KAWASAKI ER-6 User Manual

ER-6n

ER-6n ABS

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

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 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

ER-6n

ER-6n ABS

Motorcycle

Service Manual

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

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

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

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

© 2011 Kawasaki Heavy Industries, Ltd. 1st Edition (3) : Aug. 5, 2011

LIST OF ABBREVIATIONS

A

ABDC after bottom dead cente

AC alternating current L liter(s)

Ah ampere hour lb pound(s)

ATDC after top dead center LCD L iquid Crystal Display

BBDC before bottom dead center LED Light Emission Diode

BDC bottom dead center m meter(s)

BTDC before top dead center min minute(s)

°C degree(s) Celsius mph miles per hour

cmHg centimeters of mercury N newton(s)

cu in Cubic inch(s) oz ounce(s)

DC

DFI Digital Fuel Injection

ECU Electronic Contr

°F degree(s) Fahrenheit qt quart(s)

ft foot, feet r revolution

ggram(s) rpm revolution(s) perminute

gal gallon(s) TDC top dead center

h hour(s) TIR total indicator reading

HP horsepower(s) Vvolt(s)

IC Integrated Circuit W watt(s)

in. inch(s) Ω ohm(s)

ampere(s)

r

direct current

ol Unit

KDS Kawasaki Diagnostic System

km/h

Pa

PS

psi

kilometers per hour

pascal(s)

horsepower

pound(s) per squa

re inch

COUNTRY AND AREA CODES

AT Austria GB United Kingdom

AU Australia ID Indonesia

AU LAMS Australia Leaner Approved

Motorcycle Scheme model

R

B

CA Canada TH Thailand

CH Switzerland WVTA Whole Vehicle Type Approval

DE Germany WVTA (FULL H) WVTA Model with Honeycomb Catalytic

EUR Europe

B

razil

SEA-B1 Southeast Asia B1 (with Evaporative

Emission Control System)

SEA-B2 Southeast Asia B2

Converter (Full Power)

GB WVTA
(FULL H)

WVTA Model with Honeycomb Catalytic
Converter (Left Side Traffic, Full Power)

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emis­sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi­tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.

1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors

are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.

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

of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California in-

cludes a catalytic converter system.

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

stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.

“Sec. 203(a) The following acts and the causing thereof are prohibited.
(3)(A) for any person to remove or render inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.

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

motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know­ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow­ing its sale and delivery to the ultimate purchaser...”

NOTE

The phrase “remo ve or render inoperative any device or element of design” has been generally

○

interpreted as follows.

1. Tampering does not include the temporary removal or rende ring 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 p arts or accessories which adversely affect the performance

or durability of the motorcycle.

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

dards.

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

element of design of the emission control systems.

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

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.

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

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

•

with Federal regulations.

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

•

Removal of the air box or air box cover.

•

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

•

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in­formation to make it useful to the owner who de­sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce­dures must be understood in order to carry out
maintenance and repair satisfactorily. When­ever the owner has insufficient experience or
doubts his ability to do the work, all adjust­ments, maintenance, and repair should be car­ried out only by qualified mechanics.

In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor­oughly familiarize yourself with the procedures
before starting work, and then do the work care­fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad­versely affect safe operation.

For the duration of the warranty period,

we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.

To get the longest life out of your vehicle.

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference

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

For example, if you want ignition coil informa­tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap­ter to find the Ignition Coil section.

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

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

This manual contains four more symbols
which will help you distinguish different types
of information.

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient 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 inspec-

tion in the procedural step or sub-step it fol-

lows.

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-9

Unit Conversion Table ............................................................................................................ 1-12

1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera­tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra­tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, discon­nect the battery cables from the battery to prevent the en­gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca­ble to the negative terminal.

Edges of Parts

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

Solvent

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

Cleaning Vehicle before Disassembly

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

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 Remov ed 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, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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

Tightening Torque

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

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

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, c lean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces­sively. Excessive application can clog oil passages and
cause serious damage.

Before Servicing

Press

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

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between
the i nner 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.

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in­stalling to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

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

Direction of Engine Rotation

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

Electrical Leads

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

Instrument

Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor­oughly before using the meter. Incorrect values may lead
to improper adjustments.

Model Identification

ER650EC Left Side View

GENERAL INFORMATION 1-7

ER650EC Right Side View

1-8 GENERAL INFORMATION

Model Identification

ER650FC Left Side View

ER650FC Right Side View

Frame Number Engine Number

GENERAL INFORMATION 1-9

General Specifications

Items ER650EC/FC

Dimensions

Overall Length 2 110 mm (83.07 in.)

Overall Width 770 mm (30.3 in.)

Overall Height 1 110 mm (43.70 in.)

Wheelbase 1 410 mm (55.51 in.)

Road Clearance 130 mm (5.12 in.)

Seat Height 805 mm (31.7 in.)

Curb Mass:

ER650E:

Front 102 kg (225 lb)

Rear 102 kg (225 lb)

ER650F: 206 kg (454 lb)

Front

Rear

Fuel Tank Capacity 16 L (4.2 US gal.)

Performance

Minimum Turning Radius 2.7 m (8.9 ft)

Engine

Type 4-stroke, DOHC, 2-cylinder

Cooling System Liquid-cooled

Bore and Stroke 83.0 × 60.0 mm (3.27 × 2.36 in.)

Displacement

Compression Ratio

Maximum Horsepower

Maximum Torque 64 N·m (6.5 kgf·m, 47 ft·lb) @7 000 r/min (rpm)

Carburetion System FI (Fuel Injection), KEIHIN TTK38 × 2

Starting System

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (IC igniter in ECU)

Ignition Timing From 10° BTDC @1 300 r/min (rpm)

Spark Plug NGK CR9EIA-9

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Valve Timing:

Intake:

Open 31° BTDC

Close 61° ABDC

Duration 272°

204 kg (450 lb)

103 kg (227 lb)

103 kg (227 lb)

649 cm³ (39.6 cu in.)

10.8 : 1

53 kW (72.1 PS) @8 500 r/min (rpm)
(AU LAMS) 35 kW (47.6 PS) @8 000 r/min (rpm)
(CA) – – –
(SEA-B1/B2, TH) 52 kW (70.7 PS) @8 000 r/min (rpm)

(AU LAMS) 55 N·m (5.6 kgf·m, 41 ft·lb) @3 800 r/min (rpm)
(CA) – – –

Electric starter

To 37° BTDC @5 000 r/min (rpm)

1-10 GENERAL INFORMATION

General Specifications

Items ER650EC/FC

Exhaust:

Open 50° BBDC

Close 30° ATDC

Duration

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil:

Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity SAE 10W-40

Capacity 2.3L(2.4USqt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio

Clutch Type Wet multi disc

Transmission:

Type

Gear Ratios:

1st 2.438 (39/16)

2nd 1.714 (36/21)

3rd 1.333 (32/24)

4th 1.111 (30/27)

5th

6th 0.852 (23/27)

Final Drive System:

Type Chain drive

Reduction Ratio 3.067 (46/15)

Overall Drive Ratio 5.473 @Top gear

Frame

Type Tubular, diamond

Caster (Rake Angle) 25°

Trail 110 mm (4.33 in.)

Front Tire:

Type Tubeless

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

Rim Size J17M/C × MT3.50

Rear Tire:

Type Tubeless

Size 160/60 ZR17 M/C (69W)

Rim Size J17M/C × MT4.50

Front Suspension:

Type Telescopic fork

Wheel Travel 125 mm (4.92 in.)

260°

2.095 (88/42)

6-speed, constant mesh, return shift

0.966 (28/29)

GENERAL INFORMATION 1-11

General Specifications

Items ER650EC/FC

Rear Suspension:

Type Swingarm

Wheel Travel 130 mm (5.12 in.)

Brake Type:

Front Dual discs

Rear Single disc

Electrical Equipment

Battery 12 V 10 Ah

Headlight:

Type Semi-sealed beam

Bulb:

High 12 V 55 W + 55 W (quartz-halogen)

Low 12 V 55 W (quartz-halogen)

Tail/Brake Light LED

Alternator:

Type Three-phase AC

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.

1-12 GENERAL INFORMATION

Unit Conversion Table

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 = gal (IMP)

L×1.057=

L × 0.8799 =

L × 2.113 = pint (US)

L × 1.816 = pint (IMP)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (IMP)

mL × 0.06102 = cu in

qt (US)

qt (IMP)

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 × 7.233 = ft·lb

kgf·m × 86.80 = in·lb

Units of Pressure:

kPa × 0.01020 = kgf/cm²

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cmHg × 1.333 = 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

PS × 0.9863 = HP

× 0.7355 = kW

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-6

Specifications ......................................................................................................................... 2-12

Special Tools .......................................................................................................................... 2-14

Periodic Maintenance Procedures.......................................................................................... 2-15

Fuel System (DFI)................................................................................................................ 2-15

Throttle Control System Inspection................................................................................... 2-15

Engine Vacuum Synchronization Inspection..................................................................... 2-15

Idle Speed Inspection ....................................................................................................... 2-18

Idle Speed Adjustment...................................................................................................... 2-18

Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-19

Evaporative Emission Control System Inspection (SEA-B1 and TH Models)................... 2-20

Cooling System.................................................................................................................... 2-20

Coolant Level Inspection................................................................................................... 2-20

Water Hose Damage and Installation Condition Inspection.............................................. 2-21

Engine Top End ................................................................................................................... 2-21

Valve Clearance Inspection .............................................................................................. 2-21

Valve Clearance Adjustment............................................................................................. 2-22

Air Suction System Damage Inspection............................................................................ 2-25

Clutch................................................................................................................................... 2-25

Clutch Operation Inspection.............................................................................................. 2-25

Wheels/Tires........................................................................................................................ 2-26

Air Pressure Inspection..................................................................................................... 2-26

Wheel/Tire Damage Inspection......................................................................................... 2-27

Tire Tread Wear, Abnormal Wear Inspection .................................................................... 2-27

Wheel Bearing Damage Inspection .................................................................................. 2-28

Final Drive............................................................................................................................ 2-28

Drive Chain Lubrication Condition Inspection ................................................................... 2-28

Drive Chain Slack Inspection ............................................................................................ 2-29

Drive Chain Slack Adjustment .......................................................................................... 2-29

Wheel Alignment Inspection ............................................................................................. 2-30

Drive Chain Wear Inspection ............................................................................................ 2-31

Chain Guide Inspection..................................................................................................... 2-31

Brake System ...................................................................................................................... 2-32

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-32

Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-32

Brake Fluid Level Inspection............................................................................................. 2-33

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

Brake Operation Inspection .............................................................................................. 2-34

Brake Light Switch Operation Inspection .......................................................................... 2-34

Suspensions ........................................................................................................................ 2-35

Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-35

Front Fork Oil Leak Inspection .......................................................................................... 2-35

Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-36

Steering System ..................................................................................................................2-36

Steering Play Inspection ................................................................................................... 2-36

Steering Play Adjustment.................................................................................................. 2-36

Steering Stem Bearing Lubrication ................................................................................... 2-38

Electrical System ................................................................................................................. 2-39

Lights and Switches Operation Inspection ........................................................................ 2-39

2

2-2 PERIODIC MAINTENANCE

Headlight Aiming Inspection ............................................................................................. 2-41

Sidestand Switch Operation Inspection ............................................................................ 2-42

Engine Stop Switch Operation Inspection......................................................................... 2-43

Others.................................................................................................................................. 2-44

Chassis Parts Lubrication ................................................................................................. 2-44

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-45

Replacement Parts .............................................................................................................. 2-46

Air Cleaner Element Replacement.................................................................................... 2-46

Fuel Hose Replacement ................................................................................................... 2-48

Coolant Change ................................................................................................................ 2-49

Radiator Hose and O-ring Replacement ........................................................................... 2-51

Engine Oil Change............................................................................................................ 2-51

Oil Filter Replacement ...................................................................................................... 2-52

Brake Hose and Pipe Replacement .................................................................................. 2-53

Brake Fluid Change .......................................................................................................... 2-54

Master Cylinder Rubber Parts Replacement .................................................................... 2-55

Caliper Rubber Parts Replacement .................................................................................. 2-56

Spark Plug Replacement .................................................................................................. 2-59

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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

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

Periodic Inspection

FREQUENCY

ITEM Every

Fuel System

Throttle control system (play,
smooth return, no drag) - inspect

Engine vacuum synchronization

- inspect

Whichever
comes first

year

1

(0.6)6(3.75)12(7.5)18(11.25)24(15)30(18.75)36(22.5)

• • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • •

See

Page

2-15

2-15

Idle speed - inspect

Fuel leak (fuel hose and pipe) ­inspect

Fuel hose and pipe damage ­inspect

Fuel hose and pipe installation
condition - inspect

Evaporative emission control
system function (SEA-B1 and
TH Models) - inspect

Cooling System

Coolant level - inspect

Coolant leak (water hose and
pipe) - inspect

Water hose damage - inspect year

Water hose installation condition

- inspect

Engine Top End

Valve
clearance ­inspect

Air suction system damage ­inspect

Clutch

Clutch operation (play,
disengagement, engagement) ­inspect

Wheels and Tires

CA Model

Other than CA
Model

year

year

year

year

year

• • • •

• • • •

• • • •

• • • •

• • • • • • •

• • • •

• • • •

• • • •

• • • •

•

Every 42 000 km (26 250 mile)

• • •

• • • •

2-18

2-19

2-19

2-19

2-20

2-20

2-21

2-21

2-21

2-21

2-25

2-25

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear

- inspect

Wheel bearing damage - inspect year

• • •

• • •

• • •

• • •

2-26

2-27

2-27

2-28

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

ITEM Every

Final Drive

Drive chain lubrication condition

-inspect#

Drive chain slack - inspect # Every 1 000 km (600 mile)

Drive chain wear - inspect #

Chain guide wear - inspect

Brakes

Brake fluid leak (brake hose and
pipe) - inspect

Brake hose and pipe damage ­inspect

Brake hose and pipe installation
condition - inspect

Brake fluid level - inspect 6 months

Brake pad wear - inspect #

Brake operation (effectiveness,
play, no drag) - inspect

Brake light switch operation ­inspect

Suspension

Front forks/rear shock absorber
operation (damping and smooth
stroke) - inspect

Front forks/rear shock absorber
oil leak - inspect

Steering

Whichever

comes first

year

year

year

year

year

1

(0.6)6(3.75)12(7.5)18(11.25)24(15)30(18.75)36(22.5)

Every 600 km (400 mile) 2-28

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • •

• • • • • • •

• • • • • • •

* ODOMETER READING

• • •

• • •

• • •

• • •

× 1 000 km

(× 1 000 mile)

See

Page

2-29

2-31

2-31

2-32

2-32

2-32

2-33

2-34

2-34

2-34

2-35

2-35

Steering play - inspect year

Steering stem bearings ­lubricate

Electrical System

Lights and switches operation ­inspect

Headlight aiming - inspect year

Sidestand switch operation ­inspect

Engine stop switch operation ­inspect

Others

Chassis parts - lubricate year

Bolts and nuts tightness - inspect

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

frequent starting/stopping.

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

2 years

year

year

year

• • • •

•

• • •

• • •

• • •

• • •

• • •

• • • •

2-36

2-38

2-39

2-41

2-42

2-43

2-44

2-45

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY

ITEM Every

Air cleaner element # - replace every 18 000 km (11 250 mile)

Whichever

comes

first

1

(0.6)12(7.5)24(15)36(22.5)48(30)

*ODOMETER

READING

× 1 000 km

(× 1 000 mile)

See

Page

2-46

Engine oil # - change year

Oil filter - replace year

Fuel hose - replace 5 years 2-48

Coolant - change 3 years

Radiator hose and O-ring - replace 3 years

Brake hose - replace 4 years

Brake fluid - change 2 years

Rubber parts of master cylinder and caliper - replace

Spark plug - replace

#: 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.

4 years

• • • • •

• • • • •

•

•

• •

• • • •

2-51

2-52

2-49

2-51

2-53

•

2-54

2-55

•

2-59

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

EO: Apply engine oil.

L: Apply a non-permanent locking agent to the threads.

LG: Apply liquid gasket.

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.

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

Fastener

Fuel System (DFI)

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Air Cleaner Housing Cover Screws

Air Cleaner Element Screw 1.2 0.12 11 i n·lb

Air Cleaner Housing Clamp Bolt 2.0 0.20 18 in·lb

Intake Air Temperature Sensor Screw 1.2 0.12 11 in·l b

Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in·lb

Oxygen Sensor (Equipped Models) 44 4.5 32

Speed Sensor Bolt

Speed Sensor Bracket Bolts 9.8 1.0 87 in·lb

Switch Housing Screws 3.5 0.36 31 in·lb

Timing Rotor Bolt 40 4.1 30

Water Temperature Sensor 12 1.2 106 in·lb

Cooling System

Radiator Bolt 7.9 0.81 70 in·lb

Water Hose Clamp Screws 3.0 0.31 27 in·lb

Thermostat Housing Bolts 9.8 1.0 87 in·lb L

Water Pump Cover Bolts

Water Pump Drain Bolt 9.8 1.0 87 in·lb

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Water Temperature Sensor 12 1.2 106 in·lb

Engine Top End

Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb

Baffle Plate Bolts 5.9 0.60 52 in·lb

Camshaft Cap Bolts 12 1.2 106 in·lb S

Camshaft Chain Tensioner Cap Bolt 20 2.0 15

Camshaft Chain Tensioner Mounting Bolts

Camshaft Sprocket Bolts 15 1.5 11 L

Cylinder Head Bolts (M10) 56 5.7 41 MO, S

Cylinder Head Bolts (M6) 12 1.2 106 in·lb L, S

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb

N·m kgf·m ft·lb

1.2 0.12 11 in·lb

7.8 0.80 69 in·lb L

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb L

Torque

Remarks

Torque and L ocking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Rear Camshaft Chain Guide Bolt 20 2.0 15 L

Throttle Body Assy Holder Bolts 12 1.2 106 in·lb

Cylinder Bolt (M8) 27.5 2.8 20 MO, S

Cylinder Nut 49 5.0 36 MO, S

Cylinder Bolts (M6) 12 1.2 106 in·lb L, S

Exhaust Pipe Manifold Holder Nuts

Muffler Body Mounting Bolts 20 2.0 15

Clutch

Clutch Cable Clamp Bracket Bolt 9.8 1.0 87 in·lb

Clutch Cable Holder Bolts 9.8 1.0 87 in·lb L

Clutch Cover Bolts 9.8 1.0 87 in·lb

Clutch Hub Nut

Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S

Clutch Spring Bolts 9.8 1.0 87 in·lb

Timing Rotor Bolt Cap 4.9 0.50 43 in·lb

Oil Filler Plug – – – Hand-tighten

Oil Pump Chain Guide Bolts 12 1.2 106 in·lb L

Oil Pump Sprocket Bolt

Timing Inspection Cap 3.9 0.40 35 in·lb

Engine Lubrication System

Engine Oil Drain Plug 30 3.1 22

Filter Plate Bolts 9.8 1.0 87 in·lb L

Holder Mounting Bolt 25 2.5 18 L

Lower Fairing Bracket Bolts 12 1.2 106 in·lb L

Oil Filter 17.5 1.8 13 EO, R

Oil Pan Bolts 12 1.2 106 in·lb S

Oil Passage Plug

Oil Passage Plug (M6) 3.5 0.36 31 in·lb

Oil Pipe Plate Bolt 9.8 1.0 87 in·lb L

Oil Plate Bolts 9.8 1.0 87 in·lb L

Oil Pressure Relief Valve 15 1.5 11 L

Oil Pressure Switch 15 1.5 11 LG

Oil Pump Chain Guide Bolts

Oil Pump Cover Bolts 9.8 1.0 87 in·lb L

Oil Pump Sprocket Bolt 12 1.2 106 in·lb L, Lh

Engine Removal/Installation

Front Engine Mounting Bolt (Left) 44 4.5 32 S

Front Engine Mounting Bolt (Right) 49 5.0 36 S

Front Engine Bracket Bolts (Left)

Front Engine Bracket Bolts (Right) 30 3.1 22 S

Rear Engine Mounting Bolts 44 4.5 32 S

Rear Engine Mounting Nuts 44 4.5 32 R, S

Rear Engine Bracket Bolts 25 2.5 18 S

N·m kgf·m ft·lb

17 1.7 13

130 13.3 96 R

12 1.2 106 in·lb L, Lh

20 2.0 15 L

12 1.2 106 in·lb L

25 2.5 18

Torque

Remarks

S

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Engine Ground Lead Terminal Bolt 9.8 1.0 87 in·lb

Crankshaft/Transmission

Breather Plate Bolts 9.8 1.0 87 in·lb L

Race Holder Screw 4.9 0.50 43 in·lb L

Connecting Rod Big End Nuts see Text ← ← MO

Crankcase Bolt (M8, L = 110 mm)

Crankcase Bolt (M6, L = 32 mm) 19.6 2.0 14 S

Crankcase Bolts (M6, L = 38 mm) 19.6 2.0 14 S

Crankcase Bolts (M6, L = 45 mm) 19.6 2.0 14 S

Crankcase Bolt (M8, L = 50 mm) 27.5 2.8 20 S

Crankcase Bolts (M8, L = 60 mm) 25.5 2.6 19 MO, S

Crankcase Bolt (M8, L = 60 mm)

Crankcase Bolts (M8, L = 73 mm) 25.5 2.6 19 MO, S

Crankcase Bolts (M9, L = 113 mm) 44 4.5 32 MO, S

Crankcase Bolts (M9, L = 83 mm) 44 4.5 32 MO, S

Upper Crankcase Bolt (M8, L = 120 mm) 27.5 2.8 20 S

Upper Crankcase Bolts (M8, L = 110 mm) 27.5 2.8 20 S

Oil Pipe Bolts

Oil Plate Bolts 9.8 1.0 87 in·lb L

Shift Shaft Return Spring Pin 29 3.0 21 L

Timing Rotor Bolt 40 4.1 30

Drive Shaft Bearing Holder Screw 4.9 0.50 43 in·lb L

Gear Positioning Lever Bolt 12 1.2 106 in·lb L

Neutral Switch 15 1.5 11

Neutral Switch Holder Screw 4.9 0.50 43 in·lb L

Transmission Case Oil Nozzle 2.9 0.30 26 in·lb L

Shift Drum Bearing Holder Screws

Shift Drum Cam Bolt 12 1.2 106 in·lb L

Shift Pedal Bolt 12 1.2 106 in·lb

Shift Rod Plate Bolt 9.8 1.0 87 in·lb L

Shift Shaft Cover Bolts 9.8 1.0 87 in·lb L(3)

Shift Shaft Cover Screw 4.9 0.50 43 in·lb L, S

Transmission Case Bolts

Wheels/Tires

Front Axle 108 11.0 80

Front Axle Clamp Bolt

Rear Axle Nut 108 11.0 80

Final Drive

Engine Sprocket Nut 125 12.7 92 MO

Rear Axle Nut 108 11.0 80

Rear Sprocket Nuts 59 6.0 44 R

Speed Sensor Bolt 7.8 0.80 69 in·lb L

Speed Sensor Bracket Bolts 9.8 1.0 87 in·lb

N·m kgf·m ft·lb

27.5 2.8 20

27.5 2.8 20

9.8 1.0 87 in·lb L

4.9 0.50 43 in·lb L

20 2.0 15

34 3.5 25

Torque

Remarks

S

S