KAWASAKI ZZR 1400 User Manual [fr]

ZZR 1400

ZZR1400 ABS

Ninja ZX-14

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

ZZR 1400

ZZR1400 ABS

Ninja ZX-14

Motorcycle

Service Manual

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

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

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

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

© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1): Mar. 3, 2006 (M)

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

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

°C degree(s) Celsius r revolution

DC direct current rpm revolution(s) per minute

F

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

farad(s) TDC

N

newton(s)

top dead center

COUNTRY AND AREA CODES

AT Austria FR France

AU Australia

CA Canada

CAL California US United States

CH Switzerland WVTA Whole Vehicle Type Approval

DE Germany

GB

M

Y

United Kingdom

M

alaysia

EMISSION CONTROL INFORMATION

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 “remove or render inoperative any device or element of design” has been genera lly

○

interpreted as follows.

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

2. Tampering could include.

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

ceeded.

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

or durability of the motorcycle.

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

dards.

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

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE TH ESE PROVISIONS OF FEDERAL LAW,

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

TAMPERING WITH N OISE 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

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

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

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

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

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

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

lows.

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

General Specifications............................................................................................................ 1-12

Technical Information-CAN (Controller Area Network) Communication System.................... 1-15

Unit Conversion Table ............................................................................................................ 1-18

1

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following.

Battery Ground

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

Edges of Parts

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

Solvent

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

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

Cleaning vehicle before disassembly

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

Before Servicing

Arrangement and Cleaning of Removed Parts

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

Storage of Removed Parts

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

GENERAL INFORMATION 1-3

Inspection

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

Replacement Parts

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

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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

Tightening Torque

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

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 inner and outer race and result in bearing damage.

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

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

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

Circlips, Cotter Pins

Replace 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 Wires

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

Instrument

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

Model Identification

ZX1400A6F (Europe) Left Side View

GENERAL INFORMATION 1-7

ZX1400A6F (Europe) Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

Model Identification

ZX1400A6F (United States and Canada) Left Side View

ZX1400A6F (United States and Canada) Right Side View

Model Identification

ZX1400A6F (Malaysia) Left Side View

GENERAL INFORMATION 1-9

ZX1400A6F (Malaysia) Right Side View

1-10 GENERAL INFORMATION

Model Identification

ZX1400B6F (Europe) Left Side View

ZX1400B6F (Europe) Right Side View

Model Identification

ZX1400B6F (Malaysia) Left Side View

GENERAL INFORMATION 1-11

ZX1400B6F (Malaysia) Right Side View

1-12 GENERAL INFORMATION

General Specifications

Items ZX1400A6F, ZX1400B6F

Dimensions

Overall Length 2 170 mm (85.4 in.)

Overall Width 760 mm (29.9 in.)

Overall Height 1 170 mm (46.1 in.)

Wheelbase

Road Clearance 125 mm (4.9 in.)

Seat Height 800 mm (31.5 in.)

Dry Mass:

ZX1400A6F 215 kg (474 lb)

ZX1400B6F 218 kg (481 lb)

Curb Mass:

Front

ZX1400A6F 125 kg (276 lb)

ZX1400B6F 126 kg (278 lb)

Rear

ZX1400A6F 127 kg (280 lb)

ZX1400B6F 129 kg (284 lb)

Fuel Tank Capacity 22 L (5.8 US gal)

Performance

Minimum Turning Radius

Engine

Type 4-stroke, DOHC, 4-cylinder

Cooling System

Bore and Stroke 84.0 × 61.0 mm (3.3 × 2.4 in.)

Displacement 1 352 cm³ (82.5 cu in.)

Compression Ratio 12.0 : 1

Maximum Horsepower 140.0 kW (190 PS) @9 500 r/min (rpm),

Maximum Torque 154 N·m (15.7 kgf·m, 114 ft·lb) @7 500 r/min (rpm),

Carburetion System FI (Fuel injection), MIKUNI 44EIDW × 4

Starting System Electric starter

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (digital igniter in ECU)

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

Spark Plug NGK CR9EIA-9

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

Firing Order 1-2-4-3

1 460 mm (57.4 in.)

3.1 m (10.2 ft)

Liquid-cooled

(FR) 78.2 kW (106 PS) @8 500 r/min (rpm),
(MY) 132.6 kW (180 PS) @9 000 r/min (rpm),
(CA, CAL, US) – – –

(FR) 114 N·m (11.6 kgf·m, 84 ft·lb) @4 500 r/min (rpm),
(MY) 147.4 N·m (15.0 kgf·m, 109 ft·lb) @7 500 r/min (rpm),
(CA),(CAL),(US)–––

GENERAL INFORMATION 1-13

General Specifications

Items ZX1400A6F, ZX1400B6F

Valve Timing:

Inlet:

Open 41° (BTDC)

Close 71° (ABDC)

Duration

Exhaust:

Open 64° (BBDC)

Close 34° (ATDC)

Duration 278°

Lubrication System Forced lubrication (wet sump with cooler)

Engine Oil:

Type API SE, SF or SG

Viscosity SAE10W-40

Capacity 4.5 L (4.8 US qt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 1.541 (94/61)

Clutch Type

Transmission:

Type 6-speed, constant mesh, return shift

Gear Ratios:

1st 2.625 (42/16)

2nd 1.947 (37/19)

3rd 1.545 (34/22)

4th 1.333 (32/24)

5th 1.154 (30/26)

6th

Final Drive System:

Type Chain drive

Reduction Ratio 2.412 (41/17)

Overall Drive Ratio 3.849 @Top gear

Frame

Type Press, backbone

Caster (Rake Angle) 23°

Trail 94 mm (3.7 in.)

Front Tire:

Type Tubeless

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

Rear Tire:

Type Tubeless

Size 190/50 ZR17 M/C (73 W)

292°

API SH, SJ or SL with JASO MA

Wet multi disc

1.036 (29/28)

1-14 GENERAL INFORMATION

General Specifications

Items ZX1400A6F, ZX1400B6F

Rim Size:

Front 17 × 3.50

Rear 17 × 6.00

Front Suspension:

Type Telescopic fork (upside-down)

Wheel Travel 117mm(4.6in.)

Rear Suspension:

Type

Wheel Travel 122 mm (4.8 in.)

Brake Type:

Front Dual discs

Rear Single disc

Electrical Equipment

Battery 12 V 14 Ah

Headlight:

Type Semi-sealed beam

Bulb:

High 12 V 55 W + 65 W (quartz-halogen) × 2

Low 12 V 55 W (quartz-halogen) × 2

Tail/Brake Light 12 V 0.5/4.9 W (LED)

Alternator:

Type Three-phase AC

Rated Output 35 A/14 V @5 000 r/min (rpm)

Swingarm (uni-trak)

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

GENERAL INFORMATION 1-15

Technical Information-CAN (Controller Area Network) Communication System

Overview

The CAN communication system is used for transmitting and receiving data that is sent to the meter
unit and ECU. A LCD (liquid crystal display) display in the meter unit displays information such as bat­tery voltage, fuel consumption, and service codes in addition to the conventional indicator functions.

1. Meter Display

1. Fuel Mileage Range

2. Fuel Consumption (Current)

3. Fuel Consumption (Average)

4. Battery Voltage

2. CAN is a multi-cast serial bus standard (ISO protocol). Data is transmitted by changing the voltage

signal of the two bus leads which are composed of high and low voltage wires twisted together.
Since the high-speed ISO standard is used (transmission speeds of up to 500 kbps*), large quan­tities of data can be transmitted and received in a short period of time.

*bps: bit/sec → the number of signals (0 or 1) transmittable/receivable per second

5. Gear Position

6. Service Code

7. Immobilizer Registration

8. Clutch Engagement Timing

1-16 GENERAL INFORMATION

Technical Information-CAN (Controller Area Network) Communication System

Structure and Function

1. In the CAN communication system, anti-noise twisted pair leads are used (two leads).

Twisted Pair Leads [A] (In the main harness)

2. Data is transmitted from the two nodes-the ECU and meter unit-on the CAN bus and does not
contain specific bus addresses of either node.

Instead, the content of a data stream, such as engine rpm, is labeled with an identifier that is unique
throughout the network. All nodes on the network receive the data and each performs an acceptance
test on the identifier to determine if the message (and its data) is relevant to that particular node.

If a message is relevant to a particular node (meter unit), it will be processed and displayed other­wise it is ignored. The unique data identifier also determines the priority of the message. In situations
where the two nodes attempt to transmit at the same time, a non-destructive arbitration technique
guarantees that the messages are sent in order of importance.

3. The CAN data that is transmitted from the ECU to the meter unit are engine rpm, water temper-

ature, gear position, starter lockout switch, self-diagnosis information and *fuel injected volume.
And the data transmitted from the meter to the ECU is vehicle speed.

*Fuel injected volume is converted into the fuel consumption by the meter unit.

GENERAL INFORMATION 1-17

Technical Information-CAN (Controller Area Network) Communication System

System failure and maintenance

1. Detection of a system failure
When the DFI or immobilizer system fails, the information will be shown on the LCD under the "ig-

nition switch ON" c ondition.

2. System maintenance

1. Do not add a by-pass lead to the twisted pair lead. This can damage components.

2. Do not modify the twisted pair lead or loosen/tighten the number of twists. Such modifications of
the leads can cause the deterioration of the anti-noise characteristics resulting in communication
errors.

1-18 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units

Prefix Symbol Power

mega M × 1 000 000

kilo k × 1 000

centi c ×0.01

milli m ×0.001

micro µ × 0.000001

Units of Mass

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume

L × 0.2642 = gal (US)

L × 0.2200 = gal (imp)

L × 1.057 = qt (US)

L × 0.8799 =

L×2.113=

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (imp)

mL × 0.06102 = cu in

qt (imp)

pint (US)

Units of Length

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque

N·m × 0.1020 = kgf·m

N·m × 0.7376 =

N·m × 8.851 = in·lb

kgf·m × 9.807 = N·m

kgf·m

kgf·m × 86.80 = in·lb

× 7.233 =

ft·lb

ft·lb

Units of Pressure

kPa × 0.01020 = kgf/cm²

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm²

kgf/cm² × 14.22 = psi

cmHg×1.333=kPa

× 98.07 = kPa

Units of 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 =

kW ×1.341=HP

PS × 0.7355 = kW

PS

× 0.9863 = HP

PS

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

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

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

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

Maintenance Procedure ......................................................................................................... 2-15

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

Throttle Control System Inspection................................................................................... 2-15

Engine Vacuum Synchronization Inspection..................................................................... 2-15

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

Idle Speed Adjustment...................................................................................................... 2-19

Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-19

Cooling System.................................................................................................................... 2-20

Coolant Level Inspection................................................................................................... 2-20

Radiator Hose and Pipe Inspection .................................................................................. 2-20

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

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

Air Suction System .............................................................................................................. 2-21

Air Suction System Damage Inspection............................................................................ 2-21

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

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

Clutch and Drive Train ......................................................................................................... 2-27

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

Clutch Fluid Level Inspection ............................................................................................ 2-27

Clutch Fluid Leak Inspection............................................................................................. 2-28

Clutch Hose and Pipe Damage and Installation Condition Inspection.............................. 2-28

Wheels/Tires........................................................................................................................ 2-29

Air Pressure Inspection..................................................................................................... 2-29

Wheel/Tire Damage Inspection......................................................................................... 2-29

Tire Tread Wear Inspection .............................................................................................. 2-29

Wheel Bearing Damage Inspection .................................................................................. 2-30

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

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

Drive Chain Slack Inspection ............................................................................................ 2-31

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

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

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

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

Brake System ...................................................................................................................... 2-34

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-34

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

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

Brake Fluid Level Inspection ............................................................................................. 2-35

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

Brake Light Switch Operation Inspection.......................................................................... 2-37

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

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

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

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

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

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

2

2-2 PERIODIC MAINTENANCE

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

Steering P lay Inspection ................................................................................................... 2-39

Steering P lay Adjustment.................................................................................................. 2-39

Steering S tem Bearing Lubrication ................................................................................... 2-40

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

Lights and Switches Operation Inspection ........................................................................ 2-41

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

Sidestand Switch Operation Inspection ............................................................................ 2-45

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

Others.................................................................................................................................. 2-46

Chassis Parts Lubrication ................................................................................................ 2-46

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-47

Replacement P arts .............................................................................................................. 2-48

Air Cleaner Element Replacement.................................................................................... 2-48

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

Coolant Change ................................................................................................................ 2-51

Radiator Hose and O-ring Replacement ........................................................................... 2-53

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

Oil Filter Replacement ...................................................................................................... 2-54

Brake Hose and Pipe Replacement.................................................................................. 2-55

Brake Fluid Change .......................................................................................................... 2-57

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

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

Rear Caliper Assembly ..................................................................................................... 2-62

Clutch Hose and Pipe Replacement................................................................................. 2-63

Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement............................. 2-64

Clutch Fluid Change ......................................................................................................... 2-66

Spark Plug Replacement .................................................................................................. 2-66