Kawasaki VN1500 User Manual

VULCAN 1500 MEAN STREAK

VN1500 MEAN STREAK

Motorcycle

Service Manual

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

LIST OF ABBREVIATIONS

A ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch



C DC direct current r/min, 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) L liter(s)

ampere(s) lb pound(s)

degree(s) Celsius r revolution



ohm(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

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

1. Crankcase Emission Control System This system eliminates the release of cranckcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.

2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efﬁcient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.

3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as

the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed on or

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

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

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

NOTE



The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows:

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

2.Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or

durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element

of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

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

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

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

•

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

•

Removal of the air box or air box cover.

•

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

•

result in increased noise levels.

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufﬁcient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualiﬁed mechanics.

In order to perform the work efﬁciently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are speciﬁed, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

Follow the Periodic Maintenance Chart in the Service

•

Manual.

Be alert for problems and non-scheduled maintenance.

•

Use proper tools and genuine Kawasaki Motorcycle

•

parts. Special tools, gauges, and testers that are

necessary when servicing Kawasaki motorcycles are

introduced by the Special Tool Catalog or Manual.

Genuine parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual carefully. Don’t

•

take shortcuts.

Remember to keep complete records of maintenance

•

and repair with dates and any new parts installed.

How to Use This Manual

In preparing this manual, we divided the product into its major systems. These systems became 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.

If you want ignition coil information, for example, use the Quick ReferenceGuidetolocate the Electrical System chapter. Then, use the Tableof 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.

This warning symbol identiﬁes special instruc-

tions or procedures which, if not correctly fol-

lowed, could result in personal injury, or loss of

life.

CAUTION

This caution symbol identiﬁes special instruc-

tions or procedures which, if not strictly ob-

served, could result in damage 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 particular interest for more efﬁcient and convenient 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 conditionalsteporwhataction to take based

on the results of the test or inspection in the procedural

step or sub-step it follows.

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...........................................................................................................................................................1-4

General Speciﬁcations......................................................................................................................................................1-6

Torque and Locking Agent................................................................................................................................................1-8

Special Tools and Sealant...............................................................................................................................................1-13

Cable, Wire, and Hose Routing......................................................................................................................................1-20

1-2 GENERAL INFORMATION

Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal ﬁlings.

(2) Battery Leads

Disconnect the ground ( This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, ﬁrst connect the positive lead to the positive (+) terminal of the battery.

(3) Installation, Assembly

Generally, installation or assembly is the reverse of removal or disassembly. But if this Service Manual has installation or assembly procedures, follow them. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing as much as possible.

(4) Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to asnugﬁt. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, ﬁrst loosen all of them by about a quarter turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated.

(5) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.

(6) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difﬁcult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads.

(7) Edges

Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.

(8) High-Flash Point Solvent

A high-ﬂash point solvent is recommended to reduce ﬁre danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

(9) Gasket, O-Ring

Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leakage.

(10) Liquid Gasket, Non-Permanent Locking Agent

Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a nonpermanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue).

(11) Press

A part installed using a press or driver, such as a wheel bearing, should ﬁrst be coated with oil on its outer or inner circumference so that it will go into place smoothly.

(12) Ball Bearing and Needle Bearing

Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings. Install bearings with the marked side facing out applying pressure evenly with a suitable driver. Only press on the race that forms the press ﬁt with the base component to avoid damaging the bearings. This prevents severe stress on the balls or needles and races, and prevent races and balls or needles from being dented. Press a ball bearing until it stops at the stopper in the hole or on the shaft.

(13) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction.

−) lead from the battery before performing any disassembly operations on the motorcycle.

GENERAL INFORMATION 1-3

Before Servicing

(14) Circlip, Retaining Ring, and Cotter Pin

Replace any circlips and retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.

(15) Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative ﬁlm. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative ﬁlm. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.

Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulﬁde grease (MoS parts. The molybdenum disulﬁde oil is a mixture of engine oil and molybdenum disulﬁde grease with a weight ratio (10 : 1), which can be made in your work shop. Always check manufacturer recommendations before using such special lubricants.

(16) Electrical Wires

All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identiﬁed by ﬁrst the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color.

2) and molybdenum disulﬁde oil in the assembly of certain engine and chassis

(17) Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed.

(18) Inspection

When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones.

Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure

(19) Speciﬁcations

Speciﬁcation terms are deﬁned as follows:

"Standards" show dimensions or performances which brand-new parts or systems have.

"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

1-4 GENERAL INFORMATION

Model Identiﬁcation

VN1500-P1 (US, and Canada) Left Side View:

VN1500-P1 (US, and Canada) Right Side View:

Model Identiﬁcation

VN1500-P1 (Europe) Left Side View:

GENERAL INFORMATION 1-5

VN1500-P1 (Europe) Right Side View:

1-6 GENERAL INFORMATION

General Speciﬁcations

Items VN1500-P1

Dimensions:

Overall length Overall width 850 mm (33.5 in.) Overall height 1100 mm (43.3 in.) Wheelbase 1705 mm (67.1 in.) Road clearance 125 mm (4.92 in.) Seat height 700 mm (27.6 in.) Dry mass 289 kg (637 lb) Curb mass: Front 144 kg (318 lb)

Rear 172 kg (379 lb) Fuel tank capacity 17.0 L (4.49 US gal) Fuel Unleaded and high-octane gasoline (see VN1500-P1 Owner’s Manual)

Performance:

Minimum turning radius 3.1 m (10.2 ft)

Engine:

Type 4-stroke, SOHC, V2-cylinder Cooling system Liquid-cooled Bore and stroke 102290 mm (4.02 Displacement 1470 mL (89.70 cu in.) Compression ratio 9.0 : 1 Maximum horsepower 53 kW (72 PS) @5500 r/min (rpm),

Maximum torque 114 N1m (11.6 kg

Carburetion system DFI (Digital Fuel Injection) System Starting system Electric starter Ignition system Battery and coil (transistorized) Timing advance Electronically advanced (digital) Ignition timing From 5BTDC @950 r/min (rpm) 25BTDC @4500 r/min (rpm) Spark plugs NGK DPR6EA-9 or ND X20EPR-U9 Cylinder numbering method Front to Rear, 1-2 Firing order 1-2 Valve timing:

Inlet Open 28BTDC

Close 72ABDC

Duration 280

Exhaust Open 66BBDC

Close 42ATDC

Duration 288 Lubrication system Forced lubrication (wet sump) Engine oil: Type API : SE, SF or SG class

Viscosity SAE10W-40

Capacity 3.5 L (3.7US qt, when engine is completely disassembled and dry)

Drive Train:

Primary reduction system:

Type Gear Reduction ratio 1.517 (85/56)

Clutch type Wet multi disc

2410 mm (94.9 in.)

3.54 in.)

(AU) 47 kW (64 PS) @ 5300 r/min (rpm), (CA) (CN) (US) –

m, 84.1 ft1lb) @3000 r/min (rpm),

(AU) 108 N



API SH or SJ class with JASO MA

m (11.0 kg

m, 79.7 ft1lb) @3000 r/min (rpm), (CA) (CN) (US) –

GENERAL INFORMATION 1-7

General Speciﬁcations

Items VN1500-P1

Transmission:

Type 5-speed, constant mesh, return shift Gear ratios: (CA, CN, US)

1st 2.500 (40/16) 2nd 1.750 (35/20) 3rd 1.333 (32/24) 4th 1.074 (29/27) 5th 0.867 (26/30)

(other than CA, CN, US) 1st 2.500 (40/16) 2nd 1.590 (35/22) 3rd 1.192 (31/26) 4th 0.965 (28/29) 5th 0.781 (25/32)

Final drive system:

Type Shaft Reduction ratio 2.619 (15/21233/9) Overall drive ratio (CA, CN, US) 3.445 @ Top gear

(other than CA, CN, US) 3.105 @ Top gear

Final gear case oil:

Grade API Service Classiﬁcation: GL-5 Hypoid gear oil Viscosity SAE90 (above 5C), SAE80 (below 5 Capacity 200 mL

Frame:

Type Tubular, double cradle Caster (rake angel) 32 Trail 144 mm (5.67 in.) Front tire: Type Tubeless

Size 130/70R17 M/C 62H

Rear tire: Type Tubeless

Size 170/60R17 M/C 72H

Front suspension: Type Telescopic fork (upside-down)

Wheel travel 150 mm (5.91 in.)

Rear suspension: Type Swingarm, air oil shock absorber

Wheel travel 87 mm (3.43 in)

Brake Type: Front Dual disc

Rear Single disc

Electrical Equipment:

Battery Headlight: Type Semi-sealed beam

Tail/brake light 12 V 5/21 W Alternator: Type Three-phase AC

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

AU: Australian Model CA: California Model CN: Canadian Model US: United States of America Model

Capacity

Bulb 12 V 60/55 W (quartz-halogen)

Rated output 23 A214 V @6 000 r/min (rpm)



12 V 18 Ah



1-8 GENERAL INFORMATION

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

G: Apply grease to the threads.

EO: Apply engine oil to the threads and the seating

surface.

L: Apply a non-permanent locking agent to the

threads.

Lh: Left-hand threads.

MO: Apply molybdenum disulﬁde oil to the threads and

the seating surface. The molybdenum disulﬁde oil is a mixture of engine oil and molybdenum disulﬁde grease with a weight ratio (10 : 1).

S: Tighten the fasteners following the speciﬁed se-

quence.

SS: Apply silicone sealant.

St: Stake the fasteners to prevent loosening.

R: Replacement parts

Fastener

Fuel System:

Vacuum Sensor Nut 9.8 1.0 87 in Atmospheric Pressure Sensor Nut 9.8 1.0 87 in High Pressure Fuel Hose Clamp Screws 1.5 0.15 13 in Pressure Regulator Screws 4.9 0.50 43 in Delivery Joint Screws 3.4 0.35 30 in Throttle Cable Holder Screw 3.4 0.35 30 in1lb L Throttle Body Flange Bolts 4.9 0.50 43 in Throttle Assy Holder Bolts 11 1.1 95 in Inlet Manifold Bolts 12 1.2 104 in Spark Plug Lead Holder Bolts 11 1.1 95 in ISC Pipe Holder Bolts 9.8 1.0 87 in Air Cleaner Duct Holder Bolts 11 1.1 95 in1lb Left Side Right and Left Air Cleaner Base Bolts 11 1.1 95 in Right and Left Air Cleaner Base Screws 2.2 0.22 19 in Left Air Cleaner Duct Tapping Screws 2.2 0.22 19 in1lb Left Air Cleaner Cover Allen Bolt8 16 1.6 12 Right Air Cleaner Cover Allen Bolt Right Air Cleaner Allen Bolts 11 1.1 95 in Choke Cable Plate Screw 2.9 0.30 26 in1lb L, Throttle Body Inlet Air Temperature Sensor Nut (DFI) 7.8 0.80 69 in1lb Water Temperature Sensor (DFI) 18 1.8 13 SS Fuel Pump Bolts 6.9 0.70 61 in1lb S, L Return Fuel Check Valve 20 2.0 15

Cooling System:

Radiator Hose Clamp Screws 2.5 0.25 22 in1lb Thermostat Air Bleeder Bolt 7.8 0.80 69 in1lb Radiator Fan Switch 18 1.8 13 Radiator Fan Bolts 8.3 0.85 74 in1lb Water Temperature Switch 7.4 0.75 65 in1lb SS Water Pump Impeller Bolt 8.8 0.90 78 in1lb Lh Water Pump Cover Bolts 11 1.1 95 in1lb Water Pump Air Bleeder Bolt 11 1.1 95 in1lb Water Pump Drain Bolt 11 1.1 95 in1lb Water Pipe Bolts 9.8 1.0 87 in1lb Radiator Drain Bolt 7.4 0.75 65 in1lb

Engine Top End:

Spark Plugs 18 1.8 13



N1m kg1m ft1lb

16 1.6 12

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 Torque

dia. (mm) N

5 3.4 6 5.9 7.8 0.60 0.80 52 69 in1lb

8 14 10 25 12 44 61 4.5 6.2 33 45 14 73 16 115 18 165 20 225

Torque

4.9

98 155 225 325

kg1m ft1lb

1.4

2.6

7.4

1 1 1 1 1

1 1

lb lb lb lb lb

lb lb

0.50

1.9

3.5

10.0

16.0

23.0 33

Throttle Body

on Cyl. Head

L, Lower Duct

Throttle Body

0.35

11.5

17.0

10.0

19.0

83 125 165

Remarks

Right Side

43 in

13.5

115

165 240

Torque and Locking Agent

GENERAL INFORMATION 1-9

Fastener

Spark Plug Retainer 12 1.2 104 in Air Suction Valve Cover Bolts 7.4 0.75 65 in1lb Chain Tensioner Mounting Bolts 11 1.1 95 in1lb S Chain Tensioner Cap 20 2.0 15 S Chain Tensioner Lockbolt 4.9 0.50 43 in1lb S Timing Inspection Cap 1.5 0.15 13 in Rotor Bolt Cap 1.5 0.15 13 in Camshaft Sprocket Bolts 15 1.5 11 L Oil Hose Flange Bolts 9.8 1.0 87 in1lb Rocker Shafts 25 2.5 18 Rocker Case Nuts 12 mm 78 8.0 58 MO, S

8mm 25 2.5 18 S Rocker Case Bolts 6 mm 8.8 0.90 78 in Cylinder Head Nuts 25 2.5 18 S Cylinder Head Jacket Plugs 20 2.0 15 L Rocker Case Cover Bolts 8.8 0.90 78 in Camshaft Chain Guide Bolts 11 1.1 95 in1lb L Cylinder Nuts 25 2.5 18 S Inlet Manifold Bolts 12 1.2 104 in1lb on Cyl. Head Exhaust Pipe Cover Clamp Bolts 6.9 0.70 61 in Chamber Bolts 29 3.0 22 Mufﬂer Stay Mounting Bolts,8 27 2.8 20 Lower Mufﬂer Upper Mufﬂer Bracket Bolt and Nut 29 3.0 22

Clutch:

Clutch Lever Pivot Bolt 1.0 0.10 8.7 in1lb Clutch Lever Pivot Bolt Locknut 5.9 0.60 52 in Clutch Reservoir Cap Screws 1.5 0.15 13 in Clutch Slave Cylinder Bleed Valve 7.8 0.80 69 in Clutch Slave Cylinder Bolts 6.9 0.70 61 in Clutch Hose Banjo Bolts 25 2.5 18 Clutch Master Cylinder Clamp Bolts 9.8 1.0 87 in Starter Lockout Switch Screws 1.2 0.12 10 in Push Rod Guide Bolts 9.8 1.0 87 in Clutch Cover Bolts 11 1.1 95 in Clutch Cover Damper Bolts (outside) 9.8 1.0 87 in Clutch Cover Damper Bolts (inside) 9.8 1.0 87 in Clutch Cover Damper Screws 4.9 0.50 43 in Clutch Hub Nut 147 15.0 108 MO

Engine Lubrication System:

Oil Filler Cap 1.5 0.15 13 in1lb Oil Screen Plug 20 2.0 15 Engine Oil Drain Plug 20 2.0 15 Oil Filter (Cartridge type) 18 1.8 13 R, EO Oil Filter Bolt 25 2.5 18 SS Oil Pressure Relief Valve 15 1.5 11 L Oil Pressure Switch Terminal Screw 1.5 0.15 13 in1lb Oil Pressure Switch 15 1.5 11 SS Oil Pump Mounting Bolts 11 1.1 95 in1lb Oil Hose Banjo Bolts 9.8 1.0 87 in1lb Oil Hose Flange Bolt (outside) 9.8 1.0 87 in1lb Oil Pipe Holder Bolts (inside) 11 1.1 95 in1lb L Oil Pipe Clamp Bolts (inside) 11 1.1 95 in1lb L Right & Left Crankcase Oil Nozzles 2.9 0.30 26 in1lb Right Crankcase Oil Nozzle 2.9 0.30 26 in1lb Oil Bafﬂe Bolt 11 1.1 95 in1lb L

Engine Removal/Installation:

Downtube Bolts and Nuts 44 4.5 32

Torque

kg1m ft1lb

Remarks

EO (tip)

1, Lh

1-10 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Engine Mounting Bolts and Nuts 44 4.5 32 Engine Mounting Bracket Bolts 25 2.5 18 Engine Ground Terminal Bolt 7.8 0.80 69 in1lb

Crankshaft/Transmission:

Crankcase Bolts 10 mm 39 4.0 29 S

8mm 21 2.1 15 S

6mm 11 1.1 95 in Jumper Cable Ground Bracket Bolt 9.8 1.0 87 in1lb Left Crankcase Crankcase Bearing Retainer Bolts 11 1.1 95 in1lb L Camshaft Chain Guide Bolts 11 1.1 95 in1lb L Right, Left Crankcase Oil Nozzles 2.9 0.30 26 in1lb Right Crankcase Oil Nozzles 2.9 0.30 26 in Oil Bafﬂe Bolt 11 1.1 95 in Connecting Rod Big End Nuts 59 6.0 43 MO Oil Pressure Relief Valve 15 1.5 11 L Oil Filter Bolt 25 2.5 18 Oil Hose Banjo Bolts 9.8 1.0 87 in1lb Primary Gear Bolt 147 15.0 108 MO Water Pump Chain Guide Spring Hook Bolt 2.9 0.30 26 in1lb Water Pump Chain Guide Bolt 8.3 0.85 73 in Idle Shaft Holder Bolts 7.8 0.80 69 in Oil Pressure Switch Terminal Screw 1.5 0.15 13 in1lb Oil Pressure Switch 15 1.5 11 SS Oil Pipe Clamp Bolts (inside) 11 1.1 95 in Left Balancer Gear Bolt 85 8.7 63 MO Starter Clutch Bolt 85 8.7 63 MO Starter Clutch Coupling Bolts 15 1.5 11 L Gear Set Lever Bolt 11 1.1 95 in Shift Shaft Return Spring Pin (Bolt) 39 4.0 29 L Shift Pedal Clamp Bolt 17 1.7 12 mark 10 Rear Shift Lever Clamp Bolt 12 1.2 104 in Shift Rod Locknuts 11 1.1 95 in Shift Drum Bearing Holder Bolts 11 1.1 95 in Shift Drum Cam Screw – – – L Damper Cam Nut (Front Gear) 226 23 166 MO (threads) Push Rod Guide Bolts 9.8 1.0 87 in

Wheels/Tires:

Front Axle Clamp Bolts 25 2.5 18 S Front Axle 110 11 79.6 S Rear Axle Nut 110 11 79.6 Tire Air Valve Stem Nuts 1.5 0.15 13 in1lb Tire Air Valve Caps 0.15 0.015 1.3 in1lb Air Valve Cores 0.3 0.03 2.6 in1lb

Final Drive:

Oil Pipe Banjo Bolts (Front Gear) 12 1.2 104 in1lb Oil Nozzle (Front Gear) 2.9 0.30 26 in1lb Oil Nozzle (Front Gear) 18 1.8 13 Neutral Switch 15 1.5 11 Front Gear Case Bolts: 6 mm 12 1.2 104 in1lb mark 9

8mm 29 3.0 22 Speed Sensor Bolt 9.8 1.0 87 in1lb L Damper Cam Nut (Front Gear) 226 23 166 MO (threads) Drive Gear Nut (Front Gear) 265 27 195 MO, St Driven Gear Assy Mounting Bolts 25 2.5 18 Driven Gear Bolt (Front Gear) 137 14 101 MO, St Bearing Retainer Bolts (Front Gear) 8.8 0.9 78 in1lb L Final Gear Case Drain Plug 8.8 0.9 78 in1lb

Torque

kg1m ft1lb

Remarks

1, Lh

(Rear: Lh)

Torque and Locking Agent

GENERAL INFORMATION 1-11

Fastener

Final Gear Case Mounting Nuts 34 3.5 25 Final Gear Case Studs – – – L Final Gear Case Cover Bolts: 8 mm 23 2.3 17 L

10 mm 34 3.5 25 L Pinion Gear Nut (Final Gear) 127 13 93 St, MO Bearing Retainer Bolt 6.9 0.7 61 in

Brakes:

Caliper Bleed Valves 7.8 0.8 69 in1lb Brake Hose Banjo Bolts 25 2.5 18 Brake Lever Pivot Bolt 1.0 0.10 8.7 in1lb Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in1lb Front Brake Reservoir Cap Screws 1.5 0.15 13 in Front Brake Light Switch Screw 1.2 0.12 10 in Front Master Cylinder Clamp Bolts 8.8 0.9 78 in1lb G, S Front Brake Pad Spring Bolts 2.9 0.3 26 in1lb Front Caliper Mounting Bolts 34 3.5 25 Front Caliper Assembly Bolts 21 2.1 15 Rear Caliper Mounting Bolts 34 3.5 25 Rear Caliper Holder Bolt 64 6.5 47 Brake Disc Bolts 27 2.8 20 L Rear Master Cylinder Mounting Bolts 25 2.5 18 Rear Master Cylinder Push Rod Locknut 18 1.8 13 Brake Pedal Clamp Bolt 25 2.5 18

Suspension:

Upper Front Fork Clamp Bolts 20 2.0 15 Lower Front Fork Clamp Bolts 20 2.0 15 Front Fork Top Plugs 34 3.5 25 Piston Rod Nuts or Joint Rod Nut 20 2.0 15 Inner Fork Bolt (left) 98 10 73 Front Fork Bottom Allen Bolt (right) 20 2.0 15 L Front Axle Clamp Bolts 25 2.5 18 S Protector Screws 5.9 0.6 52 in Rear Shock Absorber Nuts 34 3.5 25 Shock Absorber Air Valves 5.4 0.55 47 in Swingarm Pivot Shaft 110 11 79.6 G

Steering:

Steering Stem Head Nut 54 5.5 40 Steering Stem Nut 4.9 0.5 43 in1lb Handlebar Nuts 34 3.5 25 Handlebar End Caps – – – Lh, L Handlebar Switch Housing Screws 3.4 0.35 30 in1lb Upper Front Fork Clamp Bolts 20 2.0 15 Lower Front Fork Clamp Bolts 20 2.0 15 Turn Signal Light Mounting Nuts 5.9 0.6 52 in1lb

Frame:

Downtube Bolts and Nuts 44 4.5 32 Front Footpeg Bracket Bolts 25 2.5 18 Rear Footpeg Bracket Bolts 25 2.5 18 Sidestand Nut 44 4.5 32

Electrical System:

Spark Plugs 18 1.8 13 Pickup Coil Screws 2.9 0.30 26 in1lb Stator Lead Holder Screw 9.8 1.0 87 in1lb Pickup Coil Lead Holder Bolt 9.8 1.0 87 in1lb Alternator Outer Cover Bolts 6.9 0.7 61 in1lb Alternator Outer Cover Joint Bolts 6.9 0.7 61 in1lb Alternator Outer Cover Damper Bolts 6.9 0.7 61 in1lb L

Torque

kg1m ft1lb

Remarks

L L

1-12 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Alternator Outer Cover Assembly Bolts 6.9 0.7 61 in Alternator Cover Bolts 11 1.1 95 in1lb Alternator Inner Cover Bolts 11 1.1 95 in1lb Alternator Rotor Bolt 78 8.0 57 MO Alternator Stator Bolts 13 1.3 113 in1lb L Regulator/Rectiﬁer Bolts 6.5 0.66 58 in Timing Inspection Cap 1.5 0.15 13 in Rotor Bolt Cap 1.5 0.15 13 in1lb Starter Motor Terminal Locknut 11 1.1 95 in1lb Starter Motor Terminal Nut 4.9 0.50 43 in1lb Starter Motor Assy Bolts 4.9 0.50 43 in1lb Starter Motor Mounting Bolts 11 1.1 95 in Headlight Body Mounting Nuts 7.8 0.8 62 in Headlight Rim Screws 1.4 0.14 12 in1lb L Headlight Mounting Screws 2.9 0.3 26 in1lb Headlight Body Bracket Screws 1.2 0.12 10 in Handlebar Switch Housing Screws 3.4 0.14 12 in1lb Starter Lockout Switch Screw 1.2 0.12 10 in Front Brake Light Switch Screw 1.2 0.12 10 in1lb Sidestand Switch Bolt 8.8 0.9 78 in Radiator Fan Switch 18 1.8 13 Water Temperature Switch 7.8 0.8 69 in1lb SS Oil Pressure Switch Terminal Screw 1.5 0.15 13 in Oil Pressure Switch 15 1.5 11 SS Neutral Switch 15 1.5 11 Turn Signal Light Mounting Nuts Front 5.9 0.60 52 in

Rear 6.9 0.7 61 in License Plate Lens Screws 1.0 0.1 8.7 in License Plate Light Mounting Screw 1.2 0.12 10 in

Torque

kg1m ft1lb

Remarks

Special Tools and Sealant

GENERAL INFORMATION 1-13

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

Inside Circlip Pliers: 57001-143

Outside Circlip Pliers: 57001-144

Valve Guide Arbor,

Compression Gauge: 57001-221

Valve Spring Compressor Assembly: 57001-241

7: 57001-163

Bearing Puller: 57001-158

Valve Guide Reamer, 7: 57001-162

Valve Spring Compressor Adapter,

Bearing Puller Adapter: 57001-317

28.2: 57001-243

1-14 GENERAL INFORMATION

Special Tools and Sealant

Bearing Driver: 57001-382

Piston Pin Puller Assembly: 57001-910

Gear Holder: 57001-1015

Damper Cam Holder: 57001-1025

Driven Gear Holder: 57001-1027

Oil Pressure Gauge Adapter, PT 1/8: 57001-1033

Compression Gauge Adapter, M12

Spark Plug Wrench, Hex 18: 57001-1024

1.25: 57001-1018

Oil Seal & Bearing Remover: 57001-1058

Head Pipe Outer Race Press Shaft: 57001-1075

Special Tools and Sealant

GENERAL INFORMATION 1-15

Head Pipe Outer Race Driver: 57001-1077

Piston Ring Compressor Grip: 57001-1095

Steering Stem Nut Wrench: 57001-1100



Valve Seat Cutter, 45

Valve Seat Cutter, 32

Valve Seat Cutter, 32– 38.5 : 57001–1122

35: 57001-1116



35: 57001-1121

Head Pipe Outer Race Remover: 57001-1107

Valve Seat Cutter, 45- 32: 57001-1115

Valve Seat Cutter Holder,

Valve Seat Cutter Holder Bar: 57001-1128

7: 57001-1126

1-16 GENERAL INFORMATION

Special Tools and Sealant

Bearing Driver Set: 57001-1129

Pinion Gear Holder: 57001-1165

Hexagon Wrench, Hex 27: 57001-1210

Jack: 57001-1238

Timing Light: 57001-1241

Valve Seat Cutter, 55- 35: 57001-1247

Piston Pin Puller Adapter: 57001-1211

Fork Outer Tube Weight: 57001-1218

Oil Filter Wrench: 57001-1249

Final Gear Case Holder: 57001-1250

Special Tools and Sealant

GENERAL INFORMATION 1-17

Bearing Remover Shaft, 9: 57001-1265

Bearing Remover Head, 10212: 57001-1266

Fork Piston Rod Puller, M12 x 1.25 : 57001–1289

Flywheel Holder : 57001–1313

Steering Stem Bearing Driver: 57001-1344

Steering Stem Bearing Driver Adapter: 57001-1345

Fork Oil Level Gauge: 57001-1290

Bearing Remover Head, 20222: 57001-1293

Piston Ring Compressor Belt,

Bearing Remover Shaft,

13: 57001-1377

95 108: 57001-1358

1-18 GENERAL INFORMATION

Special Tools and Sealant

Hand Tester: 57001-1394

Attachment Jack: 57001-1398

Drive Shaft Holder: 57001-1407

Driver-Filler Cap: 57001–1454

Needle Adapter Set: 57001–1457

Valve Seat Cutter, 45- 40: 57001-1496

Flywheel Holder: 57001-1410

Fuel Pressure Gauge Adapter: 57001-1417

Valve Seat Cutter, 55

Fork Cylinder Holder: 57001-1502



- 38.5: 57001-1497

GENERAL INFORMATION 1-19

Special Tools and Sealant

Kawasaki Bond (Silicone Sealant): 56019–120 Kawasaki Bond (Liquid Gasket-Black): 92104-1003

1-20 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1. Indicator Lights

2. Fuel Tank

3. Fuel Pump Base

4. Two Clamps (fuel pump leads)

5. Plastic Caps

6. Snap-on Plastic Clamps

7. Fuel Tank Breather Hose

8. Fuel Pump Harness

9. Run the harness [8] under the hose [7].

10. Indicator Light Connector : Insert the main harness side connector into the connector hole of the bracket [13] and join the connector.

11. Main Harness

12. Ignition Switch Connector : Join the connector and ﬁt them into the hole of the bracket [13].

13. Indicator Unit Bracket

14. Ignition Switch

15. Press each end of clamps by hands against the bottom of the tank. And then, make sure that the ends touch the bottom of the tank.

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-21

F: Front 11.

Front Right Spark Plug Cap

Rear Right Spark Plug Cap

2nd Lead from the left ignition coil lower side

2nd Lead from the right ignition coil lower side

Ignition Coil for Rear Spark Plugs

Ignition Coil for Front Spark Plugs

2nd Lead from the left ignition coil upper side

2nd Lead from the right ignition coil upper side

Front Left Spark Plug Cap

10.

Rear Left Spark Plug Cap

Clutch Hose

12.

Plastic Snap-on Clamps

13.

Strap

14.

BK/G Primary Lead

15.

R/G Primary Lead

16.

BK Primary Lead

17.

R/G Primary Lead

18.

Align the white mark with the back of the clamp [12].

19.

Canister Purge Hose (green, CA)

1-22 GENERAL INFORMATION

Cable, Wire, and Hose Routing

Inlet Air Flow

Rear View

Air Inlet

Left Rubber Gasket

Left Air Cleaner Cover

Air Cleaner Element

Left Air Cleaner Base

Lower Air Cleaner Duct

Vacuum Switch Valve Hose

To Vacuum Switch Valve

10.

Right Air Cleaner Base

11.

Right Rubber Gasket

12.

Right Air Cleaner Cover

13.

Locate the glued joint of the gasket within the angle.

14.

Elbow Joint: connected to crankcase breather hose

15.

Top

16.

White Mark on Hose [8] (front side): Position here.

17.

Plug

18.

Run this drain hose between cylinders.

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-23

: Bypass Air Flow

F: Front

1. Rear View

2. Throttle Assy

3. Air Cleaner Base Seal

4. Spark Plug Lead Holder

5. Right Side View

6. Harness of Inlet Air Temperature Sensor & ISC Valves

7. T-Joint

8. Vacuum Hose from Throttle Body

9. Vacuum Sensor and Pressure Regulator

10. Strap (holds [4], [6], and [11])

11. Vacuum Switch Valve Hose

12. Right Air Cleaner Base Bolts

13. Right Air Cleaner Base

14. O-rings

15. ISC Valve Hose #2 (red)

16. ISC Valve Hose #1 (blue)

17. Lower Air Cleaner Duct

18. ISC Valve #2 (rear cylinder)

19. ISC Valve Inlets

20. Blue Mark on Top

21. ISC Valve #1 (front cylinder)

22. Inlet Air Temperature Sensor

23. Section B-B

24. Crankcase Breather Hose

25. Clamp these leads [6] with a slack as little as possible.

26. Back of Right Air Cleaner Base

1-24 GENERAL INFORMATION

Cable, Wire, and Hose Routing

--!:

Vacuum Pulsation

Fuel Flow

#1:

For Front Cylinder

#2:

For Rear Cylinder

Fuel Tank (left view)

Return Fuel Check Valve

High Pressure Fuel Hoses

Delivery Joint

Fuel Injector #1

Fuel Injector #2

Pressure Regulator

Throttle Body

Inlet Manifold

10.

Throttle Assy (top view)

11.

Throttle Pulley

12.

Throttle Sensor

13.

Low Pressure (Return) Fuel Hose

14.

Vacuum Hoses from Throttle Body

15.

Front

16.

Vacuum Hose (white, CA)

17.

T-Joint

18.

Vacuum Switch Valve

19.

Vacuum Sensor

20.

Throttle Vacuum Hose

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-25

F: Front 7.

Vacuum Pulsation

Bypass Air Flow

#1:

For Front Cylinder

#2:

For Rear Cylinder

Top View

Rear View

Bottom View

Pressure Regulator

Delivery Joint

Fuel Injector #2

Fuel Injector #1

Vacuum Hoses from Throttle Body

ISC Hose #1 (blue mark)

10.

T-Joint

11.

Throttle Sensor

12.

Vacuum Hose to Vacuum Sensor

13.

Inlet Manifold

14.

ISC Hose #2 (red mark)

15.

ISC Pipe #1

16.

ISC Pipe #2

17.

Throttle Cable Holder

18.

Choke Lever Stop Screw

19.

Throttle Pulley

20.

Idle Adjusting Screw

21.

Throttle Stop Screw

22.

Throttle Body

23.

Throttle Assy

24.

ISC Pipe Damper (section A-A)

25.

Decelerator Cable

26.

Accelerator Cable

27.

Position the white marks here.

1-26 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1. Clips

2. Vacuum Switch Valve (The air hole is faced downwards.)

3. Vacuum Switch Valve Hose (for front air suction valve)

4. White Mark (Face it upwards.)

5. Vacuum Switch Valve Hose (for right air cleaner base)

6. Vacuum Switch Valve Hose (for rear air suction valve): Run the hose under the vacuum hose of the pressure regulator.

7. They will be almost the same in height by aligning punch marks.

8. Align these punch marks.

9. Left-hand Threads

10. Align the shaft punch mark with the lever slit.

11. Shift Pedal

12. 112 ± 1 mm (4.409 ± 0.039 in. the outside length of these nuts)

13. Hooks

14. Clamps

15. Rear Exhaust Pipe Cover

16. Plastic Tabs

17. Rear Exhaust Pipe

18. Front Exhaust Pipe

19. Front Exhaust Pipe Cover

20. Upper Mufﬂer

21. Lower Mufﬂer

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-27

F: Front

1. White Marks on the hose [2] and [7] :The marks faces forwards.

2. Front Coolant Hose

3. Reserve Tank Hose

4. Clip

5. Rear Coolant Hose

6. White Marks on the hose face backwards.

7. Radiator Hose

8. Water Pump

9. Clamp

10. Water Pump Drainage Outlet Hose

11. Distance between pump inlet step and clamp end: about 16 mm (0.63 in.)

12. Clamps: Position each screw head as shown.

13. Insert the hose until the end touches the water pump inlet step.

14. Align them.

1-28 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

: Fuel Flow

: Vacuum Pulsation

1. Atmospheric Pressure Sensor

2. Vacuum Sensor

3. Vacuum Sensor Hose

4. Rear Coolant Hose

5. Injector Harness

6. Low Pressure Fuel Hose (return)

7. Fuel Hose Joint #2

8. Yellow Mark: Face the yellow mark upwards and forwards, aligning with the white mark.

9. Face the screw head left.

10. Install the hose with its mark up.

11. Fuel Hose Joint #1

12. Outlet Fuel from fuel tank

13. Return Fuel to fuel tank

14. Pressure Regulator

15. High Pressure Fuel Hose (supply)

16. Fuel Filter

17. Intank-fuel Pump

18. Inlet Pipe (to delivery joint)

19. Inlet Hose (to delivery joint)

20. Return Fuel Check Valve

21. Choke Cable: Run this over the hose [22] and under the hose [3].

22. Throttle Vacuum Hose

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-29

Fuel Flow

F: Front 10.

Fuel Pump Connector (outside the fuel tank)

Bottom of Fuel Tank

Outlet Fuel Pipe

In-tank Fuel Pump Body (DFI)

Fuel Reserve Switch (thermistor)

Pump Motor (–) BK/W Lead

Pump Motor (+) W/R Lead

Fuel Reserve Switch R/BK (+) Lead

Fuel Reserve Switch BK/Y (–) Lead Pump Base Plate

11.

Base Plate Gasket

12.

Outlet Fuel Pipe Joint

13.

Fuel Pump Screen (Pump Inlet)

14.

Inlet Fuel Hose

15.

Top

16.

Bottom View

17.

Fuel Filter

18.

Return Fuel Check Valve

1-30 GENERAL INFORMATION

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-31

Cable, Wire, and Hose Routing

F: Front

1. Rubber Boot

2. Starter Motor Lead

3. Clutch Hose

4. Upper Washer (

5. Lower Washer (

6. Engine Oil Pipe

7. Clamp

8. Clutch Slave Cylinder Bleed Valve

9. Bolt

10. Pickup Coil Connector

11. Speed Sensor Connector

12. Holder

13. Speed Sensor

14. Strap (speed sensor lead)

15. Oil Pressure/Neutral Switch Lead Connector

16. White Mark (next to the slave cylinder)

17. Plastic Snap-on Clamp

18. Regulator/Rectiﬁer

19. Regulator/Rectiﬁer Connector

20. Alternator Connector

21. Sidestand Switch Lead Connector

22. Insert the oil pressure/neutral switch leads, sidestand switch leads, and regulator/rectiﬁer leads in this order between the alternator cover and the clutch slave cylinder.

23. Left Crankcase

24. Harness (alternator and pickup coil leads)

25. Bolt

26. Holder

27. Do not run leads around here.

28. Alternator Outer Cover

29. Clamps

142 252



8.2 mm)



8.2 mm)

1-32 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Fuel Tank Fill Opening (top view)

2. Fuel Tank

3. Fuel Tank Breather Pipe

4. Filler Drainpipe

5. Fuel Tank Filler Drain Hose

6. Clip (Face the tab rightwards.)

7. Fuel Tank Breather Hose (except for California Model)

8. Clip

9. Hole of Bracket (Run the hose [7] into this hole.)

10. Holder (hose [7], [5], coolant reserve tank hose, clutch hose)

11. Swingarm Pivot

12. Cross Pipe

13. Run these hoses in front of [11] and [12].

14. Clamp

15. Coolant Reserve Tank Overﬂow Hose

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-33

F: Front

1. Rear View

2. Rear Fender

3. Grommets

4. Six Clamps

5. Rear Fender Harness

6. Plastic Cover

7. Run the harness [5] into the cut of the plastic cover [6]

8. Connector of [9] (Fit the connector of [5] into the welded clamp.)

9. License Plate Light Lead (Run this lead between the ribs of the ﬂap [18].)

10. Tail/Brake Light Leads (Clamp the connector of the rear harness with the welded clamp.)

11. Run the harness [5] between the ribs of the ﬂap [18].

12. White Mark of [5]

13. Rear Left Turn Signal Light

14. Rear Right Turn Signal Light

15. Bracket

16. Connector of [13] ﬁtted into [15]

17. Connector of [14] ﬁtted into [15]

18. Flap

19. License Plate Light

20. Do not pinch leads of [13], [14].

21. Lead of [13] and [14]

22. Press by hands: Clamp the harness [5] with these clamps [4] and press each end of clamps by hands against the rear fender.

1-34 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1. Clamps

2. Rear Coolant Hose

3. Choke Cable: Starting with the choke knob, run the choke cable in front of the hose [10], over the hose [20] and under the cables [26], over the hose [5] and under the hose [2].

4. Strap (Hose [8])

5. Vacuum Switch Valve Hose (to the base [6])

6. Right Air Cleaner Base

7. Plastic Snap-on Clamp (main harness [9])

8. Coolant Reserve Tank Hose

9. Main Harness

10. Vacuum Switch Valve Hose (for front air suction valve)

11. Crankcase Breather Hose

12. Vacuum Switch Valve

13. Front Coolant Hose

14. Vacuum Hose (for valve [12]: Run this hose over the throttle cables and choke cable.)

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-35

15. Vacuum Hose (for vacuum sensor)

16. Vacuum Hose (for pressure regulator)

17. High Pressure Fuel Hose (supply from fuel tank)

18. Vacuum Switch Valve Hose (for rear air suction valve): Run the hose under the hose [16].

19. Pressure Regulator

20. Radiator Hose

21. Clamp (hose [11])

22. Clutch Hose

23. Coolant Reserve Tank Overﬂow Hose

24. Holder

25. Coolant Reserve Tank

26. Throttle Cables: Install the lower end of the accelerator cable into the lower hole of the throttle pulley.

27. Strap (hoses [10] and [11])

28. Install the strap [27] with the lock downwards in this range.

29. Run the hose [23] behind the holder [24].

30. Strap (hoses [2], [8] and harness [9])

1-36 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front 10. T: Top 11.

Install the plastic: snap-on clamps [11] [16] [26], nothing the position of the opening as shown.

Meter Connectors

Headlight Connector

Plate Clamp in [6] (lead [1] [4] [5])

Front Turn Signal Light Lead Connector (right)

Front Turn Signal Light Lead Connector (left)

Headlight Body (front view and left side view)

Left Handlebar Switch Harness

Clutch Hose

Connector of Harness [7]

12.

13.

14.

15.

16.

17.

18.

19.

20.

Indicator Unit and Ignition Switch Harness Plastic Snap-on Clamp ( Left Frame Pipe Band (clutch hose [8]): Run the clutch hose outside the frame pipe around here. Left Spark Plug Leads Main Harness Plastic Snap-on Clamp ( Right and Left Plate Clamps (outside [6], lead [4] [5]) Holder Horn Horn Terminals (Install them in the direction shown for waterprooﬁng.)



10 mm)



15 mm, rear view)

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-37

21. Run the leads through the cuts of the radiator cover.

22. Choke Knob

23. Front Coolant Hose

24. Starter Motor Lead

25. Clamp

26. Plastic Snap-on Clamp (

27. Left Frame Pipe

28. Holder (Run the clutch hose [8]. see P.1–40)

29. ECU Connector

30. Rear Harness Connector

31. Rear Fender

32. Rear Harness



17 mm, rear view)

33. Sidestand Switch Leads: Run the leads through the front and rear hooks and hold them with the clamp [11] a bit tight behind the sidestand bracket.

34. Welded Clamp

35. Left Frame Pipe

36. White Mark on the Clutch Hose next to the slave cylinder

37. Electric Starter Lead

38. ECU: Fit it into the battery case behind the case rib on the bottom.

39. Regulator/Rectiﬁer

40. Six Clamps

1-38 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1. Ignition Coil #2 (for rear cylinder)

2. Ignition Switch Connector (onto the fuel tank)

3. Throttle Cables (decelerator up and accelerator down, under the main harness [20])

4. Right Handlebar Switch Harness

5. Holders

6. Plastic Snap-on Clamps ( mm)

7. Main Harness Ground Terminal on the Frame

8. Plastic Snap-on Clamps ( mm)

9. Right Handlebar Switch Connector (outside), Radiator Fan Connector (up), Rear Brake Light Switch Connector (down): Fit these main harness side connectors into the connector holder and join the connectors.

10. Radiator Cap

11. Primary Leads for Ignition Coil #2

12. Rear Coolant Hose

13. Rectiﬁers

14. Inlet Air Temperature Sensor Connector

15. White Connector (for ISC valves and inlet air temperature sensor)

16. Harness (for ISC valves and inlet air temperature sensor)



17. Vacuum Sensor

18. Throttle Sensor Connector

19. Plastic Snap-on Clamp (main harness [20], Raise the lock to remove the clamp).

20. Main Harness (Join the connectors of its front end in the headlight body.)

21. Clutch Hose

22. Left Handlebar Switch Harness

23. Indicator Light Connector (onto the fuel tank)

24. Water Temperature Sensor Connector (on the bottom of the thermostat housing)

25. Plastic Clamp (indicator light, ignition switch, and accessory harnesses)

26. Left Handlebar Switch Connectors: Fit the main harness side connectors into the connector holder and connect them.

27. Ignition Coil #1

28. Band (clutch hose [21]): Run the clutch hose outside the frame pipe around here.

29. Primary Lead Terminals of [27]

30. Atmospheric Pressure Sensor

31. Plastic Snap-on Clamps

32. Plastic Snap-on Clamp and White Mark (location mark of the harness): Fit the clamp pin into the bracket upwards.

33. Front Coolant Hose

34. Fuel Injector #2 Connector

35. Fuel Injector #1 Connector

36. Accessory Lead Connectors (female)

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-39

F: Front

37. Fit the clamp pin of the harness into the frame.

38. Plastic Snap-on Clamp (intank-fuel pump harness)

39. Battery (-) Lead or Engine Ground Lead (to the engine ground terminal)

40. Oil Pressure Light Delay Unit

41. DFI Main Relay

42. Battery (+) Lead

43. JunctionBox(installed on the coolant reserve tank)

44. Turn Signal Control Unit

45. Starter Relay

46. Vehicle-down Sensor Connector (installed on the battery case)

47. Vehicle-down Sensor

48. Grommet

49. Six Clamps

50. Connectors (in the alternator outer coven for regulator/rectiﬁer, alternator, pickup coils, sidestand switch, neutral/oil pressure switch, and speed sensor)

51. Starter Motor Lead

52. Branch of Main Harness

53. Intank Fuel Pump Connector (installed on the battery holder)

54. ECU Connector

55. Battery (-) Lead Connector (installed on the battery holder)

56. DFI Main Fuse (installed on the battery holder)

57. Connector (installed on the battery holder)

58. Plastic Snap-on Connector

59. Battery Holder (Install it on the battery and tighten the holder bolts securely.)

60. Rear Harness Connector (installed on the battery case)

61. Rear Harness

1-40 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front 8. T: Top 18.

Fuel Tank Filler Drain Hose

Electric Starter Lead

Holder

Engine Ground Lead (Run it downward)

Main Harness

Coolant Reserve Tank Hose (from the radiator cap to the coolant reserve tank)

To the inside of the alternator outer cover

Through the alternator outer cover to the starter motor

Clutch Hose

10.

Crankcase

11.

Fuel Tank Breather Hose (except CA, Run the hose through the right hole of the bracket.)

12.

Coolant Reserve Tank

13.

Coolant Reserve Tank Overﬂow Hose

14.

Put these hoses into the holder on the bottom of engine.

15.

Junction Box Leads

16.

Junction Box

17.

19.

20.

21.

22.

23.

24.

25.

26.

Rear Coolant Hose Right Handlebar SwitchConnector Holder Fuel Tank Frame Ground Lead Ignition Coil #2 (for rear cylinder) Throttle Cables Radiator Fan Connector Rear Brake Light Switch Connector Throttle Pulley

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-41

F: Front T: Top

27. Throttle Assy

28. Starter Relay

29. Right Handlebar Switch Harness

30. Guides

31. Turn Signal Control Unit

32. DFI Main Relay

33. Battery (–) Terminal

34. Oil Pressure Light Delay Unit

35. Right Frame Pipe

36. Junction Box Connectors

37. Battery (+) Lead

38. Plastic Snap-on Clamps ( mm, rear brake light switch and radiator fan leads)

39. Plastic Snap-on Clamps ( mm)

40. Vehicle-down Sensor Connector

41. Vehicle-down Sensor

42. Rear Brake Light Switch

43. Right Handlebar Switch Harness



44. Right Spark Plug Leads

45. Fit the pin of the harness clamp into the bracket.

46. Battery (+) Terminal

47. Battery

48. Radiator Hose

49. Fuel Tank Breather Hose (through the right hole of the bracket.)

50. Frame pipe or Downtube

51. Ignition Coil Primary Leads

52. Rear BrakeLight Switch Leads

1-42 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1. Rear Brake Caliper

2. Hose Holders

3. Rear Brake Hose

4. Hose White Marks (Position here.)

5. Hose Clamps

6. Run the brake hose between the engine mounting bracket bosses and the oil ﬁlter, and then along the downtube towards the front.

7. Oil Filter

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-43

8. Rear Brake Reservoir

9. Rear Master Cylinder

10. Brake Pedal

11. Bend both ends of the cotter pin [16] as shown.

12. Clevis

13. Rear Brake Reservoir Cover

14. Downtube

15. Swingarm

16. Cotter Pin

17. Rear Brake Disc

1-44 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1. Throttle Cable (accelerator)

2. Throttle Cable (decelerator)

3. Front Brake Hose Assembly

4. Meter Bracket

5. Right Handlebar Switch Harness

6. Tachometer

7. Speedometer

8. Front Turn Signal Leads (Connect them in the headlight body.)

9. Clutch Hose

10. Clamps (leads [8])

11. Plastic Snap-on Strap (harness [5])

12. Holders

13. Main Harness

14. Left Handlebar Switch Harness

15. Punch Mark: Insert the grip until its end aligns with the mark.

16. Apply adhesive to the grip cap inside and screw the cap in counterclockwise to the grip end.

17. Three-way Joint of Hose Assembly [3]

18. Protector

19. Front Brake Disc

20. Plastic Snap-on Clamp

21. Front Brake Calipers

GENERAL INFORMATION 1-45

Cable, Wire, and Hose Routing

Evaporative Emission Control System (California Model) with fuel line

--!: Vapor Flow

: Fuel Flow

: Vacuum Pulsation

1. Fuel Return Hose

2. Fuel Tank Breather Hose

3. Separator Breather Hose

4. Canister Purge Hose

5. Vacuum Hose

6. High Pressure Fuel Hoses (supply fuel)

7. Low Pressure Fuel Hose (return fuel)

1-46 GENERAL INFORMATION

Cable, Wire, and Hose Routing

Evaporative Emission Control System (California Model)

F: Front

1. Fuel Tank

2. Filler Drainpipe

3. Fuel Filler

4. Fuel Tank Breather Pipe

5. Coolant Reserve Tank Hose

6. Separator Vacuum Hose (white): Run it over the throttle cables and choke cable.

7. Rear Coolant Hose

8. Fitting of the hose [6]

9. Radiator Cap

10. Clips

11. Throttle Assy

12. Left Air Cleaner Base

13. Canister Purge Hose (green)

14. Electric Starter Lead: Run the lead on the left of the separator [19] and all the evaporative hoses.

15. Fuel TankBreather Hose (blue, right): Run the hose between [23] and [24].

16. Separator Breather Hose (blue): Run the hose between [23] and [24].

17. Hole of Tool Case

18. Evaporative Fuel Return Hose (red, left): Run the hose between [23] and [24].

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-47

R: Rear View

19. Separator

20. Canister

21. Band

22. Holder

23. Branch of Main Harness into Alternator Outer Cover

24. Branch of Main Harness to ECU

25. Left Main Harness for ECU and alternator

Evaporative Emission Control System

26. Right Main Harness

27. Face the white mark left.

28. Run the hoses [15] [16] through these holes.

29. Run the hoses [15] [16] between harnesses [25] and [26].

30. Vacuum Switch Valve Hose (rear)

31. Strap

32. Rubber Plug

33. Choke Cable: Run this over the hose [35] and under the vacuum sensor hose.

34. Throttle Cables: Run the decelerator cable over the accelerator cable.

35. Throttle Vacuum Hose

36. Rear Main Harness

1-48 GENERAL INFORMATION

Cable, Wire, and Hose Routing

Evaporative Emission Control System (California Model)

Front

Fuel Tank

Left Air Cleaner Base

Canister Purge Hose (Green)

Canister (Rear View)

Fuel Tank Breather Hose (right, blue)

Rear View

Throttle Assy

Fuel Tank Return Hose (red, left)

Separator

10.

Fitting

11.

Separator Breather Hose (blue)

12.

Vacuum Hose

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Speciﬁcations....................................................................................................................................................................2-4

Periodic Maintenance Procedures....................................................................................................................................2-6

Fuel System (DFI).........................................................................................................................................................2-6

Fuel Hose and Connection Check.............................................................................................................................2-6

Throttle Control System Check..................................................................................................................................2-6

Idle Speed Check.......................................................................................................................................................2-7

Air Cleaner Element Cleaning....................................................................................................................................2-8

Evaporative Emission Control System Check (CA)...................................................................................................2-8

Cooling System..............................................................................................................................................................2-9

Radiator Hose and Connection Check.......................................................................................................................2-9

Coolant Change.........................................................................................................................................................2-9

Engine Top End...........................................................................................................................................................2-12

Air Suction Valve Inspection.....................................................................................................................................2-12

Clutch...........................................................................................................................................................................2-12

Clutch Hose and Connection Check........................................................................................................................2-12

Clutch Fluid Level Check..........................................................................................................................................2-12

Clutch Fluid Change.................................................................................................................................................2-13

Clutch Master Cylinder Cup and Dust Seal Replacement.......................................................................................2-13

Clutch Slave Cylinder Piston Seal Replacement ....................................................................................................2-14

Engine Lubrication System..........................................................................................................................................2-15

Engine Oil Change...................................................................................................................................................2-15

Oil Filter Replacement..............................................................................................................................................2-16

Breather Drain Cleaning...........................................................................................................................................2-16

Wheel/Tires..................................................................................................................................................................2-17

Tire Inspection..........................................................................................................................................................2-17

Final Drive....................................................................................................................................................................2-18

Oil Level Inspection..................................................................................................................................................2-18

Oil Change...............................................................................................................................................................2-18

Propeller Shaft Joint Lubrication..............................................................................................................................2-19

Brakes..........................................................................................................................................................................2-19

Brake Pad Wear Inspection......................................................................................................................................2-19

Brake Hose and Connection Check.........................................................................................................................2-20

Brake Fluid Level Inspection....................................................................................................................................2-20

Brake Fluid Change..................................................................................................................................................2-21

Brake/Master Cylinder Cup and Dust Seal Replacement........................................................................................2-22

Caliper Piston/Dust Seals Replacement..................................................................................................................2-22

Front Brake Light Switch Check...............................................................................................................................2-22

Rear Brake Light Switch Check/Adjustment............................................................................................................2-22

Suspension..................................................................................................................................................................2-23

Fork Oil Change.......................................................................................................................................................2-23

Front Fork Oil Leak Inspection.................................................................................................................................2-26

Rear Shock Absorber Oil Leak Inspection ..............................................................................................................2-26

Swingarm Pivot Lubrication......................................................................................................................................2-27

Steering........................................................................................................................................................................2-27

Stem Bearing Lubrication.........................................................................................................................................2-27

Steering Check.........................................................................................................................................................2-27

2-2 PERIODIC MAINTENANCE

Steering Adjustment.................................................................................................................................................2-28

Electrical System.........................................................................................................................................................2-28

Spark Plug Cleaning/Inspection...............................................................................................................................2-28

General Lubrication.....................................................................................................................................................2-28

Lubrication................................................................................................................................................................2-28

Nut, Bolt, and Fastener Tightness...............................................................................................................................2-30

Tightness Inspection................................................................................................................................................2-30

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.

Whichever 1 000 km * ODOMETER READING

comes (600 mile)

FREQUENCY ﬁrst 6 000 km

OPERATION (20 000 mile)

Every Reference Steering - check † Steering stem bearing - lubricate 2 years Brake hoses, connections - check † Brake ﬂuid level - check † # month Brake ﬂuid - change 2 years Brake master cylinder cup and dust seal - replace 4 years Caliper piston seal and dust seal - replace 4 years Brake lining or pad wear - check † # Tire wear - check† Front fork oil - change 2 years Front fork oil leak - check † Swingarm pivot - lubricate Rear shock absorber oil leak - check † Clutch hoses, connections - check † Clutch ﬂuid level - check † month Clutch ﬂuid - change 2 years Clutch master cylinder cup and dust seal - replace 4 years Clutch slave cylinder piston seal - replace 4 years Final gear case oil level - check † Final gear case oil - change Propeller shaft joint - lubricate Spark plug (e) - clean and gap Idle speed (e) - check † Air cleaner element (e) - clean † # Engine oil - change # 6 months Oil ﬁlter - replace Fuel hoses, connections - check † Throttle control system (e) - check † Evaporative emission control system (e) (CA) -

check † Radiator hoses, connections - check † Coolant - change 2 years

Breather drain (e) - clean Air suction valve (e) - check †

Brake light switches - check † Nut, bolt, and fastener tightness - check † General lubrication - perform

# : 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.

† : Replace, add, adjust, clean, or torque if necessary.

(CA): California model only

(DFI): Digital Fuel Injection

(e): Emission Related Items

•

• • • • • • •

• •

• • • •

• • • • • • •

• • • •

• • • • • • •

•

• • • • • • •

• • • •

(4 000 mile)

12 000 km ( 7 500 mile)

18 000 km (12 000 mile)

24 000 km (15 000 mile)

30 000 km

• • • • • •

•

• • • • • •

•

• • • • • •

•

• • •

• •

• • •

• • • • • •

•

• • •

• •

• • • • • •

• • •

• • • • • •

•

• • • • • •

• • •

36 000 km (24 000 mile)

P27 ~ P28

P19 ~ P22

P17

P23 ~ P27

P12 ~ P14

P18 ~ P19

P28

P7 ~ P8

P15 ~ P16

P6 ~ P8

P16 P12

P22

P29 ~ P30

2-4 PERIODIC MAINTENANCE

Speciﬁcations

Item Standard Service Limit

Fuel System (DFI):

Throttle grip free play 2~3mm Idle speed 950 ± 50 r/min (rpm) Air cleaner element Paper ﬁlter

Cooling System:

Coolant:

Type (recommended) Permanent type antifreeze Color Green Mixed ratio Soft water 50%, Coolant 50% Freezing point –35C(–31F) Total amount 2.3 L (2.4 US qt.)

Engine Top End:

Valve clearance Non-adjustable (hydraulic lash adjusters)

Clutch:

Clutch fuild

Grade DOT4 (provided when shipping)

Clutch lever free play Non-adjustable

Engine Lubrication System:

Engine oil:

Type API SE, SF or SG

API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 2.9 L (3.1 US qt, when ﬁlter is not removed)

3.1 L (3.3 US qt, when ﬁlter is removed)

3.5 L (3.7 US qt, when engine is completely disassem-

bled and dry) Level Between upper and lower level lines

(after idling or running)

Tires:

Tread depth:

Front DUNLOP

D220F STG

Rear DUNLOP D220

STG

Air pressure: (when cold)

Front Up to 184 kg (405 lb) load : 250 kPa (2.5 kg/cm2, 36 psi)

4.3 mm (0.17 in.)

6.9 mm (0.27 in.)

———

1 mm (0.04 in.) (DE, AT, CH)

1.6 mm (0.063 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.)

Over 130km/h (80 mph): 3 mm (0.1 in.)

———

Rear Up to 184 kg (405 lb) load : 250 kPa (2.5 kg/cm

, 36 psi)

———

Speciﬁcations

PERIODIC MAINTENANCE 2-5

Item

Standard Service Limit

Final Drive:

Final gear case oil: Grade API Service Classiﬁcation : GL-5 hy-

poid gear oil



Viscosity when above 5

when below 5

C (41

F) SAE 90



C (41F) SAE80 Oil level Filler opening bottom Amount 200 mL (6.76 US oz.)

Propeller shaft joint grease 20 mL (0.68 US oz.), high-temperature

grease

Brakes:

Brake ﬂuid: Grade DOT4 Brake pad lining thickness: Front 4 mm (0.12 in.)

Rear 7.5 mm (0.295 in.)

Brake light timing: Front Pulled ON

Rear ON after about 10 mm (0.39 in.) of

Suspension:

pedal travel

Fork Oil:

Viscosity: SAE 10W-20 Amount (Right Fork leg): When changing oil approx. 430 mL (14.5 US oz.) After disassembly and completely dry 507 ± 2.5 mL (17.1 ± 0.085 US oz.) Amount (Left Fork leg): After disassembly and completely dry 601 ± 2.5 mL (20.3 ± 0.085 US oz.)

Fork Oil Level: (fully compressed, without spring)

Right fork leg (from the top of the outer tube) 142 ± 2 mm (5.59 ± 0.08 in.) Left fork leg (from the top of the outer tube) 136 ± 2 mm (5.35 ± 0.08 in.)

Electrical System:

Spark plug gap

0.8 ~ 0.9 mm (0.031 ~ 0.035 in.) ———

AT: Republic of Austria CH: Swiss Confederation DE: Federal Republic of Germany

Special Tools - Driver-Filler Cap: 57001–1454

Fork Piston Rod Puller, M12X1.25: 57001–1289 Fork Oil Level Gauge: 57001–1290 Fork Cylinder Holder: 57001–1502 Jack: 57001–1238 Attachment Jack: 57001–1398 Steering Stem Nut Wrench: 57001–1100

———

——— ——— ———

———

1 mm (0.04 in.) 1 mm (0.04 in.)

——— ———

———

——— ———

———

——— ———

2-6 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Fuel System (DFI)

Fuel Hose and Connection Check



The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see 3. Fuel System 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 securely connected and clamps are

•

tightened correctly. When installing, route the hoses according to Cable, Wire, and Hose

•

Routing section in the General Information chapter. When installing the fuel hoses, avoid sharp bending, kinking, ﬂatten-

•

ing or twisting, and route the fuel hoses with a minimum of bending so that the fuel ﬂow will not be obstructed. Replace the hose if it has been sharply bent or kinked.

Install the hose clamps in the position shown, and securely tighten

•

the clamp screws to the speciﬁed torque. Check the fuel system for leaks after hose installation.

Fuel Hose [A] Clamp [B] Fuel Pipe [C]

22 mm [D]

18 2

3 mm [E]

Torque - High Pressure Fuel Hose Clamp Screws: 1.5 N1m (0.15 kg

13 in

lb)

Fit the fuel hose [A] onto the pipe fully and install the plate clamp [B]

•

beyond the raised rib [C].

1~2mm

Throttle Control System Check

Check the throttle grip free play [A].

•

If the free play is incorrect, adjust the throttle cable (see below).

Throttle Grip Free Play

Standard: 2

Check that the throttle grip moves smoothly from close to full open,

•

and the throttle closes quickly and completely in all steering positions by the return spring. If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar all the way

•

to the right and left to ensure that the idle speed doesn’t change. If the idle speed increases, check the throttle grip free play and the cable routing.

3mm

Periodic Maintenance Procedures

If necessary, adjust the throttle cable as follows:

•



Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play (front view).



Turn out the adjuster of the decelerator cable [C] until there is no play.



Tighten the locknut against the adjuster.



Turn the adjuster of the accelerator cable [D] until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.

Check the throttle bore for cleanliness as follows:

•



Remove the air cleaner cover Allen bolt [A] and take off the right air cleaner cover [B].

Front [C]

PERIODIC MAINTENANCE 2-7



Check the throttle bores [A] at the butterﬂy valves [B] and around them for carbon deposits by opening the valves. If any carbon accumulates, wipe the carbon off the throttle bores around the butterﬂy valves, using a lint-free cloth [C] penetrated with a high-ﬂash point solvent.

Front [D]

Idle Speed Check

Start the engine and warm it up thoroughly.

•



At ﬁrst the engine will run fast to decrease warm up time (fast idle).



Gradually the fast idle will lower to a certain RPM automatically. This is the idle speed. Check the idle speed.

•

Idle Speed

Standard: 950 ± 50 r/min (rpm)

With the engine idling, turn the handlebar to both sides.

•

If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the General Information chapter).

Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition.

2-8 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If the idle speed is out of the speciﬁed range, adjust it. Start the engine and warm it up thoroughly.

•



Wait until fast idle speed lowers to a certain value. Turn the adjusting screw [A] until the idle speed is correct.

•



Open and close the throttle a few times to make sure that the idle speed is within the speciﬁed range. Readjust if necessary.

Front [B]

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 muddy roads, the element should be cleaned immediately.

Remove:

•

Allen Bolt and Washer [A] and Left Air Cleaner Cover [B] Front [C]

Remove the element [A].

•

Push a clean, lint-free towel into the lower air cleaner duct to keep

•

dirt or other foreign material from entering.

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.

Clean the element by tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed air [A] from

•

the inside to the outside (from the clean side to the dirty side). Visually check the element for no tears or no breaks and check the

•

sponge gasket [B] also. If the element or gaskethas any tears or breaks, replace the element. Install the left air cleaner cover.

•

Torque - Left Air Cleaner Cover Allen Bolt: 16 N1m (1.6 kg

Evaporative Emission Control System Check (CA)

Inspect the canister as follows:

•



Remove the left side cover (see Frame chapter).



Remove the band [A] and take out the canister [B].



Visually inspect the canister for cracks and other damage. If the canister has any cracks or bad damage, replace it with a new one.

NOTE



The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under normal conditions.

m, 12 ft1lb)

Periodic Maintenance Procedures



Run the purge hose (green) [A] above the canister breather hose (blue) [B] through the hole [C] into the tool case [D].



Do not run these hoses side by side on the battery side of the canister. This prevents hoses from being ﬂattened when installing the left side cover.



Install the canister and the left side cover (see 15. Frame chapter).



Face the white mark [E] left as shown.

Check the liquid/vapor separator as follows:

•



Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle right side.

Front [B]



Visually inspect the separator for cracks and other damage. If the separator has any cracks or damage, replace it with a new one.



To prevent the gasoline from ﬂowing into or out of the canister, hold the separator perpendicular to the ground. Check the hoses of the evaporative emission control system as

•

follows:



Check that the hoses are securely connected and clips are in position.



Replace any kinked, deteriorated or damaged hoses.



Route the hoses according to Cable, Wire, and Hose Routing section in the General Information chapter. Refer to the diagram of the evaporative emission control system in the 3. Fuel System chapter too.



When installing the hoses, avoid sharp bending, kinking, ﬂattening or twisting, and route the hoses with a minimum of bending so that the emission ﬂow will not be obstructed.

PERIODIC MAINTENANCE 2-9

Cooling System

Radiator Hose and Connection Check



The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps are

•

tightened correctly.

Torque - Radiator Hose Clamp Screws: 2.5 N1m (0.25 kg1m, 22 in

Coolant Change

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. Since coolant is harmful to the human body, do not use for drinking.

Place a container under the radiator drain bolt [A], then remove the

•

drain bolt (front view).

lb)

2-10 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the fuel tank (see Fuel System chapter).

•

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.

Front [B]

Remove the water pump drain bolt [A]. The remaining coolant will

•

drain from the water pump [B].



Place a conduit under the drain hole of the pump cover. The conduit leads to a container.

Front [C]

Remove :

•

Right Side Cover (see 15. Frame chapter) Reserve Tank Bolts

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

•

coolant into a suitable container. Install the reserve tank.

•

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 (see Speciﬁcations in this chapter) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efﬁciency of the cooling system.

Periodic Maintenance Procedures

Water and Coolant Mixture Ratio (when shipping)

Soft Water : 50 % Coolant : 50 % Freezing Point : Total Amount : 2.3 L (2.4 US gt.)

Tighten the drain bolts.

•

Torque - Radiator Drain Bolt: 7.4 N

Water Pump Drain Bolt: 11 N

Pour the coolant into the radiator.

•



Pourin the coolant slowly so that it can expelthe air from the engine and radiator.

Check the cooling system for leaks.

•

First bleed the air from the water pump [A].

•



Loosen the air bleeder bolt [B] until the coolant seeps out around the bolt, then tighten it.

Torque - Water Pump Air Bleeder Bolt: 11 N

Next, loosen the air bleeder bolt [A] on the thermostat housing.

•

Front [B]

Replenish the coolant into the radiator until the coolant begins to ﬂow

•

out the air bleeder bolt hole (that is, all the remaining air is forced out). Tap the radiator hoses to force any air bubbles caught inside.

•

− 35



C(− 31

NOTE



m (0.75 kg

m (1.1 kg

m, 65 in

m, 95 in1lb)

m (1.1 kg

lb)

m, 95 in

PERIODIC MAINTENANCE 2-11

lb)

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

•

Install the radiator cap.

•

Tighten the air bleeder bolt [B].

•

Torque - Thermostat Air Bleeder Bolt: 7.8 N1m (0.80 kg1m, 69 in1lb)

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

•

install the cap. Install the fuel tank (see Fuel System chapter).

•

Start the engine and warm it up thoroughly until the radiator fan turns

•

on and then stop the engine. Check the coolant level in the reserve tank several times while the

•

engine is cooling down, and replenish as necessary. 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.

2-12 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Engine Top End

Air Suction Valve Inspection

Remove the air suction valve (see Air Suction Valve Removal in the

•

5. Engine Top End chapter). Visually inspect the reeds for cracks, folds, warps, heat damage or

•

other damage. If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for grooves,

•

scratches, any signs of separation from the holder or heat damage. If there is any doubt as to the condition of the reed contact areas,

•

replace the air suction valve as an assembly. If any carbon or other foreign particles have accumulated between

•

the reed and the reed contact area, wash the valve assembly clean with a high-ﬂash point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.

Clutch

Clutch Hose and Connection Check

The high pressure inside the clutch line can cause ﬂuid to lead [A]

•

or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace it if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and banjo bolts are

•

tightened correctly.

Torque - Clutch Hose Banjo Bolts: 25 N1m (2.5 kg1m, 18 ft1lb)

When installing the clutch hose, route the hoses according to Cable,

•

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

Clutch Fluid Level Check

Hold the clutch ﬂuid reservoir horizontal.

•

Check that the clutch ﬂuid level of the clutch reservoir is between the

•

lower [A] and the upper [B] level lines. If the ﬂuid level is lower than the lower level line, ﬁll the reservoir to the upper level line in the reservoir.



Since the clutch ﬂuid is the same as the brake ﬂuid, refer to Brake Fluid Section in the 12. Brakes chapter for further details.

Torque - Clutch Reservoir Cap Screws: 1.5 N

Change the ﬂuid in the clutch line completely if the ﬂuid must be reﬁlled but the type and brand of the ﬂuid that already is in the reservoir are unidentiﬁed. After changing the ﬂuid, use only the same type and brand of ﬂuid thereafter. Mixing different types and brands of ﬂuid lowers the ﬂuid boiling point and could cause the clutch to be ineffective. It may also cause the rubber clutch parts to deteriorate.

m (0.15 kg

m, 13 in1lb)

Periodic Maintenance Procedures

Clutch Fluid Change

Level the clutch ﬂuid reservoir and remove the reservoir cap.

•

Remove the alternator outer cover (see Alternator Outer Cover

•

Removal in the Electrical System chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder. Attach a clear plastic hose [A] to the bleed valve and run the other

•

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

•

Change the clutch ﬂuid as follows.

•

Open [B] the bleed valve, using a wrench. Pump the clutch lever and hold [C] it. Close [D] the bleed valve. Release [E] the clutch lever.



Repeat this operation until fresh ﬂuid comes out from the plastic hose or the color of the ﬂuid changes.



Check the ﬂuid level in the reservoir often, replenishing it as necessary.

NOTE



If the ﬂuid in the reservoir runs completely out any time during ﬂuid changing, the bleeding operation must be done over again from the beginning since air will have entered the line.

PERIODIC MAINTENANCE 2-13

Do not mix two brands of ﬂuid.

After changing the ﬂuid, check the clutch for good clutch power and

•

no ﬂuid leakage. If necessary, bleed the air from the lines (see Clutch Line Bleeding in the 6. Clutch chapter). Remove the clear plastic hose.

•

Install the reservoir cap.

•

Tighten the bleed valve, and install the rubber cap.

•

Torque - Clutch Reservoir Cap Screws: 1.5 N1m (0.15 kg1m, 13 in1lb)

Clutch Slave Cylinder Bleed Valve: 7.8 N

lb)

Clutch Master Cylinder Cup and Dust Seal Replacement

Remove the clutch master cylinder (see Clutch Master Cylinder

•

Removal in the 6. clutch chapter). Remove the reservoir cap [A] and diaphragm [B], and pour the clutch

•

ﬂuid into a container.

Unscrew the locknut [C] and pivot bolt [D], and remove the clutch

•

lever [E]. Pull the dust cover [F] out of place, and remove the circlip [G].

•

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the primary cup [H], piston assembly [I], and return spring

•

[J].

CAUTION

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

m (0.80 kg1m, 69

Check the parts of the clutch master cylinder (see Clutch Master

•

Cylinder Inspection in the 6. Clutch chapter). If any part shows signs of damage, replace it.

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Before assembly, clean all parts including the master cylinder with

•

clutch ﬂuid or alcohol.

CAUTION

Use only disc brake ﬂuid, isopropyl alcohol or ethyl alcohol, for cleaning parts. Do not use any other ﬂuid for cleaning these parts. Gasoline, motor 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 cylinder.

Apply clutch ﬂuid to the parts removed and to the inner wall of the

•

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

•

Install the push rod with the dust seal ﬁtted into the groove.

•



The push rod round end must be faced inwards.

Torque - Clutch Lever Pivot Bolt: 1.0 N1m (0.10 kg

Clutch Lever Pivot Bolt Locknut: 5.9 N

Install the clutch master cylinder (see Clutch Master Cylinder Removal

•

in the 6. Clutch chapter).

Clutch Slave Cylinder Piston Seal Replacement

Remove the clutch slave cylinder (see Clutch Slave Cylinder Removal

•

in the 6. Clutch chapter). Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it

•

loosely. Unscrew the slave cylinder bolts [B] and detach the slave cylinder

•

with the pipe installed from the engine. Pump the clutch lever until the piston comes out of the cylinder.

•

Unscrew the banjo bolt and remove the slave cylinder [C].

•

m, 8.7 in

m (0.60 kg

lb)

m, 52 in

lb)

CAUTION

Immediately wash away any clutch ﬂuid that spills. It may damage painted surfaces.

NOTE



If the clutch slave cylinder is removed and left alone, the piston will be pushed out by spring force.

Remove the spring and piston seal.

•

CAUTION

Replace the piston seal with a new one if it was removed from the piston.

Before assembly, apply clutch ﬂuid to the outside of the piston and

•

the piston seal. Install the piston seal as shown.

•

Cylinder [A] Piston [B] Piston Seal [C] Spring [D]

Periodic Maintenance Procedures Engine Lubrication System

Engine Oil Change

Situate the motorcycle so that it is vertical after warming up the

•

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

•

Front [B]

Remove:

•

Oil Screen Plug [A] Front [B]

PERIODIC MAINTENANCE 2-15

Remove the oil screen [A], the spring [B], and the washer [C].

•

Clean the oil screen with a high-ﬂash point solvent and remove any

•

particles stuck to it. Clean the screen thoroughly whenever the engine oil is changed.

•

Clean the screen in a well-ventilated area, and take care that there is no spark or ﬂame anywhere near the working area. Because of the danger of highly ﬂammable liquids, do not use gasoline or low-ﬂash point solvents.

NOTE



While cleaning the screen, check for any metal particles that might indicate internal engine damage.

Check the screen carefully for any damage: holes and broken wires.

•

If the screen is damaged, replace it. Be sure to put in the oil screen with the rubber gasket end inside.

•

Replace the screen plug O-ring with new one if it is damaged.

Torque - Oil Screen Plug: 20 N1m (2.0 kg1m, 14 ft1lb)



The oil in the ﬁlter can be drained by removing the ﬁlter (see Oil Filter Change in this section). Replace the drain plug gasket with a new one if it is damaged.

Torque - Engine Oil Drain Plug , Oil Screen Plug: 20 N1m (2.0 kg1m, 14

lb)

Oil Filter: 18 N

m (1.8 kg1m, 13 ft1lb)

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the oil ﬁller cap [A] with the driver-ﬁller cap [B] and pour in

•

the speciﬁed type and amount of oil.

Clutch Cover [C] Front [D]

Special Tool - Driver-Filler Cap: 57001–1454 Torque - Oil Filler Cap: 1.5 N

Engine Oil

Type: API SE, SF or SG class

API SH or SJ class with JASO MA Viscosity: SAE 10W-40 Amount: 2.9 L (3.1 US qt, when ﬁlter is not removed)

3.1 L (3.3 US qt, when ﬁlter is removed)

3.5 L (3.7 US qt, when engine is completely disassem-

bled and dry)



Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed according to the chart shown.

m (0.15 kg

m, 13 in

lb)

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change in this section).

•

Remove the oil ﬁlter [A] with the oil ﬁlter wrench [B] and discard the

•

oil ﬁlter.

Front [C]

Special Tool - Oil Filter Wrench: 57001-1249

NOTE



The ﬁlter has an oil ﬁlter bypass valve which can not be removed.

Replace the oil ﬁlter with the new one.

•

Apply oil to the gasket of the new ﬁlter before installation.

•

Tighten the ﬁlter with the oil ﬁlter wrench.

•

Pour in the speciﬁed type and amount of oil.

•

Torque - Oil Filter: 18 N

Breather Drain Cleaning



The air cleaner drain hose is provided beneath the right air cleaner housing, and catches the water or oil from the crankcase breather hose. Usually water or oil does not collect at the bottom. In the event that rain water is drawn in through the air cleaner or if engine oil is blown back, drain the housing. Remove the left air cleaner housing (see 3. Fuel System chapter).

•

Remove the drain plug [B] from the air cleaner drain hose [A] to drain

•

the water or breather. Install the plug on its original position.

•

m (1.8 kg1m, 13 ft

lb)

Be sure to reinstall the plug in the drain hose after draining. Oil on tires will make them slippery and can cause an accident and injury.

Periodic Maintenance Procedures Wheel/Tires

Tire 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.

Remove any imbedded stones or other foreign particles from the

•

tread.

Visually inspect the tire for cracks and cuts, replacing the tire in case

•

of damage. Swelling or high spots indicate internal damage, requiring

tire replacement.

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

Wheels/Tires chapter).

Tread Depth

Front:

Standard: 4.4 mm (0.17 in.) Service Limit: 1 mm (0.04 in.)

(DE, AT, CH) 1.6 mm (0.063 in.)

Rear:

Standard: 6.9 mm (0.28 in.) Service Limit: 2 mm (0.08 in.):

Up to 130 km/h (80 mph)

3 mm (0.1 in.):

Over to 130 km/h (80 mph)

PERIODIC MAINTENANCE 2-17

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.)

Adjust the tire air pressure according to the speciﬁcations if neces-

sary.

Air Pressure (when cold)

Front Up to 184 kg (405 lb) 250 kPa (2.5 kg/cm2, 36 psi) Rear Up to 184 kg (405 lb) 250 kPa (2.5 kg/cm2, 36 psi)

To ensure safe handling and stability, use only the recommended standard tires for replacement, inﬂated to the standard pressure. Use the same manufacture’s tires on both front and rear wheels.

NOTE



Most countries may have their own regulations requiring a minimum tire tread depth; be sure to follow them.



Check and balance the wheel when a tire is replaced with a new one (see Wheels/Tires chapter).

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Final Drive

Oil Level Inspection

Motorcycle operation with insufﬁcient, deteriorated, or contaminated oil causes accelerated wear and may result in seizure of the pinion and ring gears. Seizure can lock the rear wheel and skid the rear tire, with consequent less of control.

Support the motorcycle perpendicular to the ground.

•

Unscrew the ﬁller plug [A], using the driver-ﬁller cap [B].

•

Special Tool - Driver-Filler Cap: 57001–1454

The oil level [A] should come to the bottom of the ﬁller opening.

•

If it is low, ﬁrst check the ﬁnal gear case for oil leakage, remedy it if necessary, and add oil through the ﬁller opening. Use the same type and brand of oil that is already in the ﬁnal gear case. Install the ﬁller plug.

•

Oil Change

Warm up the oil by running the motorcycle so that the oil will pick

•

up any sediment and drain easily. Stop the motorcycle and turn the ignition switch OFF. Place an oil pan beneath the ﬁnal gear case, and remove the ﬁller

•

cap and drain plug [A].

When draining or ﬁlling the ﬁnal gear case, be careful that no oil gets on the tire, spoke, or rim. Clean off any oil that inadvertently gets on them with a high-ﬂash point solvent.

After the oil has completely drained out, install the drain plug with a

•

new gasket.

Torque - Final Gear Case Drain Plug: 8.8 N

Fill the ﬁnal gear case with the speciﬁed oil and quantity.

•

Final Gear Case Oil:

Amount: 200 mL (6.76 US oz.) Grade: API GL-5 hypoid gear oil Viscosity: When above 5

When below 5



The term “GL-5” indicates a quality and additive rating. A “GL-6” rated hypoid gear oil can also be used.

Be sure the O-ring is in place, and install the ﬁller plug.

•



C (41F) SAE 90



C (41

NOTE

m (0.90 kg



F) SAE 80

m, 78 in1lb)

Periodic Maintenance Procedures

Propeller Shaft Joint Lubrication

Remove the ﬁnal gear case and propeller shaft joint (see Final Drive

•

chapter).

Wipe the old grease off the propeller shaft sliding joint and pinion

•

joint.

Pack the propeller shaft sliding joint with 20 mL (16 grams) of high

•

temperature grease [A].

Brakes

Brake Pad Wear Inspection

Unscrew the bolts [A] and remove the pad spring [B] (Front Brake

•

Caliper)

PERIODIC MAINTENANCE 2-19

Unscrew the bolts [A] and remove the caliper [B] (Rear Brake Caliper).

•

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 (see Brakes chapter).

Pad Lining Thickness

Standard:

Front: 4.0 mm (0.12 in.) Rear: 7.5 mm (0.295 in.)

Service Limit: 1 mm (0.04 in.)

Install the pad spring or caliper.

•

Tighten the bolts.

•

Torque - Front Brake Pad Spring Bolts: 2.9 N1m (0.3 kg1m, 26 in1lb)

Rear Caliper Mounting Bolts: 34 N

m (3.5 kg1m, 25 ft1lb)

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Hose and Connection Check

Inspect the brake hose and ﬁttings for deterioration, cracks and signs

•

of leakage.



The high pressure inside the brake line can cause ﬂuid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose if any cracks [B] or bulges [C] are noticed. Tighten any loose ﬁttings.

Brake Fluid Level Inspection

Check that the brake ﬂuid level in the front brake reservoir [A] isabove

•

the lower [B] level line.

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 [A] in the reservoir [B].

Check that the brake ﬂuid level in the rear brake reservoir [A] is

•

between the upper [B] and the lower [C] level lines. If the ﬂuid level is lower than the lower level line, ﬁll the reservoir to the upper level line.



Use extra heavy-duty brake ﬂuid only from a container marked DOT4.



Brake ﬂuid of DOT4 is installed in the brake system when shipped.

Torque - Front Brake Reservoir Cap Screws: 1.5 N1m (0.15 kg1m, 13

lb)

Do not mix two brands of ﬂuid. 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 reservoir are unidentiﬁed. After changing the ﬂuid, use only the same type and brand of ﬂuid thereafter.

Periodic Maintenance Procedures

Brake Fluid Change

NOTE



The procedure to change the front brake ﬂuid is as follows. Changing the rear brake ﬂuid is almost the same as for the front brake.

Level the brake ﬂuid reservoir.

•

Remove the reservoir cap [A], plate [B] and diaphragm [C]

•

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

•

[B].

Attach a clear plastic hose [C] to the bleed valve, and run the other

•

end of the hose into a container.

Fill the reservoir with new brake ﬂuid.

•

Temporarily install the reservoir cap.

•

Change the brake ﬂuid as follows:

•

NOTE



The ﬂuid levelmust be checked often during the changing 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.



Repeat this operation until fresh brake ﬂuid comes out from the plastic

hose or the color of the ﬂuid changes.

Open the bleed valve [A]. Pump the brake lever and hold it [B]. Close the bleed valve [C]. Release the brake lever [D]. Front Brake : Repeat the above steps for other caliper.

PERIODIC MAINTENANCE 2-21

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the clear plastic hose.

•

Install the reservoir cap.

•

Tighten the bleed valve, and install the rubber cap.

•

Torque - Caliper Bleed Valve: 7.8 N1m (0.8 kg

Front Brake Reservoir Cap Screws: 1.5 N

lb)



For the rear brake caliper [A], change the brake ﬂuid for two bleed valves [B]. 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 (see Brakes chapter).

Brake/Master Cylinder Cup and Dust Seal Replacement

Refer to the Master Cylinder section in the Brakes chapter for Brake/

•

Master Cylinder Cup and Dust Seal Replacement.

m, 69 in

lb)

m (0.15 kg

m, 13

Caliper Piston/Dust Seals Replacement

Refer to the Calipers section in the Brakes chapter for Caliper Piston/

•

Dust Seals Replacement.

Front Brake Light Switch Check

Turn on the ignition switch.

•

The brake light should go on when the front brake lever is applied.

•

If it does not, replace the switch.

Rear Brake Light Switch Check/Adjustment

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by depressing the

•

brake pedal [A]. The brake light should go on after about 10 mm (0.39 in.) of the pedal travel [B].

If it does not, adjust the brake light switch. While holding the switch body, turn the adjusting nut to adjust the

•

switch.

Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D]

CAUTION

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

Periodic Maintenance Procedures Suspension

Fork Oil Change

Remove the front fork (see Suspension chapter)

•

Unscrew the top plug out of the outer tube.

•

Right Fork Leg:

Use the wrenches on the top plug [A] and piston rod nut [B] loosen

•

the piston rod nut.

Remove the top plug from the piston rod.

•

Remove:

•

Piston Rod Nut [A] Washer [B] Collar [C] Spring Seat [D] Fork Spring [E]

PERIODIC MAINTENANCE 2-23

Drain the fork oil into a suitable container.

•



Using the piston rod puller [A] pump the piston rod [B] up and down

at least ten times to expel the oil from the fork.

Left Fork Leg:

Use the wrenches on the top plug [A] and joint rod nut [B] loosen the

•

joint rod joint nut.

Remove the top plug, joint rod nut and rubber stopper [C].

•

Hold the inner tube in a vise.

•

Unscrew the inner fork bolt [A] using the fork cylinder holder [B].

•

Special Tool - Fork Cylinder Holder : 57001–1502

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Pull out the joint rod assy [A] together with the spring [B].

•

Compress and extend[B] the fork [A] upside down to draw out the fork

•

oil into a suitable container [C], then drop out the collar [D], washer [E] and fork spring [F].

Both Fork Legs:

Hold the fork tube upright, press the outer tube [A] and the piston rod

•

(Right Fork Leg) all the way down. Pour in the type and amount of fork oil speciﬁed.

•

Fork Oil

Viscosity: SAE 10W-20 Amount (Right Fork Leg):

When changing oil: approx. 430 mL (14.5 US oz.) After disassembly and completely dry

Amount (Left Fork Leg)

After disassembly and completely dry

If necessary, measure the oil level as follows.



Hold the inner tube vertically in a vise.



Fork the right fork leg; using the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil.

Special Tool - Fork Piston Rod Puller, M12

507 ± 2.5 mL (17.1 ± 0.0850 US oz.)

601 ± 2.5 mL (20.3 ± 0.085 US oz.)

1.25: 57001–1289

Periodic Maintenance Procedures



Pump the outer tube several times to expel air bubbles.



Wait until the oil level settles.



With the fork fully compressed and the piston rod fully pushed in

(Right Fork Leg), insert a tape measure or rod into the inner tube,

and measure the distance from the top of the outer tube to the oil.

Oil Level (fully compressed, without spring)

Standard: Right fork leg 142 ± 2 mm (5.59 ± 0.08 in)

Left fork leg 136 ± 2 mm (5.35 ± 0.08 in)

(from the top of the outer tube)

NOTE



Fork oil lever may also be measured using the fork oil level gauge.

Special Tool - Fork Oil Level Gauge: 57001–1290 [A]



With the fork fully compressed and without fork spring, insert the

gauge tube into the inner tube [B] and position the stopper across

the top end [F] of the outer tube [C].



Set the gauge stopper [D] so that its lower side shows the oil level

distance speciﬁed [E].



Pull the handle slowly to pump out the excess oil until the oil no longer

comes out.

If not oil is pumped out, there is insufﬁcient oil in the inner tube. Pour

in enough oil, then pump out the excess oil as shown above.

PERIODIC MAINTENANCE 2-25

Right Fork Leg:

Screw the fork piston rod puller [A] onto the end of the rod.

•

Special Tool - Fork Piston Rod Puller, M12

Pull the puller up above the outer tube top.

•

Remove the fork piston rod puller.

•

Install the fork spring [A] with the smaller end facing [B] upward.

•

Install:

•

Spring Seat [A] Collar [B] Washer [C]

Screw the piston rod nut [D] stopped on to the piston rod.

•

1.25: 57001–1289

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Left Fork Leg:

Install the fork spring [A] with the smaller end facing upward [B].

•

Install:

•

Washer Collar Joint Rod Assy together with the spring

Install the inner fork bolt using the fork cylinder holder.

•

Special Tool - Fork Cylinder Holder: 57001–1502 Torque - Inner Fork Bolt: 98 N

Install:

•

Rubber Stopper

Screw the joint rod nut stopped on to the joint rod.

•

Both Fork Legs:

Check the O-ring [A] on the top plug and replace it with a new one if

•

damaged. Screw in the top plug [B] stopped onto the piston rod or joint rod.

•

m (10 kg

m, 73 ft1lb)

Holding the top plug [A] with a wrench, tighten the piston rod nut [B]

•

or joint rod nut against the top plug.

Torque - Piston Rod Nut: 20 N

Joint Rod Nut: 20 N

Raise the outer tube and screw the top plug into it and install it.

•

Torque - Front Fork Top Plug: 34 N

Install the front fork (see Suspension chapter).

•

Front Fork Oil Leak Inspection

Visually inspect the front forks [A] for oil leakage, scoring or scratches

•

on the outer surface of the inner tubes. Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

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

•

If they are oil leaked, one unit feels weaker than the other, replace both shock absorber as a set.

m (2.0 kg1m, 15 ft

m (2.0 kg

m, 15 ft

m (3.5 kg

lb)

m, 25 ft1lb)

Periodic Maintenance Procedures

Swingarm Pivot Lubrication

Remove the swingarm (see Suspension chapter).

•

Clean the old grease out of the bearings.

•

Apply grease to the inner surface of the needle bearings [A].

•

Apply a thin coat of grease to the lips [B] of the grease seals.

•

Install the swingarm (see Suspension chapter).

•

Steering

Stem Bearing Lubrication

Remove the steering stem. (see Steering chapter).

•

Using a high-ﬂash point solvent, wash the upper and lower tapered

•

roller bearings [A] in the cages, and wipe the upper and lower outer

races, which arepress-ﬁtted into the frame head pipe, clean of grease

and dirt.

Visually check the outer races and the rollers.

•

If the rollers or races are worn, or if either race is dented, replace

both races and all the roller bearings as a set (see Steering chapter).

Pack the upper and lower tapered roller bearings in the cages with

•

grease, and apply a light coat of grease to the upper and lower outer

races.

Install the steering stem, and adjust the steering (see Steering

•

chapter).

PERIODIC MAINTENANCE 2-27

Steering Check

Check steering as follows.

•



Use the jack [A], the attachment jack [B] under the frame pipe ribs

[C], and a commercially available jack [D] under the engine [E] to lift

the front wheel [F] off the ground.

Special Tools - Jack: 57001-1238

Attachment Jack: 57001-1398



With the front wheel pointing straight ahead, alternately tap each end

of the handlebar. The front wheel should swing fully right and left

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 fork.

If you feel looseness, the steering is too loose.

NOTE



The cables and wiring will have some effect on the motion 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.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering Adjustment

Adjust the steering, if necessary. Loosen the upper fork clamp bolt [A] on both side and unscrew the

•

stem head nut [B]. Remove the O-ring (see Steering chapter).

•

Remove the steering stem head [C] together with the handlebar

•

installed.

Remove the claw washer.

•

Adjust the stem nut [A] with the stem nut wrench [B] by tightening to

•

the speciﬁed torque.

Special Tool - Steering Stem Nut Wrench: 57001-1100

Torque - Steering Stem Nut: 49 N

Install the stem head.

•

Tighten the following in the order listed.

•

Torque - Stem Head Nut: 54 N1m (5.5 kg1m, 40 ft1lb)

Upper Fork Clamp Bolts: 20 N

m (0.5 kg

m, 43 ft

lb)

m (2.0 kg1m, 14 in

lb)



Run the throttle cables, brake hose, and clutch hose in accordance with the Cable, Wire, and Hose Routing section in the General Information chapter. Check and adjust the steering and throttle cables after installation.

•

Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the ﬁrst application of the lever if this is not done.

Electrical System

Spark Plug Cleaning/Inspection

Clean the spark plug, preferably in a sandblasting device, and then

•

clean off any abrasive particles. The plug may also be cleaned using a high-ﬂash point solvent and a wire brush or other tool. If the spark plug center electrode [A] and/or side electrode [B] are corrected or damaged, or if the insulator [C] is cracked, replace the plug. Use the standard spark plug or its equivalent.

•

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

•

If the gap is incorrect, carefully bend the side electrode with a tool to obtain the correct gap.

Spark Plug Gap: 0.8 ~ 0.9 mm (0.031 ~ 0.035 in.)

General Lubrication

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.

Periodic Maintenance Procedures

Pivots: Lubricate with Motor Oil.

Rear Brake Rod Joint

Points: Lubricate with Grease.

Throttle Inner Cable Upper Ends [A] Clutch Lever Pivot (Apply silicone grease) Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Side Stand

Cable: Lubricate with Cable Lubricant.

Choke Cable Throttle Cable

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 [A] with an aerosol cable lubricant [B].

PERIODIC MAINTENANCE 2-29

With the cable disconnected at both ends, the cable should move

•

freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable is frayed

[B], or if the cable housing is kinked [C], replace the cable.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness

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 faster, ﬁrst loosen it by 1/2 turn, then tighten it. If cotter pins are damaged, replace them with new ones.

Nut, Bolt and Fastener to be checked

Wheels:

Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin

Final Drive:

Final Gear Case Mounting Nuts

Brakes:

Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Caliper Holder Bolt Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin

Suspension:

Front Fork Clamp Bolts Front Fender Mounting Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft

Steering:

Stem Head Nut Handlebar Mounting Nuts

Engine:

Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Shift Pedal Bolts Mufﬂer Mounting Bolts and Nuts Exhaust Pipe Holder Nuts Mufﬂer Connecting Clamp Bolt Clutch Master Cylinder Clamp Bolts Clutch Lever Pivot Nut Radiator Mounting Bolt

Others:

Sidestand Bolt and Nut Footpeg Mounting Bolts Footpeg Bracket Mounting Bolts Downtube Bolts (Right)

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

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

DFI Parts Location.....................................................3-6

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

DFI Wiring Diagram..................................................3-10

Speciﬁcations...........................................................3-12

DFI Servicing Precautions.......................................3-13

Throttle Grip and Cables..........................................3-15

Throttle Grip Free Play Inspection....................3-15

Throttle Grip Free Play Adjustment...................3-15

Choke Knob Operation......................................3-15

Choke Cable Free Play Inspection....................3-15

Cable Removal/Installation................................3-15

Cable Lubrication and Inspection......................3-15

Throttle Assy............................................................3-16

Idle Speed Check..............................................3-16

Idle Speed Adjustment......................................3-16

Throttle Bore Cleaning......................................3-16

High Altitude Performance Adjustment.............3-16

Throttle Assy Removal......................................3-16

Throttle Assy Installation...................................3-19

Throttle Assy Disassembly/Assembly................3-20

Air Cleaner...............................................................3-23

Element Removal..............................................3-23

Element Cleaning..............................................3-23

Left Air Cleaner Housing Removal/Installation..3-23

Right Air Cleaner Housing Removal.................3-24

Right Air Cleaner Housing Installation..............3-24

Lower Air Cleaner Duct Removal/Installation....3-25

Fuel Tank..................................................................3-26

Fuel Tank Removal............................................3-26

Fuel Tank Installation.........................................3-28

Fuel Tank and Cap Inspection..........................3-29

Fuel Tank Cleaning............................................3-30

Return Fuel Check Valve Inspection.................3-30

Evaporative Emission Control System.....................3-31

Parts Removal/Installation.................................3-31

Canister Installation...........................................3-31

Canister Inspection (Periodic Inspection)..........3-31

Separator Inspection (Periodic Inspection).......3-31

Hose Inspection (Periodic Inspection)...............3-31

Separator Operation Test..................................3-32

Troubleshooting the DFI System..............................3-33

Outline...................................................................3-33

Problems and Inspection Order............................3-38

Inquiries to Rider...................................................3-41

ECU..........................................................................3-43

ECU Identiﬁcation..............................................3-43

ECU Removal....................................................3-43

ECU Installation.................................................3-43

ECU Power Supply Inspection..........................3-44

DFI Power Source....................................................3-45

DFI Fuse Removal.............................................3-45

DFI Fuse Inspection..........................................3-45

DFI Main Relay Removal..................................3-45

DFI Main Relay Inspection................................3-45

FI Indicator LED Light..............................................3-47

LED Light Inspection.........................................3-48

ISC Valves................................................................3-49

Removal/Installation...........................................3-49

Power Source Voltage Inspection......................3-49

Output Voltage Inspection.................................3-49

Resistance Inspection.......................................3-50

Fuel Line...................................................................3-51

Fuel Pressure Inspection...................................3-51

Pressure Regulator Removal............................3-52

Fuel Flow Rate Inspection.................................3-53

Self-Diagnosis..........................................................3-54

Self-diagnosis Conducting.................................3-54

Fault Code Reading...........................................3-56

Fault Code Erasing............................................3-56

Throttle Sensor (Fault Code 11)..............................3-59

Throttle Sensor Removal/Adjustment................3-59

Input Voltage Inspection....................................3-59

Output Voltage Inspection.................................3-59

Resistance Inspection.......................................3-60

Vacuum Sensor (Fault Code 12)..............................3-61

Removal.............................................................3-61

Installation..........................................................3-61

Input Voltage Inspection....................................3-61

Output Voltage Inspection.................................3-62

Inlet Air Temperature Sensor (Fault Code 13).........3-65

Removal/Installation...........................................3-65

Output Voltage Inspection.................................3-65

Sensor Resistance Inspection...........................3-66

Water Temperature Sensor (Fault Code 14)............3-67

Removal/Installation...........................................3-67

Output Voltage Inspection.................................3-67

Sensor Resistance Inspection...........................3-68

Atmospheric Pressure Sensor (Fault Code 15).......3-69

Removal.............................................................3-69

Installation..........................................................3-69

Input Voltage Inspection....................................3-69

3-2 FUEL SYSTEM (DFI)

Output Voltage Inspection.................................3-70

Pickup Coils (#1, #2: Fault Code 21, 22)................3-72

Pickup Coil Removal/Installation.......................3-72

Pickup Coil Inspection.......................................3-72

Vehicle-down Sensor (Fault Code 31).....................3-73

Removal.............................................................3-73

Installation..........................................................3-73

Inspection..........................................................3-73

Fuel Injectors (#1, #2: Fault Code 41, 42)..............3-75

Injector Removal................................................3-75

Injector Installation.............................................3-76

Audible Inspection.............................................3-78

Power Source Voltage Inspection......................3-78

Output Voltage Inspection.................................3-79

Injector Signal Test............................................3-79

Injector Resistance Inspection..........................3-80

Injector Unit Test................................................3-80

In-tank Fuel Pump (Fault Code 45).........................3-82

Fuel Pump Removal..........................................3-82

Pump Screen, Fuel Filter Cleaning...................3-82

Fuel Pump Installation.......................................3-83

Operation Inspection.........................................3-84

Power Source Voltage Inspection......................3-84

Operating Voltage Inspection............................3-84

Ignition Coils (#1, #2: Fault Code 51, 52)...............3-86

Removal/Installation...........................................3-86

Input Voltage Inspection....................................3-86

Exploded View

FUEL SYSTEM (DFI) 3-3

T1: 11 N1m (1.1 kg1m, 95 in1lb) T2: 16 N T3: 2.2 N T4: 9.8 N T5: 18 N

SS: Apply silicone sealant CA: California Model

m (1.6 kg1m, 12 ft1lb)

m (0.22 kg1m, 19 in1lb)

m (1.0 kg1m, 87 in1lb)

m (1.8 kg1m, 13.0 ft1lb)

(Kawasaki Bond: 56019–120).

1. Water Temperature Sensor (DFI)

2. Thermostat Housing

3. Fuel Tank

4. Vacuum Switch Valve

5. Crankcase Breather Hose

6. Throttle Assy

7. Air Cleaner Element

8. Left Air Cleaner Base

9. Right Air Cleaner Base

10. Air Cleaner Drain Hose

11. FI Indicator LED (Light Emitting Diode) Light

12. Right Spark Plug Lead Holder

13. Air Cleaner Duct Holder

14. Clamp Caps of Fuel Pump Leads

15. Fuel Tank Filler Drain Hose

16. Fuel Tank Breather Hose (except CA)

17. Fuel Tank Breather Hose (CA)

18. Fuel Tank Return Hose (CA)

19. Fuel Tank Cap Seal (CA)

3-4 FUEL SYSTEM (DFI)

Exploded View

CL: Apply cable lubricant.

G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the speciﬁed tightening sequence.

T1: 9.8 N T2: 2.9 N T3: 12 N T4: 4.9 N T5: 3.4 N T6: 7.8 N T7: 6.9 N T8: 1.5 N T9: 20 N

T10: 11 N

1. Throttle Cable (accelerator)

2. Throttle Cable (decelerator)

3. Choke Cable

4. In-tank Fuel Filter

5. To vacuum sensor

6. Atmospheric Pressure Sensor

7. Vacuum Sensor

8. Fuel Pump Gasket

9. In-tank Fuel Pump (electric)

10. Fuel Pump Screen

11. Pressure Regulator

12. Pressure Regulator Screen

13. Delivery Joint

14. Throttle Sensor

15. Injector #1 for Front Cylinder

16. O-ring

17. Seal Ring

18. Injector #2 for Rear Cylinder

19. Seal

20. Inlet Manifold

21. Throttle Body

22. Throttle Assy

23. ISC Valve #1 (for Front Cylinder)

24. ISC Valve #2 (for Rear Cylinder)

25. ECU (Electronic Control Unit)

26. Inlet Air Temperature Sensor

27. Right Air Cleaner Base

28. Vehicle-down Sensor

29. Battery Case

30. DFI Main Relay

31. Return Fuel Check Valve

32. Throttle Assy Holder

33. Right Spark Plug Lead Holder

34. Throttle Cable Holder : Do not remove the throttle cable holder.

m (1.0 kg

m (0.30 kg

m (1.2 kg

m (0.50 kg

m (0.35 kg

m (0.80 kg

m (0.70 kg

m (0.15 kg

m (2.0 kg

m (1.1 kg

m, 87 in

m, 26 in

m, 104 in

m, 43 in

m, 30 in

m, 69 in

m, 61 in

m, 13 in

m, 14 ft

m, 95 in

lb)

FUEL SYSTEM (DFI) 3-5

3-6 FUEL SYSTEM (DFI)

DFI Parts Location

DFI Parts (this chapter)

DFI:

Front

Atmospheric Pressure Sensor (DFI)

Water Temperature Sensor (DFI)

Ignition Coils

Ignition Switch

Starter Motor

Water Temperature Switch

Regulator/Rectiﬁer

Pickup Coils

Alternator

10.

Sidestand Switch

11.

Neutral Switch

12.

Oil Pressure Switch

13.

In-tank Fuel Pump (DFI)

14.

Vehicle-down Sensor (DFI)

15.

ECU (DFI)

16.

DFI Fuse 15 A

17.

MF Battery

18.

Junction Box

19.

Starter Relay

20.

Turn Signal Control Unit

21.

DFI Main Relay

22.

Oil Pressure Light Delay Unit

23.

ISC Valve #1 (DFI, for Front Cylinder)

32 V

24.

ISC Valve #2 (DFI, for Rear Cylinder)

25.

Inlet Air Temperature Sensor (DFI)

26.

Injectors (DFI)

27.

Vacuum Sensor (DFI)

28.

FI Indicator LED Light (DFI) of Tachometer Unit

29.

Throttle Sensor (DFI)

30.

Front Brake Light Switch

31.

Radiator Fan

32.

Radiator Fan Switch

33.

Rear Brake Light Switch

34.

In-tank Fuel Filter (DFI)

35.

Fuel Reserve Switch

36.

Delivery Joint (DFI)

37.

Pressure Regulator (DFI)

DFI Parts Location

FUEL SYSTEM (DFI) 3-7

3-8 FUEL SYSTEM (DFI)

DFI System

#1: For Front Cylinder #2: For Rear Cylinder

1. ECU (Electronic Control Unit)

2. Pickup Coil #1

3. Pickup Coil #2

4. Pressure Regulator

5. Throttle Sensor (front view)

6. Atmospheric Pressure Sensor

7. Vacuum Sensor

8. Water Temperature Sensor

9. Inlet Air Temperature Sensor

10. FI Indicator LED Light

11. In-tank Fuel Filter

12. Delivery Joint

13. Injector #1

14. Injector #2

15. In-tank Fuel Pump

16. ISC Valve #1 (Idle Speed Control Valve #1, rear side)

17. ISC Valve #2 (Idle Speed Control Valve #2, front side)

18. Vehicle-down Sensor (rear view)

19. Fuel Tank (left view)

20. Alternator Rotor (left view)

21. MF Battery (left view)

22. Left Air Cleaner Housing (rear view)

23. Right Air Cleaner Housing (rear view)

24. Lower Air Cleaner Duct (rear view)

25. Thermostat Housing (left view)

26. Throttle Valves

27. Fuel Flow

28. Air Flow

29. Speed Sensor

30. Fuel Hose Joint #1

31. Fuel Hose Joint #2

32. Fuel Hose Plate Clamp

33. Fuel Reserve Switch

34. Return Fuel Check Valve

35. Residual Pressure Check Valve

FUEL SYSTEM (DFI) 3-9

3-10 FUEL SYSTEM (DFI)

DFI Wiring Diagram

Terminal Numbers of ECU Connectors

FUEL SYSTEM (DFI) 3-11

Terminal Names DFI and Electrical Parts

#1:

Front Cylinder, #2: Rear Cylinder

—

Interlock Circuit Signal

Self-diagnosis Signal (generated by grounding this terminal and shown by FI indicator LED light)

Tachometer Signal

Electric Starter Button Signal

—

Water Temperature Sensor (+)

9. —

10.

ECU Power Source Circuit Ground to Battery (-) Terminal

11.

Ground of Inlet Air Temperature, Water Temperature, Vacuum, Atmospheric Pressure, and Throttle Sensors

12.

—

13.

DFI Main Relay Solenoid Ground in ECU

14.

Pickup Coil #2 Signal

15.

Pickup Coil #1 Signal

16.

—

17.

FI Indicator LED Light Signal

18.

ISC Valve #1 Signal

19.

—

20.

Ignition Control Circuit Ground to Battery (-) Terminal

21.

22. 23. —

24.

Vehicle-down Sensor Signal

25.

Meter Bulb Burned-out Check Signal from ECU (forwater temperature waring light LED light and warning light [h])

26.

Throttle Sensor Signal

27.

Speed Sensor Signal

28.

Atmospheric Pressure Sensor Signal

29.

Vacuum Sensor Signal

30.

Power Supply to ECU, ISC Valves, Injectors, and Fuel Pump

31.

Inlet Air Temperature Sensor (+)

32.

ECU Power Source Circuit Ground to Battery (-) Terminal (the same as #10)

33.

34. —

35.

Power Supply to Sensors (vacuum, atmospheric pressure, and throttle sensors) from ECU

36.

38. —

37.

Fuel Pump Signal

39.

Injector #2 Signal

40.

Injector #1 Signal

41.

ISC Valve #2 Signal

42.

Ignition Control Circuit Ground to Battery (-) Terminal

43.

Ignition Coil #2 Signal

44.

Ignition Coil #1 Signal

DFI: DFI Parts ECU [A]: Electronic Control Unit (DFI) Engine Stop Switch [B] Starter Button [C] Ignition Coils [D] Pickup Coils (Crankshaft Sensors) [E] Junction Box [F] Starter Circuit Relay [G] Interlock Diodes [H] Diode [J] for water temperature warning LED light Diode [K] for fuel reserve warning light FI Indicator LED Light [L]: (DFI) Speedometer [M] Ignition Switch [N] Starter Relay [O]

Main Fuse 30 A MF Battery [Q] Fuel Injector #1 [R]: (DFI) Fuel Injector #2 [S]: (DFI) Fuel Reserve Switch [T] In-tank Fuel Pump [U]: (DFI) DFI Fuse 15 A

In-tank Fuel Pump, DFI Main Relay, and ISC

Valves) ISC Valve #1 [W]: (DFI) ISC Valve #2 [X]: (DFI) Inlet Air Temperature Sensor [Y]: (DFI) Water Temperature Sensor [Z]: (DFI) Vacuum Sensor [a]: (DFI) Atmospheric Pressure Sensor [b]: (DFI) Throttle Sensor [g]: (DFI) Vehicle-down Sensor [d]: (DFI) DFI Main Relay [e]: (for ECU, Injectors, In-tank

Fuel Pump, and ISC Valves) Ignition Fuse 10 A Fuel Reserve Warning Light [h] Speed Sensor [i] Tachometer [j] ECU Connector [l] Connector Lock [m] Self-diagnosis Check Female Connector [n]

32 V [P]

32 V [V]: (for ECU, Injectors,

32 V [f]

3-12 FUEL SYSTEM (DFI)

Speciﬁcations

Throttle Grip Free Play:

Item

2 3 mm (0.079 ~ 0.118 in.)

Standard

Air Cleaner Element: Paper ﬁlter DFI (Digital Fuel Injection) System:

Make: Mitsubishi Electric Idle Speed: 950 ± 50 r/min (rpm) Throttle Assy:

Type2Bore Two barrel type

40 mm (1.57 in.)



ECU (Electronic Control Unit):

Type Digital memory type, with built in IC igniter, sealed with resin Usable engine speed 100 6200 r/min (rpm)

ISC Valves: (Idle Speed Control Valve, or Fast Idle Solenoid Valve)

Maximum air ﬂow rate 75 ± 7 L/min

20.4

Solenoid resistance 13.6

In-tank Fuel Filter:

Filtration area More than 200 cm



Rated ﬂow 1.0 L/min

Fuel Pressure (high pressure line):

Right after Ignition SW ON 310 kPa (3.2 kg/cm After pump runs 3 sec. and stops. 280 kPa (2.9 kg/cm With engine idling 260 kPa (2.7 kg/cm

, 46 psi) with fuel pump running

, 41 psi) with fuel pump stopped

, 38 psi) with fuel pump running

With engine running at full throttle 260 280 kPa (2.7 2.9 kg/cm2,38 41 psi) with fuel pump

running

Pressure Regulator:

Regulated fuel pressure 294 ± 4.9 kPa (3.00 ± 0.05 kg/cm

, 43 ± 0.73 psi)

Throttle Sensor: Non-adjustable, and non-removable

Input voltage 4.75 5.25 V DC between BL/W and BR/BK leads Output voltage at idle throttle opening 0.584 0.604 V DC between Y/W and BR/BK leads Output voltage at full throttle opening 4.29 4.59 V DC between Y/W and BR/BK leads Resistance 4 6k



between BL/W and BR/BK leads

Atmospheric Pressure Sensor or Vacuum Sensor:

Input voltage 4.75 5.25 V DC Output voltage 3.74 ~ 4.26 V DC at standard atmospheric pressure

Inlet Air Temperature Sensor:

Resistance 5.4 6.6 k

2.26 2.86 k

0.29 0.39 k

Water Temperature Sensor:

Resistance 2.162 3.112 k

0.785 1.049 k

0.207 0.253 k





at 0



at 20C (68



at 80C (176

  



C (32



at 20C (68



at 50C (122 at 100C (212



Vehicle-down Sensor:

Detection method Magnetic ﬂux detection method Detection angle More than 45



±5for each bank

Detection time Within 0.5 1.0 sec.

Fuel Injectors:

Type INP– 786 Injection timing 60BTDC at each cylinder Static injection quantity 273.1 289.4 mL/min Nozzle type Resistance 14.2 14.8

diameter

Two spray type with 4 holes



0.3 mm (0.012 in.)

Fuel Pump:

Type In-tank pump (friction pump) 75 mL or more for 3 seconds Discharge (90 L or more/h)

with the ﬁlter installed at 12 V2atmospheric pressure

Special Tools - Oil Pressure Gauge: 57001–125

Hand Tester: 57001–1394 Driver-Filler Cap: 57001–1454 Needle Adapter Set - Hand Tester: 57001–1457 Fuel Pressure Gauge Adapter: 57001–1417 Fork Oil Level Gauge: 57001–1290

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

DFI Servicing Precautions

There are a number of important precautions that should be followed

servicing the DFI system.



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 cap [A] after ﬁlling the engine oil, using the driver-ﬁller cap [B].

Clutch Cover [C] Front [D]

Special Tool - Driver-Filler Cap: 57001–1454 Torque - Oil Filler Cap: 1.5 N



This DFI system is designed to be used with a 12 V MF battery as its power source. Do not use any other battery except for a 12 V MF battery as a power source.



Do not reverse the battery lead connections. This will damage the ECU.



Do not disconnect the battery leads or any other electrical connections when the ignition SW (switch) is on, or while the engine is running. Otherwise, surge damages the connector terminals or the DFI parts.



Take care not to short the leads that are directly connected 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.



When disconnecting the following connectors, raise the lock of the connector. Push the lock of the other connectors.

Fuel Pump Connector Vehicle-down Sensor Connector Battery (-) Lead Connector



Whenever the DFI electrical connections are to be disconnected, ﬁrst turn off the ignition SW (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].



Do not turn the ignition SW ON while any of the DFI electrical connectors are disconnected. The ECU memorizes fault codes.



Do not spray water on the electrical parts, DFI parts, connectors, leads, and wiring. Never water a vehicle with connectors unplugged because seals don’t work and terminals could corrode.



If a transceiver is installed on the motorcycle, make sure that the operation of the DFI system is not inﬂuenced by electric waveradiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU.



To prevent corrosion and deposits n the fuel system, do not add any fuel antifreeze chemicals to fuel.



When any fuel hose is disconnected, do not turn on the ignition SW. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose.



Do not operate the in-tank fuel pump if the pump is completely dry. This is to prevent pump seizure.



Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.



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.

m (0.15 kg

m, 13 in

lb)

FUEL SYSTEM (DFI) 3-13

3-14 FUEL SYSTEM (DFI)

DFI Servicing Precautions



Route the hoses according to Cable, Wire, and Hose Routing section in the General Information chapter.

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When installing the fuel hoses, avoid sharp bending, kinking, ﬂattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel ﬂow will not be obstructed. Replace the hose if it has been sharply bent or kinked.

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Install the high pressure fuel hose clamps in the position shown, and securely tighten the clamp screws to the speciﬁed torque. Check the fuel system for leaks after hose installation.

Fuel Hose [A] Clamp [B] Fuel Pipe [C]

22 mm [D]

18 2 3 mm [E]

Torque - High Pressure Fuel Hose Clamp Screws: 1.5 N1m (0.15 kg1m,

lb)

13 in

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Fit the low pressure fuel hose [A] onto the pipe fully and install the plate clamp [B] beyond the raised rib [C].

1 ~ 2 mm [D]

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Fit the outlet hose joint #1 or 2 [A] onto the pipe until the joint clicks [B].

Front [C]

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Pull [B] the hose joint #1 or 2 [A] and make sure it is locked and doesn’t come off.

Throttle Grip and Cables

Throttle Grip Free Play Inspection



Refer to Throttle Control System Check in the Periodic Maintenance Chapter (2nd chapter).

Throttle Grip Free Play Adjustment

Loosen the locknuts [A] and screw the adjusters [B] all the way in so

•

as to give the throttle grip plenty of play. Turn out the adjuster of the decelerator cable [C] until there is no play.

•

Tighten the locknut against the adjuster.

•

Turn the adjuster of the accelerator cable [D] until the proper amount

•

of throttle grip free play is obtained and tighten the locknut against the adjuster.

Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.

Choke Knob Operation



Do not use the choke knob except when the engine has a starting difﬁculty, like in cold weather (10 The DFI system has an automatic choke system, using ISC valves, a water temperature sensor, and an atmospheric pressure sensor, which provide start ability.



Pull the choke knob [A] fully when using. The choke lever [B] doesn’t work with the choke knob halfway.

Front [C]



When ﬂooded, do not crank the engine with the throttle fully opened like a carburetor. This promotes engine ﬂooding because more fuel is supplied automatically by the DFI system.



C or below) or at high altitude.

NOTE

FUEL SYSTEM (DFI) 3-15

Choke Cable Free Play Inspection



Choke cable free play cannot be adjusted. Check that the choke inner cable slides smoothly by pulling and

•

pushing the choke knob lightly. If there is any irregularity, or the choke lever doesn’t work when the choke knob is pulled fully, replace the choke cable.

Cable Removal/Installation



See Throttle Assy section in this chapter for removal/installation of the throttle cables and choke cable.

Cable Lubrication and Inspection

Whenever the choke cable or the throttle cables are removed or in

•

accordance with the Periodic Maintenance Chart, lubricate the these cables. Refer to General Lubrication in the Periodic Maintenance Chapter (2nd chapter).



Use a commercially available pressure cable lubricator to lubricate these cables.



With the cable disconnected at both ends, the cable should move freely in the cable housing.

3-16 FUEL SYSTEM (DFI)

Throttle Assy

Idle Speed Check



Refer to Idle Speed Check in the Periodic Maintenance Chapter (2nd chapter).

Idle Speed Adjustment



Refer to Idle Speed Check in the Periodic Maintenance Chapter (2nd chapter).

Throttle Bore Cleaning



Refer to Throttle Control System Check in the Periodic Maintenance Chapter (2nd chapter).

High Altitude Performance Adjustment

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Any modiﬁcation is not necessary in this model since the atmospheric pressure sensor senses atmospheric pressure change due to high altitude and the ECU compensates the change. (For reference: Mostly, Kawasakirecommends US carburetor models operated above 4000 feet, EPA - approved modiﬁcation to improve the EMISSION CONTROL PERFORMANCE).

Throttle Assy Removal

Remove the fuel tank (see this chapter).

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Remove the white connector [A] of the inlet air temperature sensor.

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Vacuum Sensor [B] (for reference) Front [C]

Gasoline is extremely ﬂammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (–) terminal. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

Remove:

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Right and Left Air Cleaner Base (see this chapter) Right Spark Plug Lead Holder [A] and Bolts [C] Throttle Assy Holder [B] Throttle Assy Holder Bolts [D] Front [E]

Disconnect:

•

Throttle Sensor Connector [A] (from the throttle sensor) Front and Rear Injector Connectors [B] Front [C]

Kawasaki VN1500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual