Kawasaki Z1000 Service Manual

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Z1000

Motorcycle

Service Manual

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

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.

Crankshaft/Transmission 9

Wheels/Tires 10

Final Drive 11

Brakes 12

Suspension 13

Steering 14

Frame 15

Electrical System 16

Appendix 17

Z1000

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products and Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center

BBDC before bottom dead center Pa pascal(s)

BDC

BTDC before top dead center psi pound(s) per square inch

°C degree(s) Celsius r revolution

DC direc

F farad(s) TDC top dead center

°F degree(s) Fahrenheit

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

t current

rpm revolution(s) per minute

TIR total indicator reading

newton(s)

horsepower

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1 the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with a only.

1. Crankcase Emission Control System This s

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 f uel and air suppl

2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust

of th designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model m otorcycle manufactured primarily for sale in California includes acat

3. Evaporative Em ission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-

ste the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

com

(3)(A) for any person to remove or render inoperative any device or element of design installed

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading

) and exhaust emission (2) control systems in compliance with applicable regulations of

pplicable regulations of the California Air Resources Board on vehicles sold in California

ystem eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors

ied by the fuel injection system.

is motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully

alytic converter system.

ad, fuel vapors are routed into the running engine to be burned, or stored in a canister when

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is

monly referred to as the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

r in a motor vehicle or motor vehicle engine in compliance with regulations under this

on o title prior to its sale and delivery to the ultimate purchaser, or for any m anufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such

e and delivery to the ultimate purchaser.

sal

motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-

ly to remove or render inoperative any device or element of design installed on or in a

ing 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 ex-

ceeded.

b.Use of replacement parts or accessories which adversely affect the performance

or dura bility of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the stan-

dards.

d.Permanently removing, disconnecting, or rendering inoperative any component or

element of design of the emission control systems.

WE RECO MMEND 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 i ts sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

Replacement of the original exhaust system or muffler with a component not in compliance

•

with Federal regulations.

Removal of the muffler(s) or any internal portion of the muffler(s).

•

Removal of the air box or air box cover.

•

Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such

•

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by

ined mechanics in a properly equipped shop.

tra However, it contains enough detail and basic information to make it useful to the owner who de-

es to perform his own basic maintenance and

sir repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce-

res must be understood in order to carry out

du maintenance and repair satisfactorily. Whenever the owner has insufficient experience or

ubts his ability to do the work, all adjust-

do ments, maintenance, and repair should be carried out only by qualified mechanics.

n order to perform the work efficiently and

I to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures

efore starting work, and then do the work care-

b fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may 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 Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Special Tool Catalog or Manual. Genuine

parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How

In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick R eference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

to Use This Manual

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and convenient operation.

Indicates a procedural step or work to be

•

done. Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it fol-

lows. In most chapters an exploded view illustration of the system components f ollows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Con tents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Technical Information – Air Inlet System ................................................................................ 1-11

Technical Information – New Ignition Interlock Sidestand ...................................................... 1-13

Technical Information – Tail/Brake Lights Employing LED ..................................................... 1-14

Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) ........... 1-16

Unit Conversion Table ............................................................................................................ 1-17

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, illustra-

photographs, cautions, and detailed descriptions have been included in each chapter wherever

tions, necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Espec

Battery Ground

Before completing any service on the motorcycle, disconnect t from accidentally turning over. Disconnect the ground wire (−) first and then the positive (+). When completed with the servi terminal of the battery then the negative (−) wire to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

ially note the following:

he battery wires from the battery to prevent the engine

ce, first connect the positive (+) wire to the positive (+)

Solvent

Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

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.

GENERAL INFORMATION 1-3

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

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

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the

ied sequence to prevent case warpage or deformation

specif which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating

nally.

diago

Tightening Torque

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

Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair 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, Oring

Hardening, shrinkage, or damage of both gaskets and grease seals after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used grease seal when re-assembling

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or 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.

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

Circlips, Cotter Pins

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

Lubrication

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

1-6 GENERAL INFORMATION

Before Servicing

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount tate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

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

of rotating direction will affect the adjustment. Ro-

Model Identification

ZR1000–A1 Left Side View:

GENERAL INFORMATION 1-7

ZR1000–A1 Right Side View:

1-8 GENERAL INFORMATION

General Specifications

Items ZR1000–A1 ∼

Dimensions:

Overall length 2 080 mm (81.9 in.)

Overall width 770 mm (30.3 in.)

Overall height 1 055 mm (41.5 in.)

Wheelbase

Road clearance 145 mm (5.7 in.)

Seat height 820 mm (32.3 in.)

Dry mass 198 kg (410.1 lb)

Curb mass:

Fuel tank capacity

Performance:

Minimum turning radius

Engine:

Type

Cooling system Liquid-cooled

Bore and stroke

Displacement 953 mL (58.15 cu in.)

Compression ratio

Maximum horsepower 93.4 kW (127 PS) @10 000 r/min (rpm),

Maximum torque 95.6 N·m (9.7 kgf·m, 71 ft·lb) @8 000 r/min (rpm),

Carburetion system FI (Fuel Injection) Keihin TTK38 × 4

Starting system

Ignition system Battery and coil (transistorized)

Timing advance

Ignition timing From 10° BTDC @1 100 r/min (rpm)

Spark plug NGK CR9EK or ND U27ETR

Cylinder numbering method Left to right, 1-2-3-4

Firing order 1-2-4-3

Valve timing:

Inlet Open 38° BTDC

Exhaust Open 57° BBDC

Front

Rear 111 kg (244.8 lb)

Close 66° ABDC

Duration 284°

Close 31° ATDC

Duration

1 420 mm (55.9 in.)

110 kg (242.6 lb)

18 L (5.0 US gal.)

2.8 m (9.2 ft)

4-stroke, DOHC, 4-cylinder

77.2 × 50.9 mm (3.0 × 2.0 in.)

11.2

(MY, AU) 90.5 kW (123 PS) @10 000 r/min (rpm)

(HR) 78.2 kW (106 PS) @10 000 r/min (rpm)

(US)---

(MY, AU) 92.7 N ·m (9.4 kgf·m, 68 ft·lb) @8 000 r/min (rpm)

(HR) 86.3 N·m (8.8 kgf·m, 64 ft·lb) @7 500 r/min (rpm)

(US)---

Electric starter

Electronically advanced(digital igniter)

to 36° BTDC @7 500 r/min (rpm)

268°

General Specifications

Items ZR1000–A1 ∼

Lubrication system

Engine oil:

Type API SE, SF or SG

Viscosity SAE10W-40

Capacity 3.8 L (4.0 US qt)

Drive Train:

Primary reduction system:

Type Gear

Reduction ratio 1.714 (84/49)

Clutch type Wet m ulti disc

Transmission:

Type

Gear ratios:

1st 2.571 (36/14)

2nd 1.941 (33/17)

3rd 1.555 (28/18)

4th 1.333 (28/21)

5th

6th

Final drive system:

Type Chain drive

Reduction ratio 2.625 (42/16)

Overall drive ratio 4.929 @Top gear

Frame:

Type Tubular, diamond

Caster (rake angle) 24°

Trail 101 mm (4.0 in.)

Front tire: Type Tubeless

Size 120/70 ZR17 M /C ( 58W)

Rear tire: Type Tubeless

Size 190/50 ZR17 M /C ( 73W)

Front suspension:

Type Telescopic fork (upside-down)

Wheel travel 120 mm (4.7 in.)

Rear suspension:

Type Swingarm (uni-trak)

Wheel travel

Brake Type: Front Dual discs

Rear

Electrical Equipment:

Battery 12 V 8 Ah

Headlight: Type Semi-sealed beam

Bulb

Forced

API SH or SJ with JASO MA

6-s

.200 (24/20)

1.095 (23/21)

138 mm (5.4 in.)

Single disc

12 V 55 W × 2/55 W (Hi/Lo)

lubrication (wet sump with cooler)

peed, constant mesh, return shift

GENERAL INFORMATION 1-9

1-10 GENERAL INFORMATION

General Specifications

Items ZR1000–A1 ∼

Tail/brake light 12 V 0.5/3.8 W (LED)

(US, CA, Cal) 12 V 0.5/5W (LED)

Alternator: Type

Rated output 24 A/ 14 V @5 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country. (AU): Australia Model (US): U.S.A. Model (CA): Canada Model (Cal): C alifornia M odel (MY): Malaysia Model (HR): with Honeycomb Catalytic Converter Model (Restricted model)

Three-phase AC

GENERAL INFORMATION 1-11

Technical Information – Air Inlet System

Subthrottle Control System

The ZR 1000–A1 ∼ employs large bore throttle bodies to increase power output. However, sudden

changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore. Therefore two throttle valves are placed in each i nlet tract, the main throttle valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract. The main throttle valve is operated by the rider when the throttle grip is turned clockwise or counterclockwise, while the subthrottle valve is operated by a stepping motor controlled by the ECU. The subthrottle valve automatically adjusts air inlet to more precisely match engine demand, so that when the main throttle is opened quickly there is no hesitation or j erky response.

The subthrottle valves allow the fuel injection system to provide smooth t hrottle response, similar to

that of a constant velocity carburetor, no matter how quickly the throttle is opened.

A. Main Throttle Valve B. Subthrottle Valve

C. Throttle Valve

D. Vacuum Piston E. Inlet Air

1-12 GENERAL INFORMATION

Technical Information – Air Inlet System

Operation

The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a

ng motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle

steppi body.

The subthrottle control system operates on the signal supplied from the ECU. The open/close operation o to change the current direction into the motor of the subthrottle valve actuator.

the EC

from fully closed position to fully opened position. The ECU memorizes these positions and turns back t

f the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU

The subthrottle sensor detects the subthrottle valve actuator movement by measuring voltage and

U determines the subthrottle valve angle based on the operation map.

When turning the ignition switch ON, every time the ECU automatically drives the subthrottle valve

he subthrottle valve to the original point to confirm the subthrottle valve idling voltage.

bthrottle Valves

A. Su B. Subthrottle Valve Actuator C. Subthrottle Sensor

ain Throttle Sensor

D.M

U (Electric Control Unit)

E. EC

F. Air Cleaner Side

G. Crankshaft Sensor

peed Sensor

H.S

GENERAL INFORMATION 1-13

Technical Informatio n – New Ignition Interlock Sidestand

Outline

The New Ignition Interlock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from the traditional one. Refer to the tables below as to the engine starts and/or the driving at each condition.

New Ignition Interlock Sidestand System

Side Stand Gear Position Clutch Lever Engine Start Engine Run

A Up Neutral Released Starts C ontinue running

B Up Neutral Pulled in Starts Continue running

C Up In Gear Released Doesn’t start Continue running

D Up In Gear Pulled in Starts Continue running

E Down Neutral Released Starts Continue running

F Down Neutral Pulled in Starts Continue running

G Down In Gear Released Doesn’t start Stops

H Down In Gear Pulled in Doesn’t start Stops

Current Ignition Interlock Sidestand System

Side Stand Gear Position Clutch Lever Engine S tart Engine Run

A Up Neutral Released Starts Continue running

B Up Neutral Pulled in Starts Continue running

C Up In G ear Released Doesn’t start Continue running

D Up In G ear Pul led in Starts Continue running

E Down Neutral Released Starts Continue running

F Down Neutral Pulled in Starts Continue running

G Down In Gear Released Doesn’t start Stops

H Down In Gear Pulled in Start Continue running

1-14 GENERAL INFORMATION

Technical Information – Tail/Brake Lights Employing LED

Outline

This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits lumino (more than 5 times longer), uses lower voltage, expends lower wattage (approx.1/5), and is quicker responsing.

Due Position of LED Installation

us beams over a longer life span than those emitted from a traditional electric heated bulb

esistors, the diodes, and the Zener diodes are

The r mounted in the electronic circuits [A] of the LED, which supplies the steady current and voltage to the light.

Light Emitting Diode (LED)

The Light Emitting Diode (LED) [A] is an element of semiconductor diode that converts applied voltage to light.

The LED emits luminous beams by the collision of negative charge electrons [A] and positive charge holes [B] when applied the forward voltage and current to the PN junction diode [C].

GENERAL INFORMATION 1-15

Technical Information – Tail/Brake Lights Employing LED

The emitting color differs according to the materials of

semi-conductors.

Materials of Semi-Conductor and Emitting Color

Materials of Semi-Conductor Emitting Color

GaAsP

GaAlAs

GaP Gree

GaN Blue

Red

Ga: Gallium

As: Arsenic

P: Phosphorus

N: Nitrogen

Al: Aluminum

1-16 GENERAL INFORMATION

Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM)

Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst protection system, according to each regulation of different countries.

The muf not use leaded gasoline and do not coast with the ignition system OFF. Running the engine without ignition damages catalyst.

Refer t (theory, maintenance, and handling precautions), including the secondary air injection system.

Honeycomb Type Catalytic Converter

The converter is a three-way catalytic converter, and its surface is covered with alumina upon which

○

platinum and rhodium are applied, and has a cylindrical metalic honeycomb structure made by bend-

ing a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter. The

honeycomb structure is convenient for the catalytic converter because it has a large surface area

but small size to react effectively and has low exhaust resistance. In addition, its inherent strength

helps resist vibration, and has simple structure welded directly on the silencer.

Generally, the temperature of the exhaust gas must be higher than activation temperature, so the

○

converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is

still high. And, the converters will be activated even under low load conditions.

After t he exhasut gas is diluted with the secondary air injection, the catalytic converter works well

○

because of rich oxygen to reduce CO, HC, and NO

emission within regulation.

This type of converter works more efficiently as a three-way catalytic converter to reduce CO, HC,

○

and NO

fler with built-in catalyst has the same durability as the conventional muffller, however, do

o the ZX900E Service Manual (Part No. 99924-1255) for more information about the KLEEN

x. A ccordingly, we can keep the exhaust gas

x than the pipe type catalytic converter because of its more and denser catalysts.

1. Manifold

2. Silencer

3. Honeycomb Type Catalyst

4. Mark for Manifold

5. Mark for Silencer

Unit Conversion Table

GENERAL INFORMATION 1-17

Prefixes for Units:

Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0.01 milli m ×0.001 micro µ × 0.000001

Units of Mass:

kg ×2.205=lb g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US) L × 0.2200 = L × 1.057 = qt (US) L × 0.8799 = qt (imp) L × 2.113 = pint (US) L × 1.816 = pint (imp) mL × 0.03381 = mL × 0.02816 = oz (imp) mL × 0.06102 = cu in

gal (imp)

oz (US)

Units of Length:

km × 0.6214 = mile m × 3.281 = ft mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m N·m × 0.7376 = ft·lb N·m × 8.851 = in·lb kgf·m × 9.807 = N·m kgf·m kgf·m × 86.80 = in·lb

× 7.233 =

ft·lb

Units of Pressure:

kPa × 0.01020 = kgf/cm² kPa × 0.1450 = psi kPa × 0.7501 = cm Hg kgf/cm² kgf/cm² × 14.22 = psi cmHg×1.333=kPa

× 98.07 = kPa

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

N × 0.1020 = kg N × 0.2248 = lb kg ×9.807=N kg ×2.205=lb

Units of Temperature:

Units of Power:

kW ×1.360=PS kW ×1.341=HP PS × 0.7355 = kW PS

× 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Con tents

Periodic Maintenance Chart .............. 2-2

Torque and Locking Agent................. 2-4

Specifications .................................... 2-9

Special Tools ..................................... 2-11

Periodic Maintenance Procedures..... 2-12

Fuel System (DFI)........................... 2-12

Fuel Hose and Connection

Inspection .................................. 2-12

Throttle Control System

Inspection .................................. 2-13

Idle Speed Inspection .................. 2-14

Idle Speed Adjustment................. 2-14

Engine Vacuum Synchronization

Inspection .................................. 2-15

Air Cleaner Element Cleaning...... 2-19

Evaporative Emission Control

System Inspection (CAL) .......... 2-20

Cooling System............................... 2-21

Radiator Hose and Connection

Inspection .................................. 2-21

Coolant Change ........................... 2-21

Engine Top End .............................. 2-23

Air Suction Valve Inspection ........ 2-23

Valve Clearance Inspection ......... 2-24

Valve Clearance Adjustment........ 2-25

Clutch.............................................. 2-28

Clutch Adjust Inspection .............. 2-28

Engine Lubrication System ............. 2-29

Engine Oil C hange....................... 2-29

Oil Filter Change .......................... 2-29

Wheels/Tires................................... 2-30

Tire Inspection ............................. 2-30

Air Pressure

Inspection/Adjustment............... 2-31

Final Drive....................................... 2-31

Drive Chain Slack Inspection ....... 2-31

Drive Chain Slack Adjustment ..... 2-31

Wheel Alignment

Inspection/Adjustment............... 2-32

Drive Chain Wear Inspection ....... 2-32

Drive Chain Lubrication................ 2-33

Brakes............................................. 2-34

Brake Pad Wear Inspection ......... 2-34

Rear Brake Light Switch

Inspection/Adjustment............... 2-34

Caliper Fluid Seal Damage .......... 2-35

Caliper Dust Seal/Friction Boot

Damage..................................... 2-35

Master Cylinder Inspection (Visual

Inspection)................................. 2-36

Level Inspection ........................... 2-37

Brake Fluid Change ..................... 2-37

Brake Line Bleeding..................... 2-39

Brake Hoses and Connections

Inspection .................................. 2-41

Suspension..................................... 2-42

Front Fork Oil Leak Check ........... 2-42

Rear Shock Absorber Oil Leak

Check ........................................ 2-42

Swingarm Pivot Lubrication ......... 2-42

Uni-trak Linkage Lubrication ........ 2-42

Steering .......................................... 2-43

Steering Inspection ...................... 2-43

Steering Adjustment..................... 2-43

Stem Bearing Lubrication............. 2-44

Electrical System ............................ 2-44

Spark Plug Cleaning and

Inspection .................................. 2-44

General Lubrication ........................ 2-47

Lubrication ................................... 2-47

Nut, Bolt, and Fastener Tightness .. 2-48

Tightness Inspection.................... 2-48

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The scheduled maintenance m ust be done in accordance with this chart to keep the motorcycle in

good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY Whichever 1 000 km *ODOMETER

READING

18 000 km (12 000 mile)

24 000 km (15 000 mile)

30 000 km (20 000 mile)

36 000 km (24 000 mile)

•

OPERATION Spark plug (e) - clean and gap †

Valve clearance (e) - inspect †

Air suction valve (e) - inspect †

Air cleaner element (e) - clean† #

Throttle control system (e) - inspect †

Idle speed (e) - inspect †

Engine vacuum synchronization (e) inspect †

comes (600 mile)

first

→ (4 000 mile)

↓ 12 000 km

Every

6 000 km

( 7 500 mile)

• • • • • •

• • •

• • • • • • •

• • • •

• • •

Fuel hoses, connections - inspect †

Engine oil - change # year

Oil filter - replace

Evaporative emission control system (e) (CAL) - inspect †

Drive chain wear - inspect †#

Brake pad wear - inspect †#

Brake light switch - inspect †

Steering - inspect †

Rear shock absorber oil leak - inspect †

Front fork oil leak - inspect †

Tire wear - inspect †

Swingarm pivot, Uni-trak linkage lubricate

General lubrication - perform

Nut, bolt, and fastener tightness - inspect †

Drive chain - lubricate # 600 km

Drive chain slack - inspect †# 1000 km

Brake hoses, connections - inspect †

Brake fluid level - inspect † month

• • • • • •

• • • •

• • • • • • •

• • • • • •

• • • • • • •

• • •

• • • • • •

• • •

• • • •

• • • • • •

• • • • • • •

Periodic Maintenance Chart

FREQUENCY Whichever 1 000 km *ODOMETER

comes (600 mile)

first 6 000 km

↓ 12 000 km

OPERATION Every Clutch-adjust †

Radiator hoses, c onnections - inspect †

Brake fluid - change

rake master cylinder cup and dust seal

- replace

2 years

4 years

PERIODIC MAINTENANCE 2-3

READING

→ (4 000 mile)

( 7 500 mile)

18 000 km (12 000 mile)

24 000 km (15 000 mile)

30 000 km (20 000 mile)

36 000 km (24 000 mile)

• • • • • • •

•

Coolant - change 2 years

Caliper piston seal and dust seal replace

Steering stem bearing - lubricate

# : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed,

or frequent starting / stopping.

* : For higher odometer readings, repeat at the frequency interval established here.

† : Replace, add, adjust, clean, or torque if necessary.

Throttle control system inspection: Inspection of throttle grip play and main throttle bore cleanliness (CAL): California Model only (e): Emission Related Items

4 years

2 years

•

2-4 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque

for the major fasteners requiring use of a non

-perma

Letter

MO: Apply molybdenum disulfide grease oil

nent locking agent or liquid gasket.

s used in the “Remarks” column mean:

L: Apply a non-permanent locking agent to

the threads.

G: Apply

solution.

EO: Apply

face.

S: Tighten the fasteners following the speci-

fied

SS: Apply silicone sealant.

Si: Apply silicone grease (ex. PBC grease).

R: Rep

AL: Tighten the two clamp bolts alternately

two times to ensure even tightening tor

grease to the threads.

oil to the threads and seating sur-

sequence.

lacement parts

que.

The table on the right lists the basic torque for the bolts and nuts, which are determined by thei bolts and nuts that are not listed in the table below according to their thread diameter. All of the ti threads that have been cleaned with solvent.

r thread diameter. Use this table for the

ghtening torque values are for use with dry

Basic Torque for General Fasteners

Threads Torque

dia. (mm) N·m kgf·m ft·lb

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb

8 14 ∼19 1.4 ∼1.9 10.0 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72 16 115 ∼ 155 11 .5 ∼ 16.0 83 ∼ 11 5 18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165 20 225 ∼ 325 23 ∼ 33 165 ∼ 240

Fastener

Fuel System:

Inlet air pressure sensor bolt 12 1.2 104 in·lb Water temperature sensor 25 2.5 18 Vehicle downsensor bolts 2 0.2 17 in·lb Cam shaft position sensor bolt Cam shaft position sensor rotor bolt 12 1.2 104 in·lb L Throttle cable plate bolt 6 0.6 52 in·lb Throttle body cover bolts 7 0.7 61 in·lb Throttle body assy holder clamp bolts 2 0.2 17 in·lb Choke link holder screws 2.1 0.21 18 in·lb Delivery pipe screws 3.4 0.35 30 in·lb Bypass screws 0.2 0.02 1.7 in·lb Air cleaner duct holder screws 3.8 0.39 34 in·lb Air cleaner housing mounting bolts 9.8 1.0 87 in·lb Air cleaner duct clamp bolts 2 0.2 17 in·lb Air cleaner housing screws 1.2 0.12 10 in·lb Air cleaner housing tapping screws 1.2 0.12 10 in·lb Speed sensor bolt 6.9 0.7 62 in·lb L Fuel pump bolts 9.8 1.0 87 in·lb Fuel level sensor bolts 6.9 0.7 62 in·lb

Cooling System:

Radiator hose clamp screws 2 0.2 17 in·lb Thermostat air bleeder bolt 7.8 0.80 69 in·lb Radiator fan bolts 8.3 0.85 74 in·lb Water pump impeller bolt 10 1.0 87 in·lb Water pump cover bolts 11 1.1 95 in·lb

N·m kgf·m ft·lb

12 1.2 104 in·lb

Torque

Remarks

S, L

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Fastener

Water p Water pipe bolts 11 1.1 95 in·lb in/outlet Therm Thermostat bracket bolt 7 0.7 61 in·lb Radi Radiator lower bolts 7 0.7 61 in·lb Rad Coolant reserve tank screws 7 0.7 61 in·lb Radiator fan switch 18 1. Water temperature sensor 25 2.5 18

ngine Top End:

Air suction valve cover bolts 10 1.0 87 in·lb Cylinder head cover bolts Camshaft cap bolts (L=45 mm) 12 1.2 104 in·lb Camshaft cap bolts (L=40 mm) Cylinder head bolts (M10 new bolts) 54 5.5 40 S, EO

Cylinder head bolts (M10 used bolts) 49 5.0 36 S, EO

Cylinder head bolts (M6) 12 1.2 104 in·lb S Cylinder head jacket plugs Throttle body holder bolts 13 1.3 113 in·lb Throttle body holder clamp screws 2.0 0.2 17 in·lb Camshaft sensor bolt 12 1.2 104 in·lb Camshaft sensor rotor bolt Front camshaft chain guide bolt (upper) 25 2.5 18 Front camshaft chain guide bolt (lower) Rear camshaft chain guide bolt 25 2.5 18 Camshaft chain tensioner mounting bolts Camshaft chain tensioner cap bolt 28 2.9 21 Spark plugs Coolant drain plug (Cylinder) 10 1.0 87 in·lb Exhaust pipe manifold holder nuts Muffler body clamp bolts 17 1.7 12 Muffler body mounting bolts Crankshaft sensor cover bolts 11 1.1 95 in·lb

Clutch:

Clutch lever clamp bolts 7.9 0.8 69 in·lb S Clutch cover bolts (L=32 mm) Clutch cover bolts (L=45 mm) 11 1.1 95 in·lb Clutch cover bolts (L=30 mm) Clutch cover bolts 11 1.1 95 in·lb Oil filler plug Clutch spring bolts 8.8 0.9 78 in·lb Clutch hub nut

ump drain bolt

ostat housing ground bolt

ator upper bolts

iator screen bolt

N·m kgf·m ft·lb

11 1.1 95 in·l

7 0.7 61 in·

7 0.7 61 in

7 0.7 61 i

10 1.0 87 in·lb

12 1.2 104 in·lb

22 2.2 16 L

12 1.2 104 in·lb L

12 1.2 104 in·lb

11 1.1 95 in·lb

13 1.3 113 in·lb

17 1.7 12

34 3.5 25

11 1.1 95 in·lb

1.5 0.15 13 in·lb

135 14 100 R

Torque

Remarks

·lb

n·lb

(Washer)

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Engine

Oil filler plug 1.5 0.15 13 in·lb Engin Oil filter (cartridge type, P/No.16097–1070) 26 2.7 20 R, EO Oil filter (cartridge type, P/No.16097–0002) 31 3.2 23 R, EO Oil cooler mounting bolt 76 7.8 56 EO Oil pan bolts 11 1.1 95 i Oil pipe holder bolts 13 1.3 113 in·lb L Oil pressure relief valve 15 1. Oil pressure switch 15 1.5 11 SS Oil pressure switch terminal bolt 1 Water pump cover bolts 11 1.1 95 in·lb Impeller bolt 10 1.0 87 in·lb Coolant drain plug (water pump) 11 1.1 95 in·lb Water hose clamp screws 2.0 0.2 17 in·lb Oil passage plugs 20 2.0 14.5 L

Engine Removal/Installation:

Adjusting collar locknut 49 5.0 36 in·lb S Engine mounting bolts and nuts 44 4.5 32 Front engine bracket bolts 44 4.5 32 S Rear engine bracket bolts 25 2.5 18

Crankshaft/Transmission:

Breather plate bolts 10 1.0 87 in·lb L Crankcase bolts (M9, L=81 mm) 42 4.3 31 MO,S Crankcase bolts (M9, L=95 mm) Crankcase bolts (M8) 27 2.8 20 S Crankcase bolts (M7) Crankcase bolts (M6) 12 1.2 104 in·lb S Starter motor clutch bolts Oil pipe holder bolts 13 1.3 113 in·lb L Shift drum bearing holder bolt Shift drum bearing holder screw 5.4 0.55 48 in·lb L Connecting rod big end nuts Crankshaft position rotor bolt 40 4.0 29 Oil pressure switch Oil pressure switch terminal bolt 1.5 0.15 13 in·lb Oil passage plugs Crankshaft sensor cover bolts 11 1.1 95 in·lb Shift pedal mounting bolt Gear positioning lever bolt 12 1.2 104 in·lb Shift shaft return spring pin Shift drum cam holder bolt 12 1.2 104 in·lb L Footpeg bracket bolts 34 3.5 25 L Shift lever bolt 6.9 0.7 61 in·lb Tie-rod locknuts 6.9 0.7 61 in·lb Neutral switch 15 1.5 11

Lubrication:

e drain plug

N·m kgf·m ft·lb

20 2.0 14.5

49 5.0 36

20 2.0 14.5

12 1.2 104 in·lb L

13 1.3 113 in·lb L

see the text ← ← ←

15 1.5 11

20 2.0 14.5 L

34 3.5 25 L

29 3.0 22 L

Torque

.15

n·lb

11 L

3in·lb

Remarks

MO,S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Wheels/Tires:

Front axle clamp bolt 34 3.5 25

axle

Front Rear axle nut 127 13 94

l Drive:

Fina

Engine sprocket nut 127 13 94 MO

ine sprocket cover bolts

Eng Engine sprocket cover damper bolt 6.9 0.7 61 in·lb L

ar sprocket nuts

Re Speed sensor bolt 6.9 0.7 61 in·lb L

rakes:

Bleed valves 7.8 0.80 69 in·lb Front brake hose joint bracket bolts 6.9 0.7 61 Brake hose banjo bolts 25 2.5 18 Brake lever pivot bolt 1.0 0.10 9in·lb Brake lever pivot bolt locknut 5.9 0.60 52 in·lb Front brake reservoir cap screws 1.5 0.15 13 in·lb Front brake light switch screws 1.2 0.12 11 i n ·l b Front master cylinder clamp bolts 8.8 0.9 78 in·lb Pad pin bolts (Front caliper) 17 1.7 12 Caliper mounting bolts (Front) Caliper assembly bolts (Front) 22 2.2 16 L Front brake disc mounting bolts 27 2.8 20 L Rear brake disc mounting bolts 27 2.8 20 L Caliper mounting bolts (Rear) Rear master cylinder mounting bolts 25 2.5 18 Rear master cylinder push rod locknut 18 1.8 13

Suspension:

Front fork clamp bolts (Upper)

Front fork clamp bolts (Upper): ZR1000–A2 ∼ 13 1.3 113 in·lb

Front fork clamp bolts (Lower)

Front fork clamp bolts (Lower): ZR1000–A2 ∼ 30 3.1 22

Front fork top plugs Piston rod nuts 20 2.0 15 Front fork bottom Allen bolts Front axle clamp bolt 20 2.0 15 Rear shock absorber nuts (Upper and lower) Swingarm pivot shaft nut 127 13 94 Swingarm pivot shaft locknut Uni-trak

Rocker arm bolt 34 3.5 25 Tie-rod nuts 59 6.0 43

Steering:

Steering stem head bolt 108 11 80 Steering stem nut Handlebar clamp bolts 25 2.5 18 S

N·m kgf·m ft·lb

127 13 94

9.8 1.0 87 i

59 6.

25 2.5 18

8.8 0.90 78 in·lb AL

20 2.0 15 AL

35 3.6 26

20 2.0 15

34 3.5 25

98 10 72

20 2.0 14.5

Torque

Remarks

n·lb

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Handle Handlebar switch housing screws 3.4 0.35 30 in·lb

Frame

Footpeg holder bolts 34 3.5 25 Muffler mounting bolts 29 3.0 22 Side stand bolt 44 4.5 33 Side stand switch bolt 8.8 0.9 78 i

Windshield screws 0.35 ∼ 0.50 0.035 ∼ 3 ∼ 4in·lb

Front fender bolts 3.9 0.4 34.7 in·lb L

Electrical System:

Spark plugs 13 1.3 115 in·lb Alternator rotor bolt 110 11 81 Stator coil bolts 11 1.1 95 in·lb Alternator lead holding plate bolt 11 1.1 95 in·lb L Engine ground cable terminal bolt 9.8 1.0 87 in·lb Alternator cover bolts 11 1.1 95 in·lb Crankshaft sensor cover bolts 11 1.1 95 in·lb Crankshaft sensor bolts Camshaft position sensor bolt 12 1.2 104 in·lb L Timing rotor bolt 39 4.0 29 Starter motor mounting bolts 11 1.1 95 in·lb Switch housing screws Radiator fan switch 18 1.8 13 Water temperature sensor 25 2.5 18 Oil pressure switch 15 1.5 11 SS Oil pressure switch terminal bolt Neutral switch 15 1.5 11 Speed sensor bolt Fuel level sensor bolts 6.9 0.7 62 in·lb Front brake light switch screw 1.2 0.12 11 in·lb Meter mounting screws 1.2 0.12 11 in·lb Tail/brake light mounting screws License plate light mounting screws 1.2 0.12 11 in·lb Headlight mounting bolts 5.9 0.6 53 in·lb Starter lockout switch screw - - - L Starter motor clutch bolts Starter relay cable terminal bolts 3.9 0.4 35 in·lb L Regulator/rectifier bolts Regulator/rectifier bracket bolts 6.9 0.7 62 in·lb Speed sensor cover bolts

bar lower clamp nuts

N·m kgf·m ft·lb

34 3.5 25

5.9 0.6 53 in·lb

3.4 0.35 30 in·lb

1.5 0.15 13 in·lb

6.9 0.7 62 in·lb

1.2 0.12 11 in·lb

12 1.2 104 in·lb L

6.9 0.7 62 in·lb

6.9 0.7 62 in·lb L

Torque

0.050

Remarks

n·lb

PERIODIC MAINTENANCE 2-9

Specifications

Item Standard Service Limit

Fuel System:

Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Idle speed 1 100 ± 50 r/min (rpm) Bypass screws (turn out) 2 ± 1/4 (for reference) Engine vacuum 32.7 ± 1.333 kPa (245 ± 10 mm Hg) Air cleaner element

Cooling System:

Coolant:

Type (recommended) Permanent type of antifreeze Color Green Mixed ratio Freezing point – 35°C (– 31°F) Total amount 2.9 L (3.1 US qt)

Engine Top End:

Valve clearance

Inlet

Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

lutch:

Clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Engine Lubrication System:

Engine Oil:

Type API SE, SF or SG

Viscosity SAE 10W-40 Capacity 3.1 L

Level Between upper and lower level lines

Tires:

Tread depth:

Front

BRIDGESTONE 3.4 mm (0.13 in.) 1 mm (0.04 in.)

r filter

Pape

Soft water 50%, Coolant 50%

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

API SH or SJ with JASO MA

(3.3 US qt, when filter is not removed)

3.3 L (3.5 US qt, when filter is removed)

3.8 L (4.0 US qt, when engine is completely

disassembled and dry)

(after idling or running)

1.6 mm (0.063 in.) (DE, AT, CH)

–––

Rear

BRIDGESTONE 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.)

2-10 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Air pressure: (when cold)

Front

Rear Up to 180 kg (396 lb) load:

Final Drive:

Drivechainslack

Drive chain (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

Brakes:

Brake fluid:

Grade DOT4 –––

ke pad lining thickness:

Bra

Front 4 mm (0.16 in.) 1 mm (0.04 in.) Rear

Brake l ight timing:

Front Pulled ON ––– Rear ON after about 10 mm (0.39 in.) of pedal

Electrical System:

Spark plug gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 mm) –––

AT: Republic of Austria

CH: Swiss Confederation

DE: Federal Republic of Germany

Up to 180 kg (396 lb) l oad:

250 kPa (2.5 kgf/cm², 36 psi)

290 kPa (2.9 kgf/cm², 41 psi)

20 ∼ 30 mm (0.8 ∼ 1.2 in.)

5 mm (0.20 in.) 1 mm (0.04 in.)

travel

–––

Special Tools

PERIODIC MAINTENANCE 2-11

Steering Stem Nut Wrench: 57001–1100

Jack: 57001–1238

Oil Filter Wrench: 57001–1249

Pilot Screw Adjuster, C: 57001–1292

Hand Tester: 57001–1394

Spark Plug Wrench (Owner ’s Tool): 92110–1132

2-12 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System (DFI)

Fuel Hose and Connection Inspection

The fuel hoses are designed to be used throughout the

○

motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause f uel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel System (DFI) chapter) and check the fuel hoses. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.

Check that the hoses are 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] Pump Outlet Hose [B] Pump Inlet Hose [C] Front [D]

Insert the pump outlet hose joint [A] straight onto the de-

•

livery pipe [B] until the hose joint clicks [C].

Front [D]

Push and pull [A] the hose joint [B] back and forth more

•

than two times, and make sure it is locked and doesn’t come off. When the hose j oint is correctly installed, it should slide on the delivery pipe about 5 mm (0.20 in.). If it does not slide, reinstall the hose joint.

WARNING

Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.

Check that the inlet hose [A] is onto the pipe fully and the

•

plate clamps [B] are installed beyond the raised rib [C].

1 ∼ 2 mm (0.039 ∼ 0.079 in.) [D]

Periodic Maintenance Procedures

Throttle Control System Inspection

Throttle Grip Play Inspection

Check the throttle grip free play [A].

•

If the free play is incorrect, adjust the throttle cable (see below).

Throttle Grip Free Play

Standard: 2 ∼ 3mm(0.08∼ 0.12 in.)

Check that the throttle grip moves smoothly from close to

•

full open, and the throttle closes quickly and completely in all steering positions by the return spring. If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle s peed, and turn the handlebar

•

all the way to the right and left to ensure that the idle speed doesn’t change. If the idle speed increases, check the throttle grip free play and the cable routing.

PERIODIC MAINTENANCE 2-13

If necessary, adjust the throttle cable as follows. Loosen the locknut [A] (right-front view).

•

Turn the adjuster [B] until the proper amount of free play

•

can be obtained. Tighten [C] the locknut against the adjuster securely.

•

If the throttle grip free play cannot be adjusted with the adjuster, use the adjusters in the middle of the throttle cables. Loosen the locknut, and screw the adjuster at the upper

•

end of the accelerator cable all the way in. Tighten the locknut against the adjuster securely.

•

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

•

Loosen the locknuts [A], and turn the lower adjusters [B]

•

until the proper amount of throttle grip free play is obtained. Tighten the locknuts against the adjusters securely.

•

Front [C] If the throttle grip free play cannot be adjusted with the lower adjusters, use the adjuster at the upper end of the cable again.

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Throttle Bore Cleaning

Check the throttle bore for cleanliness as follows:

•

Remove

○

chapter). Check the main throttle valves and throttle bores [A] for

○

carbo If any carbon accumulates, wipe the carbon off the throttle bores and throttle valves, using a cotton pad [B] penetra remove molybdenum disulfide coat (black) [C] from t he throttle valves and the bores.

Fron

the throttle body assy (see Fuel System (DFI)

n deposits by opening the main valves.

ted with a high-flash point solvent. Be careful not to

t of Throttle Body [D]

CAUTION

Do not buretor cleaning solution, which damage molybdenum disulfide coat; instead, use a high-flash point clea

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides.

•

If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter).

rub these surfaces hard and do not use a car-

ning solution and wipe slowly.

WARNING

Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe

iding condition.

Check idle speed.

•

If the idle speed is out of the specified range, adjust it.

Idle Speed

Standard: 1 100 ± 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.

•

Open and close the throttle a few times to make sure that

○

the idle speed is within the specified range. Readjust if necessary. Front [B]

Periodic Maintenance Procedures

Engine Vacuum Synchronization Inspection

NOTE

These procedures are explained on the assumption that

○

et and exhaust systems of the engine are in good

the inl condition.

Situate the motorcycle so that it is vertical.

•

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

•

Pull off the vacuum hoses and the rubber cap (s) from the

•

right fitting of each throttle body. Pull off the vacuum switch valve hose (thick) [A] from the

•

air cleaner housing [B].

Front [C]

CAUTION

Do not remove the inlet air pressure sensor hoses on the left fitting of each throttle body.

Connect a commercially available vacuum gauge to these

•

right fittings of the throttle body as shown. Connect a highly accurate tachometer to one of the stick

•

coil primary leads. Plug:

•

Vacuum Switch Valve Hose (thick) and its Air Cleaner

Housing Hole

Vacuum Hoses of Throttle Assy (see the next figure)

PERIODIC MAINTENANCE 2-15

A. Except California D. Vacuum Switch Valve Hose (small) G. Canister

B. California E. Inlet Air Pressure Sensor Hose H. Vacuum Gauge

C. Front F. Separator I. Plugs

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Install the fuel tank (see Fuel System (DFI) chapter).

•

Start the engine and warm it up thoroughly.

•

Check t

•

Tachometer [A]

If the idle speed is out of the specified range, adjust it.

Do not m easure the idle speed by the tachometer of the met

While idling the engine, inspect the engine vacuum, using the va

Front [C]

Engine Vacuum

If any vacuum is not within the specifications, first synchronize the #3 and #4 throttle valves to the #1 and #2 throttle valves by using the center adjusting screw [A].

Spe

Front [C]

Example:

#1: 165 mmH g #2: 190 mmH g #3: 170 mmH g #4: 200 mmH g

With the engine at the correct idle speed, equalize the

•

highest vacuum of #3 and #4 (example 200 mmHg) to the highest vacuum of #1 and #2 (example 190 mmHg) by turning the center adjusting screw.

he idle speed.

CAUTION

er unit.

cuum gauge [B].

Standard: 32.7 ± 1.333 kPa (245 ± 10 mmHg) at Idle

Speed 1 100 ± 50 r/min (rpm)

cial Tool -

ot Screw Adjuster, C: 57001–1292 [B]

Pil

NOTE

After adjustment, the final vacuum measurement be-

○

tween the highest throttle valves may not be 200 mmHg (in this example). The goal is to have the highest two vacuums between the left (1 and 2) and right (3 and 4) banks be the same.

Open and close the throttle after each measurement and

•

adjust the idle speed as necessary. Once the throttle valves have been synchronized, inspect

•

the main throttle sensor’s output voltage to ensure proper operation (procedure is at the end of this section).

Periodic Maintenance Procedures

If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A].

Front [B]

Special Tool - Pilot Screw Adjuster, C: 57001-1292

Adjust the lowest vacuum between #1 and #2 to the high-

•

est of #1 and #2. Adjust the lowest vacuum between #3 and #4 to the high-

•

est of #3 and #4. Open and close the throttle after each measurement and

•

adjust the idle speed as necessary. Inspect the vacuums as before.

•

If all vacuums are within the specification, finish the engine vacuum synchronization. If any vacuum cannot be adjusted within the specification,

remove the bypass screws #1 ∼ #4 and clean them.

Turn in the bypass screw and count the number of turns

○

until it seats f ully but not tightly. Record t he number of turns.

Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb)

PERIODIC MAINTENANCE 2-17

CAUTION

Do not over tighten them. They could be damaged, requiring replacement.

Remove the bypass screw [A], spring [B], washer [C] and

○

O-ring [D]. Check the bypass screw and its hole for carbon deposits.

○

If any carbon accumulates, wipe the carbon off the bypass screw and the hole, using a cotton pad penetrated with a high-flash point solvent. Replace the O-ring with a new one.

○

Check the tapered portion [E] of the bypass screw for

○

wear or damage. If the bypass screw is worn or damaged, replace it. Turn in the bypass screw until it seats fully but not tightly.

•

Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb)

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Back out the same number of turns counted when first

•

turned in. This is to set the screw to its original position.

NOTE

A throttle body has different “turns out” of the bypass

○

screw for each individual unit. When setting the bypass screw, use the “turns out” determined during disassembly. Use the specifications in this manual only if the original number is unknown.

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.

•

If the vacuums are correct, check the output voltage of the main throttle sensor (see Output Voltage Inspection of Main Throttle Sensor in the Fuel System (DFI) chapter).

Main Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → Y/W lead (terminal 2)

Meter (–) → BR/BK lead (terminal 14)

Standard:

0.99 ∼ 1 .03 V DC (at idle throttle opening)

If the output voltage is out of the r ange, check the throttle input voltage (see Input Voltage Inspection of Main Throttle Sensor in the Fuel System (DFI) chapter). Remove the vacuum gauge hoses and install the vacuum

•

hoses and rubber caps on the original position as shown.

A. Except California C. Front F. Separator B. California D . Vacuum Switch Valve Hose (small) G. Canister

E. Inlet Air Pressure Sensor Hose

Periodic Maintenance Procedures

Air Cleaner Element Cleaning

NOTE

In dusty areas, the element should be cleaned more

○

freque After riding through rain or on muddily roads, the ele-

○

ment should be cleaned immediately.

ntly than the recommended interval.

WARNING

If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possibly ca

If dirt gets through into the engine, excessive engine w

using accident.

CAUTION

ear and possibly engine damage will occur.

WARNING

Clean the element in a well-ventilated area, and take care that there are no sparks or flame anywhere near the w orking area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.

PERIODIC MAINTENANCE 2-19

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

•

Remove the fuel tank bracket [A].

•

Front [B]

Remove:

•

Screw [A] and Air Cleaner Duct Holder [B]

Pull it out [C] backwards.

Front [D]

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clean the element by tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed

•

air [A] to the dirty side). Visually inspect the element for no tears or no breaks and

•

inspe If the element or gasket has any tears or breaks, replace the element.

Install the element [A] with the flat side [B], facing for-

•

wards. Fit the tongue [C] of the air cleaner duct holder into the

•

slot of the housing the air cleaner duct holder.

Torque - Air Cleaner Duct Holder Screws: 3.8 N·m (0.39

from the outside to the inside (from the clean side

ct the sponge gaskets [B] also.

Front [D]

kgf·m, 34 in·lb)

Evaporative Emission Control System Inspection (CAL)

Inspect the canister as follows:

•

Remove the rear seat (see Frame chapter).

○

Remove the band [A] and hoses and take out the canister

○

[B]. Visually inspect the canister for cracks and other damage.

○

If the canister has any cracks or bad damage, replace it with a new one.

NOTE

The canister is designed to work well through the motor-

○

cycle’s life without any maintenance if it is used under normal conditions.

Connect the purge hose (green) [C] and the canister

○

breather hose (blue) [D] to the canister as shown. Install the canister with the inlet [E] down and the rear seat

○

(see Frame chapter).

Front [F]

Check the liquid/vapor separator as follows:

•

Remove the left f rame cover [A].

•

Periodic Maintenance Procedures

Disconnect the hoses from the separator, and remove the

○

separator [A] from the motorcycle left side.

Front [B] Visually inspect the separator for cracks and other dam-

○

age. If the separator has any cracks or damage, replace it with a new one. To prevent the gasoline from flowing into or out of the

○

canister, hold the separator perpendicular to the ground. Check the hoses of the evaporative emission control sys-

•

tem as follows: Check that the hoses are securely connected and clips

○

are beyond the raised rib of the pipe. Replace any kinked, deteriorated or damaged hoses.

○

Route the hoses according to Cable, Wire, and Hose

○

Routing section in the Appendix chapter. When installing the hoses, avoid sharp bending, kinking,

○

flattening or twisting, and route these hoses with a minimum of bending so that the emission flow will not be obstructed.

PERIODIC MAINTENANCE 2-21

Cooling System

Radiator Hose and Connection Inspection

The high pressure inside the radiator hose can cause

○

coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps

•

are tightened correctly.

Torque - Radiator Hose Clamp Screws: 2 N·m (0.2 kgf·m,

17 in·lb)

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury. Since coolant is harmful to the human body, do not use for drinking.

Place a container under the water pump drain bolt [A],

•

then remove the drain bolt.

Front [B]

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

•

Remove the radiator cap [A] in two steps. First turn the

•

cap cou it further in the same direction and remove the cap. The coolant will drain from the radiator and engine.

○

Front

Remove :

•

Left Side Cover (see Frame chapter) Reserve Tank Screws [A]

Turn over [B] the reserve tank, remove the cap [C], and

•

pour the coolant into a suitable container. Install the reserve tank.

•

Torque - Coolant Reserve Tank Screws: 7 N·m ( 0.7 kgf·m,

nterclockwise to the first stop. Then push and turn

[B]

61 in·lb)

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

CAUTION

Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)

Soft Water Coolant Freezing Point Total Amount

Tighten the drain bolt.

•

Torque - Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 95 in·lb)

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

•

Pour in the coolant slowly so that it can expel the air

○

from the engine and radiator.

50 %

− 35°C (− 31°F)

2.9 L (3.1 US qt)

NOTE

Check the cooling system for leaks.

•

Periodic Maintenance Procedures

Loosen the air bleeder bolt [A] on the thermostat housing.

•

Front [B] Replenish the coolant into the radiator until the coolant

•

begins to flow out the air bleeder bolt hole (that is, all the remaining air is forced out). Tap the radiator hoses to force any air bubbles caught

•

inside.

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

•

Tighten the air bleeder bolt [B].

•

Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m,

69 in·lb)

PERIODIC MAINTENANCE 2-23

Fill the reserve tank up to the “F” (full) level line [A] with

•

coolant and install the cap [B]. Install the fuel tank (see Fuel System (DFI) chapter).

•

Start the engine and warm it up thoroughly until the radi-

•

ator fan turns on and then stop the engine. Check the coolant level in the reserve tank several times

•

while the engine is cooling down, and replenish as necessary. If the coolant level is lower than the “L” level l ine, add coolant to the “F” level line.

CAUTION

Do not add more coolant above the “F” level line.

Engine Top End

Air Suction Valve Inspection

Remove the air suction valve (see Air Suction Valve Re-

•

moval in the 5. Engine Top End chapter). Visually inspect the reeds for cracks, folds, warps, heat

•

damage or other damage. If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for

•

grooves, scratches, any signs of separation from the holder or heat damage. If there is any doubt as to the condition of the reed contact

•

areas, replace the air suction valve as an assembly. If any carbon or other foreign particles have accumulated

•

between the reed and the reed contact area, wash the valve assembly clean with a high-flash point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assemb ly.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (at room temperature).

Remove:

•

Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Removal)

Position the crankshaft at 1,4 piston TDC.

•

TDC Mark [A] for #1, 4 Pistons

ng Mark [B]

Timi

Using a thickness gauge [A], measure the valve clearance

•

between the cam and the valve lifter.

Valve Clearance

Standard:

When positioning #4 piston TDC at the end of the

○

compression stroke:

Inlet valve clearance of #2 and #4 cylinders Exhaust valve clearance of #3 and #4 cylinders Measuring Valve [A]

When positioning #1 piston TDC at the end of the

○

compression stroke:

Inlet valve clearance of #1 and #3 cylinders Exhaust valve clearance of #1 and #2 cylinders Measuring Valve [A]

IN:

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

EX: 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

If the valve clearance is not within the specified range, first record the clearance, and then adjust it.

Periodic Maintenance Procedures

Valve Clearance Adjustment

To change the valve clearance, remove the camshaft

•

chain tensioner, camshafts and valve lifters. Replace the shim w ith one of a different thickness.

NOTE

Mark and record the valve lifter and shim locations so

○

an be reinstalled in their original positions.

they c If there is no clearance, select a shim which is several

○

sizes smaller and then measure the clearance.

To select a new shim which brings the valve clearance

•

within the specified range, refer to the Valve Clearance Adjustment Charts. Apply a thin coat of molybdenum disulfide grease to the

•

valve lifters. Install the camshafts. Be sure to time the camshafts prop-

•

erly (see Camshaft Installation). Remeasure any valve clearance that was adjusted.

•

Readjust if necessary.

PERIODIC MAINTENANCE 2-25

CAUTION

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 m ay cause it to fracture, causing extensive engine damage.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

1. Measure t he 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.

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

VALV E CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

1. Measure the clearance (when engine is cold).

2. Check present shim size.

3. Match clearance in vertical column with present shim size in horizontal column.

4. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Present shim is 2.95 mm .

Measured clearance is 0.47 mm. Replace 2.95 mm shim with 3.15 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clutch

Clutch Adjust 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 ∼ 3mm(0.08∼ 0.12 in.)

WARNING

To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.

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

•

of threads are visible.

Slide the dust cover [A] at the clutch cable lower end out

•

of place. Loosen both adjusting nuts [B] at the clutch cover as far

•

as they will go. Pull the clutch outer cable [C] tight and tighten the adjust-

•

ing nuts against the bracket [D]. Slip the rubber dust cover back onto place.

•

Turn the adjuster at the clutch lever until the free play is

•

correct.

Push the release lever [A] toward the front of the motor-

•

cycle until it becomes hard to turn. At this time, the release lever should have the proper an-

○

gle shown. If the angle is wrong, check the clutch and release parts for wear.

WARNING

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

After the adjustment, start the engine and check that the

•

clutch does not slip and that it releases properly.

Periodic Maintenance Procedures

Engine Lubrication System

Engine Oil Change

uate the motorcycle so that it is vertical after warming

Sit

•

up the engine. Remove the engine drain plug [A] to drain the oil.

•

○

•

oil in the oil filter can be drained by removing the filter

The (see Oil Filter Change). Replace the drain plug gasket [B] with a new one if it is

maged.

da Tighten the drain plug.

Torque - Engine Drain Plug: 20 N·m (2.0 kgf·m, 14.5 ft·lb)

Pour in the specified type and amount of oil.

Engine Oil

Grade: API SE, SF or SG

API SH or SJ with JASO MA Viscosity: SAE 10W–40 Amount:

Depending on the atmospheric temperature of your rid-

○

ing area, the engine oil viscosity should be changed according to the chart.

3.1 L (3.3 US qt) (when filter is not removed)

3.3 L (3.5 US qt) (when filter is removed)

3.8 L (4.0 US qt) (when engine is completely

dry)

NOTE

PERIODIC MAINTENANCE 2-29

Oil Filter Change

Drain the engine oil (see Engine Oil Change).

•

Remove:

•

Lower Fairing (see Frame chapter)

Remove the oil filter [A] with the oil filter wrench [B].

•

Special Tool - Oil Filter Wrench: 57001–1249

Replace the filter with a new one.

•

Apply engine oil to the gasket [A] before installation.

•

Tighten the filter with the oil filter wrench.

•

Torque - Oil Filter (P/No. 16097–1070): 27 N·m (2.8 kgf·m,

20 ft·lb)

Oil Filter (P/No. 16097–0002): 31 N·m (3.2 kgf·m,

23 ft·lb)

NOTE

Hand tightening of the oil filter can not be allowed since

○

it does not reach to this tightening torque.

Pour in the specified type and amount of oil (see Engine

•

Oil Change).

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Wheels/Tires

Tire 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.

Remove any imbedded stones or other foreign particles

•

from the tread.

Visually inspect the tire for cracks and cuts, replacing the

•

tire in case of damage. Swelling or high spots indicate

internal damage, requiring tire replacement.

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.

Tread Depth

Front:

Standard: 3.4 mm (0.13 in.)

Service Limit: 1 mm (0.04 in.)

1.6 mm (0.06 in.) (FG, AR, CH)

Rear:

Standard: 5.8 mm (0.23 in.)

Service Limit: 2 mm (0.08 in.)

(Upto130km/h(80mph))

3 mm (0.12 in.)

(Over 130 km/h (80 mph))

WARNING

To ensure safe handling and stability, use only the

recommended standard tires f or replacement, in-

flated to the standard pressure.

NOTE

Most countries may have t heir own regulations a mini-

○

mum tire tread depth: be sure to follow them. Check and balance the wheel when a t ire is replaced

○

with a new one.

Periodic Maintenance Procedures

Air Pressure Inspection/Adjustment

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). Adjust the tire air pressure according to the specifications if necessary.

Air Pressure (when cold)

PERIODIC MAINTENANCE 2-31

Front 250 kPa (2.5 kgf/cm², 36 psi)

Rear

Install the air valve cap certainly after air pressure inspec-

•

tion.

Torque - Air Valve Cap: 0.15 N·m (0.015 kgf·m, 1.3 in·lb)

Up to 180 kg

(396 lb)

290 kPa (2.9 kgf/cm², 41 psi)

Final Drive

Drive Chain Slack Inspection

NOTE

Check the slack with the motorcycle setting on its side

○

stand. Clean the chain if it is dirty, and lubricate it if it appears

○

dry.

Check the wheel alignment (see Wheel Alignment Inspec-

•

tion). Rotate the rear wheel to find the position where the chain

•

is tightest. Measure the vertical movement (chain slack) [A] midway

•

between the sprockets. If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard: 20 ∼ 30 mm (0.8 ∼ 1.2 in.)

Drive Chain Slack Adjustment

Remove the cotter pin [A], and loosen the axle nut [B].

•

Loosen the both chain adjuster locknuts [C].

•

If the chain is too loose, turn out the left and right chain adjuster [D] evenly. If the chain is too tight, turn in the left and right chain adjusters evenly, and kick the wheel forward. Turn both chain adjusters evenly until the drive chain has

•

the correct amount of slack. To keep the chain and wheel properly aligned, the notch [E] on the left wheel alignment indicator [F] should align with the same swingarm m ark or position [G] that the right indicator notch aligns with.

WARNING

Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tighten both chain adjuster locknuts securely.

•

Tighten the axle nut.

•

Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb)

Turn the wheel, measure the chain slack again at the tight-

•

est position, and readjust if necessary.

Insert a new cotter pin [A].

•

NOTE

When inserting the cotter pin, if the slots in the nut do

○

not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

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

•

WARNING

If the rear axle nut is not securely tightened or the

cotter pin is not installed, an unsafe riding condi-

tion may result.

Wheel Alignment Inspection/Adjustment

Check that the notch [A] on the left alignment indicator [B]

•

aligns with the sam e swingarm mark or position [C] that

the right alignment indicator notch aligns with.

If they do not, adjust t he chain slack and align the wheel

alignment (see Slack Adjustment).

NOTE

Wheel alignment can be also checked using the

○

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal

wear, and may result in an unsafe riding condition.

Drive Chain Wear Inspection

Remove:

•

Left Side Muffler Body (see Engine Top End chapter) Chain Cover Screws [A] Chain Cover [B] Mud Guard [C] (see Frame chapter)

Periodic Maintenance Procedures

Rotate the rear wheel to inspect the drive chain for dam-

•

aged rollers, and loose pins and links. If there is any irregularity, replace t he drive chain. Lubricate the drive chain if it appears dry. Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)

•

weight [A] on the chain. Measure the length of 20 links [B] on the straight part [C] of

•

the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced.

Drive Chain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit: 323 mm (12.7 in.)

WARNING

PERIODIC MAINTENANCE 2-33

If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may result. 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. For safely, use only the standard chain. It is an endless type and should not be cut for installation.

Standard Chain

Make: ENUMA Type: EK525MVXL2 Link: 112 Links

Drive Chain Lubrication

If a special lubricant is not available, a heavy oil such as

•

SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubri-

•

cation.

CAUTION

The O-rings between the side plates seal i n the lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules. Use only kerosene or diesel oil for cleaning an O

-ring drive chain. Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O-ring. Immediately blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes.

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Apply oil to the sides of the rollers so that oil will penetrate

•

to the rollers and bushings. Apply the oil to the O-rings so

that th

Wipe off any excess oil.

•

Brakes

Brake Pad Wear Inspection

Check the lining thickness [A] of the pads in each caliper.

•

If the lining thickness of either pad is less than the service

limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

e O-rings will be coated with oil.

Oil Applied Areas [A] O-ring

[B]

Standard:

Service Limit: 1 mm (0.04 in.)

Front Rear

4 mm (0.16 in.) 5 mm (0.20 in.)

Rear Brake Light Switch Inspection/Adjustment

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by de-

•

pressing the brake pedal. The brake light should go on

after about 10 mm (0.39 in.) of the pedal travel [A].

Periodic Maintenance Procedures

If it does not, adjust and inspect the brake light switch. While holding the switch body, turn the adjusting nut [A]

•

to adjust the switch.

PERIODIC MAINTENANCE 2-35

CAUTIO

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

Remove the right side cover (see Frame chapter).

•

Disconnect t he connector [A].

•

Using a hand tester, inspect to see that only the connec-

•

tion shown in the table have continuity (about zero ohms).

Special Tool - Hand Tester: 57001–1394

Rear Brake Light Switch Connections:

If the switch has an open or short, replace it with a new one.

Caliper Fluid Seal Damage

The fluid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature.

Replace the fluid seals under any of the following condi-

•

tions; (a) fluid leakage around the pad; (b) brakes over-

heat (c) there is a large difference in inner and outer pad

wear; (d) the seal is stuck to the piston.

If the fluid seal is replaced, replace the dust seal [B] as

well. Also, replace all seals every other time the pads are

changed.

Caliper Dust Seal/Friction Boot Damage

Check that the dust seals [B] and friction boot [C] are not

•

cracked, worn, swollen, or otherwise damaged.

If they show any damage, remove the caliper bracket and

•

replace them.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Master Cylinder Inspection (Visual Inspection)

Disassemble the front and rear master cylinders.

•

Check t

•

inner wall [A] of each master cylinder and on the outside of each piston [B]. If a ma them. Inspect the primary cup [C] and secondary cup [D].

•

If a c the piston assembly should be replaced to renew the cups. If fl sembly should be replaced to renew the cups.

Front Master Cylinder [J]

Check the dust covers [E] for damage.

•

If they are damaged, replace them. Check the piston return springs [F] for any damage.

•

If the springs are damaged, replace them. Check that relief port [G] and supply port [H] are not

•

plugged. If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

Rear Master Cylinder [K]

hat there are no scratches, rust or pitting on the

ster cylinder or piston shows any damage, replace

up is worn, damaged softened (rotted), or swollen,

uid leakage is noted at the brake lever, the piston as-

Periodic Maintenance Procedures

Level Inspection

Check that the brake fluid level in the front brake reservoir

•

[A] is above the lower level line [B].

NOTE

Hold the reservoir horizontal by turning the handlebar

○

when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the

reservoir to the upper level line [C] in the reservoir.

PERIODIC MAINTENANCE 2-37

Check that the brake fluid level in the rear brake reservoir

•

[A] is above the lower level line [B].

If the fluid level is lower than the lower level line, remove

the seats and fill the reservoir to the upper level line [C].

WARNING

Do not mix two brands of fluid. Change the brake

fluid in the brake line completely if the brake fluid

must be refilled but the type and brand of the brake

fluid that is already in the reservoir are unidentified.

After changing the fluid, use only the same type and

brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

Follow the procedure below to install the rear brake fluid

•

reservoir cap correctly.

First, tighten the rear brake fluid reservoir cap [B] clock-

○

wise [C] by hand until the resistance is felt fully; then,

tighten the cap an additional 1/6 turn [D] while holding the

brake fluid reservoir [A] body.

Brake Fluid Change

NOTE

The procedure to change the front brake fluid is as fol-

○

lows. Changing the rear brake fluid is the same as for the front brake.

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Level the brake fluid reservoir.

•

Remove the reservoir cap and diaphragm.

•

Remove

•

caliper. Attach a clear plastic hose [B] to the bleed valve, and run

•

the ot Fill the reservoir with fresh specified brake fluid.

•

Change the brake fluid:

•

Repeat this operation until fresh brake fluid comes out

○

from the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A].

2. Apply the brake and hold it [B].

3. Close the bleed valve [C].

4. Release the brake [D].

The fluid level must be checked often during the chang-

○

ing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line. Front Brake: Repeat the above steps for the other

○

caliper. Rear Brake: Repeat the above steps for the other bleed

○

valve.

the rubber cap from the bleed valve [A] on the

her end of the hose i nto a container.

NOTE

Remove the clear plastic hose.

•

Install the reservoir cap.

•

Tighten:

•

Torque - Front Reservoir Cap Screw: 1.5 N·m (0.15 kgf·m,

13 in·lb)

Follow the procedure below to install the rear brake fluid

•

reservoir cap correctly. First, tighten the rear brake fluid reservoir cap [B] clock-

○

wise [C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [ D] while holding the brake fluid reservoir [A] body.

Tighten the bleed valve, and install the rubber cap.

•

Torque - Bleed Valve: 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.

Periodic Maintenance Procedures

Brake Line Bleeding

The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power.

WARNING

Be sure to bleed the air from the brake line when-

ever brake lever or pedal action feels soft or

spongy after the brake fluid is changed, or when-

ever a brake line fitting has been loosened for any

reason.

NOTE

The procedure to bleed the front brake line is as follows.

○

Bleeding the rear brake line is the same as for the front brake.

PERIODIC MAINTENANCE 2-39

Remove the reservoir cap and diaphragm.

•

Fill the reservoir with fresh brake fluid to the upper level

•

einthereservoir.

lin

With the reservoir cap off, slowly pump the brake lever

•

several times until no air bubbles can be seen rising up

ough the fluid from the holes at the bottom of the reser-

thr

voir.

Bleed the air completely from the master cylinder by this

○

eration.

Remove the rubber cap from the bleed valve on the

•

caliper.

tach a clear plastic hose to the bleed valve, and run the

•

other end of the hose into a container.

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Bleed the brake line and the caliper:

•

Repeat this operation until no more air can be seen com-

○

ing out

1. Pump the brake lever until it becomes hard, and apply

2. Quick

3. Release the brake [C].

○

into the plastic hose.

thebrakeandholdit[A].

ly open and close [B] the bleed valve while hold-

ing the brake applied.

NOTE

The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding. Front Brake: Repeat the above steps for the other caliper.

Remove the clear plastic hose.

•

Install the reservoir cap.

•

Tighten:

•

Torque - Front Reservoir Cap Screw: 1.5 N·m (0.15 kgf·m,

13 in·lb)

Follow the procedure below to install the rear brake fluid

•

reservoir cap correctly. First, tighten the rear brake fluid reservoir cap [B] clock-

○

wise [C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [ D] while holding the brake fluid reservoir [A] body.

Tighten the bleed valve, and install the rubber cap.

•

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Check the fluid level.

•

After bleeding is done, check the brake for good braking

•

power, no brake drag, and no fluid leakage.

Periodic Maintenance Procedures

WARNING

When working with the disc brake, observe the pre-

cautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a s trong wind is blowing.

6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.

7. When 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.

8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.

9. If any of the brake line fittings or the bleed valve is opened at any time, the AIRMUSTBEBLEDFROM

THE BRAKE LINE.

PERIODIC MAINTENANCE 2-41

Brake Hoses and C onnections Inspection

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage. The high pressure inside the brake line can cause fluid to

○

leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose if any cracks [B] or bulges [C] are noticed. Tighten any loose fittings.

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Suspension

Front Fork Oil Leak Check

Visually inspect the front forks [A] for oil leakage, scoring

•

or scratches on the outer surface of the inner tubes. Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Check

Visually inspect the shock absorbers [A] for oil leakage.

•

If the oil leakage is found on it, replace the shock absorber with a new one.

Swingarm Pivot Lubrication

The grease nipple [A] is equipped for the lubrication of

•

swingarm bearing. Force grease into the nipple until the grease comes out from right side of the s wingarm pivot, and wipe off any excess of it.

Uni-trak Linkage Lubrication

In order for the tie-rod and rocker arm to function safely and wear slowly, it should be lubricated in accordance with the Periodic Maintenance Chart.

For the rocker arm and tie-rod needle bearings, there are

•

grease nipples [A] on the rocker arm and swingarm for

lubrication. Force grease into the nipples until it comes

out at both sides of the rocker arm and tie-rod, and wipe

off any excess.

Periodic Maintenance Procedures

Steering

Steering Inspection

t the front wheel off the ground using the jack.

Lif

•

Special Tool - Jack: 57001–1238

With the front wheel pointing straight ahead, alternately

•

tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop. If the wheel binds or catches before the stop, the steering is too tight. Feel for steering looseness by pushing and pulling the

•

forks. If you feel looseness, the steering is too loose.

NOTE

The cables and wiring will have some effect on the mo-

○

tion of the fork which must be taken into account. Be sure the wires and cables are properly routed.

○

The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

PERIODIC MAINTENANCE 2-43

Steering Adjustment

Adjust the steering, if necessary. Remove:

•

Windshield and Bracket (see Frame chapter) Inner Cover (see Frame chapter) Fairing and Bracket (see Frame chapter) Handlebar (see Steering chapter)

Loosen the upper fork clamp bolts [A] on both side.

•

Remove the steering stem head bolt plug and the stem

•

head bolt [B]. Remove the steering stem head [C].

•

Bend the claw washer tabs [A].

•

Remove the steering stem locknut [B] and claw washer

•

[C].

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Adjust the steering.

•

Special Tool - Steering Stem Nut Wrench: 57001–1100 [B]

If the steering is too tight, loosen the stem nut [A] a fraction

of a turn.

If the steering is too loose, tighten the stem nut a fraction

of a turn.

NOTE

Turn the stem nut 1/8 turn at time maximum.

○

Install the claw washer [A] so that its bent side [B] 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.

Tighten the stem locknut clockwise until the claws are

•

aligned with the grooves (ranging from 2nd to 4th) of stem

nut [D], and bend the 2 claws downward [ E].

Tighten:

•

Torque - Steering Stem Head Bolt:

108 N·m (11 kgf·m, 80 ft·lb)

Front Fork Clamp Bolts (Upper):

8.8 N·m (0.90 kgf·m, 78 in·lb)

13 N·m (1.3 kgf·m, 113 in·lb) ZR1000–A2 ∼

Check the steering again.

•

If the steering is still too tight or too loose, repeat the ad-

justment.

Stem Bearing Lubrication

Remove the steering stem.

•

Using a high flash-point solvent, wash the upper and

•

lower ball bearings 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 [A] in the cages

•

with grease, and apply a light coat of grease to the upper

and lower outer races.

Install the steering stem, and adjust the steering.

•

Electrical System

Spark Plug Cleaning and Inspection

Remove:

•

Fuel Tank (see Fuel System (DFI) chapter)

Periodic Maintenance Procedures

Unscrew the thermostat bracket bolt [A].

•

If removing the spark plug #2 or #3.

○

Disconnect:

•

Stick Coil Connectors [A]

Pull out the stick coil #1 [B].

•

Take out the camshaft position sensor connector [C] from

•

the bracket. Pull out the stick coil #2 [D].

•

CAUTION

Do not pry the connector part of the coil while removing the coil.

PERIODIC MAINTENANCE 2-45

Remove the stick coil subharness connector [A] from the

•

bracket. Remove:

•

Stick Coil Connector #4 [B] (disconnect) Stick Coil #4 [C] Stick Coil Connector #3 [D] (disconnect)

Disconnect:

•

Water Temperature Sensor Connector [A] Left Switch Housing Connector [B]

Pull the main harness [C] upward and remove the stick

•

coil #3 [D].

Remove the spark plugs using the 16 mm plug wrench

•

[A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110–1132

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clean the spark plug, preferably in a sandblasting device,

•

and then clean off any abrasive particles. The plug may

also be

brush or other tool.

If the spark plug center electrode [A] and/or side elec-

trode

is cracked, replace the plug. Use the standard spark plug

or its equivalent.

Meas

•

If the gap is incorrect, carefully bend the side electrode

with a tool to obtain the correct gap.

•

spark plug installed in the plug wrench [ A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110–1132

Tighten:

•

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 113 in·lb)

cleaned using a high-flash point solvent and a wire

[B] are corroded or dam aged, or if the insulator [C]

ure the gaps [D] with a wire-type thickness gauge.

Spark Plug Gap: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

sertthesparkplugverticallyintotheplugholewiththe

Insert the coils as shown being careful of the coil head [A]

•

direction.

Fit the coils securely.

○

CAUTION

Do not tap the coil head while i nstalling the coil.

Be sure the stick coils are installed by pulling up [B] it

○

lightly.

Connect and/or install the connectors.

•

Install:

•

Fuel Tank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt (see Cooling System chapter)

Periodic Maintenance Procedures

General Lubrication

Lubrication

ore lubricating each part, clean off any rusty spots with

Bef

•

rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication.

Pivots: Lubricate with Motor Oil

Rear Brake Rod Joint

Points: Lubricate with Grease

Throttle and Choke Inner Cable Upper Ends [A]

lutch Lever Pivot

C Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot

ide Stand

S Tie-Rod Pivots Rocker Arm Pivots

ingarm Pivot

PERIODIC MAINTENANCE 2-47

Cables: Lubricate with Cable Lubricant

Choke Cable Throttle Cables Clutch Cable

Lubricate the cables by seeping the oil between the cable

•

and housing. The cable may be lubricated by using a commercially

○

available pressure cable lubricator with an aerosol cable lubricant.

With the cable disconnected at both ends, the cable

•

should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B] or if the cable housing is kinked [C], replace the cable.

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Nut, Bolt, and Fastener Tightness

Tightness Inspection

Check the tightness of the bolts and nuts listed here. Also,

•

check to see that each cotter pin is in place and in good

condition.

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the spec-

ified torque, following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not in the appropriate chapter,

see the Standard Torque Table in this section. For each

fastener, first loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Nut, Bolt and Fastener to be checked

Wheels:

Front Axle Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin

Brakes:

Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear M aster Cylinder Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin

Suspension:

Front Fork Clamp Bolts Front Fender Mounting Bolt Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Swingarm Pivot Shaft Lock Nut Uni-Trak Link Nuts

Steering:

Stem Head Nut Handlebar Clamp Bolts

Engine:

Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Downtube Bolts Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Connecting Clamp Bolt Clutch Lever Pivot Nut Radiator Upper and Lower Bolts

Others:

Sidestand Bolt Footpeg Stay Bolts Rear Frame Mounting Bolts

Fuel System (DFI)

Table of Contents

Exploded View................................... 3-3

DFI Parts Location............................. 3-8

DFI Wiring Diagram ........................... 3-10

Specifications .................................... 3-12

Special Tools ..................................... 3-14

DFI Servicing Precautions ................. 3-15

Troubleshooting the DFI System ....... 3-17

Outline ............................................ 3-17

Inquiries to Rider............................. 3-21

DFI System Troubleshooting Guide .. 3-24

Self-Diagnosis ................................... 3-33

Self-diagnosis Outline..................... 3-33

Self-diagnosis Procedures.............. 3-33

Service Code Clearing Procedures 3-34

How to Read Service Codes........... 3-36

How to Erase Service Codes.......... 3-36

Service Code Table......................... 3-37

Backups .......................................... 3-38

Main Throttle Sensor (Service Code

11)................................................... 3-40

Main Throttle Sensor

Removal/Adjustment ................. 3-40

Input Voltage Inspection............... 3-40

Output Voltage Inspection............ 3-41

Resistance Inspection.................. 3-42

Inlet Air Pressure Sensor (Service

Code 12) ......................................... 3-43

Removal....................................... 3-43

Installation.................................... 3-43

Input Voltage Inspection............... 3-43

Output Voltage Inspection............ 3-44

Inlet Air Temperature Sensor (Service

Code 13) ......................................... 3-48

Removal/Installation..................... 3-48

Output Voltage Inspection............ 3-48

Sensor Resistance Inspection ..... 3-49

Water Temperature Sensor (Service

Code 14) ......................................... 3-50

Removal/Installation..................... 3-50

Output Voltage Inspection............ 3-50

Sensor Resistance Inspection ..... 3-51

Atmospheric Pressure Sensor

(Service Code 15)........................... 3-52

Removal....................................... 3-52

Input Voltage Inspection............... 3-52

Output Voltage Inspection............ 3-53

FUEL SYSTEM (DFI) 3-1

Crankshaft Sensor (Service Code

21)................................................... 3-55

Crankshaft Sensor

Removal/Installation .................. 3-55

Crankshaft Sensor Inspection...... 3-55

Camshaft Position Sensor (Service

Code 23) ......................................... 3-56

Camshaft Position Sensor

Removal/Installation .................. 3-56

Camshaft Position Sensor

Inspection .................................. 3-56

Speed Sensor (Service Code 24, 25) 3-57

Speed Sensor

Removal/Installation .................. 3-57

Speed Sensor Inspection............. 3-57

Input Voltage Inspection............... 3-57

Output Voltage Inspection............ 3-57

Vehicle-down Sensor (Service Code

31)................................................... 3-59

Removal....................................... 3-59

Installation.................................... 3-59

Inspection..................................... 3-59

Subthrottle Sensor (Service Code

32)................................................... 3-62

Subthrottle Sensor

Removal/Adjustment ................. 3-62

Input Voltage Inspection............... 3-62

Output Voltage Inspection............ 3-63

Resistance Inspection.................. 3-64

Stick Coils (#1, #2, #3, #4: Service

Code 51, 52, 53, 54) ....................... 3-65

Removal/Installation..................... 3-65

Input Voltage Inspection............... 3-65

Subthrottle Valve Actuator (Service

Code 62) ......................................... 3-67

Subthrottle Valve Actuator

Removal .................................... 3-67

Audible Inspection........................ 3-67

Visual Inspection.......................... 3-67

Resistance Inspection.................. 3-67

Input Voltage Inspection............... 3-68

FI Indicator LED Light........................ 3-69

LED Light Inspection.................... 3-70

ECU ................................................... 3-71

ECU Identification ........................ 3-71

ECU Removal .............................. 3-71

3-2 FUEL SYSTEM (DFI)

ECU Installation ........................... 3-71

ECU Power Supply Inspection..... 3-72

DFI Power Source ............................. 3-74

ECU Fuse Removal ..................... 3-74

ECU Fuse Installation .................. 3-74

ECU Fuse Inspection ................... 3-74

ECU Main Relay Removal ........... 3-74

ECU Main Relay Inspection ......... 3-74

Fuel Line............................................ 3-75

Fuel Pressure Inspection ............. 3-75

Fuel Flow Rate Inspection ........... 3-76

Fuel Pump ......................................... 3-78

Fuel Pump Removal .................... 3-78

Fuel Pump Installation ................. 3-78

Operation Inspection.................... 3-79

Operating Voltage Inspection....... 3-79

Pressure Regulator Removal ....... 3-80

Pump Screen, Fuel Filter

Cleaning.................................... 3-80

Fuel Pump Relay Removal .......... 3-81

Fuel Pump Relay Inspection ........ 3-81

Fuel Injectors ..................................... 3-82

Removal/Installation..................... 3-82

Audible Inspection........................ 3-82

Power Source Voltage Inspection 3-82

Output Voltage Inspection............ 3-83

Injector Signal Test....................... 3-84

Injector Resistance Inspection ..... 3-85

Injector Unit Test .......................... 3-85

Injector Fuel Line Inspection........ 3-85

Throttle Grip and Cables ................... 3-88

Throttle Grip Play

Inspection/Adjustment............... 3-88

Choke Lever O peration................ 3-88

Choke Lever Play Inspection ....... 3-88

Choke Lever Play Adjustment...... 3-88

Cable Removal/Installation .......... 3-88

Cable Lubrication and Inspection. 3-88

Throttle Body Assy ............................ 3-89

Idle Speed Inspection/Adjustment 3-89

Throttle Bore Cleaning ................. 3-89

Engine Vacuum Synchronization

Inspection/Adjustment............... 3-89

High Altitude Performance

Adjustment ................................ 3-89

Throttle Body Assy Removal........ 3-89

Throttle Body Assy Installation..... 3-91

Throttle Body Assy Disassembly . 3-92

Throttle Body Assy Assembly ...... 3-93

Air Cleaner......................................... 3-94

Element Removal/Installation ...... 3-94

Air Cleaner Oil Draining ............... 3-94

Air Cleaner Housing Removal...... 3-94

Fuel Tank ........................................... 3-95

Fuel Tank Removal ...................... 3-95

Fuel Tank Installation ................... 3-97

Fuel Tank and Cap Inspection ..... 3-98

Fuel Tank Cleaning ...................... 3-98

Evaporative Emission Control

System............................................ 3-99

Parts Removal/Installation ........... 3-99

Canister Installation ..................... 3-99

Hose Inspection ........................... 3-99

Separator Inspection.................... 3-99

Separator Operation Test............. 3-100

Exploded View

Clifornia Evaporative Emission Control System

FUEL SYSTEM (DFI) 3-3

1. Canister

2. Separator

3. Right fitting of throttle body #2

4. Right fitting of throttle body #3

5. Canister purge hose (green)

6. Fuel return hose (left, red)

7. Fuel tank breather hose (right, blue)

8. Separator breather hose (blue)

9. Separator vacuum hose (white)

3-4 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

N·m

1 Throttle cable plate bolt 6 0.6 52 in·lb

2 Throttle body cover bolts 7 0.7 61 in·lb

3 Throttle assy holder clamp bolts 2 0.2 17 in·lb

4 Choke link holder screws 2.1 0.21 18 in·lb

5 Delivery pipe screws 3.4 0.35 30 in·lb

6 Bypass screws 0.2 0.02 1.7 in·lb

7 Fuel pump bolts 9.8 1.0 87 in·lb S, L

8 Fuel level sensor bolts 6.9 0.7 62 in·lb

9. FI indicator LED light

10. Meter unit

11. Throttle cable (accelerator)

12. Throttle cable (decelerator)

13. Choke cable

14. Injector connectors

15. Main throttle sensor connector (grey)

16. Subthrottle sensor connector (black)

17. Subthrottle valve actuator connector

18. Throttle body assy connector

19. Main throttle sensor

20. Subthrottle sensor

21. Injectors

22. Center adjusting screw

CL: Apply cable lubricant.

EO: Apply engine oil to the seals and O-rings.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts.

S: Follow the specified tightening sequence.

Torque

Remarks

kgf·m ft·lb

3-6 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1 Inlet air pressure sensor bolt 12 1.2 104 in·lb

2 Water temperature sensor 25 2.5 18

3 Vehicle downsensor bolts 2 0.2 17 in·lb

4 Camshaft position sensor bolt 12 1.2 104 in·lb

Camsh

6 Air cleaner duct holder screws 3.8 0.39 34 in·lb

7 Air cleaner housing mounting bolts 9.8 1.0 87 in·lb

8 Air cleaner duct clamp bolts 2 0.2 17 in·lb

9 Air cleaner housing screws 1.2 0.12 10 in·lb

10 Air cleaner housing tapping screws 1.2 0.12 10 in·lb

11 Speed sensor bolt 6.9 0.7 62 in·lb L

12. Inlet air pressure sensor

13. Stick coils (see Electrical System chapter)

14. ECU

15. Fuel pump relay

16. ECU main relay

17. Atmospheric pressure sensor

18. Crankshaft sensor (see Electrical System chapter)

19. Inlet air temperature sensor

20. Vacuum switch valve ( see Engine Top End chapter)

21. Air suction valves

22. Grommet L: Apply a non-permanent locking agent.

aft position sensor rotor bolt

N·m

12 1.2 104 in·lb L

Torque

Remarks

kgf·m ft·lb

3-8 FUEL SYSTEM (DFI)

DFI Parts Location

DFI: DFI Parts (this chapter) 8. ECU Fuse 15A 19. Turn Signal Relay F: Front 9. ECU (DFI) 20. Subthrottle Sensor (DFI)

1. Water temperature 10. Stick Coils 21. Main Throttle Sensor (DFI) Sensor (DFI) 11. Throttle Body Assy 22. Ignition Switch

2. Inlet Air Pressure 12. Self-diagnosis Terminal 23. FI Indicator LED Light (DFI) Sensor (DFI) 13. Neutral Switch 24. Crankshaft Sensor

3. Injectors (DFI) 14. Vehicle Down Sensor (DFI) 25 Camshaft Position Sensor

4. Fuel Pump (DFI) 15. Atmospheric Pressure 26 Fuel Pump Screen

5. Inlet Air Temperature Sensor (DFI) 27 Return Fuel Check Valve Sensor (DFI) 16. Delivery Pipe 28 Pressure Regulator

6. Sealed Battery 17. ECU Main Relay 29 Fuel Filter

7. Junction Box 18. Fuel Pump Relay (DFI)

DFI Parts Location

FUEL SYSTEM (DFI) 3-9

[1], [2], [10], [13], [22] and [24] are not included.

3-10 FUEL SYSTEM (DFI)

DFI Wiring Diagram

FUEL SYSTEM (DFI) 3-11

Terminal Names

1. Power Supply to Sensors (inlet air pressure, a sensors) from ECU.

2. Main Throttle Sensor Signal

3. Subth

4. Atmospheric Pressure Sensor Signal

5. Water Temperature Sensor Signal (+)

6.7.8.–

9. Camshaft Position Sensor Signal (+)

10. –

11. Cr a n

12. –

13. Power Supply to ECU, Injectors, and Fuel Pum

14. Sensor Ground (inlet air temperature, water temperature, inlet air pressure, atmos throttle sensors)

15. –

16.Ve

17. Inlet Air Pressure Sensor Signal

18. Inlet Air Temperature Sensor Signal (+)

19.–

20. Speed Sensor Signal

21. –

22.C

23. –

24. Crankshaft Sensor (–)

25.–

tmospheric pressure, and throttle

rottle Sensor Signal for ECU

kshaft Sensor Signal (+)

pheric pressure, vehicle-down, and

hicle-down Sensor Signal

amshaft Position Sensor Signal (–)

26. ECU Power Source Circuit Ground to Battery (–) Terminal

27. Engine

28. Starter Lockout Switch Signal

29. Electric Starter Button Signal

30. Signa

31. Subthrottle Valve Actuator Drive Signal

32. Subthrottle Valve Actuator Drive Signal

33. –

34. Tachometer S ignal

35. Injector #2 Signal

36. Inje

37. Stick Coil #3 Signal

38. Stick Coil #2 Signal

39. Sti

40. Interlock C ircuit Signal

41. Self-diagnosis Signal (generated by gro FI indicator LED light)

42. –

43.Ba

44. Subthrottle Valve Actuator Drive Signal

45. Subthrottle Valve Actuator Drive Signal

46.–

47. FI Indicator LED Light Signal

48. Injector #4 Signal

njector #3 Signal

49.I

50. DFI System Ground

51. Ignition System Ground

tick Coil #4 Signal

52.S

Stop Switch Signal

l For Fuel Pump Relay

ctor #1 Signal

ck Coil #1 Signal

unding this terminal and shown by

ttery Power ON-OFF Signal

Part Name

A. ECU (Electronic Control Unit)

B. Crankshaft Sensor C. Inlet Air Pressure Sensor D. Water Temperature Sensor

E. Atmospheric P ressure Sensor

F. Inlet Air Temperature Sensor G. Camshaft Position Sensor H. Speed Sensor

I. Main Throttle Sensor

J. Subthrottle Sensor

K. Injectors #1, #2, #3, #4

L. Subthrottle Valve Actuator

M. Stick Coils #1, #2, #3, #4

N. Engine Stop Switch O. Joint Connector D

P. see Electrical System chapter Q. Ground Terminal R. Ground Terminal

S. ECU Main Relay

T. Ignition Switch

U. FI Indicator LED Light

V. Tachometer

W. Speedometer

X. Ignition Fuse 10A

Y. Junction Box

Z. Fuel Pump Relay (for fuel pump and in-

jectors) a. ECU Fuse 15A b. Vehicle-down Sensor d. Starter Relay e. Joint Connector D

f. Sealed Battery g. Fuel Pump h. Self-diagnosis Terminal

j. Joint Connector B

k. Main Fuse 30A

m. Throttle B ody Assy Connector

n: Connector Locks p: ECU Connector

3-12 FUEL SYSTEM (DFI)

Specifications

Item Standard

Digital Fuel Injection System

Idle Speed 1 100 ± 50 r/min (rpm) Throttle Assy:

Type Four b Bore 38 mm (1.5 in.)

ECU (Electronic Control Unit):

Make Denso

Typ

Usable engine speed 100 ∼ 11 160 r/min (rpm)

Fuel Pressure (high pressure line):

Right after Ignition switch ON 310 kPa (3.2 kgf/cm², 46 psi) with fuel pump running

After 3 sec from Ignition switchON290 kPa (2.9 kgf/cm², 43 psi) with fuel pump stopped With engine idling 310 kPa (3.2 kgf/cm², 46 psi) with fuel pump running

uel Pump:

Type In-tank friction pump Discharge

Fuel Injectors:

Type INP–250

Nozzle type One spray type with 4 holes Resistance

Main Throttle Sensor: Non-adjustable and non-removable

Input voltage

Output voltage at idle throttle 0.99 ∼ 1.03 V DC between Y/W and BR/BK leads

opening

Output voltage at full throttle 4.19 ∼ 4.39 V DC between Y/W and BR/BK leads

opening

Resistance 4 ∼ 6kΩ

Inlet Air Pressure Sensor or Atmospheric Pressure Sensor:

Digital memory type, with built in IC igniter, sealed with resin

67 m L (2.3 US oz) or more for 3 seconds

about 11.7 ∼ 12.3 Ω at 20°C (68°F)

4.75 ∼ 5.25 V DC between BL and BR/BK leads

arrel type

Input voltage

Output voltage 3.74 ∼ 4.26 V DC at standard atmospheric pressure (see

Inlet Air Temperature Sensor:

Resistance

Output voltage at ECU about 2.25 ∼ 2.50 V @20°C (68°F)

Water Temperature Sensor:

Resistance

Output voltage at ECU about 2.80 ∼ 2.97 V @20°C (68°F)

Speed Sensor:

Input voltage at sensor about 9 ∼ 11 V DC at Ignition Switch ON Output voltage at sensor about 0.05 ∼ 0.07 V DC at Ignition Switch ON and 0 km/h

Vehicle-down Sensor:

Detection method

Detection angle More than 60 ∼ 70° for each bank

4.75 ∼ 5.25 V DC between BL and BR/BK leads

this text for details)

1.6 ∼ 3.7 kΩ at 20°C (68°F)

0.24 ∼ 0.43 kΩ at 80°C (176°F)

see Electrical System chapter

Magnetic flux detection method

FUEL SYSTEM (DFI) 3-13

Specifications

Item Standard

Detection time Within 0.5 ∼ 1.0 sec. Output voltage with the sensor tilted 60 ∼ 70° or m ore: 3.7 ∼ 4.4 V

with sensor arrow mark pointed up: 0.4 ∼ 1.4 V

Subthrottle Sensor: Non-adjustable and non-removal

Input Voltage

Output voltage at idle throttle 0.48 ∼ 0.52 V DC between BR and BR/BK leads

opening

Output voltage at full throttle 3.6 ∼ 3.8 V DC between BR and BR/BK leads

opening

Resistance 4 ∼ 6kΩ

bthrottle Valve Actuator:

Resistance about 5 ∼ 7kΩ

Input voltage

Throttle Grip and Cables

Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Choke Cable

Choke cable free play 0 ∼ 0.5 mm (0 ∼ 0.02 in.)

∼ 5.25 V DC between BR and BR/BK leads

4.75

bout 8.5 ∼ 10.5 V DC

3-14 FUEL SYSTEM (DFI)

Special Tools

Oil Pressure Gauge: 57001–125

Carburetor Drain Plug Wrench, Hex 3: 57001–1269

Fork Oil Level Gauge: 57001–1290

Fuel Pressure Gauge Adapter: 57001–1417

Needle Adapter Set: 57001–1457

Throttle Sensor Setting Adapter: 57001–1538

Hand Tester: 57001–1394

Throttle Sensor Setting Adapter:

7001–1400

Sensor Harness Adapter: 57001–1561

Kawasaki Bond (Silicone Sealant):

6019–120

DFI Servicing Precautions

There are a number of important precautions that should

be followed servicing the DFI system.

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

○

battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. Do not reverse t he battery cable connections. This will

○

damage the ECU. To prevent damage to the DFI parts, do not disconnect the

○

battery cables or any other electrical connections when the ignition switch is on or while the engine is running. Take care not to short the leads that are directly con-

○

nected to the battery positive (+) terminal to the chassis ground. When charging, remove the battery from the motorcycle.

○

This is to prevent ECU damage by excessive voltage. Do not turn the ignition switch ON while any of the DFI

○

electrical connectors are disconnected. The ECU memorizes service codes. Do not spray water on the electrical parts, DFI parts, con-

○

nectors, leads, and wiring. Never water a vehicle with connectors unplugged because seals don’t work and terminals could corrode. If a transceiver is installed on the motorcycle, make sure

○

that the operation of the DFI system is not influenced by electric wave radiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU . When any fuel hose is disconnected, do not turn on the

○

ignition switch. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose. Do not operate the fuel pump if the pum p is completely

○

dry. This is to prevent pump seizure. Before removing the fuel system parts, blow the outer sur-

○

faces of these parts clean with compressed air. When any fuel hose is disconnected, fuel may spout out

○

by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage. To prevent corrosion and deposits in the fuel system, do

○

not add to fuel any fuel antifreeze chemicals. Whenever the DFI electrical connections are to be discon-

○

nected, first turn off the ignition switch. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine.

FUEL SYSTEM (DFI) 3-15

Whenever the DFI electrical connections are to be dis-

○

connected, first turn off the ignition switch, and disconnect the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. When disconnecting the vehicle-down sensor connector,

○

raise the lock of the connector. Push the lock of the other connectors.

3-16 FUEL SYSTEM (DFI)

DFI Servicing Precautions

To maintain the correct fuel/air m ixture (F/A), there must

○

be no inlet air leaks in the DFI system. Be sure to install the oil

Torque - Oil Filler Plug: 1.5 N·m (0.15 kgf·m, 13 in·lb)

filler plug [A] after filling the engine oil. Clutch Cover [B] Front [C]

Troubleshooting the DFI System

Outline

When an abnormality in the system occurs, the FI indica-

LED (Light Emitting Diode) light goes on to alert the rider

tor on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).

h the engine stopped and turned in the self-diagnosis

Wit mode, the service code [A] is indicated by the number of times the FI indicator LED light blinks.

en due to a malfunction, the FI indicator LED light re-

Wh mains lit, ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C].

rst, conduct a self-diagnosis inspection and then a non

•

-self-diagnosis inspection. The non–self–diagnosis items

are not indicated by the FI indicator LED light. Don’t rely

olely on the DFI self-diagnosis function, use common

sense.

FUEL SYSTEM (DFI) 3-17

Even when the DFI system is operating normally, the FI indicator LED light [A] may light up under strong electrical interference. No repair needed. Turn the ignition switch OFF to stop the indicator light.

When the FI indicator LED light goes on and the motorcycle is brought in for repair, check the service codes.

When the repair has been done, the LED light doesn’t go on. But the service codes stored in memory are not erased to preserve the problem history, and the LED light can display the codes in the self-diagnosis mode. The problem history is referred when solving unstable problems.

When the motorcycle is down, the vehicle-down sensor is turned OFF and the ECU shuts off the fuel injectors and ignition system. The FI indicator LED light blinks but the fault code cannot be displayed. The i gnition switch is left ON. If the starter button is pushed, the electric starter turns but the engine doesn’t start. To start the engine again, raise the m otorcycle, turn the ignition switch OFF, and then ON. The vehicle-down sensor is turned ON and the LED light goes OFF.

3-18 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

The DFI part connectors [A] have seals [B], including the

○

ECU. Join th

•

tool) [C] inside the seal [B] from behind the connector until the adapter reaches the terminal.

Special Tool - Needle Adapter Set: 57001–1457

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

Make sure that measuring points are correct in the con-

•

nector, noting the position of the lock [D] and the lead color before measurement. Do not reverse connections of the hand tester or a digital m eter. Be careful not to short-circuit the leads of the DFI or elec-

•

trical system parts by contact between adapters. Turn the ignition switch ON and measure the voltage with

•

the connector joined.

e connector and insert the needle adapters (special

CAUTION

Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts.

After measurement, remove the needle adapters and ap-

○

ply silicone sealant to the seals [A] of the connector [B] for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019–120)

- Seals of Connector

Always check battery condition before replacing the DFI

•

parts. A fully charged battery is a must for conducting accurate tests of the DFI system.

Trouble may involve one or in some cases all items.

•

Never replace a defective part without determining what CAUSED the problem. If the problem was caused by some other item or items, they too must be repaired or replaced, or the new replacement part will soon fail again. Measure coil winding resistance when the DFI part is cold

•

(at room temperature) Make sure all connectors in the circuit are clean and tight,

•

and examine wires for signs of burning, fraying, short, etc. Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system. If any wiring is deteriorated, replace the wiring.

Troubleshooting the DFI System

Pull each connector [A] apart and inspect it for corrosion,

•

dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

is damaged, replace it. Connect the connectors securely.

Check the wiring for continuity.

•

Use the wiring diagram to find the ends of the lead which

○

is suspected of being a problem.

Connect the hand tester between the ends of the leads.

○

Set the tester to the × 1 Ω range, and read the tester.

○

If the tester does not read 0 Ω, the lead is defective. Re-

place the lead or the main harness or the sub harness.

If both ends of a harness [A] are far apart, ground [B] the

○

one end [C], using a jumper lead [D] and check the con-

tinuity between the end [E] and the ground [F]. This en-

ables to check a long harness for continuity. If the harness

is open, repair or replace the harness.

FUEL SYSTEM (DFI) 3-19

When checking a harness [A] for short circuit, open one

○

end [B] and check the continuity between the other end

[C] and ground [D]. If there is continuity, the harness has

a short circuit to ground, and it must be repaired or re-

placed.

Narrow down suspicious locations by repeating the con-

•

tinuity tests from the ECU connectors.

If no abnormality is found in the wiring or connectors, the

DFI parts are the next likely suspects. Check the part,

starting with input and output voltages. However, there is

no way to check the ECU itself.

If an abnormality is found, replace the affected DFI part.

If no abnormality is found in the wiring, connectors, and

DFI parts, replace the ECU.

Lead Color Codes:

○

BK: Black

BL: Blue GY: Gray PU: Purple

BR: Brown LB: Light blue R: Red

CH: Chocolate LG: Light green

DG: Dark green O: Orange

G: Green

P: Pink

W: White

Y: Yellow

3-20 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

There are two ways to inspect the DFI system. One is

○

voltage Check Method and the other is Resistance Check Method

(Voltage Check Method)

This method is conducted by measuring t he input voltage

○

[B] to from the sensor. Sometimes this method can detect a fault of the ECU .

○

Refer

•

chapter. Use a fully charged battery and a digital meter [D] which

•

can b

a sensor [A] first, and then the output voltage [C]

to each sensor inspection section for detail in this

e read two decimal places voltage or resistance.

(Resistance Check Method)

This method is simple. No need for a fully charged battery

○

and the needle adapter. Just do the following especially when a sensor [A] is suspect. Turn the ignition switch OFF and disconnect the connec-

•

tors. Inspect the sensor resistance, using a digital meter (see

•

each sensor inspection in this chapter). Inspect the wiring and connectors [B] for continuity, using

•

the hand tester [C] (analog tester) r ather than a digital meter.

Special Tool - Hand Tester: 57001–1394

If the sensor, the wiring and connections are good, inspect the ECU for its ground and power supply (see this chapter). If the ground and power supply are good, the ECU is suspect. Replace the ECU.

Troubleshooting the DFI System

DFI Diagnosis Flow Chart

FUEL SYSTEM (DFI) 3-21

Inquiries to Rider

Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms

○

the rider has encountered.

Try to find out exactly what problem occurred under exactly what conditions by asking the rider;

○

knowing this information may help you reproduce the problem.

The following sample diagnosis sheet will help prevent you from overlooking any areas, and will

○

help you decide if it is a DFI system problem, or a general engine problem.

3-22 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: M ileage:

Environment when problem occurred.

Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other:

Temperature □ hot, □ warm, □ cold, □ very cold, □ always

Problem □ chronic, □ often, □ once

frequency

Road □ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble

Altitude □ normal, □ high (about 1 000 m (3 281 ft) or more)

Motorcycle conditions when problem occurred.

FI indicator □ light up immediately after ignition switch ON, and goes off after 1 ∼ 2 seconds

LED light (normal)

□ lights blinks immediately after ignition switch ON, and stays on (DFI problem)

□ lights up imm ediately after ignition switch ON, but goes off after about 10

seconds (DFI problem)

□ unlights (LED light, ECU or its wiring fault)

□ sometimes lights up (probably wiring fault)

Starting □ starter motor not rotating

difficulty □ starter motor rotating but engine doesn’t turn over

□ starter motor and engine don’t turn over

□ no fuel flow (□ no fuel in tank, □ no fuel pump sound)

□ engine flooded (do not crank engine with throttle opened, which promotes engine

flooding)

□ no spark

□ choke lever is not pulled fully when using the lever (pull it fully when using)

□ other

Engine stops □ right after starting

□ when opening throttle grip

□ when closing throttle grip

□ when moving off

□ when stopping the motorcycle

□ when cruising

□ other

FUEL SYSTEM (DFI) 3-23

Troubleshooting the DFI System

Poor running □ choke lever pulled out fully (push it in fully)

at low speed □ very low choke speed (adjust choke cable)

□ very low idle speed, □ very high idle speed, □ rough idle speed

□ battery voltage is low (charge the battery)

□ spark plug loose (tighten it)

□ spark plug dirty, broken, or gap maladjusted (remedy it)

□ backfiring

□ afterfiring

□ hesitation when acceleration

□ engine oil viscosity too high

□ brake dragging

□ engine overheating

□ clutch slipping

□ other

Poor running □ choke lever pulled out fully (push it in fully)

or no power □ spark plug loose (tighten it)

at high speed □ spark plug dirty, broken, or gap maladjusted (remedy it)

□ spark plug incorrect (replace it)

□ knocking (fuel poor quality or incorrect, → use high-octane gasoline)

□ brake dragging

□ clutch slipping

□ engine overheating

□ engine oil level too high

□ engine oil viscosity too high

□ other

3-24 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 The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and

○

circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and po

Engine Doesn’t Start, Starting Difficulty

Starter motor not rotating:

Ignition and engine stop switches not ON Turn both switches ON.

Starter lockout switch or neutral switch trouble Inspect (see chapter 16)

Starter m otor trouble Inspect (see chapter 16).

Battery voltage low Inspect and charge (see chapter 16).

Starter relays not contacting or operating Inspect the starter relay (see chapter 16).

Starter button not contacting Inspect and replace (see chapter 16).

Starter system wiring open or shorted Inspect the wiring (see chapter 16).

Ignition switch trouble Inspect and replace (see chapter 16).

Engine stop switch trouble Inspect and repair or replace (see chapter 16).

Main 30A or ignition fuse blown Inspect and replace (see chapter 16).

arter motor rotating but engine doesn’t

St turn over :

Starter clutch trouble Inspect (see chapter 9).

Starter idle gear trouble Inspect (see chapter 9).

Engine won’t turn over :

Valv e seizur e Inspect and replace (see chapter 5).

Cylinder, piston seizure Inspect and replace (see chapter 5).

Camshaft seizure Inspect and replace (see chapter 5).

Connecting rod small end seizure Inspect and replace (see chapter 9).

Connecting rod big end seizure Inspect and replace (see chapter 9).

Crankshaft seizure Inspect and replace (see chapter 9).

Transmission gear or bearing seizure Inspect and replace (see chapter 9).

Balancer bearing seizure Inspect and replace (see chapter 9).

No fuel flow :

No or little fuel in tank Supply fuel (see Owner’s Manual).

Fuel pump not rotating Inspect (see chapter 3).

Fuel injector trouble Inspect and replace (see chapter 3).

Fuel tank air vent obstructed Inspect and repair (see chapter 3).

Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).

Fuel pressure regulator clogged Inspect and replace fuel pump (see chapter 3).

Fuel line clogged Inspect and repair (see chapter 3).

Engine flooded :

Spark plug dirty, broken or gap maladjusted

Starting technique faulty

No spark or spark weak :

as a rough guide to assist the troubleshooting for some of the more common difficulties.

wer supply are checked good, replace the ECU.

Sympt

oms or possible Causes

Clean spark plugs and adjust plug gap (see chapter 2).

When flooded, don’t crank engine with throttle fully opened.

ns (chapter)

Actio

Kawasaki Z1000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual