Kawasaki Z750 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

Z750

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

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

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

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

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center 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 reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

Read OWNER’S MANUAL before operating.

Foreword

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

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

For the duration of the warranty period,

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

To get the longest life out of your vehicle:

Follow the Periodic Maintenance Chart i n the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Special Tool Catalog or Manual. Genuine

parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

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

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

The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick R eference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and convenient operation.

Indicates a procedural step or work to be

•

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

○

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

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-8

Technical Information – Air Inlet System ................................................................................ 1-10

Technical Information – New Ignition Interlock Sidestand ...................................................... 1-12

Technical Information – Tail/Brake Lights Employing LED ..................................................... 1-13

Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM ......................... 1-15

Unit Conversion Table ............................................................................................................ 1-16

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following:

Battery Ground

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

Edges of Parts

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

Solvent

Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

GENERAL INFORMATION 1-3

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

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

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence i s not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

Usecommonsenseduringdisassemblyandassembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non

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

Gasket, O-ring

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

Liquid Gasket, Locking Agent

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

Before Servicing

Press

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

Ball Bearing and Needle Bearing

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

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

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

Circlips, Cotter Pins

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

Lubrication

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

1-6 GENERAL INFORMATION

Before Servicing

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.

Model Identification

ZR750–J1 Left Side View:

GENERAL INFORMATION 1-7

ZR750–J1 Right Side View:

1-8 GENERAL INFORMATION

General Specifications

Items ZR750–J1

Dimensions:

Overall length 2 080 mm (81.9 in.)

Overall width 780 mm (30.7 in.)

Overall height 1 055 mm (41.5 in.)

Wheelbase 1 425 mm (56.1 in.)

Road clearance 165 mm (6.5 in.)

Seat height 815 mm (32.1 in.)

Dry mass 195 kg (430.0 lb)

Curb mass: Front 111 kg (244.8 lb)

Rear 107 kg (235.9 lb)

Fuel tank capacity 18 L (5.0 US gal.)

Performance:

Minimum turning radius 2.9 m (9.5 ft)

Engine:

Type 4-stroke, DOHC, 4-cylinder

Cooling system Liquid-cooled

Bore and stroke 68.4 × 50.9 mm (2.7 × 2.0 in.)

Displacement 748 mL (45.64 cu in.)

Compression ratio 11.3

Maximum horsepower 79 kW (107 PS) @10 500 r/min (rpm),

(MY, AU) 80 kW (109 PS) @11 000 r/min (rpm)

(HR) 78.2 kW (106 PS) @11 000 r/min (rpm)

Maximum torque 75 N·m (7.6 kgf·m, 55 ft·lb) @8 200 r/min (rpm),

(HR) 73 N·m (7.4 kgf·m, 54 ft·lb) @8 200 r/min (rpm)

Carburetion system FI (Fuel Injection) KEIHIN TTK34 × 4

Starting system Electric starter

Ignition system Battery and coil (transistorized)

Timing advance Electronically advanced (digital igniter)

Ignition timi

Spark plug NGK CR9EK or ND U27ETR

Cylinder numbering method Left to right, 1-2-3-4

Firing order 1-2-4-3

Valve timing:

Inlet Open 38° BTDC

Exhaust Open 57° BBDC

Lubrication system Forced lubrication (wet sump)

Engine oil:

Type API SE, SF or SG

From 10° BTDC @1 100 r/min (rpm) to 37° BTDC @5 800 r/min (rpm)

Close 66° ABDC

Duration 284°

Close 31° ATDC

Duration 268°

API SH or SJ with JASO MA

GENERAL INFORMATION 1-9

General Specifications

Items ZR750–J1

Viscosity SAE 10W-40

Capacity 3.8 L (4.0 US qt)

Drive Train:

Primary reduction system:

Type Gear

Reduction ratio 1.714 (84/49)

Clutch type Wet multi disc

Transmission:

Type 6-speed, constant mesh, return shift

Gear ratios: 1st 2.571 (36/14)

2nd 1.941 (33/17)

3rd 1.555 (28/18)

4th 1.333 (28/21)

5th 1.200 (24/20)

6th 1.095 (23/21)

Final drive system:

Type Chain drive

Reduction ratio 2.867 (43/15)

Overall drive ratio 5.382 @Top gear

Frame:

Type Tubular, diamond

Caster (rake angle) 24.5°

Trail 104 mm (4.1 in.)

Front tire: Type Tubeless

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

Rear tire: Type Tubeless

Size 180/55 ZR17 M/C (73W)

Front suspension: Type Telescopic fork ( upside-down)

Wheel travel 120 mm (4.7 in.)

Rear suspension: Type Swingarm (uni-trak)

Wheel travel 126 mm (5.0 in.)

Brake Type: Front Dual discs

Rear

Electrical Equipment:

Battery 12 V 8 Ah

Headlight: Type Semi-sealed beam

Bulb 12 V 55 W × 2/55 W (Hi/Lo)

Tail/brake light 12 V 0.5/3.8 W (LED), (CA) 12 V 0.5/5W (LED)

Alternator: Type Three-phase AC

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

Single disc

Specifications are subject to change without notice, and may not apply to every country. (AU): Australia Model (CA): Canada Model (MY): Malaysia Model (HR): with Honeycomb Catalytic Converter Model (Restricted model)

1-10 GENERAL INFORM ATION

Technical Information – Air Inlet System

Subthrottle Control System

The ZR750–J1 employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore. Therefore two throttle valves are placed in each inlet tract, the main throttle valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract. The main throttle valve is operated by the rider when the throttle grip is turned clockwise or counterclockwise, while the subthrottle valve is operated by a stepping motor controlled by the ECU. The subthrottle valve automatically adjusts air inlet to more precisely match engine demand, so that when the main throttle is opened quickly there is no hesitation or jerky response.

The subthrottle valves allow the fuel injection system to provide smooth throttle response, similar to that of a constant velocity carburetor, no matter how quickly the throttle is opened.

A. Main Throttle Valve B. Subthrottle Valve C. Throttle Valve

D. Vacuum Piston E. Inlet Air

GENERAL INFORMATION 1-11

Technical Information – Air Inlet System

Operation

The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body.

The subthrottle control system operates on the signal supplied from the ECU. The open/close operation of the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU to change the current direction into the motor of the subthrottle valve actuator.

The subthrottle sensor detects the subthrottle valve actuator movement by measuring voltage and the ECU determines the subthrottle valve angle based on the operation map.

When turning the ignition switch ON, every time the ECU automatically drives the subthrottle valve from fully closed position to fully opened position. The ECU memorizes these positions and turns back t he subthrottle valve to the original point to confirm the subthrottle valve idling voltage.

A. Subthrottle Valves B. Subthrottle Valve Actuator C. Subthrottle Sensor D. Main Throttle Sensor

E. ECU (Electric Control Unit)

F. Air Cleaner Side G. Crankshaft Sensor H. Speed Sensor

1-12 GENERAL INFORM ATION

Technical Information – New Ignition Interlock Sidestand

Outline

The New Ignition Interlock Sidestand System applied to ZR750–J1 models t hat cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from the traditional one. Refer to the tables below as to the engine starts and/or the driving at each condition.

New Ignition Interlock Sidestand System

Side Stand Gear Position Clutch Lever Engine Start Engine Run

A Up Neutral Released Starts Continue running

B Up Neutral Pulled in Starts Continue running

C Up In Gear Released Doesn’t start Continue running

D Up In Gear Pulled in Starts Continue running

E Down Neutral Released Starts Continue running

F Down Neutral Pulled in Starts Continue running

G Down In Gear Released Doesn’t start Stops

H Down In Gear Pulled in Doesn’t start Stops

Current Ignition Interlock Sidestand System

Side Stand Gear Position Clutch Lever Engine Start Engine Run

A Up Neutral Released Starts Continue running

B Up Neutral Pulled in Starts Continue running

C Up In Gear Released Doesn’t start Continue running

D Up In Gear Pulled in Starts Continue running

E Down Neutral Released

F Do

G Down In Gear Released Doesn’t start Stops

H Down In Gear Pulled in Start Continue running

utral

lled in

Starts Continue running

GENERAL INFORMATION 1-13

Technical Information – Tail/Brake Lights Employing LED

Outline

This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times longer), uses lower voltage, expends lower wattage (approx. 1/5), and is quicker responsing.

Due Position of LED Installation

The resistors, the diodes, and the Zener diodes are mounted in the electronic circuits [ A] of the LED, which supplies the steady current and voltage to the light.

Light Emitting Diode (LED)

The Light Emitting Diode (LED) [A] is an element of semiconductor diode that converts applied voltage to light.

The LED em its luminous beams by the collision of negative charge electrons [A] and positive charge holes [B] when applied the forward voltage and current to the PN junction diode [C].

1-14 GENERAL INFORM ATION

Technical Information – Tail/Brake Lights Employing LED

The em itting color differs according to the materials of

semi-conductors.

Materials of Semi-Conductor and Emitting Color

Materials of Semi-Conductor Emitting Color

GaAsP,

GaAlAs

GaP Green

GaN Blue

Ga: Gallium

As: Arsenic

P: Phosphorus N: Nitrogen

Al: Aluminum

Red

GENERAL INFORMATION 1-15

Technical Information – KAWASAKI LOW EXHAUST EMIS SION SYSTEM

Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), whi ch have no catalyst protection system, according to each regulation of different countries.

The muffler with built-in catalyst has the same durability as the conventional muffler, however, do not use leaded gasoline and do not coast with the ignition system OFF. Running the engine without ignition damages catalyst.

Refer to the ZX900E Service Manual (Part No. 99924–1255) for more i nformation about the KLEEN (theory, maintenance, and handling precautions), including the secondary air injection system.

Honeycomb Type Catalytic Converter

The converter is a three-way catalytic converter, and its surface is covered with alumina upon which

○

platinum and rhodium are applied, and has a cylindrical metallic honeycomb structure made by

bending a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter.

The honeycomb structure is convenient for the catalytic converter because it has a large surface

area but small size to react effectively and has low exhaust resistance. In addition, its inherent

strength helps resist vibration, and has simple structure welded directly on the silencer.

Generally, the temperature of the exhaust gas must be higher than activation temperature, so the

○

converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is

still high. And, the converters will be activated even under low load conditions.

After the exhaust gas is diluted with the secondary air injection, the catalytic converter works well

○

because of rich oxygen to reduce CO, HC, and NO

emission within regulation.

This type of converter works more efficiently as a three-way catalytic converter to reduce CO , HC,

○

and NO

x than the pipe type catalytic converter because of its more and denser catalysts.

x. Accordingly, we can keep the exhaust gas

1. Manifold

2. Silencer

3. Honeycomb Type Catalyst

4. Mark for Manifold

5. Mark for Silencer

1-16 GENERAL INFORM ATION

Unit Conversion Table

Prefixes for Units:

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

Units of Mass:

kg ×2.205=lb g × 0.03527 = oz

Units of Volume:

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

gal (imp)

oz (US)

Units of Length:

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

Units of Torque:

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

× 7.233 =

ft·lb

Units of Pressure:

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

× 98.07 = 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 × 0.7355 = kW PS

× 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent ................. 2-5

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

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

Periodic Maintenance Procedures..... 2-13

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

Fuel Hose and Connection

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

Throttle Control System

Inspection.................................. 2-14

Idle Speed Inspection .................. 2-15

Engine Vacuum Synchronization

Inspection.................................. 2-15

Air C leaner Element Cleaning...... 2-18

Cooling System............................... 2-20

Radiator Hose and Connection

Inspection.................................. 2-20

Coolant C hange ........................... 2-20

Engine Top End .............................. 2-22

Air S uction Valve Inspection ........ 2-22

Valve Clearance Inspection ......... 2-22

Clutch.............................................. 2-23

Clutch Adjust Inspection .............. 2-23

Engine Lubrication System ............. 2-24

Engine Oil Change....................... 2-24

Oil Filter Change .......................... 2-25

Wheels/Tires................................... 2-25

Tire Wear Inspection .................... 2-25

Air Pressure Inspection................ 2-26

Final Drive....................................... 2-27

Drive Chain Slack Inspection ....... 2-27

Drive Chain Slack Adjustment ..... 2-27

Drive Chain Wear Inspection ....... 2-28

Drive Chain Lubrication................ 2-29

Brakes............................................. 2-29

Brake Pad Wear Inspection ......... 2-29

Rear Brake Light Switch

Inspection/Adjustment ............... 2-29

Caliper Fluid Seal Damage .......... 2-30

Caliper Dust Seal/Friction Boot

Damage..................................... 2-30

Master Cylinder Inspection (Visual

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

Brake Fluid Level Inspection........ 2-32

Brake Fluid Change ..................... 2-32

Brake Line Bleeding..................... 2-34

Brake Hoses and Connections

Inspection.................................. 2-36

Suspension..................................... 2-37

Front Fork Oil Leak Check........... 2-37

Rear Shock Absorber Oil Leak

Check ........................................ 2-37

Steering .......................................... 2-37

Steering Inspection ...................... 2-37

Steering Adjustment..................... 2-37

Steering Stem Bearing

Lubrication................................. 2-38

Electrical System ............................ 2-39

Spark Plug Inspection .................. 2-39

General Lubrication ........................ 2-41

Lubrication ................................... 2-41

Nut, Bolt, and Fastener Tightness .. 2-42

Tightness Inspection .................... 2-42

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

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

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

Periodic Inspection:

FREQUENCY

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

Steering system:

Whichever

comes

first

* ODOMETER READING

km × 1000 (mile × 1000)

1 6 12 18 24 30 36 See

Steering play - inspect year

Steering stem bearings - lubricate 2 years

Brake system:

Brake hoses leak - inspect

Brake hoses damage - in

Brake hose installation condition - inspect

Brake operation (effectiveness, play-drag)

- inspect

Brake pad wear - inspec

Brake fluid level - inspect 6 month

Brake light switch operation - inspect

Wheels and tires:

Tire air pressure - inspect year

Wheels/tires damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearings damage - inspect year

Suspensions:

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

Front forks/rear shock absorber oil leak inspect

spect

year

• • • •

•

• • • • • • •

• • • • • •

• • • • • • •

• • •

2–37

2–38

2–36

—

2–29

2–32

2–29

2–26

2–25

—

2–37

Rocker arm wear - inspect

Rocker arm operation

Tie rods operation

Drive train:

Drive chain lubrication condition - inspect # 1 000 km 2–29

Drive chain slack - i nspect # 1 000 km 2–27

Drive chain wear - inspect #

Drive chain guide wear - inspect

Electrical system:

Spark plug condition - inspect

Lights and switches operation year

Headlight aiming - inspect year

Side stand switch operation year

• • •

—

2–28

—

2–39

—

Periodic Maintenance Chart

PERIODIC MAINTENANCE 2-3

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Engine stop switch operation year

Fuel system (DFI):

Air cleaner element - clean #

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

Choke operation - inspect year

Engine vacuum synchronization - inspect

Engine vacuum synchronization - adjust When necessary 2–15

Idle speed - inspect

Fuel hoses leak - inspect

Fuel hoses damage - inspect year

Fuel hoses installation condition - inspect year

Cooling system:

year

• • • •

• • •

* ODOMETER READING

km × 1000 (mile × 1000)

See

—

•

2–18

2–14

—

2–15

2–13

Coolant level - inspect

Radiator hoses leak - inspect year

Radiator hoses dam age - inspect year

Radiator hoses installation condition inspect

Engine top end:

Air suction system damage - inspect

Intake/exhaust valve clearance - inspect

Chassis:

Chassis parts lubricate year

Bolts and nuts tightness - inspect

year

• • • •

• • •

•

• • •

• • • •

—

2–20

2–22

2–41

2–42

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Periodic Replacement Parts:

FREQUENCY

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

Whichever

comes

first

* ODOMETER READING

km × 1000 (mile × 1000)

1 12 24 36 48 See

Brake hoses 4 years

Brake fluid (front and rear) 2 years

Rubber parts of master cylinder and caliper

Spark plug

Air cleaner element #

Engine oil # year

Oil filter year

Fuel hoses 4 years

Coolant 3 years

Radiator hoses and O-rings 3 years

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

frequent starting/stopping.

Throttle control system inspection: Inspection of throttle grip play.

4 years

• • • •

• • • • •

• •

•

2–36

•

2–32

2–30

•

2–39

2–18

2–24

2–25

2–13

•

2–20

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

The following tables list the tightening torque

for the major fasteners requiring use of a non

-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately

two times to ensure even tightening torque.

G: Apply grease to the threads.

L: Apply a non-permanent locking agent to

the threads.

MO: Apply molybdenum disulfide grease oil

solution.

O: Apply oil to the threads and seating sur-

face.

R: Replacement Parts

S: Tighten the fasteners following the speci-

fied sequence.

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

SS: Apply silicone sealant.

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 Torque

dia.

(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 ∼ 33 165 ∼ 240

N·m kgf·m ft·lb

Fastener

N·m kgf·m ft·lb

Fuel System:

Inlet air pressure sensor bolt 12 1.2 104 in·lb

Water temperature sensor 25 2.5 18

Vehicle-down sensor bolts 2.0 0.20 17 in·lb

Camshaft position sensor bolt 12 1.2 104 in·lb

Camshaft position sensor rotor bolt 12 1.2 104 in·

Throttle cable plate bolt 6.0 0.60 52 in·lb

Throttle body assy holder clamp bolts 2.0 0.20 17 in·lb

Choke link holder screws 2.1 0.21 18 in·lb

Delivery pipe screws 3.4 0.35 30 in·lb

Bypass screws 0.2 0.02 1.7 in·lb

Air cleaner duct holder screws 3.8 0.39 34 in·lb

Air cleaner housing mounting bolts 9.8 1.0 87 in·lb

Air cleaner duct clamp bolts 2.0 0.20 17 in·lb

Air cleaner housing screws 1.2 0.12 10 in·lb

Air cleaner housing tapping screws 1.2 0.12 10 in·lb

Speed sensor bolt 6.9 0.70 62 in·lb L

Fuel pump bolts 9.8 1.0 87 in·lb L, S

Fuel level sensor bolts 6.9 0.70 62 in·lb

Cooling System:

Radiator hose clamp screws 2.0 0.20 17 in·lb

Radiator fan bolts 8.3 0.85 74 in·lb

Water pump impeller bolt 9.8 1.0 87 in·lb

Water pump cover bolts 11 1.1 95 in·lb

Torque

Remarks

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

N·m kgf·m ft·lb

Water pump drain bolt 11 1.1 95 in·lb

Water pipe bolts 11 1.1 95 in·lb

Thermostat housing ground bolt 7.0 0.70 61 in·lb

Thermostat bracket bolt 7.0 0.70 61 in·lb

Radiator upper bolts 7.0 0.70 61 in·lb

Radiator lower bolts 7.0 0.70 61 in·lb

Radiator screen bolt 7.0 0.70 61 in·lb

Coolant reserve tank screws 7.0 0.70 61 in·lb

Radiator fan switch 18 1.8 13

Water temperature sensor 25 2.5 18

Engine Top End:

Air suction valve cover bolts 9.8 1.0 87 in·lb

Cylinder head cover bolts 9.8 1.0 87 in·lb S

Camshaft cap bolts 12 1.2 104 in·lb S

Camshaft chain guide bolts 12 1.2 104 in·lb S

Cylinder head bolts (M10 new bolts) 54 5.5 40 MO, S

Cylinder head bolts (M10 used bolts) 49 5.0 36 MO, S

Cylinder head bolts (M6) 12 1.2 104 in·lb S

Cylinder head jacket plugs 22 2.2 16 L

Throttle body holder bolts 13 1.3 113 i n · lb

Throttle body assy holder clamp bolts 2.0 0.20 17 in·lb

Camshaft sensor bolt 12 1.2 104 in·lb

Camshaft sensor rotor bolt 12 1.2 104 in·lb L

Front camshaft chain guide bolt (upper) 25 2.5 18

Front camshaft chain guide bolt (lower) 12 1.2 104 in·lb

Rear camshaft chain guide bolt 25 2.5 18

Camshaft chain tensioner mounting bolts 11 1.1 95 in·lb

Camshaft chain tensioner cap bolt 28 2.9 21

Spark plugs 13 1.3 113 in·lb

Coolant drain plug (Cylinder) 9.8 1.0 87 in·lb

Exhaust pipe manifold holder nuts 17 1.7 12

Muffler body clamp bolt 17 1.7 12

Muffler body mounting bolt 30 3.0 22

Crankshaft sensor cover bolts 11 1.1 95 in·lb

Clutch:

Clutch lever clamp bolts 7.8 0.80 69 in·lb

Clutch cover mounting bolts 11 1.1 95 in·lb

Oil filler plug 1.5 0.15 13 in·lb

Clutch spring bolts 8.8 0.90 78 in·lb

Clutch hub nut 135 14 100 R

Torque

Remarks

(Washer)

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