KAWASAKI Z 1000 SX User Manual

0 (0)

Z1000

Z1000 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

Z1000

Z1000 ABS

Motorcycle

Service Manual

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

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

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

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

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center

BBDC before bottom dead center

BDC

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 reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

N Pa PS

newton(s) pascal(s) horsepower

COUNTRY AND AREA CODES

AU Australia CA Canada MY Malaysia CAL California US United States CH Switzerland WVTA Whole Vehicle Type Approval DE Germany

ustria

rance

United Kingdom

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

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

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

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

cludes a catalytic converter system.

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

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

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

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

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

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

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

NOTE

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

○

interpreted as follows.

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

2. Tampering could include.

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

ceeded.

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

or durability of the motorcycle.

c.Addition of components or accessories thatresultinthe vehicle exceeding the stan-

dards.

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

element of design of the emission control systems.

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

TAMPERING WITH N OISE CONTROL SYSTEM PROHIBITED

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

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

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

•

with Federal regulations.

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

•

Removal of the air box or air box cover.

•

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

•

modifications result in increased noise levels.

Foreword

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

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures beforestarting 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 a re 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. Anyowner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle.

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Rememberto keepcomplete records ofmain-

•

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This manual contains four more symbols (in additionto WARNINGandCAUTION) whichwill 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 exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

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

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

1-2 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 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 removedparts forcorrosion, discoloration, or otherdamage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

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

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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

Tightening Torque

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

Force

Use common sense during disassembly and assembly, excessive forcecan 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 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 shown.

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

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

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

Circlips, Cotter Pins

Replace 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

ZR1000B7F (United States and Canada) Left Side View

GENERAL INFORMATION 1-7

ZR1000B7F (United States and Canada) Right Side View

1-8 GENERAL INFORMATION

Model Identification

ZR1000B7F (Europe) Left Side View

ZR1000B7F (Europe) Right Side View

Model Identification

ZR1000C7F Left Side View

GENERAL INFORMATION 1-9

ZR1000C7F Right Side View

Frame Number Engine Number

1-10 GENERAL INFORMATION

General Specifications

Items ZR1000B7F, ZR1000C7F

Dimensions

Overall Length 2 090 mm (82.28 in.) Overall Width 780 mm (30.71 in.) Overall Height 1 065 mm (41.93 in.) Wheelbase 1 445 mm (56.89 in.) Road Clearance 160 mm (6.30 in.) Seat Height 820 mm (32.28 in.) Dry Mass:

ZR1000B7F 205 kg (452.0 lb) ZR1000C7F 209 kg (460.8 lb)

Curb Mass:

Front:

ZR1000B7F 112 kg (247.0 lb) ZR1000C7F 114 kg (251.4 lb)

Rear:

ZR1000B7F 116 kg (255.8 lb) ZR1000C7F 118 kg (260.2 lb)

Fuel Tank Capacity 18.5 L (4.9 US gal.)

Performance

Minimum Turning Radius 3.0 m (9.8 ft)

Engine

Type 4-stroke, DOHC, 4-cylinder Cooling System Liquid-cooled Bore and Stroke 77.2 × 50.9 mm (3.04 × 2.00 in.) Displacement 953 cm³ (58.15 cu in.) Compression Ratio 11.2 : 1 Maximum Horsepower 92.0 kW (125 PS) @10 000 r/min (rpm)

(FR) 78.2 kW (106 PS) @9 000 r/min (rpm) (CA),(CAL),(US)–––

Maximum Torque 98.7 N·m (10.1 kgf·m, 72.8 ft·lb) @8 200 r/min (rpm)

(FR) 92.4 N·m (9.4 kgf·m, 68.2 ft·lb) @7 700 r/min (rpm)

(CA),(CAL),(US)––– Carburetion System FI (Fuel Injection) KEIHIN TTK36 × 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 37.5° BTDC

@5 500 r/min (rpm) Spark Plug NGK CR9EIA-9 Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order

1-2-4-3

GENERAL INFORMATION 1-11

General Specifications

Items ZR1000B7F, ZR1000C7F

Valve Timing:

Inlet:

Open 38° BTDC Close 58° ABDC Duration 276°

Exhaust:

Open 51° BBDC Close 25° ATDC

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

Type

Viscosity SAE 10W-40 Capacity 3.8L(4.0USqt)

Drive Train

Primary Reduction System:

Type

Reduction Ratio 1.714 (84/49) Clutch Type Wet multi disc Transmission:

Type

Gear Ratios:

1st 2nd 1.882 (32/17) 3rd 1.556 (28/18) 4th 1.333 (28/21) 5th 1.200 (24/20) 6th 1.095 (23/21)

Final Drive System:

Type Chain drive

Reduction Ratio 2.667 (40/15)

Overall Drive Ratio 5.007 @Top gear

Frame

Type Tubular, diamond Caster (Rake Angle) 24.5° Trail 103 mm (4.06 in.) Front Tire:

Type Tubeless

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

Rim Size 17 × 3.50

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

Gear

6-speed, constant mesh, return shift

2.571 (36/14)

1-12 GENERAL INFORMATION

General Specifications

Items ZR1000B7F, ZR1000C7F

Rear Tire:

Type Tubeless Size 190/50 ZR17 M/C (73W) Rim Size 17 × 6.00

Front Suspension:

Type Telescopic fork Wheel Travel 120 mm (4.72 in.)

Rear Suspension:

Type Swingarm (uni-trak) Wheel Travel 150 mm (5.91 in.)

Brake Type:

Front Dual discs Rear

Electrical Equipment

Battery 12 V 8 Ah Headlight:

Type Semi-sealed beam

Bulb 12 V 55 W × 2/55 W (Hi/Lo) Tail/Brake Light 12 V 0.5/4.1 W (LED) Alternator:

Type Three-phase AC

Rated Output 24 A/14 V @5 000 r/min (rpm)

Single disc

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 ×1000000 kilo k × 1 000 centi c ×0.01 milli m × 0.001 micro µ × 0.000001

Units of Mass:

kg ×2.205=lb g × 0.03527 = oz

Units of Volume:

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

gal (US) gal (imp)

oz (US) oz (imp)

Units of Length:

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

Units of Torque:

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

× 9.807 = N·m ×7.233= × 86.80 = in·lb

ft·lb

Units of Pressure:

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

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

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

Units of Temperature:

Units of Power:

kW × 1.360 = kW × 1.341 = HP PS × 0.7355 = kW PS × 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

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

Specifications ......................................................................................................................... 2-12

Special Tools.......................................................................................................................... 2-14

Periodic Maintenance Procedures.......................................................................................... 2-15

Fuel System (DFI)................................................................................................................ 2-15

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

Throttle Control System Inspection................................................................................... 2-15

Engine Vacuum Synchronization Inspection..................................................................... 2-16

Idle Speed Inspection ....................................................................................................... 2-19

Idle Speed Adjustment...................................................................................................... 2-20

Fuel Hose Inspection (fuel leak, damage, installation condition)...................................... 2-20

Evaporative Emission Control System (CAL Model) ........................................................... 2-21

Evaporative Emission Control System Inspection ............................................................ 2-21

Cooling System.................................................................................................................... 2-22

Coolant Level Inspection................................................................................................... 2-22

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .......... 2-23

Engine Top End................................................................................................................... 2-23

Valve Clearance Inspection .............................................................................................. 2-23

Valve Clearance Adjustment............................................................................................. 2-24

Exhaust Butterfly Valve Cable Inspection......................................................................... 2-28

Exhaust Butterfly Valve Cable Adjustment........................................................................ 2-29

Air Suction System .............................................................................................................. 2-32

Air Suction System Damage Inspection............................................................................ 2-32

Clutch................................................................................................................................... 2-32

Clutch Operation Inspection.............................................................................................. 2-32

Wheels/Tires........................................................................................................................ 2-33

Air Pressure Inspection..................................................................................................... 2-33

Wheel/Tire Damage Inspection......................................................................................... 2-34

Tire Tread Wear Inspection............................................................................................... 2-34

Wheel Bearing Damage Inspection .................................................................................. 2-35

Drive Train ........................................................................................................................... 2-35

Drive Chain Lubrication Condition Inspection................................................................... 2-35

Drive Chain Slack Inspection............................................................................................ 2-36

Drive Chain Slack Adjustment .......................................................................................... 2-36

Wheel Alignment Inspection ............................................................................................. 2-37

Drive Chain Wear Inspection............................................................................................ 2-38

Chain Guide Wear Inspection........................................................................................... 2-38

Brake System ...................................................................................................................... 2-39

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-39

Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-40

Brake Operation Inspection .............................................................................................. 2-40

Brake Fluid Level Inspection ............................................................................................. 2-40

Brake Pad Wear Inspection.............................................................................................. 2-41

Brake Light Switch Operation Inspection.......................................................................... 2-42

Suspensions........................................................................................................................ 2-42

Front Forks/Rear Shock Absorber Operation Inspection.................................................. 2-42

Front Fork Oil Leak Inspection.......................................................................................... 2-43

Rear Shock Absorber Oil Leak Inspection........................................................................ 2-43

Rocker Arm Operation Inspection..................................................................................... 2-43

2-2 PERIODIC MAINTENANCE

Tie-Rod Operation Inspection........................................................................................... 2-43

Steering System ..................................................................................................................2-44

Steering P lay Inspection................................................................................................... 2-44

Steering P lay Adjustment.................................................................................................. 2-44

Steering S tem Bearing Lubrication................................................................................... 2-45

Electrical System................................................................................................................. 2-46

Spark Plug Condition Inspection....................................................................................... 2-46

Lights and Switches Operation Inspection........................................................................ 2-47

Headlight Aiming Inspection ............................................................................................. 2-49

Sidestand Switch Operation Inspection............................................................................ 2-50

Engine Stop Switch Operation Inspection......................................................................... 2-51

Others.................................................................................................................................. 2-52

Chassis Parts Lubrication................................................................................................. 2-52

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-54

Replacement P arts .............................................................................................................. 2-55

Air Cleaner Element Replacement.................................................................................... 2-55

Fuel Hose Replacement ................................................................................................... 2-56

Coolant Change................................................................................................................ 2-58

Radiator Hose and O-ring Replacement........................................................................... 2-60

Engine Oil Change............................................................................................................ 2-60

Oil Filter Replacement ...................................................................................................... 2-61

Brake Hose and Pipe Replacement.................................................................................. 2-62

Brake Fluid Change.......................................................................................................... 2-64

Master Cylinder Rubber Parts Replacement .................................................................... 2-65

Caliper Rubber Parts Replacement.................................................................................. 2-66

Spark Plug Replacement.................................................................................................. 2-69

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 m aintenance is vitally important and must not be neglected.

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Fuel System

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

Air cleaner element - clean Throttle control system (play, smooth return,

no drag) - inspect Engine vacuum synchronization - inspect Idle speed - inspect Fuel leak (fuel hose and pipe) - inspect year Fuel hose and pipe damage - inspect year Fuel hose and pipe installation condition -

inspect

Evaporative Emission Control System (CAL)

Evaporative emission control system function

- inspect

Cooling System

Coolant level - inspect Coolant leak (radiator hose and pipe) -

inspect Radiator hose damage - inspect year Radiator hose installation condition - inspect year

Engine Top End

year

• •

• • • •

• • •

• • • •

• • • • • • •

• • • •

2-15 2-15 2-16

2-19 2-20 2-20

2-20

2-21

2-22 2-23 2-23

2-23

US,CA, AU Model

Valve clearance - inspect

Exhaust butterfly valve cable - inspect

Air Suction System

Air suction system damage - inspect

Clutch

Clutch operation (play, disengagement, engagement) - inspect

Wheels and Tires

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

Drive Train

Drive chain lubrication condition - inspect # Every 600 km (400 mile) 2-35

Other than US, CA, AU Model

Every 42 000 km (26 000 mile) 2-23

• • • • • • •

• • •

• • • •

• • •

•

2-23

2-28

2-32

2-33 2-34 2-34 2-35

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Drive chain slack - inspect # Every 1 000 km (600 mile) Drive chain wear - inspect #

Drive chain guide wear - inspect

Brake System

Brake fluid leak (brake hose and pipe) inspect

Brake hose and pipe damage - inspect year Brake hose and pipe installation condition -

inspect Brake operation (effectiveness, play, no

drag) - inspect Brake fluid level - inspect Brake pad wear - inspect #

Brake light switch operation - inspect

Suspensions

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

Front forks/rear shock absorber oil leak inspect

year

months

year

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • •

• • • • • •

• • •

See

Page

2-36 2-38 2-38

2-39 2-40 2-40

2-40

2-40 2-41

2-42

2-43

Rocker arm operation - inspect Tie-rods operation - inspect

Steering System

Steering play - inspect year Steering stem bearings - lubricate 2 years

Electrical System

Spark plug condition - inspect Lights and switches operation - inspect year Headlight aiming - inspect year Sidestand switch operation - inspect year Engine stop switch operation - inspect year

Others

Chassis parts - lubricate year Bolts and nuts tightness - inspect

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

frequent starting/stopping.

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

• • • •

• • •

•

• • •

2-43 2-43

2-44 2-45

2-46 2-47 2-49 2-50 2-51

2-52 2-54

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart Periodic Replacement Parts

FREQUENCY Whichever

comes

first

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

*ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

See

Page

Air cleaner element # Fuel hose 4 years Coolant Radiator hose and O-ring 3 years Engine oil # Oil filter year Brake hose and pipe 4 years Brake fluid 2 years

Rubber parts of master cylinder and caliper 4 years Spark plug

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

frequent starting/stopping.

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

3 years

year

• • • • •

• •

• • • •

•

2-55 2-56 2-58 2-60 2-60 2-61 2-62 2-64

2-65,

2-66 2-69

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a

non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

EO: Apply engine oil.

G: Apply grease.

HG: Apply high-temperature grease.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide grease oil solution.

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

R: Replacement Parts

S: Follow the specified tightening sequence.

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

SS: Apply silicone sealant.

Fastener

Fuel System (DFI)

Air Cleaner Duct Screws 3.8 0.39 34 in·lb Air Cleaner Housing Mounting Bolts 9.8 1.0 87 in·lb Air Cleaner Housing Tapping Screws 1.2 0.12 11 in·lb Air Duct Clamp Bolts 2.0 0.20 18 in·lb Bypass Screw 0.2 0.02 1.8 in·lb Camshaft Position Sensor Bolt 12 1.2 106 in·lb Crankshaft Sensor Bolts 5.8 0.59 51 in·lb Delivery Pipe Assy Mounting Screws 3.4 0.35 30 in·lb Exhaust Butterfly Valve Actuator Bracket Bolt Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Fuel Pump Bolts 9.8 1.0 87 in·lb L, S Idle Adjusting Cable Clamp Screw 3.4 0.35 30 in·lb Oxygen Sensor (Equipped Models) 44.1 4.50 32.5 Speed Sensor Bolt 12 1.2 106 in·lb Throttle Body Assy Holder Bolts 13 1.3 115 in·lb Throttle Body Assy Holder Clamp Bolts Throttle Link Holder Screws 2.0 0.20 18 in·lb Throttle Cable Plate Bolt 5.9 0.60 52 in·lb Vehicle-down Sensor Bolts 6.0 0.61 53 in·lb Water Temperature Sensor 25 2.5 18

Cooling System

Coolant Drain Bolt (Cylinder) 9.8 1.0 87 in·lb Coolant Drain Bolt (Water Pump) 11 1.1 97 in·lb Radiator Bracket Mounting Bolt 6.9 0.70 61 in·lb Radiator Lower Bolt 6.9 0.70 61 in·lb Radiator Upper Bolts 6.9 0.70 61 in·lb Radiator (Water) Hose Clamp Screws 3.0 0.31 27 in·lb Reserve Tank Bolts 9.8 1.0 87 in·lb

N·m

6.9 0.70 61 in·lb

5.0 0.51 44 in·lb

2.0 0.20 18 in·lb

Torque

Remarks

kgf·m ft·lb

+ 679 hidden pages