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

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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.

LIST OF ABBREVIATIONS

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

L liter(s)

ampere(s)

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

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

1-2 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

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 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

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

• • • •

• • • • • • •

• • • •

•

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

• • •

• • • •

2-21 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

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

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

• • • • • •

• • • • • • •

• • •

• • • •

•

• • •

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

PERIODIC MAINTENANCE 2-7

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.

G: Apply grease.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide 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)

Upper Air Cleaner Housing Screws Throttle Body Assy Holder Clamp Bolts Air Cleaner Duct Cl Delivery Pipe Assy Mounting Screws 3.4 0.35 30 in·lb Oxygen Sensor (Equipped Models) 44 4.5 32 Intake Air Temperature Sensor Mounting Screw 1.2 0.12 11 in·lb Water Temperature Sensor 30 3.0 22 Exhaust Butterfly Valve Actuator Pulley Bolt 5.0 0.51 44 in·lb Exhaust Butterfly Valve Actuator Mounting

Screws Fuel Pump Bolts 9.8 1.0 87 in·lb L

Cooling System

Hot Windshield Mounting Bolts 9.8 1.0 87 in·lb Coolant By-pass Fitting Bolt 8.8 0.90 78 in·lb L Thermostat Housing Bolts 5.9 0.60 52 in·lb L Radiator (Water) Hose Clamp Screws Water Pipe Bolts 12 1.2 106 in·lb L Water Pump Impe Water Pump Cover Bolts 11 1.1 97 in·lb Coolant Drain Bolt 11 1.1 97 in·lb

Engine Top End

Air Suction Valve Cover Bolts Spark Plugs Cylinder Head Hot Windshield Mounting Bolts 9.8 1.0 87 in·lb Camshaft Sprocket Bolts 15 1.5 11 L Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18 Rear Camshaft Chain Guide Bolt Front Camshaft Chain Guide Bolt (Lower) Throttle Body Assy Holder Bolts 12 1.2 106 in·lb L

amp Bolts

ller Bolt

Cover Bolts

N·m kgf·m ft·lb

1.1 0.11 9.7 in·lb

2.9 0.30 26 in·lb

2.0 0.20 18 in·lb

1.2 0.12 11 in·lb

2.9 0.30 26 in·lb

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb L 13 1.3 115 in·lb

9.8 1.0 87 in·lb

25 2.5 18 12 1.2 106 in·lb

Torque

Remarks

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Cylinder Head Bolts (M6) 12 1.2 106 in·lb S Upper Camshaft Chain Guide Bolts Plugs 19.6 2.0 14 L Camshaft Cap Bolts 12 1.2 106 in·lb S Cylinder Head Bolts (M10) (First) 20 2.0 15 S, MO Cylinder Head Bolts (M10) (Final) 54 5.5 40 S, MO Camshaft Chain Tensioner Mounting Bolts 11 1.1 97 in·lb Camshaft Chain Tensioner Cap Bolt Exhaust Butterfly Valve Actuator Pulley Bolt Exhaust Butterfly V Muffler Body Mounting Bolts 34 3.5 25 Premuffler Chamber Mounting Bolt 34 3.5 25 Muffler Body Clamp Bolts 21 2.1 15

Clutch

Clutch Lever Assembly Clamp Bolts 7.8 0.80 69 in·lb S Clutch Cover Bolts 9.8 1.0 87 in·lb Oil Filler Plug 2.0 0.20 18 in·lb Clutch Spring Bolts 9.0 0.90 80 in·lb Clutch Hub Nut 135 13.8 99.6 R

Engine Lubrication System

Oil Filler Plug Oil Cooler Bol Oil Passage Plug 20 2.0 15 L Radiator (Water) Hose Clamp Screws 3.0 0.31 27 in·lb Oil Pressure Switch 15 1.5 11 SS Oil Pressure Relief Valve 15 1.5 11 L Oil Filter 17 1.7 13 G, R Oil Filter Pipe 25 2.5 18 L Oil Pan Bolts 12 1.2 106 in·lb S Engine Oil Drain Bolt 29 3.0 21

Engine Removal/Installation

Upper Engine Bracket Bolts 44 4.5 32 Lower Engine Bracket Bolts 59 6.0 44 Upper Adju Upper Engine Mounting Bolt (L = 65) 44 4.5 32 S Upper Adjusting Collar Locknut 49 5.0 36 S Upper Engine Mounting Bolt (L = 40) 44 4.5 32 S Lower Engine Mounting Nut 44 4.5 32 S Lower Adjusting Collar Locknut 49 5.0 36 S Middle Engine Bracket Bolts 25 2.5 18 L, S Middle Engine Mounting Nut 44 4.5 32 S Lower Adjusting Collar 9.8 1.0 87 in·lb S

sting Collar

alve Actuator Bolts

N·m kgf·m ft·lb

12 1.2 106 in·lb

20 2.0 15

5.0 0.51 44 in·lb

1.2 0.12 11 in·lb

2.0 0.20 18 in·lb 12 1.2 106 in·lb

9.8 1.0 87 in·lb

Torque

Remarks

S S S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Crankshaft/Transmission

Balancer Shaft Clamp Bolt Balancer Shaft Lever Bolt Breather Side Plate Bo Connecting Rod Big End Nuts see the text ← ← MO Breather Plate Bolts 9.8 1.0 87 in·lb L Shift Drum Bearing Holder Bolts 12 1.2 106 in·lb L Oil Passage Plugs Oil Passage Plug Starter Motor Clutc Crankcase Bolts (M7) 20 2.0 15 S Crankcase Bolts (M9) 42 4.2 31 S, MO Crankcase Bolts (M6) 20 2.0 15 S Crankcase Bolts (M8) 27 2.8 20 S Gear Positioning Lever Bolt 12 1.2 106 in·lb Shift Drum Cam Bolt 12 1.2 106 in·lb L Neutral Switch 15 1.5 11 Shift Shaft Return Spring Pin 39 4.0 29 L Shift Pedal Mounting Bolt 25 2.5 18

Wheels/Tires

Front Axle Clamp Bolt Front Axle 108 11.0 79.7 Rear Axle Nut 98 10 72

Final Drive

Engine Sprocket Nut 125 12.7 92.2 MO Drive Chain Guide Bolts Speed Sensor Mounting Bolt Chain Adjuste Rear Sprocket Nuts 59 6.0 44

Brakes

Front Master Cylinder Reservoir Cap Stopper Screw

Brake Lever Pivot Bolt 1.0 0.10 8.8 in·lb Si Front Master Cylinder Bleed Valve 5.4 0.55 48 in·lb Front Master Cylinder Clamp Bolts 11 1.1 97 in·lb S Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb Front Brake Brake Hose Banjo Bolts 25 2.5 18 Front Caliper Assembly Bolts 22 2.2 16 Front Caliper Mounting Bolts 34 3.5 25 Bleed Valves 7.8 0.80 69 in·lb Front Brake Pad Pins 15 1.5 11 Front Brake Disc M ounting Bolts 27 2.8 20 L

r Clamp Bolts

Light Switch Screw

hBolts

N·m kgf·m ft·lb

9.8 1.0 87 in·lb 25 2.5 18 L

5.9 0.60 52 in·lb L

20 2.0 15 L

9.8 1.0 87 in·lb 12 1.2 106 in·lb L

20 2.0 15 AL

9.8 1.0 87 in·lb

6.9 0.70 61 in·lb L 64 6.5 47

1.2 0.12 11 in·lb

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Rear Master Cylinder Mounting Bolts 25 2.5 18 Brake Pedal Bolt 8.8 0.90 78 in·lb L Rear Master Cylinder Push Rod Locknut 17 1.7 12 Rear Brake Disc Mountin Rear Caliper Mounting Bolts 25 2.5 18 Brake Pipe Joint Nuts 18 1.8 13 Rear Brake Disc Mounting Bolts (ABS Equipped

Models)

Suspension

Upper Front Fork Clamp Bolts 20 2.0 15 Lower Front Fork Clamp Bolts 25 2.5 18 AL Piston Rod Nuts 20 2.0 15 Front Fork Top Plugs 34 3.5 25 Front Axle Clump Bolts 20 2.0 15 AL Front Fork Bottom Allen Bolts 35 3.6 26 Rear Shock Absorber Bolt (Upper) 34 3.5 25 Tie-rod Nuts 34 3.5 25 R Rear Shock Absorber Nut (Lower) Rocker Arm Nut 34 3.5 25 R Swingarm Pivot Adjusting Collar Locknut 98 10 72 Swingarm Pivot Shaft Nut 108 11.0 79.7 Torque Link Nuts 34 3.5 25

Steering

Left Switch Housing Screws 3.5 0.36 31 in·lb Upper Front Fork Clamp Bolts 25 2.5 18 Handlebar Holder Bolts 25 2.5 18 Handlebar Bolts 34 3.5 25 L Right Switch Housing Screws 3.5 0.36 31 in·lb Steering Stem Head Bolt Steering Stem Nut Lower Front Fork C

Frame

Lower Fairing Upper Assembly Screws 1.2 0.12 11 in·lb Lower Fairing Lower Assembly Screws 1.2 0.12 11 in·lb Front Fender Mounting Bolts 3.9 0.40 35 in·lb Stay Assembly Mounting Bolts 6.9 0.70 61 in·lb Stopper Mounting Bolts 4.2 0.42 37 in·lb L Rear Frame Bracket Bolts 44 4.5 32 Front Footpeg Bracket Bolts 25 2.5 18 Rear Footpeg Bracket Bolts 25 2.5 18 Rear Frame Bolts 25 2.5 18 L Sidestand Switch Bolt Sidestand Brack

et Bolts

gBolts

lamp Bolts

N·m kgf·m ft·lb

27 2.8 20 L

34 3.5 25 R

108 11.0 79.7

25 2.5 18 20 2.0 15 AL

8.8 0.90 78 in·lb L 49 5.0 36 L

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-11

Fastener

Sidestand Bolt 44 4.5 32 Grab Rail Mounting Bolts

Electrical System

Switch Housing Screws Oxygen Sensor (Equipped Models) 44 4.5 32 Front Brake Light Switch Screw 1.2 0.12 11 in·lb Front Turn Signal Light Mounting Screws 1.2 0.12 11 in·lb Licence Plate Light Mounting Screws 1.2 0.12 11 in·lb Intake Air Temperature Sensor Mounting Screw 1.2 0.12 11 in·ib Spark Plugs 13 1.3 115 in·lb Crankshaft Sensor Cover Bolts 12 1.2 106 in·lb Water Temperature Sensor 30 3.0 22 Timing Rotor Bolt 39 4.0 29 Crankshaft Sensor Bolts 5.9 0.60 52 in·lb Starter Motor Cable Terminal Nut 5.9 0.60 52 in·lb Starter Motor Terminal Locknut 11 1.1 97 in·lb Starter Motor Mounting Bolts 9.8 1.0 87 in·lb Alternator Rotor Bolt 155 15.8 114 Stator Coil Bolts 12 1.2 106 in·ib L Starter Motor Through Bolts 4.9 0.50 43 in·lb Brush Holder Screw 3.8 0.39 34 in·ib Oil Pressure Switch 15 1.5 11 SS Oil Pressure Switch Terminal Bolt 2.0 0.20 18 in·ib G Alternator Cover Bolts 12 1.2 106 in·lb Alternator Lead Holding Plate Bolt 12 1.2 106 in·ib L Neutral Switch 15 1.5 11 Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb Sidestand Switch Bolt 8.8 0.90 78 in·lb L Speed Sensor Mounting Bolt 6.9 0.70 61 in·lb L

N·m kgf·m ft·lb

25 2.5

3.5 0.36 31 in·lb

Torque

Remarks

18 ft·lb

2-12 PERIODIC MAINTENANCE

Torque and Locking Agent

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

Basic Torque for General Fasteners

Threads Diameter

(mm)

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

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

N·m

Torque

kgf·m ft·lb

PERIODIC MAINTENANCE 2-13

Specifications

Item Standard Service Limit

Fuel System (DFI)

Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 1 100 ±50 r/min (rpm) ––– Bypass Screws (Turn Out) 2 1/2 (for reference) Throttle Body Vacuum

Air Cleaner Element

Cooling System

Coolant:

Type (Recommended) Permanent type of antifreeze ––– Color Green ––– Mixed Ratio Soft water 50%, Coolant 50% ––– Freezing Point Total Amount

Engine Top End

Valve Clearance:

Exhaust Intake 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) –––

Clutch

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

Engine Lubrication System

Engine Oil:

Type

Viscosity Capacity 3.2 L (3.4 US qt) (when filter is not

Wheels/Tires

Tread Depth:

Front 3.6 mm (0.14 in.) 1 mm (0.04 in.),

Rear

Air Pressure (when Cold):

Front Up to 180 kg (397 lb) load:

Rear Up to 180 kg (397 lb) load:

Final Drive

Drive Chain Slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.)

40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed

Viscous paper element –––

–35°C (–31°F)

2.9 L (3.1 US qt)

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

removed)

3.8 L (4.0 US qt) (when filter is removed)

4.0 L (4.2 US qt) (when engine is completely dry)

5.3 mm (0.21 in.) Up to 130 km/h (80 mph): Over 130 km/h (80 mph):

250 kPa (2.5 kgf/cm², 36 psi)

290 kPa (2.9 kgf/cm², 42 psi)

––– –––

–––

––– –––

(AT, CH, DE)

1.6 mm (0.06 in.)

2 m m (0.08 in.),

3 mm (0.12 in.)

–––

2-14 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Drive Chain Wear (20-link Length)

Standard Chain:

Make ENUMA ––– Type EK525ZX ––– Link 112 Links –––

Brakes

Brake Fluid:

Grade DOT4 –––

Brake Pad Lining Thickness:

Front 4.0 mm (0.16 in.) 1 mm (0.04 in.) Rear

Brake Light Timing:

Front Pulled ON ––– Rear

Electrical System

Spark Plug:

Type NGK CR9EIA-9 –––

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.56 in.)

5.0 mm (0.20 in.) 1 mm (0.04 in.)

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

–––

Special Tools

PERIODIC MAINTENANCE 2-15

Inside Circlip Pliers: 57001-143

Steering Stem Nut Wrench: 57001-1100

Jack: 57001-1238

Attachment Jack: 57001-1252

Spark Plug Wrench, Hex 16: 57001-1262

Vacuum Gauge: 57001-1369

Pilot Screw Adjuster, A: 57001-1239

Oil Filter Wrench: 57001-1249

Throttle Sensor Setting Adapter: 57001-1538

Fuel Hose: 57001-1607

2-16 PERIODIC MAINTENANCE

Special Tools

Jack Attachment: 57001-1608

Periodic Maintenance Procedures Fuel System (DFI)

Throttle Control System Inspection

Check that the throttle grip [A] moves smoothly from full

•

open to close, and the throttle closes quickly and completely by the return spring in all steering positions. Ifthe throttle grip doesnot return properly,check thethrottle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Check the throttle grip free play [B].

•

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

If the free play is incorrect, adjust the throttle cable as follows. Loosen the locknuts [A] [B].

•

Screw both throttle cable adjusters [C] [D] to give the

•

throttle grip plenty of play. Turn the decelerator cable adjuster [C] until 2 ∼ 3mm

•

(0.08 ∼ 0.12 in.) of throttle grip play is obtained. Tighten the locknut [A].

•

Turn the accelerator cable adjuster [D] until 2 ∼ 3mm

•

(0.08 ∼ 0.12 in.) of throttle grip play is obtained. Tighten the locknut [B].

•

If the free play can not be adjusted with the adjusters, replace the cable.

PERIODIC MAINTENANCE 2-17

Engine Vacuum Synchronization Inspection

NOTE

Theseprocedures are explainedon the assumptionthat

○

the intake and exhaust systems of the engine are in good condition.

Situate the motorcycle so that it is vertical.

•

Removethe air cleaner housing (seeAirCleaner Housing

•

Removal in the Fuel System (DFI) chapter). Pull off the rubber caps [A] and vacuum hose [B] from the

•

fittings of each throttle body. For the California and Southeast Asia Models, pull off the

•

vacuum hose [A].

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Plug the vacuum hose end [A].

•

Connect a vacuum gauge (special tool) and hoses [A] to

•

the fittings on the throttle body.

Special Tool - Vacuum Gauge: 57001-1369

Connect a highly accurate tachometer [B] to one of the

•

stick coil primary leads.

Plug the air switching valve hose end [A] and air cleaner

•

housing fitting [B]. Install the air cleaner housing (see Air Cleaner Housing

•

Installation in the Fuel System (DFI) chapter).

Remove the fuel hose (see Fuel Hose Replacement).

•

Connect the following parts temporary.

•

Fuel Pump Lead Connector [A] Fuel Hose [B]

Special Tool - Fuel Hose: 57001-1607

Periodic Maintenance Procedures

Start the engine and warm it up thoroughly.

•

Check the idle speed, using a highly accuratetachometer

•

[A].

Idle Speed

Standard: 1 100 ±50 r/min (rpm)

If the idle speed is out of the specifiedrange, adjust it with the adjusting screw (see Idle Speed Adjustment).

NOTICE

Do not measure the idle speed by the tachometer of the meter unit.

While idling the engine, inspect the throttle body vacuum,

•

using the vacuum gauge [B].

Throttle Body Vacuum

Standard: 40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed

If any vacuum is not within specifications, first synchronize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies.

Example:

#1: 260 mmHg #2: 300 mmHg #3: 250 mmHg #4: 280 mmHg

With the engine at the correct idle speed, equalize higher

•

vacuum of #1 or #2 (for example 300 mmHg) to higher vacuum of #3 or #4 (for example 280 mmHg) by turning the center adjusting screw [A].

PERIODIC MAINTENANCE 2-19

NOTE

After adjustment, the final vacuum measurement be-

○

tween the highest throttle valves may not be 290 mmHg (for example). The goal is to have the highest two vacuums between the left (#1 and #2) and right (#3and #4) banks be the same.

Open and close the throttleafter each measurement, and

•

adjust the idle speed as necessary. Once the throttle valves have been synchronized, inspect

•

outputvoltage of themainthrottle sensortoensure proper operation (procedure is explained at the end of this section).

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If any one vacuum measurement is out of the specified range afterleft(#1, #2)and right (#2, #3) synchronization, adjust the bypass screws [A].

Special Tool - Pilot Screw A djuster, A [B]: 57001-1239

Adjust the lower vacuum between #1 and #2 tothe higher

•

vacuum of #1 and #2. Adjust the lower vacuum between #3 and #4 tothe higher

•

vacuum of #3 and #4. Open and close the throttle valves after each measure-

•

ment, and adjust the idle speed as necessary. Check the vacuums as before.

•

If all vacuums are within the specification range, finish the engine vacuum synchronization. Ifany vacuum cannot beadjustedwithin thespecification, remove the bypass screws #1 ∼ #4 and clean them.

Turn in the bypass screw [A] with counting the number of

•

turns until it seals fully but not tightly. Record the number of turns.

NOTICE

Do not over tighten them. They could be damaged, requiring replacement.

Remove:

•

Bypass Screw Spring [B] Washer [C] O-ring [D]

Check the bypass screw and its hole for carbon deposits.

•

If any carbons accumulate, wipe the carbons off from the bypassscrewand the hole, using a cotton pad penetrated with a high-flash point solvent. Replace the O-ring with a new one.

•

Check the tapered portion [E] of the bypass screw for

•

wear or damage. If the bypass screw is worn or damaged, replace it. Turn in the bypass screw until it seats fully but not tightly.

•

Periodic Maintenance Procedures

Back out the same number of turns counted when first

•

turned in. This is to set the screw to its original position.

NOTE

A throttle body has different “turns out” of the bypass

○

screw for each individual unit. On setting the bypass screw,use the “turns out” determined during disassembly.

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.

•

If the vacuums are correct, check the output voltage of the mainthrottlesensor (see Main Throttle Sensor Output Voltage Inspection in the Fuel System (DFI) chapter).

Special Tool - Throttle Sensor Setting Adapter: 57001

-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:

Digital Meter (+) → W (sensor BL/W) lead Digital Meter (–) → BK (sensor BR/BK) lead

PERIODIC MAINTENANCE 2-21

Standard: DC 0.985 ∼ 1.015 V at idle throttle opening

If the output voltage is out of the standard, check the input voltage of the main throttle sensor (see Main Throttle Sensor Input Voltage Inspection in the Fuel System (DFI) chapter).

Remove the vacuum gauge hoses and install the rubber

•

caps on the original position. For the California and Southeast Asia Models, install the

•

vacuum hoses. Run the vacuum 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 (DFI) c hapter too.

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides

•

[A]. 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 Throttle Control System Inspection and Cable, Wire, and Hose Routing section in the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to be make sure to correct any of these conditions.

Check the idle speed.

•

Idle Speed

Standard: 1 100 ±50 r/min (rpm)

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

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Turnthe 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.

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

If the motorcycle is not properly handled, the high pres-

○

sure inside the fuel line can cause fuel to leak [A] or the hose to burst. Support the fuel tank with a suitable bar (see Fuel Hose Replacement) and check the fuel hoses. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.

Checkthat the hosesare routed accordingto Cable, Wire,

•

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

Hose Joints [A] Fuel Hose [B]

Check that the hose joints are securely connected.

•

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

○

than two times, and make sure it is locked and does not come off.

Fuel Pump Side [C] Throttle Body Assy Side [D]

WARNING

Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is installed correctly on the delivery pipe.

If it comes off, reinstall the hose joint.

Periodic Maintenance Procedures

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

Inspect the canister as follows.

•

Remove the front seat (see Front Seat Removal in the

○

Frame chapter). Remove the canister [A], and disconnect the hoses from

○

the canister. Visually inspect the canister for cracks or other damage.

○

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

NOTE

Thecanister is designed to workwell through the motor-

○

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

Check the liquid/vapor separator as follows.

•

Lift up the fuel tank front side, and support the fuel tank

○

with the suitable bar (see Fuel Hose Replacement). Disconnect the hoses from the separator,and remove the

○

separator [A] from the motorcycle right side. Visually inspect the separator for cracks and other dam-

○

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

○

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

•

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

○

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

○

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

○

ing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System (DFI) chapter too. When installing the hoses, avoid sharp bending, kinking,

○

flattening or twisting, and route thehoses witha minimum ofbending so thatthe emission flowwill not beobstructed.

PERIODIC MAINTENANCE 2-23

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Cooling System

Coolant Level Inspection

NOTE

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

○

ent temperature).

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

•

motorcycle held perpendicular (Do not use the sidestand.). If the coolant level is lower than the “L” level line [B], unscrew the reserve tank cap and add coolant to the “F” level line [C].

“L”: low “F”: full

NOTICE

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

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

The high pressure inside the radiator hose can cause

○

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

•

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

•

are tightened correctly.

Torque - Radiator (Water) Hose Clamp Screws: 2.9 N·m

(0.30 kgf·m, 26 in·lb)

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (room temperature).

Remove:

•

Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)

Periodic Maintenance Procedures

Turn the crankshaft, align the #1, 4 mark on the timing

•

rotor with the crankcase timing mark.

TDC Mark [A] for #1, 4 Pistons Timing Mark [B] (Crankcase Halves Mating Surface)

Using the thickness gauge [A], measure the valve clear-

•

ance between the cam and the valve lifter.

Valve Clearance

Standard:

Exhaust Intake

0.22 ∼ 0.31 mm (0.0087 ∼ 0. 0122 in.)

0.15 ∼ 0.24 mm (0.0059 ∼ 0. 0094 in.)

PERIODIC MAINTENANCE 2-25

NOTE

Thickness gauge is horizontally inserted on the valve

○

lifter.

Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G]

When positioning #4 piston TDC at the end of the

○

compression stroke:

Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders Measuring Valve [A]

When positioning #1 piston TDC at the end of the

○

compression stroke:

Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A]

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

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Valve Clearance Adjustment

To change the valve clearance, remove the camshaft

•

chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness.

NOTE

Mark and record the locations of the valve lifters and

○

shims so that they can be reinstalled in their original positions.

Besides thestandardshims in the valve clearance adjust-

○

ment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance.

Adjustment Shims

Thickness

3.225 mm

3.275 mm

3.325 mm

2.675 mm

2.725 mm

2.775 mm

2.825 mm

2.875 mm

2.925 mm

2.975 mm

3.025 mm

3.075 mm

3.125 mm

3.175 mm

Clean the shim to remove any dust or oil.

•

Measure the thickness of the removed shim [A].

•

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE

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

2. Check present shim size.

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

4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm

Measured clearance is 0.45 mm Replace 2.95 mm shim with 3.20 mm shim .

5. Remeasure the valve clearance and readjust if necessary.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

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

2. Check present shim size.

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

4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.

Measured clearance is 0.47 mm. Replace 2.95 mm shim with 3.15 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

Periodic Maintenance Procedures

NOTICE

Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim.

If there is no valve clearance, use a shim that is a few

○

sizes smaller, and remeasure the valve clearance. Wheninstallingthe shim, face the marked side toward the

•

valve lifter.

NOTICE

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

Apply engine oil to the valve lifter surface and install the

•

lifter. Install the camshaft (see Camshaft Installation in the En-

•

gine Top End chapter). Recheck the valve clearance and readjust if necessary.

•

Install the removed parts (see appropriate chapters).

•

PERIODIC MAINTENANCE 2-29

Air Suction System Damage Inspection

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

•

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

•

Plug [A] the air switching valve hose end with your finger

•

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

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Clutch

Clutch Operation Inspection

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

•

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

•

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

Clutch Lever Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

WARNING

The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment.

Turnthe adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B]

•

of threads are visible.

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

•

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

•

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

•

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

•

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

•

correct.

Push the release lever [A] toward the front of the motor-

•

cycle until it becomes hard to turn. At this time, the release lever should have the proper an-

○

gle shown.

60° [B] If the angle is wrong, check the clutch and release parts for wear.

WARNING

Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement.

After the adjustment, start the engine and check that the

•

clutch does not slip and that it releases properly.

Periodic Maintenance Procedures Wheels/Tires

Air Pressure Inspection

Remove the air valve cap.

•

Measure the tire air pressure with an air pressure gauge

•

[A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Install the air valve cap.

•

Adjust the tire air pressureaccording to the specifications if necessary.

Air P ressure (when Cold)

Front:

Rear:

Wheel/Tire Damage Inspection

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

•

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

•

the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. Visuallyinspect the wheel forcracks, cuts and dents dam-

•

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

Upto180kg(397lb) 250 kPa (2.5 kgf/cm², 36 psi)

Upto180kg(397lb) 290 kPa (2.9 kgf/cm², 42 psi)

PERIODIC MAINTENANCE 2-31

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that90% of all tire failuresoccurduring the last 10% oftread life (90% worn). So it is false economy and unsafe to use the tires until they are bald.

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

•

depth gauge [A]. Since the tire may wear unevenly, take

measurement at several places.

If any measurement is less than the service limit, replace

the tire (see Tire Removal/Installation in the Wheels/Tires

chapter).

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tread Depth

Standard:

Front Rear

Service Limit:

Front

Rear

Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.

3.6 mm (0.14 in.)

5.3 mm (0.21 in.)

1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) 2 mm (0.08 in.)

Up to 130 km/h (80 mph) 3 mm (0.12 in.)

Over 130 km/h (80 mph)

WARNING

NOTE

Most countries may have their own regulations a mini-

○

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

○

with a new one.

Wheel Bearing Dama g e Inspection

Raise the front wheel off the ground with the jack (see

•

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

•

Inspect the roughness of the front wheel bearing by push-

•

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

•

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

Raise the rear wheel off the ground with the stand (see

•

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

•

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

•

turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear wheeland inspectthe wheelbearing (seeRear WheelRemoval, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter).

Periodic Maintenance Procedures Final Drive

Drive Chain Lubrication Condition Inspection

If a special lubricant is not available, a heavy oil such as

•

SAE 90 is preferred to a lighter oil because it will stay on

the chain longer and provide better lubrication.

If the chain appears especially dirty, clean it before lubri-

•

cation.

NOTICE

The O-rings between the side plates seal in the lu-

bricant between the pin and the bushing. To avoid

damaging the O-rings and resultant loss of lubri-

cant, observe the following rules.

Use only kerosene or diesel oil for cleaning of the O

-ring of the drive chain. Any other cleaning solution

such as gasoline or trichloroethylene will cause de-

terioration and swelling of the O-ring. Immediately

blow the chain dry with compressed air after clean-

ing. Complete cleaning and drying the chain within

10 minutes.

PERIODIC MAINTENANCE 2-33

Apply oil to the sides of the rollers so that oil willpenetrate

•

to the rollers and bushings. Apply the oil to theO-rings so

that the O-rings will be coated with oil.

Wipe off any excess oil.

•

Oil Applied Areas [A] O-rings [B]

Drive Chain Slack Inspection

NOTE

Check the slack with the motorcycle setting on its side-

○

stand. Clean the chain if it is dirty, and lubricate it if it appears

○

dry.

Checkthe wheelalignment(see WheelAlignment Inspec-

•

tion).

Rotate the rear wheel to find the position where the chain

•

is tightest.

Measure the vertical movement (chain slack) [A] midway

•

between the sprockets.

If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard: 20 ∼ 30 mm (0 .8 ∼ 1.2 in.)

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Chain Slack Adjustment

Loosen the left and right chain adjuster clamp bolts [A].

•

Using an Allen wrench [B], turn the adjusters [C] forward

•

or rearward until the drive chain has the correct amount of chain slack. Tighten:

•

Torque - Chain AdjusterClamp Bolts: 64 N·m (6.5 kgf·m, 47

ft·lb)

Wheel Alignment Inspection

Check that the left and right notches [A] the swingarm

•

should point to the same marks or positions [B] on the left and right adjuster. If they do not, adjust the chain slack (see Drive Chain Slack Adjustment) and align the wheel alignment.

WARNING

Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned.

Wheel Alignment Adjustment

Removetherightretainingring[A]fromtheaxleshaft.

•

Loosen the axle nut [B].

•

Loosen the right chain adjuster clamp bolt [C], and turn

•

the right chain adjuster [D] so that the left and right notches on the swingarm may point to the same marks or positions on the left and right adjusters. Tighten:

•

Torque - Chain Adjuster Clamp Bolt: 64 N·m (6.5 kgf·m, 47

ft·lb)

Rear Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb)

Periodic Maintenance Procedures

Drive Chain Wear Inspection

Remove the chain cover (see Drive Chain Removal inthe

•

Final Drive chapter).

Rotate the rear wheel to inspect the drive chain for dam-

•

aged rollers, and loose pins and links.

If there is any irregularity, replace the drive chain.

Lubricate the drive chain if it appears dry.

Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)

•

weight [A] on the chain.

Measurethe lengthof 20links [B]onthe straightpart [C]of

•

thechain from thepin center ofthe 1st pinto the pincenter

of the 21st pin. Since the chain may wear unevenly, take

measurements at several places.

If anymeasurementsexceedthe service limit, replace the

chain. Also, replace the frontand rear sprocketswhen the

drive chain is replaced.

Drive Chain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Service Limit: 319 mm (12.56 in.)

PERIODIC MAINTENANCE 2-35

WARNING

A chain that breaks or jumps off the sprockets

could snag on the engine sprocket or lock the

rear wheel, severely damaging the motorcycle and

causing it to go out of control. Inspect the chain for

damage and proper adjustment before each ride.

If chain wear exceeds the service limit, replace it

with the standard chain.

Standard Chain

Make: ENUMA Type: EK525ZX Link: 112 Links

Chain Guide Wear Inspection

Remove the swingarm (see Swing

•

Suspension chapter).

Visually inspect the chain guide [A].

•

Replace the chain guide if itshows any signs of abnormal

wear or damage.

arm Removal in the

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Brakes

Brake Fluid Leak (Brake Hose and Pipe) Inspection

ForABS equipped models, removethe fuel tank(see Fuel

•

Tank Removal in the Fuel System (DFI) chapter). Apply the brake lever or pedal and inspect the brake fluid

•

leak from the brake hoses [A], pipes (ABS equipped models) [B] and fittings [C]. If the brake fluid leaked from any position, inspect or replace the problem part.

Periodic Maintenance Procedures

Brake Hose and Pipe Damage and Ins tallation Condition Inspection

ForABS equipped models, removethe fuel tank(see Fuel

•

Tank Removal in the Fuel System (DFI) chapter).

Inspect the brake hoses and fittings for deterioration,

•

cracks and signs of leakage.

The high pressure inside the brake line can cause fluid to

○

leak [A] or the hose, pipe (ABSequipped models) to burst

if the line is not properly maintained. Bend and twist the

rubber hose while examining it.

Replace the hose and pipe (ABS equipped models) if any

crack [B], bulge [C] or leakage is noticed.

Tighten any brake hose banjo bolts and brake pipe joint

nuts.

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

ft·lb)

Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

(ABS Equipped Models)

Inspect the brake hose routing.

•

Ifany brake hoserouting isincorrect,route thebrakehose

accordingto Cable, Wire, and Hose Routings ection in the

Appendix chapter.

PERIODIC MAINTENANCE 2-37

Brake Operation Inspection

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

•

ning the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake

system.

WARNING

When test riding the vehicle, be aware of surround-

ing traffic for your safety.

Brake Fluid Level Inspection

Check thatthebrakefluid level inthefrontbrakereservoir

•

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

NOTE

Hold the reservoir horizontal by turning the handlebar

○

when checking brake fluid level.

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

reservoir to the upper level line [C].

Remove the stopper [D].

○

Tighten:

•

Torque - Front Master Cylinder Reservoir Cap Stopper

Screw: 1.2 N ·m (0.12 kgf·m, 11 in·lb)

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check that the brakefluid level in the rear brake reservoir

•

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

○

WARNING

Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake 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.

Recommended Disc Brake Fluid

Grade: DOT4

Follow procedure below to install thefront/rear brake fluid

•

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

○

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

Brake Pad Wear Inspection

Remove the brake pads (see Front/Rear Brake Pad Re-

•

moval in the Brakes chapter). Check the lining thickness [A] of the pads in each caliper.

•

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

[C] Front Brake Pad [D] Rear Brake Pad

Pad Lining Thickness

Standard:

Front Rear

Service Limit: 1 mm (0.04 in.)

4.0 mm (0.16 in.)

5.0 mm (0.20 in.)

Periodic Maintenance Procedures

Brake Light Switch Operation Inspection

Turn on the ignition switch.

•

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

•

applied or after the brake pedal is depressed about 10

mm (0.39 in.).

If it does not, adjust the brake light switch as follows.

Remove:

•

Rear Lower Fairing (see Rear Lower Fairing Removal in the Frame chapter) Rear Master Cylinder Mounting Bolts [A] Footpeg Bracket Bolts [B] Footpeg Bracket [C]

PERIODIC MAINTENANCE 2-39

While holding the switch body, turn the adjusting nut to

•

adjust the switch.

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

NOTICE

To avoid damaging the electrical connections in-

side the switch, be sure that the switch body does

not turn during adjustment.

If it does notgo on, inspect or replacethe following items.

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

Tighten:

•

Torque - Front Footpeg Bracket Bolt: 25 N·m (2.5 kgf·m, 18

ft·lb)

Rear Master Cylinder Mounting B olts: 25 N·m (2.5

kgf·m, 18 ft·lb)

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Suspension

Front Forks/Rear Shock Absorber Operation Inspection

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

•

the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).

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

•

the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).

Front Fork Oil Leak Inspection

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

•

Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

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

•

Ifthe oil leakage isfound on it, replace theshock absorber with a new one.

Rocker Arm Operation Inspection

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

•

smooth stroke. If the rocker arms [A] do not smoothly stroke or noise is found, inspect the fasteners and bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspension chapter).

Periodic Maintenance Procedures

Tie-Rod Operation Inspection

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

•

smooth stroke.

If the tie-rod [A] does not smoothly stroke or noise is

found, inspect the fasteners and tie-rod bearings (see

Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the

Suspension chapter).

Steering

Steering Play Inspection

Remove the lower fairing (see Lower Fairing Removal in

•

the Frame chapter).

Raise the front wheel off the ground with the jack (see

•

Front Wheel Removal in the Wheels/Tires chapter).

With the front wheel pointing straight ahead, alternately

•

tap each end of the handlebar. The front wheel should

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

fork hits the stop.

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

is too tight.

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

•

forks.

If you feel looseness, the steering is too loose.

PERIODIC MAINTENANCE 2-41

NOTE

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

○

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

○

The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

Steering Play Adjustment

Remove:

•

Upper Fairing Bracket (see Upper Fairing Bracket Removal in the Frame chapter) Handlebar (see Handlebar Removal in the Steering chapter) Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] Upper Front Fork Clamp Bolts [C] (Loosen) Stem Head [D]

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Bend the c laws [A] of the claw washer back.

•

Remove the steering stem locknut [B] and claw washer

•

[C].

Adjust the steering.

•

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

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

NOTE

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

○

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

•

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

•

touches the steering stem nut. Tighten the stem locknut clockwise until the c laws are

•

aligned with the grooves (rangingfrom2ndto 4th)of stem nut [D], and bend the 2 claws downward [E]. Install the stem head.

•

Tighten:

•

Torque - Steering Stem Head Bolt: 108 N·m (11.0 kgf·m,

79.7 ft·lb)

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

15 ft·lb)

Check the steering again.

•

If the steering is still too tight or too loose, repeat the adjustment. Install the removed parts (see appropriate chapters).

•

Periodic Maintenance Procedures

Steering Stem Bearing Lubrication

Remove the steering stem (see Stem, Stem Bearing Re-

•

moval in the Steering chapter).

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

•

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

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

head pipe, clean off grease and dirt.

Visually check the outer races and the ball bearings.

•

Replace the bearing assemblies if they show wear or

damage.

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

•

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

and lower outer races.

Install the steering stem (see Stem, Stem Bearing Instal-

•

lation in the Steering chapter).

Adjust the steering (see Steering Play Adjustment).

•

PERIODIC MAINTENANCE 2-43

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Electrical System

Lights and Switches Operation Inspection

First Step

Turn on the ignition switch.

•

Thefollowing lightsshould goon accordingtobelowtable.

•

City Lights [A] Taillight [B] License Plate Light [C] Meter Panel LCD [D] Neutral Indicator Light (LED) [E] Warning Symbol and Warning Indicator Light (LED)

[F] ABS Indicator Light (LED) [G] (ABS EquippedModels)

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

Battery (see Charging Condition Inspection in the Electrical System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Applicable Bulb (see Wiring Diagram in the Electrical System chapter) Meter Unit for Meter Panel LCD (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for Neutral Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Warning Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) ECU(see ECU PowerSupply Inspection inthe Fuel System (DFI) chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) ABS Indicator Light (LED) (ABS Equipped Models) (see ABSIndicator Light (LED)Inspection intheBrakes chapter)

goes on goes on goes on goes on goes on

goes on goes on

Turn off the ignition switch.

•

The all lights should go off.

•

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

Second Step

Turn the ignition switch to P (Park) position.

•

The city light, taillight andlicense plate light should go on.

•

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

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

Periodic Maintenance Procedures

Third Step

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

•

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

•

cording to the switch position should flash.

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

•

should flash.

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

following item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter) Meter Unitfor Turn Signal IndicatorLight(LED) (see Meter Unit Inspection in the Electrical System chapter) TurnSignal Relay Fuse 10A (seeFuse Inspection inthe Electrical System chapter) Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)

Push the turn signal switch.

•

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

•

off.

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

item.

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

PERIODIC MAINTENANCE 2-45

Fourth Step

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

•

Start the engine.

•

The low beam headlight should go on.

•

If the low beam headlight does not go on, inspect or re-

place the following item.

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

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Set the dimmer switch to high beam position.

•

The low beam [A] and high beam [B] headlights should

•

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

•

Ifthe high beamheadlightand/or high beamindicator light (LED) does not go on, inspect or replace the following item.

HeadlightHighBeam Bulb (see HeadlightBulbReplacement in the Electrical System chapter) Meter Unit for High Beam Indicator Light (LED) (seeMeter Unit Inspection in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter)

Turn off the engine stop switch.

•

The low beam and high beam headlights should stay go-

•

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

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

Turn off the ignition switch.

•

Theheadlights andhigh beam indicatorlight (LED)should

•

go off.

Headlight Aiming Inspection

Inspect the headlight beam for aiming.

•

If the headlight beam is off the point, adjust the headlight aiming.

Headlight Beam Horizontal Adjustment

Remove the meter cover (see Upper Fairing Removal in

•

the Frame chapter.) Turnthe horizontal adjuster [A] inboth headlights with the

•

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

Headlight Beam Vertical Adjustment

Turn the vertical adjuster [B] in both headlights in or out

•

to adjust the headlight vertically.

NOTE

On high beam, the brightest points should be slightly

○

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

Periodic Maintenance Procedures

NOTE

For US model, the proper angle is 0.4 degrees below

○

horizontal. This is 5 0 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.

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

7.6 m (25 ft) [C] Height of Headlight Center [D]

Sidestand Switch Operation Inspection

Inspect the sidestand switch [A] operation accordance to

•

the following table.

Sidestand Switch Operation

Sidestand

Up Neutral Released Starts

Up Neutral Pulled in Starts

Up In Gear Released

Up In Gear Pulled in Starts

Down Neutral Released Starts

Down Neutral Pulled in Starts

Down

Gear

Position

In Gear

Clutch

Lever

Released

Pulled in

Engine

Start

Doesn’t

start

Doesn’t

start

Doesn’t

start

Engine

Run

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Stops

PERIODIC MAINTENANCE 2-47

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

Battery (see Charging Condition Inspection in the Electrical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) SidestandSwitch(see Switch Inspection intheElectrical System chapter) Engine Stop Switch (see Switch Inspection in the Electrical System chapter) Starter Button (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter) Starter Relay (see Starter Relay Inspection in the Electrical System chapter) Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System

chapter) If the all parts are good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).

Engine Stop Switch Operation Inspection

First Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button.

•

The engine does not start.

•

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

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

Second Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button and run the engine.

•

Turn the engine stop switch to stop position.

•

Immediately the engine should be stop.

•

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

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

Periodic Maintenance Procedures Others

Chassis Parts Lubrication

Before lubricatingeach part, clean off any rusty spots with

•

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

•

NOTE

Whenever the vehicle has been operated under

○

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

Pivots: Lubricate with Grease.

Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand

Points: Lubricate with Grease.

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

PERIODIC MAINTENANCE 2-49

Cables: Lubricate with Rust Inhibitor.

Clutch Cable Throttle Cables

Lubricate the cables by seeping the oil between the cable

•

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

○

available pressure cable lubricator with an aerosol cable lubricant.

2-50 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.

Periodic Maintenance Procedures

Bolts, Nuts and Fasteners Tightness Inspection

Checkthe tightnessof the boltsand nuts listedhere. Also,

•

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

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

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

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Exhaust Pipe Mounting Bolt Muffler Body Clamp Bolts Muffler Body Mounting Bolt and Nuts Radiator Upper and Lower Bolts Subframe Bolts

Wheels:

Front Axle Front Axle Clamp Bolt Rear Axle Nut

Brakes:

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

Suspension:

Front Fork Clamp Bolts Rear Shock Absorber Bolt and Nut Swingarm Pivot Shaft Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Rocker Arm Nut

Steering:

Handlebar Holder Bolts Steering Stem Head Bolt

Others:

Footpeg Bracket Bolts Front Fender Bolts Sidestand Bolt

PERIODIC MAINTENANCE 2-51

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures Replacement Parts

Air Cleaner Element Replacement

NOTE

In dusty areas, the element should be replaced more

○

frequently than the recommended interval.

WARNING

If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Replace the air cleaner element according to the maintenance chart.

NOTICE

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

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Connector Bracket [A]

Screws [B]

Upper Air Cleaner Housing [C]

Discard the air cleaner element [A].

•

Install a new element so that flat side faces forward.

•

Tighten:

•

Torque - Upper Air Cleaner Housing Screws: 1.1 N·m (0.11

kgf·m, 9.7 in·lb)

Fuel Hose Replacement

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

•

System (DFI) chapter).

Periodic Maintenance Procedures

Be sure to place a piece of cloth [A] around the fuel hose

•

joint. Insert a thin blade screwdriver [B] into the slit [C] on the

•

joint lock [D]. Turn the driver to disconnect the joint lock.

•

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

•

WARNING

Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared forfuel spillage; any spilled fuel mustbe completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.

PERIODIC MAINTENANCE 2-53

Replace the fuel hose with a new one.

•

Run the fuel hose correctly (see Cable, Wire, and Hose

•

Routing section in the Appendix chapter). Insert the fuel hose joint [A] straight onto the delivery pipe

•

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

•

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

•

more than two times and make sure it is locked and does not come off.

WARNING

Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn’t leak.

If it comes off, reinstall the hose joint. Run the fuel hose correctly (see Cable, Wire, and Hose

•

Routing section in the Appendix chapter). Install the fuel tank (see Fuel Tank Installation in the Fuel

•

System (DFI) chapter). Start the engine and check the fuel hose for leaks.

•

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Coolant Change

WARNING

Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.

Remove the left lower fairing (see Lower Fairing Removal

•

in the Frame chapter). Place a container under the coolant drain bolt [A], then

•

remove the drain bolt.

Remove the right center fairing (see Center Fairing Re-

•

moval in the Frame chapter). Remove the radiator cap [A] in two steps. First turn the

•

capcounterclockwise to the firststop. Then pushand turn it further in the same direction and remove the cap. The coolant will drain from the radiator and engine.

○

Remove:

•

Right Lower Fairing Assembly (see Lower Fairing As-

sembly Removal in the Frame chapter)

Hose [A]

Reserve Tank Bolts [B] Turn over the reserve tank, remove the cap, and pour the

•

coolant into a suitable container. Install the reserve tank.

•

Replace the drain bolt gasket with a new one.

•

Tighten the drain bolt with the gasket.

•

Torque - Coolant Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)

Periodic Maintenance Procedures

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

NOTICE

Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50% Coolant: 50% Freezing Point: Total Amount:

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

•

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

○

from the engine and radiator.

–35°C (–31°F)

2.9 L (3.1 US qt)

NOTE

PERIODIC MAINTENANCE 2-55

Check the cooling system for leaks.

•

Tap the radiator hoses to force any air bubbles caught

•

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

•

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

•

coolant and install the cap [B]. Start the engine, warm it up thoroughly until the radiator

•

fan turns on and then stop the engine. Check the coolant level in the reserve tank after the en-

•

gine cools down. If the coolant level islower than the “L” (low) level line [C], add coolant to the “F” level line.

NOTICE

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

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

•

ThermostatHousing [A] (see ThermostatRemovalin the

Cooling System chapter)

WaterPump Cover [B](see WaterPump Removal in the

Cooling System chapter)

Oil Cooler [C] (see Oil Cooler Removal in the Engine

Lubrication System chapter) Replace the hoses [D] and O-rings [E] with new ones.

•

Apply grease to the O-rings and install them.

•

Install the hoses and tighten the clamps securely.

•

Torque - Radiator (Water) Hose Clamp Screws: 2.9 N·m

(0.30 kgf·m, 26 in·lb)

Fill the coolant (see Coolant Change).

•

Check the cooling system for leaks.

•

Periodic Maintenance Procedures

Engine Oil Change

Situate the motorcycle so that it is vertical after warming

•

up the engine. Remove the engine oil drain bolt [A] to drain the oil.

•

The oil in the oil filter can be drainedby removing thefilter

○

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

•

Tighten:

•

Torque - Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)

Pour in the specified type and amount of oil.

•

Recommended Engine Oil

Type:

Viscosity: Capacity: 3.2 L (3.4 US qt) (when filter is not

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

removed)

3.8 L (4.0 US qt) (when filter is removed)

4.0 L (4.2 US qt) (when engine is completely dry)

PERIODIC MAINTENANCE 2-57

NOTE

Do notaddany chemical additive to the oil. Oils fulfilling

○

theabove requirementsare fully formulatedand provide adequate lubrication for both the engine and the clutch. Although 10W-40 engine oil is the recommended oil

○

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

Check the oil level (see OilLevel Inspection in the Engine

•

Lubrication System chapter).

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change).

•

Remove the oil filter with the oil filter wrench [A].

•

Special Tool - Oil Filter Wrench: 57001-1249

Replace the filter with a new one.

•

Apply grease to the gasket [A] before installation.

•

Tighten the filter with the oil filter wrench.

•

Torque - Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb)

NOTE

Hand tightening of the oil filter can not be allowed since

○

it does not reach to this tightening torque.

Pour in the specified type and amount of oil (see Engine

•

Oil Change).

2-58 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Hose Replacement

Remove:

•

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Brake Hose Fitting Bolt [A]

NOTICE

Brake fluid quickly ruins painted plastic surfaces; anyspilled fluid should becompletely washed away immediately.

Remove the brake hose banjo bolts [A].

•

When removing the brake hose, take care not to spill the

•

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

•

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

•

There are washers on each side of the brake hose fitting.

○

Replace them with new ones when installing.

•

Fittheprojection of the brake hoseendto the calipers and

•

master cylinders, and tighten the brake hose banjo bolts to the specified torque.

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

ft·lb)

When installing the hoses, avoid sharp bending, kink-

•

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

•

Brake Fluid Change).

Periodic Maintenance Procedures

For ABS equipped models; note the following.

•

Remove:

•

Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Battery Case (see Battery Case Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Bolts [B] Clamps [C]

Open the band [D].

•

Clear the brake pipe from the holder [E].

•

Remove the exhaust butterfly valve cable clamp [F].

•

There are washers on each side of the brake hose fitting.

•

Replace them with new ones when installing. Before installing the brake pipe, check to seethat there is

•

no damage on the threads of the brake pipe joint nut. If there is any damage, replace the damaged parts with new ones.

NOTE

Hand tighten the brake pipe joint nuts at both ends of

○

the brake pipe temporarily and then tighten them to the specified torque. Tighten the brake pipe joint nuts with the flare nut

○

wrench.

PERIODIC MAINTENANCE 2-59

Tighten:

•

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

ft·lb)

Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

When installing the hoses, avoid sharp bending, kink-

•

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

•

Brake Fluid Change).

Brake Fluid Change

NOTE

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

○

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

2-60 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Level the brake fluid reservoir.

•

Remove the reservoir cap.

•

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

•

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

•

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

•

Change the brake fluid.

•

Repeat this operation until fresh brake fluid comes out

○

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

1. Open the bleed valve [A].

2. Apply the brake and hold it [B].

3. Close the bleed valve [C].

4. Release the brake [D].

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. Front Brake: Repeat the above steps for the other

○

caliper.

Tighten:

•

Torque - Front Master Cylinder Reservoir Stopper Screw:

1.2N·m(0.12kgf·m,11in·lb)

Follow the procedure below to install the front/rear brake

•

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

○

Tighten the bleed valve, and install the rubber cap.

•

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

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.

Periodic Maintenance Procedures

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

Removethe frontmaster cylinder(see Front MasterCylin-

•

der Removal in the Brakes chapter). Remove the seal cover [A], circlip [B], connector [C] and

•

O-ring [D].

Special Tool - Inside Circlip Pliers: 57001-143

Unscrewthelocknut [E] and pivot bolt [F], and remove the

•

brake lever. Remove the bleed valve [G] and rubber cap [H].

•

Remove the piston assembly [I] as follows.

•

Remove the dust cover and push rod.

○

Remove the circlip [J].

○

Pull out the piston (with primary cup and secondary cup).

○

Remove the return spring and spring guide.

○

Replace:

•

Seal Cover [A] Circlip [B] O-ring [D] Rubber Cap [H] Piston Assembly [I] Circlip [J] Diaphragm [K]

PERIODIC MAINTENANCE 2-61

Rear Master Cylinder Disassembly

Remove the rear master cylinder (see Rear Master Cylin-

•

der Removal in the Brakes chapter). Remove the circlip [A], connector [B] and O-ring [C].

•

Special Tool - Inside Circlip Pliers: 57001-143

Slide the dust cover [D] out of place, and remove the cir-

•

clip [E]. Pull out the push rod assy [F].

•

Take off the piston assy [G] and return spring [H].

•

NOTICE

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

Replace:

•

Circlip [A] O-ring [C] Circlip [E] Push Rod Assy [F] Piston Assy [G] Diaphragm [I]

2-62 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Master Cylinder Assembly

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

NOTICE

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

Apply brake fluid to the new parts and to the inner wall of

•

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

•

cylinder. Forthe front mastercylinder,apply a non-permanentlock-

•

ing agent to the reservoir screw and bolt. Apply silicone grease to the contact portion of the push

•

rod and brake lever pivot bolt. Tighten:

•

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

in·lb)

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

kgf·m, 52 in·lb)

Caliper Rubber Parts Replacement

Front Caliper Disassembly

Loosen the front caliper pad pins [A] and banjo bolt [B]

•

and tighten them loosely. Remove:

•

Front Caliper (see Front Caliper Removal in the Brakes

chapter)

BrakePads (see Front Brake PadRemoval in the brakes

chapter)

Remove:

•

Front Caliper Assembly Bolts [A] Split the front caliper.

•

Periodic Maintenance Procedures

Remove:

•

Pad Spring O-ring [A]

Using compressed air, remove the pistons. One way to

•

remove the pistons is as follows. Install a rubber gasket [A] and a wooden board [B] more

○

than 10 mm (0.4 in.) thick on the caliper half. For inside caliper half [C], fasten them together with a

○

suitable bolt and nut [D] as shown. Leave one of the oil passage [E] open. Lightly apply compressed air [F] to the oil passage until

○

the pistons hit the rubber gasket.

Push down [G]

PERIODIC MAINTENANCE 2-63

WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

Pull out the pistons by hand.

○

Remove the dust seals [A] and fluid seals [B].

•

Remove the bleed valve [C] and rubber cap [D].

•

Repeat the previous step to remove the pistons from the

•

other side of the caliper body.

NOTE

If compressed air is not available, do as follows for both

○

calipers coincidentally, with the brake hose connected to the caliper. Prepare a container for brake fluid, and perform the

○

work above it. Remove the pad springs and pads (see Front Brake

○

Pad Removal in the Brakes chapter). Pump the brake lever until the pistons come out of the

○

cylinders, and then disassemble the caliper.

2-64 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Front Caliper Assembly

Clean the caliper parts except for the pads.

•

NOTICE

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

Install the bleed valve and rubber cap.

•

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

Replace the fluid seals [A] with new ones.

•

Apply silicone grease to the fluid seals, and install them

○

into the cylinders by hand. Replace the dust seals [B] with new ones if they are dam-

•

aged. Apply silicone grease to the dust seals, and install them

○

into the cylinders by hand.

Replace the O-ring [A] and install it.

•

Apply brake fluid to the outside of the pistons, and push

•

them into each cylinder by hand. Be sure to install the O-ring.

•

Tighten:

•

Torque - Front Caliper Assembly Bolts: 22 N·m (2.2 kgf·m,

16 ft·lb)

Install the pad spring [A] as shown.

•

Install the brake pads (see Front Brake Pad Installation in

•

the Brakes chapter). Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Rear Caliper Disassembly

Remove:

•

Rear Caliper (see Rear Caliper Removal in the Brakes

chapter)

BrakePads(see Rear Brake Pad Removal in theBrakes

chapter)

Caliper Holder

Periodic Maintenance Procedures

Using a rear caliper mounting bolt [A], screw the thread

•

hole for banjo bolt to remove the piston [B]. Remove the pad spring [C].

•

Remove:

•

Dust Seal [A] and Fluid Seal [B] Bleed Valve [C] and Rubber Cap [D] Dust Boot [E] Friction Boot [F]

PERIODIC MAINTENANCE 2-65

Rear Caliper Assembly

Clean the caliper parts except for the pads.

•

NOTICE

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

Install the bleed valve and rubber cap.

•

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

Apply brake fluid to the cylinder bore.

•

Replace the fluid seal [A] with a new one.

•

Apply silicone grease to the fluid seal, and install it into

○

the cylinder by hand. Replace the dust seal [B] with a new one.

•

Apply brake fluid to the outside of the piston, and push it

•

into the cylinder by hand as far as it will go. Replace the friction boot [C] and dust boot [D] with new

•

ones. Apply silicone grease to the sliding surface of the caliper

•

holder shafts [E]. Check that the guide [F] is in place on the caliper holder.

•

Install the pad spring [G].

•

Install the pads (see Rear Brake Pad Installation in the

•

Brakes chapter). Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

2-66 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Spark Plug Replacement

Remove the stick coils (see Stick Coil Removal in the

•

Electrical System chapter). Remove the spark plugs [A] using the plug wrench [B]

•

vertically.

Special Tool - Spark Plug Wrench, Hex 16: 57001-1262

Replace the spark plug with a new one.

•

Standard Spark Plug

Type: NGK CR9EIA-9

Insert new spark plug in the plug wrench.

•

Using the plug wrench vertically, tighten the plug.

•

NOTICE

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

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)

Install the stick coils securely.

•

Be sure the stick coils are installed by pulling up it lightly.

○

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

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

DFI System............................................................................................................................. 3-10

DFI Parts Location.................................................................................................................. 3-16

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

Special Tools and Sealant...................................................................................................... 3-20

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

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

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

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

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

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

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

Self-diagnosis Outline.......................................................................................................... 3-36

Self-diagnosis Procedures................................................................................................... 3-37

Service Code Reading...................................................................................................... 3-40

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

Backups............................................................................................................................... 3-42

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

Main Throttle Sensor Removal/Adjustment ...................................................................... 3-45

Main Throttle Sensor Input Voltage Inspection................................................................. 3-45

Main Throttle Sensor Output Voltage Inspection .............................................................. 3-46

Main Throttle Sensor Resistance Inspection.................................................................... 3-48

Intake Air Pressure Sensor #1 (Service Code 12).................................................................. 3-49

Intake Air Pressure Sensor #1 Removal........................................................................... 3-49

Intake Air Pressure Sensor #1 Installation........................................................................ 3-49

Intake Air Pressure Sensor #1 Input Voltage Inspection................................................... 3-50

Intake Air Pressure Sensor #1 Output Voltage Inspection................................................ 3-51

Intake Air Temperature Sensor (Service Code 13)................................................................. 3-55

Intake Air Temperature Sensor Removal/Installation........................................................ 3-55

Intake Air Temperature Sensor Output Voltage Inspection............................................... 3-55

Intake Air Temperature Sensor Resistance Inspection..................................................... 3-56

Water Temperature Sensor (Service Code 14) ...................................................................... 3-58

Water Temperature Sensor Removal/Installation ............................................................. 3-58

Water Temperature Sensor Output Voltage Inspection..................................................... 3-59

Water Temperature Sensor Resistance Inspection........................................................... 3-60

Intake Air Pressure Sensor #2 (Service Code 16).................................................................. 3-61

Intake Air Pressure Sensor #2 Removal........................................................................... 3-61

Intake Air Pressure Sensor #2 Installation........................................................................ 3-61

Intake Air Pressure Sensor #2 Input Voltage Inspection................................................... 3-62

Intake Air Pressure Sensor #2 Output Voltage Inspection................................................ 3-63

Crankshaft Sensor (Service Code 21).................................................................................... 3-65

Crankshaft Sensor Removal/Installation........................................................................... 3-65

Crankshaft Sensor Resistance Inspection........................................................................ 3-65

Crankshaft Sensor Peak Voltage Inspection..................................................................... 3-65

Speed Sensor (Service Code 24, 25)..................................................................................... 3-66

Speed Sensor Removal/Installation.................................................................................. 3-66

Speed Sensor Inspection.................................................................................................. 3-66

Speed Sensor Input Voltage Inspection............................................................................ 3-66

Speed Sensor Output Voltage Inspection......................................................................... 3-67

Vehicle-down Sensor (Service Code 31)................................................................................ 3-69

3-2 FUEL S YSTEM (DFI)

Vehicle-down Sensor Removal......................................................................................... 3-69

Vehicle-down Sensor Installation...................................................................................... 3-70

Vehicle-down Sensor Input Voltage Inspection................................................................. 3-70

Vehicle-down Sensor Output Voltage Inspection.............................................................. 3-71

Subthrottle Sensor (Service Code 32).................................................................................... 3-74

Subthrottle Sensor Removal/Adjustment.......................................................................... 3-74

Subthrottle Sensor Input Voltage Inspection..................................................................... 3-74

Subthrottle Sensor Output Voltage Inspection.................................................................. 3-75

Subthrottle Sensor Resistance Inspection........................................................................ 3-77

Oxygen Sensor - not activated (Service Code 33, Equipped Models) ................................... 3-78

Oxygen Sensor Removal/Installation................................................................................ 3-78

Oxygen Sensor Inspection................................................................................................ 3-78

Exhaust Butterfly Valve Actuator Sensor (Service Code 34).................................................. 3-81

Exhaust Butterfly Valve Actuator Sensor Removal/Installation......................................... 3-81

Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection................................... 3-81

Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection................................ 3-82

Exhaust Butterfly Valve Actuator Sensor Resistance Inspection...................................... 3-83

Immobilizer Amplifier (Service Code 35, Equipped Models) .................................................. 3-84

Antenna Resistance Inspection ........................................................................................ 3-84

Amplifier Input Voltage Inspection..................................................................................... 3-85

Blank Key Detection (Service Code 36, Equipped Models) ................................................... 3-86

Ignition Key Inspection...................................................................................................... 3-86

ECU Communication Error (Service Code 39)....................................................................... 3-87

ECU Communication Line Inspection............................................................................... 3-87

Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)........................................................ 3-88

Stick C oil Removal/Installation.......................................................................................... 3-88

Stick C oil Primary Winding Resistance Inspection ........................................................... 3-88

Stick C oil Input Voltage Inspection.................................................................................... 3-88

Radiator Fan Relay (Service Code 56)................................................................................... 3-90

Radiator Fan Relay Removal/Installation.......................................................................... 3-90

Radiator Fan Relay Inspection.......................................................................................... 3-90

Subthrottle Valve Actuator (Service Code 62)........................................................................ 3-91

Subthrottle Valve Actuator Removal ................................................................................. 3-91

Subthrottle Valve Actuator Inspection............................................................................... 3-91

Subthrottle Valve Actuator Resistance Inspection ............................................................ 3-91

Subthrottle Valve Actuator Input Voltage Inspection......................................................... 3-92

Exhaust Butterfly Valve Actuator (Service Code 63).............................................................. 3-94

Exhaust Butterfly Valve Actuator Removal ....................................................................... 3-94

Exhaust Butterfly Valve Actuator Installation .................................................................... 3-94

Exhaust Butterfly Valve Actuator Inspection..................................................................... 3-96

Exhaust Butterfly Valve Actuator Resistance Inspection .................................................. 3-96

Air Switching Valve (Service Code 64)................................................................................... 3-98

Air Switching Valve Removal/Installation.......................................................................... 3-98

Air Switching Valve Inspection.......................................................................................... 3-98

Oxygen Sensor Heater (Service Code 67, Equipped Models) ............................................... 3-99

Oxygen Sensor Heater Removal/Installation.................................................................... 3-99

Oxygen Sensor Heater Resistance Inspection ................................................................. 3-99

Oxygen Sensor Heater Power Source Voltage Inspection ............................................... 3-100

Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)................. 3-102

Oxygen Sensor Removal/Installation................................................................................ 3-102

Oxygen Sensor Inspection................................................................................................ 3-102

Warning Indicator Light (LED) ................................................................................................ 3-105

Light (LED) Inspection ...................................................................................................... 3-105

ECU........................................................................................................................................ 3-106

ECU Identification ............................................................................................................. 3-106

ECU Removal ................................................................................................................... 3-106

ECU Installation ................................................................................................................ 3-106

FUEL SYSTEM (DFI) 3-3

ECU Power Supply Inspection.......................................................................................... 3-107

DFI Power Source..................................................................................................................3-110

ECU Fuse Removal.......................................................................................................... 3-110

ECU Fuse Installation....................................................................................................... 3-110

ECU Fuse Inspection........................................................................................................ 3-110

ECU M ain Relay Removal/Installation.............................................................................. 3-110

ECU M ain Relay Inspection.............................................................................................. 3-110

Fuel Line................................................................................................................................. 3-111

Fuel Pressure Inspection.................................................................................................. 3-111

Fuel Flow Rate Inspection ................................................................................................ 3-112

Fuel Pump.............................................................................................................................. 3-114

Fuel Pump Removal ......................................................................................................... 3-114

Fuel Pump Installation ...................................................................................................... 3-115

Fuel Pump Operation Inspection ...................................................................................... 3-115

Fuel Pump Operating Voltage Inspection ......................................................................... 3-116

Pressure Regulator Removal............................................................................................ 3-116

Pump Screen, Fuel Filter Cleaning................................................................................... 3-117

Fuel Pump Relay Removal/Installation............................................................................. 3-117

Fuel Pump Relay Inspection............................................................................................. 3-117

Fuel Injectors.......................................................................................................................... 3-119

Fuel Injector Removal/Installation..................................................................................... 3-119

Fuel Injector Audible Inspection........................................................................................ 3-119

Fuel Injector Resistance Inspection.................................................................................. 3-119

Fuel Injector Power Source Voltage Inspection................................................................ 3-120

Fuel Injector Output Voltage Inspection............................................................................ 3-121

Fuel Injector Fuel Line Inspection..................................................................................... 3-122

Throttle Grip and Cables ........................................................................................................ 3-124

Free Play Inspection......................................................................................................... 3-124

Free Play Adjustment........................................................................................................ 3-124

Cable Installation.............................................................................................................. 3-124

Cable Lubrication.............................................................................................................. 3-124

Throttle Body Assy ................................................................................................................. 3-125

Idle Speed Inspection/Adjustment .................................................................................... 3-125

Synchronization Inspection/Adjustment............................................................................ 3-125

Throttle Body Assy Removal............................................................................................. 3-125

Throttle Body Assy Installation.......................................................................................... 3-127

Throttle Body Assy Disassembly ...................................................................................... 3-128

Throttle Body Assy Assembly........................................................................................... 3-129

Air Cleaner.............................................................................................................................. 3-130

Air Cleaner Element Removal/Installation ........................................................................ 3-130

Air Cleaner Element Inspection ........................................................................................ 3-130

Air Cleaner Oil Draining.................................................................................................... 3-130

Air Cleaner Housing Removal........................................................................................... 3-130

Air Cleaner Housing Installation........................................................................................ 3-131

Fuel Tank................................................................................................................................ 3-132

Fuel Tank Removal........................................................................................................... 3-132

Fuel Tank Installation........................................................................................................ 3-135

Fuel Tank and Cap Inspection .......................................................................................... 3-137

Fuel Tank Cleaning........................................................................................................... 3-137

Evaporative Emission Control System (CAL and SEA-B1 Models)........................................ 3-138

Parts Removal/Installation................................................................................................ 3-138

Hose Inspection................................................................................................................ 3-138

Separator Inspection......................................................................................................... 3-138

Separator Operation Test.................................................................................................. 3-139

Canister Inspection .......................................................................................................... 3-139

3-4 FUEL S YSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

1 Upper Air Cleaner Housing Screws 1.1 0.11 9.7 in·lb 2 Throttle Body Assy Holder Clamp Bolts 2.9 0.30 26 in·lb 3

Air Cleaner Duct Clamp Bolts

4 Delivery Pipe Assy Mounting Screws 3.4 0.35 30 in·lb

5. Throttle Cable (Accelerator)

6. Throttle Cable (Decelerator)

7. Air Cleaner Element

8. Air Switching Valve

9. Intake Air Pressure Sensor #2

10. Intake Air Pressure Sensor #1

11. Fuel Injectors

12. other than CAL and SEA-B1 Models

CL: Apply cable lubricant.

EO: Apply engine oil

G: Apply grease.

R: Replacement Parts

N·m kgf·m ft·lb

2.0 0.20 18 in·lb

Torque

Remarks

3-6 FUEL S YSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1 Oxygen Sensor (Equipped Models) 44 4.5 32

Intake Air Temperature Sensor Mounting

Screw 3 Water Temperature Sensor 30 3.0 22 4 Exhaust Butterfly Valve Actuator Pulley Bolt 5.0 0.51 44 in·lb

Exhaust Butterfly Valve Actuator Mounting

Screws

6. Crankshaft Sensor

7. Speed Sensor

8. Intake Air Temperature Sensor

9. Stick Coils

10. Vehicle-down Sensor

11. Relay Box

12. ECU R: Replacement Parts

N·m kgf·m ft·lb

1.2 0.12 11 in·lb

Torque

Remarks

3-8 FUEL S YSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-9

No. Fastener

N·m kgf·m ft·lb

1 Fuel Pump Bolts 9.8 1.0 87 in·lb L

2. Other than CAL and SEA-B1 Models

3. CAL and SEA-B1 Models

4. Separator

5. Canister

6. Blue Hose (Breather)

7. Green Hose (Purge)

8. Red Hose (Return)

9. White Hose (Vacuum) L: Apply a non-permanent locking agent.

R: Replacement Parts

Torque

Remarks

3-10 FUEL SYSTEM (DFI)

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

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Before Servicing

Model Identification

General Specifications

Unit Conversion Table

Periodic Maintenance

Periodic Maintenance Chart

Torque and Locking Agent

Specifications

Special Tools

Throttle Control System Inspection

Engine Vacuum Synchronization Inspection

Idle Speed Inspection

Idle Speed Adjustment

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

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

Coolant Level Inspection

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

Engine Top End

Valve Clearance Inspection

Valve Clearance Adjustment

Air Suction System Damage Inspection

Clutch Operation Inspection

Air Pressure Inspection

Wheel/Tire Damage Inspection

Tire Tread Wear Inspection

Wheel Bearing Dama g e Inspection

Drive Chain Lubrication Condition Inspection

Drive Chain Slack Inspection

Drive Chain Slack Adjustment

Wheel Alignment Inspection

Wheel Alignment Adjustment

Drive Chain Wear Inspection

Chain Guide Wear Inspection

Brake Fluid Leak (Brake Hose and Pipe) Inspection

Brake Hose and Pipe Damage and Ins tallation Condition Inspection

Brake Operation Inspection

Brake Fluid Level Inspection

Brake Pad Wear Inspection

Brake Light Switch Operation Inspection

Front Forks/Rear Shock Absorber Operation Inspection

Front Fork Oil Leak Inspection

Rear Shock Absorber Oil Leak Inspection

Rocker Arm Operation Inspection

Tie-Rod Operation Inspection

Steering

Steering Play Inspection

Steering Play Adjustment

Steering Stem Bearing Lubrication

Lights and Switches Operation Inspection

Headlight Aiming Inspection

Sidestand Switch Operation Inspection

Engine Stop Switch Operation Inspection

Chassis Parts Lubrication

Bolts, Nuts and Fasteners Tightness Inspection

Air Cleaner Element Replacement

Fuel Hose Replacement

Coolant Change

Radiator Hose and O-ring Replacement

Engine Oil Change

Oil Filter Replacement

Brake Hose Replacement

Brake Fluid Change

Master Cylinder Rubber Parts Replacement

Caliper Rubber Parts Replacement

Spark Plug Replacement

Fuel System (DFI)

Exploded View

DFI System