Kawasaki Versys (2006) User Manual [ru]

Versys

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

Versys

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 make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.

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

© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1) : Aug. 21, 2006 (K)

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 GB United Kingdom

CA Canada MY Malaysia

CH Sw

DE

Germany

itzerland

WVTA Whole Vehicle Type Approval

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in­formation to make it useful to the owner who de­sires to perform his o wn 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.

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-8

Unit Conversion Table ............................................................................................................ 1-11

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

KLE650B7F Left Side View

GENERAL INFORMATION 1-7

KLE650B7F Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

General Specifications

Items KLE650A7F, KLE650B7F

Dimensions

Overall Length 2 125 mm (83.7 in.)

Overall Width 840 mm (33.1 in.)

Overall Height 1 315 mm (51.8 in.)

Wheelbase

Road Clearance 180 mm (7.1 in.)

Seat Height 840 mm (33.1 in.)

Dry Mass:

KLE650A7F 181 kg (399 lb)

KLE650B7F 184 kg (405 lb)

Curb Mass:

Front:

KLE650A7F 103 kg (227 lb)

KLE650B7F 103 kg (227 lb)

Rear:

KLE650A7F 105 kg (232 lb)

KLE650B7F 104 kg (229 lb)

Fuel Tank Capacity 19 L (5.0 US gal)

Performance

Minimum Turning Radius

Engine

Type 4-stroke, DOHC, 2-cylinder

Cooling System

Bore and Stroke 83 × 60 mm (3.3 × 2.4 in.)

Displacement 649 cm³ (39.6 cu in.)

Compression Ratio 10.6 : 1

Maximum Horsepower 47.0 kW (64 PS) @8 000 r/min (rpm),

Maximum Torque

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

Starting System Electric starter

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (digital igniter in ECU)

Ignition Timing

Spark Plug NGK CR9EIA-9

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

1 415 mm (55.7 in.)

2.7 m (8.8 ft)

Liquid-cooled

(MY) 44.0kW (60 PS) @7 000 r/min (rpm),
(CA) – – –

61 N·m (6.2 kgf·m, 114 ft·lb) @6 800 r/min (rpm),
(MY)61 N·m (6.2 kgf·m, 114 ft·lb) @6 000 r/min (rpm),
(CA) – – –

From 10° BTDC @1 300 r/min (rpm) to From 33° BTDC @5 000
r/min (rpm)

GENERAL INFORMATION 1-9

General Specifications

Items KLE650A7F, KLE650B7F

Valve Timing:

Inlet:

Open 25° (BTDC)

Close 54° (ABDC)

Duration

Exhaust:

Open 47° (BBDC)

Close 25° (ATDC)

Duration 252°

Lubrication System Forced lubrication (sem-dry sump)

Engine Oil:

Type API SE, SF or SG

Viscosity

Capacity 2.4 L (2.5 US qt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 2.095 (88/42)

Clutch Type Wet multi disc

Transmission:

Type 6-speed, constant mesh, return shift

Gear Ratios:

1st 2.438 (39/16)

2nd 1.714 (36/21)

3rd

4th 1.111 (30/27)

5th 0.966 (28/29)

6th 0.852 (23/27)

Final Drive System:

Type Chain drive

Reduction Ratio

Overall Drive Ratio 5.473 @Top gear

Frame

Type Tubular,diamond

Caster (Rake Angle) 25°

Trail 108 mm (4.2 in.)

Front Tire:

Type Tubeless

Size 120/70 ZR17 MC (58W)

Rear Tire:

Type Tubeless

Size 160/60 ZR17 MC (69W)

260°

API SH, SJ or SL with JASO MA

SAE 10W-40

1.333 (32/24)

3.067 (46/15)

1-10 GENERAL INFORMATION

General Specifications

Items KLE650A7F, KLE650B7F

Rim Size:

Front 17 × 3.50

Rear 17 × 4.50

Front Suspension:

Type Telescopic fork (upside-down)

Wheel Travel 150 mm (5.9 in.)

Rear Suspension:

Type

Wheel Travel 145 mm (5.7 in.)

Brake Type:

Front Dual discs

Rear Single disc

Electrical Equipment

Battery 12 V 10 Ah

Headlight:

Type Semi-sealed beam

Bulb

Tail/Brake Light 12 V 0.5/3.7 W (LED)

Alternator:

Type

Rated Output 8 A/14 V @4 000 r/min (rpm)

Swingarm (uni-trak)

12 V 55 W/55W (Hi/Lo)

Three-phase AC

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

Unit Conversion Table

GENERAL INFORMATION 1-11

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 = k gf·m

N·m × 0.7376 = ft·lb

N·m × 8.851 = in·lb

kgf·m

kgf·m

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

PS

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) ...................................... 2-18

Cooling System.................................................................................................................... 2-19

Coolant Level Inspection ................................................................................................... 2-19

Radiator Hose Damage and Installation Condition Inspection.......................................... 2-19

Air Suction System .............................................................................................................. 2-20

Air Suction System Damage Inspection............................................................................ 2-20

Engine Top End ................................................................................................................... 2-20

Valve Clearance Inspection .............................................................................................. 2-20

Valve Clearance Adjustment ............................................................................................. 2-21

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

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

Wheels/Tires........................................................................................................................ 2-25

Air Pressure Inspection..................................................................................................... 2-25

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

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

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

Drive Train ........................................................................................................................... 2-27

Drive Chain Lubrication Condition Inspection................................................................... 2-27

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

Drive Chain Slack Adjustment .......................................................................................... 2-28

Wheel Alignment Inspection ............................................................................................. 2-29

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

Chain Guide Inspection..................................................................................................... 2-30

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

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

Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-31

Brake Operation Inspection .............................................................................................. 2-32

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

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

Brake Light Switch Operation Inspection .......................................................................... 2-33

Suspensions ........................................................................................................................ 2-34

Front Forks/Rear Shock Absorber Operation Inspection.................................................. 2-34

Front Fork Oil Leak Inspection.......................................................................................... 2-34

Rear Shock Absorber Oil Leak Inspection........................................................................ 2-34

Steering System ..................................................................................................................2-35

Steering Play Inspection ................................................................................................... 2-35

Steering Play Adjustment.................................................................................................. 2-35

Steering Stem Bearing Lubrication ................................................................................... 2-36

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

2

2-2 PERIODIC MAINTENANCE

Lights and Switches Operation Inspection........................................................................ 2-37

Headlight Aiming Inspection ............................................................................................. 2-39

Sidestand Switch Operation Inspection ............................................................................ 2-40

Engine Stop Switch Operation Inspection......................................................................... 2-41

Others.................................................................................................................................. 2-42

Chassis Parts Lubrication ................................................................................................. 2-42

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-43

Replacement Parts .............................................................................................................. 2-44

Air Cleaner Element Replacement.................................................................................... 2-44

Fuel Hose Replacement ................................................................................................... 2-44

Coolant Change................................................................................................................ 2-45

Radiator Hose and O-ring Replacement........................................................................... 2-47

Engine Oil Change............................................................................................................ 2-48

Oil Filter Replacement ...................................................................................................... 2-48

Brake Hose and Pipe Replacement.................................................................................. 2-49

Brake Fluid Change .......................................................................................................... 2-50

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

Caliper Rubber Parts Replacement .................................................................................. 2-53

Spark Plug Replacement .................................................................................................. 2-55

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

INSPECTION Every

Fuel System

(0.6)6(4)12(7.5)18(12)24(15)30(20)36(24)

* ODOMETER READING

(× 1 000 mile)

1

× 1 000 km

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

Cooling System

Coolant level - inspect

Coolant leak (radiator hose and pipe) ­inspect

Radiator hose damage - inspect year

Radiator hose installation condition - inspect year

Air Suction System

Air suction system damage - inspect

Engine Top End

Valve clearance

- inspect

Clutch

Clutch operation (play, disengagement,
engagement) - inspect

Wheels and Tires

CA Model

Other than CA Model Every 42 000 km (26 000 mile)

year

year

year

• • •

• • • •

• • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • •

•

• • • •

2-14

2-15

2-16

2-18

2-18

2-18

2-18

2-19

2-19

2-19

2-19

2-20

2-20

2-25

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) 2-27

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

Drive chain wear - inspect #

Drive chain guide wear - inspect

Brake System

Brake fluid leak (brake hose and pipe) ­inspect

year

• • • • • • •

• • •

• • •

• • •

• • •

• • •

• • •

2-25

2-26

2-26

2-27

2-30

2-30

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

INSPECTION Every

Brake hose and pipe damage - inspect year

Brake hose and pipe installation condition ­inspect

Brake operation (effectiveness, play, n o
drag) - inspect

Brake fluid level - inspect 6months

Brake pad wear - inspect #

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

year

year

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1

(0.6)6(4)12(7.5)18(12)24(15)30(20)36(24)

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • •

• • • • • • •

• • •

• • •

See

Page

2-31

2-31

2-32

2-32

2-33

2-33

2-34

2-34

Steering play - inspect year

Steering stem bearings - lubricate

Electrical System

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, wet, muddy, high speed or

frequent starting/stopping.

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

2 years

• • • •

•

• • •

• • •

• • •

• • •

• • •

• • • •

2-35

2-36

2-37

2-39

2-40

2-41

2-42

2-43

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

comes

first

CHANGE/REPLACE ITEM Every

Air cleaner element # 2 years 2-44

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1

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

See

Page

Fuel hose 4 years

Coolant

Radiator hose and O-ring 3 years

Engine oil # year

Oil filter year

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, muddy, high speed or

frequent starting/stopping.

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

3 years

•

•

• • • • •

• • • • •

• •

• • • •

•

•

•

2-44

2-45

2-47

2-48

2-48

2-49

2-50

2-52,

2-53

2-55

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)

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Right Switch Housing Screws 3.5 0.36 31 in·lb

Sidestand Switch Bolt 3.9 0.40 35 in·lb L

Crankshaft Sensor Bolts 6.0 0.61 53 in·lb

Oxygen Sensor (Europe Models) 44.1 4.5 33

Spark Plugs

Speed Sensor Bolt 7.8 0.80 69 in·lb

Timing Rotor Bolt 40 4.1 30

Water Temperature Sensor

Cooling System

Baffle Plate Bolts 5.9 0.60 52 in·lb

Radiator Bolt 15 1.5 11

Radiator Hose Clamp Screws 2.0 0.20 18 in·lb

Thermostat Housing Bolts 9.8 1.0 87 in·lb

Water Pump Cover Bolts

Water Pump Drain Bolt 9.8 1.0 87 in·lb

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Water Temperature Sensor 12 1.2 106 in·lb

Engine Top End

Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb

Baffle Plate Bolts 5.9 0.60 52 in·lb

Camshaft Cap Bolts 12 1.2 106 in·lb S

Camshaft Chain Tensioner Cap Bolt 20 2.0 15

Camshaft Chain Tensioner Mounting Bolts

Camshaft Sprocket Bolts 15 1.5 11 L

Cylinder Head Bolts (M10) 56 5.7 41 MO, S

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

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb

Rear Camshaft Chain Guide Bolts 20 2.0 15 L

Spark Plugs

N·m kgf·m ft·lb

15 1.5 11

12 1.2 106 in·lb

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb

15 1.5 11

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Throttle Body Assy Holder Bolts 12 1.2 106 in·lb

Cylinder Bolt (M8) 27.5 2.8 20 MO,S

Cylinder Nut (M10) 49 5.0 36 MO, S

Cylinder Bolts (M6)

Exhaust Pipe Manifold Holder Nuts 17 1.7 12

Muffler Body Mounting Bolt (Front) 20 2.0 15

Muffler Body Mounting Bolt (Rear) 20 2.0 15

Clutch

Clutch Cable Clamp Bolt 9.8 1.0 87 in·lb

Clutch Cable Holder Bolts

Clutch Cover Mounting Bolts 9.8 1.0 87 in·lb

Clutch Hub Nut 130 13.3 96

Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S

Clutch Spring Bolts 9.8 1.0 87 in·lb

Timing Rotor Bolt Cap 4.9 0.50 43 in·lb

Oil Filler Plug

Oil Pump Chain Guide Bolts 12 1.2 106 in·lb L(1)

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

Timing Inspection Cap 3.9 0.40 35 in·lb

Engine Lubrication System

Engine Oil Drain Bolt 30 3.1 22

Filter Plate Bolts 9.8 1.0 87 in·lb L

Holder Mounting Bolt 25 2.5 18 L

Lower Fairing Bracket Bolts 12 1.2 106 in·lb L

Oil Filter

Oil Pan Bolts 12 1.2 106 in·lb

Oil Passage Plug 20 2.0 15 L

Oil Pipe Plate Bolt 9.8 1.0 87 in·lb L

Oil Plate Bolts 9.8 1.0 87 in·lb L

Oil Pressure Relief Valve 15 1.5 11 L

Oil Pressure Switch

Oil Pump Chain Guide Bolts 12 1.2 106 in·lb L(1)

Oil Pump Cover Bolts 9.8 1.0 87 in·lb L

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

Engine Removal/Installation

Engine Mounting Bracket Bolts 25 2.5 18 S

Front Engine Mounting Bolts 44 4.5 32

Rear Engine Mounting Nuts 44 4.5 32 S

Crankshaft/Transmission

Breather Plate Bolts 9.8 1.0 87 in·lb L

Race Holder Screw 4.9 0.50 43 in·lb L

Connecting Rod Big End Nuts see Text ← ←

Crankcase Bolt (M8, L = 110 mm) 27.5 2.8 20 S

N·m kgf·m ft·lb

12 1.2 106 in·lb

9.8 1.0 87 in·lb L

– – – Hand-tighten

17.5 1.8 13

15 1.5 11

Torque

Remarks

EO, R

SS

S

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Crankcase Bolt (M6, L = 32 mm)

Crankcase Bolts (M6, L = 38 mm) 19.6 2.0 14 S

Crankcase Bolts (M6, L = 45 mm) 19.6 2.0 14 S

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

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

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

Crankcase Bolts (M9, L = 113 mm)

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

Upper Crankcase Bolt (M8, L = 120 mm) 27.5 2.8 20 S

Upper Crankcase Bolts (M8, L = 110 mm) 27.5 2.8 20 S

Oil Pipe Bolts 9.8 1.0 87 in·lb L

Oil Plate Bolts 9.8 1.0 87 in·lb L

Shift Shaft Return Spring Pin

Timing Rotor Bolt 40 4.1 30

Drive Shaft Bearing Holder Screw 4.9 0.50 43 in·lb L

Gear Positioning Lever Bolt

Neutral Switch 15 1.5 11

Neutral Switch Holder Screw 4.9 0.50 43 in·lb L

Oil Jet Nozzle 2.9 0.30 26 in·lb L

Shift Drum Bearing Holder Screws 4.9 0.50 43 in·lb L

Shift Drum Cam Bolt 12 1.2 106 in·lb L

Shift Lever Bolt

Shift Rod Plate Bolt 9.8 1.0 87 in·lb L

Shift Shaft Cover Bolts 9.8 1.0 87 in·lb L(3)

Shift Shaft Cover Screw 4.9 0.50 43 in·lb L

Transmission Case Bolts 20 2.0 15

Wheels/Tires

Front Axle 108 11.0 80

Front Axle Clamp Bolt 20 2.0 15

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

Front Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Light Switch Screw

N·m kgf·m ft·lb

19.6 2.0 14

44 4.5 32

29 3.0 21 L

12 1.2 106 in·lb L

12 1.2 106 in·lb L

59 6.0 44

1.0 0.10 9in·lb

Torque

Remarks

MO, S

S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

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

Bleed Valve 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 25 2.5 18

Brake Pedal Bolt 8.8 0.90 78 in·lb

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

Brake Pipe Joint Nuts (KLE650B Models) 18 1.8 13

Suspension

Front Axle Clamp Bolt

Front Fork Bottom Allen Bolts 20 2.0 15

Front Fork Clamp Bolts (Lower) 29 3.0 21 AL

Front Fork Clamp Bolts (Upper)

Front Fork Top Plugs 35 3.6 26

Piston Rod Nuts 20 2.0 15

Rear Shock Absorber Bolt (Upper) 59 6.0 44

Rear Shock Absorber Nut (Lower) 59 6.0 44

Swingarm Pivot Shaft Nut 108 11. 0 80

Steering

Front Fork Clamp Bolts (Lower) 29 3.0 21 AL

Front Fork Clamp Bolts (Upper) 20 2.0 15

Upper Handlebar Holder Bolts 25 2.5 18 S

Lower 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 Holder Bolts 34 3.5 25 L

Front Footpeg Stay Bolts 25 2.5 18

Rear Footpeg Stay Bolts 25 2.5 18

Sidestand Bolt 44 4.5 32

Sidestand Switch Bolt 3.9 0.40 35 in·lb L

Lower Fairing Mounting Bolts 8.8 0.90 78 in·lb

Windshield Mounting Bolts 0.40 0.041 3.5 in·lb

Tandem Grip Mounting Bolts 25 2.5 18

Electrical System

Tail/Brake Light Mounting Bolts 1.2 0.12 11 in· lb

License Plate Light Cover Screws 0.90 0.090 8in·lb

License Plate Light Mounting Screws

N·m kgf·m ft·lb

1.5 0.15 13 in·lb

20 2.0 15

20 2.0 15

1.2 0.12 11 in·lb

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Turn Signal Light Lens Screws

Alternator Cover Bolts 9.8 1.0 87 in·lb

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

Alternator Rotor Bolt 155 15.8 114

Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

Left Switch Housing Screws 3.5 0.36 31 in·lb

Right Switch Housing Screws 3.5 0.36 31 in·lb

Sidestand Switch Bolt 3.9 0.40 35 in·lb L

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

Crankshaft Sensor Bolts

Neutral Switch 15 1.5 11

Oil Pressure Switch 15 1.5 11 SS

Oxygen Sensor (Europe Models) 44.1 4.50 32.5

Spark Plugs 15 1.5 11

Speed Sensor Bolt 7.8 0.80 69 in·lb L

Timing Rotor Bolt 40 4.1 30

Water Temperature Sensor 12 1.2 106 in·lb

Fuel Level Sensor Bolts 6.9 0.70 61 in·lb L

N·m kgf·m ft·lb

1.0 0.10 9in·lb

6.0 0.61 53 in·lb

6.0 0.61 53 in·lb

Torque

Remarks

MO

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

Basic Torque for General Fasteners

Threads D

(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

iameter

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 37.9 ±1.3 kPa (285 ±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 6.5 mm (0.26 in.) 1 mm (0.04 in.),

Rear 9.0 mm (0.35 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 25 ∼ 35 mm (1.0 ∼ 1.4 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:

Type NGK CR9EIA-9 –––

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

Throttle Sensor Setting Adapter:
57001-1538

Extension Tube:
57001-1578

Pilot Screw Adjuster, E:
57001-1603

Vacuum Gauge:
57001-1369

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]
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 [A] moves smoothly from full

•

open to close, and the throttle closes quickly and com­pletely by the return spring in all s teering 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 [B].

•

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

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

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.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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.

•

Pull off the rubber caps [A] from the fitting of each throttle

•

body.

CAUTION

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

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

•

the fittings of the throttle body as shown.

Special Tool - Vacuum Gauge: 57001-1369

Connect a highly accurate tachometer to one of the stick

•

coil primary leads.

Start the engine and warm it up thoroughly.

•

Check the idle speed, using a highly accurate 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: 37.9 ±1.3 kPa (285 ±10 mmHg) at Idle Speed

1300±50r/min(rpm)

Periodic Maintenance Procedures

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

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

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 w ithin the specification,
remove the bypass screws #1, #2 and clean them.

PERIODIC MAINTENANCE 2-17

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

•

O-ring [D].
Check the bypass screw 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.

•

Repeat the s ame 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).

Special Tool - Throttle Sensor Setting Adapter: 57001

-1538

Main Throttle Sensor Output Voltage

Connections to Adapter

Meter (+) → R (Sensor Y/W) lead

Meter (–) → W (Sensor BR/BK) lead

Standard: DC 1.005 ∼ 1.035 V (at idle throttle opening)

If the output voltage is out of the range, check the 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.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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 s peed 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.

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

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

○

sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re­moval 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 Procedures

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.

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 middle fairing (see Middle 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

PERIODIC MAINTENANCE 2-19

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 w ater 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.

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,

18 in·lb)

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Air Suction System

Air Suction System Damage Inspection

Remove:

•

Fuel Tank (see Fuel Tank Removal i n the Fuel System
chapter)
Fuel Hose (see Fuel Hose Replacement)

Connect the following parts temporary.

•

Fuel Pump Lead Connector [A]
Fuel Level Sensor Lead Connector [B]
Extension Tube [C]

Special Tool - Extension Tube: 57001-1578

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

•

housing.

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)
Timing Inspection Cap [A]
Timing Rotor Bolt Cap [B]

Check the valve clearance when the pistons are at TDC.

•

The pistons are numbered beginning with the engine left

○

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

•

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

Periodic Maintenance Procedures

Measure the valve clearance of the valves for which the

○

cams [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

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)

PERIODIC MAINTENANCE 2-21

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

○

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

NOTE

Check the valve clearance using this method only.

○

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

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke:

Inlet valve clearances of #1 piston, and

Exhaust valve clearances of #1 piston

#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.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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.

To select a new shim which brings the valve clearance

•

within the specified range, refer to the Valve Clearance
Adjustment Charts.
Apply a thin coat of molybdenum disulfide grease to the

•

valve lifters.
Install the camshafts. B e 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.

PERIODIC MAINTENANCE 2-23

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 0.42 mm.

Replace 2.95 mm shim with 3.20 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

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

2. Check present shim size.

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

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

Example: Present shim is 2.95 mm.

Measured clearance is 0.47 mm.

Replace 2.95 mm shim with 3.15 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

Periodic Maintenance Procedures

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.

PERIODIC MAINTENANCE 2-25

Open the clamp [A].

•

Slide the dust cover [B] at the middle of the clutch cable

•

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

•

Turn the adjusting nut [D] 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 Inspection

Remove the air valve cap.

•

Measure the tire air pressure with an air pressure gauge

•

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

•

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

Air Pressure (when Cold)

Front:

Rear:

Upto180kg(397lb)
225kPa(2.25kgf/cm²,32psi)

Upto180kg(397lb)
250kPa(2.50kgf/cm²,36psi)

2-26 PERIODIC MAINTENANCE

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).

Tread Depth

Standard:

Front 6.5 mm (0.26 in.)

Rear 9.0 mm (0.35 in.)

Service Limit:

Front

Rear

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.

Periodic Maintenance Procedures

Wheel Bearing Damage Inspection

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

PERIODIC MAINTENANCE 2-27

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.

2-28 PERIODIC MAINTENANCE

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 c hain if it is dirty, and lubricate it if it appears

○

dry.

Check the wheel alignment (see Wheel Alignment Inspec-

•

tion).

Rotate the rear wheel to find the position where the chain

•

is tightest.

Measure the vertical movement (chain slack) [A] midway

•

between the sprockets.

If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard: 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

Drive Chain Slack Adjustment

Raise the rear wheel off the ground with the stand.

•

Remove the cotter pin [A], and loosen the axle nut [B].

•

Loosen the both chain adjuster locknuts [C].

•

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

adjusters [D] evenly.

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

adjusters evenly, and kick the wheel forward.

Turn both chain adjusters evenly until the drive chain has

•

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

properly aligned, the notch [E] on the left wheel alignment

indicator [F] should align with the same swingarm mark or

position [G] that the right indicator notch aligns with.

WARNING

Misalignment of the wheel will result in abnormal

wear and may result in an unsafe riding condition.

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.

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.

PERIODIC MAINTENANCE 2-29

Wheel Alignment Inspection

Check that the notch [A] on the left alignment indicator [B]

•

aligns with the same swingarm m ark or position [C] that
the right alignment indicator notch aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).

NOTE

Wheel alignment can be also checked using the

○

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Chain Wear Inspection

Remove the chain cover (see Swingarm Removal in the

•

Suspension chapter).

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

•

aged rollers, and loose pins and links.

If there is any irregularity, replace the drive chain.

Lubricate the drive chain if it appears dry.

Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)

•

weight [A] on the chain.

Measure the length of 20 links [B] on the straight part [C] of

•

the chain from the pin center of the 1st pin to the pin center

of the 21st pin. Since the c hain may wear unevenly, take

measurements at several places.

If any measurements exceed the service limit, replace the

chain. Also, replace the front and rear sprockets when the

drive chain is replaced.

Drive Chain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit: 323 mm (12.7 in.)

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 the 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.

Periodic Maintenance Procedures

Brake System

Brake Fluid Leak (Brake Hose and Pipe) Inspection

For models equipped with an ABS, remove the rear fender

•

front (see Rear Fender Front Removal in the Frame chap­ter).
Apply the brake lever or pedal and inspect the brake fluid

•

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

PERIODIC MAINTENANCE 2-31

Brake Hose and Pipe Damage and Installation Condition Inspection

For models equipped with an ABS, remove the rear fender

•

front (see Rear Fender Front Removal in the Frame chap­ter).
Inspect the brake hoses, fittings and pipes (ABS equipped

•

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

○

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

Torque - Brake Ho se 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)

(KLE650B Models)

Inspect the brake hose routing.

•

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

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Operation Inspection

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

•

ning the vehicle on the dry road.

If the brake operation is 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.

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

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.)

PERIODIC MAINTENANCE 2-33

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)

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Suspensions

Front Fo rks/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).

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.

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 [A] the

•

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

NOTE

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

○

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

○

The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

PERIODIC MAINTENANCE 2-35

Steering Play Adjustment

Remove the steering stem head (see Stem, Stem Bearing

•

Removal).
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.

○

2-36 PERIODIC MAINTENANCE

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).

•

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).

•

Periodic Maintenance Procedures

Electrical System

Lights and Switches Opera tion Inspection

First Step

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

City Lights [A]

Taillight [B]

License Plate Light [C]

Meter Panel Illumination Light (LED) [D]

Meter Panel LCD [E]

Neutral Indicator Light (LED) [F]

Oil Pressure Warning Indicator Light (LED)
[G]

FI Indicator Light (LED) [H]

KLE650B Models

ABS Indicator Light (LED) [I]

goes on

goes on

goes on

goes on

goes on

goes on

goes on

goes on

(about 2 seconds)

goes on

PERIODIC MAINTENANCE 2-37

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 Meter Unit Inspec­tion in the Electrical System chapter)
Meter Unit for Neutral Indicator Light (LED) (see Meter
Unit Inspection in the Electrical System chapter)
Meter Unit for Oil Pressure Warning Indicator Light
(LED) (see Meter Unit Inspection in the Electrical Sys­tem chapter)
Meter Unit for Illumination Light (LED) (see Meter Unit
Inspection in the Electrical System chapter)
Meter Unit for FI Indicator Light (LED) (see 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)
(KLE650B 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)

Turn off the ignition switch.

•

The all lights should go off.

•

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

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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 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)

Fourth Step

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

•

Start the engine.

•

The low beam headlight should go on.

•

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

place the following item.

Headlight Low Beam Bulb (see Headlight Bulb Replace­ment in the Electrical System chapter)
Headlight Fuse 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)

Periodic Maintenance Procedures

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 chapter)
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.

PERIODIC MAINTENANCE 2-39

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

Headlight Beam Vertical Adjustment

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

•

screwdriver [B] in or out to adjust the headlight vertically.
In this photo [C], the right middle fairing has been re-

○

moved for clarity.

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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.

Low Beam [A]
Height of Headlight Center [B]
High Beam [C]

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

Up

Down Neutral Released

Down Neutral Pulled in

Down

Down

Gear

Position

In Gear

In Gear

In Gear

In Gear

Clutch

Lever

Released

Pulled in

Released

Pulled in

Engine

Start

Starts

Starts

Doesn’t

start

Starts

Starts

Starts

Doesn’t

start

Doesn’t

start

Engine

Run

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Stops

Stops

Periodic Maintenance Procedures

If the sidestand switch operation does not work, inspect
or replace the following item.

Battery (see Charging Condition Inspection in the Elec­trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the 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).

PERIODIC MAINTENANCE 2-41

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 starter 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).

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Others

Chassis Parts Lubrication

Before lubricating each part, clean off any rusty spots with

•

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

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri­cation.

Pivots: Lubricate with Grease.

Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand

Points: Lubricate with Grease.

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

Cables: Lubricate with Rust Inhibitor.

Clutch Cable
Throttle Cables

Lubricate the cables by seeping the oil between the cable

•

and housing.
The cable may be lubricated by using a commercially

○

available pressure cable lubricator with an aerosol cable
lubricant.

With the cable disconnected at both ends, the inner cable

•

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

Periodic Maintenance Procedures

Bolts, Nuts and Fasteners Tightness Inspection

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

•

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

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

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

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Nut

Engine Mounting Bolts and Nuts

Exhaust Pipe Manifold Holder Nuts

Muffler Body Mounting Bolts

PERIODIC MAINTENANCE 2-43

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:

SteeringStemHeadBolt

Handlebar Holder Bolts

Others:

Footpeg Stay Bolts

Front Fender Bolts

Sidestand Bolt

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replacement Parts

Air Cleaner Element R eplacemen t

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 the fuel tank (see Fuel Tank Removal in the Fuel

•

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

•

joint.
Insert a minus screwdriver [B] into the s lit [C] on the joint

•

lock.

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 so that the white mark [A] side

•

faces throttle body assy.
Insert [B] the fuel hose joint [C] straight onto the delivery

•

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

•

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.

•

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 Middle Fairing (see Center Fairing Removal in the

Frame chapter)

Right Front Frame Cover (see Front Frame Cover Re-

moval in the Frame chapter)

Lower Fairing (see Lower Fairing Removal in the Frame

chapter)

Reserve Tank Bolts [A]

Reserve Tank [B]

PERIODIC MAINTENANCE 2-45

Remove:

•

Bolts [A]

Reserve Tank Bracket [B]

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

•

on the frame bracket, and place the reserve tank on the
rightsideofframe.

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

•

then remove the drain bolt.

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

•

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

○

Remove the reserve tank [A] from the frame bracket [B].

•

Remove the reserve tank 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: 9.8 N·m (1.0 kgf·m, 87

in·lb)

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

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 of the cooling system.

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%

Coolant: 50%

Freezing Point:

Total Amount:

–35°C (–31°F)

1.2 L (1.3 US qt)

Periodic Maintenance Procedures

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

•

NOTE

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, and install

•

the radiator cap.

Install the reserve tank bracket and reserve tank.

•

Put the projection [A] on the reserve tank bracket into the

○

hole [B] on the frame bracket.

PERIODIC MAINTENANCE 2-47

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.

•

2-48 PERIODIC MAINTENANCE

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.

•

Recommended Engine Oil

Type: API SE, SF or SG

API SH, SJ or SL with JASO MA

Viscosity: SAE 10W-40

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

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

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

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: 17.5 N·m (1.8 kgf·m, 13 ft·lb)

NOTE

Hand tightening of the oil filter can not be allowed since

○

it does not reach to this tightening torque.

Pour in the specified type and amount of oil (see Engine

•

Oil Change).

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 2-49

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

For models equipped with an ABS, note the following.

•

Remove:

○

Rear Fender Front (see Rear Fender Front Removal in
the Frame chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Right Rear Frame Cover (see Rear Frame Cover Re­moval in the Frame chapter)

Remove the brake pipe joint nuts [C].

○

Remove the bracket bolts [D] and brackets [E].

○

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)

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

(KLE650B 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).

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.

Periodic Maintenance Procedures

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.

•

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.

PERIODIC MAINTENANCE 2-51

Remove the clear plastic hose.

•

Install the diaphragm and reservoir cap.

•

Tighten:

•

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

kgf·m, 13 in·lb)

Follow the procedure below to install the rear brake fluid

•

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

○

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

Tighten the bleed valve, and install the rubber cap.

•

Torque - Bleed Valve: 7.8 N·m (0.80 k gf·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.

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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 To o l - Inside Circlip Pliers: 57001- 14 3

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

•

and return spring [F].

KLE650A Models [G]
KLE650B Models [H]

CAUTION

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

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 To o l - Inside Circlip Pliers: 57001- 14 3

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.

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.

Periodic Maintenance Procedures

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 k gf·m, 9

in·lb)

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

kgf·m, 52 in·lb)

Caliper Rubber Parts Replacement

Front Caliper Disassembly

Remove:

•

Front Caliper (see Front Caliper Removal in the Brakes

chapter)

Brake Pads (see Front Brake Pad Removal in the Brakes

chapter)
Using compressed air, remove the pistons.

•

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

○

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

○

remove the piston.

PERIODIC MAINTENANCE 2-53

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 caliper 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 k gf·m, 69 in·lb)

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replace the fluid seals [A] with new ones.

•

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

○

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

•

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

○

the cylinders by hand.

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.

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 chapter).
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.

Periodic Maintenance Procedures

Rear Caliper Assembly

Clean the caliper 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 k gf·m, 69 in·lb)

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

•

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

○

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

•

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

○

cylinder by hand.

PERIODIC MAINTENANCE 2-55

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 boot

•

[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 R eplacement

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

Replace the spark plug with a new one.

•

Standard Spark Plug

Typ e:

CR9EIA-9

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Insertthesparkplug[A]verticallyintotheplugholewith

•

the spark plug installed in the plug wrench [B].

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

CAUTION

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

Tighten:

•

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

Install the stick coils securely.

•

Be sure the stick coils are installed by pulling up it lightly.

○

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

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

DFI System............................................................................................................................. 3-8

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

DFI Parts Location.................................................................................................................. 3-13

Specifications ......................................................................................................................... 3-14

Special Tools and Sealant ...................................................................................................... 3-16

DFI Servicing Precautions ...................................................................................................... 3-18

DFI Servicing Precautions ................................................................................................ 3-18

Troubleshooting the DFI System ............................................................................................ 3-20

Outline ................................................................................................................................. 3-20

Outline............................................................................................................................... 3-20

Inquiries to Rider.................................................................................................................. 3-24

Inquiries to Rider............................................................................................................... 3-24

DFI System Troubleshooting Guide ....................................................................................... 3-27

Self-Diagnosis ........................................................................................................................ 3-35

Self-diagnosis Outline.......................................................................................................... 3-35

Self-diagnosis Outline....................................................................................................... 3-35

Self-diagnosis Procedures................................................................................................... 3-35

Self-diagnosis Procedures................................................................................................ 3-35

Service Code Clearing Procedures ..................................................................................... 3-36

Service Code Clearing Procedures................................................................................... 3-36

How to Read Service Codes................................................................................................ 3-38

How to Read Service Codes............................................................................................. 3-38

How to Erase Service Codes............................................................................................... 3-38

How to Erase Service Codes............................................................................................ 3-38

Service Code Table.............................................................................................................. 3-39

Service Code Table........................................................................................................... 3-39

Backups............................................................................................................................... 3-40

Backups ............................................................................................................................ 3-40

Main Throttle Sensor (Service Code 11) ................................................................................ 3-42

Main Throttle Sensor Removal/Adjustment ...................................................................... 3-42

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

Main Throttle Sensor Output Voltage Inspection .............................................................. 3-43

Main Throttle Sensor Resistance Inspection .................................................................... 3-44

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-46

Inlet Air Pressure Sensor Removal................................................................................... 3-46

Inlet Air Pressure Sensor Installation................................................................................ 3-46

Inlet Air Pressure Sensor Input Voltage Inspection........................................................... 3-46

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

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-51

Inlet Air Temperature Sensor Removal/Installation........................................................... 3-51

Inlet Air Temperature Sensor Output Voltage Inspection.................................................. 3-51

Inlet Air Temperature Sensor Resistance Inspection ........................................................ 3-52

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

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

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

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

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

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

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

3

3-2 FUEL SYSTEM (DFI)

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

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

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

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

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

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

Vehicle-down Sensor Removal......................................................................................... 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 Coils #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) ..................... 3-77

Oxygen Sensor Removal/Installation................................................................................ 3-77

Oxygen Sensor Inspection................................................................................................ 3-77

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

FI Indicator Light (LED) Inspection ................................................................................... 3-80

ECU........................................................................................................................................ 3-81

ECU Removal ................................................................................................................... 3-81

ECU Installation ................................................................................................................ 3-82

ECU Power Supply Inspection.......................................................................................... 3-82

Fuel Line................................................................................................................................. 3-85

Fuel Pressure Inspection .................................................................................................. 3-85

Fuel Flow Rate Inspection ................................................................................................ 3-86

Fuel Pump .............................................................................................................................. 3-88

Fuel Pump Removal ......................................................................................................... 3-88

Fuel Pump Installation ...................................................................................................... 3-88

Fuel Pump Operation Inspection ...................................................................................... 3-89

Fuel Pump Operating Voltage Inspection ......................................................................... 3-89

Pressure Regulator Removal............................................................................................ 3-90

Pump Screen, Fuel Filter Cleaning................................................................................... 3-90

Fuel Injectors.......................................................................................................................... 3-92

Removal/Installation.......................................................................................................... 3-92

Audible Inspection............................................................................................................. 3-92

FUEL SYSTEM (DFI) 3-3

Fuel Injector Power Source Voltage Inspection ................................................................ 3-92

Fuel Injector Output Voltage Inspection ............................................................................ 3-93

Injector Signal Test............................................................................................................ 3-94

Injector Resistance Inspection .......................................................................................... 3-95

Injector Unit Test ............................................................................................................... 3-95

Injector Fuel Line Inspection ............................................................................................. 3-95

Throttle Grip and Cables ........................................................................................................ 3-98

Throttle Grip Free Play Inspection .................................................................................... 3-98

Throttle Grip Free Play Adjustment................................................................................... 3-98

Throttle Cable Installation ................................................................................................. 3-98

Throttle Cable Lubrication................................................................................................. 3-98

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

Idle Speed Inspection ....................................................................................................... 3-99

Engine Vacuum Synchronization Inspection/Adjustment.................................................. 3-99

Throttle Body Assy Removal............................................................................................. 3-99

Throttle Body Assy Installation.......................................................................................... 3-100

Throttle Body Assy Disassembly ...................................................................................... 3-101

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

Air Cleaner.............................................................................................................................. 3-103

Air Cleaner Element Removal/Installation ........................................................................ 3-103

Air Cleaner Element Inspection ........................................................................................ 3-103

Air Cleaner Oil Draining .................................................................................................... 3-103

Air Cleaner Housing Removal........................................................................................... 3-103

Air Cleaner Housing Installation........................................................................................ 3-104

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

Fuel Tank Removal ........................................................................................................... 3-105

Fuel Tank Installation ........................................................................................................ 3-107

Fuel Tank and Cap Inspection .......................................................................................... 3-108

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

3-4 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

N·m kgf·m ft·lb

1 Fuel Pump Bolts 9.8 1.0 87 in·lb

2 Right Switch Housing Screws 3.5 0.36 31 in·lb

3 Sidestand Switch Bolt 3.9 0.40 35 in·lb L

4. Injectors

5. Throttle Body Assy

6. Throttle Cable (Accelerator)

7. Throttle Cable (Decelerator)

CL: Apply cable lubricant.

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts
S: Follow the specified tightening sequence.

Torque

Remarks

L, S

3-6 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1

Crankshaft Sensor Bolts

2 Oxygen Sensor (Europe Models) 44.1 4.5 33

3 Spark Plugs 15 1.5 11

4 Speed Sensor Bolt 7.8 0.80 69 in·lb

5 Timing Rotor Bolt 40 4.1 30

6 Water Temperature Sensor 12 1.2 106 in·lb

5. Air Switching Valve

6. Battery

7. ECU (Electronic Control Unit)

8. Inlet Air Pressure Sensor

9. Inlet Air Temperature Sensor

10. Relay Box

11. Stick Coil

12. Vehicle-down Sensor
G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

SS: Apply silicone sealant.

N·m kgf·m ft·lb

6.0 0.61 53 in·lb

Torque

Remarks

3-8 FUEL SYSTEM (DFI)

DFI System

DFI System

DFI System

1. Inlet Air Pressure Sensor

2. Crankshaft Sensor

3. Injector

4. Main Throttle Sensor

5. Delivery Pipe

6. Subthrottle Sensor

7. Subthrottle Valve

8. Main Throttle Valve

9. Subthrottle Valve Actuator

10. Fuel Pump

11. Pressure Regulator

12. Fuel Tank

13. Air Cleaner Element

14. Air Switching Valve

15. Inlet Air Temperature Sensor

16. Air Cleaner Housing

17. Speed Sensor

18. Vehicle-down Sensor

19. Oxygen Sensor (Europe Models)

20. ECU (Electronic Control Unit)

21. Battery

22. Air Flow

23. Fuel Flow

24. Water Temperature Sensor

FUEL SYSTEM (DFI) 3-9

3-10 FUEL SYSTEM (DFI)

DFI System

DFI System Wiring Diag ram

DFI System

Part Name

1. Oxygen Sensor (Europe Models)

2. Crankshaft Sensor

3. Inlet Air Temperature Sensor

4. Water Temperature Sensor

5. Water-proof Joint E

6. Injectors

7. Vehicle-down Sensor

8. Water-proof Joint D

9. Inlet Air Pressure Sensor

10. Main Throttle Sensor

11. Subthrottle Sensor

12. Subthrottle Valve Actuator

13. Speed Sensor

14. Air Switching Valve

15. Water-proof Joint C

16. Stick Coils

17. Fan Motor

18. Starter Button

19. Engine Stop Switch

20. Ignition Switch

21. Frame Ground

22. FI Indicator Light (LED)

23. Water Temperature Gauge

24. Tachometer

25. Speedometer

26. Water-proof Joint A

27. Water-proof Joint B

28. Fuse Box

29. Oxygen Sensor Heater Fuse 10 A

30. Radiator Fan Fuse 15 A

31. ECU Fuse 15 A

32. Ignition Fuse 10 A

33. Radiator Fan Relay

34. ECU Main Relay

35. Fuel Pump Relay

36. Relay Box

37. Main Fuse 30 A

38. Battery 12 V 10 Ah

39. Fuel Pump

40. Kawasaki Self-diagnosis System Connector

41. Self-diagnosis Terminal

42. Joint Connector

43. ECU

FUEL SYSTEM (DFI) 3-11

3-12 FUEL SYSTEM (DFI)

DFI System

Terminal Names

1. Subthrottle Valve Actuator Drive Signal 2

2. Subthrottle Valve Actuator Drive Signal 1

3. Water Temperature Warning Light Signal

4. Unused

5. Oxygen Sensor Signal (Europe Models)

6. Speed Sensor Signal

7. Main Throttle Sensor Signal

8. Inlet Air Pressure Sensor Signal

9. Unused

10. Power Supply to Sensors

11. Vehicle-down Sensor Signal

12. Neutral Switch Signal

13. Crankshaft Sensor (+) Signal

14. Unused

15. Unused

16. Power Supply to ECU (from ECU Main Re­lay)

17. Power Supply to ECU (from Battery)

18. Subthrottle Valve Actuator Drive Signal 4

19. Subthrottle Valve Actuator Drive Signal 3

20. Water Temperature Sensor Signal

21. Unused

22. Self-diagnosis Terminal

23. Unused

24. Subthrottle Sensor Signal

25. Unused

26. Inlet Air Temperature Sensor Signal

27. Unused

28. Ground to Sensors

29. Oxygen Sensor Heater Signal (Europe
Models)

30. Crankshaft Sensor (–) Signal

31. Unused

32. External Diagnosis System Signal

33. Unused

34. Ground to ECU

35. Engine Stop Switch Signal

36. Starter Lockout Switch Signal

37. Starter Button Signal

38. Unused

39. Fuel Pump Relay Signal

40. Air Switching Valve Signal

41. Fuel Injector #2 Signal

42. Fuel Injector #1 Signal

43. Stick Coil #1 Signal

44. Sidestand Switch Signal

45. Radiator Fan Relay Signal

46. External Communication Line (Mode
Switch)

47. Tachometer Signal

48. FI Indicator Light (LED)

49. –

50. Ground for Fuel System

51. Ground for Ignition System

52. Stick Coil #2 Signal

DFI Parts Location

FUEL SYSTEM (DFI) 3-13

1. FI Indicator Light (LED)

2. Ignition Switch

3. Throttle Body Assy

4. Inlet Air Temperature Sensor

5. Injectors

6. Fuel Pump

7. Relay Box (ECU Main Relay, Fuel Pump
Relay, Radiator Fan Relay)

8. Fuse Box (ECU Fuse 15 A, Oxygen Sen­sor Heater Fuse 10 A)

9. ECU

10. Battery 12 V 10 Ah

11. Oxygen Sensor (Europe Models)

12. Speed Sensor

13. Neutral Switch

14. Water Temperature Sensor

15. Main Throttle Sensor

16. Subthrottle Sensor

17. Subthrottle Valve Actuator

18. Stick Coils

19. Inlet Air Pressure Sensor

20. Kawasaki Self-diagnosis System Con­nector

21. Self-diagnosis Indicator Terminal

22. Air Switching Valve

23. Crankshaft Sensor

24. Vehicle-down Sensor

3-14 FUEL SYSTEM (DFI)

Specifications

Item Standard

Digital Fuel Injection System

Idle Speed 1 300 ±50 r/min (rpm)

Throttle Body Assy:

Type Two barrel type

Bore

ECU (Electronic Control Unit):

Make DENSO

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

Usable Engine Speed 100 ∼ 10 650 r/min (rpm)

Fuel Pressure (High Pressure Line):

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

Fuel Pump:

Type In-tank friction pump

Discharge 60 mL or more for 3 seconds

Fuel Injectors:

Type INP-287

Nozzle Type One spray type with 12 holes

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

Main Throttle Sensor: Non-adjustable and non-removable

Input Voltage DC 4.75 ∼ 5.25 V between BL and BR/BK leads
Output Voltage at Idle Throttle Opening DC 1.005 ∼ 1.035 V between Y/W and BR/BK leads
Output Voltage at Full Throttle Opening DC 4.2 ∼ 4.4 V between Y/W and BR/BK leads
Resistance 4 ∼ 6kΩ

Inlet Air Pressure Sensor:

Input Voltage DC 4.75 ∼ 5.25 V between BL and BR/BK leads
Output Voltage DC 3.80 ∼ 4.20 V at standard atmospheric pressure

Inlet Air Temperature Sensor:

Resistance 5.4 ∼ 6.6 kΩ at 0°C (32°F)

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

Water Temperature Sensor:

Resistance see Electrical System chapter

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

Speed Sensor:

Input Voltage at Sensor About DC 9 ∼ 11 V at Ignition Switch ON
Output Voltage at Sensor About DC 0.05 ∼ 0.07 V or DC 4.5 ∼ 4.9 V at Ignition

Vehicle-down Sensor:

Detection Method

Detection Angle more than 60 ∼ 70° for each bank
Output Voltage with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V

38 mm (1.50 in.)

with resin

(see this text for details)

0.29 ∼ 0.39 kΩ at 80°C (176°F)

Switch ON and 0 km/h

Magnetic flux detection method

with sensor arrow mark pointed up: 3.55 ∼ 4.45 V

FUEL SYSTEM (DFI) 3-15

Specifications

Item Standard

Subthrottle Sensor: Non-adjustable and non-removal

Input Voltage

Output Voltage at Idle Throttle Opening DC 0.4 ∼ 0.6 V between BL/W and BR/BK leads
Output Voltage at Full Throttle Opening DC 3.825 ∼ 3.975 V between BL/W and BR/BK leads
Resistance 4 ∼ 6kΩ

Subthrottle Valve Actuator:

Resistance About 5.5 ∼ 7.5 Ω

Input Voltage

Oxygen Sensor (Europe Models):

Output Voltage (Rich) 0.7 V or more

Output Voltage (Lean) 0.2 V or less

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

Throttle Grip and Cables

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

DC 4.75 ∼ 5.25 V between BL and BR/BK leads

About DC 8.5 ∼ 10.5 V

3-16 FUEL SYSTEM (DFI)

Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm²:
57001-125

Fork Oil Level Gauge:
57001-1290

Hand Tester:
57001-1394

Needle Adapter Set:
57001-1457

Throttle Sensor Setting Adapter:
57001-1538

Sensor Harness Adapter:
57001-1561

Throttle Sensor Setting Adapter #1:
57001-1400

Peak Voltage Adapter:
57001-1415

Fuel Pressure Gauge Adapter:
57001-1593

Fuel Hose:
57001-1607

Special Tools and Sealant

FUEL SYSTEM (DFI) 3-17

Oxygen Sensor Measuring Adapter:
57001-1682

Kawasaki Bond (Silicone Sealant):
56019-120

3-18 FUEL SYSTEM (DFI)

DFI Servicing Precautions

DFI Servicing Preca utions

There are a number of important precautions that should

be followed servicing the DFI system.

This DFI system is designed to be used with a 12 V sealed

○

battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
Do not reverse the battery cable connections. This will

○

damage the ECU.
To prevent damage to the DFI parts, do not disconnect the

○

battery cables or any other electrical connections when
the ignition switch is on or while the engine is running.
Take care not to short the cables that are directly con-

○

nected to the battery positive (+) terminal to the chassis
ground.
When charging, remove the battery from the motorcycle.

○

This is to prevent ECU damage by excessive voltage.
Do not turn the ignition switch ON while any of the DFI

○

electrical connectors are disconnected. The ECU memo­rizes service codes.
Do not spray water on the electrical parts, DFI parts, con-

○

nectors, leads, and wiring.

Whenever the DFI electrical connections are to be dis-

○

connected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the con­nector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the en­gine.
Connect these connectors until they click [A].

○

If a transceiver is installed on the motorcycle, make sure

○

that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.
When any fuel hose is disconnected, fuel may spout out

○

by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
When any fuel hose is disconnected, do not turn on the

○

ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
Do not operate the fuel pump if the pump is completely

○

dry. This is to prevent pump seizure.
Before removing the fuel system parts, blow the outer sur-

○

faces of these parts clean with compressed air.
To prevent corrosion and deposits in the fuel system, do

○

not add to fuel any fuel antifreeze chemicals.

DFI Servicing Precautions

To maintain the correct fuel/air mixture (F/A), there must

○

be no inlet air leaks in the DFI system. Be sure to install
the oil filler plug [A] after filling the engine oil.

Clutch Cover [B]

Torque - Oil Filler Plug: Hand-tighten

FUEL SYSTEM (DFI) 3-19

3-20 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Outline

Outline

When an abnormality in the DFI system occurs, the FI
indicator light (LED) goes on to alert the rider on the meter
panel. In addition, the condition of the problem is stored in
the memory of the ECU (electronic control unit). With the
engine stopped and turned in the self-diagnosis mode, the
service code [A] is indicated by the number of times the FI
indicator light (LED) blinks.

When due to a malfunction, the FI indicator light (LED) re­mains lit, ask the rider about the conditions [B] under which
the problem occurred and try to determine the cause [C].

First, conduct a self-diagnosis inspection and then a
non-self-diagnosis inspection. The non-self-diagnosis
items are not indicated by the FI indicator light (LED). Don’t
rely solely on the DFI self-diagnosis function, use common
sense.

Even when the DFI system is operating normally, the FI
indicator light (LED) [A] may light up under strong electrical
interference. No repair needed. Turn the ignition switch
OFF to stop the indicator light.

When the FI indicator light (LED) goes on and the motor­cycle is brought in for repair, check the service codes.

When the repair has been done, the light (LED) doesn’t go
on. But the service codes stored in memory are not erased
to preserve the problem history, and the light (LED) can
display the codes in the self-diagnosis mode. The problem
history is referred when solving unstable problems.

When the motorcycle is down, the vehicle-down sensor
is turned OFF and the ECU shuts off the fuel injectors and
ignition system. The FI indicator light (LED) blinks but the
service code cannot be displayed. The ignition switch is left
ON. If the starter button is pushed, the electric starter turns
but the engine doesn’t start. To start the engine again, raise
the motorcycle, turn the ignition switch OFF, and then ON.
The vehicle-down sensor is turned ON and the light (LED)
goes OFF.

Troubleshooting the DFI System

The DFI part connectors [A] have seals [B], including the

○

ECU.
Join the connector and insert the needle adapters [C]

•

inside the seals [B] from behind the connector until the
adapter reaches the terminal.

Special Tool - Needle Adapter Set: 57001-1457

CAUTION

Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.

Make sure that measuring points are correct in the con-

•

nector, noting the position of the lock [D] and the lead
color before measurement. Do not reverse connections
of the hand tester or a digital meter.
Be careful not to short-circuit the leads of the DFI or elec-

•

trical system parts by contact between adapters.
Turn the ignition switch ON and measure the voltage with

•

the connector joined.

FUEL SYSTEM (DFI) 3-21

CAUTION

Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.

After measurement, remove the needle adapters and ap-

○

ply silicone sealant to the seals [A] of the connector [B]
for waterproofing.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Always check battery condition before replacing the DFI

•

parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.

Trouble may involve one or in some cases all items.

•

Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
Measure coil winding resistance when the DFI part is cold

•

(at room temperature).
Make sure all connectors in the circuit are clean and tight,

•

and examine wires for signs of burning, fraying, short,
etc. Deteriorated wires and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.

3-22 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Pull each connector [A] apart and inspect it for corrosion,

•

dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

is damaged, replace it. Connect the connectors securely.

Check the wiring for continuity.

•

Use the wiring diagram to find the ends of the lead which

○

is suspected of being a problem.

Connect the hand tester between the ends of the leads.

○

Set the tester to the × 1 Ω range, and read the tester.

○

If the tester does not read 0 Ω, the lead is defective. Re-

place the lead or the main harness or the sub harness.

If both ends of a harness [A] are far apart, ground [B] the

○

one end [C], using a jumper lead [D] and check the con-

tinuity between the end [E] and the ground [F]. This en-

ables to check a long harness for continuity. If the harness

is open, repair or replace the harness.

When checking a harness [A] for short circuit, open one

○

end [B] and check the continuity between the other end

[C] and ground [D]. If there is continuity, the harness has

a short circuit to ground, and it must be repaired or re-

placed.

Narrow down suspicious locations by repeating the con-

•

tinuity tests from the ECU connectors.

If no abnormality is found in the wiring or connectors, the

DFI parts are the next likely suspects. Check the part,

starting with input and output voltages. However, there is

no way to check the ECU itself.

If an abnormality is found, replace the affected DFI part.

If no abnormality is found in the wiring, connectors, and

DFI parts, replace the ECU.

Lead Color Codes:

○

BK: Black

BL: Blue
BR: Brown
CH: Chocolate

DG: Dark Green

G: Green

GY: Gray

LB: Light Blue

LG: Light Green

O: Orange

P: Pink

PU: Purple

R: Red

W: White

Y: Yellow

Troubleshooting the DFI System

There are two ways to inspect the DFI system. One is

○

voltage Check Method and the other is Resistance Check
Method.

(Voltage Check Method)

This method is conducted by measuring the input voltage

○

[B] to a sensor [A] first, and then the output voltage [C]
from the sensor.
Sometimes this method can detect a fault of the ECU.

○

Refer to each sensor inspection section for detail in this

•

chapter.
Use a fully charged battery and a digital meter [D] which

•

can be read two decimal places voltage or resistance.

FUEL SYSTEM (DFI) 3-23

(Resistance Check Method)

This method is simple. No need for a fully charged battery

○

and the needle adapter. Just do the following especially
when a sensor [A] is suspect.
Turn the ignition switch OFF and disconnect the connec-

•

tors.
Inspect the sensor resistance, using a digital meter (see

•

each sensor inspection).
Inspect the wiring and connectors [B] for continuity, using

•

the hand tester [C] (analog tester) rather than a digital
meter.

Special Tool - Hand Tester: 57001-1394

If the sensor, the wiring and connections are good, inspect
the ECU for its ground and power supply (see ECU Power
Supply Inspection).
If the ground and power supply are good, the ECU is sus­pect. Replace the ECU.

3-24 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

DFI Diagnosis Flow Chart

Inquiries to Rider

Inquiries to Rider

Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms

○

the rider has encountered.
Try to find out exactly what problem occurred under exactly what conditions by asking the rider;

○

knowing this information may help you reproduce the problem.
The following sample diagnosis sheet will help prevent you from overlooking any areas, and will

○

help you decide if it is a DFI system problem, or a general engine problem.