Kawasaki VN900 CLASSIC Service Manual

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

Crankshaft/Transmission 9 j

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

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

•Refer to the sectional table of contents
for the exact pages to locate the spe­cific topic required.

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

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 Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.

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

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

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

© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1): Feb. 7, 2006 (M)

LIST OF ABBREVIATIONS

A ampere(s) lb pounds(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC

BTDC before top dead center

°C degree(s) Celsius

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

PS

psi

r revolution

horsepower

pound(s) per square inch

EMISSION CONTROL INFORMATION

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

1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors

are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.

2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust

of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California in-

cludes a catalytic converter system.

3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-

stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

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

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

on or in a motor vehicle or m otor 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 v ehicles or motor vehicle engines, or who operates a fleet of motor vehicles know­ingly to remove or render inoperative any devic e 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 t hat the emission standards are ex-

ceeded.

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

or durability of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the stan-

dards.

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

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE 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 intake 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 c lean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad­versely affect safe operation.

For the duration of the warranty period,

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

To get the longest life out of your vehicle:

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In preparing this manual, we divided the prod­uct into its major systems. These systems be­came the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a sin­gle chapter.

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.

The Periodic Maintenance Chart is located in
the Periodic Maintenance chapter. The chart
gives a time schedule for required maintenance
operations.

If you want spark plug information, for exam­ple, go to the Periodic Maintenance Chart first.
The chart tells you how frequently to clean and
gap the plug. Next, use the Quick Reference
Guide to locate the Periodic Maintenance chap­ter. Then, use the Table of Contents on the first
page of the chapter to find the Spark Plug sec­tion.

Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and 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 conditional step or what action to
take based on the results of the test or inspec­tion in the procedural step or sub-step it fol-

lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec­ified tightening torque, oil, grease or a locking
agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

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

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

1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera­tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra­tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, discon­nect the battery cables from the battery to prevent the en­gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca­ble to the negative terminal.

Edges of Parts

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

Solvent

Use a high-flush point solvent when cleaning parts. High

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

Cleaning Vehicle before Disassembly

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

Before Servicing

Arrangement and Cleaning of Removed Parts

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

Storage of Removed Parts

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

GENERAL INFORMATION 1-3

Inspection

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

Replacement Parts

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

Assembly Order

In most cases assembly order is the reverse of disassem­bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se­quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar­ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.

Force

Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam­age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per­formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling

Liquid Ga sket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces­sively. Excessive application can clog oil passages and
cause serious damage.

Before Servicing

Press

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

Ball Bearing and Needle Bearing

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

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

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in­stalling to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

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

Direction of Engine Rotation

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

Electrical Wires

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

Instrument

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

Model Identification

VN900B6F (US and Canada) Left Side View:

GENERAL INFORMATION 1-7

VN900B6F (US and Canada) Right Side View:

Frame Number

Engine Number

[A] Frame Number
[B] Front Fork (Right side)

[A] Engine Number
[B] Right Engine Cover

1-8 GENERAL INFORMATION

Model Identification

VN900B6F (Europe and Australia) Left Side View:

VN900B6F (Europe and Australia) Right Side View:

Model Identification

VN900D6F (US and Canada) Left Side View:

GENERAL INFORMATION 1-9

VN900D6F (US and Canada) Right Side View:

1-10 GENERAL INFORMATION

General Specifications

Items VN900B6F/D6F

Dimensions

Overall Length 2 465 mm (97.05 in.)

Overall Width 1 005 mm (39.57 in.), (AU) 980 mm (38.6 in.)

Overall Height

(VN900B) 1 065 mm (41.93 in.)

(VN900D) 1 480 mm (58.27 in.)

Wheelbase

Road Clearance 135 mm (5.31 in.)

Seat Height 680mm(26.8in.)

Dry Mass

(VN900B) 253 kg (558 lb), (EU) 254 kg (560 lb)

(VN900D) 270 kg (595 lb)

Curb Mass:

Front

(VN900B) 130 kg (287 lb), (EU) 131 kg (289 lb)

(VN900D) 134 kg (295 lb)

Rear

(VN900B) 151 kg (333 lb)

(VN900D) 164 kg (362 lb)

Fuel Tank Capacity 20L(5.3USgal)

Performance

Minimum Turning Radius 2.9 m (9.5 ft)

Engine

Type 4-stroke, SOHC, V2-cylinder

Cooling System Liquid-cooled

Bore And Stroke 88.0 × 74.2 mm (3.46 × 2.92 in.)

Displacement 903mL(55.1cuin.)

Compression Ratio 9.5 : 1

Maximum Horsepower

Maximum Torque

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 0° BTDC @1 000r/min (rpm) to 53° BTDC @5 800 r/min

Spark Plugs NGK CPR7EA-9

Cylinder Numbering Method Front to Rear, 1-2

Firing Order 1-2

1 645 mm (64.76 in.)

37 kW (50 PS) @5 700 r/min (rpm), (CA) (CAL) (US) –

78 N·m (8.0 kgf·m, 58 ft·lb) @3 700 r/min (rpm),
(CA) (CAL) (US) –

(rpm)
(AU) From 3.5° BTDC @1 000r/min (rpm) to 53° BTDC
@5 800 r/min (rpm)

GENERAL INFORMATION 1-11

General Specifications

Items VN900B6F/D6F

Valve Timing:

Inlet

open 40° BTDC

close 40° ABDC

duration 260°

Exhaust

Open 55° BBDC

Close 25° ATDC

Duration 260°

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type

Viscosity SAE10W-40

Capacity 3.7L(3.9USqt)

Drive Train

Primary Reduction System:

Type

Reduction Ratio 2.184 (83/38)

Clutch Type Wet multi disc

Transmission:

Type

Gear Ratios:

1st

2nd 1.889 (34/18)

3rd 1.360 (34/25)

4th 1.107 (31/28)

5th 0.963 (26/27)

Final Drive System:

Type Belt

Reduction Ratio 2.063 (66/32)

Overall Drive Ratio 4.338 @ Top gear

Frame

Type Tubular, double cradle

Caster (Rake Angel) 32°

Trail 160 mm (6.30 in.)

Front Tire:

Type Tubeless

Size 130/90-16M/C 67H

Rim Size 16M/C × MT3.00

Rear Tire:

Type Tubeless

Size 180/70-15M/C 76H

Rim Size 15M/C × MT4.50

API SE, SF or SG class
API SH or SJ class with JASO MA

Chain

5-speed, constant mesh, return shift

2.786 (39/14)

1-12 GENERAL INFORMATION

General Specifications

Items VN900B6F/D6F

Front Suspension:

Type

Wheel Travel

Rear Suspension:

Type Swingarm (uni-trak)

Wheel Travel 103 mm (4.06 in.)

Brake Type:

Front

Rear

Electrical Equipment

Battery:

Capacity 12 V 10 Ah

Headlight:

Type

Bulb

Tail/brake Light 12 V 5/21 W

Alternator:

Type Three-phase AC

Rated Output 32 A × 14 V @5 000 r/min (rpm)

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

AU: Australia
CA: Canada

CAL: California

EU: Europe
US: United States of America

Telescopic fork

150 mm (5.90 in.)

Single disc

Single disc

Semi-sealed beam

12 V 60/55W (quartz-halogen)

Unit Conversion Table

GENERAL INFORMATION 1-13

Prefixes for Units:

Prefix Symbol Power

mega M ×1000000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units of Mass:

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US)

L × 0.2200 =

L × 1.057 =

L × 0.8799 = qt (imp)

L × 2.113 = pint (US)

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 =

mL × 0.06102 = cu in

gal (imp)

qt (US)

oz (imp)

Units of Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m

N·m × 0.7376 = ft·lb

N·m × 8.851 = in·lb

kgf·m

kgf·m

kgf·m

× 9.807 = N·m

×7.233=

× 86.80 = in·lb

ft·lb

Units of Pressure:

kPa × 0.01020 =

kPa × 0.1450 = psi

kPa × 0.7501 = cm Hg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cm Hg × 1.333 = kPa

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature:

Units of Power:

kW × 1.360 =

kW × 1.341 = HP

PS × 0.7355 = kW

PS × 0.9863 = HP

PS

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

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

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

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

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

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

Fuel Hose Inspection (fuel leak, damage, installation condition)...................................... 2-14

Throttle Control System Inspection................................................................................... 2-14

Idle Speed Inspection ....................................................................................................... 2-15

Idle Speed Adjustment...................................................................................................... 2-15

Cooling System.................................................................................................................... 2-16

Coolant Level Inspection................................................................................................... 2-16

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ......... 2-16

Air Suction System .............................................................................................................. 2-17

Air Suction System Damage Inspection............................................................................ 2-17

Engine Top End ................................................................................................................... 2-17

Valve Clearance Inspection .............................................................................................. 2-17

Valve Clearance Adjustment............................................................................................. 2-17

Clutch................................................................................................................................... 2-21

Clutch Operation Inspection.............................................................................................. 2-21

Wheels and Tires ................................................................................................................. 2-22

Tire Air Pressure Inspection.............................................................................................. 2-22

Wheel/Tire Damage Inspection......................................................................................... 2-22

Tire Tread Wear Inspection............................................................................................... 2-22

Wheel Bearing Damage Inspection .................................................................................. 2-23

Spoke Tightness and Rim Runout Inspection................................................................... 2-24

Drive Train ........................................................................................................................... 2-25

Belt Deflection Inspection ................................................................................................. 2-25

Belt Deflection Adjustment................................................................................................ 2-27

Wheel Alignment Inspection/Adjustment .......................................................................... 2-28

Belt Wear and Damage Inspection ................................................................................... 2-28

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

Brake Fluid Leak Inspection.............................................................................................. 2-31

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

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

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

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

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

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

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

Front Fork Oil Leak Inspection.......................................................................................... 2-35

Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-35

Swingarm Pivot Lubrication .............................................................................................. 2-35

Rocker Arm Operation Inspection..................................................................................... 2-35

Tie-Rod Operation Inspection ........................................................................................... 2-35

Uni-trak Linkage Lubrication ............................................................................................. 2-36

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

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

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

Steering Stem Bearing Lubrication ................................................................................... 2-38

2

2-2 PERIODIC MAINTENANCE

Electrical System ................................................................................................................. 2-39

Lights and Switches Operation Inspection........................................................................ 2-39

Headlight Aiming Inspection ............................................................................................. 2-41

Sidestand Switch Operation Inspection ............................................................................ 2-42

Engine Stop Switch Operation Inspection......................................................................... 2-43

Others.................................................................................................................................. 2-44

Chassis Parts Lubrication ................................................................................................. 2-44

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-45

Evaporative Emission Control SystemInspection (CAL)...................................................... 2-46

Evaporative Emission Control System Inspection ............................................................ 2-46

Replacement Parts .............................................................................................................. 2-47

Air Cleaner Element Replacement.................................................................................... 2-47

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

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

Fuel Hose Replacement ................................................................................................... 2-49

Coolant Change ................................................................................................................ 2-51

Radiator Hose and O-ring Replacement........................................................................... 2-53

Brake Hose Replacement ................................................................................................. 2-53

Brake Fluid Change .......................................................................................................... 2-54

Master Cylinder Rubber Parts Replacement .................................................................... 2-56

Caliper Rubber Parts Replacement .................................................................................. 2-57

Spark Plug Replacement .................................................................................................. 2-60

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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

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

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Fuel System

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

Idle speed - inspect

Fuel leak (fuel hose and pipe) - inspect

Fuel hose - inspect year

Fuel hoses installation condition - inspect year

Cooling System

Coolant level - inspect

Coolant leak (radiator hose and pipe) ­inspect

Radiator hose damage - inspect year

Radiator hose installation condition ­inspect

Air Suction System

Air suction system damage - inspect

Evaporative Emission Control System
(CAL)

Evaporative emission control system
function - inspect

Engine Top End

Valve clearance - inspect (US and CA)

Valve clearance - inspect (EU and AU) Every 42 000 km (26 000 mile) 2-17

Clutch

Clutch operation (play, disengagement,
engagement) - inspect

Wheels and Tires

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearings damage - inspect year

Spoke tightness and rim runout-inspect

Drive Train

Belt deflection - inspect

Belt wear and damage - inspect

Brake System

Brake fluid leak - inspect

year

year

year

year

year

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • • • • •

• • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • •

•

• • •

• • •

• • •

• • •

See

Page

2-14

2-15

2-14

2-14

2-14

2-16

2-16

2-16

2-16

2-17

2-46

2-17

2-21

2-22

2-22

2-22

2-23

2-24

2-25

2-28

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Brake hose damage - inspect year

Brake hose installation condition - inspect year

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

Brake fluid level - inspect 6 m onths

Brake pad wear - inspect #

Brake light switch operation - inspect

Suspensions

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

Front forks/rear shock absorber oil leak ­inspect

Swingarm pivot - lubricate

Uni - trak rocker arm operation - inspect

Uni - trak tie rod operation - inspect

Uni - trak rocker arm bearings - lubricate

Uni - trak tie rod bearings - lubricate

Steering System

Steering play - inspect year

Steering stem bearings - lubricate 2 years

Electrical System

Lights and switches operation - inspect year

Headlight aiming - inspect year

Sidestand switch operation - inspect

Engine stop switch operation - inspect year

Others

Chassis parts - lubricate year

Bolts and nuts tightness - inspect

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

frequent starting/stopping.

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

year

year

year

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • •

• • • •

* ODOMETER READING

×1000km

(× 1 000 mile)

• • • • • •

• • •

• • •

•

• • •

• • •

•

•

•

• • •

• • •

• • •

• • •

• • •

See

Page

2-32

2-32

2-32

2-32

2-33

2-33

2-34

2-35

2-35

2-35

2-35

2-36

2-36

2-35

2-38

2-39

2-41

2-42

2-43

2-44

2-45

(AU): Australia
(CA): Canada
(CAL):California
(EU): Europe
(US): United States

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

comes

first

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

Air c leaner element # Every 18 000 km (12 000 mile) 2-47

Engine oil # year

Oil filter year

Fuel hose 4 years

Coolant 3 years

Radiator hoses and O-rings

Brake hoses 4 years

Brake fluid (Front and Rear) 2 years

Rubber parts of master cylinder and caliper 4 years

Spark plug

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

frequent starting/stopping.

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

3 years

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

• • • • •

• • • • •

•

•

• •

• • • •

See

Page

2-48

2-49

2-49

•

2-51

2-53

2-53

•

2-54

2-57

•

2-60

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

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

Letters used in the “Remarks” column mean:

2T: Apply 2-stroke oil.

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand threads

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)

S: Tighten the fasteners following the specified sequence.

Si: Apply silicone grease (ex. PBC grease).

SS: Apply silicone sealant.

Fastener

Fuel System

Water Temperature Sensor 12 1.2 106 in·lb

Speed Sensor Mounting Bolt 9.8 1.0 87 in·lb L

Fuel Pump Bolts 9.8 1.0 87 in·lb L

Oxygen Sensor 25 2.5 18

Fuel Level Sensor Mounting Bolts 6.9 0.70 61 in·lb L

Air Cleaner Housing Bolts 9.8 1.0 87 in·lb

Air Cleaner Cover Bolts

Air Cleaner Element Screw 4.9 0.50 43 in·lb

Throttle Body Assy Holder Bolts 9.8 1.0 87 in·lb

Inlet Manifold Bolts

Delivery Joint Bolts 9.8 1.0 87 in·lb L

Delivery Joint Bracket Bolts 9.8 1.0 87 in·lb

Vehicle-down Sensor Bolts 4.9 0.50 43 in·lb

Inlet Air Pressure Sensor Bolt 6.9 0.70 61 in·lb

Inlet Air Temperature Sensor Screw 1.2 0.12 11 in·lb

Cooling System

Radiator Hose Clamp Screws 2.0 0.20 18 in·lb

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Coolant Drain Bolt

Thermostat Housing Cover Bracket Bolts 6.9 0.70 61 in·lb

Thermostat Housing Cover Bolts 4.9 0.50 43 in·lb L

Radiator Bolts 6.9 0.70 61 in·lb

Radiator Screen Screws 6.9 0.70 61 in·lb

Radiator Fan Bolts 8.3 0.85 73 in·lb

Water Hose Fitting Bolts 9.8 1.0 87 in·lb

Reserve Tank Bolts 6.9 0.70 61 in·lb

Engine Top End

Cylinder Head nuts (M10) (First)

Cylinder Head nuts (M10) (Final) 49 5.0 36 MO, S

Cylinder Head nuts (M8) 25 2.5 18 S

Camshaft Cap Bolts 25 2.5 18

N·m kgf·m ft·lb

4.9 0.50 43 in·lb

9.8 1.0 87 in·lb L

9.8 1.0 87 in·lb

20 2.0 15

Torque

Remarks

MO, S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Cylinder Head Cover Bolts

Cylinder Head Outer Cover Bolts 9.8 1.0 87 in·lb

Plug (PT1/4) 15 1.5 11 L

Plug (PT1/2) 20 2.0 15 L

Muffler Mounting Bolts 25 2.5 18

Muffler Mounting Nut 25 2.5 18

Muffler Joint Clamp Bolt

Exhaust Pipe Cover Clamp Bolts 6.9 0.70 61 in·lb

Exhaust Pipe Cover Bolts 6.9 0.70 61 in·lb

Exhaust Pipe Holder Nuts 17 1.7 12

Camshaft Sprocket Bolts 49 5.0 36 L

Camshaft Chain Tensioner Cap Bolts 20 2.0 15

Camshaft Chain Guide Bolts 9.8 1.0 87 in·lb L

Clutch

Right Engine Cover Mounting Bolts 9.8 1.0 87 in·lb L(1)

Clutch Spring Bolts

Clutch Hub Nut 130 13.2 95.9

Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S

Engine Lubrication

Engine Oil Drain Plug 20 2.0 15

Oil Pump Cover Bolt 9.8 1.0 87 in·lb L

Oil Pump Drive Chain Guide Bolt 9.8 1.0 87 in·lb L

Oil Filter Plate Bolts 7.8 0.80 69 in·lb

Oil Pressure Switch 15 1.5 11 SS

Oil Pipe Bolts

Oil Return Pipe Bolts 9.8 1.0 87 in·lb

Oil Pressure Switch Adapter 20 2.0 15

Oil Filter 18 1.8 13

Oil Screen Plug 20 2.0 15

Oil Pressure Relief Valve 15 1.5 11 L

Engine Removal/Installation

Engine Mounting Nuts 44 4.5 32

Engine Mounting Bracket Bolts (M10) 44 4.5 32

Engine Mounting Bracket Bolts (M8)

Downtube Bolts 44 4.5 32

Crankshaft/Transmission

Balancer Gear Bolt

Starter Motor Clutch Gear Bolt 69 7.0 51

Primary Gear Bolt 98 10 72 MO

Connecting Rod Big End Bolts 46 4.7 34 MO

Shift Drum Bearing Stopper Bolts 9.8 1.0 87 in·lb L

Shift Drum Cam Bolt 12 1.2 106 in·lb L

Neutral Switch

N·m kgf·m ft·lb

12 1.2 106 in·lb

17 1.7 12

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb L

25 2.5 18

69 7.0 51

15 1.5 11

Torque

Remarks

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Rear Shift Lever Clamp Bolt

Shift Pedal Clamp Bolt 12 1.2 106 in·lb

Shift Rod Locknut (Front) 9.8 1.0 87 in·lb

Oil Nozzle 3.9 0.40 34 in·lb

Shift Rod Locknut (Rear) 9.8 1.0 87 in·lb Lh

Rear Shift Pedal Pad Screw 6.9 0.70 61 in·lb

Shift Drum Position Lever Bolt

Shift Shaft Return Spring Pin 29 3.0 21 L

Bearing Retainer Bolts 9.8 1.0 87 in·lb L

Balancer Shaft Bearing Stopper Plate Bolts

Crankcase Bolts (M10) 39 4.0 29 S

Crankcase Bolts (M6) 9.8 1.0 87 in·lb S

Engine Ground Lead Bolt 9.8 1.0 87 in·lb

Clamp Mounting Bolts 9.8 1.0 87 in·lb

External Shift Mechanism Cover Bolts 9.8 1.0 87 in·lb

Wheels/Tires

Front Axle Nut 108 11.0 79.7

Front Axle Clamp Bolt 20 2.0 15

Rear Axle Nut 108 11 .0 79.7

Spoke Nipples 5.2 0.53 46 in·lb

Final Drive

Rear Pulley Mounting Nuts 59 6.0 44

Rear Pully Plate Bolts 6.9 0.70 61 in·lb L

Engine Pully Mounting Nut 127 13.0 93.7 M

Engine Pullly Plate Bolts 9.8 1.0 87 in·lb

Engine Pulley Cover Bolts 9.8 1.0 87 in·lb

Engine Pulley Cover Clamp Mounting Bolt 9.8 1.0 87 in·lb

Drive Belt Guide Bolts 9.8 1.0 87 in·lb

Brakes

Bleed Valves 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 25 2.5 18

Brake Lever Pivot Bolt 1.0 0.10 88 in·lb Si

Brake Lever Pivot Locknut 5.9 0.60 52 in·lb

Brake Pedal Clamp Bolt 25 2.5 18

Front Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

Front Brake Reservoir Cap Screws 1.5 0.15 13 in·lb

Front Caliper Mounting Bolts 34 3.5 25

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

Rear Brake Disc Mounting Bolts 27 2.8 20 L

Rear Caliper Mounting Bolts 34 3.5 25

Rear Master Cylinder Mounting Bolts 25 2.5 18

Rear Master Cylinder Push Rod Locknut

N·m kgf·m ft·lb

12 1.2 106 in·lb

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb

17 1.7 12

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Suspension

Swingarm Pivot Shaft Nut 98 10 72

Rear Shock Absorber Nuts 59 6.0 44

Lower Tie-Rod Nut 59 6.0 44

Upper Tie-Rod Nut 108 11.0 80

Rocker Arm Pivot Shaft Nut 59 6.0 44

Upper Front Fork Clamp Bolts

Lower Front Fork Clamp Bolts 34 3.5 25

Front Fork Bottom Allen Bolts 20 2.0 15 L

Front Fork Upper Cover Stopper Bolts

Steering

Handlebar Holder Nuts 34 3.5 25

Handlebar Clamp Bolts

Steering Stem Head Bolt 49 5.0 36

Steering Stem Nut 4.9 0.50 43 in·lb

Frame

Sidestand Mounting Nut 44 4.5 32

Sidestand Mounting Bolt 44 4.5 32

Footboard Bracket Bolts 34 3.5 25

Left Footpeg Bracket Bolts 25 2.5 18

Right Footpeg Bracket Bolts 25 2.5 18

Lower Muffler Bracket Bolts

Upper Muffler Bracket Bolts 34 3.5 25

Electrical System

Alternator Outer Cover Bolts 9.8 1.0 87 in·lb

Tail/Brake Light Unit Mounting Nuts 5.9 0.60 52 in·lb

Alternator Cover Bolts 9.8 1.0 87 in·lb

Timing Inspection Plate Bolts 9.8 1.0 87 in·lb

Alternator Lead Holder Plate Bolts 5.9 0.60 52 in·lb

Stator Coil Bolts 12 1.2 106 in·lb L

Alternator Rotor Bolt (First) 69 7.0 51 S

Alternator Rotor Bolt (Final) 160 16.3 118 S, MO

Regulator/Rectifier Bolts 6.9 0.70 61 in·lb

Starter Motor Mounting Bolts

Starer Relay Terminal Screws 3.9 0.40 34 in·lb

Starter Motor Cable Terminal Nut 5.9 0.60 52 in·lb

Starter Motor Terminal Locknut 11 1.1 97 in·lb

Starter Motor Through Bolts 4.9 0.50 43 in·lb

Headlight Rim Screws 2.9 0.30 26 in·lb L

Crankshaft Sensor Bolts

Ignition Coil Bracket Bolt 9.8 1.0 87 in·lb

Ignition Coil Mounting Nuts 6.9 0.70 61 in·lb

Fuel Level Sensor Mounting Bolts 6.9 0.70 61 in·lb

N·m kgf·m ft·lb

20 2.0 15

4.2 0.43 37 in·lb

34 3.5 25

34 3.5 25

9.8 1.0 87 in·lb

5.9 0.60 52 in·lb

Torque

Remarks

S, 2T

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Spark Plugs

Sidestand Switch Mounting Bolts 8.8 0.90 78 in·lb L

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

N·m kgf·m ft·lb

18 1.8 13 in·lb

Torque

Remarks

Basic Torque for General Fasteners

Threads Diameter

(mm)

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb

8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

N·m kgf·m ft·lb

Torque

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Fuel System

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

Idle Speed 1000±50r/min(rpm) –––

Air Cleaner Element Polyurethane Foam –––

Cooling System

Coolant:

Type (recommended) Permanent type of antifreeze –––

Color Green

Mixed Ratio Soft water 50%, Coolant 50% –––

Freezing Point –35°C (–31°F) –––

Total Amount 2.2 L (2.3 US qt) –––

Engine Top End

Valve Clearance:

Exhaust 0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.) –––
Inlet 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) –––

Clutch

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

Engine Lubrication System

Engine Oil:

Type API SE, SF or SG –––

API SH, SJ or SL with JASO MA

Viscosity SAE 10W-40 –––

Capacity 3.0 L (3.2 US qt) (when filter is not

removed)

3.2 L (3.4 US qt) (when filter is removed) –––

3.7 L (3.9 US qt) (when engine is
completely dry)

Level Between upper and lower level lines

(after idling or running)

Wheels/Tires

Tread Depth:

Front

Rear

Air Pressure (when Cold):

Front Up to 180 kg (397 lb) load:

Rear Up to 97.5 kg (215 lb) load:

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

(AT, CH, DE)

1.6 mm (0.06 in.)

7.4 mm (0.29 in.) Up to 130 km/h (80 mph):

2 mm (0.08 in.),

Over 130 km/h (80 mph):

3 mm (0.1 in.)

200 kPa (2.00 kgf/cm², 28 psi)

200 kPa (2.00 kgf/cm², 28 psi)

97.5 ∼ 180 kg (215 ∼ 397 lb) load:

225 kPa (2.25 kgf/cm², 32 psi)

–––

–––

–––

–––

–––

–––

–––

–––

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Final Drive

Drive Belt Deflection:

(45 N, 4.6 kgf, 10 lb fprce) 1.5 ∼ 4.0 mm (0.059 ∼ 0.16 in.)

When Installing New Belt
or Engine Remounted

Brakes

Brake Fluid:

Grade DOT4

Brake Pad Lining
Thickness:

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

Rear 7.0 mm (0.28 in.) 1 mm (0.04 in.)

Brake Light Timing:

Front Pulled ON –––

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

Electrical System

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

AT: A u stria

CH: Switzerland

DE: Germany

1.5 mm (0.059 in.)

pedal travel

–––

–––

–––

–––

–––

Special Tools

PERIODIC MAINTENANCE 2-13

Inside Circlip Pliers:
57001-143

Steering Stem Nut Wrench:
57001-1100

Jack:
57001-1238

Oil Filter Wrench:
57001-1249

Spark Plug Wrench, Hex 16:
57001-1262

Tension Gauge:
57001-1585

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System (DFI)

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

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

○

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

Check that the hoses are routed according to Cable, Wire

•

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

Hose Joints [A]
Fuel Hose [B]

Check that the hose joints are securely connected.

•

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

○

than two times, and make sure it is locked.
If it does not locked, reinstall the hose joint.

WARNING

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

Throttle Control System Inspection

Check the throttle grip free play [A].

•

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

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

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.

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.
Turn out the adjuster of the decelerator cable [D] until

○

thereisnoplay.
Tighten the locknut against the adjuster.

○

Turn the adjuster of the accelerator cable [C] until the

○

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

Idle Speed Inspection

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 auto-

○

matically. This is the idle speed.
Check the idle speed.

•

Idle Sp eed

Standard: 1 000 ±50 r/min (rpm)

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

•

If handlebar movement changes the idle speed, the
throttle c ables 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 Appendix chapter).

PERIODIC MAINTENANCE 2-15

WARNING

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

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

Idle Speed Adjustment

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]

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cooling System

Coolant Level Ins pection

NOTE

Check the level when the engine is cold (room or ambi-

○

ent temperature).

Check the coolant level in the reserve tank [A] with the

•

motorcycle held upright.
If the coolant level is lower than the “L” level line [B], re­move the reserve tank cover and unscrew the reserve
tank cap, and add coolant to the “F” level line [C].

“L”: low
“F”: full

CAUTION

For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en­gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

Radiator Hose and Pipe Inspection (coolant leak,
damage, installation condition)

The high pressure inside the radiator hose and pipe can

○

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

•

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

•

are tightened correctly.

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

18 in·lb)

Periodic Maintenance Procedures

Air Suction System

Air Suction System Damage Inspection

Pull the air switching valve hose [A] out of the right air

•

cleaner housing.
Start the engine and run it at idle speed.

•

Plug the air switching valve hose end with your finger and

•

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

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (room temperature).

Remove:

•

Cylinder Head Cover (see Cylinder Head Cover Re­moval in the Engine Top End chapter)
Timing Inspection Plate (Engine Left Side)

Set the front piston at TDC (see Camshaft Installation in

•

the Engine Top End chapter).
Using a thickness gauge [A], measure the valve clearance

•

between the rocker arm [B] and the shim [C].

PERIODIC MAINTENANCE 2-17

Set the rear piston at TDC by turning the crankshaft

•

counterclockwise 305° (see Crankshaft Installation in the
Crankshaft/Transmission chapter).
Using a thickness gauge, measure the valve clearance

•

between the rocker arm and the shim.

Valve Clearance

Standard:

Exhaust: 0.20 ∼ 0.25 m m (0.079 ∼ 0.0098 in.)
Inlet: 0.10∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

If the valve clearance is not within the specified range and
then adjust it.

Valve Clearance Adjustment

To change the valve clearance, slide [A] the rocker arm

•

[B] sideways and change the shim [C]. R eplace the shim
with one of a different thickness.

NOTE

Mark and record the shim locations so that the shims

○

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

○

sizes smaller and then measure the clearance.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

To select a new shim which brings the valve clearance

•

within the specified range, refer to the Valve Clearance
Adjustment Charts.
Remeasure any valve clearance that was adjusted.

•

Readjust if necessary.

CAUTION

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

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

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

2. Check present shim size.

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

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

Example: Present shim is 2.60 mm (0.102 in.)

Measured clearance is 0.25 mm (0.010 in.)
Replace 2.60 mm (0.102 in.) shim with 2.70 mm (0.106 in.) shim.

5. Remeasure the valve clearance and readjust if necessary.

NOTE

If there is no clearance, select a shim which is several

○

sizes smaller and then measure the clearance.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

VALVE CLEARANCE ADJU STMEN T CHART EXHAUST VALVE

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

2. Check present shim size.

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

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

Example: Present shim is 2.55 mm (0.100 in.)

Measured clearance is 0.50 mm (0.020 in.)
Replace 2.55 mm (0.100 in.) shim with 2.75 mm (0.108 in.) shim.

5. Remeasure the valve clearance and readjust if necessary.

NOTE

If there is no clearance, select a shim which is several

○

sizes smaller and then measure the clearance.

Periodic Maintenance Procedures

Clutch

Clutch Operation Inspection

Clutch Lever Free Play Inspection

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

•

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

•

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

Clutch Lever Free Play

Standard: 2 ∼ 3mm(0.08∼ 0.12 in.)

Clutch Lever Free Play Adjustment

Loosen the locknut [A] at the clutch lever.

•

Turn the adjuster [B] until the proper amount of clutch

•

lever free play is obtained.
Tighten the locknut securely.

•

If it cannot be done, use the adjuster at the middle of the
cable.

WARNING

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

PERIODIC MAINTENANCE 2-21

Loosen the locknut [A] at the middle of the clutch cable.

•

Turn the adjuster nut [B] until the proper amount of clutch

•

lever free play is obtained.
Tighten the locknut securely.

•

If it cannot be done, use the mounting nuts at the lower
end of the cable.

Slide the dust cover [A] at the clutch cable lower end out

•

of place.
Loosen both adjusting nuts [B] at the clutch cover as far

•

as they will go.
Pull the clutch outer cable [C] tight and tighten the adjust-

•

ing nuts against the bracket [D].
Slip the rubber dust cover back onto place.

•

Turn the adjuster at the clutch lever until the free play is

•

correct.
Tighten the knurled locknut at the clutch lever.

•

WARNING

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

After the adjustment, start the engine and check that the

•

clutch does not slip and that it releases properly.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Wheels and Tires

Tire Air Pressure Inspection

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 necessary.

Air Pressur e (when cold)

Front:

Rear:

To ensure safe handling and stability, use only the
recommended standard tires for replacement, in­flated to the standard pressure.

Up to 180 kg (397 lb)

200kPa(2.00kgf/cm²,28psi)

Up to 97.5 kg (215 lb)

200kPa(2.00kgf/cm²,28psi)

97.5 ∼ 180 kg (215 ∼ 397 lb)

225kPa(2.25kgf/cm²,32psi)

WARNING

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.

Wheel/Tire Damage Inspection

Remove any imbedded stones [A] or other foreign parti-

•

cles [B] from tread.
Visually inspect the tire for cracks and cuts replacing the

•

tire in case of damage. Swelling or high spots indicate
internal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents dam-

•

age.
If any damage is found, replace the wheel if necessary.

Tire Tread Wear 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.

Periodic Maintenance Procedures

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.

Tread Dep th

Standard:

Front

Rear

Service Limit:

Front

Rear

Wheel Bearing Damage Inspection

Using a jack raise the front wheel off the ground (see Front

•

Wheel Removal in the Wheels/Tires chapter).
Turn the handlebar all the way to the right or left.

•

Inspect the roughness of the front wheel bearing by push-

•

ing and pulling [A] the wheel.
Spin [B] the front wheel lightly, and check for smoothly

•

turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel (see Front Wheel Removal in the Wheel/Tires
chapter) and inspect the wheel bearing (see Hub Bearing
Inspection in the Wheels/Tires chapter).

4.5 mm (0.18 in.)

7.4 mm (0.29 in.)

1 mm (0.04 in.) (DE, AT, CH) 1.6 mm
(0.063 in.)

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 2-23

Using a jack raise the rear wheel off the ground (see Rear

•

Wheel Removal in the Wheels/Tires chapter).
Inspect the roughness of the rear wheel bearing by push-

•

ing and pulling [A] the wheel.
Spin [B] the rear wheel lightly, and check for smoothly

•

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

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Spoke Tightness and Rim Runout Inspection

Check that all the spokes are tightened evenly.

•

If spoke tightness is uneven or loose, tighten the s poke

nipples evenly.

Torque - Spoke Nipples: 5.2 N·m (0.53 kgf·m, 46 in·lb)

Check the rim runout.

•

WARNING

If any spoke breaks, it should be replaced immedi-

ately. A missing spoke places an additional load on

the other spokes, which will eventually cause other

spokes to break

Raise the front/rear wheel off the ground.

•

Special Tool - Jack: 57001-1238

Spin the wheel lightly, and check for roughness or binding.

•

If roughness or binding is found, replace the hub bearings.

Inspect the rim for small cracks, dents, bending, or warp-

•

ing.

If there is any damage to the rim, it must be replaced.

NOTE

Avoid the curved part and the uneven part, and mea-

○

sure the rim runout on the side without the mark.

Measure the axial [A] and radial [B] rim runout with a dial

•

gauge.

If rim runout exceeds the service limit, check the hub

bearings first. Replace them if they are damaged. If the

problem is not due to the bearings, correct the rim warp

(runout). A certain amount of rim warp can be corrected

by recentering the rim. Loosen some spokes and tighten

others within the standard torque to change the position

of different parts of the rim. If the rim is badly bent, how-

ever, it must be replaced.

Rim Runout (with tire installed)

Standard:

Radial 1.0 mm (0.039 in.)

Axial 0.8 mm (0.03 in.)

Service Limit:

Radial 2.0 mm (0.079 in.)

Axial 2.0 mm (0.079 in.)

Periodic Maintenance Procedures

Drive Train

Belt Deflection Inspection

NOTE

Belt deflection must be checked and adjusted when the

○

belt is cold (at room temperature).
Belt deflection also should be checked at first 1000 km

○

ride after belt replacement.

Check to see if wheel alignment is properly adjusted.

•

The left and right notches on the belt adjuster should point

○

to the same marks or positions on the swingarm.
If they do not, adjust wheel alignment (see Wheel Align­ment Inspection/Adjustment).
Remove:

•

Reserve Tank Cover (see Reserve Tank Removal in the
Cooling System chapter)

Using the jack under the frame, lift the rear wheel off the

•

ground (see Rear Wheel Removal in the Wheels/Tires
chapter).
Visually inspect the belt for damage (see Belt Wear and

•

Damage Inspection).
If the belt is damaged, replace it with a new one.
Mark the initial belt position [A] on the belt cover window.

•

PERIODIC MAINTENANCE 2-25

Using the tension gauge [A], push up 45 N (4.5 kgf, 10

•

lb) of force from under and on the center of the belt at the
front side of the swingarm cross pipe [B].

Measure the deflection (length between initial belt posi-

•

tion [A] and position [B] after it measure it) of the belt (at
the belt cover window).

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

Push the belt by the gauge until the top surface [A] of

○

the stopper comes to the 45 N loaded scale [B], marked
“45N”.
Push up on the center of the belt. An inaccurate reading

○

will occur if the edge of the belt is pushed up.
Look parallel to the belt during inspection. An inaccu-

○

rate reading will occur if looking from any other angle.

Inspect the belt deflection at two positions by rotating the

•

rear wheel.

Special Tool - Tension Gauge: 57001-1585

Inspect the drive belt deflection at arbitrary position, and

•

record the value [A].

Turn the rear wheel 90 degrees.

•

Inspect the drive belt deflection, and record the value [B].

•

Periodic Maintenance Procedures

Decide the belt deflection at the position [C] of one where

•

deflection is large.

Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force)

Standard: 1.5 ∼ 4.0 mm (0.059 ∼ 0.16 in.)

Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force,
when installing new belt or engine remounted)

Standard: 1.5 mm (0.059 in.)

If the deflection is out of the specification, adjust it.

Belt Deflection Adjustment

Remove:

•

Muffler (see Muffler Removal in the Engine Top End
chapter)

Remove the axle cotter pin, and loosen the axle nut.

•

Using the jack under the frame pipe ribs, lift the rear

•

wheel off the ground (see Rear Wheel Removal in the
Wheels/Tires chapter).

PERIODIC MAINTENANCE 2-27

Loosen the left and right belt adjuster locknuts [A].

•

If the belt is too tight, back out the left and right belt ad­juster nuts [B], and kick the wheel forward until the belt is
too loose.
Turn in the left and right belt adjuster nuts evenly until the

•

drive belt has the correct amount of deflection.
To keep the belt and wheel aligned, the notch on the left

○

belt adjuster should align with the same swingarm mark
[C] that the right belt adjuster notch aligns with.

Tighten both belt adjuster locknuts.

•

WARNING

Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
Tighten both belt adjuster locknuts, and make sure
the axle stays aligned.

Tighten the axle nut.

•

Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb)

Inspect the drive belt deflection (see Belt Deflection In-

•

spection).
Readjust if necessary.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Insert a new cotter pin [A].

•

NOTE

When inserting the cotter pin, if the slots in the nut do

○

not align w ith the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

Bend the cotter pin [A] over the nut.

•

WARNING

If the rear axle nut is not securely tightened or the

cotter pin is not installed, an unsafe riding condi-

tion may result.

Check the rear brake for weak braking power and brake

•

drag.

Wheel Alignment Inspection/Adjustment

Check that the notch [A] on the left belt adjuster [B] aligns

•

with the same swingarm mark [C] or position that the right

belt adjuster notch aligns with.

If they do not, adjust the belt deflection (see Belt Deflec-

tion Adjustment) and align the wheel alignment.

NOTE

Wheel alignment can be also checked using the

○

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal

wear, and may result in an unsafe riding condition.

Belt Wear and Damage Inspe ction

Using the jack and jack attachment under the frame pipe

•

ribs, lift the rear wheel off the ground (see Rear Wheel

Removal in the Wheels/Tires chapter).

Remove:

•

Bolts [A] and Washers
Upper Belt Cover [B]

Periodic Maintenance Procedures

Visually inspect the belt [A] for wear and damage.

•

If the nylon fabric facing of any portion is worn off, and the
polyurethane compound is exposed, or belt is damaged,
replace the belt immediately with a new one.
Otherwise, refer to the Drive Belt Tooth Wear Patterns

•

and perform the according to the table of Drive Belt Wear
Analysis.
Whenever the belt is replaced, inspect the engine and
rear pulleys (see Pulley Wear Inspection in the Final Drive
chapter).

WARNING

A belt worn past the nylon fabric facing must be
replaced. Such a worn belt may cause a serious
accident.

PERIODIC MAINTENANCE 2-29

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Belt Tooth Wear and Damage Patterns

A. Belt Cross Section
B. Edge Bevel Wear
C. Rub Wear
D. Stone

PERIODIC MAINTENANCE 2-31

Periodic Maintenance Procedures

Drive Belt Wear and Damage Analysis

Pattern Condition Required Action

1

2 Scuffing to side of teeth

3 Fraying edge cord

4 Beveled wear

5 External tooth cracks (severe) Replace the drive belt.

6 Severe fractured or missing teeth Replace the drive belt.

7 Tooth hook wear

8 Stone damage

Internal tooth cracks (slight)

O.K. for continued use, but inspect the
belt periodically.

O.K. for continued use, but inspect the
belt periodically. Also check the pulley
flange.

O.K. for continued use, but inspect
the belt periodically (replace the belt if
excessive).

O.K. for continued use, check the pulley
alignment and flange condition.

Replace the drive belt. Inspect the
pulley for
wear.

Remove stone, O.K. for continued use
it not near edge of the belt. Inspect the
pulley for damage.

Brake System

Brake Fluid Leak Inspection

Apply the brake lever or pedal and inspect the brake fluid

•

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

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Hose Damage and Installation Condition
Inspection

Inspect the brake hoses 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 main-

tained. Bend and twist the rubber hose while examining

it.

Replace the hose if any crack [B], bulge [C] or leakage is

noticed.

Tighten any brake hose banjo bolts.

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

ft·lb)

Inspect the brake hose routing.

•

If any brake hose routing is incorrect, route the brake hose

according to Cable, Wire and Hose Routing section in the

Appendix chapter.

Brake Operation Inspection

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

•

ning the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake

system.

WARNING

When inspecting by running the vehicle, note a

surrounding traffic situation enough in the place of

safety.

Brake Fluid Level Inspection

Check that the brake fluid level in the front brake reservoir

•

[A] is above the lower level line [B].

NOTE

Hold the reservoir horizontal by turning the handlebar

○

when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the

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

Tighten:

•

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

kg·fm, 13 in·lb)

Periodic Maintenance Procedures

Check that the brake fluid level in the rear brake reservoir

•

[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].

WARNING

Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that is already in the reser­voir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

Follow the procedure below to install the rear brake fluid

•

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

○

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

PERIODIC MAINTENANCE 2-33

Brake Pad Wear Inspection

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

•

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

Pad Lining Thickness

Standard:

Front

Rear

Service Limit: 1 mm (0.04 in.)

Brake Light Switch Operation Inspection

Turn on the ignition switch.

•

The brake light [A] should go on when the brake lever is

•

applied or after the brake pedal is depressed about 10
mm (0.39 in.).

4.5 mm (0.18 in.)

7.0 mm (0.28 in.)

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If it does not, adjust the brake light switch.

While holding the switch body, turn the adjusting nut [A]

•

to adjust the switch.

CAUTION

To avoid damaging the electrical connections in-

side the switch, be sure that the switch body does

not turn during adjustment.

If it does not go on, inspect or replace the following items.

Battery (see Charging Condition Inspection in the Elec­trical System chapter)
Brake Light (see Tail/Brake Light Removal/Installation in
the Electrical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In­spection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Suspensions

Front Forks/Rear Shock Absorber Operation
Inspection

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

•

the smooth stroke.

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

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

the Suspension chapter).

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

•

the smooth stroke.

If the shock absorber does not smoothly stroke or noise

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

Oil Leak Inspection).

Periodic Maintenance Procedures

Front Fork Oil Leak Inspection

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

•

Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

Remove the left side cover (see Left Side Cover Removal

•

in the Frame chapter).
Visually inspect the shock absorber [A] for oil leakage.

•

If the oil leakage is found on it, replace the shock absorber
with a new one.

PERIODIC MAINTENANCE 2-35

Swingarm Pivot Lubrication

Remove the swingarm (see Swingarm Removal in the

•

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 of the grease seals.

•

Install the swingarm (see Swingarm Installation in the

•

Suspension chapter).

Rocker Arm Operation Inspection

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

•

smooth stroke.
If the rocker arm [A] does not smoothly stroke or noise is
found, inspect the fasteners and bearings.

Tie-Rod Operation Inspection

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

•

smooth stroke.
If the tie-rod [A] do not smoothly stroke or noise is found,
inspect the fasteners and tie-rod bearings.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Uni-trak Linkage Lubrication

Remove:

•

Tie-Rod (see Tie-Rod Removal in the Suspension chap­ter)

Apply grease to the inner surfaces of the needle bearings

•

[A]

For the rocker arm it has grease nipples [A] on the rocker

•

arm for lubrication. Force grease into the nipple until it

comes out both sides of the rocker arm, and wipe off any

excess.

Apply a thin coat of grease to the lips of the grease seals.

•

Steering System

Steering Play Inspection

Raise the front wheel off the ground with jack.

•

Special Tool - Jack: 57001-1238

With the front wheel pointing straight ahead, alternately

•

tap each end of the handlebar. The front wheel should

swing fully left and right from the force of gravity until the

fork hits the stop.

If the wheel binds or catches before the stop, the steering

is too tight.

Feel for steering looseness by pushing and pulling the

•

forks.

If you feel looseness, the steering is too loose.

NOTE

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

○

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

○

The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

Steering Play Adjustment

Remove:

•

Windshield (VN900D Models) (see Windshield Removal
in the Frame chapter)
Handlebar Holder Nuts [A]
Handlebar Holders [B] together with the Handlebar
Upper Front Fork Clamp Bolt (Both Sides) [C]
Steering Stem Head Nut [D]

Remove the steering stem head [E].

•

Periodic Maintenance Procedures

Straighten the claws [A] of the claw washer.

•

Remove the steering stem locknut [B] and claw washer

•

[C].

Adjust the steering.

•

Special Tool - Steering Stem Nut Wrench [A]: 57001-1100

If the steering is too tight, loosen the stem nut [B] a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.

NOTE

Turn the stem nut 1/8 turn at time maximum.

○

PERIODIC MAINTENANCE 2-37

Replace the claw washer with a new one.

•

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

•

upward, and engage the bent claws with the grooves of
stem locknut [C].
Hand tighten the stem locknut until it touches the claw

•

washer.
Tighten the stem locknut clockwise until the claws are

•

aligned with the grooves (ranging from 2nd to 4th) of stem
nut [D], and bend the 2 claws downward [E].
Install the steering stem head.

•

Install the washer, and tighten the stem head nut.

•

Tighten:

•

Torque - Steering Stem Head Nut: 49 N·m (5.0 kgf·m, 36

ft·lb)

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

15 ft·lb)

Check the steering again.

•

If the steering is still too tight or too loose, repeat the ad­justment.
Install the removed parts.

•

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering Stem Bearing Lubrication

Remove the steering stem (see Steering Stem Removal

•

in the Steering chapter).

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

•

lower ball bearings in the cages, and wipe the upper and

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

head pipe, clean off grease and dirt.

Visually check the outer races and the ball bearings.

•

Replace the bearing assemblies if they show wear or

damage.

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

•

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

and lower outer races.

Install the steering stem (see Steering Stem Installation

•

in the Steering chapter).

Adjust the steering (see Steering Play Adjustment).

•

Periodic Maintenance Procedures

Electrical System

Lights and Switches Operation Inspection

First Step

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

Position Lights [A] ( US and Canada
Models)

City Light [B] (Europe Models)

Taillight [C]

License Plate Light [D]

Neutral Indicator Light [E]

Oil Pressure Warning Indicator Light (LED)
[F]

Water Temperature Warning Indicator
Light (LED) [G]

FI Indicator Light (LED) [H]

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

Battery (see Charging Condition Inspection in the Elec­trical System chapter)
Applicable Bulb (see Wiring Diagram section in the Elec­trical System chapter)
Meter Unit for Neutral Indicator Light (LED) (see Meter
Unit Inspection in the Electrical System chapter)
Meter Unit for Oil Pressure/Water Temperature Warning
Indicator Light (LED) (see Meter Unit Inspection in the
Electrical System chapter)
Meter Unit for FI Indicator Light (LED) (see Meter Unit
Inspection in the Electrical System chapter)
ECU (see ECU Power Supply Inspection in the Fuel Sys­tem (DFI) chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In­spection in the Electrical System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Turn off the ignition switch.

•

The all lights should go off.

•

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

goes on

goes on

goes on

goes on

goes on

goes on

goes on

goes on

(about 2 seconds)

PERIODIC MAINTENANCE 2-39

Second Step

Turn the ignition switch to P (Park) position.

•

The city light, taillight and license plate light should go on.

•

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

Ignition Switch (see Switch Inspection in the Electrical
System chapter)

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Third Step

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

•

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

•

cording to the switch position should flash.

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

•

should flash.

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

following item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Re­placement in the Electrical System chapter)
Meter Unit for Turn Signal Light Indicator Light (LED)
(see Meter Unit Inspection in the Electrical System chap­ter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in the
Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri­cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Push the turn signal switch.

•

The turn signal lights and indicator light (LED) should go

•

off.

If the light does not go off, inspect or replace the following

item.

Turn Signal Switch (see Switch Inspection in the Electri­cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)

Fourth Step

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

•

Start the engine.

•

The low beam should go on.

•

If the low beam does not go on, inspect or replace the

following item.

Headlight Low Beam Bulb (see Headlight Bulb Replace­ment in the Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electri­cal System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay in Relay Box (see Relay Circuit Inspec­tion in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Periodic Maintenance Procedures

Set the dimmer switch to high beam position.

•

The high beam should go on.

•

The high beam indicator light (LED) [A] should go on.

•

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

Headlight Bulb (see Headlight Bulb Replacement in the
Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)

Turn off the engine stop switch.

•

The high beam should stay going on.

•

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

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

Turn off the ignition switch.

•

The headlights and high beam indicator light (LED) should

•

go off.

Headlight Aiming Inspection

Inspect the headlight beam for aiming.

•

If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.

PERIODIC MAINTENANCE 2-41

Headlight Beam Horizontal Adjustment

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

•

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

Headlight Beam Vertical Adjustment

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

•

screwdriver in or out to adjust the headlight vertically.

NOTE

ON high beam, the brightest points should be slightly

○

below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an­gle according to local regulations.

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

For US model, the proper angle is 0.4 degrees below

○

horizontal. This is 50 mm (2 in.) drop at 7.6 m (25
ft.) measured from the center of the headlight with the
motorcycle on its wheels and the rider seated.

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

7.6 m (25 ft.) [C]

Sidestand Switch Operation Inspection

Inspect the sidestand switch [A] operation accordance to

•

below table.

Sidestand Switch Operation

Sidestand

Up Neutral Released

Up Neutral Pulled in

Up In Gear Released

Up

Down Neutral Released

Down Neutral Pulled in

Down

Down

Gear

Position

In Gear

In Gear

In Gear

Clutch

Lever

Pulled in

Released

Pulled in

Engine

Start

Starts

Starts

Doesn’t

start

Starts

Starts

Starts

Doesn’t

start

Doesn’t

start

Engine

Run

Continue

running

Continue

running

Stops

Continue

running

Continue

running

Continue

running

Stops

Stops

Periodic Maintenance Procedures

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

Battery (see Charging Condition Inspection in the Elec­trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the Electrical
System chapter)
Engine Stop Switch (see Switch Inspection in the Elec­trical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Elec­trical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

If the all parts are good condition, replace the ECU.

PERIODIC MAINTENANCE 2-43

Engine Stop Switch Operation Inspection

First Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button.

•

The engine does not start.

•

If the engine starts, inspect or replace the following item.

Engine Stop Switch (see Switch Inspection in the Elec­trical System chapter)

Second Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button and run the engine.

•

Turn the engine stop switch to stop position.

•

Immediately the engine should be stop.

•

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

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)
If the engine stop switch is good condition, replace the
ECU.

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Others

Chassis Parts Lubrication

Before lubricating each part, clean off any rusty spots with

•

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

•

NOTE

Whenever the vehicle has been operated under

○

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

Pivots: Lubricate with Grease.

Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand

Points: Lubricate with Grease.

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

Cables: Lubricate with Rust Inhibitor.

Clutch Cable
Throttle Cables

Lubricate the cables by seeping the oil between the cable

•

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

○

available pressure cable lubricator with an aerosol cable
lubricant.

With the cable disconnected at both ends, the inner cable

•

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

Periodic Maintenance Procedures

Bolts, Nuts and Fasteners Tightness Inspection

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

•

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

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

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

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Nut

Engine Mounting Bolts and Nuts

Exhaust Pipe Holder Nuts

Muffler Mounting Bolt and Nut

PERIODIC MAINTENANCE 2-45

Wheels:

Front Axle Nut

Front Axle Clamp Bolt

Rear Axle Nut

Rear Axle Nut Cotter Pin

Brakes:

Brake Lever Pivot Nut

Brake Pedal Bolt

Brake Rod Joint Cotter Pin

Caliper Mounting Bolts

Front Master Cylinder Clamp Bolts

Rear Master Cylinder Mounting Bolts

Suspension:

Front Fork Clamp Bolts

Rear Shock Absorber Bolt and Nut

Swingarm Pivot Shaft Nut

Steering:

Steering Stem H ead Nut

Handlebar Clamp Bolts

Others:

Footboard Bracket Bolts

Footpeg Bracket Bolts

Front Fender Bolts

Sidestand Bolt

Downtube Bolts

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Evaporative Emission Control System
Inspection (CAL)

Evaporative Emission Control System Inspection

Inspect the canister as follows:

•

Remove:

○

Muffler (see Muffler Removal in the Engine Top End
chapter)

Remove the bolts [A].

○

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

○

Disconnect the hoses [A] from the canister.

○

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 motor-

○

cycle’s life without any maintenance if it is used under
normal conditions.

Install the canister and hoses.

○

Route the hoses according to Cable, Wire and Hose Rout-

○

ing section in the Appendix chapter. Refer to the diagram
of the evaporative emission control system in the Fuel
System (DFI) chapter too.

Check the liquid/vapor separator as follows:

•

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

○

Disconnect the hoses [C] from the separator.

○

Visually inspect the separator for cracks and other dam-

○

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

○

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

•

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

○

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

○

Route the hoses according to Cable, Wire and Hose Rout-

○

ing section in the Appendix chapter. Refer to the diagram
of the evaporative emission control system in the 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 Procedures

Replacement Parts

Air Cleaner Element Replacement

WARNING

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

CAUTION

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

Remove:

•

Air Cleaner Cover Bolts [A] and Washer

Air Cleaner Cover [B]

PERIODIC MAINTENANCE 2-47

Unscrew the air cleaner element screw [A] and remove

•

the air cleaner element [B].
Discard:

•

Air Cleaner Element

Install a new element [A] with the mesh side facing up

•

-ward.

CAUTION

Use only the recommended air cleaner element
(Kawasaki part number 11013-0015). Using another
air cleaner element will wear the engine prema­turely or lower the engine performance.

Torque - Air Cleaner Element Screw: 4.9 N·m (0.50 kgf·m,

43in·lb)

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Engine Oil Change

Situate the motorcycle so that it is vertical after warning

•

up the engine.
Remove:

•

Oil Filler Cap [A]

Special Tool - Filler Cap Driver: 57001-1454

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

•

The oil in the oil filter can be drained by removing the filter

○

(see Oil Filter Replacement).
Replace the drain plug gasket with a new one.

Tighten the drain plugs.

•

Torque - Engine Oil Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)

Pour in the specified type and amount of oil.

•

Recommended Engine Oil

Type:

Viscosity:

Amount:

Although 10W-40 engine oil is the recommended oil

○

for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.

Check the oil level (see Oil Level Inspection in the Engine

•

Lubrication System chapter).

API SE, SF or SG class

API SH, SJ or SL class with JASO MA

SAE 10W-40

2.7 L (2.8 US qt) (when filter is not
removed)

2.9 L (3.1 US qt) (when filter is removed)

3.2 L (3.4 US qt) (when engine is
completely disassembled and dry)

NOTE

Periodic Maintenance Procedures

Oil Filter Re pla cement

Drain the engine oil (see Engine Oil Change).

•

Remove:

•

Regulator/Rectifier (see Regulator/Rectifier Removal in

the Electrical System chapter)

Bolts [A]

Bracket [B]

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

•

discard the oil filter.

Special Tool - Oil Filter Wrench: 57001-1249

PERIODIC MAINTENANCE 2-49

Replace the oil filter with the new one.

•

Apply grease to the gasket [A] of the new filter before

•

installation.
Tighten the filter with the oil filter wrench.

•

Torque - Oil F ilter: 18 N·m (1.8 k gf·m, 13 ft ·lb)

Pour in the specified type and amount of oil.

•

Fuel Hose Replacement

CAUTION

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

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

•

System (DFI) chapter).
Insert a minus screw driver [A] into the slit [B] on the joint

•

lock.

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Twist the driver to disconnect the joint lock [A].

•

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

•

WARNING

Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe. Cover the hose connec­tion with a clean shop towel to prevent fuel spillage.

Pull [A] the joint lock [B] on the fuel hose fully as shown.

•

Insert the fuel hose joint [A] straight onto the delivery pipe.

•

Push [B] the joint lock [C] until the hose joint clicks.

•

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

•

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

WARNING

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

If it comes off, reinstall the hose joint.
Run the fuel hose in accordance with the Cable, Wire and

•

Hose Routing section in the Appendix chapter.
Install the removed parts.

•

Start the engine and check the fuel hose for leaks.

•

Periodic Maintenance Procedures

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down.
Coolant on tires will make them slippery, and can
cause an accident and injury.
Since coolant is harmful to the human body, do not
use for drinking.

Remove:

•

Left Side Cover (see Left Side Cover Removal in the

Frame chapter)

Bolt [A]

Reserve Tank Cover [B]

Remove:

•

Bolts [A]

Reserve Tank Cap [B]
Turn over the reserve tank, and pour the coolant into the

•

suitable container.

PERIODIC MAINTENANCE 2-51

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

•

System (DFI) 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.

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

○

remove the drain bolt.
The coolant will drain from the radiator and engine.

○

Install the reserve tank.

•

CAUTION

Soft or distilled water must be used with the an­tifreeze (see Specifications section) 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.

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Water and Coolant Mixture Ratio (when recommended)

Soft Water

Coolant

Freezing Point

Total Amount

Tighten:

•

Torque - Coolant Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

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

•

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

○

from the engine and radiator.
Choose a suitable mixture ratio by referring to the

○

coolant manufacturer’s directions.

Check the cooling system for leaks.

•

Tap the radiator hoses to force any air bubbles caught

•

inside.
Fill the radiator up to the filler neck with coolant.

•

Install the radiator cap.

•

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

•

coolant and install the cap.
Install the fuel tank (see Fuel Tank Installation in the Fuel

•

System (DFI) chapter).
Start the engine and warm it up thoroughly until the radi-

•

ator 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 [B], add
coolant to the “F” level line.

:

50%

:

50%

:

−35°C (−31°F)

:

2.2 L (2.3 US gt.)

NOTE

CAUTION

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

Periodic Maintenance Procedures

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

•

Thermostat Bracket [A] (see Thermostat Removal in the

Cooling System chapter)
Loosen the radiator hose clamps and remove the hoses

•

[B].
Unscrew the bolts and remove the water hose fittings [C]

•

and O-rings [D].
Apply sorp and water solution to the new O-ring and install

•

the water hose fittings.
Torque the water hose fitting bolts [E].

•

Torque - Water Hose Fitting Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Install the new radiator hose and tighten the hose clamps.

•

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

18 in·lb)

Thermostat Housing Cover Bracket Bolt: 6.9 N·m

(0.70 kgf·m, 61 in·lb)

Fill the coolant (see Coolant Change).

•

Check the cooling system for leaks.

•

Brake Hose Replacemen t

PERIODIC MAINTENANCE 2-53

CAUTION

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

When removing the brake hose [A], take care not to spill

•

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

•

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

•

Install new brake hoses.

•

There are washers [B] on each side of the brake hose

•

fitting. Replace them with new ones when installing.
Tighten the banjo bolts [C] on the hose fittings.

•

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

ft·lb)

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

When installing the hoses [A], avoid s harp bending, kink-

•

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

•

Brake Fluid Change).

Brake Fluid Change

NOTE

The procedure to change the front brake fluid is as fol-

○

lows. Changing the rear brake fluid is almost the same
as for the front brake.

Level the brake fluid reservoir.

•

Remove:

•

Reservoir Cap [A]
Plate [B]
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 level must be checked often during the chang-

○

ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.

Periodic Maintenance Procedures

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 2-55

Remove the clear plastic hose.

•

Install the reservoir cap.

•

Follow the procedure below to install the rear brake fluid

•

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

○

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

•

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

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

kgf·m, 13 in·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 Brake Line
Bleeding in the Brakes chapter).

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

Remove the front master cylinder (see Front Master Cylin-

•

der Removal in the Brakes chapter).
Remove the reservoir cap [A], plate [B], and diaphragm

•

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

•

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

•

[G].

Special Tool - In side Circlip Pliers: 57001-143

Pull out the piston assy [H], and return spring [I].

•

Replace:

•

Diaphragm
Dust Cover
Circlip
Piston Assy

Rear Master Cylinder Disassembly

NOTE

Do not remove the push rod clevis [A] for master cylin-

○

der disassembly since removal requires brake pedal po­sition adjustment.

Remove the rear master cylinder (see Rear Master Cylin-

•

der Removal in the Brakes chapter).
Remove the reservoir cap [B] plate [C] and diaphragm [D].

•

Slide the dust cover [E] on the push rod out of place, and

•

remove the circlip [F].

Special Tool - In side Circlip Pliers: 57001-143

Pull out the push rod with the piston stop.

•

Take off the piston assy [G] (piston [H] primary cup [I],

•

secondary cup [J]), and return spring [K].
Replace:

•

Piston Assy
Dust Cover
Brake Hose [L]
Diaphragm
O-ring [M]
Circlips

Periodic Maintenance Procedures

Master Cylinder Assembly

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

CAUTION

Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi­cult to wash off completely, and will eventually de­teriorate the rubber used in the disc brake.

Apply brake fluid to the removed parts and to the inner

•

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

•

cylinder.

CAUTION

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

PERIODIC MAINTENANCE 2-57

Tighten the brake lever pivot bolt and the locknut.

•

Silicone Grease - Brake Lever Pivot Bolt, Brake Lever

Pivot Contact, Push Rod Contact,
Dust Co ver

Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.8

in·lb)

Brake Lever Pivot Locknut: 5.9 N·m (0.60 kgf·m,

52 in·lb)

Caliper Rubber Parts Replacement

Front Caliper Disassembly

Remove:

•

Front Caliper (see Front Caliper Removal in the Brakes

chapter)

Cotter Pin [A]

Pin [B]

Pads [C] (see Front Brake Pad Removal in the Brakes

chapter)
Push the piston in.

•

Remove:

•

Pad Springs [A]

Caliper Holder [B]

2-58 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Using compressed air, remove the piston.

•

WARNING

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

Insert a wooden board [A] 5 mm (0.2 in.) thick inside the

○

caliper opening.
Apply compressed air [B] to the banjo bolt hole to allow

○

the pistons [C] to protrude and stop at the wooden board.
Remove the wooden board and pull out the piston by

○

hand.
If compressed air is not available, with the brake hose
still attached, apply the brake lever to remove the pistons.
The remaining process is as described above.

Remove:

•

Dust Seals [A]
Fluid Seals (Piston Seals) [B]
Friction Boot [C]
Bleed Valve

CAUTION

Immediately wash away any brake fluid that spills.

Front Caliper Assembly

Clean all parts other than the outer and inner pads.

•

CAUTION

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

Install the bleed valve [A] and the rubber cap [B].

•

Torque - Front Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69

in·lb)

Replace the fluid seals [A] with new ones, apply brake

•

fluid to them, and install them in the caliper body. Either
side of the fluid seal may face outboard.
Check the dust seals [B] and replace them with new ones

•

if they are damaged.

Periodic Maintenance Procedures

Apply brake fluid to the inside of the cylinders and to the

•

outside of the pistons and push the pistons [A] into the
cylinders.
Check the friction boot [B] and dust boot [C] and replace

•

them with new ones if they are damaged.
Apply a thin coat of silicon grease to the holder shafts [D]

•

and the holder holes.

Install the pad springs [A].

•

Install the pads (see Front Brake Pad Installation in the

•

Brakes chapter).
Wash the caliper with water to remove brake fluid and

•

wipe it off.

PERIODIC MAINTENANCE 2-59

Rear Caliper Disassembly

Remove:

•

Rear Caliper (see Rear Caliper Removal in the Brakes

chapter)

Rear Brake Pad (see Rear Brake Pad Removal in the

Brakes chapter)

Antirattle Spring [A]
Pull out the caliper holder [B].

•

Insert a wooden board [A] 5 mm (0.2 in.) thick inside the

•

caliper opening.
Remove the pistons using the compressed air.

•

WARNING

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

Remove the board and pull out the pistons [A] by hand.

•

CAUTION

Immediately wash away any brake fluid that spills.

2-60 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove:

•

Antirattle Spring [A]
Dust Seals [B] and Fluid Seals [C]
Rubber Friction Boots [D]
Bleed Valves [E] and Rubber Caps [F]

Rear Caliper Assembly

Tighten the bleed valve.

•

Torque - Rear Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69

in·lb)

It is recommended that the fluid seal (piston seal) which

○

is removed, be replaced with a new one.
Replace the dust seals [A] if they are damaged.

•

Install the fluid seal [B]. Either side of the seal may face

•

outboard.

Install the antirattle spring [A] in the caliper as shown.

•

Apply brake fluid to the cylinders, pistons, and fluid seals

•

(piston seals), and push the pistons into the cylinders by
hand. Take care that neither the cylinder nor the piston
skirt gets scratched.

Replace the caliper holder shaft rubber friction boot [A]

•

and dust boot [B] if they are damaged.
Apply a thin coat of silicone or PBC grease to the caliper

•

holder shafts [C] and holder holes (Silicone or PBC
grease is a special high temperature, water-resistance
grease).
Install the pads (see Rear Brake Pad Installation in the

•

Brakes chapter).

Spark Plug Repla cement

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Spark Plug Caps [A]

Remove the spark plug using the 16 mm (0.63 in.) plug

•

wrench vertically.

Special Tool - Spark Plug Wrench, Hex16: 57001-1262

Periodic Maintenance Procedures

CAUTION

The insulator [A] of the spark plug may break if
when the wrench is inclined during loosening.

Inclined Spark Plug Wrench [B]

Contact (Spark Plug and Plug Wrench) [C]

Bad [D]

Vertically Spark Plug Wrench [E]

Good [F]

Replace the spark plug with a new one.

•

Standard Spark Plug

Typ e :

Insert new spark plug in the plug hole, and finger-tighten

•

it first.
Using the plug wrench [A] vertically, tighten the plug.

•

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

NGK CPR7EA

CAUTION

PERIODIC MAINTENANCE 2-61

Special Tool - Spark Plug Wrench, Hex16: 57001-1262

Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)

Install the spark plug caps securely.

•

Be sure the spark plug caps are installed by pulling up it

○

lightly.

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

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

DFI Parts Location .................................................................................................................. 3-8

Specifications ......................................................................................................................... 3-11

Special Tools and Sealant ...................................................................................................... 3-13

DFI System............................................................................................................................. 3-14

DFI Servicing Precautions...................................................................................................... 3-22

DFI Servicing Precautions ................................................................................................ 3-22

Troubleshooting the DFI System ............................................................................................ 3-24

Outline ................................................................................................................................. 3-24

Outline............................................................................................................................... 3-24

Inquiries to Rider.................................................................................................................. 3-28

Inquiries to Rider ............................................................................................................... 3-28

DFI System Troubleshooting Guide ....................................................................................... 3-31

Self-Diagnosis ........................................................................................................................ 3-39

Self-diagnosis Outline.......................................................................................................... 3-39

Self-diagnosis Outline ....................................................................................................... 3-39

Self-diagnosis Procedures................................................................................................... 3-39

Self-diagnosis Procedures ................................................................................................ 3-39

Service Code Clearing Procedures ..................................................................................... 3-40

Service Code Clearing Procedures................................................................................... 3-40

How to Read Service Codes................................................................................................ 3-42

How to Read Service Codes............................................................................................. 3-42

How to Erase Service Codes............................................................................................... 3-42

How to Erase Service Codes ............................................................................................ 3-42

Service Code Table.............................................................................................................. 3-43

Service Code Table........................................................................................................... 3-43

Backups............................................................................................................................... 3-45

Backups ............................................................................................................................ 3-45

Main Throttle Sensor (Service Code 11) ................................................................................ 3-47

Main Throttle Sensor Removal/Adjustment ...................................................................... 3-47

Input Voltage Inspection.................................................................................................... 3-47

Output Voltage Inspection................................................................................................. 3-48

Resistance Inspection....................................................................................................... 3-49

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-51

Inlet Air Pressure Sensor Removal................................................................................... 3-51

Inlet Air Pressure Sensor Installation................................................................................ 3-51

Input Voltage Inspection.................................................................................................... 3-51

Output Voltage Inspection................................................................................................. 3-52

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-56

Inlet Air Temperature Sensor Removal/Installation........................................................... 3-56

Output Voltage Inspection................................................................................................. 3-56

Sensor Resistance Inspection .......................................................................................... 3-57

Water Temperature Sensor (Service Code 14) ...................................................................... 3-59

Removal/Installation.......................................................................................................... 3-59

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

Water Temperature Sensor Resistance Inspection........................................................... 3-59

Crankshaft Sensor (Service Code 21).................................................................................... 3-61

Crankshaft Sensor Removal/Installation ........................................................................... 3-61

Crankshaft Sensor Inspection ........................................................................................... 3-61

Speed Sensor (Service Code 24, 25)..................................................................................... 3-63

3

3-2 FUEL SYSTEM (DFI)

Speed Sensor Removal .................................................................................................... 3-63

Speed Sensor Installation ................................................................................................. 3-63

Speed Sensor Inspection .................................................................................................. 3-63

Input Voltage Inspection.................................................................................................... 3-63

Output Voltage Inspection................................................................................................. 3-64

Vehicle-down Sensor (Service Code 31)................................................................................ 3-66

Vehicle-down Sensor Removal......................................................................................... 3-66

Vehicle-down Sensor Installation...................................................................................... 3-66

Vehicle-down Sensor Inspection....................................................................................... 3-66

Subthrottle Sensor (Service Code 32).................................................................................... 3-69

Subthrottle Sensor Removal/Adjustment .......................................................................... 3-69

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

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

Resistance Inspection....................................................................................................... 3-71

Oxygen Sensor-not activated (#1, #2: Service Code 33, 83)-Europe Models ....................... 3-73

Oxygen Sensor Removal/Installation................................................................................ 3-73

Oxygen Sensor Inspection ................................................................................................ 3-73

Ignition Coils (#1, #2: Service Code 51, 52)........................................................................... 3-75

Ignition Coil Removal/Installation ...................................................................................... 3-75

Input Voltage Inspection.................................................................................................... 3-75

Radiator Fan Relay (Service Code 56)................................................................................... 3-77

Radiator Fan Relay Removal/Installation.......................................................................... 3-77

Radiator Fan Relay Inspection.......................................................................................... 3-77

Subthrottle Valve Actuator (Service Code 62)........................................................................ 3-79

Subthrottle Valve Actuator Removal ................................................................................. 3-79

Subthrottle Valve Actuator Inspection ............................................................................... 3-79

Resistance Inspection....................................................................................................... 3-79

Input Voltage Inspection.................................................................................................... 3-80

Air Switching Valve (Service Code 64)................................................................................... 3-82

Air Switching Valve Removal/Installation .......................................................................... 3-82

Air Switching Valve Inspection .......................................................................................... 3-82

Oxygen Sensor Heaters (#1, #2: Service Code 67)-Europe Models ..................................... 3-84

Oxygen Sensor Heater Removal/Installation.................................................................... 3-84

Oxygen Sensor Heater Inspection ................................................................................... 3-84

Oxygen Sensors-Incorrect Output Voltage (#1, #2: Service Code 94, 95)-Europe Models ... 3-86

Oxygen Sensor Removal/Installation................................................................................ 3-86

Oxygen Sensor Inspection ................................................................................................ 3-86

FI Indicator LED Light.............................................................................................................3-88

LED Light Inspection ......................................................................................................... 3-89

ECU........................................................................................................................................ 3-91

ECU Removal ................................................................................................................... 3-91

ECU Installation ................................................................................................................ 3-91

ECU Power Supply Inspection.......................................................................................... 3-91

Fuel Line................................................................................................................................. 3-93

Fuel Pressure Inspection .................................................................................................. 3-93

Fuel Flow Rate Inspection ................................................................................................ 3-95

Fuel Pump .............................................................................................................................. 3-97

Fuel Pump Removal ......................................................................................................... 3-97

Fuel Pump Installation ...................................................................................................... 3-97

Pump Screen, Fuel Filter Cleaning................................................................................... 3-98

Operation Inspection......................................................................................................... 3-98

Operating Voltage Inspection............................................................................................ 3-99

Power Source Voltage Inspection ..................................................................................... 3-100

Fuel Injectors .......................................................................................................................... 3-103

Injector Removal ............................................................................................................... 3-103

Injector Installation ............................................................................................................ 3-104

Injector Fuel Line Inspection............................................................................................. 3-105

FUEL SYSTEM (DFI) 3-3

Audible Inspection............................................................................................................. 3-106

Fuel Injector Power Source Voltage Inspection ................................................................ 3-106

Output Voltage Inspection................................................................................................. 3-107

Injector Signal Test............................................................................................................ 3-108

Injector Resistance Inspection .......................................................................................... 3-108

Injector Unit Test............................................................................................................... 3-109

Throttle Grip and Cables ........................................................................................................ 3-112

Throttle Grip Free Play Inspection .................................................................................... 3-112

Throttle Grip Free Play Adjustment................................................................................... 3-112

Cable Removal/Installation ............................................................................................... 3-112

Cable Lubrication and Inspection...................................................................................... 3-112

Throttle Body Assy ................................................................................................................. 3-113

Idle Speed Inspection ....................................................................................................... 3-113

Idle Speed Adjustment...................................................................................................... 3-113

Throttle Bore Cleaning ...................................................................................................... 3-113

High Altitude Performance Adjustment............................................................................. 3-113

Throttle Body Assy and Intake Manifold Removal ............................................................ 3-113

Throttle Body Assy and Intake manifold Installation ......................................................... 3-115

Air Cleaner.............................................................................................................................. 3-118

Air Cleaner Element Removal/Installation ........................................................................ 3-118

Air Cleaner Housing Removal........................................................................................... 3-118

Air Cleaner Housing Installation........................................................................................ 3-118

Fuel Tank................................................................................................................................ 3-120

Fuel Tank Removal ........................................................................................................... 3-120

Fuel Tank Installation ........................................................................................................ 3-123

Fuel Tank and Cap Inspection .......................................................................................... 3-124

Fuel Tank Cleaning ........................................................................................................... 3-124

Breather Check Valve Inspection...................................................................................... 3-124

Evaporative Emission Control System ................................................................................... 3-126

Parts Removal/Installation ................................................................................................ 3-126

Canister Installation .......................................................................................................... 3-126

Canister Inspection (Periodic Inspection) ......................................................................... 3-126

Separator Inspection (Periodic Inspection)....................................................................... 3-126

Hose Inspection (Periodic Inspection) .............................................................................. 3-126

Separator Operation Test.................................................................................................. 3-127

3-4 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

1 Fuel Pump Bolts 9.8 1.0 87 in·lb L

2 Air Cleaner Housing Bolts 9.8 1.0 87 in·lb

3 Air Cleaner Cover Bolts 4.9 0.50 43 in·lb

4 Throttle Body Assy Holder Bolts 9.8 1.0 87 in·lb

5 Inlet Manifold Bolts 9.8 1.0 87 in·lb L

6 Delivery Joint Bolts 9.8 1.0 87 in·lb L

7 Delivery Joint Bracket Bolts 9.8 1.0 87 in·lb

8 Vehicle-down Sensor Bolts 4.9 0.50 43 in·lb

9 Speed Sensor Mounting Bolt 9.8 1.0 87 in·lb

10

Inlet Air Pressure Sensor Bolt

11 Inlet Air Temperature Sensor Screw 1.2 0.12 11 in·lb

12 Air Cleaner Element Screw 4.9 0.50 43 in·lb

13 Water Temperature Sensor 12 1.2 106 in·lb

CL: Apply cable lubricant.

G: Apply grease.

L: Apply a non-permanent locking agent.

N·m kgf·m ft·lb

6.9 0.70 61 in·lb

Torque

Remarks

3-6 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1 Fuel Level Sensor Mounting Bolts 6.9 0.70 61 in·lb L

2. California Model

3. Breather Hose (Other than California Models)

L: Apply a non-permanent locking agent.

R: Replacement Parts

N·m kgf·m ft·lb

Torque

Remarks

3-8 FUEL SYSTEM (DFI)

DFI Parts Location

1. Ignition Coil #1

2. Fuel Pump

3. Ignition Coil #2

4. Main Fuse 30 A

5. Relay Box

6. Fuse Box

7. Vehicle Down Sensor

8. ECU

9. Battery

10. Crankshaft Sensor

11. Injector #2

12. Injector #1

13. Water Temperature Sensor

14. Main Throttle Sensor

15. Subthrottle Sensor

16. Subthrottle Valve Actuator

17. Air Switching Valve

18. Inlet Air Pressure Sensor

19. Inlet Air Temperature Sensor

20. Oxygen Sensors (Europe Models)

21. Speed Sensor

DFI Parts Location

FUEL SYSTEM (DFI) 3-9

3-10 FUEL SYSTEM (DFI)

DFI Parts Location

FUEL SYSTEM (DFI) 3-11

Specifications

Item Standard

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

Air Cleaner Element
DFI System

Make Denso

Idle Speed 1 000 ±50 r/min (rpm)

Throttle Body Assy:

Type × Bore Two barrel type × 34 mm (1.34 in.)

ECU (Electronic Control Unit):

Type

Fuel Pressure (High P ressure Line):

Right After Ignition Switch ON 304 kPa (3.1 k gf/cm², 44 psi) with fuel pump running

After Pump Runs 3 seconds and Stops. 280 kPa (2.9 kgf/cm², 41 psi) with fuel pump stopped

With Engine Idling 304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

Throttle Sensor: Non-adjustable and non-removable

Input Voltage 4.75 ∼ 5.25 V DC between BL and BR/BK leads
Output Voltage 1.05 ∼ 4.26 V DC between Y/W and BR/BK leads

Resistance 4 ∼ 6kΩ

Inlet Air Pressure Sensor:

Input Voltage 4.75 ∼ 5.25 V DC between BL and BR/BK leads
Output Voltage 3.80 ∼ 4.20 V DC between Y/BL and BR/BK leads

Inlet Air Temperature Sensor:

Resistance 5.4 ∼ 6.6 kΩ at 0°C (32°F)

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

Water Temperature Sensor:

Resistance

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

Vehicle-Down Sensor:

Detection Method Magnetic flux detection method

Detection Angle More than 45° ±5° for each bank

Fuel Injectors:

Type INP-287

Nozzle Type × Diameter One spray type with 12 holes

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

Fuel Pump:

Type Friction pump

Discharge 50 mL (1.7 US oz.) or more for 3 seconds

Speed Sensor:

Input Voltage at Sensor 4.75 ∼ 5.25 V DC at Ignition Switch ON
Output Voltage at Sensor about 0.05 ∼ 0.09 V DC or 4.5 ∼ 4.9 V at Ignition

Viscous paper element

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

(at idle throttle opening to full throttle opening)

(at standard atmospheric pressure)

0.29 ∼ 0.39 kΩ at 80°C (176°F)

see Electrical System chapter

Switch ON and 0 km/h

3-12 FUEL SYSTEM (DFI)

Specifications

Item Standard

Subthrottle Sensor: Non-adjustable and non-removable

Input Voltage 4.75 ∼ 5.25 V DC between BL and BR/BK leads
Output Voltage 0.93 ∼ 4.59 V DC between BL/W and BR/BK leads

(at idle throttle opening to full throttle opening)

Resistance 4 ∼ 6kΩ

Subthrottle Valve Actuator:

Resistance about 5.2 ∼ 7.8 Ω

Input Voltage

Oxygen Sensor:

Output Voltage (Rich) 0.45 ∼ 2.5 V
Output Voltage (Lean) 0.05 ∼ 0.45 V

Heater Resistance about 8 Ω at 20°C (68°F)

about 8.9 ∼ 10.9 V DC

Special Tools and Sealant

FUEL SYSTEM (DFI) 3-13

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

Fork Oil Level Gauge:
57001-1290

Hand Tester:
57001-1394

Needle Adapter Set:
57001-1457

Fuel Pressure Gauge Adapter:
57001-1593

Fuel Hose:
57001-1607

Peak Voltage Adapter:
57001-1415

Filler Cap Driver:
57001-1454

Speed Sensor Measuring Adapter:
57001-1667

Kawasaki Bond (Silicone Sealant):
56019-120

3-14 FUEL SYSTEM (DFI)

DFI System

DFI System