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

Torque and L ocking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb

Brakes

Caliper Bleed Valves 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 25 2.5 18

Brake Lever Pivot Bolt 1.0 0.10 9in·lb Si

Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb R

Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Light Switch Screw 1.2 0.12 11 in·l b

Front Brake Reservoir Cap Screws

Front Caliper Mounting Bolts 34 3.5 25

Front Master Cylinder Clamp Bolts 11 1.1 97 in·lb S

Brake Pedal Bolt 8.8 0.90 78 in·lb

Rear Caliper Mounting Bolts 25 2.5 18

Rear Master Cylinder Mounting Bolts 25 2.5 18

Rear Master Cylinder Push Rod Locknut 17 1.7 13

Brake Pipe Joint Nuts (ER650F Model) 18 1.8 13

Wheel Rotation Sensor Bolts (ER650F Model) 20 2.0 15

Suspension

Front Axle Clamp Bolt 34 3.5 25

Front Fork Bottom Allen Bolts 30 3.1 22 L

Front Fork Clamp Bolts (Lower)

Front Fork Clamp Bolts (Upper) 20 2.0 15

Front Fork Top Plugs 22.5 2.3 17

Rear Shock Absorber Mounting Bolts

Swingarm Bracket Bolts 44 4.5 32 S

Swingarm Bracket Bolt (Lower Left) 59 6.0 44 S

Swingarm Pivot Shaft Nut 108 11.0 80 S

Steering

Front Fork Clamp Bolts (Lower) 20.5 2.1 15 AL

Front Fork Clamp Bolts (Upper)

Handlebar Hol

Handlebar Holder Mounting Nuts 34 3.5 25 R

Switch Housing Screws

Steering Stem Head Bolt 108 11.0 80

Steering Stem Nut 20 2.0 15

Frame

Footpeg Stay Bolts 25 2.5 18 S

Front Turn Signal Light Mounting Bolts 4.2 0.43 37 in·lb

Grab Rail Mounting Bolts 25 2.5 18

Lower Fairing Bracket Bolts 12 1.2 106 in·lb L

Lower Fairing Mounting Bolts 8.8 0.90 78 in·lb L

Seat Lock Mounting Screws

Sidestand Bolt 44 4.5 32

der Bolts

N·m kgf·m ft·lb

1.5 0.15 13 in·lb

20.5 2.1 15 AL

59 6.0 44

20 2.0 15

25 2.5 18 S

3.5 0.36 31 in·lb

0.4 0.04 4in·lb

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Sidestand Switch Bolt 8.8 0.90 78 in·lb L

Electrical System

License Plate Light Mounting Screws

Alternator Cover Bolts 9.8 1.0 87 in·lb

Alternator Lead Holding Plate Bolt 9.8 1.0 87 in·lb L

Alternator Rotor Bolt 155 15.8 114

Engine Ground Lead Terminal Bolt 9.8 1.0 87 in·lb

Front Brake Light Switch Screw 1.2 0.12 11 in·l b

Front Turn Signal Light Mounting Bolts 4.2 0.43 37 in·lb

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Regulator/Rectifier Bolts 9.8 1.0 87 in·lb

Switch Housing Screws

Sidestand Switch Bolt 8.8 0.90 78 in·lb L

Starter Motor Cable Terminal Nut 6.0 0.61 53 in·lb

Starter Motor Clutch Bolts 34 3.5 25 L

Starter Motor Mounting Bolts 9.8 1.0 87 in·lb L

Starter Motor Terminal Locknut 11 1.1 97 in·lb

Starter Motor Through Bolts

Starter Replay Terminal Bolts 3.6 0.36 31 in·lb

Stator Coil Bolts 12 1.2 106 in·lb L

Crankshaft Sensor Bolts 6.0 0.61 53 in·lb

Neutral Switch 15 1.5 11

Oil Pressure Switch 15 1.5 11 LG

Oxygen Sensor (Equipped Models)

Spark Plugs 15 1.5 11

Speed Sensor Bolt 7.8 0.80 69 in·lb L

Timing Rotor Bolt 40 4.1 30

Water Temperature Sensor 12 1.2 106 in·lb

N·m kgf·m ft·lb

1.2 0.12 11 in·lb

3.5 0.36 31 in·lb

5.0 0.51 44 in·lb

44 4.5 32

Torque

Remarks

MO

PERIODIC MAINTENANCE 2-11

Torque and L ocking Agent

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads Diameter

(mm)

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 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

N·m kgf·m ft·lb

Torque

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System (DFI)

Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Idle Speed 1 300 ±50 r/min (rpm) –––

Bypass Screws (Turn out) 0 ∼ 2 1/2 (for reference) –––

Engine Vacuum 35.3 ±1.3 kPa (265 ±10 mmHg) –––

Air Cleaner Element Polyurethane Foam –––

Cooling System

Coolant:

Type (recommended) Permanent type of antifreeze –––

Color Green –––

Mixed Ratio Soft water 50%, Coolant 50% –––

Freezing Point –35°C (–31°F) –––

Total Amount

Engine Top End

Valve Clearance:

Exhaust

Intake 0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.) –––

Clutch

Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Engine Lubrication System

Engine Oil:

Type

Viscosity SAE 10W-40 –––

Capacity 1.6 L (1.7 US qt) (when filter is not

Level Between upper and lower level lines

Wheels/Tires

Tread Depth:

Front

Rear

Air Pressure (when Cold):

Front Up to 200 kg (441 lb) load:

Rear Up to 200 kg (441 lb) load:

1.2 L (1.3 US qt)

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

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

removed)

1.8 L (1.9 US qt) (when filter is removed) –––

2.3 L (2.4 US qt) (when engine is
completely dry)

(after idling or running)

4.5 mm (0.18 in.) 1 mm (0.04 in.),

6.4 mm (0.25 in.) Up to 130 km/h (80 mph):

Over 130 k m/h (80 mph):

225 kPa (2.25 kgf/cm², 32 psi)

250 kPa (2.50 kgf/cm², 36 psi)

–––

–––

–––

–––

–––

–––

(AT, CH, DE)

1.6 mm (0.06 in.)

2 m m (0.08 in.),

3 mm (0.12 in.)

–––

–––

PERIODIC MAINTENANCE 2-13

Specifications

Item Standard Service Limit

Final Drive

Drive Chain Slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.)
Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 i n.)

Standard Chain:

Make DAIDO –––

Type DID 520VP2-T –––

Link 11 4 link s –––

Brakes

Brake Fluid:

Grade DOT4 –––

Brake Pad Lining
Thickness:

Front

Rear

Brake Light Timing:

Front

Rear

Electrical System

Spark Plug:

Type NGK CR9EIA-9 –––

4.5 mm (0.18 in.) 1 mm (0.04 in.)

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

Pulled ON

ON after about 10 mm (0.39 in.) of
pedal travel

–––

–––

–––

2-14 PERIODIC MAINTENANCE

Special Tools

Inside Circlip Pliers:
57001-143

Steering Stem Nut Wrench:
57001-1100

Jack:
57001-1238

Vacuum Gauge:
57001-1369

Throttle Sensor Setting Adapter:
57001-1538

Extension Tube:
57001-1578

Oil Filter Wrench:
57001-1249

Pilot Screw Adjuster, E:
57001-1603

Periodic Maintenance Procedures

Fuel System (DFI)

Throttle Control System Inspection

Check that the throttle grip [A] moves smoothly from full

•

open to close, and the throttle closes quickly and com­pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throt­tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
Check the throttle grip free play [B].

•

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

If the free play is incorrect, adjust the throttle cable as
follows.
Loosen the locknut [A] at the upper end of the accelerator

•

cable.
Turn the adjuster [B] in completely so as to give the throttle

•

grip plenty of play.

PERIODIC MAINTENANCE 2-15

Loosen the locknut [A] at the middle of the decelerator

•

cable.
Turn the adjuster [B] until there is no play when the throttle

•

grip is completely closed.
Tighten the locknut.

•

Turn the accelerator cable adjuster until the proper

•

amount of throttle grip free play is obtained.
Tighten the locknut.

•

Engine Vacuum Synchronization Inspection

NOTE

These procedures are explained on the assumption that

○

the intake and exhaust systems of the engine are
good condition.

Situate the motorcycle so that it is vertical.

•

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Fuel Hose (see Fuel Hose Replacement)

Remove the rubber caps [A] from the fittings on the throt-

•

tle body

in

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

For SEA-B1 and TH models, remove the tubes [A] from

•

the fittings on the throttle body.

Connect a vacuum gauge (special tool) and hoses [A] to

•

the fittings on the throttle body.

Special Tool - Vacuum Gauge: 57001-1369

Connect a highly accurate tachometer to one of the stick

•

coil primary leads.

Install:

•

Air Cleaner Housing (see Air Cleaner Housing Installa­tion in the Fuel System (DFI) chapter)
ECU (see ECU Installation in the Fuel System (DFI)
chapter)
Intake Air Temperature Sensor Connector (Connect)

Connect the following temporarily:

•

Fuel Pump Lead Connector [A]
Extension Tube [B]

Special Tool - Extension Tube: 57001-1578

Start the engine and warm it up thoroughly.

•

Check the idle speed using a highly accurate tachometer.

•

Idle Speed

Standard: 1 300 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it (see
Idle Speed Adjustment).

NOTICE

Do not measure the idle speed by the tachometer of
the meter unit.

While idling the engine, inspect the engine vacuum, using

•

the vacuum gauge.

Engine Vacuum

Standard: 35.3 ±1.3 kPa (265 ±10 mmHg) at Idle Speed

Periodic Maintenance Procedures

If any one vacuum is not within the specification, turn in
the bypass screws until it seats fully but not tightly.

Special Tool - Pilot Screw Adjuster, E [A]: 57001-1603

NOTICE

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

Turn out the bypass screw of the higher vacuum between

•

#1 [A] and #2 [B] to the lower vacuum.
Open and close the throttle valves after each measure-

•

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

•

If both vacuums are within the specification, finish the en­gine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
remove the bypass screws #1, #2 and clean them.

PERIODIC MAINTENANCE 2-17

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

•

O-ring [D].
Check the bypass screw hole in the throttle body for car-

•

bon deposits.
If any carbons accumulate, wipe the carbons off from the
hole, using a cotton pad penetrated with a high flash-point
solvent.
Replace the bypass screw, spring, washer and O-ring as

•

aset.
Turn in the bypass screw until it seats fully but not tightly.

•

NOTICE

Do not over-tighten the bypass screw. The tapered
portion [E] of the bypass screw could be damaged.

Repeat the same procedure for other bypass screw.

•

Inspect the synchronization again.

•

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

Special Tool - Throttle Sensor Setting Adapter: 57001

-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:

Meter (+) → R (Sensor Y/BL) lead

Meter (–) → W (Sensor BR/BK) lead

Standard: DC 1.005 ∼ 1.035 V at idle throttle opening

If the output voltage is out of the range, check the main
throttle sensor input voltage (see Main Throttle Sensor In­put Voltage Inspection in the Fuel System (DFI) chapter).

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Disconnect:

•

Fuel Pump Lead Connector
Extension Tube

Remove the air cleaner housing (see Air Cleaner Housing

•

Removal in the Fuel System (DFI) chapter), take off the
vacuum gauge hoses and install the rubber caps onto the
fittings on the throttle body assy.
For SEA-B1 and TH Models, install the tubes onto the

•

fittings on the throttle body assy.
Install:

•

Air Cleaner Housing (see Air Cleaner Housing Installa­tion in the Fuel System (DFI) chapter)
Fuel Tank (see Fuel Tank Installation in the Fuel System
(DFI) chapter)

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn [A] 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 Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.

Check the idle speed.

•

Idle Speed

Standard: 1 300 ±50 r/min (rpm)

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

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.

Periodic Maintenance Procedures

Fuel Hose Inspection (fuel leak, damage, installation condition)

If the motorcycle is not properly handled, the high pres-

○

sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re­moval i n the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.

Check that the hoses are routed correctly according to

•

Cable, Wire, and Hose Routing section in the Appendix
chapter.
Replace the hose if it has been sharply bent or kinked.

Hose Joints [A]
Fuel Hose [B]

PERIODIC MAINTENANCE 2-19

Check that the hose joints are securely connected.

•

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

○

than 2 times, and make sure it is locked.
If it does not locked, reinstall the hose joint.

WARNING

Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in­stalled correctly on the delivery pipe by sliding the
joint.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

Inspect the canister as follows.

•

Remove:

○

Left Frame Cover (see Frame Cover Removal in the
Frame chapter)
Canister Bracket Bolts [A]

Unhook the band [B] to remove the canister [C], and dis-

○

connect the tubes [D] from the canister.
Visually inspect the canister for cracks or other damage.

○

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

NOTE

The canister is designed to work well through the motor-

○

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

Inspect the purge valve (see Purge Valve Inspection in

•

the Fuel System (DFI) chapter).
Check that the hoses are s ecurely connected and clips

○

are in position.
Replace any kinked, deteriorated or damaged hoses.

○

Run the hoses according to Cable, Wire, and Hose Rout-

○

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

○

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

Cooling System

Coolant Level Inspection

NOTE

Check the level when the engine is cold (room or ambi-

○

ent temperature).

Check the coolant level in the reserve tank [A] with the

•

motorcycle held perpendicular (do not use the sidestand).
If the coolant level is lower than the “L” level line [B], re­move the right center fairing (see Center Fairing Removal
in the Frame chapter), unscrew the reserve tank cap, and
add coolant to the “F” level line [C].

“L”: Low
“F”: Full

NOTICE

For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en­gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

Periodic Maintenance Procedures

Water Hose Damage and Installation Condition Inspection

The high pressure inside the water 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 - Water Hose Clamp Screws: 3.0 N· m (0.31 kgf·m,

27 in·lb)

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (room temperature).

PERIODIC MAINTENANCE 2-21

Remove:

•

Cylinder Head Cover (see Cylinder Head Cover Re­moval in the Engine Top End chapter)
Timing Inspection Cap [A]
Timing Rotor Bolt Cap [B]

Special Tool - Filler Cap Driver [C]: 57001-1454

Check the valve clearance when the pistons are at TDC.

•

The pistons are numbered beginning with the engine left

○

side.
Using a wrench on the timing rotor bolt, turn the crank-

•

shaft clockwise until the 1/T mark line [A] on the timing
rotor is aligned with the notch [B] in the edge of the timing
inspection hole [C] in the clutch cover for #1 piston and
2/T mark line [D] for #2 piston.

Measure the valve clearance of the valves for which the

○

cams [A] are turned away from each other.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Using the thickness gauge [A], measure the valve clear-

•

ance between cam and valve lifter.

Valve Cleara nce

Standard:

Exhaust

Intake

Each piston has two intake and two exhaust valves.

○

Measure these two intake or exhaust valves at the same
crankshaft position.

Check the valve clearance using this method only.

○

Checking the clearance at any other cam position may
result in improper valve clearance.

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke:

Intake valve clearances of #1 piston, and

Exhaust valve clearances of #1 piston

#2 Piston TDC at End of Compression Stroke:

Intake valve clearances of #2 piston, and

Exhaust valve clearances of #2 piston

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)

NOTE

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

Valve Clearance Adjustment

To change the valve clearance, remove the camshaft

•

chain tensioner, camshafts and valve lifters (see the
Engine Top End chapter). Replace the shim with one of
a different thickness.

NOTE

Mark and record the locations of the valve lifters and

○

shims so that they can be reinstalled in their original
positions.

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 in the Engine Top End
chapter).
Remeasure any valve clearance that was adjusted.

•

Readjust if necessary.

NOTICE

Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex­tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE

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

2. Check present shim size.

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

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

Example: Present shim is 2.95 mm.

Measured clearance is 0.42 mm.
Replace 2.95 mm shim with 3.20 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

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

2. Check present shim size.

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

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

Example: Present shim is 2.95 mm.

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

5. Remeasure the valve clearance and readjust if necessary.

Periodic Maintenance Procedures

Air Suction System Damage Inspection

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)

Take the air switching valve hose end [A] outside of the

•

frame [B].

Reinstall the air cleaner housing [A] (see Air Cleaner

•

Housing Installation in the Fuel System (DFI) chapter).
Connect the fuel pump lead connector [B].

•

Using the extension tube [C], connect the fuel tank [D] to

•

the throttle body.

Special Tool - Extension Tube: 57001-1578

Start the engine and run it at idle speed.

•

Plug the air switching valve hose end [E] with your finger

•

and feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical Sys­tem chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).
Remove:

•

Extension Tube
Fuel Pump Lead Connector (Disconnect)

Remove the air cleaner housing (see Air Cleaner Housing

•

Removal in the Fuel System (DFI) chapter).

PERIODIC MAINTENANCE 2-25

Apply a soap and water solution or rubber lubricant to the

•

end of the air switching valve hose [A] and install the hose
on the fitting.
Install:

•

Air Cleaner Housing (see Air Cleaner Housing I nstalla­tion in the Fuel System (DFI) chapter)
Fuel Tank (see Fuel Tank Installation in the Fuel System
(DFI) chapter).

Clutch

Clutch Operation Inspection

Pull the clutch lever just enough to take up the free play

•

[A].
Measure the gap between the lever and the lever holder.

•

Clutch Lever Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

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.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

WARNING

The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.

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

•

of threads are visible.

Open the clamp [A].

•

Slide the dust cover [B] out of place.

•

Loosen the locknut [C].

•

Turn the adjusting nut [D] until the free play is correct.

•

WARNING

Too much cable play can prevent clutch disengage­ment and cause an accident resulting in serious in­jury or death. When adjusting the clutch or replac­ing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.

Tighten the locknut, and slip the dust cover back onto

•

place.
After the adjustment, start the engine and check that the

•

clutch does not slip and that it releases properly.

Wheels/Tires

Air Pressure Inspection

Remove the air valve cap.

•

Measure the tire air pressure with an air pressure gauge

•

[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).

Air P ressure (when Cold)

Front:

Rear:

Adjust the tire air pressure according to the specifications
if necessary.
Install the air valve cap.

•

Upto200kg(441lb)
225kPa(2.25kgf/cm²,32psi)

Upto200kg(441lb)
250kPa(2.50kgf/cm²,36psi)

Periodic Maintenance Procedures

Wheel/Tire Damage Inspection

Remove any imbedded stones [A] or other foreign parti-

•

cles [B] from tread.
Visually inspect the tire for cracks and cuts, and replace

•

the tire if necessary. Swelling or high spots indicate inter­nal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents dam-

•

age.
If any damage is found, replace the wheel.

Tire Tread Wear, Abnormal Wear Inspection

As the tire tread wears down, the tire becomes more sus­ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.

Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take

measurement at several places.

PERIODIC MAINTENANCE 2-27

Tread Depth

Standard:

Front

Rear

Service Limit:

Front

Rear

If any measurement is less than the service limit, replace

the tire (see Tire Removal/Installation in the Wheels/Tires

chapter).

4.5 mm (0.18 in.)

6.4 mm (0.25 in.)

1 mm (0.04 in.)

(AT, CH, DE) 1.6 mm (0.06 in.)

2 mm (0.08 in.)

(Up to 130 km/h (80 mph))

3 mm (0.12 in.)

(Over 130 km/h (80 mph))

WARNING

Some replacement tires may adversely affect han-

dling and cause an accident resulting in serious in-

jury or death. To ensure proper handling and sta-

bility, use only the recommended standard tires for

replacement, inflated to the standard pressure.

NOTE

Most countries may have their own regulations a mini-

○

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

○

with a new one.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Wheel Bearing Damag e Inspection

Raise the front wheel off the ground with the jack.

•

Special Tool - Jack: 57001-1238

Turn the handlebar all the way to the right or left.

•

Inspect the roughness of the front wheel bearing by push-

•

ing and pulling [A] the wheel.
Spin [B] the front wheel lightly, and check for smoothly

•

turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).

Raise the rear wheel off the ground with the stand (see

•

Rear Wheel Removal in the Wheels/Tires chapter).
Inspect the roughness of the rear wheel bearing by push-

•

ing and pulling [A] the wheel.
Spin [B] the rear wheel lightly, and check for smoothly

•

turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Re­moval, Hub Bearing Inspection in the Wheels/Tires chap­ter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).

Final Drive

Drive Chain Lubrication Condition Inspection

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 c hain appears especially dirty, clean it before lubri-

•

cation.

NOTICE

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

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

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 the O-rings will be coated with oil.

Wipe off any excess oil.

•

Oil Applied Areas [A]
O-rings [B]

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.

PERIODIC MAINTENANCE 2-29

Drive Chain Slack

Standard: 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

If the chain slack is not within the standard, adjust it.

Drive Chain Slack Adjustment

Raise the rear wheel off the ground with the stand.

•

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 right and left chain

adjusters [D] evenly.

If the chain is too tight, turn in the right and left chain

adjusters evenly, and kick the wheel forward.

Turn the 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 mark 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.

Be sure the wheel is properly aligned.

Tighten the both chain adjuster locknuts securely.

•

Tighten:

•

Torque - Rear Axle Nut: 108 N·m (11.0 kgf ·m, 80 ft·lb)

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

•

est position, and readjust if necessary.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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 degrees.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

Bend the cotter pin [A] over the nut.

•

WARNING

A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.

Wheel Alignment Inspection

Check that the notch [A] on the left wheel alignment indi-

•

cator [B] aligns with the same swingarm mark or position
[C] that the right wheel alignment indicator notch aligns
with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain 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.
Be sure the wheel is properly aligned.

Periodic Maintenance Procedures

Drive Chain Wear Inspection

Remove the chain cover (see Swingarm Removal in the

•

Suspension chapter).

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

•

aged rollers, and loose pins and links.

If there is any irregularity, replace the drive chain.

Lubricate the drive chain if it appears dry.

Stretch the chain taut by hanging a 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.)

PERIODIC MAINTENANCE 2-31

WARNING

A chain that breaks or jumps off the sprockets

could snag on the engine sprocket or lock the

rear wheel, severely damaging the motorcycle and

causing it to go out of control. Inspect the chain for

damage and proper adjustment before each ride.

If chain wear exceeds the service limit, replace it

with the standard chain. It is an endless type and

should not be cut for installation.

Standard Chain

Make:

Type: DID 520VP2-T

Link: 114 links

Chain Guide Inspection

Visually inspect the chain guide on the swingarm.

•

Replace the chain guide if it shows any signs of abnormal

wear or damage.

Remove:

○

Swingarm (see Swingarm Removal in the Suspension
chapter)
Chain Guide Bolt [A]
Chain Guide [B]

Installation is the reverse of removal.

○

DAIDO

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake System

Brake Fluid Leak (Brake Hose and Pipe) Inspection

For models equipped with an ABS, remove the right

•

swingarm bracket (see ABS Hydraulic Unit Removal in
the Brakes chapter).
Apply the brake lever or pedal, and inspect the brake fluid

•

leak from the brake hoses [A], pipes (ABS equipped mod­els) [B] and fittings [C].
If the brake fluid leaked from any position, inspect or re­place the problem part.

Brake Hose and P ipe Damage and Installation Condition Inspection

For models equipped with an ABS, remove the right

•

swingarm bracket (see ABS Hydraulic Unit Removal in
the Brakes chapter).
Inspect the brake hoses, fittings and pipes (ABS equipped

•

models) for deterioration, cracks and signs of leakage.
The high pressure inside the brake line can cause fluid

○

to leak [A] or the hose, pipes (ABS equipped models) to
burst if the line is not properly maintained. Bend and twist
the rubber hose while examining it.
Replace the hose and pipe (ABS equipped models) if any
crack [B], bulge [C] or leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.

Torque - Brake Hose Banjo B olts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

(ABS Equipped Models)

Inspect the brake hose routing.

•

If any brake hose and pipe (ABS equipped models) rout­ing is incorrect, correct the routing according to Cable,
Wire, and Hose Routing section in the Appendix c hapter.

Periodic Maintenance Procedures

Brake Fluid 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, remove

the reservoir cap and fill the reservoir to the upper level

line [A].

Tighten:

•

Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

PERIODIC MAINTENANCE 2-33

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 front seat (see Front Seat Removal in the Frame chap-

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

WARNING

Mixing brands and types of brake fluid can reduce

the brake system’s effectiveness and cause an ac-

cident resulting in injury or death. Do not mix two

brands of brake fluid. Change the brake fluid in the

brake line completely if the brake fluid must be re-

filled but the type and brand of the brake fluid that

is already in the reservoir are unidentified.

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 slight resistance is felt indicating

that the cap is seated on the reservoir body, then tighten

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

fluid reservoir body [A].

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Pad Wear Inspection

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

•

Pad Lining Thickness

Standard:

Front [C] 4.5 mm (0.18 in.)

Rear [D]

Service Limit: 1 mm (0.04 in.)

If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.

5.0 mm (0.20 in.)

Brake Operation Inspection

Inspect the operation of the front and rear brake by run-

•

ning the vehicle on the dry road.
If the brake operation is insufficient, inspect the brake sys­tem.

WARNING

When test riding the vehicle, be aware of surround­ing traffic for your safety.

Brake Light Switch Operation Inspection

TurntheignitionswitchtoON.

•

The brake light [A] should go on when the brake lever is

•

applied or after the brake pedal is depressed about 10
mm (0.39 in.).

If it does not, adjust the brake light switch.
Remove the right frame cover (see Frame Cover Removal

•

in the Frame chapter).
While holding the switch body [A], turn the adjusting nut

•

[B] to adjust the switch.

Light sooner as the body rises [C]
Light later as the body lowers [D]

NOTICE

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

Periodic Maintenance Procedures

If it does not go on, inspect or replace the following items.

Battery (see Charging Condition Inspection in the Elec­trical System chapter)
Brake Light (see Tail/Brake Light (LED) Unit Removal in
the Electrical System chapter)
Main Fuse 30 A and Brake/Horn Fuse 10 A (see Fuse
Inspection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Suspensions

Front Forks/Rear Shock Absorber Operation Inspection

Pump the forks down and up [A] 4 or 5 times to inspect

•

the smooth stroke.

If the forks do not smoothly stroke or noise is found, i n-

spect the fork oil level or fork clamps (see Front Fork Oil

Change in the Suspension chapter).

PERIODIC MAINTENANCE 2-35

Pump the seat down and up [A] 4 or 5 times to inspect the

•

smooth stroke.

If the shock absorber does not smoothly stroke or noise

is found, inspect the oil leak (see Rear Shock Absorber

Oil Leak Inspection).

Front Fork Oil Leak Inspection

Visually inspect the front forks [A] for oil leakage.

•

Replace or repair any defective parts if necessary.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rear Shock Absorber Oil Leak Inspection

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

•

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

Steering System

Steering Play Inspection

Raise the front wheel off the ground using the jack.

•

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 [A] 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 leads and cables are properly routed.

○

The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

Steering Play Adjustment

Remove:

•

Handlebar (see Handlebar Removal in the Steering
chapter)
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Bolt [A]
Guide [B]

Remove the bolts [A].

•

Periodic Maintenance Procedures

Loosen the upper front fork clamp bolts [A].

•

Remove:

•

Steering Stem Head Bolt Plug [B]
Steering Stem Head Bolt [C] and Washer
Steering Stem Head [D]

Bend the claws [A] of the claw washer straighten.

•

Remove the steering stem locknut [B] and claw washer.

•

Special Tool - Steering Stem Nut Wrench: 57001-1100

PERIODIC MAINTENANCE 2-37

Adjust the steering.

•

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

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

of a turn.

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

of a turn.

NOTE

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

○

Install the new claw washer [A] so that its bent claws [B]

•

face upward, and engage the bent claws with the grooves

of stem locknut [C].

Hand tighten the stem locknut until it touches the claw

•

washer.

Hand tighten the stem locknut clockwise until the claws

•

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

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

Install:

•

Steering Stem Head
Washer
Steering Stem Head Bolt

Tighten:

•

Torque - Steering S tem Head Bolt: 108 N·m (11.0 kgf·m, 80

ft·lb)

Front Fork Cl

kgf·m, 15 ft·lb)

Check the steering again.

•

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

justment.

Install the other removal parts (see appropriate chapters).

•

amp Bolts (Upper): 20 N·m (2.0

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering Stem Bearing Lubrication

Remove the steering stem (see Stem, Stem Bearing Re-

•

moval in the Steering chapter).
Using a high flash-point solvent, wash the upper and

•

lower ball bearings [A] in the cages, and wipe the upper
and lower outer races, which are press-fitted into the
frame head pipe, clean off grease and dirt.
Visually inspect the outer races and the ball bearings.

•

Replace them if they show wear or damage.
Pack the upper and lower ball bearings in the cages with

•

grease, and apply a light coat of grease to the upper and
lower outer races.
Install the steering stem (see Stem, Stem Bearing Instal-

•

lation in the Steering chapter).
Adjust the steering (see Steering Play Adjustment).

•

Periodic Maintenance Procedures

Electrical System

Lights and Switches Operation Inspection

First Step

Set the gear position in the neutral position.

•

Turn the ignition switch to ON.

•

The following lights should go on according to the table

•

below.

City Lights [A]

Taillight [B]

License Plate Light [C]

Meter Panel Illumination Light (LED) [D]

Meter Panel LCD [E]

Green Neutral Indicator Light (LED) [F]

Red Warning Indicator Light (LED) [G]

Oil Pressure Warning Symbol [H]

Yellow Engine Warning Indicator Light
(LED) [I]

goes on

goes on

goes on

goes on

goes on

goes on

goes on

goes on

goes on

(about 2 seconds)

PERIODIC MAINTENANCE 2-39

ER650F Model

Yellow ABS Indicator Light (LED) [J]

If the light does not go on, inspect or replace the following

item.

Battery (see Charging Condition Inspection in the Elec­trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Applicable Bulb (see Wiring Diagram in the Electrical
System chapter)
Meter Unit for Meter Panel LCD (see Electronic Com­bination Meter Unit Inspection in the E lectrical System
chapter)
Meter Unit for Illumination Light (LED) (see Electronic
Combination Meter Unit Inspection in the Electrical Sys­tem chapter)
Meter Unit for Green Neutral Indicator Light (LED) (see
Electronic Combination Meter Unit Inspection in the
Electrical System chapter)
Meter Unit for Red Warning Indicator Light (LED) (see
Electronic Combination Meter Unit Inspection in the
Electrical System chapter)
Meter Unit for Yellow Engine Warning Indicator Light
(LED) (see Electronic Combination Meter Unit Inspec­tion in the Electrical System chapter)
ECU (see ECU Power Supply Inspection in the Fuel Sys­tem (DFI) chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Meter Unit for Yellow ABS Indicator Light (LED) (ER650F
Model, see Yellow ABS Indicator Light (LED) Inspection
in the Brakes chapter)

goes on

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Turn the ignition switch to OFF.

•

The all lights should go off.

•

If any light does not go off, replace the ignition switch.

Second Step

Turn the ignition switch to P (Park) position.

•

The city light, taillight and license plate light should go on.

•

If the light does not go on, inspect or replace the following
item.

Ignition Switch (see Switch Inspection in the Electrical
System chapter)

Third Step

TurntheignitionswitchtoON.

•

Turn on the turn signal switch [A] (left or right position).

•

The left or right turn signal lights [B] (front and rear) should

•

blink according to the switch position.
The green turn signal indicator light (LED) [C] in the meter

•

unit should blink.
If any light does not blink, inspect or replace the following
item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Re­placement in the Electrical System chapter)
Meter Unit for Green Turn Signal Indicator Light (LED)
(see Electronic Combination Meter Unit Inspection in the
Electrical System chapter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in the
Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri­cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Push the turn signal switch.

•

The turn signal lights and indicator light (LED) should go

•

off.
If the light does not go off, inspect or replace the following
item.

Turn Signal Switch (see Switch Inspection in the Electri­cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)

Periodic Maintenance Procedures

Fourth Step

Set the dimmer switch [A] to low beam position.

•

Start the engine.

•

The low beam headlight should go on.

•

If the low beam headlight does not go on, inspect or re-

place the following item.

Headlight Low Beam Bulb (see Headlight Bulb Replace­ment in the Electrical System chapter)
Headlight Fuse 15 A (see Fuse Inspection in the Electri­cal System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Circuit Relay in Relay Box (see Relay Circuit
Inspection in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Set the dimmer switch to high beam position.

•

The low beam [A] and high beam [B] headlights should

•

go on.

The blue high beam indicator light (LED) [C] should go on.

•

If the high beam headlight and/or indicator light (LED)

does not go on, inspect or replace the following item.

Headlight High Beam Bulb (see Headlight Bulb Replace­ment in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)

Turn the engine stop switch to stop position.

•

The low beam and high beam headlights should stay go-

•

ing on.

If the headlights and/or the blue high beam indicator light

(LED) goes off, inspect or replace the following item.

Headlight Circuit Relay in Relay Box (see Relay Circuit
Inspection in the Electrical System chapter)

Turn the ignition switch to OFF.

•

The headlights and the indicator light (LED) should go off.

•

PERIODIC MAINTENANCE 2-41

Headlight Aiming Inspection

Inspect the headlight beam for aiming.

•

If the headlight beam points to one side rather than

straight ahead, adjust the horizontal beam.

Headlight Beam Horizontal Adjustment

Turn the horizontal adjuster [A] on the headlight in or out

•

until the beam points straight ahead.

If the headlight beam points too low or high, adjust the

vertical beam.

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Headlight Beam Vertical Adjustment

Turn the vertical adjuster [A] on the headlight in or out to

•

adjust the headlight vertically.

NOTE

On high beam, the brightest points should be slightly

○

below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an­gle according to local regulations.

NOTE

For CA model, the proper angle is 0.4 degrees below

○

horizontal. This is 50 mm (2.0 in.) drop at 7.6 m (25
ft) measured from the center of the headlight with the
motorcycle on its wheels and the rider seated.

50 mm (2.0 in.) [A]
Center of Brightest Spot [B]

7.6 m (25 ft) [C]
Height of Headlight Center [D]

Sidestand Switch Operation Inspection

Inspect the sidestand switch [A] operation according to

•

the table below.

Sidestand Switch Operation

Sidestand

Up Neutral Released Starts

Up Neutral Pulled in Starts

Up In Gear Released

Up In Gear Pu lled in Starts

Down Neutral Released Starts

Down Neutral Pulled in Starts

Down

Down

Gear

Position

In Gear

In Gear

Clutch

Lever

Released

Pulled in

Engine

Start

Does not

start

Does not

start

Does not

start

Engine

Run

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Stops

Stops

Periodic Maintenance Procedures

If the sidestand switch operation does not work, inspect

or replace the following item.

Battery (see Charging Condition Inspection in the Elec­trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the E lectrical
System chapter)
Engine Stop Switch (see Switch Inspection in the Elec­trical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Elec­trical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System

chapter)
If the all parts are in good condition, replace the ECU
(see ECU Removal/Installation in the Fuel System (DFI)
chapter).

PERIODIC MAINTENANCE 2-43

Engine Stop Switch Operation Inspection

First Step

Turn the ignition switch to ON.

•

Set the gear position in the neutral position.

•

Turn the engine stop switch to stop position [A].

•

Push the starter button [B].

•

The engine should not start.

•

If the engine starts, inspect or replace the following item.

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

Second Step

Turn the ignition switch to ON.

•

Set the gear position in the neutral position.

•

Turn the engine stop switch to run position [A].

•

Push the starter button [B] and run the engine.

•

Turn the engine stop switch to stop position.

•

Immediately the engine should stop.

•

If the engine does not stop, inspect or replace the follow­ing item.

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)
If the engine stop switch is in good condition, replace the
ECU (see ECU Removal/Installation in the Fuel System
(DFI) chapter).

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Others

Chassis Parts Lubrication

Before lubricating each part, clean off any rusty spots with

•

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

•

NOTE

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 Grease.

Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends

Cables: Lubricate with Rust Inhibitor.

Clutch Cable
Throttle Cables

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 inner cable

•

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

Periodic Maintenance Procedures

Bolts, Nuts and Fasteners Tightness Inspection

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

•

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

NOTE

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 spec­ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Bolt Locknut

Engine Bracket Bolts

Engine Mounting Bolts and Nuts

Exhaust Pipe Manifold Holder Nuts

Muffler Body Mounting Bolts

PERIODIC MAINTENANCE 2-45

Wheels:

Front Axle

Front Axle Clamp Bolt

Rear Axle Nut

Rear Axle Nut Cotter Pin

Brakes:

Brake Lever Pivot Nut

Brake Pedal Bolt

Caliper Mounting Bolts

Front Master Cylinder Clamp Bolts

Rear Master Cylinder Mounting Bolts

Rear Master Cylinder Push Rod Joint Cotter Pin

Suspension:

Front Fork Clamp Bolts

Rear Shock Absorber Bolt and Nut

Swingarm Pivot Shaft Nut

Swingarm Bracket Bolts

Steering:

Steering Stem Head Bolt

Handlebar Holder Bolts

Others:

Footpeg Stay Bolts

Sidestand Bolt

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replacement Parts

Air Cleaner Element Rep lacement

NOTE

In dusty areas, the element should be replaced more

○

frequently than the recommended interval.

WARNING

If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident. Replace the air cleaner
element according to the maintenance chart.

NOTICE

If dirt gets through into the engine, excessive en­gine wear and possibly engine damage will occur.

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
ECU [A]
Screw [B]
Clamp [C]
Intake Air Pressure Sensor Connector [D] (Disconnect)

Remove:

•

Bolts [A]
Fuel Tank Bracket [B]
Rubber Cover [C]

Remove the bolts [A] and move the bracket [B] aside.

•

Periodic Maintenance Procedures

Remove:

•

Screws [A]

Air Cleaner Housing Cover [B]

Loosen the screw [A] to remove the air cleaner element

•

[B].
Remove the screw from the element.

•

Install a new element so that the screen side faces up-

•

ward.

NOTICE

Use only the recommended air cleaner element
(Kawasaki part number 11013-0713). Using another
air cleaner element will wear the engine prema­turely or lower the engine performance.

PERIODIC MAINTENANCE 2-47

Tighten:

•

Torque - Air Cleaner Element Scre w: 1.2 N·m (0.12 kgf·m,

11 in·lb )

Install the air cleaner housing cover and tighten the

•

screws.

Torque - Air Cleaner Housing Cover Screws: 1.2 N·m (0.12

kgf·m, 11 in·lb)

Install the other removed parts (see appropriate chapter).

•

Run the harness and leads correctly (see Cable, Wire,

○

and Hose Routing section in the Appendix chapter).

Install the bracket and tighten the bolts following the spec-

○

ified tightening sequence shown in the figure.

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel Hose Replacement

Remove the fuel tank (see Fuel Tank Removal in the Fuel

•

System (DFI) chapter).
Be sure to place a piece of cloth [A] around the fuel hose

•

joint.
Insert a standard tip screwdriver [B] into the slit on the

•

joint lock [C].

Turn [A] the driver to unlock the joint lock [B].

•

Pull the fuel hose joint [C] out of the delivery pipe.

•

WARNING

Fuel is flammable and explosive under certain con­ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis­connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.

Replace the fuel hose with a new one.

•

Insert the fuel hose joint [A] straight onto the delivery pipe

•

until the hose joint clicks.
Push [B] the joint lock [C].

•

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

•

more than two times and make sure it is locked and does
not come off.

WARNING

Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.

If it comes off, reinstall the hose joint.
Run the fuel hose correctly (see Cable, Wire, and Hose

•

Routing section in the Appendix chapter).
Install the fuel tank (see Fuel Tank Removal in the Fuel

•

System (DFI) chapter).
Start the engine and check the fuel hose for leaks.

•

Periodic Maintenance Procedures

Coolant Change

WARNING

Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.

Remove:

•

Right Center Fairing (see Center Fairing Removal in the

Frame chapter)

Lower Fairing (see Lower Fairing Removal in the Frame

chapter)

Reserve Tank Bolts [A]

Reserve Tank [B]

Reserve Tank Over Flow Hose [C]

PERIODIC MAINTENANCE 2-49

Hook the projection [A] of the reserve tank into the hole

•

[B] on the frame.

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

•

then remove the drain bolt.

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

•

cap counterclockwise to the first s top. Then push and turn
it further in the same direction and remove the cap.
The coolant will drain from the radiator and engine.

○

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Take off the reserve tank from the frame.

•

Remove the reserve tank cap, and pour the coolant into

•

a suitable container.
Hook the reserve tank to the frame again.

•

Tighten the drain bolt with a new gasket.

•

Torque - Water Pump Drain Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

NOTICE

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

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%

Coolant: 50%

Freezing Point:

Total Amount:

–35°C (–31°F)

1.2 L (1.3 US qt)

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

•

NOTE

Pour in the coolant slowly as it can expel the air from

○

the engine and radiator.

Check the cooling system for leaks.

•

Tap the radiator hoses to force any air bubbles caught

•

inside.
Fill the radiator up to the filler neck with coolant, and install

•

the radiator cap.

Install the reserve tank.

•

Tighten:

•

Torque - Coolant Reserve Tank Mounting Bolts: 7.9 N·m

(0.81 kgf·m, 70 in·lb)

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

•

coolant and install the cap [B].
Start the engine, warm it up thoroughly until the radiator

•

fan turns on, and then stop the engine.
Check the coolant level in the reserve tank after the en-

•

gine cools down.
If the coolant level is lower than the “L” (low) level line [C],
add coolant to the “F” level line.

NOTICE

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

Periodic Maintenance Procedures

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

•

Thermostat Housing [A] (see Thermostat Removal in the

Cooling System chapter)

Water Pump C over [B] (see Water Pump Removal in the

Cooling System chapter)

Hoses [C]

O-rings [D]
Apply grease to the new O-rings and install them.

•

Install the new hoses and tighten the clamps securely.

•

Tighten:

•

Torque - Water Hose Clamp Screws: 3.0 N· m (0.31 kgf·m,

27 in·lb)

Fill the coolant (see Coolant Change).

•

Check the cooling system for leaks.

•

PERIODIC MAINTENANCE 2-51

Engine Oil Change

Situate the motorcycle so that it is vertical after warming

•

up the engine.
Unscrew the oil filler plug [A].

•

Remove the lower fairing (see Lower Fairing Removal in

•

the Frame chapter).
Place the oil pan beneath the engine.

•

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

•

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

○

(see Oil Filter Replacement).
Replace the drain plug gasket with a new one.

•

Tighten:

•

Torque - Engine Oil Drain Plug: 30 N·m (3.1 kgf·m, 22 ft·lb)

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Pour in the specified type and amount of oil.

•

Recommended Engine Oil

Typ e:

Viscosity:

Capacity: 1.6 L (1.7 US qt) (when filter is not

Do not add any chemical additive to the oil. Oils fulfilling

○

the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
Although 10W-40 engine oil is the recommended oil

○

for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.

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

SAE 10W-40

removed)

1.8 L (1.9 US qt) (when filt er is removed)

2.3 L (2.4 US qt) (when engine is
completely dry)

NOTE

Check the oil level (see Oil Level Inspection in the Engine

•

Lubrication System chapter).

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change).

•

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 grease to the O-ring [A] before installation.

•

Tighten the filter with the oil filter wrench.

•

Torque - Oil Filter: 17.5 N·m (1.8 kgf·m, 13 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).

Periodic Maintenance Procedures

Brake Hose and Pipe Replacement

NOTICE

Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.

Remove the brake hose banjo bolts [A].

•

Remove the brake hoses [B], noting the following.

•

Take care not to spill the brake fluid on the painted or

○

plastic parts.
Temporarily secure the end of the brake hose to some

○

high place to keep fluid loss to a minimum.

PERIODIC MAINTENANCE 2-53

For models equipped with an ABS, note the following.

•

NOTE

When removing the brake pipes and hoses on the hy-

○

draulic unit, remove them according to each assembly
of the exploded view in the Brakes chapter.

Remove the bracket bolts [A] and the brackets [B].

•

Remove the brake pipe joint nuts [C].

•

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Install the brake hose, noting the following.

•

Replace the washers [A] on each side of hose fitting [B]

○

with new ones.
Avoid sharp bending, kinking, flattening or twisting, and

○

route the hoses according to Cable, Wire, and Hose Rout­ing section in the Appendix chapter.
Before installing the brake pipe, check to see that there is

•

no damage on the threads of the brake pipe joint nut.
If there is any damage, replace the damaged parts with
new ones.

NOTE

Tighten the brake pipe joint nuts at both ends of the

○

brake pipe temporarily and then tighten them to the
specified torque.

Install the brake pipes at the specified angle (see Cable,

•

Wire, and Hose Routing section in the Appendix chapter).
Tighten the brake pipe joint nuts with the flare nut wrench.

•

Tighten:

•

Torque - Brake Hose Banjo B olts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Brake Pipe Joint Nuts (ER650F Model): 18 N·m

(1.8 kgf·m, 13 ft·lb)

Fill the brake line (see Brake Fluid Change).

•

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.

Level the brake fluid reservoir.

•

Remove the reservoir cap and diaphragm.

•

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

•

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

•

run the other end of the hose into a container.
Fill the reservoir with fresh specified brake fluid.

•

Periodic Maintenance Procedures

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].

NOTE

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.

Remove the clear plastic hose.

•

Install the diaphragm and reservoir cap.

•

Tighten:

•

Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

PERIODIC MAINTENANCE 2-55

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 slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].

Tighten the bleed valve, and install the rubber cap.

•

Torque - Caliper 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.

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

Remove the front master cylinder (see Front Master Cylin-

•

der Removal in the Brakes chapter).
Remove the reservoir cap and diaphragm, and pour the

•

brake fluid into a container.
Unscrew the locknut and pivot bolt, and remove the brake

•

lever.
Pull the dust cover [A] out of place, and remove the circlip

•

[B].

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the piston [C], secondary cup [D], primary cup [E],

•

and return spring [F].

NOTICE

Do not remove the secondary cup from the piston
since removal will damage it.

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rear Master Cylinder Disassembly

NOTE

Do not remove the push rod clevis for master cylinder

○

disassembly since removal requires brake position ad­justment.

Remove the rear master cylinder (see Rear Master Cylin-

•

der Removal in the Brakes chapter).
Remove the circlip [A].

•

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the push rod with the piston stop.

•

Take off the piston [B], secondary cup [C], primary cup [D]

•

and return spring [E].
Remove the circlip [F] and pull out the brake hose con-

•

nector [G] and O-ring [H].

Special Tool - Inside Circlip Pliers: 57001-143

NOTICE

Do not remove the secondary cup from the piston
since removal will damage it.

Master Cylinder Assembly

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

NOTICE

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

Apply brake fluid to the new parts and to the inner wall of

•

the cylinder.
Take care not to scratch the piston or the inner wall of the

•

cylinder.
Apply silicone grease to the brake lever pivot bolt and the

•

push rod.
Replace the brake lever pivot bolt locknut with a new one.

•

Tighten:

•

Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9

in·lb)

Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60

kgf·m, 52 in·lb)

Caliper Rubber Parts Replacement

Front Caliper Disassembly

Remove:

•

Front Caliper (see Front Caliper Removal in the Brakes
chapter)
Brake Pads (see Front Brake Pad Removal in the Brakes
chapter)
Pad Spring

Periodic Maintenance Procedures

Using compressed air, remove the pistons.

•

Cover the piston area with a clean, thick cloth [A].

○

Blow compressed air [B] into the hole for the banjo bolt to

○

remove the piston.

WARNING

The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.

Pull out the pistons by hand.

•

Remove:

•

Caliper Holder

Dust Seals

Fluid Seals

Bleed Valve

Rubber Cap

PERIODIC MAINTENANCE 2-57

NOTE

If compressed air is not available, do as follows with the

○

brake hose connected to the caliper.
Prepare a container for brake fluid, and perform the

○

work above it.
Remove the brake pads (see Front Brake Pad Removal

○

in the Brakes chapter).
Pump the brake lever until the pistons come out of the

○

cylinders, and then disassemble the caliper.

Front Caliper Assembly

Clean the caliper parts except for the pads.

•

NOTICE

For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.

Install the bleed valve and rubber cap.

•

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

Replace the fluid seals [A] with new ones.

•

Apply brake fluid to the fluid seals, and install them into

○

the cylinders by hand.
Replace the dust seals [B] with new ones if they are dam-

•

aged.
Apply brake fluid to the dust seals, and install them into

○

the cylinders by hand.

2-58 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Apply brake fluid to the outside of the pistons, and push

•

them into each cylinder by hand.
Check the friction boot [A] and the dust cover [B] replace

•

them with new ones if they are damaged.
Apply a thin coat of PBC (Poly Butyl Cuprysil) grease

•

to the caliper holder shafts [C] (PBC is a special high

-temperature, water-resistance grease).

Install the pad spring [A].

•

Install the pads (see Front Brake Pad Installation in the

•

Brakes chapter).
Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Rear Caliper Disassembly

Remove:

•

Rear Caliper (see Rear Caliper Removal in the Brakes
chapter)
Brake Pads (see Rear Brake Pad Removal in the Brakes
chapter)
Pad Spring

Using compressed air, remove the piston.

•

Cover the piston area with a clean, thick cloth [A].

○

Blow compressed air [B] into the hole for the banjo bolt to

○

remove the piston.

WARNING

The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.

Pull out the pistons by hand.

•

Remove:

•

Caliper Holder
Dust Seal
Fluid Seal
Bleed Valve
Rubber Cap

NOTE

If compressed air is not available, do as follows with the

○

brake hose connected to the caliper.
Prepare a container for brake fluid, and perform the

○

work above it.
Remove the brake pads (see Rear Brake Pad Removal

○

in the Brakes chapter).
Pump the brake pedal until the piston come out of the

○

cylinder, and then disassemble the caliper.

Periodic Maintenance Procedures

Rear Caliper Assembly

Clean the caliper parts except for the pads.

•

NOTICE

For cleaning of the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.

Install the bleed valve and rubber cap.

•

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

Replace the fluid seal [A] with a new one.

•

Apply brake fluid to the fluid seal, and install it into the

○

cylinder by hand.
Replace the dust seal [B] with a new one if it is damaged.

•

Apply brake fluid to the dust seal, and install it i nto the

○

cylinder by hand.

PERIODIC MAINTENANCE 2-59

Apply brake fluid to the outside of the piston, and push it

•

into the cylinder by hand.
Replace the friction boot [A] and dust cover [B] with new

•

ones if they are damaged.
Apply a thin coat of PBC (Poly Butyl Cuprysil) grease

•

to the caliper holder shafts [C] (PBC is a special high

-temperature, water-resistance grease).

Install the pad spring [A] in the caliper as shown.

•

Install the pads (see Rear Brake Pad Installation in the

•

Brakes chapter).
Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Spark Plug Replacement

Remove:

•

Air Cleaner Housing (see Air Cleaner Housing Removal

in the Fuel System (DFI) chapter)

Stick Coils (see Stick Coil Removal in the Electrical Sys-

tem chapter)
Remove the spark plugs using the 16 mm (0.63 in.) plug

•

wrench [A] vertically.

2-60 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replace the spark plugs with new ones.

•

Standard Spark Plug

Typ e:

Insert the spark plug [A] into the plug wrench [B].

•

Install the spark plug into the plug hole, and hand-tighten

•

it first.

The insulator of the spark plug may break if when
the wrench is inclined during tightening.

Tighten:

•

Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft·lb)

Install the stick coils securely.

•

Pull the stick coils lightly to check the installation condi-

○

tion.
Run the leads correctly (see Cable, Wire, and Hose Rout-

•

ing section in the Appendix chapter).
Install the other removed parts (see appropriate chap-

•

ters).

CR9EIA-9

NOTICE

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

Exploded View........................................................................................................................ 3-4

DFI System ............................................................................................................................. 3-10

DFI Parts Location.................................................................................................................. 3-15

Specifications ......................................................................................................................... 3-17

Special Tools and Sealant ...................................................................................................... 3-19

DFI Servicing Precautions ...................................................................................................... 3-21

DFI Servicing Precautions ................................................................................................ 3-21

Troubleshooting the DFI System ............................................................................................ 3-23

Outline............................................................................................................................... 3-23

Inquiries to Rider............................................................................................................... 3-27

DFI System Troubleshooting Guide ....................................................................................... 3-29

Self-Diagnosis ........................................................................................................................ 3-34

Self-diagnosis Outline.......................................................................................................... 3-34

Self-diagnosis Procedures ................................................................................................... 3-34

Service Code Reading ...................................................................................................... 3-37

Service Code Erasing ....................................................................................................... 3-37

Service Code Table........................................................................................................... 3-38

Backups ............................................................................................................................ 3-39

Main Throttle Sensor (Service Code 11) ................................................................................ 3-41

Main Throttle Sensor Removal/Adjustment ...................................................................... 3-41

Main Throttle Sensor Input Voltage Inspection ................................................................. 3-41

Main Throttle Sensor Output Voltage Inspection .............................................................. 3-42

Main Throttle Sensor Resistance Inspection .................................................................... 3-43

Intake Air Pressure Sensor (Service Code 12)....................................................................... 3-44

Intake Air Pressure Sensor Removal................................................................................ 3-44

Intake Air Pressure Sensor Installation............................................................................. 3-44

Intake Air Pressure Sensor Input Voltage Inspection........................................................ 3-44

Intake Air Pressure Sensor Output Voltage Inspection..................................................... 3-45

Intake Air Temperature Sensor (Service Code 13)................................................................. 3-50

Intake Air Temperature Sensor Removal/Installation........................................................ 3-50

Intake Air Temperature Sensor Output Voltage Inspection ............................................... 3-50

Intake Air Temperature Sensor Resistance Inspection..................................................... 3-51

Water Temperature Sensor (Service Code 14) ...................................................................... 3-53

Water Temperature Sensor Removal/Installation ............................................................. 3-53

Water Temperature Sensor Output Voltage Inspection..................................................... 3-53

Water Temperature Sensor Resistance Inspection........................................................... 3-54

Crankshaft Sensor (Service Code 21).................................................................................... 3-55

Crankshaft Sensor Removal/Installation........................................................................... 3-55

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

Crankshaft Sensor Peak Voltage Inspection..................................................................... 3-55

Speed Sensor (Service Code 24, 25)..................................................................................... 3-56

Speed Sensor Removal/Installation.................................................................................. 3-56

Speed Sensor Inspection.................................................................................................. 3-56

Speed Sensor Input Voltage Inspection............................................................................ 3-56

Speed Sensor Output Voltage Inspection ......................................................................... 3-57

Vehicle-down Sensor (Service Code 31)................................................................................ 3-59

Vehicle-down Sensor Removal/Installation....................................................................... 3-59

Vehicle-down Sensor Inspection....................................................................................... 3-59

Subthrottle Sensor (Service Code 32).................................................................................... 3-62

Subthrottle Sensor Removal/Adjustment .......................................................................... 3-62

3

3-2 FUEL SYSTEM (DFI)

Subthrottle Sensor Input Voltage Inspection..................................................................... 3-62

Subthrottle Sensor Output Voltage Inspection .................................................................. 3-63

Subthrottle Sensor Resistance Inspection ........................................................................ 3-65

Oxygen Sensor-not activated (Service Code 33) (Equipped Models) .................................... 3-66

Oxygen Sensor Removal/Installation................................................................................ 3-66

Oxygen Sensor Inspection................................................................................................ 3-66

Stick Coils #1, #2: (Service Code 51, 52) .............................................................................. 3-69

Stick C oil Removal/Installation.......................................................................................... 3-69

Stick C oil Primary Winding Resistance Inspection ........................................................... 3-69

Stick C oil Input Voltage Inspection.................................................................................... 3-69

Radiator Fan Relay (Service Code 56)................................................................................... 3-71

Radiator Fan Relay Removal/Installation.......................................................................... 3-71

Radiator Fan Relay Inspection.......................................................................................... 3-71

Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-72

Subthrottle Valve Actuator Removal ................................................................................. 3-72

Subthrottle Valve Actuator Inspection ............................................................................... 3-72

Subthrottle Valve Actuator Resistance Inspection ............................................................ 3-72

Subthrottle Valve Actuator Input Voltage Inspection ......................................................... 3-73

Air Switching Valve (Service Code 64) ................................................................................... 3-75

Air Switching Valve Removal/Installation .......................................................................... 3-75

Air Switching Valve Inspection .......................................................................................... 3-75

Oxygen Sensor Heater (Service Code 67) (Equipped Models).............................................. 3-76

Oxygen Sensor Heater Removal/Installation .................................................................... 3-76

Oxygen Sensor Heater Inspection ................................................................................... 3-76

Oxygen Sensor Heater Power Source Voltage Inspection ............................................... 3-77

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models).................. 3-79

Oxygen Sensor Removal/Installation................................................................................ 3-79

Oxygen Sensor Inspection................................................................................................ 3-79

Purge Valve (Service Code 3A) (SEA-B1 and TH Models) .................................................... 3-82

Purge Valve Removal/Installation ..................................................................................... 3-82

Purge Valve Inspection ..................................................................................................... 3-82

Yellow Engine Warning Indicator Light (LED) ......................................................................... 3-84

Yellow Engine Warning Indicator Light (LED) Inspection.................................................. 3-84

ECU........................................................................................................................................ 3-85

ECU Identification ............................................................................................................. 3-85

ECU Removal ................................................................................................................... 3-85

ECU Installation ................................................................................................................ 3-85

ECU Power Supply Inspection .......................................................................................... 3-85

DFI Power Source ..................................................................................................................3-88

ECU Fuse Removal .......................................................................................................... 3-88

ECU Fuse Installation ....................................................................................................... 3-88

ECU Fuse Inspection ........................................................................................................ 3-88

ECU M ain Relay Removal/Installation .............................................................................. 3-88

ECU M ain Relay Inspection .............................................................................................. 3-88

Fuel Line................................................................................................................................. 3-89

Fuel Pressure Inspection .................................................................................................. 3-89

Fuel Flow Rate Inspection ................................................................................................ 3-90

Fuel Pump .............................................................................................................................. 3-92

Fuel Pump Removal ......................................................................................................... 3-92

Fuel Pump Installation ...................................................................................................... 3-92

Fuel Pump Operation Inspection ...................................................................................... 3-93

Fuel Pump Operating Voltage Inspection ......................................................................... 3-94

Pressure Regulator Removal............................................................................................ 3-95

Fuel Filter Cleaning........................................................................................................... 3-95

Fuel Injectors .......................................................................................................................... 3-96

Fuel Injector Removal/Installation..................................................................................... 3-96

Fuel Injector Audible Inspection........................................................................................ 3-96

FUEL SYSTEM (DFI) 3-3

Fuel Injector Resistance Inspection .................................................................................. 3-96

Fuel Injector Power Source Voltage Inspection ................................................................ 3-97

Fuel Injector Output Voltage Inspection ............................................................................ 3-98

Fuel Injector Fuel Line Inspection ..................................................................................... 3-99

Throttle Grip and Cables ........................................................................................................ 3-101

Throttle Grip Free Play Inspection .................................................................................... 3-101

Throttle Grip Free Play Adjustment................................................................................... 3-101

Throttle Cable Installation ................................................................................................. 3-101

Throttle Cable Lubrication................................................................................................. 3-101

Throttle Body Assy ................................................................................................................. 3-102

Idle Speed Inspection/Adjustment .................................................................................... 3-102

Synchronization Inspection/Adjustment............................................................................ 3-102

Throttle Body Assy Removal............................................................................................. 3-102

Throttle Body Assy Installation.......................................................................................... 3-103

Throttle Body Assy Disassembly ...................................................................................... 3-104

Throttle Body Assy Assembly ........................................................................................... 3-105

Air Cleaner.............................................................................................................................. 3-106

Air Cleaner Element Removal/Installation ........................................................................ 3-106

Air Cleaner Element Inspection ........................................................................................ 3-106

Air Cleaner Oil Draining .................................................................................................... 3-106

Air Cleaner Housing Removal........................................................................................... 3-106

Air Cleaner Housing Installation........................................................................................ 3-107

Fuel Tank ................................................................................................................................ 3-108

Fuel Tank Removal ........................................................................................................... 3-108

Fuel Tank Installation ........................................................................................................ 3-110

Fuel Tank and Cap Inspection .......................................................................................... 3-111

Fuel Tank Cleaning ........................................................................................................... 3-112

Evaporative Emission Control System (SEA-B1 and TH Models).......................................... 3-113

Parts Removal/Installation ................................................................................................ 3-113

Hose Inspection ................................................................................................................ 3-113

Purge Valve Inspection ..................................................................................................... 3-113

Canister Inspection .......................................................................................................... 3-113

3-4 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

1

Air Cleaner Element Screw

2 Air Cleaner Housing Cover Screws 1.2 0.12 11 in ·l b

3 Intake Air Temperature Sensor Screw 1.2 0.12 11 in·lb

4 Air Cleaner Housing Clamp Bolt 2.0 0.20 18 in·lb

5 Timing Rotor Bolt 40 4.1 30

6 Crankshaft Sensor Bolts 6.0 0.61 53 in·lb

7 Water Temperature Sensor 12 1.2 106 in·lb

8 Oxygen Sensor (Equipped Models) 44 4.5 32

9

Speed Sensor Bracket Bolts

10

Speed Sensor Bolt

11. Vehicle-down Sensor

12. Intake Air Pressure Sensor

13. ECU (Electronic Control Unit)

14. Intake Air Temperature Sensor

15. Air Switching Valve
G: Apply grease.

L: Apply a non-permanent locking agent.

LG: Apply liquid gasket.

R: Replacement Parts

S: Follow the specified tightening sequence.

N·m

1.2 0.12 11 in·lb

9.8 1.0 87 in·lb

7.8 0.80 69 in·lb L

Torque

kgf·m ft·lb

Remarks

3-6 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1

Switch Housing Screws

2 Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

3. Other than SEA-B1 and TH Models

4. SEA-B1 and TH Models

5. AU LAMS Model

6. Throttle Cable (Accelerator)

7. Throttle Cable (Decelerator)

CL: Apply c able lubricant.

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

N·m

3.5 0.36 31 in·lb

Torque

Remarks

kgf·m ft·lb

3-8 FUEL SYSTEM (DFI)

Exploded View

SEA-B1 and TH Models

Exploded View

FUEL SYSTEM (DFI) 3-9

No. Fastener

N·m

1 Purge Valve Mounting Nut 7.0 0.71 62 in·lb

2. Canister

3. Purge Valve

Torque

kgf·m ft·lb

Remarks

3-10 FUEL SYSTEM (DFI)

DFI System

DFI System

DFI System

1. ECU (Electronic Control Unit)

2. Battery

3. Fuel Tank

4. Fuel Pump

5. Pressure Regulator

6. Delivery Pipe

7. Intake Air Temperature Sensor

8. Subthrottle Valve

9. Air Cleaner Housing

10. Subthrottle Sensor

11. Main Throttle Valve

12. Air Switching Valve

13. Fuel Injectors

14. Main Throttle Sensor

15. Water Temperature Sensor

16. Subthrottle Valve Actuator

17. Intake Air Pressure Sensor

18. Speed Sensor

19. Vehicle-down Sensor

20. Crankshaft Sensor

21. Oxygen Sensor (Equipped Models)

FUEL SYSTEM (DFI) 3-11

3-12 FUEL SYSTEM (DFI)

DFI System

DFI System Wiring Diagram

DFI System

Part Name

1. ECU

2. Joint Connector B

3. Kawasaki Diagnostic System Connector

4. Fuel Pump

5. Frame Ground 1

6. Frame Ground 2

7. Battery 12 V 10 Ah

8. Main Fuse 30 A

9. Relay Box

10. Fuel Pump Relay

11. ECU Main Relay

12. Radiator Fan Relay

13. Fuse Box 1

14. FI Fuse 15 A

15. Radiator Fan Fuse 15 A

16. Ignition Fuse 10 A

17. Meter Unit

18. Yellow Engine Warning Indicator Light (LED)

19. Speedometer

20. Tachometer

21. Ignition Switch

22. Engine Stop Switch

23. Starter Button

24. Radiator Fan Motor

25. Stick Coils

26. Air Switching Valve

27. Speed Sensor

28. Subthrottle Valve Actuator

29. Joint Connector C

30. Subthrottle Sensor

31. Main Throttle Sensor

32. Joint Connector D

33. Intake Air Pressure Sensor

34. Vehicle-down Sensor

35. Fuel Injectors

36. Water Temperature Sensor

37. Intake Air Temperature Sensor

38. Crankshaft Sensor

39. Oxygen Sensor (Equipped Models)

FUEL SYSTEM (DFI) 3-13

Lead Color Codes:

○

BK: Black

BL: Blue
BR: Brown
CH: Chocolate

DG: Dark Green

G: Green

GY: Gray

LB: Light Blue

LG: Light Green

O: Orange

P: Pink

PU: Purple

R: Red

W: White

Y: Yellow

3-14 FUEL SYSTEM (DFI)

DFI System

Terminal Numbers of ECU Connectors

Terminal Names

1. Subthrottle Valve Actuator: BK/O

2. Subthrottle Valve Actuator: G/Y

3. Unused

4. Oxygen Sensor (Equipped Models): BL/Y

5. Speed Sensor: LG/R

6. Main Throttle Sensor: Y/R

7. Intake Air Pressure Sensor: Y/BL

8. Power Supply to Sensors: BL

9. Vehicle-down Sensor: Y/G

10. Neutral Switch: LG

11. Crankshaft Sensor (+): R/BK

12. Power Supply to ECU (from ECU Main Re­lay): BR/W

13. External Communication Line (Self

-diagnosis System): P/BL

14. Subthrottle Valve Actuator: P

15. Subthrottle Valve Actuator: W /BL

16. Unused

17. Water Temperature Sensor: O

18. Unused

19. Subthrottle Sensor: BR

20. Intake Air Temperature Sensor: R

21. Unused

22. Ground for Sensors: BR/BK

23. Oxygen Sensor Heater (Equipped Models):
P/BK

24. Crankshaft Sensor (–): Y/BK

25. Purge Valve (SEA-B1 and TH Models): R/Y

26. Ground for ECU: BK

27. Power Supply to ECU (from Battery): W/BK

28. Engine Stop Switch: R

29. Starter Lockout Switch: R/G

30. Starter Button: BK/R

31. Fuel Pump Relay: BR/Y

32. Air Switching Valve: R/BL

33. Injector #2: BL/Y

34. Injector #1: BL/R

35. Stick Coil #1: BK

36. Sidestand Switch: G/BK

37. Radiator Fan Relay: P/BL

38. External Communication Line: LG/BK

39. Meter Unit (Tachometer): LB

40. External Communication Line (Meter):
BL/O

41. –

42. Ground for Fuel System: BK/Y

43. Ground for Ignition System: BK/Y

44. Stick Coil #2: BK/O

DFI Parts Location

Ignition Switch [A]
Relay Box [B] (ECU Main Relay, Radiator Fan Relay,
Fuel Pump Relay)
ECU [C]
Intake Air Temperature Sensor [D]
Vehicle-down Sensor [E]
Fuse Box [F] (Oxygen Sensor Heater Fuse 10 A, Radia­tor Fan Fuse 15 A, ECU Fuse 15 A, Ignition Fuse 10 A)
Intake Air Pressure Sensor [G]

Subthrottle Sensor [A]
Main Throttle Sensor [B]
Subthrottle Valve Actuator [C]

FUEL SYSTEM (DFI) 3-15

Fuel Injectors #1, #2 [A]

Water Temperature Sensor [A]

Fuel Pump [A]

3-16 FUEL SYSTEM (DFI)

DFI Parts Location

Battery 12 V 10 Ah [A]
Kawasaki Diagnostic System Connector [B]

Crankshaft Sensor [A]

Speed Sensor [A]
Neutral Switch [B]

Oxygen Sensor [A] (Equipped Models)

Purge Valve [A] (SEA-B1 and TH Models)

FUEL SYSTEM (DFI) 3-17

Specifications

Item Standard

Digital Fuel Injection System

Idle Speed 1 300 ±50 r/min (rpm)

Throttle Body Assy:

Throttle Valve Dual throttle valve

Bore

Bypass Screws (Turn out) 0 ∼ 2 1/2 (for reference)

ECU (Electronic Control Unit):

Make DENSO

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

Usable Engine Speed 100 ∼ 11 350 r/min (rpm)

Fuel Pressure (High Pressure Line):

With Engine Idling

Fuel Pump:

Type In-tank friction pump

Discharge

Fuel Injectors:

Type INP-287

Nozzle Type One spray type with 12 holes

Resistance About 11.7 ∼ 12.3 Ω at 20°C (68°F)

Main Throttle Sensor: Non-adjustable and non-removable

Input Voltage

Output Voltage DC 1.005 ∼ 1.035 V at Idle Throttle Opening

Resistance 4 ∼ 6kΩ

Intake Air Pressure Sensor:

Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 3.80 ∼ 4.20 V at standard atmospheric pressure

Intake Air Temperature Sensor:

Resistance

Output Voltage About 2.25 ∼ 2.50 V at 20°C (68°F)

Water Temperature Sensor:

Resistance see Electrical System chapter

Output Voltage About 2.80 ∼ 2.97 V at 20°C (68°F)

Speed Sensor:

Input Voltage

Output Voltage About DC 0.05 ∼ 0.07 V or DC 4.5 ∼ 4.9 V at Ignition

Vehicle-down Sensor:

Detection Method Magnetic flux detection method

Detection Angle more than 60 ∼ 70° for each bank
Input Voltage DC 4.75 ∼ 5.25 V

38 mm (1.5 in.)

with resin

294 kPa (3.0 kgf/cm², 43 psi) with fuel pump running

30 mL (1.0 US oz.) or more for 3 seconds

DC 4.75 ∼ 5.25 V

DC 4.2 ∼ 4.4 V at Full Throttle Opening

(see this text for details)

5.4 ∼ 6.6 kΩ at 0°C (32°F)

0.29 ∼ 0.39 kΩ at 80°C (176°F)

About DC 9 ∼ 11 V at Ignition Switch ON

SwitchONand0km/h(0mph)

3-18 FUEL SYSTEM (DFI)

Specifications

Item Standard

Output Voltage with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V

with the sensor arrow mark pointed up: 3.55 ∼ 4.45 V

Subthrottle Sensor: Non-adjustable and non-removable

Input Voltage

Output Voltage DC 0.6 ∼ 0.8 V at Idle Throttle Opening

Resistance 4 ∼ 6kΩ

Subthrottle Valve Actuator:

Input Voltage About DC 8.5 ∼ 10.5 V

Resistance

Oxygen Sensor (Equipped Models):

Output Voltage (Rich) DC 0.7 V or more

Output Voltage (Lean) DC 0.2 V or less

Heater Resistance 11.7 ∼ 14.5 Ω at 20°C (68°F)

Purge Valve:

Resistance 30 ∼ 34 Ω at 20°C (68°F)

Throttle Grip and Cables

ThrottleGripFreePlay 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

DC 4.75 ∼ 5.25 V

DC 4.08 ∼ 4.12 V at Full Throttle Opening

About 5.5 ∼ 7.5 Ω