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

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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