAL DRIVE 11-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Sprocket Cover Bolt, L = 30 mm (1.2 in.) 9.8 1.0 87 in·lb 2 Engine Sprocket Cover Bolt, L = 20 mm (0.8 in.) 9.8 1.0 87 in·lb 3 Engine Sprocket Nut 165 16.8 122 MO 4 Rear Sprocket Nuts 59 6.0 44 R, S G: Apply grease. 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  30 mm (0.8  1.2 in.) – – – Drive Chain Wear (20-link Length) 317.5  318.2 mm (12.50  12.53 in.) 319 mm (12.6 in.) Standard Chain: Make DAIDO – – – Type DID520VE – – – Link 114 links – – – Link Pin Outside Diameter (When drive chain replacing) 5.4  5.8 mm (0.21  0.23 in.) – – – Link Pin Length (When drive chain replacing) 19.6 mm (0.77 in.) or less – – – Sprockets Rear Sprocket Warp TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm (0.020 in.) Special Tools Inside Circlip Pliers: 57001-143 ST570143ST C Bearing Driver Set: 57001-1129 FINAL DRIVE 11-5 ST571 129ST C 11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection •Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment •Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter. Drive Chain Wear Inspection •Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter. Drive Chain Lubrication •Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter. Drive Chain Removal •Remove: Engine Sprocket (see Engine Sprocket Removal) Shift Pedal (see Shift Pedal Removal in the Crankshaft/ Transmission chapter) Mud Guard and Drive chain Cover (see Mud Guard Removal in the Frame chapter) Frame Covers (see Frame Cover Removal in the Frame chapter) •Loosen: Right Swingarm Bracket Bolt [A] •Loosen: Left Swingarm Bracket Bolts [A] •Remove: Swingarm Pivot Shaft Nut [B] Left Swingarm Bracket Bolts Left Swingarm Bracket [C] Drive Chain • Disengage the drive chain from the rear sprocket. • Remove the drive chain [A] from the output shaft [B]. Drive Chain Installation • Install the drive chain, and engage the rear sprocket. • Install: Left Swingarm Bracket [A] • Tighten the bolts and nut following the tightening sequence [1 – 4]. Torque · Swingarm Pivot Shaft Nut (1): 108 N·m (11.0 kgf·m, 79.7 ft·lb) Left Swingarm Bracket Bolts (2, 3): 25 N·m (2.5 kgf·m, 18 ft·lb) Right Swingarm Bracket Bolt (4): 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the removed parts (see appropriate chapters). • Adjust the chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). Drive Chain Replacement NOTE 0 Since the drive chain is installed through the swingarm, the chain cannot be removed other than by cutting it. Prepare the new link pin, link plate, grease seals, and tools for rejoining the chain. • Using a suitable tool, replace the drive chain. Recommended Tool • DID Chain Joint “ZJ” Make DAIDO KOGYO NOTICE Read the Tool Manual before replacing the chain. Body [A] Pin Holder [B] Position ing Pin [C] “U” Holder [D] Plate Holder [E] Cutting and Riveting Pin [F] Part for Riveting [G] Part for Cutting [H] FINAL DRIVE 11-7 B 11-8 FINAL DRIVE Drive Chain • Grind [A] the heads of the link pin to make it flat. • Set the cutting and riveting pin [B] in the pin holder [C] as shown. • Set the “U” holder and body, align the positioning pin [A] with the “A” mark [B]. • Tighten the pin holder by hand until the cutting and riveting pin touches the link pin. • Be sure that the cutting and riveting pin hits center of the link pin. • Hold the body with a wrench [A]. • Turn the pin holder clockwise [B] with another wrench, and remove the link pin. • Do the same procedure for removal of the other link pin. Drive Chain Installation • Engage the new drive chain to the old drive chain, and change the position of the chains by pulling the old chain. • Remove the old drive chain from the new drive chain. • Replace the link pin [A], link plate and grease seals [B] [C] with new ones. • Apply grease to the link pin and grease seals. • Install the grease seals on the link pin and insert it in the ends of the drive chain. • Install the link plate so that the mark [D] faces out. • Set the cutting and riveting pin [A] in the pin holder [B] as shown. Li u ®ij Li Li GK0 40908S1 C FINAL DRIVE 11-9 Drive Chain •Set the plate holder [A] on the cutting and riveting pin [B] as shown. •Set the “U” holder and body, align the positioning pin [A] with the “A” mark [B]. •Tighten the pin holder by hand until the cutting and riveting pin touches the link pin. •Hold the body with a wrench [A]. •Turn the pin holder clockwise [B] with another wrench and press in the link plate on the link pin. •Remove the “U” holder and body. •Remove the plate holder. •Set the “U” holder and body, align the positioning pin [A] with the “B” mark [B]. •Tighten the pin holder by hand until the cutting and riveting pin touches the link pin. •Hold the body with a wrench [A]. •Turn the pin holder clockwise [B] with another wrench until the cutting and riveting pin touches the link plate. •Do the same procedure for installation of the other link pin. 11-10 FINAL DRIVE Drive Chain • After riveting, check the ends of the riveted pins for cracks. • Measure the outside diameter [A] and the length [B] of the link pin. Link Pin Outside Diameter Standard: 5.4 – 5.8 mm (0.21 – 0.23 in.) Link Pin Length Standard: 19.6 mm (0.77 in.) or less * If the reading is not within the specified range, cut and rejoin the chain again. • Check that the rollers move smoothly. • Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). A J—– -14E– ® GK0 41 028SI C FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Removal •Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] •Flatten out the bended washer [A]. •Remove the engine sprocket nut [B] and washer. NOTE ○When loosening the engine sprocket nut, hold the rear brake on. •Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). •Loosen the drive chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). •Remove the drive chain from the rear sprocket toward the right. •Disengage the drive chain [A] from the engine sprocket [B]. •Pull the engine sprocket off the output shaft [C]. Engine Sprocket Installation •Replace the sprocket washer. •Install the engine sprocket so that “OUT SIDE” letters [A] face outward. •Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut. •Tighten: Torque – Engine Sprocket Nut: 165 N·m (16.8 kgf·m, 122 ft·lb) NOTE ○Tighten the engine sprocket nut while applying the rear brake. 11-12 FINAL DRIVE Sprocket, Coupling •After torquing the engine sprocket nut, bend [A] the one side of the washer over the nut. •Adjust the drive chain slack after installing the engine sprocket (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). •Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Install the engine sprocket cover [A]. •Tighten: Torque – Engine Sprocket Cover Bolt, L = 30 mm (1.2 in.) [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Engine Sprocket Cover Bolt, L = 20 mm (0.8 in.) [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Rear Sprocket Removal •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. •Remove: Rear Sprocket Nuts [A] Rear Sprocket [B] Rear Sprocket Installation •Replace the rear sprocket nuts with new ones. •Install the sprocket facing the tooth number marking [A] outward. Sprocket, Coupling • Tighten the rear sprocket nuts following the specified tightening sequence [1 – 8]. Torque • Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) • After tightening, check that the bolt ends protrude from the nuts. • Install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter). Coupling Installation • Apply high-temperature grease to the following. Coupling Grease Seal Lips [A] Coupling Internal Surface [B] • Replace the 0-ring [A] with a new one, and apply grease to it. • Install: 0-ring Collar [B] Coupling [C] Coupling Bearing Removal • Remove: Coupling Grease Seal [A] Collar [B] • Remove the circlip [A]. Special Tool • Inside Circlip Pliers: 57001-143 FINAL DRIVE 11-13 GK0S10J8$1 0 11-14 FINAL DRIVE Sprocket, Coupling • Remove the bearing [A] by tapping from the wheel side. Special Tool· Bearing Driver Set [BJ: 57001-1129 Coupling Bearing Installation • Replace the bearing with a new one. • Press in the bearing [A] until it is bottomed. Special Tool· Bearing Driver Set [BJ: 57001-1129 • Replace the circlip with a new one. Special Tool· Inside Circlip Pliers: 57001-143 • Install the collar. • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. Special Tool· Bearing Driver Set: 57001-1129 • Apply high-temperature grease to the grease seal lip. Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE Oft is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one. • Turn the bearing in the coupling back and forth [A] while checking for plays, roughness or binding. * If the bearing play, roughness or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. * If the seal is torn or is leaking, replace the bearing. Coupling Bearing Lubrication NOTE 0 Since the coupling bearing is packed with grease and sealed, lubrication is not required. Glt0:i039BS 1 C B GK050388S1 C B GJ0&0()2BS 1 C Sprocket, Coupling Coupling Damper Inspection • Remove the rear wheel coupling, and inspect the rubber dampers [AJ. • Replace the damper if it appears damaged or deteriorated. Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. *If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter). Worn Tooth (Engine Sprocket) [AJ Worn Tooth (Rear Sprocket) [BJ Direction of Rotation [CJ NOTE Off a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the chain. Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with the stand so that it will turn freely. • Set a dial gauge [AJ against the rear sprocket [BJ near the teeth as shown, and rotate [CJ 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.) FINAL DRIVE 11-15 .d © GK050118SI C GK050008S I C BRAKES 12-1 12 Brakes Table of Contents Exploded View 12-3 Specifications . 12-10 Special Tools 12-11 Brake Lever, Brake Pedal. 12-12 Brake Lever Position Adjustment 12-12 Brake Pedal Position Inspection . 12-12 Brake Pedal Position Adjustment 12-12 Brake Pedal Removal . 12-12 Brake Pedal Installation 12-13 Calipers 12-14 Front Caliper Removal 12-14 Front Caliper Installation . 12-14 Rear Caliper Removal. 12-14 Rear Caliper Installation 12-15 Front Caliper Disassembly 12-15 Front Caliper Assembly. 12-15 Rear Caliper Disassembly 12-15 Rear Caliper Assembly . 12-16 Caliper Fluid Seal Damage Inspection 12-16 Caliper Dust Boot and Friction Boot Damage Inspection 12-16 Caliper Piston and Cylinder Damage Inspection 12-17 Caliper Holder Shaft/Pin/Collar Inspection 12-17 Brake Pads. 12-18 Front Brake Pad Removal. 12-18 Front Brake Pad Installation 12-18 Rear Brake Pad Removal . 12-19 Rear Brake Pad Installation 12-19 Brake Pad Wear Inspection 12-19 Master Cylinder 12-20 Front Master Cylinder Removal 12-20 Front Master Cylinder Installation . 12-20 Rear Master Cylinder Removal. 12-21 Rear Master Cylinder Installation 12-21 Front Master Cylinder Disassembly 12-22 Rear Master Cylinder Disassembly. 12-22 Master Cylinder Assembly 12-22 Master Cylinder Inspection (Visual Inspection). 12-23 Brake Disc 12-24 Brake Disc Removal . 12-24 Brake Disc Installation 12-24 Brake Disc Wear Inspection 12-24 Brake Disc Warp Inspection 12-25 Brake Fluid . 12-26 Brake Fluid Level Inspection. 12-26 Brake Fluid Change 12-26 Brake Line Bleeding 12-26 Brake Hose. 12-29 Brake Hose Removal/Installation 12-29 Brake Hose and Pipe Inspection. 12-29 Anti-Lock Brake System (Equipped Models) 12-30 12-2 BRAKES Parts Location . 12-30 ABS Servicing Precautions . 12-34 ABS Troubleshooting Outline 12-36 Inquiries to Rider. 12-39 Self-diagnosis Outline . 12-43 Self-diagnosis Procedures 12-43 Service Code Clearing Procedures. 12-44 How to Read Service Codes. 12-47 How to Erase Service Codes 12-47 Yellow ABS Indicator Light (LED) Inspection 12-49 Solenoid Valve Inspection (Service Code 13, 14, 17, 18). 12-49 ABS Solenoid Valve Relay Inspection (Service Code 19) 12-49 Front, Rear Tire Abnormal (Service Code 25) 12-50 ABS Motor Relay Inspection (Service Code 35) . 12-50 Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) 12-51 Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) 12-52 Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44). 12-52 Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 12-53 Power Supply Voltage Abnormal [Low-Voltage] (Service Code 52) 12-53 Power Supply Voltage Abnormal [Over-Voltage] (Service Code 53) 12-54 ABS Solenoid Valve Relay Supply Voltage Inspection [Low-Voltage] (Service Code 54). 12-54 ECU Inspection (Service Code 55) . 12-54 ABS Hydraulic Unit Removal 12-55 ABS Hydraulic Unit Installation . 12-57 ABS Hydraulic Unit Inspection 12-58 Front Wheel Rotation Sensor Removal 12-58 Front Wheel Rotation Sensor Installation . 12-59 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 8L02665BW5 C BRAKES 12-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Hose Banjo Bolts 25 2.5 18 2 Front Brake Fluid Reservoir Cap Screws 1.5 0.15 13 in·lb 3 Brake Lever Pivot Bolt 1.0 0.10 8.9 in·lb Si 4 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb 5 Front Master Cylinder Clamp Bolts 11 1.1 97 in·lb S 6 Front Brake Light Switch Screw 1.2 0.12 11 in·lb 7 Front Caliper Mounting Bolts 25 2.5 18 8 Front Caliper Holder Shaft 22 2.2 16 L, Si 9 Bleed Valve 7.8 0.80 69 in·lb 10 Front Brake Pad Pin 17 1.7 13 11 Front Brake Disc Mounting Bolts 27 2.8 20 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 v· 1ew 8L02666BW5 C BRAKES 12-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Hose Banjo Bolts 25 2.5 18 2 Rear Caliper Holder Pin Bolt 27 2.8 20 Si 3 Bleed Valve 7.8 0.80 69 in·lb 4 Rear Brake Pad Pin 17 1.7 13 5 Rear Caliper Holder Bolt 22 2.2 16 6 Rear Master Cylinder Mounting Bolts 25 2.5 18 7 Rear Master Cylinder Push Rod Locknut 17 1.7 13 8 Rear Wheel Rotation Sensor Bolt 22 2.2 16 9 Brake Pedal Bolt 8.8 0.90 78 in·lb 10 Rear Brake Disc Mounting Bolts 27 2.8 20 L, S 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 Exploded View ABS Equipped Models 8L02668BW5 C BRAKES 12-9 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Hose Banjo Bolts 25 2.5 18 2 Brake Pipe Joint Nuts 18 1.8 13 3 Front Wheel Rotation Sensor Rotor Bolts 4.2 0.43 37 in·lb 4 Front Wheel Rotation Sensor Bolt 8.0 0.82 71 in·lb L 5. ABS Hydraulic Unit L: Apply a non-permanent locking agent. R: Replacement Parts NOTE ○When disassembling the brake hose and pipe, disassemble them by the unit as shown in the exploded view. 12-10 BRAKES Specifications Item Standard Service Limit Brake Fluid Grade: Front DOT4 – – – Rear DOT4 – – – Brake Lever Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Position 52 mm (2.1 in.) – – – Brake Pads Lining Thickness: Front 4 mm (0.16 in.) 1 mm (0.04 in.) Rear 5 mm (0.20 in.) 1 mm (0.04 in.) Brake Discs Thickness: Front 4.8  5.2 mm (0.19  0.20 in.) 4.5 mm (0.18 in.) Rear 4.8  5.2 mm (0.19  0.20 in.) 4.5 mm (0.18 in.) Runout TIR 0.15 mm (0.0059 in.) or less TIR 0.3 mm (0.013 in.) ABS (Equipped Models) ABS Hydraulic Unit: Make BOSCH – – – Wheel Rotation Sensor Air Gap: Front 0.4  1.6 mm (0.02  0.06 in.) – – – Rear 0.4  1.6 mm (0.02  0.06 in.) – – – Special Tools Jack: 57001-1238 ST571238ST C Needle Adapter Set: 57001-1457 BRAKES 12-11 ST5 71 457ST C 12-12 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. •Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever. ○The distance from the grip to the lever is minimum at number 5 and maximum at number 1. Brake Pedal Position Inspection •Check that the brake pedal [A] is in the correct position. Footpeg [B] Pedal Position Standard: 52 mm (2.1 in.) [C] If it is incorrect, adjust the brake pedal position. Brake Pedal Position Adjustment NOTE ○Usually it is not necessary to adjust the pedal position, but always adjust it when the push rod locknut has been loosened. •Remove: Rear Master Cylinder Mounting Bolts [A] Guard [B] Bracket and Damper [C] •Temporary tighten the rear master cylindermounting bolts [A]. •Loosen the locknut [B] and turn the push rod with the hex head [C] to achieve the correct pedal position. If the length [D] shown is 70 ±1 mm (2.76 ±0.04 in.), the pedal position will be within the standard range. •Tighten: Torque – Rear Master Cylinder Push Rod Locknut: 17 N·m (1.7 kgf·m, 13 ft·lb) •Check the brake light switch operation (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter). Brake Pedal Removal •Remove: Muffler (see Muffler Removal in the Engine Top End chapter) Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] and Washers Brake Pedal [F] BRAKES 12-13 Brake Lever, Brake Pedal Brake Pedal Installation •Set the return spring [A] to the brake pedal [B] as shown. •Install: Brake Pedal [A] Washers [B] •Apply a non-permanent locking agent to the threads of the brake pedal bolt [C], and tighten it. Torque – Brake Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) •Hook the return spring [D] on the frame bracket hook. •Hook the rear brake light switch spring [E] between the switch and brake pedal as shown. •Replace the cotter pin [A] with a new one. •Insert the cotter pin into the joint pin [B] and bend the pin ends [C]. •Check the brake pedal position (see Brake Pedal Position Inspection). 12-14 BRAKES Calipers Front Caliper Removal •Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. •Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. •Unscrew the banjo bolt and disconnect the brake hoses [D] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). NOTICE Immediately wash away any brake fluid that spills. Front Caliper Installation •Installation is the reverse of removal. •Replace the washers on each side of hose fitting with new ones. •Connect the brake hoses [A] to the caliper [B] with the new washers [C] and banjo bolt [D]. ○Position the brake hose fitting to the stopper on the caliper. ○Fit the brake hose fittings [E] into the groove on the caliper. •Install the front caliper mounting bolts [F]. •Tighten: Torque – Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •Bleed the brake line (see Brake Line Bleeding). •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 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 Caliper Removal •Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. •Remove the rear caliper holder bolt [B], and detach the caliper [C] from the disc. •Remove the banjo bolt and disconnect the brake hose [D] from the caliper. NOTICE Immediately wash away any brake fluid that spills. BRAKES 12-15 Calipers Rear Caliper Installation •Installation is the reverse of removal. •Replace the washers on each side of hose fitting with new ones. •Connect the brake hose [A] to the caliper [B] with the new washers [C] and banjo bolt [D]. ○Position the brake hose fitting to the stopper on the caliper. ○Fit the brake hose fitting [E] into the groove on the caliper. •Apply a silicone grease to the sliding surface of the caliper holder pin bolt [F]. •Insert the caliper holder pin bolt into the boot [G] of the caliper holder. ○Fit the boot into the groove [H] on the caliper holder pin bolt. •Install the brake pad [A] to the caliper. ○Fit the tabs [B] of the brake pads on the step [C] of the caliper holder. •Install the rear caliper holder bolt [A]. •Tighten: Torque – Brake Hose Banjo Bolt [B]: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear Caliper Holder Bolt: 22 N·m (2.2 kgf·m, 16 ft·lb) •Bleed the brake line (see Brake Line Bleeding). •Check the brake for good braking power, no brake drag, and no fluid leakage. 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. Front Caliper Disassembly •Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. Front Caliper Assembly •Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Caliper Disassembly •Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter. 12-16 BRAKES Calipers Rear Caliper Assembly • 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 flu id to increase. • Replace the fluid seal if it exhibits any of the conditions listed below. OBrake fluid leakage around the pad. 0 Brakes overheat. OConsiderable difference in inner and outer pad wear. 0 Seal and piston are stuck together. *If the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed. Front Caliper [C] Rear Caliper [D] Caliper Dust Boot and Friction Boot Damage Inspection • Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged. * If they show any damage, replace it. Front Caliper [C] Rear Caliper [D] © GLOS3l 9BS1 C ® OLOS34SBSI C © GLOS3808S 1 C OLOS381BSI C Calipers Caliper Piston and Cylinder Damage Inspection • Visually inspect the pistons [A] and cylinder surfaces [B]. * Replace the caliper if the cylinder and piston are badly scores or rusty. Front Caliper [C] Rear Caliper [D] Caliper Holder Shaft/Pin/Collar Inspection The caliper body must slide smoothly on the front caliper holder shafts [A] and pin [B], rear caliper holder pin bolt [C] and collar [D]. If the caliper body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature. • Check to see that the front caliper holder shafts, rear caliper holder pin bolt and collar 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 front caliper holder shaft, rear caliper holder pin bolt and collar are damaged, replace them. OApply a non-permanent locking agent to the threads of the front caliper holder shaft. Torque – Front Caliper Holder Shaft: 22 N·m (2.2 kgf·m, 16 ft·lb) Front Caliper [E] Rear Caliper [F] BRAKES 12-17 GL053828S I C ® GL053’98S I C ® GL053838S I C 12-18 BRAKES Brake Pads Front Brake Pad Removal •Loosen the pad pin [A]. •Remove: Front Caliper Mounting Bolts [B] •Remove the front caliper [C] with the hose connected. •Pull out the pad pin [A] and remove the brake pads [B] from the caliper [C]. Front Brake Pad Installation •Check that the pad spring [A] is in place on the caliper [B]. •Push the caliper pistons [C] in by hand as far as they will go. •Install the brake pads [A] to the caliper. ○Fit the tabs [B] of the brake pads on the step [C] of the caliper holder. •Apply a silicone grease to the O-ring [D] on the pad pin. •Insert the pad pin [E] through the brake pads and tighten the pad pin temporarily. •Install the front caliper (see Caliper Installation). •Tighten: Torque – Front Brake Pad Pin: 17 N·m (1.7 kgf·m, 13 ft·lb) WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc. BRAKES 12-19 Brake Pads Rear Brake Pad Removal •Remove the caliper holder bolt [A]. •Loosen the pad pin [B]. •Turn the rear caliper [C] forward. •Remove the pad pin [D]. •Remove the brake pads [E] from the rear caliper. Rear Brake Pad Installation •Check that the pad spring [A] is in place on the caliper [B]. •Push the caliper piston [C] in by hand as far as they will go. •Install the brake pads [A] to the caliper. ○Fit the tabs [B] of the brake pads on the step [C] of the caliper holder. •Lower the rear caliper over the brake pads. •Apply a silicone grease to the O-ring [D] on the pad pin. •Insert the pad pin [E] through the brake pads and tighten the pad pin temporarily. •Tighten: Torque – Rear Caliper Holder Bolt [A]: 22 N·m (2.2 kgf·m, 16 ft·lb) Rear Brake Pad Pin [B]: 17 N·m (1.7 kgf·m, 13 ft·lb) •Secure the brake hose to the clamp on the swingarm. 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 •Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter. 12-20 BRAKES Master Cylinder Front Master Cylinder Removal •Loosen the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). •Disconnect the front brake light switch connectors [C]. •Remove the clamp bolts [D] and front master cylinder clamp [E] to remove the master cylinder assembly. NOTICE Immediately wash away any brake fluid that spills. Front Master Cylinder Installation •Install the front master cylinder so that the punch mark [A] of the handlebar is aligned with the mating surface [B] of the master cylinder and clamp. •Install the master cylinder clamp [C]. •Tighten the upper clamp bolt [D] first, and then the lower clamp bolt [E]. ○There will be a gap at the lower part of the clamp after tightening. Torque – Front Master Cylinder Clamp Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) •Connect the front brake light switch connectors. •Replace the washers that are on each side of the hose fitting with new ones. •Install the brake hose. ○Touch the brake hose to the stopper of the front master cylinder. •Tighten: Torque – Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •Bleed the brake line (see Brake Line Bleeding). •Check the brake for good braking power, no brake drag, and no fluid leakage. BRAKES 12-21 Master Cylinder Rear Master Cylinder Removal •Remove the muffler (see Muffler Removal in the Engine Top End chapter). •Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. •Remove: Cotter Pin [A] Joint Pin [B] •Remove: Rear Master Cylinder Mounting Bolts [A] Guard [B] Bracket and Damper [C] •Slide the reservoir hose lower end clamp [A]. •Pull off the reservoir hose lower end [B], and drain the brake fluid into a container. •Remove the brake hose banjo bolt [C] to disconnect the brake hose [D] from the rear master cylinder [E]. Rear Master Cylinder Installation •Installation is the reverse of removal. •Replace the washers on each side of the hose fitting with new ones. •Connect the brake hose [A] to the rear master cylinder [B] with the new washers [C] and banjo bolt [D]. ○Fit the brake hose fitting [E] into the groove on the rear master cylinder. •Run the brake hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). 12-22 BRAKES Master Cylinder •Install: Guard [A], Bracket and Damper [B] Rear Master Cylinder Mounting Bolts [C] •Tighten: Torque – Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •Replace the cotter pin [A] with a new one. •Install the joint pin [B]. •Insert the cotter pin into the joint pin and bend the pin ends [C]. •Tighten the brake hose banjo bolt [A]. Torque – Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •Install the muffler (see Muffler Installation in the Engine Top End chapter). Front Master Cylinder Disassembly •Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Rear Master Cylinder Disassembly •Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Assembly •Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter). • Check that there are no scratches, rust or pitting on the inner wall [AJ of each master cylinder and on the outside of each piston [BJ. * If a master cylinder or piston shows any damage, replace them. • Inspect the primary cup [CJ and secondary cup [DJ. • If a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups. * If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups. • Check the dust covers [EJ for damage. * If they are damaged, replace them. • Check the piston return springs [FJ for any damage. • If the springs are damaged, replace them. • Check that relief port [GJ and supply port [HJ 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 [IJ Rear Master Cylinder [JJ BRAKES 12-23 CD GL071828S I C 0 GL07 1968SZ C 12-24 BRAKES Brake Disc Brake Disc Removal •Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). •Remove the brake disc mounting bolts [A] and brake disc [B]. NOTE ○For the ABS equipped model, do not try to remove the wheel rotation sensor rotor. Brake Disc Installation •Install the brake disc on the wheel so that the marked side [A] faces out. •For the ABS equipped model, install the front brake disc with the wheel rotation sensor rotor [B] to the left side. •Apply a non-permanent locking agent to the threads of the front and rear brake disc mounting bolts. •Tighten the front and rear brake disc mounting bolts following the specified tightening sequence. Front Brake Disc [C] Rear Brake Disc [D] Torque – Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb) Brake Disc Wear Inspection •Measure the thickness of each disc [A] at the point where it has worn the most. Measuring Area [B] Brake Discs Thickness Standard: Front 4.8  5.2 mm (0.19  0.20 in.) Rear 4.8  5.2 mm (0.19  0.20 in.) Service Limit: Front 4.5 mm (0.18 in.) Rear 4.5 mm (0.18 in.) If the disc has worn past the service limit, replace it. Brake Disc Brake Disc Warp Inspection • Raise the front/rear wheel off the ground. Special Tool· Jack: 57001-1238 OFor front disc inspection, turn the handlebars fully to one side. • 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 Service Limit TIR 0.15 mm (0.0059 in.) or less TIR 0.3 mm (0.013 in.) BRAKES 12-25 GL080418$1 0 12-26 BRAKES Brake Fluid Brake Fluid Level Inspection •Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change •Refer to the Brake Fluid Change in the Periodic 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 ○The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake. •Remove the reservoir cap [A] and diaphragm. •Fill the reservoir with fresh brake fluid to the upper level line in the reservoir. •Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir. ○Bleed the air completely from the master cylinder by this operation. •Remove the rubber cap [A] from the bleed valve on the caliper. •Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. BRAKES 12-27 Brake Fluid •Bleed the brake line and the master cylinder. ○Repeat this operation until no more air can be seen coming out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release the brake lever [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 ○The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. ○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding. ○Front Brake: First bleeding the right caliper then repeat the above steps for the left caliper. •Remove the clear plastic hose. •Tighten the bleed valve [A], and install the rubber cap [B]. Torque – Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •Check the fluid level (see Brake Fluid Level Inspection in the Periodic Maintenance chapter). •Install the diaphragm and reservoir cap [A]. •Tighten: Torque – Front Brake Fluid Reservoir Cap Screws [B]: 1.5 N·m (0.15 kgf·m, 13 in·lb) 12-28 BRAKES Brake Fluid • Follow the procedure below to install the rear brake fluid reservoir cap correctly. OFirst, 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. • After bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage. AWARNING When working with the disc brake, observe the precautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. • 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. • Do not leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. • Do not change the fluid in the rain or when a strong wind is blowing. • 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. • 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. • Brake fluid quickly damages painted surfaces; any spilled fluid should be completely wiped up immediately. • If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE. BRAKES 12-29 Brake Hose Brake Hose Removal/Installation •Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection •Refer to the Brake Hose and Pipe Damage and Installation Condition Inspection in the Periodic Maintenance chapter. 12-30 BRAKES Anti-Lock Brake System (Equipped Models) Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator Light (LED) [A] ABS Hydraulic Unit [A] ABS Self-diagnosis Terminal [A] ABS Kawasaki Diagnostic System Connector [B] BRAKES 12-31 Anti-Lock Brake System (Equipped Models) Fuse Box (3) [A] 12-32 BRAKES Anti-Lock Brake System (Equipped Models) ABS System Wiring Diagram CD CD @ ·l ! i:MF l:ir”il=·:=rn=·:==::t:t==========l—.1.~ 0 ~~~~~tt:::;;;;;;;;;;:::gdd~:::~ © ~—l-l–+.l—-+—–:::t:=====1+====1==1:=1~:i=:”:m: :: ::§3-® 1. Ignition Switch 2. Front Brake Light Switch 3. ECU 4. Rear Wheel Rotation Sensor 5. Rear Brake Light Switch 6. Engine Ground 7. Battery 8. Main Fuse 30 A 9. Frame Ground (3) 10. Frame Ground (2) 11 . Fuse Box (1) OColor 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 . ; § I t ~ ~2.Sl ~• In . @® ® -~ 0© Gl1413 2CW3 C 12. Brake Light/Horn Fuse 1 O A 13. Ignition Fuse 1 O A 14. Fuse Box (3) 15. ABS Motor Relay Fuse 25 A 16. ABS Solenoid Valve Relay Fuse 15 A 17. Frame Ground (7) 18. ABS Kawasaki Diagnostic System Connector 19. ABS Hydraulic Unit 20. ABS Self-diagnosis Terminal 21. Front Wheel Rotation Sensor 22. Meter Unit PU: Purple R: Red V: Violet W: White Y: Yellow BRAKES 12-33 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Terminal Names Ql.l 4S4S8W2 C 1. Ground: BK/BL 2. Unused 3. Front Wheel Rotation Sensor Signal Input: BK/W 4. Power Supply: BR/W 5. ABS Kawasaki Diagnostic System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7. ABS Self-diagnosis Terminal: GY 8. Ground: BK/Y 9. Power Supply to ABS Solenoid Valve Relay: R/BK 10. Ground for Motor: BK 11. Unused 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/0 15. Unused 16. Rear Wheel Rotation Sensor Signal Output: G/R 17. Yellow ABS Indicator Light (LED): BL/Y 18. Power Supply to ABS Motor Relay: R/W 12-34 BRAKES Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○Do not reverse the battery cable connections. This will damage the ABS hydraulic unit. ○To prevent damage to the ABS parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running. ○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. ○Do not turn the ignition switch on while any of the ABS electrical connectors are disconnected. The ABS hydraulic unit memorizes service codes. ○Do not spray water on the electrical parts, ABS parts, connectors, leads and wiring. ○If a transceiver is installed on the motorcycle, make sure that the operation of the ABS system is not influenced by electric wave radiated from the antenna. Locate the antenna as far as possible away from the ABS hydraulic unit. ○Whenever the ABS electrical connections are to be disconnected, first turn off the ignition switch. ○The ABS parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. ○The ABS parts cannot be disassembled. Even if a fault is found, do not try to disassemble and repair the ABS parts, replace it. ○The ABS has many brake lines, pipes, and leads. And the ABS cannot detect problems with the conventional braking system (brake disc wear, unevenly worn brake pad, and other mechanical faults). To prevent trouble, check the brake lines and pipes for correct routing and connection, the wiring for correct routing, and the brakes for proper braking power. Be sure to check for fluid leakage, and bleed the brake line thoroughly. BRAKES 12-35 Anti-Lock Brake System (Equipped Models) WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line. If the brake lever has a soft or “spongy” feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately. NOTICE Do not ride the motorcycle with air in the brake line, or the ABS could malfunction. ○The yellow ABS indicator light (LED) [A] may come on if the tire pressure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light comes on, 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. 12-36 BRAKES Anti-Lock Brake System (Equipped Models) ○The yellow ABS indicator light (LED) may come on if the engine is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn the ignition switch off, then clear service code 42, which indicates a “Faulty front wheel rotation sensor.” ○When the ABS operates, the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal. This is a normal condition. It informs the rider that the ABS is operating normally. ○Service codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit. Therefore, after maintenance work is finished, be sure to erase the service codes. Do not erase the service codes during troubleshooting. Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work. ○Before delivering the motorcycle to the customer, be sure to erase any service codes which might be stored in the ABS hydraulic unit. Using the self-diagnosis feature, make sure that the yellow ABS indicator light (LED) function. 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 light (LED) does not come on. Finally, test run the motorcycle at a speed of more than 30 km/h (20 mph) and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally (The reaction force generated is felt in the brake lever and pedal.). This completes the final inspection. ABS Troubleshooting Outline When an abnormality in the system occurs, the yellow ABS indicator light (LED) comes on 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 light (LED) blinks. The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected. Therefore, after correcting the problem, always erase the service codes and then run the self-diagnosis program to confirm normal signal output. When, due to a malfunction, the yellow ABS indicator light (LED) remains on, 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. Anti-Lock Brake System (Equipped Models) Even when the ABS is operating normally, the yellow ABS indicator light (LED) may come on under the conditions listed below. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the indicator light may come on again. OAfter continuous riding on a rough road. OWhen the engine is started with the stand raised and the transmission engaged, and the rear wheel turns. OWhen accelerating so abruptly that the front wheel leaves the ground. OWhen the ABS has been subjected to strong electrical interference. OWhen tire pressure is abnormal. Adjust tire pressure. OWhen a tire different in size from the standard size is being used. Replace with standard size. OWhen the wheel is deformed. Replace the wheel. Much of the ABS troubleshooting work consists of confirming continuity of the wiring. The ABS parts are assembled and adjusted by the manufacturer, so there is no need to disassemble or repair them. Replace the ABS hydraulic unit. The basic troubleshooting procedures are listed below. • Carry out pre-diagnosis inspections as a preliminary inspection. • Determine the fault using the self-diagnosis function. • Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part, using a tester. • Visually inspect the wiring for signs of burning or fraying. * If any wiring is poor, replace the damaged wiring. • 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. • Check the wiring for continuity. OUse the wiring diagram to find the ends of the lead which is suspected of being a problem. OConnect a tester between the ends of the leads. * If the tester does not read about On, the lead is defective. Replace the main harness [A] if necessary. • 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 12-37 Gl141 5 1CS1 C 12-38 BRAKES Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart I Problem occurs. I \ I I Confirm problems. I \ I I Gather information from rider. I \V I Conduct pre-diagnosis inspection 1, 2. I \V ,I Conduct self-diagnosis. ‘I I ‘ I ,v I Check by other than self-diagnosis. I I Check by self-diagnosis. I ” \ I I If harness or connector is faulty. I I If ABS part is faulty. I ” \ I I Repair or replace I I Check ABS parts. I ‘ I I Replace I NG ” \ I/ I Final inspection. I I OK \ I I End I GLl40 11B F jil ~ ~ Inquiries to Rider oEach rider reacts to problems in different ways. so it is important to confirm what kind of problem the rider is experiencing. oTry to find out exacUy what problem occurs under exacUy what conditions by askin9 the rider; knowin9 this information may help you reproduce the problem in the workshop. oThe diagnosis sheet will help prevent you from overlooking any key information. so always use it. Sample Diagnosis Sheet 1 Rider Name: Date of registration: Vin No.: Engine No.: Question Descriotion Ve/low ABS indicator light (LED) Which illuminated? statemenUs best ABS not worlcing describes the ABS operates too frequently fault with the Stopping distance too long Registration No. (license plate No.): Model: Odometer reading: . . . km or miles Odometer reading when problem first occured: Answer Flashing Continuous Not working ABS system? Does the wheel lock when you apply the brakes Brake cen1 be releasl:ld Other Nonna! Do the front and l ong stroke (lever feels soft and rear brake levers moves back close to the handle feel normal Abnonnal bar) during limited stroke (lever feels hard and has little movement) application? Pulsing/vibrating Which lever? (front rear or both) During start up I stationary {Is a centre stand or service stand used) Driving be/ow 6 km/h (4mph) (Speeds vary depending on model) When does the Driving above 6 km/h (4mph) (Speeds vary depending on model) front only fault occur? Gradual braking rear only both brakes When slowing or stopping front only (Rate of brake application) During abrupt braking rearonty both brakes There is no specific pattern Other km or miles Advice to customer A fault has been detected with the ABS system. Further inspection by technician required. Continuous riding on rough or un-even surfaces can cause the ABS to operate more frequently. Further inspection by technician required. Further inspection by technician required. This Indicates a probable fault with the braking system and shOuld b8 inspected immediately. If the motorcycle engine is left running whilst on its centre or service stand, mechanieal drag can cause the rear wheel to rotate. If the rear wheel rotates the ABS system may detect a fault. Turning off the ignition switch and restarting should reset the yellow ABS indicator light (LED) if no problems are detected. However the service code will be stored in the ABS ECU and should be reset by the dealer. The ABS system is not active at these speeds. This may be nonnal ABS operation If the road conditions are poor. Abrupt braking may cause the ABS to function early as the suspension may not have had enough time to react to the situation. 5″ )> Q ::::, s::: – :;· “i” ;· r c,, 0 n 0 ” ::0 m g: “”I C,) , ” CD C/) ‘-u<, CD -3 m .Q C “C “C CD C. 3:: 0 C. CD -u, m ~ ;;,;; m CJ) a. I\) I w U) I” s ~ Question How often does the fault occur? During which riding conditions does the fault occur? In what road conditions does the problem occur? Motorcycle condition Description Every time ignition is switched on Every time the brakes are used (Continually) No regularity (Intermittent) Other Highway riding C,1yriding Minor/country roads ridli1g Any comment on riding style maybe applicable. Cross country riding Track/closed circuit riding All Dry Wei Snow/Ice Loose/rough surface (gravel) Has the machine been regularly serviced according to the periodic maintenance schedule? Have there been any prev;ous braking problems? Have any aftermarket parts been OE Tires and brakes? filled? Have the daily safety checks been carried out? {tire pressures I condlu’on etc.) )> .Ji,. -•::::•:, I~\) r 0 Answer Advice to customer Further inspection by technician required. 0 OJ 0 ” ;;o .U.,J )> C) ” ” m fD CJ) CJ) ‘< Braking and handling characteristics can vary with vehicle speed, therefore ABS operation during braking at highway speed may be more frequent. -(n fD Accelerating abruptly between traffic signals so that the front wheel leaves 3 the ground can trigger the ABS warning indicator. Normal riding on good condition roads should allow the yellow ABS indicator light (LED) to reset automatically. -m .c C Continuous riding on rough or uneven surfaces can cause the ABS to operate more frequently. “C “C Continuous riding on loose or off road surfaces can trigger the ABS warning indicator. Normal riding on good condition roads should allow the yellow ABS Indicator light (LED) to reset automatically. fD C. 3: Excessive use of the ABS system due to continuous fast riding can trigger the ABS warning indicator. Normal riding on good condition roads should 0 C. fD allow the yellow ABS indicator light (LED) to reset automatically. (n Further inspection by technician required. – Further inspection by technician required. In wet conditions n is possible that the ABS is operating normally In snow/icy conditions it is possible that the ABS is operating normally On loose/rough surfaces ii is possible thal the ABS is operating normally If the service history is incomplete it is possible lhat a fault may become apparent. For example, failure to replace the brake fluid during periodic ma intenance can cause the hydraulic unit to become internally damaged. Any previous braking problems may be related to the ABS complaint. II is important lhat lhe customer provides as much infomiation as possible so that diagnosis can be made as quickly as possible. Further inspection by technician required. Worn tires or tires with incorrect pressures can cause an ABS fault. It is important to regularly check both tire condition and pressure. BRAKES 12-41 Anti-Lock Brake System (Equipped Models) Dealer Findings Sample Diagnosis Sheet 2 Question/Action Description Answer Advice to technician Review customer Carefully analyze the information Ula/ feedback has been collected from the customer. Use this information to help you informalion perform your In/Ila/ diagnosis. 1 Check to see if 2 any diagnostic 3 If codes are present refer to service manual. codes are present 4 5 The ABS Is designed to be used with a 12 v sealed battery as its power source. Only use the Batlery voltage batlery specified by the service m<1nual as a power source. If low battery voltage is detected service codes: 852 or 853 will be displayed. Tires type/size Front . . ,.,, . . . Rear. . . Refer to service manual. Tire pressures Front . . . Rear. , . . •••. . . •. Inspect the Front Excessive or abnormal wear can be recognized Tire condition . . . . following Rear . . . . . as an ABS fault. Wheel rotation sensor air gap Front . . Refer to service manual. Also check that the Rear . ” . wheel orientation is ccrrect . Wheel condilion (damaged or Front . . . . Refer to service manual. deformed) Rear . . . Brake system general condition Front . . . Pad wear/Front and rear operation/Condition of Rear. ,.,, . ” . . hoses etc. Brake disc run-our Front . . . . Refer to service manual. Rear . ” . . Stays on all the time while ignition on Turns off when first Continuous moving off but turns on again and stays on Check for diagnostic trouble codes. Turns on when brake{s) are operated Add it ional Otller. information on the Turns off soon after Test the operation of the tight by turning on the yellow ABS moving off ignition. If the light fails lo illuminate ensure that indicator light No/working Turns off after riding for a the bike is equipped with ASS before inspecting {LED) while the meter panel for faults as per the service Other: manual. By 0<1shing the ABS unit is indicating additional 5, 15. or 20 fault cedes lhat may not be listed in the service How many limes does it flash per 10 manu3t. Please carefully count the number of seconds? flashes per 10 seconds before cootacting Other: times Kawasaki. (Kawasaki may request a video of the Hashing sequence) Cl.14055C S 12-42 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1 NG Check brake fluid level in brake reservoir. Replenish brake fluid. I OK \ I Check for brake fluid leakage. NG I Repair brake line. I OK \ I Check brake lever and brake pedal function. ~-1 I , 1 Repair or replace master cylinder. OK \ I Check brake pad and brake disc. NG_ I Replace faulty parts. I ‘ I OK \ I Front and rear wheels should rotate smoothly without NG_ I Repair or replace caliper. I brake drag. ‘ I OK \ I There shouldn’t be a lot of play in the wheel bearing. NG._ I There shouldn’t be excessive axle bending or disc runout. Replace wheel bearing or axle. I ‘ I GLl4012B F BRAKES 12-43 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 No (Unlit) Check the yellow ABS indicator light (LED). ‘ Check the power source wiring and meter 0 Does the indicator light come on with , unit. the ignition switch to ON? Yes (lit) , 11 Drive at 10 km/h (6.2 mph) or above for one minute or more. , 11 Yes When the motorcycle is running, does the indicator ~ I ABS is normal. I light go off? No \V Count the number of times the indicator light blinks in ~ Ask the rider if the problem the self-diagnosis mode to find the service code. ;’ happens again. GL1 49508 f Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code (16 codes including “Normal Code”) for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch. The ABS hydraulic unit can memorize up to six service codes. Further service codes are memorized after erasing the preceding six service codes. If there is no fault, only the start code 12 is shown, indicating that “The ABS is normal.” Self-diagnosis Procedures OWhen a problem occurs with the ABS system, the yellow ABS indicator light (LED) [A] come on. NOTE OUse a fully charged battery when conducting self-diagnosis. Otherwise, the indicator light blinks very slowly or doesn’t blink. o The motorcycle is stopped. OKeep the self-diagnosis terminal grounded during self -diagnosis, with an auxiliary lead. 12-44 BRAKES Anti-Lock Brake System (Equipped Models) •Remove the front seat (see Front Seat Removal in the Frame chapter). •Ground the self-diagnosis terminal [A] (Gray) to the battery (–) terminal, using a suitable lead. •Turn the ignition switch on. ○Count the blinks of the indicator light to read the service code. Keep the auxiliary lead ground until you finish reading the service code. Service Code Clearing Procedures •Start the service code erase mode with the following procedure. ○The erase mode starts when the ABS self-diagnosis terminal is disconnected from the battery (–) terminal after starting the self-diagnosis mode. ○The service code can be erased by grounding and ungrounding (each time for at least one second) the ABS self-diagnosis terminal three times within about 12.5 seconds after starting the erase mode. ○The yellow ABS indicator light (LED) remains on during the erase mode. ○Once erasing is finished, enter the self-diagnosis mode again to confirm that the service codes have been erased. If the ABS has been reset and all codes have been erased, only start code 12 will be shown. Anti-Lock Brake System (Equipped Models) Erasing of Service Code Yellow ABS Indicator Light(LED) ON OFF ABS Self – diagnosis Terminal Open Ground Service code erase mode starts . I ~ I 11S or more Within 12. 5s _j BRAKES 12-45 1 Exection of L Service Code Erase Gl.1 4933812 C 12-46 BRAKES Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart Turn the ignition switch off. l Connect the ABS self-diagnosis terminal to the ground terminal. ! Turn the ignition switch on. Self-diagnosis mode starts. ! The yellow ABS indicator light (LED) blinks to display the service code(s) in about 3 seconds after entering the self-diagnosis mode. (1) ! If the service code(s) is not displayed, drive at 20 km/h (12 mph) or more for 1 minute, stop, and try self-diagnosis again. ! Check the faulty point with the service code table and repair according to fault inspection 1 to 15. ! Erase the service code memorized in the ABS hydraulic unit ! Start the self-diagnosis mode to confirm that erasing has been completed. ! Disconnect the ABS self-diagnosis terminal to the ground terminal. ending the self-diagnosis mode. ! Activate the ABS by driving the motorcycle at 20 km/h (12 mph) or NG (litL above in order to confirm that the ABS is normal. , I Repeat self-diagnosis. ! OK (Unlit} Activate the ABS at a safe place in order to confirm that it operates normally. (2) ! OK End (1 ): The self -diagnosis mode continues for a maximum of 5 minutes, after which time it terminates. Self-diagnosis ends when either disconnect the ABS self-diagnosis terminal to the ground terminal after about 12.5 seconds in the self-diagnosis mode, or after executing the service code erase, or when the motorcycle is driven while in the self-diagnosis mode. (2): Apply brake suddenly at 30 km/h (19 mph) or more to confirm that the motorcycle stops smoothly and steady with pulsation on the brake lever and pedal. Gll4932B f BRAKES 12-47 Anti-Lock Brake System (Equipped Models) How to Read Service Codes OService codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ORead 10th digit and unit digit as the ABS indicator light (LED) blinks. OWhen 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. OFor the display pattern, first, the start code 12 is shown, next up to 6 service codes then the display is repeated from the start code once again. Star t ~ Ser v Ice code 12 code AA Se r v i ce code BB Service code CC Serv i ce code DD Service code EE Service code FF * The se rv i ce c o de s d i s p l ay a t ra ndom. Olf there is no fault, the ellow ABS indicator Ii ht LED blinks as shown. Indication of Service Code Ye I l ow ABS I ndica t o r Li ght ( LED) ON OFF I lgn·io nt ~ Switch ON Ex . 1 St ar t Code 12 (ABS i s norma I) i s s hown . Star t Code 12 10th a digit digit 0. 6s 0. 3 s St a r t Co de 12 Star t Code 12 Sta r t Co de 12 I I i–H,.J-i-H–1 ,3. 0s,, 1111 3. 3s, 0 . 6s 0.3s 0 . 9s 1–1 I 3. 3S I 1–1 I 3. 3S I 1–1 I 3. 3S I Ex. 2 Se rvi ce Code 13 and 42 a re s hown. Se r v i ce Code 42 If any. Gll -4949811 C Yel l ow ABS Indi c a t or Li ght ( LED) Sta r t Code 12 Se rv ic e Code 13 0. 6s 0. 3s 0 . 6s 0.3s four or more service codes ON OFF I lgn it~·on Switch ON 1–~ 1–1 H H r:–:–1 1-1 1-1 1-1 1–1 H I ,3. 0s, I 11113. 3s, I 1111113.3s , ,, I I I I ,,. 1111 0. 6s 0 . 3s 0. 9s 0 . 3 s 0 . 6s 0 . 3s 0 . 9s 0 . 9s How to Erase Service Codes GLI 458 46W2 C OEven if the ignition switch is turned off, the battery or the ABS hydraulic unit are disconnected, all service codes remain in the ABS hydraulic unit. ORefer to the Service Code Clearing Procedure for the service code erasure. 12-48 BRAKES Anti-Lock Brake System (Equipped Models) Service Code Table Service Yellow ABS Indicator Light (LED) Problems Light State Code 12 JUUl Start code (not fault) After starts, turn off 13 JUUUl Rear intake solenoid valve trouble ON (shorted or open, stuck valve) 14 JUUUUl Rear outlet solenoid valve trouble ON (shorted or open, stuck valve) 17 JUUUUUUUl Front intake solenoid valve trouble ON (shorted or open, stuck valve) 18 JUUUUUUUUl Front outlet solenoid valve trouble ON (shorted or open, stuck valve) 19 JUUUUUUUUUl ABS solenoid valve relay trouble (wiring ON shorted or open, stuck relay) JlfUUlfUUl Front, rear tire abnormal (substandard 25 tire, deformation wheel, sensor rotor ON teeth number wrong) 35 JlfUl__JlflJlfl ABS motor relay trouble (wiring shorted, ON open or lock, stuck relay) Front wheel rotation sensor signal 42 IlililfUUl abnormal (sensor or rotor missing, too ON large clearance, rotor tooth worn or missing) 43 JlfUlJUUUl Front wheel rotation sensor wiring ON abnormal (wiring shorted or open) Rear wheel rotation sensor signal 44 IlililfLJUUUl abnormal (sensor or rotor missing, too ON large clearance, rotor tooth worn or missing) 45 nnnrLJUUUUl Rear wheel rotation sensor wiring ON abnormal (wiring shorted or open) 52 JlfUl.flfUUl Power supply voltage abnormal ON (low-voltage) 53 JlfUlJlfUUUl Power supply voltage abnormal ON (over-voltage) 54 nnnruLJUUUl ABS solenoid valve relay supply voltage ON abnormal (low voltage) 55 ECU trouble (ECU operation abnormal) ON Anti-Lock Brake System (Equipped Models) Yellow ABS Indicator Light (LED) Inspection Oln this model, the yellow ABS indicator light (LED) [A] goes on or blinks by the control of the ABS hydraulic unit. • Turn the ignition switch on. •If the yellow ABS indicator light (LED) comes on, it is normal. •If the yellow ABS indicator light (LED) does not come on, refer to the Meter Unit Inspection in the Electrical System chapter. * If the meter is good, check the wiring continuity of the BL/Y lead in the main harness. Special Tool· Needle Adapter Set: 57001-1457 Wiring Continuity Inspection Meter Connector [A] ABS Hydraulic Unit – _, Connector [B] Meter Terminal 8 [C] ABS Hydraulic Unit – _, Terminal 17 [D] * If there is not the continuity in the lead, replace or repair the main harness. * If there is the continuity in the lead, replace the ABS hydraulic unit. Solenoid Valve Inspection (Service Code 13, 14, 17, 18) • 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 light (LED) [A] comes on, the solenoid valve in the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. •If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). ABS Solenoid Valve Relay Inspection (Service Code 19) • Remove: Fairing Cover (see Fairing Cover Removal in the Frame chapter) • Check the ABS solenoid valve relay fuse (15 A) [A] (see Fuse Inspection in the Electrical System chapter). BRAKES 12-49 D Gl141 39CS 1 C 12-50 BRAKES Anti-Lock Brake System (Equipped Models) *If the fuse is good, check the wiring continuity between the positive ( +) terminal [A] of the battery and R/BK lead terminal [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 continu ity in the lead, go to next step. • 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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. * If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). Front, Rear Tire Abnormal (Service Code 25) • Check the following and correct the faulty part. Incorrect Tire Pressure Tires not recommended for the motorcycle were installed (incorrect tire size). Deformation of Wheel or Tire Missing Teeth and Clogging with Foreign Matter of Sensor Rotor (see Wheel Rotation Sensor Inspection) * If the all parts correct, recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. * If the yellow ABS indicator light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. * If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). ABS Motor Relay Inspection (Service Code 35) • Remove: Fairing Cover (see Fairing Cover Removal in the Frame chapter) • Check the ABS motor relay fuse (25 A) [A] (see Fuse Inspection in the Electrical System chapter). GL1 492HS1 C Anti-Lock Brake System (Equipped Models) •If the fuse is good, check the wiring continuity between the positive ( +) terminal [A] of the battery and R/W lead terminal [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. • 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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. • If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) • Measure the air gap between the front wheel rotation sensor and sensor rotor (see Wheel Rotation Sensor Air Gap Inspection). • Check the front wheel rotation sensor (see Wheel Rotation Sensor Inspection). • If both inspections are good, go to next step. • Check that there is iron or other magnetic deposits between the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. • Check the installation condition of the sensor for looseness. • Check the sensor rotor tip for deformation or damage (e.g., chipped sensor rotor teeth ). * If the sensor rotor in bad condition, remove the any deposits. Install the proper part or replace faulty part. • If the all items are good, go to next step. • 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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. • If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). BRAKES 12-51 GL1492l 8S I C 12-52 BRAKES Anti-Lock Brake System (Equipped Models) Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) • Disconnect: ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal) Front Wheel Rotation Sensor Connector (see Front Wheel Rotation Sensor Removal) • Check the wiring continuity of the BK/W lead and W/BK lead. Wiring Continuity Inspection ABS Hydraulic Unit — Front Wheel Rotation Connector [AJ Sensor Connector [BJ ABS Hydraulic Unit Terminal 3 [CJ ABS Hydraulic Unit Terminal 12 [EJ — Sensor Terminal 1 [DJ — Sensor Terminal 2 [FJ * If there is not the continuity in the lead, replace or repair the main harness. * If the wiring is good, go to next step. • 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 light (LED) [A] comes on, 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 light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44) • Measure the air gap between the rear wheel rotation sensor and sensor rotor (see Wheel Rotation Sensor Air Gap Inspection). • Check the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Inspection). *If both inspections are good, go to next step. • Check that there is iron or other magnetic deposits between the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. • Check the installation condition of the sensor for looseness. • Check the sensor rotor tip for deformation or damage (e.g., chipped sensor rotor teeth ). * If the sensor rotor in bad condition, remove the any deposits. Install the proper part or replace faulty part. * If the all items are good, go to next step. D OL14 HIOCS1 C Anti-Lock Brake System (Equipped Models) • 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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. •If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) • Disconnect: ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal) Rear Wheel Rotation Sensor Connector (see Rear Wheel Rotation Sensor Removal) • Check the wiring continuity of the BK/0 lead and WIG lead. Wiring Continuity Inspection ABS Hydraulic Unit — Connector [AJ Rear Wheel Rotation Sensor Connector [BJ ABS Hydraulic Unit Terminal 14 [CJ — Sensor Terminal 1 [DJ ABS Hydraulic Unit Terminal 13 [EJ — Sensor Terminal 2 [FJ •If there is not the continuity in the lead, replace or repair the main harness. •If the wiring is good, go to next step. • 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 light (LED) [A] comes on, 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 light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure .). Power Supply Voltage Abnormal [Low-Voltage] (Service Code 52) • Check the battery condition (see Charging Condition Inspection in the Electrical System chapter). * If the battery is good condition, go to next step. BRAKES 12-53 D C Gl14141 CS 1 C 12-54 BRAKES Anti-Lock Brake System (Equipped Models) •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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure.). Power Supply Voltage Abnormal [Over-Voltage] (Service Code 53) •Check the charging voltage (see Charging Voltage Inspection in the Electrical System chapter). If the charging voltage is good, go to next step. •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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure.). ABS Solenoid Valve Relay Supply Voltage Inspection [Low-Voltage] (Service Code 54) •Check the charging voltage (see Charging Voltage Inspection in the Electrical System chapter). If the charging voltage is good, go to next step. •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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure.). ECU Inspection (Service Code 55) •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 light (LED) [A] comes on, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit. If the yellow ABS indicator light (LED) does not come on, ABS system is normal (service code is not stored; temporary failure.). BRAKES 12-55 Anti-Lock Brake System (Equipped Models) 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. •Drain the brake fluid from the front and rear brake lines. ○Drain the brake fluid through the bleed valve by pumping the brake lever and pedal. •Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) •Clean the ABS hydraulic unit thoroughly. 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. •Pull the main harness [A] to rearward and release the clamp [B] from the bracket. •Remove: Vehicle-down Sensor [C] Intake Air Pressure Sensor [D] Bolts [E] Bracket [F] •Remove: Bolt [A] Bracket [B] 12-56 BRAKES Anti-Lock Brake System (Equipped Models) •Temporarily install the bolt [A]. •Using the flare nut wrench, loosen the brake pipe joint nuts [1  4] fully and disconnect the brake pipes [B] in sequence numbers. NOTICE Brake fluid quickly damages painted plastic surface; any spilled fluid should be completely washed away immediately. •Make sure that the ignition switch has been turned off. NOTICE To protect the ABS hydraulic unit from the electrical surge, always disconnect the ABS hydraulic unit connector while the ignition switch is turned off. •Push the lock tab [A] and turn the connector lever [B] forward to disconnect the ABS hydraulic unit connector [C]. •Disconnect the front wheel rotation sensor lead connector [A]. •Remove the front wheel rotation sensor connector from the bracket [B]. •Remove: ABS Hydraulic Unit Mounting Bolts [A] ABS Hydraulic Unit [B] with Bracket BRAKES 12-57 Anti-Lock Brake System (Equipped Models) •Plug the ports on the ABS hydraulic unit to prevent entering a foreign matter into the unit. •Wrap the brake pipe openings with a vinyl bag to prevent brake fluid leakage and entering a foreign matter into the hydraulic system. NOTICE Do not allow entering a foreign matter into the hydraulic system while disconnecting the hydraulic lines. •Remove: Bolts [A] Washers [B] Bracket [C] ABS Hydraulic Unit [D] 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. •Installation is the reverse of removal. •Check that the damper [A] is in place on the ABS hydraulic unit [B]. •Be sure to install the dampers [A] and flanged collars [B] on the bracket [C]. 12-58 BRAKES Anti-Lock Brake System (Equipped Models) •Push the lever [A] forward until locked by the lock tab [B] to connect the ABS hydraulic unit connector [C]. •Connect the brake pipes to the ABS hydraulic unit [A] and tighten the brake pipe joint nuts with the following order. To Rear Caliper [1] To Rear Master Cylinder [2] To Front Master Cylinder [3] To Front Calipers [4] Torque – Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb) •Run the brake pipes and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Bleed the brake line (see Brake Line Bleeding). •Check the brake for good braking power, no brake drag, and no fluid leakage. ABS Hydraulic Unit Inspection •Remove the ABS hydraulic unit (see ABS Hydraulic Unit Removal). •Visually inspect the ABS hydraulic unit. Replace the ABS hydraulic unit if any of them are cracked, or otherwise damaged. •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. BRAKES 12-59 Anti-Lock Brake System (Equipped Models) •Remove: Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter) Front Wheel Rotation Sensor Bolt [A] Front Wheel Rotation Sensor [B] •Clear the sensor lead from the clamp [C]. •Clear the sensor lead from the clamps [A]. •Disconnect the front wheel rotation sensor lead connector [A]. •Remove the front wheel rotation sensor connector from the bracket [B]. Front Wheel Rotation Sensor Installation •Installation is the reverse of removal. •Run the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Apply a non-permanent locking agent to the threads of the front wheel rotation sensor bolts, and tighten it. •Tighten: Torque – Front Wheel Rotation Sensor Bolt: 8.0 N·m (0.82 kgf·m, 71 in·lb) ○When installing the sensor which is fastened by bolt, tighten the bolt after placing the sensor on the bottom surface completely. 12-60 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to get water or mud on the wheel rotation sensor. Do not try to disassemble or repair the wheel rotation sensor. •Remove: Right Fuel Tank Side Cover (see Fuel Tank Side Cover Removal in the Frame chapter) Right Frame Cover (see Frame Cover Removal in the Frame chapter) Mud Guard (see Mud Guard Removal in the Frame chapter) Rear Wheel Rotation Sensor Bolt [A] Rear Wheel Rotation Sensor [B] •Clear the sensor lead [C] from the clamps [D]. •Clear the sensor lead [A] from the clamps [B]. •Disconnect the rear wheel rotation sensor lead connector [A]. •Remove the rear wheel rotation sensor lead connector from the bracket [B] on the frame. BRAKES 12-61 Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Installation •Installation is the reverse of removal. •Run the lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Tighten: Torque – Rear Wheel Rotation Sensor Bolt: 22 N·m (2.2 kgf·m, 16 ft·lb) ○When installing the sensor which is fastened by bolt, tighten the bolt after placing the sensor on the bottom surface completely. Wheel Rotation Sensor Inspection •Remove the front wheel rotation sensor [A] from the front fork. •Remove the rear wheel rotation sensor [B] from the caliper bracket. •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 •Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). •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 0.4  1.6 mm (0.02  0.06 in.) Rear 0.4  1.6 mm (0.02  0.06 in.) NOTE ○The sensor air gap cannot be adjusted. If the air gap is not within the specification, inspect the hub bearing (see Hub Bearing Inspection in the Wheels/Tires chapter), sensor installation condition and sensor (see Wheel Rotation Sensor Inspection). 12-62 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Rotor Inspection • 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 • Refer to the Fuse Box Fuse Removal in the Electrical System chapter. ABS Motor Relay Fuse (25 A) Removal • Refer to the Fuse Box Fuse Removal in the Electrical System chapter. 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 (see Fuse Installation in the Electrical System chapter). Fuse Inspection • Remove the fuses (see ABS Solenoid Valve Relay Fuse (15 A)/ABS Motor Relay Fuse (25 A) Removal). • Refer to the Fuse Inspection in the Electrical System chapter. 0L1•oous1 c SUSPENSION 13-1 13 Suspension Table of Contents Exploded View 13-2 Specifications . 13-6 Special Tools 13-7 Front Fork. 13-9 Front Fork Removal (Each Fork Leg) . 13-9 Front Fork Installation (Each Fork Leg) 13-9 Front Fork Oil Change 13-9 Front Fork Disassembly 13-11 Front Fork Assembly. 13-12 Inner Tube, Outer Tube Inspection . 13-14 Dust Seal Inspection . 13-14 Spring Tension Inspection. 13-14 Rear Shock Absorber . 13-15 Spring Preload Adjustment . 13-15 Rear Shock Absorber Removal 13-15 Rear Shock Absorber Installation . 13-16 Rear Shock Absorber Inspection 13-16 Rear Shock Absorber Scrapping 13-17 Rear Shock Absorber Bearing Removal. 13-17 Rear Shock Absorber Bearing Installation 13-17 Swingarm 13-18 Swingarm Removal. 13-18 Swingarm Installation 13-19 Swingarm Bearing Removal . 13-20 Swingarm Bearing Installation 13-21 Swingarm Bearing, Sleeve Inspection 13-22 Swingarm Bearing Lubrication 13-22 Chain Guide Inspection. 13-22 Tie-Rod, Rocker Arm 13-23 Tie-Rod Removal 13-23 Tie-Rod Installation . 13-24 Rocker Arm Removal 13-24 Rocker Arm Installation. 13-25 Tie-Rod and Rocker Arm Bearing Removal 13-25 Tie-Rod and Rocker Arm Bearing Installation. 13-26 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-27 Rocker Arm/Tie-Rod Bearing Lubrication . 13-27 13-2 SUSPENSION Exploded View o-©B 0 8–® ~ © • I I I I © • I I I I ~ 0 ®——–8 ~ o• ouHBWS C SUSPENSION 13-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Front Fork Clamp Bolts 20 2.0 15 2 Front Fork Top Plugs 22 2.2 16 3 Lower Front Fork Clamp Bolts 20 2.0 15 AL 4 Front Fork Bottom Allen Bolts 30 3.1 22 L AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts 1E3x-p4lo SdeUd VSiePwE NSION——=======-========—~ SUSPENSION 13-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Rear Shock Absorber Nut 34 3.5 25 R, S 2 Swingarm Bracket Bolts 25 2.5 18 S 3 Tie-Rod Bolt (Lower) 44 4.5 32 S 4 Side Stand Bracket Bolts 49 5.0 36 L, S 5 Swingarm Pivot Shaft Nut 108 11.0 79.7 S 6 Tie-Rod Bolt (Upper) 44 4.5 32 S 7 Rocker Arm Bolt 59 6.0 44 S 8 Lower Rear Shock Absorber Bolt 34 3.5 25 S G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. 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) Suspension Oil Kawasaki KHL34-G10 or equivalent Amount: After Disassembly and Completely Dry 479 ± 4 mL (16.2 ± 0.135 US oz.) When Changing Oil Approx. 410 mL (13.9 US oz.) Fork Oil Level 101 ± 2 mm (4.0 ± 0.08 in.) (Fully Compressed, without Spring, below from the Top of the Inner Tube) Fork Spring Free Length 327.8 mm (12.91 in.) (Service Limit: 322 mm (12.7 in.)) Rear Shock Absorber (Uni-Trak): Rear Shock Absorber Spring Preload 3rd position (Adjustable Range: 1st ←→ 7th position) Gas Pressure 1 500 kPa (15.30 kgf/cm², 217.5 psi, non-adjustable) Special Tools Inside Circlip Pliers: 57001-143 Fork Cylinder Holder Handle: 57001-183 Fork Cylinder Holder Adapter: 57001-1057 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 ST570 143ST C ST570 183ST C ST571057ST C ST571129ST C SUSPENSION 13-7 Jack: 57001-1238 Fork Oil Seal Driver, q,41: 57001-1288 Fork Oil Level Gauge: 57001-1290 Hook Wrench T=3.2 R37: 57001-1539 Needle Bearing Driver, q,17/q,18: 57001-1609 ST571238ST C S1571288ST C ST571539ST C ST571609ST C 13-8 SUSPENSION Special Tools Fork Oil Seal Driver Weight, ¢ 26 -¢46: 57001-1795 ST571795ST C Fork Oil Seal Driver Attachment, ¢ 36 -¢46: 57001-1798 ST571798ST C Front Fork Front Fork Removal (Each Fork Leg) • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Middle Fairing (see Middle Fairing Removal in the Frame chapter) * If fork leg is to be disassembled, loosen the upper front fork clamp bolt [A] and the front fork top plug [B] beforehand. • Loosen the lower front fork clamp bolts [C]. • With a twisting motion, work the fork leg down and out. Front Fork Installation (Each Fork Leg) • Install the fork so that the distance between the top end [A] of the inner tube and upper surface [B] of the steering stem head is the 6 mm (0.24 in.) [C]. * Tighten the front fork top plug to the specified torque if the front fork top plug is removed. Torque – Front Fork Top Plugs: 22 N·m (2.2 kgf·m, 16 ft-lb) • Tighten: Torque – Lower Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft-lb) NOTE o Tighten the top plug before tightening the upper front fork clamp bolt. o Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. • Tighten: Torque – Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft-lb) • Install the removed parts (see appropriate chapters). Front Fork Oil Change • Remove: Front Fork (see Front Fork Removal) Front Fork Top Plug [A] with 0 -ring Spacer [B] Fork Spring Seat [C] Fork Spring [D] SUSPENSION 13-9 13-10 SUSPENSION Front Fork • Drain the fork oil into a suitable container [A]. OPump the inner tube up and down at least 10 times to expel the oil from the fork. • Hold the fork tube upright, pour in the specified type and amount of fork oil. Suspension Oil· KHL34-G10 (1 L): 44091-0002 KHL34-G10 (4 L): 44091-0011 Amount (Per Side): When changing oil: approx. 410 ml (13.9 US oz.) After disassembly and completely dry: 479 ±4 ml (16.2 ±0.135 US oz.) NOTE OMove the outer tube up and down a few times to remove the air that is trapped in the fork oil in order to stabilize the oil level. • Hold the outer tube vertically in a vise and compress the fork completely. • Wait until the oil level stabilizes. • Use the fork oil level gauge [A] to measure the distance from the top of the inner tube to the oil level. Special Tool • Fork Oil Level Gauge: 57001-1290 0 Set the oil level gauge stopper [B] so that the distance [C] from the bottom of the stopper to the lower end of the pipe is the standard oil level distance. OA correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube. Oil Level (fully compressed, without spring) Standard: 101 ±2 mm (4.0 ±0.08 in.) OPlace the stopper of the level gauge at the top [D] of the inner tube [E] and pull the handle slowly to draw out the excess oil from fork into the gauge, thus attaining the standard level. * If no oil is drawn out, there is not enough oil in the fork. Pour in some more oil and measure again. • Repeat the same procedure for adjusting the other fork. a • o 45498S I C G• 0 45258S1 C o • 04303BS2. C Front Fork • Install: Fork Spring [A] Fork Spring Seat [B] Spacer [C] • Replace the top plug 0 -ring with a new one. • Apply grease to the top plug 0-ring. • Install: Front Fork Top Plug Front Fork (see Front Fork Installation) Front Fork Disassembly • Drain the fork oil (see Front Fork Oil Change). • Remove the front fork bottom Allen bolt [A] and gasket from the bottom of the fork. Special Tools – Fork Cylinder Holder Handle [BJ: 57001 -183 Fork Cylinder Holder Adapter [CJ: 57001 -1057 NOTE OHold the outer tube in a vise [DJ, stop the cylinder unit [El from turning by using the special tools, and unscrew the Allen bolt. • Remove the cylinder unit [A] and the spring [B] from the inner tube. • Remove the following parts from the top of the outer tube. Dust Seal [A] Retaining Ring [B] Fork Guard [C] SUSPENSION 13-11 B C E A D GM042988$1 0 13-12 SUSPENSION Front Fork • Separate the inner tube [A] from the outer tube [B]. NOTE OFrom the compressed state, firmly pull down the outer tube a few times towards the direction of elongation. • Remove the following parts from the inner tube. Inner Guide Bushing [A] Outer Guide Bushing [B] Washer [C] Oil Seal [D] • Remove the cylinder base [A] from the bottom of the outer tube. Front Fork Assembly • Replace the following parts with new ones. Retaining Ring [A] Dust Seal [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Front Fork Bottom Allen Bolt Gasket [F] • Install the inner guide bushing to the groove on the inner tube. • Insert the cylinder unit [A] and the spring into the inner tube. • Be sure that the spring [B] is in position. • Install the cylinder base [C] onto the end of the cylinder unit as shown. • Install the inner tube, cylinder unit, and cylinder base as a set into the outer tube. @ I lmll1S/J I .-.01IO • GM04 054CS 1 C Front Fork • Install the outer guide bushing [AJ and washer [BJ into the outer tube using the fork oil seal driver [CJ, until the washer is bottomed. Special Tools· Fork Oil Seal Driver, q,41: 57001-1288 or Fork Oil Seal Driver Weight, q,26 -q,46: 57001-1795 Fork Oil Seal Driver Attachment, q,36 -q,46: 57001-1798 • Apply grease to the oil seal lips, and install the oil seal [AJ to the outer tube from the top. Olnstall the oil seal with its lip side (marked side) [BJ facing up. • Install the oil seal into the bottom case using the fork oil seal driver [CJ until the oil seal is bottomed. Special Tools· Fork Oil Seal Driver, q,41: 57001-1288 or Fork Oil Seal Driver Weight, q,26 – q,46: 57001-1795 Fork Oil Seal Driver Attachment, q,36 -q,46: 57001-1798 • Install the retaining ring [AJ to the groove in the outer tube. OMake sure that the retaining ring is properly seated into the groove. • Install the fork guard [BJ to the outer tube aligning the tab [CJ with the groove [DJ on the outer tube. • Install the dust seal [EJ. • Apply non-permanent locking agent to the threads of the bottom Allen bolt [AJ. • Hold the front fork horizontally in a vise [BJ. • Hold the cylinder unit [CJ with the special tools and tighten the bottom Allen bolt to secure the cylinder in place. Special Tools· Fork Cylinder Holder Handle [DJ: 57001-183 Fork Cylinder Holder Adapter [E]: 57001 -1057 Torque· Front Fork Bottom Allen Bolt: 30 N·m (3.1 kgf·m, 22 ft-lb) • Pour in the specified type of oil (see Front Fork Oil Change). • Install the front fork (see Front Fork Installation). D SUSPENSION 13-13 E C B -@ J A I (,mOl1 , A GM043008$1 0 13-14 SUSPENSION Front Fork Inner Tube, Outer Tube Inspection • 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. • Temporarily assemble the inner [A] and outer [B] tubes, and pump them back and forth manually to check for smooth operation. *If you feel binding or catching, the inner and outer tubes must be replaced. AWARNING 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 • Inspect the dust seal [A] for any signs of deterioration or damage. * Replace it if necessary. Spring Tension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. * If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability. Spring Free Length Standard: 327.8 mm (12.91 in.) Service Limit: 322 mm (12.7 in.) a • o 43018SI C OM041288SI C GM0401 USl C SUSPENSION 13-15 Rear Shock Absorber Spring Preload Adjustment •Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Left Side Cover (see Side Cover Removal in the Frame chapter) •Using the hook wrench [A], turn the adjusting nut [B] to adjust the spring preload. Special Tool – Hook Wrench T = 3.2 R 37: 57001-1539 Spring Preload Setting Standard Position: 3rd position Adjustable Range: 1st to 7th position •If the compression of the spring is not suited to the operating conditions, adjust it to an appropriate position by referring to the table below. Spring Preload Adjustment Adjuster Position Damping Force Shock Absorber Hardness Load Road Conditions Driving Speed 1st Weak Soft Light Good Low ↑ ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓ ↓ 7th Strong Hard Heavy Bad Highway Rear Shock Absorber Removal •Remove: Muffler (see Muffler Removal in the Engine Top End chapter) •Raise the rear wheel off the ground using the jack. Special Tool – Jack: 57001-1238 •Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. •Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) 13-16 SUSPENSION Rear Shock Absorber •Remove: Upper Rear Shock Absorber Bolt and Nut [A] Lower Rear Shock Absorber Bolt and Nut [B] •Remove the rear shock absorber [C]. Rear Shock Absorber Installation •Replace the rear shock absorber nuts with new ones. •Apply grease to the lip of grease seals. ○Be sure to install the grease seals to the rear shock absorber. •Install the rear shock absorber so that the label side faces inside. •Pull up the swingarm, and tighten the rear shock absorber bolts and nuts. Torque – Upper Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Lower Rear Shock Absorber Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) •Install the removed parts (see appropriate chapters). Rear Shock Absorber Inspection •Remove the rear shock absorber (see Rear Shock Absorber Removal). •Visually inspect the following items. Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace it. •Visually inspect the rubber bushing. If it show any signs of damage, replace it. Rear Shock Absorber Rear Shock Absorber Scrapping AWARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber without first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [A] shown to release the nitrogen gas completely. Wear safety glasses when drilling the hole, as the gas may blow out bits of drilled metal when the hole opens. Rear Shock Absorber Bearing Removal • Remove: Rear Shock Absorber (see Rear Shock Absorber Removal) Sleeve [A] Grease Seals [B] • Remove the needle bearing, using a suitable tool. Rear Shock Absorber Bearing Installation • Replace the needle bearing [A] and grease seals [B] with new ones. • Install the needle bearing position as shown. 5.5 mm (0.22 in.) [C] • Apply plenty of grease to the lips of the grease seals. • Install the grease seals and sleeve [D]. SUSPENSION 13-17 13-18 SUSPENSION Swingarm Swingarm Removal •Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Shift Pedal (see Shift Pedal Removal in the Crankshaft/ Transmission chapter) Mud Guard and Chain Cover (see Mud Guard Removal in the Frame chapter) Frame Covers (see Frame Cover Removal in the Frame chapter) Muffler (see Muffler Removal in the Engine Top End chapter) •Support the frame using the jack. Special Tool – Jack: 57001-1238 •Remove: Rocker Arm (see Rocker Arm Removal) Rear Brake Hose Bracket Bolt [A] Rear Brake Hose Bracket [B] •Clear the rear wheel rotation sensor lead from the clamp [A]. •Loosen: Right Swingarm Bracket Bolt [A] Swingarm • Loosen: Left Swingarm Bracket Bolts [A] • Remove: Swingarm Pivot Shaft Nut [B] • Pull out the swingarm pivot shaft [C] to the right side, and remove the swingarm. OAfter removing the swingarm, insert the swingarm pivot shaft [A] to hold the right swingarm bracket [B]. Swingarm Installation • Visually inspect the chain guide [A]. * Replace the chain guide if it shows any signs of abnormal wear or damage. • Apply grease to the lip of the grease seals [A]. • Be sure to install the grease seals and sleeves [B] to the swingarm. • Fit the collar [C] on the grease seal. Left Side [D] Right Side [E] SUSPENSION 13-19 ._® .® 13-20 SUSPENSION Swingarm • Install the swingarm [A] and insert the swingarm pivot shaft [B]. • Tighten the bolts and nut following the tightening sequence [1 – 4]. Torque – Swingarm Pivot Shaft Nut (1): 108 N·m (11.0 kgf·m, 79.7 ft·lb) Left Swingarm Bracket Bolts (2, 3): 25 N·m (2.5 kgf·m, 18 ft·lb) Right Swingarm Bracket Bolt (4): 25 N·m (2.5 kgf·m, 18 ft·lb) • Move the swingarm up and down to check for abnormal friction. • Install the removed parts (see appropriate chapters). Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collars [A] Grease Seals [B] Sleeves [C] Circlip (Right Side) [D] Special Tool – Inside Circlip Pliers: 57001-143 o•o&2HBW2 C Swingarm • Remove the ball bearing and needle bearings. Special Tool – Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation • Replace the needle bearings [AJ, ball bearing [BJ, grease seals [CJ and circlip [DJ with new ones. • Apply grease to the left needle bearing and the lip of the grease seals. • Install the needle bearings, ball bearing, grease seals and circlip as shown. 11 .6 mm (0.46 in.) [EJ 24 mm (0.94 in.) [FJ 5.5 mm (0.22 in.) [GJ 17 mm (0.67 in.) [HJ 26.7 mm (10.05 in.) [IJ Left Side [JJ Right Side [KJ OUsing a suitable bearing driver and the bearing driver set (special tool: 57001-1129). Special Tool – Bearing Driver Set: 57001-1129 ® ® ® C A C NOTE .©. . O!nsta/1 the needle and ball bearings so that the marked side faces out. SUSPENSION 13-21 ® GM062758W2 C 13-22 SUSPENSION Swingarm ○Press in the ball bearing until it bottomed. Special Tool – Bearing Driver Set: 57001-1129 ○Install the circlip. Special Tool – Inside Circlip Pliers: 57001-143 ○Press in the grease seals so that seal surface is flushed with the end of housing. Special Tool – Bearing Driver Set: 57001-1129 Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Removal may damage them. •Inspect the needle bearings [A] and ball bearing [B] installed in the swingarm. ○The rollers and ball in a bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually inspect the bearing for abrasion, discoloration, or other damage. If the needle bearing and sleeves [C] show any sings of abnormal wear, discoloration, or damage, replace them as a set. •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. •Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing. Swingarm Bearing Lubrication •Refer to the Suspension System Inspection in the Periodic Maintenance chapter. NOTE ○Since the ball bearing [A] is packed with grease and sealed, lubrication is not required. Chain Guide Inspection •Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter. SUSPENSION 13-23 Tie-Rod, Rocker Arm Tie-Rod Removal •Squeeze the brake lever slowly and hold it with a band [A]. •Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal). 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. •Remove: Frame Covers (see Frame Cover Removal in the Frame chapter) Shift Pedal (see Shift Pedal Removal in the Crankshaft/ Transmission chapter) •Loosen: Right Swingarm Bracket Bolt [A] •Loosen: Left Swingarm Bracket Bolts [A] •Remove: Swingarm Pivot Shaft Nut [B] Left Swingarm Bracket Bolts Left Swingarm Bracket [C] •Remove: Tie-Rod Bolt (Upper) [A] and Nut Tie-Rod Bolt (Lower) [B] and Nut Tie-Rod 13-24 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Installation • Apply grease to the inside of the grease seals. • Pull up the swingarm, and install the tie-rod. • Replace the tie-rod nuts with new ones. • Tighten: Torque -Tie-Rod Bolt (Lower): 44 N·m (4.5 kgf·m, 32 ft-lb) • Pull up the swingarm, and tighten the bolt. Torque – Tie-Rod Bolt (Upper): 44 N·m (4.5 kgf·m, 32 ft·lb) • Install: Left Swingarm Bracket [A] • Tighten the bolts and nut following the tightening sequence [1 – 4]. Torque – Swingarm Pivot Shaft Nut (1): 108 N·m (11.0 kgf·m, 79.7 ft·lb) Left Swingarm Bracket Bolts (2, 3): 25 N·m (2.5 kgf·m, 18 ft·lb) Right Swingarm Bracket Bolt (4): 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the removed parts (see appropriate chapters). Rocker Arm Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal). AWARNING 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. • Remove: Lower Rear Shock Absorber Bolt [A] and Nut Tie-Rod Bolt (Upper) [B] and Nut Rocker Arm Bolt [C] and Nut Rocker Arms [D] 0M01UIOBS1 C Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the oil seals. • Replace the following nuts with new ones. Rocker Arm Nut Upper Tie-Rod Nut Lower Rear Shock Absorber Nut • Pull up the swingarm, and tighten the bolts following the tightening sequence [1 – 3]. Torque – Rocker Arm Bolt [1]: 59 N·m (6.0 kgf·m, 44 ft·lb) Tie-Rod Bolt (Upper) [2]: 44 N·m (4.5 kgf·m, 32 ft·lb) Lower Rear Shock Absorber Bolt [3]: 34 N·m (3.5 kgf·m, 25 ft·lb) • Install the removed parts (see appropriate chapters). Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rod (see Tie-Rod Removal) Rocker Arms (see Rocker Arm Removal) Swingarm [A] (see Swingarm Removal) Sleeves [B] Grease Seals [C] • Remove the needle bearings [D], using a suitable tool. SUSPENSION 13-25 GM011628W2 C 13-26 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearings and grease seals with new ones. • Apply grease to the lips of the grease seals. • Install the new needle bearings and grease seals position as shown. For Tie-Rod Bearing OScrew the needle bearing driver into the driver holder. Olnsert the needle bearing driver into the needle bearing and press the needle bearing. NOTE OFor 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, ¢ 171</>18: 57001 -1609 For Rocker Arm Bearing OUsing a suitable bearing driver and the bearing driver set (special tool: 57001-1129). Special Tool – Bearing Driver Set: 57001-1129 NOTE Olnsta/1 the needle bearings so that the marked side faces outward. CD t Needle Bearings [A] Grease Seals [B] = Rear Shock Absorber [C] Tie-Rod [D] Swingarm [E] B G Rocker Arms [F] 7.5 mm (0.30 in.) [G] Front [H] Right Side [I] Left Side [J] 0• 011e1ew2 c SUSPENSION 13-27 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Removal may damage them. •Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. •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 ○Since 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 Steering Stem, Stem Bearing Removal 14-6 Steering Stem, Stem Bearing Installation . 14-7 Steering Stem Bearing Lubrication . 14-9 Steering Stem Warp Inspection 14-9 Stem Cap Deterioration, Damage Inspection . 14-9 Handlebars . 14-10 Handlebar Removal 14-10 Handlebar Installation . 14-10 14•2 STEERING Exploded View GN02273BW5 C STEERING 14-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Handlebar Bolts 34 3.5 25 L 2 Steering Stem Head Bolt 108 11.0 79.7 3 Upper Front Fork Clamp Bolts 20 2.0 15 4 Handlebar Holder Mounting Nuts 34 3.5 25 R 5 Switch Housing Screws 3.5 0.36 31 in·lb 6 Steering Stem Nut 20 2.0 15 7 Lower Front Fork Clamp Bolts 20 2.0 15 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. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant. 14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver, <f,54.5: 57001-1077 Steering Stem Nut Wrench: 57001-1100 ST571075ST C ST571077ST C ST571 100ST C Steering Stem Bearing Driver, q,42.5: 57001-1344 Steering Stem Bearing Driver Adapter, <f,41.5: 57001-1345 ST571345ST C STEERING 14-5 Steering Steering Inspection •Refer to the Steering Play Inspection in the PeriodicMaintenance chapter. Steering Adjustment •Refer to the Steering Play Adjustment in the Periodic Maintenance chapter. 14-6 STEERING Steering Stem Steering Stem, Stem Bearing Removal •Remove: Handlebars (see Handlebar Removal) Ignition Switch Cover (see Ignition Switch Cover Removal in the Frame chapter) Upper Harness Bracket Bolts [A] Upper Harness Bracket [B] •Remove the steering stem head bolt plug [A]. •Loosen the steering stem head bolt [B]. •Remove: Front Forks (see Front Fork Removal (Each Fork Leg) in the Suspension chapter) Brake Hose Bracket Bolts [A] •Remove: Steering Stem Head Bolt [A] Washer [B] Steering Stem Head [C] •Bend the claws [A] of claw washer straighten. •Remove the steering stem locknut [B]. Special Tool – Steering Stem Nut Wrench: 57001-1100 •Remove the claw washer. Steering Stem • Pushing up the stem base, and remove the steering stem nut [A]. Special Tool· Steering Stem Nut Wrench [BJ: 57001-1100 • Remove: Steering Stem Stem Cap [C] Upper Ball Bearing Inner Race and Ball Bearing • To remove the bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses [D] of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE Off 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. • Remove the lower ball bearing from the steering stem. • 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]. Steering Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. • Apply grease to the outer races, and drive them into the head pipe at the same time using the head pipe outer race press shaft [A] and drivers. Special Tools • Head Pipe Outer Race Press Shaft: 57001 -1075 Head Pipe Outer Race Driver, cf>54.5 [BJ: 57001-1077 • Apply grease to the outer races. • Replace the bearing inner races and oil seal with new ones. • Apply grease to the oil seal. • Install the oil seal [A] on the steering stem. • Apply grease to the stem and hammer the lower ball bearing inner race [B]. Special Tools • Steering Stem Bearing Driver, cf>42.5 [CJ: 57001-1344 Steering Stem Bearing Driver Adapter, t/>41.5 [DJ: 57001-1345 STEERING 14-7 GNOS0998$1 0 14-8 STEERING Steering Stem • Apply grease to the lower ball bearing [AJ, and install it onto the steering stem. OThe lower and upper ball bearings are identical. • Apply grease to the upper ball bearing [BJ and inner race [C]. • Install the lower ball bearing to the steering stem. • Install the stem [AJ through the head pipe and install the ball bearing [BJ and inner race [CJ on it. • Install: Stem Cap [DJ Steering Stem Nut [EJ • Settle the bearings in place as follows. OTighten the steering stem nut with 65 N·m (6.6 kgf·m, 48 ft-lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [AJ. OCheck that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged. Special Tool· Steering Stem Nut Wrench: 57001-1100 Torque· Steering Stem Nut: 20 N·m (2.0 kgf·m, 15 ft·lb) • Install the claw washer [AJ so that its bent side [BJ faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer. • Hand tighten the stem locknut clockwise until the claws are aligned with the second groove of stem nut [DJ, and bend the 2 claws downward [EJ. • Install the stem head. • Install the washer, and temporary tighten the steering stem head bolt. • Install the front forks (see Front Fork Installation (Each Fork Leg) in the Suspension chapter). GNOS0604 S1 C GS 15 0648S2 C STEERING 14-9 Steering Stem NOTE ○Tighten the upper front fork clamp bolts first, next the stem head bolt, last the lower front fork clamp bolts. ○Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. Torque – Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 79.7 ft·lb) Lower Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) WARNING If the 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). •Install the removed parts (see appropriate chapters). Steering Stem Bearing Lubrication •Refer to the Steering Stem Bearing Lubrication in the Periodic Maintenance chapter. Steering Stem Warp Inspection •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. Stem Cap Deterioration, Damage Inspection Replace the stem cap if its oil seal [A] shows damage. 14-10 STEERING Handlebars Handlebar Removal •Remove: Clutch Lever Holder Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] Left Handlebar Grip [E] Handlebar Bolt [F] Left Handlebar •Remove: Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter) Right Switch Housing [B] Handlebar Weight [C] Throttle Grip [D] Handlebar Bolt [E] Right Handlebar •When removing the handlebar holders, remove the following parts. Harness Bracket Bolts [A] Harness Bracket [B] Snap Pin [C] (Both Sides) Handlebar Holder Mounting Nut [D] (Both Sides) Washer [E] (Both Sides) Handlebar Holder [F] Damper (Both Sides) [G] Handlebar Installation •Install the damper [A] (both sides) and handlebar holder [B] if removed. •Replace the handlebar holder nut [C] on both sides with new ones. •Install (Both Sides): Washer [D] Handlebar Holder Nut •Tighten: Torque – Handlebar Holder Mounting Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) •Install the snap pin [E] from forward. Handlebars • Fit the pin [A] of the handlebar to the recess [B] of the handlebar holder. • Apply a non-permanent locking agent to the threads of the handlebar bolts. • Tighten: Torque – Handlebar Bolts: 34 N·m (3.5 kgf·m, 25 ft-lb) • 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. • Apply adhesive to the inside of the left handlebar grip. • Install the left handlebar grip and left handlebar weight. • Apply a non-permanent locking agent to the threads of the left handlebar weight bolt, and tighten it. • Install the left switch housing. OF it the projection [A] into a small hole [B] of the handlebar. • Tighten: Torque – Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Install: Throttle Grip Throttle Cable Tips [A] Right Switch Housing OF it the projection [B] into a small hole [C] of the handlebar. • Tighten: Torque – Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • When installing the handlebar weight shaft, note the following. • Prepare a new clamp [A] and handlebar weight shaft [B] with dampers [C]. • Apply a non-permanent locking agent to the threads of the handlebar weight bolt. •Assemble: Clamp Handlebar Weight [D] Handlebar Weight Bolt [E] STEERING 14-11 GN06 1’68SI C 14-12 STEERING Handlebars • Apply soap and water solution or rubber lubricant to the handlebar weight [A] and inside of the handlebars [B]. • Insert the handlebar weight shaft assembly [C] into the handlebar [D] until it stops at the stoppers [E] of the clamp. Holes [F] of the Handlebar • Tighten the bolt securely. • Install: Clutch Lever Assembly (see Clutch Lever Assembly Installation in the Clutch chapter) Front Master Cylinder (see Front Master Cylinder Installation in the Brakes chapter) • Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). • Adjust the throttle grip free play (see Throttle Control System Inspection in the Periodic Maintenance chapter). GN081478 S2 C FRAME 15-1 15 Frame Table of Contents Exploded View 15-3 Seats 15-14 Rear Seat Removal. 15-14 Rear Seat Installation 15-14 Front Seat Removal 15-14 Front Seat Installation . 15-14 Fairings. 15-15 Upper Inner Fairing Removal 15-15 Upper Inner Fairing Installation. 15-16 Lower Inner Fairing Removal 15-17 Lower Inner Fairing Installation. 15-18 Fairing Cover Removal . 15-18 Fairing Cover Installation 15-19 Middle Fairing Removal 15-20 Middle Fairing Installation . 15-22 Middle Fairing Disassembly 15-23 Middle Fairing Assembly. 15-24 Upper Fairing Removal. 15-25 Upper Fairing Installation 15-25 Covers 15-27 Frame Cover Removal 15-27 Frame Cover Installation. 15-27 Side Cover Removal. 15-27 Side Cover Installation 15-27 Ignition Switch Cover Removal. 15-27 Ignition Switch Cover Installation 15-28 Fuel Tank Side Cover Removal 15-28 Fuel Tank Side Cover Installation . 15-28 Seat Cover Removal. 15-29 Seat Cover Installation 15-30 Fenders 15-31 Front Fender Removal 15-31 Front Fender Installation . 15-31 Rear Fender Removal. 15-31 Rear Fender Installation 15-33 Flap Removal 15-33 Flap Installation. 15-33 Frame . 15-34 Frame Inspection 15-34 Battery Case. 15-35 Battery Case Removal 15-35 Battery Case Installation . 15-35 Guard 15-36 Mud Guard Removal. 15-36 Mud Guard Installation 15-36 Windshield 15-37 Windshield Height Adjustment 15-37 Windshield Removal . 15-37 Windshield Installation 15-37 Side Stand 15-38 15-2 FRAME Side Stand Removal . 15-38 Side Stand Installation 15-39 Rear View Mirrors. 15-41 Rear View Mirror Removal 15-41 Rear View Mirror Installation. 15-41 FRAME 15-3 Exploded View This page intentionally left blank. 15-4 FRAME Exploded View e d ef 8002825BW5 C FRAME 15-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Windshield Bolts 0.50 0.05 4.4 in·lb 2 Meter Cover Bolts 0.50 0.05 4.4 in·lb 3 Upper Fairing Bolts 0.50 0.05 4.4 in·lb 4 Upper Inner Fairing Bolts 0.50 0.05 4.4 in·lb 5 Fairing Bracket Nuts 35 3.6 26 6. ID and IN Models 15-6 FRAME Exploded View 8002826BW5 C FRAME 15-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Fairing Cover Bolts 0.50 0.05 4.4 in·lb 2 Oil Pan Bracket Bolts 12 1.2 106 in·lb L, S(2) L: Apply a non-permanent locking agent. S: Follow the specified tightening sequence. 15-8 FRAME Exploded View , 8002827BW5 C FRAME 15-9 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Seat Cover Bolts 3.0 0.31 27 in·lb 15-10 FRAME Exploded View FRAME 15-11 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Battery Holder Bolts, L = 18 mm (0.71 in.) 1.0 0.10 8.9 in·lb 2 Rear Reflector Nuts 3.0 0.31 27 in·lb 3 Rear Reflector Nuts (CN Model) 4.0 0.41 35 in·lb 4. US, CA and CAL Models 5. US, CA, CAL, AU, AU LAMS, SEA-B1, MY and WVTA(FULL) Models 6. CN Model 7. SEA-B3, PH, MY, IN, TH, and CN Models 15-12 FRAME Exploded v· 1ew FRAME 15-13 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Grab Rail Mounting Bolts 17 1.7 13 2 Saree Guard Mounting Bolt 17 1.7 13 3 Swingarm Bracket Bolts 25 2.5 18 S 4 Rear Footpeg Bracket Bolts 25 2.5 18 5 Side Stand Switch Bolt 8.8 0.90 78 in·lb L 6 Side Stand Bracket Bolts 49 5.0 36 L, S 7 Side Stand Bolt 29 3.0 21 8 Side Stand Nut 44 4.5 32 R 9. IN Model G: Apply grease. L: Apply a non-permanent locking agent. S: Follow the specified tightening sequence. R: Replacement Parts 15-14 FRAME Seats Rear Seat Removal •Insert the ignition switch key [A] into the seat lock. •Turn the key clockwise, and pull up the front part of the rear seat [B]. •Remove the rear seat forward. Rear Seat Installation •Insert the seat hook [A] into the frame hole [B]. •Push down the front part of the seat until the lock clicks. Front Seat Removal •Remove the rear seat (see Rear Seat Removal). •Pull up the rear part of the front seat [A]. •Slide the front seat rearward [B] to remove it. Front Seat Installation •Insert the front seat tab [A] under the front seat bracket [B]. •Position the damper [C] to the bracket [D] on the frame. FRAME 15-15 Fairings Upper Inner Fairing Removal •Remove: Middle Fairings (see Middle Fairing Removal) Ignition Switch Cover (see Ignition Switch Cover Removal) Windshield (see Windshield Removal) Bolts [A] (Both Sides) Bracket [B] (Both Sides) •Remove: Quick Rivets [A] Bolts [B] •Clear the hook portions [C]. •Remove the meter cover [D]. •Slide out the dust cover [A], and disconnect the connector [B]. •Remove: Quick Rivet [A] •Remove: Bolt [A] and Washer (Both Sides) Bolt [B] (Both Sides) •Clear the hook portions [C] (Both Sides). 15-16 FRAME Fairings •Clear the projections [A] on the upper inner fairing [B] by pulling up the center part of the upper inner fairing. •Clear the upper inner fairing [A] while warping the end of the upper inner fairing to prevent other components from damaging the upper inner fairing on both sides. •Remove the upper inner fairing [A] while warping the both ends of the upper inner fairing to prevent other components from damaging the upper inner fairing. Upper Inner Fairing Installation •Installation is the reverse of removal. •Be sure to install the grommets [A] on the bracket. •Insert the projections [A] on the upper inner fairing [B] into the grommets [C]. FRAME 15-17 Fairings •Fit the upper inner fairing [A] into the slit [B] on the upper fairing on both sides. •Insert the hooks [A] on the upper inner fairing into the holes [B] on the fuel tank side cover on both sides. •Insert the hooks [A] on the meter cover into the slits [B] on the upper fairing. •Tighten: Torque – Meter Cover Bolts [A]: 0.50 N·m (0.05 kgf·m, 44 in·lb) Lower Inner Fairing Removal •Remove: Upper Fairing (see Upper Fairing Removal) Headlight Unit (see Headlight Unit Removal in the Electrical System chapter) Bolts [A] Quick Rivets [B] 15-18 FRAME Fairings •Remove: Screws [A] Lower Inner Fairing [B] Lower Inner Fairing Installation •Installation is the reverse of removal. •Be sure to install the clip nuts [A] on the lower inner fairing. •Insert the projection [A] on the lower inner fairing into the hole [B] on the upper fairing. Fairing Cover Removal Hooks [A] Projection [B] FRAME 15-19 Fairings •Remove: Bolts [A] •Pull out the fairing cover [B] outward to clear the projection [C]. •Clear the upper hooks [D]. •Clear the lower hooks [E], and remove the fairing cover. NOTE ○Clear the lower hooks last. Fairing Cover Installation •Installation is the reverse of removal. •Check that the grommet [A] is in place on the upper fairing. •Insert the lower hooks [A] on the fairing cover into the holes [B] on the upper fairing. •Insert the upper hooks [A] on the fairing cover into the holes [B] on the upper fairing and side center fairing. •Insert the upper hook [A] on the fairing cover into the hole [B] on the upper fairing. •Insert the projection [C] on the fairing cover into the grommet [D] on the upper fairing. 15-20 FRAME Fairings ○Tighten: Torque – Fairing Cover Bolts [A]: 0.50 N·m (0.05 kgf·m, 44 in·lb) Middle Fairing Removal Slots [A] Projections [B] Tabs [C] Hook [D] Pad [E] •Remove: Fairing Cover (see Fairing Cover Removal) Bolts [A] FRAME 15-21 Fairings •Free the clamp [A] from the frame. •Disconnect the turn signal light lead connector [B] •Remove: Bolt [C] and Collar •Remove the quick rivets [A]. •Remove: Bolt [A], Collar and Washer 15-22 FRAME Fairings •Pull the middle fairing [A] outward to clear the projections [B]. •Pull the middle fairing forward to clear the hook [C] and tabs [D], and remove it with the lower fairing. NOTE ○If difficult to remove the middle fairing tab [E], pull the middle fairing upward while pushing down the upper inner fairing to clear the tab behind the middle fairing. Middle Fairing Installation •Installation is the reverse of removal. •Check that the grommets [A] and clip nuts [B] are in place on the upper inner fairing, upper fairing bracket and frame. •Check that the pad [A] is in place on the front turn signal light [B]. •Insert the hook [A] on the middle fairing into the hole [B] on the lower inner fairing. •Insert the hooks [A] on the middle fairing into the holes [B] on the upper fairing. •Insert the projection [C] on the middle fairing into the grommet [D] on the upper fairing bracket. FRAME 15-23 Fairings •Insert the slots [A] on the middle fairing to the tabs [B] on the lower inner fairing. •Insert the slots [A] on the middle fairing to the upper inner fairing [B]. •Insert the projections [A] on the middle fairing into the grommets [B] on the frame. Middle Fairing Disassembly •Remove: Middle Fairing with Lower Fairing (see Middle Fairing Removal) Left Side [A] Right Side [B] Screws [C]. Screws [D] and Washers •Clear the tabs [E] from the middle fairing, and remove the lower front fairing [F] and lower fairing [G]. 15-24 FRAME Fairings •Clear the front turn signal light lead [A] from the middle fairing. •Remove: Screws [B] Bracket [C] Rubber Damper [D] Front Turn Signal Light [E] •Remove: Screws [A] •Clear the tabs [B] from the center fairing [C], and remove the side center fairing [D]. Middle Fairing Assembly •Assembly is the reverse of disassembly. •Fit the rear end [A] of the side center fairing to the center fairing [B]. •Insert the hooks [A] on the side center fairing into the holes [B] on the center fairing. •Fit the tab [C] on the center fairing into the hole [D] on the side center fairing. •Insert the tab [A] on the lower fairing [B] into the hole [C] on the center fairing. FRAME 15-25 Fairings •Insert the tabs [A] on the lower front fairing [B] into the holes [C] on the center fairing and lower fairing. •Run the front turn signal light lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Upper Fairing Removal •Remove: Middle Fairings (see Middle Fairing Removal) Upper Inner Fairing (see Upper Inner Fairing Removal) Rear View Mirrors (see Rear View Mirror Removal) •Disconnect: Headlight and City Light Lead Connector [A] (Both Sides) •Remove: Bolt [B] (Both Sides) •Pull the upper fairing [A] upward to clear the projections [B] on both sides. •Pull the upper fairing [A] forward to clear the projections [B], and remove the upper fairing with lower inner fairing. Upper Fairing Installation •Installation is the reverse of removal. •Check that the grommets [A] and dampers [B] are in place on the fairing bracket. 15-26 FRAME Fairings •Check that the grommets [A], dampers [B] and pads [C] are in place on the upper fairing and headlight unit. •Run the leads and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). FRAME 15-27 Covers Frame Cover Removal •Remove: Bolts [A] and Washers Frame Cover [B] Frame Cover Installation •Installation is the reverse of removal. Side Cover Removal •Remove: Frame Cover (see Frame Cover Removal) Bolts [A] Side Cover [B] Side Cover Installation •Installation is the reverse of removal. Ignition Switch Cover Removal Hooks [A] Ignition Switch Cover [B] 15-28 FRAME Covers •Remove: Bolt [A] and Collar [B] (Both Sides) Bolt [C], Washer and Plastic Washer (Both Sides) •Slide the ignition switch cover [D] forward to clear the hooks, and remove it. Ignition Switch Cover Installation •Installation is the reverse of removal. •Insert the hooks [A] of the ignition switch cover into the slits [B] on the upper inner fairing. Fuel Tank Side Cover Removal •Remove: Front Seat (see Front Seat Removal) Upper Inner Fairing (see Upper Inner Fairing Removal) Bolts [A] and Washers Bolt [B] Collar Damper •Pull out the fuel tank side cover [C] outward to clear the projections [D], and remove it. Fuel Tank Side Cover Installation •Installation is the reverse of removal. •Check that the grommets [A] are in place on the fuel tank. •Install the fuel tank side cover [A] so that the projections [B] fit into the grommets. FRAME 15-29 Covers Seat Cover Removal Tab [A] Hooks [B] •Remove: Front Seat (see Front Seat Removal) Seat Cover Bolts [A] •Remove: Bolt [A] •Pull out the seat cover [B] rearward to clear the hooks [C] and tab [D], and remove it. 15-30 FRAME Covers Seat Cover Installation •Installation is the reverse of removal. •Insert the hooks [A] and tab [B] of the seat cover into the slits [C] on the rear fender. •Tighten: Torque – Seat Cover Bolts [A]: 3.0 N·m (0.31 kgf·m, 27 in·lb) FRAME 15-31 Fenders Front Fender Removal •Remove: Bolt [A] and Washer (Both Sides) Bolt [B] (Both Sides) Front Fender [C] Front Fender Installation •Install the front fender [A] together with the brake hose clamp [B] on both sides. Rear Fender Removal •Remove: Seat Cover (see Seat Cover Removal) Tail/Brake Light (LED) Unit (see Tail/Brake Light (LED) Unit Removal in the Electrical System chapter) Bolts [A] Clamps [B] Bracket [C] •Remove: Bolts [A] Bracket [B] •Remove: Screws [A] 15-32 FRAME Fenders •Clear the tab [A] on the cover [B] from the rear fender [C], and remove the cover. •Remove: Canister [A] (Evaporative Emission Control System Equipped Models) •Disconnect: License Plate Light Lead Connector [A] Turn Signal Light Lead Connectors [B] •Remove: Bolts [A] Kawasaki Diagnostic System connector [B] ABS Kawasaki Diagnostic System connector (ABS Equipped models) •Clear the seat lock cable [C] from the guide [D] on the frame. •Remove the bolts [E], and remove the rear fender [F] together with the flap. FRAME 15-33 Fenders Rear Fender Installation •Installation is the reverse of removal. •Tighten: Torque – Battery Holder Bolts, L=18 mm (0.71 in.) [A]: 1.0 N·m (0.10 kgf·m, 8.9 in·lb) •Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Flap Removal •Remove the rear fender (see Rear Fender Removal). •Clear the license plate light and turn signal light leads [A] from the clamp [B]. •Remove: Screw [C] •Remove the flap [D] together with the reinforce. Flap Installation •Installation is the reverse of removal. •Install the flap [A] so that the projections [B] fit into the holes [C] on the rear fender. •Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). 15-34 FRAME Frame Frame Inspection •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. FRAME 15-35 Battery Case Battery Case Removal •Remove: Rear Fender (see Rear Fender Removal) Battery (see Battery Removal in the Electrical System chapter) Bolt [A] Battery Case [B] Battery Case Installation •Installation is the reverse of removal. 15-36 FRAME Guard Mud Guard Removal •Remove: Bolts [A] Mud Guard [B] •Remove the following parts if necessary. Bolt [C] Chain Cover [D] Mud Guard Installation •Installation is the reverse of removal. Windshield Windshield Height Adjustment OThe windshield can be adjusted within 3 positions in height to suit the rider’s preference. • Remove: Windshield (see Windshield Removal) Bolts [A] (Both Sides) • Move the position of the brackets [B] evenly and adjust the windshield height. High Position [C] Middle Position [D] Low Position [E] • Install the windshield (see Windshield Installation). Windshield Removal • Remove: Windshield Bolts [A] and Washers Windshield [B] • Remove (Both Sides): Bolts [A] Windshield Bracket [B] Windshield Installation • Install: Windshield Brackets [A] Bolts [B] Nuts [C] Windshield [D] Washers [E] Windshield Bolts [F] • Tighten: Torque· Windshield Bolts: 0.50 N·m (0.05 kgf·m, 4.4 in·lb) FRAME 15-37 60 160200 S 15-38 FRAME Side Stand Side Stand Removal •Raise the rear wheel off the ground using a stand [A]. •Remove the side stand switch bolt [A] and plate [B] to free the side stand switch [C]. •Remove: Spring [A] Side Stand Nut [B] Side Stand Bolt [C] Collar [D] Side Stand [E] If the side stand bracket removal is necessary, follow the below procedures. •Remove the shift lever bolt [A]. •Take the shift lever [B] off the shift shaft. •Remove: Swingarm Bracket Bolts [A] Side Stand Bracket Bolt [B] Side Stand Bracket [C] Link Arm [D] Side Stand Side Stand Installation • Apply a non-permanent locking agent to the side stand bracket bolts. • Apply grease to the side stand bracket [A] as shown. Outside of the Vehicle [B] • Install the side stand bracket [A] to the frame. • Tighten: Torque· Side Stand Bracket Bolts [BJ: 49 N·m (5.0 kgf·m, 36 ft·lb) Swingarm Bracket Bolts [CJ: 25 N·m (2.5 kgf·m, 18 ft·lb) • Apply grease to sliding areas [A] of the side stand [B], link arm [C] and spring [D] as shown. FRAME 15-39 G0200918 S 60200958 S 15-40 FRAME Side Stand • Install: Side Stand [A] Collar [B] Side Stand Bolt [C] • Tighten: Torque· Side Stand Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb) • Replace the side stand nut [D] with new one. • Tighten: Torque • Side Stand Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) OF ace the flat side of the side stand nut to outside. • Install the link arm [E] and the spring [F]. OCheck that the spring ends fit to the groove of the installation portion. • Install the plate [G] and side stand switch [H] Olnsert the side stand switch arm [I] to the pin on the side stand. • Apply a non-permanent locking agent to the side stand switch bolt [J], and tighten it. Torque· Side Stand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb FRAME 15-41 Rear View Mirrors Rear View Mirror Removal •Remove: Bolts [A] Rear View Mirror [B] Rear View Mirror Installation •Installation is the reverse of removal. 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. 16-12 Wiring Diagram (ER650G) 16-14 Wiring Diagram (ER650H) 16-16 Precautions. 16-18 Electrical Wiring 16-19 Wiring Inspection 16-19 Battery 16-20 Battery Removal . 16-20 Battery Installation 16-20 Battery Activation 16-21 Precautions . 16-23 Interchange . 16-24 Charging Condition Inspection 16-24 Refreshing Charge 16-24 Charging System 16-26 Alternator Cover Removal. 16-26 Alternator Cover Installation 16-26 Stator Coil Removal 16-27 Stator Coil Installation . 16-28 Alternator Rotor Removal . 16-28 Alternator Rotor Installation 16-29 Charging Voltage Inspection. 16-31 Alternator Inspection . 16-31 Regulator/Rectifier Removal. 16-33 Regulator/Rectifier Installation 16-33 Regulator/Rectifier Inspection. 16-33 Ignition System. 16-36 Crankshaft Sensor Removal. 16-36 Crankshaft Sensor Installation 16-37 Crankshaft Sensor Inspection. 16-37 Crankshaft Sensor Peak Voltage Inspection. 16-38 Timing Rotor Removal 16-38 Timing Rotor Installation . 16-38 Stick Coil Removal 16-39 Stick Coil Installation. 16-39 Stick Coil Inspection 16-39 Stick Coil Primary Peak Voltage Inspection 16-39 Spark Plug Removal . 16-40 Spark Plug Installation 16-40 Spark Plug Condition Inspection. 16-41 Interlock Operation Inspection 16-41 IC Igniter Inspection 16-42 Electric Starter System. 16-45 Starter Motor Removal 16-45 Starter Motor Installation. 16-45 Starter Motor Disassembly 16-46 Starter Motor Assembly 16-47 16-2 ELECTRICAL SYSTEM Brush Inspection . 16-48 Commutator Cleaning and Inspection. 16-49 Armature Inspection 16-49 Brush Lead Inspection 16-49 Right-hand End Cover Inspection. 16-49 Starter Relay Inspection 16-50 Lighting System 16-52 Headlight Beam Horizontal Adjustment 16-52 Headlight Beam Vertical Adjustment. 16-52 Headlight Bulb Replacement 16-52 Headlight Unit Removal 16-53 Headlight Unit Installation . 16-53 City Light Bulb Replacement. 16-54 Tail/Brake Light (LED) Unit Removal 16-54 Tail/Brake Light (LED) Unit Installation . 16-54 License Plate Light Bulb Replacement . 16-55 Front Turn Signal Light Bulb Replacement . 16-56 Rear Turn Signal Light Bulb Replacement 16-57 Turn Signal Relay Inspection 16-58 Switches and Sensors 16-60 Brake Light Timing Inspection. 16-60 Brake Light Timing Adjustment . 16-60 Switch Inspection 16-60 Water Temperature Sensor Removal/Installation . 16-60 Water Temperature Sensor Inspection . 16-61 Rear Wheel Rotation Sensor Removal. 16-61 Rear Wheel Rotation Sensor Installation 16-61 Rear Wheel Rotation Sensor Inspection. 16-61 Fuel Level Sensor Inspection 16-61 Oxygen Sensor Removal 16-62 Oxygen Sensor Installation . 16-62 Oxygen Sensor Inspection 16-63 Gear Position Sensor Removal. 16-63 Gear Position Sensor Installation 16-64 Gear Position Sensor Inspection 16-64 Accessory Relay Inspection 16-64 Air Switching Valve . 16-66 Air Switching Valve Operation Test . 16-66 Air Switching Valve Unit Test 16-66 Radiator Fan System 16-68 Fan Motor Removal 16-68 Fan Motor Installation . 16-68 Fan Motor Inspection 16-68 Meter, Gauge, Indicator Unit. 16-69 Meter Unit Removal 16-69 Meter Unit Installation . 16-69 Meter Unit Disassembly/Assembly . 16-69 Meter Operation Inspection. 16-70 Meter System Inspection 16-71 Meter Unit Inspection 16-72 Fuel Level Sensor Line Self-Diagnosis Mode Inspection 16-79 Relay Box . 16-82 Relay Box Removal 16-82 Relay Box Installation . 16-82 Relay Circuit Inspection 16-82 Diode Circuit Inspection 16-83 Fuses 16-85 ELECTRICAL SYSTEM 16-3 Main Fuse (30 A) Removal . 16-85 Fuse Box Fuse Removal. 16-85 Fuse Installation 16-85 Fuse Inspection. 16-86 16-4 ELECTRICAL SYSTEM Exploded View GP02840BW5 C ELECTRICAL SYSTEM 16-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Tail/Brake Light Bolts 0.50 0.05 4.4 in·lb 2 Turn Signal Light Lens Screw 1.0 0.10 8.9 in·lb 3 License Plate Light Screws 1.2 0.12 11 in·lb 16-6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Switch Housing Screws 3.5 0.36 31 in·lb 2 Front Brake Light Switch Screw 1.2 0.12 11 in·lb 3 Starter Motor Cable Terminal Nut 6.0 0.61 53 in·lb 4 Starter Relay Terminal Bolts 3.6 0.37 32 in·lb 5 Starter Motor Through Bolts 5.0 0.51 44 in·lb 6 Brush Holder Screw 3.8 0.39 34 in·lb 7 Starter Motor Mounting Bolts 9.8 1.0 87 in·lb L 8 Starter Motor Terminal Locknut 11 1.1 97 in·lb 9 Timing Rotor Bolt 40 4.1 30 10 Crankshaft Sensor Bolts 6.0 0.61 53 in·lb 11 Alternator Cover Bolts, L = 35 mm (1.4 in.) 12 1.2 106 in·lb S 12 Alternator Cover Bolts, L = 25 mm (1.0 in.) 12 1.2 106 in·lb S 13 Alternator Cover Bolts, L = 70 mm (2.8 in.) 12 1.2 106 in·lb S 14 Stator Coil Bolts 12 1.2 106 in·lb L 15 Alternator Lead Holding Plate Bolt 9.8 1.0 87 in·lb L 16 Alternator Rotor Bolt 200 20.4 148 MO 17 Starter Motor Clutch Bolts 34 3.5 25 L 18 Oil Pressure Switch 15 1.5 11 LG 19 Engine Ground Terminal Bolt 9.8 1.0 87 in·lb 20 Gear Position Sensor Bolt 9.8 1.0 87 in·lb 21 Side Stand Switch Bolt 8.8 0.90 78 in·lb L 22 Battery Holder Bolts, L = 18 mm (0.71 in.) 1.0 0.10 8.9 in·lb 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. 16-8 ELECTRICAL SYSTEM Exploded View / GP02837BW5 C ELECTRICAL SYSTEM 16-9 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel Pump Bolts 9.8 1.0 87 in·lb L, S 2 Regulator/Rectifier Bolts 9.8 1.0 87 in·lb 3 Regulator/Rectifier Bracket Bolt 9.8 1.0 87 in·lb 4 Spark Plugs 15 1.5 11 5 Oxygen Sensor 25 2.5 18 6 Water Temperature Sensor 12 1.2 106 in·lb L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. 16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name (AU, IN, MY, PH, TH) YTZ10 (US, CA, CAL, EUR, SEA-B1, SEA-B3, CN) YTZ10S (ID) YT12A-BS Capacity (Other than ID) 12 V 8.6 Ah (10 HR) (ID) 12 V 10 Ah (10 HR) Voltage 12.8 V or more Gross Weight (Other than ID) 3.2 kg (7.1 lb) (ID) 3.5 kg (7.7 lb) Electrolyte Volume (Other than ID) 0.45 L (27 cu in.) (ID) 0.47 L (29 cu in.) Charging System Alternator Type Three-phase AC Alternator Output Voltage (no load) AC41  62 V @4 000 r/min (rpm) Stator Coil Resistance 0.176  0.264 Ω @20°C (68°F) Charging Voltage (Regulator/Rectifier Output Voltage) 14.3  14.7 V @25°C (77°F) Ignition System Crankshaft Sensor: Resistance 376  564 Ω @20°C (68°F) Peak Voltage 3.0 V or more Stick Coil: Primary Winding Resistance 1.11  1.50 Ω @20°C (68°F) Secondary Winding Resistance 6.4  9.6 kΩ @20°C (68°F) Primary Peak Voltage 110 V or more Spark Plug: Type NGK CR9EIA-9 Gap 0.8  0.9 mm (0.031  0.035 in.) Electric Starter System Starter Motor: Brush Length 12 mm (0.47 in.) [Service Limit: 6.5 mm (0.26 in.)] Air Switching Valve Resistance 18  22 Ω @20°C (68°F) Switches and Sensors Rear Brake Light Switch Timing ON after about 10 mm (0.39 in.) of pedal travel Engine Oil Pressure Switch Connections When engine is stopped: ON When engine is running: OFF Water Temperature Sensor Resistance in the text Fuel Level Sensor Resistance: Full Position 9  11 Ω Empty Position 213  219 Ω Special Tools and Sealant Peak Voltage Adapter: 57001-1415 Lead Wire • Peak Voltage Adapter: 57001-1449 Needle Adapter Set: 57001-1457 Rotor Holder: 57001-1567 ST571449ST C ST5 71 457ST C ST571567ST C ELECTRICAL SYSTEM 16-11 Grip: 57001-1591 ST571591ST C Flywheel Puller Assembly, M38 x 1.5/M35 x 1.5: 57001-1615 Rotor Holder: 57001-1658 Liquid Gasket, TB1211F: 92104-0004 ST571615ST C ST571658ST C ST920004ST C 16-12 ELECTRICAL SYSTEM Parts Location ECU [A] Battery [A] Starter Relay [B] Fuse Box (1) [A] Fuse Box (2) [B] Fuse Box (3) [C] (ABS Equipped Models) Water Temperature Sensor [D] Starter Motor [E] Turn Signal Relay [A] Accessory Relay [B] Relay Box [C] Gear Position Sensor [A] Alternator [B] Side Stand Switch [C] Oxygen Sensor [D] ELECTRICAL SYSTEM 16-13 Parts Location Regulator/Rectifier [A] Radiator Fan Motor [B] Rear Brake Light Switch [A] Crankshaft Sensor [B] Timing Rotor [C] Oil Pressure Switch [D] Air Switching Valve [A] Stick Coils [B] Spark Plugs [C] Starter Lockout Switch [A] Meter Unit [B] Ignition Switch [C] Front Brake Light Switch [D] 16-14 ELECTRICAL SYSTEM Wiring Diagram (ER650G) ••t • r \ln i t L l’ellu &• l tt.- 110 l e ilicetc, Liah t. (l[ O) 2 . Gr ee 11 ltt t T11,,. S i t • • • I nd l cetot U t lol(Lfb) 3 . C, , , n Ri tht 1 11 ,n S i t n t l l nd i11-t tor U 11tt<lU) 4. &h t 111,• l o • l ,ull~HOf ltclilt ( L tO) ! . 4h e,n II• • • • • • , ,., i c,tor li111t (L£0 ) t . ‘hllo• fot i ” • 1’1re i o 1 ln d i c • t0t Ut1t,t(LI&) l. t , d l ar• <11t t n dl l ,ttor Li1ll1(LEf)) (O i I f rcu• ul8utuy/ l ot, 1 , ,,.,o , ,,tu1,) •.•• , . 1 11,1 1, 11 l i 1 t.t ( l ( t) t . Speed•••tu 10. hcllo• ete, 1 L 0 111Gn,ter/h ip Me t e r 11. C1;11rot 11 10010 /,huore Ii i heae/ c, . ~ i fl’ ·~··· 13 . Chck 1,. r .,1 l «••• 01 111• 1$. Geu , ,,ttio” ‘ ” ‘-c•to, au:o:Ll 1ht leH thr tl,d• ,.1 t ; . ,. • • toh * ~– !! Er’E @© 1I ~ ::::::il–‘;.;.; ‘ “” ~I 4> I <!> I IIIII!I :1~ 0 liID 0 I DID 01 !g!g oL~J – “/ ~ l – ‘ _ _,- . ‘s r, . t lt i ,ht I l Ut n $ i •no I lrl1- 4 -fl’\- U ±=~111-t-t—–t-t-t–tt-t——-i–t lisnt 1:UlOI ~ 1~ 1, – I 11’1U ~ V I ff tl 1 11 t ! whc!t. l o u l•t 1.f,on t a , ,,, Li t h t S11 itch 2 . E, , ;.,., Stop $ • it.ch s. St u tH ‘ ” Ho” . l o tor Sou t , ,,,i ” ,1 f St t c• f , , r r rn:_h~;;;::~1hi~·1 · h : , , . ~ . ·h+—+W—-!—U+–U——U-~*=1:===l=*=~-ni-i–rr-i- · 1v, •• ~,u lll’f – L _____ _J t:~:~::::·~–~J- I I 2Y S5W ,, I L,ft @]:: L () I t)’ l t f <\ t VI •fl====:tt—-, I fY I I Vt ff ——- r,on t l.eft huna11••• @):_’, .-~m- 0, LI th t I VIOi’ Mo,11 ~ :—————-~ LEFT SWITCH HOUS ING I Ltft $ . h e h Mo • tht I . !t ot• 8 11 t ten ll . !h ru4 811 110• 3 , f••• $ ‘•” • I S• i toh 4 , 0 10110 , S o l toll $.$tutor look~vt lS • itc.~ 6 . , ••• • • • , ,, . CONNECTIO NS Horn Bu t ton Hazard Switch Turn Si2nal Swi tch Di1111e r Switch Starter lockoot Switch Color BK/W BK/Y Color G 0 GY Color G 0 8Y Color RIV BL/Y R/ BK Color BK BR Releued OFF L =– HI =– letchlefn Push 0–0 ON ~FF {Push) Rel eased R =– LO =-_, Pul lod in =– l:ohy 8 ox f. feit It, I or , .• ,o411 SIH 0Ho o ll ••• • ., J. t eu , ., . ,,.,,. ( .foel t u”‘• lolo, t. St” t,r c 1,e~ 1 t t ohy – Pass in2 Button Co l o r R/BK BL/Y Push 0–0 W2LI 254BW5 C ELECTRICAL SYSTEM 16-15 Wiring Diagram (ER650G) s . t llrotth Vo I Yf Ac t ,nto, i i 0 S >– :::: J ~ – = – •I; II tJ/ ~,~ I – ~ /ti, · – t. n – F, u 8oc (2) – , I “‘ -, -;-i ‘.” ‘ ‘” U t l Fvu 801 ( I) LECe fvu 1SA t . llot•• f”t t IOA 3 . Ft • F u s t 1SA ·- ,._ 4 . 8ttli.t Ll tht / llore f 1.11 , I OA S . lt• i t i on f11•• 1• 1. $ . Mudti iht r 11u 10 IGNITION SWITCH CONNECTIONS Ignit ion Battery Signal Color BR ‘ BL ~FF. Loci ON All ,$: i :;i (If(!~ ::f> f:” >ilH I I I I I I 1111 t- I ~iu~u .'””.,” ff sti• r •• , n I • ( I) (2} (3) (0 CS) 0) • • ~ tj~ ~ • • ••• G<‘ o11n ih Fuu loa(2) I.Ac~• ••••r r. , , SA St>r t t , I O t O I t , 11 r 11 $i 1 110 I llo l or fuot I OI. . r~,, ‘” lhtto •tt• t • n • f ••I F .-,1 t r o on • L•vt I f> ll’ • t $11aor i £S I g I tltJ , S i dt St111d RIGHT SWI TCH HOUSI NG . , . {(·0 11 , r, t i .,, ( 11 ) ui, n c,, t , ot s,,, •• t4, i • 11•d ··~·•·> ‘ < ~ – , — –. – ‘ _- y,:,1! -•IClO 1-, 10 “”‘ L. l =. fil HU iro , ,,,t i tit1n0Jt I~ $•Ht• ” c,,.n, cl •• ~- . ::ffi , , t P 1,,11. / ll~R l l ,l! t S• l “toh , Color Code BK Black BL Blue BR Brown G Green SY Gray LB Li2ht Blue LG Li ght Gr een CONN ECTI ONS 0 Or an~e rront Bn ke li,J,t S.itch Enrine Stop Sr itch Star tor But ton p Pink Co lo r l BK I BK Color lY/RI R Co I or l!K/ RIBK/ R PU Purple ~ake lewrl I OFF I I I I R Red Pull ed lnl =- RUN I c-, Push I =- w Wh i te (98052 – 12538. 12548) y Ye 11 ow 12R I 2S48IS C 16-16 ELECTRICAL SYSTEM Wiring Diagram (ER650H) l t l u U• i t 1. Yt ll • • , as l n 4 1 t •t•r l , 1 1>1(1. lt) t . h llo. Slll f t•vt> l tdl utor ltf !H(l (O} a . 6 t ee• left l 11rn S h,.•1 l e d l e•to, Li 1 h t (u•> 4. Clr ••• IH a ll t Tv r • Si c • t l l n iictltr li1ht (Ut> $ . II 11t 11 , 1 11 8••• l n cl , e• t • r ‘- ‘ 1 1>t ( l(t) 6 . ., tul l •dh lt(H l lrlltH!DI l .Ycll o• f a c l ae , .,.,,., l n llc·tt<)t Li l h t(Utt a. hcl Wtr a >• i l t1 d iea \ o• I i ,11 t{LCOl (Oi l , . ,.,,,, e . ttu 1/ ••t •r lu1p•r•t•r•} t . I I l11 ,.l111t1011 l I 1ht fl(OI 1 0 . Spee llo,utu 1 1. T1c11 o•cter IL O<ft•ttc , /l# ip II e t c, t S, cc.,. ,.,r,r .,n ,t at ,,, h.,a, 1+/ A.,,, ,,, •i h •1• / 14, ~I••• IS. fuel Lc,tl 61 uae U . hH Posh h n l • d h ltcH • lfO:licllt E,.it t i nc Oiocl, .(O<.H. OCH I o n t ft•O• ~—~ :~:”:=c:–=-=-====1m=~::; ,r_.-,.’.’ ,-~.· – ,-. ,-. I! i r, ••• Gto11nd “‘ fuu lodJ) I. l8$ • oto• llel•r fw,o 25A 11 1 , i., s. l teh w • • , , ,., 1.frut 8ttkc ll 1llt S•IUII t. l!nfl 11e Stot> S •I uh 3 . S t•• tc , s tt.tn I I I ! i r; :~7;H J ,= L,fl $.-iuh llow5i a s I lloro Bwt ton 2. “u.ud a uon h l o r In l. f’tll . . , z . 181 ~oto•oi 4 1’oho lto l ,y fo,o 15A S f ., , . S Ot • 1 Swi t”h ‘ Oii,o.or $• i t~II t . ” • •d f i J Iit Ci , c u i t *• l 11 J 5 S to,t, , l.oc; t. o• t s i tc;II S ECU • • • ” hhv f “•~ • • ” ‘ e t t o • f . 1’111 1 1>1,.p lt1l oy 5 . $tO,tU C: it~uH !tt h )’ LEFT SWITCH HOUSING CONNECT IONS Ho rn Button Hazard Switch Turn Siena I Switch Di11111er Switch Starter Loc:kcut S,itch Passing Button Color BK/W BK/Y Color G 0 GY Co lor G 0 GY Color R/Y ~L/Y l!/BK Color BK BR Color l!/BK ~L/Y Re I eased OFF L =– HI =– lot,b lem Push ca a:> ON IFF (Push) Released Push ca .:> R =– LO =– Pulled in =– W2L I 249BW5 C Wiring Diagram (ER650H) – ELECTRICAL SYSTEM 16-17 : :~ !: (l •••••t I •• l•f u f o • to• trol 11,t •, h•••··’ h 4 e h ) -:.o.~v. , – ~,;,’::, “,, “‘,”v’ ‘{.’ “‘ . ‘”M ‘+——-+-+——+——+– • “\’/’, ; ” , ‘–t-11———-11t======:i==========::::t:t==·’rr:r. –++-+-+,,”:rBj::_ – f use 8ett<2.) F11u lo.CO 1 eeu , 1 J A t • 11tor F•n• l(h\ J . r “” r $. HA • &r ,ke l t 1 • 1 t 11orn f•l• IOA I . t , i t l o ” F 11 to JOA , lud l 1, tr. t r,u ISA IGNITION SI ITCH CONNECT IONS lcnition Battery Sill’IOI Color BR w BL OFF, l<><:1 ON 6. Fuu 80,,(2:) L Acc c ,so r y F11,c l A t . 1 11 ~,. $ i&nf l Ro l •y F11, c I OA I I ., u .~’; ~’l-___ J ku•• ••• O i •cnott i c St• t •• Con ,uGtor Co lor Code BK Black BL Blue BR Brown G Green GY Grav LB Li rht Blue LG l ight Green 0 Orange p Pink PU Purple R Red w Wh ite (98052-12498. 12508) y Ye II OW 1 2Rl24G81S C 16-18 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests. ○The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. ○To prevent damage to electrical parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. ○Because of the large amount of current, never keep the starter button pushed when the starter motor will not turn over, or the current may burn out the starter motor windings. ○Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis ground. ○Troubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the failure. If the failure was caused by some other item or items, they must be repaired or replaced, or the new replacement will soon fail again. ○Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation. ○Measure coil and winding resistance when the part is cold (at room temperature). Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. * If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. * If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. • Check the wiring for continuity. OUse the wiring diagram to find the ends of the lead which is suspected of being a problem. OConnect a tester between the ends of the leads. * If the tester does not read about On, the lead is defective. Replace the lead or the wiring harness [B] if necessary. ELECTRICAL SYSTEM 16-19 GP070028S I C GP0708S8S I C 16-20 ELECTRICAL SYSTEM Battery Battery Removal •Turn the ignition switch off. •Remove: Front Seat (see Front Seat Removal in the Frame chapter) Bolts [A] Clamps [B] Bracket [C] •Remove the bolts [A] and holder [B]. •Disconnect the negative (–) cable [C]. NOTICE Be sure to disconnect the negative (–) cable first. •Slide out the positive (+) terminal cap [D] and disconnect the positive (+) cable [E]. •Remove the battery. Battery Installation •Turn the ignition switch off. •Put the battery into the battery case. •Connect the positive (+) cable [A] first. •Connect the negative (–) cable [B]. •Apply a light coat of grease on the terminals to prevent corrosion. •Cover the positive (+) terminal with the cap [C]. •Check that the damper [A] is in place on the holder [B]. •Install the holder. •Tighten the bolt [C]. •Tighten: Torque – Battery Holder Bolts, L = 18 mm (0.71 in.) [D]: 1.0 N·m (0.10 kgf·m, 8.9 in·lb) •Install: Bracket [A] Clamps [B] Bolts [C] Front Seat (see Front Seat Installation in the Frame chapter) Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These names must be the same. Battery Model Name EX650K: YT12A-BS (ID Model) 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. NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [BJ until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. A 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. • Place the battery on a level surface. • Check to see that the sealing sheet has no peeling, tears, or holes in it. • Remove the sealing sheet. NOTE o The battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge. • Remove the electrolyte container from the vinyl bag. • Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE ODo not pierce or otherwise open the sealed cells [BJ of the electrolyte container. Do not attempt to separate individual cells. ELECTRICAL SYSTEM 16-21 GP08 1358$1 0 NE0211 28$1 0 A GP08 1398$1 0 16-22 ELECTRICAL SYSTEM Battery • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill. NOTE ODo not tilt the electrolyte container. • Check the electrolyte flow. * If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. NOTE OBe careful not to have the battery fall down. • Keep the container in place. Don’t remove the container from the battery, the battery requires all the electrolyte from the container for proper operation. NOTICE Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the container until it is completely empty. • After filling, let the battery sit for 20 – 60 minutes with the electrolyte container kept in place, which is required for the electrolyte to fully permeate into the plates. • Make sure that the container cells have emptied completely, and remove the container from the battery. • Place the strip of caps [A] loosely over the filler ports, press down firmly with both hands to seat the strip of caps into the battery (don’t pound or hammer). When properly installed, the strip of caps will be level with the top of the battery. NOTICE Once the strip of caps is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery. NOTE OCharging the battery immediately after filling can shorten service life. 0$ ~ 01//JJJ; t·A c::::::::Jiio~ GP090()0lS1 C ME021 148S1 C GP0 8 0 128 S1 C GP0 8 0 10 BS1 C ELECTRICAL SYSTEM 16-23 Battery Initial Charge •Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 A × 5  10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060 Christie C10122S If the above chargers are not available, use equivalent one. •Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. (Voltage immediately after charging becomes temporarily high. For accurate measuring, let the battery sit for given time.) NOTE ○Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. If voltage is not at least 12.8 V, repeat charging cycle. ○To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test. If still below 12.8 V the battery is defective. Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge. If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see Refreshing Charge). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery. NOTICE This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap during refresh charge. If by chance an excessive amount of gas is generated due to overcharging, the relief valve releases the gas to keep the battery normal. 3) When you do not use the motorcycle for months. Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage. 4) Battery life. 16-24 ELECTRICAL SYSTEM Battery If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem). A 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 battery’s life will be shortened. Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital meter [A]. • Remove: Battery (see Battery Removal) • Measure the battery terminal voltage. NOTE OMeasure 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 • Remove the battery [A] (see Battery Removal). • Do refresh charge by following method according to the battery terminal voltage. AWARNING This battery is sealed type. Never remove sealing cap [BJ even at charging. Never add water. Charge with current and time as stated below. 13.2 13. 1 13.0 12 .9 GD) {A\ 12. 7 ~ 12 . 6 v 12 . s ~ 12 . 4 12 . 3 ” I’- GP080108S1 C ” ” I’-. ” 12.2 ® 12 · 1 100 90 807570 60 50 40 30 20 10 OS ‘ ~ss, c 0 D GP090012S1 C Battery Terminal Voltage: 11.5 – less than 12.8 V Standard Charge (see following chart): YTZ10NTZ10S: 0.9 A x 5 – 10 h YT12A-BS: Quick Charge: YTZ10NTZ10S: YT12A-BS: 1.2 A x 5 – 10 h 4.5 Ax 1 h 5A x 1h NOTICE If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal Voltage: less than 11.5 V Charging Method: YTZ10NTZ10S: 0.9 A x 20 h YT12A-BS: 1.2 A x 20 h NOTE Olncrease 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] • Determine the battery condition after refresh charge. ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria Judgement 12.8 V or higher Good 12.0 – lower than 12.8 V Charge insufficient – Recharge lower than 12.0 V Unserviceable – Replace (Other than ID Models) • After recharging, record [A] the charging date and the name of person in charge of this job to the battery recharging record label [B] if necessary. ELECTRICAL SYSTEM 16-25 11 ~ 10 J:: ., e ·- 6 1- ,. 4 I 1 2 (.’) 0 F’-, ._ ~ ~ ~ “r,. ” ~ . , “- 11.6 11 . 8 12. 0 12.2 12. 4 12.6 12.8 13.0 Bat te ry Te r mi na l Voltage(V) GP0802 I 8S 1 C V ® A [dJ GnJ 000 -00-0- — GP081368S1 0 16-26 ELECTRICAL SYSTEM Charging System Alternator Cover Removal •Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). •Remove : Left Side Cover (see Side Cover Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Cover Removal in the Final Drive chapter) •Disconnect the alternator lead connector [A]. •Open the rubber band [B]. •Place a suitable container under the alternator cover [A]. •Remove: Alternator Cover Bolts [B] Clamp [C] Alternator Cover Alternator Cover Installation •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. •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 •Check that dowel pins [B] are in place on the crankcase. •Replace the alternator cover gasket with a new one. •Install: Alternator Cover [A] Alternator Cover Bolts, 25 mm (1.0 in.) [B] Alternator Cover Bolts, 35 mm (1.4 in.) [C] Alternator Cover Bolts, 70 mm (2.8 in.) [D] Clamp [E] Charging System • Tighten the alternator cover bolts following the specified tighten sequence [1 – 14]. Torque -Alternator Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) • Run the alternator lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Connect the alternator lead connector. • Install the removed parts (see appropriate chapters). Stator Coil Removal • Remove: Alternator Cover (see Alternator Cover Removal) Alternator Lead Holding Plate Bolt [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] • Remove the stator coil [D] from the alternator cover. ELECTRICAL SYSTEM 16-27 GP0 9 46l8S2 C 16-28 ELECTRICAL SYSTEM Charging System Stator Coil Installation •Install the stator coil [A] to the alternator cover. •Apply a non-permanent locking agent to the threads of the stator coil bolts [B] and tighten them. Torque – Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •Secure the alternator lead with a holding plate [C]. ○Align the cut-out [D] on the holding plate with the pin on the alternator cover. •Apply a non-permanent locking agent to the threads of the plate bolt [E] and tighten it. Torque – Alternator Lead Holding Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •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. •Apply liquid gasket to the circumference of the alternator lead grommet [F], and fit the grommet into the notch of the cover securely. Sealant – Liquid Gasket, TB1211F: 92104-0004 •Install the alternator cover (see Alternator Cover Installation). Alternator Rotor Removal •Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear [A] and Shaft [B] Torque Limiter [C] and Shaft [D] •Hold the alternator rotor steady with the rotor holder [A]. •Remove the rotor bolt [B] and washer. Special Tools – Grip [C]: 57001-1591 Rotor Holder: 57001-1658 Charging System • Using the flywheel puller [AJ, remove the alternator rotor [BJ from the crankshaft. Special Tool – Flywheel Puller Assembly, M38 x 1.5/M35 x 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. • Remove: Washer [AJ Starter Clutch Gear [BJ Alternator Rotor Installation • Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth. Crankshaft Tapered Portion [AJ Alternator Rotor Tapered Portion [BJ • Apply a thin coat of molybdenum disulfide grease [CJ to the crankshaft. • Install the starter clutch gear [AJ and washer [BJ. • Again, clean the crankshaft tapered portion [CJ and dry there. • Install the alternator rotor [AJ while turning the starter clutch gear [BJ clockwise [CJ. ELECTRICAL SYSTEM 16-29 B GP091 H8$1 0 16-30 ELECTRICAL SYSTEM Charging System •Install the washer [A]. •Apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt [B]. NOTE ○Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. •Install the rotor bolt and tighten it with 70 N·m (7.1 kgf·m, 52 ft·lb) of torque. •Remove the rotor bolt and washer. •Check the tightening torque with flywheel puller [A]. Special Tool – Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1615 If the rotor [B] is not pulled out with 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, it is installed correctly. If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, clean off any oil dirt or flaw of the crankshaft and rotor tapered portion, and dry them with a clean cloth. Then, confirm that it is not pulled out with above torque. •Apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt [A]. •Install the washer and rotor bolt. •Tighten the alternator rotor bolt while holding the alternator rotor steadily with the holder [B]. Special Tools – Grip [C]: 57001-1591 Rotor Holder: 57001-1658 Torque – Alternator Rotor Bolt: 200 N·m (20.4 kgf·m, 148 ft·lb) •Apply a thin coat of molybdenum disulfide grease to the shafts [A]. •Instal: Shafts Torque Limiter [B] Starter Idle Gear [C] Alternator Cover (see Alternator Cover Installation) ELECTRICAL SYSTEM 16-31 Charging System Charging Voltage Inspection •Check the battery condition (see Charging Condition Inspection). •Warm up the engine to obtain actual alternator operating conditions. •Remove the front seat (see Front Seat Removal in the Frame chapter). •Check that the ignition switch is turned off, and connect a tester [A] to the battery terminals [B]. •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 @25°C (77°F) Connections Tester (+) to Tester (–) to Reading Battery (+) Battery (–) DC 14.3  14.7 V •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. 16-32 ELECTRICAL SYSTEM Charging System •To check the alternator output voltage, do the following procedures. ○Turn the ignition switch off. ○Remove the left front frame cover (see Front Frame Cover Removal in the Frame chapter). ○Remove the left side cover (see Side Cover Removal in the Frame chapter) ○Disconnect the alternator lead connector [A]. ○Connect a tester as shown in the table 1. ○Start the engine. ○Run it at the rpm given in the table 1. ○Note the voltage readings (total 3 measurements). Table 1 Alternator Output Voltage @ 4 000 r/min (rpm) Connections Tester (+) to Tester (–) to Reading One Black lead Another Black lead AC 41  62 V 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. •Check the stator coil resistance as follows. ○Stop the engine. ○Connect the tester as shown in the table 2. ○Note the readings (total 3 measurements). Table 2 Stator Coil Resistance @ 20°C (68°F) Connections Tester (+) to Tester (–) to Reading One Black lead Another Black lead 0.176  0.264 Ω •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. •Measure the resistance between each of the black leads and chassis ground. Any tester reading less than infinity (∞) indicates a short, necessitating stator replacement. If the stator coils have normal resistance, but the voltage check showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced. ELECTRICAL SYSTEM 16-33 Charging System Regulator/Rectifier Removal •Remove : Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Regulator/Rectifier Bolts [A] •Disconnect the connector [B] and remove the regulator/ rectifier [C]. •Remove the regulator/rectifier bracket bolt and collar to remove the bracket if necessary. Regulator/Rectifier Installation •Install the rubber dampers [A] so that its thicker side [B] faces to the downward [C] or upward [D] as shown. •Install the regulator/rectifier bracket [E]. •Tighten: Torque – Regulator/Rectifier Bracket Bolt [F]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •Install the regulator/rectifier [A] on the bracket. •Tighten: Torque – Regulator/Rectifier Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •Connect the connector [C] to the regulator/rectifier. Regulator/Rectifier Inspection •Refer to the Charging System Troubleshooting for the Regulator/Rectifier Inspection. Charging System Troubleshooting •Before inspection, remove all accessories that consume electrical power. NOTE ○Even when the charging system is working properly, the battery may discharge if themotorcycle is equipped with too many accessories. •Pay attention to riding conditions and the customer’s riding habits which could affect the charging system such as: Frequent use at low engine speed Frequent and unnecessary brake pedal dragging → Battery Discharged •Recharge the battery if it is discharged. 16-34 ELECTRICAL SYSTEM Charging System Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Alternator 4. Regulator/Rectifier 5. Engine Ground 6. Battery 7. Main Fuse 30 A 8. Frame Ground (4) ELECTRICAL SYSTEM 16-35 0 GP09701812 C 16-36 ELECTRICAL SYSTEM 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. •Remove the right frame cover (see Frame Cover Removal in the Frame chapter). •Disconnect: Oil Pressure Switch Lead [A] (see Oil Pressure Switch Removal in the Engine Lubrication chapter) •Clear the crankshaft sensor lead from the clamp [B] and guide [C]. •Remove the clutch cover [D] (see Clutch Cover Removal in the Clutch chapter). •Remove: Crankshaft Sensor Bolts [A] •Pull out the grommet [B] to remove the crankshaft sensor [C]. •Disconnect the crankshaft sensor lead connector [A]. •Remove the crankshaft sensor. ELECTRICAL SYSTEM 16-37 Ignition System Crankshaft Sensor Installation •Install the crankshaft sensor [A]. ○When installing the sensor which is fastened by bolt, tighten the bolt after placing the sensor on the bottom surface completely. •Tighten: Torque – Crankshaft Sensor Bolts [B]: 6.0 N·m (0.61 kgf·m, 53 in·lb) •Using a high flash-point solvent, clean off any oil or dirt and apply liquid gasket to the circumference of the crankshaft sensor lead grommet [C]. Sealant – Liquid Gasket, TB1211F: 92104-0004 •Insert the grommet into the groove of the crankcase. •Run the crankshaft sensor lead and oil pressure switch lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Connect the crankshaft sensor lead connector [A]. •Connect the oil pressure switch lead to the oil pressure switch terminal (see Oil Pressure Switch Installation in the Engine Lubrication chapter). •Install the removed parts (see appropriate chapters). Crankshaft Sensor Inspection •Remove the right frame cover (see Frame Cover Removal in the Frame chapter). •Disconnect the crankshaft sensor lead connector [A]. •Using a digital meter, measure the resistance between the yellow lead terminal [B] and black lead terminal [C] in the connector. Crankshaft Sensor Resistance: Standard: 376  564 Ω @20°C (68°F) 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. •Measure the resistance between the crankshaft sensor leads and chassis ground. Any tester reading less than infinity (∞) indicates a short, necessitating replacement of the crankshaft sensor. 16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○Be sure the battery is fully charged. ○Using the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. •Disconnect the crankshaft sensor lead connector [B] (see Alternator Cover Removal). •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 •Connect the adapter to the terminals of the crankshaft sensor lead connector. Connections: Crankshaft Sensor Lead Peak Voltage Adapter Tester Y lead ← R lead → (+) BK lead ← BK lead → (–) •Turn the engine stop switch to run position. •Turn the ignition switch on. •Pushing the starter button, turn the engine 4  5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. •Repeat the measurement 5 or more times. Crankshaft Sensor Peak Voltage Standard: 3.0 V or more If the reading is less than the standard, inspect the crankshaft sensor (see Crankshaft Sensor Inspection). Timing Rotor Removal •Remove the crankshaft sensor (see Crankshaft Sensor Removal). •Holding the timing rotor [A] with the rotor holder [B] and remove the timing rotor bolt [C] and washer. Special Tool – Rotor Holder: 57001-1567 •Remove the timing rotor. Timing Rotor Installation •Install the timing rotor [A] with its stepped side [B] facing inward. ○Align the pin [C] on the crankshaft to the groove [D] of the timing rotor. •Holding the timing rotor with the rotor holder and tighten the timing rotor bolt with washer. Torque – Timing Rotor Bolt: 40 N·m (4.1 kgf·m, 30 ft·lb) Special Tool – Rotor Holder: 57001-1567 •Install the crankshaft sensor (see Crankshaft Sensor Installation). 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. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the stick coil connectors [A]. • Remove the stick coils [B]. NOTICE Do not pry the connector part of the coil while removing the coil. Stick Coil Installation • Insert the stick coils [A] so that the coil heads faces the arrow marks [B] on the cylinder head cover. NOTICE Do not tap the coil head while installing the coil. • After installation, be sure the stick coils are installed securely by pulling up them lightly. • Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). Stick Coil Inspection • Remove the stick coils (see Stick Coil Removal). • Measure the primary winding resistance [A] as follows. OConnect a tester between the coil terminals. • Measure the secondary winding resistance [B] as follows. OConnect the tester between the plug terminal and (- ) coil terminal. Stick Coil Winding Resistance Primary Windings: 1.11 – 1.50 a @20°C (68°F) Secondary Windings: 6.4 – 9.6 kO @20°C (68°F) *If the tester does not read as specified, replace the coil. Stick Coil Primary Peak Voltage Inspection NOTE OBe sure the battery is fully charged. ELECTRICAL SYSTEM 16-39 © D ® D GP 106318SZ C 16-40 ELECTRICAL SYSTEM Ignition System • Remove the stick coils (see Stick Coil Removal), but do not remove the spark plugs. • Measure the primary peak voltage as follows. Olnstall the new spark plug [A] into each stick coil [B], and ground them onto the engine. OConnect the peak voltage adapter [C] into a tester [D]. OConnect 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 (R) Adapter (BK, -) to lead wire-peak voltage adapter (W) AWARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the engine stop switch to run position. • Turn the ignition switch on. • Pushing the starter button, turn the engine 4 – 5 seconds with the transmission in neutral to measure the primary peak voltage. • Repeat the measurements 5 times for one stick coil. Stick Coil Primary Peak Voltage Standard: 110 V or more • Repeat the test for the other stick coil. *If the reading is less than the specified value, check the following. Stick Coils (see Stick Coil Inspection) Crankshaft Sensor (see Crankshaft Sensor Inspection) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) Spark Plug Removal • Refer to the Spark Plug Replacement in the Periodic Maintenance chapter. Spark Plug Installation • Refer to the Spark Plug Replacement in the Periodic Maintenance chapter. GP1 09398S1 C Ignition System Spark Plug Condition Inspection • Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). • Visually inspect the spark plugs. * If the spark plug center electrode [A] and/or side 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. • Measure the gap [D] with a wire-type thickness gauge. * If the gap is incorrect, replace the spark plug. Spark Plug Gap: 0.8 – 0.9 mm (0.031 – 0.035 in.) • Use the standard spark plug or its equivalent. Spark Plug: NGK CR9EIA-9 Interlock Operation Inspection • Raise the rear wheel off the ground with the stand. • Turn the engine stop switch on (run position). 1st Check • Start the engine to the following conditions. Condition: Transmission Gear – 1st Position Clutch Lever – Release Side Stand – Down or Up OTurn the ignition switch on and push the starter button. OThen 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 • Start the engine to the following conditions. Condition: Transmission Gear – 1st Position Clutch Lever – Pulled in Side Stand – Up OTurn the ignition switch on and push the starter button. OThen 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. ELECTRICAL SYSTEM 16-41 GS 170098$ I C 16-42 ELECTRICAL SYSTEM Ignition System 3rd Check •Inspect the engine for its secure stop after the following operations are completed. •Run the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Release Side Stand → Up •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 ○The IC igniter is built in the ECU [A]. •Refer to the following items. Interlock Operation Inspection (see Interlock Operation Inspection) Ignition System Troubleshooting (see Ignition System section) ECU Power Supply Inspection (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) ELECTRICAL SYSTEM 16-43 Ignition System Ignition System Troubleshooting Faulty ignition (No spark) ,, No good Battery Inspection ~1 Charge or replace battery. I Good ” Ignition system wiring and connector No good Repair or replace ~ inspection , damaged part. Good ,, No good Spark plug inspection ~1 Replace spark plug. I Good ,, No good Stick coil winding resistance inspection ~1 Replace stick coil. I Good ,, No good Stick coil primary peak voltage inspection ‘- ., Voltage is less than the specified value. Good No good w ,, ” Stick coil is defective. Voltage is zero Inspect: No goo Replace stick coil. or almost zero. 1. Lower resistance in a tester. d 2. Crankshaft sensor peak voltage – ,, Good ‘ , No good Inspect: Replace bad parts or 1. Adapter connection is incorrect, or inspect them with a – adapter is defective. tester. 2. Ignition switch and engine stop switch 3. Crankshaft sensor peak voltage Good ” ,, •II Replace bad parts. ECU is defective. Replace ECU. CJ’108028 F 16-44 ELECTRICAL SYSTEM Ignition System Ignition System Circuit } • =~ -i~ I r ~: I I . . . 1. Ignition Switch 2. Engine Stop Switch 3. Spark Plugs 4. Stick Coils 5. Main Throttle Sensor 6. Subthrottle Sensor 7. Vehicle-down Sensor 8. Gear Position Sensor 9. Water Temperature Sensor 10. Crankshaft Sensor 11. ECU 12. Side Stand Switch il”u1 \U;. ,s~ t_/f/~ !5 l J 1 ·i I I – ~ :@@ : ! I I 1 ~ ~@@ •– (Q)@ __.,., ,_ – _ _J 13. Engine Ground 14. Battery 15. Main Fuse 30 A 16. Frame Ground (5) 17. Frame Ground (4) 18. Fuse Box (1) 19. ECU Fuse 15 A 20. Ignition Fuse 1 O A 21 . Relay Box 22. ECU Main Relay 23. Starter Lockout Switch ss GP1 0029CW4 C ELECTRICAL SYSTEM 16-45 Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. •Remove the left fairing cover (see Fairing Cover Removal in the Frame chapter). •Disconnect the water temperature sensor connector [A]. •Slide back the rubber cap [A]. •Remove the starter motor cable terminal nut [B]. •Remove the mounting bolts [C]. •Pull out the starter motor [D] to the right side. •Remove the starter motor [A] from the left side on the engine. Starter Motor Installation NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. •When installing the starter motor, clean the starter motor legs [A] and crankcase [B] where the starter motor is grounded. •Replace the O-ring [A] with a new one. •Apply grease to the O-ring. •Apply a non-permanent locking agent to the threads of the bolts and tighten them. Torque – Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) 16-46 ELECTRICAL SYSTEM Electric Starter System • Position the starter motor cable [A] as shown. About 90° [B] Rear [C] • Tighten: Torque · Starter Motor Cable Terminal Nut: 6.0 N·m (0.61 kgf·m, 53 in·lb) • Slide back the rubber cap to the original position. • Install the removed parts (see appropriate chapters). Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B]. • Remove the armature [A] from the commutator side. NOTE ODo not remove the circlip [BJ from the shaft. • Remove: Starter Motor Terminal Locknut [A] Washer Collar • Pull out the brushes from the brush holder [A]. • Remove: Brush Springs [B] Starter Motor Terminal [C] and 0-ring Positive Brush Assy [D] Starter Motor Brush Holder Screw [E] Negative Brush Assy [F] Brush Holder Electric Starter System Starter Motor Assembly • Align the hole [AJ of the brush holder [BJ to the boss [CJ of the right-hand end cover [DJ. • Align the stoppers [AJ of the negative brush assy [BJ to the grooves [CJ of the brush holder [DJ. • Tighten: Torque – Brush Holder Screw: 3.8 N·m (0.39 kgf·m, 34 in·lb) • Align the stoppers [AJ of the positive brush assy [BJ to the grooves [CJ of the brush holder [DJ. • Install the starter motor terminal. • Replace the 0-ring [AJ with a new one. • Install the following parts to the starter motor terminal [BJ. New 0 -ring Collar [CJ Washer [DJ Starter Motor Terminal Locknut [EJ Olnstall the collar so that stepped side faces outward. • Tighten: Torque -Starter Motor Terminal Locknut: 11 N·m (1.1 kgf·m, 97 in·lb) • Install the brush springs [AJ and insert the brushes [BJ. ELECTRICAL SYSTEM 16-47 16-48 ELECTRICAL SYSTEM Electric Starter System •Apply thin coat of grease to the oil seal [A]. •Replace the O-rings [A] with new ones. •Insert the armature [B] so that commutator side [C] faces hollow side [D] of the yoke. •Install the end cover [A] so that the stopper [B] is aligned with the hollow [C] of the yoke. •Align the marks [A] to assembly the yoke and the end covers [B] as shown. •Tighten the through bolts. Torque – Starter Motor Through Bolts: 5.0 N·m (0.51 kgf·m, 44 in·lb) Brush Inspection •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: 12.0 mm (0.47 in.) Service Limit: 6.5 mm (0.26 in.) ELECTRICAL SYSTEM 16-49 Electric Starter System Commutator Cleaning and Inspection •Clean the metallic debris off the between commutator segments [A]. NOTE ○Do not use emery or sand paper on the commutator. •Check the commutator for damage or abnormal wear. Replace the starter motor with a new one if there is any damage or wear. •Visually inspect the commutator segments for discoloration. Replace the starter motor with a new one if discoloration is noticed. Armature Inspection •Using a tester, measure the resistance between any two commutator segments [A]. If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced. •Using the 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 ○Even 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 •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 •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. 16-50 ELECTRICAL SYSTEM Electric Starter System Starter Relay Inspection • Disconnect the negative (- ) cable (see Battery Removal) • Remove the left side cover (see Side Cover Removal in the Frame chapter). • Pull the starter relay [A] out from the bracket. • Slide the dust cover [A]. • Disconnect: Connector [B] • Remove: Cable Terminal Bolts [C] Starter Relay [D] • 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 – 0 Q When battery is disconnected – 00 Q GP1 IH7BS1 C ELECTRICAL SYSTEM 16-51 Electric Starter System Electric Starter Circuit © Lr CD i:mit: 1:.n11=·:=m=~ 11 s~ ii I :: –1 I I -d@ ssi~ = @ ~ -J·, n ij I _,, ,._ I :. • . GP113 19 8W3 C 1. Ignition Switch 11 . Starter Motor 2. Engine Stop Switch 12. Frame Ground (6) 3. Starter Button 13. Frame Ground (5) 4. Gear Position Sensor 14. Fuse Box (1) 5. ECU 15. Ignition Fuse 1 O A 6. Side Stand Switch 16. Relay Box 7. Engine Ground 17. Starter Circuit Relay 8. Battery 18. Starter Lockout Switch 9. Main Fuse 30 A 10. Starter Relay 16-52 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight circuit relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released. Headlight Beam Horizontal Adjustment •Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Beam Vertical Adjustment •Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Bulb Replacement •Turn the dust cover [A] counterclockwise until it unlocked. •Pull the dust cover out from the headlight unit. •Disconnect the headlight connector [A]. •Release the hook [B] and remove the headlight bulb [C]. NOTICE When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. Use the correct type of headlight bulb with specified voltage and wattage only. NOTE ○Clean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution. •Replace the headlight bulb [A] with a new one. •Install the new headlight bulb to the headlight unit. ○Align the tab [B] on the bulb with the cutout [C] of the housing and install the headlight bulb. Lighting System • Hook the end of the hook [A] to the groove of the stopper [B]. • Connect the headlight connector to the headlight bulb [C]. • Fit the dust cover [A] firmly onto the bulb so that its “6” mark [B] is aligned with the index mark [C] on the headlight unit. • Turn the dust cover clockwise until it stops. • Make sure that the “6” mark has been aligned with the stop mark [D] on the headlight unit. Headlight Unit Removal • Remove the upper fairing (see Upper Fairing Removal in the Frame chapter). • Remove: Screws [A] Bolt [B] Headlight Unit [C] Headlight Unit Installation • Check that the pad [A] is in place on the headlight unit [B] on both sides. OAttach the pad by aligning its top edge with the line [C] on the headlight unit if necessary. • Install the headlight unit [A] to the upper fairing [B] by inserting the rubber pads [C] behind the projections [D] on the headlight unit. • Install the removed parts (see appropriate chapters). ELECTRICAL SYSTEM 16-53 C B GP 121118S I C 16-54 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement • Remove: Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter) • Pull out the socket [A] from the headlight unit. • Pull the bulb [A] out from the socket [B]. NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified valve. • Replace the bulb with a new one. • Insert the socket into the headlight unit. Tail/Brake Light (LED) Unit Removal • Remove: Rear Seat Covers (see Rear Seat Cover Removal in the Frame chapter) • Disconnect the tail/brake light lead connector [A]. • Remove: Tail/Brake Light Bolts [B] and Washers Tail/Brake Light Unit [C] Tail/Brake Light (LED) Unit Installation • Installation is the reverse of removal. • If necessary, attach the pad [A] on the lens [B] along the edge of the rounded line [C] as shown. • Install the grommets [A] to the tail/brake light unit [B] with its larger diameter side [C] facing upward [D]. • Install the collars [E] from underside. B ~ GP127&11l S ELECTRICAL SYSTEM 16-55 Lighting System •Insert the rubber damper [A] into the slot [B] to install the tail/brake light unit on the frame. •Tighten the tail/brake light bolts [A] with washers. Torque – Tail/Brake Light Bolts: 0.50 N·m (0.05 kgf·m, 4.4 in·lb) •Connect the tail/brake light lead connector [B]. •Install the removed parts (see appropriate chapters). License Plate Light Bulb Replacement •Remove: License Plate Light Cover Screws [A] License Plate Light Cover [B] and Lens •Pull out the bulb [A] straight from the socket [B]. NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified valve. •Replace the bulb with a new one. •Insert the new bulb into the socket. •Install the license plate light cover and lens. •Tighten the license plate light cover screws. 16-56 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit CD i:81? L!t’ll l=·:9]f·:==1================i—-. ~ 10:—~ @@:~:[ :: © @ ~ ‘ “=t~ -i–. 1—-1+—1-1—i-.-., .: ::[]:·~·~ @~’ [ ·:: @ @J:::;: ;;—-+i–t—t+—–t-t @ ,.m@1 _ .+!—– ~ ‘L@ __’ J’ i W° ·1 n H • 0 u a ©® © GP 127758fl’3 C 1. Ignition Switch 2. Alternator 3. Tail/Brake Light (LED) 4. License Plate Light 12 V 5 W 5. Engine Ground 6. Battery 7. Main Fuse 30 A 8. Frame Ground (6) 9. Frame Ground (2) 10. Fuse Box (1) 11 . Brake Light/Horn Fuse 1 O A Front Turn Signal Light Bulb Replacement • Remove: 12. Headlight Fuse 15 A 13. Relay Box 14. Headlight Circuit Relay 15. Passing Button 16. Dimmer Switch 17. City Lights 12 V 5 W 18. Headlight (High) 12 V 55 W 19. Headlight (Low) 12 V 55 W 20. Meter Unit Middle Fairing (see Middle Fairing Removal in the Frame chapter) • Turn the bulb socket [A] counterclockwise until it unlocked, and pull it off. Lighting System • Push and turn the bulb [A] counterclockwise and remove the bulb from the bulb socket [B]. • Replace the bulb with a new one. • Insert the bulb by aligning its pins [C] with the grooves [D] in the bulb socket, and turn the bulb clockwise until it stops. • Fit the projections [A] of the bulb socket into the grooves [B] on the turn the signal light. OAlign the size of the projection with the grooves. • Turn the bulb socket clockwise until it stops. • Make sure that the rubber cover [A] had not been turned up on the bulb socket [B]. Wrong [C] 0 Be sure to place the rubber cover between the bulb socket and the light housing [D] as shown. • Install the removed parts (see appropriate chapters). Rear Turn Signal Light Bulb Replacement • Remove: Turn Signal Light Lens Screw [A] Turn Signal Light Lens Housing [B] • Turn the socket [A] counterclockwise and remove the lens housing [B]. • 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. ELECTRICAL SYSTEM 16-57 A / © GP 121108S I C 16-58 ELECTRICAL SYSTEM Lighting System • Replace the bulb [AJ with a new one. • Push the new bulb into the socket. • Insert the socket by aligning its tabs [BJ with the cutout [CJ of the lens. • Turn the socket clockwise until it stops. • Fit the lens housing [AJ to the light case [BJ by inserting the projection [CJ on the lens housing to the inside of the light case. • Tighten the turn signal light lens screw. Torque • Turn Signal Light Lens Screw: 1.0 N·m (0.10 kgf·m, 8.9 in·lb) Turn Signal Relay Inspection • Remove: Left Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) • Remove the turn signal relay [AJ. • Disconnect the turn signal relay connector [BJ. • 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 [AJ Turn Signal Lights [BJ 12 V Battery [CJ * If the lights do not blink as specified, replace the turn signal relay. Testing Turn Signal Relay Load The Number of Turn Blinking nmes Signal Lights Wattage (W) (c/m*) 1 ** 10 140 – 250 2 20 75 – 95 (*): Cycle(s) per minute (**): Correspond to “one light burned out.” A + © GP1 20’402S1 C Lighting System Turn Signal Light Circuit . . ” ” ,_, _ -” / :-.1. ,,_, . ,_ I 11 wo :; rdJj a •o; •o:; ([D m @@ 1. Ignition Switch 2. Rear Right Turn Signal Light 12 V 10 W 3. Rear Left Turn Signal Light 12 V 10 W 4. Engine Ground 5. Battery 6. Main Fuse 30 A 7. Frame Ground (6) 8. Frame Ground (2) ELECTRICAL SYSTEM 16-59 ,—-, ‘\ ) · @ · I I •~ n ® . t . 9. Fuse Box (2) 10. Turn Signal Relay Fuse 10 A 11 . Turn Signal Relay 12. Turn Signal Switch 13. Hazard Button GP12l69 8W3 C 14. Front Left Turn Signal Light 12 V 10 W 15. Front Right Turn Signal Light 12 V 10 W 16. Meter Unit 16-60 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection • Using a tester, check to see that only the connections shown in the table have continuity (about zero ohms). OFor 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 Rea r Brake Li ght Switch Con nect i o ns Col o r BR BL When brake peda l is pushed down When brake peda l is re leased Side Stand Switch Connections S id e Sta nd Swi tc h Co nn ect i o ns Co lor BK G When side stand is down When side stand is up 0 D Oil Pressure Switch Connections* 0 i I Pr ess ure Swi tch Co nn ect ion s * Col o r SW. Term ina l Ground When eng i ne i s stopped When eng i ne i s runn i ng *: Engine lubrication system is in good condition. Water Temperature Sensor Removal/Installation • Refer to the water temperature Sensor Removal/Installation in the Fuel System (DFI) chapter. Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the threaded portion is submerged. • Suspend an accurate thermometer [B] with temperature sensing portions [C] located in almost the same depth. NOTE o The sensor and thermometer must not touch the container side or bottom. • Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently. • 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 (kO) – 20°C (-4°F) *18.80 ±2.37 0°C (32°F) *(about 6.544) 40°C (104°F) 1.136 ±0.095 100°C (212°F) 0.1553 ±0.0070 *: Reference Information Rear Wheel Rotation Sensor Removal • Refer to the Rear Wheel Rotation Sensor Removal/Installation in the Fuel System (DFI) chapter. Rear Wheel Rotation Sensor Installation • Refer to the Rear Wheel Rotation Sensor Removal/Installation in the Fuel System (DFI) chapter. Rear Wheel Rotation Sensor Inspection • Refer to the Rear Wheel Rotation Sensor Inspection in the Fuel System (DFI) chapter. Fuel Level Sensor Inspection • Remove: Fuel Pump (see Fuel Pump Removal in the Fuel System (DFI) chapter) • Check that the float moves up and down smoothly without binding. It should go down under its own weight. * If the float does not move smoothly, replace the fuel pump. Float in Full Position [A] Float in Empty Position [B] ELECTRICAL SYSTEM 16-61 A C GP l80558S2 C 16-62 ELECTRICAL SYSTEM Switches and Sensors •Using a digital meter [A], measure the resistance across the terminals in the fuel level sensor lead connector [B]. 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 Connections: R/BK lead ← → BK/W lead Standard: Full position: 9  11 Ω Empty position: 213  219 Ω 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. •Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). •Slide the dust cover [A] and disconnect the oxygen sensor lead connector [B]. •Open the clamp [C]. •Open the clamp [A]. •Remove the oxygen sensor [B]. 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. •Tighten: Torque – Oxygen Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb) •Run the oxygen sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Install the removed parts (see appropriate chapters). ELECTRICAL SYSTEM 16-63 Switches and Sensors •When removing the dust cover, install it as following. •Remove the left frame cover (see Frame Cover Removal in the Frame chapter). •Run the side stand switch lead [A] through the slit [B] of the dust cover [C]. •Wrap the oxygen sensor connector [D] and side stand switch lead. •Insert the tab [A] into the slit [B]. •Insert the dust cover [A] into the side cover [B]. Oxygen Sensor Inspection •Refer to the Oxygen Sensor Inspection in the Fuel System (DFI) chapter. Gear Position Sensor Removal •Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Left Side Cover (see Side Cover Removal in the Frame chapter) •Disconnect the gear position sensor connector [A]. •Open the rubber band [B]. 16-64 ELECTRICAL SYSTEM Switches and Sensors •Remove: Gear Position Sensor Bolt [A] and Washer Gear Position Sensor [B] Gear Position Sensor Installation •Replace the O-ring [A] with a new one. •Apply grease to the O-ring. •Install the gear position sensor so that the slit [B] fits to the projection [C] of the holder. ○When installing the sensor which is fastened by bolt, tighten the bolt after placing the sensor on the bottom surface completely. •Tighten: Torque – Gear Position Sensor Bolt [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •Install the removed parts (see appropriate chapters). Gear Position Sensor Inspection •Refer to the Gear Position Sensor Output Voltage Inspection in the Fuel System (DFI) chapter. Accessory Relay Inspection •Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) •Remove the accessory relay [A]. •Disconnect the accessory relay connector [B]. Switches and Sensors • Connect a digital meter [A] between the relay terminals [3] and [4]. • Connect a 12 V battery [B] between the relay terminals [1] and [2] as shown. * If the relay [C] does not work as specified, the relay is defective. Replace the relay. Testing Relay Criteria: When battery is connected – 0 0 When battery is disconnected – co Q ELECTRICAL SYSTEM 16-65 00 [] ©CD GP 18l668S I C 16-66 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter). • Connect a tester [A] to the air switching valve terminals as shown. Air Switching Valve Resistance Standard: 18 – 22 Q @20°C (68°F) • If the resistance reading is out of the specified value, replace it with a new one. • Connect the 12 V battery [A] to the air switching valve terminals as shown. • Blow the air to the intake air duct [A], and make sure does not flow the blown air from the outlet air ducts [B]. • Disconnect the 12 V battery. • Blow the air to the intake air duct [A] again, and make sure flow the blown air from the outlet air duct [B]. * If the air switching valve does not operate as described, replace it with a new one. NOTE o To check air flow through the air switching valve, Just blow through the air switching valve hose (intake side) [CJ. GE040308 S 1 C e ® ® OE0 4 03 38 S I C 0 Air Switching Valve Air Switching Valve Circuit ® w 15 I .l =c:=:!h H 1. Ignition Switch 2. Air Switching Valve 3. ECU 4. Engine Ground 5. Battery 6. Main Fuse 30 A 7. Frame Ground (4) 8. Frame Ground (3) 9. Fuse Box (1) 10. ECU Fuse 15 A 11. Ignition Fuse 1 O A 12. Relay Box 13. ECU Main Relay , –1 1@ 1 ‘” I ·- – a• r. M• – Q L __ _l ® ELECTRICAL SYSTEM 16-67 < = < = M ©0 0 !MIT – . GC11083Hl 2 C 16-68 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Removal • Refer to the Radiator and Radiator Fan Removal in the Cooling System chapter. Fan Motor Installation • Refer to the Radiator and Radiator Fan Installation in the Cooling System chapter. Fan Motor Inspection • Remove the left middle fairing (see Middle Fairing Removal in the Frame chapter). • Disconnect the connector [A]. • 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. Radiator Fan Circuit 1. Ignition Switch 2. Fan Motor ® ~ ~ 15 ,.’.:t::==============i—l——ll–., , • • I tlt J_ 3. Water Temperature Sensor 4. ECU 5. Engine Ground 6. Battery 7. Main Fuse 30 A 8. Frame Ground (3) 9. Frame Ground (1) 10. Fuse Box (1) 11. Fan Fuse 15 A 12. Ignition Fuse 1 O A 13. Relay Box 14. Radiator Fan Relay © GPISU38W2 C ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Meter Unit Removal •Remove the upper fairing (see Upper Fairing Removal in the Frame chapter). •Remove: Meter Mounting Screws [A] and Washers Meter Unit [B] Dampers (If necessary) Meter Unit Installation •Installation is the reverse of removal. •Install the removed parts (see appropriate chapters). Meter Unit Disassembly/Assembly •Remove: Meter Unit (see Meter Unit Removal) Meter Assembly Screws [A] Lower Meter Cover [B] •Separate the meter assembly [A] and upper meter cover [B]. •Assembly is the reverse of removal. 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Operation Inspection Check 1: Meter Unit Switching Inspection Display Mode Setting •Turn the ignition switch on and check the following. •By pushing the upper meter button [A] or lower meter button [B] each time, check that the display changes as shown. Pushing Upper Meter Button [C] Pushing Lower Meter Button [D] If the display function does not work, replace the meter assembly. Unit Setting •Set the ODO mode by pushing the upper meter button. •By pushing the lower meter button each time while the upper meter button pushed in, check that the display changes as shown. NOTE ○Mile/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 assembly. Clock Setting •Push the upper meter button [A] and lower meter button [B] and hold it. ○The clock setting menu (hour and minute) should blink [C]. Meter, Gauge, Indicator Unit • Push the lower meter button and hold it. 0 “12h” or “24h” display is appeared. • Push the upper meter button to select “12h” or “24h” [A]. • Push the lower meter button. OThe hour display [A] starts blinking. • By pushing the upper meter button each time, check that the hour display changes. • By pushing the lower meter button, check that the hour display decides and minute display [A] starts blinking. • By pushing the upper meter button each time, check that the minute display changes. • By pushing the lower meter button, check that the hour and minute display start blinking. • By pushing the upper meter button, check that the hour and minute display decide. • When both hour and minute display is blinking, by pushing the lower meter button, check that the hour display start blinking. This blinking returns the hour setting display. * If the display function does not work, replace the meter assembly. Meter System Inspection Check 2-1: Battery Warning Indicator Inspection • When the battery condition is low voltage (10.8 – 11.2 V or less) or high voltage (15.5 – 16.5 V or more), the battery warning indicator [A] and red warning indicator light (LED) [BJ go on. * If the battery warning indicator and red warning indicator light (LED) go on, inspect the charging voltage (see Charging Voltage Inspection). * If the charging voltage is good, replace the meter assembly. ELECTRICAL SYSTEM 16-71 11’11it/ I, GP118088$1 0 GP118098$1 0 GP118 108$1 0 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 2-2: Gear Position Indication Inspection • Turn the ignition switch on and shift the transmission gear into neutral position. OThe green neutral indicator light (LED) [A] goes on, and the gear position indicator is display the “N” position [B]. • Set the low gear position, and check that the display changes to “1” mark [A] and the green neutral indicator light (LED) [B] goes off. • Using the rear stand, raise the rear wheel off the ground. • Rotate the rear wheel by hand and change the gear position. • 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 Inspection) Wiring (see Meter Unit Circuit) * If the above parts are good, replace the meter unit and/or ECU. Meter Unit Inspection • Remove the meter unit [A] (see Meter Unit Removal). [1] Unused [2] Unused [3] Unused [4] Unused [5] Unused [6] Red Warning Indicator Light (LED) (-) [7] Green Neutral Indicator Light (LED) (- ) [8] Yellow ABS Indicator Light (LED)(- ) [Equipped Models] [9] Ground (- ) [1 O] Ignition ( +) [1 1] Fuel Level Sensor [12] Rear Wheel Rotation Sensor Pulse [13] ECU Communication Line [14] Unused [15] Tachometer Pulse [16] Green Right Turn Signal Indicator Light (LED)(+) [17] Blue High Beam Indicator Light (LED)(+) [18] Unused [19] Green Left Turn Signal Indicator Light (LED)(+) [20] Battery ( +) NOTICE Do not drop the meter unit. Do not short each terminal. ~rlAIO I GP1l783DS2 C Meter, Gauge, Indicator Unit Check 3-1: Meter Unit Primary Operation Check • Using the auxiliary leads, connect the 12 V battery to the meter unit connector as follows. OConnect the battery positive (+) terminal to the terminal [20J. OConnect the battery negative (- ) terminal to the terminal [9J. • Connect the terminal [1 OJ to the battery ( +) terminal. • Check the following items. OThe LCD display and meter illuminations should turn on. OAII the LCD segments [AJ appear for few seconds. OFollowing indicators are goes on for few seconds. Yellow Shift-up Indicator Light (LED) [BJ Red Warning Indicator Light (LED) [CJ OFollowing indicators are remains on. Yellow Engine Warning Indicator Light (LED) [DJ Yellow ABS Warning Indicator Light (LED) [EJ (if equipped) * If the meter unit does not work properly, replace the meter assembly. NOTE o This meter unit has a failure detection function of the communication. When the communication error was detected, the meter unit alerts the rider by the yellow engine warning indicator light (LED) goes on. OMake sure that the fuel level gauge segments [AJ and indicator on the LCD start blinking approx. 5 seconds after turning on the meter unit. * If the meter unit does not work properly, replace the meter assembly. NOTE o This meter unit has a failure detection function (for open or short) of the fuel level gauge. When the fuel level gauge is open or short, the meter unit alerts the rider by the all fuel level gauge segments blink in the display. ELECTRICAL SYSTEM 16-73 GP 17l640S1 C + GP 171650SI C GP! r~30 IJ 16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Make sure that the following indicators on the LCD start blinking approx. 1 O seconds after turning on the meter unit. Gear Position Indicator with “- -” Message [A] All Segments of Water Temperature Gauge [B] and Indicator Multifunction Display with”–.-” Message [C] NOTE o This meter unit has a failure detection function (for open or short) of the fuel level gauge. When the fuel level gauge is open or short, the meter unit alerts the rider by the all coolant temperature gauge segments blink in the display. * If the meter unit does not work properly, replace the meter assembly. Check 3-2: Meter Communication Line (Service Code 39) Check • Connect the leads in the same circuit as Check 3-1. • The yellow engine warning indicator light (LED) should remains on. • Set the ODO mode [A] by pushing the upper meter button [B]. • Push the upper meter button and lower meter button [C] simultaneously for more than 2 seconds. • Check the following items. OThe number “39” [A] in the display appears. • Push the upper meter button and lower meter button again for more than 2 seconds. • Check the following items. OThe display returns ODO mode from number “39.” * If the meter unit does not work, replace the meter assembly. NOTE OThe number “39” is service code of Self-Diagnosis (see Fuel System (OF/) chapter). It is the service code of the meter communication line error. o The number “39” in the display disappear when the meter unit is connected to main harness of the normal motorcycle. + GP1 7765DS1 C Meter, Gauge, Indicator Unit Check 3-3: Blue High Beam Indicator Light (LED) Inspection • Connect the terminal [9] to the battery (- ) terminal. • Connect the terminal [17] to the battery ( +) terminal. • Check that the blue high beam indicator light (LED) [A] goes on. * If the indicator light (LED) does not go on, replace the meter unit. Check 3-4: Green Left Turn Signal Indicator Light (LED) Inspection • Connect the terminal [9] to the battery (- ) terminal. • Connect the terminal [19] to the battery ( +) terminal. • Check that the green left turn signal indicator light (LED) [A] goes on. * If the indicator light (LED) does not go on, replace the meter unit. Check 3-5: Green Right Turn Signal Indicator Light (LED) Inspection • Connect the terminal [9] to the battery (- ) terminal. • Connect the terminal [16] to the battery ( +) terminal. ELECTRICAL SYSTEM 16-75 GP 176340S I C GP 1763SOS I C GP 1763 60S I C 16-76 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Check that the green right turn signal indicator light (LED) [A] goes on. * If the indicator light (LED) does not go on, replace the meter unit. Check 3-6: Green Neutral Indicator Light (LED) Inspection • Connect the leads in the same circuit as Check 3-1 . • Connect the terminal [7] to the battery (- ) terminal. • Check that the green neutral indicator light (LED) [A] goes on. *If the indicator light (LED) does not go on, replace the meter assembly. Check 3-7: Yellow ABS Indicator Light (LED) Inspection (Equipped Model) • Connect the leads in the same circuit as Check 3-1 . OThe yellow ABS indicator light (LED) goes on. • Connect the terminal [8] to the battery (- ) terminal. • Check that the yellow ABS indicator light (LED) [A] goes off. *If the indicator light (LED) does not go off, replace the meter assembly. + GPl 7770DS1 C + GP1 777IDS1 C Meter, Gauge, Indicator Unit Check 3-8: Red Warning Indicator Light (LED) Inspection (Oil Pressure Warning) • Connect the leads in the same circuit as Check 3-1 . • Connect the terminal [6] to the battery (- ) terminal. • Check that the oil pressure warning indicator [A] and red warning indicator light (LED) [B] goes on approx. 5 seconds later. * If the oil pressure warning indicator and indicator light (LED) does not go on, replace the meter unit. Check 3-9: Fuel Gauge Inspection • Connect the leads in the same circuit as Check 3-1 . OThe all segments of the fuel gauge in the display will blink. • Connect the variable rheostat [A] to the terminal [11] and the battery (- ) terminal. • Check that the number of segments on the fuel level gauge [A] matches the resistance value of the variable rheostat. OWhen the terminal [11] is connected, 1 segment in the fuel level gauge should appear about every 15 seconds. Variable Rheostat Resistance (0 ) Display Segments 15 6 segments go on 40 5 segments go on 70 4 segments go on 100 3 segments go on 140 2 segments go on 170 1 segment goes on 210 1 segment blinks * If the display function does not work, replace the meter assembly. ELECTRICAL SYSTEM 16-77 + GP 171120S I C + GP 171130S I C 16-78 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3-1 O: Speedometer Inspection • Connect the leads in the same circuit as Check 3-1 . • The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [12]. Olndicates approximately 60 km/h if the input frequency is approximately 435 Hz. Olndicates approximately 60 mph if the input frequency is approximately 700 Hz. * If the meter function does not work, replace the meter unit. NOTE o The input frequency of the oscillator adds the integrated value of the odometer. o The integrated value of the odometer cannot be reset. Check 3-11 : Odometer Check • Check the odometer with the speedometer check in the same way. * If value indicated in the odometer is not added, replace the meter unit. NOTE o The data is maintained even if the battery is disconnected. OWhen the figures come to 999999, they are stopped and locked. o The integrated value of the odometer cannot be reset. Check 3-12: Trip A/B Meter Check • Check the trip meter with the speedometer in the same way. * If value indicated in the trip meter is not added, replace the meter unit. • Check that when the 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. duty =t / TX100=50% ~ Ii fl —- 5V _J L__J L_ – – – ov ODO ODO D . :235 GP 177740S2 C , =, =-u •c -‘–. t:m D 1235 t:m ‘,IC – :23~ ‘ – D “‘ ‘ 1235. – Meter, Gauge, Indicator Unit Check 3-1 3: Tachometer Inspection • Connect the leads in the same circuit as Check 3-1 . • The engine speed (rpm) equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [1 5). Olndicates approximately 6 000 rpm if the input frequency is approximately 200 Hz. * If the meter function does not work, replace the meter assembly. Check 3-14: Other Inspection OThe following items are displayed while running. AVERAGE CURRENT RANGE ECO Mark • 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 (Service Code 41 , 42) 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 assembly and/or ECU. Fuel Level Sensor Line Self-Diagnosis Mode Inspection NOTE OUsual/y when the open or short of the fuel level sensor circuit is detected, ;t becomes the Fuel Level Sensor Line Self-Diagnosis Mode. OThe all segments of the fuel level gauge [A] and fuel level warning indicator [BJ 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 assembly. ELECTRICAL SYSTEM 16-79 + du t y=t / TX100=50% GPl71750SZ C 16-80 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit (ER650G) D ~’ r : ~: ,”. 0 @ ~9IF – – v @ _ _, @ -l; @ , – –i ,@ , ~ , -~· 1. Ignition Switch 2. Gear Position Sensor 3. Water Temperature Sensor 4. Oil Pressure Switch 5. Crankshaft Sensor 6. ECU 7. Rear Wheel Rotation Sensor 8. Fuel Level Sensor 9. Engine Ground 10. Battery 11. Main Fuse 30 A I . – ,._ .s•~j S• l ; -~ – ~ ::: . ll f-·1 $. =$ ~ n = 12. Frame Ground (5) 13. Frame Ground (2) 14. Fuse Box (1) 15. Meter Fuse 1 O A 16. Ignition Fuse 1 O A 17. to Headlight Hi Beam Ol /t ” Ult . uu- 18. to Turn Signal Switch (Left) 19. to Turn Signal Switch (Right) 20. Meter Unit © GP179050fl’3 C Meter, Gauge, Indicator Unit Meter Circuit (ER650H) ~’:’=m=’:’ . O<- .” .”‘ ‘ ,,,, ‘ D @ ~ v ~./ ~v @ @ @ II ,—i ~i 5~ ,@, ~. —-ea,, 1. Ignition Switch 2. Gear Position Sensor 3. Water Temperature Sensor 4. Oil Pressure Switch 5. Crankshaft Sensor 6. ECU 7. Rear Wheel Rotation Sensor 8.Fuel Level Sensor 9. Engine Ground 10. Battery 11. Main Fuse 30 A I . – ,._ ELECTRICAL SYSTEM 16-81 .;, if i s~ – – ~ ‘” . !~ t -1n ~ • 12. Frame Ground (5) 13. Frame Ground (2) 14. Fuse Box (1) 15. Meter Fuse 1 O A 16. Ignition Fuse 1 O A 17. ABS Hydraulic Unit 18. to Headlight Hi Beam “,,” 19. to Turn Signal Switch (Left) 20. to Turn Signal Switch (Right) 21. Meter Unit © G;PJ l 9060W3 C 16-82 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal NOTICE Never drop the relay box especially on a hard surface. Such a shock to the relay box can damage it. •Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) •Pull the relay box [A] out from the brackets [B]. •Disconnect the connectors [C]. •Remove the relay box. Relay Box Installation •Installation is the reverse of removal. Relay Circuit Inspection •Remove the relay box (see Relay Box Removal). •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 (Ω) Headlight Circuit Relay 1-3 ∞ 7-6 ∞ ECU Main Relay 4-5 Not ∞* 7-8 ∞ Fuel Pump Relay 9-10 Not ∞* 11-16 ∞ Starter Circuit Relay 11-12 ∞ 17-20 ∞ Fan Relay 18-19 Not ∞* *: The actual reading varies with the tester used. ELECTRICAL SYSTEM 16-83 Relay Box Relay Circuit Inspection (with the battery connected) Battery Connection (+) (–) Tester Connection Tester Reading (Ω) 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 (+) (–) Tester Connection (+) (–) Tester Reading (V) Starter Circuit Relay 16-12 11-12 Battery Voltage (+): Apply positive lead. (–): Apply negative lead. Diode Circuit Inspection •Remove the relay box (see Relay Box Removal). •Check conductivity of the following pairs of terminals (see Relay Box Internal Circuit in this section). Diode Circuit Inspection 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 ○The actual meter reading varies with the meter or tester used and the individual diodes, but generally speaking, the lower reading should be from zero to one half the scale. 16-84 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit 1 2 3 4 © A: Headlight Circuit Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay ® ® OP1901 0812 C ELECTRICAL SYSTEM 16-85 Fuses Main Fuse (30 A) Removal •Remove the left side cover (see Side Cover Removal in the Frame chapter). •Pull the starter relay [A] out from the bracket. •Remove the fuse cap [A]. •Pull out the main fuse (30 A) from the starter relay with a needle nose pliers. Spare Fuse (30 A) [B] Fuse Box Fuse Removal Inside of the Right Radiator Cover •Remove: Left Fairing Cover (see Fairing Cover Removal in the Frame chapter) •Unlock the hook to open the lid. Fuse Box (1) [A] Fuse Box (2) [B] Fuse Box (3) [C] (ABS Equipped Models) •Pull the fuses [A] straight out of the fuse box with a 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. •Install the fuse box fuses on the original position as specified on the lid. 16-86 ELECTRICAL SYSTEM Fuses Fuse Inspection • Remove the fuse (see Main Fuse (30 A)/Fuse Box Fuse Removal). • Inspect the fuse element. * If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Housing [A] Fuse Element [B] Terminals [C] Blown Element [D] 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. GP200()01S 1 C APPENDIX 17-1 17 Appendix Table of Contents Cable, Wire, and Hose Routing 17-2 Troubleshooting Guide . 17-63 17-2 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Front Brake Hoses (Routing for ABS Equipped Models) 2. Bracket (Run the brake hose, throttle cables and right switch housing lead to the inside of the bracket.) 3. Throttle Cable (Decelerator Cable) 4. Right Switch Housing Lead 5. Clutch Cable 6. Left Switch Housing Lead 7. Bracket (Run the clutch cable and left switch housing lead to the inside of the bracket.) 8. Throttle Cable (Accelerator Cable) 9. Accessory Leads 10. Clamp (Hold the accessory lead. Insert the clamp to the frame bracket.) 11. Clamp (Hold the meter/accessory lead. Insert the clamp to the frame bracket.) 12. Front Wheel Rotation Sensor Lead (ABS Equipped Models) 13. Meter Lead 17-4 APPENDIX Cable, Wire, and Hose Routing 1. Left Headlight Lead 2. Left City Light Lead APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Right Headlight Lead 2. Right City Light Lead 17-6 APPENDIX Cable, Wire, and Hose Routing 1. Left Headlight Lead Connector (Insert the connector to the frame.) 2. Turn Signal Light Relay 3. Accessory Relay 4. Left Headlight Lead 5. White Tape 6. Main Harness 7. Clamp (Hold the main harness. Insert the clamp to the bracket.) 8. Clamp (Hold the right headlight lead. Insert the clamp to the frame.) 9. Right Headlight Lead 10. Right Headlight Lead Connector (Insert the connector to the frame.) APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Clamp (Hold the horn leads. Insert the clamp to the horn bracket.) 2. Horn Leads 3. Front Wheel Rotation Sensor Lead (ABS Equipped Models) 4. Horn 5. Clamp (Hold the front wheel rotation sensor lead. Insert the clamp to the horn bracket.) 6. Intake Air Pressure Sensor Lead 7. Main Harness 8. Front Left Turn Signal Light Lead 9. Frame Ground Lead 17-8 APPENDIX Cable, Wire, and Hose Routing 1. Relay Box 2. About 20°  40° 3. Fuse Boxes (Insert the fuse boxes to the bracket.) 4. Relay Box Leads 5. Frame Ground Terminal 6. Fuse Box Lead APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Regulator/Rectifier 2. Clamp (Hold the right headlight lead. Insert the clamp to the frame.) 3. Right Headlight Lead 4. Regulator/Rectifier Lead 5. Front Right Turn Signal Light Lead 6. Reserve Tank Hose 7. Run the front right turn signal light lead under the regulator/rectifier lead. 17-10 APPENDIX Cable, Wire, and Hose Routing 1. Clutch Cable 2. Run the clutch cable through the guide 3. Reserve Tank Hose APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Insert the front left turn signal light lead connector to the left middle fairing. 2. Front Left Turn Signal Light Lead 3. Front Right Turn Signal Light Lead 4. Insert the front right turn signal light lead connector to the right middle fairing. 5. Regulator/Rectifier Lead 6. Reserve Tank Hose 17-12 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Clutch Cable 2. Left Switch Housing Lead 3. Front Wheel Rotation Sensor Lead Connector (Inset the connector to the bracket.) (ABS Equipped Models) 4. Front Wheel Rotation Sensor Lead (ABS Equipped Models) 5. ABS Hydraulic Unit Lead (ABS Equipped Models) 6. Vehicle-down Sensor Lead 7. Vehicle-down Sensor 8. Clamp (Hold the main harness. Insert the clamp to the vehicle down sensor bracket.) 9. Main Harness 10. Do not twist the main harness around here. 17-14 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Intake Air Pressure Sensor 2. Vehicle-down Sensor 3. Vehicle-down Sensor Lead 4. Run the main harness in front of the rear brake pipes. (ABS Equipped Models) 5. Rear Brake Pipes (ABS Equipped Models) 6. Clamp (Hold the main harness. Insert the clamp to the vehicle-down sensor bracket.) 7. ECU 8. Intake Air Pressure Sensor Lead 9. Clamp (Hold the main harness. Insert the clamp to the frame.) 10. Brackets (Hold the main harness to the guide of the bracket.) 11. ECU Leads 12. Clamps (Hold the main harness. Insert the clamp to the air cleaner housing.) 13. Frame Ground Terminal 14. Intake Air Temperature Sensor 15. Intake Air Temperature Sensor Lead 17-16 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Main Harness 2. Front Wheel Rotation Sensor Lead (ABS Equipped Models) 3. Clamps (Hold the main harness. Insert the clamp to the frame.) 4. Clamp (Hold the main harness. Insert the clamp to the frame cross pipe.) 5. Intake Air Pressure Vacuum Hose 6. Relay Box Lead 7. Regulator/Rectifier Lead 8. Radiator Fan Lead Connector 9. Radiator Fan Lead 10. Reserve Tank Hose 11. Throttle Cable (Decelerator Cable) 12. Throttle Cable (Accelerator Cable) 13. Air Switching Valve 14. Clamp (Hold the stick coil lead. Do not touch the lead to the uncoated edge of the clamp.) 15. Stick Coil Leads 16. Air Switching Valve Lead 17-18 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Left Switch Housing Lead 2. Ignition Switch Lead 3. Right Switch Housing Lead 4. Rubber Boot 5. Throttle Cable (Decelerator Cable) 6. Throttle Cable (Accelerator Cable) 7. Run the radiator fan lead to the outside of the throttle cables. Run the radiator fan lead in back of the regulator/rectifier lead. 8. Radiator Fan Lead 9. Clamp (Hold the reserve tank hose.) 10. Reserve Tank Hose 11. Run the clutch cable, left switch housing lead, ignition switch lead, right switch housing lead and throttle cables over the steering stem. 12. Clutch Cable 13. Clamp (Hold the clutch cable. Position the clamp so that the open side faces rightward.) 14. Run the clutch cable in front of the main harness. 17-20 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Clamp (Hold the main harness. Insert the clamp to the air cleaner housing.) 2. Fuel Tank Drain Hose 3. Fuel Hose 4. Clamp (Hold the main harness. Insert the clamp to the frame.) 5. Fuel Tank Breather Hose (Fuel Tank  Canister (Evaporative Emission Control System Equipped Models)) 6. Main Harness 7. Fuel Pump Lead 8. Starter Relay Lead 9. Oxygen Sensor Lead 10. Band (Hold the gear position sensor lead, alternator lead and side stand switch lead.) 11. Water Temperature Sensor Lead 12. Alternator Lead 13. Clamp (Hold the fuel tank drain hose and oxygen sensor lead.) 14. Gear Position Sensor 15. Clamp (Hold the fuel tank drain hose, oxygen sensor lead and side stand switch lead.) 16. Side Stand Switch Lead 17-22 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Gear Position Sensor Lead 2. Band (Hold the gear position sensor lead, alternator lead and side stand switch lead.) 3. Alternator Lead 4. Fuel Pump Lead 5. Starter Relay Lead 6. Air Cleaner Oil Drain Hose (Run the drain hose to inside of other leads. Place the drain hose between the engine sprocket cover and crankcase.) 7. Side Stand Switch Lead 8. Clamp (Hold the fuel tank drain hose and oxygen sensor lead.) 9. Fuel Tank Drain Hose 10. Oxygen Sensor Lead 11. Place the all hose and leads between the engine sprocket cover and crankcase. 12. Clamp (Hold the fuel tank drain hose, oxygen sensor lead and side stand switch lead.) 13. White Tape (Hold the side stand switch lead and oxygen sensor lead.) 14. Wrap the rubber cover. 17-24 APPENDIX Cable, Wire, and Hose Routing US, CA, AU, ID, PH and MY Models APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Clamp (Hold the main harness. Insert the clamp to the air cleaner housing.) 2. Fuel Tank Drain Hose 3. Fuel Hose 4. Fuel Tank Breather Hose 5. Main Harness 6. Fuel Pump Lead 7. Starter Relay Lead 8. Oxygen Sensor Lead 9. Band (Hold the gear position sensor lead, alternator lead and side stand switch lead.) 10. Water Temperature Sensor Lead 11. Alternator Lead 12. Clamp (Hold the fuel tank breather hose, fuel tank drain hose and oxygen sensor lead.) 13. Gear Position Sensor 14. Clamp (Hold the fuel tank breather hose, fuel tank drain hose, oxygen sensor lead and side stand switch lead.) 15. Side Stand Switch Lead 17-26 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Rear Wheel Rotation Sensor Lead 2. Reserve Tank Hose 3. Battery Negative (–) Cable 4. Rear Brake Pipe (ABS Hydraulic Unit  Rear Caliper) (ABS Equipped Models) 5. Rear Brake Pipe (ABS Hydraulic Unit  Rear Master Cylinder) (ABS Equipped Models) 6. Reserve Tank Overflow Hose 7. Clamp (Hold the crankshaft sensor/oil pressure switch lead. Insert the clamp to the frame pipe.) 8. Reserve Tank Hose 9. Rear Brake Light Switch Lead 10. Crankshaft Sensor Lead 11. Oil Pressure Switch 12. Bracket (Hold the reserve tank overflow hose to the guide of the bracket.) 13. Clamp (Hold the crankshaft sensor/oil pressure switch lead and reserve tank overflow hose.) 14. Bracket (Hold the crankshaft sensor/oil pressure switch lead and reserve tank overflow hose to the guide of the bracket.) 15. Oil Pressure Switch Lead 16. Reserve Tank Overflow Hose 17-28 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Rear Wheel Rotation Sensor Lead 2. White Tape 3. Clamp (Hold the main harness at the white tape, and hold the battery negative (–) cable. Insert the clamp to the frame pipe. Position the clamp so that the open side faces upward.) 4. Rear Brake Pipe (ABS Hydraulic Unit  Rear Caliper) 5. Rear Brake Pipe (ABS Hydraulic Unit  Rear Master Cylinder) 6. Clamp (Hold the crankshaft sensor/oil pressure switch lead. Insert the clamp to the frame pipe.) 7. Crankshaft Sensor/Oil Pressure Switch Lead Connector 8. Crankshaft Sensor/Oil Pressure Switch Lead 9. Reserve Tank Hose 10. Rear Brake Light Switch Lead 11. Crankshaft Sensor Lead 12. Oil Pressure Switch 13. Bracket (Hold the reserve tank overflow hose to the guide of the bracket.) 14. Clamp (Hold the crankshaft sensor/oil pressure switch lead and reserve tank overflow hose.) 15. Bracket (Hold the crankshaft sensor/oil pressure switch lead and reserve tank overflow hose to the guide of the bracket.) 16. Oil Pressure Switch Lead 17. Reserve Tank Overflow Hose. 17-30 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Main Harness 2. Clamp (Hold the main harness, and insert the clamp to the air cleaner housing.) 3. Rear Brake Light Switch Lead 4. Rear Wheel Rotation Sensor Lead 5. Rear Wheel Rotation Sensor Lead Connector (Insert the rear wheel rotation sensor lead connector to the frame bracket.) 6. Reserve Tank Overflow Hose 7. Battery Negative (–) Cable 8. Frame Ground Terminal 9. Clamp (Hold the main harness and battery negative (–) cable.) 10. Reserve Tank Hose 11. Clamp (Hold the main harness, and insert the clamp to the frame pipe.) 12. Crankshaft Sensor/Oil Pressure Switch Lead 13. Clamp (Hold the battery positive (+) lead. Insert the clamp to the frame pipe. Position the clamp so that the open side faces upward.) (ABS Equipped Models) 14. Clamp (Hold the main harness at the white tape, and hold the battery negative (–) cable. Insert the clamp to the frame pipe. Position the clamp so that the open side faces upward.) 15. White Tape 16. Alternator Lead 17. Intake Air Temperature Sensor Lead 18. Gear Position Sensor Lead Connector 17-32 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Fuel Injector #1 Lead 2. Fuel Injector #2 Lead 3. Throttle Body Assy 4. Clamp (Hold the fuel injector #2 lead.) 5. Purge Hose (Purge Valve  Throttle Body Assy) 6. Fuel Injector #2 Lead Connector 7. Fuel Hose 8. Subthrottle Valve Actuator Lead Connector 9. Run the subthrottle valve actuator lead under the fuel hose. 10. Subthrottle Valve Actuator Lead 11. Alternator Lead 12. Fuel Tank Drain Hose 13. Main Harness 14. Fuel Injector #1 Lead Connector 15. Starter Motor Cable 16. Purge Hose (Canister  Purge Valve) (Evaporative Emission Control System Equipped Models) 17. Battery Negative (–) Cable 18. Rear Wheel Rotation Sensor Lead 19. Crankshaft Sensor Lead 20. Rear Wheel Rotation Sensor Lead Connector (Insert the rear wheel rotation sensor lead connector to the frame pipe.) 21. Reserve Tank Overflow Hose 22. Reserve Tank 23. Purge Valve (Evaporative Emission Control System Equipped Models) 24. Purge Valve Lead (Evaporative Emission Control System Equipped Models) 25. Clamp (Hold the starter motor cable and frame.) 26. Fuel Tank Breather Hose 27. Fuel Tank Drain Hose 17-34 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-35 Cable, Wire, and Hose Routing 1. Rear Wheel Rotation Sensor Lead Connector (Insert the rear wheel rotation sensor lead connector to the frame bracket.) 2. Clamp (Hold the crankshaft sensor/oil pressure switch lead. Insert the clamp to the frame pipe.) 3. Clamp (Hold the main harness at the white tape, and hold the battery negative (–) cable. Insert the clamp to the frame pipe. Position the clamp so that the open side faces upward.) 4. Rear Brake Light Switch Lead 5. White Tape 6. Rear Wheel Rotation Sensor Lead 7. Reserve Tank Hose 8. Reserve Tank Overflow Hose 9. Crankshaft Sensor/Oil Pressure Switch Lead 10. Battery Negative (–) Cable 17-36 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Clamp (Hold the main harness. Insert the clamp to the air cleaner housing.) 2. Rear Brake Light Switch Lead 3. Main Harness 4. Crankshaft Sensor/Oil Pressure Switch Lead 5. Rear Wheel Rotation Sensor Lead Connector (Insert the rear wheel rotation sensor lead connector to the frame bracket.) 6. Frame Ground Terminal 7. Rear Wheel Rotation Sensor Lead 8. Battery Negative (–) Cable 9. Reserve Tank Hose 10. Clamp (Hold the main harness at the white tape, and hold the battery negative (–) cable. Insert the clamp to the frame pipe. Position the clamp so that the open side faces upward.) 11. White Tape 12. Reserve Tank Overflow Hose 13. Clamp (Hold the crankshaft sensor/oil pressure switch lead. Insert the clamp to the frame pipe.) 14. Rear Brake Pipe (ABS Hydraulic Unit  Rear Master Cylinder) 15. Rear Brake Pipe (ABS Hydraulic Unit  Rear Caliper) 17-38 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-39 Cable, Wire, and Hose Routing 1. Battery 2. Clamp (Hold the battery negative (–) cable.) 3. Battery Negative (–) Cable 4. Clamp (Hold the battery negative (–) cable and main harness.) 5. Main Harness 6. Clamp (Hold the main harness.) 7. Fuel Tank Breather Hose 8. Run the batter positive (+) cable to the outside of the fuel tank breather hose. 9. Clamp (Hold the battery positive (+) cable.) 10. Battery positive (+) Cable 17-40 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Rear Left Turn Signal Light Lead Connector (Insert the connector to the bracket of the frame.) 2. Rear Right Turn Signal Light Lead Connector (Insert the connector to the bracket of the frame.) 3. License Plate Light Lead Connector (Insert the connector to the bracket of the frame.) 4. Kawasaki Diagnostic System Connector 5. ABS Kawasaki Diagnostic System Connector (ABS Equipped Models) 6. Clamp (Run the rear turn signal light leads and license plate light through the clamp. The open side of the clamp faces backward.) 7. Run the tail/brake light lead to the back side of the bracket. 8. Tail/Brake Light Lead 9. Clamp (Hold the main harness.) 10. Do not twist the main harness around here. 11. Tail/Brake Light Lead Connector 17-42 APPENDIX Cable, Wire, and Hose Routing ~II ,- 8609051 FW5 C APPENDIX 17-43 Cable, Wire, and Hose Routing 1. Air Cleaner Housing 2. ECU 3. Breather Hose 4. Clamps 5. Air Switching Valve Hose (Install the air switching valve hose so that the white paint mark faces right side of vehicle.) 6. White Paint Marks 7. Air Switching Valve 8. Throttle Body Assy 9. Air Switching Valve Hose (Install the air switching valve hose so that the white paint mark faces upward of vehicle.) 10. Viewed from A 17-44 APPENDIX Cable, Wire, and Hose Routing Ve t5 8609052FW5 C APPENDIX 17-45 Cable, Wire, and Hose Routing 1. Reserve Tank Hose 2. Install the clamps as shown. 3. Water Hose (Install the water hose so that the white paint mark faces right side of vehicle.) 4. White Paint Marks 5. 45° 6. Front Side of Vehicle 7. Right Side of Vehicle 8. Upper Side of Vehicle 9. Left Side of Vehicle 10. Water Hose (Install the water hose so that the white paint mark faces left side of vehicle.) 17-46 APPENDIX Cable, Wire, and Hose Routing 811 8609053FW5 C APPENDIX 17-47 Cable, Wire, and Hose Routing 1. Clamp 2. Reserve Tank Hose 3. Clamps (Hold the reserve tank hose.) 4. Reserve Tank Overflow Hose 5. Section A – A 6. ABS Equipped Models 7. White Paint Mark (The white paint mark faces outside.) 17-48 APPENDIX Cable, Wire, and Hose Routing GB09156FW4 C 1. Front Brake Hoses 2. Clamps (Hold the front brake hose.) 3. Clamp (Hold the front brake hoses.) APPENDIX 17-49 Cable, Wire, and Hose Routing 1. Front Brake Hoses 2. Clamp (Hold the front brake hose.) 3. Clamp (Hold the front brake hoses.) 17-50 APPENDIX Cable, Wire, and Hose Routing © GB09056FW4 C 1. Clamps (Hold the rear brake hose and rear wheel rotation sensor lead at the white marks.) 2. Clamp (Hold the rear brake hose.) 3. Clamps (Hold the rear wheel rotation sensor lead.) 4. Rear Brake Hose 5. Rear Wheel Rotation Sensor Lead 6. Detail A (Viewed from the inside) 7. Rear Wheel Rotation Sensor APPENDIX 17-51 Cable, Wire, and Hose Routing 1. Clamp (Insert the clamp so that its open side faces upward.) 2. Clamps (Insert the clamp from the outside.) 3. Clamp (Insert the clamp from the upside.) 4. Rear Wheel Rotation Sensor Lead 5. Rear Brake Hose 17-52 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models GB09158FW4 C 1. Clamps (Hold the front brake hose.) 2. Clamps (Hold the front wheel rotation sensor lead.) 3. Front Wheel Rotation Sensor Lead 4. Clamps (Hold the front brake hose and front wheel rotation sensor lead at the white mark of the front wheel rotation sensor lead.) 5. Clamp (Hold the front brake hose and front wheel rotation sensor lead.) 6. Clamp (Hold the front brake hoses.) 7. Front Wheel Rotation Sensor 8. Front Brake Hose APPENDIX 17-53 Cable, Wire, and Hose Routing ABS Equipped Models G8091 59 F’IC C 1. Pads 2. 5 mm (0.20 in.) 3. Contact the side of the pad with the bracket. 4. 90° 5. 72.6° 6. Clamps (Hold the front wheel rotation sensor lead.) 7. Clamp (Hold the front brake hose.) 8. Clamp (Hold the front brake hose and front wheel rotation sensor lead.) 9. Clamps (Hold the front brake hose and front wheel rotation sensor lead at the white mark of the front wheel rotation sensor lead.) 10. Front Wheel Rotation Sensor 17-54 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models 1. Front Brake Hose 2. Clamps (Insert the clamp from the back side.) 3. Front Wheel Rotation Sensor Lead 4. Clamp (Insert the clamp so that its open side faces backward.) 5. Front Wheel Rotation Sensor 6. Clamp (Hold the front brake hoses.) APPENDIX 17-55 Cable, Wire, and Hose Routing ABS Equipped Models 1. Run the front brake hose to the outside of the frame pipe. 2. Front Brake Hose (Front Master Cylinder  ABS Hydraulic Unit) 3. Front Brake Hose (ABS Hydraulic Unit  Front Caliper) 4. Run the front brake hose to the inside of the frame pipe. 5. Clamps (Hold the brake pipes.) 6. Rear Brake Hose (ABS Hydraulic Unit  Rear Caliper) 7. Rear Brake Hose (Rear Master Cylinder  ABS Hydraulic Unit) 17-56 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models ~ GIi 8 11 86090e2FW5 C APPENDIX 17-57 Cable, Wire, and Hose Routing 1. Clamps (Hold the rear brake hose and rear wheel rotation sensor lead at the white marks.) 2. Clamps (Hold the rear wheel rotation sensor lead.) 3. Clamps (Hold the rear brake hose.) 4. Clamps (Hold the brake pipes.) 5. 90° 6. Section A – A 7. Detail B (Viewed from the inside) 8. Rear Wheel Rotation Sensor 17-58 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models 1. Clamp (Insert the clamp so that its open side faces upward.) 2. Clamps (Insert the clamp from the outside.) 3. Clamp (Insert the clamp from the upside.) 4. Rear Brake Hose 5. Rear Wheel Rotation Sensor Lead 6. Rear Wheel Rotation Sensor APPENDIX 17-59 Cable, Wire, and Hose Routing Evaporative Emission Control System Equipped Models G809066 F’IC C 1. Green Paint 2. Run the purge hose to the right side of the breather hose. 3. Purge Valve 4. Purge Hose (Purge Valve – Throttle Body Assy) 5. Purge Hose (Canister – Purge Valve) 6. Breather Hose 7. Starter Relay 8. Install the clamps as shown. 9. Fuel Tank Breather Hose (Fuel Tank – Canister) 10. Clamp (Hold the fuel tank breather hose.) 11. Run the purge hose through the hole of the starter relay holder. 12. Starter Motor Cable 17-60 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System Equipped Models GB09067ffl’3 C 1. Canister 2. Install the purge hose so that the green paint mark faces upward. 3. Install the fuel tank breather hose so that the blue paint mark faces upward. 4. Install the clamps as shown. 5. Purge Hose (Canister – Purge Valve) 6. Fuel Tank Breather Hose (Fuel Tank – Canister) APPENDIX 17-61 Cable, Wire, and Hose Routing Evaporative Emission Control System Equipped Models 1. Starter Motor Cable 2. Fuel Tank Breather Hose (Fuel Tank  Canister) 3. Run the battery positive (+) cable to the outside of the fuel tank breather hose. 4. Battery Positive (+) Cable 5. Purge Hose (Canister  Purge Valve) 6. Purge Hose (Purge Valve  Throttle Body Assy) 7. Purge Valve 8. Purge Valve Lead 17-62 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System Equipped Models 1. Starter Motor Cable 2. Fuel Tank Drain Hose 3. Purge Valve Lead 4. Battery Positive (+) Cable 5. Purge Valve 6. Purge Hose (Canister  Purge Valve) 7. Purge Hose (Purge Valve  Throttle Body Assy) 8. Fuel Pump Lead 9. Starter Relay Lead 10. Fuel Tank Breather Hose (Fuel Tank  Canister) 11. Oxygen Sensor Lead APPENDIX 17-63 Troubleshooting Guide NOTE ○Refer to the Fuel System (DFI) chapter for most of DFI trouble shooting guide. ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Starter motor not rotating: Ignition and engine stop switch not on Starter lockout switch or 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 doesn’t turn over: Vehicle-down sensor (DFI) coming off Starter clutch trouble Starter idle gear trouble Engine won’t turn over: Valve seizure Valve lifter seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure Balancer bearing seizure No fuel flow: No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark; spark weak: Vehicle-down sensor (DFI) coming off Ignition switch not on Engine stop switch turned to stop position Clutch lever not pulled in or gear not in neutral Battery voltage low 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 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 Fuel line clogged Throttle body assy holder loose Air cleaner housing holder loose Compression low: Spark plug loose Cylinder head not sufficiently tightened down 17-64 APPENDIX Troubleshooting Guide 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 worn 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 won’t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worn Air suction valve trouble Air switching valve trouble Catalytic convertermelt 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 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 APPENDIX 17-65 Troubleshooting Guide Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect 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: Cooling system component incorrect: Thermostat trouble Radiator fan relay trouble Clutch Operation Faulty: Clutch slipping: Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly: Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble Gear Shifting Faulty: Doesn’t go into gear; shift pedal doesn’t return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear: Shift fork ear worn, bent Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Gear positioning lever spring weak or broken Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts: Gear positioning lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise: Knocking: ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise: Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring/groove clearance excessive Piston ring worn, broken, or stuck 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 17-66 APPENDIX Troubleshooting Guide Catalytic convertermelt down due to muffler overheating (KLEEN) Balancer gear worn or chipped Balancer shaft position maladjusted Balancer bearing worn Abnormal Drive Train Noise: Clutch noise: 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) Doesn’t 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 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 Right and left front fork oil level incorrect Shock absorption unsatisfactory: (Too hard) Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent (Too soft) Tire air pressure too low Front fork oil insufficient and/or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking APPENDIX 17-67 Troubleshooting Guide Brake Doesn’t Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble: Battery discharged: Charge insufficient Battery faulty (too low terminal voltage) Battery cable making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Alternator trouble Wiring faulty Regulator/rectifier trouble Battery overcharged: Alternator trouble Regulator/rectifier trouble Battery faulty EX650J Meter Unit 1.Yellow Shift-up Indicator Light(LED) 2.Green Left Tum Signal Indicator Light(LED) 3.Green Right Tum Signal Indicator Light(LED) 4.Blue High Beam Indicator Light(LED) 5.Green Neutral Indicator Light(LED) 6. Yellow Engine Warning Indicator Light(LED) 7.Red Warning Indicator Light(LED) (Oil Pressure/Battery/ Water Temperature) 8.lllumination Light(LED) 9.Speedometer 10.Tachometer 11.0dometer/Trip Meter 12.Current Mileage/Average Mileage/ Crusing Range 13.Clock 14.Fuel Level Gauge 15.Gear Position Indicator e LED:Light Emitting Diode (D ~ @ @ @ <ID <7) @ ® IIIIIII ® G) @ lllllllililll lilililil Ignition Switch Meter U-nit -, __ , >-OUR f- LG Right Switch Housing l<D-~-@1 Alternator Right Switch Housing 1.Front Brake Light Switch 2.Engine Stop Switch 3.Starter Button Spark Plugs #1 #2 l:r;i;i~I:@ ~~7or ~ ~ Regulator ~ f Stick f Air . . iiiril!i m o ~ ,-, w ~~ t r~ jjt______Jj~~ • ~~ ,~ r§ I~ ~-++———+<—<—>-+–+–+–++–~ Fuel Injectors #1 #2 ~ w -BK/Y ~~ 1–+——-+->-+—++-++————+-l->-+—+——–+–+—-<—<f—-+–++-+–+—+-~ p – f-BlJO >- LB ~GY–+——-+->-+—++-++——-~ Subthrotde Valve Actuator Main Throttle Sensor Subthrottle Sensor Intake Air Pressure Sensor Vehide -down Sensor Intake Air Temperature Sensor ‘t ‘U~J1 ~p~ ~Pf w·r I ~g=t:t======tt:t:=::t:t=t======:i.-.l.-1—–++-++—l——–+—+—-1—–1–W—l—1–+—lW-l-l-J.–, Gear Position Sensor Water W~f ?i to=1fri I Crank- Oil shaft ~l~ ~~ Purge r~~iorative Emission ~.~rm Equipped Models) ~ 1~ r– – ~- ~———ii——–tt-t—-t-t-t—–t-t—i——t-t-1–t—t—–t-t–t—–;—–t-t—t—-t–;—t-t-t,t:t.::.::,t::.l.::.::.::.::.::.::.::.::.::.t.::.::.::.::.1.t.t::.::.::.=1+–++—–+–1-+-+——+–+—–+—-+—+– – I Front Right T~m Signal ~ G ~ GY Light 12V10W \.=::;l.rBKN-ll.J-BKIY- _____J I 12V5W \.=::;l.rBKIY BKIY- – ECU 81</0 BKIY BK/Y GY BUO LO LG/BK PIBL GIBK OK BUR OLIY R/8L BR/Y BKIR RIG R WIBK BK R/Y BK/0 p YIBK PIBK BR/BK R GIBK BR 0 WIBL G PIBL BRM< WIG R/8K LG/R VIG aL YIBL Y/R BL/Y LG GN BK/0 ~ht headl;g~t~;ght -frll.-:~ J BR/Y j Headllght(LO) ~ • BL/YL_Jl1L_J_JlLJL–il-Si==i=======i=~11—r-n-r-rrr-1~1nr—-o-=–rr—-r1t1 12V55W BK BKtY-+—~ – LGIBKfil Kawasaki I D—-<—<f———-+-+—-+—-<-+—-<f———————<f———++–+–BRJW Diagnostic L ___________ _J – P/Bl Connector Left headlight I I (i BKN System I ~ I .___8~RearWheel ——-w1G ~ Rotation : Headl;ght(HI) R J’ Rl8l( Sensor I 12V55W BK BKIYt—,- tt-ii——tt,-tt,–4411-i-i111 ___ lll———lll–llll——————4——-i1;:::::==== ~ G ~ Rear RightTum a:R-llJ-BKN–Ll.::=} ~~~1a6~ghl I Left ~ I City Light \.=::;l.r BR/Y BR/Y::::-::_-::_-::_-:_-:_.++—~ L__ 12V5W ____ “”” ‘”” BUR:::flc BL~ ).QI Tail/Brake :~~B~ ~ Light(LED) Front Left ~ G ~ 0 —–+—-++—————t L, Tum Signal \.=::;l.rBKN~BKIY—-~ t-+—–+-++-+—+——–+-++–+++—+-++-+—-<—-<>+–+—–++-+-+———–+–+–1—-++-++-+——————-+———-<>+-,-, Light 12V10W ~—————<f-1——-+-+++—+——–+->+—+-++—+-+++—+—+-+–+——H ~ Hom -,_.~BKIY –i.-~B~——————–~ Horn Button Hazard Switch Color BK/W BK/Y Color G 0 Released OFF Push ca , ON Left Switch Housing 1.Hom Button 2.Hazard Button 3.Tum Signal Switch 4.Dimmer Switch 5.Starter Lockout Switch 6.Passing Button 11 a LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Dimmer Switch Starter Lockout Switch GY Color G 0 GY Color R/Y BL/Y R/BK Color BK BR L ca ~ HI ca , Clutch Lever OFF(Push) Released R ca ~ LO ca ~ Pulled in ca , Relay Box Relay Box 1.Fan Relay 2.Headlight Circuit Relay 3.ECU Main Relay 4.Fuel Pump Relay 5.Starter Circuit Relay Passing Button Color R/BK BL/Y Push ca , Fuse Box(1 ) 1.ECU Fuse 15A 2.Meter Fuse 10A 3.Fan Fuse 15A 4.Brake LighUHom Fuse 10A 5.lgnition Fuse 10A 6.Headlight Fuse 15A IGNITION SWITCH CONNECTIONS Ignition Battery Signal Color BR w BL OFF,Lock ON ~ Fuse Box(2) 1.Accessory Fuse 5A 2.Tum Signal Relay Fuse 10A Fuel Fuel Level Pump Sensor ! 11 ~- t_,: $$ ~~ ON[!t] OFF Side Stand Switch r+—H-:~::[Il::B~–Ll.::=) t:;r~~~~ — :@ Rear Left Tum = B~::[Il::B~ Signal Light 12V10W Rear -R~BR~Brake -BUR~ BL -t::::=J Light Switch Color Code BK Black BL Blue BR Brown G Green GY Grav LB Liaht Blue LG Liaht Green 0 Oranoe p Pink PU Purole R Red w White y Yellow EX650K Meter Unit 1.Yellow ABS Indicator Light(LED) 2.Yellow Shift-up Indicator Light(LED) 3.Green Left Tum Signal Indicator Light(LED) 4.Green Right Tum Signal Indicator Light(LED) 5.Blue High Beam Indicator Llght(LED) 6.Green Neutral Indicator Light(LED) 7.Yellow Engine Warning Indicator Light(LED) 8.Red Warning Indicator Light(LED) (OIi Pressure/Battery/ Water Temperature) 9.lllumination Light(LED) 1 O.Speedometer 11 .Tachometer 12.0dometerfTrip Meter 13.Current Mileage/Average Mileage/ Cruslng Range 14.Clock 15.Fuel Level Gauge 16.Gear Position Indicator • LED:Light Emitting Diode ITIIIII G) Ignition Switch Accessory f”A~,y, 1 Socket 1 ‘~(-)-~:= r—c-:l<w>-~·J Accessory Reray w’:.- BRK!-YRight Switch Housing I<!)-~ -0) I Alternator Right Switch Housing 1.Front Brake Light Switch 2.Englne Stop Switch 3.Starter Button I : @ at@ I: ~ Regulator ‘ U ~· H ‘ ~ /Rectifier Fan Motor i ~! ~! !~ i ™ g i~ 11~ nur~· Spark Plugs #1 #2 f Stick f Air wr ‘ Switching valve #1 ~ ~ r ,~ -~~~ i~ Subthrottle Valve Actuator ~ Fuel Injectors #2 ffio11.~ ~ ~ i~ i~o~ Main Throttle Sensor I Intake Ge~r. 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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 . 2-11 Special Tools 2-13 Periodic Maintenance Procedures 2-14 Fuel System (DFI) 2-14 Air Cleaner Element Replacement 2-14 Idle Speed Inspection . 2-15 Idle Speed Adjustment 2-15 Throttle Control System Inspection. 2-16 Engine Vacuum Synchronization Inspection. 2-16 Fuel System Inspection. 2-20 Fuel Filter Replacement 2-20 Fuel Hose Replacement . 2-22 Evaporative Emission Control System Inspection (Equipped Models) . 2-24 Cooling System 2-25 Coolant Level Inspection. 2-25 Cooling System Inspection . 2-25 Coolant Change 2-25 Water Hose and O-ring Replacement. 2-28 Engine Top End . 2-28 Valve Clearance Inspection 2-28 Valve Clearance Adjustment. 2-30 Air Suction System Damage Inspection 2-33 Clutch. 2-34 Clutch Operation Inspection . 2-34 Engine Lubrication System 2-35 Engine Oil Change 2-35 Oil Filter Replacement 2-36 Wheels/Tires 2-36 Air Pressure Inspection. 2-36 Wheels and Tires Inspection. 2-36 Wheel Bearing Damage Inspection 2-37 Final Drive 2-38 Drive Chain Lubrication Condition Inspection . 2-38 Drive Chain Slack Inspection 2-39 Drive Chain Slack Adjustment 2-39 Wheel Alignment Inspection . 2-40 Drive Chain Wear Inspection 2-41 Chain Guide Wear Inspection . 2-41 Brakes 2-42 Brake System Inspection 2-42 Brake Operation Inspection 2-43 Brake Fluid Level Inspection. 2-43 Brake Fluid Change 2-44 Brake Hose and Pipe Replacement 2-46 Master Cylinder Rubber Parts Replacement 2-50 Caliper Rubber Parts Replacement 2-51 Brake Pad Wear Inspection 2-55 Brake Light Switch Operation Inspection 2-55 Suspension 2-56 Suspension System Inspection. 2-56 Steering . 2-58 Steering Play Inspection . 2-58 Steering Play Adjustment 2-58 Steering Stem Bearing Lubrication . 2-60 Electrical System . 2-61 Lights and Switches Operation Inspection 2-61 Headlight Aiming Inspection . 2-63 Side Stand Switch Operation Inspection. 2-64 Engine Stop Switch Operation Inspection. 2-65 Spark Plug Replacement 2-66 Others 2-66 Chassis Parts Lubrication 2-66 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-67 Fuel System (DFI) Table of Contents Exploded View 3-4 DFI System. 3-10 DFI Components Naming . 3-12 DFI Parts Location 3-19 Specifications . 3-22 Special Tools and Sealant 3-24 DFI Servicing Precautions 3-26 DFI Servicing Precautions . 3-26 Troubleshooting the DFI System 3-28 Outline . 3-28 Inquiries to Rider 3-31 DFI System Troubleshooting Guide . 3-34 Self-Diagnosis 3-39 Self-Diagnosis Outline 3-39 Self-Diagnosis Procedures . 3-39 Service Code Reading 3-42 Service Code Erasing . 3-42 Backups 3-43 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) 3-46 Main Throttle Sensor Removal/Adjustment 3-46 Main Throttle Sensor Input Voltage Inspection . 3-46 Main Throttle Sensor Resistance Inspection 3-47 Main Throttle Sensor Output Voltage Inspection 3-47 Intake Air Pressure Sensor (Service Code 12) (DTC P0105, P0106, P0107) 3-50 Intake Air Pressure Sensor Removal 3-50 Intake Air Pressure Sensor Installation. 3-50 Intake Air Pressure Sensor Input Voltage Inspection 3-51 Intake Air Pressure Sensor Output Voltage Inspection. 3-52 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112). 3-56 Intake Air Temperature Sensor Removal/Installation 3-56 Intake Air Temperature Sensor Output Voltage Inspection . 3-56 Intake Air Temperature Sensor Resistance Inspection . 3-57 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) 3-59 Water Temperature Sensor Removal/Installation . 3-59 Water Temperature Sensor Output Voltage Inspection. 3-59 Water Temperature Sensor Resistance Inspection. 3-60 Crankshaft Sensor (Service Code 21) (DTC P0335) 3-62 Crankshaft Sensor Removal/Installation. 3-62 Crankshaft Sensor Resistance Inspection 3-62 Crankshaft Sensor Peak Voltage Inspection. 3-62 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158) 3-63 Rear Wheel Rotation Sensor Signal Inspection 3-63 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0917) 3-66 Gear Position Sensor Removal/Installation 3-66 Gear Position Sensor Input Voltage Inspection 3-66 Gear Position Sensor Output Voltage Inspection 3-67 Vehicle-down Sensor (Service Code 31) (DTC C0064) . 3-69 Vehicle-down Sensor Removal. 3-69 Vehicle-down Sensor Installation 3-69 Vehicle-down Sensor Input Voltage Inspection. 3-70 Vehicle-down Sensor Output Voltage Inspection 3-71 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) . 3-73 Subthrottle Sensor Removal/Adjustment 3-73 Subthrottle Sensor Input Voltage Inspection. 3-73 Subthrottle Sensor Output Voltage Inspection 3-74 Subthrottle Sensor Resistance Inspection 3-76 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132). 3-77 Oxygen Sensor Removal/Installation 3-77 Oxygen Sensor Inspection 3-77 ECU Communication Error (Service Code 39). 3-80 ECU Communication Line Inspection . 3-80 Fuel Injectors (Service Code 41, 42) (DTC P0201, P0202) . 3-81 Fuel Injector Removal/Installation. 3-81 Fuel Injector Audible Inspection 3-81 Fuel Injector Resistance Inspection 3-81 Fuel Injector Power Source Voltage Inspection 3-82 Fuel Injector Output Voltage Inspection 3-83 Fuel Injector Fuel Line Inspection. 3-84 Stick Coils #1, #2 (Service Code 51, 52) (DTC P0351, P0352) . 3-86 Stick Coil Removal/Installation 3-86 Stick Coil Primary Winding Resistance Inspection . 3-86 Stick Coil Input Voltage Inspection 3-86 Radiator Fan Relay (Service Code 56) (DTC P0480) 3-88 Radiator Fan Relay Removal/Installation 3-88 Radiator Fan Relay Inspection 3-88 Subthrottle Valve Actuator (Service Code 62) (DTC P2100) 3-89 Subthrottle Valve Actuator Removal . 3-89 Subthrottle Valve Actuator Inspection . 3-89 Subthrottle Valve Actuator Resistance Inspection 3-89 Subthrottle Valve Actuator Input Voltage Inspection . 3-90 Air Switching Valve (Service Code 64) (DTC P0410). 3-92 Air Switching Valve Removal/Installation 3-92 Air Switching Valve Inspection 3-92 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 3-93 Oxygen Sensor Heater Removal/Installation 3-93 Oxygen Sensor Heater Resistance Inspection . 3-93 Oxygen Sensor Heater Power Source Voltage Inspection . 3-94 Fuel Supply System (Service Code 94) (DTC P0170) . 3-96 Fuel Supply System Inspection. 3-96 Purge Valve (Service Code 3A) (DTC P0443) (Equipped Models) 3-97 Purge Valve Removal/Installation . 3-97 Purge Valve Inspection . 3-97 Warning Indicator Light (LED) 3-99 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-99 ECU 3-100 ECU Identification . 3-100 ECU Removal . 3-100 ECU Installation 3-100 ECU Power Supply Inspection 3-101 DFI Power Source 3-104 ECU Fuse Removal 3-104 ECU Fuse Installation . 3-104 ECU Fuse Inspection 3-104 ECU Main Relay Removal/Installation 3-104 ECU Main Relay Inspection 3-104 Fuel Line. 3-105 Fuel Pressure Inspection 3-105 Fuel Flow Rate Inspection 3-106 Fuel Pump 3-108 Fuel Pump Removal . 3-108 Fuel Pump Installation 3-109 Fuel Pump Operation Inspection 3-109 Fuel Pump Operating Voltage Inspection . 3-109 Pressure Regulator Removal 3-111 Fuel Pump Relay Removal/Installation. 3-111 Fuel Pump Relay Inspection . 3-111 Throttle Grip and Cables 3-113 Throttle Grip Free Play Inspection 3-113 Throttle Grip Free Play Adjustment. 3-113 Throttle Cable Installation . 3-113 Throttle Cable Lubrication. 3-113 Throttle Body Assy . 3-114 Idle Speed Inspection/Adjustment 3-114 Throttle Bore Cleaning 3-114 Synchronization Inspection/Adjustment 3-114 Throttle Body Assy Removal. 3-114 Throttle Body Assy Installation 3-116 Throttle Body Assy Disassembly 3-117 Throttle Body Assy Assembly . 3-118 Air Cleaner 3-120 Air Cleaner Element Removal/Installation 3-120 Air Cleaner Element Inspection 3-120 Air Cleaner Oil Draining 3-120 Air Cleaner Housing Removal. 3-120 Air Cleaner Housing Installation 3-121 Fuel Tank 3-122 Fuel Tank Removal . 3-122 Fuel Tank Installation 3-125 Fuel Tank and Cap Inspection 3-127 Fuel Tank Cleaning . 3-127 Evaporative Emission Control System (Equipped Models) 3-128 Parts Removal/Installation 3-128 Hose Inspection 3-128 Purge Valve Inspection . 3-128 Canister Inspection 3-128 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 . 4-9 Coolant Reserve Tank Installation 4-10 Water Pump 4-11 Water Pump Removal. 4-11 Water Pump Installation 4-11 Water Pump Inspection. 4-12 Mechanical Seal Inspection 4-12 Water Pump Housing Disassembly 4-13 Water Pump Housing Assembly . 4-13 Impeller Assembly. 4-13 Pump Impeller Inspection . 4-13 Radiator 4-14 Radiator and Radiator Fan Removal 4-14 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection . 4-15 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection . 4-16 Thermostat . 4-17 Thermostat Removal. 4-17 Thermostat Installation 4-17 Thermostat Inspection 4-18 Water Hose and Pipes 4-19 Water Hose Installation. 4-19 Water Hose Inspection 4-19 Water Hose and O-ring Replacement. 4-19 Water Temperature Sensor 4-20 Water Temperature Sensor Removal/Installation . 4-20 Water Temperature Sensor Inspection . 4-20 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-8 Special Tools and Sealant . 5-10 Clean Air System. 5-12 Air Suction Valve Removal. 5-12 Air Suction Valve Installation 5-12 Air Suction Valve Inspection 5-13 Air Switching Valve Removal . 5-13 Air Switching Valve Installation 5-13 Air Switching Valve Operation Test 5-13 Air Switching Valve Unit Test . 5-13 Clean Air System Hose Inspection 5-14 Cylinder Head Cover . 5-15 Cylinder Head Cover Removal 5-15 Cylinder Head Cover Installation . 5-15 Camshaft Chain Tensioner 5-17 Camshaft Chain Tensioner Removal 5-17 Camshaft Chain Tensioner Installation . 5-17 Camshaft, Camshaft Chain . 5-19 Camshaft Removal 5-19 Camshaft Installation . 5-21 Camshaft, Camshaft Cap Wear Inspection 5-24 Camshaft Runout Inspection 5-24 Cam Wear Inspection 5-25 Camshaft Chain Removal 5-25 Cylinder Head 5-26 Cylinder Compression Measurement 5-26 Cylinder Head Removal. 5-27 Cylinder Head Installation 5-28 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). 5-32 Valve Seat Inspection 5-33 Valve Seat Repair 5-33 Cylinder, Pistons 5-38 Cylinder Removal. 5-38 Cylinder Installation 5-38 Piston Removal 5-39 Piston Installation. 5-39 Cylinder Wear Inspection. 5-40 Piston Wear Inspection 5-41 Piston Ring, Piston Ring Groove Wear Inspection 5-41 Piston Ring Groove Width Inspection 5-41 Piston Ring Thickness Inspection 5-42 Piston Ring End Gap Inspection 5-42 Throttle Body Assy Holder. 5-43 Throttle Body Assy Holder Removal 5-43 Throttle Body Assy Holder Installation . 5-43 Muffler 5-44 Muffler Removal. 5-44 Muffler Installation 5-45 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 . 6-7 Clutch Lever Removal. 6-7 Clutch Lever Installation 6-8 Clutch Lever Position Adjustment. 6-8 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation . 6-9 Release Shaft Removal 6-9 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 Measurement. 6-16 Clutch Plate Assembly 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 . 7-6 Special Tools and Sealant 7-7 Engine Oil and Oil Filter 7-8 Oil Level Inspection. 7-8 Engine Oil Change 7-8 Oil Filter Replacement 7-8 Oil Pan 7-9 Oil Pan Removal. 7-9 Oil Pan Installation 7-10 Oil Screen. 7-12 Oil Screen Removal 7-12 Oil Screen Installation . 7-12 Oil Screen Cleaning 7-12 Oil Pressure Relief Valve 7-13 Oil Pressure Relief Valve Removal . 7-13 Oil Pressure Relief Valve Installation 7-13 Oil Pressure Relief Valve Inspection. 7-13 Oil Pumps. 7-14 Oil Pump Chain and Sprocket Removal . 7-14 Oil Pump Chain and Sprocket Installation 7-14 Oil Pump Removal 7-14 Oil Pump Installation . 7-16 Oil Pressure Measurement. 7-18 Oil Pressure Measurement . 7-18 Oil Pressure Switch 7-19 Oil Pressure Switch Removal . 7-19 Oil Pressure Switch Installation 7-19 Oil Pipes . 7-20 Oil Pipe Removal 7-20 Oil Pipe Installation . 7-20 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. 8-8 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-9 Crankcase Splitting 9-10 Crankcase Splitting 9-10 Crankcase Assembly . 9-12 Crankshaft and Connecting Rods 9-21 Crankshaft Removal 9-21 Crankshaft Installation . 9-21 Connecting Rod Removal 9-21 Connecting Rod Installation . 9-22 Crankshaft/Connecting Rod Cleaning 9-25 Connecting Rod Bend Inspection 9-26 Connecting Rod Twist Inspection. 9-26 Connecting Rod Big End Side Clearance Inspection 9-26 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-27 Crankshaft Side Clearance Inspection 9-28 Crankshaft Runout Inspection 9-29 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-29 Balancer 9-31 Balancer Removal 9-31 Balancer Installation. 9-31 Balancer Shaft Bearing Insert/Journal Wear Inspection . 9-31 Starter Motor Clutch 9-34 Starter Motor Clutch Removal/Installation 9-34 Starter Motor Clutch Inspection . 9-34 Starter Motor Clutch Disassembly 9-34 Starter Motor Clutch Assembly 9-34 External Shift Mechanism 9-35 Shift Pedal Removal 9-35 Shift Pedal Installation . 9-35 External Shift Mechanism Removal 9-36 External Shift Mechanism Installation . 9-37 External Shift Mechanism Inspection 9-38 Transmission . 9-40 Transmission Assy Removal 9-40 Transmission Assy Installation. 9-41 Transmission Assy Disassembly . 9-42 Transmission Assy Assembly 9-42 Transmission Shaft Removal . 9-44 Transmission Shaft Installation 9-44 Transmission Shaft Disassembly. 9-45 Transmission Shaft Assembly 9-45 Shift Drum and Fork Removal 9-48 Shift Drum and Fork Installation. 9-48 Shift Drum Disassembly. 9-48 Shift Drum Assembly . 9-48 Shift Fork Bending Inspection 9-48 Shift Fork/Gear Groove Wear Inspection 9-48 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-48 Gear Dog and Gear Dog Hole Damage Inspection . 9-49 Ball Bearing, Needle Bearing, and Oil Seal. 9-50 Ball and Needle Bearing Replacement. 9-50 Ball and Needle Bearing Wear Inspection 9-50 Oil Seal Inspection . 9-50 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 10-7 Rear Wheel Installation. 10-8 Wheel Inspection 10-11 Axle Inspection 10-11 Balance Inspection 10-12 Balance Adjustment 10-12 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 Drive Chain Installation . 11-8 Sprocket, Coupling . 11-11 Engine Sprocket Removal 11-11 Engine Sprocket Installation . 11-11 Rear Sprocket Removal 11-12 Rear Sprocket Installation. 11-12 Coupling Installation 11-13 Coupling Bearing Removal . 11-13 Coupling Bearing Installation 11-14 Coupling Bearing Inspection . 11-14 Coupling Bearing Lubrication 11-14 Coupling Damper Inspection. 11-15 Sprocket Wear Inspection. 11-15 Rear Sprocket Warp Inspection 11-15 Brakes Table of Contents Exploded View 12-3 Specifications . 12-10 Special Tools 12-11 Brake Lever, Brake Pedal. 12-12 Brake Lever Position Adjustment 12-12 Brake Pedal Position Inspection . 12-12 Brake Pedal Position Adjustment 12-12 Brake Pedal Removal . 12-12 Brake Pedal Installation 12-13 Calipers 12-14 Front Caliper Removal 12-14 Front Caliper Installation . 12-14 Rear Caliper Removal. 12-14 Rear Caliper Installation 12-15 Front Caliper Disassembly 12-15 Front Caliper Assembly. 12-15 Rear Caliper Disassembly 12-15 Rear Caliper Assembly . 12-16 Caliper Fluid Seal Damage Inspection 12-16 Caliper Dust Boot and Friction Boot Damage Inspection 12-16 Caliper Piston and Cylinder Damage Inspection 12-17 Caliper Holder Shaft/Pin/Collar Inspection 12-17 Brake Pads. 12-18 Front Brake Pad Removal. 12-18 Front Brake Pad Installation 12-18 Rear Brake Pad Removal . 12-19 Rear Brake Pad Installation 12-19 Brake Pad Wear Inspection 12-19 Master Cylinder 12-20 Front Master Cylinder Removal 12-20 Front Master Cylinder Installation . 12-20 Rear Master Cylinder Removal. 12-21 Rear Master Cylinder Installation 12-21 Front Master Cylinder Disassembly 12-22 Rear Master Cylinder Disassembly. 12-22 Master Cylinder Assembly 12-22 Master Cylinder Inspection (Visual Inspection). 12-23 Brake Disc 12-24 Brake Disc Removal . 12-24 Brake Disc Installation 12-24 Brake Disc Wear Inspection 12-24 Brake Disc Warp Inspection 12-25 Brake Fluid . 12-26 Brake Fluid Level Inspection. 12-26 Brake Fluid Change 12-26 Brake Line Bleeding 12-26 Brake Hose. 12-29 Brake Hose Removal/Installation 12-29 Brake Hose and Pipe Inspection. 12-29 Anti-Lock Brake System (Equipped Models) 12-30 Parts Location . 12-30 ABS Servicing Precautions . 12-34 ABS Troubleshooting Outline 12-36 Inquiries to Rider. 12-39 Self-diagnosis Outline . 12-43 Self-diagnosis Procedures 12-43 Service Code Clearing Procedures. 12-44 How to Read Service Codes. 12-47 How to Erase Service Codes 12-47 Yellow ABS Indicator Light (LED) Inspection 12-49 Solenoid Valve Inspection (Service Code 13, 14, 17, 18). 12-49 ABS Solenoid Valve Relay Inspection (Service Code 19) 12-49 Front, Rear Tire Abnormal (Service Code 25) 12-50 ABS Motor Relay Inspection (Service Code 35) . 12-50 Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) 12-51 Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) 12-52 Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44). 12-52 Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 12-53 Power Supply Voltage Abnormal [Low-Voltage] (Service Code 52) 12-53 Power Supply Voltage Abnormal [Over-Voltage] (Service Code 53) 12-54 ABS Solenoid Valve Relay Supply Voltage Inspection [Low-Voltage] (Service Code 54). 12-54 ECU Inspection (Service Code 55) . 12-54 ABS Hydraulic Unit Removal 12-55 ABS Hydraulic Unit Installation . 12-57 ABS Hydraulic Unit Inspection 12-58 Front Wheel Rotation Sensor Removal 12-58 Front Wheel Rotation Sensor Installation . 12-59 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 Front Fork Removal (Each Fork Leg) . 13-9 Front Fork Installation (Each Fork Leg) 13-9 Front Fork Oil Change 13-9 Front Fork Disassembly 13-11 Front Fork Assembly. 13-12 Inner Tube, Outer Tube Inspection . 13-14 Dust Seal Inspection . 13-14 Spring Tension Inspection. 13-14 Rear Shock Absorber . 13-15 Spring Preload Adjustment . 13-15 Rear Shock Absorber Removal 13-15 Rear Shock Absorber Installation . 13-16 Rear Shock Absorber Inspection 13-16 Rear Shock Absorber Scrapping 13-17 Rear Shock Absorber Bearing Removal. 13-17 Rear Shock Absorber Bearing Installation 13-17 Swingarm 13-18 Swingarm Removal. 13-18 Swingarm Installation 13-19 Swingarm Bearing Removal . 13-20 Swingarm Bearing Installation 13-21 Swingarm Bearing, Sleeve Inspection 13-22 Swingarm Bearing Lubrication 13-22 Chain Guide Inspection. 13-22 Tie-Rod, Rocker Arm 13-23 Tie-Rod Removal 13-23 Tie-Rod Installation . 13-24 Rocker Arm Removal 13-24 Rocker Arm Installation. 13-25 Tie-Rod and Rocker Arm Bearing Removal 13-25 Tie-Rod and Rocker Arm Bearing Installation. 13-26 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-27 Rocker Arm/Tie-Rod Bearing Lubrication . 13-27 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 Steering Stem, Stem Bearing Removal 14-6 Steering Stem, Stem Bearing Installation . 14-7 Steering Stem Bearing Lubrication . 14-9 Steering Stem Warp Inspection 14-9 Stem Cap Deterioration, Damage Inspection . 14-9 Handlebars . 14-10 Handlebar Removal 14-10 Handlebar Installation . 14-10 Frame Table of Contents Exploded View 15-3 Seats 15-14 Rear Seat Removal. 15-14 Rear Seat Installation 15-14 Front Seat Removal 15-14 Front Seat Installation . 15-14 Fairings. 15-15 Upper Inner Fairing Removal 15-15 Upper Inner Fairing Installation. 15-16 Lower Inner Fairing Removal 15-17 Lower Inner Fairing Installation. 15-18 Fairing Cover Removal . 15-18 Fairing Cover Installation 15-19 Middle Fairing Removal 15-20 Middle Fairing Installation . 15-22 Middle Fairing Disassembly 15-23 Middle Fairing Assembly. 15-24 Upper Fairing Removal. 15-25 Upper Fairing Installation 15-25 Covers 15-27 Frame Cover Removal 15-27 Frame Cover Installation. 15-27 Side Cover Removal. 15-27 Side Cover Installation 15-27 Ignition Switch Cover Removal. 15-27 Ignition Switch Cover Installation 15-28 Fuel Tank Side Cover Removal 15-28 Fuel Tank Side Cover Installation . 15-28 Seat Cover Removal. 15-29 Seat Cover Installation 15-30 Fenders 15-31 Front Fender Removal 15-31 Front Fender Installation . 15-31 Rear Fender Removal. 15-31 Rear Fender Installation 15-33 Flap Removal 15-33 Flap Installation. 15-33 Frame . 15-34 Frame Inspection 15-34 Battery Case. 15-35 Battery Case Removal 15-35 Battery Case Installation . 15-35 Guard 15-36 Mud Guard Removal. 15-36 Mud Guard Installation 15-36 Windshield 15-37 Windshield Height Adjustment 15-37 Windshield Removal . 15-37 Windshield Installation 15-37 Side Stand 15-38 Side Stand Removal . 15-38 Side Stand Installation 15-39 Rear View Mirrors. 15-41 Rear View Mirror Removal 15-41 Rear View Mirror Installation. 15-41 Electrical System Table of Contents Exploded View 16-4 Specifications . 16-10 Special Tools and Sealant 16-11 Parts Location. 16-12 Wiring Diagram (ER650G) 16-14 Wiring Diagram (ER650H) 16-16 Precautions. 16-18 Electrical Wiring 16-19 Wiring Inspection 16-19 Battery 16-20 Battery Removal . 16-20 Battery Installation 16-20 Battery Activation 16-21 Precautions . 16-23 Interchange . 16-24 Charging Condition Inspection 16-24 Refreshing Charge 16-24 Charging System 16-26 Alternator Cover Removal. 16-26 Alternator Cover Installation 16-26 Stator Coil Removal 16-27 Stator Coil Installation . 16-28 Alternator Rotor Removal . 16-28 Alternator Rotor Installation 16-29 Charging Voltage Inspection. 16-31 Alternator Inspection . 16-31 Regulator/Rectifier Removal. 16-33 Regulator/Rectifier Installation 16-33 Regulator/Rectifier Inspection. 16-33 Ignition System. 16-36 Crankshaft Sensor Removal. 16-36 Crankshaft Sensor Installation 16-37 Crankshaft Sensor Inspection. 16-37 Crankshaft Sensor Peak Voltage Inspection. 16-38 Timing Rotor Removal 16-38 Timing Rotor Installation . 16-38 Stick Coil Removal 16-39 Stick Coil Installation. 16-39 Stick Coil Inspection 16-39 Stick Coil Primary Peak Voltage Inspection 16-39 Spark Plug Removal . 16-40 Spark Plug Installation 16-40 Spark Plug Condition Inspection. 16-41 Interlock Operation Inspection 16-41 IC Igniter Inspection 16-42 Electric Starter System. 16-45 Starter Motor Removal 16-45 Starter Motor Installation. 16-45 Starter Motor Disassembly 16-46 Starter Motor Assembly 16-47 16-2 ELECTRICAL SYSTEM Brush Inspection . 16-48 Commutator Cleaning and Inspection. 16-49 Armature Inspection 16-49 Brush Lead Inspection 16-49 Right-hand End Cover Inspection. 16-49 Starter Relay Inspection 16-50 Lighting System 16-52 Headlight Beam Horizontal Adjustment 16-52 Headlight Beam Vertical Adjustment. 16-52 Headlight Bulb Replacement 16-52 Headlight Unit Removal 16-53 Headlight Unit Installation . 16-53 City Light Bulb Replacement. 16-54 Tail/Brake Light (LED) Unit Removal 16-54 Tail/Brake Light (LED) Unit Installation . 16-54 License Plate Light Bulb Replacement . 16-55 Front Turn Signal Light Bulb Replacement . 16-56 Rear Turn Signal Light Bulb Replacement 16-57 Turn Signal Relay Inspection 16-58 Switches and Sensors 16-60 Brake Light Timing Inspection. 16-60 Brake Light Timing Adjustment . 16-60 Switch Inspection 16-60 Water Temperature Sensor Removal/Installation . 16-60 Water Temperature Sensor Inspection . 16-61 Rear Wheel Rotation Sensor Removal. 16-61 Rear Wheel Rotation Sensor Installation 16-61 Rear Wheel Rotation Sensor Inspection. 16-61 Fuel Level Sensor Inspection 16-61 Oxygen Sensor Removal 16-62 Oxygen Sensor Installation . 16-62 Oxygen Sensor Inspection 16-63 Gear Position Sensor Removal. 16-63 Gear Position Sensor Installation 16-64 Gear Position Sensor Inspection 16-64 Accessory Relay Inspection 16-64 Air Switching Valve . 16-66 Air Switching Valve Operation Test . 16-66 Air Switching Valve Unit Test 16-66 Radiator Fan System 16-68 Fan Motor Removal 16-68 Fan Motor Installation . 16-68 Fan Motor Inspection 16-68 Meter, Gauge, Indicator Unit. 16-69 Meter Unit Removal 16-69 Meter Unit Installation . 16-69 Meter Unit Disassembly/Assembly . 16-69 Meter Operation Inspection. 16-70 Meter System Inspection 16-71 Meter Unit Inspection 16-72 Fuel Level Sensor Line Self-Diagnosis Mode Inspection 16-79 Relay Box . 16-82 Relay Box Removal 16-82 Relay Box Installation . 16-82 Relay Circuit Inspection 16-82 Diode Circuit Inspection 16-83 Fuses 16-85 Main Fuse (30 A) Removal . 16-85 Fuse Box Fuse Removal. 16-85 Fuse Installation 16-85 Fuse Inspection. 16-86

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Last update on 2025-04-17 / Affiliate links / Images from Amazon Product Advertising API

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