Kawasaki Z1000SX, Z1000SX ABS, Ninja 1000, Ninja 1000 ABS Service manual

Z1000SX

Z1000SX ABS

Ninja 1000

Ninja 1000 ABS

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Clutch 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j

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

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

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

Crankshaft/Transmission 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
Appendix 17 j

Z1000SX

Z1000SX ABS

Ninja 1000

Ninja 1000 ABS

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 Division/Motorcycle & Engine Company/Kawasaki
Heavy Industries, Ltd., Japan.

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

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

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

© 2010 Kawasaki Heavy Industries, Ltd. 2nd Edition (0) : Jun. 20, 2011

LIST OF ABBREVIATIONS

A

ABDC after bottom dead cente

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

°C degree(s) Celsius r revolution

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator rea

ft foot, feet

g

h

L liter(s)

ampere(s)

r

gram(s)
hour(s) Ω ohm(s)

lb
m

V
W

pound(s)
meter(s)

ding
volt(s)
watt(s)

COUNTRY AND AREA CODES

AT Austria
AU Australia
BR Brazil

CA Canada US United States
CAL California

CH Switzerland

DE Germany

GB
SEA-B1 Southeast Asia B1 (with Evaporative

SEA-B2 Southeast Asia B2

A

WVT
(FULL H)

GB WVTA
(FULL H)

WVTA
(78.2 H)

United Kingdom

ssion Control System)

Emi

TA Model with Honeycomb

WV
Catalytic Converter (Full Power)

WVTA Model with Honeycomb Catalytic
Converter (Left Side Traffic, Full Power)

WVTA Model with Honeycomb
Catalytic Converter (78.2 Kw Power)

EMISSION CONTROL INFORMATION

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

1. Crankcase Emission Control System
Thissystemeliminatesthereleaseof crankcase vapors intothe atmosphere. Instead, thevapors

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

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

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

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

cludes a catalytic converter system.

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

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

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

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

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

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

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

NOTE

The phrase “remo ve or render inoperative any device or element of design” has been generally

○

interpreted as follows.

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

2. Tampering could include.

a.Maladjustment of vehicle components such that the emission standards are ex-

ceeded.

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

or durability of the motorcycle.

c.Addition of components or accessories that result in thevehicle exceedingthestan-

dards.

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

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW,THE VIOLATIONOF WHICH IS PUNISHABLE BY CIVIL PENALTIESNOT EXCEEDING
$10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

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

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

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

•

with Federal regulations.

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

•

Removal of the air box or air box cover.

•

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

•

modifications result in increased noise levels.

Foreword

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

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

For the duration of the warranty period,

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

To get the longest life out of your vehicle.

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Rememberto keep completerecords of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

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

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

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

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

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

This manual contains four more symbols
which will help you distinguish different types
of information.

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

takebased on the results ofthe test or inspec-

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

lows.

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

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

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

1

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following.

Battery Ground

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

Edges of Parts

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

Solvent

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

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

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or
otherforeign materials entering into sealedareas during ve­hicle disassembly can cause excessive wear and decrease
performance of the vehicle.

Before Servicing

Arrangement and Cleaning of Removed Pa rts

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 Remov ed Parts

After all the partsincluding 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 partsfor 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, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.

Force

Use common sense during disassembly and assembly,
excessive forcecancause 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 the new gaskets and replace the used O-rings when
re-assembling.

Liquid Gasket, Non-permanent Locking Agent

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

Before Servicing

Press

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

Ball Bearing and Needle Bearing

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

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

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

Donot removepressedoil orgrease seals unlessremoval
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

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

Circlips, Cotter Pins

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

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

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

Direction of Engine Rotation

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

Electrical Wires

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

Instrument

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

Model Identification

ZX1000GB (United States and Canada) Left Side View

GENERAL INFORMATION 1-7

ZX1000GB (United States and Canada) Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

Model Identification

ZX1000GB (Europe) Left Side View

ZX1000GB (Europe) Right Side View

Model Identification

ZX1000HB Left Side View

GENERAL INFORMATION 1-9

ZX1000HB Right Side View

1-10 GENERAL INFORMATION

General Specifications

Items ZX1000GB ∼ GC/HB ∼ HC

Dimensions

Overall Length 2 105 mm (82.87 in.)
Overall Width 790 mm (31.1 in.)
Overall Height/High Position 1 170 mm (40.06 in.)/1 230 mm (48.43 in.)
Wheelbase
Road Clearance 135 mm (5.31 in.)
Seat Height 820 mm (32.28 in.)
Curb Mass:

ZX1000G 228 kg (503 lb)
ZX1000H 231 kg (509 lb)
Front:

ZX1000G 117 kg (258 lb)
ZX1000H 118 kg (260 lb)

Rear:

ZX1000G 111kg(245lb)
ZX1000H

Fuel Tank Capacit

Performance

Minimum Turning Radius 3.1 m (10.1 ft)

Engine

Type
Cooling System
Bore and Stroke 77.0 × 56.0 mm (3
Displacement 1043cm³(63.64cuin.)
Compression Ratio 11.8 : 1
Maximum Horsepower 101.5 kW (138 PS) @9 600 r/min (rpm)

Maximum Torque 110 N·m (11.2 kgf·m, 81.1 ft·lb) @7 800 r/min (rpm)

Carburetion System FI (Fuel Injection) KEIHIN TTK38 × 4
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter)
Ignition Timing From 10° BTDC @1 100 r/min (rpm) to 40.2° BTDC

Spark Plug NGK CR9EIA-9
Cylinder Numbering Method Left to right, 1-2-3-4
Firing Orde
Valve Timing:

Intake:

Open 31° BTDC
Close 65° ABDC

r

y

1 445 mm (56.89 in.)

113 kg (249 lb)
19 L (5.0 US gal.)

4-stroke, DOHC, 4-cylinder
Liquid-cooled

.03 × 2.20 in.)

(SEA-B1/B2) 100 kW (136 PS) @9 000 r/min (rpm)
(WVTA (78.2 H)) 78.2 kW (106 PS) @9 100 r/min (rpm)
(CA, US) – – –

(WVTA (78.2 H)) 95 N·m (9.7 kgf·m, 70 ft·lb) @7 500 r/min (rpm)
(CA, US) – – –

@5 200 r/min (rpm)

1-2-4-3

GENERAL INFORMATION 1-11

General Specifications

Items ZX1000GB ∼ GC/HB ∼ HC

Duration 276°

Exhaust:

Open 58° BBDC
Close 18° ATDC

Duration 256°
Lubrication System Forced lubrication (wet sump)
Engine Oil:

Type
Viscosity
Capacity 4.0 L (4.2 US qt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio
Clutch Type
Transmission:

Type 6-speed, constant mesh, return shift

Gear Ratios:

1st 2.600 (39/15)
2nd
3rd
4th
5th 1.238 (26/21)
6th 1.136 (25/22)

Final Drive System:

Type Chain drive

Reduction Ratio 2.733 (41/15)

Overall Drive Ratio 5.055 @Top gear

Frame

Type Tubular, diamond
Caster (Rake Angle) 24.5°
Trail
Front Tire:

Type Tubeless

Size 120/70 ZR17 M/C (58W)

Rim Size J17M/C × MT3.50
Rear Tire:

Type Tubeless

Size 190/50 ZR17 M/C (73W)

Rim Size J17M/C × MT6.00
Front Suspension:

Type Telescopic fork (upside-down)

Wheel Travel 120 mm (4.72 in.)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40

1.627 (83/51)
Wet multi disc

1.950 (39/20)

1.600 (24/15)

1.389 (25/18)

102 mm (4.02 in.)

1-12 GENERAL INFORMATION

General Specifications

Items ZX1000GB ∼ GC/HB ∼ HC

Rear Suspension:

Type Swingarm
Wheel Travel 138 mm (5.43 in.)

Brake Type:

Front Dual discs
Rear Single disc

Electrical Equipment

Battery 12 V 8 Ah
Headlight:

Type Semi-sealed beam
High Beam 12 V 55 W

Low Beam 12 V 55 W
Tail/Brake Light LED
Alternator:

Type Three-phase AC

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

Unit Conversion Table

GENERAL INFORMATION 1-13

Prefixes for Units:

Prefix Symbol Power
mega M × 1 000 000
kilo k ×1000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001

Units of Mass:

kg ×2.205=lb
g × 0.03527 = oz

Units of Volume:

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

qt (US)
qt (IMP)

Units of Length:

km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb

Units of Pressure:

kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa

Units of Speed:

km/h

× 0.6214 = mph

Units of Force:

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

Units of Temperature:

Units of Power:

kW ×1.360=PS
kW ×1.341=HP
PS
PS × 0.9863 = HP

× 0.7355 = kW

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent...................................................................................................... 2-7

Specifications ......................................................................................................................... 2-13

Special Tools .......................................................................................................................... 2-15

Periodic Maintenance Procedures.......................................................................................... 2-17

Fuel System (DFI)................................................................................................................ 2-17

Throttle Control System Inspection................................................................................... 2-17

Engine Vacuum Synchronization Inspection..................................................................... 2-17

Idle Speed Inspection ....................................................................................................... 2-21

Idle Speed Adjustment...................................................................................................... 2-22

Fuel Hose Inspection (fuel leak, damage, installation condition)...................................... 2-22

Evaporative Emission Control System (CAL and SEA-B1 Models) Inspection................. 2-23

Cooling System.................................................................................................................... 2-24

Coolant Level Inspection................................................................................................... 2-24

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .......... 2-24

Engine Top End ................................................................................................................... 2-24

Valve Clearance Inspection .............................................................................................. 2-24

Valve Clearance Adjustment............................................................................................. 2-26

Air Suction System Damage Inspection............................................................................ 2-29

Clutch................................................................................................................................... 2-30

Clutch Operation Inspection.............................................................................................. 2-30

Wheels/Tires........................................................................................................................ 2-31

Air Pressure Inspection..................................................................................................... 2-31

Wheel/Tire Damage Inspection......................................................................................... 2-31

Tire Tread Wear Inspection............................................................................................... 2-31

Wheel Bearing Damage Inspection .................................................................................. 2-32

Final Drive............................................................................................................................ 2-33

Drive Chain Lubrication Condition Inspection................................................................... 2-33

Drive Chain Slack Inspection............................................................................................ 2-33

Drive Chain Slack Adjustment .......................................................................................... 2-34

Wheel Alignment Inspection ............................................................................................. 2-34

Wheel Alignment Adjustment............................................................................................ 2-34

Drive Chain Wear Inspection............................................................................................ 2-35

Chain Guide Wear Inspection........................................................................................... 2-35

Brakes.................................................................................................................................. 2-36

Brake Fluid Leak (Brake Hose and Pipe) Inspection........................................................ 2-36

Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-37

Brake Operation Inspection .............................................................................................. 2-37

Brake Fluid Level Inspection............................................................................................. 2-37

Brake Pad Wear Inspection.............................................................................................. 2-38

Brake Light Switch Operation Inspection.......................................................................... 2-39

Suspension.......................................................................................................................... 2-40

Front Forks/Rear Shock Absorber Operation Inspection.................................................. 2-40

Front Fork Oil Leak Inspection.......................................................................................... 2-40

Rear Shock Absorber Oil Leak Inspection........................................................................ 2-40

Rocker Arm Operation Inspection..................................................................................... 2-40

Tie-Rod Operation Inspection........................................................................................... 2-41

Steering ............................................................................................................................... 2-41

Steering Play Inspection................................................................................................... 2-41

Steering Play Adjustment.................................................................................................. 2-41

2

2-2 PERIODIC MAINTENANCE

Steering Stem Bearing Lubrication................................................................................... 2-43

Electrical System ................................................................................................................. 2-44

Lights and Switches Operation Inspection........................................................................ 2-44

Headlight Aiming Inspection ............................................................................................. 2-46

Sidestand Switch Operation Inspection............................................................................ 2-47

Engine Stop Switch Operation Inspection......................................................................... 2-48

Others.................................................................................................................................. 2-49

Chassis Parts Lubrication................................................................................................. 2-49

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-51

Replacement Parts.............................................................................................................. 2-52

Air Cleaner Element Replacement.................................................................................... 2-52

Fuel Hose Replacement ................................................................................................... 2-52

Coolant Change................................................................................................................ 2-54

Radiator Hose and O-ring Replacement........................................................................... 2-56

Engine Oil Change............................................................................................................ 2-57

Oil Filter Replacement ...................................................................................................... 2-57

Brake Hose Replacement................................................................................................. 2-58

Brake Fluid Change.......................................................................................................... 2-59

Master Cylinder Rubber Parts Replacement.................................................................... 2-61

Caliper Rubber Parts Replacement.................................................................................. 2-62

Spark Plug Replacement.................................................................................................. 2-66

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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

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

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Fuel System

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

Engine vacuum synchronization ­inspect

year

• • • •

• • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-17

2-17

Idle speed - inspect
Fuel leak (fuel hose and pipe) -

inspect
Fuel hose and pipe damage -

inspect
Fuel hose and pipe installation

condition - inspect
Evaporative emission control

system function (CAL), (SEA-B1)

-inspect

Cooling System

Coolant level - inspect
Coolant leak (water hose and

pipe) - inspect
Water hose damage - inspect year
Water hose installation condition -

inspect

Engine Top End

US,CA,CAL

Valve clearance ­inspect

Air suction system damage ­inspect

Clutch

Clutch operation (play,
disengagement, engagement) ­inspect

Wheels and Tires

Model
Other than

US,CA,CAL
Models

year

year

year

year

year

• • • •

• • • •

• • • •

• • • •

• • • • • • •

• • • •

• • • •

• • • •

• • • •

•

Every 42 000 km (26 250 mile) 2-24

• • •

• • • •

2-21
2-22

2-22

2-22

2-23

2-24
2-24
2-24
2-24

2-24

2-29

2-30

Tire air pressure - inspect year
Wheel/tire damage - inspect
Tire tread wear, abnormal wear -

inspect
Wheel bearing damage - inspect year

• • •

• • •

• • •

• • •

2-31
2-31

2-31
2-32

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Final Drive

Drive chain lubrication condition ­inspect #

Drive chain slack - inspect # Every 1 000 km (600 mile) 2-33
Drive chain wear - inspect #
Drive chain guide wear - inspect

Brakes

Brake fluid leak (brake hose and
pipe) - inspect

Brake hose and pipe damage ­inspect

Brake hose and pipe ins
condition - inspect

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

Brake fluid level - inspect

tallation

year

year

year

year

6

months

Every 600 km (400 mile) 2-33

• • •

• • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

* O DOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-35
2-35

2-36

2-37

2-37

2-37

2-37

Brake pad wear - inspect #
Brake light switch operation -

inspect

Suspension

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

Front forks/rear shock absorber
oil leak - inspect

Rocker arm operation - inspect
Tie-rods operation - inspect

Steering

Steering play - inspect
Steering stem bearings - lubricate 2 years

Electrical System

Lights and switches operation ­inspect

Headlight aimin
Sidestand switch operation -

inspect
Engine stop switch operation -

inspect

Others

g - inspect

year

year

year
year
year

year

• • • • • •

• • • • • • •

• • •

• • •

• • •

• • •

• • • •

•

• • •

• • •

• • •

• • •

2-38
2-39

2-40

2-40
2-40

2-41

2-41
2-43

2-44
2-46
2-47

2-48

Chassis parts - lubricate year
Bolts and nuts tightness - inspect

• • •

• • • •

2-49
2-51

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

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

frequent starting/stopping.

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

2-6 PERIODIC MAINTENANCE

Periodic Maintenance Chart
Periodic Replacement Parts

FREQUENCY Whichever

comes

first

ITEM Every (0.6) (7.5) (15) (22.5) (30)
Air cleaner element # - replace Every 18 000 km (11 250 mile) 2-52
Fuel hose - replace 5 years 2-52

*ODOMETE R READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

See

Page

Coolant - change 3 years
Radiator hose and O-ring - replace 3 years
Engine oil # - change year
Oilfilter-replace
Brake hose - replace 4 years
Brake fluid - change 2 years
Rubber parts of master cylinder and caliper -

replace
Spark plug - replace

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

frequent starting/stopping.

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

year

4 years

• • • • •

• • • • •

• •

• • • •

•

•

•

•

2-54
2-56
2-57
2-57
2-58
2-59

2-61,

2-62
2-66