Kawasaki NINJA 650R (2005) User Manual [ru]

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.

© 2005 Kawasaki Heavy Industries, Ltd. First Edition (1) : Nov. 2, 2005 (M)

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

PS

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

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]