Z750
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber 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 spe-
cific topic required.
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
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.
© 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Sep. 16, 2003 (M)
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 in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work care-
fully 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 ad-
versely 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 prod-
uct into its major systems. These systems be-
came the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a sin-
gle 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 exam-
ple, 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 chap-
ter. Then, use the Table of Contents on the first
page of the chapter to find the Spark Plug sec-
tion.
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 informa-
tion.
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 t ext of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
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 opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, 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, discon-
nect 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 neg-
ative 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 ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
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.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, 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 be-
yond 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 disassem-
bly, 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 dam-
age. 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 per-
formance. 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 be-
fore applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil pas-
sages and cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact 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.
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. Lubri-
cation 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. Ro-
tate 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.
GENERAL INFORMATION 1-7
Model Identification
ZR750–J1 Left Side View:
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
ng
From 10° BTDC @1 100 r/min (rpm) to 37° BTDC
@5 800 r/min (rpm)
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
Close 66° ABDC
Duration 284°
Exhaust Open 57° BBDC
Close 31° ATDC
Duration 268°
Lubrication system Forced lubrication (wet sump)
Engine oil:
Type API SE, SF or SG
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
Single disc
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)
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 oper-
ation 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
Starts Continue running
F Do
wn
Ne
utral
Pu
lled in
Starts Continue running
G Down In Gear Released Doesn’t start Stops
H Down In Gear Pulled in Start 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 semi-
conductor diode that converts applied voltage to light.
The LED em its luminous beams by the collision of nega-
tive 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
Red
GaP Green
GaN Blue
Ga: Gallium
As: Arsenic
P: Phosphorus
N: Nitrogen
Al: Aluminum
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 sys-
tem, 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
x. Accordingly, we can keep the exhaust gas
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.
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 =
gal (imp)
L × 1.057 = qt (US)
L × 0.8799 = qt (imp)
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
Units of Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
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 Power:
kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS
× 0.9863 = HP
Units of Temperature:
PERIODIC MAINTENANCE 2-1
2
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
Whichever
comes
first
* ODOMETER READING
km × 1000 (mile × 1000)
1 6 12 18 24 30 36 See
INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page
Steering system:
Steering play - inspect year
• • • •
2–37
Steering stem bearings - lubricate 2 years
•
2–38
Brake system:
Brake hoses leak - inspect
• • • • • • •
2–36
Brake hoses damage - in
spect
• • • • • • •
2–36
Brake hose installation condition - inspect
• • • • • • •
2–36
Brake operation (effectiveness, play-drag)
- inspect
year
• • • • • • •
—
Brake pad wear - inspec
t#
• • • • • •
2–29
Brake fluid level - inspect 6 month
• • • • • • •
2–32
Brake light switch operation - inspect
• • • • • • •
2–29
Wheels and tires:
Tire air pressure - inspect year
• • •
2–26
Wheels/tires damage - inspect
• • •
2–25
Tire tread wear, abnormal wear - inspect
• • •
2–25
Wheel bearings damage - inspect year
• • •
—
Suspensions:
Front forks/rear shock absorber operation
(damping and smooth stroke)
• • •
—
Front forks/rear shock absorber oil leak -
inspect
year
• • •
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 #
• • •
2–28
Drive chain guide wear - inspect
• • •
—
Electrical system:
Spark plug condition - inspect
• • •
2–39
Lights and switches operation year
• • •
—
Headlight aiming - inspect year
• • •
—
Side stand switch operation year
• • •
—
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
* ODOMETER READING
km × 1000 (mile × 1000)
1 6 12 18 24 30 36
See
INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page
Engine stop switch operation year
• • •
—
Fuel system (DFI):
Air cleaner element - clean #
•
2–18
Throttle control system (play, smooth
return, no drag) - inspect
year
• • • •
2–14
Choke operation - inspect year
• • • •
—
Engine vacuum synchronization - inspect
• • •
2–15
Engine vacuum synchronization - adjust When necessary 2–15
Idle speed - inspect
• • • •
2–15
Fuel hoses leak - inspect
• • • •
2–13
Fuel hoses damage - inspect year
• • • •
2–13
Fuel hoses installation condition - inspect year
• • •
2–13
Cooling system:
Coolant level - inspect
• • • •
—
Radiator hoses leak - inspect year
• • • •
2–20
Radiator hoses dam age - inspect year
• • • •
2–20
Radiator hoses installation condition -
inspect
year
• • • •
2–20
Engine top end:
Air suction system damage - inspect
• • •
2–22
Intake/exhaust valve clearance - inspect
•
2–22
Chassis:
Chassis parts lubricate year
• • •
2–41
Bolts and nuts tightness - inspect
• • • •
2–42
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
Periodic Replacement Parts:
FREQUENCY
Whichever
comes
first
* ODOMETER READING
km × 1000 (mile × 1000)
1 12 24 36 48 See
CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page
Brake hoses 4 years
•
2–36
Brake fluid (front and rear) 2 years
• •
2–32
Rubber parts of master cylinder and caliper
4 years
•
2–30
Spark plug
• • • •
2–39
Air cleaner element #
•
2–18
Engine oil # year
• • • • •
2–24
Oil filter year
• • • • •
2–25
Fuel hoses 4 years
•
2–13
Coolant 3 years
•
2–20
Radiator hoses and O-rings 3 years
•
2–20
# : 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.
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
The following tables list the tightening torque
for the major fasteners requiring use of a non
-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
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)
N·m kgf·m ft·lb
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
Torque
Fastener
N·m kgf·m ft·lb
Remarks
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·
lb
L
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
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
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
(Washer)
Cylinder head bolts (M10 used bolts) 49 5.0 36 MO, S
(Washer)
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
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