KAWASAKI ZZR1400 2008 - 2011, Ninja ZX-14 2008 - 2011 SERVICE MANUAL

ZZR1400

ZZR1400 ABS

Ninja ZX-14

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 Periodic Maintenance 2 Fuel System (DFI) 3 Cooling System 4 Engine Top End 5 Clutch 6 Engine Lubrication System 7 Engine Removal/Installation 8

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.

•Refertothe sectionaltable ofcontents for the exact pages to locate the specific topic required.

Crankshaft/Transmission 9 Wheels/Tires 10 Final Drive 11 Brakes 12 Suspension 13 Steering 14 Frame 15 Electrical System 16 Appendix 17

ZZR1400

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 in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.

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

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

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

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s) ABDC after bottom dead center AC ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h L

alternating current min

hour(s) Ω ohm(s) liter(s)

meter(s) minute(s)

COUNTRY AND AREA CODES

AT Austria GB United Kingdom AU Australia MY Malaysia BR Brazil SEA Southeast Asia CA Canada TH Thailand CAL California US United States CH Switzerland WVTA

(FULL H)

DE Germany GB WVTA

LH)

(FUL

EUR Europe WVTA

(78.2 H)

WVTA Model with Honeycomb

Catalytic Converter (Full Power)

WVTA ModelwithHoneycombCatalytic

Conver Power)

WVTA Model with Honeycomb Catalytic

Converter (Restricted Power)

ter (Left Side Traffic Full

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 Thissystem eliminates the releaseof crankcase vaporsinto the atmosphere. Instead, thevapors

are routed through an oil separator to the inlet side of the engine. While t he 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 r unning 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 r ender inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this titleprior to itssale and delivery to the ultimatepurchaser,or for any manufacturer or dealer knowingly to remove or r ender 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 m otor 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 generally

○

interpreted as follows.

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

2. Tampering could include.

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

ceeded.

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

or durability of the motorcycle.

c.Additionof componentsor accessoriesthatresult inthe vehicleexceeding the stan-

dards.

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

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,THE VIOLATIONOF WHICH IS PUNISHABLE BY CIVIL PENALTIESNOT EXCE EDING $10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperativeby 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 i ts 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,itcontainsenough detailand basic informationto make it useful tothe ownerwho desiresto 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 beforestarting work, and then do the work ca fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurem 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 thisservice manual. Anyowner maintenanceor repair procedure not performed in accordance with this manual may void

To get the longest life out of your vehicle.

Follow the Periodic M aintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki moto

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the p

•

fully. Don’t take shortcuts.

Remembertokeep completerecordsofmain-

•

tenance a

parts installed.

rcycles are introduced by the

rocedures in this manual care-

nd repair with dates and any new

genuine Kawasaki Mo-

accordance with

the warranty.

re-

ents

How to Use This Manu al

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 symbols, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

CAUTION

CAUTION indicates a hazardous situa-

tion which, if not avoided, could result

in minor or moderate injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

This manual contains four more s which will help you distinguish different types of information.

ymbols

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and convenient 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 takebased on the results of the test orinspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructionsindicating 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............................................................................................................ 1-10

Unit Conversion Table ............................................................................................................ 1-13

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a m otorcycle, 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 so

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

lvent when cleaning parts. High

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or otherforeign materials enteringintosealed areas duringvehicle disassembly can cause excessive wear and decrease performance of the vehicle.

Before Servicing

Arrangement and Cleaning o f 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 subassemblyparts 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, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverseof 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 m alfunction. 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 t ightening 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 disas excessiveforce cancause expensiveor hardto repairdamage. When necessary, remove screws that have a non

-permanent locking agent Use a plastic-faced mallet whenever tapping is necessary.

applied using an impact driver.

sembly and assembly,

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasketmaterial or othermaterial 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

Donot remove pressed oilorgrease seals unlessremoval is necessary. Replace with new ones whenever removed. Pressnew oil seals with manufactureand 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 identifie then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

d first by the primary color and

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

ZX1400C8F ( US and CA) Left Side View

GENERAL INFORMATION 1-7

ZX1400C8F ( US and CA) Right Side View

1-8 GENERAL INFORMATION

Model Identification

ZX1400C8F (EUR) Left Side View

ZX1400C8F (EUR) Right Side View

Model Identification

ZX1400D8F (EUR) Left Side View

GENERAL INFORMATION 1-9

ZX1400D8F (EUR) Right Side View

Frame Number Engine Number

1-10 GENERAL INFORMATION

General Specifications

Items ZX1400C8F ∼ CBF, ZX1400D8F ∼ DBF

Dimensions

Overall Length 2 170 mm (85.43 in.) Overall Width 760 mm (29.92 in.) Overall Height 1 170 mm (46.06 in.) Wheelbase 1 460 mm (57.48 in.) Road C learance 125 mm (4.92 in.) Seat Height 800 mm (31.50 in.) Dry Mass:

ZX1400C8F 220 kg (485.1 lb) ZX1400D8F 224 kg (493.9 lb)

Curb Mass:

ZX1400C9F ∼ CBF 257 kg (566.7 lb) ZX1400D9F ∼ DBF 261 kg (575.5 lb) Front

ZX1400C8F ∼ CBF 128 kg (282.2 lb) ZX1400D8F ∼ DBF 130 kg (286.6 lb)

Rear

ZX1400C8F ∼ CBF 129 kg (284.4 lb) ZX1400D8F ∼ DBF 131 kg (288.8 lb)

Fuel Tank Capacity 22 L (5.8 US gal.)

Performance

Minimum Turning Radius

Engine

Type Cooling System Bore and Stroke 84.0 × 61.0 mm (3.31 × 2.40 in.) Displacement 1 352 cm³ (82.50 cu in.) Compression Ratio 12.0 : 1 Maximum Horsepower 142.0 kW (193 PS) @9 500 r/min (rpm)

Maximum Torque 154.0 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 Firing Order 1-2-4-3

3.1 m (10.2 ft)

4-stroke, DOHC, 4-cylinder Liquid-cooled

WVTA (78.2 H) 78.2 kW (106 PS) @8 000 r/min (rpm) (MY), (SEA) 140.0 kW (190 PS) @9 000 r/min (rpm) (CA), (CAL), (US) – – –

WVTA (78.2 H) 119.0 N·m (12.1 kgf·m, 87.8 ft·lb) @4 500 r/min (rpm) (CA), (CAL), (US) – – –

Left to right, 1-2-3-4

GENERAL INFORMATION 1-11

General Specifications

Items ZX1400C8F ∼ CBF, ZX1400D8F ∼ DBF

V alve Timing:

Inlet:

Open 41° (BTDC) Close 71° (ABDC) Duration 292°

Exhaust:

Open 64° (BBDC) Close 34° (ATDC)

Duration 278° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil:

Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 4.5 L (4.8 US qt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio Clutch Type Transmission:

Type

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 1.036 (29/28)

Final Drive System:

Type Chain drive

Reduction Ratio 2.412 (41/17)

Overall Drive Ratio 3.886 @Top gear

Frame

Type Press, backbone Caster (Rake Angle) 23° Trail 94 mm (3.70 in.) Front Tire:

Type Tubeless

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

Rim Size J17M/C × MT3.50

1.556 (84/54) Wet multi disc

6-speed, constant mesh, return shift

1-12 GENERAL INFORMATION

General Specifications

Items ZX1400C8F ∼ CBF, ZX1400D8F ∼ DBF

Rear Tire:

Type Tubeless Size 190/50 ZR17 M /C (73W) Rim Size J17M/C × MT6.00

Front Suspension:

Type Telescopic fork (upside-down) Wheel Travel 117 mm (4.61 in.)

Rear Suspension:

Type Swingarm (uni-trak) Wheel Travel 122 mm (4.80 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 O utput 35 A/14 V @5 000 r/min (rpm)

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

Unit Conversion Table

GENERAL INFORMATION 1-13

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 = qt (IMP) L × 2.113 = pint (US) L × 1.816 = pint (IM P) mL × 0.03381 = oz (US) mL × 0.02816 = oz (IMP) mL × 0.06102 = cu in

Units of Length:

km × 0.6214 = mile m × 3.281 = mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m N·m × 0.7376 = ft·lb N·m × 8.851 = in·lb kgf·m × 9.807 = N·m kgf·m × 7.233 = ft·lb kgf·m × 86.80 = in·lb

Units of Pressure:

kPa × 0.01020 = kgf/cm² kPa × 0.1450 = psi kPa × 0.7501 = cmHg kgf/cm² kgf/cm² cmHg×1.333=kPa

× 98.07 = kPa × 14.22 = psi

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

N × 0.1020 = kg N × 0.2248 = lb kg ×9.807=N kg ×2.205=lb

Units of Temperature:

Units of Power:

kW ×1.360=PS kW ×1.341=HP PS × 0.7355 = kW PS × 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent...................................................................................................... 2-7

Specifications ......................................................................................................................... 2-14

Special Tools and Sealant...................................................................................................... 2-16

Periodic Maintenance Procedures.......................................................................................... 2-17

Fuel System (DFI)................................................................................................................ 2-17

Throttle Control System Inspection................................................................................... 2-17

Engine Vacuum Synchronization Inspection..................................................................... 2-17

Idle Speed Inspection ....................................................................................................... 2-21

Idle Speed Adjustment...................................................................................................... 2-21

Fuel Hose Inspection (fuel leak, damage, installation condition)...................................... 2-21

Evaporative Emission Control System Inspection (CAL, SEA and TH Models) .............. 2-22

Cooling System.................................................................................................................... 2-23

Coolant Level Inspection................................................................................................... 2-23

Radiator Hose and Pipe Inspection .................................................................................. 2-24

Engine Top End ................................................................................................................... 2-24

Va lve Clearance Inspection .............................................................................................. 2-24

Va lve Clearance Adjustment............................................................................................. 2-26

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

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

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

Clutch Fluid Level Inspection............................................................................................ 2-30

Clutch Fluid Leak Inspection............................................................................................. 2-30

Clutch Hose and Pipe Damage and Installation Condition Inspection.............................. 2-30

Wheels/Tires........................................................................................................................ 2-31

Air Pressure Inspection..................................................................................................... 2-31

Wheel/Tire Damage Inspection......................................................................................... 2-31

Tire Tread Wear Inspection .............................................................................................. 2-31

Wheel Bearing Damage Inspection .................................................................................. 2-32

Final Drive............................................................................................................................ 2-33

Drive Chain Lubrication Condition Inspection................................................................... 2-33

Drive Chain Slack Inspection............................................................................................ 2-33

Drive Chain Slack Adjustment .......................................................................................... 2-34

Wheel Alignment Inspection ............................................................................................. 2-35

Drive Chain Wear Inspection ............................................................................................ 2-35

Drive Chain Guide Wear Inspection.................................................................................. 2-36

Brakes.................................................................................................................................. 2-36

Brake Fluid Leak (Brake Hose and Pipe) Inspection........................................................ 2-36

Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-37

Brake Operation Inspection .............................................................................................. 2-37

Brake Fluid Level Inspection............................................................................................. 2-37

Brake Pad Wear Inspection .............................................................................................. 2-38

Brake Light Switch Operation Inspection.......................................................................... 2-39

Suspension.......................................................................................................................... 2-39

Front Forks/Rear Shock Absorber Operation Inspection.................................................. 2-39

Front Fork O il Leak Inspection.......................................................................................... 2-40

Rear Shock Absorber Oil Leak Inspection........................................................................ 2-40

Rocker Arm Operation Inspection..................................................................................... 2-40

Tie-Rod Operation Inspection........................................................................................... 2-40

Steering ............................................................................................................................... 2-41

2-2 PERIODIC MAINTENANCE

Steering Play Inspection................................................................................................... 2-41

Steering Play Adjustment.................................................................................................. 2-41

Steering Stem Bearing Lubrication................................................................................... 2-42

Electrical System................................................................................................................. 2-43

Lights and Switches Operation Inspection........................................................................ 2-43

Headlight Aiming Inspection ............................................................................................. 2-46

Sidestand Switch Operation Inspection ............................................................................ 2-47

Engine Stop Switch Operation Inspection......................................................................... 2-48

Others.................................................................................................................................. 2-48

Chassis Parts Lubrication ................................................................................................ 2-48

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-49

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

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

Fuel Hose Replacement ................................................................................................... 2-52

Coolant Change................................................................................................................ 2-53

Radiator Hose and O-ring Replacement........................................................................... 2-55

Clutch Hose Replacement................................................................................................ 2-56

Clutch Fluid Change ......................................................................................................... 2-57

Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement............................. 2-58

Engine Oil Change............................................................................................................ 2-59

Oil Filter Replacement ...................................................................................................... 2-60

Brake Hose Replacement................................................................................................. 2-61

Brake Fluid Change.......................................................................................................... 2-63

Master Cylinder Rubber Parts Replacement .................................................................... 2-64

Caliper Rubber Parts Replacement.................................................................................. 2-65

Spark Plug Replacement.................................................................................................. 2-69

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.

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Fuel System

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

Engine vacuum synchronization inspect

year

• • • •

• • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-17

Idle speed - inspect Fuel leak (fuel hose and pipe) -

inspect Fuel hose and pipe damage -

inspect Fuel hose and pipe installation

condition - inspect Evaporative emission control

system function - inspect (CAL, SEA and TH Models)

Cooling System

Coolant level - inspect Coolant leak (water hose and

pipe) - inspect Water hose damage - inspect year Water hose installation condition -

inspect

Engine Top End

US, CA, AU

Valve clearance

- inspect

Air suction system dam age inspect

Clutch

Clutch operation (play, disengagement, engagement) inspect

Clutch fluid level - inspect Clutch fluid leak (clutch hose and

pipe) - inspect Clutch hose and pipe damage -

inspect

Models Other than

US, CA, AU Models

year

months

year

• • • •

• • • • • • •

• • • •

•

Every 42 000 km (26 250 mile)

• • •

• • • •

• • • • • • •

2-21 2-21

2-21

2-22

2-23 2-24 2-24 2-24

2-24

2-29

2-30

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Clutch hose installation condition

- inspect

Wheels and Tires

Tire air pressure - inspect year Wheel/tire damage - inspect

Tire tread wear, abnormal wear inspect

Wheel bearing damage - inspect year

Final Drive

Drive chain lubrication condition inspect #

Drive chain slack - inspect # Every 1 000 km (600 mile) 2-33 Drive chain wear - inspect # Drive chain guide wear - inspect

Brakes

Brake fluid leak (brake hose and pipe) - inspect

Brake hose and pipe damage inspect

Brake hose installation condition inspect

Brake operation (effectiveness, play, no drag) - inspect

Brake fluid level - inspect

year

months

• • • • • • •

• • •

Every 600 km (400 mile) 2-33

• • •

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-30

2-31 2-31

2-31 2-32

2-35 2-36

2-36

2-37

Brake pad wear - inspect # Brake light switch operation -

inspect

Suspension

Front forks/rear shock absorber operation (damping and smooth stroke) - inspect

Front forks/rear shock absorber oil l eak - inspect

Rocker arm operation - inspect Tie-rods operation - inspect

Steering

Steering play - inspect year Steering stem bearings - lubricate 2 years

Electrical System

Lights and switches operation inspect

year

• • • • • •

• • • • • • •

• • •

• • • •

•

• • •

2-38 2-39

2-39

2-40 2-40

2-40

2-41 2-42

2-43

Periodic Maintenance Chart

PERIODIC MAINTENANCE 2-5

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36 ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Headlight aiming - inspect year Sidestand switch operation -

inspect Engine stop switch operation -

inspect

Others

Chassis parts - lubricate year Bolts and nuts tightness - inspect

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

frequent starting/stopping.

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

year

• • • •

• • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

See

Page

2-46 2-47

2-48

2-48 2-49

2-6 PERIODIC MAINTENANCE

Periodic Maintenance Chart Periodic Replacement Parts

FREQUENCY

ITEM Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element - replace # Every 18 000 km (11250 mile) 2-50

Whichever

comes

first

1 12 24 36 48

* ODOMETE R

READING

× 1 000 km

(× 1 000 mile)

See

Page

Fuel hose - replace 4 years Coolant - change 3 years Radiator hose and O-ring - replace 3 years Clutch hose - replace 4 years Clutch fluid - change 2 years

Rubber parts of clutch master cylinder/slave cylinder - replace

Engine oil - change # year Oil filter - replace year Brake hose - replace 4 years Brake fluid - change 2 years Rubber parts of brake master cylinder/caliper -

replace Spark plug - replace

#: Service more frequentl

frequent starting/stopping.

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

y when operating in severe conditions; dusty, wet, muddy, high s peed or

4 years

• • • • •

4 years

• •

• • • •

•

2-52 2-53 2-55 2-56 2-57

2-58 2-59

2-60 2-61 2-63

2-64,

2-65 2-69

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