KAWASAKI ZZR 1400 User Manual [fr]

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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.

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 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

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

United Kingdom

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

1-2 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

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

× 0.9863 = HP

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 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

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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.

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

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 - inspect

Coolant leak (radiator hose and pipe) - inspect year

Radiator hose damage - inspect year

Radiator hose installation condition - inspect year

Evaporative Emission Control System (CAL)

Evaporative emission control system function

- inspect

Air Suction System

year

• • • •

• • •

• • • •

• • • • • • •

*ODOMETER

READING

×1000km

(× 1000 mile)

See

Page

2-15

2-19

2-20

2-21

Air suction system damage - inspect

Engine Top End

Valve clearance - inspect

Clutch and Drive Train

Clutch operation (play, disengagement, engagement) - inspect

Clutch fluid level - inspect 6 months

Clutch fluid leak (clutch hose and pipe) inspect

Clutch hose and pipe damage - inspect year

Clutch hose installation condition - inspect year

Wheels and Tires

Tire air pressure - inspect year

Wheels/tires damage - inspect

Tire tread wear abnormal wear - inspect

Wheel bearing damage - inspect year

US, CA, AU Model

Other than US, CA, AU Model

year

• • •

•

Every 42 000 km (26 000 mile)

• • • •

• • • • • • •

• • •

2-21

2-22

2-27

2-28

2-29

2-30

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

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

Final Drive

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

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

Brake hose and pipe damage - inspect year

Brake hose installation condition - inspect year

Brake operation (effectiveness, play, no drag)

- inspect

Brake fluid level - inspect 6months

Brake pad wear - 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

Whichever

comes

first

year

*ODOMETER

READING

× 1000 km

(× 1000 mile)

1 6 12 18 24 30 36

• • •

• • • • • • •

• • • • • •

• • • • • • •

• • •

See

Page

2-31

2-32

2-33

2-34

2-35

2-36

2-37

2-38

Rocker arm operation - inspect

Tie-rods operation - inspect

Steering System

Steering play - inspect year

Steering stem bearings-lubricate 2 years

Electrical System

Lights and switches operation - inspect year

Headlight aiming - inspect year

Sidestand switch operation - inspect

Engine stop switch operation - inspect year

Others

Chassis parts-lubricate

Bolts, nuts and fasteners tightness - inspect

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

frequent starting/stopping.

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

year

• • • •

• • •

•

• • •

2-38

2-39

2-41

2-44

2-45

2-46

2-47

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

come

first

1 12 18 24 36 48

CHANGE/REPLACEMENT Every (0.6) (7.5) (12) (15) (24) (30)

Air cleaner element # Every 18 000 km (12 000 mile) 2-48

* ODOMETER READING

× 1000 km

(× 1000 mile)

See

Page

Fuel hose 4 years

Coolant 3 years

Radiator hoses and O-rings 3 years

Engine oil # year

Oil filter

Brake hose and pipe 4 years

Brake fluid 2 years

Rubber parts of brake master cylinder/caliper 4 years

Clutch hose and pipe 4 years

Rubber parts of clutch master cylinder/slave cylinder

Clutch fluid 2 years

Spark plugs

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

frequent starting/stopping.

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

year

4 years

• • • • •

• •

• • • •

•

2-49

2-51

2-53

2-54

2-55

2-57

2-58

2-63

2-64

2-66

2-6 PERIODIC MAINTENANCE

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.

M: Apply molybdenum disulfied grease.

MO: Apply molybdenum disulfide grease oil

(mixture of engine oil and molybdenum disulfide grease in a weight ration is 10 : 1). R: Replacement Parts S: Tighten the fasteners following the specified sequence.

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

SS: Apply silicone sealant.

Fastener

Fuel System

Air Cleaner Element Cover Bolts 6.9 0.70 61 in·lb

Air Cleaner Element Holder Screws 6.9 0.70 61 in·lb

Bypass Screws 0.2 0.02 1.8 in·lb

Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb

Crankshaft Sensor Bolts

Delivery Pipe Mounting Screws

Duct Clamp Bolts

Front Air Inlet Duct Mounting Bolts 9.8 1.0 87 in·lb

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Gear Position Switch Lead Clamp Bolts 9.8 1.0 87 in·lb

Gear Position Switch Screws

Inlet Air Pressure Sensor Bracket Screws

Middle Air Inlet Duct Clamp Bolts

Middle Air Inlet Duct Mounting Bolts 9.8 1.0 87 in·lb

Rear Air Inlet Duct Mounting Bolts 9.8 1.0 87 in·lb

Speed Sensor Bolt 3.9 0.40 35 in·lb L

Throttle Body Assy Holder Bolts 9.8 1.0 87 in·lb S

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

Vehicle-down Sensor Bolts 5.9 0.60 52 in·lb

Water Temperature Sensor 25 2.5 18

Cooling System

Coolant Drain Plug 12 1.2 106 in·lb

Coolant Fitting Bolts

Oil Cooler Mounting Bolts

Radiator Hose Clamp Screws

Thermostat Housing Cover Bolts 5.9 0.60 52 in·lb

Thermostat Housing Mounting Bolts 9.8 1.0 87 in·lb

Water Pump Cover Bolts 9.8 1.0 87 in·lb

Water Temperature Sensor

N·m kgf·m ft·lb

5.9 0.60 52 in·lb L

5.0 0.51 44 in·lb

2.0 0.20 18 in·lb

2.9 0.30 26 in·lb L

3.5 0.36 31 in·lb

2.9 0.30 26 in·lb

8.8 0.90 78 in·lb L

12 1.2 106 in·lb

2.0 0.20 18 in·lb

25 2.5 18

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Engine Top End

Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb L

Camshaft Cap Bolts 12 1.2 106 in·lb S

Camshaft Chain Guide Bolts 12 1.2 106 in·lb S

Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb

Camshaft Position Sensor Bolt

Cam Sprocket Mounting Bolts

Crankshaft Sensor Cover Bolts

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

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb S

Cylinder Head Bolts (M11, First) 39 4.0 29 MO, S

Cylinder Head Bolts (M11, Final) 71 7.2 52 MO, S

Engine Bracket Bolts (M8) 25 2.5 18 R, S

Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18

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

Front Engine Mounting Bolts (M10) 59 6.0 44 R, S

Muffler Body Mounting Bolts 34 3.5 25

Spark Plugs

Throttle Body Holder Bolts 9.8 1.0 87 in·lb

Throttle Body Assy Holder Clamp Bolts

Water Passage Plugs 20 2.0 15 L

Clutch

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

Clutch Hose Banjo Bolt

Clutch Hub Nut

Clutch Lever Pivot Bolt

Clutch Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb

Clutch Master Cylinder Bleed Valve 7.8 0.80 69 in·lb

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

Clutch Slave Cylinder Bleed Valve 7.8 0.80 69 in·lb

Clutch Slave Cylinder Bolts – – – L

Clutch Spring Bolts 8.8 0.90 78 in·lb

Oil Filler Cap – – –

Engine Lubrication System

Engine Oil Drain Bolt 30 3.0 22

Holder Mounting Bolt 35 3.6 26 L

Oil Cooler Mounting Bolts 12 1.2 106 in·lb S

Oil Filter 31 3.2 23 G, R

Oil Pan Bolts 9.8 1.0 87 in·lb

Oil Pan Plate Bolts 9.8 1.0 87 in·lb L

Oil Passage Plug 20 2.0 15 L

Oil Pressure Relief Valve 15 1.5 11 L

N·m

9.8 1.0 87 in·lb

15 1.5 11 L

9.8 1.0 87 in·lb

13 1.3 115 in·lb

2.0 0.20 18 in·lb

25 2.5 18

135 14 100 R

1.0 0.10 8.9 in·lb

Torque

Remarks

kgf·m ft·lb

L(1)

Hand

-tighten

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Oil Pressure Switch 15 1.5 11 SS

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

Oil Pump Cover Bolts 9.8 1.0 87 in·lb

Engine Removal/Installation

Adjusting Collars 25 2.5 18 M

Engine Bracket Bolts (M8)

Engine Mounting Nuts (M12)

Front Engine Mounting Bolts (M10)

Subframe Bolts 23 2.3 17 R

Crankshaft/Transmission

Balancer Shaft Clamp Bolts 9.8 1.0 87 in·lb

Balancer Shaft Clamp Lever Bolts 25 2.5 18

Bearing Position Plate Screws 4.9 0.50 43 in·lb L

Breather Cover Bolts 9.8 1.0 87 in·lb

Breather Plate Screws 9.8 1.0 87 in·lb L

Connecting Rod Big End Nuts

Crankcase Bolts (M6, L = 25 mm) 12 1.2 106 in·lb S

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

Crankcase Bolt (M6, L = 50 mm) 12 1.2 106 in·lb S

Crankcase Bolt (M6, L = 65 mm)

Crankcase Bolts (M7, L = 45 mm)

Crankcase Bolt (M7, L = 50 mm)

Crankcase Bolts (M7, L = 60 mm) 20 2.0 15 S

Crankcase Bolts (M7, L = 65 mm) 20 2.0 15 S

Crankcase Bolt (M7, L = 85 mm) 20 2.0 15 S

Crankcase Bolt (M7, L = 110 mm) 20 2.0 15 S

Crankcase Bolts (M8, L = 70 mm) 27 2.8 20 S

Crankcase Bolts (M8, L = 80 mm) 27 2.8 20 S

Crankcase Bolts (M10, L = 90 mm) 47 4.8 35 MO, S

Crankcase Bolts (M10, L = 120 mm) 47 4.8 35 MO, S

Drive Shaft Cover Bolts 25 2.5 18 L

Gear Positioning Lever Bolt

Gear Position Switch Lead Clamp Bolt

Gear Position Switch Screws

Oil Passage Plugs 20 2.0 15 L

Shift Drum Bearing Holder Screws 4.9 0.50 43 in·lb L

Starter Clutch Shaft Bolt 9.8 1.0 87 in·lb L

Starter Clutch Shaft Plate Bolt 9.8 1.0 87 in·lb L

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

Shift Shaft Return Spring Pin 29 3.0 21 L

Timing Rotor Bolt 39 4.0 29

Torque Limiter Bolt 25 2.5 18 L

N·m kgf·m ft·lb

25 2.5 18

59 6.0 44

see the

text

12 1.2 106 in·lb

20 2.0 15

12 1.2 106 in·lb

9.8 1.0 87 in·lb

2.9 0.30 26 in·lb L

Torque

Remarks

S, R

← ← ←

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Wheels/Tires

Front Axle Clamp Bolts

Front Axle Nut 127 13.0 94

Rear Axle Nut 127 13.0 94

Final Drive

Chain Guide Bolt

Chain Guide Bolts

Engine Sprocket Cover Bolts

Engine Sprocket Nut 125 13.0 92 MO

Rear Axle Nut 127 13.0 94

Rear Sprocket Nuts 69 7.0 51

Speed Sensor Bolt

Stud Bolts

Brakes

Bleed Valves 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 25 2.5 18

Brake Lever Pivot Bolt 1.0 0.10 9in·lb Si

Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb

Brake Pedal Bolt 8.8 0.90 78 in·lb

Brake Pipe Joint Nuts (ZX1400B Models)

Front Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

Front Brake Pad Pins 17.2 1.8 13

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

Front Caliper Assembly Bolts 27 2.8 20 L

Front Caliper Mounting Bolts 34 3.5 25

Front Master Cylinder Bleed Valve 7.8 0.80 69 in·lb

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

Rear Brake Disc Mounting Bolts 27 2.5 18 L

Rear Brake Pad Pin 17.2 1.8 13

Rear Caliper Assembly Bolts

Rear Caliper Mounting Bolts

Rear Master Cylinder Mounting Bolts 25 2.5 18

Rear Master Cylinder Push Rod Locknut 17.2 1.8 13

Suspension

Front Axle Clamp Bolts 20 2.0 15 AL

Front Fork Bottom Allen Bolts 23 2.3 17 L

Front Fork Clamp Bolts (Upper)

Front Fork Clamp Bolts (Lower) 30 3.1 22 AL

Front Fork Top Plugs 22 2.2 16

Piston Rod Nuts 28 2.9 21

Rear Shock Absorber Nut (Upper) 34 3.5 25

Rear Shock Absorber Nut (Lower) 34 3.5 25

N·m

20 2.0 15 AL

12 1.2 106 in·lb L

9.8 1.0 87 in·lb L

9.8 1.0 87 in·lb

3.9 0.40 35 in·lb L

14.7 1.5 11 L

18 1.8 13

37 3.8 27 L

25 2.5 18

20 2.0 15

Torque

Remarks

kgf·m ft·lb

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Swingarm Pivot Adjusting Collar 20 2.0 15

Swingarm Pivot Adjusting Collar Locknut 98 10.0 72

Swingarm Pivot Shaft Nut 108 11 .0 80

Tie-Rod Nuts 59 6.0 44

Uni-Trak Rocker Arm Nut 34 3.5 25

Steering

Front Fork Clamp Bolts (Upper)

Front Fork Clamp Bolts (Lower)

Handlebar Bolts 34 3.5 25 L

Handlebar Holder Bolts 25 2.5 18 AL

Steering Stem Head Nut 78 8.0 58

Steering Stem Nut 23 2.3 17

Switch Housing Screws 3.5 0.36 31 in·lb

Frame

Center Stand Bolts 44 4.5 32

Front Footpeg Bracket Bolts 25 2.5 18

Grab Rail Mounting Bolts 25 2.5 18

Rear Fender Mounting Screws

Rear Footpeg Bracket Bolts 25 2.5 18

Rear Frame Bolts 44 4.5 32 L

Rear Frame Pipe Bolts 44 4.5 32

Rear Frame Pipe Nuts 44 4.5 32

Seat Lock Bracket Screws 1.2 0.12 11 in·lb

Sidestand Bolt 44 4.5 32

Sidestand Bracket Bolts 49 5.0 36 L

Sidestand Switch Bolt 8.8 0.90 78 in·lb L

Windshield Mounting Bolts 0.42 0.043 3.7 in·lb

Electrical System

Alternator Cover Bolts 9.8 1.0 87 in·lb

Alternator Lead Holding Plate Bolts 8.3 0.85 73 in·lb L

Alternator Rotor Bolt (First)

Alternator Rotor Bolt (Final)

Camshaft Position Sensor Bolt 9.8 1.0 87 in·lb

Crankshaft Sensor Bolts 5.9 0.60 52 in·lb L

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

Engine Ground Terminal Bolt 9.8 1.0 87 in·lb

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

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

Fuel Level Sensor Bolts 6.9 0.70 61 in·lb L

Gear Position Switch Lead Clamp Bolts 9.8 1.0 87 in·lb

Gear Position Switch Screws 2.9 0.30 26 in·lb L

Headlight Mounting Screws

Left Switch Housing Screws

N·m kgf·m ft·lb

20 2.0 15

30 3.1 22 AL

1.2 0.12 11 i n · l b

69 7.0 51

110 11.2 81

1.2 0.12 11 i n · l b

3.5 0.36 31 in·lb

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-11

Fastener

Licence Plate Light Cover Mounting Screws

Licence Plate Light Mounting Screws

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

RegulatorRectifier Bolts 9.8 1.0 87 in·lb

Right Switch Housing Screws 3.5 0.36 31 in·lb

Sidestand Switch Bolt 8.8 0.90 78 in·lb L

Spark Plugs 13 1.3 115 in·lb

Speed Sensor Bolt 3.9 0.40 34 in·lb L

Starter Lockout Switch Screw 0.7 0.07 6in·lb

Starter Motor Cable Mounting Bolt 3.9 0.40 34 in·lb

Starter Motor Cable Terminal Nut 5.9 0.60 52 in·lb

Starter Motor Mounting Bolts

Starter Motor Terminal Locknut

Starter Motor Through Bolts

Stator Coil Bolts 12 1.2 106 in·lb

Tail/Brake Light Mounting Screws 1.2 0.12 11 i n · lb

Water Temperature Sensor 25 2.5 18

N·m

0.9 0.09 8in·lb

1.2 0.12 11 in·lb

9.8 1.0 87 in·lb

6.9 0.70 61 in·lb

3.4 0.35 30 in·lb

Torque

Remarks

kgf·m ft·lb

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

10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72 16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115 18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165 20 225 ∼ 325 23 ∼ 33 165 ∼ 240

∼ 19

4 ∼ 1.9

.0 ∼ 13.5

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System

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

Idle Speed 1 100 ±50 r/min (rpm) –––

Throttle Body Vacuum 39 ±1.33 kPa (293 ±10 mmHg) at idle speed –––

Air Cleaner Element

Cooling System

Coolant:

Type (Recommended) Permanent type antifreeze –––

Color Green –––

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

Freezing Point

Total Amount 3.4 L (3.6 US qt) –––

Engine Top End

Valve Clearance:

Exhaust 0.22 ∼ 0.27 mm (0.0087 ∼ 0.0106 in.) ––– Inlet 0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.) –––

Clutch

Clutch Fluid:

Grade DOT4 –––

Clutch Lever Free Play

Engine Lubrication System

Engine Oil:

Type API SE, SF or SG –––

Viscosity SAE 10W-40 –––

Capacity 3.7 L (3.9 US qt) (when filter is not removed)

Level

Wheels/Tires

Tread Depth:

Front 3.8 mm (0.15 in.) 1 mm (0.04 in.),

Rear

Air Pressure (when Cold):

Front

Rear

Viscous paper element –––

–35°C (–31°F)

Non-adjustable –––

API SH, SJ or SL with JASO MA

4.1 L (4.3 US qt) (when filter is removed)

4.5 L (4.8 US qt) (when engine is completely dry)

Between upper and lower level lines (Wait 2 ∼

3 minutes after idling or running)

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

4.8 mm (0.19 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.), Over 130 km/h (80 mph): 3 mm (0.12 in.)

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

–––

PERIODIC MAINTENANCE 2-13

Specifications

Item Standard Service Limit

Final Drive

DriveChainSlack 32 ∼ 38 mm (1.3 ∼ 1.5 in.) –––

Drive Chain Wear (20-link Length)

Standard Chain:

Make DAIDO –––

Type DID50ZVM4 GC&B –––

Link 116 links –––

Brakes

Brake Fluid:

Grade DOT4

Brake Pad Lining Thickness:

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

Rear

Brake Light Timing:

Front Pulled ON –––

Rear

Electrical System

Spark Plug:

Type NGK CR9EIA-9 –––

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

–––

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

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

–––

2-14 PERIODIC MAINTENANCE

Special Tools

Inside Circlip Pliers: 57001-143

Steering Stem Nut Wrench: 57001-1100

Jack: 57001-1238

Pilot Screw Adjuster, C: 57001-1292

Vacuum Gauge: 57001-1369

Pilot Screw A dj u ster Adapter, 5: 57001-1372

Oil Filter Wrench: 57001-1249

Jack Attachment: 57001-1608

Maintenance Procedure

Fuel System (DFI)

Throttle Control System Inspection

Check the throttle grip free play [A].

•

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

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

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

•

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

•

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

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

•

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

•

throttle grip plenty of play.

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

•

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

Tighten the locknut [A].

•

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

•

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

Tighten the locknut [B].

•

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

PERIODIC MAINTENANCE 2-15

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:

•

Fuel Tank Cover (see Fuel Tank Removal in the Fuel System (DFI) chapter) Left and Right Middle Fairings (see Middle Fairing Removal in the Frame chapter)

Pull off the rubber caps [A] from the fittings of each throttle

•

body.

Front [B]

2-16 PERIODIC MAINTENANCE

Maintenance Procedure

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

•

Pull off the air switching valve hose [A] from the air cleaner

•

housing. Plug the air switching valve hose end and air cleaner

•

housing hole.

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

•

the fittings on the throttle body.

Special Tool - Vacuum Gauge: 57001-1369

Connect a highly accurate tachometer [B] to one of the

•

stick coil primary leads.

Start the engine and warm it up thoroughly.

•

Check the idle speed, using a highly accurate tachometer

•

[A]. If the idle speed is out of the specified range, adjust it w ith the adjust screw.

CAUTION

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

While idling the engine, inspect the throttle body vacuum,

•

using the vacuum gauge [B].

Throttle Body Vacuum

Standard: 39 ±1.33 kPa (293 ±10 mmHg) at Idle Speed

1 100 ±50 r/min (rpm)

Maintenance Procedure

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

Example:

#1: 260 mmHg #2: 290 mmHg #3: 250 mmHg #4: 270 mmHg

With the engine at the correct idle speed, equalize higher

•

vacuum of #1 or #2 (for example 290 mmHg) to higher vacuum of #3 or #4 (for example 270 mmHg) by turning the center adjusting screw [A].

Right Side View [B]

In this photo [C], the throttle body has been removed for

○

clarity.

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

Pilot Screw Adjuster Adapter,

-1372

5: 57001

PERIODIC MAINTENANCE 2-17

NOTE

After adjustment, the final vacuum measurement be-

○

tween the highest throttle valves may not be 290 mmHg (for example). The goal is to have the highest two vacuums between the left (#1 and #2) and right (#3 and #4) banks be the same and be within the service limits.

Open and close the throttle after each measurement, and

•

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

•

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

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

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

Pilot Screw Adjuster Adapter,

-1372

Rear View [B]

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

•

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

•

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

•

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

•

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

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

5: 57001

2-18 PERIODIC MAINTENANCE

Maintenance Procedure

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

•

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

Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.8 in·lb)

CAUTION

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

Remove:

•

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

Check the bypass screw and its hole for carbon deposits.

•

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

•

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

•

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

•

Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.8 in·lb)

Back out the same number of turns counted when first

•

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

NOTE

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

○

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

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.

•

If the vacuums are correct, check the output voltage of the main throttle sensor (see Output Voltage Inspection of Main Throttle Sensor in the Fuel System (DFI) chapter).

Main Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → Y/W lead (terminal 26)

Meter (–) → BR/BK lead (terminal 34)

Standard: DC 0.63 ∼ 0.65 V (at idle throttle opening)

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

Remove the vacuum gauge hoses and install the rubber

•

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

•

Route the vacuum hoses according to Cable, Wire, and

○

Hose Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System (DFI) chapter too.

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: 1 100 ±50 r/min (rpm)

PERIODIC MAINTENANCE 2-19

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Turn the adjusting screw [A] until the idle speed is correct.

•

Open and close the throttle a few times to make sure that

○

the idle speed is within the specified range. Readjust if necessary.

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

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

○

sure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and left middle fairing (see Middle Fairing Removal in the Frame c hapter), and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.

Check that the hoses are routed according to Cable, Wire,

•

and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked.

Hose Joints [A] Fuel Hose [B]

2-20 PERIODIC MAINTENANCE

Maintenance Procedure

Check that the hose joints are securely connected.

•

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

○

than two times, and make sure it is locked. If it does not locked, reinstall the hose joint.

WARNING

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

Cooling System

Coolant Level Inspection

NOTE

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

○

ent temperature).

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

•

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

“L”: low “F”: full

CAUTION

For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts.

Radiator Hose and Pipe Inspection

(Coolant leak, damage, Installation Condition)

The high pressure inside the radiator hose can cause

○

coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.

•

Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps

•

are tightened correctly.

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

18 in·lb)

PERIODIC MAINTENANCE 2-21

Maintenance Procedure

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Inspect the canister as follows.

•

Remove the seat (see Seat Removal in the Frame chap-

○

ter). Remove the canister [A], and disconnect the hoses from

○

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

○

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

NOTE

The canister is designed to work well through the motor-

○

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

Check the liquid/vapor separator as follows.

•

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

○

System (DFI) chapter). Disconnect the hoses from the separator, and remove the

○

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

○

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

○

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

•

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

○

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

○

Route the hoses according to Cable, Wire, and Hose

○

Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System (DFI) chapter too. 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.

Air Suction System

Air Suction System Damage Inspection

Remove the right middle fairing (see Middle Fairing Re-

•

moval in the Frame chapter). Pull the air switching vale hose [A] out of the air cleaner

•

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

•

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

•

and feel vaccum pulsing in the hose. If there is n o vaccum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve Inspection in the Engine Top End chapter).

2-22 PERIODIC MAINTENANCE

Maintenance Procedure

Engine Top 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) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Crankshaft Sensor Cover 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)

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

•

between the cam and the valve lifter.

Valve Clearance

Standard:

Exhaust

Inlet

Thickness gauge is horizontally inserted on the valve

○

lifter.

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

0.22 ∼ 0.27 mm (0.0087 ∼ 0.0106 in.)

0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.)

NOTE

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]

PERIODIC MAINTENANCE 2-23

If the valve clearance is not within the specified range, first record the clearance, and then adjust it.

Valve Clearance Adjustment

To change the valve clearance, remove the camshaft

•

chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness.

NOTE

Mark and record the locations of the valve lifters and

○

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

2-24 PERIODIC MAINTENANCE

Maintenance Procedure

Bisides the standard shims in the valve clearance adjust-

○

ment charts, the following additional shims maybe used.

Adjustment Shims

Part Number Thickness

92025-1982 2.425 mm

92025-1983 2.475 mm

92025-1984 2.525 mm

92025-1985 2.575 mm

92180-1058 2.375 mm

92180-1059 2.625 mm

92180-1194 2.675 mm

92180-1195 2.725 mm

92180-1196 2.775 mm

92180-0209 2.025 mm

92180-0210 2.075 mm

92180-0211 2.125 mm

92180-0212 2.175 mm

92180-0213 2.225 mm

92180-0214 2.275 mm

92180-0215 2.325 mm

92180-0216 2.825 mm

92180-0217 2.875 mm

92180-0218 2.925 mm

92180-0219 2.975 mm

Clean the shim to remove any dust or oil.

•

Measure the thickness of the removed shim [A].

•

PERIODIC MAINTENANCE 2-25

Maintenance Procedure

EXHAUST- VALVE CLEARANCE ADJUSTMENT CHART

1. Measure the clearance (with engine 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 2.60 mm.

Measured clearance is 0.33 mm. Replace 2.60 mm shim with 2.70 mm shim.

2-26 PERIODIC MAINTENANCE

Maintenance Procedure

INLET- VALVE CLEARANCE ADJUSTMENT CHART

1. Measure the clearance (with engine 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 2.55 mm.

Measured clearance is 0.36 mm. Replace 2.55 mm shim with 2. 75 mm shim.

Maintenance Procedure

CAUTION

Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified rage, use the additional shim.

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

○

sizes smaller, and remeaasure the valve clearance. When installing the shim, face the marked side toward the

•

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

CAUTION

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

Apply engine oil to the valve lifter surface and install the

•

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

•

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

•

Install the removed parts (see appropriate chapters).

•

PERIODIC MAINTENANCE 2-27

Clutch and Drive Train

Clutch Operation Inspection

Start the engine and check that the clutch does not slip

•

and that it releases properly. If the clutch operation is insufficiency, inspect the clutch system.

WARNING

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

Clutch Fluid Level Inspection

Hold the clutch fluid reservoir [A] horizontal.

•

Check that the clutch fluid level of the clutch reservoir is

•

between the lower [B] and the upper [C] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir. Since the clutch fluid is the same as the brake fluid, refer

○

to Brake Fluid Section in the Brake chapter for further details.

2-28 PERIODIC MAINTENANCE

Maintenance Procedure

Follow the procedure below to instal the clutch fluid reser-

•

voir cap correctly. First, tighten the clutch 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 clutch fluid reservoir body [A].

WARNING

Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter.

Clutch Fluid Leak Inspection

Apply the clutch lever and inspect the clutch fluid leak

•

from the clutch hose/pipe [A] and fittings. If the clutch fluid leaked form any position, inspect or replace the problem part.

Clutch Hose and Pipe Damage and Installation Condition Inspection

Inspect the clutch hoses and fittings for deterioration,

•

cracks, corrosion and signs of leakage. The high pressure inside the clutch 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 it if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and banjo

•

bolts are tightened correctly.

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

ft·lb)

Inspect the clutch hose routing.

•

If any clutch hose routing is incorrect, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if the has been sharply bent or kinked.

Maintenance Procedure

Wheels/Tires

Air Pressure Inspection

Remove the air valve cap.

•

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 P ressure (when Cold)

Front: Up to 180 kg (397 lb)

290 kPa (2.9 kgf/cm², 42 psi)

Rear: Up to 180 kg (397 lb)

290 kPa (2.9 kgf/cm², 42 psi)

Wheel/Tire Damage Inspection

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.

PERIODIC MAINTENANCE 2-29

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).

Tread Depth

Standard:

Front

Rear

Service Limit:

Front

Rear

3.8 mm (0.15 in.)

4.8 mm (0.19 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 (80 mph))

3 mm (0.12 in.) (Over 130 km/h (80 mph))

2-30 PERIODIC MAINTENANCE

Maintenance Procedure

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.

Wheel Bearing Damage Inspec tion

Raise the front wheel off the ground with the jack (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).

Raise the rear wheel off the ground with the stand (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 i s 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).

Drive Train

Drive Chain Lubrication Condition Inspection

If a special lubricant is not available, a heavy oil such as

•

SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubri-

•

cation.

CAUTION

The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules. Use only kerosene or diesel oil for cleaning of the O

-ring of the drive chain. Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O-ring. Immediately blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes.

Maintenance Procedure

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. Check the slack with the motorcycle setting on its center

○

stand (center stand equipped models). Clean the chain if it is dirty, and lubricate it if it appears

○

dry.

PERIODIC MAINTENANCE 2-31

Check the wheel alignment (see Wheel Alignment Inspec-

•

tion).

Rotate the rear wheel to find the position where the chain

•

is tightest.

Measure the vertical movement (chain slack) [A] m idway

•

between the sprockets.

If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard: 32 ∼ 38 mm (1.3 ∼ 1.5 in.)

Drive Chain Slack Adju s tment

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 right and left chain

adjusters [D] evenly.

If the chain is too tight, turn in the right and left 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 right wheel align-

ment indicator [F] should align with the same swingarm

mark or position [G] that the left 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 (13.0 kgf·m, 94 ft·lb)

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

•

est position, and readjust if necessary.

2-32 PERIODIC MAINTENANCE

Maintenance Procedure

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°.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

Bend the cotter pin [A] over the nut.

•

WARNING

If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result.

Wheel Alignment Inspection

Check that the notch [A] on the right alignment indicator

•

[B] aligns with the same swingarm mark or position [C] that the left alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).

NOTE

Wheel alignment can be also checked using the

○

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition.

Drive Chain Wear Inspection

Remove the chain cover (see Drive Chain Removal in the

•

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

•

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

•

weight [A] on the chain. Measure the length of 20 links [B] on the straight part [C] of

•

the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced.

Drive C hain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 i n.)

Service Limit: 323 mm (12.7 in.)

Maintenance Procedure

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: DAIDO

Type: DID50ZVM4 GC&B

Link: 116 links

Chain Guide Wear Insp ection

Remove the 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.

PERIODIC MAINTENANCE 2-33

2-34 PERIODIC MAINTENANCE

Maintenance Procedure

Brake System

Brake Fluid Leak (Bra ke Hose and Pipe) Inspection

For ABS equipped models; note the following.

•

Remove:

•

Fuel Tank (see Fuel Tank Removal i n the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter)

Apply the brake lever or pedal and inspect the brake fluid

•

leak from the brake hoses [A], pipes (ABS equipped models) [B] and fittings [C]. If the brake fluid leaked from any position, inspect or replace the problem part.

Maintenance Procedure

Brake Hose and Pipe Damage and Installation Condition Inspection

For ABS equipped models; note the following.

•

Remove:

•

Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter)

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, pipes (ABS equipped models) to

burst if the line is not properly maintained. Bend and twist

the rubber hose while examining it.

Replace the hose and pipe (ABS equipped models) if any

crack [B], bulge [C] or leakage is noticed.

Tighten any brake hose banjo bolts.

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

ft·lb)

Inspect the brake hose routing.

•

If any brake hose and pipe (ABS equipped models) rout-

ing is incorrect, route the brake hose and pipe according

to Cable, Wire, and Hose Routing section in the Appendix

chapter.

PERIODIC MAINTENANCE 2-35

Brake Operation Inspec tion

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

•

ning the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake

system.

WARNING

When inspecting by running the vehicle, note a

surrounding traffic situation enough in the place of

safety.

Brake Fluid Level Inspection

Check that the brake fluid level in the front brake reservoir

•

[A] is above the lower level line [B].

NOTE

Hold the reservoir horizontal by turning the handlebar

○

when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the

reservoir to the upper level line [C].

2-36 PERIODIC MAINTENANCE

Maintenance Procedure

Follow the procedure below to install the front brake fluid

•

reservoir cap correctly. First, tighten the front brake fluid reservoir cap [B] clock-

○

wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].

Remove the seat (see Seat Removal in the Frame chap-

•

ter). Check that the brake fluid level in the rear brake reservoir

•

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

WARNING

Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

Follow the procedure below to install the rear brake fluid

•

reservoir cap correctly. First, tighten the rear brake fluid reservoir cap [B] clock-

○

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 Li mit: 1 mm (0.04 in.)

4.0 mm (0.16 in.)

5.0 mm (0.20 in.)

Maintenance Procedure

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.).

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

PERIODIC MAINTENANCE 2-37

To avoid damaging the electrical connections in-

side 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)

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).

2-38 PERIODIC MAINTENANCE

Maintenance Procedure

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 (see Rear Shock Absorber Oil Leak Inspection).

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 rear fairing (see Rear 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 Suspension chapter).

Tie-Rod Operation Inspection

Remove the rear fairing (see Rear 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 Suspension chapter).

Maintenance Procedure

Steering System

Steering Play Inspection

Remove the lower fairings (see Lower Fairing Removal in

•

the Frame chapter).

Raise the front wheel off the ground with the j ack.

•

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 l ooseness 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 leads 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:

•

Handlebars (see Handlebar Removal in the Steering chapter) Stem Head Nut [A] and Washer [B] Upper Fork Clamp Bolts [C] (Loosen) Stem Head [D]

Bend the claws [A] of the claw washer straighten.

•

Remove the steering stem locknut [B] and claw washer

•

[C].

2-40 PERIODIC MAINTENANCE

Maintenance Procedure

Adjust the steering.

•

Special Tool - Steering Stem Nut Wrench [A]: 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.

○

Install the claw washer [A] so that its bent side [B] faces

•

upward, and engage the bent claws with the grooves of stem locknut [C]. Hand tighten the stem locknut until it touches the claw

•

washer. Tighten the stem locknut clockwise until the claws are

•

aligned with the grooves (ranging from 2nd to 4th) of stem nut [D], and bend the 2 claws downward [E]. Install the stem head.

•

Install the washer, and tighten the stem head nut.

•

Tighten:

•

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

15 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. Install the handlebars (see Handlebar Installation in the

•

Steering chapter).

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).

•

Maintenance Procedure

Electrical System

Lights and Switches Opera tion Inspection

First Step

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

City Light [A]

Taillight [B]

License Plate Light [C]

Meter Panel Illumination Light (LED) [D]

Meter Panel LCD [E]

Neutral Indicator Light (LED) [F]

Oil Pressure Warning Indicator Light (LED) [G]

ABS Indicator Light (LED) [H] (Equipped Models)

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 Meter Unit Inspection in the Electrical System chapter) Meter Unit for Neutral Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Warning Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Oil Pressure Warning Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) Meter Unit for Illumination Light (LED) (see Meter Unit Inspection in the Electrical System chapter) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Gear Position Switch (see Gear Position Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) ABS Indicator Light (LED) (Equipped Models) (see ABS Indicator Light (LED) Inspection in the Brakes chapter)

Turn off the ignition switch.

•

The all lights should go off.

•

For the immobilizer model, Warning Indicator Light (LED)

•

will blinks (see Immobilizer System (Equipped Models)

section in the Electrical System chapter).

If the light does not go off, replace the ignition switch.

goes on

PERIODIC MAINTENANCE 2-41

2-42 PERIODIC MAINTENANCE

Maintenance Procedure

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)

Third Step

Turn on the ignition switch.

•

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 either of turn signal indicator lights (LED) [C] in the

•

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

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

Push the turn signal switch.

•

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

•

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

Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter)

Maintenance Procedure

Fourth Step

Set the dimmer switch [A] to low beam position.

•

Start the engine.

•

The low beam headlights [B] should go on.

•

If the low beam headlight does not go on, inspect or re-

place the following item.

Headlight Low Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter) Headlight Fuse (Low) 15 A (see Fuse Inspection in the Electrical System chapter) Headlight Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Headlight Circuit Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Headlight Relay (Low) (see Headlight Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)

PERIODIC MAINTENANCE 2-43

Push the passing button (equipped models) or set the

•

dimmer switch to high beam position.

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

•

go on.

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

•

If the high beam headlight and/or high beam indicator light

(LED) does not go on, inspect or replace the following

item.

Headlight High Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter) Headlight Fuse (High) 15 A (see Fuse Inspection in the Electrical System chapter) Headlight Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Passing Button (Equipped Models) (see Switch Inspection in the Electrical system c hapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) Headlight Circuit Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Headlight Relay (High) (see Headlight Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)

Turn off the engine stop switch.

•

The low beam and high beam headlights should stay go-

•

ing on.

If the headlights and high beam indicator light (LED) does

go off, inspect or replace the following item.

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

Turn off the ignition switch.

•

The headlights and high beam indicator light (LED) should

•

go off.

2-44 PERIODIC MAINTENANCE

Maintenance Procedure

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 [A] in both headlights in or out

•

to adjust the headlight vertically.

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]

Maintenance Procedure

Sidestand Switch Operation Inspection

Inspect the sidestand switch [A] operation accordance to

•

table the below.

Sidestand Switch Operation

Sidestand

Up Neutral Released Starts

Up Neutral Pulled in Starts

Up In Ge ar Released

Up In Ge ar Pulle d in Starts

Down Neutral Released Starts

Down Neutral Pulled in Starts

Down

Gear

Position

In Gear

Clutch

Lever

Released

Pulled in

Engine

Start

Doesn’t

start

Doesn’t

start

Doesn’t

start

Engine

Run

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Stops

PERIODIC MAINTENANCE 2-45

If the sidestand switch operation does not work, inspect

or replace the following item.

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

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

2-46 PERIODIC MAINTENANCE

Maintenance Procedure

Engine Stop Switch Operation Inspection

First Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the starter button.

•

The engine does not start.

•

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

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

Second Step

Turn on the ignition switch.

•

Set the neutral position.

•

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

•

Push the s tarter button and run the engine.

•

Turn the engine stop switch to stop position.

•

Immediately the engine should be stop.

•

If the engine does not stop, inspect or replace the following item.

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

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 Center Stand (Equipped Models) Rear Brake Joint Pin Sidestand

Points: Lubricate with Grease.

Throttle Inner Cable Upper and Lower Ends [A]

Maintenance Procedure

Cables: Lubricate with Rust Inhibitor.

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.

With the cable disconnected at both ends, the inner cable

•

should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable

is frayed [B], or if the cable housing is kinked [C], replace

the cable.

PERIODIC MAINTENANCE 2-47

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 spec-

ified torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not in the appropriate chapter,

see the Standard Torque Table. For each fastener, first

loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

2-48 PERIODIC MAINTENANCE

Maintenance Procedure

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts Muffler 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 Holder Bolts Steering Stem Head Nut

Others:

Center Stand (Equipped Models) Footpeg Bracket Bolts Sidestand Bolt

Replacement Parts

Air Cleaner Element R eplacemen t

NOTE

In dusty areas, the element should be replaced more

○

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

○

should be replaced immediately.

WARNING

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

CAUTION

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

Maintenance Procedure

Remove:

•

Fuel Tank Cover (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Element Cover Bolts [A] Air Cleaner Element Cover [B]

Discard the air cleaner element [A].

•

PERIODIC MAINTENANCE 2-49

Install a new element [A] so that screen side [B] faces

•

upward.

CAUTION

Use only the recommended air cleaner element

(Kawasaki part number 11013-0014). Using another

air cleaner element will wear the engine prema-

turely or lower the engine performance.

Install the air cleaner element cover [A] so that arrow mark

•

[B] faces foward.

Tighten:

•

Torque - Air Cleaner Element Cover Bolts: 6.9 N·m (0.70

kgf·m, 61 in·lb)

Fuel Hose Replacement

Pull out the throttle body assy [A] from the holder (see

•

Throttle Body Assy Removal in the Fuel System (DFI)

chapter).

Be sure to place a piece of cloth [B] around the fuel hose

•

joint.

Push the joint lock claws [C].

•

2-50 PERIODIC MAINTENANCE

Maintenance Procedure

Pull the joint lock [A] as shown.

•

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

•

Remove the throttle body assy (see Throttle Body Assy

•

Removal in the Fuel System (DFI) chapter). Pull out the fuel hose to foward [C].

•

WARNING

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

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

•

faces throttle body assy. Run the fuel hose correctly (see Cable, Wire, and Hose

•

Routing section in the Appendix chapter). Pull [B] the joint lock [C] fully as shown.

•

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 the fuel hose joint [A] 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. Install the throttle body assy (see Throttle Body Assy In-

•

stallation in the Fuel System (DFI) chapter). Start the engine and check the fuel hose for leaks.

•

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:

•

Right Middle Fairing (see Middle 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.

PERIODIC MAINTENANCE 2-51

Remove:

•

Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Left Middle Fairing (see Frame chapter)

Place a containers under the drain plug [A] at the bottom

•

of the water pump cover.

Drain the coolant from the radiator and engine by remov-

•

ing the drain plug.

Remove:

•

Hoses [A] Mounting Bolts [B] Coolant Reserve Tank [C]

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

•

Install the reserve tank, and reconnect the reserve tank

•

hose and overflow hose correctly (see Cable, Wire, and

Hose Routing in the Appendix chapter).

Tighten the drain plug with the washer.

•

Replace the drain plug gasket with a new one.

○

Torque - Coolant Drain Plug: 12 N·m (1.2 kgf·m, 106 in·lb)

2-52 PERIODIC MAINTENANCE

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:

Total Amount:

–35°C (–31°F)

3.4 L (3.6 US qt)

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.

Maintenance Procedure

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

•

Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body 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 the Periodic Main-

•

tenance chapter).

Check the cooling system for leaks.

•

PERIODIC MAINTENANCE 2-53

Engine Oil Change

Situate the motorcycle so that it is vertical after warming

•

up the engine.

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

•

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

○

(see Oil Filter Replacement).

Replace the drain bolt gasket [B] with a new one.

Tighten the drain bolt.

•

Torque - Engine Oil Drain Bolt: 30 N·m (3.0 kgf·m, 22 ft·lb)

Pour in the specified type and amount of oil.

•

2-54 PERIODIC MAINTENANCE

Maintenance Procedure

Recommended Engine Oil

Type:

Viscosity:

Capacity: 3.7 L (3.9 US qt) (when filter is not

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).

•

Remove:

•

Lower Fairing (see Frame chapter)

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

•

Special Tool - Oil Filter Wrench: 57001-1249

API SE, SF or SG

API SH, SJ or SL with JASO MA

SAE 10W-40

removed)

4.1 L (4.3 US qt) (when filter is removed)

4.5 L (4.8 US qt) (when engine is completely dry)

NOTE

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).

Maintenance Procedure

Brake Hose and Pipe Replacement

CAUTION

Brake fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

Remove the brake hose banjo bolts [A].

•

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

•

brake fluid on the painted or plastic parts.

When removing the brake hoses [B], 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.

•

PERIODIC MAINTENANCE 2-55

2-56 PERIODIC MAINTENANCE

Maintenance Procedure

For ABS equipped models; note the following.

•

Remove:

•

Fuel Tank (see Fuel Tank Removal i n the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Bolts [B] Bracket [C]

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

•

Replace them with new ones when installing. Tighten:

•

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

ft·lb)

BrakePipeJointNuts:18N·m(1.8kgf·m,13ft·lb)

(ZX1400B Models)

When installing the hoses, 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).

Maintenance Procedure

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.

Level the brake fluid reservoir.

•

Remove the reservoir cap and diaphragm.

•

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].

PERIODIC MAINTENANCE 2-57

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.

Remove the clear plastic hose.

•

Install the diaphragm and reservoir cap.

•

Follow the procedure below to install the front brake fluid

•

reservoir cap correctly.

First, tighten the front brake fluid reservoir cap [B] clock-

○

wise [C] by hand until slight resistance is felt indicating

that the cap is seated on the reservoir body, then tighten

the cap an additional 1/6 turn [D] while holding the brake

fluid reservoir body [A].

2-58 PERIODIC MAINTENANCE

Maintenance Procedure

Tighten:

•

Torque - Front Brake Reservoir Cap Stopper Screw: 1.2

N·m (0.12 kgf·m, 11 in·lb)

Tighten the bleed valve, and install the rubber cap.

•

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

After changing the fluid, check the brake for good braking

•

power, no brake drag, and no fluid leakage. If necessary, bleed the air from the lines.

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

Remove the front master cylinder (see Front Master Cylin-

•

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

•

O-ring [D].

Special Tool - Inside Circlip Pliers: 57001-143

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

•

brake lever. Remove the circlip [G].

•

Pull out the piston assy [H].

•

Replace:

•

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

Rear Master Cylinder Disassembly

Remove the rear master cylinder (see Rear Master Cylin-

•

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

•

Special Tool - Inside Circlip Pliers: 57001-143

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

•

clip [E]. Pull out the push rod 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]

Maintenance Procedure

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 diffi-

cult to wash off completely, and will eventually de-

teriorate the rubber used in the disc brake.

Apply brake fluid to the new parts and to the inner wall of

•

the cylinder.

Take care not to scratch the piston or the inner wall of the

•

cylinder.

Apply silicone grease to the brake lever pivot bolt.

•

Tighten the brake lever pivot bolt and the locknut.

•

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)

PERIODIC MAINTENANCE 2-59

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 [C] (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the brakes chapter) Front Caliper Assembly Bolts O-ring

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 fas-

ten 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 [F] and Nut Push down [G].

2-60 PERIODIC MAINTENANCE

Maintenance Procedure

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.

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 springs and pads (see Front Brake

○

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

○

cylinders, and then disassemble the caliper.

Front Caliper Assembly

Clean the c aliper parts except for the pads.

•

CAUTION

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

Install the bleed valve and rubber cap.

•

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

Replace the fluid seals [A] with new ones.

•

Apply silicone grease to the fluid seals, and install them

○

into the cylinders by hand. Replace the dust s eals [B] with new ones if they are dam-

•

aged. Apply silicone grease 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-ring.

•

Apply a non-permanent locking agent to the threads of

•

the front caliper assembly bolts, and tighten them.

Torque - Front Caliper Assembly Bolts: 27 N·m (2.8 kgf·m,

20 ft·lb)

Maintenance Procedure

Install the pads (see Front Brake Pad Installation in the

•

Brakes chapter).

Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Rear Caliper Disassembly

Loosen the rear caliper pad pin [A] and banjo bolt [B], and

•

tighten them loosely.

Remove:

•

Rear Caliper [C] (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Rear Caliper Assembly Bolts O-ring

Removetheleftsidepistonasfollows.

•

Removal of the left side piston is the same as for the front

•

caliper.

Left Side Caliper [A] Rubber Gasket [B] Wooden Board [C] Bolt [D] and Nut Apply compressed air [E]

PERIODIC MAINTENANCE 2-61

WARNING

To avoid serious injury, never place your fingers or

palm in rear of the piston. If you apply compressed

air into the caliper, the piston may crush your hand

or fingers.

Remove the right side piston as follows.

•

Using the rear caliper assembly bolt [A], remove the pis-

•

ton [B] as shown in the figure.

2-62 PERIODIC MAINTENANCE

Maintenance Procedure

Remove the dust seals [A] and fluid seals [B].

•

Remove the bleed valves [C] and rubber caps [D].

•

NOTE

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

○

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

○

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

○

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

○

Rear Caliper Assembly

Clean the c aliper parts except for the pads.

•

CAUTION

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

Install the bleed valves and rubber caps.

•

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

Apply brake fluid to the cylinder bores.

•

Replace the fluid seals [A] with new ones.

•

Apply silicone grease to the fluid seals, and install them

○

into each cylinder by hand. Replace the dust seals [B] with new ones.

•

Maintenance Procedure

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-ring.

•

Apply a non-permanent locking agent to the threads of

•

the rear caliper assembly bolts, and tighten them.

Torque - Rear Caliper Assembly Bolts: 37 N·m (3.8 kgf·m,

27 ft·lb)

Install the pads (see Rear Brake Pad Installation in the

•

Brakes chapter).

Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Clutch Hose and Pipe Replacement

CAUTION

Clutch fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

PERIODIC MAINTENANCE 2-63

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

•

clutch fluid on the painted or plastic parts.

When removing the clutch hose [A], temporarily secure

•

the end of the clutch hose to some high place to keep

fluidlosstoaminimum.

Immediately wash away any clutch fluid that spills.

•

There are washers on each side of the clutch hose fittings.

•

Replace them with new ones when installing.

Tighten:

•

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

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 Appendix chap-

ter.

Fill the clutch line after installing the clutch hose (see

•

Clutch Fluid Change).

2-64 PERIODIC MAINTENANCE

Maintenance Procedure

Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement

Clutch Master Cylinder Cup and Dust Seal Replacement

Remove the clutch master cylinder (see Clutch Master

•

Cylinder Removal i n the Clutch 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

•

clutch lever. Pull the circlip [G].

•

Pull out the piston assy [H].

•

Replace:

•

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

Before assembly, clean all parts including the master

•

cylinder with clutch fluid or alcohol.

CAUTION

Use only disc brake fluid, isopropyl alcohol or ethyl alcohol for cleaning parts. Do not use any other fluid for cleaning these parts. Gasoline, motor 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 cylinder.

Apply clutch fluid to the parts removed and to the inner

•

wall of the cylinder. Take care not to scratch the piston or the inner wall of the

•

cylinder.

Torque - Clutch Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9

in·lb)

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

kgf·m, 52 in·lb)

Install the clutch master cylinder (see Clutch Master Cylin-

•

der Removal in the Clutch chapter).

Maintenance Procedure

Clutch Slave Cylinder Piston Seal Replacement

Remove the left lower fairing (see Lower Fairing Removal

•

in the Frame chapter).

Remove the coolant reserve tank.

•

Loosen the banjo bolt [A] at the clutch pipe lower end, and

•

tighten it loosely.

Unscrew the slave cylinder bolts [B] and detach the slave

•

cylinder with the pipe installed from the engine.

Pump the clutch lever until the piston comes out of the

•

cylinder.

Unscrew the banjo bolt and remove the slave cylinder [C].

•

CAUTION

Immediately wash away any clutch fluid that spills.

It may damage painted surfaces.

NOTE

If the clutch slave cylinder is removed and left alone, the

○

piston will be pushed out by spring force.

PERIODIC MAINTENANCE 2-65

Remove the spring and piston seal.

•

CAUTION

Replace the p iston seal with a new one if it was re-

moved from the piston.

Before assembly, apply c lutch fluid to the outside of the

•

piston and the piston seal.

Install the piston seal as shown.

•

Cylinder [A] Piston [B] Piston Seal [C] Spring [D]

WARNING

Motorcycle operation with insufficient, deteriorated

or contaminated engine oil will cause accelerated

wear and may result in engine or transmission

seizure, accident, and injury.

2-66 PERIODIC MAINTENANCE

Maintenance Procedure

Clutch Fluid Change

Level the clutch fluid reservoir and remove the reservoir

•

cap. Remove the left lower fairing (see Frame chapter).

•

Remove the rubber cap from the bleed valve on the clutch

•

slave cylinder. Attach a clear plastic hose [A] to the bleed valve and run

•

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

•

Change the clutch fluid as follows.

•

Open [B] the bleed valve, using a wrench. Pump the clutch lever and hold [C] it. Close [D] the bleed valve. Release [E] the clutch lever.

Repeat this operation until fresh fluid comes out from the

○

plastic hose or the color of the fluid changes. Check the fluid level in the reservoir often, replenishing it

○

as necessary.

NOTE

If the fluid in the reservoir runs completely out any time

○

during fluid changing, the bleeding operation must be done over again from the beginning since air will have entered the line.

WARNING

Do not mix two brands of fluid.

After changing the fluid, check the clutch for good clutch

•

power and no fluid leakage. If necessary, bleed the air from the lines (see Clutch Line Bleeding in the Clutch chapter). Remove the clear plastic hose.

•

Install the reservoir cap.

•

Tighten the bleed valve, and install the rubber cap.

•

Torque - Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80

kgf·m, 69 in·lb)

Spark Plug Replacement

Remove:

•

Stick Coils (see Stick Coil Removal in the Electrical System chapter)

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

•

wrench [A] vertically.

Maintenance Procedure

Replace the spark plug with a new one.

•

Standard Spark Plug

Typ e :

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

•

it first.

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

•

The insulator of the spark plug may break if when

the wrench is inclined during tightening.

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

Install the stick coils securely.

•

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

○

NGK CR9EIA-9

CAUTION

PERIODIC MAINTENANCE 2-67

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

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

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

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

Specifications ......................................................................................................................... 3-18

Special Tools and Sealant ...................................................................................................... 3-20

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

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

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

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

Inquiries to Rider.................................................................................................................. 3-29

DFI System Troubleshooting Guide ....................................................................................... 3-32

Self-Diagnosis ........................................................................................................................ 3-37

Self-diagnosis Outline .......................................................................................................... 3-37

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

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

Resistance Inspection....................................................................................................... 3-50

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-51

Removal............................................................................................................................ 3-51

Installation......................................................................................................................... 3-51

Input Voltage Inspection.................................................................................................... 3-52

Output Voltage Inspection................................................................................................. 3-53

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-57

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

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

Sensor Resistance Inspection .......................................................................................... 3-58

Water Temperature Sensor (Service Code 14) ...................................................................... 3-60

Removal/Installation.......................................................................................................... 3-60

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

Sensor Resistance Inspection .......................................................................................... 3-61

Atmospheric Pressure Sensor (Service Code 15).................................................................. 3-62

Removal............................................................................................................................ 3-62

Installation......................................................................................................................... 3-62

Input Voltage Inspection.................................................................................................... 3-62

Output Voltage Inspection................................................................................................. 3-63

Crankshaft Sensor (Service Code 21).................................................................................... 3-66

Crankshaft Sensor Removal/Installation........................................................................... 3-66

Crankshaft Sensor Inspection........................................................................................... 3-66

Camshaft Position Sensor (Service Code 23) ........................................................................ 3-67

Camshaft Position Sensor Removal/Installation ............................................................... 3-67

Camshaft Position Sensor Inspection ............................................................................... 3-67

Speed Sensor (Service Code 24)........................................................................................... 3-68

Speed Sensor Removal/Installation.................................................................................. 3-68

Speed Sensor Inspection.................................................................................................. 3-68

Input Voltage Inspection.................................................................................................... 3-68

3-2 FUEL SYSTEM (DFI)

Output Voltage Inspection................................................................................................. 3-69

Gear Position Switch (Service Code 25) ................................................................................ 3-71

Gear Position Switch Removal/Installation ....................................................................... 3-71

Gear Position Switch Inspection ....................................................................................... 3-71

Input Voltage Inspection.................................................................................................... 3-71

Vehicle-down Sensor (Service Code 31) ................................................................................ 3-73

Removal............................................................................................................................ 3-73

Installation......................................................................................................................... 3-73

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

Subthrottle Sensor (Service Code 32).................................................................................... 3-76

Subthrottle Sensor Removal/Adjustment .......................................................................... 3-76

Input Voltage Inspection.................................................................................................... 3-76

Output Voltage Inspection................................................................................................. 3-78

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

Immobilizer Amplifier (Service Code 35) ................................................................................ 3-81

Antenna Resistance Inspection ........................................................................................ 3-81

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

Blank Key Detection (Service Code 36) ................................................................................. 3-82

User Key Inspection.......................................................................................................... 3-82

Fuel Pump Relay (Service Code 46) ...................................................................................... 3-83

Fuel Pump Relay Removal ............................................................................................... 3-83

Fuel Pump Relay Inspection............................................................................................. 3-83

Stick C oils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) ...................................................... 3-85

Removal/Installation.......................................................................................................... 3-85

Input Voltage Inspection.................................................................................................... 3-85

Subthrottle Valve Actuator (Service Code 62) ........................................................................ 3-87

Subthrottle Valve Actuator Removal ................................................................................. 3-87

Subthrottle Valve Actuator Inspection ............................................................................... 3-87

Resistance Inspection ....................................................................................................... 3-87

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

ECU M ain Relay (Service Code 75) ....................................................................................... 3-90

ECU Main Relay Inspection .............................................................................................. 3-90

ECU........................................................................................................................................ 3-91

ECU Identification ............................................................................................................. 3-91

ECU Removal ................................................................................................................... 3-91

ECU Installation ................................................................................................................ 3-92

ECU Power Supply Inspection.......................................................................................... 3-93

CAN Communication Line Resistance Inspection ............................................................ 3-95

DFI Power Source ..................................................................................................................3-97

ECU Fuse Removal .......................................................................................................... 3-97

ECU Fuse Installation ....................................................................................................... 3-97

ECU Fuse Inspection ........................................................................................................ 3-97

Warning Indicator Light (LED) ................................................................................................ 3-98

Light (LED) Inspection ...................................................................................................... 3-98

Fuel Line................................................................................................................................. 3-99

Fuel Pressure Inspection .................................................................................................. 3-99

Fuel Flow Rate Inspection ................................................................................................ 3-100

Fuel Pump .............................................................................................................................. 3-103

Fuel Pump Removal ......................................................................................................... 3-103

Fuel Pump Installation ...................................................................................................... 3-103

Operation Inspection......................................................................................................... 3-104

Operating Voltage Inspection............................................................................................ 3-104

Fuel Injectors.......................................................................................................................... 3-106

Removal/Installation.......................................................................................................... 3-106

Power Source Voltage Inspection ..................................................................................... 3-106

Output Voltage Inspection................................................................................................. 3-107

Audible Inspection............................................................................................................. 3-108

FUEL SYSTEM (DFI) 3-3

Injector Signal Test............................................................................................................ 3-109

Injector Resistance Inspection .......................................................................................... 3-109

Injector Unit Test ............................................................................................................... 3-110

Injector Fuel Line Inspection............................................................................................. 3-110

Throttle Grip and Cables ........................................................................................................ 3-112

Free Play Inspection ......................................................................................................... 3-112

Free Play Adjustment........................................................................................................ 3-112

Cable Installation .............................................................................................................. 3-112

Cable Lubrication.............................................................................................................. 3-112

Throttle Body Assy ................................................................................................................. 3-113

Idle Speed Inspection ....................................................................................................... 3-113

Throttle Bore Cleaning ...................................................................................................... 3-113

Synchronization Inspection............................................................................................... 3-113

Synchronization Adjustment ............................................................................................. 3-113

Throttle Body Assy Removal............................................................................................. 3-113

Throttle Body Assy Installation.......................................................................................... 3-116

Throttle Body Assy Disassembly ...................................................................................... 3-118

Throttle Body Assy Assembly ........................................................................................... 3-119

Air Line ................................................................................................................................... 3-121

Element Removal.............................................................................................................. 3-121

Element Installation........................................................................................................... 3-121

Air Cleaner Element Inspection ........................................................................................ 3-121

Air Cleaner Element Holder Removal ............................................................................... 3-121

Air Cleaner Element Holder Installation ............................................................................ 3-121

Oil Draining ....................................................................................................................... 3-122

Rear Air Inlet Duct Removal ............................................................................................. 3-122

Rear Air Inlet Duct Installation .......................................................................................... 3-122

Front and Middle Air Inlet Duct Removal .......................................................................... 3-123

Front and Middle Air Inlet Duct Installation ....................................................................... 3-123

Fuel Tank ................................................................................................................................ 3-125

Fuel Tank Removal ........................................................................................................... 3-125

Fuel Tank Installation ........................................................................................................ 3-127

Fuel Tank and Cap Inspection .......................................................................................... 3-129

Fuel Tank Cleaning ........................................................................................................... 3-129

Evaporative Emission Control System ................................................................................... 3-130

Parts R emoval/Installation ................................................................................................ 3-130

Hose Inspection ................................................................................................................ 3-130

Separator Inspection......................................................................................................... 3-130

Separator Operation Test.................................................................................................. 3-131

Canister Inspection ........................................................................................................... 3-131

3-4 FUEL SYSTEM (DFI)

Exploded View

KAWASAKI ZZR 1400 User Manual [fr]

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF ABBREVIATIONS

COUNTRY AND AREA CODES

EMISSION CONTROL INFORMATION

TAMPERING WITH N OISE CONTROL SYSTEM PROHIBITED

Foreword

General Information

Battery Ground

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Non-permanent Locking Agent

Press

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

Lubrication

Direction of Engine Rotation

Electrical Wires

Instrument

ZX1400A6F (Europe) Left Side View

ZX1400A6F (Europe) Right Side View

Frame Number Engine Number

ZX1400A6F (United States and Canada) Left Side View

ZX1400A6F (United States and Canada) Right Side View

ZX1400A6F (Malaysia) Left Side View

ZX1400A6F (Malaysia) Right Side View

ZX1400B6F (Europe) Left Side View

ZX1400B6F (Europe) Right Side View

ZX1400B6F (Malaysia) Left Side View

ZX1400B6F (Malaysia) Right Side View

Overview

Structure and Function

System failure and maintenance

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 Replacement Parts

Basic Torque for General Fasteners

Fuel System (DFI)

Throttle Control System Inspection

Throttle Grip Free Play

Engine Vacuum Synchronization Inspection

Throttle Body Vacuum

Main Throttle Sensor Output Voltage

Idle Speed Inspection

Idle Speed

Idle Speed Adjustment

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

Cooling System

Coolant Level Inspection

Radiator Hose and Pipe Inspection

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

Air Suction System

Air Suction System Damage Inspection

Engine Top End

Valve Clearance Inspection

Valve Clearance

Adjustment Shims