Kawasaki Z750S (2004) User Manual [ru]

Z750S

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

Z750S

Motorcycle

Service Manual

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

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to m ake 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 a re intended for reference use only and may
not depict actual model component parts.

© 2004 Kawasaki Heavy Industries, Ltd. First Edition (1) : Nov. 8, 2004 (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

BTDC before top dead center

°C degree(s) Celsius

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

PS

psi

r revolution

horsepower

pound(s) per square inch

Read OWNER’S MANUAL before operating.

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
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors

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 includes
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 ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.

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

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

NOTE

The phrase "re move or render inoperative any device or e lement of design" has been generally

○

interpreted as follows:

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

2. Tampering could include:

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

ceeded.

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

or durability of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the stan-

dards.

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

element of design of the emission control systems.

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

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

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

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

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

•

with Federal regulations.

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

•

Removal of the air box or air box cover.

•

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

•

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it 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 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

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 Reference
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 a nd 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 text 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............................................................................................................ 1-9

Technical Information - Air Inlet System ................................................................................. 1-12

Technical Information - New Ignition Interlock Side Stand ..................................................... 1-14

Technical Information - Tail/Brake Lights Employing LED ...................................................... 1-15

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM .......................... 1-17

Technical Information - Immobilizer System (Equipped Models)............................................ 1-18

Unit Conversion Table ............................................................................................................ 1-21

1

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, discon­nect the battery 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 m ust be replaced with
new ones whenever disassembled.

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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

Tightening Torque

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

Force

Use common sense during disassembly and assembly,
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 material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent

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

Before Servicing

Press

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

Ball Bearing and Needle Bearing

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

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

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

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

Circlips, Cotter Pins

Replace 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 Eng ine 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.

GENERAL INFORMATION 1-7

Model Identification

ZR750-K1 (United States and Canada) Left Side View

ZR750-K1 (United States and Canada) Right Side View

1-8 GENERAL INFORMATION

Model Identification

ZR750-K1 (Europe) Left Sid e View

ZR750-K1 (Europe) Right Side View

GENERAL INFORMATION 1-9

General Specifications

Items ZR750-K1

Dimensions

Overall Length 2 080 mm (81.9 in.)

Overall Width 780 mm (30.7 in.)

Overall Height 1 180 mm (46.5 in.)

Wheelbase 1 425 mm (56.1 in.)

Road Clearance 165 mm (6.5 in.)

Seat Height 805 mm (31.7 in.)

Dry Mass

Curb Mass:

Front 113 kg (249.2 lb)

Rear 109 kg (240.3 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 : 1

Maximum Horsepower 81 kW (110 PS) @11 000 r/min (rpm),

Maximum Torque

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

Spark Plug NGK CR9EK or ND U27ETR

Cylinder Numbering Method Left to right, 1-2-3-4

Firing Order

Valve Timing:

Inlet

Open 38° BTDC

Close 66° ABDC

Duration 284°

Exhaust

Open 57° BBDC

Close 31° ATDC

199 kg (438.8 lb)

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

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

(US, CA) – – –

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)

(US, CA) – – –

r/min (rpm)

1-2-4-3

1-10 GENERAL INFORMATION

General Specifications

Items ZR750-K1

Duration 268°

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type API SE, SF or SG

API SH or SJ with JASO MA

Viscosity SAE 10W-40

Capacity 3.8L(4.0USqt)

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

5th

6th

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) 25°

Trail 107 mm (4.2 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

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

1.333 (28/21)

1.200 (24/20)

1.095 (23/21)

Single disc

GENERAL INFORMATION 1-11

General Specifications

Items ZR750-K1

Electrical Equipment

Battery 12 V 8 Ah

Headlight:

Type Semi-sealed beam

Bulb 12 V 55 W × 2/55 W (Hi/Lo)

Tail/Brake Light 12 V 0.5/4.1 W (LED)

Alternator:

Type Three-phase AC

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

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

CA: Canada Model
US: United States
HR: With Honeycomb Catalytic Converter (Restricted Model)
MY: Malaysia Model

1-12 GENERAL INFORMATION

Technical Information - Air Inlet System

Subthrottle Control System

The ZR750-K models 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 1-13

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 the 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 (Electronic Control Unit)

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

1-14 GENERAL INFORMATION

Technical Information - New Ignition Interlock Side Stand

Outline

The New Ignition Interlock Side Stand System applied to ZR750-K models that cannot function if
gears are engaged and/or the side stand 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 Side Stand 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 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

Starts Continue running

Current Ignition Interlock Side Stand System

Side Stand Gear Position Clutch Lever Engine Start

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

Down

G

H Down In Gear Pulled in Start Continue running

In Gear

Relea

sed

Starts Continue running

Doesn

’t start

Engine Run

Stops

GENERAL INFORMATION 1-15

Technical Informatio n - Tail/Brake Lights Employing LED

Outline

This model employs a tail/brake light containing 9 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 emits 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].

1-16 GENERAL INFORMATION

Technical Information - Tail/Brake Lights Employing LED

The emitting 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

Al: Aluminum

As: Arsenic

Ga: Gallium

N: Nitrogen
P: Phosphorus

Red

Blue

GENERAL INFORMATION 1-17

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM

Since the emission regulations become more severe, Kawasaki has adopted a type of simplified
KAWASAKI LOW EXHAUST EMISSION SY STEM (KLEEN), which 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 m ore information 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 s piral 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 a s 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

1-18 GENERAL INFORMATION

Technical Information - Immobilizer System (Equipped Models)

Overview

This system provides a theft proof device by means of matching a code between the inbuilt key
transponder and the ECU (Electronic Control Unit). If this code does not match, the fuel pump, injec­tors, ignition system, sub-throttle valve actuator and exhaust butterfly valve actuator will not operate
and the engine will not start.

Related Parts and Function

1. Transponder (Inside Keys)

2. Master Key

3. User Keys

4. FI Indicator Light

5. Immobilizer Antenna

6. Ignition Switch

7. Immobilizer Amplifier

Master Key (1 piece)

The master key (colored red) has an inbuilt transponder, containing a master key code. These
codes are unique to each key. This code and an additional two user key codes must be registered
in the ECU for the system to operate. The master key is necessary when registering user keys and
should not be used as the main key to start the motorcycle except in emergencies (loss or damage of
user keys). It should b e kept in a safe place.

8. Starter Relay

9. Battery

10. Electronic Control Unit (ECU)

11. Junction Box

12. Immobilizer/Kawasaki Diagnostic System
Connector

GENERAL INFORMATION 1-19

Technical Information - Immobilizer System (Equipped Models)

Transponder (in Keys)

The transponder (made by Texas Instruments, Inc.) has an integrated circuit with a unique code
that also calculates data sent by the ECU. When the ignition switch is turned ON, the transponder
is excited by the radio wave transmitted from the antenna and then transmits a unique code to the
antenna.

User Key (2 pieces)

The user keys (colored black) should be used when riding the motorcycle. These keys have unique
codes which differ from the master key. Up to a maximum of five user key codes can be stored by
the ECU at any one time. These codes can not be registered to the ECU without firstly registering the
master key code.

Antenna

The antenna transmits a radio wave to excite the transponder, receives the code from the transpon­der and then transmits the code to the ECU through the amplifier.

Ignition Switch

The ignition switch turns the main circuit ON and OFF.

Amplifier

The amplifier (which is approximately the same size as a match box), amplifies signals from the
antenna and the ECU.

ECU

The ECU has the capacity to store a maximum of six key code memories (one master and five user
keys). The owner can have a total of five user keys at any one time. The master key memory can not
be rewritten after initial registration, whereas the user key memories can be rewritten as necessary.
When the ECU communicates with the transponder, a cipher generator changes the code every time
it is used to avoid cloning.

FI Indicator Light

The condition or the failure of the immobilizer system is indicated by various patterns of the FI indi­cator light blinking.

Sequence of Operation

1. Turn ON the ignition switch, the ECU, amplifier and antenna start working, and the meter assembly

FI indicator lights up.

2. The transponder excited by radio waves transmitted from the antenna receives the ciphered code

from the ECU.

3. The transponder transmits the calculated result from the key’s unique code to the ECU.

4. The ECU compares this with its memorized code, and if they match the engine can start. At this

time, the FI indicator in the meter assembly is switched off.

1-20 GENERAL INFORMATION

Technical Information - Immobilizer System (Equipped Models)

Immobilizer System Circuit

1. Ignition Switch

2. Meter Ground

3. Frame Ground

4. Joint Connector B

5. Immobilizer Amplifier

6. FI Indicator Light (LED)

7. Meter Unit

8. Immobilizer Antenna

9. Joint Connector A

10. Junction Box

11. Ignition Fuse 10 A

12. ECU Main Relay

13. ECU Fuse 15 A

14. Main Fuse 30 A

15. Starter Relay

16. Battery 12 V 8 Ah

17. Immobilizer/Kawasaki Diagnostic System
Connector

18. Electronic Control Unit (ECU)

Unit Conversion Table

GENERAL INFORMATION 1-21

Prefixes fo r Units:

Prefix Symbol Power

mega M ×1000000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units o f 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

cmHg × 1.333 = kPa

× 14.22 = psi

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................. 2-6

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

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

Periodic Maintenance Procedures..... 2-15

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

Fuel Hose Inspection (fuel leak,

damage, installation condition).. 2-15

Throttle Control System

Inspection.................................. 2-16

Idle Speed Inspection .................. 2-17

Idle Speed Adjustment................. 2-17

Choke Operation Inspection ........ 2-17

Air Cleaner Element Cleaning...... 2-18

Engine Vacuum Synchronization

Inspection.................................. 2-19

Evaporative Emission Control

System Inspection (CAL) .......... 2-22

Cooling System ............................... 2-23

Coolant Level Inspection.............. 2-23

Radiator Hose and Pipe

Inspection (coolant leak,

damage, installation condition) . 2-24

Air Suction System ......................... 2-24

Air Suction System Damage

Inspection.................................. 2-24

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

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

Valve Clearance Adjustment........ 2-25

Clutch.............................................. 2-29

Clutch Operation Inspection......... 2-29

Wheels/Tires................................... 2-30

Air Pressure Inspection................ 2-30

Wheel/Tire Damage Inspection.... 2-30

Tire Tread Wear, Abnormal Wear

Inspection.................................. 2-30

Wheel Bearing Damage

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

Drive Train ...................................... 2-32

Drive Chain Lubrication Condition

Inspection.................................. 2-32

Drive Chain Slack Inspection ....... 2-32

Drive Chain Slack Adjustment ..... 2-33

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

Drive Chain Wear Inspection ....... 2-34

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

2

Brake System ................................. 2-35

Brake Fluid Leak (Brake Hose

and Pipe) Inspection ................. 2-35

Brake Hose Damage and

Installation Condition

Inspection.................................. 2-35

Brake Operation Inspection ......... 2-36

Brake Fluid Level Inspection........ 2-36

Brake Pad Wear Inspection ......... 2-37

Brake Light Switch Operation

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

Suspensions ................................... 2-38

Front Forks/Rear Shock Absorber

Operation Inspection................. 2-38

Front Forks/Rear Shock Absorber

Oil Leak Inspection.................... 2-38

Rocker Arm Operation Inspection 2-39

Tie-rod Operation Inspection ....... 2-39

Steering System ............................. 2-39

Steering Play Inspection .............. 2-39

Steering Play Adjustment............. 2-40

Steering Stem Bearing

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

Electrical System ............................ 2-41

Lights and Switches Operation

Inspection.................................. 2-41

Headlight Aiming Inspection ........ 2-43

Side Stand Switch Operation

Inspection.................................. 2-44

Engine Stop Switch Operation

Inspection.................................. 2-45

Others............................................. 2-45

Chassis Parts Lubrication ............ 2-45

Bolts, Nuts and Fasteners

Tightness Inspection ................. 2-47

Replacement Parts ......................... 2-48

Air Cleaner Element

Replacement............................. 2-48

Engine Oil Change....................... 2-48

Oil Filter Replacement ................. 2-49

Fuel Hose Replacement .............. 2-49

Coolant Change........................... 2-50

Radiator Hose and O-ring

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

Brake Hose and Pipe

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

2-2 PERIODIC MAINTENANCE

Brake Fluid Change ..................... 2-53

Master Cylinder Rubber Parts

Replacement ............................. 2-54

Caliper Rubber Parts

Replacement ............................. 2-56

Spark Plug Replacement ............. 2-58

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

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

Fuel System

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

Air cleaner element - clean

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

Choke operation - inspection

Engine vacuum synchronization - inspect

Idle speed - inspect

Fuel leak (fuel hose and pipe) - inspect year

Fuel hose and pipe damage - inspect year

Fuel hose and pipe installation condition

- inspect

Evaporative Emission Control System
(CAL)

Evaporative Emission Control System
function - inspect

Cooling System

Coolant level - inspect

Coolant leak (radiator hose and pipe) ­inspect

Radiator hose damage - inspect year

Radiator hose installation condition ­inspect

Air Suction System

year

year

year

year

year

• •

• • • •

• • • •

• • •

• • • •

• • • •

• • • •

• • • •

• • • • • • •

• • • •

• • • •

• • • •

• • • •

2-18

2-16

2-17

2-19

2-17

2-15

2-15

2-15

2-22

2-23

2-24

2-24

2-24

Air suction system damage - inspect

Engine Top End

Valve clearance - inspect

Clutch

Clutch operation (play, disengagement,
engagement) - inspect

Wheels and Tires

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearing damage - inspect year

Drive Train

Drive chain lubrication condition - inspect # Every 600 km (400 mile) 2-32

Drive chain slack - inspect # Every 1 000 km (600 mile) 2-32

• • • •

• • •

•

• • •

• • •

• • •

• • •

2-24

2-24

2-29

2-30

2-30

2-30

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Drive chain wear - inspect #

Chain guide wear - inspect

Brake System

Brake fluid leak (brake hose and pipe) ­inspect

Brake hose and pipe damage - inspect year

Brake hose installation condition - inspect year

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

Brake fluid level - inspect 6 months

Brake pad wear - inspect #

Brake light switch operation - inspect

Suspensions

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

Front forks/rear shock absorber oil leak ­inspect

year

year

year

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

* ODOMETER READING

×1000km

(× 1 000 mile)

• • •

• • •

• • • • • •

• • •

• • •

See

Page

2-34

2-35

2-35

2-35

2-35

2-36

2-36

2-37

2-37

2-38

2-38

Rocker arm operation - inspect

Tie-rods operation - inspect

Steering System

Steering play - inspect year

Steering stem bearings - lubricate 2 years

Electrical System

Lights and switches operation - inspect year

Headlight aiming - inspect year

Side stand switch operation - inspect

Engine stop switch operation - inspect year

Others

Chassis parts - lubricate

Bolts and nuts tightness - inspect

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

frequent starting/stopping.

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

CAL: California Model

year

year

• • • •

• • • •

• • •

• • •

•

• • •

• • •

• • •

• • •

• • •

2-39

2-39

2-39

2-41

2-41

2-43

2-44

2-45

2-45

2-47

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

comes

first

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

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

See

Page

Air cleaner element #

Engine oil # year

Oil filter

Fuel hose 4 years

Coolant

Radiator hose and O-ring 3 years

Brake hose and pipe 4 years

Brake fluid 2 years

Rubber parts of master cylinder and caliper 4 years

Spark plug

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

frequent starting/stopping.

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

year

3 years

• • • • •

• • • • •

• •

• • • •

•

•

•

•

•

•

2-48

2-48

2-49

2-49

2-50

2-52

2-52

2-53

2-54

2-58

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

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

non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

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

EO: Apply engine oil.

G: Apply grease to the threads.

L: Apply a non-permanent locking agent to the threads.

MO: Apply m olybdenum disulfide oil solution.

R: Replacement Parts

S: Tighten the fasteners following the specified sequence.

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

SS: Apply silicone sealant.

Fastener

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

Bypass Screws

Air Cleaner Duct Holder Screws

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 L

TORX Screws 2.06 0.20 17 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

Coolant Drain Bolt (Water Pump) 11 1.1 95 in·lb L

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

N·m

3.4 0.35 30 in·lb

0.2 0.02 1.7 in·lb

3.8 0.39 34 in·lb

11 1.1 95 in·lb

Torque

Remarks

kgf·m ft·lb

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

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 Water Jacket Plugs 22 2.2 16 L

Throttle Body Holder Bolts 13 1.3 113 in·lb

Throttle Body Assy Holder Clamp 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

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

Camshaft Chain Tensioner Mounting Bolts

Camshaft Chain Tensioner Cap Bolt

Spark Plugs 13 1.3 11 3 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 B olt 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

Clutch Spring Bolts

Clutch Hub Nut

Engine Lubrication

Oil Filler Plug 1.5 0.15 13 in·lb

Engine Oil Drain Bolt 29 3.0 21

Oil Filter

Holder Mounting Bolt 76 7.8 56

Oil Pan Bolts

Oil Pipe Holder Bolts 13 1.3 11 3 in·lb L

Oil Pressure Relief Valve 15 1.5 11 L

Oil Pressure Switch 15 1.5 11 SS

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Water Pump Cover Bolts 11 1.1 95 in·lb

N·m kgf·m ft·lb

25 2.5 18

11 1.1 95 in·lb

28 2.9 21

1.5 0.15 13 in·lb

8.8 0.90 78 in·lb

135 14 100 R

31 3.2 23

11 1.1 95 in·lb

Torque

Remarks

EO, R

EO

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Coolant Drain Plug (Water Pump)

Oil Passage Plugs 20 2.0 14 L

Engine Removal/Installation

Adjusting Collar Locknut 49 5.0 36 S

Engine Mounting Bolts and Nuts 44 4.5 33 S

Front Engine Bracket Bolts 44 4.5 33 S

Rear Engine Bracket Bolts 25 2.5 18 S

Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb

Crankshaft/Transmission

Breather Plate Bolts 9.8 1.0 87 in·lb L

Crankcase Bolts (M9, L = 95 mm) 42 4.3 31 MO, S

Crankcase Bolts (M9, L = 81 mm) 42 4.3 31 MO, S

Crankcase Bolts (M8) 27 2.8 20 S

Crankcase Bolts (M7) 20 2.0 14 S

Crankcase Bolts (M6) 12 1.2 104 in·lb S

Starter Motor Clutch Bolts 12 1.2 104 in·lb L

Oil Pipe Holder Bolts

Shift Drum Bearing H older Bolt

Shift Drum Bearing Holder Screw

Connecting Rod Big End Nuts see the text ← ← ←

Timing Rotor Bolt 39 4.0 29

Oil Pressure Switch 15 1.5 11 SS

Oil Pressure Switch Terminal Bolt

Oil Passage Plugs

Crankshaft Sensor Cover Bolts

Shift Pedal Mounting Bolt 34 3.5 25 L

Gear Positioning Lever Bolt 12 1.2 104 in·lb

Shift Shaft Return Spring pin 29 3.0 22 L

Shift Drum Cam Holder Bolt 12 1.2 104 in·lb L

Footpeg Bracket Bolts 34 3.5 25 L

Shift Lever Bolt

Tie-rod Locknuts 6.9 0.70 61 in·lb

Neutral Switch 15 1.5 11

Wheels/Tires

Front Axle Clamp Bolt

Front Axle 108 11 80

Rear Axle Nut 108 11 80

Final Drive

Engine Sprocket Nut 125 13 92 MO

Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb

Speed Sensor Cover Bolts

Rear Sprocket Nuts

N·m kgf·m ft·lb

11 1.1 95 in·lb

13 1.3 11 3 in·lb L

13 1.3 11 3 in·lb L

5.4 0.55 48 in·lb L

1.5 0.15 13 in·lb

20 2.0 14 L

11 1.1 95 in·lb

6.9 0.70 61 in·lb

34 3.5 25

6.9 0.70 61 in·lb L

59 6.0 43

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Speed Sensor Bolt 6.9 0.70 61 in·lb L

Brakes

Bleed Valves 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 34 3.5 25

Brake Lever Pivot Bolt 1.0 0.10 9in·lb Si

Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb

Front Brake Reservoir Cap Screws

Front Brake Light Switch Screws

Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S

Front Caliper Mounting Bolts 34 3.5 25

Front Brake Disc Mounting Bolts 27 2.8 20 L

Rear Brake Disc Mounting Bolts 27 2.8 20 L

Rear Caliper Mounting Bolts 25 2.5 18

Rear Master Cylinder Mounting Bolts 25 2.5 18

Rear Master Cylinder Push Rod Locknut 18 1.8 13

Suspension

Front Fork Clamp Bolts (Upper) 20 2.0 14

Front Fork Clamp Bolts (Lower)

Front Fork Top Plugs 23 2.5 18

Front Fork Bottom Allen Bolts 30 3.1 22 L

Front Axle Clamp Bolt 34 3.5 25

Rear Shock Absorber Nuts (Upper and Lower) 34 3.5 25

Swingarm Pivot Shaft Nut 108 11 80

Swingarm Pivot Shaft Locknut 98 10 72

Uni-trak:

Rocker Arm Nut 34 3.5 25

Tie-rod Nuts 59 6.0 43

Steering

Steering Stem Head Bolt 108 11 80

Steering Stem Nut 27 2.8 20

Handlebar Holder Bolts 25 2.5 18 S

Handlebar Lower Holder Nuts 34 3.5 25

Switch Housing Screws 3.5 0.36 31 in·lb

Front Fork Clamp Bolts (Upper) 20 2.0 14

Front Fork Clamp Bolts (Lower) 20 2.0 14 AL

N·m kgf·m ft·lb

1.5 0.15 9in·lb

1.2 0.12 10 in·lb

20 2.0 14 AL

Torque

Remarks

Frame

Windshield Screws

Footpeg Bracket Bolts 34 3.5 25

Footpeg Holder Bolts 34 3.5 25 L

Side Stand Bolt 44 4.5 33

Frame Cover Bolts 0.3 0.03 3in·lb

Side Stand Switch Bolt 8.8 0.90 78 in·lb L

0.4 0.04 4in·lb

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Front Fender Bracket Bolts 8.8 0.90 78 in·lb L

Front Fender Bolts 3.9 0.40 35 in·lb L

Side Stand Bracket Bolts 49 5.0 36

Electrical System

Spark Plugs 13 1.3 11 3 in·lb

Alternator Rotor Bolt 110 11 81

Stator Coil Bolts 12 1.2 104 in·lb L

Alternator Lead Holding Plate Bolt 12 1.2 104 in·lb L

Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb

Alternator Cover Bolts 11 1.1 95 in·lb

Crankshaft Sensor Cover Bolts 11 1.1 95 in·lb

Crankshaft Sensor Bolts 5.9 0.60 52 in·lb

Camshaft Position Sensor Bolt 12 1.2 104 in·lb L

Timing Rotor Bolt 39 4.0 29

Starter Motor Mounting Bolts 11 1.1 95 in·lb

Switch Housing Screws 3.5 0.36 31 in·lb

Radiator Fan Switch 18 1.8 13

Water Temperature Sensor 25 2.5 18

Oil Pressure Switch 15 1.5 11 SS

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb G

Neutral Switch 15 1.5 11

Speed Sensor Bolt 6.9 0.70 61 in·lb L

Fuel Level Sensor Bolts 6.9 0.70 61 in·lb L

Front Brake Light Switch Screw

Meter Mounting Screws

Tail/Brake Light Mounting Screws

License Plate Light Mounting Screws 1.2 0.12 10 in·lb

Turn Signal Light Screws 1.2 0.12 10 in·lb

Headlight Mounting Bolts 5.9 0.60 52 in·lb

Starter Lockout Switch Screws

Starter Motor Clutch Bolts

Starter Relay Cable Terminal Bolts

Regulator/Rectifier Bolts 6.9 0.70 61 in·lb

Regulator/Rectifier Bracket Bolts 6.9 0.70 61 in·lb

Speed Sensor Cover Bolts 6.9 0.70 61 in·lb L

Side Stand Switch Bolt 8.8 0.90 78 in·lb

N·m kgf·m ft·lb

1.2 0.12 10 in·lb

1.2 0.12 10 in·lb

1.2 0.12 10 in·lb

– – – L

12 1.2 104 in·lb L

3.9 0.40 35 in·lb L

Torque

Remarks

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

Torque and Locking Agent

PERIODIC MAINTENANCE 2-11

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 11 5 ∼ 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

Torque

N·m kgf·m ft·lb

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System

ThrottleGripFreePlay 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Idle Speed 1 100 ±50 r/min (rpm) –––

Bypass Screws (Turn Out) 0 ∼ 1 1/2 (for reference) –––

Engine Vacuum

Air Cleaner Element Paper filter –––

Cooling System

Coolant:

Type (recommended) Permanent type of antifreeze –––

Color Green –––

Mixed Ratio

Freezing Point –35°C (–31°F) –––

Total Amount 2.9 L (3.1 US qt) –––

Engine Top End

Valve Clearance:

Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) –––
Inlet 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 API SE, SF or SG –––

Viscosity SAE 10W-40 –––

Capacity 3.1 L (3.3 US qt) (when filter is not

Level Between upper and lower level lines

Wheels/Tires

Tread Depth:

Front

BRIDGESTONE 3.4 mm (0.13 in.) 1 mm (0.04 in.)

Rear

BRIDGESTONE 5.8 mm (0.23 in.) Up to 130 km/h (80 mph):

Air Pressure (When Cold):

Front

29.7 ±1.333 kPa (225 ±10 mmHg)

Soft water 50%, Coolant 50%

API SH or SJ with JASO MA

removed)

3.3 L (3.5 US qt) (when filter is removed) –––

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

(after idling or running)

Over 130 km/h (80 mph):

Up to 180 kg (397 lb) load:

250 kPa (2.5 kgf/cm², 36 psi)

–––

–––

–––

–––

–––

(AT, CH, DE)

1.6 mm (0.06 in.)

2 mm (0.08 in.)

3 mm (0.12 in.)

–––

PERIODIC MAINTENANCE 2-13

Specifications

Item Standard Service Limit

Rear Up to 180 kg (397 lb) load:

290 kPa (2.9 kgf/cm², 42 psi)

Final Drive

Drive Chain Slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) –––
Drive Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

Brakes

Brake Fluid:

Grade DOT4

Brake Pad Lining
Thickness:

Front 4.5 mm (0.18 in.) 1 mm (0.04 in.)

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

Brake Light Timing:

Front Pulled ON –––

Rear ON after about 10 mm (0.39 in.) of

pedal travel

Electrical System

Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) –––

–––

–––

–––

AT: Republic of Austria
CH: Swiss Confederation
DE: Federal Republic of Germany

2-14 PERIODIC MAINTENANCE

Special Tools

Inside Circlip Pliers:
57001-143

Steering Stem Nut Wrench:
57001-1100

Jack:
57001-1238

Oil Filter Wrench:
57001-1249

Extension Tube:
57001-1578

Periodic Maintenance Procedures

Fuel System (DFI)

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

The fuel hose is designed to be used throughout the mo-

○

torcycle’s life without any maintenance. However, if the
motorcycle is not properly handled, the high pressure in­side the fuel line can cause fuel to leak [A] or the hose
to burst. Remove the fuel tank (see Fuel System (DFI)
chapter) and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.

Check that the hoses are routed according to Cable, Wire,

•

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

Hose Joints [A]
Pump Outlet Hose [B]
Pump Inlet Hose [C]
Front [D]

PERIODIC MAINTENANCE 2-15

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 doesn’t
come off. When the hose joint is correctly installed, it
should slide on the delivery pipe about 5 mm (0.2 in.).
If it does not slide, reinstall the hose joint.

WARNING

Make sure the hose joint is installed correctly on the
delivery pipe by sliding the joint, or the fuel could
leak.

Check that the inlet hose [A] is onto the pipe fully and the

○

plate clamps [B] are installed beyond the raised rib [C].

1 ~ 2 mm (0.039 ~ 0.079 in.) [D]

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Throttle Control System Inspection

Check that the throttle grip moves smoothly from full open

•

to close [A], and the throttle closes quickly and completely
by the return spring in all steering positions.
If the throttle grip doesn’t return properly, check the throt­tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.

Check the throttle grip free play [A].

•

If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

If necessary, adjust the throttle cable as follows.
Loosen the locknut [A].

•

Turn the adjuster [B] until the proper amount of free play

•

can be obtained.
Tighten the locknut against the adjuster securely.

•

Ifthethrottlegripfreeplaycannotbeadjustedwiththe
adjuster, use the adjusters in the middle of the throttle
cables.
Loosen the locknut, and screw the adjuster at the upper

•

end of the accelerator cable all the way in.
Tighten the locknut against the adjuster securely.

•

Loosen the locknuts [A], and turn the lower adjusters [B]

•

until the proper amount of throttle grip free play is ob­tained.
Tighten the locknuts against the adjusters securely.

•

Ifthethrottlegripfreeplaycannotbeadjustedwiththe
lower adjusters, use the adjuster at the upper end of the
cable again.

Periodic Maintenance Procedures

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 or 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.

Check idle speed.

•

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

Idle Speed

Standard: 1 100 ±50 r/m in (rpm)

PERIODIC MAINTENANCE 2-17

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Turn the 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.

Choke Operation Inspection

Push the choke lever [A] fully and ensure by y our finger

•

that the choke cam [B] has the specified play.

Choke Lever Free Play [C]

Standard: 0 ∼ 0.5 mm (0 ∼ 0.02 in.)

Pull the choke lever fully and ensure that the choke cam

•

turns the choke link [D].
If the free play is incorrect, adjust the choke cable.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Loosen the locknut [A], and turn the adjuster [B] until the

•

cable has the proper amount of free play.
Tighten the locknut against the adjuster securely.

•

Air Cleaner Element Cleaning

NOTE

In dusty areas, the element should be cleaned more

○

frequently than the recommended interval.
After riding through rain or on muddily roads, the ele-

○

ment should be cleaned immediately.

WARNING

If dirt or dust is allowed to pass through into the
throttle assy, the throttle may become stuck, possi­bly causing accident.

CAUTION

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

Remove the fuel tank (see Fuel System (DFI) chapter).

•

Remove the fuel tank bracket [A].

•

Front [B]

Remove:

•

Screws [A]
Air Cleaner Duct Holder [B]

Pull it out [C] backwards.

•

Front [D]

Periodic Maintenance Procedures

Clean the element by tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed

•

air [A] from the outside to the inside (from the clean side
to the dirty side).
Visually inspect the element for no tears or no breaks and

•

inspect the sponge gaskets [B] also.
If the element or gasket has any tears or breaks, replace
the element.

Install the element [A] with the flat side [B], facing for-

•

wards.
Fit the tongue [C] of the air cleaner duct holder into the

•

slot of the housing.

Front [D]

Torque - Air Cleaner Duct Holder Screws: 3.8 N·m (0.39

kgf·m, 34 in·lb)

PERIODIC MAINTENANCE 2-19

Engine Vacuum Synchronization Inspection

NOTE

These procedures are explained on the assumption that

○

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

Situate the motorcycle so that it is vertical.

•

Remove the fuel tank (see Fuel System (DFI) chapter).

•

Pull off the vacuum hoses and the rubber cap(s) from the

•

right fitting of each throttle body.
Pull off the vacuum switch valve hose (thick) [A] from the

•

air cleaner housing [B].

Front [C]

CAUTION

Do not remove the inlet air pressure sensor hoses
on the left fitting of each throttle body.

Connect a commercially available vacuum gauge [A] to

•

these right fittings of the throttle body as shown.

Front [B]

Connect a highly accurate tachometer to one of the stick

•

coil primary leads.
Plug:

•

Vacuum Switch Valve Hose (Thick) and its Air Cleaner
Housing Hole
Vacuum Switch Valve Vacuum Hose Ends [C]

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Connect:

•

Fuel Pump Lead Connector [A]
Extension Tube [B]

Special Tool - Extension Tube: 57001-1578

Start the engine and warm it up thoroughly.

•

Check the idle speed.

•

Tachometer [A]

Open and close the throttle.

•

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

CAUTION

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

While idling the engine, inspect the engine vacuum, using

•

the vacuum gauge [B].

Engine Vacuum

Standard: 29.7 ±1.333 kPa (225 ±10 mmHg) at Idle

Speed 1 100 ±50 r/min (rpm)

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

Example:

#1: 165 mmHg
#2: 190 mmHg
#3: 170 mmHg
#4: 200 mmHg

With the engine at the correct idle speed, equalize the

•

lower vacuum of #3 and #4 (example 170 mmHg) to the
lower vacuum of #1 and #2 (example 165 mmHg) by turn­ing the center adjusting screw [A].

NOTE

After adjustment, the final vacuum measurement be-

○

tween the lowest throttle valves may not be 165 mmHg
(in this example). The goal is to have the lower two vac­uums between the left (#1 and #2) and right (#3 and #4)
banks be the same.

Open and close the throttle after each measurement and

•

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

•

the main throttle sensor’s output voltage to ensure proper
operation (procedure is at the end of this section).

Periodic Maintenance Procedures

If any one vacuum measurement is out of the standard
measurement after left and right synchronization, turn in
the bypass screws [A] until it seats fully but not tightly.

Torque - Bypass Screws: 0.2 N·m (0.02 kgf·m, 1.7 in·lb)

CAUTION

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

Turn out the bypass screw of the higher vacuum between

•

#1 and #2 to the lower vacuum.
Turn out the bypass screw of the higher vacuum between

•

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

•

ment and adjust the idle speed as necessary.
Inspect the vacuums as before.

•

If all vacuums are within the specification, finish the en­gine vacuum synchronization.
If any vacuum can not be adjusted within the specification,

remove the bypass screws #1 ∼ #4 and clean them.

PERIODIC MAINTENANCE 2-21

Remove the bypass screw [A], spring [B], washer [C] and

•

O-ring [D].
Check the bypass screw and its hole for carbon deposits.

○

If any carbon accumulates, wipe the carbon off the bypass
screw and 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.

•

Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb)

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.

•

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

Main Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → Y/W lead (terminal 2)

Meter (–) → BR/BK lead (terminal 14)

Connections to ECU (Immobilizer Equipped Models)

Meter (+) → Y/W lead (terminal 6)

Meter (–) → BR/BK lead (terminal 20)

Standard:

0.99 ∼ 1.03 V DC (at idle throttle opening)

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

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the vacuum gauge hoses and install the vacuum

•

hoses [A] and rubber caps [B] on the original position as
shown.

Front [C]

Evaporative Emission Control System Inspection (CAL)

Inspect the canister as follows:

•

Remove the s eat cover (see Frame chapter).

○

Remove the band [A] and hoses and take out the canister

○

[B].
Visually inspect the canister for cracks and other damage.

○

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

NOTE

The canister is designed to work well through the motor-

○

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

Connect the purge hose (white) [C] and the canister

○

breather hose (blue) [D] to the canister as shown.
Install the canister with the inlet [E] down and the seat

○

(see Frame chapter).

Clamps [F]

Check the liquid/vapor separator as follows:

•

Remove:

•

Bolts [A] with Washer
Left Frame Cover [B]

Periodic Maintenance Procedures

Disconnect the hoses from the separator, and remove the

○

separator [A] from the motorcycle left 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 beyond the raised rib of the pipe.
Replace any kinked, deteriorated or damaged hoses.

○

Route the hoses according to Cable, Wire, and Hose

○

Routing section in the Appendix chapter.
When installing the hoses, avoid sharp bending, kinking,

○

flattening or twisting, and route these hoses with a mini­mum of bending so that the emission flow will not be ob­structed.

PERIODIC MAINTENANCE 2-23

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 side
stand).
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

CAUTION

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 w ater 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.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

The high pressure inside the radiator hose and pipe 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 soft 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 Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

17 in·lb)

Air Suction System

Air Suction System Damag e Inspection

Pull the vacuum switch valve hose [A] out of the air

•

cleaner.

Start the engine and run it at idle speed.

•

Plug [A] the vacuum switch valve hose end with your fin-

•

ger 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 vacuum switch valve
or air suction valve (see Engine Top End chapter).

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (at room temperature).

Remove:

•

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

Periodic Maintenance Procedures

Position the crankshaft at 1,4 piston TDC.

•

TDC Mark [A] for #1, 4 Pistons
Timing Mark (Crankcase halves mating surface) [B]

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

•

ance between the cam and the valve lifter.

Valve Clearance

Standard:

Exhaust

Inlet

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

PERIODIC MAINTENANCE 2-25

When positioning #4 piston TDC at the end of the

○

compression stroke:

Inlet 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:

Inlet 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.

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.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

Mark and record the valve lifter and shim locations so

○

they can be reinstalled in their original positions.
If there is no clearance, select a shim which is several

○

sizes smaller and then measure the clearance.

To select a new shim which brings the valve clearance

•

within the specified range, refer to the Valve Clearance
Adjustment Charts.
Apply a thin coat of molybdenum disulfide grease to the

•

valve lifters.
Install the camshafts. Be sure to time the camshafts prop-

•

erly (see Engine Top End chapter).
Remeasure any valve clearance that was adjusted.

•

Readjust if necessary.

CAUTION

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

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART INLET 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

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

To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.

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

•

of threads are visible.

PERIODIC MAINTENANCE 2-29

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 cover [D].
Slip the rubber 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

Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, 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.

2-30 PERIODIC MAINTENANCE

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).
Adjust the tire air pressure according to the specifications
if necessary.

Air Pressure (When Cold)

Front:

Rear:

Install the air valve cap certainly after air pressure inspec-

•

tion.

Torque - Air Valve Cap: 0.15 N·m (0.015 kgf·m, 1.3 in·lb)

Up to 180 kg (397 lb)
250 kPa (2.5 kgf/cm², 36 psi)

Up to 180 kg (397 lb)
290 kPa (2.9 kgf/cm², 42 psi)

Wheel/Tire Damage In spection

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.
Visually inspect the wheel for cracks, cuts and dents dam-

•

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

Tire Tread Wear, Abnormal Wear Inspection

As the tire tread wears down, the tire becomes more sus­ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
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 Wheels/Tires chapter).

Periodic Maintenance Procedures

Tread Depth

Front:

Standard: 3.4 mm (0.13 in.)

Service Limit: 1 mm (0.04 in.)

1.6 mm (0.06 in.) (AT, CH, DE)

Rear:

Standard: 5.8 mm (0.23 in.)

Service Limit: 2 mm (0.08 in.)

(Upto130km/h(80mph))

3 mm (0.12 in.)

(Over 130 km/h (80 mph))

WARNING

To ensure safe handling and stability, use only the
recommended standard tires for replacement, in­flated to the standard pressure.

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.

PERIODIC MAINTENANCE 2-31

Wheel Bearing Damage Inspection

Using a jack and attachment, raise the front wheel off the

•

ground (see 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 Wheels/Tires
chapter).

Using a stand, raise the rear wheel off the ground (see

•

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
wheel and inspect the wheel bearing (see Wheels/Tires
chapter) and coupling (see Final Drive chapter).

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Train

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.

CAUTION

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 an O

-ring drive chain. Any other cleaning solution such

as gasoline or trichloroethylene will cause deterio-

ration and swelling of the O-ring. Immediately blow

the chain dry with compressed air after cleaning.

Complete cleaning and drying the chain within 10

minutes.

Apply oil to the sides of the rollers so that oil will penetrate

•

to the rollers and bushings. Apply the oil to the O-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.

Check the wheel alignment (see Wheel Alignment 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: 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

Periodic Maintenance Procedures

Drive Chain Slack Adjustment

Remove the cotter pin [A], and loosen the axle nut [B].

•

Loosen the both chain adjuster locknuts [C].

•

If the chain is too loose, turn out the left and right chain
adjuster nut [D] evenly.
If the chain is too tight, turn in the left and right chain
adjusters evenly, and kick the wheel forward.
Turn both chain adjusters evenly until the drive chain has

•

the correct amount of slack. To keep the chain and wheel
properly aligned, the notch [E] on the left wheel alignment
indicator [F] should align with the same swingarm mark
[G] or position that the right indicator notch aligns with.

WARNING

Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.

Tighten both chain adjuster locknuts securely.

•

Tighten the axle nut.

•

Torque - Rear Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)

Turn the wheel, measure the chain slack again at the tight-

•

est position, and readjust if necessary.

PERIODIC MAINTENANCE 2-33

Insert a new cotter pin [A].

•

NOTE

When inserting the cotter pin, if the slots in the nut do

○

not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

Bend the cotter pin [A] over the nut.

•

WARNING

If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi­tion may result.

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Wheel Alignment Inspectio n

Check that the notch [A] on the left alignment indicator [B]

•

aligns with the same swingarm mark [C] or position that

the right alignment indicator notch aligns with.

If they do not, adjust the chain slack and align the wheel

alignment (see Drive Chain Slack Adjustment).

NOTE

Wheel alignment can be also checked using the

○

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal

wear, and may result in an unsafe riding condition.

Drive Chain Wear Inspection

Remove:

•

Chain Cover Bolts [A]
Chain Cover [B]

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.

Measure the length of 20 links [B] on the straight part [C] of

•

the chain from the pin center of the 1st pin to the pin center

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

measurements at several places.

If any measurements exceed the service limit, replace the

chain. Also, replace the front and rear sprockets when the

drive chain is replaced.

Drive C hain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit: 323 mm (12.7 in.)

WARNING

If the drive chain wear exceeds the service limit, re-

place the chain or an unsafe riding condition may

result. A chain that breaks or jumps off the sprock-

ets could snag on the engine sprocket or lock the

rear wheel, severely damaging the motorcycle and

causing it to go out of control.

For safely, use only the standard chain. It is an end-

less type and should not be cut for installation.

Standard Chain

Make: ENUMA

Type: EK520MVXL

Link: 112 Links

Periodic Maintenance Procedures

Chain Guide Inspection

Visually inspect the chain guide [A].

•

Replace the chain guide if it shows any signs of abnormal
wear or damage.

Brake System

Brake Fluid Leak (Brake Hose and Pipe) Inspection

Apply the brake lever or pedal and inspect the brake fluid

•

leak from the brake hoses [A] and fittings [B].
If the brake fluid leaked from any position, inspect or re­place the problem part.

PERIODIC MAINTENANCE 2-35

Brake Hose Damage and Installation Condition Inspection

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 to burst if the line is not properly main­tained. Bend and twist the rubber hose while examining
it.
Replace the hose if any crack [B], bulge [C] or leakage is
noticed.
Tighten any banjo bolts.

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

ft·lb)

Inspect the brake hose routing.

•

If any brake hose routing is incorrect, route the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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 inspecting by running the vehicle, note a

surrounding traffic situation enough in the place of

safety.

Brake Fluid Level Inspection

Check that the brake fluid level in the front brake reservoir

•

[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] in the reservoir.

Check that the brake fluid level in the rear brake reservoir

•

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

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

the seats and fill the reservoir to the upper level line [C].

WARNING

Do not mix two brands of 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.

After changing the fluid, use only the same type and

brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

Periodic Maintenance Procedures

Follow procedure below to 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

Check the lining thickness [A] of the pads in each caliper.

•

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

Pad Lining Thickness

Standard:

Front

Rear

Service Limit: 1 mm (0.04 in.)

4.5 m m (0.18 in.)

5.0 m m (0.20 in.)

PERIODIC MAINTENANCE 2-37

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.
While holding the switch body, turn the adjusting nut [A]

•

to adjust the switch.

CAUTION

To avoid damaging the electrical connections in­side the switch, be sure that the switch body does
not turn during adjustment.

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If it does not go on, inspect or replace the following items.

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

Suspensions

Front Forks/Rear Shock Absorber Opera tion 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 Suspension chapter).

Pump the rear portion of the motorcycle 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) or shock absorber clamps (see Sus-

pension chapter).

Front Forks/Rear Shock Absorber Oil Leak In spection

Visually inspect the front forks [A] for oil leakage, scoring

•

or scratches on the inner surface of the inner tubes.

Replace or repair any defective parts, if necessary.

Periodic Maintenance Procedures

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

•

If the oil leakage is found on it, replace the shock absorber
with a new one.

Rocker Arm Operation Inspection

Pump the rear portion of the motorcycle down and up 4

•

or 5 times, and inspect the smooth stroke.
If the rocker arm [A] does not smoothly stroke or noise is
found, inspect the fasteners and bearings (see Suspen­sion chapter).

PERIODIC MAINTENANCE 2-39

Tie-rod Operation Inspection

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

•

smooth stroke.
If the tie-rods [A] do not smoothly stroke or noise is found,
inspect the fasteners and tie-rod bearings (see Suspen­sion chapter).

Steering System

Steering Play Inspection

Lift the front wheel off the ground using the jack.

•

Special Tool - Jack: 5700-1238

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 l ooseness by pushing and pulling the

•

forks.
If you feel looseness, the steering is too loose.

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 wires and cables are properly routed.

○

The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering Play Adjustment

Remove:

•

Handlebar (see Steering chapter)
Upper Fork Clamp Bolts [A]
Steering Stem Head Bolt Plug
Stem Head Bolt [B]
Clamp Bolts [C] with Clamp

Remove the steering stem head [D].

•

Straighten the c law [A] of the claw washer.

•

Remove the steering stem locknut [B] and claw washer

•

[C].

Adjust the steering.

•

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

If the steering is too tight, loosen the stem nut [A] 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 it touches the claw

•

washer.

Tighten the stem locknut clockwise until the claws are

•

aligned with the grooves (ranging from 2nd to 4th) of stem

nut [D], and bend the 2 claws downward [E].

Tighten:

•

Torque - Steering Stem Head Bolt: 108 N·m (11 kgf·m, 80

ft·lb)

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

kgf·m, 14 ft·lb)

Check the steering again.

•

If the steering is still too tight or too loose, repeat the ad-

justment.

Install the removed parts.

•

Periodic Maintenance Procedures

Steering Stem Bearing Lubrication

Remove the steering stem (see 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, and adjust the steering.

•

Electrical System

Lights and Switches Operation Inspection

First Step

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

City Light [A]

Taillight [B]

License Plate Light [C]

Meter Panel LCD [D]

Neutral Indicator Light [E]

Oil Pressure Warning Indicator Light [F]

FI Indicator Light (LED) [G]

goes on

goes on

goes on

goes on

goes on

goes on

goes on

(about 2 seconds)

PERIODIC MAINTENANCE 2-41

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

Battery (see Electrical System chapter)
Applicable Bulb (see Electrical System chapter)
Meter Unit for Meter Panel LCD (see Electrical System
chapter)
Meter Unit for Neutral Indicator Light (see Electrical Sys­tem chapter)
Meter Unit for Oil Pressure Warning Indicator Light (see
Electrical System chapter)
Meter Unit and ECU for FI Indicator Light (LED, see Elec­trical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Electrical
System chapter)
Ignition Switch (see Electrical System chapter)
Neutral Switch (see Electrical System chapter)
Harness (see Electrical System chapter)

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 and license plate light should go on.

•

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

Ignition Switch (see Electrical System chapter)

2-42 PERIODIC MAINTENANCE

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 [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 Electrical System chapter)
Meter Unit for Turn Signal Indicator Light (see Electrical
System chapter)
Turn Signal Relay Fuse 10 A (see Electrical System
chapter)
Turn Signal Switch (see Electrical System chapter)
Turn Signal Relay (see Electrical System chapter)
Harness (see light Electrical System chapter)

Push the turn signal switch.

•

The turn signal lights and indicator light should go off.

•

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

item.

Turn Signal Switch (see Electrical System chapter)
Turn Signal Relay (see Electrical System chapter)

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 Electrical System chap­ter)
Headlight Fuse 10 A (see Electrical System chapter)
Dimmer Switch (see Electrical System chapter)
Headlight Relay in Junction Box (see Electrical System
chapter)
Harness (see Electrical System chapter)

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 [C] should go on.

•

If the high beam headlight and/or high beam indicator light
does not go on, inspect or replace the following item.

Headlight High Beam Bulb (see Electrical System chap­ter)
Dimmer Switch (see 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 does go off,
inspect or replace the following item.

Headlight Relay in Junction Box (see Electrical System
chapter)

Turn off the ignition switch.

•

The headlights and high beam indicator light should go

•

off.

PERIODIC MAINTENANCE 2-43

Headlight Aiming Inspection

Inspect the headlight beam for aiming.

•

If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.

Headlight Beam Horizontal Adjustment

Turn the horizontal adjuster [A] on the headlight 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 [A] on the headlight with the

•

screwdriver in or out to adjust the headlight vertically.

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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.
For US model, the proper angle is 0.4 degrees below

○

horizontal. This is 50 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]
Low Beam [D]
Height of Headlight Center [E]
High Beam [F]

Side Stand Switch Operation Inspection

Inspect the side stand switch [A] operation accordance to

•

below table.

Side Stand Switch Operation

Side Stand

Up Neutral Released

Up Neutral Pulled in

Up

Up

Down Neutral Released

Down Neutral Pulled in

Down

Down

Gear

Position

In Gear

In Gear

In Gear

In Gear

Clutch

Lever

Released

Pulled in

Released

Pulled in

Engine

Start

Starts

Starts

Doesn’t

start

Starts

Starts

Starts

Doesn’t

start

Starts

Engine

Run

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Stops

Continue

running

Periodic Maintenance Procedures

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

Battery (see Electrical System chapter)
Main Fuse 30 A (see Electrical System chapter)
Ignition Fuse 10 A (see Electrical System chapter)
Ignition Switch (see Electrical System chapter)
Side Stand Switch (see Electrical System chapter)
Engine Stop Switch (see Electrical System chapter)
Starter Button (see Electrical System chapter)
Neutral Switch (see Electrical System chapter)
Starter Circuit Relay (see Electrical System chapter)
Junction Box (see Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

If the all parts are good condition, replace the ECU.

Engine Stop Switch Operation Inspection

First Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button.

•

The engine does not start.

•

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

Engine Stop Switch (see Electrical System chapter)

PERIODIC MAINTENANCE 2-45

Second Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the s tarter 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 Electrical System chapter)
If the engine stop switch is good condition, replace the
ECU.

Others

Chassis Parts Lubrication

Before lubricating each 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 Motor Oil

Rear Brake Rod Joint

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Points: Lubricate with Grease

Throttle and Choke Inner Cable Upper Ends [A]
Clutch Lever Pivot
Brake Lever Pivot (Apply silicone grease)
Brake Pedal Pivot
Side Stand

Cables: Lubricate with Rust Inhibitor

Choke Cable
Throttle Cables
Clutch Cable

Lubricate the cables by seeping the oil between the c able

•

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

○

available pressure cable lubricator with an aerosol cable
lubricant.

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

Check the tightness of the bolts and nuts listed here. 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 in this section. For each
fastener, first loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.

Bolt, Nut and Fastener to be checked

Wheels:

Front Axle

Front Axle Clamp Bolt

Rear Axle Nut

Rear Axle Nut Cotter Pin
Brakes:

Front Master Cylinder Clamp Bolts

Caliper Mounting Bolts

Rear Master Cylinder Mounting Bolts

Brake Lever Pivot Nut

Brake Pedal Bolt

Brake Rod Joint Cotter Pin
Suspension:

Front Fork Clamp Bolts

Front Fender Mounting Bolts

Rear Shock Absorber Mounting Nuts

Swingarm Pivot Shaft Nut

Swingarm Pivot Shaft Lock Nut

Uni-trak Link Nuts
Steering:

Stem Head Bolt

Handlebar Clamp Bolts

PERIODIC MAINTENANCE 2-47

Engine:

Throttle Cable Adjuster Locknuts

Engine Mounting Bolts and Nuts

Muffler Mounting Bolts

Exhaust Pipe Holder Nuts

Muffler Connecting Clamp Bolt

Clutch Lever Pivot Nut

Radiator Upper and Lower Bolts
Others:

Side Stand Bolt

Footpeg Stay Bolts

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replacement Parts

Air Cleaner Element Replacement

Refer to the Air Cleaner Element Cleaning in this chapter.

•

Engine Oil Change

Situate the motorcycle so that it is vertical after warming

•

up the engine.
Unscrew the oil filler cap [A].

•

Place on oil pan beneath the engine.

•

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

•

The oil in the oil filter can be drained by removing the filter

○

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

•

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: 3.1 L (3.3 US qt) (when filter is not

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 Engine Lubrication System chap-

•

ter).

API SE, SF or SG

API SH or SJ with JASO MA

SAE 10W-40

removed)

3.3 L (3.5 US qt) (when filter is removed)

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

NOTE

Periodic Maintenance Procedures

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change).

•

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

•

Special Tool - Oil Filter Wrench: 57001-1249

Replace the filter with a new one.

•

Apply engine oil to the gasket [A] before installation.

•

Tighten the filter with the oil filter wrench.

•

Torque - Oil Filter: 31 N·m (3.2 kgf·m, 23 ft·lb)

NOTE

Hand tightening of the oil filter can not be allowed since

○

it does not reach to this tightening torque.

PERIODIC MAINTENANCE 2-49

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

•

Oil Change).

Fuel Hose Replacement

Remove the fuel tank (see Fuel System (DFI) chapter).

•

Be sure to place a piece of cloth around the fuel hose joint.

○

Remove:

•

Hose Joint [A]

Fuel Hose [B]

Clamps [C]

Fuel Pump Inlet Hose [D]

Install the pump inlet hose clamps as shown.

•

The pinch [A] direction inside.

○

Insert the fuel hose j oint [A] straight onto the delivery pipe

•

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

Front [D]

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

•

more than two times and make sure it is locked and
doesn’t come off.
If it comes off, reinstall the hose joint.

WARNING

Make sure the fuel hose joint is installed correctly
on the delivery pipe or the fuel could leak.

Run the fuel hose in accordance with the Cable, Wire and

•

Hose Routing section in the Appendix chapter.
Install the removed part.

•

Start the engine and check the fuel hose for leaks.

•

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down. Coolant on tires will
make them slippery and can cause an accident
and injury. Immediately wipe up or wash away any
coolant that spills on the frame, engine, or other
painted parts.
Since coolant is harmful to the human body, do not
use for drinking.

Place a container under the water pump drain bolt [A],

•

then remove the drain bolt.

Remove:

•

Fuel Tank (see Fuel System (DFI) chapter)

Remove the radiator cap [A] in two steps. First turn the

○

cap counterclockwise to the first stop. Then push and turn
it further in the same direction and remove the cap.
The coolant will drain from the radiator and engine.

○

Periodic Maintenance Procedures

Remove:

•

Left Side Cover (see Frame chapter)

Reserve Tank Screws [A]
Turn over [B] the reserve tank, remove the cap [C], and

•

pour the coolant into a suitable container.
Install the reserve tank.

•

Torque - Coolant Reserve Tank Screws: 7.0 N·m (0.70

kgf·m, 61 in·lb)

Tighten the drain bolt with the gasket.

•

Replace the drain bolt gasket with a new one.

○

Torque - Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 95 in·lb)

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

CAUTION

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 o f the cooling system.

PERIODIC MAINTENANCE 2-51

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%

Coolant: 50%

Freezing Point:

Total Am ount:

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.

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].
Install the fuel tank (see Fuel System (DFI) chapter).

•

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 is lower than the “L” level line, add
coolant to the “F” level line.

–35°C (–31°F)

2.9 L (3.1 US qt)

NOTE

CAUTION

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

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

•

Fuel Tank (see Fuel System (DFI) chapter)
Thermostat Housing [A]
Hoses [B]
O-rings [C]

Apply grease to the new O-rings and install them.

•

Instal the new hoses and tighten the clamps securely.

•

Fill the coolant (see Coolant Change).

•

Check the cooling system for leaks.

•

Brake Hose and Pipe Replacement

CAUTION

Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.

Remove:

•

Banjo Bolt [A]

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

•

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

•

theendofthebrakehosetosomehighplacetokeep
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.
Tighten:

•

Torque - Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Periodic Maintenance Procedures

When installing the hoses [B], 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.

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.

•

PERIODIC MAINTENANCE 2-53

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.
Rear Brake: Repeat the above steps for the other bleed

○

valve.

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Follow the procedure below to 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].

Tighten the bleed valve, and install the rubber cap.

•

Torque - Bleed Valve: 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.

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

Remove the front master cylinder (see Brakes chapter).

•

Remove the reservoir cap and diaphragm, and pour the

•

brake fluid into a container.
Unscrew the locknut and pivot bolt, and remove the brake

•

lever.
Pull the dust cover [A] out of place, and remove the circlip

•

[B].

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the piston [C], secondary cup [D], primary cup [E],

•

and return spring [F].

CAUTION

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

Periodic Maintenance Procedures

Rear Master Cylinder Disassembly

NOTE

Do not remove the push rod clevis for master cylinder

○

disassembly since removal reguires brake position ad­justment.

Remove the rear master cylinder (see Brakes chapter).

•

Slide the dust cover on the push rod out of place, and

•

remove the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the push rod with the piston stop.

•

Take off the piston [A], secondary cup [B], primary cup [C]

•

and return spring [D].

CAUTION

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

PERIODIC MAINTENANCE 2-55

Master Cylinder Assembly

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

CAUTION

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 distillate will 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.
Apply silicone grease (ex. PBC grease).

•

Brake Lever Pivot Bolt

Brake Lever Pivot Contact

Push Rod Contact

Dust Covers
Tighten:

•

Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9

in·lb)

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

kgf·m, 52 in·lb)

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Caliper Rubber Parts Rep lacement

Front Caliper Disassembly

Remove:

•

Front Caliper (see Brakes chapter)
Brake Pads

Using compressed air, remove the pistons.

•

Cover the piston area with a clean, thick cloth [A].

○

Blow compressed air [B] into the hole for the banjo bolt to

○

remove the piston.

WARNING

To avoid serious injury, never place your fingers or
palm in front of the piston. If you apply compressed
air into the caliper, the piston may crush your hand
or fingers.

Pull out the pistons by hand.

○

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

•

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

•

NOTE

If compressed air is not available, with the brake hose

○

still attached, apply the brake lever to remove the pis­ton. The remaining process is as described above.

Front Caliper Assembly

Clean the c aliper parts except for the pads.

•

CAUTION

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)

Replace the fluid seals [A] with new ones.

•

Apply brake fluid to the fluid seals, and install them into

○

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

•

aged.
Apply brake fluid to the dust seals, and install them into

○

the cylinders by hand.

Periodic Maintenance Procedures

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

•

them into each cylinder by hand.
Check the shaft rubber friction boot [A] and the dust cover

•

[B] replace them with new ones if they are damaged.
Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

•

the caliper holder shafts [C] and holder holes [D] (PBC is
a special high temperature, water-resistance grease).

Install the anti-rattle spring [A].

•

Install the pads (see Brakes chapter).

•

Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

PERIODIC MAINTENANCE 2-57

Rear Caliper Disassembly

Remove the rear caliper.

•

Remove the pads and anti-rattle spring (see Brakes chap-

•

ter).
Using compressed air, remove the piston.

•

Cover the piston area with a clean, thick cloth [B].

○

Blow compressed air [A] into the hole for the banjo bolt to

○

remove the piston.

WARNING

To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com­pressed air into the caliper, the piston may crush
your hand or fingers.

Remove the dust seal and fluid seal.

•

Remove the bleed valve and rubber cap.

•

NOTE

If compressed air is not available, with the brake hose

○

still attached, apply the brake pedal to remove the pis­ton. The remaining process is as described above.

Rear Caliper Assembly

Clean the c aliper parts except for the pads.

•

CAUTION

For cleaning of 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)

2-58 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

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

•

Apply brake fluid to the fluid seal, and install it into the

○

cylinder by hand.
Replace the dust seal [B] with a new one if it is damaged.

•

Apply brake fluid to the dust seal, and install it into the

○

cylinder by hand.

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

•

into the cylinder by hand.
Replace the shaft rubber friction boot [A] and dust cover

•

[B] if they are damaged.
Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

•

the caliper holder shafts [C] and holder holes [D] (PBC is
a special high temperature, water-resistance grease).

Install the anti-rattle spring [A] in the caliper as shown.

•

Install the pads (see Brakes chapter).

•

Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Spark Plug Replacement

Remove:

•

Fuel Tank (see Fuel System (DFI) chapter)

If removing the spark plug #3, unscrew the thermostat

•

bracket bolt [A].

Disconnect:

•

Stick Coil Connectors [A]

Pull out the stick coil #1 [B].

•

Take out the camshaft position sensor connector [C] from

•

the bracket.
Pull out the stick coil #2 [D].

•

CAUTION

Do not pry the connector part of the coil while re­moving the coil.

Periodic Maintenance Procedures

Remove the ignition harness connector [A] from the

•

bracket.
Remove:

•

Stick Coil Connector #4 [B] (Disconnect)

Stick Coil #4 [C]

Stick Coil Connector #3 [D] (Disconnect)
Pull the main harness upward and remove the stick coil

•

#3.

Remove the spark plugs using the 16 mm plug wrench

•

[A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1146

PERIODIC MAINTENANCE 2-59

Insert the spark plug vertically into the plug hole with the

•

spark plug i nstalled in the plug wrench [A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1146

Tighten:

•

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 113 in·lb)

Insert the coils as shown being careful of the coil heads

•

[A] direction.
Fit the coils securely.

○

CAUTION

Do not tap the coil head while installing the coil.

Be sure the stick coils are installed by pulling up [A] it

○

lightly.
Connect the connectors.

•

Install:

•

Thermostat Bracket Bolt (see Cooling System chapter)

Fuel Tank (see Fuel System (DFI) c hapter)

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

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

DFI System............................................................................................................................. 3-8

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

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

Specifications ......................................................................................................................... 3-17

Special Tools and Sealant ...................................................................................................... 3-19

DFI Servicing Precautions ...................................................................................................... 3-21

DFI Servicing Precautions ................................................................................................ 3-21

Troubleshooting the DFI System ............................................................................................ 3-23

Outline ................................................................................................................................. 3-23

Outline............................................................................................................................... 3-23

Inquiries to Rider.................................................................................................................. 3-27

Inquiries to Rider............................................................................................................... 3-27

DFI System Troubleshooting Guide ....................................................................................... 3-30

Self-Diagnosis ........................................................................................................................ 3-38

Self-diagnosis Outline .......................................................................................................... 3-38

Self-diagnosis Outline....................................................................................................... 3-38

Self-diagnosis Procedures ................................................................................................... 3-38

Self-diagnosis Procedures................................................................................................ 3-38

Service Code Clearing Procedures ..................................................................................... 3-39

Service Code Clearing Procedures................................................................................... 3-39

How to Read Service Codes................................................................................................ 3-41

How to Read Service Codes............................................................................................. 3-41

How to Erase Service Codes............................................................................................... 3-41

How to Erase Service Codes............................................................................................ 3-41

Service Code Table.............................................................................................................. 3-42

Service Code Table........................................................................................................... 3-42

Backups............................................................................................................................... 3-43

Backups ............................................................................................................................ 3-43

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

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

Input Voltage Inspection.................................................................................................... 3-45

Output Voltage Inspection................................................................................................. 3-46

Resistance Inspection....................................................................................................... 3-47

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-48

Removal............................................................................................................................ 3-48

Installation......................................................................................................................... 3-48

Input Voltage Inspection.................................................................................................... 3-48

Output Voltage Inspection................................................................................................. 3-49

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-54

Removal/Installation.......................................................................................................... 3-54

Output Voltage Inspection................................................................................................. 3-54

Sensor Resistance Inspection .......................................................................................... 3-55

Water Temperature Sensor (Service Code 14) ...................................................................... 3-56

Removal/Installation.......................................................................................................... 3-56

Output Voltage Inspection................................................................................................. 3-56

3

3-2 FUEL SYSTEM (DFI)

Sensor Resistance Inspection .......................................................................................... 3-57

Atmospheric Pressure Sensor (Service Code 15).................................................................. 3-58

Removal............................................................................................................................ 3-58

Input Voltage Inspection.................................................................................................... 3-58

Output Voltage Inspection................................................................................................. 3-59

Crankshaft Sensor (Service Code 21).................................................................................... 3-62

Crankshaft Sensor Removal/Installation........................................................................... 3-62

Crankshaft Sensor Inspection........................................................................................... 3-62

Camshaft Position Sensor (Service Code 23) ........................................................................ 3-63

Camshaft Position Sensor Removal/Installation ............................................................... 3-63

Camshaft Position Sensor Inspection............................................................................... 3-63

Speed Sensor (Service Code 24, 25)..................................................................................... 3-64

Speed Sensor Removal/Installation.................................................................................. 3-64

Speed Sensor Inspection.................................................................................................. 3-64

Input Voltage Inspection.................................................................................................... 3-64

Output Voltage Inspection................................................................................................. 3-64

Vehicle-down Sensor (Service Code 31) ................................................................................ 3-66

Removal............................................................................................................................ 3-66

Installation......................................................................................................................... 3-66

Inspection.......................................................................................................................... 3-66

Subthrottle Sensor (Service Code 32).................................................................................... 3-69

Subthrottle Sensor Removal/Adjustment .......................................................................... 3-69

Input Voltage Inspection.................................................................................................... 3-69

Output Voltage Inspection................................................................................................. 3-70

Resistance Inspection ....................................................................................................... 3-71

Immobilizer Amplifier (Immobilizer Equipped Models, Service Code 35) ............................... 3-72

Antenna Resistance Inspection ........................................................................................ 3-72

Amplifier Input Voltage Inspection..................................................................................... 3-72

Blank Key Detection (Immobilizer Equipped Models, Service Code 36) ................................ 3-73

User Key Inspection.......................................................................................................... 3-73

Stick C oils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) ...................................................... 3-74

Removal/Installation.......................................................................................................... 3-74

Input Voltage Inspection.................................................................................................... 3-74

Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-76

Subthrottle Valve Actuator Removal ................................................................................. 3-76

Audible Inspection............................................................................................................. 3-76

Visual Inspection ............................................................................................................... 3-76

Resistance Inspection ....................................................................................................... 3-76

Input Voltage Inspection.................................................................................................... 3-77

FI Indicator Light (LED) .......................................................................................................... 3-78

FI Indicator Light (LED) Inspection ................................................................................... 3-79

ECU........................................................................................................................................ 3-80

ECU Removal ................................................................................................................... 3-80

ECU Installation ................................................................................................................ 3-80

ECU Power Supply Inspection.......................................................................................... 3-80

DFI Power Source ..................................................................................................................3-83

ECU Fuse Removal .......................................................................................................... 3-83

ECU Fuse Installation ....................................................................................................... 3-83

ECU Fuse Inspection ........................................................................................................ 3-83

ECU Main Relay Removal ................................................................................................ 3-83

ECU Main Relay Inspection .............................................................................................. 3-83

Fuel Line................................................................................................................................. 3-84

Fuel Pressure Inspection .................................................................................................. 3-84

Fuel Flow Rate Inspection ................................................................................................ 3-85

Fuel Pump .............................................................................................................................. 3-87

Fuel Pump Removal ......................................................................................................... 3-87

Fuel Pump Installation ...................................................................................................... 3-87

FUEL SYSTEM (DFI) 3-3

Operation Inspection......................................................................................................... 3-88

Operating Voltage Inspection ............................................................................................ 3-88

Pressure Regulator Removal............................................................................................ 3-89

Pump Screen, Fuel Filter Cleaning................................................................................... 3-89

Fuel Pump Relay .................................................................................................................... 3-90

Fuel Pump Relay Removal ............................................................................................... 3-90

Fuel Pump Relay Inspection............................................................................................. 3-90

Fuel Injectors.......................................................................................................................... 3-92

Removal/Installation.......................................................................................................... 3-92

Audible Inspection............................................................................................................. 3-92

Power Source Voltage Inspection ..................................................................................... 3-92

Output Voltage Inspection................................................................................................. 3-93

Injector Signal Test............................................................................................................ 3-94

Injector Resistance Inspection .......................................................................................... 3-95

Injector Unit Test ............................................................................................................... 3-95

Injector Fuel Line Inspection............................................................................................. 3-95

Throttle Grip and Cables ........................................................................................................ 3-98

Free Play Inspection ......................................................................................................... 3-98

Free Play Adjustment........................................................................................................ 3-98

Cable Installation .............................................................................................................. 3-98

Cable Lubrication.............................................................................................................. 3-98

Choke Cable........................................................................................................................... 3-99

Free Play Inspection ......................................................................................................... 3-99

Free Play Adjustment........................................................................................................ 3-99

Choke Cable Installation ................................................................................................... 3-99

Cable Lubrication.............................................................................................................. 3-99

Throttle Body Assy ................................................................................................................. 3-100

Idle Speed Inspection ....................................................................................................... 3-100

Engine Vacuum Synchronization Inspection/ Adjustment................................................. 3-100

High Altitude Performance Adjustment ............................................................................. 3-100

Throttle Body Assy Removal............................................................................................. 3-100

Throttle Body Assy Installation.......................................................................................... 3-102

Throttle Body Assy Disassembly ...................................................................................... 3-104

Throttle Body Assy Assembly ........................................................................................... 3-104

Air Cleaner.............................................................................................................................. 3-105

Element Removal/Installation ........................................................................................... 3-105

Air Cleaner Element Inspection ........................................................................................ 3-105

Air Cleaner Oil Draining .................................................................................................... 3-105

Air Cleaner Housing Removal........................................................................................... 3-105

Fuel Tank................................................................................................................................ 3-106

Fuel Tank Removal ........................................................................................................... 3-106

Fuel Tank Installation ........................................................................................................ 3-107

Fuel Tank and Cap Inspection .......................................................................................... 3-109

Fuel Tank Cleaning ........................................................................................................... 3-109

Evaporative Emission Control System (California Model) ...................................................... 3-110

Parts R emoval/Installation ................................................................................................ 3-110

Hose Inspection ................................................................................................................ 3-110

Separator Inspection......................................................................................................... 3-110

Separator Operation Test.................................................................................................. 3-111

Canister Inspection .......................................................................................................... 3-111

3-4 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

1

Throttle Cable Plate Bolt

2 Throttle Body Assy Holder Clamp Bolts 2.0 0.20 17 in·lb

3 Choke Link Holder Screws 2.1 0.21 18 in·lb

4 Delivery Pipe Screws 3.4 0.35 30 in·lb

5 Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

6 Fuel Level Sensor Bolts 6.9 0.70 62 in·lb L

7

Bypass Screws

8. California Model

9. FI Indicator LED Light

10. Throttle Cable (Accelerator)

11. Throttle Cable (Decelerator)

12. Choke Cable

13. Subthrottle Valve Actuator Connectors

14. Center Adjusting Screw

15. Injectors

16. Throttle Body Assy

CL: Apply c able lubricant.

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

N·m kgf·m ft·lb

6.0 0.60 52 in·lb

0.2 0.02 1.7 in·lb

Torque

Remarks

3-6 FUEL SYSTEM (DFI)

Exploded View

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1

Inlet Air Pressure Sensor Bolt

2 Water Temperature Sensor 25 2.5 18

3 Vehicle Down Sensor Bolts 2.0 0.20 17 in·lb

4 Camshaft Position Sensor Bolt 12 1.2 104 in·lb

5 Camshaft Position Sensor Rotor Bolt 12 1.2 104 in·lb L

6 Air Cleaner Duct Holder Screws 3.8 0.39 34 in·lb

7

Air Cleaner Housing Mounting Bolts

8 Air Cleaner Duct Clamp Bolts 2.0 0.20 17 in·lb

9 Air Cleaner Housing Screws 1.2 0.12 10 in·lb

10 Air Cleaner Housing Tapping Screws 1.2 0.12 10 in·lb

11 Speed Sensor Bolt 6.9 0.70 62 in·lb L

12. Inlet Air Pressure Sensor

13. Stick Coils

14. ECU

15. Fuel Pump Relay

16. ECU Main Relay

17. Atmospheric Pressure Sensor

18. Crankshaft Sensor

19. Inlet Air Temperature Sensor

20. Grommet

21. Immobilizer Antenna

22. Immobilizer Amplifier
L: Apply a non-permanent locking agent.

R: Replacement Parts

SS: Apply s ilicone sealant.

N·m kgf·m ft·lb

12 1.2 104 in·lb

9.8 1.0 87 in·lb

Torque

Remarks

3-8 FUEL SYSTEM (DFI)

DFI System

DFI System