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ZZR1400 ABS
Ninja ZX-14R
Ninja ZX-14R ABS
Quick Reference Guide
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.
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 |
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 |
ZX1400H/J
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.
Copyright © 2015 Kawasaki Heavy Industries, Ltd. |
Fourth Edition (0) : May 17, 2018 |
LIST OF ABBREVIATIONS
A |
ampere(s) |
in. |
inch(es) |
ABDC |
after bottom dead center |
ISC |
idle speed control |
ABS |
antilock brake system |
JASO |
Japanese Automotive Standards |
|
Organization |
||
|
|
|
|
AC |
alternating current |
km/h |
kilometers per hour |
Ah |
ampere hour |
L |
liter(s) |
API |
American Petroleum Institute |
lb |
pound(s) |
ATDC |
after top dead center |
LCD |
liquid crystal display |
BBDC |
before bottom dead center |
LED |
light emitting diode |
BDC |
bottom dead center |
m |
meter(s) |
BTDC |
before top dead center |
min |
minute(s) |
°C |
degree(s) celsius |
mmHg |
millimeters of mercury |
cmHg |
centimeters of mercury |
mph |
miles per hour |
CPU |
central processing unit |
N |
newton(s) |
cu in. |
cubic inch(es) |
oz |
ounce(s) |
DC |
direct current |
Pa |
pascal(s) |
DFI |
digital fuel injection |
PS |
horsepower |
DOHC |
double overhead camshaft |
psi |
pound(s) per square inch |
DOT |
Department of Transportation |
qt |
quart(s) |
ECU |
electronic control unit |
r |
revolution |
F |
farad(s) |
rpm |
revolution(s) per minute |
°F |
degree(s) fahrenheit |
s |
second(s) |
FI |
fuel injection |
SAE |
Society of Automotive Engineers |
ft |
foot, feet |
TDC |
top dead center |
g |
gram(s) |
TIR |
total indicator reading |
gal |
gallon(s) |
V |
volt(s) |
h |
hour(s) |
W |
watt(s) |
HP |
horsepower(s) |
Ω |
ohm(s) |
IC |
integrated circuit |
|
|
COUNTRY AND AREA CODES
AT |
Austria |
IN |
India |
AU |
Australia |
MY |
Malaysia |
CA |
Canada |
PH |
Philippines |
CAL |
California |
SEA-B1 |
Southeast Asia B1 |
CH |
Switzerland |
SEA-B3 |
Southeast Asia B3 |
CN |
China |
TH |
Thailand |
DE |
Germany |
US |
United States |
EUR |
Europe |
WVTA |
WVTA Model (Full Power) |
(FULL) |
|
||
|
|
|
|
GB |
United Kingdom |
GB WVTA |
GB WVTA Model (Full Power) |
(FULL) |
|
||
|
|
|
|
ID |
Indonesia |
|
|
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 intake 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 includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped.
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 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 exceeded.
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 standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
•Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.
•Removal of the muffler(s) or any internal portion of the muffler(s).
•Removal of the air box or air box cover.
•Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.
Foreword
(About this manual)
This service manual explains maintenance procedures for removing, installing, disassembling, assembling, and adjusting, as necessary, including periodic inspection and maintenance of major parts of recording models.
(Disclaimer)
1.This book does not describe all the matters concerning maintenance. This book is made for people who have basic skills and knowledge on maintenance of Kawasaki products (authorized Kawasaki dealers or other repairers). So those who do not have these skills and knowledge do not do maintenance or inspection with this manual. Skill shortage and lack of knowledge may cause maintenance troubles, parts breakage, etc.
2.All information contained in this publication is based on the latest product information available at the time of publication. 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.
3.Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
4.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. Please accept beforehand that the description content, illustration, photographs etc. may differ from actual vehicle due to vehicle specification change.
5.The content of the description may be changed without prior notice for vehicle specification change etc.
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 stick 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 Stick Coil section.
Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
This manual contains four more symbols which will help you distinguish different types of information.
NOTE
○NOTE indicates information that may help or guide you in the operation or service of the vehicle.
•Indicatesdone. a procedural step or work to be ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information |
|
Table of Contents |
|
|
1 |
Before Servicing ..................................................................................................................... |
1-2 |
Model Identification................................................................................................................. |
1-7 |
General Specifications............................................................................................................ |
1-9 |
Unit Conversion Table ............................................................................................................ |
1-12 |
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High flash-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.
GENERAL INFORMATION 1-3
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.
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 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.
All of the tightening torque values are for use with dry, solvent - cleaned threads unless otherwise indicated. If a fastener which should have dry, clean threads gets contaminated with lubricant, etc., applying even the specified torque could damage it.
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 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.
GENERAL INFORMATION 1-5
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.
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.
Handling Electronic Parts
Severe impacts to electronic parts such as the ECU, sensor, and relay can damage them. If dropped on a hard surface, replace such parts with new ones.
If a high voltage that is created by static electricity is applied to the electric parts, it could cause them to fail. To avoid this, touch a non-painted metal surface to discharge any static electricity that is accumulated on your body before inspecting or replacing electric parts.
Be careful not to touch the electrical terminals of the electronic parts. The static electricity discharged from your body could damage them or deform the electrical terminals.
GENERAL INFORMATION 1-7
Model Identification
ZX1400HG Left Side View
ZX1400HG Right Side View
Frame Number |
|
Engine Number |
|
|
|
|
|
|
1-8 GENERAL INFORMATION
Model Identification
ZX1400JG Left Side View
ZX1400JG Right Side View
|
GENERAL INFORMATION 1-9 |
|
General Specifications |
|
|
|
|
|
Items |
ZX1400HG HK/JG JK |
|
Dimensions |
|
|
Overall Length |
2 170 mm (85.43 in.) |
|
Overall Width |
770 mm (30.3 in.) |
|
|
(ID, MY, PH, SEA-B1, TH) 780 mm (30.7 in.) |
|
Overall Height |
1 170 mm (46.06 in.) |
|
Wheelbase |
1 480 mm (58.27 in.) |
|
Road Clearance |
125 mm (4.92 in.) |
|
Seat Height |
800 mm (31.5 in.) |
|
Curb Mass: |
269 kg (593 lb) |
|
Front |
135 kg (298 lb) |
|
Rear |
134 kg (295 lb) |
|
Fuel Tank Capacity |
22 L (5.8 US gal.) |
|
Performance |
|
|
Minimum Turning Radius |
3.1 m (10.2 ft) |
|
Engine |
|
|
Type |
4-stroke, DOHC, 4-cylinder |
|
Cooling System |
Liquid-cooled |
|
Bore and Stroke |
84.0 × 65.0 mm (3.3 × 2.6 in.) |
|
Displacement |
1 441 cm³ (87.93 cu in.) |
|
Compression Ratio |
12.3:1 |
|
Maximum Horsepower |
147.2 kW (200 PS) @10 000 r/min (rpm) |
|
|
(ZX1400HG HH/JG JH AU) 147 kW (200 PS) @10 000 r/min |
|
|
(rpm) |
|
|
(CA, CAL, US) – – – |
|
Maximum Torque |
158.2 N·m (16.1 kgf·m, 117 ft·lb) @7 500 r/min (rpm) |
|
|
(ZX1400HG HH/JG JH AU) 158 N·m (16.1 kgf·m, 117 ft·lb) |
|
|
@7 500 r/min (rpm) |
|
|
(CA, CAL, US) – – – |
|
Fuel System |
FI (Fuel Injection), MIKUNI 44EIDW × 4 |
|
Fuel Type: |
|
|
Minimum Octane Rating: |
|
|
Research Octane |
95 |
|
Number (RON) |
||
|
||
Antiknock Index |
90 |
|
(RON + MON)/2 |
||
|
||
Starting System |
Electric starter |
|
Ignition System |
Battery and coil (transistorized) |
|
Timing Advance |
Electronically advanced (IC igniter in ECU) |
|
Ignition Timing |
10° BTDC @1 100 r/min (rpm) to 40.1° BTDC @6 000 r/min (rpm) |
|
Spark Plug |
NGK CR9EIA-9 |
|
Cylinder Numbering Method |
Left to right, 1-2-3-4 |
|
Firing Order |
1-2-4-3 |
|
|
|
1-10 GENERAL INFORMATION
General Specifications
Items |
ZX1400HG HK/JG JK |
Valve Timing: |
|
Intake: |
|
Open |
34° BTDC |
Close |
72° ABDC |
Duration |
286° |
Exhaust: |
|
Open |
66° BBDC |
Close |
36° ATDC |
Duration |
282° |
Lubrication System |
Forced lubrication (wet sump) |
Engine Oil: |
|
Type |
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 |
Viscosity |
SAE 10W-40 |
Capacity |
4.6 L (4.9 US qt) |
Drive Train |
|
Primary Reduction System: |
|
Type |
Gear |
Reduction Ratio |
1.556 (84/54) |
Clutch Type |
Wet multi disc |
Transmission: |
|
Type |
6-speed, constant mesh, return shift |
Gear Ratios: |
|
1st |
2.611 (47/18) |
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 |
2.471 (42/17) |
Overall Drive Ratio |
3.980 @Top gear |
Frame |
|
Type |
Press backbone |
Caster (Rake Angle) |
23.0° |
Trail |
93 mm (3.7 in.) |
Front Tire: |
|
Type |
Tubeless |
Size |
120/70ZR17 M/C (58W) |
Rim Size |
17M/C × MT3.50 |
Rear Tire: |
|
Type |
Tubeless |
Size |
190/50ZR17 M/C (73W) |
Rim Size |
17M/C × MT6.00 |
|
GENERAL INFORMATION 1-11 |
General Specifications |
|
|
|
Items |
ZX1400HG HK/JG JK |
Front Suspension: |
|
Type |
Telescopic fork (upside-down) |
Wheel Travel |
117 mm (4.61 in.) |
Rear Suspension: |
|
Type |
Swingarm (uni-trak) |
Wheel Travel |
124 mm (4.88 in.) |
|
(Öhlins) 120 mm (4.72 in.) |
Brake Type: |
|
Front |
Dual discs |
Rear |
Single disc |
Electrical Equipment |
|
Battery |
12 V 12 Ah (10 HR) |
Headlight: |
|
Type |
Semi-sealed beam |
High Beam |
12 V (65 W + 55 W) × 2 |
Low Beam |
12 V 55 W × 2 |
Brake/Tail Light |
LED |
Alternator: |
|
Type |
Three-phase AC |
Maximum Output |
14.0 V – 35.0 A @5 000 r/min (rpm) |
Specifications are subject to change without notice, and may not apply to every country.
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units: Units of Length:
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 |
km |
× |
0.6214 |
= |
mile |
m |
× |
3.281 |
= |
ft |
mm |
× |
0.03937 |
= |
in. |
Units of Torque:
N·m |
× |
0.1020 |
= |
kgf·m |
N·m |
× |
0.7376 |
= |
ft·lb |
N·m |
× |
8.851 |
= |
in·lb |
kgf·m |
× |
9.807 |
= |
N·m |
kgf·m |
× |
7.233 |
= |
ft·lb |
kgf·m |
× |
86.80 |
= |
in·lb |
Units of 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 (IMP) |
mL |
× |
0.03381 |
= |
oz (US) |
mL |
× |
0.02816 |
= |
oz (IMP) |
mL |
× |
0.06102 |
= |
cu in. |
Units of Force:
N |
× |
0.1020 |
= |
kg |
N |
× |
0.2248 |
= |
lb |
kg |
× |
9.807 |
= |
N |
kg |
× |
2.205 |
= |
lb |
Units of Temperature:
Units of Pressure:
kPa |
× |
0.01020 |
= |
kgf/cm² |
kPa |
× |
0.1450 |
= |
psi |
kPa |
× |
0.7501 |
= |
cmHg |
kgf/cm² |
× |
98.07 |
= |
kPa |
kgf/cm² |
× |
14.22 |
= |
psi |
cmHg |
× |
1.333 |
= |
kPa |
Units of Speed:
km/h × 0.6214 = mph
Units of 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...................................................................................................... |
2-5 |
2 |
|
Specifications |
2-15 |
|
|
|
|
||
Special Tools and Sealant ...................................................................................................... |
2-17 |
|
|
Periodic Maintenance Procedure ........................................................................................... |
2-18 |
|
|
Fuel System (DFI)................................................................................................................ |
2-18 |
|
|
Air Cleaner Element Replacement.................................................................................... |
2-18 |
|
|
Idle Speed Inspection ....................................................................................................... |
2-19 |
|
|
Idle Speed Adjustment...................................................................................................... |
2-19 |
|
|
Throttle Control System Inspection................................................................................... |
2-19 |
|
|
Engine Vacuum Synchronization Inspection..................................................................... |
2-20 |
|
|
Fuel System Inspection..................................................................................................... |
2-23 |
|
|
Fuel Filter Replacement.................................................................................................... |
2-23 |
|
|
Fuel Hose Replacement ................................................................................................... |
2-26 |
|
|
Evaporative Emission Control System Inspection (Other than US, CA, AU, ID, PH and |
|
|
|
ZX1400JJ of SEA-B3 Models) ....................................................................................... |
2-28 |
|
|
Cooling System.................................................................................................................... |
2-29 |
|
|
Coolant Level Inspection................................................................................................... |
2-29 |
|
|
Cooling System Inspection ............................................................................................... |
2-29 |
|
|
Coolant Change................................................................................................................ |
2-29 |
|
|
Water Hose and O-ring Replacement............................................................................... |
2-32 |
|
|
Engine Top End ................................................................................................................... |
2-32 |
|
|
Valve Clearance Inspection .............................................................................................. |
2-32 |
|
|
Valve Clearance Adjustment............................................................................................. |
2-34 |
|
|
Air Suction System Damage Inspection............................................................................ |
2-36 |
|
|
Clutch................................................................................................................................... |
2-36 |
|
|
Clutch System Inspection ................................................................................................. |
2-36 |
|
|
Clutch Operation Inspection ............................................................................................. |
2-37 |
|
|
Clutch Fluid Level Inspection ............................................................................................ |
2-37 |
|
|
Clutch Fluid Change ......................................................................................................... |
2-38 |
|
|
Clutch Hose Replacement ................................................................................................ |
2-39 |
|
|
Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement ............................. |
2-40 |
|
|
Engine Lubrication............................................................................................................... |
2-41 |
|
|
Engine Oil Change............................................................................................................ |
2-41 |
|
|
Oil Filter Replacement ...................................................................................................... |
2-42 |
|
|
Wheels/Tires........................................................................................................................ |
2-43 |
|
|
Air Pressure Inspection..................................................................................................... |
2-43 |
|
|
Wheels and Tires .............................................................................................................. |
2-43 |
|
|
Wheel Bearing Damage Inspection .................................................................................. |
2-44 |
|
|
Final Drive............................................................................................................................ |
2-45 |
|
|
Drive Chain Lubrication Condition Inspection ................................................................... |
2-45 |
|
|
Drive Chain Slack Inspection ............................................................................................ |
2-45 |
|
|
Drive Chain Slack Adjustment .......................................................................................... |
2-46 |
|
|
Wheel Alignment Inspection ............................................................................................. |
2-47 |
|
|
Drive Chain Wear Inspection ............................................................................................ |
2-47 |
|
|
Chain Guide Wear Inspection ........................................................................................... |
2-48 |
|
|
Brakes.................................................................................................................................. |
2-49 |
|
|
Brake System Inspection .................................................................................................. |
2-49 |
|
|
Brake Operation Inspection .............................................................................................. |
2-50 |
|
|
Brake Fluid Level Inspection............................................................................................. |
2-50 |
|
|
2-2 PERIODIC MAINTENANCE
Brake Fluid Change .......................................................................................................... |
2-52 |
Brake Hose and Pipe Replacement.................................................................................. |
2-54 |
Master Cylinder Rubber Parts Replacement .................................................................... |
2-56 |
Caliper Rubber Parts Replacement .................................................................................. |
2-58 |
Brake Pad Wear Inspection .............................................................................................. |
2-62 |
Brake Light Switch Operation Inspection .......................................................................... |
2-63 |
Suspension.......................................................................................................................... |
2-63 |
Suspension System Inspection......................................................................................... |
2-63 |
Steering ............................................................................................................................... |
2-65 |
Steering Play Inspection ................................................................................................... |
2-65 |
Steering Play Adjustment.................................................................................................. |
2-65 |
Steering Stem Bearing Lubrication ................................................................................... |
2-66 |
Electrical System ................................................................................................................. |
2-67 |
Lights and Switches Operation Inspection........................................................................ |
2-67 |
Headlight Aiming Inspection ............................................................................................. |
2-69 |
Side Stand Switch Operation Inspection........................................................................... |
2-71 |
Engine Stop Switch Operation Inspection......................................................................... |
2-72 |
Spark Plug Replacement .................................................................................................. |
2-72 |
Others.................................................................................................................................. |
2-73 |
Chassis Parts Lubrication ................................................................................................ |
2-73 |
Bolts, Nuts and Fasteners Tightness Inspection............................................................... |
2-74 |
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
*A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
*B: For higher odometer readings, repeat at the frequency interval established here.
*C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
*D: Other than US, CA, AU, ID, PH and ZX1400JJ of SEA-B3 Models ○: Emission Related Item
: Inspection
: Change or Replace 
: Lubrication
|
|
|
|
Odometer Reading (*B) |
|
|||
|
|
year |
|
× 1 000 km (× 1 000 mile) |
See |
|||
|
Items |
(*A) |
1 |
6 |
12 |
18 |
24 |
Page |
|
|
(0.6) |
(3.8) |
(7.6) |
(11.4) |
(15.2) |
|
|
Fuel System |
|
|
|
|
|
|
|
|
○ |
Air cleaner element (*C) |
|
|
|
|
|
|
2-18 |
○ |
Idle speed |
|
|
|
|
|
|
2-19 |
○ |
Throttle control system (play, smooth return, |
:1 |
|
|
|
|
|
2-19 |
no drag) |
|
|
|
|
|
|||
○ |
Engine vacuum synchronization |
|
|
|
|
|
|
2-20 |
|
Fuel system |
:1 |
|
|
|
|
|
2-23 |
|
Fuel filter |
|
|
|
|
|
|
2-23 |
|
|
|
|
|
|
|
|
|
|
Fuel hose |
:5 |
|
|
|
|
|
2-26 |
○ |
Evaporative emission control system (*D) |
|
|
|
|
|
|
2-28 |
Cooling System |
|
|
|
|
|
|
|
|
|
Coolant level |
|
|
|
|
|
|
2-29 |
|
|
|
|
|
|
|
|
|
|
Cooling system |
:1 |
|
|
|
|
|
2-29 |
|
Coolant, water hose and O-ring |
:3 |
|
: every 36 000 km |
2-29, |
|||
|
|
(22 500 mile) |
|
2-32 |
||||
|
|
|
|
|
||||
Engine Top End |
|
|
|
|
|
|
|
|
○ |
Valve clearance (US and CA Models) |
|
|
|
|
|
|
2-32 |
|
Valve clearance (Other than US and CA |
|
|
: every 42 000 km |
2-32 |
|||
|
Models) |
|
|
(26 250 mile) |
|
|||
|
|
|
|
|
||||
○ |
Air suction system |
|
|
|
|
|
|
2-36 |
Clutch |
|
|
|
|
|
|
|
|
|
Clutch operation (play, engagement, |
|
|
|
|
|
|
2-37 |
|
disengagement) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Clutch fluid level |
:1 |
|
|
|
|
|
2-37 |
|
Clutch fluid, hose and pipe |
:1 |
|
|
|
|
|
2-36 |
|
Clutch fluid |
:2 |
|
|
|
|
|
2-38 |
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
|
|
|
|
|
|
|
|
|
|
|
|
|
Odometer Reading (*B) |
|
|||
|
|
year |
|
× 1 000 km (× 1 000 mile) |
See |
|||
|
|
(*A) |
1 |
6 |
12 |
18 |
24 |
Page |
|
Items |
|
(0.6) |
(3.8) |
(7.6) |
(11.4) |
(15.2) |
|
|
Clutch hose/rubber parts of clutch master |
:4 |
|
: every 48 000 km |
2-39, |
|||
|
cylinder and slave cylinder |
|
(30 000 mile) |
|
2-40 |
|||
|
|
|
|
|||||
Engine Lubrication System |
|
|
|
|
|
|
|
|
|
Engine oil and oil filter (*C) |
:1 |
|
|
|
|
|
2-41, |
|
|
|
|
|
|
2-42 |
||
|
|
|
|
|
|
|
|
|
Wheels and Tires |
|
|
|
|
|
|
|
|
|
Tire air pressure |
:1 |
|
|
|
|
|
2-43 |
|
Wheel and tire |
:1 |
|
|
|
|
|
2-43 |
|
Wheel bearing damage |
:1 |
|
|
|
|
|
2-44 |
Final Drive |
|
|
|
|
|
|
|
|
|
Drive chain lubrication condition (*C) |
|
: every 600 km (400 mile) |
2-45 |
||||
|
|
|
|
|
|
|
||
|
Drive chain slack (*C) |
|
: every 1 000 km (600 mile) |
2-45 |
||||
|
Drive chain wear (*C) |
|
|
|
|
|
|
2-47 |
|
|
|
|
|
|
|
|
|
|
Drive chain guide wear |
|
|
|
|
|
|
2-48 |
|
|
|
|
|
|
|
|
|
Brakes |
|
|
|
|
|
|
|
|
|
Brake system |
:1 |
|
|
|
|
|
2-49 |
|
Brake operation (effectiveness, play, no |
:1 |
|
|
|
|
|
2-50 |
|
drag) |
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
Brake fluid level |
:1 |
|
|
|
|
|
2-50 |
|
Brake fluid (front and rear) |
:2 |
|
|
|
|
|
2-52 |
|
Brake hose |
:4 |
|
|
|
|
|
2-54 |
|
Rubber parts of brake master cylinder and |
:4 |
|
: every 48 000 km |
2-56, |
|||
|
caliper |
|
(30 000 mile) |
|
2-58 |
|||
|
|
|
|
|||||
|
Brake pad wear (*C) |
|
|
|
|
|
|
2-62 |
|
|
|
|
|
|
|
|
|
|
Brake light switch operation |
|
|
|
|
|
|
2-63 |
|
|
|
|
|
|
|
|
|
Suspension |
|
|
|
|
|
|
|
|
|
Suspension system |
:1 |
|
|
|
|
|
2-63 |
Steering |
|
|
|
|
|
|
|
|
|
Steering play |
:1 |
|
|
|
|
|
2-65 |
|
Steering stem bearing |
:2 |
|
|
|
|
|
2-66 |
Electrical System |
|
|
|
|
|
|
|
|
|
Electrical system |
:1 |
|
|
|
|
|
2-67 |
○ |
Spark plug |
|
|
|
|
|
|
2-72 |
Others |
|
|
|
|
|
|
|
|
|
Chassis parts |
:1 |
|
|
|
|
|
2-73 |
|
Condition of bolts, nuts and fasteners |
|
|
|
|
|
|
2-74 |
|
|
|
|
|
|
|
|
|
PERIODIC MAINTENANCE 2-5
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. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated.
Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G:Apply grease.
L:Apply a non-permanent locking agent. LG: Apply liquid gasket.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R:Replacement Parts
S:Follow the specified tightening sequence. Si: Apply silicone grease.
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Fuel System (DFI) |
|
|
|
|
|
Front Air Intake Duct Mounting Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Idle Speed Control Valve Actuator Bracket Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Idle Speed Control Valve Actuator Mounting Bolts |
6.0 |
0.61 |
53 in·lb |
|
|
Intake Air Temperature Sensor Screw |
0.50 |
0.05 |
4.4 in·lb |
|
|
Air Cleaner Cap Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Rear Air Intake Duct Mounting Bolts |
10 |
1.0 |
89 in·lb |
L |
|
Air Intake Duct Clamp Bolts |
7.0 |
0.71 |
62 in·lb |
|
|
Air Cleaner Element Cover Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Duct Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
|
Drain Hose Fitting |
20 |
2.0 |
15 |
L |
|
Breather Pipe Bolt |
8.0 |
0.82 |
71 in·lb |
L |
|
Throttle Case Cover Screws (ZX1400H Model) |
3.5 |
0.36 |
31 in·lb |
|
|
Throttle Case Cover Screws (ZX1400J Model) |
3.0 |
0.31 |
27 in·lb |
|
|
Delivery Pipe Mounting Screws |
5.0 |
0.51 |
44 in·lb |
|
|
Throttle Cable Holder Screw |
4.0 |
0.41 |
35 in·lb |
|
|
Throttle Body Assy Holder Bolts |
10 |
1.0 |
89 in·lb |
S |
|
Throttle Body Assy Holder Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
|
Vehicle-down Sensor Bracket Bolt |
8.0 |
0.82 |
71 in·lb |
|
|
Vehicle-down Sensor Mounting Bolts |
6.0 |
0.61 |
53 in·lb |
|
|
Spark Plugs |
13 |
1.3 |
115 in·lb |
|
|
Water Temperature Sensor |
12 |
1.2 |
106 in·lb |
|
|
Gear Position Sensor Bolt |
10 |
1.0 |
89 in·lb |
L |
|
Gear Position Sensor Holder Bolts (L = 20 mm) |
5.0 |
0.51 |
44 in·lb |
L |
|
Crankshaft Sensor Bolts |
6.0 |
0.61 |
53 in·lb |
L |
|
Oxygen Sensor |
25 |
2.5 |
18 |
|
|
Fuel Tank Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Fuel Tank Cap Bolts |
4.5 |
0.46 |
40 in·lb |
|
|
Fuel Level Sensor Bolts |
7.0 |
0.71 |
62 in·lb |
L |
|
Bracket Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Fuel Pump Assembly Screws |
0.98 |
0.10 |
8.7 in·lb |
R |
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Fuel Pump Bolts |
10 |
1.0 |
89 in·lb |
L, S |
|
Canister Bracket Screws |
1.2 |
0.12 |
11 in·lb |
|
|
Hose Bracket Bolt |
8.0 |
0.82 |
71 in·lb |
|
|
Purge Valve Bracket Bolt |
8.0 |
0.82 |
71 in·lb |
|
|
Purge Valve Mounting Nut |
8.0 |
0.82 |
71 in·lb |
|
|
Cooling System |
|
|
|
|
|
Radiator Upper Bolts |
20 |
2.0 |
15 |
|
|
Water Hose Clamp Screws |
3.0 |
0.31 |
27 in·lb |
|
|
Coolant Fitting Bolts |
9.0 |
0.92 |
80 in·lb |
L |
|
Thermostat Housing Mounting Bolts |
10 |
1.0 |
89 in·lb |
|
|
Radiator Stay Bolt |
8.0 |
0.82 |
71 in·lb |
|
|
Radiator Lower Bolt |
8.0 |
0.82 |
71 in·lb |
|
|
Thermostat Housing Cover Bolts |
6.0 |
0.61 |
53 in·lb |
|
|
Cylinder Fitting Mounting Bolts |
10 |
1.0 |
89 in·lb |
|
|
Oil Cooler Mounting Bolts |
12 |
1.2 |
106 in·lb |
L, S |
|
Water Pump Mounting Bolts |
12 |
1.2 |
106 in·lb |
|
|
Coolant Reserve Tank Cap |
– |
– |
– |
Hand-tighten |
|
Water Pump Cover Bolts |
12 |
1.2 |
106 in·lb |
|
|
Coolant Drain Bolt |
10 |
1.0 |
89 in·lb |
|
|
Coolant Reserve Tank Bolts |
8.0 |
0.82 |
71 in·lb |
L |
|
Engine Top End |
|
|
|
|
|
Air Suction Valve Cover Bolts |
10 |
1.0 |
89 in·lb |
L |
|
Cylinder Head Cover Bolts |
10 |
1.0 |
89 in·lb |
S |
|
Camshaft Sprocket Mounting Bolts |
15 |
1.5 |
11 |
L |
|
Throttle Body Assy Holder Bolts |
10 |
1.0 |
89 in·lb |
S |
|
Throttle Body Assy Holder Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
|
Camshaft Cap Bolts |
12 |
1.2 |
106 in·lb |
S |
|
Water Passage Plugs |
20 |
2.0 |
15 |
L |
|
Front Camshaft Chain Guide Bolt (Upper) |
25 |
2.5 |
18 |
|
|
Cylinder Head Bolts (M6) |
12 |
1.2 |
106 in·lb |
S |
|
Cylinder Head Bolts (M11) |
see the |
– |
– |
MO, S |
|
text |
|||||
|
|
|
|
||
Camshaft Chain Tensioner Mounting Bolts |
10 |
1.0 |
89 in·lb |
|
|
Front Camshaft Chain Guide Bolt (Lower) |
12 |
1.2 |
106 in·lb |
|
|
Engine Bracket Bolts |
25 |
2.5 |
18 |
R, S |
|
Front Engine Mounting Bolts |
60 |
6.1 |
44 |
R, S |
|
Muffler Cover Bolts |
10 |
1.0 |
89 in·lb |
|
|
Muffler Guard Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Muffler Body Mounting Bolts |
34 |
3.5 |
25 |
|
|
Muffler Body Cover Bolts |
8.0 |
0.82 |
71 in·lb |
L |
|
Exhaust Pipe Manifold Holder Nuts |
17 |
1.7 |
13 |
S |
|
Muffler Body Clamp Bolts |
17 |
1.7 |
13 |
|
|
|
|
|
|
|
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Clutch |
|
|
|
|
|
Clutch Reservoir Cap Stopper Screw (ZX1400H |
2.0 |
0.20 |
18 in·lb |
|
|
Model) |
|
||||
|
|
|
|
||
Clutch Reservoir Cap Stopper Screw (ZX1400J |
1.2 |
0.12 |
11 in·lb |
|
|
Model) |
|
||||
|
|
|
|
||
Clutch Reservoir Bracket Bolt |
9.0 |
0.92 |
80 in·lb |
|
|
Clutch Cover Bolts |
10 |
1.0 |
89 in·lb |
L (1), S |
|
Oil Filler Plug |
– |
– |
– |
Hand-tighten |
|
Clutch Hose Banjo Bolts |
25 |
2.5 |
18 |
|
|
Clutch Reservoir Bolt |
8.0 |
0.82 |
71 in·lb |
|
|
Clutch Lever Pivot Bolt |
1.0 |
0.10 |
8.9 in·lb |
Si |
|
Clutch Master Cylinder Bleed Valve |
8.0 |
0.82 |
71 in·lb |
|
|
Clutch Lever Pivot Bolt Locknut |
5.9 |
0.60 |
52 in·lb |
|
|
Starter Lockout Switch Screw |
0.70 |
0.07 |
6.2 in·lb |
L |
|
Clutch Master Cylinder Clamp Bolts |
10.3 |
1.05 |
91 in·lb |
S |
|
Clutch Hose Clamp Bolts |
8.0 |
0.82 |
71 in·lb |
|
|
Clutch Spring Bolts |
11 |
1.1 |
97 in·lb |
|
|
Sub Clutch Hub Bolts |
25 |
2.5 |
18 |
L |
|
Clutch Hub Nut |
135 |
13.8 |
100 |
R |
|
Clutch Slave Cylinder Bleed Valve |
8.5 |
0.87 |
75 in·lb |
|
|
Clutch Slave Cylinder Bolts |
8.0 |
0.82 |
71 in·lb |
L |
|
Engine Lubrication System |
|
|
|
|
|
Oil Pipe Mounting Bolts |
10 |
1.0 |
89 in lb |
L |
|
Oil Pipe Bolts |
10 |
1.0 |
89 in lb |
L |
|
Oil Passage Plug (R1/4) |
15 |
1.5 |
11 |
L |
|
Oil Cooler Mounting Bolts |
12 |
1.2 |
106 inlb |
L, S |
|
Oil Pump Cover Bolts |
10 |
1.0 |
89 in lb |
|
|
Oil Pan Plate Bolts |
10 |
1.0 |
89 in lb |
L |
|
Oil Filter |
17 |
1.7 |
13 |
G, R |
|
Oil Filter Holder Mounting Bolt |
35 |
3.6 |
26 |
L |
|
Oil Pressure Relief Valve |
15 |
1.5 |
11 |
L |
|
Oil Pan Bolts |
10 |
1.0 |
89 in lb |
|
|
Oil Pressure Switch Terminal Bolt |
2.0 |
0.20 |
18 in lb |
G |
|
Oil Pressure Switch |
15 |
1.5 |
11 |
LG |
|
Engine Oil Drain Bolt |
29 |
3.0 |
21 |
|
|
Oil Passage Plug (R3/8) |
20 |
2.0 |
15 |
L |
|
Engine Removal/Installation |
|
|
|
|
|
Engine Bracket Bolts |
25 |
2.5 |
18 |
R, S |
|
Front Engine Mounting Bolts |
60 |
6.1 |
44 |
R, S |
|
Adjusting Collars |
15 |
1.5 |
11 |
M, S |
|
Engine Mounting Nuts |
60 |
6.1 |
44 |
R, S |
|
Crankshaft/Transmission |
|
|
|
|
|
Breather Cover Bolts (L = 25 mm) |
10 |
1.0 |
89 in·lb |
L |
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Breather Cover Bolt (L = 35 mm) |
10 |
1.0 |
89 in·lb |
|
|
Breather Cover Plate Screws |
10 |
1.0 |
89 in·lb |
L |
|
Connecting Rod Big End Nuts |
see the |
← |
← |
MO, R |
|
text |
|||||
|
|
|
|
||
Oil Nozzle Pipe Mounting Bolts |
25 |
2.5 |
18 |
|
|
Oil Passage Plugs (R3/8) |
20 |
2.0 |
15 |
L |
|
Bearing Position Plate Screws |
10 |
1.0 |
89 in·lb |
L |
|
Shift Drum Bearing Holder Screws |
10 |
1.0 |
89 in·lb |
L |
|
Drive Shaft Cover Bolts |
25 |
2.5 |
18 |
L |
|
Crankcase Bolts (M7, L = 60 mm) |
20 |
2.0 |
15 |
S |
|
Crankcase Bolt (M7, L = 110 mm) |
20 |
2.0 |
15 |
S |
|
Crankcase Bolts (M7, L = 45 mm) |
20 |
2.0 |
15 |
S |
|
Crankcase Bolts (M10, L = 90 mm) |
49 |
5.0 |
36 |
MO, S |
|
Crankcase Bolt (M7, L = 85 mm) |
20 |
2.0 |
15 |
S |
|
Crankcase Bolt (M7, L = 50 mm) |
20 |
2.0 |
15 |
S |
|
Crankcase Bolts (M10, L = 120 mm) |
49 |
5.0 |
36 |
MO, S |
|
Crankcase Bolts (M7, L = 65 mm) |
20 |
2.0 |
15 |
S |
|
Crankcase Bolts (M6, L = 40 mm) |
12 |
1.2 |
106 in·lb |
S |
|
Crankcase Bolts (M8, L = 70 mm) |
27 |
2.8 |
20 |
S |
|
Crankcase Bolt (M6, L = 50 mm) |
12 |
1.2 |
106 in·lb |
S |
|
Crankcase Bolts (M6, L = 25 mm) |
12 |
1.2 |
106 in·lb |
S |
|
Crankcase Bolts (M8, L = 80 mm) |
27 |
2.8 |
20 |
S |
|
Crankcase Bolt (M6, L = 65 mm) |
12 |
1.2 |
106 in·lb |
S |
|
Balancer Shaft Clamp Bolts |
10 |
1.0 |
89 in·lb |
|
|
Balancer Shaft Clamp Lever Bolts |
25 |
2.5 |
18 |
|
|
Starter Clutch Shaft Bolt |
10 |
1.0 |
89 in·lb |
L |
|
Starter Clutch Shaft Plate Bolt |
10 |
1.0 |
89 in·lb |
L |
|
Shift Shaft Return Spring Pin |
29 |
3.0 |
21 |
L |
|
Torque Limiter Bolt |
25 |
2.5 |
18 |
L |
|
Gear Positioning Lever Bolt |
12 |
1.2 |
106 in·lb |
|
|
Shift Drum Cam Holder Bolt |
12 |
1.2 |
106 in·lb |
L |
|
Gear Position Sensor Holder Bolt (L = 14 mm) |
6.0 |
0.61 |
53 in·lb |
L |
|
Shift Pedal Bolt |
8.0 |
0.82 |
71 in·lb |
|
|
Gear Position Sensor Holder Bolts (L = 20 mm) |
5.0 |
0.51 |
44 in·lb |
L |
|
Wheels/Tires |
|
|
|
|
|
Front Axle Clamp Bolts |
20 |
2.0 |
15 |
AL |
|
Front Axle Nut |
130 |
13.3 |
95.9 |
|
|
Rear Axle Nut |
130 |
13.3 |
95.9 |
|
|
Final Drive |
|
|
|
|
|
Engine Sprocket Cover Bolts |
10 |
1.0 |
89 in·lb |
L (1) |
|
Plate Mounting Bolts |
10 |
1.0 |
89 in·lb |
L |
|
Chain Guide Bolts (M6) |
10 |
1.0 |
89 in·lb |
L |
|
Chain Guide Bolt (M8) |
12 |
1.2 |
106 in·lb |
L |
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