Kawasaki ZX-10R User Manual

Ninja ZX-10R

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Motorcycle

Service Manual

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Quick Reference Guide

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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

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Ninja ZX-10R

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Motorcycle

Service Manual

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

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

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

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

LIST OF ABBREVIATIONS

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A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

°C degree(s) Celsius r revolution

DC direct current rpm revolution(s) per minute

F

°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)

farad(s) TDC

N

newton(s)

top dead center

COUNTRY AND AREA CODES

AT Austria FR France

AU Australia

CA Canada

CAL California US United States

CH Switzerland WVTA Whole Vehicle Type Approval

DE Germany

GB

M

Y

United Kingdom

M

alaysia

EMISSION CONTROL INFORMATION

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

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

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

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

cludes a catalytic converter system.

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

stead, fuel vapors are routed into the running engine to be burned, or stored in a c anister 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 “remove or render inoperative an y device or element of design” has been generally

○

interpreted as follows.

1. Tampering does not include the temporary removal or rendering inoperative of devices or elements 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

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Federal law prohibits the following acts or the causing 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

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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 s tarting 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

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference

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

For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section.

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows.

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

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GENERAL INFORMATION 1-1

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General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-9

Unit Conversion Table ............................................................................................................ 1-12

1

1-2 GENERAL INFORMATION

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Before Servicing

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

Especially note the following.

Battery Ground

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

Edges of Parts

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

Solvent

Use a high-flush point solvent when cleaning parts. High

-flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

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

Before Servicing

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Arrangement and Cleaning of Removed Parts

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

Storage of Removed Parts

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

GENERAL INFORMATION 1-3

Inspection

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

Replacement Parts

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

Assembly Order

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

1-4 GENERAL INFORMATION

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Before Servicing

Tightening Sequence

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

Tightening Torque

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

Force

Use common sense during disassembly and assembly, excessive 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 the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent

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

Before Servicing

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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. M ake sure the seal is aligned properly when installing.

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

Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION

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Before Servicing

Lubrication

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

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

Model Identification

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ZX1000D6F (Europe) Left Side View

GENERAL INFORMATION 1-7

ZX1000D6F (Europe) Right Side View

1-8 GENERAL INFORMATION

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Model Identification

ZX1000D6F (United States and Canada) Left Side View

ZX1000D6F (United States and Canada) Right Side View

Frame Number Engine Number

GENERAL INFORMATION 1-9

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General Specifications

Items ZX1000D6F (Ninja ZX-10R)

Dimensions

Overall Length 2 065 mm (81.3 in.)

Overall Width (CA), (CAL), (US) 730 mm (28.7 in.)

705 mm (27.8 in.)

Overall Height 1 130 mm (44.5 in.)

Wheelbase 1 390 mm (54.7 in.)

Road Clearance 120 mm (4.7 in.)

Seat Height 825 mm (32.5 in.)

Dry Mass 175 kg (386 lb)

Curb Mass:

Front 102 kg (225 lb)

Rear 100 kg (221 lb)

Fuel Tank Capacity 17 L (4.5 US gal)

Performance

Minimum Turning Radius 3.3 m (10.8 ft)

Engine

Type

Cooling System Liquid-cooled

Bore and Stroke 76.0 × 55.0 mm (3.0 × 2.2 in.)

Displacement 998mL(60.9cuin.)

Compression Ratio 12.7 : 1

Maximum Horsepower 128.7 kW (175 PS) @11 700 r/min (rpm),

Maximum Torque 115 N·m (11.7 k gf·m, 85 ft·lb) @9 500 r/min (rpm),

Carburetion System FI (Fuel injection), MIKUNI 43EIDW × 4

Starting System Electric starter

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (digital igniter in ECU)

Ignition Timing From 10° BTDC @1 100 r/min (rpm)

Spark Plug NGK CR9EIA-9

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

Firing Order 1-2-4-3

Valve Timing:

Inlet:

Open 46° BTDC

Close 74° ABDC

Duration 300°

Exhaust:

Open 66° BBDC

Close 46° ATDC

4-stroke, DOHC, 4-cylinder

(FR) 78.2 kW (106 PS) @10 500 r/min (rpm), (AU) 128.7 kW (175 PS) @11 500 r/min (rpm), (MY) 120.5 kW (164 PS) @10 000 r/min (rpm), (CA),(CAL),(US)–––

(FR) 86 N·m (8.8 kgf·m, 63 ft·lb) @5 200 r/min (rpm), (CA),(CAL),(US)–––

1-10 GENERAL INFORMATION

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General Specifications

Items ZX1000D6F (Ninja ZX-10R)

Duration 292°

Lubrication System Forced lubrication (wet sump with cooler)

Engine Oil:

Type API SE, SF or SG

API SH, SJ or SL with JASO MA

Viscosity SAE10W-40

Capacity 4.0 L (4.2 US qt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio

Clutch Type Wet multi disc

Transmission:

Type

Gear Ratios:

1st 2.533 (38/15)

2nd 2.053 (39/19)

3rd 1.737 (33/19)

4th 1.524 (32/21)

5th

6th 1.304 (30/23)

Final Drive System:

Type Chain drive

Reduction Ratio 2.353 (40/17)

Overall Drive Ratio 4.945 @Top gear

Frame

Type Tubular, diamond

Caster (Rake Angle) 24.5°

Trail 102 mm (4.0 in.)

Front Tire:

Type Tubeless

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

Rear Tire:

Type Tubeless

Size 190/55 ZR17 M/C (75 W)

Rim Size:

Front 17 × 3.50

Rear 17 × 6.00

Front Suspension:

Type Telescopic fork (upside-down)

Wheel Travel 120 mm (4.7 in.)

Rear Suspension:

Type Swingarm (uni-trak)

Wheel Travel

1.611 (87/54)

6-speed, constant mesh, return shift

1.381 (29/21)

125 mm (4.9 in.)

General Specifications

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Items ZX1000D6F (Ninja ZX-10R)

Brake Type:

Front Dual discs

Rear Single disc

Electrical Equipment

Battery 12 V 10 Ah

Headlight:

Type Semi-sealed beam

Bulb:

High 12 V 55 W + 65 W (quartz-halogen)

Low 12 V 55 W (quartz-halogen)

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

Alternator:

Type Three-phase AC

Rated Output 31 A/14 V @5 000 r/min (rpm)

GENERAL INFORMATION 1-11

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

1-12 GENERAL INFORMATION

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Unit Conversion Table

Prefixes for Units

Prefix Symbol Power

mega M × 1 000 000

kilo k × 1 000

centi c ×0.01

milli m ×0.001

micro µ × 0.000001

Units of Mass

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume

L × 0.2642 = gal (US)

L × 0.2200 = gal (imp)

L × 1.057 = qt (US)

L × 0.8799 =

L×2.113=

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (imp)

mL × 0.06102 = cu in

qt (imp)

pint (US)

Units of Length

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque

N·m × 0.1020 = kgf·m

N·m × 0.7376 =

N·m × 8.851 = in·lb

kgf·m × 9.807 = N·m

kgf·m

kgf·m × 86.80 = in·lb

× 7.233 =

ft·lb

Units of Pressure

kPa × 0.01020 = kgf/cm²

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm²

kgf/cm² × 14.22 = psi

cmHg×1.333=kPa

× 98.07 = kPa

Units of S peed

km/h × 0.6214 = mph

Units of F orce

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature

Units of Power

kW × 1.360 =

kW ×1.341=HP

PS × 0.7355 = kW

PS

× 0.9863 = HP

PS

PERIODIC MAINTENANCE 2-1

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Periodic Maintenance

Table of Contents

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

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

Specifications ......................................................................................................................... 2-13

Special Tools .......................................................................................................................... 2-15

Maintenance Procedure ......................................................................................................... 2-16

Fuel System (DFI)................................................................................................................ 2-16

Throttle Control System Inspection................................................................................... 2-16

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

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

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

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

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

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

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

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

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .......... 2-22

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

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

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

Air Suction System .............................................................................................................. 2-26

Air Suction System Damage Inspection............................................................................ 2-26

Clutch................................................................................................................................... 2-27

Clutch Operation Inspection ............................................................................................. 2-27

Wheels/Tires........................................................................................................................ 2-28

Air Pressure Inspection..................................................................................................... 2-28

Wheel/Tire Damage Inspection......................................................................................... 2-28

Tire Tread Wear Inspection .............................................................................................. 2-28

Wheel Bearing Damage Inspection .................................................................................. 2-29

Drive Train ........................................................................................................................... 2-30

Drive Chain Lubrication Condition Inspection................................................................... 2-30

Drive Chain Slack Inspection ............................................................................................ 2-30

Drive Chain Slack Adjustment .......................................................................................... 2-31

Wheel Alignment Inspection ............................................................................................. 2-32

Drive Chain Wear Inspection ............................................................................................ 2-32

Chain Guide Wear Inspection ........................................................................................... 2-33

Brake System ...................................................................................................................... 2-33

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-33

Brake Hose Damage and Installation Condition Inspection.............................................. 2-33

Brake Operation Inspection .............................................................................................. 2-33

Brake Fluid Level Inspection ............................................................................................. 2-34

Brake Pad Wear Inspection .............................................................................................. 2-34

Brake Light Switch Operation Inspection.......................................................................... 2-34

Suspensions ........................................................................................................................ 2-35

Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-35

Front Fork Oil Leak Inspection.......................................................................................... 2-36

Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-36

Rocker Arm Operation Inspection..................................................................................... 2-36

Tie-Rod Operation Inspection ........................................................................................... 2-36

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

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

2

2-2 PERIODIC MAINTENANCE

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

Steering Stem Bearing Lubrication ................................................................................... 2-38

Steering Damper Oil Leak Inspection ............................................................................... 2-38

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

Lights and Switches Operation Inspection ........................................................................ 2-39

Headlight Aiming Inspection ............................................................................................. 2-41

Sidestand Switch Operation Inspection ............................................................................ 2-42

Engine Stop Switch Operation Inspection......................................................................... 2-43

Others.................................................................................................................................. 2-44

Chassis Parts Lubrication ................................................................................................ 2-44

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-45

Replacement Parts .............................................................................................................. 2-47

Air Cleaner Element Replacement.................................................................................... 2-47

Fuel Hose Replacement ................................................................................................... 2-48

Coolant Change ................................................................................................................ 2-49

Radiator Hose and O-ring Replacement ........................................................................... 2-52

Engine Oil Change............................................................................................................ 2-53

Oil Filter Replacement ...................................................................................................... 2-53

Brake Hose and Pipe Replacement.................................................................................. 2-54

Brake Fluid Change .......................................................................................................... 2-54

Master Cylinder Rubber Parts Replacement .................................................................... 2-56

Caliper Rubber Parts Replacement .................................................................................. 2-57

Spark Plug Replacement .................................................................................................. 2-60

PERIODIC MAINTENANCE 2-3

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Periodic Maintenance Chart

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

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

Periodic Inspection

FREQUENCY Whichever

comes

first

INSPECTION Every

Fuel System

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

year

1

(0.6)6(4)12(7.5)18(12)24(15)30(20)36(24)

• • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-16

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

Engine Top End

Valve clearance-inspect

Air Suction System

year

• • •

• • • •

• • • • • • •

• • • •

•

2-16

2-19

2-20

2-21

2-22

Air suction system damage-inspect

Clutch

Clutch operation (play, disengagement, engagement)-inspect

Wheels and Tires

Tire air pressure-inspect year

Wheel/tire damage-inspect

Tire tread wear, abnormal wear-inspect

Wheel bearing damage-inspect year

Drive Train

Drive chain lubrication condition-inspect # Every 600 km (400 mile) 2-30

Drive chain slack-inspect # Every 1 000 km (600 mile) 2-30

Drive chain wear-inspect #

Drive chain guide wear-inspect

• • •

• • • •

• • •

2-26

2-27

2-28

2-29

2-32

2-33

2-4 PERIODIC MAINTENANCE

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Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

INSPECTION Every

Brake System

Brake fluid leak (brake hose and pipe)-inspect

Brake hose and pipe damage-inspect year

Brake pad wear-inspect #

Brake hose installation condition-inspect year

Brake fluid level-inspect 6 months

Brake operation (effectiveness, play, no drag)-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

* ODOMETER READING

×1000km

(× 1 000 mile)

1

(0.6)6(4)12(7.5)18(12)24(15)30(20)36(24)

• • • • • • •

• • • • • •

• • • • • • •

• • •

See

Page

2-33

2-34

2-33

2-34

2-33

2-34

2-35

2-36

Rocker arm operation-inspect

Tie-Rods operation-inspect

Steering System

Steering play-inspect year

Steering stem bearings-lubricate

Steering damper oil leak-inspect

Electrical System

Lights and switches operation-inspect year

Headlight aiming-inspect year

Sidestand switch operation-inspect year

Engine stop switch operation-inspect year

Others

Chassis parts-lubricate year

Bolts and nuts tightness-inspect

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

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

frequent starting/stopping.

2years

• • • •

• • •

•

• • • • • •

• • •

2-36

2-37

2-38

2-39

2-41

2-42

2-43

2-44

2-45

PERIODIC MAINTENANCE 2-5

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Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

come

first

CHANGE/REPLACE ITEM Every

Air cleaner element # Every 18 000 km (12 000 mile) 2-47

(0.6)12(7.5)24(15)36(24)48(30)

* ODOMETER READING

×1000km

(× 1 000 mile)

1

See

Page

Fuel hose 4 years

Coolant

Radiator hose and O-ring 3 years

Engine oil # year

Oil filter year

Brake hose and pipe 4 years

Brake fluid

Rubber parts of master cylinder and caliper 4 years

Spark plug

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

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

frequent starting/stopping.

3 years

2 years

•

• • • • •

• •

• • • •

•

2-48

2-49

2-52

2-53

2-54

2-56

2-60

2-6 PERIODIC MAINTENANCE

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Torque and Locking Agent

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

non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

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

G: Apply grease.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1.) R: Replacement Parts S: Follow the specified tightening sequence.

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

SS: Apply silicone sealant.

Fastener

Fuel System

Air Cleaner Element Cover Screws 1.1 0.11 9.7 in·lb

Air Cleaner Housing Holder Clamp Screws 2.0 0.20 18 in·lb

Air Cleaner Housing Mounting Bolts 7.0 0.71 62 in·lb

Air Inlet Duct Mounting Bolts 7.0 0.71 62 in·lb L

Bypass Screws 0.2 0.02 17 in·lb

Camshaft Position Sensor Bolt 10 1.0 89 in·lb

Canister Bracket Mounting Bolt (M5) 4.3 0.44 38 in·lb

Canister Bracket Mounting Screws (M5) 4.3 0.44 38 in·lb

Crankshaft Sensor Bolts

Delivery Pipe Mounting Screws 5.0 0.51 44 in·lb

Exhaust Butterfly Valve Actuator Mounting Bolts 0.8 0.08 7in·lb

Exhaust Butterfly Valve Actuator Pulley Bolts 5.0 0.51 44 in·lb

Fuel Pump Bolts 10 1.0 89 in·lb L, S

Gear Position Switch Screws 3.0 0.31 27 in·lb L

Inlet Air Pressure Sensor Bracket Screws

Separator Bracket Mounting Bolts 7.0 0.71 62 in·lb

Separator/Canister Hose Clamp Bolt 7.0 0.71 62 in·lb

Speed Sensor Bolt 10 1.0 89 in·lb

Throttle Body Assy Holder Bolts 10 1.0 89 in·lb

Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in·lb

Vehicle-down Sensor Bolts 6.0 0.61 53 in·lb

Water Temperature Sensor 25 2.5 18 SS

Cooling System

Coolant By-pass Fitting Bolt

Coolant Drain Bolt (Cylinder) 10 1.0 89 in·lb

Coolant Drain Bolt (Water Pump) 10 1.0 89 in·lb

Coolant Reserve Tank Mounting Bolts 7.0 0.71 62 in·lb

Oil Cooler Mounting Bolts 20 2.0 15

Thermostat Housing Cover Bolts 6.0 0.61 53 in·lb

Thermostat Housing Mounting Bolts 10 1.0 89 in·lb

Radiator Bracket Mounting Bolt 7.0 0.71 62 in·lb

N·m kgf·m ft·lb

6.0 0.61 53 in·lb L

3.5 0.36 31 in·lb

9.0 0.92 80 in·lb L

Torque

Remarks

Torque and Locking Agent

www.zxforums.com

PERIODIC MAINTENANCE 2-7

Fastener

Radiator Lower Bolt 7.0 0.71 62 in·lb

Radiator Upper Bolt 7.0 0.71 62 in·lb

Water Hose Clamp Screws 2.0 0.20 18 in·lb

Water H ose Fitting Bolts 10 1.0 89 in·lb

Water Passage Plugs 19.6 2.0 14 L

Water Pump Cover Bolts 10 1.0 89 in·lb

Water Temperature Sensor 25 2.5 18 SS

Engine Top End

Air Suction Valve Cover Bolts 10 1.0 89 in·lb L

Camshaft Cap Bolts 12 1.2 106 in·lb S

Camshaft Chain Tensioner Cap Bolt 20 2.0 15

Camshaft Chain Tensioner Mounting Bolts 10 1.0 89 in·lb

Camshaft Position Sensor Bolt

Cam Sprocket Mounting Bolts 15 1.5 11 L

Coolant Drain Plug (Cylinder) 10 1.0 89 in·lb

Cylinder Head Bolts (M6) 12 1.2 106 in·lb

Cylinder Head Bolts (M10 New Bolts) 59 6.0 44 MO, S

Cylinder Head Bolts (M10 Used Bolts) 57 5.8 42 MO, S

Cylinder Head Cover Bolts

Exhaust Butterfly Valve Cable Adjuster Locknuts 7.0 0.71 62 in·lb

Exhaust Butterfly Valve Cable Locknuts 7.0 0.71 62 in·lb

Exhaust Pipe Manifold Mounting Bolts 14 1.4 10

Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18

Front Camshaft Chain Guide Bolt (Lower) 12 1.2 106 in·lb

Front Exhaust Pipe Manifold Holder Nuts

Idle Gear Cover Bolts 10 1.0 89 in·lb

Middle Exhaust Pipe Clamp Bolt 17 1.7 13

Middle Exhaust Pipe Stay Bolt 25 2.5 18

Muffler Body Assembly Nuts 22 2.2 16

Muffler Body Cover Bolts 7.0 0.71 62 in·lb

Muffler Body Mounting Bolts

Oxygen Sensors (Europe Models) 25 2.5 18

Rear Exhaust Pipe Clamp Bolt 17 1.7 13

Right Engine Bracket Bolts (Cylinder Head Side) 10 1.0 89 in·lb L

Spark Plugs 13 1.3 115 in·lb

Starter Clutch Bolt Cap – – – Hand-tighten

Starter Clutch Cover Bolts (M6, L = 30 mm)

Starter Clutch Cover Bolts (M6, L = 20 mm) 10 1.0 89 in·lb

Throttle Body Assy Holder Bolts 10 1.0 89 in·lb S

Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in·lb S

Timing Inspection Cap – – – Hand-tighten

Upper Camshaft Chain Guide Bolts 12 1.2 106 in·lb S

Water Passage Plugs 19.6 2.0 14 L

N·m kgf·m ft·lb

10 1.0 89 in·lb

17 1.7 13

25 2.5 18

10 1.0 89 in·lb

Torque

Remarks

2-8 PERIODIC MAINTENANCE

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Torque and Locking Agent

Fastener

Clutch

Clutch Cover Mounting Bolts 10 1.0 89 in·lb S

Clutch Hub Nut 130 13.3 96 R

Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S

Clutch Spring Bolts 9.8 1.0 87 in·lb

Oil Filler Plug – – – Hand-tighten

Sub Clutch Hub Bolts

Engine Lubrication System

Engine Oil Drain Bolt 20 2.0 15

Oil Cooler Mounting Bolts 20 2.0 15 L

Oil Filter 31 3.2 23 EO, R

Oil Cooler/Oil Filter Case Mounting Bolts 20 2.0 15 L

Oil Filter Pipe

Oil Pan Bolts 10 1.0 89 in·lb

Oil Passage Plugs 20 2.0 15 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 G

Oil Pump Cover Bolts

Oil Pump Gear Bolts 10 1.0 89 in·lb L

Engine Removal/Installation

Adjusting Collar Locknut 49 5.0 36 S

Left Engine Bracket Bolts (M10, L = 30 mm) 44 4.5 32 S

Left Front Engine Mounting Bolt (M10, L = 42 mm) 44 4.5 32 S

Lower Engine Mounting Bolt 9.8 1.0 87 in·lb

Lower Engine Mounting Nut 44 4.5 32 S

Middle Engine Mounting Bolt 9.8 1.0 87 in·lb S

Middle Engine Mounting Nut 44 4.5 32 S

Right Engine Bracket Bolt (M10, L = 35 mm) 44 4.5 32 S

Right Engine Bracket Bolts (M10, L = 30 mm) 44 4.5 32 S

Right Engine Bracket Bolts (Cylinder Head Side)

Right Front Engine Mounting Bolt (M10, L = 67 mm) 44 4.5 32 S

Crankshaft/Transmission

Bearing Position Plate Screws 5.0 0.51 44 in·lb L

Breather Plate Bolts 10 1.0 89 in·lb L

Connecting Rod Bid End Bolts see Text ← ← MO

Coolant Drain Plug (Cylinder) 10 1.0 89 in·lb

Crankcase Bolts (M9) 39 4.0 29 MO, S

Crankcase Bolts (M8) 27 2.8 20 S

Crankcase Bolts (M7, L = 85 mm)

Crankcase Bolts (M7, L = 50 mm) 20 2.0 15 S

Crankcase Bolts (M7, L = 32 mm) 20 2.0 15 S

Crankcase Bolts (M6, L = 45 mm) 12 1.2 106 in·lb S

N·m kgf·m ft·lb

25 2.5 18 L

35 3.6 26 L

10 1.0 89 in·lb

10 1.0 89 in·lb L

20 2.0 15

Torque

Remarks

S

Torque and Locking Agent

www.zxforums.com

PERIODIC MAINTENANCE 2-9

Fastener

Crankcase Bolts (M6, L = 40 mm) 12 1.2 106 in·lb S

Drive Shaft Cover Bolts 25 2.5 18

Gear Position Lever Bolt 12 1.2 106 in·lb

Oil Passage Plugs

Piston Oil Jet 3.0 0.31 27 in·lb

Plate Screw 5.0 0.51 44 L

Plug 20 2.0 15

Shift Drum Bearing Holder Screws 5.0 0.51 44 in·lb L

Shift Drum Cam Holder Bolt 12 1.2 106 in·lb L

Shift Fork Hold Bolt 12 1.2 106 in·lb L

Shift Lever Bolt 7.0 0.71 62 in·lb

Shift Pedal Mounting Bolt 25 2.5 18

Shift Shaft Return Spring Pin

Tie-Rod Locknuts 7.0 0.71 62 in·lb

Wheels/Tires

Front Axle Clamp Bolts

Front Axle Nut 127 13.0 94

Rear Axle Nut 108 11.0 80

Final Drive

Engine Sprocket Cover Bolts 10 1.0 89 in·lb

Engine Sprocket Nut 125 12.7 92 MO

Rear Axle Nut 108 11.0 80

Rear Sprocket Nuts 59 6.0 44

Brakes

Brake Hose Banjo Bolts 25 2.5 18

Brake Lever Pivot Bolt 1.0 0.10 9in·lb Si

Brake Lever Pivot Bolt Nut 5.9 0.60 52 in·lb

Brake Pedal Bolt 8.8 0.90 78 in·lb

Bleed Valves 7.8 0.80 69 in·lb

Front Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

Front Brake M aster Cylinder Bleed Valve 5.4 0.55 48 in·lb

Front Brake Pad Pins 15 1.5 11

Front Brake Reservoir Cap Stopper Screw 1.2 0.12 11 in·lb

Front Caliper Assembly Bolts 22 2.2 16

Front Caliper Mounting Bolts 34 3.5 25

Front Master Cylinder Clamp Bolts

Rear Brake Disc Mounting Bolts 27 2.8 20 L

Rear Caliper Mounting Bolts 25 2.5 18

Rear Master Cylinder Mounting Bolts

Rear Master Cylinder Push Rod Locknut 17 1.7 13

Suspension

Front Axle Clamp Bolts 20 2.0 15 AL

N·m kgf·m ft·lb

20 2.0 15 L

29 3.0 21 L

20 2.0 15 AL

8.8 0.90 78 in·lb

25 2.5 18

Torque

Remarks

S

2-10 PERIODIC MAINTENANCE

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Torque and Locking Agent

Fastener

Front Fork Bottom Allen Bolts 23 2.3 17 L

Front Fork Clamp Bolts (Lower) 30 3.1 22 AL

Front Fork Clamp Bolts (Upper) 20 2.0 15

Front Fork Top Plugs 23 2.3 17

Piston Rod Nuts 15 1.5 11

Rear Shock Absorber Bracket Nut 59 6.0 44

Rear Shock Absorber Nut (Lower) 34 3.5 25

Rear Shock Absorber Nut (Upper) 34 3.5 25

Swingarm Pivot Adjusting Shaft 20 2.0 15

Swingarm Pivot Shaft Nut

Swingarm Pivot Adjusting Collar Locknut 98 10.0 72

Tie-Rod Nuts 59 6.0 44

Uni-Trak Rocker Arm Nut 34 3.5 25

Steering

Front Fork Clamp Bolts (Lower) 30 3.1 22 AL

Front Fork Clamp Bolts (Upper)

Handlebar Bolts 25 2.5 18

Handlebar Position Bolts 9.8 1.0 87 in·lb L

Steering Stem Nut 20 2.0 15

Steering Stem Head Nut 78 8.0 58

Steering Stem Locknut – – – Hand-tighten

Switch Housing Screws

Frame

Front Fender Mounting Bolts 3.9 0.40 35 in·lb

Front Footpeg Bracket Bolts 25 2.5 18

Rear Master Cylinder Mounting Bolts 25 2.5 18

Rear Frame Bolts 44 4.5 32

Sidestand Bolt

Sidestand Bracket Bolts 49 5.0 36 L

Sidestand Switch Bolt 8.8 0.90 78 in·lb L

Rear Footpeg Bracket Bolts 25 2.5 18

Windshield Mounting Bolts 0.4 0.04 4in·lb

Electrical System

Alternator Cover Bolts

Alternator Lead Holding Plate Bolt 10 1.0 89 in·lb L

Alternator Rotor Bolt 155 15.8 114

Battery Cable Mounting Bolt 4.0 0.41 35 in·lb

Camshaft Position Sensor Bolt 10 1.0 89 in·lb

Crankshaft Sensor Bolts 6.0 0.61 53 in·lb L

Frame Earth Mounting Bolt 10 1.0 89 in·lb

Front Turn Signal Light Mounting Screws 1.2 0.12 10 in·lb

Front Brake Light Switch Screw 1.2 0.12 10 in·lb

Fuel Pump Bolts 10 1.0 89 in·lb

N·m kgf·m ft·lb

108 11.0 80

20 2.0 15

3.5 0.36 31 in·lb

44 4.5 32

10 1.0 89 in·lb

Torque

Remarks

G

L, S

Torque and Locking Agent

www.zxforums.com

PERIODIC MAINTENANCE 2-11

Fastener

Gear Position Switch Screws 3.0 0.31 27 in·lb L

Headlight Mounting Screws 1.2 0.12 11 in·lb

Idle Gear Cover Bolts 10 1.0 89 in·lb

Left Handlebar Switch Housing Screws (M5, L = 25)

License Plate Light Cover Screws 1.2 0.12 11 i n · l b

License Plate Light Mounting Screws 1.2 0.12 11 in·lb

Meter Unit Mounting Screws 1.2 0.12 11 in · l b

Oil Pressure Switch 15 1.5 11 SS

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

Oxygen Sensors (Europe Models)

Rear Turn Signal Light Lens Screws 1.2 0.12 11 in·lb

Rear Turn Signal Light Mounting Screws 1.2 0.12 11 in·l b

Regulator/Rectifier Bolts 10 1.0 89 in·lb

Right Handlebar Switch Housing Screws (M5, L = 45) 3.5 0.36 31 in·lb

Sidestand Switch Bolts 8.8 0.90 78 in·lb L

Spark Plugs

Speed Sensor Bolt 10 1.0 89 in·lb

Starter Clutch Bolt 49 5.0 36

Starter Clutch Bolt Cap – – – Hand-tighten

Starter Clutch Cover Bolts (M6, L = 30) 10 1.0 89 in·lb

Starter Clutch Cover Bolts (M6, L = 20) 10 1.0 89 in·lb

Starter Motor Cable Mounting Bolt

Starter Motor Cable Terminal Nut 6.0 0.61 53 in·lb

Starter Motor Mounting Bolts 10 1.0 89 in·lb

Starter Motor Terminal Locknut 6.9 0.70 61 in·lb

Starter Motor Through Bolts 3.4 0.35 30 in·lb

Stator Coil Bolts 12 1.2 106 in·lb

Vehicle-down Sensor Bolts

Water Temperature Sensor 25 2.5 18 SS

N·m kgf·m ft·lb

3.5 0.36 31 in·lb

25 2.5 18

13 1.3 115 in·lb

4.0 0.41 35 in·lb

6.0 0.61 53 in·lb

Torque

Remarks

2-12 PERIODIC MAINTENANCE

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Torque and Locking Agent

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

Basic Torque for General Fasteners

Threads Diameter

(mm)

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

8 14 ∼ 19 1.4 ∼ 1.9 10 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72 16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 11 5 18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165 20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

N·m kgf·m ft·lb

Torque

PERIODIC MAINTENANCE 2-13

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Specifications

Item Standard Service Limit

Fuel System (DFI)

Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Idle Speed 1 100 ±50 r/min (rpm) –––

Throttle Body Vacuum 31.5 ±1.3 kPa (236 ±10 mmHg) at idle speed –––

Air Cleaner Element Viscous paper element –––

Cooling System

Coolant:

Type (Recommended) Permanent type antifreeze

Color Green –––

Mixed Ratio Soft water 50%, coolant 50% –––

Freezing Point –35°C (–31°F) –––

Total Amount 2.9L(3.1USqt) –––

Engine Top End

Valve Clearance:

Exhaust 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 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 –––

API SH, SJ or SL with JASO MA

Viscosity

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

Level Between upper and lower level lines (Wait 2 ∼ 3

Wheels/Tires

Tread Depth:

Front

Rear 6.5 mm (0.26 in.) Up to 130 km/h

Air Pressure (when Cold):

Front Up to 180 kg (397 lb) load:

Rear

SAE 10W-40

3.7 L (3.9 US qt) (when filter is removed)

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

minutes after idling or running)

6.0 mm (0.24 in.) 1 mm (0.04 in.),

250 kPa (2.50 kgf/cm², 36 psi)

Up to 180 kg (397 lb) load: 290 kPa (2.90 kgf/cm², 42 psi)

–––

(AT, CH, DE)

1.6 mm (0.06 in.)

(80 mph):

2 mm (0.08 in.),

Over 130 km/h

(80 mph):

3 mm (0.12 in.)

–––

2-14 PERIODIC MAINTENANCE

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Specifications

Item Standard Service Limit

Final Drive

Drive Chain Slack 30 ∼ 35 mm (1.2 ∼ 1.4 in.)

Drive Chain Wear (20-link Length)

Standard Chain:

Make RK EXCEL –––

Type RK 525MFO, Endless –––

Link 108 links –––

Brakes

Brake Fluid:

Grade DOT4 –––

Brake Pad Lining Thickness:

Front

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

Brake Light Timing:

Front

Rear On after about 10 mm (0.39 in.) of pedal travel –––

Electrical System

Spark Plug

Type NGK CR9EIA-9 –––

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

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

Pulled ON

–––

Special Tools

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PERIODIC MAINTENANCE 2-15

Inside Circlip Pliers: 57001-143

Steering Stem Nut Wrench: 57001-1100

Jack: 57001-1238

Vacuum Gauge: 57001-1369

Extension Tube: 57001-1578

Pilot Screw Adjuster, D: 57001-1588

Oil Filter Wrench: 57001-1249

Jack Attachment: 57001-1608

2-16 PERIODIC MAINTENANCE

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Maintenance Procedure

Fuel System (DFI)

Throttle Control System Inspection

Check the throttle grip free play [A].

•

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

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

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

•

open to close, and the throttle closes quickly and completely by the return spring in all steering positions. If the throttle grip does not return properly, check the throttle cables routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar

•

all the way to the right and left to ensure that the idle speed does not change. If the idle speed increases, check the throttle cable free play and the cable routing.

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

•

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

•

throttle grip plenty of play.

Turn the decelerator cable adjuster [C] until 2 ∼ 3mm

•

(0.08 ∼ 0.12 in.) of throttle grip play is obtained.

Tighten the locknut [A].

•

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

•

(0.08 ∼ 0.12 in.) of throttle grip play is obtained.

Tighten the locknut [B].

•

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

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 air cleaner housing (see Air Cleaner Housing

•

Removal in the Fuel System (DFI) chapter). Pull off the rubber caps [A] from the fittings of each throttle

•

body. For the California Model, pull off the vacuum hoses [B].

•

Plug the engine breather hose end [A].

•

Maintenance Procedure

www.zxforums.com

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

•

the fittings on the throttle body.

Special Tool - Vacuum Gauge: 57001-1369

Connect a highly accurate tachometer to one of the stick

•

coil primary leads.

Connect:

•

Fuel Pump Lead Connector Extension Tube [A]

Special Tool - Extension Tube: 57001-1578

Start the engine and warm it up thoroughly.

•

Check the idle speed, using a highly accurate tachometer

•

[B]. If the idle speed is out of the s pecified range, adjust it with the adjust screw.

PERIODIC MAINTENANCE 2-17

CAUTION

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

While idling the engine, inspect the throttle body vacuum,

•

using the vacuum gauge [C].

Throttle Body Vacuum

Standard: 31.5 ±1.3 kPa (236 ±10 mmHg) at Idle Speed

1 100 ±50 r/min (rpm)

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

Example:

#1: 210 mmHg #2: 240 mmHg #3: 200 mmHg #4: 220 mmHg

With the engine at the correct idle speed, equalize higher

•

vacuum of #1 or #2 (for example 240 mmHg) to higher vacuum of #3 or #4 (for example 220 mmHg) by turning the center adjusting screw [A].

NOTE

After adjustment, the final vacuum measurement be-

○

tween the highest throttle valves may not be 240 mmHg (for example). The goal is to have the highest two vacuums between the left (#1 and #2) and right (#3 and #4) banks be the same and be within the service limits.

Open and close the throttle after each measurement, and

•

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

•

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

2-18 PERIODIC MAINTENANCE

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Maintenance Procedure

If a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [A].

Special Tool - Pilot Screw Adjuster, D: 57001-1588

Adjust lower vacuum between #1 and #2 to higher vac-

•

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

•

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

•

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

•

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

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

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

•

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

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

CAUTION

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

Remove:

•

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

Check the bypass screw and its hole for carbon deposits.

•

If any carbons accumulate, wipe the carbons off from the 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)

Maintenance Procedure

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Back out the same number of turns counted when first

•

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

NOTE

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

○

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

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.

•

If the vacuums are correct, check the output voltage of the 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 26)

Meter (–) → BR/BK lead (terminal 34)

Standard: DC 0.65 ∼ 0.67 V (at idle throttle opening)

PERIODIC MAINTENANCE 2-19

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

Remove the vacuum gauge hoses and install the rubber

•

caps on the original position. For the California Model, install the vacuum hoses.

•

Route the vacuum hoses according to Cable, Wire, and

○

Hose Routing section in the Appendix chapter.

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 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 the idle speed.

•

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

Idle Speed

Standard: 1 100 ±50 r/min (rpm)

2-20 PERIODIC MAINTENANCE

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Maintenance Procedure

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.

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

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

○

sure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the 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] Fuel Hose [B]

Check that the hose joints are securely connected.

•

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

○

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

PERIODIC MAINTENANCE 2-21

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Maintenance Procedure

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Inspect the canister as follows.

•

Remove the right upper inner fairing (see Upper Inner

○

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

○

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

○

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

NOTE

The canister is designed to work well through the motor-

○

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

Check the liquid/vapor separator as follows.

•

Remove the right middle fairing (see Middle Fairing Re-

○

moval in the Frame chapter). Disconnect the hoses from the separator, and remove the

○

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

○

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

○

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

•

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

○

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

○

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 the hoses with a minimum of bending so that the emission flow will not be obstructed.

2-22 PERIODIC MAINTENANCE

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Maintenance Procedure

Cooling System

Coolant Level Inspection

NOTE

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

○

ent temperature).

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

•

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

“L”: low “F”: full

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 water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts.

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

The high pressure inside the radiator hose can cause

○

coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be 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,

18 in·lb)

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (at room temperature).

Maintenance Procedure

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Remove the cylinder head cover (see Cylinder Head

•

Cover Removal in the Engine Top End chapter). Remove the timing inspection cap [A] and starter clutch

•

bolt cap [B] on the starter clutch cover [C].

Using a wrench on the starter clutch bolt [A], turn the

•

crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch is aligned with the notch [C] in the edge of the timing inspection hole [D] in the crankshaft sensor cover.

PERIODIC MAINTENANCE 2-23

Using a thickness gauge [A], measure the valve clearance

•

between the cam and the valve lifter.

Valve Clearance

Standard:

Exhaust

Inlet

Thickness gauge is horizontally inserted on the valve

○

lifter.

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

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

NOTE

2-24 PERIODIC MAINTENANCE

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Maintenance Procedure

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]

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]

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.

NOTE

Mark and record the locations of the valve lifters and

○

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

Clean the shim to remove any dust or oil.

•

Measure the thickness of the removed shim [A].

•

Select a new shim thickness calculation as follows.

•

a+b–c=d [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance (Mean Value = 0.195) [d] Replace Shim Thickness

Example:

1.600 + 0.31 – 0.195 = 1. 715 mm

Exchange the shim for the 1.725 size shim.

○

CAUTION

Don’t use the shims for another models. This could cause wear of the valve stem end, and valve stem damage.

Maintenance Procedure

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Adjustment Shims

Thickness Part Number Mark

1.300 92180-0108 130

1.325 92180-0109 132

1.350 92180-0110 135

1.375 92180-0111 138

1.400 92180-0112 140

1.425 92180-0113 142

1.450 92180-0114 145

1.475 92180-0115 148

1.500 92180-0116 150

1.525 92180-0117 152

1.550 92180-0118 155

1.575 92180-0119 158

1.600 92180-0120 160

1.625 92180-0121 162

1.650 92180-0122 165

1.675 92180-0123 168

1.700 92180-0124 170

1.725 92180-0125 172

1.750 92180-0126 175

1.775 92180-0127 178

1.800 92180-0128 180

1.825 92180-0129 182

1.850 92180-0130 185

1.875 92180-0131 188

1.900 92180-0132 190

1.925 92180-0133 192

1.950 92180-0134 195

1.975 92180-0135 198

2.000 92180-0136 200

2.025 92180-0137 202

2.050 92180-0138 205

2.075 92180-0139 208

2.100 92180-0140 210

2.125 92180-0141 212

2.150 92180-0142 215

2.175 92180-0143 218

2.200 92180-0144 220

2.225 92180-0145 222

2.250 92180-0146 225

2.275 92180-0147 228

2.300 92180-0148 230

PERIODIC MAINTENANCE 2-25

2-26 PERIODIC MAINTENANCE

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Maintenance Procedure

CAUTION

Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance.

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

○

sizes smaller, and remeasure the valve clearance.

When installing the shim, face the marked side toward the

•

valve lifter. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation.

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.

Apply engine oil to the valve lifter surface and install the

•

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

•

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

•

Install the removed parts (see appropriate chapters).

•

Air Suction System

Air Suction System Damage Inspection

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

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

•

housing holder.

Connect the following parts temporary.

•

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

Special Tool - Extension Tube: 57001-1578

Maintenance Procedure

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Start the engine and run it at idle speed.

•

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

•

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

•

end of the air switching hose and install the hose on the fitting.

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.

PERIODIC MAINTENANCE 2-27

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 4 ∼ 6 mm (0.16 ∼ 0.24 in.) [B]

•

of threads is visible.

Remove the right middle fairing [A] (see Middle Fairing

•

Removal in the Frame chapter). Slide the dust cover [B] at the clutch cable lower end out

•

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

•

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

•

ing nuts against the bracket [E]. Slip the rubber dust cover back onto place.

•

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

•

correct.

2-28 PERIODIC MAINTENANCE

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Maintenance Procedure

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.

Wheels/Tires

Air Pressure Inspection

Measure the tire air pressure with an air pressure gauge

•

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

•

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

Air Pressure (when Cold)

Front:

Rear:

Wheel/Tire Damage Inspection

Remove any imbedded stones [A] or o ther 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 Inspection

As the tire tread wears down, the tire becomes more sus-

ceptible 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 Tire Removal/Installation in the Wheels/Tires chapter).

Upto180kg(397lb)

250kPa(2.50kgf/cm²,36psi)

Upto180kg(397lb)

290kPa(2.90kgf/cm²,42psi)

Maintenance Procedure

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Tread Depth

Standard:

Front 6.0 mm (0.24 in.)

Rear 6.5 mm (0.26 in.)

Service Limit :

Front 1 mm (0.04 in.)

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

Rear 2 mm (0.08 in.) (Up to 130 km/h)

3 mm (0.12 in.) (Over 130 km/h)

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 2-29

Wheel Bearing Damage Inspection

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

•

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

•

Inspect the roughness of the front wheel bearing by push-

•

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

•

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

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

•

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

•

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

•

turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter).

2-30 PERIODIC MAINTENANCE

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Maintenance Procedure

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 lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules. Use only kerosene or diesel oil for cleaning of the O-ring of the drive chain. Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration 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-ring [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: 30 ∼ 35 mm (1.2 ∼ 1.4 in.)

Maintenance Procedure

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Drive Chain Slack Adjustment

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

•

[B]. Loosen the both chain adjuster locknuts [C].

•

If the c hain is too loose, turn out the left and right chain adjuster [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 or position [G] 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 rear axle nut.

•

Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)

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

•

est position, and readjust if necessary. Insert a new cotter pin into the axle and bend its end se-

•

curely.

PERIODIC MAINTENANCE 2-31

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.

•

2-32 PERIODIC MAINTENANCE

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Maintenance Procedure

Wheel Alignment Inspection

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

•

aligns with the same swingarm mark or position [C] 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 (see Drive Chain Removal in the Final Drive

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

•

aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)

•

weight [A] on the chain. 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 Chain 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, replace the chain or an unsafe r iding condition may result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. For safety, use only the standard chain. It is an endless type and should not be cut for installation.

Standard Chain

Make:

Type:

Link: 108 links

RK EXCEL

RK 525MFO

Maintenance Procedure

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Chain Guide Wear Insp ection

Remove:

•

Swingarm (see Swingarm Removal in the Suspension chapter)

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. If the brake fluid leaked from any position, inspect or replace the problem part.

PERIODIC MAINTENANCE 2-33

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 brake hose banjo bolts.

Torque - Brake Hose Banjo Bol ts: 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.

Brake Operation Inspec tion

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.

2-34 PERIODIC MAINTENANCE

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Maintenance Procedure

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].

Check that the brake fluid level in the rear brake reservoir

•

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

WARNING

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

Brake Pad Wear Inspection

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

•

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

•

If the lining thickness of 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.)

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.).

4.0 mm (0.16 in.)

5.0 mm (0.20 in.)

Maintenance Procedure

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If it does not, adjust the brake light switch. While holding the switch body, turn the adjusting nut to

•

adjust the switch.

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

CAUTION

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

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

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

PERIODIC MAINTENANCE 2-35

Suspensions

Front Forks/Rear Shock Absorber Operation Inspection

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

•

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

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

•

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

2-36 PERIODIC MAINTENANCE

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Maintenance Procedure

Front Fork Oil Leak Inspection

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

•

Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

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

•

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

Rocker Arm Operation Inspection

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

•

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

Tie-Rod Operation Inspection

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

•

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

Maintenance Procedure

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Steering System

Steering Play Inspection

Remove the lower fairings (see Lower Fairing Removal in

•

the Frame chapter). Lift the front wheel off the ground using the jack.

•

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

With the front wheel pointing straight ahead, alternately

•

tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop. If the wheel binds or catches before the stop, the steering is too tight. Feel for steering looseness by pushing and pulling 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.

PERIODIC MAINTENANCE 2-37

Steering Play Adjustment

Remove:

•

Steering Damper (see Steering Damper Removal in the Steering chapter) Stem Head Nut [A] and Washer [B]

Loosen the upper fork clamp bolts [C] and handlebar bolts

•

[D]. Remove the stem head [E] with handlebar.

•

Bend the claws [A] of lock washer straighten.

•

Remove the steering stem locknut [B] and claw washer

•

[C].

Special Tool - Steering Stem Nut Wrench: 57001-1100

Adjust the steering.

•

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

NOTE

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

○

2-38 PERIODIC MAINTENANCE

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Maintenance Procedure

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

15 ft·lb) Handlebar Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58

ft·lb)

Check the steering again.

•

If the steering is still too tight or too loose, repeat the adjustment.

Steering Stem Bearing Lubrication

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

•

moval in the Steering chapter). Using a high-flash point solvent, wash the upper and

•

lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. Visually check the outer races and the ball bearings.

•

Replace the bearing assemblies if they show wear or damage. Pack the upper and lower ball bearings [A] in the cages

•

with grease, and apply a light coat of grease to the upper and lower outer races. Install the steering stem (see Stem, Stem Bearing Instal-

•

lation in the Steering chapter). Adjust the steering (see Steering Play Adjustment).

•

Steering Damper Oil Leak Inspection

Visually inspect the steering damper [A] for oil leakage.

•

If the oil leakage is found on it, replace the steering damper with a new one.

Maintenance Procedure

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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 Illumination L ig ht (LED) [D]

Meter Panel LCD [E]

Neutral Indicator Light (LED) [F]

Oil Pressure Warning Symbol [G] and Warning Indicator Light (LED) [H]

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

Battery (see Charging Condition Inspection in the Electrical System chapter) Applicable Bulb (see Wiring Diagram in the Electrical System chapter) Meter Unit for Meter Panel LCD (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for Neutral Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for Warning Indicator Light (LED) (Oil Pressure Warning) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter) Meter Unit for Illumination Light (LED) (see Electric Combination Meter Unit Inspection in the Electrical System chapter) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)

Turn off the ignition switch.

•

The all lights should go off (for the immobilizer model,

•

Warning Indicator Light (LED) will blinks. see Abstract in the Electrical System chapter). If the light does not go off, replace the ignition switch.

goes on

blinks (ab o ut 3

seconds after)

PERIODIC MAINTENANCE 2-39

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 Switch Inspection in the Electrical System chapter)

2-40 PERIODIC MAINTENANCE

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Maintenance Procedure

Third Step

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

•

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

•

cording to the switch position should flash. The turn signal indicator light (LED) [C] in the meter unit

•

should flash. If the each light does not flash, inspect or replace the following item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter) Meter Unit for Turn Signal Indicator Light (LED) (see Electronic Combination Meter Assembly Inspection in the Electrical System chapter) Turn Signal Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)

Push the turn signal switch.

•

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

•

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

Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the 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 replace the following item.

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

Maintenance Procedure

www.zxforums.com

Set the dimmer switch to high beam position.

•

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

•

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

•

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

Headlight High Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter)

Turn off the engine stop switch.

•

The low beam and high beam headlights should stay go-

•

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

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

Turn off the ignition switch.

•

The headlights and high beam indicator light (LED) should

•

go off.

PERIODIC MAINTENANCE 2-41

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] in both headlights in or out

•

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

Headlight Beam Vertical Adjustment

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

•

to adjust the headlight vertically.

2-42 PERIODIC MAINTENANCE

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Maintenance Procedure

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]

Sidestand Switch Operation Inspection

Inspect the sidestand switch [A] operation accordance to

•

below table.

Sidestand Switch Operation

Sidestand

Up Neutral Released

Up Neutral Pulled in

Up

Down Neutral Released

Down Neutral Pulled in

Down

Gear

Position

In Gear

Clutch

Lever

Released

Pulled in

Released

Pulled in

Engine

Start

Starts

Doesn’t

start

Starts

Doesn’t

start

Doesn’t

start

Engine

Run

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Stops

Maintenance Procedure

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

Battery (see Charging Condition Inspection in the Electrical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Sidestand Switch (see Switch Inspection in the Electrical System chapter) Engine Stop Switch (see Switch Inspection in the Electrical System chapter) Starter Button (see Switch Inspection in the Electrical System chapter) Gear Position Switch (see Gear Position Switch Inspection in the Electrical System chapter) Starter Relay (see Starter Relay Inspection in the Electrical System chapter) Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Starter Circuit Relay (see Relay Circuit Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)

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

PERIODIC MAINTENANCE 2-43

Engine Stop Switch Operation Inspection

First Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button.

•

The engine does not start.

•

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

Engine Stop Switch (see Switch Inspection in the Electrical System chapter)

Second Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

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 Switch Inspection in the Elec-

trical System chapter) If the engine stop switch is good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).

2-44 PERIODIC MAINTENANCE

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Maintenance Procedure

Others

Chassis Parts L ubric ation

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 Grease.

Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand

Points: Lubricate with Grease.

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

Cables: Lubricate with Rust Inhibitor

Clutch Cable Throttle Cables Lubricate the cables by seeping the oil between the cable

•

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

○

available pressure cable lubricator with an aerosol cable lubricant.

Maintenance Procedure

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With the cable disconnected at both ends, the inner 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 2-45

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

2-46 PERIODIC MAINTENANCE

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Maintenance Procedure

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Nut Engine Mounting Bolts Exhaust Pipe Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts

Wheels:

Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin

Brakes:

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

Suspension:

Front Fork Clamp Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Uni-Trak Link Nuts

Steering:

Handlebar Bolts Steering Stem Head Nut

Others:

Footpeg Bracket Bolts Front Fender Mounting Bolts Sidestand Bolt

Maintenance Procedure

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Replacement Parts

Air Cleaner Element Replacement

NOTE

In dusty areas, the element should be replaced more

○

frequently than the recommended interval. After riding through rain or on muddy roads, the element

○

should be replaced immediately.

WARNING

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

CAUTION

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

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Cleaner Element Cover Screws [A]

Air Cleaner Element Cover [B]

PERIODIC MAINTENANCE 2-47

Discard the air cleaner element [A].

•

2-48 PERIODIC MAINTENANCE

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Maintenance Procedure

Install a new element [A] so that the element ends [B]

•

insert along the rib [C] in the housing.

CAUTION

Use only the recommended air cleaner element (Kawasaki part number 11013-0004). Using another air cleaner element will wear the engine prematurely or lower the engine performance.

Tighten:

•

Torque - Air Cleaner Element Cover Screws: 1.1 N·m (0.11

kgf·m, 9.7 in·lb)

Fuel Hose Replacement

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

•

System (DFI) chapter). Be sure to place a piece of cloth [A] around the fuel hose

•

joint. Insert a minus screw driver [B] into the slit [C] on the joint

•

lock.

Turn [A] the driver to disconnect the joint lock [B].

•

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

•

WARNING

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.

Install the new fuel hose so that the white mark [A] side

•

faces throttle body assy. Insert [B] the fuel hose joint [C] straight onto the delivery

•

pipe until the hose joint clicks. Push [D] the joint lock [E].

•

Maintenance Procedure

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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.

WARNING

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

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

•

Routing section in the Appendix chapter). Install the removed parts (see appropriate chapters).

•

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.

PERIODIC MAINTENANCE 2-49

Remove:

•

Right Upper Inner Fairing (see Upper Inner Fairing Re-

moval in the Frame chapter)

Radiator Cap [A] Remove the radiator cap 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.

Remove the left middle fairing (see Middle Fairing Re-

•

moval in the Frame chapter). Place a containers under the drain bolts [A] [B] of the wa-

•

ter pump cover and cylinder. Drain the coolant from the radiator and engine by remov-

•

ing the drain bolts.

2-50 PERIODIC MAINTENANCE

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Maintenance Procedure

Remove:

•

Bolts [A] Coolant Reserve Tank [B]

Remove the cap [C] and pour the coolant into a container.

•

Install the coolant reserve tank.

•

Torque - Coolant Reserve Tank Mounting Bolts: 7.0 N·m

(0.71 kgf·m, 62 in·lb)

Tighten the drain bolts.

•

Replace the drain bolt gasket with a new one.

Torque - Coolant Drain Bolt (Water Pump): 10 N·m (1.0

kgf·m, 89 in·lb)

Coolant Drain Bolt (Cylinder): 10 N·m (1.0 kgf·m,

89 in·lb)

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

•

coolant, and install the radiator cap.

NOTE

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

○

from the engine and radiator.

Fill the reserve tank up to the full level line with coolant,

•

and install the cap.

CAUTION

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

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%

Coolant: 50%

Freezing Point:

Total Amount:

–35°C (–31°F)

2.6 L (2.7 US qt)

NOTE

Choose a suitable mixture ratio by referring to the

○

coolant manufacturer’s directions.

Maintenance Procedure

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Bleed the air from the cooling system as follows.

•

Start the engine with the radiator cap removed and run it

○

until no more air bubbles [A] can be seen in the coolant. Tap the radiator hoses to force any air bubbles caught

○

inside. Stop the engine and add coolant up to the radiator filler

○

neck. Install the radiator cap.

•

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 low level line, add coolant to the full level line.

CAUTION

Do not add more coolant above the full level line.

PERIODIC MAINTENANCE 2-51

2-52 PERIODIC MAINTENANCE

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Maintenance Procedure

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

•

Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body Assembly (see Throttle Body Assembly Removal in the Fuel System (DFI) chapter) Thermostat Housing [A] (see Thermostat Housing Removal in the Cooling System chapter) Oil Cooler [B] (see Oil Cooler Removal in the Engine Lubrication System chapter) Water Pump [C] (see Water Pump Removal in the Cooling System chapter) Fitting [D] Hoses [E] O-rings [F]

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

•

Instal the new hoses and tighten the clamps securely.

•

Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

18 in·lb)

Fill the coolant (see Coolant Change).

•

Check the cooling system for leaks.

•

Maintenance Procedure

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Engine Oil Change

Situate the motorcycle so that it is vertical after warming

•

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

•

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

○

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

•

Torque - Engine Oil Drain Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)

Remove the oil filler plug [A].

•

PERIODIC MAINTENANCE 2-53

Pour in the specified type and amount of oil.

•

Recommended E ngine Oil

Typ e :

Viscosity:

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

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.

Replace the O-ring of the oil filler plug with a new one.

•

Apply engine oil to the new O-ring.

•

Install the oil filler plug.

•

Torque - Oil Filler Plug: Hand-tighten

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change).

•

Remove the lower fairings (see Lower Fairing Removal in

•

the Frame chapter). Remove the oil filter [A] with the oil filter wrench [B].

•

Special Tool - Oil Filter Wrench: 57001-1249

API SE, SF or SG

API SH, SJ or SL with JASO MA

SAE 10W-40

3.7 L (3.9 US qt) (when filter is removed)

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

NOTE

2-54 PERIODIC MAINTENANCE

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Maintenance Procedure

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 kg f·m, 2 3 ft·lb)

NOTE

Hand tightening of the oil filter can not be allowed since

○

it does not reach to this tightening torque.

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

•

Oil Change).

Brake Hose and Pipe Replacement

CAUTION

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

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

•

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

•

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

•

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

•

Replace them with new ones when installing. Tighten:

•

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

ft·lb)

When installing the hose [A], 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.

Maintenance Procedure

www.zxforums.com

Level the brake fluid reservoir.

•

Remove the reservoir cap.

•

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

•

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

•

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

•

Change the brake fluid.

•

Repeat this operation until fresh brake fluid comes out

○

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

1. Open the bleed valve [A].

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

3. Close the bleed valve [C].

4. Release the brake [D].

NOTE

The fluid level must be checked often during the chang-

○

ing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line. Front Brake: Repeat the above steps for the other

○

caliper.

PERIODIC MAINTENANCE 2-55

Follow the procedure below to install the front/rear brake

•

fluid reservoir cap correctly. First, tighten the front/rear brake fluid reservoir cap [B]

○

clockwise [C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].

Tighten:

•

Torque - Front Brake Reservoir Cap Stopper Screw: 1.2

N·m (0.12 kgf·m, 11 in·lb)

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.

2-56 PERIODIC MAINTENANCE

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Maintenance Procedure

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

Remove the front master cylinder (see Front Master Cylin-

•

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

•

O-ring [D].

Special Tool - Inside Circlip Pliers: 57001-143

Unscrew the locknut [E] and pivot bolt [F], and remove the

•

brake lever. Remove the circlip [G].

•

Pull out the piston assembly [H].

•

Replace:

•

Seal Cover [A] Circlip [B] O-ring [D] Circlip [G] Piston Assembly [H] Diaphragm [I]

Rear Master Cylinder Disassembly

Remove the rear master cylinder (see Rear Master Cylin-

•

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

•

Special Tool - Inside Circlip Pliers: 57001-143

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

•

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

•

CAUTION

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

Replace:

•

Circlip [A] O-ring [C] Circlip [E] Push Rod Assembly [F] Piston Assembly [G] Diaphragm [H]

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.

Maintenance Procedure

www.zxforums.com

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. Tighten the brake lever pivot bolt and the nut.

•

Silicone Grease -

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

in·lb)

Brake Lever Pivot Bolt Nut: 5.9 N·m (0.60 kgf·m,

52 in·lb)

Front Brake Light Switch Screw: 1.2 N·m (0.12

kgf·m, 11 in·lb)

Caliper Rubber Parts Replacement

Front Caliper Disassembly

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

•

and tighten them loosely. Remove:

•

Front Caliper (see Front Caliper Removal in the Brakes

chapter) [C]

Brake Pad

Front Caliper Assembly Bolts

O-rings

Brake Lever Pivot Bolt

PERIODIC MAINTENANCE 2-57

Using compressed air, remove the pistons. One way to

•

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

○

than 10 mm (0.4 in.) thick on the caliper half, and fasten them together with a suitable bolt and nut as shown. Leave one of the oil passages [C] open. Lightly apply compressed air [D] to the oil passage until

○

the pistons hit the rubber gasket. Block the hose joint opening [E] during this operation if the caliper half has the opening.

Bolt and Nut [F]

Oil Passage Sealed by Rubber Gasket [G]

Push down [H].

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].

•

Repeat the previous step to remove the pistons from the

•

other side of the caliper body.

2-58 PERIODIC MAINTENANCE

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Maintenance Procedure

NOTE

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

○

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

○

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

○

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

○

cylinders, and then disassemble the caliper.

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, 6 9 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 seals [B] with new ones if they are dam-

•

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

○

the cylinders by hand.

Replace the O-ring [A].

•

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

•

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

•

Tighten:

•

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

16 ft·lb)

Install the pads (see Front Brake Pad Installation in the

•

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

•

cloth.

Maintenance Procedure

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Rear Caliper Disassembly

Remove the rear caliper (see Rear Caliper Removal in

•

the Brakes chapter). Remove the pads and pad spring (see Rear Brake Pad

•

Removal in the Brakes chapter). Using compressed air, remove the piston.

•

Cover the caliper opening with a clean, heavy cloth [A].

○

Remove the piston by lightly applying compressed air [B]

○

to where the brake line fits into the caliper.

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.

•

PERIODIC MAINTENANCE 2-59

NOTE

If compressed air is not available, do as follows with the

○

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

○

work above it. Remove the pads and pad spring (see Rear Brake Pad

○

Removal in the Brakes chapter). Pump the brake pedal to remove the caliper piston.

○

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)

Replace the fluid s eal [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.

•

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

○

cylinder by hand.

2-60 PERIODIC MAINTENANCE

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Maintenance Procedure

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 boot

•

[B]. 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 pad spring [A] in the caliper as shown.

•

Install the pads (see Rear Brake Pad Installation in the

•

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

•

cloth.

Spark Plug Replacement

Remove:

•

Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chapter)

Remove the spark plug using the 16 mm (0.63 in.) plug

•

wrench [A] vertically.

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

Replace the spark plug with a new one.

•

Standard Spark Plug

Type: NG K CR9EIA-9

Insert new spark plug in the plug hole, and finger-tighten

•

it first. Using the plug wrench [A] vertically, tighten the plug.

•

CAUTION

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

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

Install the stick coils securely.

•

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

○

FUEL SYSTEM (DFI) 3-1

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Fuel System (DFI)

Table of Contents

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

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

Specifications ......................................................................................................................... 3-12

Special Tools and Sealant ...................................................................................................... 3-14

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

DFI System............................................................................................................................. 3-18

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

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

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

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

Inquiries to Rider.................................................................................................................. 3-30

DFI System Troubleshooting Guide ....................................................................................... 3-33

Self-Diagnosis ........................................................................................................................ 3-41

Self-diagnosis Outline .......................................................................................................... 3-41

Self-diagnosis Procedures ................................................................................................... 3-42

Service Code Reading ...................................................................................................... 3-45

Service Code Erasing ....................................................................................................... 3-45

Backups............................................................................................................................... 3-47

Main Throttle Sensor (Service Code 11) ................................................................................ 3-50

Main Throttle Sensor Removal/Adjustment ...................................................................... 3-50

Input Voltage Inspection.................................................................................................... 3-50

Output Voltage Inspection................................................................................................. 3-52

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

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-56

Removal............................................................................................................................ 3-56

Installation......................................................................................................................... 3-56

Input Voltage Inspection.................................................................................................... 3-56

Output Voltage Inspection................................................................................................. 3-57

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-61

Removal/Installation.......................................................................................................... 3-61

Output Voltage Inspection................................................................................................. 3-61

Sensor Resistance Inspection .......................................................................................... 3-62

Water Temperature Sensor (Service Code 14) ...................................................................... 3-64

Removal/Installation.......................................................................................................... 3-64

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

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

Atmospheric Pressure Sensor (Service C ode 15).................................................................. 3-66

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

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

Input Voltage Inspection.................................................................................................... 3-66

Output Voltage Inspection................................................................................................. 3-67

Crankshaft Sensor (Service Code 21).................................................................................... 3-70

Crankshaft Sensor Removal/Installation........................................................................... 3-70

Crankshaft Sensor Inspection........................................................................................... 3-70

Camshaft Position Sensor (Service Code 23) ........................................................................ 3-71

Camshaft Position Sensor Removal/Installation ............................................................... 3-71

Camshaft Position Sensor Inspection ............................................................................... 3-71

Speed Sensor (Service Code 24)........................................................................................... 3-72

Speed Sensor Removal/Installation.................................................................................. 3-72

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

3

3-2 FUEL SYSTEM (DFI)

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Output Voltage Inspection................................................................................................. 3-73

Gear Position Switch (Service Code 25) ................................................................................ 3-75

Gear Position Switch Removal/Installation ....................................................................... 3-75

Gear Position Switch Inspection ....................................................................................... 3-75

Input Voltage Inspection.................................................................................................... 3-75

Vehicle-down Sensor (Service Code 31)................................................................................ 3-77

Removal............................................................................................................................ 3-77

Installation......................................................................................................................... 3-77

Inspection.......................................................................................................................... 3-77

Subthrottle Sensor (Service Code 32).................................................................................... 3-80

Subthrottle Sensor Removal/Adjustment .......................................................................... 3-80

Input Voltage Inspection.................................................................................................... 3-80

Output Voltage Inspection................................................................................................. 3-81

Resistance Inspection....................................................................................................... 3-83

Oxygen Sensor #1-not activated (Service Code 33) - Europe Models................................... 3-84

Oxygen Sensor #1 Removal/Installation........................................................................... 3-84

Oxygen Sensor #1 Inspection........................................................................................... 3-84

Exhaust Butterfly Valve Actuator Sensor (Service Code 34).................................................. 3-87

Exhaust Butterfly Valve Actuator Sensor Inspection......................................................... 3-87

Immobilizer Amplifier (Service Code 35) ................................................................................ 3-88

Antenna Resistance Inspection ........................................................................................ 3-88

Amplifier Input Voltage Inspection..................................................................................... 3-88

Blank Key Detection (Service Code 36) ................................................................................. 3-89

User Key Inspection.......................................................................................................... 3-89

Fuel Pump Relay (Service Code 46) ...................................................................................... 3-90

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

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

Stick C oils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) ...................................................... 3-91

Removal/Installation.......................................................................................................... 3-91

Input Voltage Inspection.................................................................................................... 3-91

Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-93

Subthrottle Valve Actuator Removal ................................................................................. 3-93

Subthrottle Valve Actuator Inspection ............................................................................... 3-93

Resistance Inspection....................................................................................................... 3-93

Input Voltage Inspection.................................................................................................... 3-94

Exhaust Butterfly Valve Actuator (Service Code 63) .............................................................. 3-96

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

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

Exhaust Butterfly Valve Actuator Inspection ..................................................................... 3-97

Output Voltage Inspection................................................................................................. 3-98

Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Europe Models ......................... 3-99

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

Oxygen Sensor Heaters Inspection ................................................................................. 3-99

ECU M ain Relay (Service Code 75) ....................................................................................... 3-102

ECU Main Relay Inspection .............................................................................................. 3-102

Oxygen Sensor #2-not activated (Service Code 83) - Europe Models................................... 3-103

Oxygen Sensor #2 Removal/Installation........................................................................... 3-103

Oxygen Sensor #2 Inspection........................................................................................... 3-103

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

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

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

ECU Installation ................................................................................................................ 3-107

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

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

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

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

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

FUEL SYSTEM (DFI) 3-3

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Warning Indicator Light (LED) ................................................................................................ 3-111

Light (LED) Inspection ...................................................................................................... 3-111

Fuel Line................................................................................................................................. 3-112

Fuel Pressure Inspection .................................................................................................. 3-112

Fuel Flow Rate Inspection ................................................................................................ 3-113

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

Fuel Pump Removal ......................................................................................................... 3-115

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

Operation Inspection......................................................................................................... 3-116

Operating Voltage Inspection............................................................................................ 3-116

Fuel Injectors.......................................................................................................................... 3-118

Removal/Installation.......................................................................................................... 3-118

Power Source Voltage Inspection ..................................................................................... 3-118

Output Voltage Inspection................................................................................................. 3-119

Audible Inspection............................................................................................................. 3-120

Injector Signal Test............................................................................................................ 3-121

Injector Resistance Inspection .......................................................................................... 3-121

Injector Unit Test ............................................................................................................... 3-122

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

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

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

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

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

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

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

Idle Speed Inspection ....................................................................................................... 3-125

Throttle Bore Cleaning ...................................................................................................... 3-125

Synchronization Inspection............................................................................................... 3-125

Synchronization Adjustment ............................................................................................. 3-125

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

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

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

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

Air Line ................................................................................................................................... 3-131

Element Removal.............................................................................................................. 3-131

Element Installation........................................................................................................... 3-131

Air Cleaner Element Inspection ........................................................................................ 3-131

Air Cleaner Housing Removal........................................................................................... 3-131

Air Cleaner Housing Installation........................................................................................ 3-132

Air Cleaner Housing Disassembly .................................................................................... 3-133

Air Cleaner Housing Assembly ......................................................................................... 3-133

Oil Draining ....................................................................................................................... 3-133

Air Inlet Duct Removal ...................................................................................................... 3-134

Air Inlet Duct Installation ................................................................................................... 3-134

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

Fuel Tank Removal ........................................................................................................... 3-135

Fuel Tank Installation ........................................................................................................ 3-137

Fuel Tank and Cap Inspection .......................................................................................... 3-138

Fuel Tank Cleaning ........................................................................................................... 3-138

Evaporative Emission Control System ................................................................................... 3-139

Parts R emoval/Installation ................................................................................................ 3-139

Hose Inspection ................................................................................................................ 3-139

Separator Inspection......................................................................................................... 3-139

Separator Operation Test.................................................................................................. 3-140

Canister Inspection ........................................................................................................... 3-140

3-4 FUEL SYSTEM (DFI)

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Exploded View

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FUEL SYSTEM (DFI) 3-5

No. Fastener

1

Air Cleaner Housing Holder Clamp Screws

2 Air Cleaner Element Cover Screws 1.1 0.11 9.7 in·lb

3 Air Inlet Duct Mounting Bolts 7.0 0.71 62 in·lb L

4

Air Cleaner Housing Mounting Bolts

5. Air Cleaner Element

6. Air Inlet Duct

7. Air Switching Valve L: Apply a non-permanent locking agent.

LG: Apply liquid gasket (Kawasaki Bond: 92104-0002).

WL: Apply a soap and water solution.

N·m kgf·m ft·lb

2.0 0.20 18 in·lb

7.0 0.71 62 in·lb

Torque

Remarks

3-6 FUEL SYSTEM (DFI)

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Exploded View

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FUEL SYSTEM (DFI) 3-7

No. Fastener

1

Speed Sensor Bolt

2 Crankshaft Sensor Bolts 6.0 0.61 53 in·lb L

3 Gear Position Switch Screws 3.0 0.31 27 in·lb L

4 Camshaft Position Sensor Bolt 10 1.0 89 in·lb

5 Vehicle-down Sensor Bolts 6.0 0.61 53 in·lb

6 Water Temperature Sensor 25 2.5 18 SS

7

Throttle Body Assy Holder Clamp Bolts

8 Throttle Body Assy Holder Bolts 10 1.0 89 in·lb S

9 Inlet Air Pressure Sensor Bracket Screws 3.5 0.36 31 in·lb

10 Delivery Pipe Mounting Screws 5.0 0.51 44 in·lb

11 Bypass Screws 0.2 0.02 17 in·lb

12. Atmospheric Pressure Sensor

13. Inlet Air Pressure Sensor

14. Main Throttle Valve Sensor

15. Fuel Injectors

16. Subthrottle Valve Actuator

17. Subthrottle Valve Sensor

18. Throttle Cable (Accelerator)

19. Throttle Cable (Decelerator)

20. Relay Box

21. ECU

22. Stick Coils

CL: Apply cable lubricant.

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).

N·m kgf·m ft·lb

10 1.0 89 in·lb

2.0 0.20 18 in·lb

Torque

Remarks

S

3-8 FUEL SYSTEM (DFI)

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Exploded View

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FUEL SYSTEM (DFI) 3-9

No. Fastener

1

Exhaust Butterfly Valve Actuator Mounting Bolts

2 Exhaust Butterfly Valve Actuator Pulley Bolt 5.0 0.50 44 in·lb

3 Fuel Pump Bolts 10 1.0 89 in·lb L, S

4 Canister Bracket Mounting Bolt (M5) 4.3 0.44 38 in·lb

5 Canister Bracket Mounting Screws (M5) 4.3 0.44 38 in·lb

6 Separator Bracket Mounting Bolts 7.0 0.71 62 in·lb

7

Separator/Canister Hose Clamp Bolt

8Canister

9 Separator 10 Fitting 11 Red H o s e 12 Blue Hose 13 Green Hose 14 White Hose

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

N·m kgf·m ft·lb

0.8 0.08 7in·lb

7.0 0.71 62 in·lb

Torque

Remarks

3-10 FUEL SYSTEM (DFI)

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DFI System

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1. ECU

2. Crankshaft Sensor

3. Camshaft Position Sensor

4. Main Throttle Sensor

5. Subthrottle Sensor

6. Subthrottle Valve Actuator

7. Inlet Air Pressure Sensor

8. Atmospheric Pressure Sensor

9. Water Temperature Sensor

10. Inlet Air Temperature Sensor

11. Gear Position Switch

12. Vehicle-down Sensor

13. Fuel Injectors

14. Delivery Pipe

15. Pressure Regulator

16. Fuel Pump

17. Fuel Filter

18. Speed Sensor

19. Exhaust Butterfly Valve Actuator

20. Oxygen Sensors (Europe Models)

21. Battery 12 V 10 Ah

22. Air Flow

23. Fuel Flow

FUEL SYSTEM (DFI) 3-11

3-12 FUEL SYSTEM (DFI)

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Specifications

Item Standard

Digital Fuel Injection System

Idle Speed 1 100 ±50 r/min (rpm)

Throttle Assy:

Type Four barrel type

Bore

Throttle Body Vacuum 31.5 ±1.3 kPa (236 ±10 mmHg)

Bypass Screws –––

ECU:

Make Mitsubishi Electric

Type

Usable Engine Speed 100 ∼ 12 987 r/min (rpm)

Fuel Pressure (high pressure line):

Right after Ignition Switch ON, with fuel pump running for 4 seconds with engine idling

Fuel Pump:

Type In-tank pump (in fuel tank), or Wesco pump (friction pump)

Discharge 72 mL (2.43 US oz.) or more for 4 seconds

Fuel Injectors:

Type INP-286

Nozzle Type One spray type with 10 holes

Resistance About 11.7 ∼ 12.3 Ω at 20°C (68°F)

Main Throttle Sensor: Non-adjustable and non-removable

Input Voltage DC 4.75 ∼ 5.25 V between BL and BR/BK leads Output Voltage DC 0.65 ∼ 3.90 V between Y/W and BR/BK leads (at idle

Resistance 4 ∼ 6kΩ

Inlet Air Pressure Sensor/Atmospheric Pressure Sensor:

Input Voltage DC 4.75 ∼ 5.25 V between BL and BR/BK leads Output Voltage DC 3.80 ∼ 4.20 V at standard atmospheric pressure (see

Inlet Air Temperature Sensor:

Resistance

Output Voltage at ECU About 2.25 ∼ 2.50 V at 20°C (68°F)

Water Temperature Sensor:

Resistance see Electrical System chapter

Output Voltage at ECU About 2.80 ∼ 2.97 V at 20°C (68°F)

Speed Sensor:

Input Voltage at Sensor DC 4.75 ∼ 5.25 V between BL and BR/BK leads Output Voltage at Sensor About DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.9 at Ignition Switch

43 mm (1.7 in.)

Digital memory type, with built in IC igniter, sealed with resin

304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

280 kPa (2.9 kgf/cm², 41 psi) with fuel pump stopped

304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

throttle opening to full throttle opening)

this text for details)

2.09 ∼ 2.81 kΩ at 20°C (68°F)

About 0.322 kΩ at 80°C (176°F) (reference value)

ONand0km/h

FUEL SYSTEM (DFI) 3-13

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Specifications

Item Standard

Vehicle-down sensor:

Detection Method Magnetic flux detection method

Detection Angle More than 60 ∼ 70° for each bank Output Voltage with sensor arrow mark pointed up: 3.55 ∼ 4.45 V

with sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V

Subthrottle Sensor: Non-adjustable and non-removal

Input Voltage DC 4.75 ∼ 5.25 V between BL and BR/BK leads Output Voltage DC 0.77 ∼ 4.22 V between BL/W and BR/BK leads (at idle

throttle opening to full throttle opening)

Resistance 4 ∼ 6kΩ

Exhaust Butterfly Valve Actuator Sensor:

Resistance 4 ∼ 6kΩ

Immobilizer Antenna:

Resistance About 0.6 ∼ 0.9 Ω

Exhaust Butterfly Valve Actuator:

Output Voltage 3.46 ∼ 3.76 V

Subthrottle Valve Actuator:

Resistance About 5 ∼ 7 Ω

Input Voltage

Oxygen Sensors (Europe Models):

Output Voltage (Rich) 0.45 ∼ 2.5 V Output Voltage (Lean) 0.05 ∼ 0.45 V

Heater Resistance About 8 Ω at 20°C (68°F)

Throttle Grip and Cables

Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

About DC 10.5 ∼ 12.5 V

3-14 FUEL SYSTEM (DFI)

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Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Fork Oil Level Gauge: 57001-1290

Vacuum Gauge: 57001-1369

Peak Voltage Adapter: 57001-1415

Needle Adapter Set: 57001-1457

Throttle Sensor Setting Adapter: 57001-1538

Hand Tester: 57001-1394

Throttle Sensor Setting Adapter #1: 57001-1400

Sensor Harness Adapter: 57001-1561

Extension Tube: 57001-1578

Special Tools and Sealant

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FUEL SYSTEM (DFI) 3-15

Fuel Pressure Gauge Adapter: 57001-1593

Fuel Hose: 57001-1607

Speed Sensor Measuring Adapter: 57001-1667

Kawasaki Bond (Silicone Sealant): 56019-120

Kawasaki Bond (Liquid Gasket - Black): 92104-0002

Kawasaki Bond (Silicone Sealant): 92104-0004

3-16 FUEL SYSTEM (DFI)

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DFI Parts Location

Main Throttle Sensor [A] Subthrottle Sensor [B] Subthrottle Valve Actuator [C] Inlet Air Pressure Sensor [D] Stick Coils #1, #2, #3, #4 [E]

Water Temperature Sensor [A] Fuel Injectors #1, #2, #3, #4 [B]

Battery [A] Relay Box (Fuel Pump Relay) [B] Immobilizer/Kawasaki Diagnostic System Connector [C] ECU [D]

Exhaust Butterfly Valve Actuator [A] Atmospheric Pressure Sensor [B] Vehicle-down Sensor [C] Fuse Box (ECU Fuse 15 A, Oxygen Sensor Heater Fuse 10 A) [D]

Inlet Air Temperature Sensor [A]

DFI Parts Location

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Camshaft Position Sensor [A] Crankshaft Sensor [B]

Speed Sensor [A] Gear Position Switch [B]

FUEL SYSTEM (DFI) 3-17

Ignition Key [A] (Transponder, Immobilizer Models) Ignition Switch [B] Immobilizer Antenna [C] (Immobilizer Models) Immobilizer Amplifier [D] (Immobilizer Models)

Oxygen Sensor #1 [A] (Europe Models) Oxygen Sensor #2 [B] (Europe Models)

3-18 FUEL SYSTEM (DFI)

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DFI System

Kawasaki ZX-10R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF ABBREVIATIONS

COUNTRY AND AREA CODES

EMISSION CONTROL INFORMATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Foreword

General Information

Battery Ground

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Non-permanent Locking Agent

Press

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

Lubrication

Direction of Engine Rotation

Electrical Wires

Instrument

ZX1000D6F (Europe) Left Side View

ZX1000D6F (Europe) Right Side View

ZX1000D6F (United States and Canada) Left Side View

ZX1000D6F (United States and Canada) Right Side View

Frame Number Engine Number

Prefixes for Units

Units of Mass

Units of Volume

Units of Length

Units of Torque

Units of Pressure

Units of S peed

Units of F orce

Units of Temperature

Units of Power

Periodic Maintenance

Periodic Inspection

Periodic Replacement Parts

Basic Torque for General Fasteners

Fuel System (DFI)

Throttle Control System Inspection

Throttle Grip Free Play

Engine Vacuum Synchronization Inspection

Throttle Body Vacuum

Main Throttle Sensor Output Voltage

Idle Speed Inspection

Idle Speed

Idle Speed Adjustment

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

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Cooling System

Coolant Level Inspection

Engine Top End

Valve Clearance Inspection

Valve Clearance

Valve Clearance Adjustment

Example:

Adjustment Shims

Air Suction System

Air Suction System Damage Inspection

Clutch

Clutch Operation Inspection

Clutch Lever Free Play

Wheels/Tires

Air Pressure Inspection

Air Pressure (when Cold)

Wheel/Tire Damage Inspection