Kawasaki ER 6 N, ER-6n ABS Service manual

ER-6n

ER-6n ABS

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 Periodic Maintenance 2 Fuel System (DFI) 3 Cooling System 4 Engine Top End 5 Clutch 6 Engine Lubrication System 7 Engine Removal/Installation 8

This quick reference guide will assist you in locating a desired topic or procedure.

•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.

•Refertothe sectionaltable ofcontents for the exact pages to locate the specific topic required.

Crankshaft/Transmission 9 Wheels/Tires 10 Final Drive 11 Brakes 12 Suspension 13 Steering 14 Frame 15 Electrical System 16 Appendix 17

ER-6n

ER-6n ABS

Motorcycle

Service Manual

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

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

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 afte

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

r this publication.

Division/Consumer Products & Machinery

ssible.

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 bottom dead center PS horsepower

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

°C degree(s) Celsius r revolution

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)

COUNTRY AND AREA CODES

AT Austria GB United Kingdom AU Australia MY Malaysia BR Brazil SEA South East Asia CA Canada TH Thailand CAL California US United States CH Switzerland WVTA (FULL H) WVTA Model with Honeycomb Catalytic

Converter (Full Power)

DE Germany GB WVTA

(FULL H)

EUR Europe

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

EMISSION CONTROL INFORMATION

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

1. Crankcase Emission Control System Thissystemeliminatesthe releaseof crankcasevapors intothe atmosphere. Instead, thevapors

are routed through an oil separator to the inlet side of the engine. While t he 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 r unning 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 r ender inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this titleprior to its sale anddelivery to the ultimatepurchaser,or for any manufacturer ordealer knowingly to remove or render inoperativeany 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 m otor 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 of design” has been generally

○

interpreted as follows.

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

2. Tampering could include.

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

ceeded.

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

or durability of the motorcycle.

c.Additionof componentsoraccessories thatresult inthevehicle exceedingthe stan-

dards.

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

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,THE VIOLATION OF WHICH ISPUNISHABLE BY CIVIL PENALTIESNOT EXCEEDING $10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

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

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

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

•

with Federal regulations.

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

•

Removal of the air box or air box cover.

•

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

•

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by trained mechanicsin a properly equippedshop. However,it containsenough detailand basicinformationto makeituseful tothe ownerwho desiresto performhis own basicmaintenance 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 beforestarting work, andthen dothe work ca fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurem 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 thisservice manual. Any ownermaintenance or repair procedure not performed in accordance with this manual may void

To get the longest life out of your vehicle.

Follow the Periodic M aintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki moto

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the p

•

fully. Don’t take shortcuts.

Rememberto keepcomplete recordsofmain-

•

tenance a

parts installed.

rcycles are introduced by the

rocedures in this manual care-

nd repair with dates and any new

genuine Kawasaki Mo-

accordance with

the warranty.

re-

ents

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 additionto WARNINGand CAUTION)whi 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 te

Indicates a conditional step or w hat action to

takebased on theresultsofthe testor inspec-

tion in the proced

lows.

In most chaptersan exploded view illustration of the system com Contents. In these illustrations you will find the instructionsindicating which partsrequire specified tighten agent during assembly.

ing torque, oil, grease or a locking

xt of a NOTE.

ural step or sub-step it fol-

ponents follows the Table of

chwill

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

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

Unit Conversion Table ............................................................................................................ 1-13

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a m otorcycle, 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 completingany service on the motorcycle,disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts

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

Solvent

Use a high-flash point so

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

lvent when cleaning parts. High

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or otherforeign materialsentering intosealed areasduring vehicle disassembly can cause excessivewear and decrease performance of the vehicle.

Before Servicing

Arrangement and Cleaning o f 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 theparts 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 inspectremoved parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of thismanual for servicelimits on individualparts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In mostcases assembly order isthereverse 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 m alfunction. 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 t ightening 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 disas excessiveforce can causeexpensive or hardto repair damage. When necessary, remove screws that have a non

-permanent locking agent Use a plastic-faced mallet whenever tapping is necessary.

applied using an impact driver.

sembly and assembly,

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

Donot removepressed oilorgreasesealsunless removal is necessary. Replace with new ones whenever removed. Pressnewoil seals withmanufacture and sizemarks 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

Replacecirclips orcotterpins thatwere removedwithnew ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

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

Direction of Engine Rotation

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

Electrical Leads

A two-color lead is identifie then the stripe color. Unless instructed otherwise, electrical leads must be connected to those of the same color.

d first by the primary color and

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

ER650C9F (EUR Models) Left Side View

GENERAL INFORMATION 1-7

ER650C9F (EUR Models) Right Side View

1-8 GENERAL INFORMATION

Model Identification

ER650C9F (US, CA Models) Left Side View

ER650C9F (US, CA Models) Right Side View

Model Identification

ER650D9F Left Side View

GENERAL INFORMATION 1-9

ER650D9F Right Side View

Frame Number Engine Number

1-10 GENERAL INFORMATION

General Specifications

Items ER650C9F, ER650D9F

Dimensions

Overall Length 2 100 mm (82.68 in.) Overall Width 760 mm (29.9 in.) Overall Height 1 100 mm (43.31 in.) Wheelbase 1 405 mm (55.31 in.) Road Clearance 140 mm (5.51 in.) Seat Height 785 mm (30.9 in.) Curb Mass:

ER650C Models: 200 kg (441 lb)

Front 100 kg (221 lb) Rear 100 kg (221 lb)

ER650D Models:

Front Rear 103 kg (227 lb)

Fuel Tank Capacity 15.5 L (4.10 US gal.)

Performance

Minimum Turning Radius 2.7 m (8.9 ft)

Engine

Type 4-stroke, DO HC, 2-cylinder Cooling System Liquid-cooled Bore and Stroke 83.0 × 60.0 mm (3.27 × 2.36 in.) Displacement 649 cm³ (39.6 cu in.) Compression Ratio 11.3 : 1 Maximum Horsepower 53 kW (72 PS) @8 500 r/min (rpm)

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 Ignition System Battery and coil (transistorized) Timing Advance Electronically advanced (IC igniter in ECU) Ignition Timing From 10° BTDC @1 300 r/min (rpm)

Spark Plug NGK CR9EIA-9 Cylinder Numbering Method Left to right, 1-2 Firing Order 1-2 Valve Timing:

Inlet:

Open 31° BTDC Close 61° ABDC Duration 272°

204 kg (450 lb) 101 kg (223 lb)

(MY) 52 kW (71 PS) @8 000 r/min (rpm) (US, CA, CAL) – – –

(US, CA, CAL) – – –

Electric starter

To 34° BTDC @5 000 r/min (rpm)

GENERAL INFORMATION 1-11

General Specifications

Items ER650C9F, ER650D9F

Exhaust:

Open 50° BBDC Close 30° ATDC

Duration 260° Lubrication System Forced lubrication (semi-dry sump) Engine Oil:

Grade API SE, SF or SG

API SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.4 L (2.5 US qt)

Drive Train

Primary Reduction System:

Type Reduction R atio

Clutch Type Wet multi disc Transmission:

Type Gear Ratios:

1st 2.438 (39/16) 2nd 1.714 (36/21) 3rd 1.333 (32/24) 4th 1.111 (30/27) 5th 0.966 (28/29) 6th 0.852 (23/27)

Final Drive System:

Type Chain drive Reduction R atio 3.067 (46/15) Overall Drive Ratio 5.473 @Top gear

Frame

Type Tubular, diamond Caster (Rake Angle) 24.5° Trail 102 mm (4.02 in.) 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 (4.72 in.)

Gear

2.095 (88/42)

6-speed, constant mesh, return shift

1-12 GENERAL INFORMATION

General Specifications

Items ER650C9F, ER650D9F

Rear Suspension:

Type Swingarm Wheel Travel 125 mm (4.92 in.)

Brake Type:

Front Dual discs Rear Single disc

Electrical Equipment

Battery 12 V 10 Ah Headlight:

Type Semi-sealed beam Bulb:

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

Low 12 V 55 W (quartz-halogen) Tail/Brake Light LED Alternator:

Type Three-phase AC Rated Output 24 A/14 V @5 000 r/min (rpm)

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

Unit Conversion Table

GENERAL INFORMATION 1-13

Prefixes for Units:

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

Units of Mass:

kg ×2.205=lb g × 0.03527 = oz

Units of Volume:

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

Units of Length:

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

Units of Torque:

N·m × 0.1020 = kgf·m N·m × 0.7376 = ft·lb N·m × 8.851 = in·lb kgf·m × 9.807 = N·m kgf·m × 7.233 = ft·lb kgf·m × 86.80 = in·lb

Units of Pressure:

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

× 98.07 = kPa × 14.22 = psi

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

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

Units of Temperature:

Units of Power:

kW ×1.360=PS kW ×1.341=HP PS × 0.7355 = kW PS × 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

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

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

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

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

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

Air Cleaner Element Cleaning........................................................................................... 2-15

Throttle Control System Inspection................................................................................... 2-16

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

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

Idle Speed Adjustment...................................................................................................... 2-19

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

Evaporative Emission Control System Inspection (CAL, SEA and TH Models) ............... 2-19

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

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

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

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

Va lve Clearance Inspection .............................................................................................. 2-21

Va lve Clearance Adjustment............................................................................................. 2-22

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

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

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

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

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

Wheel/Tire Damage Inspection......................................................................................... 2-26

Tire Tread Wear, Abnormal Wear Inspection.................................................................... 2-26

Wheel Bearing Damage Inspection .................................................................................. 2-27

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

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

Drive Chain Slack Inspection............................................................................................ 2-28

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

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

Drive Chain Wear Inspection ............................................................................................ 2-30

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

Brake System ...................................................................................................................... 2-31

Brake Fluid Leak (Brake Hose and Pipe) Inspection........................................................ 2-31

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

Brake Fluid Level Inspection............................................................................................. 2-32

Brake Pad Wear Inspection .............................................................................................. 2-33

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

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

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

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

Front Fork O il 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

Steering Stem Bearing Lubrication................................................................................... 2-37

Electrical System................................................................................................................. 2-38

2-2 PERIODIC MAINTENANCE

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 Parts.............................................................................................................. 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............................................................................................................ 2-48

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.................................................................................. 2-53

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

ITEM Every

Fuel System

Whichever comes first

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

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

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 Fuel hose and pipe damage -

inspect Fuel hose and pipe installation

condition - inspect Evaporative emission control

system function (CAL, TH, SEA Models) - inspection

Cooling System

Coolant level - inspect Coolant leak (water hose and

pipe) - inspect Water hose damage - inspect year Water hose installation condition

- inspect

Engine Top End

Valve clearance inspect

Air suction system damage inspect

Clutch

Clutch operation (play, disengagement, engagement) inspect

Wheels and Tires

US, CA, CAL Models

Other than US, CA, CAL Models

year

• • •

• • • •

• • •

• • • •

• • • • • • •

• • • •

•

Every 42 000 km (26 250 mile)

• • •

• • • •

2–15 2–16

2–16 2–18 2–19

2–19

2–20 2–21 2–21 2–21

2–21

2–25

Tire air pressure - i nspect year Wheel/tire damage - inspect Tire tread wear, abnormal wear

- inspect Wheel bearing damage - inspect year

• • •

2–26 2–26

2–26 2–27

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

ITEM Every

Final Drive

Drive chain lubrication condition

- inspect # Drive chain slack - inspect # Every 1 000 km (600 mile) 2–28 Drive chain wear - inspect #

Chain guide wear - inspect

Brakes

Brake fluid leak (brake hose and pipe) - inspect

Brake hose and pipe damage inspect

Brake hose and pipe installation condition - inspect

Brake fluid level - inspect Brake pad wear - inspect # Brake operation (effectiveness,

play, no drag) - inspect Brake light switch operation -

inspect

Suspension

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

Front forks/rear shock absorber oil l eak - inspect

Steering

Whichever

comes first

year

6 months

year

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

Every 600 km (400 mile) 2–28

• • • • • • •

• • • • • •

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • •

See

Page

2–30 2–31

2–31

2–32

2–32 2–32

2–33 2–34

2–34

2–35

Steering play - inspect year Steering stem bearings -

lubricate

Electrical System

Lights and switches operation inspect

Headlight aiming - inspect year Sidestand switch operation -

inspect Engine stop switch operation -

inspect

Others

Chassis parts - lubricate year Bolts andnuts tightness - inspect

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

frequent starting/stopping.

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

2 years

year

• • • •

•

• • •

• • • •

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

ITEM Every Air cleaner element # - replace 2 years 2–45

Whichever

comes

first

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

* ODOMETER

READING

× 1 000 km

(× 1 000 mile)

See

Page

Fuel hose - replace 4 years Coolant - change 3 years Radiator hose and O-ring - replace 3 years Engine oil # - change year Oil filter - replace year Brake hose and pipe - replace 4 years Brake fluid - change 2 years Rubber parts of master cylinder and caliper - replace 4 years Spark plug - replace

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

frequent starting/stopping.

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

• • • • •

• • • •

•

• •

•

2–45 2–46 2–48 2–48 2–49 2–50 2–51 2–52 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 i n 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)

Crankshaft Sensor Bolts 6.0 0.61 53 in·lb Fuel Level Sensor Bolts 6.9 0.70 61 in·lb L Fuel Pump Bolts 9.8 1.0 87 in·lb L, S Oxygen Sensor (Equipped Models) Speed Sensor Bolt Speed S ensor Bracket Bolts 9.8 1.0 87 in·lb Switch Housing Screws 3.5 0.36 31 in·lb Timing Rotor Bolt 40 4.1 30 Water Temperature Sensor 12 1.2 106 in·lb

Cooling System

Baffle Plate Bolts 5.9 0.60 52 in·lb Radiator Bolt 15 1.5 11 Water Hose Clamp Screws 2.0 0.20 18 in·lb Thermostat Housing Bolts 9.8 1.0 87 in·lb Water Pump Cover Bolts 9.8 1.0 87 in·lb Water Pump Drain Bolt 9.8 1.0 87 in·lb Water Pump Impeller Bolt 9.8 1.0 87 in·lb Water Temperature Sensor 12 1.2 106 in·lb

Engine Top End

Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb Baffle Plate Bolts 5.9 0.60 52 in·lb Camshaft Cap Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb Camshaft Sprocket Bolts 15 1.5 11 L Cylinder Head Bolts (M10) 56 5.7 41 MO, S Cylinder Head Bolts (M6) 12 1.2 106 in·lb S Cylinder Head Cover Bolts 9.8 1.0 87 in·lb Rear Camshaft Chain Guide Bolts 20 2.0 15 L Spark Plugs 15 1.5 11

N·m kgf·m ft·lb

44 4.5 32

7.8 0.80 69 in·lb L

12 1.2 106 in·lb 20 2.0 15

Torque

Remarks

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