![Kawasaki NINJA 650R (2005) [402/625] 22 brakes](/img/pdf.png)
Kawasaki NINJA 650R (2005) [402/625] 22 brakes
![Kawasaki ER-6F (2005) [402/625] 22 brakes](/views2/1121253/page402/bg192.png)
12-22 BRAKES
Master Cylinder
Rear Master Cylinder Removal
•
Unscrew the brake hose banjo bolt [A] on the master cylin-
der (see Brake Hose Removal/Installation).
•
Unscrew the master cylinder mounting bolts [A].
•
Remove the cotter pin [B].
NOTE
○
Pull off the joint pin while pressing down the brake
pedal.
•
Pull off the reservoir hose lower end [C], and drain the
brake fluid into a c ontainer.
•
Remove the master cylinder.
Rear Master Cylinder Installation
•
Replace the cotter pin [A] with a new one.
•
Replace the washers on each side of hose fitting with new
ones.
•
Tighten the following bolts.
Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
BrakeHoseBanjoBolt: 25N·m(2.5kgf·m,18ft·lb)
•
Bleed the brake line (see Brake Line Bleeding).
•
Check the brake for good braking power, no brake drag,
and no fluid leakage.
Front Master Cylinder Disassembly
•
Refer to the Master Cylinder Rubber Parts R eplacement
in the Periodic Maintenance chapter.
Rear Master Cylinder Disass embly
•
Refer to the Master Cylinder Rubber Parts R eplacement
in the Periodic Maintenance chapter.
Master Cylinder Assembly
•
Refer to the Master Cylinder Rubber Parts R eplacement
in the Periodic Maintenance chapter.
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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