Kawasaki ZX6R 636 Service Manual Service_05

Ninja ZX-6R

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

This quick reference guide will assist
you in locating a desired topic or pro­cedure.

•Bend the pages back to match the
black tab of the desired chapter num­ber with the black tab on the edge at
each table of contents page.

•Refer to the sectional table of contents
for the exact pages to locate the spe­cific topic required.

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

Ninja ZX-6R

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 Assurance Department/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.

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

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

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

© 2004 Kawasaki Heavy Industries, Ltd. First Edition (1): Sep. 30, 2004 (M)

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center

AC

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 farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h

L

alternating current min

hour(s) Ω ohm(s)

liter(s)

m

N

meter(s)

minute(s)

newton(s)

Read OW

NER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emis­sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi­tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.

1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors

are routed through an oil separator to the 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 canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.

“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.

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

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

NOTE

The phrase “remo ve or render inoperative any 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 of 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 p arts or accessories which adversely affect the performance

or durability of the motorcycle.

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

dards.

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

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,

THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10
000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the 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

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

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

For the duration of the warranty period,

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

To get the longest life out of your vehicle.

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Special Tool Catalog or Manual. Genuine

parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

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

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

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

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

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient 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 inspec­tion in the procedural step or sub-step it fol­lows.

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

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

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

1

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following.

Battery Ground

Before completing any service on the motorcycle, discon­nect the battery 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

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

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

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 i nner and outer race and result in bearing damage.

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

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

Circlips, Cotter Pins

Replace 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

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 Wire s

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

Model Identification

ZX636-C1 (Europe) Left Side View

GENERAL INFORMATION 1-7

ZX636-C1 (Europe) Right Side View

1-8 GENERAL INFORMATION

Model Identification

ZX636-C1 (US and Canada) Left Side View

ZX636-C1 (US and Canada) Right Side View

GENERAL INFORMATION 1-9

General Specifications

Items ZX636-C1 (Ninja ZX-6R)

Dimensions

Overall Length 2 065 mm (81.3 in.)

Overall Width 715 mm (28.1 in.)

Overall Height 1 110 mm (43.7 in.)

Wheelbase 1 390 mm (54.7 in.)

Road Clearance 120 mm (4.7 in.)

Seat Height 820 mm (32.3 in.)

Dry Mass

Curb Mass:

Front

Rear 97 kg (214 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 68.0 × 43.8 mm (2.7 × 1.7 in.)

Displacement 636 mL (38.8 cu in.)

Compression Ratio 12.9 : 1

Maximum Horsepower 95.5 kW (130 PS) @14 000 r/min (rpm),

Maximum Torque 70.5 N·m (7.1 kgf·m, 52 ft·lb) @11 500 r/min (rpm),

Carburetion System FI (Fuel injection)

Starting System

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (digital igniter in ECU)

Ignition Timing From 12.5° BTDC @1 300 r/min (rpm) to 35° BTDC @4 600 r/min

Spark Plug NGK CR9E

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

Firing Order

Valve Timing:

Inlet:

Open 59° BTDC

Close 81° ABDC

Duration 320°

Exhaust:

Open 61° BBDC

Close 31° ATDC

164 kg (362 lb)

95 kg (209 lb)

4-stroke, DOHC, 4-cylinder

(FR) 78.2 kW (106 PS) @13 000 r/min (rpm),
(MY) 90.8 kW (123 PS) @12 500 r/min (rpm),
(CA), (CAL), (US) – – –

(FR) 63 N·m (6.4 kgf·m, 46 ft·lb) @11 500 r/min (rpm),
(CA), (CAL), (US) – – –

Primary: KEIHIN TTK 38 × 4
Secondary: KEIHIN Multihole (3 holes) × 4

Electric starter

(rpm)

1-2-4-3

1-10 GENERAL INFORMATION

General Specifications

Items ZX636-C1 (Ninja ZX-6R)

Duration 272°

Lubrication System Forced lubrication (wet sump with cooler)

Engine Oil:

Type API SE, SF or SG

API SH or SJ with JASO MA

Viscosity

Capacity 4.0 L (4.2 US qt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 1.891 (87/46)

Clutch Type

Transmission:

Type 6-speed, constant mesh, return shift

Gear Ratios:

1st 2.923 (38/13)

2nd 2.055 (37/18)

3rd

4th

5th

6th 1.153 (30/26)

Final Drive System:

Type Chain drive

Reduction Ratio 2.866 (43/15)

Overall Drive Ratio 6.255 @Top gear

Frame

Type Tubular, diamond

Caster (Rake Angle) 25°

Trail 106 mm (4.2 in.)

Front Tire:

Type Tubeless

Size 120/65 ZR17 M/

Rear Tire:

Type Tubeless

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

Front Suspension:

Type Telescopic fork (upside-down)

Wheel Travel 120 mm (4.7 in.)

Rear Suspension:

Type Swingarm (uni-trak)

Wheel Travel 135 mm (5.3 in.)

Brake Type:

Front Dual discs

Rear

SAE10W-40

Wet multi disc

1.666 (35/21)

1.450 (29/20)

1.272 (28/22)

C(56W)

Single disc

GENERAL INFORMATION 1-11

General Specifications

Items ZX636-C1 (Ninja ZX-6R)

Electrical Equipment

Battery 12 V 8 Ah

Headlight:

Type Semi-sealed beam

Bulb:

High 12 V 55 W (quartz-halogen) × 2

Low 12 V 55 W (quartz-halogen)

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

Alternator:

Type

Rated Output 22.5 A/14 V @5 000 r/min (rpm)

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

CA: Canada Model

CAL: California Model

FR: France Model
MY: M alaysia Model
US: United States Model

Three-phase AC

1-12 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units

Prefix Symbol

mega M × 1 000 000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Power

Units of Mass

kg × 2.205 = lb

g × 0.03527 = oz

Units of Volume

L × 0.2642 = gal (US)

L × 0.2200 = gal (imp)

L × 1.057 = qt (US)

L × 0.8799 = qt (imp)

L×2.113=

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (imp)

mL × 0.06102 = cu in

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 = ft·lb

N·m × 8.851 = in·lb

kgf·m × 9.807 = N ·m

kgf·m × 7.233 = ft·lb

kgf·m × 86.80 = in·lb

Units of Pressure

kPa × 0.01020 = kgf/cm²

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cmHg × 1.333 = kPa

Units of Speed

km/h

× 0.6214 = mph

Units of Force

N × 0.1020 = kg

N × 0.2248 = lb

kg × 9.807 = N

kg × 2.205 = lb

Units of Temperature

Units of Power

kW × 1.360 = PS

kW × 1.341 = HP

PS

PS × 0.9863 = HP

× 0.7355 = kW

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart (United States, Canada Model) ................................................. 2-3

Periodic Maintenance Chart (Other than United States, Canada Model)............................... 2-6

Torque and Locking Agent...................................................................................................... 2-9

Specifications ......................................................................................................................... 2-15

Special Tools .......................................................................................................................... 2-17

Maintenance Procedure ......................................................................................................... 2-18

Fuel System (DFI)................................................................................................................ 2-18

Throttle Control System Inspection................................................................................... 2-18

Engine Vacuum Synchronization Inspection..................................................................... 2-18

Idle Speed Inspection ....................................................................................................... 2-22

Idle Speed Adjustment...................................................................................................... 2-22

Fuel Hose Damage and Installation Condition Inspection ................................................ 2-22

Evaporative Emission Control System (California Model) ................................................... 2-23

Evaporative Emission Control System Inspection ............................................................ 2-23

Cooling System.................................................................................................................... 2-24

Coolant Level Inspection................................................................................................... 2-24

Radiator Hose Damage and Installation Condition Inspection.......................................... 2-24

Engine Top End ................................................................................................................... 2-25

Valve Clearance Inspection .............................................................................................. 2-25

Valve Clearance Adjustment............................................................................................. 2-26

Air Suction System .............................................................................................................. 2-29

Air Suction System Damage Inspection............................................................................ 2-29

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

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

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

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

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

Tire Tread Wear Inspection .............................................................................................. 2-30

Wheel Bearing Damage Inspection .................................................................................. 2-31

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

Drive Chain Lubrication Condition Inspection ................................................................... 2-32

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

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

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

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

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

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

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-35

Brake Hose Damage and Installation Condition Inspection.............................................. 2-35

Brake Operation Inspection .............................................................................................. 2-35

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

Brake Pad Wear Inspection .............................................................................................. 2-36

Brake Light Switch Operation Inspection .......................................................................... 2-36

Suspensions ........................................................................................................................ 2-37

Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-37

Front Fork Oil Leak Inspection .......................................................................................... 2-38

2

2-2 PERIODIC MAINTENANCE

Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-38

Rocker Arm Operation Inspection..................................................................................... 2-38

Tie-Rod Operation Inspection ........................................................................................... 2-38

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

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

Steering Play Adjustment.................................................................................................. 2-39

Steering Stem Bearing Lubrication ................................................................................... 2-40

Electrical System ................................................................................................................. 2-40

Spark Plug Clean and G ap Inspection.............................................................................. 2-40

Lights and Switches Operation Inspection........................................................................ 2-42

Headlight Aiming Inspection ............................................................................................. 2-44

Side Stand Switch Operation Inspection........................................................................... 2-45

Engine Stop Switch Operation Inspection......................................................................... 2-46

Others.................................................................................................................................. 2-47

Chassis Parts Lubrication ................................................................................................ 2-47

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-48

Replacement Parts .............................................................................................................. 2-50

Air Cleaner Element Replacement.................................................................................... 2-50

Fuel Hose Replacement ................................................................................................... 2-50

Coolant Change ................................................................................................................ 2-52

Radiator Hose and O-ring Replacement ........................................................................... 2-54

Engine Oil Change............................................................................................................ 2-55

Oil Filter Replacement ...................................................................................................... 2-55

Brake Hose and Pipe Replacement .................................................................................. 2-56

Brake Fluid Change .......................................................................................................... 2-56

Master Cylinder Rubber Parts Replacement .................................................................... 2-58

Caliper Rubber Parts Replacement .................................................................................. 2-59

Spark Plug Replacement .................................................................................................. 2-62

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart (United States, Canada Model)

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

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

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Fuel System

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

year

• • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-18

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

year

year

• • •

• • • •

• • • •

• • • •

• • • •

• • • • • • •

• • • •

• • • •

• • • •

• • • •

•

2-18

2-22

2-22

2-22

2-22

2-23

2-24

2-24

2-24

2-24

2-25

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) 2-32

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

Drive chain wear-inspect #

Drive chain guide wear-inspect

• • • •

• • •

• • •

• • •

• • •

• • •

• • •

• • •

2-29

2-29

2-30

2-30

2-30

2-31

2-34

2-35

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart (United States, Canada Model)

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

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 6months

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

year

year

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • • • • •

• • •

• • •

See

Page

2-35

2-35

2-36

2-35

2-36

2-35

2-36

2-37

2-38

Rocker arm operatio

Tie-Rods operation-inspect

Steering System

Steering play-inspect year

Steering stem bearings-lubricate 2 years

Electrical System

Spark plug c ondition – inspect

Lights and switches operation-inspect year

Headlight aiming-inspect year

Side stand switch operation-inspect

Engine stop switch operation-inspect year

Others

Chassis parts-lubricate 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, wet, muddy, high speed or

frequent starting/stopping.

n-inspect

year

• • •

• • •

• • • •

•

• • •

• • •

• • •

• • •

• • •

• • •

• • • •

2-38

2-38

2-39

2-40

2-40

2-42

2-44

2-45

2-46

2-47

2-48

CAL: California Model

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart (United States, Canada Model)

Periodic Replacement Parts

FREQUENCY

Whichever

come

first

* ODOMETER READING

1 12 24 36 48

× 1 000 km

(× 1 000 mile)

See

Page

CHANGE/REPLACE ITEM

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

Fuel hose 4 years

Coolant 3 years

Radiator hose and O-ring 3 years

Engine oil #

Oil filter year

Brake hose and pipe 4 years

Brake fluid 2 years

Rubber parts of master cylinder and caliper

Spark plug

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

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

frequent starting/stopping.

Every

year

4 years

(0.6) (7.5) (15) (24) (30)

•

•

•

• • • • •

• • • • •

•

• •

•

• • • •

2-50

2-50

2-52

2-54

2-55

2-55

2-56

2-56

2-58,

2-59

2-62

2-6 PERIODIC MAINTENANCE

Periodic Maintenance Chart (Other than United States, Canada Model)

The scheduled maintenance must be done in accordance with this chart to k eep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Fuel System

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

year

• • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-18

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

Cooling System

Coolant level-inspe

Coolant leak (radiator hose and
pipe)-inspect

Radiator hose damage-inspect year

Radiator hose installation condition

-inspect

Engine Top End

Valve clearance-inspect Every 42 000 km (26 000 mile) 2-25

Air Suction System

Air suction system damage-inspect

Clutch

Clutch operation (play, disengagement,
engagement)-inspect

Wheels and Tires

ct

year

year

year

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • •

• • •

2-18

2-22

2-22

2-22

2-22

2-23

2-24

2-24

2-24

2-29

2-29

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
#

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

Drive chain wear-inspect #

Drive chain guide wear-inspect

Brake System

Brake fluid leak (brake hose and
pipe)-inspect

year

Every 600 km (400 mile)

• • • • • • •

• • •

• • •

• • •

• • •

• • •

• • •

2-30

2-30

2-30

2-31

2-32

2-32

2-34

2-35

2-35

PERIODIC MAINTENANCE 2-7

Periodic Maintenance Chart (Other than United States, Canada Model)

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

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

Rocker arm operation-inspect

Tie-Rods operation-inspect

Steering System

year

year

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • • • • •

• • •

• • •

• • •

• • •

See

Page

2-35

2-36

2-35

2-36

2-35

2-36

2-37

2-38

2-38

2-38

Steering play-inspect year

Steering stem bearings-lubricate 2 years

Electrical System

Spark plug c ondition – inspect

Lights and switches operation-inspect year

Headlight aiming-inspect year

Side stand 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, wet, muddy, high speed or

frequent starting/stopping.

• • • •

•

• • •

• • •

• • •

• • •

• • •

• • •

• • • •

2-39

2-40

2-40

2-42

2-44

2-45

2-46

2-47

2-48

2-8 PERIODIC MAINTENANCE

Periodic Maintenance Chart (Other than United States, Canada Model)

Periodic Replacement Parts

FREQUENCY Whichever

come

first

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

Air cleaner element # Every 18 000 km (12 000 mile) 2-50

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

See

Page

Fuel hose 4 years

Coolant 3 years

Radiator hose and O-ring

Engine oil # year

Oil filter year

Brake hose and pipe 4 years

Brake fluid 2 years

Rubber parts of master cylinder and caliper 4 years

Spark plug

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

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

frequent starting/stopping.

3 years

• • • • •

• • • • •

• •

• • • •

•

•

•

•

•

2-50

2-52

2-54

2-55

2-55

2-56

2-56

2-58,

2-59

2-62