Kawasaki ZX6R Ninja Service Manual

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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.

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center

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)

alternating current min

hour(s) Ω ohm(s)

liter(s)

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

1-2 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 × 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 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

• • •

• • • •

• • • • • • •

• • • •

•

2-18

2-22

2-23

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

2-30

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

• • • • • • •

* 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

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

2-39

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

2-52

2-54

2-55

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

year

• • • •

• • •

2-18

2-22

2-23

2-24

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

2-31

2-32

2-34

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

• • • • • • •

* 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

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

2-42

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

2-56

2-58,

2-59

2-62

PERIODIC MAINTENANCE 2-9

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 to the threads.

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

MO: Apply molybdenum disulfide grease oil solution.

R: Replacement Parts

S: Tighten the fasteners following the specified sequence.

SI: Apply s ilicone grease.

SS: Apply silicone sealant.

Fastener

Fuel System

Air Cleaner Housing Clamp Bolts 2.0 0.20 17 in·lb

Air Cleaner Housing Mounting Bolt

Air Inlet Duct Mounting Bolts 6.9 0.70 61 in·lb L

Canister Bracket Mounting Bolt (M6) 6.9 0.70 61 in·lb

Canister Bracket Mounting Bolt (M5) 0.4 0.04 4in·lb

Camshaft Position Sensor Bolt 12 1.2 104 in·lb

Crankshaft Sensor Bolts 5.9 0.60 52 in·lb

Delivery Pipe Mounting Screws (Nozzle Assy)

Delivery Pipe Mounting Screws (Throttle Body)

Exhaust Butterfly Valve Actuator Mounting Bolts

Exhaust Butterfly Valve Actuator Pulley Bolt 4.9 0.50 43 in·lb

Fuel Hose Mounting Screw 4.9 0.50 43 in·lb

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Nozzle Assy Mounting Bolts 6.9 0.70 61 in·lb

Separator Bracket Mounting Bolt

Throttle Body Assembly Holder Clamp Bolts

Throttle Body Holder Bolts 12 1.2 104 in·lb L

Throttle Cable Holder Bolt 3.9 0.40 35 in·lb

Vehicle-down Sensor Bolts 5.9 0.60 52 in·lb

Water Temperature Sensor

Cooling System

Coolant By-pass Fitting Bolt

Coolant Drain Bolt (Cylinder) 9.8 1.0 87 in·lb

Coolant Drain Bolt (Water Pump) 8.8 0.90 78 in·lb

Coolant Reserve Tank Mounting Bolts 6.9 0.70 61 in·lb

Impeller Bolt 9.8 1.0 87 in·lb

Oil Cooler Mounting Bolts

Radiator Bracket Mounting Bolt 6.9 0.70 61 in·lb

Radiator Lower Bolt 6.9 0.70 61 in·lb

Radiator Upper Bolt 12 1.2 104 in·lb

Thermostat Housing Cover Bolts 5.9 0.60 52 in·lb

Water Hose Clamp Screws

N·m kgf·m ft·lb

6.9 0.70 61 in·lb

3.4 0.35 30 in·lb

6.9 0.70 61 in·lb

0.8 0.08 7in·lb

3.0 0.30 27 in·lb

25 2.5 18

8.8 0.90 78 in·lb L

12 1.2 104 in·lb

2.0 0.20 17 in·lb

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Water Hose Fitting Bolts 12 1.2 104 in·lb

Water Pump Cover Bolts 12 1.2 104 in·lb L

Water Temperature Sensor 25 2.5 18 SS

Engine Top End

Air Suction Valve Cover Bolts 12 1.2 104 in·lb L

Camshaft Cap Bolts 12 1.2 104 in·lb S

Camshaft Chain Tensioner Cap Bolt 20 2.0 15

Camshaft Chain Tensioner Mounting Bolts 11 1.1 97 in·lb

Cam Sprocket Mounting Bolts 15 1.5 11 L

Coolant Drain Bolt (Cylinder) 9.8 1.0 87 in·lb

Crankshaft Sensor Cover Bolts 9.8 1.0 87 in·lb L(1)

Cylinder Head Bolts (M9) 39 4.0 29 MO, S

Cylinder Head Bolts (M6) 12 1.2 104 in·lb S

Cylinder Head Cover Bolts

Exhaust Butterfly Valve Actuator Mounting Bolts

Exhaust Butterfl

Exhaust Butterfly Valve Cable Adjuster Locknuts 6.9 0.70 61 in·lb

Exhaust Butterfly Valve Cable Locknuts 6.9 0.70 61 in·lb

Exhaust Butterfly Valve Cover Bolt 6.9 0.70 61 in·lb

Exhaust Pipe Clamp Bolt 17 1.7 12

Exhaust Pipe Manifold Holder Nuts 17 1.7 12

Exhaust Pipe Mo

Front Camshaft Chain Guide Bolt (Lower) 12 1.2 104 in·lb

Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18

Muffler Body Clamp Bolt 17 1.7 12

Muffler Body Mounting Bolts 25 2.5 18

Muffler Rear Cover Bolts 6.9 0.70 61 in·lb

Muffler Upper Cover Bolts 6.9 0.70 61 in·lb

Rear Camshaft Chain Guide Bolt 25 2.5 18

Spark Plugs 13 1.3 113 i n ·lb

Throttle Body Assy Holder Clamp Bolts 2.9 0.30 26 in·lb

Throttle Body Holder Bolts 12 1.2 104 in·lb L

Water Passage Plug (Left) 20 2.0 15 L

Water Passage Plugs (Upper) 20 2.0 15 L

Clutch

Clutch Cover Bolt (M6, L = 50 mm) 12 1.2 104 in·lb

Clutch Cover Bolt (M6, L = 40 mm) 12 1.2 104 in·lb L(1)

Clutch Cover Bolts (M6, L = 30 mm)

Clutch Hub Nut

Clutch Lev

Clutch Spring Bolts 8.8 0.90 78 in·lb

Oil Filler Plug 1.5 0.15 13 in·lb

SubClutchHubBolts 25 2.5 18 L

y Valve Actuator Pulley Bolt

unting Bolt

er Clamp Bolts

N·m kgf·m ft·lb

9.8 1.0 87 in·lb

6.9 0.70 61 in·lb

4.9 0.50 43 in·lb

25 2.5 18

12 1.2 104 in·lb

135 14 100 R

7.8 0.80 69 in·lb

Torque

Remarks

L(1)

Torque and Locking Agent

PERIODIC MAINTENANCE 2-11

Fastener

Engine Lubrication System

Coolant Drain Bolt (Water Pump) 8.8 0.90 78 in·lb

Engine Oil Drain Bolt 29 3.0 22

Impeller Bolt 9.8 1.0 87 in·lb

Oil Cooler Mounting Bolts 12 1.2 104 in·lb S

Oil Filter 31 3.2 23 EO, R

Oil Filter Mounting Bolt 25 2.5 18 L

Oil Jet Nozzle Bolts 6.9 0.70 61 in·lb L

Oil Pan Bolts 9.8 1.0 87 in·lb

Oil Pan Clamp Bolt 9.8 1.0 87 in·lb

Oil Passage Plug (Left Side) 20 2.0 15 L

Oil Passage Plug (Right Side) 15 1.5 11

Oil Pipe Bolts

Oil Pressure Relief Valve

Oil Pressure Switch

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Water Hose Clamp Screws 2.0 0.20 17 in·lb

Water Pump Cover Bolts 12 1.2 104 in·lb L

Engine Removal/Installation

Adjusting Collar Locknut 49 5.0 36 S

Lower Engine Mounting Bolt 10 1.0 87 in·lb S

Lower Engine Mounting Nut 44 4.5 33 S

Middle Engine Mounting Bolt 10 1.0 87 in·lb S

Middle Engine Mounting Nut 44 4.5 33 S

Upper Engine Mounting Bolts 44 4.5 33

Crankshaft/Transmission

Breather Plate Bolts 5.9 0.60 52 in·lb L

Connecting Rod Big End Nuts see the text

Crankcase Bolts (M8) 31 3.2 23 MO, S

Crankcase Bolts (M7, L = 38 mm) 27 2.8 20 S

Crankcase Bolt (M7, L = 70 mm)

Crankcase Bolts (M6, L = 65 mm)

Crankcase Bolts (M6, L = 50 mm)

Crankcase Bolts (M6, L = 38 mm) 12 1.2 104 in·lb S

Crankcase Bolt (M6, L = 95 mm) 12 1.2 104 in·lb S

Crankcase Bolt (M6, L = 85 mm) 12 1.2 104 in·lb S

Crankcase Bolt (M6, L = 35 mm) 12 1.2 104 in·lb S

Neutral Switch 15 1.5 11 L

Gear Positioning Lever Bolt 12 1.2 104 in·lb

Harness Clamp Bolt 8.8 0.90 78 in·lb L

Oil Passage Plug (Left Side) 20 2.0 15 L

Oil Passage Plug (Right Side) 15 1.5 11

Oil Pressure Switch

N·m kgf·m ft·lb

12 1.2 104 in·lb

15 1.5 11 L

15 1.5 11

20 2.0 14

12 1.2 104 in·lb

15 1.5 11

Torque

Remarks

← ← ←

2-12 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Plate Screws

Shift Drum Bearing Holder Bolts

Shift Drum Cam Holder B

Shift Lever Bolt 6.9 0.70 61 in·lb

Shift Pedal Mounting Bolt 25 2.5 18

Shift Shaft Return Spring Pin 28 2.9 21 L

Tie-Rod Locknuts 6.9 0.70 61 in·lb

Wheels/Tires

Front Axle Clamp Bol

Front Axle Nut 127 13 94

Rear Axle Nut 127 13 94

Final Drive

Engine Sprocket Cover Bolts

Engine Sprocket Nut

Rear Axle Nut 127 13 94

Rear Sprocket Nuts 59 6.0 43

Brakes

Bleed Valves 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 34 3.5 25

Brake Lever Pivot Bolt 1.0 0.10 9in·lb SI

Brake Lever Pivot Bo

Brake Pedal Bolt 8.8 0.90 78

Front Brake Light Switch Screw 1.2 0.12 10 in·lb

Front Brake Reservoir Cap Stopper Screw 1.2 0.12 10 in·lb

Front Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Pad Pins 15 1.5 11

Front Caliper Asse

Front Caliper Mounting Bolts 34 3.5 25

Front Master Cylinder Bleed Valve 5.9 0.60 52 in·lb

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

Rear Brake Disc Mounting Bolts 27 2.8 20 L

Rear Caliper Mounting Bolts

Rear Master Cylin

Rear Master Cylinder Push Rod Locknut 18 1.8 13

Suspension

Front Axle Clamp Bolts 20 2.0 15 AL

Front Fork Bottom Allen Bolts 35 3.5 26 L

Front Fork Clamp Bolts (Lower)

Front Fork Clamp

Front Fork Top Plugs 35 3.5 26

Piston Rod Nuts 20 2.0 15

Rear Shock Absorber Bracket Nut 59 6.0 43

mbly Bolts

der Mounting Bolts

Bolts (Upper)

olt

lt Locknut

N·m kgf·m ft·lb

5.9 0.60 52 in·lb L

12 1.2 104 in·lb L

20 2.0 15 AL

6.9 0.70 61 in·lb

125 13 92

5.9 0.60 52 in·lb

22 2.2 16

25 2.5 18

25 2.5 18 AL

20 2.0 15

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-13

Fastener

Rear Shock Absorber Nut (Lower) 34 3.5 25

Rear Shock Absorber Nut (Upper) 34 3.5 25

Swingarm Pivot Adjusting Collar 20 2.0 15

Swingarm Pivot Adjusting Collar Locknut 98 10 72

Swingarm Pivot Shaft Nut 108 11 81

Tie-Rod Nuts 59 6.0 43

Uni-Trak Rocker Arm Nut 34 3.5 25

Steering

Front Fork Clamp Bolts (Lower)

Front Fork Clamp Bolts (Upper) 20 2.0 15

Handlebar Bolts 25 2.5 18

Handlebar Position Bolts 9.8 1.0 87 in·lb L

Steering Stem Head Nut 78 8.0 58

Steering Stem Nut 20 2.0 15

Switch Housing Screws 3.5 0.36 31 in·lb

Frame

Air Inlet Duct Mounting Bolts 6.9 0.70 61 L

Front Fender Mounting Bolts 3.9 0.40 35 in·lb

Front Footpeg Bracket Bolts 25 2.5 18

Rear Footpeg Bracket Bolts 25 2.5 18

Rear Frame Bolts 59 6.0 44 L(2)

Side Stand Bolt 44 4.5 32 G

Side Stand Bracket Bolts 49 5.0 36 L

Side Stand Switch Bolt 8.8 0.90 78 in·lb L

Side Stand Switch Bracket Bolt

Windshield Mounting Bolts 0.4 0.04 4in·lb

Electrical System

Alternator Cover Bolts 12 1.2 104 in·lb

Alternator Lead Holding Plate Bolts 6.9 0.70 61 in·lb L

Alternator Rotor Bolt 110 11 81

Camshaft Position Sensor Bolt

Crankshaft Sensor Bolts

Crankshaft Sensor Cover Bolts

Engine Ground Lead Terminal Bolt 9.8 1.0 87 in·lb

Front Brake Light Switch Screw 1.2 0.12 10 in·lb

Front Turn Signal Light Lens Screws 1.0 0.10 9in·lb

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

Headlight Mounting Screws 1.2 0.12 10 in·lb

Licence Light Assembly Screws 0.9 0.09 8in·lb

Licence Light Mounting Screws 1.2 0.12 10 in·lb

Meter Mounting Screws 1.2 0.12 10 in·lb

Neutral Switch 15 1.5 11 L

Rear Turn Signal Light Lens Screws

N·m kgf·m ft·lb

25 2.5 18 AL

3.9 0.40 35 in·lb L

12 1.2 104 in·lb

5.9 0.60 52 in·lb

9.8 1.0 87 in·lb

1.0 0.10 9in·lb

Torque

Remarks

L(1)

2-14 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

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

Regulator/Rectifier Bolts

Side Stand Switch Bolt

Side Stand Switch Brac

Spark Plugs 13 1.3 115 i n ·lb

Speed Sensor Bolt 12 1.2 104 in·lb

Stator Coil Bolts 12 1.2 104 in·lb L

Starter Motor Cable Terminal Bolt 2.7 0.28 24 in·lb

Starter Motor Clutch Bolts 34 3.5 25 L

Starter Motor Mounting Bolts 11 1.1 97 in·lb

Starter Relay Cable Terminal Bolts 3.9 0.40 35 in·lb

Switch Housing Screws 3.5 0.36 31 in·lb

Tail/Brake Light Mounting Screws 4.0 0.40 35 in·lb

Timing Rotor Bolt 45 4.5 33

Vehicle-down Sensor Bolts 5.9 0.60 52 in·lb

Water Temperature Sensor 25 2.5 18 SS

ket Bolt

N·m kgf·m ft·lb

6.9 0.70 61 in·lb

8.8 0.90 78 in·lb L

3.9 0.40 35 in·lb L

Torque

Remarks

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

Basic Torque for General Fasteners

Threads Torque

Diameter (mm) N·m kgf·m ft·lb

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

8 14 ∼19 1.4 ∼1.9 10 ∼ 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 ∼ 1 16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115 18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165 20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

0.0

54 ∼ 72

PERIODIC MAINTENANCE 2-15

Specifications

Item Standard Service Limit

Fuel System

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

Idle Speed 1 300 ±50 r/min (rpm) –––

Throttle Body Vacuum

Air Cleaner Element

Cooling System

Coolant:

Type (Recommended) Permanent type antifreeze –––

Color Green –––

Mixed Ratio

Freezing Point

Total Amount 2.6 L (2.7 US qt) –––

Engine Top End

Valve Clearance:

Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) ––– Inlet 0.11 ∼ 0.19 mm (0.0043 ∼ 0.0075 in.) –––

Clutch

Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Engine Lubrication System

Engine Oil:

Type

Viscosity

Capacity 3.4 L (3.6 US qt) (when filter is not removed) –––

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

Tires

Tread Depth:

Front

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

Air Pressure (when Cold):

Front

Rear

27.3 ±1.3 kPa (205 ±10 mmHg) at idle speed

Viscous paper element –––

Soft water 50%, coolant 50%

–35°C (–31°F)

API SE, SF or SG API SH or SJ with JASO MA

SAE 10W-40

3.6 L (3.8 US qt) (when filter is removed) –––

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

minutes after idling or running)

BRIDGESTONE: 3.6 mm (0.14 in.) 1 mm (0.04 in.),

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

(80 mph): 2 mm (0.08 i n.), Over 130 km/h (80 mph): 3 mm (0.12 in.)

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

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

–––

2-16 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Final Drive

DriveChainSlack 30 ∼ 35 mm (1.2 ∼ 1.4 in.) –––

Drive Chain Wear (20-link Length)

Standard Chain:

Make ENUMA –––

Type EK520MVXL –––

Link 110 links –––

Brakes

Brake Fluid:

Grade DOT4 –––

Brake Pad Lining Thickness:

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

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

Brake Light Timing:

Front Pulled ON –––

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

Electrical System

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

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

AT: Au s t ria

CH: Switzerland

DE: Germany US: United States

Special Tools

PERIODIC MAINTENANCE 2-17

Inside Circlip Pliers: 57001-143

Steering Stem Nut Wrench: 57001-1100

Jack: 57001-1238

Pilot Screw Adjuster, C: 57001-1292

Extension Tube: 57001-1578

Jack Attachment: 57001-1608

Oil Filter Wrench: 57001-1249

2-18 PERIODIC MAINTENANCE

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 G rip 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 fuel tank (see Fuel Tank Removal in the Fuel

•

System (DFI) chapter). Pull off the vacuum hoses and the rubber cap(s) from the

•

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

•

air cleaner housing [B].

CAUTION

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

Maintenance Procedure

Connect a commercially available vacuum gauge [A] to

•

these right fittings of the throttle body as shown.

Front [B]

Connect a highly accurate tachometer to one of the stick

•

coil primary leads. Plug:

•

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

Install:

•

Air C leaner Housing [A] (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Tachometer [B] Vacuum Gauge [C]

Connect:

•

Extension Tube [D]

Special Tool - Extension Tube: 57001-1578

Start the engine and warm it up thoroughly.

•

Check the idle speed.

•

Open and close the throttle.

•

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

PERIODIC MAINTENANCE 2-19

CAUTION

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

While idling the engine, inspect the engine vacuum, using

•

the vacuum gauge [B].

Engine Vacuum

Standard: 27.3 ±1.333 kPa (205 ±10 mmHg) at Idle

Speed 1 300 ±50 r/min (rpm)

2-20 PERIODIC MAINTENANCE

Maintenance Procedure

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

Example:

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

With the engine at the correct idle speed, equalize the

•

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

Special Tool - Pilot Screw Adjuster, C: 57001-1292

Front [B]

NOTE

After adjustment, the final vacuum measurement be-

○

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

Open and close the throttle after each measurement and

•

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

•

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

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

Front [B]

CAUTION

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

Turn out the bypass screw of the higher vacuum between

•

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

•

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

•

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

•

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

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

Maintenance Procedure

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

•

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

○

If any carbon accumulates, wipe the carbon off the bypass screw and the hole, using a cotton pad penetrated with a high-flash point solvent. Replace the O-ring with a new one.

○

Check the tapered portion [E] of the bypass screw for

○

wear or damage. If the bypass screw is worn or damaged, replace it. Turn in the bypass screw until it seats fully but not tightly.

•

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 the Main Throttle Sensor in the Fuel System (DFI) chapter).

Main Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → Y/W lead (terminal 7) Meter (–) → BR/BK lead (terminal 28)

PERIODIC MAINTENANCE 2-21

Standard: 1.02 ∼ 1.06 V DC (at idle throttle opening)

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

•

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

Front [C] Except California Model [D] California Model [E] Separator [F] Canister [G]

2-22 PERIODIC MAINTENANCE

Maintenance Procedure

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: 1 300 ±50 r/min (rpm)

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 Damage and Installation Condition Inspection

The motorcycle is not properly handled, the high pressure

○

inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose [A]. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hose joints are securely connected.

•

When installing the fuel hose, avoid sharp bending, kink-

•

ing, flattening or twisting. Replace the hose if it has been sharply bent or kinked.

PERIODIC MAINTENANCE 2-23

Maintenance Procedure

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Inspect the canister as follows.

•

Remove:

○

Left 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:

○

Left Center Fairing (see Center Fairing Removal in the Frame chapter)

Disconnect the hoses from the separator, and remove the

○

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

○

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

○

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

•

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

○

are 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.

2-24 PERIODIC MAINTENANCE

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 side stand). If the coolant level is lower than the “L” level line [B], unscrew the reserve tank cap and add coolant to the “F” level line [C].

“L”: low “F”: full

CAUTION

For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft 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 Damage and Installation Condition Inspection

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,

17 in·lb)

Maintenance Procedure

Engine To p End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (at room temperature).

Remove:

•

Lower Fairings (see Lower Fairing Removal in the Frame chapter) Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)

Position the crankshaft at #1, 4 piston TDC.

•

TDC Mark [A] for #1, 4 Pistons Timing Mark [B] (Crankcase Halves Mating Surface)

PERIODIC MAINTENANCE 2-25

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

•

between the cam and the valve lifter.

Valve Cleara nce

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]

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

0.11 ∼ 0.19 mm (0.0043 ∼ 0.0075 in.)

NOTE

2-26 PERIODIC MAINTENANCE

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 (see appropriate chapters). Replace the shim with one of a different thickness.

NOTE

Mark and record the v alve lifter and shim locations so

○

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

○

sizes smaller and then measure the clearance.

To select a new shim which brings the valve clearance

•

within the specified range, refer to the Valve Clearance Adjustment Charts. Apply a thin coat of engine oil to the valve lifter surface

•

and install the lifter. Install the camshafts. Be sure to time the camshafts prop-

•

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

•

Readjust if necessary.

CAUTION

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

PERIODIC MAINTENANCE 2-27

Maintenance Procedure

VA LVE CLEARANCE ADJUSTMENT CHART INLET VALVE

1. Measure the clearance (when engine is cold).

2. Check present shim size.

3. Match clearance in vertical column with present shim size in horizontal column.

4. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example:

Present shim is 3.05 mm. Measured clearance is 0.35 mm. Replace 3.05 mm shim with 3.25 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

2-28 PERIODIC MAINTENANCE

Maintenance Procedure

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

1. Measure the clearance (when engine is cold).

2. Check present shim size.

3. Match clearance in vertical column with present shim size in horizontal column.

4. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example:

Present shim is 3.10 mm. Measured clearance is 0.40 mm. Replace 3.10 mm shim with 3.20 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

Maintenance Procedure

Air Suction System

Air Suction System Damage Inspection

Pull the v acuum switch valve hose [A] out of the air

•

cleaner. Start the engine and run it at idle speed.

•

Plug the vacuum switch valve hose 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 vacuum switch valve or air suction valve (see Vacuum Switch Valve Test, Air Suction Valve Inspection in the Engine Top End chapter).

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 2-29

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 center fairing (see Center Fairing Re-

•

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

•

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

•

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

•

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

•

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

•

correct.

2-30 PERIODIC MAINTENANCE

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 Inspectio n

Remove any imbedded stones [A] or other foreign parti-

•

cles [B] from tread. Visually inspect the tire for cracks and cuts, and replace

•

the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. Visually inspect the wheel for cracks, cuts and dents dam-

•

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

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald.

Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take

measurement at several places.

If any measurement is less than the service limit, replace

the tire (see Tire Removal/Installation in the Wheels/Tires

chapter).

Up to 180 kg (397 lb)

250 kPa (2.5 kgf/cm², 36 psi)

Up to 180 kg (397 lb)

290 kPa (2.9 kgf/cm², 42 psi)

Maintenance Procedure

Tread Depth

Standard:

Front

Rear

Service Limit:

Front

Rear

3.6 mm (0.14 in.)

5.8 mm (0.23 in.)

1 mm (0.04 in.)

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

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 2-31

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).

2-32 PERIODIC MAINTENANCE

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 c hain appears especially dirty, clean it before lubri-

•

cation.

CAUTION

The O-rings between the side plates seal in the lu-

bricant between the pin and the bushing. To avoid

damaging the O-rings and resultant loss of lubri-

cant, observe the following rules.

Use only kerosene or diesel oil for cleaning 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 in this chapter).

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

Drive Chain Slack Adjustment

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

•

Loosen the both chain adjuster locknuts [C].

•

If the chain is too loose, turn out the left and right chain adjuster [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 axle nut.

•

Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 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 2-33

Insert a new cotter pin [A].

•

NOTE

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

○

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

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

Bend the cotter pin [A] over the nut.

•

2-34 PERIODIC MAINTENANCE

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 in this chap-

ter).

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 c hain 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. S ince 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, re-

place the chain or an unsafe riding condition may

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

ets could snag on the engine sprocket or lock the

rear wheel, severely damaging the motorcycle and

causing it to go out of control.

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

less type and should not be cut for installation.

Standard Chain

Make: ENUMA

Type: EK520MVXL

Link: 110 links

Maintenance Procedure

Chain Guide Wear Inspection

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 2-35

Brake Hose Damage and Installation Condition Inspection

Inspect the brake hoses and fittings for deterioration,

•

cracks and signs of leakage. The high pressure inside the brake line can cause fluid to

○

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

Torque - Brake Hose Banjo B olts: 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 s ection in the Appendix chapter.

Brake Operation Inspection

Inspect the operation of the front and rear brake by run-

•

ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system.

WARNING

When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.

2-36 PERIODIC MAINTENANCE

Maintenance Procedure

Brake Fluid Le vel 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 reser-

voir 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

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 Tail/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 2-37

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).

2-38 PERIODIC MAINTENANCE

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

Remove the lower fairings (see Lower Fairing Removal in

•

the Frame chapter).

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 Suspen-

sion chapter).

Tie-Rod Operation Inspection

Remove the lower fairings (see Lower Fairing Removal in

•

the Frame chapter).

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

•

smooth stroke.

If the tie-rods [A] do not smoothly stroke or noise is found,

inspect the fasteners and tie-rod bearings (see Rocker

Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen-

sion chapter).

Maintenance Procedure

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 2-39

Steering Play Adjustment

Remove:

•

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 claw washer tabs [A].

•

Remove the steering stem locknut [B] and claw washer

•

[C].

Adjust the steering.

•

Special Tool - Steering Stem Nut Wrench: 57001-1100

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.

○

2-40 PERIODIC MAINTENANCE

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 c laws 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 in this

•

chapter).

Electrical System

Spark Plug Clean and Gap Inspection

Remove the spark plug (see Spark Plug Replacement in

•

this chapter), and visually inspect. Clean the spark plug, preferably in a sandblasting device,

•

and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

Maintenance Procedure

Measure the gap [A] with a wire-type thickness gauge.

•

If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap.

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

CAUTION

Use only the recommended spark plugs (special marks [C] on the insulator, as shown. Other spark plugs will wear prematurely.

). These spark plugs have special marks

PERIODIC MAINTENANCE 2-41

2-42 PERIODIC MAINTENANCE

Maintenance Procedure

Lights and Switches Operation Inspection

First Step

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

City Light [A]

Taillight [B]

License Plate Light [C]

Meter Panel LCD [D]

Neutral Indicator LED [E]

Oil Pressure Warning Indicator LED [F]

FI Indicator LED [G]

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 Assembly Inspection in the Electrical System chapter) Meter Unit for Neutral Indicator LED (see Electronic Combination Meter Assembly Inspection in the Electrical System chapter) Meter Unit for Oil Pressure Warning Indicator LED (see Electronic Combination Meter Assembly Inspection in the Electrical System chapter) Meter Unit for FI Indicator LED (see Electronic Combination Meter Assembly 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,

•

FI indicator LED will blink. see Abstract in the Electrical System chapter). If the light does not go off, replace the ignition switch.

goes on

(about 2 seconds)

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)

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 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 Light Indicator 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 E lectrical 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 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 E lectrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter)

PERIODIC MAINTENANCE 2-43

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)

2-44 PERIODIC MAINTENANCE

Maintenance Procedure

Set the dimmer switch to high beam position.

•

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

•

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

•

If the high beam headlight and/or high beam indicator 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 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 LED should go

•

off.

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

•

with a screwdriver to adjust the headlight vertically.

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]

PERIODIC MAINTENANCE 2-45

Side Stand Switch Operation Inspection

Inspect the side stand switch [A] operation accordance to

•

below table.

Side Stand Switch Operation

Side Stand

Up Neutral Released

Up Neutral Pulled in

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

2-46 PERIODIC MAINTENANCE

Maintenance Procedure

If the side stand 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) Side Stand 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) Neutral Switch (see Switch Inspection in the Electrical System chapter) Starter Control 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.

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 starter 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).

Maintenance Procedure

Others

Chassis Parts Lubrication

Before lubricating each part, clean off any rusty spots with

•

rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication

Pivots: Lubricate with Grease.

Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Side Stand

Points: Lubricate with Grease.

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

PERIODIC MAINTENANCE 2-47

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.

2-48 PERIODIC MAINTENANCE

Maintenance Procedure

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.

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.

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 Side Stand Bolt

PERIODIC MAINTENANCE 2-49

2-50 PERIODIC MAINTENANCE

Maintenance Procedure

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 assy, 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:

•

Front Seat (see Front Seat Removal in the Frame chap-

ter) Lift up the fuel tank, and clamp the fuel tank by wood.

•

Remove:

•

Air Cleaner Element Cover Screws [A]

Air Cleaner Element Cover [B] Discard:

•

Air Cleaner Element

Install a new element [A].

•

CAUTION

Use only the recommended air cleaner element (Kawasaki part number 11013-0010). Using another air cleaner element will wear the engine prematurely or lower the engine performance.

NOTE

Be sure to install the fuel tank drain hose.

○

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. Push [B] the joint lock claws [C].

•

Maintenance Procedure

Pull the joint lock [A] as shown.

•

Pull the fuel hose joint [B] 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.

•

Pull [A] the joint lock [B] fully as shown.

•

PERIODIC MAINTENANCE 2-51

Insert the fuel hose joint [A] straight onto the delivery pipe

•

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

•

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 in accordance with the 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.

•

2-52 PERIODIC MAINTENANCE

Maintenance Procedure

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.

Remove:

•

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Right Center Fairing (see Center Fairing Removal 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:

•

Left Center Fairing (see Center Fairing Removal 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.

Remove:

•

Coolant Reserve Tank [A] (see Coolant Reserve Tank

Removal in the Cooling System chapter) Remove the cap [B] and pour the coolant into a container.

•

Install the coolant reserve tank (see Coolant Reserve

•

Tank Installation in the Cooling System chapter). Tighten the drain bolts with the washers.

•

Replace the drain bolt gasket with a new one if it is dam-

○

aged.

Torque - Coolant Drain Bolt (Water Pump): 8.8 N·m (0.90

kgf·m, 78 in·lb)

Coolant Drain Bo lt (Cylinder): 9.8 N·m (1.0 kgf·m,

87 in·lb)

Maintenance Procedure

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: –35°C (–31°F)

Total Amount: 2.6 L (2.7 US qt)

PERIODIC MAINTENANCE 2-53

NOTE

Choose a suitable mixture ratio by referring to the

○

coolant manufacturer’s directions.

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.

2-54 PERIODIC MAINTENANCE

Maintenance Procedure

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change in this chapter).

•

Remove:

•

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Center Fairings (see Center Fairing Removal in the

Frame chapter)

Throttle Body Assy (see Throttle Body Assy Removal in

the Fuel System (DFI) chapter)

Thermostat Housing [A]

Fitting [B]

Hoses [C]

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

•

Instal the new hoses and tighten the clamps securely.

•

Fill the coolant (see Coolant Change in this chapter).

•

Check the cooling system for leaks.

•

Maintenance Procedure

Engine Oil Change

Remove the lower fairings (see Lower Fairing Removal in

•

the Frame chapter). 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 in this chapter). Replace the drain bolt gasket with a new one. Tighten the drain bolt.

•

Torque - Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 22 ft·lb)

Pour in the specified type and amount of oil.

•

Recommended Engine Oil

Typ e :

Viscosity:

Capacity: 3.4 L (3.6 US qt) (when filter is not

API SE, SF or SG

API SH or SJ with JASO MA

SAE 10W-40

removed)

3.6 L (3.8 US qt) (when filter is removed)

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

PERIODIC MAINTENANCE 2-55

NOTE

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.

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change in this chap-

•

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

•

Special Tool - Oil Filter Wrench: 57001-1249

Replace the filter with a new one.

•

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

•

Tighten the filter with the oil filter wrench.

•

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

NOTE

Hand tightening of the oil filter can not be allowed since

○

it does not reach to this tightening torque.

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

•

Oil Change in this chapter).

2-56 PERIODIC MAINTENANCE

Maintenance Procedure

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 B olts: 34 N·m (3.5 kgf·m, 25

ft·lb)

When installing the hoses [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 in this chapter).

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

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 2-57

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, 10 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.

2-58 PERIODIC MAINTENANCE

Maintenance Procedure

Master Cylinder Rubber Parts Repla c ement

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. Pull the dust cover [G] and push rod [H] out of place, and

•

remove the circlip [I]. Pull out the piston assy [J].

•

Replace:

•

Seal Cover [A]

Circlip [B]

O-ring [D]

Dust Cover [G]

Circlip [I]

Piston Assy [J]

Diaphragm [K]

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 assy [F].

•

Take off the piston assy [G] and return spring [H].

•

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 Assy [F]

Piston Assy [G]

Diaphragm [I]

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

Apply brake fluid to the new parts and to the i nner 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 locknut.

•

Silicone Grease - Brake Lever Pivot Bolt

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

in·lb)

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

kgf·m, 52 in·lb)

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

PERIODIC MAINTENANCE 2-59

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.

2-60 PERIODIC MAINTENANCE

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 caliper parts except for the pads.

•

CAUTION

For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

Install the bleed valve and rubber cap.

•

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Replace the fluid seals [A] with new ones.

•

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

○

the cylinders by hand. Replace the dust 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

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 2-61

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 caliper 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 seal [A] with a new one.

•

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

○

cylinder by hand. Replace the dust seal [B] with a new one.

•

Apply brake fluid to the dust seal, and install it i nto the

○

cylinder by hand.

2-62 PERIODIC MAINTENANCE

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 chap-

ter) 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

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, 113 in·lb)

Install the stick coils securely.

•

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

○

Fuel System (DFI)

Table of Contents

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

Specifications .................................... 3-10

Special Tools and Sealant ................. 3-12

DFI Parts Location............................. 3-14

DFI System ........................................ 3-16

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

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

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

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

DFI System Troubleshooting Guide .. 3-30

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

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

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

Service Code Clearing Procedures 3-39

Service Code Reading ................. 3-41

Service Code Erasing .................. 3-41

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

Main Throttle Sensor (Service Code

11)................................................... 3-45

Main Throttle Sensor

Removal/Adjustment ................. 3-45

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

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

Resistance Inspection.................. 3-48

Inlet Air Pressure Sensor (Service

Code 12)......................................... 3-49

Removal ....................................... 3-49

Installation.................................... 3-49

Input Voltage Inspection............... 3-49

Output Voltage Inspection............ 3-50

Inlet Air Temperature Sensor (Service

Code 13)......................................... 3-54

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

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

Sensor Resistance Inspection ..... 3-55

Water Temperature Sensor (Service

Code 14)......................................... 3-57

Removal/Installation..................... 3-57

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

Sensor Resistance Inspection ..... 3-58

Atmospheric Pressure Sensor

(Service Code 15)........................... 3-59

Removal ....................................... 3-59

Installation.................................... 3-59

Input Voltage Inspection............... 3-59

Output Voltage Inspection............ 3-60

FUEL SYSTEM (DFI) 3-1

Crankshaft Sensor (Service Code

21)................................................... 3-63

Crankshaft Sensor

Removal/Installation.................. 3-63

Crankshaft Sensor Inspection...... 3-63

Camshaft Position Sensor (Service

Code 23)......................................... 3-64

Camshaft Position Sensor

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

Camshaft Position Sensor

Inspection .................................. 3-64

Speed Sensor (Service Code 24) ...... 3-65

Speed Sensor Removal/Installa-

tion ............................................ 3-65

Speed Sensor Inspection............. 3-65

Input Voltage Inspection............... 3-65

Output Voltage Inspection ............ 3-65

Vehicle-down Sensor (Service Code

31)................................................... 3-67

Removal ....................................... 3-67

Installation.................................... 3-67

Inspection..................................... 3-67

Subthrottle Sensor (Service Code

32)................................................... 3-70

Subthrottle Sensor

Removal/Adjustment ................. 3-70

Input Voltage Inspection............... 3-70

Output Voltage Inspection ............ 3-71

Resistance Inspection.................. 3-73

Exhaust Butterfly Valve Actuator

Sensor (Service Code 34) .............. 3-74

Exhaust Butterfly Valve Actuator

Sensor Inspection ..................... 3-74

Immobilizer Amplifier (Service Code

35)................................................... 3-75

Antenna Resistance Inspection ... 3-75 Amplifier Input Voltage Inspection 3-75

Blank Key Detection (Service Code

36)................................................... 3-76

User Key Inspection..................... 3-76

Stick Coils #1, #2, #3, #4: (Service

Code 51, 52, 53, 54)....................... 3-78

Removal/Installation..................... 3-78

Input Voltage Inspection............... 3-78

Subthrottle Valve Actuator (Service

Code 62)......................................... 3-80

3-2 FUEL SYSTEM (DFI)

Subthrottle Valve Actuator

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

Subthrottle Valve Actuator

Inspection .................................. 3-80

Resistance Inspection.................. 3-80

Input Voltage Inspection............... 3-81

Exhaust Butterfly Valve Actuator

(Service Code 63)........................... 3-82

Exhaust Butterfly Valve Actuator

Removal .................................... 3-82

Exhaust Butterfly Valve Actuator

Installation ................................. 3-82

Exhaust Butterfly Valve Actuator

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

Output Voltage Inspection............ 3-84

ECU................................................... 3-85

ECU Identification ........................ 3-85

ECU Removal .............................. 3-85

ECU Installation ........................... 3-86

ECU Power Supply Inspection..... 3-86

DFI Power Source ............................. 3-88

ECU Fuse Removal ..................... 3-88

ECU Fuse Installation .................. 3-88

ECU Fuse Inspection ................... 3-88

FI Indicator Light (LED) ..................... 3-89

Light (LED) Inspection ................. 3-89

Fuel Line............................................ 3-90

Fuel Pressure Inspection ............. 3-90

Fuel Flow Rate Inspection ........... 3-91

Fuel Pump ......................................... 3-93

Fuel Pump Removal .................... 3-93

Fuel Pump Installation ................. 3-93

Operation Inspection.................... 3-94

Operating Voltage Inspection....... 3-94

Fuel Injectors ..................................... 3-96

Audible Inspection ........................ 3-96

Injector Signal Test....................... 3-96

Injector Resistance Inspection ..... 3-97

Injector Unit Test .......................... 3-98

Injector Voltage Inspection........... 3-99

Injector Fuel Line Inspection ........ 3-101

Throttle Grip and Cables ................... 3-103

Free Play Inspection .................... 3-103

Free Play Adjustment................... 3-103

Cable Installation ......................... 3-103

Cable Lubrication......................... 3-103

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

Idle Speed Inspection .................. 3-104

Throttle Bore Cleaning ................. 3-104

Synchronization Inspection.......... 3-104

Synchronization Adjustment ........ 3-104

Throttle Body Assy Removal........ 3-104

Throttle Body Assy Installation..... 3-106

Throttle Body Assy Disassembly . 3-106

Throttle Body Assy Assembly ...... 3-107

Nozzle Assy....................................... 3-108

Nozzle Assy Removal .................. 3-108

Nozzle Assy Installation ............... 3-108

Nozzle Assy Disassembly............ 3-108

Nozzle Assy Assembly................. 3-109

Air Cleaner......................................... 3-111

Element Removal......................... 3-111

Element Installation...................... 3-111

Air Cleaner Element Inspection ... 3-111

Air Cleaner Housing Removal...... 3-111

Air Cleaner Housing Installation... 3-112 Air Cleaner Housing Disassembly 3-113

Air Cleaner Housing Assembly .... 3-113

Oil Draining .................................. 3-113

Air Inlet Duct Removal ................. 3-113

Air Inlet Duct Installation .............. 3-113

Fuel Tank........................................... 3-114

Fuel Tank Removal ...................... 3-114

Fuel Tank Installation ................... 3-116

Fuel Tank and Cap Inspection ..... 3-117

Fuel Tank Cleaning ...................... 3-117

Evaporative Emission Control System

(California Model) ........................... 3-118

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

Hose Inspection ........................... 3-118

Separator Inspection.................... 3-118

Separator Operation Test............. 3-119

Canister Inspection ..................... 3-119

Exploded View

Dummy Page

FUEL SYSTEM (DFI) 3-3

3-4 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

N·m kgf·m ft·lb

1 Air Cleaner Housing Clamp Bolts 2.0 0.20 17 in·lb

2 Air Cleaner Housing Mounting Bolt 6.9 0.70 62 in·lb

3 Air Inlet Duct Mounting Bolts 6.9 0.70 62 in·lb L

4. Air Cleaner Element

5. Air Inlet Duct

6. Vacuum Switch Valve

7. Inlet Air Temperature Sensor L: Apply a non-permanent locking agent.

Torque

Remarks

3-6 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

1 Delivery Pipe Mounting Screws (Nozzle Assy) 3.4 0.35 30 in·lb

2 Delivery Pipe Mounting Screws (Throttle Body) 3.4 0.35 30 in·lb

Fuel Hose Mounting Screw

4 Nozzle Assy Mounting Bolts 6.9 0.70 61 in·lb

5 Throttle Body Assembly Holder Clamp Bolts 3.0 0.30 27 in·lb

6 Throttle Body Holder Bolts 12 1.2 104 in·lb L

7 Throttle Cable Holder Bolt 3.9 0.40 35 in·lb

8. Atmospheric Pressure Sensor

9. Bypass Screw

10. Inlet Air Pressure Sensor

11. Main Throttle Valve Sensor

12. Primary Fuel Injectors

13. Secondary Fuel Injectors

14. Subthrottle Valve Actuator

15. Subthrottle Valve Sensor

16. Throttle Cable (Accelerator)

17. Throttle Cable (Decelerator)

CL: Apply cable lubricant.

EO: Apply engine oil.

G: Apply grease.

HG: Apply high-temperature grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

N·m kgf·m ft·lb

4.9 0.50 43 in·lb

Torque

Remarks

3-8 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-9

No. Fastener

1 Camshaft Position Sensor Bolt 12 1.2 104 in·lb

2 Canister Bracket Mounting Bolt (M6) 6.9 0.70 61 in·lb

Canister Bracket Mounting Bolt (M5)

4 Crankshaft Sensor Bolts 5.9 0.60 52 in·lb

5 Exhaust Butterfly Valve Actuator Mounting Bolts 6.9 0.70 61 in·lb

6 Exhaust Butterfly Valve Actuator Pulley Bolt 4.9 0.50 43 in·lb

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

8 Separator Bracket Mounting Bolt 0.8 0.08 7in·lb

Vehicle-down Sensor Bolts

10 Water Temperature Sensor 25 2.5 18 SS

11. Vacuum Switch Valve

12. Canister

13. ECU

14. Exhaust Butterfly Valve Cable (Accelerator)

15. Exhaust Butterfly Valve Cable (Decelerator)

16. Fitting

17. Relay Box

18. Separator

19. Stick Coil

20. Blue Tube

21. Green Tube

22. Red Tube

23. White Tube

24. California Model

HG: Apply high-temperature grease.

L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specific tightening sequence.

SS: Apply silicone sealant.

N·m kgf·m ft·lb

0.4 0.04 4in·lb

5.9 0.60 52 in·lb

Torque

Remarks

3-10 FUEL SYSTEM (DFI)

Specifications

Item Standard

Digital Fuel Injection System

Idle Speed 1 300 ±50 r/min (rpm)

Throttle Assy:

Type

Bore 38 mm (1.5 in.)

Throttle Body Vacuum 27.3 ±1.3 kPa (205 ±10 mmHg)

Bypass Screws –––

ECU (Electronic Control Unit):

Make Denso

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

Usable Engine Speed 100 ∼ 14 960 r/min (rpm)

Fuel Pressure (High Pressure Line):

Right after Ignition Switch ON, with fuel pump running for 3 seconds with engine idling

Fuel Pump:

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

Discharge 67 mL (2.27 US oz) or more for 3 seconds

Primary Fuel Injectors:

Type INP-200

Nozzle Type Fine atomizing type with 12 holes

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

Secondary Fuel Injectors:

Nozzle Type Multihole type with 3 holes

Resistance About 11.1 ∼ 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 1.02 ∼ 4.62 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 About DC 9 ∼ 11 V at Ignition Switch ON Output Voltage at Sensor About DC 0.05 ∼ 0.07 V at Ignition Switch ON and 0 km/h

Oval type

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)

FUEL SYSTEM (DFI) 3-11

Specifications

Item Standard

Vehicle-down Sensor:

Detection Method Magnetic flux detection method

Detection Angle More than 60 ∼ 70° for each bank Detection Time Within 1.0 ∼ 1.5 second 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:

Input Voltage

Output Voltage DC 1.08 ∼ 4.60 V between BR and BR/BK leads (at idle

Resistance

Exhaust Butterfly Valve Actuator Sensor:

Resistance

Immobilizer Amplifier:

Antenna Resistance About 0.6 ∼ 0.9 Ω

Exhaust Butterfly Valve Actuator:

Output Voltage 3.46 ∼ 3.76 V

Subthrottle Valve Actuator:

Resistance

Input Voltage About DC 8.5 ∼ 10.5 V

Throttle Grip and Cables

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

Non-adjustable and non-removal

DC 4.75 ∼ 5.25 V between BL and BR/BK leads

throttle opening to full throttle opening)

4 ∼ 6kΩ

About 5.5 ∼ 7.5 Ω

3-12 FUEL SYSTEM (DFI)

Special Tools and Sealant

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

Fork Oil Level Gauge: 57001-1290

Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

Throttle Sensor Setting Adapter: 57001-1538

Sensor Harness Adapter: 57001-1561

Throttle Sensor Setting Adapter #1: 57001-1400

Peak Voltage Adapter: 57001-1415

Fuel Pressure Gauge Adapter: 57001-1593

Fuel Hose: 57001-1607

Special Tools and Sealant

FUEL SYSTEM (DFI) 3-13

Speed Sensor Measuring Adapter: 57001-1635

Kawasaki Bond (Silicone Sealant): 56019-120

3-14 FUEL SYSTEM (DFI)

DFI Parts Location

Subthrottle Sensor [A] Subthrottle Valve Actuator [B] Fuel Injectors (Primary) #1, #2, #3, #4 [C]

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

Battery [A] Relay Box [B] Exhaust Butterfly Valve Actuator [C] ECU (Electronic Control Unit) [D]

Self-diagnosis Terminal [A] Kawasaki Diagnosis System (KDS) Connector [B] Vehicle-down Sensor [C]

Inlet Air Temperature Sensor [A]

DFI Parts Location

Camshaft Position Sensor [A] Crankshaft Sensor [B]

Speed Sensor [A]

FUEL SYSTEM (DFI) 3-15

Neutral Switch [A]

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

Immobilizer Amplifier [A]

3-16 FUEL SYSTEM (DFI)

Kawasaki ZX6R Ninja Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF ABBREVIATIONS

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 Wire s

ZX636-C1 (Europe) Left Side View

ZX636-C1 (Europe) Right Side View

ZX636-C1 (US and Canada) Left Side View

ZX636-C1 (US and Canada) Right Side View

Prefixes for Units

Units of Mass

Units of Volume

Units of Length

Units of Torque

Units of Pressure

Units of Speed

Units of Force

Units of Temperature

Units of Power

Periodic Maintenance

Periodic Inspection

Periodic Replacement Parts

Periodic Inspection

Periodic Replacement Parts

Basic Torque for General Fasteners

Fuel System (DFI)

Throttle Control System Inspection

Throttle G rip Free Play

Engine Vacuum Synchronization Inspection

Engine Vacuum

Main Throttle Sensor Output Voltage

Idle Speed Inspection

Idle Speed

Idle Speed Adjustment

Fuel Hose Damage and Installation Condition Inspection

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Cooling System

Coolant Level Inspection

Radiator Hose Damage and Installation Condition Inspection

Engine To p End

Valve Clearance Inspection

Valve Cleara nce

Valve Clearance Adjustment

VA LVE CLEARANCE ADJUSTMENT CHART INLET VALVE

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

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 Inspectio n