Kawasaki VULCAN 1600, VN1600 User Manual

VULCAN 1600 MEAN STREAK

VN1600 MEAN STREAK

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

This quick reference guide w ill 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 con-

•

tents for the exact pages to locate
the specific topic required.

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

VULCAN 1600 MEAN STREAK

VN1600 MEAN STREAK

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

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

The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer f or 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.

© 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Jul. 1, 2003 (M)

LIST OF ABBREVIATIONS

A

ABDC after bottom dead center m meter(s)

AC

ATDC after top dead center N newton(s)

BBDC before bottom dead center

BDC bottom dead center PS horsepower

BTDC before top dead center

°C degree(s) Celsius r revolution

DC

F farad(s) TDC top dead center

°F degree(s) Fahrenheit

ft foot, feet V volt(s)

g

h hour(s) Ω ohm(s)

kg

kgf (force)

L

ampere(s)

alternating current min

direct current

gram(s) (mass)

(mass)

liter(s)

lb

Pa

psi

r/min, rpm revolution(s) per minute

TIR total indicator reading

W

pound(s)

minute(s)

pascal(s)

pound(s) per square inch

watt(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emis­sion (1) and 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 vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know­ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow­ing its sale and delivery to the ultimate purchaser..."

NOTE

The phrase "remove or render inoperative any device or element of design" has been generally

○

interpreted as follows:

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

2. Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are 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 R ECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF F EDERAL LAW,

THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING
$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 i ncorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.

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

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

•

with Federal regulations.

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

•

Removal of the air box or air box cover.

•

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

•

modifications result in increased noise levels.

Foreword

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

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

For the duration of the warranty period,

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

To get the longest life out of your vehicle:

Follow the Periodic M aintenance 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

Special Tool Catalog or Manual. Genuine

parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Ta­ble of Contents.

For example, if you want ignition coil informa­tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use t he
Table of Contents on the first page of the chap­ter to find the Ignition Coil section.

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-9

Unit Conversion Table ............................................................................................................ 1-12

1

1-2 G ENERAL 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 wires from the battery to prevent the engine
from accidentally turning over. Disconnect the ground wire
(-) first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative (-) wire 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 G ENERAL INFORMATION

Before Servicing

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the
specified sequence to prevent case warpage or deformation
which can lead to malfunction. 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 c an 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. Rem ove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling

Liquid Gasket, Locking Agent

For applications that require Liquid G asket or a Locking
Agent, clean the surfaces so that no oil residue remains be­fore applying liquid gasket or 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 w henever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Install the circlip with its sharp edge facing outward
and its chamfered side facing inward to prevent the clip from
being pushed out of its groove when loaded. Take care
not to open the clip excessively when installing to prevent
deformation.

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.

1-6 G ENERAL INFORMATION

Before Servicing

Direction o f 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.

Model Identification

VN1600-B1 (US, and Canada) Left Side View:

GENERAL INFORMATION 1-7

VN1600-B1 (US, and Canada) Right Side View:

1-8 G ENERAL INFORMATION

Model Identification

VN1600-B1 (Europe) Left Side View:

VN1600-B1 (Europe) Right Side View:

GENERAL INFORMATION 1-9

General Specifications

Items VN1600–B1

Dimensions:

Overall length 2 410 mm (94.9 in.)

Overall width 850 mm (33.5 in.)
Overall height 1 100 mm (43.3 in.)
Wheelbase

Road clearance 125 mm (4.92 in.)

Seat height 700 mm (27.6 in.)
Dry mass 290 kg (639 lb)

Curb mass:

Fuel tank capacity

Fuel Unleaded and high-octane gasoline

Performance:

Minimum turning radius

Engine:

Type

Cooling system Liquid-cooled
Bore and stroke

Displacement 1 552 mL (94.70 cu in.)

Compression ratio
Maximum horsepower 54 kW (74 PS) @5 300 r/min (rpm),

Maximum torque 125 N·m (12.7 kgf·m, 92.2 ft·lb) @2 800 r/min (rpm),

Carburetion system DFI (Digital Fuel Injection) System

Starting system
Ignition system Battery and coil (transistorized)
Timing advance

Ignition timing From 5° BTDC @950 r/min (rpm) ∼

Spark plugs NGK DPR6EA-9 or ND X20EPR-U9

Cylinder numbering method
Firing order 1-2
Valve timing:

Inlet Open 22° BTDC

Exhaust

Lubrication system Forced lubrication (wet sump)
Engine oil: Type

Front

Rear 172 kg (379 lb)

Close 66° ABDC
Duration 268°

Open
Close 26° ATDC
Duration

Viscosity

1 705 mm (67.1 in.)

145 kg (320 lb)

17.0 L (4.49 US gal)

(see Owner’s Manual)

3.1 m (10.2 ft)

4-stroke, SOHC, V2-cylinder

102 × 95 mm (4.02 × 3.74 in.)

9.0 : 1

(CAL)(CA)(US)–

(CAL)(CA)(US)–

Electric starter

Electronically advanced (digital)

25° BTDC @4 500 r/min (rpm)

Front to Rear, 1-2

66° BBDC

272°

API SE, SF or SG class
API SH or SJ class with JASO M A

SAE10W-40

1-10 GENERAL INFORMATION

General S pecifications

Items VN1600–B1

Capacity 3.5 L (3.7US qt, when engine is completely

disassembled and dry)

Drive Train:

Primary reduction system:

Type Gear

Reduction ratio 1.517 (85/56)
Clutch type Wet multi disc

Transmission:

Type 5-speed, constant mesh, return shift

Gear ratios: (CAL, CA, US)

1st 2.500 (40/16)

2nd 1.750 (35/20)
3rd 1.333 (32/24)

4th 1.074 (29/27)
5th 0.867 (26/30)

(other than CAL, CA, US)
1st 2.500 (40/16)

2nd 1.590 (35/22)
3rd 1.192 (31/26)

4th 0.965 (28/29)
5th 0.781 (25/32)

Final drive system:

Type Shaft

Reduction ratio 2.619 (15/21 × 33/9)
Overall drive ratio (CAL, CA, US) 3.445 @ Top gear

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

Final gear case oil:

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

Capacity 200 mL (12.2 cu in.)

Frame:

Type Tubular, double cradle
Caster (rake angel) 32°

Trail 144 mm (5.67 in.)

Front tire: Type Tubeless

Size 130/70R17 M/C 62H

Rear tire: Type Tubeless

Size 170/60R17 M/C 72H

Front suspension: Type Telescopic fork (upside-down)

Wheel travel 150 mm (5.91 in.)

Rear suspension: Type Swingarm, air oil shock absorber

Wheel travel 87 mm (3.43 in.)

Brake Type: Front Dual disc

Rear Single disc

GENERAL INFORMATION 1-11

General Specifications

Items VN1600–B1

Electrical Equipment:

Battery Capacity 12 V 18 A h
Headlight: Type

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

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

Rated output

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

CAL: California Model

CA: Canadian Model
US: United States of America Model

Semi-sealed beam

23 A × 14 V @6 000 r/min (rpm)

1-12 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units:

Prefix Symbol Power

mega M × 1 000 000

kilo k × 1 000
centi c ×0.01

milli m × 0.001
micro µ × 0.000001

Units of Mass:

kg × 2.205 = lb
g × 0.03527 = oz

Units of Volume:

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

qt (US)

pint (US)

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 × 9.807 = N·m
kgf·m
kgf·m × 86.80 = in·lb

× 7.233 =

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
cmHg×1.333=kPa

kgf/cm²

Units of Speed:

km/h × 0.6214 = m ph

Units of Force:

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

Units of Temperature:

kgf

Units of Power:

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

× 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent ................. 2-4

Specifications .................................... 2-10

Special Tools ..................................... 2-12

Periodic Maintenance Procedures..... 2-13

Fuel System (DFI)........................... 2-13

Fuel Hose and Connection

Inspection .................................. 2-13

Throttle Control System

Inspection .................................. 2-13

Idle Speed Inspection .................. 2-14

Air Cleaner Element Cleaning...... 2-14

Evaporative Emission Control

System Inspection(CAL) ........... 2-15

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

Radiator Hose and Connection

Inspection .................................. 2-16

Coolant Change ........................... 2-16

Engine Top End .............................. 2-18

Air Suction Valve Inspection ........ 2-18

Clutch.............................................. 2-19

Clutch Hose and Connection

Inspection .................................. 2-19

Clutch Fluid Level Inspection ....... 2-19

Clutch Fluid Change .................... 2-20

Clutch Master Cylinder Cup and

Dust SealReplacement ............. 2-21

Clutch Slave Cylinder Piston Seal

Replacement ............................ 2-22

Engine Lubrication System ............. 2-22

Engine Oil Change....................... 2-22

Oil Filter Replacement ................. 2-24

Wheels/Tires................................... 2-24

2

Tire Inspection ............................. 2-24

Final Drive....................................... 2-25

Oil Level Inspection...................... 2-25

Oil Change ................................... 2-26

Brakes............................................. 2-27

Brake Pad Wear Inspection ......... 2-27

Brake Hose and Connection

Inspection.................................. 2-27

Brake Fluid Level Inspection ........ 2-28

Brake Fluid Change ..................... 2-29

Brake Master Cylinder Cup and

Dust Seal Replacement . ........... 2-30

Caliper Piston/Dust Seals

Replacement............................. 2-30

Front Brake Light Switch

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

Rear Brake Light Switch

Check/Adjustment..................... 2-30

Suspension..................................... 2-31

Front Fork Oil Leak Inspection..... 2-31

Rear Shock Absorber Oil Leak

Inspection ................................. 2-31

Swingarm Pivot Lubrication ......... 2-31

Steering .......................................... 2-32

Stem Bearing Lubrication............. 2-32

Steering Check ............................ 2-32

Steering Adjustment..................... 2-32

Electrical System ............................ 2-33

Spark Plug Cleaning/Inspection... 2-33

General Lubrication ........................ 2-33

Lubrication ................................... 2-33

Nut, Bolt, and Fastener Tightness .. 2-34

Tightness Inspection .................... 2-34

2-2 P ERIODIC M AINTENANCE

Periodic Maintenance Chart

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

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

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36 See

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

Air suction valve (e) - inspect †

Air cleaner element (e) - clean†#

Throttle control system (e) - inspect †

Idle speed (e) - inspect †

Fuel hoses, connections - inspect †

Evaporative emission control system (e)
(CAL) - inspect †

Final gear case oil level - inspect †

Brake pad wear - inspect † #

Brake light switch - inspect †

Steering - inspect † year

Tire damage and wear - inspect † #

Tire air pressure - inspect year

Wheel damage - inspect year

Wheel bearing wear and damage - inspect

Front fork and rear shock absorber ­operation

• • • •

• • • •

• • • •

• • • • • • •

• • • •

• • •

• • • • • •

• • •

• • • • • •

• • •

• • •

• • •

• • •

• • •

* ODOMETER READING

km × 1000 (mile × 1000)

2–18

• •

2–14

2-13

2-14

2-13

2-15

2–25

2–27

2–30

2–32

2–24

2–24

–

–

–

General lubrication - perform year

Nut, bolt, and fastener tightness - inspect †

Brake/clutch hoses, connections - inspect †

Brake/clutch fluid level - inspect † month

Coolant hoses, connections - inspect † year

Steering stem bearing - lubricate 2 years

• • •

• • • •

• • • • • • •

• • • • • • •

• • • •

•

2–33

2–34

2–19,

2–27

2–19,

2–28

2–16

2–32

Periodic Maintenance Chart

PERIODIC MAINTENANCE 2-3

FREQUENCY Whichever

comes

first

1 12 24 36 48 See

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

Spark plug (e)

Engine oil # year

Oil filter year

Coolant 3 years

Brake/clutch master cylinder cup and dust seal 4 years

Caliper piston seal and dust seal 4 years 2–30

Clutch slave cylinder position seal 4 years 2–22

Brake/clutch fluid 2 years

Final gear case oil

Fuel hose 4 years

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

frequent starting/stopping.

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

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

• • • •

• • • •

• •

* ODOMETER READING

km × 1000 (mile × 1000)

• • •

•

•

•

2–33

2–22

2–24

2–16

2–21,

2–30

2–20,

2–29

2–25

–

Throttle control system inspection: Inspection of throttle grip play and throttle bore cleanliness.

(CAL): California

(e): Emission Related Items

2-4 P ERIODIC M AINTENANCE

Torque and Locking Agent

The following tables list the tightening torque

for the major fasteners requiring use of a non

-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

G: Apply grease to the threads.

EO: Apply engine oil to the threads and the

seating surface.

L: Apply a non-permanent locking agent to

the threads.

Lh: Left-hand threads.

MO: Apply molybdenum disulfide oil to the

threads and the seating surface. The
molybdenum disulfide oil is a mixture
of engine oil and molybdenum disulfide
grease w ith a w eight ratio (10 : 1).

S: Tighten the fasteners following the speci-

fied sequence.

SS: Apply silicone sealant.

St: Stake the fasteners to prevent loosening.

R: Replacement parts

AL: Tighten the two clamp bolts alternately

two times to ensure even tightening
torque.

WL: Apply a soap and water solution or rubber

lubricant.

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 f or use with dry
solvent-cleaned threads.

Basic Torque for General Fasteners

Threads Torque

dia. (mm) N·m

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 ∼ 33 165 ∼ 240

kgf·m ft·lb

Fastener

N·m kgf·m ft·lb

Fuel System:

High pressure fuel hose clamp screws 1.5 0.15 13 in·lb

Pressure regulator screws 4.9 0.50 43 in·lb

Delivery joint screws 3.4 0.35 30 in·lb Throttle Body

Throttle body flange bolts 4.9 0.50 43 in·lb

Throttle body assy holder bolts 11 1.1 97 in·lb Right Side

Inlet manifold bolts 12 1.2 106 in·lb on Cyl. Head

Spark plug lead holder bolts 11 1.1 97 in·lb Right Side

ISC pipe bolts 11 1.1 97 in·lb

Air cleaner duct holder bolts 11 1.1 97 in·lb Left Side

Right and left air cleaner base bolts 11 1.1 97 in·lb

Right and left air cleaner base screws 2.2 0.22 19 in·lb L, Lower Duct

Left air cleaner cover Allen bolt 16 1.6 12

Right air cleaner cover Allen bolt 16 1.6 12

Right air cleaner Allen bolts 11 1.1 97 in·lb Throttle Body

Choke cable plate screw 2.9 0.30 26 in·lb L, Throttle Body

Inlet air temperature sensor nut (DFI) 7.8 0.80 69 in·lb

Water temperature sensor (DFI) 18 1.8 13 SS

Fuel pump bolts 6.9 0.70 61 in·lb S, L

Return fuel check valve 20 2.0 15

Cooling System:

Radiator hose clamp screws 2.5 0.25 22 in·lb

Thermostat air bleeder bolt 7.8 0.80 69 in·lb

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Fastener

Radiator fan switch

Radiator fan bolts

Water temperature switch 7.8 0.80 69 in·lb SS

Water pump impeller bolt 8.8 0.90 78 in·lb Lh

Water pump cover bolts 11 1.1 97 in·lb

Water pump air bleeder bolt 11 1.1 97 in·lb

Water pump drain bolt 11 1.1 97 in·lb

Water pipe bolts 11 1.1 97 in·lb

Radiator drain Bolt 2.2 0.22 19 in·lb

Engine Top End:

Spark plugs 18 1.8 13

Spark plug retainers 12 1.2 106 in·lb

Air suction valve cover bolts 7.4 0.75 65 in·lb

Chain tensioner mounting bolts 11 1.1 97 in·lb S

Chain tensioner cap 20 2.0 15 S

Chain tensioner lockbolt 4.9 0.50 43 in·lb S

Timing inspection cap 1.5 0.15 13 in·lb

Rotor bolt cap 1.5 0.15 13 in·lb

Camshaft sprocket bolts 15 1.5 11 L

Oil hose flange bolts 9.8 1.0 87 in·lb

Rocker shafts 25 2.5 18

Rocker case nuts 12 mm 78 8.0 58 MO, S

8mm 25 2.5 18 S

Rocker case bolts 6 mm 8.8 0.90 78 in·lb S

Cylinder head nuts 25 2.5 18 S

Cylinder head jacket plugs 20 2.0 15 L

Rocker case cover bolts 8.8 0.90 78 in·lb S

Camshaft chain guide bolts 11 1.1 97 in·lb L

Cylinder nuts 25 2.5 18 S

Inlet manifold bolts 12 1.2 106 in·lb on Cyl. Head

Exhaust pipe cover clamp bolts 6.9 0.70 61 in·lb

Premuffler chamber bolts

Muffler stay mounting bolts, 8 25 2.5 18 Lower Muffler

Upper muffler mounting nuts 25 2.5 18

Upper muffler bracket nut 29 3.0 21

Clutch:

Clutch lever pivot bolt 1.0 0.10 8.9 in·lb

Clutch lever pivot bolt locknut 5.9 0.60 52 in·lb Si

Clutch reservoir cap screws 1.5 0.15 13 in·lb

Clutch slave cylinder bleed valve 7.8 0.80 69 in·lb

Clutch slave cylinder bolts 6.9 0.70 61 in·lb L

Clutch hose banjo bolts 25 2.5 18

Clutch master cylinder clamp bolts 9.8 1.0 87 in·lb S

N·m

18 1.8 13

8.3 0.85 74 in·lb

29 3.0 21

Torque

Remarks

kgf·m ft·lb

2-6 P ERIODIC M AINTENANCE

Torque and Locking Agent

Fastener

Starter lockout switch screws

Push rod guide bolts 11 1.1 95 in·lb L

Clutch cover bolts 11 1.1 95 in·lb

Clutch damper cover bolts 9.8 1.0 87 in·lb L

Clutch damper plate bolts 9.8 1.0 87 in·lb EO

Clutch cover damper screws 4.9 0.50 43 in·lb L

Clutch hub nut 147 15 108 MO

Engine Lubrication System:

Oil filler cap 1.5 0.15 13 in·lb

Oil screen plug 20 2.0 15

Engine oil drain plug 20 2.0 15

Oil filter (cartridge type)

Oil filter pipe

Oil pressure relief valve

Oil pressure switch terminal screw 1.5 0.15 13 in·lb

Oil pressure switch 15 1.5 11 SS

Oil pump mounting bolts 11 1.1 97 in·lb

Oil hose banjo bolts 9.8 1.0 87 in·lb

Oil hose flange bolt (outside) 9.8 1.0 87 in·lb

Oil pipe holder bolts (inside) 11 1.1 97 in·lb L

Oil pipe clamp bolts (inside) 11 1.1 97 in·lb L

Right & left crankcase oil nozzles 2.9 0.30 26 in·lb ×3

Right crankcase oil nozzle 2.9 0.30 26 in·lb ×1,Lh

Oil pipe nozzle (left side) 2.9 0.30 26 in·lb

Oil baffle bolt 11 1.1 97 in·lb L

Engine Removal/Installation:

Downtube bolts and nuts 44 4.5 32

Engine mounting bolts and nuts 44 4.5 32

Engine mounting bracket bolts 25 2.5 18

Engine ground terminal bolt 7.8 0.80 69 in·lb

Crankshaft/Transmission:

Crankcase bolts

Frame ground bracket bolt 11 1.1 97 in·lb Left Crankcase

Crankcase bearing retainer bolts 11 1.1 97 in·lb L

Camshaft chain guide bolts 11 1.1 97 in·lb L

Right, l eft crankcase oil nozzles 2.9 0.30 26 in·lb ×3

Right crankcase oil nozzles 2.9 0.30 26 in·lb ×1,Lh

Oil baffle bolt 11 1.1 97 in·lb L

Connecting rod big end nuts 59 6.0 44 MO

Oil pressure relief valve 15 1.5 11 L

Oil filter pipe 25 2.5 18 SS

10 mm

8mm 21 2.1 15 S

6mm 11 1.1 97 in·lb S

N·m

1.2 0.12 10 in·lb

18 1.8 13

25 2.5 18

15 1.5 11 L

39 4.0 29

Torque

Remarks

kgf·m ft·lb

R, EO

SS

S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Oil hose banjo bolts

Primary gear bolt 147 15 108

Water pump chain guide spring hook bolt 2.9 0.30 26 in·lb

Water pump chain guide bolt 8.3 0.85 73 in·lb

Idle shaft holder bolts 8.3 0.85 73 in·lb

Oil pressure switch terminal screw 1.5 0.15 13 in·lb

Oil pressure switch 15 1.5 11 SS

Oil return pipe bolts (inside) 11 1.1 97 in·lb L

Oil pipe holder bolts (inside) 11 1.1 97 in·lb L

Oil pipe clamp bolts (inside) 11 1.1 97 in·lb L

Left balancer gear bolt 85 8.7 63 MO

Starter clutch bolt

Starter clutch coupling bolts

Gear set lever bolt

Shift shaft return spring pin (bolt) 39 4.0 29 L

Shift pedal clamp bolt 30 3.1 22

Rear shift lever clamp bolt 12 1.2 106 in·lb

Shift rod locknuts 9.8 1.0 87 in·lb (Rear: Lh)

Shift drum cam bolt 15 1.5 11 in·lb L

Damper cam nut (front gear) 195 20 144 MO (threads)

Clutch push rod guide bolts 11 1.1 97 in·lb L

Wheels/Tires:

Front axle clamp bolts 29 3.0 21 AL

Front axle 108 11 79.6

Rear axle nut 108 11 79.6

Tire air valve nuts 1.5 0.15 13 in·lb

Tire air valve caps 0.15 0.015 1.3 in·lb

Air valve cores 0.30 0.030 2.6 in·lb

Final Drive:

Oil pipe banjo bolts (front gear) 12 1.2 106 in·lb

Oil nozzle (front gear) 2.9 0.30 26 in·lb

Oil nozzle (front gear) 18 1.8 13

Neutral switch 15 1.5 11

Front gear case bolts: 6 mm 12 1.2 106 in·lb S

8mm 29 3.0 21 S

Speed sensor bolt

Damper cam nut (front gear)

Drive gear nut (front gear)

Driven gear assy mounting bolts 25 2.5 18

Driven gear bolt (front gear) 120 12 89 MO, St

Bearing retainer bolts (front gear) 8.8 0.90 78 in·lb L

Final gear case drain plug 8.8 0.90 78 in·lb

Final gear case mounting nuts 34 3.5 25

N·m

9.8 1.0 87 in·lb

85 8.7 63

15 1.5 11 L

11 1.1 97 in·lb L

9.8 1.0 87 in·lb L

195 20 144

265 27 195

Torque

Remarks

kgf·m ft·lb

MO

MO

MO (threads)

MO, St

2-8 P ERIODIC M AINTENANCE

Torque and Locking Agent

Fastener

Final gear case Studs

Final gear case cover bolts: 8 mm 23 2.3 17 L

10 mm 34 3.5 25 L

Pinion gear nut (final gear) 127 13 93 MO, St

Bearing retainer bolt 6.9 0.70 61 in·lb L

Brakes:

Caliper 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 8.9 in·lb Si

Brake lever pivot bolt locknut 5.9 0.60 52 in·lb

Front brake reservoir cap screws 1.5 0.15 13 in·lb

Front brake light switch screw 1.2 0.12 11 in·lb

Front master cylinder clamp bolts 8.8 0.90 78 in·lb S

Front brake pad spring bolts 2.9 0.30 26 in·lb

Front caliper mounting bolts 34 3.5 25

Front caliper assembly bolts 21 2.1 15

Rear caliper mounting bolts 34 3.5 25

Rear caliper holder bolt 64 6.5 47

Brake disc bolts 27 2.8 20 L

Rear master cylinder mounting bolts 25 2.5 18

Rear m aster cylinder push rod locknut 18 1.8 13

Brake pedal clamp bolt 25 2.5 18

Suspension:

Upper front fork clamp bolts 29 3.0 21

Lower front fork clamp bolts 29 3.0 21

Front fork top plugs 34 3.5 25

Piston rod nuts or joint rod nut 20 2.0 15

Inner fork bolt (left) 98 10 72

Front fork bottom Allen bolt (right) 20 2.0 15 L

Front axle clamp bolts 29 3.0 21 AL

Protector screws 5.9 0.60 52 in·lb

Rear shock absorber nuts 34 3.5 25

Shock absorber air valves 5.4 0.55 48 in·lb

Swingarm pivot shaft 108 11 79.6 G

Steering:

Steering stem head nut 88 9.0 65

Steering stem nut 4.9 0.50 43 in·lb S

Handlebar nuts 34 3.5 25

Upper front fork clamp bolts 29 3.0 21

Lower front fork clamp bolts 29 3.0 21 AL

Frame:

Downtube bolts and nuts 44 4.5 32

Rear footpeg bracket bolts 25 2.5 18 L

N·m

– – – L

Torque

Remarks

kgf·m ft·lb

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Sidestand nut

Electrical System:

Spark plugs 18 1.8 13

Crankshaft sensor screws 2.9 0.30 26 in·lb

Stator lead holder screw 9.8 1.0 87 in·lb L

Crankshaft sensor lead holder bolt 2.9 0.30 26 in·lb L

Alternator outer cover bolts 6.9 0.70 61 in·lb WL

Alternator outer cover joint bolts 6.9 0.70 61 in·lb L

Alternator outer cover damper bolts 6.9 0.70 61 in·lb L

Alternator outer cover assembly bolts 6.9 0.70 61 in·lb

Alternator cover bolts 11 1.1 97 in·lb

Alternator inner cover bolts 11 1.1 97 in·lb

Alternator rotor bolt 78 8.0 58

Alternator stator bolts 13 1.3 115 i n·lb L

Regulator/rectifier bolts 6.5 0.66 58 in·lb

Timing inspection cap 1.5 0.15 13 in·lb

Rotor bolt cap 1.5 0.15 13 in·lb

Starter motor terminal locknut

Starter motor terminal nut

Starter motor assembly bolts

Starter motor mounting bolts 11 1.1 97 in·lb

Headlight body mounting nuts 7.8 0.80 69 in·lb

Headlight rim screws 1.4 0.14 12 in·lb

Headlight mounting screws 2.9 0.30 26 in·lb

Headlight body bracket screws 1.2 0.12 11 i n·lb

Starter lockout switch screw 1.2 0.12 11 in·lb

Front brake light switch screw 1.2 0.12 11 in·lb

Sidestand switch bolt 8.8 0.90 78 in·lb L

Radiator fan switch 18 1.8 13

Water temperature switch 7.8 0.80 69 in·lb SS

Oil pressure switch terminal screw 1.5 0.15 13 in·lb

Oil pressure switch 15 1.5 11 SS

Neutral switch 15 1.5 11

Speed sensor mounting bolt 9.8 1.0 87 in·lb

Turn signal light mounting nuts

Front 5.9 0.60 52 in·lb

Rear 6.9 0.70 61 in·lb

License plate lens screws 1.0 0.10 8.9 in·lb

License plate light m ounting screw 1.2 0.12 11 in· lb

N·m

44 4.5 32

11 1.1 97 in·lb

4.9 0.50 43 in·lb

4.9 0.50 43 in·lb

Torque

Remarks

kgf·m ft·lb

MO

2-10 PERIODIC MA INTENANCE

Specifications

Item Standard Service Limit

Fuel System (DFI):

Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Idle speed 950 ±50 r/min (rpm) –––

Air cleaner element Paper filter –––

Cooling System:

Coolant:

Type (recommended) Permanent type antifreeze –––

Color Green

Mixed ratio

Freezing point

Total amount 2.3L(2.4USqt) –––

Engine Top End:

Valve clearance

Clutch:

Clutch fluid:

Grade DOT4 –––

Clutch lever free play Non-adjustable –––

Engine Lubrication System:

Engine oil:

Type API SE, SF or SG –––

Viscosity SAE 10W-40 –––

Capacity 2.9 L (3.1 US qt, when filter is not removed) –––

Level Between upper and lower level lines (Wait

Tires:

Tread depth:

Front DUNLOP D220F STG: 4.4 mm (0.17 in.) 1 mm (0.04 in.),

Rear DUNLOP D220 STG: 6.9 mm (0.27 in.) Up to

Air pressure: (when cold)

Front Up to 184 kg (405 lb) load: –––

Rear Up to 184 kg (405 lb) load: –––

Soft water 50%, Coolant 50% –––

– 35°C (– 31°F) –––

Non-adjustable (hydraulic lash adjusters) –––

API SH or S J with JASO MA

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

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

2 ∼ 3 minutes after idling or running)

1.6 mm (0.063 in.)

130 km/h (80 mph):

130 km/h (80 mph):

250 kPa (2.5 kgf/cm², 36 psi)

250 kPa (2.5 kgf/cm², 36 psi)

–––

–––

–––

(DE, AT, CH):

2 mm (0.08 in.)

3mm(0.1in.)

Over

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Final Drive:

Final gear case oil:

Grade API Service Classification: GL-5 –––

hypoid gear oil

Viscosity when above 5°C (41°F) SAE90 –––

when below 5°C (41°F) SAE80

Oil level Filler opening bottom –––

Amount 200 mL (6.76 US oz) –––

Propeller shaft joint grease 20 mL (0.68 US oz), –––

high-temperature grease

Brakes:

Brake fluid

Grade DOT4 –––

Brake pad lining thickness:

Front 4.0 mm (0.12 in.) 1 mm (0.04 in.)

Rear 7.5 mm (0.295 in.) 1 mm (0.04 in.)

Brake light timing:

Front Pulled ON –––

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

travel

–––

Electrical System:

Spark plug gap 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.) –––

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

2-12 PERIODIC MA INTENANCE

Special Tools

Steering Stem Nut Wrench:
57001–1100

Jack:
57001–1238

Attachment Jack:
57001–1398

Driver-Filler Cap:
57001–1454

Periodic Ma intenance Proce dures

Fuel System (DFI)

Fuel Hose and Connection Inspection

The fuel hoses are designed to be used throughout the

○

motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the high pressure in­side the fuel line can cause fuel to leak [A] or the hose to
burst. Remove the fuel tank (see Fuel System chapter)
and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
Check that the hoses are securely connected and clamps

•

are tightened correctly.
When installing, route the hoses according to Cable,

•

Wire, and Hose Routing section in the Appendix chapter.
When installing the fuel hoses, avoid sharp bending, kink-

•

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

PERIODIC M AINTENANCE 2-13

Throttle Control System Inspection

Check the throttle grip free play [A].

•

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

Throttle Grip Free Play

Standard: 2 ∼ 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.

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 (rear
view).
Turn out the adjuster of the decelerator cable [C] until

○

thereisnoplay.
Tighten the locknut against the adjuster.

○

Turn the adjuster of the accelerator c able [D] until the

○

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

2-14 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Idle Speed Inspection

Start t he 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 Speed

Standard: 950 ±50 r/min (rpm)

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

•

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

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.
Start t he engine and warm it up thoroughly.

•

Wait until fast idle speed lowers to a certain value.

○

Turn the adjusting screw [A] until the idle speed is correct.

•

Open and close the throttle a few times to make sure that

○

the idle speed is within the specified range. Readjust if
necessary.

Front [B]

Air Cleaner Element Cleaning

NOTE

In dusty areas, the element should be cleaned more

○

frequently than the recommended interval.
After riding through rain or on muddy roads, the element

○

should be cleaned immediately.

Remove:

•

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

Remove the element [A].

•

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

•

to keep dirt or other foreign material from entering.

WARNING

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

CAUTION

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

Periodic Ma intenance Proce dures

Clean the element by tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed

•

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

•

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

•

Torque - Left Air Cleaner Cover Allen Bolt: 16 N·m (1.6

kgf·m, 12 ft·lb)

Evaporative Emission Control System Inspection (CAL)

Inspect the canister as follows:

•

Remove the left side cover (see Frame chapter).

○

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

○

Visually inspect the canister for cracks and other damage.

○

If the canister has any cracks or bad damage, replace it
with a new one.

PERIODIC M AINTENANCE 2-15

NOTE

The canister is designed to work well through the motor-

○

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

Run the purge hose (green) [A] above the canister

○

breather hose (blue) [B] through the hole [C] into the tool
case [D].
Do not run these hoses side by side on the battery side

○

of the canister. This prevents hoses from being flattened
when installing the left side cover.
Install the canister and the left side cover (see Frame

○

chapter).
Face the white mark [E] left as shown.

○

Check the liquid/vapor separator as follows:

•

Disconnect the hoses from the separator, and remove the

○

separator [A] from the motorcycle right side.

Front [B]

Visually inspect the separator for cracks and other dam-

○

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

○

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

○

Routing 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.

2-16 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Cooling System

Radiator Hose and Connection Inspection

The high pressure inside the radiator hose can cause

○

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

•

are tightened correctly.

Torque - Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m,

22 in·lb)

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.

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

•

remove the drain bolt (front view).

Remove the fuel tank (see 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.
The coolant will drain from the radiator and engine.

○

Front [B]

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

•

coolant will drain from the water pump [B].
Place a conduit under the drain hole of the pump cover.

○

The conduit leads to a container.

Front [C]

Periodic Ma intenance Proce dures

Remove :

•

Right Side Cover (see Frame chapter)
Reserve Tank Bolts

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

•

pour the coolant into a suitable container.
Install the reserve tank.

•

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

CAUTION

Soft or distilled water must be used with the an­tifreeze (see Specifications in this chapter) in the
cooling system.
If hard water is used in the system, it causes scale
accumulation in the water passages, and consider­ably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio ( when shipping)

Soft Water
Coolant
Freezing Point
Total Amount

Tighten the drain bolts.

•

Torque - Radiator Drain Bolt: 2.2 N·m (0.22 kgf·m, 19 in·lb)

Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)

Fill the coolant into the radiator.

•

Fill in the coolant slowly so that it can expel the air from

○

the engine and radiator.

:

50 %

:

50 %

:

− 35°C (− 31°F)

:

2.3 L (2.4 US qt)

NOTE

PERIODIC M AINTENANCE 2-17

Check the cooling system for leaks.

•

Bleed the air from the water pump [A].

•

Loosen the air bleeder bolt [B] until the coolant seeps out

○

around the bolt, then tighten it.

Torque - Water Pump Air Bleeder Bolt: 11 N·m (1.1 kgf·m,

97 in·lb)

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

•

housing.

Front [B]

Replenish the coolant into the radiator until the coolant

•

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

•

inside.

2-18 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

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

•

Install the radiator cap.

•

Tighten the air bleeder bolt [B].

•

Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m,

69 in·lb)

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

•

coolant and install the cap.
Install the fuel tank (see Fuel System (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, add
coolant to the “F” level line.

CAUTION

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

Engine Top End

Air Suction Valve Inspection

Remove the air suction valve (see Engine Top End chap-

•

ter).
Visually inspect the reeds for cracks, folds, warps, heat

•

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

•

grooves, scratches, any signs of separation from the
holder or heat damage.

If there is any doubt as to the condition of the reed contact

•

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

•

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

CAUTION

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

Periodic Ma intenance Proce dures

Clutch

Clutch Hose and Connection Inspection

Thehighpressureinsidetheclutchlinecancausefluid

•

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

•

bolts are tightened correctly.

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

ft·lb)

When installing the clutch hose, route the hoses accord-

•

ing to Cable, Wire, and Hose Routing s ection in the Ap­pendix chapter.
Replace the hose if it has been sharply bent or kinked.

Clutch Fluid Level Inspection

Hold the clutch fluid reservoir horizontal.

•

Check that the clutch fluid level of the clutch reservoir is

•

between the lower [A] and the upper [B] level lines.
If the fluid level is lower than the lower level line, fill the
reservoir to t he upper level line i n the reservoir.
Since the clutch fluid is the same as the brake fluid, refer

○

to Brakes Section in the this chapter for further details.

T orque - Clutch Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

PERIODIC M AINTENANCE 2-19

WARNING

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

2-20 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Clutch Fluid Change

Level the clutch fluid reservoir and remove the reservoir

•

cap.
Remove the alternator outer cover (see Electrical System

•

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

•

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

•

Change the clutch fluid as follows.

•

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

Repeat this operation until fresh fluid comes out from the

○

plastic hose or the color of the fluid changes.
Check the fluid level in the reservoir often, replenishing it

○

as necessary.

NOTE

If the fluid in the reservoir runs completely out any time

○

during fluid changing, the bleeding operation must be
done over again from the beginning since air will have
entered the line.

WARNING

Do not mix two brands of fluid.

After changing the fluid, check the clutch for good clutch

•

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

•

Install the reservoir cap.

•

Tighten the bleed valve, and install the rubber cap.

•

T orque - Clutch Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80

kgf·m, 69 in·lb)

Periodic Ma intenance Proce dures

Clutch Master Cylinder Cup and Dust Seal Replacement

Remove the clutch master cylinder (see Clutch chapter).

•

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

•

pour the clutch fluid into a container.
Unscrew the locknut [C] and pivot bolt [D], and remove

•

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

•

[G].

Special Tool - Inside Circlip Pliers: 57001-143

Pullouttheprimarycup[H],pistonassembly[I],andre-

•

turn spring [J].

CAUTION

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

Check the parts of the clutch master cylinder (see Clutch

•

chapter).
If any part shows signs of damage, replace it.

PERIODIC M AINTENANCE 2-21

Before assembly, clean all parts including the master

•

cylinder with clutch fluid or alcohol.

CAUTION

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

Apply clutch fluid to the parts removed and to the i nner

•

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

•

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

•

groove.
The push rod round end must be faced inwards.

○

Torque - Clutch Lever Pivot Bolt: 1 .0 N·m (0.10 kgf·m, 8.9

in·lb)

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

kgf·m, 52 in·lb)

Install the clutch master cylinder (see Clutch chapter).

•

2-22 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Clutch Slave Cylinder Piston Seal Replacement

Remove the alternator outer cover (see Electrical System

•

chapter)
Loosen the banjo bolt [A] at the clutch pipe lower end, and

•

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

•

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

•

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

•

CAUTION

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

NOTE

If the clutch slave cylinder is removed and left alone, the

○

piston will be pushed out by spring force.

Remove the spring and piston seal.

•

CAUTION

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

Before assembly, apply clutch fluid to the outside of the

•

piston and the piston seal.
Install the piston seal as shown.

•

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

Engine Lubrication System

Engine Oil Change

Situate the motorcycle so that it is vertical after warming

•

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

•

Periodic Ma intenance Proce dures

Remove:

•

Oil Screen Plug [A]

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

•

[C].
Clean the oil screen with a high-flash point solvent and

•

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

•

changed.

WARNING

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

PERIODIC M AINTENANCE 2-23

NOTE

While cleaning the screen, check for any metal particles

○

that might indicate internal engine damage.

Check the screen carefully for any damage of holes, bro-

•

ken wires, and so on.
If the screen is damaged, replace it.
Be sure to put in the oil screen with the rubber gasket end

•

inside.
Replace the screen plug O-ring with new one.

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

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

○

(see Oil Filter Change in this section).
Replace the drain plug gasket with a new one if it is dam­aged.

Torque - Engine Oil Drain Plug , Oil Screen Plug: 20 N·m

(2.0 kgf·m, 15 ft·lb)

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

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

•

and pour in the specified type and amount of oil.

Clutch Cover [C]

Special Tool - Driver-Filler Cap: 57001–1454

Torque - Oil Filler Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb)

2-24 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Engine Oil

Typ e:

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.

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change in this sec-

•

tion).
Remove the oil filter [A] with the oil filter wrench [B] and

•

discard the oil filter.

Special Tool - Oil Filter Wrench: 57001-1249

API SE, SF or SG class

API SH or SJ class with JASO MA

SAE 10W-40

2.9 L (3.1 US qt, when filter is not removed)

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

3.5 L (3.7 US qt, when engine is completely

disassembled and dry)

NOTE

NOTE

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

○

removed.

Replace the oil filter with the new one.

•

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

•

Tighten the filter with the oil filter wrench.

•

Pour in the specified type and amount of oil.

•

Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

Wheels/Tires

Tire Inspection

As the tire tread wears down, the tire becomes more sus­ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.

Remove any imbedded stones or other foreign particles

•

from the tread.

Visually inspect the tire for cracks and cuts, replacing the

•

tire in case of damage. Swelling or high spots indicate

internal damage, requiring tire replacement.

Periodic Ma intenance Proce dures

Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Wheels/Tires chapter).

Tread Depth

Front:

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

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

Rear:

Standard: 6.9 mm (0.27 in.)
Service Limit: 2 mm (0.08 in.):

Up to 130 km/h (80 mph)

3mm(0.1in.):

Over to 130 km/h (80 mph)

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 m ore than a mile during the past 3
hours.)
Adjust the tire air pressure according to the specifications
if necessary.

PERIODIC M AINTENANCE 2-25

Air Pressure (when cold)

Front

Rear

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

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

WARNING

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

NOTE

Most countries may have their own regulations requiring

○

a minimum tire tread depth; be sure to follow them.
Check and balance the wheel when a tire is replaced

○

with a new one (see Wheels/Tires chapter).

Final Drive

Oil Level Inspection

WARNING

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

Support the motorcycle perpendicular to the ground.

•

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

•

Special Tool - Driver-Filler Cap: 57001–1454

2-26 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

The oil level [A] should com e to the bottom of the filler

•

opening.

If it is low, first check the final gear case for oil leakage,

remedy it if necessary, and add oil through the filler open-

ing. Use the same type and brand of oil that is already in

the final gear case.

Install the filler plug.

•

Oil Change

Warm up the oil by running the m otorcycle so that the

•

oil will pick up any sediment and drain easily. Stop the

motorcycle and turn the ignition switch OFF.

Place an oil pan beneath the final gear case, and remove

•

the filler cap and drain plug [A].

WARNING

When draining or filling the final gear case, be care-

ful that no oil gets on the tire, spoke, or rim. Clean

off any oil that inadvertently gets on them with a

high-flash point solvent.

After the oil has completely drained out, install the drain

•

plug with a new gasket.

Torque - Final Gear Case Drain Plug: 8.8 N·m (0.90 kgf·m,

78 in·lb)

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

•

Final Gear Case Oil:

Amount: 200 mL (6.76 US oz)

Grade: API GL-5 hypoid gear oil

Viscosity: When above 5°C (41°F) SAE 90

When below 5°C (41°F) SAE 80

NOTE

The term “GL-5” indicates a quality and additive rating.

○

A “GL-6” rated hypoid gear oil can also be used.

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

•

Periodic Ma intenance Proce dures

Brakes

Brake Pad Wear Inspection

Unscrew the bolts [A] and remove the pad spring [B]

•

(Front Brake Caliper)

Unscrew the bolts [A] and remove the caliper [B] (Rear

•

Brake Caliper).

PERIODIC M AINTENANCE 2-27

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

•

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

Pad Lining Thickness

Standard:

Front:
Rear:

Service Limit: 1 mm (0.04 in.)

Install the pad spring or caliper.

•

Tighten the bolts.

•

Torque - Front Brake Pad Spring Bolts: 2.9 N·m (0.30 kgf·m,

26 in·lb)

Rear C aliper Mounting Bolts: 34 N·m (3.5 kgf·m,

25 ft·lb)

Brake Hose and Connection Inspection

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage.
Thehighpressureinsidethebrakelinecancausefluidto

○

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

4.0 mm (0.157 in.)

7.5 mm (0.295 in.)

2-28 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Brake Fluid Level Inspection

Check that the brake fluid level in the front brake reservoir

•

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

NOTE

Hold the reservoir horizontal by turning the handlebar

○

when checking brake fluid level.

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

reservoir to the upper level line [A] in the reservoir [B].

Check that the brake fluid level in the rear brake reservoir

•

[A] is between the upper [B] and the lower [C] level lines.

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

reservoir to the upper level line.

Use extra heavy-duty brake fluid only from a container

○

marked DOT4.

Brake fluid of DOT4 is installed in t he brake system when

○

shipped.

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

kgf·m, 13 in·lb)

WARNING

Do not mix two brands of fluid. Change the brake

fluid in the brake line completely if the brake fluid

must be refilled but the type and brand of the brake

fluid that is already in the reservoir are unidentified.

After changing the fluid, use only the same type and

brand of fluid thereafter.

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 the resistance is f elt 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 Ma intenance Proce dures

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

•

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

•

front caliper [B].
Attach a clear plastic hose [C] to the bleed valve, and run

•

the other end of the hose into a container.
Fill the reservoir with new brake fluid.

•

Temporarily install the reservoir cap.

•

Change the brake fluid as follows:

•

NOTE

The fluid 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 M AINTENANCE 2-29

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.

2-30 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

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 the resistance is f elt 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 Brakes

chapter).

Brake Master Cylinder Cup and Dust Seal Replacement

Refer to the Master Cylinder section in the Brakes chapter

•

for Brake/Master Cylinder Cup and Dust Seal Replace-

ment.

Caliper Piston/Dust Seals Replacement

Refer to the Calipers section in the Brakes chapter for

•

Caliper Piston/Dust Seals Replacement.

Front Brake Light Switch Inspection

Turn on the ignition switch.

•

The brake light should go on when the front brake lever

•

is applied.

If it does not, replace the switch.

Rear Brake Light Switch C heck/Adjustment

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by de-

•

pressing the brake pedal [A]. The brake light should go

on after about 10 mm (0.39 in.) of the pedal travel [B].

Periodic Ma intenance Proce dures

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

•

adjust the switch.

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

CAUTION

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

Suspension

Front Fork Oil Leak Inspection

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

•

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

PERIODIC M AINTENANCE 2-31

Rear Shock Absorber Oil Leak Inspection

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

•

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

Swingarm Pivot Lubrication

Remove the swingarm (see Suspension chapter).

•

Clean the old grease out of the bearings.

•

Apply grease to the inner surface of the needle bearings

•

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

•

seals.
Install the swingarm (see Suspension chapter).

•

2-32 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Steering

Stem Bearing Lubrication

Remove the steering stem. (see Steering chapter).

•

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

•

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

the upper and lower outer races, which are press-fitted

into the frame head pipe, clean of grease and dirt.

Visually check the outer races and the rollers.

•

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

replace both races and all the roller bearings as a set (see

Steering chapter).

Pack the upper and lower tapered roller bearings in the

•

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

upper and lower outer races.

Install the steering stem, and adjust the steering (see

•

Steering chapter).

Steering Check

Check steering as follows.

•

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

○

pipe ribs [C], and a commercially available jack [D] under

the engine [E] to lift the front wheel [F] off the ground.

Special Tools - Jack: 57001-1238

Attachment Jack: 57001-1398

With the front wheel pointing straight ahead, alternately

○

tap each end of the handlebar. The front wheel should

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

fork hits the stop.

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

is too tight.

Feel for steering looseness by pushing and pulling [A] the

○

fork.

If you feel looseness, the steering is too loose.

NOTE

The cables and wiring will have some effect on the 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 Adjustment

Adjust the steering, if necessary.

Loosen the upper fork clamp bolt [A] on both side and

•

unscrew the stem head nut [B].

Remove the O-ring (see Steering chapter).

•

Remove the steering stem head [C] together w ith the han-

•

dlebar installed.

Periodic Ma intenance Proce dures

Remove the claw washer.

•

Tighten the stem nut [A] firmly with the stem nut wrench

•

[B], and loosen it.
Tighten the stem nut again with the specified torque.

•

Special Tool - Steering Stem Nut Wrench: 57001-1100

Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)

Install the stem head.

•

Tighten the following in the order listed.

•

Torque - Stem Head Nut: 88 N·m (9.0 kgf·m, 65 ft·lb)

Upper Fork Clamp Bolts: 29 N·m (3.0 kgf·m, 21

in·lb)

Run the throttle cables, brake hose, and clutch hose in

○

accordance with the Cable, Wire, and Hose Routing sec­tion in the Appendix chapter.
Check and adjust the steering and throttle cables after

•

installation.

WARNING

PERIODIC M AINTENANCE 2-33

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

Electrical System

Spark Plug Cleaning/Inspection

Clean the spark plug, preferably in a sandblasting device,

•

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

•

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

•

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

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

General Lubrication

Lubrication

Before lubricating each part, clean off any rusty spots with

•

rust remover and wipe off any grease, oil, dirt, or grime.
Lubricate the points listed below w ith 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 Motor Oil.

Rear Brake Rod Joint

2-34 PERIODIC MA INTENANCE

Periodic Maintenance Procedures

Points: Lubricate with G rease.

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

Cable: Lubricate with Cable Lubricant.

Choke 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 [A] with an aerosol ca-

ble lubricant [B].

With the cable disconnected at both ends, the cable

•

should m ove 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.

Nut, Bolt, and Fastener Tightness

Tightness Inspection

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

•

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

condition.

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the spec-

ified 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 in this chapter. For each

fastener, first loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Periodic Ma intenance Proce dures

Nut, Bolt and Fastener to be checked

Wheels:

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

Final Drive:

Final Gear Case Mounting Nuts

Brakes:

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

Suspension:

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

Steering:

Stem Head Nut
Handlebar Nuts

PERIODIC M AINTENANCE 2-35

Engine:

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

Others:

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

Fuel System (DFI)

Table of Contents

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

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

DFI System ........................................ 3-12

DFI Wiring Diagram ........................... 3-14

Specifications .................................... 3-17

Special Tools and Sealant ................. 3-19

DFI Servicing Precautions ................. 3-20

Troubleshooting the D FI System ....... 3-23

Outline ............................................ 3-23

Inquiries to Rider............................. 3-27

DFI System Troubleshooting Guide .. 3-30

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

Self-diagnosis Conducting ........... 3-39

Service Code Reading ................. 3-41

Service Code Erasing .................. 3-41

Throttle Sensor (Service Code 11) .... 3-45

Throttle Sensor

Removal/Adjustment................. 3-45

Input Voltage Inspection............... 3-45

Output Voltage Inspection............ 3-45

Resistance Inspection.................. 3-46

Inlet Air Pressure S ensor (Service

Code 12) ......................................... 3-48

Removal ....................................... 3-48

Installation.................................... 3-48

Input Voltage Inspection............... 3-48

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

Inlet Air Temperature Sensor (Service

Code 13) ......................................... 3-53

Removal/Installation..................... 3-53

Output Voltage Inspection............ 3-53

Sensor Resistance Inspection ..... 3-54

Water Temperature Sensor (Service

Code 14) ......................................... 3-55

Removal/Installation..................... 3-55

Output Voltage Inspection............ 3-55

Sensor Resistance Inspection ..... 3-56

Atmospheric Pressure Sensor

(Service Code 15)........................... 3-57

Removal ....................................... 3-57

Installation.................................... 3-57

Input Voltage Inspection............... 3-57

Output Voltage Inspection............ 3-58

Crankshaft Sensors (#1, #2: Service

Code 21, 22)................................... 3-61

FUEL SYSTEM (DFI) 3-1

3

Crankshaft Sensor

Removal/Installation.................. 3-61

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

Vehicle-down Sensor (Service Code

31)................................................... 3-62

Removal....................................... 3-62

Installation .................................... 3-62

Inspection..................................... 3-62

Fuel Injectors (#1, #2: Service Code

41, 42)............................................. 3-65

Injector Removal.......................... 3-65

Injector Installation....................... 3-66

Audible Inspection........................ 3-69

Power Source Voltage Inspection 3-69

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

Injector Signal Test....................... 3-71

Injector Resistance Inspection ..... 3-71

Injector Unit Test .......................... 3-72

Fuel Pump (Service Code 45) ........... 3-73

Fuel Pump Removal .................... 3-73

Pump Screen, Fuel Filter

Cleaning.................................... 3-73

Fuel Pump Installation ................. 3-74

Operation Inspection.................... 3-75

Power Source Voltage Inspection 3-75

Operating Voltage Inspection....... 3-76

Ignition C oils (#1, #2: Service Code

51, 52)............................................. 3-78

Removal/In stallation..................... 3-78

Input Voltage Inspection............... 3-78

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

LED Light Inspection.................... 3-80

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

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

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

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

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

DFI Power Source ............................. 3-83

DFI Fuse Removal....................... 3-83

DFI Fuse Inspection..................... 3-83

DFI Main Relay Removal ............. 3-83

DFI Main Relay Inspection........... 3-83

ISC Valves......................................... 3-85

Removal/In stallation..................... 3-85

Power Source Voltage Inspection 3-85

Output Voltage Inspection............ 3-86

3-2 FUEL SYSTEM (DFI)

Resistance Inspection.................. 3-86

Fuel Line............................................ 3-88

Fuel Pressure Inspection ............. 3-88

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

Fuel Flow Rate Inspection ........... 3-90

Throttle Grip and Cables ................... 3-92

Throttle Grip Free Play Inspection 3-92
Throttle Grip Free Play

Adjustment ................................ 3-92

Choke Knob Operation ................ 3-92

Choke Cable Free Play

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

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

Cable Lubrication and Inspection. 3-92

Throttle Body Assy ............................ 3-93

Idle Speed Check......................... 3-93

Idle Speed Adjustment................. 3-93

High Altitude Performance

Adjustment ................................ 3-93

Throttle Body Assy Removal........ 3-93

Throttle Body Assy Installation..... 3-96

Throttle Body A ssy

Disassembly/Assembly ............. 3-97

Air Cleaner......................................... 3-100

Air Cleaner Element Removal...... 3-100

Air Cleaner Element Cleaning...... 3-100

Left Air Cleaner Housing

Removal/Installation.................. 3-100

Right Air Cleaner Housing

Removal .................................... 3-101

Right Air Cleaner Housing

Installation................................. 3-101

Lower Air Cleaner Duct

Removal/Installation.................. 3-102

Fuel Tank ........................................... 3-103

Fuel Tank Removal ...................... 3-103

Fuel Tank Installation ................... 3-106

Fuel Tank and Cap Inspection ..... 3-107

Fuel Tank C leaning ...................... 3-108

Return Fuel Check Valve

Inspection.................................. 3-108

Evaporative Emission Control

System............................................ 3-109

Parts Removal/Installation ........... 3-109

Canister Installation ..................... 3-109

Canister Inspection (Periodic

Inspection)................................. 3-109

Separator Inspection (Periodic

Inspection)................................. 3-109

Hose Inspection (Periodic

Inspection)................................. 3-110

Separator Operation Test............. 3-110

3-4 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

1 Water temperature sensor 18 1.8 13 SS

2 Left air cleaner cover Allen bolt 16 1.6 12

3 Left air cleaner base bolts 11 1.1 97 in·lb

4 Left air cleaner base screws 2.2 0.22 19 in·lb L

5 Right air cleaner base screws 2.2 0.22 19 in·lb L

6 Right air cleaner base bolt 11 1.1 97 in·lb

7 Right air cleaner Allen bolts 11 1.1 97 in·lb

8 Right air cleaner cover Allen bolt 16 1.6 12

9 Throttle body assy holder bolts 11 1.1 97 in·lb

10

Spark plug lead holder bolts

11 Air cleaner duct holder bolts 9.8 1.0 69 in·lb

12. Air switching valve

13. Air cleaner element

14. Left air cleaner base

15. Air cleaner duct holder

16. Crankcase breather hose

17. Air cleaner drain hose

18. Right air cleaner base

19. Right spark plug lead holder

20. Throttle body assy

CAL: California Model

L: Apply a non-permanent locking agent.

SS: Apply silicone sealant (Kawasaki Bond: 56019–120).

N·m kgf·m ft·lb

11 1.1 97 in·lb

Torque

Remarks

3-6 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

N·m kgf·m ft·lb

1 Fuel pump bolts 6.9 0.70 61 in·lb S, L

2 Inlet air temperature sensor nut 7.8 0.80 69 in·lb

3 ISC pipe bolts 11 1.1 97 in·lb

4 Throttle body assy holder bolts 11 1.1 97 in·lb

5 Spark plug lead holder bolts 11 1.1 97 in·lb

6 Choke cable plate screw 2.9 0.30 26 in·lb L

7 Inlet manifold bolt 12 1.2 106 in·lb

8 High pressure fuel hose clamp screws 1.5 0.15 13 in·lb

9 Delivery joint screws 3.4 0.35 30 in·lb

10 Pressure regulator screws 4.9 0.50 43 in·lb

11 Throttle body flange bolts 4.9 0.50 43 in·lb

12 Return fuel check valve 20 2.0 15

13. Vehicle-down sensor

14. Atmospheric pressure sensor

15. Inlet air pressure sensor

16. Choke cable

17. Throttle cable (accelerator)

18. Throttle cable (decelerator)

19. ECU (Electronic control unit)

20. DFI main relay

21. Battery case

22. ISC valve #1 (for Front cylinder)

23. ISC valve #2 (for Rear cylinder)

24. Right air cleaner base

25. Inlet air temperature sensor

26. Throttle body

27. Inlet manifold

28. Seal

29. Injector #1 for front cylinder

30. Injector #2 for rear cylinder

31. O-ring

32. Delivery joint

33. Pressure regulator

34. Pressure regulator screen

35. Seal ring

36. Throttle sensor

37. Throttle body assy holder

38. Right spark plug lead holder

39. To inlet air pressure sensor

40. Throttle body assy

41. Fuel filter

42. Fuel pump

43. Fuel pump screen

44. United States of America and Canadian models

CL: Apply cable lubricant.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

Torque

Remarks

3-8 FUEL SYSTEM (DFI)

DFI Par ts Location

DFI Parts Location

DFI: DFI parts (this chapter)

F: Front

1. Atmospheric pressure sensor (DFI)

2. Water temperature sensor (DFI)

3. Ignition coils

4. Ignition switch

5. Starter motor

6. Water temperature switch

7. Regulator/rectifier

8. Crankshaft sensors

9. Alternator

10. Sidestand switch

11. Neutral switch

12. Oil pressure switch

13. Fuel pump (DFI)

14. Vehicle-down sensor (DFI)

15. ECU (DFI)

16. DFI fuse 15 A

17. Sealed battery

18. Junction box

19. Starter relay

20. Turn signal control unit

21. DFI main relay

22. Oil pressure light delay unit

23. ISC valve #1 (DFI, for front cylinder)

24. ISC valve #2 (DFI, for rear cylinder)

25. Inlet air temperature sensor (DFI)

26. Injectors (DFI)

27. Inlet air pressure sensor (DFI)

28. FI indicator LED light (DFI) of tachometer unit

29. Throttle sensor (DFI)

30. Radiator fan

31. Radiator fan switch

32. Fuel filter (DFI)

33. Fuel reserve switch

34. Delivery joint (DFI)

35. Pressure regulator (DFI)

FUEL SYSTEM (DFI) 3-9

3-10 FUEL SYSTEM (DFI)

DFI Par ts Location

DFI Parts Location

DFI: DFI Parts (this chapter)

F: Front

1. Atmospheric pressure sensor (DFI)

2. Water temperature sensor (DFI)

3. Ignition coils

4. Ignition switch

5. Starter motor

6. Water temperature switch

7. Regulator/rectifier

8. Crankshaft sensors

9. Alternator

10. Sidestand switch

11. Neutral switch

12. Oil pressure switch

13. Fuel pump (DFI)

14. Vehicle-down sensor (DFI)

15. ECU (DFI)

16. DFI fuse 15 A

17. Sealed battery

18. Junction box

19. Starter relay

20. Turn signal control unit

21. DFI main relay

22. Oil pressure light delay unit

23. ISC valve #1 (DFI, for front cylinder)

24. ISC valve #2 (DFI, for rear cylinder)

25. Inlet air temperature sensor (DFI)

26. Injectors (DFI)

27. Inlet air pressure sensor (DFI)

28. FI indicator LED light (DFI) of tachometer unit

29. Throttle sensor (DFI)

30. Radiator fan

31. Radiator fan switch

32. Fuel filter (DFI)

33. Fuel reserve switch

34. Delivery joint (DFI)

35. Pressure regulator (DFI)

FUEL SYSTEM (DFI) 3-11

3-12 FUEL SYSTEM (DFI)

DFI System

DFI System

#1: For front cylinder
#2: For rear cylinder

1. ECU (electronic control unit)

2. Crankshaft sensor #1

3. Crankshaft sensor #2

4. Pressure regulator

5. Throttle sensor (front view)

6. Atmospheric pressure sensor

7. Inlet air pressure sensor

8. Water temperature sensor

9. Inlet air temperature sensor

10. FI indicator LED light

11. Fuel filter

12. Delivery joint

13. Injector #1

14. Injector #2

15. Fuel pump

16. ISC valve #1 (idle speed control valve #1, front side)

17. ISC valve #2 (idle speed control valve #2, rear side)

18. Vehicle-down sensor (rear view)

19. Fuel tank (left view)

20. Alternator rotor (left view)

21. Sealed battery (left view)

22. Left air cleaner housing (rear view)

23. Right air cleaner housing (rear view)

24. Lower air cleaner duct (rear view)

25. Thermostat housing (left view)

26. Throttle valves

27. Fuel flow

28. Air flow

29. Speed sensor

30. Fuel hose joint #1

31. Fuel hose joint #2

32. Fuel hose plate clamp

33. Fuel reserve switch

34. Return fuel check valve

35. Residual pressure check valve

36. Air switching valve

FUEL SYSTEM (DFI) 3-13

3-14 FUEL SYSTEM (DFI)

DFI Wiring Diagram

FUEL SYSTEM (DFI) 3-15

DFI Wiring Diagram

DFI and Electrical Parts

DFI: DFI parts
A. ECU: electronic control unit (DFI)
B. Engine stop switch
C. Starter button
D. Ignition coils
E. Crankshaft sensors
F. Junction box
G. Starter circuit relay
H. Interlock diodes
J. Diode: (for water temperature warning LED light)
K. Diode: (for fuel reserve warning light)
L. FI indicator LED light: (DFI)
M. S peedometer
N. Ignition switch
O. S tarter relay
P. M ai n fu s e 3 0 A
Q. Sealed battery
R. Fuel injector #1: (DFI)
S. Fuel injector #2: (DFI)
T. Fuel reserve switch
U. Fuel pump: (DFI)
V. DFI fuse 15 A: (for ECU, injectors, fuel pump, DFI main relay, and ISC valves)
W. ISC valve #2: (DFI)
X. ISC valve #1: (DFI)
Y. Inlet air temperature sensor: (DFI)
z. Water temperature sensor: (DFI)
a. Inlet air pressure sensor: (DFI)
b. Atmospheric pressure sensor: (DFI)
c. Throttle sensor: (DFI)
d. Vehicle-down sensor: (DFI)
e. DFI main relay: (for ECU, injectors, fuel pump, and ISC valves)
f. Ignition fuse 10 A
g. Speed sensor
h. Self-diagnosis check female connector
i. Tachometer
j. Fuel reserve warning light
k. Air switching valve
l. EC U connector
m. Connector lock

3-16 FUEL SYSTEM (DFI)

DFI Wiring Diagram

Terminal Numbers of ECU Connectors

Terminal Names

#1: Front cylinder, #2: Rear Cylinder

1. Starter lockout switch signal

2. Interlock circuit signal

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

4. Tachometer signal

5. Electric starter button signal

6. Anti theft signal

7. Water temperature sensor (+)

8. Power source for diagnosis tool

9. —

10. ECU power source circuit ground to battery (–) terminal

11. Ground of inlet air temperature, water temperature, inlet air pressure, atmospheric pressure, and throttle
sensors

12. Neutral switch

13. DFI main relay solenoid ground in ECU

14. Crankshaft sensor #2 signal

15. Crankshaft sensor #1 signal

16. Com. line A

17. FI indicator LED light signal

18.ISCvalve#2signal

19. —

20. Ignition control circuit ground to battery (–) terminal

21. Engine stop signal

22. 23. —

24. Vehicle-down sensor signal

25. Meter bulb burned-out check signal

26. Throttle sensor signal

27. Speed sensor signal

28. Atmospheric pressure sensor signal

29. Inlet air pressure sensor signal

30. Power supply to ECU, ISC valves, injectors, and fuel pump, vehicle-down sensor

31. Inlet air temperature sensor (+)

32. ECU power source circuit ground to battery (–) terminal (the same as #10)

33. Power source ground for diagnosis tool

34. —

35. Power supply to sensors (inlet air pressure, atmospheric pressure, and throttle sensors) from ECU

36. Com. line B

37. Fuel pump signal

38. Air switching valve signal

39. Injector #2 signal

40. Injector #1 signal

41.ISCvalve#1signal

42. Ignition control circuit ground to battery (–) terminal

43. Ignition coil #2 signal

44. Ignition coil #1 signal

FUEL SYSTEM (DFI) 3-17

Specifications

Item Standard

Throttle Grip Free Play: 2 ∼ 3 mm (0.079 ∼ 0.118 in.)

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

Make: Mitsubishi Electric
Idle speed: 950 ±50 r/min (rpm)
Throttle assy:

Type × bore Two barrel type × 40 mm (1.57 in.)

ECU (electronic control unit):

Type Digital memory type, with built in

IC igniter, sealed with resin

Usable engine speed 100 ∼ 6 300 r/min (rpm)

ISC valves: (Idle speed control valve, or fast Idle

solenoid valve)

Maximum air flow rate 75 ±7 L/min

Solenoid resistance 13.6 ∼ 20.4 Ω

Fuel Filter:

Filtration area More than 200 cm²
Rated flow 1.0 L/min

Fuel pressure (high pressure line):

Right after Ignition SW ON 310 kPa (3.2 kgf/cm², 46 psi)

with fuel pump running

After pump runs 3 sec. and stops. 280 kPa (2.9 kgf/cm², 41 psi)

with fuel pump stopped

With engine idling 260 kPa (2.7 kgf/cm², 38 psi)

with fuel pump running

With engine running at full throttle 260 ∼ 280 kPa (2.7 ∼ 2.9 kgf/cm²,

38 ∼ 41 psi) with fuel pump running

Pressure regulator:

Regulated fuel pressure 294 ±4.9 kPa (3.00 ±0.05 kgf/cm²,

43 ±0.73 psi)

Throttle sensor: Non-adjustable, and non-removable

Input voltage

Output voltage at idle throttle opening 0.584 ∼ 0.604 V DC between Y/W

Output voltage at full throttle opening 4.29 ∼ 4.59 V DC between Y/W

Resistance 4 ∼ 6kΩ between BL/W and BR/BK leads

Atmospheric pressure sensor
or inlet air pressure sensor:

Input voltage 4.75 ∼ 5.25 V DC
Output voltage 3.74 ∼ 4.26 V DC at standard

Inlet Air temperature sensor:

Resistance 5.4 ∼ 6.6 kΩ at 0° C (32° F)

4.75 ∼ 5.25 V DC between BL/W

and BR/BK leads

and BR/BK leads

and BR/BK leads

atmospheric pressure

2.26 ∼ 2.86 kΩ at 20° C (68° F)

0.29 ∼ 0.39 kΩ at 80° C (176° F)

3-18 FUEL SYSTEM (DFI)

Specifications

Item Standard

Water temperature sensor:

Resistance 2.162 ∼ 3.112 kΩ at 20° C (68° F)

0.785 ∼ 1.049 kΩ at 50° C (122° F)

0.207 ∼ 0.253 kΩ at 100° C (212° F)

Vehicle-down sensor:

Detection method
Detection angle More than 45° ±5° for each bank

Detection time Within 0.5 ∼ 1.0 sec.

Fuel injectors:

Type INP– 786
Injection timing

Static injection quantity 273.1 ∼ 289.4 mL/min

Nozzle type × diameter Two s pray type with 4 holes × 0.3 mm (0.012 in.)

Resistance 14.2 ∼ 14.8 Ω

Fuel pump:

Type

Discharge

Magnetic flux detection method

60° BTDC at each cylinder

In-tank pump (friction pump) 75 mL or more

for 3 seconds

(90 L or more/h)

with the filter installed at 12 V
atmospheric pressure

Special Tools and Sealant

FUEL SYSTEM (DFI) 3-19

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

Fork Oil Level Gauge :
570101–1290

Hand Tester :
57001–1394

Filler Cap Driver :
57001–1454

Needle Adapter Set :
57001–1457

Kawasaki Bond (Silicone Sealant) :
56019–120

Fuel Pressure Gauge Adapter :
57001–1417

3-20 FUEL SYSTEM (DFI)

DFI Servicing Precautions

There are a number of important precautions that should

be followed servicing the DFI system.

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

○

be no inlet air leaks in the DFI system. Be sure to install
the oil filler cap [A] after filling the engine oil, using the
driver-filler cap [B].

Clutch Cover [C]
Front [D]

Special Tool - Driver-Filler Cap: 57001–1454

Torque - Oil Filler Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb)

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

○

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

○

damage the ECU.
Do not disconnect the battery leads or any other electrical

○

connections when the ignition SW (switch) is on, or while
the engine is running. Otherwise, surge damages the
connector terminals or the DFI parts.
Take care not to short the leads that are directly con-

○

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

○

This is to prevent ECU damage by excessive voltage.
Whenever the DFI electrical connections are to be discon-

○

nected, first turn off the ignition SW (switch), and discon­nect the battery (−) terminal. Do not pull the lead, only the
connector. Conversely, make sure that all the DFI elec­trical connections are firmly reconnected before starting
the engine.

Connect these connectors until they click [A].

○

Do not turn the ignition SW ON while any of the DFI elec-

○

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

○

nectors, leads, and wiring. Never water a vehicle with
connectors unplugged because seals don’t work and ter­minals could corrode.
If a transceiver is installed on the motorcycle, make sure

○

that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.

DFI Servicing Precautions

To prevent corrosion and deposits n the fuel system, do

○

not add any fuel antifreeze chemicals to fuel.
When any fuel hose is disconnected, do not turn on the

○

ignition SW. O therwise, the fuel pum p will operate and
fuel will spout from the fuel hose.
Do not operate the fuel pump if the pump is completely

○

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

○

faces of these parts clean with compressed air.
When any fuel hose is disconnected, fuel may spout out

○

by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.

The fuel hoses are designed to be used throughout the

○

motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the high pressure in­side the fuel line can cause fuel to leak [A] or the hose to
burst.
Replace the fuel hose if any cracks [B] or bulges [C] are
noticed.
Route the hoses according to Cable, Wire, and Hose

○

Routing section in the Appendix chapter.
When installing the fuel hoses, avoid sharp bending, kink-

○

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

FUEL SYSTEM (DFI) 3-21

Install the high pressure fuel hose clamps in the posi-

○

tion shown, and securely tighten the clamp screws to the
specified torque. Check the fuel system for leaks after
hose installation.

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

18 ∼ 22 mm [D]
2 ∼ 3mm[E]

Torque - High Pressure Fuel Hose Clamp Screws: 1.5 N·m

(0.15 kgf·m, 13 in·lb)

Fit the low pressure fuel hose [A] onto the pipe fully and

○

install the plate clamp [B] beyond the raised rib [C].

1 ∼ 2mm[D]

3-22 FUEL SYSTEM (DFI)

DFI Servicing Precautions

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

○

joint clicks [B].

Front [C]

Push and pull [A] the hose joint #1 or #2 [B] back and

○

forth more than two times and make sure it is locked and
doesn’t come off. When the hose joint is correctly in­stalled, it should slide on the delivery pipe about 5 mm
(0.2 in.).

Troubleshooting the DFI System

Outline

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

When due to a malfunction, the FI indicator LED light re­mains lit, ask the rider about the conditions [B] under which
the problem occurred and try to determine the cause [C].
Don’t rely solely on the DFI self-diagnosis function, use
common sense; first conduct a pre-diagnosis inspection,
check the E CU for ground and power supply, the fuel line for
no fuel leaks, and for correct pressure. The pre-diagnosis
items are not indicated by the FI indicator LED light.

FUEL SYSTEM (DFI) 3-23

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

When the FI indicator LED light goes on and the m otor­cycle is brought in for repair, check the service codes.

When the repair has been done, the LED light goes OFF
in 4 seconds and will not show the service code any more.

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

3-24 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

There are two ways t o inspect the DFI system. One is

○

Voltage Check Method and the other is Resistance Check
Method.

Voltage Check Method

This method is conducted by measuring the input voltage

○

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

○

Refer to each Sensor Inspection section for detail in this

○

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

•

can be read two decimal places voltage or resistance.

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

○

ECU (except for ISC valves).
Join the connector [A] and insert the needle adapter (spe-

•

cial tool) [C] inside the seal [B] from behind the connector
until the adapter reaches the terminal.

Special Tool - Needle Adapter Set: 57001–1457

CAUTION

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

Make sure that measuring points are correct in t he con-

•

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

•

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

•

the connector joined.

CAUTION

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

Troubleshooting the DFI System

After measurement, remove the needle adapters and ap-

○

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

for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of Connectors

Always check battery condition before replacing the DFI

•

parts. A fully charged battery is a must for conducting

accurate tests of the DFI system.

Resistance Check Method

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

○

and the needle adapter. Just do the following especially

when a sensor [A] is suspect.

Turn the ignition SW OFF and disconnect the connectors.

•

Inspect the sensor resistance, using a digital meter (see

•

each Sensor Inspection in this chapter).

Inspect the wiring and connections [B] for continuity, using

•

the hand tester [C] (special tool, analog tester) rather than

a digital meter.

Special Tool - Hand Tester: 57001–1394

If the sensor, the wiring and connections are good, in-

spect the ECU for its ground and power supply (see this

chapter). If the ground and power supply are good, the

ECU is suspect. Replace the ECU.

FUEL SYSTEM (DFI) 3-25

Trouble may involve one or in some cases all items.

•

Never replace a defective part without determining what

CAUSED the problem. If the problem was caused by

some other item or items, they too must be repaired or

replaced, or the new replacement part will soon fail again.

Measure coil winding resistance when the DFI part is cold

•

(at room temperature).

Make sure all connectors in the circuit are clean and tight,

•

and examine wires for signs of burning, fraying, short,

etc. Deteriorated wires and bad connections can cause

reappearance of problems and unstable operation of the

DFI system.

3-26 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

If any wiring is deteriorated, replace the wiring.
Pull each connector [A] apart and inspect it for corrosion,

•

dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect the connectors securely.
Check the wiring for continuity.

•

Use the wiring diagram to find the ends of the lead w hich

○

is suspected of being a problem.
Connect the hand tester between the ends of the leads.

○

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

○

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

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

○

the one end [C], using an auxiliary wire [D] and check
the continuity between the end [E] and the ground [F].
This enables to check a long harness for continuity. If the
harness i s open, repair or replace the harness.

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

○

end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or re­placed.

Narrow down suspicious locations by repeating the con-

•

tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.
The following diagnosis flow chart illustrates the above

○

procedures.

Wire Color Codes:

○

BK: Black

BL: Blue
BR: Brown LB: Light blue R: Red
CH: Chocolate LG: Light green

DG: Dark green O: Orange

G: Green

GY: Gray

P: Pink

PU: Purple

W: White

Y: Yellow

Troubleshooting the DFI System

DFI Diagnosis Flow Chart

FUEL SYSTEM (DFI) 3-27

Inquiries to Rider

Refer to the next sample diagnosis chart.

•

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

○

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

○

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

○

is a DFI system problem, or a general engine problem.

3-28 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Sample Diagnosis Sheet

Rider name: Year of initial registration:
Registration No. (license plate No.): Frame No.:
Model: Engine No.: Mileage:
Date problem occurred:

Environment when problem occurred.

Weather □fine, □cloudy, □rain, □snow, □always, □other:
Temperature □hot, □warm, □cold, □very cold, □always

Problem

frequency

Road □street, □highway, □mountain road (□uphill, □downhill), □bumpy, □pebble
Altitude □normal, □high (about 1 000 m or more)

FI indicator

LED light

□chronic, □often, □once

Motorcycle conditions when problem occurred.

□light up immediately after ignition SW ON, and goes off after engine oil

pressure is high enough (with engine running) (normal).

□lights up immediately after ignition SW ON, and stays on after engine oil

pressure is high enough (with engine running) (DFI problem)

□lights up immediately after ignition SW ON, but goes off after about 10 seconds

though engine oil pressure is high enough (with engine running) (DFI problem).

□unlights (LED light, ECU or its wiring fault).
□sometimes lights up (probably wiring fault).

Starting □starter motor not rotating.

difficulty □starter motor rotating but engine doesn’t turn over.

□starter motor and engine don’t turn over.
□no fuel flow (□no fuel in tank, □no fuel pump sound).

□engine flooded (do not crank engine with throttle opened, which promotes

engine flooding).

□no spark.
□choke knob is not pulled fully when using the knob (pull it f ully when using).
□other:

Engine stops □right after starting.

□when opening throttle grip.
□when closing throttle grip.
□when moving off.
□when stopping the motorcycle.
□when cruising.
□other:

Poor running □choke knob left pulled out fully (push it in fully).

at low speed □very low fast idle speed.

□very low idle speed, □very high idle speed, □rough idle speed.
□battery voltage is low (charge the battery).
□spark plug loose (tighten it).
□spark plug dirty, broken, or gap maladjusted ( adjust it).
□backfiring.
□afterfiring.
□hesitation when acceleration.
□engine oil viscosity too high.
□brake dragging.
□engine overheating.
□clutch slipping.
□other:

Troubleshooting the DFI System

FUEL SYSTEM (DFI) 3-29

Poor running

or no power
at high speed

□choke knob left pulled out fully (push it in fully).
□spark plug loose (tighten it).
□spark plug dirty, broken, or gap maladjusted (remedy it).
□spark plug incorrect (replace it).
□knocking (fuel poor quality or incorrect, → use high-octane gasoline).
□brake dragging.
□clutch slipping.
□engine overheating.
□engine oil level too high.
□engine oil viscosity too high.
□other:

3-30 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

NOTE

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant

○

simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and

○

circuits checked out good, be sure to check the ECU for ground and power supply. If the ground
and power supply are checked good, replace the ECU.

Engine Doesn’t Start, Starting Difficulty

Symptoms or Possible Causes Actions (chapter)

Starter motor not rotating:

Ignition and engine stop switches not ON Turn both switches ON.

Starter lockout switch or neutral switch trouble Inspect (see chapter 16).

Starter motor trouble Inspect (see chapter 16).

Battery voltage low Inspect and charge (see chapter 16).

Starter relays not contacting or operating Inspect the starter relay (see chapter 16).

Starter button not contacting Inspect and replace (see chapter 16).

Starter system w iring open or shorted Inspect the wiring (see chapter 16).

Ignition switch trouble Inspect and replace (see chapter 16).

Engine stop switch trouble Inspect and repair or replace (see chapter 16).

Main 30A or ignition fuse blown Inspect and replace (see c hapter 16).

Starter motor rotating but engine doesn’t
turn over:

Starter clutch trouble Inspect (see chapter 9).

Starter idle gear trouble Inspect (see chapter 9).

Engine won’t turn over:

Valve s eizure Inspect and replace (see chapter 5).

Rocker arm seizure Inspect and replace (see chapter 5).

Cylinder, piston seizure Inspect and replace (see chapter 5).

Camshaft seizure Inspect and replace (see chapter 5).

Connecting rod small end seizure Inspect and replace (see chapter 9).

Connecting rod big end seizure Inspect and replace (see chapter 9).

Crankshaft seizure Inspect and replace (see chapter 9).

Transmission gear or bearing seizure Inspect and replace (see chapter 9).

Balancer bearing seizure Inspect and replace (see chapter 9).

No fuel flow:

No or little fuel in tank Supply fuel (see Owner’s Manual).

Fuel pump not rotating Inspect (see chapter 3).

Fuel injector trouble Inspect and replace (see chapter 3).

Fuel tank air vent obstructed Inspect and repair (see chapter 3).

Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).

Fuel pressure regulator clogged Inspect and replace fuel pum p (see chapter 3).

Fuel line clogged Inspect and repair (see chapter 3).

Engine flooded:

Spark plug dirty, broken or gap maladjusted

Starting technique faulty

Clean spark plugs and adjust plug gap (see
chapter 2).

When flooded, don’t crank engine with throttle
fully opened.

FUEL SYSTEM (DFI) 3-31

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

No spark or spark weak:

Ignition and engine stop switches not ON Turn both switches O N.

Clutch lever not pulled in and gear not in neutral

whether sidestand up or not

Though clutch lever pulled in but sidestand up

and gear not in neutral

Vehicle-down sensor coming off Reinstall (see chapter 3).

Vehicle-down sensor trouble Inspect (see chapter 3).

ECU ground or power supply trouble Inspect (see chapter 3).

Battery voltage low Inspect and charge (see chapter 16).

Spark plug dirty, broken or gap maladjusted

Spark plug cap or high tension wiring trouble Inspect the ignition coil (see chapter 16).

Spark plug cap shorted or not in good contact Reinstall or inspect the cap (see chapter 16).

Spark plug incorrect Replace it with the correct plug ( see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Neutral, starter lockout or sidestand switch

trouble

Crankshaft sensor trouble Inspect (see chapter 16).

Ignition coil trouble Inspect (see chapter 16).

Ignition switch shorted Inspect and replace (see chapter 16).

Engine stop switch shorted Inspect and repair or replace (see chapter 16).

Starter system wiring shorted or open Inspect and repair or replace (see chapter 16).

Main 30A or ignition fuse blown Inspect and replace (see chapter 16).

Fuel/air mixture incorrect:

Air cleaner clogged, poorly sealed or missing Clean or reinstall (see chapter 3).

Leak from oil filler cap, crankcase breather hose

or air cleaner drain hose

Water or foreign matter in fuel

Fuel pressure regulator trouble

Throttle sensor trouble Inspect (see chapter 3).

Fuel pressure may be low Inspect (see chapter 3).

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

ISC valve trouble Inspect (see chapter 3).

Crankshaft sensor trouble Inspect (see chapter 3).

Compression low:

Spark plug loose Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down Tighten (see chapter 5).

Pull the lever in and shift the gear in neutral.

Sidestand down and clutch lever pulled in
whether gear in neutral, or not.

Clean spark plug and adjust plug gap (see
chapter 2).

Inspect each switch (see chapter 16).

Inspect and repair or replace (see chapter 3).

Change fuel. Inspect and clean fuel system (see
chapter 3).

Inspect fuel pressure and replace fuel pump (see
chapter 3).

Inspect (see chapter 3).

3-32 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Cylinder, piston worn Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive Inspect and replace ( see chapter 5).

Cylinder head gasket damaged Replace (see chapter 5).

Cylinder head warped Inspect and replace (see chapter 5).

Valve guide worn Inspect and replace (see chapter 5).

Valve spring broken or weak Inspect and replace (see chapter 5).

Valve not seating properly (valve bent, worn or
carbon accumulating on seating surface)

KACR (compression release cam) sticks open Inspect and repair or replace (see chapter 5).

(Engine stalls when moving off)

HLA (hydraulic lash adjuster) damaged (worn,
seizure or spring broken)

HLA oil passage clogged

Inspect and repair or replace (see chapter 5).

Inspect and replace (see chapter 5).

Inspect and repair or replace (see chapter 5).

Poor Running at Low Speed

Symptoms or Possible Causes Actions (chapter)

Spark weak:

Battery voltage low Inspect and charge (see chapter 16).

Spark plug dirty, broken, or gap maladjusted

Spark plug cap or high tension wiring trouble Inspect the ignition coil (see chapter 16).

Spark plug cap shorted or not in good contact Reinstall or inspect the cap (see chapter 16).

Spark plug incorrect Replace i t with the correct plug (see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Crankshaft sensor trouble Inspect (see chapter 16).

Ignition coil trouble Inspect (see chapter 16).

Fuel/air mixture incorrect :

Little fuel in tank Supply fuel (see Owner’s Manual).

Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3).

Air cleaner duct loose Reinstall (see chapter 3).

Air cleaner O-ring damaged Replace (see chapter 3).

Fuel tank air vent obstructed

Throttle body assy loose

Throttle body assy O-ring damage Replace (see chapter 3).

Choke knob left pulled out Push in (see chapter 3).

Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).

Fuel pressure regulator clogged

Fuel line clogged Inspect and repair (see chapter 3).

Thermostat trouble Inspect and replace (see chapter 4).

Inlet air temperature sensor trouble

Inlet air pressure sensor trouble

Unstable (rough) idling:

ISC valve trouble Inspect (see chapter 3).

Clean spark plugs and adjust plug gap (see
chapter 2).

Inspect and repair (see chapter 3).

Reinstall (see chapter 3).

Inspect fuel pressure and replace fuel pump (see
chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

FUEL SYSTEM (DFI) 3-33

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Fuel injector trouble Inspect (see chapter 3).

Throttle sensor trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble

Fuel pressure too low or too high Inspect (see chapter 3).

Battery voltage low Inspect and charge (see chapter 16).

Incorrect idle speed:

Water temperature sensor trouble Inspect (see chapter 3).

Throttle sensor trouble Inspect (see chapter 3).

ISC valve trouble Inspect (see chapter 3).

Engine stalls easily:

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Throttle sensor trouble (engine stops when

opening the throttle)

Fuel pressure too low or too high Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Fuel pressure too low or too high Inspect (see chapter 3).

Fuel pressure regulator trouble

Crankshaft sensor trouble Inspect (see chapter 16).

Ignition coil trouble Inspect (see chapter 16).

Compression Low :

Spark plug loose Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down Tighten (see chapter 5).

Cylinder, piston worn Inspect and replace ( see c hapter 5).

Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive Inspect and replace (see chapter 5).

Cylinder head gasket damaged Replace (see chapter 5).

Cylinder head warped Inspect and replace (see chapter 5).

Valve guide worn or stem seal damaged Inspect and replace (see chapter 5).

Valvespringbrokenorweak

Valve not seating properly (valve bent, worn or

carbon accumulating on seating surface)

Camshaft cam worn Inspect and replace (see chapter 5).

KACR (compression release cam) sticks open Inspect and repair or replace (see chapter 5).

HLA (hydraulic lash adjuster) damaged Inspect and replace (see chapter 5).

HLA oil passage clogged Inspect and repair or replace (see chapter 5).

Hesitation:

Too low fuel pressure Inspect (see chapter 3).

Clogged fuel line Inspect and repair (see chapter 3).

Cracked or obstructed inlet air pressure sensor

hose

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect (see chapter 3).

Inspect and replace (see chapter 3).

Inspect and replace (see chapter 5).

Inspect and repair or replace (see chapter 5).

Inspect and repair or replace (see chapter 3).

3-34 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Inlet air temperature sensor trouble Inspect (see chapter 3).

Throttle sensor malfunction Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Loose injector connectors Remedy (see chapter 3).

Crankshaft sensor trouble Inspect and repair or replace (see chapter 16).

Ignition coil trouble

Loose terminal of battery (–) lead or engine Inspect and repair (see chapter 16).

ground lead

Delay of ignition timing

Poor acceleration:

Choke knob left pulled out Push in (see chapter 3).

Too low fuel pressure Inspect (see chapter 3).

Water or foreign matter in fuel

Clogged fuel filter Inspect (see chapter 3) and replace fuel pump.

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Ignition coil trouble Inspect and replace (see chapter 16).

Engine oil level too high Repair (see chapter 7).

Spark plug dirty, broken or gap maladjusted

Stumble:

Too low fuel pressure Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Throttle sensor malfunction Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Surge:

Unstable fuel pressure

Fuel injector trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Backfiring w hen deceleration:

Spark plug dirty, broken or gap maladjusted

Too low fuel pressure Inspect (see chapter 3).

Crankshaft sensor trouble Inspect (see chapter 3).

Fuel pump trouble Inspect (see chapter 3).

Inspect and repair or replace (see chapter 16).

Inspect crankshaft sensor and IC igniter in EC U
(see chapter 16).

Change fuel. Inspect and clean fuel system (see
chapter 3).

Inspect (see chapter 3).

Clean spark plugs and adjust plug gap (see
chapter 2).

Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and repair fuel line) (see chapter 3).

Clean spark plugs and adjust plug gap (see
chapter 2).

FUEL SYSTEM (DFI) 3-35

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

Throttle sensor malfunction Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble

Air switching valve broken Inspect and replace (see chapter 5).

Air suction valve trouble Inspect and replace (see chapter 5).

After fire:

Spark plug burned or gap maladjusted Adjust plug gap or replace plug (see chapter 16).

Crankshaft sensor trouble Inspect (see chapter 3).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Fuel injector trouble Inspect (see chapter 3).

Run-on (dieseling):

Ignition switch trouble

Engine switch trouble Inspect and repair or replace (see chapter 16).

Fuel injector trouble Inspect (see chapter 3).

Engine overheating

Other:

Engine oil viscosity too high Change (see chapter 2).

Drive train trouble

Final gear case oil viscosity too high Change (see chapter 2).

Brake dragging

Clutch slipping Inspect friction plates for wear (see chapter 6).

Engine overheating

Air switching valve trouble Inspect and replace (see chapter 5).

Air suction valve trouble Inspect and replace (see chapter 5).

Intermittent any DFI f ault and its recovery

Inspect (see chapter 3).

Inspect and replace (see chapter 16).

(see Overheating of Troubleshooting G uide, see
chapter 17).

Inspect tightness of bolts and nuts (see chapter

2) or bearing wear (see chapter 11).

Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (see
chapter 12).

(see Overheating of Troubleshooting Guide in
chapter 17).

Check that DFI connectors are clean and tight,
and examine wires for signs of burning or fraying
(see chapter 3).

3-36 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Poor Running or No Power at High Speed:

Symptoms or Possible Causes Actions (detailed reference)

Firing incorrect:

Spark plug dirty, broken or maladjusted

Spark plug cap or high tension wiring trouble

Spark plug cap shorted or not in good contact Reinstall or inspect the cap (see chapter 16).

Spark plug incorrect Replace i t with the correct plug (see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Crankshaft sensor trouble Inspect (see chapter 16).

Ignition coil trouble Inspect (see chapter 16).

Fuel/mixture incorrect:

Choke knob left pulled out Push in (see chapter 3).

Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3).

Air cleaner duct loose Reinstall (see chapter 3).

Air cleaner O-ring damaged Replace (see chapter 3).

Water or foreign matter in fuel

Throttle body assy loose Reinstall (see chapter 3).

Throttle body assy O-ring damaged Replace (see chapter 3).

Fuel tank air vent obstructed Inspect and repair (see chapter 3).

Fuel line clogged Inspect and repair (see chapter 3).

Fuel pump operates intermittently and often DFI
fuse blows.

Fuel pump trouble

Inlet air temperature sensor trouble Inspect (see chapter 3).

Throttle sensor malfunction Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Inlet air pressure sensor trouble Inspect (see chapter 3).

Cracked or obstructed inlet air pressure sensor
hose

Injector clogged Visually inspect and replace (see chapter 3).

Compression low:

Spark plug loose Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down Tighten (see chapter 5).

Cylinder, piston worn Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive Inspect and replace (see chapter 5).

Cylinder head gasket damaged Replace (see chapter 5).

Cylinder head warped Inspect and replace (see chapter 5).

Valve spring broken or weak Inspect and replace (see chapter 5).

Valve not seating properly (valve bent , worn or
carbon accumulating on the seating surface)

KACR (compression release cam) sticks open
(engine stalls when moving off)

Clean spark plug and adjust plug gap (see
chapter 2).

Inspect plug cap and ignition coil (see chapter

16).

Change fuel. Inspect and clean fuel system (see
chapter 3).

Pump bearings may wear. Replace t he pump
(see chapter 3).

Inspect (see chapter 3).

Inspect and repair or replace (see chapter 3).

Inspect and repair or replace (see chapter 5).

Inspect and repair or replace (see chapter 5).

FUEL SYSTEM (DFI) 3-37

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (detailed reference)

HLA (hydraulic lash adjuster) damaged (worn,

seizure or spring broken)

Knocking:

Carbon buit up in combustion chamber Repair (see chapter 5).

Fuel poor quality or incorrect (Use high-octane

gasoline recommended in the Owner’s Manual)

Spark plug incorrect Replace it with the correct plug (see chapter 16).

Ignition coil trouble Inspect (see chapter 16).

IC igniter in ECU trouble Inspect (see chapter 16).

Inlet air temperature sensor trouble Inspect (see chapter 3).

Atmospheric pressure sensor trouble Inspect (see chapter 3).

Miscellaneous:

Throttle valves won’t fully open

Brake dragging

Clutch slipping Inspect friction plates for wear (see chapter 6).

Engine overheating

Engine oil level too high Repair (see chapter 7).

Engine oil viscosity too high Change (see chapter 3).

Drive train trouble

Final gear case oil viscosity too high Change (see chapter 2).

Camshaft cam worn Inspect and replace (see chapter 5).

Air switching valve trouble Inspect and replace (see chapter 5).

Air suction valve trouble Inspect and replace (see chapter 5).

Catalytic converters melt down due to muffler

overheating (KLEEN)

Exhaust Smokes Excessively:

White smokes:

Piston oil ring worn Inspect and replace (see chapter 5).

Cylinder worn Inspect and replace (see chapter 5).

Valve oil seal damaged Replace (see chapter 5).

Valve guide worn Replace the guide (see chapter 5).

Engine oil level too high Repair (see chapter 7).

Black smoke:

Air cleaner clogged Clean (see chapter 3).

Choke knob left pulled out Push in (see chapter 3).

Too high fuel pressure Inspect (see chapter 3).

Injection stuck open Inspect (see chapter 3).

Water temperature sensor trouble Inspect and replace (see chapter 3).

Inlet air temperature sensor trouble Inspect and replace ( see c hapter 3).

Brown smoke :

Air cleaner duct loose Reinstall (see chapter 3).

Inspect and replace (see chapter 5).

Change fuel (see chapter 3).

Inspect throttle cable and lever linkage (see
chapter 3).

Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (see
chapter 12).

(see Overheating of Troubleshooting Guide in
chapter 17).

Inspect tightness of bolts and nuts (see chapter

2) or bearing wear (see chapter 11).

Replace muffler (see chapter 5).

3-38 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (detailed reference)

Air cleaner O-ring damaged Replace (see chapter 3).

Too low fuel pressure Inspect (see chapter 3).

Water temperature sensor trouble Inspect and replace (see chapter 3).

Inlet air temperature sensor trouble Inspect and replace (see chapter 3).

Self-Diagnosis

Self-diagnosis Conducting

When a problem occurs with the DFI system, the DFI in-

○

dicator LED light [A] goes on.
Remove the seat (see Frame chapter).

•

With the ECU connector joined, the self-diagnosis mode

•

by grounding the self-diagnosis check female connector
[C] (yellow lead from ECU [B]) to the battery (−) connector
[D], using a wire [E]. The LED light blinks in 2 seconds
after grounding.

Battery [F]

Count the blinks of the LED light to read the service code.

○

NOTE

Use a fully charged battery when conducting

○

self-diagnosis. Otherwise, the LED light blinks very
slowly or doesn’t blink.
Keep the self- diagnosis female connector grounded

○

during self-diagnosis, using a wire.

FUEL SYSTEM (DFI) 3-39

3-40 FUEL SYSTEM (DFI)

Self-Diagnosis

FUEL SYSTEM (DFI) 3-41

Self-Diagnosis

Service Code Reading

Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown

○

below.
Read 10th digit and unit digit as the FI indicator LE D light blinks.

○

When there are a number of problems, all the service codes can be stored and the display will

○

begin starting from the lowest number service code in the numerical order. Then after completing
all codes, the display is repeated until the ignition SW is turned OFF.
For example, if four problems occurred in the order of 31, 15, 41, 12, the service codes are displayed

○

from the lowest number in the order listed.

(12 → 15 → 31 → 41) → (12 → 15 → 31 → 41) → ···(repeated)

If there is no problem or when the repair has been done, no service code is shown.

○

If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator

○

LED light doesn’t go on, and no service codes can be displayed.

FI Indicator LED Light
ISC Valves
Pressure Regulator (Fuel Pressure, Fuel Flow Rate)
DFI Main Relay
Ignition Coil Secondary Wiring (check the internal resistance, see Electrical System chapter)
ECU Power Source Wiring and Ground Wiring (see ECU Inspection in this chapter)

For example, if two problems of 12 and 15 occur, the service code 12 and 15 are shown as follows.

○

Each service code is continuously repeated three times until the ignition SW is turned OFF.

○

ServiceCodeErasing

When the repair has been done, the LED light will not show service codes any more.

○

But even if the repair has been done, the ignition SW is turned OFF, or the battery is disconnected,
all the service codes remain in the ECU, which need not be absolutely erased.

3-42 FUEL SYSTEM (DFI)

Self-Diagnosis

Service Code Table

Service

Code

11 Throttle sensor malfunction, wiring open or short

12 Inlet air pressure sensor malfunction, wiring open or short

13 Inlet air temperature sensor malfunction, wiring open or short

14 Water t emperature sensor malfunction, wiring open or short

15

21 Crankshaft sensor #1 malfunction, wiring open or short

22 Crankshaft sensor #2 malfunction, wiring open or short

FI Indicator LED Light Problems (1)

Atmospheric pressure sensor malfunction, wiring open or
short

31 Vehicle-down sensor, malfunction, wiring open or short

41 Injector #1 malfunction, wiring open or short

42 Injector #2 malfunction, wiring open or short

45 Fuel pump malfunction, wiring open or short

51

52

Footnotes:

(1) The ECU may be involved in these problems. If all the parts and circuits checked out good, be

sure to check the ECU for ground and power supply. If the ground and power supply are checked
good, replace the ECU.

(2) When no service code is displayed, the electrical parts of the DFI system has no fault, and the

mechanical parts of the DFI system and the engine are suspect.

Ignition coil primary winding #1 malfunction, wiring open or
short

Ignition coil primary winding #2 malfunction, wiring open or
short

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