Kawasaki NINJA 650R (2005) [12/625] 2 general information
![Kawasaki NINJA 650R (2005) [12/625] 2 general information](/views2/1121253/page12/bgc.png)
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, c autions, 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, discon-
nect the battery cables from the battery to prevent the en-
gine 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 (–) ca-
ble to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can c ause excessive wear and decrease
performance of the vehicle.
Содержание
- Motorcycle service manual 1
- Quick reference guide 3
- Motorcycle service manual 5
- Ninja 650r er 6f er 6f abs 5
- Emission control information 6
- 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 de vices or elements of design in order to perform maintenance 2 tampering could include a maladjustment of vehicle components such that the emission standards are ex ceeded b use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c addition of components or accessories that result in the vehicle exceeding the stan dards d permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems 6
- Tampering with noise control system prohibited 7
- Foreword 8
- How to use this manual 8
- Country and area codes 9
- List of abbreviations 9
- General information 11
- General information 1 1 11
- Table of contents 11
- 2 general information 12
- Battery ground 12
- Before servicing 12
- Before starting to perform an inspection service or carry out a 12
- Cleaning vehicle before disassembly 12
- Edges of parts 12
- Solvent 12
- Arrangement and cleaning of removed parts 13
- Assembly order 13
- Before servicing 13
- General information 1 3 13
- Inspection 13
- Replacement parts 13
- Storage of removed parts 13
- 4 general information 14
- Before servicing 14
- Gasket o ring 14
- Liquid gasket non permanent locking agent 14
- Tightening sequence 14
- Tightening torque 14
- Ball bearing and needle bearing 15
- Before servicing 15
- Circlips cotter pins 15
- General information 1 5 15
- Oil seal grease seal 15
- 6 general information 16
- Before servicing 16
- Direction of engine rotation 16
- Electrical wires 16
- Instrument 16
- Lubrication 16
- General information 1 7 17
- Model identification 17
- 8 general information 18
- Model identification 18
- General information 1 9 19
- Model identification 19
- 10 general information 20
- General specifications 20
- General information 1 11 21
- General specifications 21
- 12 general information 22
- General specifications 22
- Cassette type transmission the transmission of the current model is unable to be removed without disassembling upper and lower crankcase halves the ex650a b enables transmission to be removed from the right side of engine as an assy without disassembling crankcase halves see transmission assy removal in the crankshaft transmission chapter 23
- General information 1 13 23
- Technical information cassette type transmission 23
- 14 general information 24
- Technical information inlet air pressure sensor 24
- Abs total system 25
- General information 1 15 25
- Technical information abs anti lock brake system 25
- 16 general information 26
- Abs system block diagram 26
- Technical information abs anti lock brake system 26
- General information 1 17 27
- Related parts and function 27
- Technical information abs anti lock brake system 27
- 18 general information 28
- Technical information abs anti lock brake system 28
- General information 1 19 29
- Technical information abs anti lock brake system 29
- 20 general information 30
- Technical information abs anti lock brake system 30
- General information 1 21 31
- Technical information abs anti lock brake system 31
- 22 general information 32
- Technical information abs anti lock brake system 32
- General information 1 23 33
- Technical information abs anti lock brake system 33
- 24 general information 34
- Technical information abs anti lock brake system 34
- General information 1 25 35
- Technical information abs anti lock brake system 35
- 26 general information 36
- Technical information abs anti lock brake system 36
- Warning 36
- General information 1 27 37
- Prefixes for units 37
- Unit conversion table 37
- Units of force 37
- Units of length 37
- Units of mass 37
- Units of power 37
- Units of pressure 37
- Units of speed 37
- Units of temperature 37
- Units of torque 37
- Units of volume 37
- Periodic maintenance 39
- Periodic maintenance 2 1 39
- Table of contents 39
- 2 periodic maintenance 40
- Periodic inspection 41
- Periodic maintenance 2 3 41
- Periodic maintenance chart 41
- Periodic maintenance 2 5 43
- Periodic maintenance chart 43
- Periodic replacement parts 43
- 6 periodic maintenance 44
- Torque and locking agent 44
- Periodic maintenance 2 7 45
- Torque and locking agent 45
- 8 periodic maintenance 46
- Torque and locking agent 46
- Periodic maintenance 2 9 47
- Torque and locking agent 47
- 10 periodic maintenance 48
- Basic torque for general fasteners 48
- Torque and locking agent 48
- Periodic maintenance 2 11 49
- Specifications 49
- 12 periodic maintenance 50
- Specifications 50
- Periodic maintenance 2 13 51
- Special tools 51
- 14 periodic maintenance 52
- Fuel system dfi 52
- Periodic maintenance procedures 52
- Warning 52
- Periodic maintenance 2 15 53
- Periodic maintenance procedures 53
- Throttle control system inspection 53
- Warning 53
- 16 periodic maintenance 54
- Periodic maintenance procedures 54
- Periodic maintenance 2 17 55
- Periodic maintenance procedures 55
- 18 periodic maintenance 56
- Periodic maintenance procedures 56
- Warning 56
- Evaporative emission control system california model 57
- Periodic maintenance 2 19 57
- Periodic maintenance procedures 57
- Warning 57
- 20 periodic maintenance 58
- Cooling system 58
- Periodic maintenance procedures 58
- Air suction system 59
- Engine top end 59
- Periodic maintenance 2 21 59
- Periodic maintenance procedures 59
- 22 periodic maintenance 60
- Periodic maintenance procedures 60
- Periodic maintenance 2 23 61
- Periodic maintenance procedures 61
- 24 periodic maintenance 62
- Periodic maintenance procedures 62
- Valve clearance adjustment chart inlet valve 62
- Periodic maintenance 2 25 63
- Periodic maintenance procedures 63
- Valve clearance adjustment chart exhaust valve 63
- 26 periodic maintenance 64
- Air pressure inspection 64
- Clutch 64
- Clutch operation inspection 64
- Periodic maintenance procedures 64
- Warning 64
- Wheels tires 64
- Periodic maintenance 2 27 65
- Periodic maintenance procedures 65
- Warning 65
- 28 periodic maintenance 66
- Caution 66
- Drive chain lubrication condition inspection 66
- Drive train 66
- Periodic maintenance procedures 66
- Wheel bearing damage inspection 66
- Periodic maintenance 2 29 67
- Periodic maintenance procedures 67
- Warning 67
- 30 periodic maintenance 68
- Periodic maintenance procedures 68
- Warning 68
- Chain guide inspection 69
- Drive chain wear inspection 69
- Periodic maintenance 2 31 69
- Periodic maintenance procedures 69
- Warning 69
- 32 periodic maintenance 70
- Brake system 70
- Periodic maintenance procedures 70
- Periodic maintenance 2 33 71
- Periodic maintenance procedures 71
- Warning 71
- 34 periodic maintenance 72
- Periodic maintenance procedures 72
- Front fork oil leak inspection 73
- Front forks rear shock absorber operation inspection 73
- Periodic maintenance 2 35 73
- Periodic maintenance procedures 73
- Rear shock absorber oil leak inspection 73
- Suspensions 73
- 36 periodic maintenance 74
- Periodic maintenance procedures 74
- Steering system 74
- Electrical system 75
- Periodic maintenance 2 37 75
- Periodic maintenance procedures 75
- Spark plug condition inspection 75
- Steering stem bearing lubrication 75
- 38 periodic maintenance 76
- Lights and switches operation inspection 76
- Periodic maintenance procedures 76
- Periodic maintenance 2 39 77
- Periodic maintenance procedures 77
- 40 periodic maintenance 78
- Headlight aiming inspection 78
- Periodic maintenance procedures 78
- Periodic maintenance 2 41 79
- Periodic maintenance procedures 79
- 42 periodic maintenance 80
- Engine stop switch operation inspection 80
- Periodic maintenance procedures 80
- Others 81
- Periodic maintenance 2 43 81
- Periodic maintenance procedures 81
- 44 periodic maintenance 82
- Periodic maintenance procedures 82
- Air cleaner element replacement 83
- Caution 83
- Fuel hose replacement 83
- Periodic maintenance 2 45 83
- Periodic maintenance procedures 83
- Replacement parts 83
- Warning 83
- 46 periodic maintenance 84
- Coolant change 84
- Periodic maintenance procedures 84
- Warning 84
- Periodic maintenance 2 47 85
- Periodic maintenance procedures 85
- 48 periodic maintenance 86
- Caution 86
- Periodic maintenance procedures 86
- Radiator hose and o ring replacement 86
- Periodic maintenance 2 49 87
- Periodic maintenance procedures 87
- 50 periodic maintenance 88
- Periodic maintenance procedures 88
- Periodic maintenance 2 51 89
- Periodic maintenance procedures 89
- 52 periodic maintenance 90
- Periodic maintenance procedures 90
- Periodic maintenance 2 53 91
- Periodic maintenance procedures 91
- 54 periodic maintenance 92
- Periodic maintenance procedures 92
- Warning 92
- Periodic maintenance 2 55 93
- Periodic maintenance procedures 93
- Warning 93
- 56 periodic maintenance 94
- Periodic maintenance procedures 94
- Fuel system dfi 95
- Fuel system dfi 3 1 95
- Table of contents 95
- 2 fuel system dfi 96
- Fuel system dfi 3 3 97
- Exploded view 99
- Fuel system dfi 3 5 99
- Exploded view 101
- Fuel system dfi 3 7 101
- Exploded view 103
- Fuel system dfi 3 9 103
- Dfi system 105
- Fuel system dfi 3 11 105
- Dfi system 107
- Fuel system dfi 3 13 107
- 14 fuel system dfi 108
- Dfi system 108
- Terminal names 108
- Dfi parts location 109
- Fuel system dfi 3 15 109
- 16 fuel system dfi 110
- Specifications 110
- Fuel system dfi 3 17 111
- Specifications 111
- 18 fuel system dfi 112
- Special tools and sealant 112
- Fuel system dfi 3 19 113
- Special tools and sealant 113
- 20 fuel system dfi 114
- Dfi servicing precautions 114
- Dfi servicing precautions 115
- Fuel system dfi 3 21 115
- 22 fuel system dfi 116
- Outline 116
- Troubleshooting the dfi system 116
- Fuel system dfi 3 23 117
- Troubleshooting the dfi system 117
- 24 fuel system dfi 118
- Troubleshooting the dfi system 118
- Fuel system dfi 3 25 119
- Troubleshooting the dfi system 119
- 26 fuel system dfi 120
- Dfi diagnosis flow chart 120
- Inquiries to rider 120
- Troubleshooting the dfi system 120
- Fuel system dfi 3 27 121
- Sample diagnosis sheet 121
- Troubleshooting the dfi system 121
- 28 fuel system dfi 122
- Troubleshooting the dfi system 122
- Dfi system troubleshooting guide 123
- Engine doesn t start starting difficulty 123
- Fuel system dfi 3 29 123
- 30 fuel system dfi 124
- Dfi system troubleshooting guide 124
- Dfi system troubleshooting guide 125
- Fuel system dfi 3 31 125
- Poor running at low speed 125
- 32 fuel system dfi 126
- Dfi system troubleshooting guide 126
- Dfi system troubleshooting guide 127
- Fuel system dfi 3 33 127
- 34 fuel system dfi 128
- Dfi system troubleshooting guide 128
- Poor running or no power at high speed 128
- Dfi system troubleshooting guide 129
- Fuel system dfi 3 35 129
- 36 fuel system dfi 130
- Dfi system troubleshooting guide 130
- Fuel system dfi 3 37 131
- Self diagnosis 131
- Self diagnosis outline 131
- Self diagnosis procedures 131
- 38 fuel system dfi 132
- Self diagnosis 132
- Service code clearing procedures 132
- 40 fuel system dfi 134
- How to erase service codes 134
- How to read service codes 134
- Self diagnosis 134
- Fuel system dfi 3 41 135
- Self diagnosis 135
- Service code table 135
- 42 fuel system dfi 136
- Backups 136
- Self diagnosis 136
- Fuel system dfi 3 43 137
- Self diagnosis 137
- 44 fuel system dfi 138
- Main throttle sensor service code 11 138
- Fuel system dfi 3 45 139
- Main throttle sensor output voltage inspection 139
- Main throttle sensor service code 11 139
- 46 fuel system dfi 140
- Main throttle sensor circuit 140
- Main throttle sensor resistance inspection 140
- Main throttle sensor service code 11 140
- Fuel system dfi 3 47 141
- Inlet air pressure sensor service code 12 141
- 48 fuel system dfi 142
- Inlet air pressure sensor service code 12 142
- Fuel system dfi 3 49 143
- Inlet air pressure sensor service code 12 143
- Pv 24 55 cmhg 143
- 50 fuel system dfi 144
- Inlet air pressure sensor service code 12 144
- Pv 55 86 cmhg 144
- Fuel system dfi 3 51 145
- Inlet air pressure sensor circuit 145
- Inlet air pressure sensor service code 12 145
- 52 fuel system dfi 146
- Inlet air temperature sensor service code 13 146
- Fuel system dfi 3 53 147
- Inlet air temperature sensor service code 13 147
- 54 fuel system dfi 148
- Water temperature sensor service code 14 148
- Fuel system dfi 3 55 149
- Water temperature sensor circuit 149
- Water temperature sensor resistance inspection 149
- Water temperature sensor service code 14 149
- 56 fuel system dfi 150
- Crankshaft sensor service code 21 150
- Fuel system dfi 3 57 151
- Speed sensor service code 24 25 151
- 58 fuel system dfi 152
- Speed sensor service code 24 25 152
- Fuel system dfi 3 59 153
- Vehicle down sensor service code 31 153
- Warning 153
- 60 fuel system dfi 154
- Vehicle down sensor service code 31 154
- Fuel system dfi 3 61 155
- Vehicle down sensor circuit 155
- Vehicle down sensor service code 31 155
- 62 fuel system dfi 156
- Subthrottle sensor service code 32 156
- Fuel system dfi 3 63 157
- Subthrottle sensor service code 32 157
- 64 fuel system dfi 158
- Subthrottle sensor resistance inspection 158
- Subthrottle sensor service code 32 158
- Fuel system dfi 3 65 159
- Subthrottle sensor circuit 159
- Subthrottle sensor service code 32 159
- 66 fuel system dfi 160
- Oxygen sensor inspection 160
- Oxygen sensor not activated service code 33 europe models 160
- Oxygen sensor removal installation 160
- Fuel system dfi 3 67 161
- Oxygen sensor circuit 161
- Oxygen sensor not activated service code 33 europe models 161
- 68 fuel system dfi 162
- Stick coils 1 2 service code 51 52 162
- Fuel system dfi 3 69 163
- Stick coil circuit 163
- Stick coils 1 2 service code 51 52 163
- 70 fuel system dfi 164
- Radiator fan relay circuit 164
- Radiator fan relay inspection 164
- Radiator fan relay removal installation 164
- Radiator fan relay service code 56 164
- Fuel system dfi 3 71 165
- Subthrottle valve actuator service code 62 165
- 72 fuel system dfi 166
- Subthrottle valve actuator service code 62 166
- Air switching valve circuit 167
- Air switching valve inspection 167
- Air switching valve removal installation 167
- Air switching valve service code 64 167
- Fuel system dfi 3 73 167
- 74 fuel system dfi 168
- Oxygen sensor heater service code 67 europe models 168
- Fuel system dfi 3 75 169
- Oxygen sensor circuit 169
- Oxygen sensor heater service code 67 europe models 169
- 76 fuel system dfi 170
- Oxygen sensor incorrect output voltage service code 94 europe models 170
- Oxygen sensor inspection 170
- Oxygen sensor removal installation 170
- Fuel system dfi 3 77 171
- Oxygen sensor circuit 171
- Oxygen sensor incorrect output voltage service code 94 europe models 171
- Fi indicator light led 173
- Fi indicator light led circuit 173
- Fi indicator light led inspection 173
- Fuel system dfi 3 79 173
- 80 fuel system dfi 174
- Caution 174
- Ecu installation 174
- Ecu removal 174
- Fuel system dfi 3 81 175
- 82 fuel system dfi 176
- Ecu power source circuit 176
- Fuel line 177
- Fuel system dfi 3 83 177
- Warning 177
- 84 fuel system dfi 178
- Fuel line 178
- Fuel line 179
- Fuel system dfi 3 85 179
- Warning 179
- 86 fuel system dfi 180
- Fuel line 180
- Fuel pump 181
- Fuel system dfi 3 87 181
- Warning 181
- 88 fuel system dfi 182
- Fuel pump 182
- Fuel pump 183
- Fuel system dfi 3 89 183
- 90 fuel system dfi 184
- Fuel pump 184
- Fuel pump circuit 184
- Fuel injectors 185
- Fuel system dfi 3 91 185
- 92 fuel system dfi 186
- Caution 186
- Fuel injector output voltage inspection 186
- Fuel injectors 186
- Injector signal test 186
- Fuel injectors 187
- Fuel system dfi 3 93 187
- 94 fuel system dfi 188
- Fuel injectors 188
- Fuel injectors 189
- Fuel system dfi 3 95 189
- 96 fuel system dfi 190
- Throttle cable installation 190
- Throttle cable lubrication 190
- Throttle grip and cables 190
- Throttle grip free play adjustment 190
- Throttle grip free play inspection 190
- Warning 190
- Engine vacuum synchronization inspection ad justment 191
- Fuel system dfi 3 97 191
- High altitude performance adjustment 191
- Idle speed inspection 191
- Throttle body assy 191
- Throttle body assy removal 191
- Warning 191
- 98 fuel system dfi 192
- Caution 192
- Throttle body assy 192
- Throttle body assy installation 192
- Caution 193
- Fuel system dfi 3 99 193
- Throttle body assy 193
- Throttle body assy disassembly 193
- Warning 193
- 100 fuel system dfi 194
- Throttle body assy 194
- Air cleaner 195
- Air cleaner element inspection 195
- Air cleaner element removal installation 195
- Air cleaner housing removal 195
- Air cleaner oil draining 195
- Fuel system dfi 3 101 195
- Warning 195
- 102 fuel system dfi 196
- Air cleaner 196
- Air cleaner housing installation 196
- Fuel system dfi 3 103 197
- Fuel tank 197
- Warning 197
- 104 fuel system dfi 198
- Caution 198
- Fuel tank 198
- Warning 198
- Fuel system dfi 3 105 199
- Fuel tank 199
- Warning 199
- 106 fuel system dfi 200
- Fuel tank 200
- Warning 200
- Fuel system dfi 3 107 201
- Fuel tank 201
- Fuel tank cleaning 201
- Warning 201
- 108 fuel system dfi 202
- Caution 202
- Evaporative emission control system california model 202
- Hose inspection 202
- Parts removal installation 202
- Separator inspection 202
- Warning 202
- Evaporative emission control system california model 203
- Fuel system dfi 3 109 203
- Warning 203
- Cooling system 205
- Cooling system 4 1 205
- Table of contents 205
- Cooling system 4 3 207
- Exploded view 207
- Coolant flow chart 209
- Cooling system 4 5 209
- 6 cooling system 210
- Specifications 210
- Cooling system 4 7 211
- Special tools 211
- 8 cooling system 212
- Coolant 212
- Caution 213
- Coolant 213
- Coolant reserve tank removal installation 213
- Cooling system 4 9 213
- Cooling system flushing 213
- 10 cooling system 214
- Water pump 214
- Water pump installation 214
- Water pump removal 214
- Cooling system 4 11 215
- Water pump 215
- 12 cooling system 216
- Impeller assembly 216
- Pump impeller inspection 216
- Water pump 216
- Caution 217
- Cooling system 4 13 217
- Radiator 217
- Radiator and radiator fan removal 217
- 14 cooling system 218
- Radiator 218
- Cooling system 4 15 219
- Radiator 219
- 16 cooling system 220
- Thermostat 220
- Thermostat inspection 220
- Thermostat installation 220
- Thermostat removal 220
- Cooling system 4 17 221
- Thermostat 221
- 18 cooling system 222
- Hose and pipes 222
- Caution 223
- Cooling system 4 19 223
- Water temperature sensor 223
- Water temperature sensor inspection 223
- Water temperature sensor removal installation 223
- Engine top end 225
- Engine top end 5 1 225
- Table of contents 225
- 2 engine top end 226
- Engine top end 5 5 229
- Exploded view 229
- Engine top end 5 7 231
- Exploded view 231
- 8 engine top end 232
- Exhaust system 232
- Exhaust system ex650a6f ex650b6f 232
- Engine top end 5 9 233
- Exhaust system 233
- 10 engine top end 234
- Specifications 234
- Engine top end 5 11 235
- Specifications 235
- 12 engine top end 236
- Special tools and sealant 236
- Engine top end 5 13 237
- Special tools and sealant 237
- 14 engine top end 238
- Air suction valve inspection 238
- Air suction valve installation 238
- Air suction valve removal 238
- Air switching valve installation 238
- Air switching valve removal 238
- Caution 238
- Clean air system 238
- Air switching valve operation test 239
- Air switching valve unit test 239
- Clean air system 239
- Clean air system hose inspection 239
- Engine top end 5 15 239
- 16 engine top end 240
- Cylinder head cover 240
- Cylinder head cover 241
- Engine top end 5 17 241
- 18 engine top end 242
- Camshaft chain tensioner 242
- Camshaft chain tensioner installation 242
- Camshaft chain tensioner removal 242
- Caution 242
- Camshaft camshaft chain 243
- Engine top end 5 19 243
- 20 engine top end 244
- Camshaft camshaft chain 244
- Camshaft camshaft chain 245
- Engine top end 5 21 245
- 22 engine top end 246
- Camshaft camshaft chain 246
- Cam wear 247
- Camshaft camshaft chain 247
- Camshaft chain removal 247
- Camshaft runout 247
- Engine top end 5 23 247
- 24 engine top end 248
- Cylinder head 248
- Cylinder head 249
- Engine top end 5 25 249
- 26 engine top end 250
- Cylinder head 250
- Cylinder head 251
- Engine top end 5 27 251
- 28 engine top end 252
- Cylinder head 252
- Engine top end 5 29 253
- Valves 253
- 30 engine top end 254
- Valves 254
- Engine top end 5 31 255
- Valves 255
- 32 engine top end 256
- Valves 256
- Engine top end 5 33 257
- Valves 257
- 34 engine top end 258
- Valves 258
- 36 engine top end 260
- Cylinder pistons 260
- Cylinder pistons 261
- Engine top end 5 37 261
- 38 engine top end 262
- Cylinder pistons 262
- Cylinder pistons 263
- Engine top end 5 39 263
- 40 engine top end 264
- Cylinder pistons 264
- Piston ring end gap 264
- Engine top end 5 41 265
- Throttle body holder 265
- 42 engine top end 266
- Exhaust pipe removal 266
- Muffler 266
- Muffler body removal 266
- Warning 266
- Engine top end 5 43 267
- Muffler 267
- Clutch 269
- Clutch 6 1 269
- Table of contents 269
- Clutch 6 3 271
- Exploded view 271
- 4 clutch 272
- Specifications 272
- Clutch 6 5 273
- Special tool and sealant 273
- 6 clutch 274
- Clutch cable installation 274
- Clutch cable lubrication 274
- Clutch cable removal 274
- Clutch lever and cable 274
- Clutch lever free play adjustment 274
- Clutch lever free play inspection 274
- Clutch 6 7 275
- Clutch lever and cable 275
- 8 clutch 276
- Clutch cover 276
- Clutch cover installation 276
- Clutch cover removal 276
- Caution 277
- Clutch 6 9 277
- Clutch cover 277
- Clutch cover disassembly 277
- Release shaft installation 277
- Release shaft removal 277
- 10 clutch 278
- Clutch cover 278
- Clutch 279
- Clutch 6 11 279
- 12 clutch 280
- Clutch 280
- Clutch 281
- Clutch 6 13 281
- 14 clutch 282
- Clutch 282
- Clutch housing finger inspection 282
- Clutch housing spline inspection 282
- Clutch plate warp inspection 282
- Clutch spring free length measurement 282
- Engine lubrication system 283
- Engine lubrication system 7 1 283
- Table of contents 283
- Engine lubrication system 7 3 285
- Exploded view 285
- 6 engine lubrication system 288
- Specifications 288
- Engine lubrication system 7 7 289
- Special tools and sealant 289
- 8 engine lubrication system 290
- Engine oil and oil filter 290
- Warning 290
- Engine lubrication system 7 9 291
- Oil pan 291
- Oil pan removal 291
- 10 engine lubrication system 292
- Oil pan 292
- Engine lubrication system 7 11 293
- Oil pressure relief valve 293
- Warning 293
- 12 engine lubrication system 294
- Oil pump 294
- Oil pump removal 294
- Engine lubrication system 7 13 295
- Oil pump 295
- 14 engine lubrication system 296
- Oil pressure measurement 296
- Warning 296
- Engine lubrication system 7 15 297
- Oil pressure switch 297
- Oil pressure switch installation 297
- Oil pressure switch removal 297
- Engine removal installation 299
- Engine removal installation 8 1 299
- Table of contents 299
- Engine removal installation 8 3 301
- Exploded view 301
- 4 engine removal installation 302
- Caution 302
- Engine removal 302
- Engine removal installation 302
- Warning 302
- Engine removal installation 303
- Engine removal installation 8 5 303
- 6 engine removal installation 304
- Engine removal installation 304
- Engine removal installation 305
- Engine removal installation 8 7 305
- Crankshaft transmission 307
- Crankshaft transmission 9 1 307
- Table of contents 307
- Crankshaft transmission 9 3 309
- Exploded view 309
- Crankshaft transmission 9 5 311
- Exploded view 311
- 6 crankshaft transmission 312
- Specifications 312
- Crankshaft transmission 9 7 313
- Specifications 313
- 8 crankshaft transmission 314
- Specifications 314
- Crankshaft transmission 9 9 315
- Special tools and sealant 315
- 10 crankshaft transmission 316
- Crankcase splitting 316
- Crankcase splitting 317
- Crankshaft transmission 9 11 317
- 12 crankshaft transmission 318
- Crankcase splitting 318
- Crankcase splitting 319
- Crankshaft transmission 9 13 319
- 14 crankshaft transmission 320
- Crankcase splitting 320
- Crankcase splitting 321
- Crankshaft transmission 9 15 321
- 16 crankshaft transmission 322
- Crankcase splitting 322
- Crankshaft and connecting rods 323
- Crankshaft transmission 9 17 323
- 18 crankshaft transmission 324
- Crankshaft and connecting rods 324
- Crankshaft and connecting rods 325
- Crankshaft transmission 9 19 325
- Warning 325
- 20 crankshaft transmission 326
- Caution 326
- Crankshaft and connecting rods 326
- Warning 326
- Crankshaft and connecting rods 327
- Crankshaft transmission 9 21 327
- 22 crankshaft transmission 328
- Crankshaft and connecting rods 328
- Crankshaft and connecting rods 329
- Crankshaft transmission 9 23 329
- 24 crankshaft transmission 330
- Crankshaft and connecting rods 330
- Crankshaft transmission 9 25 331
- 26 crankshaft transmission 332
- Crankshaft and connecting rods 332
- Balancer 333
- Crankshaft transmission 9 27 333
- 28 crankshaft transmission 334
- Crankshaft transmission 9 29 335
- External shift mechanism removal 335
- Shift pedal installation 335
- Shift pedal removal 335
- Transmission 335
- 30 crankshaft transmission 336
- Transmission 336
- Crankshaft transmission 9 31 337
- Transmission 337
- 32 crankshaft transmission 338
- Transmission 338
- Transmission assy removal 338
- Crankshaft transmission 9 33 339
- Transmission 339
- Transmission assy assembly 339
- Transmission assy disassembly 339
- 34 crankshaft transmission 340
- Transmission 340
- Crankshaft transmission 9 35 341
- Transmission 341
- 36 crankshaft transmission 342
- Transmission 342
- Crankshaft transmission 9 37 343
- Transmission 343
- 38 crankshaft transmission 344
- Transmission 344
- Crankshaft transmission 9 39 345
- Shift drum and fork installation 345
- Shift drum and fork removal 345
- Shift drum assembly 345
- Shift drum disassembly 345
- Shift fork bending 345
- Shift fork gear groove wear 345
- Transmission 345
- 40 crankshaft transmission 346
- Gear dog and gear dog hole damage 346
- Shift fork guide pin drum groove wear 346
- Transmission 346
- Ball bearing needle bearing and oil seal 347
- Crankshaft transmission 9 41 347
- Table of contents 349
- Wheels tires 349
- Wheels tires 10 1 349
- Exploded view 351
- Wheels tires 10 3 351
- 4 wheels tires 352
- Specifications 352
- Warning 352
- Special tools 353
- Wheels tires 10 5 353
- 6 wheels tires 354
- Wheels rims 354
- Warning 355
- Wheels rims 355
- Wheels tires 10 7 355
- 8 wheels tires 356
- Caution 356
- Rear wheel installation 356
- Rear wheel removal 356
- Wheels rims 356
- Warning 357
- Wheels rims 357
- Wheels tires 10 9 357
- 10 wheels tires 358
- Axle inspection 358
- Warning 358
- Wheel inspection 358
- Wheels rims 358
- Warning 359
- Wheels rims 359
- Wheels tires 10 11 359
- 12 wheels tires 360
- Wheels rims 360
- Warning 361
- Wheels tires 10 13 361
- 14 wheels tires 362
- Warning 362
- Wheels tires 10 15 363
- 16 wheels tires 364
- Hub bearing 364
- Hub bearing 365
- Wheels tires 10 17 365
- Final drive 367
- Final drive 11 1 367
- Table of contents 367
- Exploded view 369
- Final drive 11 3 369
- 4 final drive 370
- Specifications 370
- Final drive 11 5 371
- Special tools 371
- 6 final drive 372
- Drive chain 372
- Drive chain 373
- Drive chain installation 373
- Final drive 11 7 373
- 8 final drive 374
- Drive chain 374
- Drive chain 375
- Final drive 11 9 375
- 10 final drive 376
- Sprocket coupling 376
- Final drive 11 11 377
- Sprocket coupling 377
- 12 final drive 378
- Coupling bearing installation 378
- Coupling bearing removal 378
- Coupling installation 378
- Sprocket coupling 378
- Final drive 11 13 379
- Sprocket coupling 379
- 14 final drive 380
- Rear sprocket warp inspection 380
- Sprocket coupling 380
- Brakes 381
- Brakes 12 1 381
- Table of contents 381
- 2 brakes 382
- Brakes 12 5 385
- Exploded view 385
- Brakes 12 7 387
- Exploded view 387
- Brakes 12 9 389
- Exploded view 389
- Brakes 12 11 391
- Exploded view 391
- 12 brakes 392
- Specifications 392
- Brakes 12 13 393
- Special tools 393
- 14 brakes 394
- Brake lever brake pedal 394
- Brake lever brake pedal 395
- Brake pedal installation 395
- Brake pedal removal 395
- Brakes 12 15 395
- 16 brakes 396
- Brake lever brake pedal 396
- Brakes 12 17 397
- Calipers 397
- Warning 397
- 18 brakes 398
- Calipers 398
- Brakes 12 19 399
- Caliper piston and cylinder damage 399
- Calipers 399
- Rear caliper holder shaft wear 399
- 20 brakes 400
- Brake pad wear inspection 400
- Brake pads 400
- Front brake pad installation 400
- Front brake pad removal 400
- Rear brake pad installation 400
- Rear brake pad removal 400
- Warning 400
- Brakes 12 21 401
- Caution 401
- Front master cylinder installation 401
- Front master cylinder removal 401
- Master cylinder 401
- 22 brakes 402
- Master cylinder 402
- Brakes 12 23 403
- Master cylinder 403
- Master cylinder inspection 403
- 24 brakes 404
- Brake disc 404
- Brake fluid 405
- Brakes 12 25 405
- Warning 405
- 26 brakes 406
- Brake fluid 406
- Brake fluid 407
- Brakes 12 27 407
- Warning 407
- 28 brakes 408
- Brake hose 408
- Brake hose inspection 408
- Brake hose removal installation 408
- Anti lock brake system 409
- Brakes 12 29 409
- Parts location 409
- 30 brakes 410
- Abs system wiring diagram 410
- Anti lock brake system 410
- Anti lock brake system 411
- Brakes 12 31 411
- Terminal names 411
- 32 brakes 412
- Abs servicing precautions 412
- Anti lock brake system 412
- Caution 412
- Warning 412
- Anti lock brake system 413
- Brakes 12 33 413
- Warning 413
- 34 brakes 414
- Anti lock brake system 414
- Anti lock brake system 415
- Brakes 12 35 415
- Anti lock brake system 417
- Brakes 12 37 417
- Sample diagnosis sheet 417
- Anti lock brake system 419
- Brakes 12 39 419
- Pre diagnosis inspection 2 419
- Self diagnosis outline 419
- Self diagnosis procedures 419
- 40 brakes 420
- Anti lock brake system 420
- 42 brakes 422
- Anti lock brake system 422
- How to erase service codes 422
- How to read service codes 422
- Anti lock brake system 423
- Brakes 12 43 423
- Service code table 423
- 44 brakes 424
- Anti lock brake system 424
- Anti lock brake system 425
- Brakes 12 45 425
- 46 brakes 426
- Anti lock brake system 426
- Anti lock brake system 427
- Brakes 12 47 427
- 48 brakes 428
- Anti lock brake system 428
- Anti lock brake system 429
- Brakes 12 49 429
- 50 brakes 430
- Anti lock brake system 430
- Anti lock brake system 431
- Brakes 12 51 431
- 52 brakes 432
- Anti lock brake system 432
- Anti lock brake system 433
- Brakes 12 53 433
- 54 brakes 434
- Anti lock brake system 434
- Abs hydraulic unit inspection 435
- Anti lock brake system 435
- Brakes 12 55 435
- Caution 435
- Front wheel rotation sensor removal 435
- 56 brakes 436
- Anti lock brake system 436
- Anti lock brake system 437
- Brakes 12 57 437
- 58 brakes 438
- Abs motor relay fuse removal 438
- Abs solenoid valve relay fuse removal 438
- Anti lock brake system 438
- Brake hose and pipe inspection 438
- Fuse installation 438
- Anti lock brake system 439
- Brakes 12 59 439
- Caution 439
- Fuse inspection 439
- Suspension 441
- Suspension 13 1 441
- Table of contents 441
- Exploded view 443
- Suspension 13 3 443
- Exploded view 445
- Suspension 13 5 445
- 6 suspension 446
- Specifications 446
- Special tools 447
- Suspension 13 7 447
- 8 suspension 448
- Special tools 448
- Front fork 449
- Suspension 13 9 449
- 10 suspension 450
- Front fork 450
- Front fork 451
- Suspension 13 11 451
- 12 suspension 452
- Front fork 452
- Caution 453
- Dust seal inspection 453
- Front fork 453
- Inner tube inspection 453
- Suspension 13 13 453
- Warning 453
- 14 suspension 454
- Fork spring inspection 454
- Front fork 454
- Rear shock absorber 455
- Suspension 13 15 455
- Warning 455
- 16 suspension 456
- Rear shock absorber 456
- Suspension 13 17 457
- Swingarm 457
- 18 suspension 458
- Swingarm 458
- Swingarm bearing installation 458
- Swingarm bearing removal 458
- Suspension 13 19 459
- Swingarm 459
- 20 suspension 460
- Swingarm 460
- Steering 461
- Steering 14 1 461
- Table of contents 461
- Exploded view 463
- Steering 14 3 463
- 4 steering 464
- Special tools 464
- Steering 465
- Steering 14 5 465
- Steering adjustment 465
- Steering inspection 465
- 6 steering 466
- Steering stem 466
- Stem stem bearing removal 466
- Steering 14 7 467
- Steering stem 467
- 8 steering 468
- Steering stem 468
- Warning 468
- Steering 14 9 469
- Steering stem 469
- Steering stem warp 469
- Stem bearing lubrication 469
- Stem cap deterioration damage 469
- 10 steering 470
- Handlebar 470
- Handlebar installation 470
- Handlebar removal 470
- Handlebar 471
- Steering 14 11 471
- Frame 15 1 473
- Table of contents 473
- Exploded view 475
- Frame 15 3 475
- Exploded view 477
- Frame 15 5 477
- Exploded view 479
- Frame 15 7 479
- 8 frame 480
- Seat installation 480
- Seat removal 480
- Center fairing installation 481
- Center fairing removal 481
- Fairings 481
- Frame 15 9 481
- Lower fairing installation 481
- Lower fairing removal 481
- 10 frame 482
- Fairings 482
- Upper fairing removal 482
- Windshield installation 482
- Windshield removal 482
- Fairings 483
- Frame 15 11 483
- Upper fairing assembly 483
- Upper fairing bracket removal 483
- Upper fairing disassembly 483
- Upper fairing installation 483
- Upper inner fairing installation 483
- Upper inner fairing removal 483
- 12 frame 484
- Fairings 484
- Inner fairing installation 484
- Inner fairing removal 484
- Frame 15 13 485
- Side cover installation 485
- Side cover removal 485
- Side covers 485
- 14 frame 486
- Seat cover installation 486
- Seat cover removal 486
- Seat covers 486
- Fenders 487
- Flap and rear fender rear installation 487
- Flap and rear fender rear removal 487
- Frame 15 15 487
- Front fender installation 487
- Front fender removal 487
- 16 frame 488
- Fenders 488
- Rear fender front installation 488
- Rear fender front removal 488
- Frame 15 17 489
- Warning 489
- 18 frame 490
- Sidestand 490
- Frame 15 19 491
- Frame cover 491
- Frame cover installation 491
- Frame cover removal 491
- Electrical system 493
- Electrical system 16 1 493
- Table of contents 493
- 2 electrical system 494
- Electrical system 16 5 497
- Exploded view 497
- Electrical system 16 7 499
- Exploded view 499
- Electrical system 16 9 501
- Exploded view 501
- 10 electrical system 502
- Specifications 502
- Electrical system 16 11 503
- Special tools and sealants 503
- 12 electrical system 504
- Parts location 504
- 22 electrical system 514
- Precautions 514
- 24 electrical system 516
- Electrical wiring 516
- Battery 517
- Electrical system 16 25 517
- 26 electrical system 518
- Battery 518
- Battery 519
- Electrical system 16 27 519
- 28 electrical system 520
- Battery 520
- Caution 520
- Interchange 520
- Precautions 520
- Warning 520
- Battery 521
- Electrical system 16 29 521
- Warning 521
- 30 electrical system 522
- Battery 522
- Alternator cover installation 523
- Alternator cover removal 523
- Charging system 523
- Electrical system 16 31 523
- Stator coil removal 523
- 32 electrical system 524
- Charging system 524
- Charging system 525
- Electrical system 16 33 525
- 34 electrical system 526
- Charging system 526
- Charging system 527
- Electrical system 16 35 527
- Regulator rectifier inspection 527
- 36 electrical system 528
- Charging system 528
- Charging system 529
- Electrical system 16 37 529
- 38 electrical system 530
- Charging system 530
- Charging voltage inspection 530
- Charging system 531
- Charging system circuit 531
- Electrical system 16 39 531
- 40 electrical system 532
- Starter motor clutch 532
- Caution 533
- Crankshaft sensor removal 533
- Electrical system 16 41 533
- Ignition system 533
- Warning 533
- 42 electrical system 534
- Ignition system 534
- Electrical system 16 43 535
- Ignition system 535
- 44 electrical system 536
- Ignition system 536
- Electrical system 16 45 537
- Ignition system 537
- Warning 537
- 46 electrical system 538
- Ignition system 538
- 48 electrical system 540
- Ignition system 540
- Ignition system circuit 540
- Caution 541
- Electric starter system 541
- Electrical system 16 49 541
- Starter motor installation 541
- Starter motor removal 541
- 50 electrical system 542
- Electric starter system 542
- Brush inspection 543
- Commutator cleaning and inspection 543
- Electric starter system 543
- Electrical system 16 51 543
- 52 electrical system 544
- Electric starter system 544
- Caution 545
- Electric starter system 545
- Electrical system 16 53 545
- Starter relay inspection 545
- 54 electrical system 546
- Electric starter circuit 546
- Electric starter system 546
- Electrical system 16 55 547
- Lighting system 547
- 56 electrical system 548
- Caution 548
- City light bulb replacement europe models 548
- Headlight removal installation 548
- Lighting system 548
- Tail brake light installation 548
- Tail brake light removal 548
- Electrical system 16 57 549
- Lighting system 549
- 58 electrical system 550
- Lighting system 550
- Electrical system 16 59 551
- Lighting system 551
- 60 electrical system 552
- Lighting system 552
- Turn signal light circuit 552
- Air switching valve 553
- Air switching valve operation test 553
- Air switching valve unit test 553
- Electrical system 16 61 553
- 62 electrical system 554
- Air switching valve 554
- Electrical system 16 63 555
- Fan motor inspection 555
- Radiator fan circuit 555
- Radiator fan system 555
- 64 electrical system 556
- Caution 556
- Meter gauge disassembly 556
- Meter gauge indicator unit 556
- Meter unit removal installation 556
- Electrical system 16 65 557
- Meter gauge indicator unit 557
- 66 electrical system 558
- Meter gauge indicator unit 558
- Electrical system 16 67 559
- Meter gauge indicator unit 559
- 68 electrical system 560
- Meter gauge indicator unit 560
- Electrical system 16 69 561
- Meter gauge indicator unit 561
- 70 electrical system 562
- Meter gauge indicator unit 562
- Electrical system 16 71 563
- Meter gauge indicator unit 563
- 72 electrical system 564
- Meter circuit 564
- Meter gauge indicator unit 564
- Electrical system 16 73 565
- Switches and sensors 565
- 74 electrical system 566
- Switches and sensors 566
- Electrical system 16 75 567
- Switches and sensors 567
- 76 electrical system 568
- Switches and sensors 568
- Electrical system 16 77 569
- Relay box 569
- Relay box removal 569
- Relay circuit inspection 569
- 78 electrical system 570
- Relay box 570
- Electrical system 16 79 571
- Relay box 571
- Relay box internal circuit 571
- 80 electrical system 572
- A ecu fuse removal 572
- A main fuse removal 572
- Fuse box fuse removal 572
- Caution 573
- Electrical system 16 81 573
- Fuse inspection 573
- Fuse installation 573
- Appendix 575
- Appendix 17 1 575
- Table of contents 575
- Appendix 17 3 577
- Cable wire and hose routing 577
- Appendix 17 5 579
- Cable wire and hose routing 579
- Appendix 17 7 581
- Cable wire and hose routing 581
- Appendix 17 9 583
- Cable wire and hose routing 583
- Appendix 17 11 585
- Cable wire and hose routing 585
- Appendix 17 13 587
- Cable wire and hose routing 587
- Appendix 17 15 589
- Cable wire and hose routing 589
- Appendix 17 17 591
- Cable wire and hose routing 591
- Appendix 17 19 593
- Cable wire and hose routing 593
- Appendix 17 21 595
- Cable wire and hose routing 595
- Appendix 17 23 597
- Cable wire and hose routing 597
- Appendix 17 25 599
- Cable wire and hose routing 599
- Appendix 17 27 601
- Cable wire and hose routing 601
- Appendix 17 29 603
- Cable wire and hose routing 603
- Appendix 17 31 605
- Cable wire and hose routing 605
- Appendix 17 33 607
- Cable wire and hose routing 607
- Appendix 17 35 609
- Cable wire and hose routing 609
- Appendix 17 37 611
- Cable wire and hose routing 611
- Appendix 17 39 613
- Cable wire and hose routing 613
- Appendix 17 41 615
- Cable wire and hose routing 615
- Appendix 17 43 617
- Cable wire and hose routing 617
- Appendix 17 45 619
- Cable wire and hose routing 619
- 46 appendix 620
- Engine doesn t start starting difficulty 620
- Poor running at low speed 620
- Troubleshooting guide 620
- Appendix 17 47 621
- Overheating 621
- Poor running or no power at high speed 621
- Troubleshooting guide 621
- 48 appendix 622
- Abnormal engine noise 622
- Clutch operation faulty 622
- Gear shifting faulty 622
- Over cooling 622
- Troubleshooting guide 622
- Abnormal drive train noise 623
- Abnormal frame noise 623
- Appendix 17 49 623
- Exhaust smokes excessively 623
- Handling and or stability unsatisfactory 623
- Oil pressure warning light goes on 623
- Troubleshooting guide 623
- 50 appendix 624
- Battery trouble 624
- Brake doesn t hold 624
- Troubleshooting guide 624
- Model application 625
- Part no 9924 1361 01 625
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