![Kawasaki NINJA ZX-10R (2004) [7/595] Tampering with noise control system prohibited](/img/pdf.png)
Kawasaki NINJA ZX-10R (2004) [7/595] Tampering with noise control system prohibited
![Kawasaki NINJA ZX-10R (2004) [7/595] Tampering with noise control system prohibited](/views2/1121163/page7/bg7.png)
Содержание
- Kawasaki 1
- Quick reference guide 2
- Kawasaki 4
- Motorcycle service manual 4
- Ninja zx 10r 4
- List of abbreviations 5
- Read owner s manual before operating 5
- Emission control information 6
- Tampering with noise control system prohibited 7
- Foreword 8
- How to use this manual 8
- Warning 8
- General information 1 1 10
- General information g 10
- Table of contents 10
- 2 general information ______________ _____ 11
- Before servicing ___________ ___________ ________________ _____ 11
- Before servicing_________________________ _ __ 12
- General information 1 3 12
- Ball bearing and needle bearing 14
- Before servicing 14
- General information 1 5 14
- 6 general information 15
- Before servicing 15
- 8 general information 17
- General information 1 9 18
- General specifications 18
- 10 general information 19
- General specifications 19
- General specifications 20
- ___________________________________ general information 1 11 20
- 12 general information ___________ 21
- Technical information immobilizer system 21
- General information 1 13 22
- Technical information immobilizer system 22
- 14 general information ___________ 23
- Technical information immobilizer system 23
- Exhaust device system 24
- General information 1 15 24
- Technical information exhaust device system 24
- 16 general information 25
- Technical information 25
- General information 1 17 26
- Prefixes for units units of length 26
- Unit conversion table 26
- Units of force 26
- Units of mass 26
- Units of power 26
- Units of pressure 26
- Units of speed 26
- Units of temperature 26
- Units of torque 26
- Units of volume 26
- Periodic maintenance 28
- Periodic maintenance 2 1 28
- Table of contents 28
- 2 periodic maintenance 29
- Inspectio 30
- 4 periodic maintenance 31
- Periodic maintenance chart______ _____ 32
- Periodic maintenance2 5 32
- Periodic replacemen parts________ 32
- 6 periodic maintenance 33
- Basic torque for general fasteners 33
- Torque and locking agent 33
- Periodic maintenance 2 7 34
- Torque and locking agent 34
- 8 periodic maintenance 35
- Torque and locking agent 35
- Periodic maintenance 2 9 36
- Torque and locking agent 36
- 10 periodic maintenance 37
- Torque 37
- Torque and locking agent 37
- Fastener 38
- Periodic maintenance 2 11 38
- Torque and locking agent 38
- 12 periodic maintenance 39
- Specifications 39
- Periodic maintenance2 13 40
- Specifications 40
- 14 periodic maintenance 41
- Special tools 41
- Maintenance procedure 42
- Periodic maintenance 2 15 42
- Steering system 42
- 16 periodic maintenance_____________ 43
- Brake system 43
- Maintenance procedure_______________________ 43
- A warning 44
- Maintenance procedure 44
- Periodic maintenance 2 17 44
- 18 periodic maintenance 45
- Caution 45
- Maintenance procedure 45
- Maintenance procedure 46
- Periodic maintenance 2 19 46
- Wheels tires 46
- 20 periodic maintenance 47
- A warning 47
- Maintenance procedure 47
- Suspensions 47
- Maintenance procedure 48
- Periodic maintenance 2 21 48
- 22 periodic maintenance 49
- Clutch and drive train 49
- Maintenance procedure 49
- Warning 49
- Caution 50
- Maintenance procedure 50
- Periodic maintenance 2 23 50
- 24 periodic maintenance 51
- A warning 51
- Maintenance procedure 51
- Maintenance procedure 52
- Periodic maintenance 2 25 52
- Warning 52
- 26 periodic maintenance_____________ 53
- Electrical system 53
- Maintenance procedure_______________________ 53
- Maintenance procedure 54
- Periodic maintenance 2 27 54
- 28 periodic maintenance 55
- Maintenance procedure 55
- Maintenance procedure 56
- Periodic maintenance 2 29 56
- 30 periodic maintenance 57
- Engine top end 57
- Maintenance procedure 57
- Maintenance procedure 58
- Periodic maintenance 2 31 58
- 32 periodic maintenance 59
- Maintenance procedure 59
- Maintenance procedure 60
- Periodic maintenance 2 33 60
- 34 periodic maintenance 61
- Caution 61
- Fuel system dfi 61
- Maintenance procedure 61
- Maintenance procedure 62
- Periodic maintenance 2 35 62
- 36 periodic maintenance 63
- Caution 63
- Maintenance procedure 63
- Caution 64
- Maintenance procedure 64
- Periodic maintenance 2 37 64
- 38 periodic maintenance 65
- Maintenance procedure 65
- Warning 65
- Caution 66
- Cooling system 66
- Maintenance procedure 66
- Periodic maintenance 2 39 66
- 40 periodic maintenance 67
- Evaporative emission control system california model 67
- Maintenance procedure 67
- Air suction system 68
- Caution 68
- Maintenance procedure 68
- Others 68
- Periodic maintenance 2 41 68
- 42 periodic maintenance 69
- Maintenance procedure 69
- Maintenance procedure 70
- Periodic maintenance 2 43 70
- 44 periodic maintenance 71
- Maintenance procedure___________________________________________ _ 71
- Replacement parts 71
- _caution_ _________ 71
- Maintenance procedure 72
- Periodic maintenance 2 45 72
- 46 periodic maintenance 73
- Caution 73
- Maintenance procedure 73
- A warning 74
- Caution 74
- Maintenance procedure 74
- Periodic maintenance 2 47 74
- 48 periodic maintenance 75
- Caution 75
- Maintenance procedure 75
- Caution 76
- Maintenance procedure 76
- Periodic maintenance 2 49 76
- Warning 76
- 50 periodic maintenance 77
- Caution_________________ 77
- Maintenance procedure 77
- Caution 78
- Maintenance procedure 78
- Periodic maintenance 2 51 78
- Warning 78
- 52 periodic maintenance 79
- L i 1 1 1 79
- Maintenance procedure __________ 79
- Maintenance procedure 80
- Periodic maintenance 2 53 80
- Warning 80
- 54 periodic maintenance 81
- A warning 81
- Maintenance procedure 81
- Caution 82
- Do not add more coolant above the full level line 82
- Maintenance procedure 82
- Periodic maintenance 2 55 82
- 56 periodic maintenance __________ 83
- Maintenance procedure 83
- Contents 84
- Fuel system dfi 84
- Fuel system dfi 3 1 84
- Table of 84
- 2 fuel system dfi 85
- 4 fuel system dfi 87
- Exploded view 88
- Fuel system dfi 3 5 88
- 6 fuel system dfi 89
- Exploded view 90
- Fuel system dfi 3 7 90
- 8 fuel system dfi 91
- Ded view 92
- Fuel system dfi 3 9 92
- 10 fuel system dfi 93
- Specifications 93
- Fuel system dfi 3 11 94
- Specifications 94
- 12 fuel system dfi 95
- Special tools 95
- 14 fuel system dfi 97
- Dfi parts location 97
- Dfi parts location 98
- Fuel system dfi 3 15 98
- Dfi system 100
- Fuel system dfi 3 17 100
- 18 fuel system dfi 101
- Dfi system 101
- Terminal numbers of ecu connectors 101
- Dfi system 102
- Fuel system dfi 3 19 102
- 20 fuel system dfi ___________________ 103
- Dfi servicing precautions _____________________ 103
- Dpi servicing precautions 104
- Fuel system dfi 3 21 104
- 22 fuel system dfi 105
- Caution 105
- Outline 105
- Troubleshooting the dfi system 105
- Fuel system dfi 3 23 106
- Troubleshooting the dfi system 106
- 24 fuel system dfi 107
- Troubleshooting the dfi system 107
- Fuel system dfi 3 25 108
- Troubleshooting the dfi system 108
- 26 fuel system dfi 109
- Dfi diagnosis flow chart 109
- Inquiries to rider 109
- Troubleshooting the dfi system 109
- Fuel system dfi 3 27 110
- Sample diagnosis sheet 110
- Troubleshooting the dfi system 110
- 28 fuel system dfi 111
- Troubleshooting the dfi system 111
- Dfi system troubleshooting guide 112
- Enaine doesn t start starting difficulty 112
- Fuel system dfi 3 29 112
- 30 fuel system dfi 113
- Dfi system troubleshooting guide 113
- Dfi system troubleshooting guide 114
- Fuel system dfi 3 31 114
- Poor at low 114
- 32 fuel system dfi _________ 115
- Dfi system troubleshooting guide 115
- Dfi system troubleshooting guide 116
- Fuel system dfi 3 33 116
- 34 fuel system dfi 117
- Dfi system troubleshooting guide 117
- Or no power at 117
- Dfi system troubleshooting guide 118
- Fuel system dfi 3 35 118
- 36 fuel system dfi 119
- Dfi system troubleshooting guide 119
- Fuel system dfi 3 37 120
- Self diagnosis 120
- Self diagnosis outline 120
- Self diagnosis procedures 120
- 38 fuel system dfi 121
- Self diagnosis 121
- Finn tl 122
- Fuel system dfi 3 39 122
- J ltltltl 122
- Jirltirltl 122
- Jitltl 122
- Jltlonfinn 122
- Jn_jinnnn 122
- Jt_nnnn 122
- Jutfunfl 122
- Rlttrlttfinn 122
- Self diagnosis 122
- Tl tut 122
- Tltlnrltltl 122
- 40 fuel system dfi 123
- Intln n 123
- J tnnn_ntl 123
- Jinfirl ttrlfl 123
- Jinnn jnntltl 123
- Jirlnnnrltltln 123
- Jnj ltmn_nn 123
- Jnnnrt 123
- Jnrittrltl tl 123
- N nrln_nrltl 123
- Nnnrltl 123
- Nrinrtrlrinrlrl 123
- Self diagnosis 123
- Tinnjn jnjnnnrltl 123
- Tinrin_rln_tltl 123
- Backups 124
- Fuel system dfi 3 41 124
- Self diagnosis 124
- 42 fuel system dfi 125
- Self diagnosis 125
- Fuel system dfi 3 43 126
- Self diagnosis 126
- 44 fuel system dfi ____________ 127
- Caution 127
- Main throttle sensor service code 11 127
- Fuel system dfi 3 45 128
- Main throttle sensor service code 11 128
- 46 fuel system dfi __________________ 129
- Caution 129
- Main throttle sensor service code 11 129
- Caution 130
- Fuel system dfi 3 47 130
- Main throttle sensor service code 11 130
- 48 fuel system dfi 131
- Main throttle sensor service code 11 131
- Caution 132
- Fuel system dfi 3 49 132
- Inlet air pressure sensor service code 12 132
- 50 fuel system dfi 133
- Inlet air pressure sensor service code 12 133
- Fuel system dfi 3 51 134
- Inlet air pressure sensor service code 12 134
- 52 fuel system dfi ___________________ 135
- Inlet air pressure sensor service code 12 135
- Fuel system dfi 3 53 136
- Inlet air pressure sensor service code 12 136
- 54 fuel system dfi 137
- Caution_________________ 137
- Inlet air temperature sensor service code 13 137
- Fuel system dfi 3 55 138
- Inlet air temperature sensor service code 13 138
- Fuel system dfi 3 57 140
- Water temperature sensor service code 14 140
- 58 fuel system dfi 141
- Water temperature sensor service code 14 141
- Atmospheric pressure sensor service code 15 142
- Fuel system dfi 3 59 142
- 60 fuel system dfi 143
- Atmospheric pressure sensor service code 15 143
- Atmospheric pressure sensor service code 15 144
- Fuel system dfi 3 61 144
- 62 fuel system dfi ____________________ 145
- Atmospheric pressure altitude relationship 145
- Atmospheric pressure sensor service code 15 145
- Crankshaft sensor service code 21 146
- Fuel system dfi 146
- 64 fuel system dfi __________________ 147
- Camshaft position sensor service code 23 147
- Fuel system dfi 3 65 148
- Speed sensor service code 24 148
- 66 fuel system dfi 149
- Speed sensor service code 24 149
- Fuel system dfi 3 67 150
- Gear position switch service code 25 150
- A warning 152
- Caution 152
- Fuel system dfi 152
- Vehicle down sensv service code 31 152
- Û up 6 5 152
- 70 fuel system dfi _____________ 153
- Vehicle down sensor service code 31 153
- Fuel system dfi 3 71 154
- Vehicle down sensor service code 31 154
- 72 fuel system dfi 155
- Caution 155
- Subthrottle sensor service code 32 155
- Fuel system dfi 3 73 156
- Subthrottle sensor service code 32 156
- 74 fuel system dfi 157
- Caution 157
- Subthrottle sensor service code 32 157
- Fuel system dfi 3 75 158
- Subthrottle sensor service code 32 158
- 76 fuel system dfi _____________________________ 159
- Exhaust butterfly valve actuator sensor service code 34 159
- Fuel system dfi 3 77 160
- Immobilizer amplifier service code 35 160
- 78 fuel system dfi 161
- Blank key detection service code 36 161
- Caution 162
- Fuel injectors 1 2 3 4 service code 41 42 43 44 162
- Fuel system dfi 3 79 162
- 80 fuel system dfi ____________________________ 163
- Fuel injectors 1 2 3 4 service code 41 42 43 44 163
- If the reading is good and the power source voltage is normal check the output voltage 163
- If the reading is normal remove the air cleaner housing and check the power source voltage at the injector con nector b with a digital volt meter a 163
- If the reading is out of the standard check the wiring see wiring diagram in this section 163
- Injector 1 bur lead injector 2 bug lead injector 3 bubk lead injector 4 buy lead injector power supply w r lead 163
- Measure the power source voltage with the engine stopped and the connector joined with a digital meter and needle adapter set c 163
- Output voltage inspection measure the output voltage at the ecu connector in the same way as power source voltage inspection note the following 163
- Turn the ignition switch off 163
- Turn the ignition switch on 163
- Fuel injectors 1 2 3 4 service code 41 42 43 44 164
- Fuel system dfi 3 81 164
- If the output voltage is normal check the ecu for its ground and power supply see this chapter if the ground and power supply are good replace the ecu 164
- If the output voltage is normal check the wiring for con tinuity see next diagram if the wiring is good perform audible inspection for confirmation 164
- If the output voltage is out of the standard perform au dible inspection for confirmation 164
- If the output voltage is out of the standard remove the air cleaner housing and check the output voltage at the injector connector b using a digital meter a and needle adapter set c when the lead is open the output voltage is 0 v 164
- Turn the ignition switch on 164
- 82 fuel system dfi ___________________________ 165
- Fuel injectors 1 2 3 4 service code 41 42 43 44 165
- Caution 166
- Fuel injectors 1 2 3 4 service code 41 42 43 44 166
- Fuel system dfi 3 83 166
- 84 fuel system dfi ________________________________ 167
- Fuel injectors 1 2 3 4 service code 41 42 43 44f 167
- ________________caution________________ 167
- Fuel injectors 1 2 3 4 service code 41 42 43 44 168
- Fuel system dfi 3 85 168
- 86 fuel system dfi 169
- Caution 169
- Fuel pump relay service code 45 46 169
- Fuel pump relay service code 45 46 170
- Fuel system dfi 3 87 170
- 88 fuel system dfi _________________________ 171
- Caution 171
- Stick coils 1 2 3 4 service code 51 52 53 54 171
- Fuel system dfi 3 89 172
- Stick coils 1 2 3 4 service code 51 52 53 54 172
- 90 fuel system dfi _________________ 173
- Caution________________ 173
- Subthrottle valve actuator service code 62 173
- Fuel system dfi 3 91 174
- Subthrottle valve actuator service code 62 174
- 92 fuel system dfi 175
- Exhaust butterfly valve actuator service code 63 175
- Exhaust butterfly valve actuator service code 63 176
- Fuel system dfi 3 93 176
- 94 fuel system dfi ______________________ 177
- Exhaust butterfly valve actuator service code 63 177
- Caution 178
- Ecu main relay service code 75 ______________ 178
- Fuel system dfi 3 95 178
- 96 fuel system dfi 179
- Fuel system dfi 3 97 180
- 98 fuel system dfi 181
- Battery c 181
- Check the ecu power source voltage with a tester a oposition the terminal in accordance with terminal numbers 181
- Ecu _____________________ 181
- Ecu fuse 15 a 181
- If the tester does not read as specified check the follow 181
- Of ecu connectors b in this chapter figure 181
- Power source wiring see wiring diagram below main fuse 30 a see electrical system chapter ecu fuse 15 a see dfi power source section ecu main relay see dfi power source section 181
- Dfi power source 182
- Fuel system dfi 3 99 182
- 100 fuel system dfi __________________ ______ 183
- Fl indicator led light______________________________ ______________________ 183
- Caution 184
- Fuel line 184
- Fuel system dfi 3 101 184
- Warning 184
- 102 fuel system dfi 185
- A warning 185
- Fuel line 185
- A warning 186
- Fuel line 186
- Fuel system dfi 3 103 186
- 104 fuel system dfi 187
- A warning 187
- Caution 187
- Fuel pump 187
- Fuel pump 188
- Fuel system dfi 3 105 188
- 106 fuel system dfi 189
- A warning 190
- Fuel system dfi 3 107 190
- Throttle grip and cables 190
- 108 fuel system dfi 191
- A warning 191
- Caution 191
- Throttle body assy 191
- Caution 192
- Fuel system dfi 3 109 192
- Throttle body assy 192
- 110 fuel system dfi 193
- Caution 193
- Throttle body assy 193
- 112 fuel system dfi 195
- Air line 195
- Air line 196
- Fuel system dfi 3 113 196
- 114 fuel system dfi 197
- A warning 197
- Air line 197
- Air line 198
- Fuel system dfi 3 115 198
- 116 fuel system dfi 199
- Fuel tank 199
- Warning 199
- Fuel system dfi 3 117 200
- Fuel tank 200
- Warning 200
- 118 fuel system dfi 201
- A warning 201
- Fuel tank 201
- Caution 202
- Fuel system dfi 3 119 202
- Fuel tank 202
- Warning 202
- 120 fuel system dfi _________________ 203
- A warning 203
- Evaporative emission control system 203
- ________________ caution_________________ 203
- Evaporative emission control system 204
- Fuel system dfi 3 121 204
- Warning 204
- Cooling system 206
- Cooling system 4 1 206
- Table of contents 206
- Cooling system 4 3 208
- 4 cooling system 209
- Coolant flow chart__________________________________________ 210
- Cooling system 4 5 210
- 6 cooling system 211
- Specifications 211
- Coolant 212
- Cooling system 4 7 212
- 8 cooling system 213
- Caution 213
- Coolant 213
- Cooling system 4 9 214
- Water pump 214
- 10 cooling system 215
- Water pump 215
- Caution 216
- Cooling system 4 11 216
- Radiator 216
- 12 cooling system 217
- Radiator 217
- Cooling system 4 13 218
- F the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one 218
- Radiator 218
- 14 cooling system 219
- Radiator 219
- Cooling system 4 15 220
- Thermostat 220
- 16 cooling system _______ ________ 221
- Thermostat 221
- Cooling system 4 17 222
- Hoses and pipes 222
- 18 cooling system 223
- Caution 223
- Water temperature sensor 223
- Engine top end 224
- Engine top end 5 1 224
- Table of contents 224
- 2 engine top end 225
- Engine top end 5 3 226
- Exploded view 226
- 4 engine top end 227
- Engine top end 5 5 228
- Exploded view 228
- 6 engine top end 229
- Specifications 229
- 8 engine top end 231
- Special tools and sealant 231
- Clean air system 232
- Engine top end 5 9 232
- 10 engine top end_______________ 233
- Clean air system 233
- Cylinder head cover 234
- Engine top end 5 11 234
- 12 engine top end 235
- Cylinder head cover 235
- Camshaft chain tensioner 236
- Caution 236
- Engine top end 5 13 236
- 14 engine top end 237
- Camshaft camshaft chain 237
- Caution 237
- Camshaft camshaft chain _____________________________________________ 238
- Engine top end 5 15 238
- 16 engine top end 239
- Cam wear remove the camshaft see camshaft removal measure the height a of each cam with a micrometer 239
- Camshaft camshaft chain 239
- Camshaft runout remove the camshaft see camshaft removal set the camshaft in a camshaft alignment jig or on v blocks 239
- If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer 239
- If the cams are worn down past the service limit replace the camshaft 239
- If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again 239
- If the clearance still remains out of the limit replace the cylinder head unit 239
- If the runout exceeds the service limit replace the shaft 239
- Measure runout with a dial gauge at the specified place as shown 239
- Odo not turn the camshaft when the plastigage is be tween the journal and camshaft cap 239
- Tighten 239
- Camshaft camshaft chain 240
- Engine top end 5 17 240
- 18 engine top end cylinder head 241
- Cylinder head 242
- Engine top end 5 19 242
- 20 engine top end 243
- Cylinder head 243
- Caution 244
- Engine top end 5 21 244
- Valves 244
- 22 engine top end 245
- Caution 245
- Valves 245
- Engine top end 5 23 246
- Good f 246
- If the manufacturer s instructions are not available use the following procedure 246
- If the outside diameter is too large or too small repair the seat see seat repair 246
- If the width is too wide g too narrow h or uneven j repair the seat see valve seat repair 246
- Omeasure the outside diameter d of the seating pattern on the valve seat 246
- Omeasure the seat width e of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper 246
- Valve seat inspection remove the valve see valve removal check the valve seating surface a between the valve b and valve seat c 246
- Valve seat repair repair the valve seat with the valve seat cutters a 246
- Valves 246
- 24 engine top end 247
- Caution 247
- Valves 247
- Caution 248
- Engine top end 5 25 248
- Valves 248
- 26 engine top end 249
- Caution 249
- Valves 249
- 28 engine top end 251
- Throttle body holder 251
- Throttle body holder installation be sure to install the o rings a install the clamps b as shown tighten the holder bolts following the tightening sequence 251
- Upside e 251
- Engine top end 5 29 252
- Muffler 252
- Warning 252
- 30 engine top end 253
- Muffler 253
- Engine top end 5 31 254
- Muffler 254
- 32 engine top end 255
- Muffler 255
- Engine top end 5 33 256
- Muffler 256
- 34 engine top end 257
- Muffler 257
- Caution 258
- Engine top end 5 35 258
- Muffler 258
- 36 engine top end 259
- Caution 259
- Muffler 259
- Clutch 262
- Clutch 6 1 262
- Table of contents 262
- _____________________________ clutch 6 3 exploded view 264
- 4 clutch 265
- Specifications 265
- Clutch 6 5 266
- Special tool and sealant 266
- 6 clutch 267
- Clutch lever and cable 267
- Clutch 6 7 268
- Clutch cover 268
- 8 clutch 269
- Clutch cover 269
- Clutch 6 9 270
- Clutch cover 270
- Clutch cover assembly 270
- Install the needle bearings a and oil seal b position as shown 270
- Press the bearing until the bottom c press the bearing so that the bearing surface d is flush with the housing end of clutch cover e 270
- Replace the needle bearings and oil seal with new ones 270
- 10 clutch 271
- Clutch 271
- Be sure to confirm the marking on the clutch housing gear 272
- Clutch 272
- Clutch 6 11 272
- Clutch installation install the following parts on the drive shaft 272
- Gear assembly alternator a clutch housing gear b 272
- If the clutch housing is replaced with a new one select the 272
- Install the spacer a so that the stepped side b faces 272
- Inward 272
- Proper clutch housing in accordance with the combination of the clutch housing gear and gear assembly alternator markings 272
- Spacer a needle bearing b sleeve c clutch housing d spacer e clutch hub f sub clutch hub g torque limiter springs h nut i 272
- 12 clutch 273
- Be sure to confirm the marking on the clutch housing gear 273
- Clutch 273
- Clutch housing gear a 273
- Engage the clutch housing gear a with the oil pump gear 273
- Gear assembly b and crankshaft gear c 273
- If the clutch housing is replaced with a new one select the 273
- Install the four torque limiter springs a as shown 273
- Install the needle bearing and sleeve 273
- Proper clutch housing in accordance with the combination of the clutch housing gear marking and needle bearing 273
- Replace the clutch hub nut with a new one oholding the sub clutch hub tighten the clutch hub nut 273
- Caution 274
- Clutch 274
- Clutch 6 13 274
- 14 clutch 275
- Clutch 275
- Clutch 276
- Clutch 6 15 276
- Engine lubrication system 278
- Engine lubrication system 7 1 278
- Table of contents 278
- Engine lubrication system 7 3 280
- Exploded view 280
- Engine lubrication system 7 5 282
- Item standard 282
- Specifications 282
- 6 engine lubrication system 283
- Special tools and sealant 283
- A warning 284
- Engine lubrication system 7 7 284
- Engine oil and oil filter 284
- 8 engine lubrication system 285
- Install the bracket a as shown replace the oil pan gasket with a new one tighten 285
- Oil pan 285
- Engine lubrication system 7 9 286
- Oil pressure relief valve 286
- Warning 286
- 10 engine lubrication system 287
- Oil pump 287
- Engine lubrication system 7 11 288
- Oil pump 288
- 12 engine lubrication system 289
- Oil cooler 289
- A warning 290
- Engine lubrication system 7 13 290
- Oil pressure measurement 290
- 14 engine lubrication system 291
- Oil pressure switch 291
- Engine removal installation 8 1 292
- Engine removal lnstallation 292
- Table of contents 292
- ___________ ____________________engine removal installation 8 3 exploded view 294
- 4 engine removal installation 295
- Special tool 295
- A warning 296
- Caution 296
- Engine removal installation 8 5 296
- Engine removal lnstallation 296
- 6 engine removal installation 297
- Engine removal lnstallation 297
- Engine removal installation 8 7 298
- Engine removal lnstallation 298
- 8 engine removal installation 299
- Engine removal lnstallation 299
- Engine removal installation 8 9 300
- Engine removal lnstallation 300
- 10 engine removal installation 301
- Engine removal lnstallation 301
- Ofifth tighten the middle e and lower f engine mounting nuts 301
- Ofourth install the middle a and lower b engine mount ing bolts and tighten the bolts counterclockwise 301
- Oseventh tighten the bolt 301
- Osixth pull out bolt d temporally and turn the adjust ing collar g until the clearance h between the cylinder head and frame come to 0 mm 301
- Othird tighten the bolts a b c d temporally and tighten the bolt c 301
- Engine removal 1nstallation 8 11 302
- Engine removal lnstallation 302
- Crankshaft transmission 304
- Crankshaft transmission 9 1 304
- Table of contents 304
- Crankshaft transmiss1on 9 3 306
- Exploded view 306
- Remarks nm 306
- Crankshaft transmission 9 5 308
- Exploded view 308
- 0 08 3 4 in 309
- 6 crankshaft transmission 309
- Specifications 309
- Crankshaft transmission 9 7 310
- Specifications 310
- 8 crankshaft transmission 311
- Specifications 311
- Crankshaft transmission 9 9 312
- Special tools and sealant 312
- 10 crankshaft transmission 313
- Crankcase splitting 313
- Be sure to confirm the marking on the crankcase 314
- Crankcase splitting 314
- Crankshaft transmission 9 11 314
- If the crankcase is replaced with a new one select the 314
- Olf the crankcase is replaced with a new one refer to 314
- Olf the selection mark is missing or not selection refer to 314
- Proper crankcase in accordance with the combination of the crankcase crankshaft and clutch housing gear mark ings 314
- The connecting rod big end bearing crankshaft main bearing insert selection in the selection section 314
- The selection section in this chapter 314
- Upper crankcase a crankshaft clutch side b clutch housing gear c 314
- 12 crankshaft transmission 315
- Caution ________________ 315
- Crankcase splitting 315
- Crankcase splitting 316
- Crankshaft transmission 9 13 316
- 14 crankshaft transmission 317
- Apply molybdenum disulfide oil solution to the crankshaft 317
- Be sure to confirm the marking on the crankshaft 317
- Caution 317
- Crankshaft and connecting rods 317
- Crankshaft installation if the crankshaft is replaced with a new one select the 317
- Crankshaft removal split the crankcase see crankcase splitting remove the crankshaft see connecting rod removal 317
- Halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed 317
- If the crankshaft bearing inserts or crankcase 317
- Main bearing inserts 317
- Olf the crankshaft is replaced with a new one refer to 317
- Olfthe selection mark is missing or not selection refer to 317
- Proper crankshaft in accordance with the combination of the crankshaft crankcase and clutch housing gear mark ings 317
- The connecting rod big end bearing crankshaft main bearing insert selection in the selection section 317
- The selection section in this chapter 317
- Upper crankcase a crankshaft clutch side b clutch housing gear c 317
- Caution 318
- Crankshaft and connecting rods 318
- Crankshaft transmission 9 15 318
- 16 crankshaft transmission 319
- Caution 319
- Crankshaft and connecting rods 319
- 1 bolt length measurement method be sure to clean the bolts nuts and connecting rods 320
- A warning 320
- Apply a small amount of molybdenum disulfide oil to the 320
- Caution 320
- Check the length of the connecting rod bolts 320
- Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area this in cludes any appliance with a pilot light because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean them 320
- Connecting rod a dent here with a punch bj nuts c fit micrometer pins into dents d 320
- Crankshaft and connecting rods 320
- Crankshaft transmission9 17 320
- Following 320
- If the stretch is more than the usable range the bolt has 320
- Immediately dry the bolts and nuts with com pressed air after cleaning clean and dry the bolts and nuts completely 320
- Install new bolts in reused connecting rods dent both bolt head and bolt tip with a punch as shown before tightening use a point micrometer to measure the 320
- Length of new connecting rod bolts and record the values to find the bolt stretch 320
- Stretched too much an overelongated bolt may break in use 320
- The length specified in the table 320
- Thoroughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution _________________________________ 320
- Threads of nuts and bolts seating surfaces of nuts and connecting rods 320
- Tighten the big end nuts until the bolt elongation reaches 320
- 18 crankshaft transmission 321
- Caution 321
- Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area this in cludes any appliance with a pilot light because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean them 321
- Crankshaft and connecting rods 321
- Immediately dry the bolts and nuts with com pressed air after cleaning clean and dry the bolts and nuts completely 321
- Warning 321
- Crankshaft and connecting rods 322
- Crankshaft transmiss1on 9 19 322
- 20 crankshaft transmission 323
- After measurement replace the connecting rod bolts 323
- Crankshaft and connecting rods 323
- ________________ caution________________ 323
- Bearing and the crank web at the no journal b to de termine clearance 324
- Big end cap a connecting rod b weight mark alphabet c diameter mark around weight mark d q 324
- Combination of the connecting rod and crankshaft coding 324
- Crankcase halves as a set 324
- Crankshaft 324
- Crankshaft and connecting rods 324
- Crankshaft transmission 9 21 324
- If the clearance exceeds the service limit replace the 324
- If the measurement exceeds the service limit replace the 324
- Insert a thickness gauge a between the crankcase main 324
- Insert crankpin clearance with the plastigage 324
- Install the new inserts in the connecting rod and check 324
- Measure the crankshaft runout 324
- Select the proper bearing insert a in accordance with the 324
- Size color bj 324
- 22 crankshaft transmission 325
- Crankshaft and connecting rods 325
- A crankcase main bearing inside diameter marks q 326
- Combination of the crankcase and crankshaft coding 326
- Crankcase assembly 326
- Crankshaft and connecting rods 326
- Crankshaft transmission 9 23 326
- Insert journal clearance with the plastigage 326
- Install the new inserts in the crankcase halves and check 326
- Mark or no mark 326
- Measure the main bearing inside diameter and mark the 326
- Select the proper bearing insert a in accordance with the 326
- Size color b 326
- Tighten the crankcase bolts to the specified torque see 326
- Upper crankcase half in accordance with the inside diam eter 326
- 24crankshaft transmission pistons 327
- Caution 328
- Crankshaft transmission 9 25 328
- Pistons 328
- 26 crankshaft transmission pistons 329
- Crankshaft transmission 9 27 330
- Pistons 330
- 28crankshaft transmission 331
- Transmission 331
- Crankshaft transmission 9 29 332
- Transmission 332
- 30 crankshaft transmission 333
- Transmission 333
- Crankshaft transmission 9 31 334
- Transmission 334
- 32 crankshaft transmission 335
- Caution 335
- Transmission 335
- Crankshaft transmission 9 33 336
- Transmission 336
- 34 crankshaft transmission 337
- Transmission 337
- Crankshaft transmission 9 35 338
- Transmission 338
- Table of contents 340
- Wheels tires 340
- Wheels tires 10 1 340
- Exploded view 342
- Fastener torque remarks 342
- Wheels tires 10 3 342
- 4 wheels tires 343
- A warning 343
- Item standard service limit 343
- Specifications 343
- Use the same manufacturer s tires on both front and rear wheels 343
- Special tools 344
- Wheels tires 10 5 344
- 6 wheels tires 345
- Caution 345
- Do not lay the wheel down on one of the discs this can damage or warp the disc place blocks un der the wheel so that the disc does not touch the ground 345
- Wheels rims 345
- A warning 346
- Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc the brake will not function on the first application of the lever if this is not done 346
- Wheels rims 346
- Wheels tires 10 7 346
- 8 wheels tires 347
- Caution 347
- Do not lay the wheel on the ground with the disc facing down this can damage or warp the disc place blocks under the wheel so that the disc does not touch the ground 347
- Wheels rims 347
- Wheels rims 348
- Wheels tires 10 9 348
- 10 wheels tires 349
- A warning 349
- Never attempt to repair a damaged wheel if there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion 349
- Wheels rims 349
- A warning 350
- Caution 350
- Do not tap the screwdrivers the rim could be dam aged 350
- If the balance weight has any play on the rib of the rim the blade and or clip have been stretched re place the loose balance weight do not reuse used balance weight unbalanced wheels can create an unsafe riding condition 350
- Wheels rims 350
- Wheels tires 10 11 350
- A warning 352
- Caution 352
- Wheels tires 10 13 352
- 14 wheels tires 353
- 57 psi overinflation can explode the tire with possibility of injury and loss of life 353
- A warning 353
- Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kpa 4 kgf c 353
- Caution________________ 353
- Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber 353
- Wheels tires 10 15 354
- 16 wheels tires 355
- Caution 355
- Do not lay the wheel on the ground with the disc facing down this can damage or warp the disc place blocks under the wheel so that the disc does not touch the ground 355
- Hub bearing 355
- Hub bearing 356
- Wheels tires 10 17 356
- Final drive 358
- Final drive 11 1 358
- Table of contents 358
- Exploded view 360
- Final drive 11 3 360
- No fastener torque 360
- 4 final drive 361
- Drive chain 361
- Item standard service limit 361
- Specifications 361
- Sprockets 361
- Final drive 11 5 362
- Special tools 362
- 6 final drive 363
- Caution 363
- Drive chain 363
- Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition 363
- Read the tool manual before removing 363
- Warning 363
- Drive chain 364
- Final drive 11 7 364
- 8 final drive 365
- Drive chain 365
- Drive chain ___________________________________ _____ 366
- Final drive 11 9 366
- 10 final drive________ 367
- Sprocket coupling 367
- Caution 368
- Final drive 11 11 368
- Sprocket coupling 368
- 12 final drive 369
- Coupling bearing lubrication 369
- Final drive 11 13 370
- Sprocket coupling_______________________ 370
- Brakes 372
- Brakes 12 1 372
- Table of contents 372
- Brakes 12 3 374
- Exploded view 374
- Fastener 374
- Torque remarks 374
- Brakes 12 5 376
- Exploded view 376
- Kgfm ft lb 376
- No fastener 376
- Torque remarks 376
- 6 brakes 377
- Item standard service limit 377
- Specifications 377
- Brakes 12 7 378
- Special tools 378
- 8 brakes 379
- Brake lever brake pedal 379
- Brake lever brake pedal 380
- Brakes 12 9 380
- 10 brakes 381
- Caution 381
- Brakes 12 11 382
- Calipers 382
- Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc the brakes will not function on the first appli cation of the lever or pedal if this is not done 382
- Warning 382
- 12 brakes 383
- Calipers 383
- Brake pads 384
- Brakes 12 13 384
- Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever and the pads are against the disc the brake will not function on the first application of the lever if this is not done 384
- Warning 384
- 14 brakes 385
- A warning 385
- Brake pads 385
- Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc the brake will not function on the first application of the pedal if this is not done ______________________________ 385
- Brakes 12 15 386
- Caution________________ 386
- Immediately wash away any brake fluid that spills 386
- Master cylinder 386
- 16 brakes_____________________ _____ 387
- Master cylinder ___ 387
- Brakes 12 17 388
- Master cylinder 388
- 18 brakes 389
- Brake disc 389
- Be sure to bleed the air from the brake line when ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason 390
- Brake fluid 390
- Brakes 12 19 390
- Warning 390
- 20 brakes 391
- Brake fluid 391
- Brake fluid 392
- Brakes 12 21 392
- Warning 392
- When working with the disc brake observe the pre cautions listed below 392
- 22 brakes 393
- Brake hose 393
- Suspension 394
- Suspension 13 1 394
- Table of contents 394
- Booooazz 395
- Exploded view 396
- Suspension 13 3 396
- 4 suspension 397
- Exploded view 398
- No fastener torque remarks 398
- __________________________________________________ suspension 13 5 398
- 6 suspension 399
- Front fork per one unit 399
- Item standard 399
- Rear shock absorber 399
- Specifications 399
- Special tools 400
- Suspension 13 7 400
- 8 suspension 401
- Special tools 401
- Compression damping force adjustment to adjust the compression damping force turn the com 402
- Damping adjuster a until you feel a click 402
- Front fork 402
- If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result 402
- It should be adjusted harder for high speed riding or riding with a passenger if the damping feels too soft or too stiff adjust it in accordance with the following table 402
- Of 68 kg 150 lb with no passenger and no accessories is the 7th click from the 1st click of the fully clockwise position 402
- Of 68 kg 150 lb with no passenger and no accessories is the 9th click from the 1st click of the fully clockwise position 402
- Othe damping force can be left soft for average riding but 402
- Othe standard adjuster setting for the average build rider 402
- Pression damping adjuster a until you feel a click 402
- Rebound damping force adjustment to adjust the rebound damping force turn the rebound 402
- Suspension 13 9 402
- Warning 402
- 10 suspension 403
- A warning 403
- Front fork 403
- If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result _______________ 403
- Front fork 404
- Suspension 13 11 404
- 12 suspension 405
- Front fork 405
- Front fork 406
- Suspension 13 13 406
- 14 suspension 407
- Front fork 407
- Front fork 408
- Suspension 13 15 408
- 16 suspension 409
- Front fork 409
- Front fork 410
- Suspension 13 17 410
- 18 suspension 411
- A straightened inner or outer fork tube may fall in use possibly causing an accident replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it 411
- A warning 411
- Caution 411
- Front fork 411
- If the inner tube is badly bent or creased replace it excessive bending followed by subsequent straightening can weaken the inner tube 411
- Front fork 412
- Suspension 13 19 412
- 20 suspension 413
- Compression damping force adjustment to adjust the compression damping force turn the upper 413
- Damping adjuster a to the desired position until you feel a click 413
- I i i 1 413
- Loosen the locknut and turn out the adjusting nut to free 413
- Of 68 kg 150 lb with no passenger and no accessories is the 1 3 4 turns out from the fully clockwise position 413
- Of 68 kg 150 lb with no passenger and no accessories is the 3 turns out from the fully clockwise position 413
- Othe standard adjuster setting for an average build rider 413
- Othe standard adjuster setting for the average build rider 413
- Rear shock absorber 413
- Rear shock absorber removal 413
- Rebound damping force adjustment to adjust the rebound damping force turn the lower 413
- Spring preload adjustment remove the rear shock absorber from the frame see 413
- T t t t t t 413
- The spring 413
- Î t t 1 1 413
- Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over it could cause an accident and injury 414
- Rear shock absorber 414
- Suspension 13 21 414
- Warning 414
- 22 suspension 415
- Rear shock absorber 415
- Since the high pressure gas is dangerous do not point the valve toward your face or body 415
- Since the reservoir tank of the rear shock absorber contains nitrogen gas do not incinerate the reser voir tank without first releasing the gas or it may explode 415
- Warning 415
- Suspension 13 23 416
- Swingarm 416
- 24 suspension 417
- Insert the pivot shaft a into the frame from the right side tighten the pivot shaft so that the clearance between the adjusting collar b and the ball bearing c come to zero mm zero in 417
- Tighten the adjusting collar locknut a with the swingarm pivot nut wrench b 417
- Suspension 13 25 418
- Swingarm 418
- 26 suspension 419
- Caution_______________ 419
- Swingarm 419
- Suspension 13 27 420
- Tie rod rocker arm 420
- 28 suspension_______________________ 421
- Tie rod rocker arm 421
- Caution 422
- Suspension 13 29 422
- Tie rod rocker arm 422
- Steering 424
- Steering 14 1 424
- Table of contents 424
- No fastener torque remarks 426
- _____________________________________________________ steering 14 3 exploded view 426
- 4 steering 427
- Special tools 427
- Steering 428
- Steering 14 5 428
- Steering inspection 428
- 6 steering ________________ 429
- Steering stem 429
- Apply grease 430
- Outer races 430
- Pushing up the stem base and remove the steering stem nut with stem cap a 430
- Remove 430
- Remove the lower bearing inner race with its grease seal a which is pressed onto the steering stem b with the bearing puller c and adapter d 430
- Replace the bearing inner races with new ones install the oil seal d on the steering stem and drive the lower ball bearing inner race a applied the grease onto the stem 430
- Steering 14 7 430
- Steering stem 430
- Steering stem c upper ball bearing inner race 430
- Stem stem bearing installation replace the bearing outer races with new ones drive them into the head pipe at the same time 430
- To remove the bearing outer races a pressed into the head pipe b insert a bar c into the recesses d of head pipe and applying it to both recess alternately hammer it to drive the race out 430
- 8 steering____________________ 431
- Steering stem 431
- A warning 432
- Steering 14 9 432
- Steering stem 432
- 10 steering 433
- Steering stem 433
- Handlebar 434
- Steering 14 11 434
- 12 steering 435
- Handlebar 435
- Frame 15 1 436
- Table of contents 436
- Exploded view 438
- No fastener torque remarks 438
- ___________ _______________________ frame 15 3 438
- Exploded view 440
- Frame 15 5 440
- No fastener torque remarks 440
- Exploded view 442
- Fastener torque remarks n m kgfm ft lb 442
- Frame 15 7 442
- 8 frame 443
- 10 frame _________ 445
- Fairings 445
- Fairings 446
- Frame 15 11 446
- 12 frame 447
- Fairings 447
- For the california model 447
- Fairings 448
- For the california model 448
- For the immobilizer models 448
- Frame 15 13 448
- Remove 448
- Fairings 450
- Frame 15 15 450
- 16 frame 451
- Side covers 451
- Frame 15 17 452
- Seat cover 452
- 18 frame 453
- Seat cover 453
- Fenders 454
- Frame 15 19 454
- 20 frame fenders 455
- Fenders 456
- Frame 15 21 456
- 22 frame frame 457
- A repaired frame may fail in use possibly causing an accident if the frame is bent dented cracked or warped replace it 457
- A warning 457
- Frame 15 23 458
- Side stand 458
- Electrical system 460
- Electrical system 16 1 460
- Table of contents 460
- 2 electrical system 461
- Electrical system 16 3 462
- Parts location 462
- 4 electrical system 463
- Electrical system 16 5 464
- Exploded view 464
- No fastener 464
- Torque remarks 464
- _______ 464
- Electrical system 16 7 466
- Exploded view 466
- Electrical system 16 9 468
- Exploded view 468
- No fastener torque remarks n m 468
- 14 electrical system 473
- Charging system 473
- Electric starter system 473
- Ignition system 473
- Item standard 473
- Specifications 473
- Switch and sensor 473
- Electrical system 16 15 474
- Flywheel and pulley holder 474
- Special tools and sealant 474
- 16 electrical system 475
- Precautions 475
- Electrical system 16 17 476
- Precautions 476
- 18 electrical system 477
- Electrical wiring 477
- Battery 478
- Caution 478
- Caution_________________ 478
- Electrical system 16 19 478
- 20 electrical system 479
- Battery 479
- Caution 479
- Battery 480
- Caution 480
- Check the electrolyte flow 480
- Electrical system 16 21 480
- Gently remove the container from the battery let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance 480
- If no air bubbles a are coming up from the filler ports or if the container cells have not emptied completely tap the container b a few times 480
- If the above chargers are not available use equivalent one 480
- If using a recommended battery charger follow the charger s instructions for newly activated sealed battery 480
- Initial charge 480
- Keep the container in place for 20 minutes or more don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation _________________________________ 480
- Place the strip a of caps loosely over the filler ports newly activated sealed batteries require an initial charge 480
- Removal of the container before it is completely empty can shorten the service life of the battery do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed 480
- 22 electrical system 481
- Battery 481
- Caution 481
- Once a month 481
- Once the strip of the caps a is installed onto the battery never remove the caps nor add water or electrolyte to the battery 481
- This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above however the battery s performance may be reducedno ticeably if charged under onditions other than given above never remove the seal cap during refresh charge if by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal ________________________________________ 481
- Battery 482
- Be sure to disconnect the negative cable first 482
- Caution 482
- Electrical system 16 23 482
- Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen when using a battery charger connect the battery to the charger before turning on the charger this procedure prevents sparks at the battery terminals which could ignite any battery gases no fire should be drawn near the battery or no terminals should have the tightening loos ened the electrolyte contains sulfuric acid be careful not to have it touch your skin or eyes if touched wash it off with liberal amount of water get medial attention if severe 482
- This battery is sealed type never remove sealing cap b even at charging never add water charge with current and time as stated below 482
- Warning 482
- 24 electrical system 483
- After completion of the charge by measuring the terminal voltage according to the table below 483
- Battery 483
- Battery a battery charger b standard value c current starts to flow d 483
- Caution 483
- Determine the battery condition after refresh charge odetermine the condition of the battery left for 30 minutes 483
- If possible do not quick charge if quick charge is done unavoidably do standard charge later on 483
- Charging system 484
- Electrical system 16 25 484
- 26 electrical system___________ 485
- Charging system 485
- Caution 486
- Charging system 486
- Electrical system 16 27 486
- Apply molybdenum disulfide oil solution a to the alterna 488
- Charging system 488
- Clutch housing gear mark c gear assembly mark d 488
- Electrical system 16 29 488
- Groove a tooth b 488
- If the gear assembly a is replaced with new one select 488
- Olnstall the toothed washers as shown 488
- Spacer c toothed washer d new circlip e alternator rotor assembly f spacer toothed washer new circlip 488
- The proper gear assembly in accordance with the combi nation of the gear assembly and clutch housing gear b markings 488
- Tor shaft b 488
- 30 electrical system_______________ 489
- Alternator rotor assembly alternator cover with stator see this chapter 489
- Charging system _____________ ______________ 489
- Circlip toothed washer 489
- If the clearance is not within the specified range adjust it 489
- Install 489
- Install the clutch housing c see clutch chapter 489
- Odo not use two or more toothed washer at same time 489
- Oremove 489
- Oreplace the following toothed washer s ________________ 489
- Remove 489
- Replace the toothed washer which brings the clearance 489
- Right lower fairing see frame chapter clutch see clutch chapter 489
- Tighten 489
- Tighten the spring bolt a first then tighten the clamp bolt 489
- Tween the spacer b and toothed washer c 489
- Using a thickness gauge a measure the clearance be 489
- Within the specified range 489
- Charging system ______ 490
- Electrical system 16 31 490
- 32 electrical system 491
- Charging system ____________ 491
- Bolts a regulator rectifier b 492
- Caution 492
- Charging system 492
- Connect the hand tester to the regulator rectifier 492
- Connectors a 492
- Electrical system 16 33 492
- If the tester readings are not as specified replace the 492
- Measurements shown in the table 492
- Regulator rectifier 492
- Regulator rectifier inspection remove 492
- Regulator rectifier inspection set the hand tester to the 1 kq range and make the 492
- Tester lead connection 492
- Use only kawasaki hand tester 57001 1394 for this test a tester other than the kawasaki hand tester may show different readings if a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged 492
- 34 electrical system 493
- Charging system 493
- A warning 496
- Electrical system 16 37 496
- Ignition system 496
- 38 electrical system 497
- Ignition system 497
- Electrical system 16 39 498
- Ignition system 498
- Timing rotor removal 498
- 40 electrical system 499
- Caution 499
- Do not pry the connector part of the coil while re moving the coil 499
- Ignition system 499
- Caution_________________ 500
- Do not tap the coil head while installing the coil 500
- Electrical system 16 41 500
- Ignition system 500
- 42 electrical system_______________ 501
- Ignition system 501
- To avoid extremely high voltage shocks do not touch the spark plugs or tester connections 501
- Warning 501
- Electrical system 16 43 502
- Ignition system___________ 502
- 44 electrical system ignition system 503
- Camshaft position sensor lead connector see this chapter 504
- Camshaft position sensor peak voltage inspection 504
- Condition 504
- Connect commercially available peak voltage adapter b to the hand tester and camshaft position sensor leads in the terminals 504
- Cturn the ignition switch on and push the starter button othen the starter motor should not turn when the starter system circuit is normality 504
- Electrical system 16 45 504
- If the engine is start inspect the starter lockout switch gear position switch and relay box 504
- If the peak voltage is lower than the standard inspect the camshaft position sensor 504
- Ignition system 504
- Interlock operation inspection using the stand a raise the rear wheel off the ground 504
- Repeat the measurement 5 or more times 504
- Set the commercially available tester a to the 10 v dc 504
- Start the engine to the following conditions 504
- Turn the ignition switch and engine stop switch on pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the camshaft position sensor peak voltage 504
- 46 electrical system 505
- Ignition system 505
- Nd check 505
- Rd check 505
- Electrical systemj6 47 506
- 48 electrical system 507
- Electric starter system 507
- Electric starter system 508
- Electrical system 16 49 508
- 50 electrical system 509
- Electric starter system 509
- Electrical system 16 51 510
- 52 electrical system 511
- Electric starter system 511
- Electric starter system 512
- Electrical system 16 53 512
- 54 electrical system 513
- Electric starter system 513
- Electric starter system 514
- Electrical system 16 55 514
- 56electrical system 515
- Electric starter circuit 515
- Electric starter system 515
- Caution 516
- Electrical system 16 57 516
- Lighting system 516
- When handling the quartz halogen bulb never touch the glass portion with bare hands always use a clean cloth oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode 516
- 58 electrical system 517
- Caution 517
- Lighting system 517
- Electrical system 16 59 518
- Lighting system 518
- Screws a 518
- 60 electrical system 519
- Headlight tail light circuit 519
- Lighting system 519
- 62 electrical system 521
- Lighting system 521
- Electrical system 16 63 522
- Lighting system 522
- Turn signal light circuit 522
- 64 electrical system 523
- Air switching valve 523
- Air switching valve 524
- Electrical system 16 65 524
- 66 electrical system 525
- Radiator fan system 525
- Caution___________________ 526
- Electrical system 16 67 526
- Meter gauge indicator unit 526
- Place the meter unit so that the face is up if a meter unit is left upside down or sideways for any length of time it will malfunction 526
- 68 electrical system 527
- Meter gauge indicator unit 527
- ________________ caution 527
- ________________ caution________________ 527
- Oo nopo 528
- 70 electrical system 529
- Meter gauge indicator unit 529
- Electrical system 16 71 530
- Meter gauge indicator unit 530
- Odometer check 530
- Speed sensor electric source check 530
- Trip meter check 530
- Water temperature meter check 530
- 72 electrical system meter gauge indicator unit 531
- Tachometer check 531
- Electrical system 16 73 532
- Led lights inspection 532
- Meter gauge indicator unit 532
- Neutral indicator light led 532
- Stop watch check 532
- 74 electrical system 533
- Fl indicator light led 533
- Fuel level warning indicator light led 533
- High beam indicator light led 533
- Meter gauge indicator unit 533
- Oil pressure warning indicator light led 533
- Right and left turn signal indicator light led 533
- Electrical system 16 75 534
- Meter circuit 534
- Meter gauge indicator unit 534
- Shift up indicator light led 534
- 76 electrical system___________________________________________ 535
- Case 1 when the user key has been lost or additional spare user key is required 535
- Immobilizer system equipped models 535
- Electrical system 16 77 536
- Immobilizer system equipped models 536
- Not verified 536
- Verified 536
- 78 electrical system 537
- Immobilizer system equipped models 537
- Electrical system 16 79 538
- Immobilizer system equipped models 538
- 80 electrical system 539
- Immobilizer system equipped models 539
- Electrical system 16 81 540
- Immobilizer system equipped models 540
- Spare user key registration flow chart 540
- 82 electrical system 541
- Case 2 when the ignition switch is faulty and to be replaced 541
- Immobilizer system equipped models 541
- Verified 541
- Electrical system 16 83 542
- Immobilizer system equipped models 542
- Not verified 542
- 84 electrical system 543
- Immobilizer system equipped models 543
- Insert the user key 2 to the ignition switch and turn it on 543
- The user key 1 is successfully registered in the ecu othe fl indicator light a blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1 543
- Turn off and remove user key 1 othe fl indicator light a blinks to display the registration mode 543
- User key collation error 543
- When registered user key is inserted 543
- Electrical system 16 85 544
- Immobilizer system equipped models 544
- 86 electrical system 545
- Case 3 when the electric control unit ecu is faulty and has to be replaced 545
- Immobilizer system equipped models 545
- Electrical system 16 87 546
- Immobilizer system equipped models 546
- 88 electrical system_________ 547
- Immobilizer system equipped models 547
- Case 4 when master key is faulty or lost 548
- Electrical system 16 89 548
- Immobilizer system equipped models 548
- 90 electrical system 549
- Case 5 when replacing the antenna 549
- Immobilizer system equipped models 549
- 92 electrical system_______________ 551
- Immobilizer amplifier replacement 551
- Immobilizer antenna 551
- Immobilizer system equipped models 551
- Caution 552
- Do not pinch the leads ________________________ 552
- Ecu electric control unit replacement for european model 552
- Electrical system 16 93 552
- Immobilizer system equipped models 552
- 94 electrical system_________ 553
- Immobilizer amplifier 8 fuse box 9 ignition fuse 10 a 10 ecu fuse 15 a 11 relay box 553
- Immobilizer relational parts replacement chart 553
- Immobilizer system circuit 553
- Immobilizer system equipped models 553
- Immobilizer system inspection refer to immobilizer amplifier and blank key detection 553
- Joint connector 4 2 immobilizer antenna 3 ignition switch 4 joint connector 2 5 meter unit 553
- Main fuse 30 a 15 battery 12 v 10 ah 16 immobillzer kawasaki 553
- Section in fuel system dfi chapter 553
- Self diagnostic system 553
- Electrical system 16 95 554
- Switches and sensors 554
- 96 electrical system 555
- Switches and sensors 555
- Electrical system 16 97 556
- Switches and sensors 556
- 98 electrical system switches and sensors 557
- C internal circuit 1 green lead 2 blue lead 3 black lead 558
- Connect it to the terminals in the gear position switch lead connector b and ground 558
- Disconnect the gear position switch lead connector cj 558
- Electrical system 16 99 558
- Gear position switch inspection 558
- If the tester reading is not as specified replace the gear 558
- Obe sure the transmission mechanism is good condition 558
- Position switch with a new one 558
- Remove 558
- Seats see frame chapter fuel tank see fuel system chapter fuel hose a screw b 558
- Set the hand tester a to the 1 kq or 100 o range and 558
- Switches and sensors 558
- 100 electrical system relay box 559
- By connecting the hand tester and one 12v battery to the relay box as shown see relay box internal circuit 559
- If the tester does not read as specified replace the relay 559
- Relay circuit inspection remove the relay box check conductivity of the following numbered terminals 559
- The actual reading varies with the hand tester used 559
- Apply positive lead apply negative lead 560
- Diode circuit inspection remove the relay box check conductivity of the following pairs of terminals see 560
- Electrical system 16 101 560
- Othe actual meter reading varies with the meter or tester 560
- Relay box 560
- Relay box internal circuit 560
- Than ten times as much in the other direction if any diode shows low or high in both directions the diode is defective and the relay box must be replaced 560
- The resistance should be low in one direction and more 560
- Used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale 560
- 102 electrical system 561
- Relay box 561
- Relay box internal circuit 561
- Electrical system 16 103 562
- 104 electrical system fuse 563
- Caution 563
- When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit installation of a fuse with a higher rating may cause damage to wiring and components 563
- Appendix 17 3 566
- Cable wire and hose routing 566
- Appendix 17 5 568
- Cable wire and hose routing 568
- Appendix 17 7 570
- Cable wire and hose routing 570
- Appendix 17 9 572
- Cable wire and hose routing 572
- Appendix 17 11 574
- Cable wire and hose routing 574
- Appendix 17 13 576
- Cable wire and hose routing 576
- 14 appendix 577
- Cable wire and hose routing 577
- Appendix 17 15 578
- Cable wire and hose routing 578
- 16 appendix 579
- Cable wire and hose routing 579
- Appendix 17 17 580
- Cable wire and hose routing 580
- 18 appendix 581
- Appendix 17 19 582
- Cable wire and hose routing 582
- Appendix 17 21 584
- Cable wire and hose routing 584
- 22 appendix 585
- Cable wire and hose routing 585
- Appendix 17 23 586
- Cable wire and hose routing 586
- Appendix 17 25 588
- Cable wire and hose routing 588
- 26 appendix 589
- Cable wire and hose routing 589
- California model 589
- Appendix 17 27 590
- Cable wire and hose routing 590
- 28 appendix 591
- Compression low 591
- Engine doesn t start starting difficulty 591
- Engine flooded 591
- Engine won t turn over 591
- Fuel air mixture incorrect 591
- No fuel flow 591
- No spark spark weak 591
- Poor running at low speed 591
- Spark weak 591
- Starter motor not rotating 591
- Starter motor rotating but engine doesn t turn over 591
- Troubleshooting guide 591
- Appendix 17 29 592
- Compression low 592
- Firing incorrect 592
- Fuel air mixture incorrect 592
- Knocking 592
- Miscellaneous 592
- Muffler overheating 592
- Overheating 592
- Poor running or no power at high speed 592
- Troubleshooting guide 592
- 30 appendix 593
- Abnormal engine noise 593
- Clutch not disengaging properly 593
- Clutch operation faulty 593
- Clutch slipping 593
- Compression high 593
- Coolant incorrect 593
- Cooling system component incorrect 593
- Doesn t go into gear shift pedal doesn t return 593
- Engine load faulty 593
- Gauge incorrect 593
- Gear shifting faulty 593
- Jumps out of gear 593
- Knocking 593
- Lubrication inadequate 593
- Oil cooler incorrect 593
- Other noise 593
- Over cooling 593
- Overshifts 593
- Piston slap 593
- Troubleshooting guide 593
- Valve noise 593
- Abnormal drive train noise 594
- Abnormal frame noise 594
- Appendix 17 31 594
- Black smoke 594
- Brown smoke 594
- Clutch noise 594
- Disc brake noise 594
- Drive line noise 594
- Exhaust smokes excessively 594
- Front fork noise 594
- Handlebar hard to turn 594
- Handlebar pulls to one side 594
- Handlebar shakes or excessively vibrates 594
- Handling and or stability unsatisfactory 594
- Oil pressure warning light goes on 594
- Other noise 594
- Rear shock absorber noise 594
- Shock absorption unsatisfactory 594
- Transmission noise 594
- Troubleshooting guide 594
- White smoke 594
- 32 appendix 595
- Battery discharged 595
- Battery overcharged 595
- Battery trouble 595
- Brake doesn t hold 595
- Troubleshooting guide 595
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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 deSelement of design incorporated into any new vehicle for the prior to its sale or delivery to the ultimate purchaser or wh le it is in use or 2 he use oF tl e vehicle after such device or element of design has been removed or rendered inoperative by aAmPonSgOthose 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 if
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