Kawasaki VULCAN 1600 CLASSIC Service Manual

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Page 1

VULCAN 1600 CLASSIC

VN1600 CLASSIC

Motorcycle

Service Manual

Page 2

Page 3

Quick Reference Guide

General Information

Periodic Maintenance

Fuel System (DFI

) 3 j

Cooling System

Engine Top End

1 j

2 j

4 j

5 j

Clutch 6 j

Engine Lubrication System

7 j

8 jEngine Removal/Installation

9 jCrankshaft/Transmission

Wheels/Tires 10

Final Dr 11

ive j

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

•Bend the pages back to match the ack tab of the desired chapter num-

bl ber with the black tab on the edge at each table of contents page.

•Refer to the sectional table of contents

or t he exact pages to locate the spe-

f cific topic required.

Brakes j

Suspension 13

Steering

14 j

Frame 15

Electrical System

16 j

Appendix 17 j

Page 4

Page 5

VULCAN 1600 CLASSIC

VN1600 CLASSIC

Motorcycle

Service Manual

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

No liability can be accepted for any inaccuracies or omis 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

o make such changes to products manufactured previously. See your Motorcycle dealer for the latest

t information on product improvements incorporated after this publication.

All information contained in this publication is based on t of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

sions in this publication, although every possible

he latest product information available at the time

Edition (1) : Aug. 25, 2003 (M)

Page 6

LIST OF ABBREVIATIONS

ABDC after bottom dead center m meter(s)

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

F farad(s) TDC top dead center

°F degree(s) Fahrenheit

ft foot, feet V volt(s)

h hour(s) Ω ohm(s)

kgf (force)

ampere(s)

alternating current min

direct current

gram(s) (mass)

(mass)

liter(s)

psi

r/min, rpm revolution(s) per minute

TIR total indicator r eading

pound(s)

minute(s)

pascal(s)

pound(s) per square inch

watt(s)

Read OWNER’S M ANUAL before operating.

Page 7

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 A gency 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

e routed through an oil separator to the inlet side of the engine. While the engine is operating,

ar 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

this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully

of 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 inudes a catalytic converter system.

3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Inead, fuel vapors are routed into the running engine to be burned, or stored in a canister when

st 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

"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

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

referred to as the Act’s "tampering provisions."

or in a motor vehicle or motor vehicle engine in compliance with regulations under this

on 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.

otor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-

m ingly 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 deces or elements of design in order to perform m aintenance.

2. Tampering could include:

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 durab ility 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

eleme

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,

THEVIOLATION OF WHICHISPUNISHABLEBYCIVIL PENALTIES NOTEXCEEDING $10,000 PER VIOLATION.

nt of design of the emission control systems.

Page 8

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery t o 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.

Page 9

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

avoid costly mistakes, read the text, thor-

to oughly 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,

recommend that all repairs and scheduled

we maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

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 t ake shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

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

The Quick Reference Guide shows you all

the product’s system and assists in locating

of their chapters. Each chapter in turn has its own comprehensive Table of Contents.

The Periodic Maintenance Chart is located in

he Periodic Maintenance chapter. The chart

t gives a time schedule for required maintenance operations.

If you want spark plug information, for exam-

e, go to the Periodic Maintenance Chart first.

pl The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

Whenever you see these WARNING and CAUTION Always follow safe operating and maintenance practices.

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

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

tion to WARNING and CAUTION) which will

addi help you distinguish different types of information.

symbols, heed their instructions!

WARNING

CAUTION

Page 10

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and convenient operation.

Indicates a procedural step or work to be

•

done. Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration

the system components follows the Table of

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.

Page 11

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

Model Identification..............................................................................................................

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

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

... 1-7

Page 12

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery 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 w hen 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.

Page 13

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

Page 14

1-4 GENERAL 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 t orque wrench.

Often, the tightening sequence is followed twice-initial

ightening and final tightening with torque wrench.

Force

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

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

Gasket, O-ring

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

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket 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.

Page 15

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

inner and outer race and result in bearing damage.

the

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

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.

Page 16

1-6 GENERAL INFORMATION

Before Servicing

Direction of Engine Rotation

When rotating the crankshaft by hand, the f ree 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.

Page 17

Model Identification

VN1600-A1 (US, and Canada) Left Side View:

GENERAL INFORMATION 1-7

VN1600-A1 (US, and Canada) Right Side View:

Page 18

1-8 GENERAL INFORMATION

Model Identification

VN1600-A1 (Europe) Left Side View:

VN1600-A1 (Europe) R ight Side View:

Page 19

GENERAL INFORMATION 1-9

General Specifications

Items VN1600-A1 ∼

Dimensions:

Overall length 2 505 mm (98.62 in.) Overall width 1 040 mm (40.9 in.), (AU) 990 mm (39 in.) Overall height 1 130 mm (44.5 in.) Wheelbase Road clearance 130 mm (5.12 in.) Seat height 680 mm (26.8 in.) Dry mass 306 kg (675 lb), (AU) 307 kg (677 lb) Curb mass:

Fuel tank capacity Fuel Unleaded and high-octane gasoline

Performance:

Minimum turning radius

Engine:

Ty Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque

Carburetion system Starting system Ignition system Timing advance Ignition timing

Spark plugs Cylinder numbering method Firing order Valve timing:

Inlet Open

Exhaust Open

Lubrication system Engine oil: Type

Front Rear 181 kg (399 lb), (AU) 182 kg (401 lb)

Close Duration

Viscosity Capacity

1 680 mm (66.1 in.)

156 kg (345 lb)

20 L (5.3 US gal)

(see VN1600-A1 ∼ Ow

3.5 m (11.5 ft)

4-stroke, SOHC, V2-cylinder

quid-cooled

Li 102 × 95 mm (4.02 × 3.74 in.) 1 552 mL (94.70 cu in.)

9.0 : 1 49 kW (67 PS) @ 4 700 r/min (rpm), (CA) (CAL) (US) – 127 N·m (12.95 kgf·m, 93.7 ft·lb) @ 2 700 r/min (rpm),

(CA) (CAL) (US) – DFI (Digital Fuel Injection) System Electric starter Battery and coil (transistorized) Electronically advanced (digital)

From 0° BTDC @ 950 r/min (rpm) ∼ 25° BTDC @ 4 500

r/min (rpm)

NGK DPR6EA-9 or ND X20EPR-U9 Front to Rear, 1-2 1-2

22° BTDC 66° ABDC 268° 66° BBDC 26° ATDC 272° Forced lubrication (wet sump) API SE, SF or SG class API SH or SJ class with JASO M A SAE10W-40

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

ner’s Manual)

Page 20

1-10 GENERAL INFORMATION

General Specifications

Items V N1600-A1 ∼

Drive Train:

mary reduction system:

Pri

Type

Reduction ratio Clutch type Transmission:

Type

Gear ratios: 1st

2nd 3rd 4th 5th

Final drive system:

Type

Reduction ratio

Overall drive ratio Final gear case oil:

Grade

Viscosity

Capacity

Frame:

Ty Caster (rake angel) Trail Front tire: Type

Size

Rear tire: Type

Size

Front suspension: Type

Wheel travel

Rear suspension: Type

Wheel travel

Brake Type: Front

Rear

Electrical Equipment:

tery Capacity 12 V 18 Ah

Bat Headlight: T

Tail/brake light 12 V 5/21 W Alternator: T

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

AU: Australia

L: California

CA: Canada US: United States of America

ype Semi-sealed beam

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

ype Three-phase AC, twin rotor

Rated output 42A × 14 V @ 6 000 r/min (rpm)

Gear

(85/56)

1.517 Wet multi disc

5-speed, constant mesh, return shift

2.500 (40/16)

1.590 (35/22)

1.192 (31/26)

0.965 (28/29)

0.781 (25/32)

Shaft

2.619 (15/21 × 33/9)

3.105 @ Top gear

API Service Classification: GL-5 Hypoid gear oil SAE90 (above 5°C), SAE80 (below 5°C) 200 mL (6.76 US oz)

Tubular, double cradle 32°

mm (6.61 in.)

168 Tubeless 130/90 - 16 M/C 67H Tubeless 170/70B16 M/C 75H Telescopic fork 150 mm (5.91 in.) Swingarm 95 mm (3.74 in.) Dual disc Single disc

Page 21

GENERAL INFORMATION 1-11

Unit Conversion Table

Prefixes for Units: Units of Length:

Prefix

mega

kilo k × 1 000 centi c ×0.01

milli

cro

Symbol

Power

× 1 000 000

× 0.001 × 0.000001

Units of Mass:

kg g

× ×

2.205

03527 = =

lb oz

km m mm

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

·m

kgf

× × ×

× ×

0.6214

3.281

0.03937

7.233

86.

mile = =

= =

in.

ft·lb

n·lb

Units of Volume:

L L L L L L mL × 0.03381 = oz (US) mL × 0.02816 = oz (imp) mL × 0.06102 = cu in.

× × × × × ×

0.2642 200

0.2

1.057

0.8799

2.113

1.816

= = = = = =

gal (US)

(imp)

gal qt (US) qt (imp) pint (US) pint (imp)

Units of Force:

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

kgf

Units of Pressure:

kPa kPa kPa

/cm²

kgf kgf/cm² cm Hg

× × × × × ×

0.01020

0.1450

0.7501

98.07

14.22 .333

kgf/cm²

cm Hg

kPa

psi

kPa

Units of Speed:

km/h × 0.6214 = mph

Units of Power:

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

× 0.9863 = HP

Units of Temperature:

Page 22

Page 23

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

nspection .................................. 2-13

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

Air Cleaner Element Cleaning...... 2-15

Evaporative Emission Control

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

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

Radiator Hose and Connection

nspection .................................. 2-16

Coolant Change ........................... 2-17

Engine Top End .............................. 2-19

Air Suction Valve Inspection ........ 2-19

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

Clutch Hose and Connection

nspection .................................. 2-19

Clutch Fluid Level Inspection ....... 2-20

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

Clutch Master Cylinder C up and

ust Seal Replacement ............ 2-21

Clutch Slave Cylinder Piston Seal

eplacement ............................ 2-22

Engine Lubrication System ............. 2-23

Engine Oil Change....................... 2-23

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

Wheel/Tires..................................... 2-24

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

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

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

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

Propeller Shaft Joint Lubrication .. 2-26

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

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

Brake Hose and Connection

nspection .................................. 2-27

Brake Fluid Level Inspection........ 2-27

Brake Fluid Change .....................

Brake Master Cylinder Cup and

Dust Seal Replacement ............ 2-29

Caliper Piston/Dust Seals

Replacement ............................. 2-29

Front Brake Light Switch

Inspection .................................. 2-29

Rear Brake Light Switch

heck/Adjustment ..................... 2-30

Suspension ..................................... 2-30

Front Fork Oil Leak Inspection..... 2-30

Rear Shock Absorber Oil Leak

nspection ................................. 2-31

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

Steering .......................................... 2-31

Stem Bearing Lubrication............. 2-31

Steering Check ............................ 2-31

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

2-28

Page 24

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

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

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

FREQUENCY Whichever 1 000 km * ODOMETER

comes (600 mile)

first 6 000 km

→ (4 000 mile)

↓ 12 000 km

(7 500 mile)

000 km

18 (12 000 mile)

24 000 km (15 000 mile)

30 (20 000 mile)

OPERATION Every See Page

k plug (e) - clean and gap † 2–35

Spar

Air suction valve (e) - inspect † 2–20

Air cleaner element (e) - clean†# 2–16

Throttle control system (e) - inspect † 2–14

Idle speed (e) - inspect † 2–15

Fuel hoses, connections - inspect † 2–14

Engine oil - change # year 2–24

Oil filter - replace 2–26

Evaporative em ission control system (e) (CAL) - inspect †

Final gear case oil level - inspect † 2–28

Final gear case oil - change 2–28

Propeller shaft joint - lubricate 2–29

Brake pad wear - inspect † # 2–29

Brake light switch - inspect † 2–32

Steering - inspect † 2–34

Rear shock absorber oil leak - inspect † 2–33

Front fork oil leak - inspect † 2–33

Tire wear - inspect † 2–27

Swingarm pivot - lubricate 2–33

General lubrication - perform 2–36

Nut, bolt, and fastener tightness - inspect † 2–37

Brake/clutch hoses, connections - inspect † 2–21, 2–29

Brake/clutch fluid level - inspect †

Coolant hoses, connections - inspect † 2–18

Brake/clutch fluid - change 2 years 2–22, 2–30

month 2–21, 2–29

• • • • • •

• • •

• • • • • • •

• • • •

• • • • • •

• • • •

• • • • • • •

• • •

• •

• • • • • •

• • • • • • •

• • •

• • • • • •

• •

• • •

• • • •

• • • • • •

• • • • • • •

•

READING

000 km

36 000 km

24 000 mile)

(

2–17

Page 25

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

FREQUENCY Whichever 1 000 km * ODOMETER

comes

first 6 000 km

→

↓ 12 000 km

OPERATI ON Every See Page

Brake/clutch master cylinder cup and dust

- replace

seal

Coolant - change

Caliper piston seal and dust seal - replace 4 years 2–32

Steering stem bearing - lubricate 2 years

Clutch slave cylinder piston seal - replace 4 years 2–24

# : Service more freque

frequent starting/stopping.

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

† : Replace, add, adjust,

ntl

y when operating in severe conditions; dusty, wet, muddy, high speed or

ean, or torque if necessary.

4 years 2–23, 2–32

2 years

(600 mile)

(4 000 mile)

(7 500 mile)

18 000 km

(12 000 mile)

24 000 km

(15 000 mile)

30 000 km

(20 000 mile)

•

READING

36 000 km

(24 000 mile)

2–28

2–34

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

(CAL)

: California

(e): Emission Related Items

Page 26

2-4 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque

for the major fasteners requiring use of a non

-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

L: Apply a non-permanent locking agent to

he threads.

G: Apply grease to the threads.

MO: Appl

O: Apply oil to the threads and seating sur-

S: Tighten the fasteners following the s peci-

SS: Appl

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

R: Replacement parts

Lh: Lef

St: Stake the fasteners to prevent loosening.

AL: Tighten the two clamp bolts alternately

Fuel System:

Throttle body assy holder bolts 11 1.1 95 in·lb Right Side

Inlet manifold bolts 12 1.2 104 in·lb on Cyl. Head

Spark plug lead holder bolts 11 1.1 95 in·lb Right Side

ISC pipe holder bolts 11 1.1 95 in·lb

Air cleaner duct holder bolts 9.8 1.0 69 in·lb Left Side

Right and left air cleaner base bolts 11 1.1 95 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 8 16 1.6 12

Right air cleaner cover Allen bolt 8 16 1.6 12

Right air cleaner Allen bolts 11 1.1 95 in·lb Throttle Body

Choke cable plate screw 2.9 0.30 26 in·lb

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 9.8 1.0 87 in·lb S, L

Cooling System:

Radiator hose clamp screws 2.5 0.25 22 in·lb

Radiator fan switch 18 1.8 13

Radiator fan bolts

Water temperature switch 7.8 0.80 69 in·lb

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

y molybdenum disulfide grease oil

solution.

ce.

ied sequence.

y silicone sealant.

t-hand-threads

two times to ensure even tightening

orque.

Fastener

The table below, relating tightening torque to

ead diameter, lists the basic torque for the

thr bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads

dia. (mm)

5 6

8 10

12 14

16 18

Torque

N·m kgf·m ft·lb

8.3 0.85 74 in·lb

N·m

3.4 ∼ 4.

5.9 ∼ 7.8 14 ∼19

25 ∼ 34 44 ∼ 61

73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325

Torque

kgf·m ft·lb

0.35 ∼ 0.

0.60 ∼ 0.80

1.4 ∼1.9

2.6 ∼ 3.5

4.5 ∼ 6.2

7.4 ∼ 10.0

11.5 ∼ 16.0

17.0 ∼ 23.0 23 ∼ 33

30 ∼ 43 52 ∼ 69 in·lb

10.0 ∼ 13.5

19.0 ∼ 25 33 ∼ 45 54 ∼ 72

83 ∼ 115 125 ∼ 165 165 ∼ 240

Remarks

L, Throttle Body

in·lb

Page 27

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Fastener

Radiator drain bolt 7.4 0.75 65 in·lb

Water temperature sensor (DFI) 18 1.8 13 SS

Engine Top End:

Spark plugs 18 1.8 13

Spark plug retainer 12 1.2 104 in·lb

Air suction valve cover bolts 7.4 0.75 65 in·lb

Chain tensioner mounting bolts

Chain tensioner cap

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

Rocker case bolts 6

Cylinder head nuts

Cylinder head jacket plugs

Rocker case cover bolts 8.8 0.90 78 in·lb

Camshaft chain guide bolts 11 1.1 95 in·lb L

Cylinder nuts 25 2.5 18 S

Inlet manifold bolts 12 1.2 104 in·lb on Cyl. Head

Exhaust pipe cover clamp bolts 6.9 0.70 61 in·lb

Chamber bolts 29 3.0 22 except US, CA

Muffler stay mounting bolts and nuts, 8 25 2.5 18

Muffler bracket bolt and nut 29 3.0 22

Clutch:

Clutch lever pivot bolt 1.0 0.10 8.7 in·lb Si

Clutch lever pivot bolt locknut 5.9 0.60 52 in·lb

Clutch reservoir cap crews 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 11 1.1 95 in·lb S

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 (outside) 9.8 1.0 87 in·lb L

Clutch cover damper plate bolts 9.8 1.0 87 in·lb EO (tip)

Clutch cover damper screws 4.9 0.50 43 in·lb L

Clutch hub nut 147 15.0 108 MO

mm 78 8.0 58 MO, S

8mm 25 2.5 18 S

mm 8.8 0.90 78 in·lb S

N·m

11 1.1 95 in·lb

20 2.0 14

25 2.5 18

20 2.0 14 L

1.2 0.12 10 in·lb

Torque

kgf·m ft·lb

Remarks

Page 28

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Engine Lubrication System:

Oil filler cap

Oil screen plug 20 2.0 14

Engine oil drain plug 20 2.0 14

Oil filter (cartridge type) 18 1.8 13 R, EO

Oil filter Pipe 25 2.5 18 SS

Oil pressure relief valve 15 1.5 11 L

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 95 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 95 in·lb L

Oil pipe clamp bolts (inside) 11 1.1 95 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 baffle bolt 11 1.1 95 in·lb L

Engine Removal/Installation:

Downtube bolts and nuts 44 4.5 33

Engine mounting bolts and nuts 44 4.5 33

Engine mounting bracket bolts 25 2.5 18

Engine ground terminal bolt 7.8 0.80 69 in·lb

Crankshaft/Transmission:

Crankcase bolts: 1

Frame ground bracket bolt 1.1 1.1 95 in·lb Left Crankcase

Crankcase bearing retainer bolts 11 1.1 95 in·lb L

Camshaft chain guide bolts 11 1.1 95 in·lb L

Right, left 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

Connecting rod big end nuts 59 6.0 43 MO

Oil pressure relief valve 15 1.5 11 L

Oil f ilter Pipe 25 2.5 18 SS

Oil hose banjo bolts 9.8 1.0 87 in·lb

Primary gear bolt 147 15.0 108 MO

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

Oil pipe clamp bolts (inside)

0 mm 39 4.0 29 S

8mm 21 2.1 15 S

6mm 11 1.1 95 in·lb S

N·m

1.5 0.15 13 in·lb

11 1.1 95 in·lb L

15 1.5 11

11 1.1 95 in·lb L

Torque

kgf·m ft·lb

Remarks

Page 29

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Left balancer gear bolt

Starter clutch bolt

Starter clutch coupling bolts 15 1.5 11 L

Gear set lever bolt 11 1.1 95 in·lb

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

Shift pedal clamp bolt 25 2.5 18

Shift pedal clamp bolts (VN1600–A2 ∼) 30 3.1 22

Rear shift lever clamp bolt 12 1.2 104 in·lb

Shift rod locknuts 11 1.1 95 in·lb (Rear: Lh)

Shift drum bearing holder bolts 11 1.1 95 in·lb L

Shift drum cam screw 15 1.5 11 L

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

Push rod guide bolts 9.8 1.0 87 in·lb L

Wheels/Tires:

Front axle clamp bolts 20 2.0 14 AL

Front axle 108 11.0 79.6 S

Rear axle nut 108 11.0 79.6

Tire air valve stem nuts 1.5 0.15 13 in·lb

Tire air valve caps 0.15 0.015 1.3 in·lb

Air valve cores 0.3 0.03 2.6 in·lb

Final Drive:

Oil pipe banjo bolts (front gear) 12 1.2 104 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 1.2 104 in·lb

8mm 29 3.0 22

Speed sensor bolt 9.8 1.0 87 in·lb L

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

Drive gear nut (front gear) 265 27

Driven gear assy mounting bolts 25 2.5 18

Driven gear bolt (front gear)

Bearing retainer bolts (front gear) 8.8 0.9 78 in·lb L

Final gear case drain plug 8.8 0.9 78 in·lb

Final gear case m ounting nuts 34 3.5 25

Final gear case studs – – – L

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

10 mm 34 3.5 25 L

Pinion gear nut (final gear) 130 13 94 St, MO

Bearing retainer bolt 6.9 0.7 61 in·lb L

Brakes:

Caliper bleed valves 7.8 0.8 69 in·lb

Brake hose banjo bolts 25 2.5 18

N·m

85 8.7 63

137 14 101

Torque

kgf·m ft·lb

195 MO, St

Remarks

MO, St

Page 30

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Brake lever pivot bolt 1.0 0.10 8.7 in·lb

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 10 in·lb

Front master cylinder clamp bolts 8.8 0.9 78 in·lb G, S

Front caliper mounting bolts 34 3.5 25

Rear caliper mounting bolts 34 3.5 25

Rear caliper holder bolt 64 6.5 47

Brake disc bolts 27 2.8 20 L

Rear master cylinder mounting bolts 25 2.5 18

Rear master cylinder push rod locknut 18 1.8 13

Brake pedal clamp bolt 25 2.5 18

Suspension:

Upper front fork clamp bolts 20 2.0 14

Lower front fork clamp bolts 29 3.0 21 AL

Front fork top plugs 22 2.2 16

Piston rod nuts or joint rod nut 20 2.0 14

Front fork bottom allen bolt 30 3.1 22 L

Front axle clamp bolts 20 2.0 14 AL

Rear shock absorber nuts 34 3.5 25

Swingarm pivot shaft 108 11 . 0 79.6 G

Steering:

Steering stem head nut 88 9.0 65

Steering stem nut 5 0.5 43 in·lb

Handlebar clamp bolts 34 3.5 25

Handlebar holder nuts 34 3.5 25

Upper front fork clamp bolts 20 2.0 14

Lower front fork clamp bolts 29 3.0 21 AL

Turn signal light mounting nuts 5.9 0.6 52 in·lb

Frame:

Downtube bolts and nuts 44 4.5 33

Footboard bracket bolts 34 3.5 25

Footpeg bracket bolts 25 2.5 18 rear, L

Sidestand nut 44 4.5 33

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

Inside stator holder bolts 11 1.1 95 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

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

N·m

Torque

kgf·m ft·lb

Remarks

front

Page 31

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Alternator outer cover assembly bolts 6.9 0.70 61 in·lb

Alternator cover bolts 11 1.1 95 in·lb

Alternator inner cover bolts 11 1.1 95 in·lb

Alternator rotor bolt 78 8.0 58 MO

Alternator stator bolts 13 1.3 113 in·lb L

Regulator/rectifier bolts 6.5 0.66 57 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 11 1.1 95 in·lb

Starter motor terminal nut 4.9 0.50 43 in·lb

Starter motor assembly bolts 4.9 0.50 43 in·lb

Starter motor mounting bolts

Headlight rim screws 2.9 0.30 26 in·lb

Headlight unit bracket screws 1.0 0.10 8.7 in·lb L

Starter lockout switch screw 1.2 0.12 10 in·lb

Front brake light switch screw 1.2 0.12 10 in·lb

Sidestand switch bolt 8.8 0.90 78 in·lb L

Radiator fan switch

Radiator fan bolts

Fuel level sensor mounting bolts 6.9 0.70 61 in·lb L

Fuel pump mounting bolts 9.8 1.0 87 in·lb S

Water temperature switch 7.8 0.80 69 in·lb SS

Water temperature sensor 18 1.8 13 SS

Oil pressure switch terminal screw 1.5 0.15 13 in·lb G

Oil pressure switch 15 1.5 11 SS

Neutral switch 15 1.5 11

Speed sensor mounting bolt 9.8 1.0 8.7 in·lb L

Turn signal light mounting screws 6.9 0.70 61 in·lb

Turn signal light lens screws 1.0 0.10

Tail/brake light m ounting nuts 5.9 0.60 52 in·lb

Tail/brake light lens screws 1.2 0.12 10 in·lb

Tail/brake light assembly screws 1.2 0.12 10 in·lb

N·m

11 1.1 95 in·lb

18 1.8 13

8.3 0.85 7.4 in·lb

Torque

kgf·m ft·lb

8.7 in·lb

Remarks

Page 32

2-10 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System (DFI):

Throttle grip free play 2 ∼ 3

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

Tot al am o u n t 2.3 L (2.4 US qt) –––

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

Level Between upper and lower level lines –––

Tires:

Tread depth:

Front BRIDGESTONE EXEDRA G721:

Rear BRIDGESTONE EXEDRA G722:

Air pressure: (when cold)

Front Up to 186 kg (410 lb) load: 200 kPa –––

Rear Up to 186 kg (410 lb) load: 250 kPa –––

mm (0.08 ∼ 0.12 in.) –––

–––

Soft water 50%, Coolant 50% –––

– 35°C (– 31°F) –––

Non-adjustable (hydraulic lash adjusters) –––

API SH or SJ with JASO MA

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)

(Wait 2 ∼ 3

running)

4.3 mm (0.17 in.) (DE, AT, CH): 1.6 mm

7.2 mm (0.28 in.) 2mm (0.08 in.)

(2.0 kgf/cm², 28 psi)

(2.5 kgf/cm², 36 psi)

minutes after idling or

1 mm (0.04 in.),

(0.063 in.)

Up to 130km/h(80 mph):

Over 130km/h (80mph):

3mm(0.1in.)

–––

Page 33

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

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

Brakes:

Brake fluid

Grade DOT4 –––

Brake pad lining thickness:

Front 4.5 mm (0.18 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

Electrical System:

Spark plug gap 0.8 ∼ 0.

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

200 mL (6.76 US oz)

grease

travel

9 mm (0.031 ∼ 0.035 in.) –––

–––

Page 34

2-12 PERIODIC MAINTENANCE

Special Tools

Steering Stem Nut Wrench : Attachment Jack : 57001–1100 57001–1398

Jack : Filler Cap Driver : 57001–1238 57001–1454

Page 35

Periodic Maintenance Procedures

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.

Throttle Control System Inspection

Throttle Grip Play Inspection

Check the throttle grip free play [A].

•

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

PERIODIC MAINTENANCE 2-13

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 cable [D] until the

○

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

Page 36

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Throttle Bore Cleaning

Check the thrott e bore for cleanliness as follows:

•

Remove the a r c eaner cover A en bolt A] and take off

○

the right a r c eaner cover

Front [C]

i l ll [

i l [B].

Check the thrott e bores at the thrott e valves [B] and

○

around them for carbon deposits by opening the valves. If any carbon accumulates, wipe the carbon off the throttle bores around the throttle valves, using a nt-free cloth penetrated with a high-flash point solvent.

Front [D]

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

At first the engine will run fast to decrease warm up time

○

(fast idle). Gradually the fast idle will lower to a certain RPM auto-

○

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

•

Idle 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).

l [A] l

li [C]

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 the engine and warm it up thoroughly.

•

Wait until fast idle speed lowers to a certain value.

○

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

•

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

○

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

Front [B]

Page 37

Periodic Maintenance Procedures

Air Cleaner Element Cleaning

NOTE

In dusty areas, the element should be cleaned more

○

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

○

should be cleaned immediately.

Remove:

•

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

ont [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 may become stuck, possibly causing accident.

CAUTION

PERIODIC MAINTENANCE 2-15

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

Clean the element by tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed

•

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

•

check the sponge gasket [B] also. If the element or 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.

NOTE

The canister is designed to work well through the motor-

○

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

Page 38

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

○

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

○

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

[B]

Front

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 t he 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.

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 s igns of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should i t be soft or swollen. Replace t he 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)

Page 39

Periodic Maintenance Procedures

lCoo ant 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).

PERIODIC MAINTENANCE 2-17

Remove the fuel tank see Fuel System (DFI chapter).

•

Remove the radiator cap n 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 wil drain from the radiator and engine.

○

[B]

Front

Remove the water pump drain bolt . The rema ng

•

coolant wil drain from the water pump Pl

ace a conduit under the drain hole of the pump cover.

○

The conduit eads to a container.

[C]

Front

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 f ng the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s d rections.

illi

l [B].

( )

[A] i

[A] ini

(

CAUTION

Soft or distilled water must be used with the antifreeze see Specif cations 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.

( i )

Page 40

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Water and Coolant Mixture Ratio (when shipping)

Soft Water Coolant Freezing Point Tota l A m o unt

Tighten the drain bolts.

•

Torque - Radiator Drai n Bolt: 7.4 N·m (0.75 kgf·m, 65 in·lb)

Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 95 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.

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,

95 in·lb)

50 %

50 % : :

NOTE

°C (− 31°F)

− 35

2.3 L (2.4 US qt)

Tap the radiator hoses to force any air bubbles caught

•

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

•

Install the radiator cap.

•

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

•

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

Page 41

Periodic Maintenance Procedures

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, w arps, heat

•

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

•

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

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

•

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

•

between the reed and the reed contact area, wash the valveassemblycleanwithahigh-flashpoint 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 MAINTENANCE 2-19

Clutch

Clutch Hose and Connection Inspection

Thehigh pressureinsidethe clutchlinecan causefluid

•

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

Page 42

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clutch Fluid Leve Inspection

Hold the clutch f reservoir horizontal.

•

Check that the c utch fluid evel o the clutch reservoir

•

between the ower [A] and the upper [B] If the fluid leve ower than the evel ne, fill the reservoir to the upper evel ne n the reservoir. Since the c utch fluid s the same as the brake fluid, refer

○

to Brake F uid Section n the Brakes chapter for further details.

Torque - Clutch Reservoir Cap Screws: 1.5 N·m 0.15

luid

l l f is

l level lines.

l is l lower l li

l li i

l i

kgf·m, 13 in·lb)

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.

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

over again from the beginning since air will have

done entered the line.

WARNING

Do not mix two brands of fluid.

Page 43

Periodic Maintenance Procedures

After changing the f luid, 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.

•

Torque - 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)

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

Pullout theprimarycup[H], pistonassembly[I], andre-

•

turn spring [J].

PERIODIC MAINTENANCE 2-21

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.

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.

Page 44

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Apply clutch fluid to the parts removed and to the inner

•

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

•

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

•

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

○

Torque - Clutch Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.7

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).

•

Clutch Slave Cylinder Piston Seal Replacement

Remove the clutch slave cylinder (see Clutch chapter).

•

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

•

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

•

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

•

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

•

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 w as 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]

Page 45

Periodic Maintenance Procedures

Engine Lubrication System

Engine Oi Change

Si it i

tuate the motorcycle so that s vertical after warming

•

up the engine. Remove the engine oi drain plug and drain the oil.

•

Remove:

•

Oil Screen Plug Engine r ght s

l [A]

[A] ( i ide)

PERIODIC MAINTENANCE 2-23

Remove the o screen A], the spring B], and the washer

•

[C]. Cl igh-fl

ean the oil screen with a h ash point solvent and

•

remove any part es stuck to Cl is

ean the screen thoroughly whenever the engine oil

•

changed.

il [ [

icl it.

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.

NOTE

While cleaning the screen, check for any metal particles

○

that might indicate internal engine damage.

Check the screen carefully for any damage: holes and

•

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

•

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

Torque - Oil Screen Plug: 20 N·m (2.0 kgf·m, 14 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, 14 ft·lb)

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

Page 46

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

•

and pour in the specified type and amount of oil.

utch Cover [C]

Special Tool - Driver-Filler Cap: 57001–1454

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

Engine Oil

pe:

iscosity: SAE 10W-40

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.

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

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

3.1 L (3.3 US qt, when filter is removed) .5 L (3.7 US qt, when engine is completely

3 disassembled and dry)

NOTE

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

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)

Wheel/Tires

Tire Inspection

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

Remove any imbedded stones or other foreign particles

•

from the tread.

Visually inspect the tire for cracks and cuts, replacing the

•

tire in case of damage. Swelling or high spots indicate

internal damage, requiring tire replacement.

Page 47

Periodic Maintenance Procedures

PERIODIC MAINTENANCE 2-25

Measure the tread depth at the center of the tread th

•

depth gauge [A]. S nce the t re may wear unevenly, take measurement at several places. If any measurement s less than the service t, replace the tire see Wheels/T res chapter).

Tread Depth

Measure the t re air pressure with an air pressure gauge

•

[A] when the t res are cold s, when the motorcycle has not been ridden more than a mile during the past 3 hours.) Ad ust the tire a r pressure according to the specif cat if necessary.

Air Pressure when cold)

Front Up to 186kg(410lb 200 kPa 2.0kgfcm²,28ps

Rear

( i

Front:

Standard: 4.3 mm (0.17 in.) Service Limit: mm (0.04 in.

Rear:

Standard: 7.2 mm (0.28 in.) Service Limit: 2 mm (0.08 in.):

j i i ions

(

Up to 186kg(410lb 250 kPa 2.5kgfcm²,36ps

i i

i limi

1 )

DE, AT, CH) 1.6 mm 0.063 in.

( ( )

Up to 130 km/h (80 mph)

m(0.1 in.):

Over to 130 km/h (80 mph)

i (that i

) ( / i)

wi a

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

Page 48

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

•

opening.

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

remedy it if necessary, and add oil through the filler 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 motorcycle so that the

•

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

motorcycle and turn the ignition switch OFF.

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

•

the filler cap and drain plug [A].

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 t he oil has completely drained out, i nstall 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: Grade: API GL-5 hypoid gear oil Viscosity:

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

○

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

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

•

Propeller Shaft Joint Lubrication

Remove the final gear case and propeller shaft joint (see

•

Final Drive chapter).

Wipe the old grease off the propeller shaft sliding joint and

•

pinion joint.

Pack the propeller shaft sliding joint with 20 mL (16

•

grams) of high temperature grease [A].

200 mL (6.76 US oz)

When above 5°C (41°F) SAE 90 When below 5°C (41°F) SAE 80

NOTE

Page 49

Periodic Maintenance Procedures

Brakes

Brake Pad Wear Inspection

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

•

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

Pad Lining Thickness

Standard:

Front: Rear:

Service Limit: 1 mm (0.04 in.)

Brake Hose and Connection Inspection

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage. Thehighpressureinside thebrakeline cancausefluidto

○

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.

4.5 mm (0.18 in.)

7.5 mm (0.295 in.)

PERIODIC MAINTENANCE 2-27

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

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

reser

Page 50

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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 DO T4 is installed in the brake system when

○

shipped.

Torque - 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.

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 t he 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.

Page 51

Periodic Maintenance Procedures

Repeat this operation until fresh brake fluid comes out

○

from the plastic hose or the color of the fluid changes.

the bleed valve [A].

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

PERIODIC MAINTENANCE 2-29

Remove the clear plastic hose.

•

Install the reservoir cap.

•

Tighten the bleed valves, and install the rubber caps.

•

Torque - Caliper Bleed Valves: 7.8 N·m (0.8 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 B rake/Master Cylinder Cup and Dust Seal Replacement.

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.

Page 52

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rear Brake Light Switch Check/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].

If it does not, adjust the brake light switch.

While holding the switch body, turn the adjusting nut to

•

adjust the switch.

itch Body [A]

Sw Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D]

CAUTION

To avoid damaging the electrical connections in-

side the switch, be sure that the switch body does

not turn during adjustment.

Suspension

Front Fork Oil Leak Inspection

Remove the bolts [A] and then slide the cover downward.

•

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.

Page 53

Periodic Maintenance Procedures

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).

•

PERIODIC MAINTENANCE 2-31

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 t he 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 w heel binds or catches before the stop, the steering is too tight.

Page 54

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Feel for steering ooseness by pushing and pulling the

○

fork.

If you feel looseness, the steer ng s too

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

○

tion of the fork which m ust be taken nto account. Be sure the w res and cables are properly routed. The bearings must be in good condition and properly

○

ubricated in order for any test to be valid.

i j

Steer ng Ad ustment

Adjust the steer necessary.

Loosen the upper fork clamp bo A] on both side and

•

unscrew the stem head nut

Remove the O-r ng see Steering chapter).

•

Remove the steering stem head together w th the han-

•

dlebar nstalled.

Remove the claw washer.

•

Adjust the stem nut with the stem nut wrench B] by

•

ti i

Special Tool Steering Stem Nut Wrench: 57001-1100

ghtening to the specif ed torque.

l [A]

i i loose.

NOTE

ill

ing, if

lt [

[B].

i (

[C] i

[A] [

Torque - Steering Stem Nut: 49 N·m (0.5 kgf·m, 43 ft·lb)

Instal the stem head.

•

ghten the following in the order listed.

•

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

Upper Fork Clamp Bolts: 20 N·m 2.0 kgf·m, 14

in·lb)

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

○

accordance with the Cable, Wire, and Hose Routing sec-

tion in the General Information chapter.

Check and adjust the steering and throttle cables after

•

installation.

(

WARNING

Do not attempt to ride the motorcycle until a full

brake lever is obtained by pumping the brake lever

until the pads are against the disc. The brakes will

not function on the first application of the lever if

this is not done.

Page 55

Periodic Maintenance Procedures

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 corroded or damaged, or if the insulator [C] is cracked, replace the plug. Use the standard spark plug or its equivalent.

•

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

•

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

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

General Lubrication

Lubrication

Before lubricating each part, clean off any rusty spots with

•

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

•

NOTE

Whenever the vehicle has been operated under

○

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

PERIODIC MAINTENANCE 2-33

Pivots: Lubricate w ith Motor Oil.

Rear Brake Rod Joint

Points: Lubricate with Grease.

Throttle Inner Cable Upper Ends [A]

utch Lever Pivot (Apply silicone grease)

Cl Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Sidestand

Cable: Lubricate with Cable Lubricant.

Choke Cable

ottle Cables

Thr

Lubricate the cables by seeping the oil between the cable

•

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

○

available pressure cable lubricator [A] with an aerosol cable lubricant [B].

Page 56

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

With the cable disconnected at both ends, the cable

•

should move freely [A] within the cable housing.

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

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

the cable.

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 t he 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.

Nut, Bolt and Fastener to be checked

Wheels:

Axle

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

Final Drive:

Gear Case Mounting Nuts

Final

Brakes:

Master Cylinder Clamp Bolts

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

Suspension:

Fork Clamp Bolts

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

Steering:

Head Nut

Stem Handlebar Clamp Bolts

Page 57

Periodic Maintenance Procedures

Engine:

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

Others:

destand Bolt and Nut

Si Footboard Bracket Bolts Footpeg Bracket Mounting Bolts Downtube Bolts (Right)

PERIODIC MAINTENANCE 2-35

Page 58

Page 59

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 ................. 3-18

DFI Servicing Precautions ................. 3-19

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

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

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

DFI System Troubleshooting Guide .. 3-27

Self-Diagnosis ................................... 3-36

Self-diagnosis Procedures ........... 3-36

Service Code Reading ................. 3-37

Service Code Erasing .................. 3-38

Throttle Sensor (Service Code 11) .... 3-41

Throttle Sensor

Removal/Adjustment ................. 3-41

Input Voltage Inspection............... 3-41

Output Voltage Inspection............ 3-42

Resistance Inspection.................. 3-43

Inlet Air Pressure Sensor (Service

ode 12) ......................................... 3-44

Removal ....................................... 3-44

Installation.................................... 3-44

Input Voltage Inspection............... 3-44

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

Inlet Air Temperature Sensor (Service

ode 13) ......................................... 3-49

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

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

Sensor Resistance Inspection ..... 3-50

Water Temperature Sensor (Service

Code 14) ......................................... 3-51

Removal/Installation..................... 3-51

Output Voltage Inspection............ 3-51

Water Temperature Sensor

Resistance Inspection ............... 3-52

Atmospheric Pressure Sensor

(Service Code 15)........................... 3-53

Removal ....................................... 3-53

Installation.................................... 3-53

Input Voltage Inspection............... 3-53

Output Voltage Inspection............ 3-54

Crankshaft Sensors (#1, #2: Service

ode 21, 22) ................................... 3-57

FUEL SYSTEM (DFI) 3-1

Crankshaft Sensor

Removal/Installation.................. 3-57

Crankshaft Sensor Inspection...... 3-57

Vehicle-down Sensor (Service Code

1)................................................... 3-58

Vehicle-down Sensor Removal .... 3-58

Installation .................................... 3-58

Vehicle-down Sensor Inspection.. 3-59

Fuel Injectors (#1, #2: Service Code

42)............................................. 3-61

41,

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

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

Audible Inspection........................ 3-64

Power Source Voltage Inspection 3-64

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

Injector Signal Test....................... 3-65

Injector Resistance Inspection ..... 3-66

Injector Unit Test .......................... 3-66

Fuel Pump (Service Code 45) ........... 3-68

Fuel Pump Removal .................... 3-68

Fuel Pump Installation ................. 3-68

Pressure Regulator Removal....... 3-69

Pump Screen, Fuel Filter

Cleaning.................................... 3-69

Operation Inspection.................... 3-69

Operating Voltage Inspection....... 3-70

Power Source Voltage Inspection 3-71

Operating Voltage Inspection....... 3-71

Ignition Coils (#1, #2: Service Code

52)............................................. 3-73

51,

Removal/Installation..................... 3-73

Input Voltage Inspection............... 3-73

FI Indicator LED Light........................ 3-74

LED Light Inspection .................... 3-75

ECU ................................................... 3-76

ECU Identification ........................ 3-76

ECU Removal .............................. 3-76

ECU Installation ........................... 3-76

ECU Power Supply Inspection..... 3-76

DFI Power Source ............................. 3-78

DFI Fuse Removal

DFI Fuse Inspection ..................... 3-78

DFI Main Relay Removal ............. 3-78

DFI Main Relay Inspection ........... 3-78

ISC Valves ......................................... 3-80

Removal/Installation..................... 3-80

....................... 3-78

Page 60

3-2 FUEL SYSTEM (DFI)

Power Source Voltage Inspection 3-80

Output Voltage Inspection............ 3-81

Resistance Inspection.................. 3-81

Fuel Line............................................ 3-83

Fuel Pressure Inspection ............. 3-83

Fuel Flow Rate Inspection ........... 3-85

Throttle Grip and Cables ................... 3-86

Throttle Grip Free Play Inspection 3-86 Throttle Grip Free Play

djustment ................................ 3-86

Choke Knob Operation ................ 3-86

Choke Cable Free Play

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

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

Cable Lubrication and Inspection. 3-86

Throttle Body Assy ............................ 3-87

Idle Speed Check......................... 3-87

Idle Speed Adjustment................. 3-87

Throttle Bore Cleaning ................. 3-87

High Altitude Performance

Adjustment ................................ 3-87

Throttle Body Assy Removal........ 3-87

Throttle Assy Installation.............. 3-90

Throttle Assy

Disassembly/Assembly ............. 3-91

Air Cleaner......................................... 3-94

Element Removal......................... 3-94

Element Cleaning......................... 3-94

Left Air Cleaner Housing

Removal/Installation.................. 3-94

Right Air Cleaner Housing

Removal .................................... 3-95

Right Air Cleaner Housing

Installation ................................. 3-95

Lower Air Cleaner Duct

emoval/Installation.................. 3-96

Fuel Tank........................................... 3-97

Fuel Tank Removal ...................... 3-97

Fuel Tank Installation ................... 3-100

Fuel Tank and Cap Inspection ..... 3-101

Fuel Tank C leaning ...................... 3-102

Evaporative Emission Control

ystem............................................ 3-103

Parts Removal/Installation ........... 3-103

Canister Installation ..................... 3-103

Canister Inspection (Periodic

spection)................................. 3-103

Separator Inspection (Periodic

Inspection)................................. 3-103

Hose Inspection (Periodic

Inspection)................................. 3-104

Separator Operation Test............. 3-104

Page 61

Page 62

3-4 FUEL SYSTEM (DFI)

Exploded View

Page 63

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 8 16 1.6 12

3 Left air cleaner base bolts 11 1.1 95 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 95 in·lb

7 Right air cleaner Allen bolts 11 1.1 95 in·lb

8 Right air cleaner cover Allen bolt 8 16 1.6 12

9 Throttle body assy holder bolts 11 1.1 95 in·lb

Spark plug lead holder bolts

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

12. Vacuum switch 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 California Model

CA: CN: Canadian Model

U.S.: United States Model

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

SS:

L: Apply a non-permanent locking agent.

N·m kgf·m ft·lb

11 1.1 95 in·lb

Torque

Remarks

Page 64

3-6 FUEL SYSTEM (DFI)

Exploded View

Page 65

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1 Fuel pump bolts 9.8 1.0 87 in·lb S, L

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

3 ISC pipe bolts 11 1.1 95 in·lb

4 Throttle body assy holder bolts 11 1.1 95 in·lb

5 Spark plug lead holder bolts 11 1.1 95 in·lb

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

7 Inlet manifold bolt 12 1.2 104 in·lb

8. Fuel tank

9. Vehicle-down sensor

10. Atmospheric pressure sensor

11. Inlet air pressure sensor

12. Choke cable

13. Throttle cable (accelerator)

14. Throttle cable (decelerator)

15. ECU (Electronic control unit)

16. DFI main relay

17. Battery case

18. ISC valve #1 (for Front cylinder)

19. ISC valve #2 (for Rear cylinder)

20. Right air cleaner base

21. Inlet air temperature sensor

22. Throttle body

23. Inlet manifold

24. Seal

25. Injector #1 for front cylinder

26. Injector #2 for rear cylinder

27. O-ring

28. Delivery joint

R: Replacement Parts

L: Apply a non-permanent locking agent.

G: Apply grease.

CL: Apply cable lubricant.

S: Follow the specified tightening sequence.

N·m kgf·m ft·lb

Torque

Remarks

Page 66

3-8 FUEL SYSTEM (DFI)

DFI Parts Location

Page 67

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 (see next page)

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) (see next page)

14. Vehicle-down Sensor (DFI)

15. ECU (DFI)

16. DFI Fuse 15 A × 32 V

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 S ensor (DFI)

28. FI Indicator LED Light (DFI) (see next page)

29. Throttle Sensor (DFI)

30. Rear Brake Light Switch

31. Radiator Fan

32. Radiator Fan Switch

33. Delivery Joint (DFI)

34. Pump Screen (see next page)

35. Fuel Filter (see next page)

36. Fuel Tank (reverse side)

FUEL SYSTEM (DFI) 3-9

Page 68

3-10 FUEL SYSTEM (DFI)

DFI Parts Location

Page 69

DFI Parts Location

FUEL SYSTEM (DFI) 3-11

Page 70

3-12 FUEL SYSTEM (DFI)

DFI System

Page 71

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, rear side)

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

18. Vehicle-dow n 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 (upper view)

30. Fuel Hose Joint #1

31. Fuel Hose Joint #2

FUEL SYSTEM (DFI) 3-13

Page 72

3-14 FUEL SYSTEM (DFI)

DFI Wiring Diagram

Page 73

FUEL SYSTEM (DFI) 3-15

DFI Wiring Diagram

Terminal Numbers of ECU Connectors

Ter m inal 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. —

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,

Throttle Sensors

and

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. ISC Valve #1 Signal

19. —

20. Ignition Control Circuit Ground to Battery (–) Terminal

21. Engine Stop Signal

22. 23. —

24. Vehicle-down Sensor Signal

25. —

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

36. Com. Line B

37. Fuel Pump Signal

38. —

39. Injector #2 Signal

40. Injector #1 Signal

41. ISC Valve #2 Signal

42. Ignition Control Circuit Ground to Battery (–) Terminal

43. Ignition Coil #2 Signal

Page 74

3-16 FUEL SYSTEM (DFI)

DFI Wiring Diagram

44. Ignition Coil #1 Signal

DFI and Electrical Parts

DFI: DFI Parts

U [A]: Electronic Control Unit (DFI)

EC Engine Stop Switch [B] Starter Button [C] Ignition Coils [D] Crankshaft Sensors (Crankshaft Sensors) [E] Junction Box [F] Starter Circuit Relay [G] Interlock Diodes [H] LCD (Liquid Crystal Display) [J] MODE Button [K] FI Indicator LED Light [L]: (DFI) Speedometer [M] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A × 32 V [P] Sealed Battery [Q] Fuel Injector #1 [R]: (DFI) Fuel Injector #2 [S]: (DFI) RESET Button [T] Fuel Pump [U]: (DFI) DFI Fuse 15 A × 32 V [V]: (for ECU, Injectors, Fuel Pump, DFI Main Relay, and ISC Valves) ISC Valve #1 [W]: (DFI) ISC Valve #2 [X]: (DFI) Inlet Air Temperature Sensor [Y]: (DFI) Water Temperature Sensor [Z]: (DFI) Inlet Air Pressure Sensor [a]: (DFI) Atmospheric Pressure Sensor [b]: (DFI) Throttle Sensor [g]: (DFI) Vehicle-down Sensor [d]: (DFI) DFI Main Relay [e]: (for ECU, Injectors, Fuel Pump, and ISC Valves) Ignition Fuse 10 A × 32 V [f] Speed Sensor [i] ECU Connector [l] Connector Lock [m] Self-diagnosis Check Female Connector [n] Joint Connector 1 [p] Frame Earth [q]

Page 75

FUEL SYSTEM (DFI) 3-17

Specifications

Item Standard

Throttle Grip Free Play: 2 ∼ 3

Air Cleaner Element: Paper filter DFI System:

Make: Mitsubishi Electric

e Speed: 950 ± 50 r/min (rpm)

Idl

tle Body Assy:

Throt

Type × Bore

CU (Electronic Control Unit):

Type

Usable engine speed 100 ∼ 6

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

um air flow rate 75 ± 7 L (19.8 ± 1.8 US gal)/min

Maxim

enoid resistance 13.6 ∼ 20.

Sol

Fuel Pressure (high pressure line):

ght after Ignition SW ON 304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

ter pump runs 3 sec. and stops. 280 kPa (2.9 kgf/cm², 41 psi) with fuel pump stopped

h engine idling 304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

Wit

tle Sensor:

Throt

Input voltage 4.75 ∼ 5.25 Output voltage at idle throttle opening 0.584 ∼ 0.60 Output voltage at full throttle opening 4.29 ∼ 4. Resistance 4 ∼ 6kΩ

Atmospheric Pressure Sensor or Inlet Air Pressure Sensor:

Input voltage 4.75 ∼ 5.25 Output voltage 3.74 ∼ 4.26

Inlet Air Temperature Sensor:

stance 5.4 ∼ 6.6

Resi

Water Temperature Sensor:

stance 2.162 ∼ 3.

Resi

Vehicle-down Sensor:

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

ection time Within 0.5 ∼ 1.0

Det

Fuel Injectors:

Type INP– 281

tatic injection quantity 273.0 ∼ 289.

Nozzle type × diameter One spray type with 4 holes

stance 11.7 ∼ 12.

Resi

Fuel Pump:

pe Friction pump

scharge 67 mL (2.27 US oz) or more for 3 seconds

mm (0.08 ∼ 0.12 in.)

Two barrel type × 36 mm (1.42 in.)

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

sin

200 r/min (rpm)

4 Ω

V DC between BL/W and BR/BK leads

4 V DC between Y/W and BR/BK leads

59 V DC between Y/W and BR/BK leads

between BL/W and BR/BK leads

V DC

V DC at standard atmospheric pressure

kΩ at 0° C (32° F)

2.26 ∼ 2.86

0.29 ∼ 0.

0.785 ∼ 1

0.207 ∼ 0.253

kΩ at 20° C (68° F)

39 kΩ at 80° C (176° F)

112 kΩ at 20° C (68° F)

.049 kΩ at 50° C (122° F)

kΩ at 100° C (212° F)

sec.

8 mL (9.23 ∼ 9.80 US oz)/min

3 Ω at 20° C (68° F)

Page 76

3-18 FUEL SYSTEM (DFI)

Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm² : Filler Cap Driver : 57001–125 57001–1454

Fork Oil Level Gauge : Needle Adapter Set : 57001–1290 57001–1457

Hand Tester : Kawasaki Bond (Silicone Sealant) : 57001–1394 56019–120

Fuel Pressure Gauge Adapter : 57001–1417

Page 77

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]

ont [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 (sw itch) 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.

FUEL SYSTEM (DFI) 3-19

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 mem orizes fault 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. To prevent corrosion and deposits in the fuel system, do

○

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

○

ignition SW. Otherwise, the fuel 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 pum p 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.

Page 78

3-20 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Outline

When an abnormality in the system occurs, the FI indicator LED light [A] and FI symbol [B] go 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 and

symbol remains lit, ask the rider about the conditions [B]

FI under which the problem occurred and try to determine the cause. Don’t rely solely on the DFI self-diagnosis function, use common sense.

First conduct a self-diagnosis inspection, and then a non

self-diagnosis. The non-self-diagnosis items are not indi-

cated by the FI indicator LED light.

Even when the DFI system is operating normally, the FI

ndicator LED light and FI symbol may light up under strong

i electrical interference. No repair needed. Turn the ignition SW (switch) OFF to stop the indicator light and FI symbol.

When the FI indicator LED light and FI symbol go on and

he motorcycle is brought in for repair, check the service

t codes.

When the repair has been done, the LED light and FI

ymbol do not go on.

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

○

Voltage Check Method and the other is Resistance Check

Method.

Voltage Check Method

This method is conducted by measuring the input voltage

○

[B] to a sensor [A] first, and then the output voltage [C]

rom 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.

Page 79

Troubleshooting the DFI System

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 the con-

•

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

•

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

•

the connector joined.

FUEL SYSTEM (DFI) 3-21

CAUTION

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

After measurement, remove the needle adapters and ap-

○

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

Silicone Sealant-

Always check battery condition before replacing the DFI

•

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

(Kawasaki Bond: 56019–120)-Seals

Connector

Page 80

3-22 FUEL SYSTEM (DFI)

Troubleshooting 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

adigital 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 i s suspect. Replace the ECU.

Trouble may involve one or in some cases all items.

•

Never replace a defective part without determining what

CAUSED the problem. If the problem was caused by

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

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

Measure coil winding resistance when the DFI part is cold

•

(at room temperature)

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

•

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

etc. Deteriorated wires and bad connections can cause

reappearance of problems and unstable operation of the

DFI system.

If any wiring is deteriorated, replace the wiring.

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

•

dirt, and damage.

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

is damaged, replace it. Connect the connectors securely.

Check the wiring for continuity.

•

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

○

is suspected of being a problem.

Connect the hand tester between the ends of the leads.

○

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

○

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

place the lead.

Page 81

Troubleshooting the DFI System

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 is open, repair or replace the harness.

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

○

end [B] and check the continuity between the other end [C] and ground [D]. If there i s continuity, the harness has

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

a placed.

FUEL SYSTEM (DFI) 3-23

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 Y: Yellow

G: Green

GY: Gray

P: Pink

PU: Purple

W: White

Page 82

3-24 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

DFI Diagnosis Flow Chart

Inquiries to Rider

Refer t o 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.

Page 83

FUEL SYSTEM (DFI) 3-25

Troubleshooting the DFI System

Sample Diagnosis Sheet

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

Environment when problem occurred.

Weather

Temperature

Problem

equency

Road

Altitude

FI indicator LED

light

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

□

chronic, □ often, □ once

□ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble □ normal, □ high (about 1 000 m (3 281 ft) or more)

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 O N, 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

ficulty

dif

□ starter motor not rotating. □ 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 fully 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

low speed

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

Page 84

3-26 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

□ brake dragging. □ engine overheating. □ clutch slipping. □ other:

Poor running or no power at

gh 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:

Page 85

FUEL SYSTEM (DFI) 3-27

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 t rouble 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 wiring 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 chapter 16).

Starter m otor rotating but engine doesn’t

n over:

tur

Starter clutch trouble Inspect (see chapter 9).

Starter idle gear trouble Inspect (see chapter 9).

Engine won’t turn over:

Valv e seizure 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

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

Engine flooded:

Spark plug dirty, broken or gap maladjusted Clean spark plugs and adjust plug gap (see

Starting technique faulty When flooded, don’t crank engine with throttle

Inspect and replace fuel pump (see chapter 3).

er 2).

chapt

ully opened.

Page 86

3-28 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

No spark or spark weak:

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

Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral. whether sidestand up or not

Though clutch lever pulled in but sidestand up S idestand down and clutch lever pulled in 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 pow er supply trouble Inspect (see chapter 3).

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

Spark plug dirty, broken or gap maladjusted Clean spark plug and adjust plug gap (see

Spark plug c ap 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).

Neutral, starter lockout or sidestand switch Inspect each switch (see chapter 16). 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 w iring 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

Leak from oil filler cap, crankcase breather hose Inspect and repair or replace (see chapter 3). or air cleaner drain hose

Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see

Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see

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 Inspect (see chapter 3).

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).

whether gear in neutral, or not.

chapter

Clean or reinstall (see chapter 3).

chapter 3).

2).

Page 87

FUEL SYSTEM (DFI) 3-29

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).

Valvespringbrokenor weak Inspect and replace (see chapter 5).

Valve not seating properly (valve bent, worn or Inspect and repair or replace (see chapter 5). 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, Inspect and replace (see chapter 5). seizure or spring broken)

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

Poor Running at Low Speed

Symptoms or Possible Causes Actions (chapter)

Spark weak:

Batte

Spark plug dirty, broken, or gap maladjusted Clean spark plugs and adjust plug gap (see

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).

Crankshaft sensor trouble Inspect (see chapter 16).

Ignition coil trouble

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 Inspect and repair (see chapter 3).

Throttle body assy loose Reinstall (see chapter 3).

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 c hapter 3).

Fuel pressure regulator clogged Inspect fuel pressure and replace fuel pump (see

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

Thermostat trouble Inspect and replace (see chapter 4).

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

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

Unstable (rough) idling:

ISC valve trouble Inspect (see chapter 3).

Fuel injector trouble Inspect ( see chapter 3).

voltage low Inspect and charge (see chapter 16).

chapter 2).

Inspect (see chapter 16).

er 3).

chapt

Page 88

3-30 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

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 Inspect (see chapter 3).

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 Inspect (see chapter 3). 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 Inspect and replace (see chapter 3).

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 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 or stem seal damaged 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 Inspect and repair or replace (see chapter 5). 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 Inspect and repair or replace (see chapter 3). hose

Fuel pump trouble Inspect (see chapter 3).

Fuel injector trouble

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

Inspect (see chapter 3).

Page 89

FUEL SYSTEM (DFI) 3-31

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

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

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

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

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

Delay of ignition timing Inspect pickup coil and IC igniter in ECU (see

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 Change fuel. Inspect and clean fuel system (see

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

Fuel pump trouble Inspect (see chapter 3).

Fuel injector 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).

Ignition coil trouble

Engine oil level too high Repair (see chapter 7)

Spark plug dirty, broken or gap maladjusted Clean spark plugs and adjust plug gap (see

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

Surge:

Unstable fuel pressure Fuel pressure regulator trouble (Inspect and

Fuel injector trouble Inspect ( see chapter 3).

Water temperature sensor trouble

Backfiring when deceleration:

Spark plug dirty, broken or gap maladjusted Clean spark plugs and adjust plug gap (see

Too low fuel pressure Inspect (see chapter 3).

Crankshaft sensor trouble Inspect (see chapter 3).

Fuel pump trouble Inspect (see chapter 3).

Throttle sensor malfunction Inspect (see chapter 3).

Remedy (see chapter 3).

chapter 16).

chapter 3).

Inspect and replace (see chapter 16).

chapter 2)

Inspect (see chapter 3).

replace fuel pump) or kinked fuel line (Inspect and repair fuel line) (see chapter 3).

Inspect (see chapter 3).

chapter 2)

Page 90

3-32 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (chapter)

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).

Vacuum switch valve broken Inspect and replace (see chapter 5).

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

After f ire:

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 Inspect and replace (see chapter 16).

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

Fuel injector trouble Inspect (see chapter 3).

Engine overheating (see Overheating of Troubleshooting Guide, see

chapter 17)

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 (see Overheating of Troubleshooting Guide in

Vacuum switch valve trouble Inspect and replace (see chapter 5).

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

Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight,

Inspect tightness of bolts and nuts (see chapter

or bearing wear (see chapter 11).

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

chapter 17)

and examine wires for signs of burning or fraying (see chapter 3).

Page 91

FUEL SYSTEM (DFI) 3-33

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 Clean spark plug and adjust plug gap (see

chapt

er 2).

Spark plug cap or high tension wiring trouble Inspect plug cap and 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).

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 Change fuel. Inspect and clean fuel system (see

er 3).

chapt

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

e blows.

fus

Fuel pump trouble Inspect (see chapter 3).

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 l oose 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).

Valvespringbrokenor weak Inspect and replace (see chapter 5).

Valve not seating properly (valve bent , worn or

on accumulating on the seating surface)

carb

KACR (compression release cam) sticks open (engi

ne stalls when moving off)

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

Inspect and repair or replace (see chapter 3)

Inspect and repair or replace (see chapter 5).

Page 92

3-34 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes Actions (detailed reference)

HLA ( hydraulic lash adjuster) damaged (worn,

eizure or spring broken)

Knocking:

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

Fuel poor quality or incorrect (Use high-octone Change fuel (see chapter 3). gasoline recommended in the Owner’s Manual)

Spark plug incorrect Replace i t 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 Inspect caliper fluid seal damage or clogging

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

Engine overheating (see Overheating of Troubleshooting Guide in

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

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

Drive train trouble Inspect tightness of bolts and nuts (see chapter

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

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

Vacuum switch 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 Replace muffler (see chapter 5). overheating (KLEEN)

Exhaust Smokes Excessively: White sm okes:

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

Brown smoke :

Air cleaner duct loose Reinstall (see chapter 3).

Inspect and replace (see chapter 5).

Inspect t hrottle cable and lever linkage (see

apter 3).

of master cylinder relief and supply ports (see chapter 12).

chapter 17)

2) or bearing wear (see chapter 11).

Inspect and replace (see chapter 3).

Page 93

FUEL SYSTEM (DFI) 3-35

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).

Page 94

3-36 FUEL SYSTEM (DFI)

Self-Diagnosis

Self-diagnosi s Procedures

When a problem occurs with the DFI system, the FI indi-

○

cator LED light [A] and FI symbol [B] go on.

Remove the r ear and front seats (see Frame chapter).

•

Ground [A] the self-diagnosis terminal [B] (yellow lead) to

•

the battery (–) terminal [C], using a wire [D].

Turn the ignition SW ON.

•

Push the MODE button [A] and display the odo meter.

•

Push the RESET button [B] for more than two seconds.

•

The LCD FI characters [C] are displayed.

Count the blinks of the LED light [D] 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.

Any of the following procedures (conditions) ends self

•

-diagnosis.

When pushing the RESET button more than 2 seconds

○

and 2 seconds passed.

When the ignition SW is turned to OFF.

○

Pushing the MODE button and the trip meter is displayed.

○

When the ECU receives the speed sensor signal.

○

Page 95

Self-Diagnosis

FUEL SYSTEM (DFI) 3-37

Service Code Reading

Service codes are shown by a series of long and short blinks of t he FI indicator LED light as shown

○

below. Read 10th digit and unit digit as the FI indicator LED light blinks.

○

When there are a number of problem s, all the fault codes can be stored and the display will be-

○

gin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is r epeated until the ignition SW is turned OFF. For example, if four problems occurred in the order of 31, 15, 41, 12, the fault codes are displayed

○

from the lowest number in the order listed.

2 → 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 l ight doesn’t go on, and no fault codes can be displayed.

FI Indicator LED Light

C Valves

IS 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.

○

Page 96

3-38 FUEL SYSTEM (DFI)

Self-Diagnosis

Each service code is conti i ion SW is turned OFF. nuously repeated three times until the gnit

○

ServiceCodeErasing

When the repair has been done, the LED light will not show fault codes any more.

○

But even if the repair has been done, the ignition SW is t urned OFF, or the battery is disconnected,

all the fault codes remain in the ECU, which need not be absolutely erased.

Service Code Table

Service

Code

11 Throttle sensor malfunction, wiring open or short

12 Vacuum sensor malfunction, wiring open or short

14 Water temperature sensor malfunction, wiring open or short

21 Pickup coil #1 malfunction, wiring open or short

FI Indicator LED Light

Problems (1)

Inlet air temperature sensor malfunction, wiring open or

hort

Atmospheric pressure sensor m alfunction, wiring open or

hort

22 Pickup coil #2 malfunction, wiring open or short

31 Vehicle-down sensor malfunction wiring open or short

41 Injector #1 malfunction, wiring open or short

Page 97

Self-Diagnosis

FUEL SYSTEM (DFI) 3-39

Service

Code

42 Injector #2 malfunction, wiring open or short

45 Fuel pump malfunction, wiring open or short

Footnotes:

(1) The ECU may be involved in these problems. If all the parts and circuits checked out good, be

sure 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.

For Front Cylinder

#1: #2: For Rear Cylinder

Backups

The ECU takes the following measures to prevent engine damage when the DFI electronical or the

○

ignition system parts have troubles.

Service

Codes

FI Indicator LED Light Problems (1)

Ignition coil primary winding #1 malfunction, wiring open

short

Ignition coil primary winding #2 malfunction, wiring open

short

to check the ECU for ground and power supply. If the ground and power supply are checked

Parts

Throttle

Sensor

Vacuum

Sensor

Inlet Air

emperature

Sensor

Water

emperature

Sensor

Atmospheric

essure

Sensor

Output Signal U sable

Range

Throttle Valve Opening Angle α

Absolute Vacuum

= 63 mmHg ∼ 860 mmHg

Inlet Air Temperature

a = – 47°C ∼ + 178°C

Water Temperature

w = – 28C° ∼ + 161°C

Absolute Atmospheric Pressure

Pa = 63 mmHg ∼ 860 mmHg

or Criteria

=– 4° ∼ + 85°

Backups by ECU

If the throttle sensor system fails (the

ignal is out of the usable range, wiring

s short or open), the ECU locks ignition timing into the ignition timing at full throttle open position and sets the DFI in the D-J method (1).

If the inlet air pressure sensor system f

ails (the signal Pv is out of the usable

range, wiring short or open), the ECU sets the DFI in the α - N method (1).

If the inlet air temperature sensor fails (

the signal is out of the usable range, wiring short or open), the ECU sets Ta at 45°C.

If the water temperature sensor system f

ails (the signal is out of the usable range, wiring short or open), the ECU sets Tw at 86°C.

If the atmospheric pressure sensor

ystem fails (the signal is out of the

s usable range, wiring short or open), the ECU sets Pa at 760 mmHg (the standard atmospheric pressure).

Page 98

3-40 FUEL SYSTEM (DFI)

Self-Diagnosis

Service

Codes

45 Fuel Pump

Note:

(1) When the engine load is light like at idling or low speed, the ECU determines injection quan-

ity by calculating from throttle vacuum (inlet air pressure sensor output voltage) and engine speed

t (crankshaft sensor output voltage). This method is called D-J method (low-speed mode). As engine speed increases, and the engine load turns middle to heavy, the ECU determines injection quantity by calculating from throttle opening (throttle sensor output voltage) and engine speed. This method is called α – N method (high-speed mode).

Parts

Crankshaft

Sensor

Ignition

l #1

Coi

Ignition

l #2

Coi

Sensor

Crankshaft

Sensor

Vehicle-down

Fuel Injector

Output Signal Usable

Range

Either crankshaft sensor

send signals

must (output voltage)

8 or more times continuously to the ECU.

Vehicle-down Sensor

put Voltage (signal)

Out

Vd = 0.2 V ∼ 4.6 V

The injector must send

ignals (output voltage)

s 16 or more times continuously to the ECU.

The injector must send

ignals (output voltage)

s 16 or more times continuously to the ECU.

The pump must send

ignals (output voltage)

s continuously to the ECU.

The ignition coil primary

nding must send signals

wi (output voltage) continuously to the ECU.

The ignition coil primary

nding must send signals

wi (output voltage) continuously to the ECU.

or Criteria

Backups by ECU

If either crankshaft sensor generates 8 or more signals, the ECU runs the engine by the signal of the good crankshaft sensor, but neither crankshaft sensors generate signals, the engine stops by itself.

If the vehicle-down sensor system has

lures (the output voltage Vd is out of

fai the usable range, wiring short or open), the ECU shuts off the fuel pump, the fuel injectors and the ignition system.

If the injector #1 fails (signals less than

times, wiring short or open), the ECU

16 shuts off the signal to the injector. Fuel is not supplied to the cylinder #1, though the engine keeps running.

If the injector #2 fails (signals less than

times, wiring short or open), the ECU

16 shuts off the signal to the injector. Fuel is not supplied to the cylinder #2, though the engine keeps running.

If the fuel pump fails (no signals to ECU,

ing short or open), the ECU shuts off

wir the pum p, and then the engine stops because of fuel pressure drop.

If the ignition primary winding #1 has

lures (no signal, wiring short or open),

fai the ECU shuts off the injector #1 to stop fuel to the cylinder #1, though the engine keeps running.

If the ignition primary winding #2 has

lures (no signal, wiring short or open),

fai the ECU shuts off the injector #2 to stop fuel to the cylinder #2, though the engine keeps running.

Page 99

Throttle Sensor (Service Code 11)

Throttle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.

Front View [B]

Input Voltage Inspection

NOTE

Be sure the battery is fully charged.

○

The inspection is the same as “Input Voltage Inspec-

○

tion” of the inlet air pressure sensor or the atmospheric pressure sensor.

Turn the ignition SW OFF.

•

Remove the ECU (see this chapter). Do not disconnect

•

the ECU connectors. Connect a digital voltmeter [A] to the connector [B], using

•

two needle adapters [ C].

Special Tool - Needle Adapter Set: 57001–1457

Measure the input voltage to the throttle sensor with the

•

engine stopped, and with the connectors joined. Turn the ignition SW ON.

•

FUEL SYSTEM (DFI) 3-41

Throttle Sensor Input Voltage

Connections to ECU Connector

Met

er (+) → BL/W lead (terminal 35)

Meter (–) → BR /BK lead (terminal 11)

Standard: 4.75 ∼ 5.2

Turn the ignition SW OFF.

•

If the reading of input voltage is less than the standard, check the ECU for its ground, and power supply (see ECU section). If the input voltage is within the standard range, remove the fuel tank, and check t he wiring from the ECU to the throttle sensor for continuity. If the wiring is good, check the output voltage of the throttle sensor.

5 V DC

Page 100

3-42 FUEL SYSTEM (DFI)

Throttle Sensor (Service Code 11)

Output Voltage Inspection

Start the engine and warm it up thoroughly.

•

Check idle speed to make sure the throttle opening is cor-

•

rect.

Idle Speed

Standard: 950 ± 50 r/min (rpm)

If the idle speed is out of the specified range, adjust the idle speed (see this chapter). Turn off the ignition switch.

•

Remove the ECU (see this chapter). Do not disconnect

•

the ECU connectors. Connect a digital meter [A] to the connector [B], using the

•

needle adapters [C].

Special Tool - Needle Adapter Set: 57001–1457

CAUTION

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

Measure the output voltage of the sensor with the engine

•

stopped, and with the connector joined. Turn the ignition SW ON.

•

Throttle Sensor Output Voltage

Connections to Sensor

ter (+) → Y/W lead (terminal 26)

Meter (–) → BR/BK lead (terminal 11)

Standard: 0

If the output voltage is normal, replace the ECU. If the reading is out of the standard range, inspect the throttle sensor resistance.

After throttle sensor inspection, remove the needle

•

adapters, and apply silicone sealant to the seals [A] of the connector [B] for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of Connectors

.584 ∼ 0.604 V DC

(at idle throttle opening)

4.29 ∼ 4.

(at full throttle opening)

59 V DC

Kawasaki VULCAN 1600 CLASSIC Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual