Kawasaki ER-6f (2005) User Manual [ru]

Download

NINJA 650R

ER-6f ABS

ER-6f

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

NINJA 650R

ER-6f

ER-6f ABS

Motorcycle

Service Manual

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

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to m ake 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 a re intended for reference use only and may not depict actual model component parts.

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 inlet 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. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

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

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

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

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

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

NOTE

The phrase “remove or render inoperative any device or element o f design” has been gen erally

○

interpreted as follows.

1. Tampering does not include the temporary removal or rendering inoperative of de vices or elements o f design in order to perform maintenance.

2. Tampering could include.

a.Maladjustment of vehicle components such that the emission standards are ex-

ceeded.

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

or 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 TH ESE PROVISIONS OF FEDERAL LAW,

THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.

TAMPERING WITH N OISE 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 inlet system by cutting, drilling, or other means if such

•

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use b y 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 these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and 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 view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC

BTDC before top dead center

°C degree(s) Celsius

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

psi

r revolution

horsepower

pound(s) per square inch

COUNTRY AND AREA CODES

AT Austria DE Germany

CA Canada GB United Kingdom

CAL Cali

CH Switzerland

fornia

US Unit

WVTA Whole Vehicle Type Approval

ed States

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-10

Technical Information - Cassette Type Transmission ............................................................. 1-13

Technical Information - Inlet Air Pressure Sensor ................................................................. 1-14

Technical Information – ABS (Anti – Lock Brake System)...................................................... 1-15

Unit Conversion Table ............................................................................................................ 1-27

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-flush point solvent when cleaning parts. High

-flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly

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

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

GENERAL INFORMATION 1-3

Inspection

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

Replacement Parts

Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins m ust 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, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

Before Servicing

Press

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

Ball Bearing and Needle Bearing

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

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

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 Wires

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

Instrument

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

Model Identification

EX650A6F (United States and Canada) Left Side View

GENERAL INFORMATION 1-7

EX650A6F (United States and Canada) Right Side View

1-8 GENERAL INFORMATION

Model Identification

EX650A6F (Europe) Left Side View

EX650A6F (Europe) Right Side View

Model Identification

EX650B6F Left Side View

GENERAL INFORMATION 1-9

EX650B6F Right Side View

Frame Number Engine Number

1-10 GENERAL INFORMATION

General Specifications

Items EX650A6F, EX650B6F

Dimensions

Overall Length 2 105 mm (82.9 in.)

Overall Width 760 mm (29.9 in.)

Overall Height 1 210 mm (47.6 in.)

Wheelbase

Road Clearance 145 mm (5.7 in.)

Seat Height 790 mm (31.1 in.)

Dry Mass:

EX650A6F 178 kg (392.5 lb)

EX650B6F 182 kg (401.3 lb)

Curb Mass:

Front:

EX650A6F 101 kg (222.7 lb)

EX650B6F 103 kg (227.1 lb)

Rear:

EX650A6F 99 kg (216.1 lb)

EX650B6F 101 kg (222.7 lb)

Fuel Tank Capacity 15.5 L (4.1 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 × 60 mm (3.3 × 2.4 in.)

Displacement 649 cm³ (39.60 cu in.)

Compression Ratio 11.3 : 1

Maximum Horsepower

Maximum Torque 66 N·m ( 6.7 kgf·m, 49 ft·lb) @7 000 r/min (rpm),

Carburetion System FI (Fuel Injection) KEIHIN TTK38 × 2

Starting System Electric starter

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (digital igniter)

Ignition Timing

Spark Plug NGK CR9EIA-9

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Valve Timing:

Inlet:

Open 31° BTDC

Close 61° ABDC

Duration

1 410 mm (55.5 in.)

(CAL) 178.5 kg (393.6 lb)

(CAL) 99.5 kg (219.4 lb)

53 kW (72 PS) @8 500 r/min (rpm),

From 10° BTDC @1 300 r/min (rpm) to 35° BTDC @4 800 r/min (rpm)

272°

GENERAL INFORMATION 1-11

General Specifications

Items EX650A6F, EX650B6F

Exhaust:

Open 50° BBDC

Close 30° ATDC

Duration 260°

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil:

Type API SE, SF or SG

API SH, SJ or SL with JASO MA

Viscosity SAE 10W-40

Capacity 2.4L(2.5USqt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 2.095 (88/42)

Clutch Type Wet multi disc

Transmission:

Type 6-speed, constant mesh, return shift

Gear Ratios:

1st 2.438 (39/16)

2nd

3rd 1.333 (32/24)

4th 1.111 (30/27)

5th 0.966 (28/29)

6th 0.852 (23/27)

Final Drive System:

Type

Reduction Ratio 3.067 (46/15)

Overall Drive Ratio 5.473 @Top gear

Frame

Type Tubular, diamond

Caster (Rake Angle) 25°

Trail

Front Tire:

Type Tubeless

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

Rim Size 17 × 3.50

Rear Tire:

Type Tubeless

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

Rim Size 17 × 4.50

Front Suspension:

Type Telescopic fork

Wheel Travel 120 mm (4.7 in.)

Rear Suspension:

1.714 (36/21)

Chain drive

106 mm (4.2 in.)

1-12 GENERAL INFORMATION

General Specifications

Items EX650A6F, EX650B6F

Type Swingarm

Wheel Travel

Brake Type:

Front Dual discs

Rear Single disc

Electrical Equipment

Battery 12 V 10 Ah

Headlight:

Type Semi-sealed beam

Bulb 12 V 55 W × 2/55 W (Hi/Lo)

Tail/Brake Light 12 V 5/21 W

Alternator:

Type Three-phase AC

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

125 mm (4.9 in.)

Specifications are subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-13

Technical Information - Cassette Type Transmission

Cassette Type Transmission

The transmission of the current model is unable to be removed without disassembling upper and

lower crankcase halves.

The EX650A/B enables transmission to be removed from the right side of engine as an assy, without disassembling crankcase halves (see Transmission Assy Removal in the Crankshaft/Transmission chapter).

Transmission Assy :

Drive Shaft [A] Output Shaft [B] Shift Rods [C] Shift Dram [D] Shift Forks [E] Transmission Case [F]

1-14 GENERAL INFORMATION

Technical Information - Inlet Air Pressure Sensor

Atmospheric pressure sensor and camshaft position sensor are not equipped with the EX650A/B. As a substitute of these sensors above, the EX650A/B recognizes atmospheric pressure and intake stroke of #1 by the signal of inlet air pressure sensor.

The ECU detects atmospheric pressure when the ignition is switched ON. While the engine is running, the ECU also presumes atmospheric pressure by analyzing the waveform of boost pressure over fixed period. The intake stroke is recognized by waveform of boost pressure, therefore the system can recognize the difference of each stroke.

GENERAL INFORMATION 1-15

Technical Information – ABS (Anti – Lock B rake System)

Outline

ABS controls the brake caliper fluid pressure by means of mechatronics - a combination of electronic and hydraulic control technology in order to keep the friction force between the tires and the road surfaces close to the maximum value and prevent wheel lock. But it does not operate during cruising.

ABS Total System

1. ECU

2. ABS Indicator Light (LED)

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Inlet Solenoid Valve

7. Front Outlet Solenoid Valve

8. Rear Inlet Solenoid Valve

9. Rear Outlet Solenoid Valve

10. Brake Lever

11. Brake Pedal

12. ABS Hydraulic Unit

13. Front Brake Caliper

14. Front Wheel Rotation Sensor

15. Front Wheel Rotation Sensor Rotor

16. Rear Brake Caliper

17. Rear Wheel Rotation Sensor

18. Rear Wheel Rotation Sensor Rotor

19. ABS Kawasaki Self-diagnosis System Connector

20. ABS Solenoid Valve Relay

21. ABS Motor Relay

22. Rear Reservoir

1-16 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

ABS System Block Diagram

1. Power Source

2. Ignition Power Source

3. Battery Power Source

4. Indicator Light Output

5. ABS Indicator Light (LED)

6. ECU

7. ABS Solenoid Valve Relay

8. Output

9. Monitor Input

10. Valve Output

11. Outlet Solenoid Valve

12. Inlet Solenoid Valve

13. ABS Motor Relay

14. Pump Motor

15. Hydraulic Unit

16. ABS Controller

17. ABS Hydraulic Unit

18. ABS Kawasaki Self-diagnosis System Connector

19. Wheel Rotation Input

20. Wheel Rotation Sensor

GENERAL INFORMATION 1-17

Technical Information – ABS (Anti – Lock B rake System)

Related Parts and Function

1. Front Wheel Rotation Sensor

2. Front Wheel Rotation Sensor Rotor

3. Rear Wheel Rotation Sensor

4. Rear Wheel Rotation Sensor Rotor

5. ABS Indicator Light (LED)

6. ABS Hydraulic Unit

7. ABS Fuse Box

8. ABS Kawasaki Self-diagnosis System Connector

Wheel Rotation Sensor

The wheel rotation sensors output the rotation speed of each wheel to the ECU in the ABS hydraulic unit. The wheel rotation sensor is installed to the front fork and rear caliper bracket, and the sensor rotor is pressed into the brake disc. The number of teeth on the front and rear sensor rotor is 50.

ABS Indicator Light (LED)

The condition or the failure of the ABS system is indicated by various patterns of the ABS indicator light (LED) blinking.

1-18 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

ABS Hydraulic Unit

The outlet and inlet solenoid valves, reservoir, pump motor, solenoid valve relay, motor relay, and

ECU are built in the ABS hydraulic unit.

1. Brake Lever

2. Brake Pedal

3. Pump Motor

4. Rear Inlet Solenoid Valve

5. Rear Outlet Solenoid Valve

6. Rear Reservoir

7. Rear Caliper

8. Front Inlet Solenoid Valve

9. Front Outlet Solenoid Valve

10. Front Caliper

11. Front Reservoir

12. Orifice

13. Filter

14. Check Valve

GENERAL INFORMATION 1-19

Technical Information – ABS (Anti – Lock B rake System)

Inlet Solenoid Valve

Inlet solenoid valves control the brake pressure of each wheel by combining the operation of the outlet solenoid valve. The ECU changes the electric current in the solenoids of the inlet solenoid valve (2 way, 2 position electromagnetic valve) to move the tappet and change the fluid pressure to “Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1. Increase Mode

2. Hold and Decrease Mode

3. Tappet

4. Valve Body

5. From Master Cylinder

Outlet Solenoid Valve

Outlet solenoid valves control the brake pressure of each wheel by combining the operation of the inlet solenoid valve. The ECU changes the electric current in the solenoids of the outlet solenoid valve (2 way, 2 position electromagnetic valve) to move the armature and change the fluid pressure to “Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1. Decrease Mode

2. Increase and Hold Mode

3. Armature

4. Valve

5. To Reservoir

1-20 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

Reservoir

When the passage opens between the caliper and the reservoir with the outlet solenoid valve in “Decrease Mode”, the brake fluid flows into the reservoir by pushing the piston, stays there temporarily, and then returns to the master cylinder. With the outlet solenoid valve “Increase or Hold Mode”, the pump returns the remaining brake fluid in the reservoir to the master cylinder.

1. From Outlet Solenoid Valve

2. To Pump

Pump Motor

The pump motor operates the pump, supply or return the brake fluid from the pump.

Pump

The pump operates continuously when the ABS is activated. The pump is driven by the motor and supply the brake fluid to the caliper or return the brake fluid in the reservoir to the master cylinder. The piston is reciprocated by the eccentric cam [A] on the end of the motor shaft and the pump sucks in or discharge the brake fluid.

When the pump pulls fluid in, the piston [B] is moved right by the force of the spring [C]. At this time, the spring [D] is compressed by the pressure of the brake fluid in the reservoir to open the inlet valve [E] and the brake fluid flows into the cylinder [F]. The outlet valve [G] is held closed by the force of the spring [H].

When the pump discharges the brake fluid, the inlet valve [E] is closed by the spring [D], and the piston [B] is moved left by the cam [A], producing pressure in the cylinder [F]. The pressure pushes the spring [H], opens the outlet valve [G], and the brake fluid returns to the master cylinder.

Spring [C]

GENERAL INFORMATION 1-21

Technical Information – ABS (Anti – Lock B rake System)

ABS Solenoid Valve Relay

ABS solenoid valve relay supply or intercept the power to the inlet or outlet solenoid valves.

ABS Motor Relay

ABS motor relay supply or intercept the power to the pump motor.

ECU

ECU inputs the sensor signal. ECU calculates the wheel condition for the slip. ECU controls the hydraulic unit. ECU sends the actuating signals to the ABS indicator light (LED).

1-22 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

ABS Operation

The ABS has two independent hydraulic lines, one for the front wheel and the other for the rear wheel. The front wheel system is explained here and is identical to the rear wheel system.

ABS in Action

(Increase Mode)

When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens (normally open). The brake fluid flows through the valve body as shown in the diagram below to increase the brake fluid pressure in the caliper. The master cylinder pressurizes to the brake caliper directly, increasing the braking force.

1. Brake Lever

2. Front Inlet Solenoid Valve

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Outlet Solenoid Valve

7. Front Caliper

GENERAL INFORMATION 1-23

Technical Information – ABS (Anti – Lock B rake System)

(Hold Mode)

When the caliper fluid pressure is to be hold, the tappet of inlet solenoid valve closes, and the passage (master cylinder side) to the valve body is intercepted. No matter how hard the brake lever is pulled, the brake fluid pressure in the caliper is maintained at a given level.

1. Brake Lever

2. Front Inlet Solenoid Valve

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Outlet Solenoid Valve

7. Front Caliper

1-24 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

(Decrease Mode)

When the caliper fluid pressure is to be decreased, the tappet of inlet solenoid valve closes, and the passage to the valve body is intercepted. The valve of outlet solenoid valve is opened by the operation of the armature, and the brake fluid flows to the reservoir. ECU operates pump, and the pump returns the brake fluid in the reservoir to the master cylinder. The brake fluid pressure is decreased, and the wheel is prevented from locking.

1. Brake Lever

2. Front Inlet Solenoid Valve

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Outlet Solenoid Valve

7. Front Caliper

GENERAL INFORMATION 1-25

Technical Information – ABS (Anti – Lock B rake System)

ABS Disabled (Conventional Mode)

During cruising (without braking) or in case of a malfunction with the ABS, the ECU stops operating.

This is “Conventional Mode”.

When the caliper fluid pressure is to be incr eased, first the tappet of inlet solenoid valve opens (normally open). The brake fluid flows through the valve body as shown in the diagram below to increase the brake fluid pressure in the caliper. The master cylinder pressurizes to the brake caliper directly, increasing the braking force.

1. Brake Lever

2. Front Inlet Solenoid Valve

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Outlet Solenoid Valve

7. Front Caliper

1-26 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

Riding Characteristics of ABS

ABS is designed to help prevent the wheels from locking up when hard brakes are applied while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.

Brake control function is identical to that of a conventional motorcycle. The brake lever is used for the front brake and the brake pedal for the rear brake.

Although the ABS provides stability while stopping by preventing wheel lock-up, remember the following characteristics:

ABS cannot compensate for adverse road conditions, misjudgement or improper application of

○

brakes. You must take the same care as with motorcycles not equipped with ABS.

ABS is not designed to shorten the braking distance. On loose, uneven or downhill surfaces, the

○

stopping distance of a motorcycle with ABS may be longer than that of an equivalent motorcycle

without ABS. Use special caution in such areas.

ABS will help prevent wheel lock-up during straight-up braking, but it cannot control wheel slip which

○

may be caused by braking during cornering. When turning a corner, it is better to limit braking to

the light application of both brakes or not to brake at all. Reduce your speed before you get into the

corner.

The ECU integrated in the ABS compare vehicle speed with wheel speed. Since non-recommended

○

tires can affect wheel speed, they may confuse the ECU, which can extend braking distance.

WARNING

Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended

braking distance. The rider could have an accident as a result. Always use recommended

standard tires for this motorcycle.

NOTE

When the ABS is functioning, you may feel a pulsing in the brake lever or pedal. This is normal.

○

You need not suspend applying brakes. Immediately after turning the ignition switch on, you may hear a click of the relay operating. This

○

is the sound of self-checking and is quite normal. ABS does not function at the speed of approx. 6 km/h or below.

○

ABS does not function if the battery is discharged.

○

Unit Conversion Table

GENERAL INFORMATION 1-27

Prefixes fo r Units:

Prefix Symbol Power

mega M ×1000000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units o f Mass:

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 =

L × 0.2200 =

L × 1.057 = qt (US)

L × 0.8799 = qt (imp)

L × 2.113 = pint (US)

L × 1.816 = pint (imp)

mL × 0.03381 =

mL × 0.02816 =

mL × 0.06102 = cu in

gal (US)

gal (imp)

oz (US)

oz (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

×7.233=

× 86.80 = in·lb

ft·lb

Units of Pressure:

kPa × 0.01020 =

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cmHg × 1.333 = kPa

kgf/cm²

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 =

kW × 1.341 = HP

PS × 0.7355 = kW

PS × 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

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

Specifications ......................................................................................................................... 2-11

Special Tools .......................................................................................................................... 2-13

Periodic Maintenance Procedures.......................................................................................... 2-14

Fuel System (DFI)................................................................................................................ 2-14

Air Cleaner Element Cleaning........................................................................................... 2-14

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

Engine Vacuum Synchronization Inspection..................................................................... 2-16

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

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

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

Evaporative Emission Control System (California Model) ................................................... 2-19

Evaporative Emission Control System Inspection ............................................................ 2-19

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

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

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

Air Suction System .............................................................................................................. 2-21

Air Suction System Damage Inspection............................................................................ 2-21

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

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

Valve Clearance Adjustment ............................................................................................. 2-23

Clutch................................................................................................................................... 2-26

Clutch Operation Inspection.............................................................................................. 2-26

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

Drive Train ........................................................................................................................... 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 Operation Inspection .............................................................................................. 2-33

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

Brake Pad Wear 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 ........................................................................ 2-35

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

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

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

2-2 PERIODIC MAINTENANCE

Steering S tem Bearing Lubrication ................................................................................... 2-37

Electrical System ................................................................................................................. 2-37

Spark Plug Condition Inspection....................................................................................... 2-37

Lights and Switches Operation Inspection ........................................................................ 2-38

Headlight Aiming Inspection ............................................................................................. 2-40

Sidestand Switch Operation Inspection ............................................................................ 2-41

Engine Stop Switch Operation Inspection......................................................................... 2-42

Others.................................................................................................................................. 2-43

Chassis Parts Lubrication ................................................................................................. 2-43

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-44

Replacement P arts .............................................................................................................. 2-45

Air Cleaner Element Replacement.................................................................................... 2-45

Fuel Hose Replacement ................................................................................................... 2-45

Coolant Change ................................................................................................................ 2-46

Radiator Hose and O-ring Replacement ........................................................................... 2-48

Engine Oil Change............................................................................................................ 2-49

Oil Filter Replacement ...................................................................................................... 2-49

Brake Hose and Pipe Replacement.................................................................................. 2-50

Brake Fluid Change .......................................................................................................... 2-51

Master Cylinder Rubber Parts Replacement .................................................................... 2-52

Caliper Rubber Parts Replacement .................................................................................. 2-54

Spark Plug Replacement .................................................................................................. 2-56

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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

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

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)

Fuel System

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

Air cleaner element - clean

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

Engine vacuum synchronization - inspect

Idle speed - inspect

Fuel leak (fuel hose and pipe) - inspect year

Fuel hose and pipe damage - inspect year

Fuel hose and pipe installation condition inspect

Evaporative Emission Control System (CAL)

Evaporative emission control system function - inspect

Cooling System

Coolant level - inspect

Coolant leak (radiator hose and pipe) inspect

Radiator hose damage - inspect year

Radiator hose installation condition inspect

Air Suction System

year

• • •

• • • •

• • •

• • • •

• • • • • • •

• • • •

2-14

2-15

2-16

2-18

2-19

2-20

2-21

Air suction system damage - inspect

Engine Top End

Valve clearance - inspect Every 42 000 km (26 000 mile) 2-21

Clutch

Clutch operation (play, disengagement, engagement) - inspect

Wheels and Tires

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearing damage - inspect year

Drive Train

Drive chain lubrication condition - inspect # Every 600 km (400 mile)

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

Drive chain wear - inspect #

• • • •

• • •

2-21

2-26

2-27

2-28

2-29

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)

Drive chain guide wear - inspect

Brake System

Brake fluid leak (brake hose and pipe) inspect

Brake hose and pipe damage - inspect year

Brake hose and pipe installation condition

- inspect

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

Brake fluid level - inspect 6 months

Brake pad wear - i nspect #

Brake light switch operation - inspect

Suspensions

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

Front forks/rear shock absorber oil leak inspect

Steering System

year

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • •

• • • • • •

• • •

See

Page

2-31

2-32

2-33

2-34

2-35

Steering play - inspect year

Steering stem bearings - lubricate

Electrical System

Spark plug condition - inspect

Lights and switches operation - inspect year

Headlight aiming - inspect year

Sidestand switch operation - inspect year

Engine stop switch operation - inspect year

Others

Chassis parts - lubricate year

Bolts and nuts tightness - inspect

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

frequent starting/stopping.

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

2 years

• • • •

•

• • •

• • • •

2-36

2-37

2-38

2-40

2-41

2-42

2-43

2-44

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

comes

first

CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30)

Air cleaner element # 2 years 2-45

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

See

Page

Fuel hose 4 years

Coolant 3 years

Radiator hose and O-ring 3 years

Engine oil # year

Oil filter

Brake hose and pipe 4 years

Brake fluid 2 years

Rubber parts of master cylinder and caliper 4 years

Spark plug

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

frequent starting/stopping.

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

year

• • • • •

• •

• • • •

•

2-45

2-46

2-48

2-49

2-50

2-51

2-52,

2-54

2-56

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.

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).

SS: Apply silicone sealant.

Fastener

Fuel System (DFI)

Water Temperature Sensor 12 1.2 106 in·lb

Speed Sensor Bolt 7.8 0.80 69 in·lb L

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Oxygen Sensor (Europe Models) 44.1 4.50 32.5

Cooling System

Radiator Hose Clamp Screws

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Water Pump Cover Bolts 9.8 1.0 87 in·lb

Water Pump Drain Bolt 7.0 0.70 62 in·lb

Thermostat Housing Bolts 9.8 1.0 87 in·lb

Water Temperature Sensor 12 1.2 106 in·lb

Baffle Plate Bolts 5.9 0.60 52 in·lb

Engine Top End

Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb

Camshaft Cap Bolts 12 1.2 106 in·lb S

Cylinder Head Bolts (M10 New Bolts) 54 5.5 40 MO, S

Cylinder Head Bolts (M10 Used Bolts)

Cylinder Bolt (M8) 27.5 2.8 20 MO, S

Cylinder Nut (M10) 49 5.0 36 MO, S

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

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

Throttle Body Holder Bolts 12 1.2 106 in·lb

Rear Camshaft Chain Guide Bolt 20 2.0 15 L

Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb

Camshaft Chain Tensioner Cap Bolt 20 2.0 15

Camshaft Sprocket Bolts

Spark Plugs 15 1.5 11

Exhaust Pipe Manifold Holder Nuts 17 1.7 12

Muffler Body Mounting Bolt (Front) 20 2.0 15

N·m kgf·m ft·lb

2.0 0.20 17 in·lb

49 5.0 36

15 1.5 11 L

Torque

Remarks

MO, S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Muffler Body Mounting Bolt (Rear)

Baffle Plate Bolts 5.9 0.60 52 in·lb

Clutch

Upper Cap on Clutch Cover 3.9 0.40 35 in·lb

Lower Cap on Clutch Cover – – – Hand-tighten

Oil Filler Plug – – – Hand-tighten

Clutch Cover Mounting Bolts

Clutch Spring Bolts 9.8 1.0 87 in·lb

Clutch Hub Nut 132 13.5 98 R

Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S

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

Clutch Cable Holder Bolts 9.8 1.0 87 in·lb L

Clutch Cable Clamp Bolt

Engine Lubrication

Engine Oil Drain Bolt 30 3.0 22

Filter Plate Bolts 9.8 1.0 87 in·lb L

Oil Filter 17.2 1.75 13 EO, R

Holder Mounting Bolt 25 2.5 18 L

Oil Pan Bolts 12 1.2 106 in·lb

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

Oil Pipe Plate Bolt 9.8 1.0 87 in·lb L

Oil Pressure Relief Valve

Oil Pressure Switch 15 1.5 11 SS

Oil Pump Cover Bolts 9.8 1.0 87 in·lb L

Lower Fairing Bracket Bolts 12 1.2 106 in·lb L

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

Oil Passage Plug 20 2.0 15 L

Oil Plate Bolts 9.8 1.0 89 in·lb L

Engine Removal/Installation

Rear Engine Mounting Nuts 44 4.5 32 S

Engine Mounting Bracket Bolts 25 2.5 18

Front Engine Mounting Bolts 44 4.5 32 S

Crankshaft/Transmission

Oil Plate Bolts 9.8 1.0 87 in·lb L

Breather Plate Bolts 9.8 1.0 87 in·lb L

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

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

Crankcase Bolts (M8, L = 73 mm) 35 3.6 26 MO, S

Crankcase Bolts (M8, L = 60 mm) 35 3.6 26 MO, S

Crankcase Bolts (M8, L = 110 mm)

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

Crankcase Bolts (M6) 19.6 2.0 15 S

Upper Crankcase Bolts 27.5 2.8 20 S

N·m kgf·m ft·lb

20 2.0 15

9.8 1.0 87 in·lb

15 1.5 11 L

27.5 2.8 20

Torque

Remarks

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Shift Drum Bearing Holder Screw

Connecting Rod Big End Nuts see Text ← ← MO

Timing Rotor Bolt 40 4.1 30

Oil Pressure Switch

Oil Passage Plug 20 2.0 15 L

Gear Positioning Lever Bolt 12 1.2 106 in·lb L

Shift Shaft Return Spring pin 29 2.9 22 L

Shift Drum Cam Bolt 12 1.2 106 in·lb L

Neutral Switch 15 1.5 11

Transmission Case Bolts

Shift Rod Plate Bolt 9.8 1.0 87 in·lb

Neutral Switch Holder Screw 4.9 0.50 43 in·lb L

Shift Shaft Cover Bolts 9.8 1.0 87 in·lb L(2)

Shift Shaft Cover Screw 4.9 0.50 43 in·lb L

Wheels/Tires

Front Axle 108 11.0 80

Front Axle Clamp Bolt 34 3.5 25

Rear Axle Nut 108 11. 0 80

Final Drive

Engine Sprocket Nut 125 12.7 92 MO

Rear Axle Nut 108 11. 0 80

Rear Sprocket Nuts

Speed Sensor Bolt 7.8 0.80 69 in·lb L

Speed Sensor Bracket Bolts 9.8 1.0 87 in·lb

Brakes

Bleed Valve 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

Brake Pedal Bolt 8.8 0.90 78 in·lb

Brake Pipe Joint Nuts (EX650B Models)

Front Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Light Switch Screw 1.0 0.10 9in·lb

Front Brake Reservoir Cap Screws

Front Caliper Mounting Bolts 34 3.5 25

Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S

Rear Brake Disc Mounting Bolts 27 2.8 20 L

Rear Caliper Mounting Bolts 25 2.5 18

Rear Master Cylinder Mounting Bolts 25 2.5 18

Rear Master Cylinder Push Rod Locknut 18 1.8 13

Suspension

Front Axle Clamp Bolt 34 3.5 25

Front Fork Bottom Allen Bolts 30 3.1 22 L

N·m kgf·m ft·lb

4.9 0.50 43 in·lb L

15 1.5 11

20 2.0 15

59 6.0 44

18 1.8 13

1.0 0.10 9in·lb

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Front Fork Clamp Bolts (Lower)

Front Fork Clamp Bolts (Upper) 20 2.0 15

Front Fork Top Plugs 25 2.5 18

Rear Shock Absorber Bolt

Rear Shock Absorber Nut 59 6.0 44

Swingarm Pivot Shaft Nut 108 11.0 80

Steering

Front Fork Clamp Bolts (Lower) 20 2.0 15 AL

Front Fork Clamp Bolts (Upper) 20 2.0 15

Handlebar Holder Bolts 25 2.5 18

Left Switch Housing Screws 3.5 0.36 31 in·lb

Right Switch Housing Screws 3.5 0.36 31 in·lb

Steering Stem Head Bolt 108 11 . 0 80

Steering Stem Nut 20 2.0 15

Frame

Footpeg Stay Bolts 34 3.5 25

Front Fender Bolts 3.9 0.40 35 in·lb

Front Fender Bracket Bolts 8.8 0.90 78 in·lb L

Front Turn Signal Light Mounting Screws

Grab Rail Mounting Bolts 25 2.5 18

Seat Lock Mounting Screws 1.2 0.12 11 in·lb

Sidestand Bolt 44 4.5 32

Sidestand Switch Bolt 8.8 0.90 78 in·lb L

Electrical System

Alternator Cover Bolts

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

Alternator Rotor Bolt 155 15.8 114 MO

Crankshaft Sensor Bolts

Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

Front Turn Signal Light Mounting Screws 1.2 0.12 11 in·lb

Left Switch Housing Screws 3.5 0.36 31 in·lb

License Plate Light Cover Screws 0.90 0.090 8in·lb

License Plate Light Mounting Screws

Meter Screws 1.2 0.12 11 i n·lb

Neutral Switch 15 1.5 11

Oil Pressure Switch 15 1.5 11 SS

Oxygen Sensor 44.1 4.50 32.5

Regulator/Rectifier Bolts 8.8 0.90 78 in·lb

Right Switch Housing Screws

Sidestand Switch Bolt 8.8 0.90 78 in·lb L

Spark Plugs 15 1.5 11

Speed Sensor Bolt 7.8 0.80 69 in·lb L

N·m kgf·m ft·lb

20 2.0 15 AL

59 6.0 44

1.2 0.12 11 in·lb

9.8 1.0 87 in·lb

6.0 0.60 53 in·lb

1.2 0.12 11 in·lb

3.5 0.36 31 in·lb

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Starter Motor Cable Terminal Nut

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 4.9 0.50 43 in·lb

Stator Coil Bolts 12 1.2 106 in·lb L

Timing Rotor Bolt 40 4.1 30

Water Temperature Sensor 12 1.2 106 in·lb

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

N·m kgf·m ft·lb

6.0 0.60 53 in·lb

Torque

Remarks

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

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Fuel System (DFI)

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

Idle Speed 1300±50r/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 1.2 L (1.3 US qt) –––

Engine Top End

Valve Clearance:

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

Inlet

Clutch

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

Engine Lubrication System

Engine Oil:

Type API SE, SF or SG –––

Viscosity SAE 10W-40 –––

Capacity 1.7 L (1.8 US qt) (when filter is not

Level Between upper and lower level lines

Wheels/Tires

Tread Depth:

Front 4.3 mm (0.17 in.) 1 mm (0.04 in.),

Rear 7.0 mm (0.28 in.) Up to 130 km/h (80 mph):

Air Pressure (when Cold):

Front

Rear

0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)

API SH, SJ or SL with JASO MA

removed)

1.9 L (2.0 US qt) (when filter is removed) –––

2.4 L (2.5 US qt) (when engine is completely dry)

(after idling or running)

Over 130 km/h (80 mph):

Up to 180 kg (397 lb) load:

225 kPa (2.25 kgf/cm², 32 psi)

Up to 180 kg (397 lb) load:

250 kPa (2.50 kgf/cm², 36 psi)

–––

(AT, CH, DE)

1.6 mm (0.06 in.)

2 mm (0.08 in.),

3 mm (0.12 in.)

–––

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Final Drive

Drive Chain Slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.)

Drive Chain Wear (20-link Length)

Standard Chain:

Make ENUMA –––

Type EK520MVXL1 –––

Link 114 links –––

Brakes

Brake Fluid:

Grade DOT4 –––

Brake Pad Lining Thickness:

Front

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

Brake Light Timing:

Front

Rear

Electrical System

Spark Plug Gap 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.) –––

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

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

Pulled ON

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

–––

Special Tools

PERIODIC MAINTENANCE 2-13

Inside Circlip Pliers: 57001-143

Steering Stem Nut Wrench: 57001-1100

Oil Filter Wrench: 57001-1249

Extension Tube: 57001-1578

Pilot Screw Adjuster, E: 57001-1603

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System (DFI)

Air Cleaner Element Cleaning

NOTE

In dusty areas, the element should be cleaned more

○

frequently than the recommended interval. After riding through rain or on muddily roads, the ele-

○

ment should be cleaned immediately.

WARNING

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

CAUTION

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

Remove:

•

Fuel Tank (see Fuel Tank Removal i n the Fuel System (DFI) chapter) Air Switching Valve Hose [A] (Disconnect) Air Cleaner Element Screw [B] Air Cleaner Element [C]

Remove:

•

Upper Plastic Holder [A] Element [B]

NOTE

The wire screen [A] is fastened with an adhesive for the

○

shaded portion [B]. Do not remove the wire screen.

Periodic Maintenance Procedures

WARNING

Clean the element in a well-ventilated area, and make sure that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element.

Clean the element [A] in a bath of high-flash point solvent,

•

and then dry it with compressed air or by shaking it. After cleaning, saturate a clean, lint-free towel with SE,

•

SF, or SG class SAE 30 oil and apply the oil to the element by tapping the element outside with the towel. Visually check the element for tears or breaks.

•

If the element has any tears or breaks, replace the ele-

•

ment.

Install the element unit [A] with the foam element side

•

(gray) [B] facing down.

PERIODIC MAINTENANCE 2-15

Throttle Control System Inspection

Check that the throttle grip moves smoothly from full open

•

to close [A], and the throttle closes quickly and completely by the return spring in all steering positions. If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

Check the throttle grip free play [A].

•

If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If necessary, 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.

Remove the right center fairing (see Center Fairing Re-

•

moval in the Frame chapter). 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 inlet and exhaust systems of the engine are in good condition.

Situate the motorcycle so that it is vertical.

•

Remove the center fairings (see Center Fairing Removal

•

in the Frame chapter). Pull off the rubber caps [A] from the fitting of each throttle

•

body (In the photo, the throttle body has been removed for clarity.).

CAUTION

Do not remove the inlet air pressure sensor hose [B] on the left fitting of the throttle body.

Connect a commercially available vacuum gauge and

•

hoses [A] to the fittings of the throttle body as shown. Connect a highly accurate tachometer to one of the stick

•

coil primary leads.

Periodic Maintenance Procedures

Start the engine and warm it up thoroughly.

•

Check the idle speed.

•

Tachometer [A]

Open and close the throttle.

•

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

CAUTION

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 [B].

Engine Vacuum

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

Speed 1 300 ±50 r/min (rpm)

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

PERIODIC MAINTENANCE 2-17

CAUTION

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.

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

•

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

○

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

○

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

○

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

•

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.

•

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

Main Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → Y/ W lead (terminal 7)

Meter (–) → BR/BK lead (terminal 28)

Standard:

1.055 ∼ 1.095 V DC (at idle throttle opening)

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

•

hoses and rubber caps.

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides

•

[A]. 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 or 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.

Check idle speed.

•

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

Idle Speed

Standard: 1 300 ±50 r/min (rpm)

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Turn the adjusting screw [A] until the idle speed is correct.

•

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)

The fuel hose is designed to be used throughout the mo-

○

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

Check that the hoses are routed according to Cable, Wire,

•

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

Hose Joints [A] 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 two times, and make sure it is locked. If it does not locked, reinstall the hose joint.

WARNING

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

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Inspect the canister as follows.

•

Remove:

○

Left Center Fairing (see Center Fairing Removal in the Frame chapter)

Remove the canister [A], and disconnect the hoses 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.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check the liquid/vapor separator as follows.

•

Remove:

○

Left Center Fairing (see Center Fairing Removal in the Frame chapter)

Disconnect the hoses from the separator, and remove the

○

separator [A] from the motorcycle left side. Visually inspect the separator for cracks and other dam-

○

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

○

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

•

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

○

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

○

Route the hoses according to Cable, Wire, and Hose

○

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

○

flattening or twisting, and route 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) and unscrew the reserve tank cap, and add coolant to the “F” level line [C].

“L”: low “F”: full

CAUTION

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

Radiator Hose Damage and Installation Condition Inspection

The high pressure inside the radiator hose and pipe can

○

cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.

•

Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps

•

are tightened correctly.

Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

17 in·lb)

Air Suction System

Air Suction System Damage Inspection

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

•

System (DFI) chapter). Remove the fuel hose (see Fuel Hose Replacement).

•

Connect:

•

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

Special Tool - Extension Tube: 57001-1578

Pull the air switching valve hose [C] out of the air cleaner

•

housing.

PERIODIC MAINTENANCE 2-21

Start the engine and run it at idle speed.

•

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

•

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

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (room temperature).

Remove:

•

Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter)

Unscrew the upper [A] and lower [B] caps on the clutch

•

cover.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check the valve clearance when the pistons are at TDC.

•

The pistons are numbered beginning with the engine left

○

side. Using a wrench [A] on the crankshaft rotation bolt, turn

•

the crankshaft clockwise until the "1/T" mark on the timing rotor is aligned with the notch [B] in the edge of the upper hole in the clutch cover for #1 piston and "2/T" mark for #2 piston.

1/T Mark [A] 2/T Mark [B] Hole [C] of Upper Cap Notch [D] in Edge of Upper Hole

Measure the valve clearance of the valves for which the

○

cam [A] are turned away from each other.

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

•

ance between cam and valve lifter.

Valve Clearance

Standard:

Exhaust

Inlet

Each piston has two inlet and two exhaust valves. Mea-

○

sure these two inlet or exhaust valves at the same crankshaft position.

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #1 piston, and

Exhaust valve clearances of #1 piston

NOTE

Check the valve clearance using this method only.

○

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

Periodic Maintenance Procedures

Valve Clearance Measuring Position

#2 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #2 piston, and

Exhaust valve clearances of #2 piston

If the valve clearance is not with in the specified range, first record the clearance, and adjust it.

Valve Clearance Adjustment

To change the valve clearance, remove the camshaft

•

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

NOTE

Mark and record the valve lifter and shim locations so

○

they can be reinstalled in their original positions. If there is no clearance, select a shim which is several

○

sizes smaller and then measure the clearance.

PERIODIC MAINTENANCE 2-23

To select a new shim which brings the v alve 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.

CAUTION

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

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART INLET 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 0.45 mm. Replace 2.95 mm shim with 3.20 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART EXHA UST VALVE

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

2. Check present shim size.

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

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

Example: Present shim is 2.95 mm.

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

5. Remeasure the valve clearance and readjust if necessary.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clutch

Clutch Operation Inspection

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

•

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

•

If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it.

Clutch Lever Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

WARNING

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

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

•

of threads are visible.

Remove the right center fairing (see Center Fairing Re-

•

moval in the Frame chapter). Slide the dust cover [A] at the middle of the clutch cable

•

out of place. Loosen the locknut [B] at the middle of clutch cable.

•

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

•

WARNING

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

After the adjustment, tighten the locknut and start the en-

•

gine and check that the clutch does not slip and that it releases properly.

Wheels/Tires

Air Pressure I nspection

Remove the air valve cap.

•

Measure the tire air pressure with an air pressure gauge

•

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

•

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

Air Pressure (when Cold)

Front:

Rear:

Up to 180 kg (397 lb) 225kPa(2.25kgf/cm²,32psi)

Up to 180 kg (397 lb) 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 if necessary.

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.

If any measurement is less than the service limit, replace

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

chapter).

PERIODIC MAINTENANCE 2-27

Tread Depth

Standard:

Front

Rear

Service Limit:

Front

Rear

4.3 m m (0.17 in.)

7.0 m m (0.28 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

To ensure safe handling and stability, use only the

recommended standard tires for replacement, in-

flated 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 Damage Inspec tion

Raise the front wheel off the ground with jack (see Front

•

Wheel Removal in the Wheels/Tires chapter). 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 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 i s 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).

Drive Train

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 chain appears especially dirty, clean it before lubri-

•

cation.

CAUTION

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

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] m idway

•

between the sprockets.

If the chain slack exceeds the standard, adjust it.

PERIODIC MAINTENANCE 2-29

Chain Slack

Standard: 30 ∼ 40 mm (1.2 ∼ 1.6 in.)

Drive Chain Slack Adju s tment

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 in the left and right chain

adjuster nuts [D] evenly.

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

adjuster nuts evenly, and kick the wheel forward.

Turn both chain adjuster nuts evenly until the drive chain

•

has the correct amount of slack. To keep the chain and

wheel properly aligned, the value [E] on the left wheel

alignment adjuster [F] should align with the same (left or

right) edge [G] of inspection window on the swingarm that

the right wheel alignment adjuster value aligns with.

WARNING

Misalignment of the wheel will result in abnormal

wear and may result in an unsafe riding condition.

Tighten both chain adjuster locknuts securely.

•

Tighten the axle nut.

•

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°.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

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

•

WARNING

If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result.

Wheel Alignment Inspection

Check that the value [A] on the left wheel alignment ad-

•

juster [B] aligns with the same (left or right) edge [C] of inspection window on the swingarm that the right wheel alignment adjuster value 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.

Periodic Maintenance Procedures

Drive Chain Wear Inspection

Remove:

•

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 c enter

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 Lim it : 323 mm (12.7 in.)

PERIODIC MAINTENANCE 2-31

WARNING

If the drive chain wear exceeds the service limit, re-

place the chain or an unsafe riding condition may

result. A chain that breaks or jumps off the sprock-

ets could snag on the engine sprocket or lock the

rear wheel, severely damaging the motorcycle and

causing it to go out of control.

For safely, use only the standard chain. It is an end-

less type and should not be cut for installation.

Standard Chain

Make: ENUMA

Type: EK520MVXL1

Link: 114 links

Chain Guide Inspection

Remove:

•

Swingarm (see Swingarm Removal in the Suspension chapter)

Visually inspect the chain guide [A].

•

Replace the chain guide if it shows any signs of abnormal

wear or damage.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake System

Brake Fluid Leak (Bra ke Hose and Pipe) Inspection

Apply the brake lever or pedal and inspect the brake fluid

•

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

Brake Hose and Pipe Damage and Installatio n Condition Inspection

Inspect the brake hoses, fittings and pipes for deteriora-

•

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

○

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

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

ft·lb)

BrakePipeJointNuts:18N·m(1.8kgf·m,13ft·lb)

(EX650B Models)

Inspect the brake hose routing.

•

If any brake hose routing is incorrect, route the brake hose according to Cable, Wire, and Hose Routing section in the Appendix chapter.

Periodic Maintenance Procedures

Brake Operation Inspec tion

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

•

ning the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake

system.

WARNING

When inspecting by running the vehicle, note a

surrounding traffic situation enough in the place of

safety.

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, fill the

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

PERIODIC MAINTENANCE 2-33

Remove the seat (see Seat Removal in the Frame chap-

•

ter).

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, fill the

reservoir to the upper level line [C].

WARNING

Change the brake fluid in the brake line completely

if the brake fluid must be refilled but the type and

brand of the brake fluid that is already in the reser-

voir are unidentified. After changing the fluid, use

only the same type and brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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].

Brake Pad Wear Inspection

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

•

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

Pad Lining Thickness

Standard:

Front

Rear

Service Limit: 1 mm (0.04 in.)

4.5 mm (0.18 in.)

5.0 mm (0.20 in.)

Brake Light Switch Operation Inspection

Turn on the ignition switch.

•

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. Disconnect the connector [A].

•

Turn the brake light switch to adjust the switch.

•

Connect the connector.

•

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 Removal in the Electrical System chapter) Main Fuse 30 A and Taillight 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)

Periodic Maintenance Procedures

Suspensions

Front Forks/Rear Shock Absorber Operation Inspection

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

•

the smooth stroke.

If the forks do not smoothly or noise is found, inspect the

fork oil level or fork clamps (see Front Fork Oil Change in

the Suspension chapter).

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

•

the smooth stroke.

If the shock absorber does not smoothly stroke or noise

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

Oil Leak Inspection).

PERIODIC MAINTENANCE 2-35

Front Fork Oil Leak Inspection

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

•

Replace or repair any defective parts, if necessary.

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.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering System

Steering Play Inspection

Raise the front wheel off the ground with jack (see Front

•

Wheel Removal in the Wheels/Tires chapter). With the front wheel pointing straight ahead, alternately

•

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

•

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

NOTE

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

○

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

○

The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

Steering Play Adjustment

Remove:

•

Upper Inner Fairings (see Upper Inner Fairing Removal in the Frame chapter) Handlebar (see Handlebar Removal in the Steering chapter) Upper Fork Clamp Bolts [A] Steering Stem Head Bolt Plug [B] Stem Head Bolt [C]

Remove the steering stem head [D].

•

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

•

Remove the steering stem locknut [B] and claw washer

•

[C].

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.

○

Periodic Maintenance Procedures

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

•

upward, and engage the bent claws with the grooves of

stem locknut [C].

Hand tighten the stem locknut until it touches the claw

•

washer.

Tighten the stem locknut clockwise until the claws are

•

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

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

Install the steering stem head.

•

Install the washer, and tighten the stem head bolt.

•

Tighten:

•

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

ft·lb)

Front Fork Clamp Bolts (Upper): 20 N·m (2.0

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 removed parts (see appropriate chapters).

•

PERIODIC MAINTENANCE 2-37

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 in the cages, and wipe the upper and

lower outer races, which are press-fitted into the frame

head pipe, clean off grease and dirt.

Visually check the outer races and the ball bearings.

•

Replace the bearing assemblies if they show wear or

damage.

Pack the upper and lower ball bearings [A] in the cages

•

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

and lower outer races.

Install the steering stem (see Stem, Stem Bearing Instal-

•

lation in the Steering chapter).

Adjust the steering (see Steering Play Adjustment).

•

Electrical System

Spark Plug Condition Inspection

Remove the spark plugs (see Spark Plug Replacement).

•

Visually inspect the spark plugs.

•

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

trode [B] are corroded or damaged, or if the insulator [C]

is cracked, replace the plug.

If the spark plug is dirtied or the carbon is accumulated,

replace the spark plug.

Measure the gap [D] with a wire-type thickness gauge.

•

If the gap is incorrect, replace the spark plug.

Spark Plug Gap: 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)

Use the standard spark plug or its equivalent.

•

Spark Plug: CR9EIA-9

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Lights and Switches Operation Inspection

First Step

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

City Light [A]

Taillight [B]

License Plate Light [C]

Meter Panel LCD [D]

Neutral Indicator Light (LED) [E]

Oil Pressure Warning Indicator Light (LED) [F]

Water Temperature Warning Indicator Light (LED) [G]

FI Indicator Light (LED) [H]

EX650B Models

ABS Indicator Light (LED) [I]

goes on

(about 2 seconds)

goes on

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

Battery (see Charging Condition 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 Electrical System chapter) Meter U nit f or Neutral Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for Oil Pressure Warning Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for FI Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for Water Temperature Warning Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for ABS Indicator Light (LED) (see ABS Indicator Light (LED) Inspection in the Brakes chapter) (EX650B Models) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System 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)

Periodic Maintenance Procedures

Turn off the ignition switch.

•

The all lights should go off.

•

If the 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

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

•

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

•

cording to the switch position should flash.

The turn signal indicator light (LED) [C] in the meter unit

•

should flash.

If the each light does not flash, inspect or replace the

following item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter) Meter Unit for Turn Signal Light 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 2-39

2-40 PERIODIC MAINTENANCE

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 replace the following item.

Headlight Low Beam Bulb (see Headlight Bulb Replacement in the Electrical System c hapter) Headlight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) Headlight 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 high beam indicator light (LED) [C] should go on.

•

If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.

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

Turn off the engine stop switch.

•

The low beam and high beam headlights should stay go-

•

ing on. If the headlights and high beam indicator light (LED) does go off, inspect or replace the following item.

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

Turn off the ignition switch.

•

The headlights and high beam indicator light (LED) should

•

go off.

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 with the

•

screwdriver in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam.

Periodic Maintenance Procedures

Headlight Beam Vertical Adjustment

Turn the vertical adjuster [A] on the headlight with the

•

screwdriver 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. For US model, the proper angle is 0.4 degrees below

○

horizontal. This is 50 mm (2 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.

PERIODIC MAINTENANCE 2-41

50 mm (2 in.) [A] Center of Brightest Spot [B]

7.6 m (25 ft) [C] Low Beam [D] Height of Headlight Center [E] High Beam [F]

Sidestand Switch Operation Inspection

Inspect the sidestand switch [A] operation accordance to

•

below table.

Sidestand Switch Operation

Sidestand

Up Neutral Released

Up Neutral Pulled in

Up In Gear Released

Down Neutral Released

Down Neutral Pulled in

Down

Gear

Position

In Gear

Clutch

Lever

Pulled in

Released

Pulled in

Engine

Start

Starts

Doesn’t

start

Starts

Doesn’t

start

Doesn’t

start

Engine

Run

Continue

running

Continue

running

Stops

Continue

running

Continue

running

Continue

running

Stops

2-42 PERIODIC MAINTENANCE

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 Electrical 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 good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).

Engine Stop Switch Operation Inspection

First Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button.

•

The engine does 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 on the ignition switch.

•

Set the neutral position.

•

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

•

Push the s tarter button and run the engine.

•

Turn the engine stop switch to stop position.

•

Immediately the engine should be stop.

•

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

Engine Stop Switch (see Switch Inspection in the Elec-

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

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

PERIODIC MAINTENANCE 2-43

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.

2-44 PERIODIC MAINTENANCE

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 Nut

Engine Mounting Bolts and Nuts

Exhaust Pipe Manifold Holder Nuts

Muffler Body Mounting Bolts

Wheels:

Front Axle

Front Axle Clamp Bolt

Rear Axle Nut

Rear Axle Nut Cotter Pin

Brakes:

Brake Lever Pivot Nut

Brake Pedal Bolt

Brake Rod Joint Cotter Pin

Caliper Mounting Bolts

Front Master Cylinder Clamp Bolts

Rear Master Cylinder Mounting Bolts

Suspension:

Front Fork Clamp Bolts

Rear Shock Absorber Bolt and Nut

Swingarm Pivot Shaft Nut

Steering:

Steering Stem Head Bolt

Handlebar Holder Bolts

Others:

Footpeg Stay Bolts

Front Fender Bolts

Sidestand Bolt

Periodic Maintenance Procedures

Replacement Parts

Air Cleaner Element Replacement

Refer to the Air Cleaner Element Cleaning.

•

Fuel Hose Replacement

CAUTION

When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made from resin could be damaged.

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Left Center Fairing (see Center Fairing Removal in the Frame chapter)

Be sure to place a piece of cloth [A] around the fuel hose

•

joint. Insert a minus screw driver [B] into the slit [C] on the joint

•

lock.

PERIODIC MAINTENANCE 2-45

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

•

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

•

WARNING

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.

Install the new fuel hose.

•

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

•

pipe until the hose joint clicks. Push [C] the joint lock [D].

•

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

•

more than two times and make sure it is locked and doesn’t come off.

WARNING

Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could 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 removed parts (see appropriate chapters).

•

Start the engine and check the fuel hose for leaks.

•

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine, or other painted parts. Since coolant is harmful to the human body, do not use for drinking.

Remove:

•

Right Center Fairing (see Center Fairing Removal in the

Frame chapter)

Reserve Tank Bolts [A]

Reserve Tank [B]

Put [A] the projection [B] on the reserve tank into the hole

•

[C] on the frame bracket, and place the reserve tank on the right side of frame.

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

•

then remove the drain bolt.

Periodic Maintenance Procedures

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

•

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

○

Turn over [A] the reserve tank, remove the cap, and pour

•

the coolant into a suitable container. Place the reserve tank on the right side of frame.

•

Tighten the drain bolt with the gasket.

•

Replace the drain bolt gasket with a new one.

○

Torque - Water Pump Drain Bolt: 7.0 N·m (0.70 kgf·m, 62

in·lb)

PERIODIC MAINTENANCE 2-47

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

CAUTION

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

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%

Coolant: 50%

Freezing Point:

Total Am ount:

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

•

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

○

from the engine and radiator.

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.

•

–35°C (–31°F)

1.2 L (1.3 US qt)

NOTE

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Temporarily install the reserve tank to the frame with two

•

bolts. 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” level line, add coolant to the “F” level line.

CAUTION

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

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

•

Thermostat Housing [A] (see Water Pump Removal in

the Cooling System chapter)

Water Pump Cover [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.

•

Fill the coolant (see Coolant Change).

•

Check the cooling system for leaks.

•

Periodic Maintenance Procedures

Engine Oil Change

Situate the motorcycle so that it is vertical after warming

•

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

•

Place on oil pan beneath the engine.

•

Remove the engine oil drain bolt [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 bolt gasket [B] with a new one. Tighten the drain bolt.

•

Torque - Engine Oil Drain Bolt: 30 N·m (3.0 kgf·m, 22 ft·lb)

Pour in the specified type and amount of oil.

•

PERIODIC MAINTENANCE 2-49

Recommended E ngine Oil

Typ e :

Viscosity:

Capacity: 1.7 L (1.8 US qt) (when filter is not

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.

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

API SE, SF or SG

API SH, SJ or SL with JASO MA

SAE 10W-40

removed)

1.9 L (2.0 US qt) (when filter is removed)

2.4 L (2.5 US qt) (when engine is completely dry)

NOTE

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replace the filter with a new one.

•

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

•

Tighten the filter with the oil filter wrench.

•

Torque - Oil Filter: 17.2 N·m (1.75 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).

Brake Hose and Pipe Replacement

CAUTION

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

Remove the banjo bolts [A].

•

When removing the brake hose, take care not to spill the

•

brake fluid on the painted or plastic parts. When removing the brake hoses [B], temporarily secure

•

the end of the brake hose to some high place to keep fluid loss to a minimum. Immediately wash away any brake fluid that spills.

•

Periodic Maintenance Procedures

Remove:

•

Rear Fender Front (see Rear Fender Front Removal in the Frame chapter) (EX650B Models) Right Center Fairing (see Center Fairing Removal in the Frame chapter) (EX650B Models) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) (EX650B Models)

Remove the brake pipe joint nuts [C] (EX650B Models).

•

Remove the bracket bolt [D] and bracket [E] (EX650B

•

Models). There are washers on each side of the brake hose fitting.

•

Replace them with new ones when installing. Tighten:

•

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

ft·lb)

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

(EX650B Models)

When installing the hoses, avoid sharp bending, kink-

•

ing, flatting or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. Fill the brake line after installing the brake hose (see

•

Brake Fluid Change).

PERIODIC MAINTENANCE 2-51

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 from the bleed valve [A] on the

•

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

•

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

•

2-52 PERIODIC MAINTENANCE

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: 1.0 N·m (0.10

kgf·m, 9 in·lb)

Follow the procedure below to install the rear brake fluid

•

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

○

Tighten the bleed valve, and install the rubber cap.

•

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

After changing the fluid, check the brake for good braking

•

power, no brake drag, and no fluid leakage. If necessary, bleed the air from the lines.

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].

CAUTION

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

Periodic Maintenance Procedures

Rear Master Cylinder Disassembly

NOTE

Do not remove the push rod clevis for master cylinder

○

disassembly since removal reguires brake position adjustment.

Remove the rear master cylinder (see Rear Master Cylin-

•

der Removal in the Brakes chapter). Slide the dust cover on the push rod out of place, and

•

remove the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the push rod with the piston stop.

•

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

•

and return spring [D].

CAUTION

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

PERIODIC MAINTENANCE 2-53

Master Cylinder Assembly

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

CAUTION

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. Tighten the brake lever pivot bolt and locknut.

•

Apply silicone grease.

•

Brake Lever Pivot Bolt

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)

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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) 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

To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers.

Pull out the pistons by hand.

○

Remove the dust seals [A] and fluid seals [B].

•

Remove the bleed valve [C] and rubber cap [D].

•

NOTE

If compressed air is not available, with the brake hose

○

still attached, apply the brake lever to remove the piston. The remaining process is as described above.

Front Caliper Assembly

Clean the c aliper parts except for the pads.

•

CAUTION

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

Install the bleed valve and rubber cap.

•

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

Replace the fluid seals [A] with new ones.

•

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

○

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

•

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

○

the cylinders by hand.

Periodic Maintenance Procedures

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

•

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

•

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

•

the caliper holder shafts [C] and holder holes [D] (PBC is a special high-temperature, water-resistance grease).

Install the anti-rattle 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.

PERIODIC MAINTENANCE 2-55

Rear Caliper Disassembly

Remove the rear caliper (see Rear Caliper Removal in

•

the Brakes chapter). Remove the pads and anti-rattle spring (see Rear Brake

•

Pad Removal in the Brakes c hapter). Using compressed air, remove the piston.

•

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

○

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

○

remove the piston.

WARNING

To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.

Remove the dust seal and fluid seal.

•

Remove the bleed valve and rubber cap.

•

NOTE

If compressed air is not available, with the brake hose

○

still attached, apply the brake pedal to remove the piston. The remaining process is as described above.

Rear Caliper Assembly

Clean the c aliper parts except for the pads.

•

CAUTION

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

Install the bleed valve and rubber cap.

•

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

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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 into the

○

cylinder by hand.

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

•

into the cylinder by hand. Replace the shaft rubber friction boot [A] and dust cover

•

[B] if they are damaged. Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

•

the caliper holder shafts [C] and holder holes [D] (PBC is a special high-temperature, water-resistance grease).

Install the anti-rattle 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:

•

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Removal in the Electrical System chap-

ter) Remove the spark plugs using the 16 mm plug wrench

•

[A].

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

Insert the spark plug vertically into the plug hole with the

•

spark plug installed in the plug wrench [A].

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

Tighten:

•

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

Install:

•

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Installation in the Electrical System

chapter)

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

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

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

DFI System............................................................................................................................. 3-12

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

Specifications ......................................................................................................................... 3-16

Special Tools and Sealant ...................................................................................................... 3-18

DFI Servicing Precautions ...................................................................................................... 3-20

DFI Servicing Precautions ................................................................................................ 3-20

Troubleshooting the DFI System ............................................................................................ 3-22

Outline ................................................................................................................................. 3-22

Outline............................................................................................................................... 3-22

Inquiries to Rider.................................................................................................................. 3-26

Inquiries to Rider............................................................................................................... 3-26

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

Self-Diagnosis ........................................................................................................................ 3-37

Self-diagnosis Outline .......................................................................................................... 3-37

Self-diagnosis Outline....................................................................................................... 3-37

Self-diagnosis Procedures ................................................................................................... 3-37

Self-diagnosis Procedures................................................................................................ 3-37

Service Code Clearing Procedures ..................................................................................... 3-38

Service Code Clearing Procedures................................................................................... 3-38

How to Read Service Codes................................................................................................ 3-40

How to Read Service Codes............................................................................................. 3-40

How to Erase Service Codes............................................................................................... 3-40

How to Erase Service Codes............................................................................................ 3-40

Service Code Table.............................................................................................................. 3-41

Service Code Table........................................................................................................... 3-41

Backups............................................................................................................................... 3-42

Backups ............................................................................................................................ 3-42

Main Throttle Sensor (Service Code 11) ................................................................................ 3-44

Main Throttle Sensor Removal/Adjustment ...................................................................... 3-44

Main Throttle Sensor Input Voltage Inspection ................................................................. 3-44

Main Throttle Sensor Output Voltage Inspection .............................................................. 3-45

Main Throttle Sensor Resistance Inspection .................................................................... 3-46

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-47

Inlet Air Pressure Sensor Removal ................................................................................... 3-47

Inlet Air Pressure Sensor Installation................................................................................ 3-47

Inlet Air Pressure Sensor Input Voltage Inspection........................................................... 3-47

Inlet Air Pressure Sensor Output Voltage Inspection........................................................ 3-48

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-52

Inlet Air Temperature Sensor Removal/Installation........................................................... 3-52

Inlet Air Temperature Sensor Output Voltage Inspection .................................................. 3-52

Inlet Air Temperature Sensor Resistance Inspection ........................................................ 3-53

Water Temperature Sensor (Service Code 14) ...................................................................... 3-54

Water Temperature Sensor Removal/Installation ............................................................. 3-54

Water Temperature Sensor Output Voltage Inspection..................................................... 3-54

Water Temperature Sensor Resistance Inspection........................................................... 3-55

Crankshaft Sensor (Service Code 21).................................................................................... 3-56

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

Crankshaft Sensor Inspection........................................................................................... 3-56

3-2 FUEL SYSTEM (DFI)

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

Speed Sensor Removal/Installation.................................................................................. 3-57

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

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

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

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

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

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

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

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

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

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

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

Subthrottle Sensor Resistance Inspection ........................................................................ 3-64

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

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

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

Stick C oils #1, #2: (Service Code 51, 52) .............................................................................. 3-68

Stick Coil Removal/Installation.......................................................................................... 3-68

Stick Coil Input Voltage Inspection.................................................................................... 3-68

Radiator Fan Relay (Service Code 56)................................................................................... 3-70

Radiator Fan Relay Removal/Installation.......................................................................... 3-70

Radiator Fan Relay Inspection.......................................................................................... 3-70

Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-71

Subthrottle Valve Actuator Removal ................................................................................. 3-71

Subthrottle Valve Actuator Audible Inspection .................................................................. 3-71

Subthrottle Valve Actuator Inspection ............................................................................... 3-71

Subthrottle Valve Actuator Resistance Inspection ............................................................ 3-71

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

Air Switching Valve (Service Code 64) ................................................................................... 3-73

Air Switching Valve Removal/Installation .......................................................................... 3-73

Air Switching Valve Inspection .......................................................................................... 3-73

Oxygen Sensor Heater (Service Code 67) (Europe Models) ................................................. 3-74

Oxygen Sensor Heater Removal/Installation.................................................................... 3-74

Oxygen Sensor Heater Inspection ................................................................................... 3-74

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models) ..................... 3-76

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

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

FI Indicator Light (LED) .......................................................................................................... 3-78

FI Indicator Light (LED) Inspection ................................................................................... 3-79

ECU........................................................................................................................................ 3-80

ECU Removal ................................................................................................................... 3-80

ECU Installation ................................................................................................................ 3-80

ECU Power Supply Inspection.......................................................................................... 3-81

Fuel Line................................................................................................................................. 3-83

Fuel Pressure Inspection .................................................................................................. 3-83

Fuel Flow Rate Inspection ................................................................................................ 3-85

Fuel Pump .............................................................................................................................. 3-87

Fuel Pump Removal ......................................................................................................... 3-87

Fuel Pump Installation ...................................................................................................... 3-87

Fuel Pump Operation Inspection ...................................................................................... 3-88

Fuel Pump Operating Voltage Inspection ......................................................................... 3-88

Pressure Regulator Removal............................................................................................ 3-89

Pump Screen, Fuel Filter Cleaning ................................................................................... 3-89

Fuel Injectors.......................................................................................................................... 3-91

Removal/Installation.......................................................................................................... 3-91

Audible Inspection............................................................................................................. 3-91

FUEL SYSTEM (DFI) 3-3

Fuel Injector Power Source Voltage Inspection ................................................................ 3-91

Fuel Injector Output Voltage Inspection............................................................................ 3-92

Injector Signal Test............................................................................................................ 3-92

Injector Resistance Inspection .......................................................................................... 3-93

Injector Unit Test ............................................................................................................... 3-94

Injector Fuel Line Inspection............................................................................................. 3-94

Throttle Grip and Cables ........................................................................................................ 3-96

Throttle Grip Free Play Inspection .................................................................................... 3-96

Throttle Grip Free Play Adjustment................................................................................... 3-96

Throttle Cable Installation ................................................................................................. 3-96

Throttle Cable Lubrication................................................................................................. 3-96

Throttle Body Assy ................................................................................................................. 3-97

Idle Speed Inspection ....................................................................................................... 3-97

Engine Vacuum Synchronization Inspection/Adjustment.................................................. 3-97

High Altitude Performance Adjustment ............................................................................. 3-97

Throttle Body Assy Removal............................................................................................. 3-97

Throttle Body Assy Installation.......................................................................................... 3-98

Throttle Body Assy Disassembly ...................................................................................... 3-99

Throttle Body Assy Assembly ........................................................................................... 3-100

Air Cleaner.............................................................................................................................. 3-101

Air Cleaner Element Removal/Installation ........................................................................ 3-101

Air Cleaner Element Inspection ........................................................................................ 3-101

Air Cleaner Oil Draining .................................................................................................... 3-101

Air Cleaner Housing Removal........................................................................................... 3-101

Air Cleaner Housing Installation........................................................................................ 3-102

Fuel Tank ................................................................................................................................ 3-103

Fuel Tank Removal ........................................................................................................... 3-103

Fuel Tank Installation ........................................................................................................ 3-105

Fuel Tank and Cap Inspection .......................................................................................... 3-106

Fuel Tank Cleaning ........................................................................................................... 3-107

Evaporative Emission Control System (California Model) ...................................................... 3-108

Parts R emoval/Installation ................................................................................................ 3-108

Hose Inspection ................................................................................................................ 3-108

Separator Inspection......................................................................................................... 3-108

Separator Operation Test.................................................................................................. 3-109

Canister Inspection .......................................................................................................... 3-109

3-4 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

Torque

N·m kgf·m ft·lb

1 Fuel Pump Bolts 9.8 1.0 87 in·lb

2. FI Indicator Light (LED)

3. Throttle Cable (Accelerator)

4. Throttle Cable (Decelerator)

5. Throttle Body Assy

6. Injectors

7. Meter Unit (EX650B Models)

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.

Remarks

L, S

3-6 FUEL SYSTEM (DFI)

Exploded View

Kawasaki ER-6f (2005) User Manual [ru]

Specifications and Main Features

Frequently Asked Questions

User Manual

EMISSION CONTROL INFORMATION

TAMPERING WITH N OISE CONTROL SYSTEM PROHIBITED

Foreword

LIST OF ABBREVIATIONS

COUNTRY AND AREA CODES

General Information

Battery Ground

Edges of Parts

Solvent

Cleaning Vehicle before Disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Non-permanent Locking Agent

Press

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

Lubrication

Direction of Engine Rotation

Electrical Wires

Instrument

EX650A6F (United States and Canada) Left Side View

EX650A6F (United States and Canada) Right Side View

EX650A6F (Europe) Left Side View

EX650A6F (Europe) Right Side View

EX650B6F Left Side View

EX650B6F Right Side View

Frame Number Engine Number

Cassette Type Transmission

Outline

ABS Total System

ABS System Block Diagram

Related Parts and Function

Prefixes fo r Units:

Units o f Mass:

Units of Volume:

Units of Length:

Units of Torque:

Units of Pressure:

Units of Speed:

Units of Force:

Units of Temperature:

Units of Power:

Periodic Maintenance

Periodic Inspection

Periodic Replacement Parts

Basic Torque for General Fasteners

Fuel System (DFI)

Air Cleaner Element Cleaning

Throttle Control System Inspection

Throttle Grip Free Play

Engine Vacuum Synchronization Inspection

Engine Vacuum

Main Throttle Sensor Output Voltage

Idle Speed Inspection

Idle Speed

Idle Speed Adjustment

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

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Cooling System

Coolant Level Inspection

Radiator Hose Damage and Installation Condition Inspection

Air Suction System

Air Suction System Damage Inspection

Engine Top End

Valve Clearance Inspection

Valve Clearance

Valve Clearance Measuring Position