KAWASAKI ER-6 User Manual

ER-6n

ER-6n ABS

Motorcycle

Service Manual

This quick reference guide will assist

you in locating a desired topic or pro-

cedure.

•Bend the pages back to match the

black tab of the desired chapter num-

ber with the black tab on the edge at

each table of contents page.

•Refer to the sectional table of contents

for the exact pages to locate the spe-

cific topic required.

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

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

ampere(s)

KDS Kawasaki Diagnostic System

ABDC after bottom dead cente

r

km/h

kilometers per hour

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

direct current

Pa

pascal(s)

DFI Digital Fuel Injection

PS

horsepower

ECU Electronic Contr

ol Unit

psi

pound(s) per squa

re inch

°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)

COUNTRY AND AREA CODES

AT Austria GB United Kingdom

AU Australia ID Indonesia

AU LAMS Australia Leaner Approved

Motorcycle Scheme model

SEA-B1 Southeast Asia B1 (with Evaporative

Emission Control System)

B

R

B

razil

SEA-B2 Southeast Asia B2

CA Canada TH Thailand

CH Switzerland WVTA Whole Vehicle Type Approval

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

Converter (Full Power)

EUR Europe

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 emis-

sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of

the United States Environmental Protection Agency and California Air Resources Board. Addi-

tionally, 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 know-

ingly 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 follow-

ing 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 de-

vices 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 in-

formation to make it useful to the owner who de-

sires to perform his own basic maintenance and

repair work. A basic knowledge of mechanics,

the proper use of tools, and workshop proce-

dures must be understood in order to carry out

maintenance and repair satisfactorily. When-

ever the owner has insufficient experience or

doubts his ability to do the work, all adjust-

ments, maintenance, and repair should be car-

ried out only by qualified mechanics.

In order to perform the work efficiently and

to avoid costly mistakes, read the text, thor-

oughly familiarize yourself with the procedures

before starting work, and then do the work care-

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 ad-

versely 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 Ta-

ble of Contents.

For example, if you want ignition coil informa-

tion, use the Quick Reference Guide to locate

the Electrical System chapter. Then, use the

Table of Contents on the first page of the chap-

ter to find the Ignition Coil section.

Whenever you see symbols, heed their in-

structions! 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 spec-

ified tightening torque, oil, grease or a locking

agent during assembly.

GENERAL INFORMATION 1-1

1

General Information

Table of Contents

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

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

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

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

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera-

tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-

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

necessary. This section explains the items that require particular attention during the removal and

reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, discon-

nect the battery cables from the battery to prevent the en-

gine from accidentally turning over. Disconnect the ground

cable (–) first and then the positive (+). When completed

with the service, first connect the positive (+) cable to the

positive (+) terminal of the battery then the negative (–) ca-

ble to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury

from possible sharp edges on the parts.

Solvent

Use a high 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 ve-

hicle disassembly can cause excessive wear and decrease

performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the

parts according to the order the parts were disassembled

and clean the parts in order prior to assembly.

Storage of 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.

Inspection

Reuse of worn or damaged parts may lead to serious ac-

cident. Visually inspect removed parts for corrosion, discol-

oration, or other damage. Refer to the appropriate sections

of this manual for service limits on individual parts. Replace

the parts if any damage has been found or if the part is be-

yond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or

recommended by KAWASAKI. Gaskets, O-rings, oil seals,

grease seals, circlips, 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 disassem-

bly, however, if assembly order is provided in this Service

Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts,

or screws, start them all in their holes and tighten them to

a snug fit. Then tighten them according to the specified se-

quence to prevent case warpage or deformation which can

lead to malfunction. Conversely when loosening the bolts,

nuts, or screws, first loosen all of them by about a quar-

ter turn and then remove them. If the specified tightening

sequence is not indicated, tighten the fasteners alternating

diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may

lead to serious damage. Tighten fasteners to the specified

torque using a good quality torque wrench. 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 dam-

age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets

and O-rings after disassembly can reduce sealing per-

formance. 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 exces-

sively. Excessive application can clog oil passages and

cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be

pressed into place, apply small amount of oil to the con-

tact area. Be sure to maintain proper alignment and use

smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is

absolutely necessary. Replace with new ones whenever

removed. Press bearings with the manufacturer and size

marks facing out. Press the bearing into place by putting

pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between

the i nner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal

is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing

out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing

the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new

ones. Take care not to open the clip excessively when in-

stalling to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during

assembly to minimize wear during initial operation. Lubri-

cation points are called out throughout this manual, apply

the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play

amount of rotating direction will affect the adjustment. Ro-

tate the crankshaft to positive direction (clockwise viewed

from output side).

Electrical 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 thor-

oughly before using the meter. Incorrect values may lead

to improper adjustments.

GENERAL INFORMATION 1-7

Model Identification

ER650EC Left Side View

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:

204 kg (450 lb)

Front 102 kg (225 lb)

Rear 102 kg (225 lb)

ER650F: 206 kg (454 lb)

Front

103 kg (227 lb)

Rear

103 kg (227 lb)

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

649 cm³ (39.6 cu in.)

Compression Ratio

10.8 : 1

Maximum Horsepower

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)

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

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

(CA) – – –

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

Starting System

Electric starter

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (IC igniter in ECU)

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

To 37° BTDC @5 000 r/min (rpm)

Spark Plug NGK CR9EIA-9

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Valve Timing:

Intake:

Open 31° BTDC

Close 61° ABDC

Duration 272°

1-10 GENERAL INFORMATION

General Specifications

Items ER650EC/FC

Exhaust:

Open 50° BBDC

Close 30° ATDC

Duration

260°

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

2.095 (88/42)

Clutch Type Wet multi disc

Transmission:

Type

6-speed, constant mesh, return shift

Gear Ratios:

1st 2.438 (39/16)

2nd 1.714 (36/21)

3rd 1.333 (32/24)

4th 1.111 (30/27)

5th

0.966 (28/29)

6th 0.852 (23/27)

Final Drive System:

Type Chain drive

Reduction Ratio 3.067 (46/15)

Overall Drive Ratio 5.473 @Top gear

Frame

Type Tubular, diamond

Caster (Rake Angle) 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.)

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=

qt (US)

L × 0.8799 =

qt (IMP)

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

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg × 9.807 = N

kg × 2.205 = lb

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 Power:

kW × 1.360 = PS

kW × 1.341 = HP

PS

× 0.7355 = kW

PS × 0.9863 = HP

Units of Temperature:

PERIODIC MAINTENANCE 2-1

2

Periodic Maintenance

Table of Contents

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

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

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 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

Whichever

comes first

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

ITEM Every

1

(0.6)

6

(3.75)

12

(7.5)

18

(11.25)

24

(15)

30

(18.75)

36

(22.5)

See

Page

Fuel System

Throttle control system (play,

smooth return, no drag) - inspect

year

• • • •

2-15

Engine vacuum synchronization

- inspect

• • •

2-15

Idle speed - inspect

• • • •

2-18

Fuel leak (fuel hose and pipe) -

inspect

year

• • • •

2-19

Fuel hose and pipe damage -

inspect

year

• • • •

2-19

Fuel hose and pipe installation

condition - inspect

year

• • • •

2-19

Evaporative emission control

system function (SEA-B1 and

TH Models) - inspect

• • • • • • •

2-20

Cooling System

Coolant level - inspect

• • • •

2-20

Coolant leak (water hose and

pipe) - inspect

year

• • • •

2-21

Water hose damage - inspect year

• • • •

2-21

Water hose installation condition

- inspect

year

• • • •

2-21

Engine Top End

CA Model

•

Valve

clearance -

inspect

Other than CA

Model

Every 42 000 km (26 250 mile)

2-21

Air suction system damage -

inspect

• • •

2-25

Clutch

Clutch operation (play,

disengagement, engagement) -

inspect

• • • •

2-25

Wheels and Tires

Tire air pressure - inspect year

• • •

2-26

Wheel/tire damage - inspect

• • •

2-27

Tire tread wear, abnormal wear

- inspect

• • •

2-27

Wheel bearing damage - inspect year

• • •

2-28

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

Whichever

comes first

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

ITEM Every

1

(0.6)

6

(3.75)

12

(7.5)

18

(11.25)

24

(15)

30

(18.75)

36

(22.5)

See

Page

Final Drive

Drive chain lubrication condition

-inspect#

Every 600 km (400 mile) 2-28

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

2-29

Drive chain wear - inspect #

• • •

2-31

Chain guide wear - inspect

• • •

2-31

Brakes

Brake fluid leak (brake hose and

pipe) - inspect

year

• • • • • • •

2-32

Brake hose and pipe damage -

inspect

year

• • • • • • •

2-32

Brake hose and pipe installation

condition - inspect

year

• • • • • • •

2-32

Brake fluid level - inspect 6 months

• • • • • • •

2-33

Brake pad wear - inspect #

• • • • • •

2-34

Brake operation (effectiveness,

play, no drag) - inspect

year

• • • • • • •

2-34

Brake light switch operation -

inspect

• • • • • • •

2-34

Suspension

Front forks/rear shock absorber

operation (damping and smooth

stroke) - inspect

• • •

2-35

Front forks/rear shock absorber

oil leak - inspect

year

• • •

2-35

Steering

Steering play - inspect year

• • • •

2-36

Steering stem bearings -

lubricate

2 years

•

2-38

Electrical System

Lights and switches operation -

inspect

year

• • •

2-39

Headlight aiming - inspect year

• • •

2-41

Sidestand switch operation -

inspect

year

• • •

2-42

Engine stop switch operation -

inspect

year

• • •

2-43

Others

Chassis parts - lubricate year

• • •

2-44

Bolts and nuts tightness - inspect

• • • •

2-45

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

frequent starting/stopping.

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

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY

Whichever

comes

first

*ODOMETER

READING

× 1 000 km

(× 1 000 mile)

ITEM Every

1

(0.6)

12

(7.5)

24

(15)

36

(22.5)

48

(30)

See

Page

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

2-46

Engine oil # - change year

• • • • •

2-51

Oil filter - replace year

• • • • •

2-52

Fuel hose - replace 5 years 2-48

Coolant - change 3 years

•

2-49

Radiator hose and O-ring - replace 3 years

•

2-51

Brake hose - replace 4 years

•

2-53

Brake fluid - change 2 years

• •

2-54

Rubber parts of master cylinder and caliper - replace

4 years

•

2-55

Spark plug - replace

• • • •

2-59

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

frequent starting/stopping.

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

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a

non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

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).

Torque

Fastener

N·m kgf·m ft·lb

Remarks

Fuel System (DFI)

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Air Cleaner Housing Cover Screws

1.2 0.12 11 in·lb

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

7.8 0.80 69 in·lb L

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

9.8 1.0 87 in·lb

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

9.8 1.0 87 in·lb L

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

PERIODIC MAINTENANCE 2-7

Torque and L ocking Agent

Torque

Fastener

N·m kgf·m ft·lb

Remarks

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

17 1.7 13

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

130 13.3 96 R

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

12 1.2 106 in·lb L, Lh

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

20 2.0 15 L

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

12 1.2 106 in·lb L

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)

25 2.5 18

S

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

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m kgf·m ft·lb

Remarks

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)

27.5 2.8 20

S

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)

27.5 2.8 20

S

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

9.8 1.0 87 in·lb L

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

4.9 0.50 43 in·lb L

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

20 2.0 15

Wheels/Tires

Front Axle 108 11.0 80

Front Axle Clamp Bolt

34 3.5 25

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