Инструкция для KAWASAKI Z1000 (2003)

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Z1000

Motorcycle

Service Manual

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Оглавление инструкции
  • Страница 1 из 516
    Z1000 Motorcycle Service Manual
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    Quick Reference Guide General Information 1 j Periodic Maintenance 2 j Fuel System (DFI) 3 j Cooling System 4 j Engine Top End 5 j Clutch 6 j Engine Lubrication System 7 j Engine Removal/Installation 8 j Crankshaft/Transmission 9 j Wheels/Tires Final Drive 11 j Brakes 12 j Suspension 13 j Steering
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    Z1000 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance
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    LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s)
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    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
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    WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or
  • Страница 9 из 516
    Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper
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    NOTE ○This note symbol indicates points of particular interest for more efficient and convenient operation. • Indicates a procedural step or work to be done. ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a
  • Страница 11 из 516
    GENERAL INFORMATION 1-1 General Information 1 Table of Contents Before Servicing ..................................................................................................................... Model
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    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions
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    GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including
  • Страница 14 из 516
    1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating
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    GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed
  • Страница 16 из 516
    1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is
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    GENERAL INFORMATION 1-7 Model Identification ZR1000–A1 Left Side View: ZR1000–A1 Right Side View:
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    1-8 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 770 mm (30.3 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 420 mm (55.9 in.) Road clearance 145 mm (5.7 in.) Seat height 820 mm (32.3 in.) Dry mass 198 kg (410.1 lb)
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    GENERAL INFORMATION 1-9 General Specifications ZR1000–A1 ∼ Items Lubrication system Engine oil: Type Viscosity Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th 6th Final drive system: Type Reduction ratio Overall
  • Страница 20 из 516
    1-10 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Tail/brake light 12 V 0.5/3.8 W (LED) (US, CA, Cal) 12 V 0.5/5W (LED) Alternator: Type Three-phase AC Rated output 24 A/ 14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country.
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    GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Subthrottle Control System The ZR1000–A1 ∼ employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a
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    1-12 GENERAL INFORMATION Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body. The
  • Страница 23 из 516
    GENERAL INFORMATION 1-13 Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs
  • Страница 24 из 516
    1-14 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5
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    GENERAL INFORMATION 1-15 Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor GaAsP, GaAlAs Emitting Color Red GaP Green GaN Blue Ga: Gallium As:
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    1-16 GENERAL INFORMATION Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst protection system, according to each regulation of different countries. The
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    GENERAL INFORMATION 1-17 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro Symbol M k c m µ Units of Length: × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Mass: kg g × × 2.205 0.03527 = = lb oz = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US)
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    PERIODIC MAINTENANCE 2-1 Periodic Maintenance 2 Table of Contents Periodic Maintenance Chart .............. Torque and Locking Agent................. Specifications .................................... Special Tools ..................................... Periodic Maintenance Procedures..... Fuel
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    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever comes first → ↓ OPERATION Spark plug
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    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first → ↓ OPERATION Clutch-adjust † Every Radiator hoses, connections - inspect † Brake fluid - change Brake master cylinder cup and dust seal - replace 2 years Coolant - change 2 years Caliper piston seal and dust seal
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    2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non -permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. G: Apply
  • Страница 33 из 516
    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Water pump drain bolt Water pipe bolts Thermostat housing ground bolt Thermostat bracket bolt Radiator upper bolts Radiator lower bolts Radiator screen bolt Coolant reserve tank screws Radiator fan switch Water temperature sensor Engine Top
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    2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Engine Lubrication: Oil filler plug Engine drain plug Oil filter (cartridge type, P/No.16097–1070) Oil filter (cartridge type, P/No.16097–0002) Oil cooler mounting bolt Oil pan bolts Oil pipe holder bolts Oil pressure relief valve Oil
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    PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Wheels/Tires: Front axle clamp bolt Front axle Rear axle nut Final Drive: Engine sprocket nut Engine sprocket cover bolts Engine sprocket cover damper bolt Rear sprocket nuts Speed sensor bolt Brakes: Bleed valves Front brake hose joint
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    2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Handlebar lower clamp nuts Handlebar switch housing screws Frame: Footpeg holder bolts Muffler mounting bolts Side stand bolt Side stand switch bolt Windshield screws Front fender bolts Electrical System: Spark plugs Alternator rotor bolt
  • Страница 37 из 516
    PERIODIC MAINTENANCE 2-9 Specifications Item Fuel System: Throttle grip free play Idle speed Bypass screws (turn out) Engine vacuum Air cleaner element Cooling System: Coolant: Type (recommended) Color Mixed ratio Freezing point Total amount Engine Top End: Valve clearance Inlet Exhaust Clutch:
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    2-10 PERIODIC MAINTENANCE Specifications Item Air pressure: (when cold) Front Rear Final Drive: Drive chain slack Drive chain (20-link length) Brakes: Brake fluid: Grade Brake pad lining thickness: Front Rear Brake light timing: Front Rear Electrical System: Spark plug gap AT: Republic of Austria
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    PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench: 57001–1100 Pilot Screw Adjuster, C: 57001–1292 Jack: 57001–1238 Hand Tester: 57001–1394 Oil Filter Wrench: 57001–1249 Spark Plug Wrench (Owner’s Tool): 92110–1132
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    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel
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    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable (see below). • Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) the
  • Страница 42 из 516
    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Bore Cleaning Check the throttle bore for cleanliness as follows: ○Remove the throttle body assy (see Fuel System (DFI) chapter). ○Check the main throttle valves and throttle bores [A] for carbon deposits by opening the main valves.
  • Страница 43 из 516
    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. so is vertical. • Situate the motorcycle(seethat it System (DFI)
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    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures the fuel tank (see Fuel System (DFI) • Installthe engine and warm it up thoroughly. chapter). Start • Check the idle speed. • Tachometer [A] If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by
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    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Special Tool - Pilot Screw Adjuster, C: 57001-1292 the lowest • Adjust#1 and #2. vacuum between #1 and #2 to the
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    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures number of turns counted • Back out the same set the screw to its originalwhen first turned in. This is to position. NOTE ○A throttle body has different “turns out” of the bypass screw for each individual unit. When setting the bypass screw,
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    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○In dusty areas, the element should be cleaned more frequently than the recommended interval. ○After riding through rain or on muddily roads, the element should be cleaned immediately. WARNING If dirt or
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    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures the lightly to loosen dust. • Cleanawayelement by tapping it by applying compressed Blow the remaining dust • air [A] from the outside to the inside (from the clean side • to the dirty side). Visually inspect the element for no tears or no
  • Страница 49 из 516
    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures ○Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. Front [B] ○Visually inspect the separator for cracks and other damage. If the separator has any cracks or damage, replace it with a new
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    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures (see Fuel System (DFI) chapter). • Remove the fuel tank cap [A] in two steps. First turn the Remove the radiator • cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○The coolant
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    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures the • Loosen[B] air bleeder bolt [A] on the thermostat housing. Front the coolant into the radiator until the • Replenishflow out the air bleeder bolt hole (that is,coolant begins to all the • remaining air is forced out). Tap the radiator
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    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Removal)
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    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○Mark and record the valve lifter and shim locations so
  • Страница 54 из 516
    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where
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    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where
  • Страница 56 из 516
    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Adjust Inspection • Pull the clutch lever just enough to take up the free play [A]. gap between the lever and • Measure thetoo wide, the clutch may notthe lever holder. If the gap is release fully. If the gap is too narrow, the
  • Страница 57 из 516
    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change the motorcycle so that it is vertical after warming • Situateengine. up the plug [A] to drain the oil. • Remove the engine drainbe drained by removing the filter ○The oil in the oil filter can •
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    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Tire Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90 % of all tire failures occur during the last 10 % of tread life (90 % worn). So it is false
  • Страница 59 из 516
    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Air Pressure Inspection/Adjustment • Remove the air valve cap. with an air pressure gauge • Measure the tire air pressure is, when the motorcycle [A] when the tires are cold (that has not been ridden more than a mile during the past 3
  • Страница 60 из 516
    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures chain adjuster locknuts securely. • Tighten bothaxle nut. Tighten the • Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) chain slack • Turn the wheel, measure thenecessary. again at the tightest position, and readjust if • Insert a new
  • Страница 61 из 516
    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures inspect • Rotate the rear wheel topins and the drive chain for damaged rollers, and loose links. • • If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. Stretch the chain taut by hanging a 98 N
  • Страница 62 из 516
    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures oil to the sides of the oil will penetrate • Apply rollers and bushings.rollers so thatto the O-rings so to the Apply the oil • that the O-rings will be coated with oil. Wipe off any excess oil. Oil Applied Areas [A] O-ring [B] Brakes Brake
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    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • If it does not, adjust and inspect the brake light switch. While holding the switch body, turn the adjusting nut [A] to adjust the switch. CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body
  • Страница 64 из 516
    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) and rear master • Disassemble the frontno scratches, rustcylinders. on the there are or pitting that • Checkwall [A] of each master cylinder and on the outside inner • of each piston [B]. If a
  • Страница 65 из 516
    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Level Inspection that the • Checkabovethe brake fluid level in[B]. front brake reservoir [A] is the lower level line NOTE ○Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower
  • Страница 66 из 516
    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures brake fluid • Level thethe reservoirreservoir. diaphragm. Remove cap and • Remove the rubber cap from the bleed valve [A] on the • caliper. plastic hose [B] the bleed • Attach a clear of the hose into to container. valve, and run a the other
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    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air
  • Страница 68 из 516
    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bleed the brake line and the caliper:air can be seen com○Repeat this operation until no more ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B]
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    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures WARNING When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types
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    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check the front for oil leakage, scoring • Visually inspect the outerforks [A] of the inner tubes. or scratches on surface Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Check
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    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Steering Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001–1238 the wheel pointing straight ahead, alternately • Witheach front of the handlebar. The front wheel should tap end • swing fully
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    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001–1100 [B] If the steering is too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn. NOTE ○Turn
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    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures thermostat bracket • Unscrew thethe spark plug #2 or bolt [A]. #3. ○If removing • Disconnect:Connectors [A] Stick Coil Pull out the stick coil #1 [B]. • Take out the camshaft position sensor connector [C] from • the bracket. • Pull out the
  • Страница 74 из 516
    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures spark plug, preferably • Clean theclean off any abrasive in a sandblasting device, and then particles. The plug may • also be cleaned using a high-flash point solvent and a wire brush or other tool. If the spark plug center electrode [A]
  • Страница 75 из 516
    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures General Lubrication Lubrication each part, clean off spots with • Before lubricating wipe off any grease,any rusty or grime. rust remover and oil, dirt, • Lubricate the points listed below with indicated lubricant. ○Whenever NOTE the vehicle
  • Страница 76 из 516
    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection the tightness of and here. • Check to see that eachthe boltspin isnuts listedand in Also, check cotter in place good condition. NOTE ○For the engine fasteners, check the tightness of
  • Страница 77 из 516
    FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View................................... DFI Parts Location............................. DFI Wiring Diagram ........................... Specifications .................................... Special Tools
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    3-2 FUEL SYSTEM (DFI) ECU Installation ........................... ECU Power Supply Inspection..... DFI Power Source ............................. ECU Fuse Removal ..................... ECU Fuse Installation .................. ECU Fuse Inspection ................... ECU Main Relay Removal
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    FUEL SYSTEM (DFI) 3-3 Exploded View Clifornia Evaporative Emission Control System 1. Canister 2. Separator 3. Right fitting of throttle body #2 4. Right fitting of throttle body #3 5. Canister purge hose (green) 6. Fuel return hose (left, red) 7. Fuel tank breather hose (right, blue) 8. Separator
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    3-4 FUEL SYSTEM (DFI) Exploded View
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    FUEL SYSTEM (DFI) 3-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Throttle cable plate bolt 6 0.6 52 in·lb 2 Throttle body cover bolts 7 0.7 61 in·lb 3 Throttle assy holder clamp bolts 2 0.2 17 in·lb 4 Choke link holder screws 2.1 0.21 18 in·lb 5 Delivery pipe screws 3.4 0.35 30 in·lb 6
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    3-6 FUEL SYSTEM (DFI) Exploded View
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    FUEL SYSTEM (DFI) 3-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Inlet air pressure sensor bolt 12 1.2 104 in·lb 2 Water temperature sensor 25 2.5 18 3 Vehicle downsensor bolts 2 0.2 17 in·lb 4 Camshaft position sensor bolt 12 1.2 104 in·lb 5 Camshaft position sensor rotor bolt 12 1.2 104
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    3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) F: Front 1. Water temperature Sensor (DFI) 2. Inlet Air Pressure Sensor (DFI) 3. Injectors (DFI) 4. Fuel Pump (DFI) 5. Inlet Air Temperature Sensor (DFI) 6. Sealed Battery 7. Junction Box 8. 9. 10. 11. 12. 13. 14. 15. ECU Fuse
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    FUEL SYSTEM (DFI) 3-9 DFI Parts Location [1], [2], [10], [13], [22] and [24] are not included.
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    3-10 FUEL SYSTEM (DFI) DFI Wiring Diagram
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    FUEL SYSTEM (DFI) 3-11 DFI Wiring Diagram Terminal Names 1. Power Supply to Sensors (inlet air pressure, atmospheric pressure, and throttle sensors) from ECU. 2. Main Throttle Sensor Signal 3. Subthrottle Sensor Signal for ECU 4. Atmospheric Pressure Sensor Signal 5. Water Temperature Sensor Signal
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    3-12 FUEL SYSTEM (DFI) Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Usable engine speed Fuel Pressure (high pressure line): Right after Ignition switch ON After 3 sec from Ignition switch ON engine idling With Fuel
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    FUEL SYSTEM (DFI) 3-13 Specifications Item Detection time Output voltage Subthrottle Sensor: Input Voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Subthrottle Valve Actuator: Resistance Input voltage Throttle Grip and Cables Throttle grip free play
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    3-14 FUEL SYSTEM (DFI) Special Tools Oil Pressure Gauge: 57001–125 Fuel Pressure Gauge Adapter: 57001–1417 Carburetor Drain Plug Wrench, Hex 3: 57001–1269 Needle Adapter Set: 57001–1457 Fork Oil Level Gauge: 57001–1290 Throttle Sensor Setting Adapter: 57001–1538 Hand Tester: 57001–1394 Sensor
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    FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a
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    3-16 FUEL SYSTEM (DFI) DFI Servicing Precautions ○To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Clutch Cover [B] Front [C] Torque - Oil Filler Plug: 1.5 N·m (0.15 kgf·m, 13
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    FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indicator LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control
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    3-18 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○The DFI part connectors [A] have seals [B], including the • ECU. Join the connector and insert the needle adapters (special tool) [C] inside the seal [B] from behind the connector until the adapter reaches the terminal. Special Tool - Needle
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    FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System connector • Pull eachdamage. [A] apart and inspect it for corrosion, dirt, and If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. Check the wiring for continuity. ○Use the
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    3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output
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    FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○Try to find out exactly what problem occurred under exactly what
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    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Model: Registration No. (license plate No.): Year of initial registration: Engine No.: Date problem occurred: Frame No.: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □
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    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Poor running at low speed □ choke lever pulled out fully (push it in fully) □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idle speed □ battery voltage is low (charge the battery) □ spark plug
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    3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant as a rough guide to assist the troubleshooting for some of the more common difficulties. simply ○The ECU may be involved in the DFI
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    FUEL SYSTEM (DFI) 3-25 DFI System Troubleshooting Guide Symptoms or possible Causes Ignition and engine stop switches not ON Clutch lever not pulled in and gear not in neutral whether sidestand up or not Though clutch lever pulled in, sidestand up and gear not in neutral Vehicle-down sensor coming
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    3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Piston ring /groove clearance excessive Cylinder head gasket damaged Cylinder head warped No valve clearance Valve guide worn Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon
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    FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes Atmospheric pressure sensor trouble Fuel pressure too low or too high Battery voltage low Incorrect idle speed : Water temperature sensor trouble Main throttle sensor trouble Engine stalls easily : Fuel pump trouble
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    3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Subthrottle sensor trouble Subthrottle valve actuator trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor
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    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Spark plug dirty, broken or gap maladjusted Too low fuel pressure Fuel pump trouble Main throttle sensor trouble Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor
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    3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Firing incorrect : Spark plug dirty, broken or maladjusted Spark plug cap trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble
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    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil
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    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Too low fuel pressure Water temperature sensor trouble Inlet air temperature sensor trouble Actions (chapter) Inspect fuel line and fuel pump (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace
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    FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode: The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when
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    3-34 FUEL SYSTEM (DFI) Self-Diagnosis the self-diagnosis dealer 2, and • To enter[A] the lead more than five mode [F] open [B] secground times within 2 onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds. ○Count the blinks of the LED light
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    FUEL SYSTEM (DFI) 3-35 Self-Diagnosis
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    3-36 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○Read 10th digit and unit digit as the FI indicator LED light blinks. ○When there are a number of problems, all the service
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    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table Service Code FI Indicator LED Light 11 Problems Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water
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    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Codes Parts 11 Main Throttle Sensor 12 Inlet Air Pressure Sensor 13 14 15 21 23 24 and 25 31 32 Inlet Air Temperature Sensor
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    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Codes 51 52 53 54 62 Output Signal Usable Range or Criteria The stick coil primary Stick Coil winding must send #1 (Ignition signals (output voltage) Coil)* continuously to the ECU. The stick coil primary Stick Coil winding must send #2 (Ignition
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    3-40 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to
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    FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection output at the main throttle sensor • Measure the way as voltagevoltage inspection, Note the in the same input • following. Disconnect the main throttle sensor (gray) [A] and connect the harness adapter [B]
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    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection switch OFF. • Turn the ignitionmain throttle sensor connector. the • Disconnect digital meter [A] to the main throttle sensor • Connect a[B]. connector • Measure the main throttle sensor resistance. Main Throttle
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    FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: (see Fuel System chapter) Fuel Tank • Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B]
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    3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○The output voltage changes according to the local atmospheric pressure. the output voltage ECU in the • Measurevoltage inspection. at thethe following.same way as input Note Inlet Air Pressure Sensor
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    FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) ○Turn the ignition switch ON. ○Measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. ○Check the inlet air pressure sensor output voltage, using the
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    3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 24 ∼ 55 cmHg
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    FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (absolute) Ps: Standard Atmospheric Pressure (absolute) A. ECU C. Inlet Air Pressure Sensor ID: Idling TO:
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    3-48 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. fuel tank (see Fuel Tank Removal). • Remove thethe connector [A] from the inlet air tempera• Disconnect
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    FUEL SYSTEM (DFI) 3-49 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this section). the sensor [A] in a • Suspendheat-sensitive portioncontainer of machine oil so that the is submerged. Suspend a thermometer [B] with the
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    3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). 200 mL (6.76 • Drain the coolant aboutconnector, and US oz).
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    FUEL SYSTEM (DFI) 3-51 Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection the water temperature sensor this • Remove the Electrical System chapter (seewatersection). Refer to for temper• ature sensor
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    3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○The atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure
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    FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection the output voltage ECU in the • Measurevoltage inspection. at thethe following.same way as input Note Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU
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    3-54 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) H: Altitude (m or feet) A. ECU E. Atmospheric Pressure Sensor ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
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    FUEL SYSTEM (DFI) 3-55 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of
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    3-56 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic
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    FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation Switches • See the chapter. and Sensors section in the Electrical System Speed Sensor Inspection Switches • See the chapter. and Sensors section in the Electrical System Input Voltage Inspection NOTE ○Be
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    3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) sensor connector [A] and connect • Disconnect the speed[B] between the harness connector the harness adapter • and speed sensor connector. Engine Sprocket Cover [C] Connect a digital meter to the harness adapter leads. Special Tool -
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    FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: and Vehicle-down Sensor [A] Connection Bolts and Washers [B] Front [C] Installation • The UP mark [A] of the
  • Страница 136 из 516
    3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Turn the ignition switch OFF. the sensor. • Remove a digital volt meter [A] to the connector with nee• Connect set [B]. dle adapter Special Tool - Needle Adapter Set: 57001–1457 Vehicle-down Sensor Output Voltage Connections to Sensor
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    FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) A. ECU S. ECU Main Relay T. Ignition Switch a. ECU Fuse 15A b. Vehicle-down Sensor d. Starter Relay f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A
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    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the
  • Страница 139 из 516
    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). in • Measure the output voltage at the subthrottle sensorfolthe same way as input voltage inspection. Note the • lowing. Disconnect the subthrottle
  • Страница 140 из 516
    3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection switch OFF. • Turn the ignitionsubthrottle sensor connector. the • Disconnectdigital meter [A] to the subthrottle sensor con• Connect a nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor
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    FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Stick Stick Stick Coil Coil Coil Coil #1: #2: #3: #4: Ignition Ignition Ignition Ignition Coil (Service Coil (Service Coil (Service Coil (Service Code Code Code Code 51) 52) 53) 54) Removal/Installation CAUTION
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    3-66 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) A. ECU M. Stick Coils N. Engine Stop Switch T. Ignition Switch X. Ignition Fuse 10 A Y. Junction Box d. Starter Relay e. Joint Connector D f. Sealed Battery k. Main Fuse 30 A
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    FUEL SYSTEM (DFI) 3-67 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard surface. Such a shock to
  • Страница 144 из 516
    3-68 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○Be sure the battery is fully charged. • Turn the ignition switch OFF. (see Throttle Body Assy • Remove the throttle body assy Removal). [A] and a digital meter • Connect the peak voltage adapterneedle
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    FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light Inspection Flow Chart
  • Страница 146 из 516
    3-70 FUEL SYSTEM (DFI) FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). auxiliary leads, • Using twoLED light [A]. supply battery power to the FI indicator 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected)
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    FUEL SYSTEM (DFI) 3-71 ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU’s with each other and use only the ECU’s for
  • Страница 148 из 516
    3-72 FUEL SYSTEM (DFI) ECU If the rubber protector [A] is removed, install it. ECU [B] ECU Power Supply Inspection terminals [A] of the • Visually inspect theclogged with mud orECU connectors. If the connector is dust, blow it off with compressed air. Replace the main harness if the terminals of
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    FUEL SYSTEM (DFI) 3-73 ECU • Check the ECU power source voltage with a digital meter [A]. ○Position the terminal in accordance with terminal numbers of ECU connectors [B] in this chapter figure. Battery [C] ECU Power Source Inspection Meter between Terminal 13 (W/Y) and Connections: Battery (–)
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    3-74 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation • If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. Refer to the
  • Страница 151 из 516
    FUEL SYSTEM (DFI) 3-75 Fuel Line Fuel Pressure Inspection NOTE ○This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○It is preferable to measure the fuel pressure while running the motorcycle just when trouble occurred in order to know symptom well. ○Be
  • Страница 152 из 516
    3-76 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. the engine idling. • Measure the fuel pressure with Fuel Pressure (idling) Standard: 310 kPa (3.2 kgf/cm², 46 psi) NOTE ○The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. •
  • Страница 153 из 516
    FUEL SYSTEM (DFI) 3-77 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. Front [B] • Be sure to place a piece of cloth around the fuel pump outlet hose. the fuel pump outlet hose [A] • Removethe delivery pipe [C] (see Fuelfrom the fuel pump [B] and Pump Removal). Front [D]
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    3-78 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any
  • Страница 155 из 516
    FUEL SYSTEM (DFI) 3-79 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Check that the fuel pump (–) terminal [A] and band [B] are in place. • • • Front [C] Apply a non-permanent locking agent to the threads of the fuel pump bolts. Tighten the fuel pump bolts to a snug fit, following
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    3-80 FUEL SYSTEM (DFI) Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump connector [A] with needle adapter set. Front [B] Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○Measure the operating voltage with the engine stopped, and with the connector joined. Turn
  • Страница 157 из 516
    FUEL SYSTEM (DFI) 3-81 Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. cover • Remove the seat pump (see Frame chapter). of the the fuel • Removecompartment. relay [A] from the tongue storage • Disconnect the
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    3-82 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine.a screwdriver [A] to the injector [C]. Put of • Apply the tiponto your ear, and listen whether the injector the grip end is clicking or not. ○A
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    FUEL SYSTEM (DFI) 3-83 Fuel Injectors Output Voltage Inspection ignition OFF. • Turn the the ECUswitch ECU section). (see • Remove a digital voltmeter [A] to the ECU connector [B] Connect • with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001–1457 Injector Output Voltage
  • Страница 160 из 516
    3-84 FUEL SYSTEM (DFI) Fuel Injectors Injector Signal Test two test light sets • Prepare of Bulb [A]: 12 V ×with maleWterminals as shown. 3 ∼ 3.4 Rating Terminal Width [B]: 1.8 mm (0.071 in.) Terminal Thickness [C]: 0.8 mm (0.031 in.) CAUTION Do not use larger terminals than specified above. A
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    FUEL SYSTEM (DFI) 3-85 Fuel Injectors Injector Resistance Inspection fuel tank (see Fuel Tank Removal). • Remove thethe connector from the injector [A] (see Throt• Disconnect Disassembly/Assembly). tle Body Assy • Measure the injector resistance with the hand tester [B]. Front [C] Special Tool -
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    3-86 FUEL SYSTEM (DFI) Fuel Injectors • Check theainjector fuel line for leakage as follows: ○Connect commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with the clamps [D]) as shown. Torque - Fuel Hose
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    FUEL SYSTEM (DFI) 3-87 Fuel Injectors A. ECU K. Fuel Injectors N. Engine Stop Switch T. Ignition Switch X. Ignition Fuse 10 A Y. Junction Box Z. Fuel Pump Relay (for fuel pump an injectors) d. Starter Relay e. Joint Connector C f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A
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    3-88 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment Control • Refer to the Throttlechapter. System Inspection in the PeMaintenance riodic Choke Lever Operation ○Do not use the choke lever except when the engine has a starting difficulty like in cold weather (10
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    FUEL SYSTEM (DFI) 3-89 Throttle Body Assy Idle Speed Inspection/Adjustment the Idle • Refer to chapter .Speed Inspection in the Periodic Maintenance Throttle Bore Cleaning Control • Refer to the Throttlechapter. System Inspection in the Periodic Maintenance Engine Vacuum Inspection/Adjustment
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    3-90 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen: Assy Holder Clamp Bolts [A] Throttle Air Cleaner Duct Clamp Bolts [B] Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001–1269 • Remove: Left Side Covers (see Frame chapter) Right and Coolant Reserve Tank (see Coolant Change in the Periodic
  • Страница 167 из 516
    FUEL SYSTEM (DFI) 3-91 Throttle Body Assy bolt [A] • Remove thebody frontand the throttle cable plate [B] from the throttle side. • Remove the throttle cable lower ends from the throttle pulley. • Remove:Cable Upper End (From choke lever) Choke • Choke Cable Lower End [A] Throttle Body #2 [B] After
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    3-92 FUEL SYSTEM (DFI) Throttle Body Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip (see Throttle Body Assy Removal). • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar (front
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    FUEL SYSTEM (DFI) 3-93 Throttle Body Assy CAUTION Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it. the [B]. • Pull out [A] the injectors along withfrom delivery pipepipe. If necessary, remove the injectors the delivery Replace the O-rigs of the
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    3-94 FUEL SYSTEM (DFI) Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. Visually check
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    FUEL SYSTEM (DFI) 3-95 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the
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    3-96 FUEL SYSTEM (DFI) Fuel Tank piece • Be sure to place a[B]. of cloth [A] around the fuel hose pump outlet joint hose joint • While pinching thethe deliverylocks [C] with fingers, pull the joint out along pipe. Front [D] WARNING Be prepared for fuel spillage; any spilled fuel must be completely
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    FUEL SYSTEM (DFI) 3-97 Fuel Tank Fuel Tank Installation (see Fuel Tank Removal). • Note the above WARNING(see Appendix chapter). • Route the hoses correctly [A] are on the frame and • Check that the rubber dampers the fuel tank. Front [B] • Check that the dampers [A] are in place on the fuel tank
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    3-98 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. • Replace the gasket if it is damaged. Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also.
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    FUEL SYSTEM (DFI) 3-99 Evaporative Emission Control System Parts Removal/Installation WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;
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    3-100 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;
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    COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................................................................................................................ Coolant Flow
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    4-2 COOLING SYSTEM Exploded View
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    COOLING SYSTEM 4-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 2 0.2 Remarks 17 in·lb 1 Radiator hose clamp screws 2 Thermostat air bleeder bolt 7.8 0.80 69 in·lb 3 Radiator fan bolts 8.3 0.85 74 in·lb 4 Water pump impeller bolt 9.8 1.0 87 in·lb 5 Water pump cover bolts 11 1.1 95 in·lb 6
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    4-4 COOLING SYSTEM Coolant Flow Chart
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    COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 2. Water Pump 3. Cylinder Jacket 4. Cylinder Head Jacket 5. Thermostat Housing 6. Thermostat Air Bleeder Bolt 7. Radiator Cap 8. Radiator 9. Oil Filter 10. Outlet Hose 11. Inlet Hose 12. Oil Cooler 13. Reserve Tank 14. Reserve Tank Hose 15.
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    4-6 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping: Type (recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50%
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    COOLING SYSTEM 4-7 Special Tool Bearing Driver Set: 57001–1129 Bearing Driver: 57001–382 Kawasaki Bond (Silicone Sealant): 56019–120
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    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection the left side cover • Removeinspect the coolant (seeinFrame chapter). [A] the reserve tank. • Visually[B] Front If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or
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    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel Systema(DFI) chapter). and install • Remove the radiator cap,filler neck [B]. cooling system pressure tester [A] on the NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. up pressure in
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    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to Oil Pump Removal in the Engine Lubrication System chapter. Water Pump [A] Front [B] Water Pump Installation Oil Pump • Refer tochapter. Installation in the Engine Lubrication System Water Pump Inspection drainage • Check thepump
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    COOLING SYSTEM 4-11 Water Pump seal, oil seal, and O • Be sure to replace the mechanicalparts will be damaged -ring with new ones because these • • • • by removal. Apply plenty of high temperature grease to the oil seal lips. Apply oil to the outer circumference of the oil seal. Press the oil seal
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    4-12 COOLING SYSTEM Radiator Radiator Removal WARNING The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS
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    COOLING SYSTEM 4-13 Radiator necessary, • IfRadiator Fanremove: Bolts [A] Mounting Radiator Fan [B] Radiator Inspection • Check the radiator core.to air flow, remove them. If there are obstructions If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the
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    4-14 COOLING SYSTEM Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. pump the pressure tester • Watching the pressure gauge,the relief valve opens: the to build up the pressure until gauge
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    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: : Drain about 200 mL Coolant • Fuel Tank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt [A] Water Temperature Sensor Connector [B] Three Water Hoses [C] Remove the thermostat housing [D]. Front [E] • Remove the screws [A], take
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    4-16 COOLING SYSTEM Thermostat opening suspend the ther• To check valvecontainer temperature, raise the temperamostat [A] in a of water and ture of the water. ○The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the
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    COOLING SYSTEM 4-17 Hose and Pipes Hose Installation pipes, being careful to • Install the hoses andsharp bending, kinking, follow bending direction. Avoid flattening or twisting. Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. Wet the internal
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    4-18 COOLING SYSTEM Radiator Fan Switch, Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator Fan Switch Removal • Drain the coolant (see Coolant Change in the
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    ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Clean Air System............................... Air Suction Valve Removal........... Air Suction Valve
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    5-2 ENGINE TOP END Exploded View
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    ENGINE TOP END 5-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Air suction valve cover bolts 10 1.0 87 in·lb 2 Cylinder head cover bolts 10 1.0 87 in·lb 3 Camshaft cap bolts (L=45 mm) 12 1.2 104 in·lb 4 Camshaft cap bolts (L=40 mm) 12 1.2 104 in·lb 5 Cylinder head bolts (M10 new bolts) 54
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    5-4 ENGINE TOP END Exploded View
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    ENGINE TOP END 5-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Coolant Drain Plug (Cylinder) 10 1.0 87 in·lb 2 Exhaust pipe manifold holder nuts 17 1.7 12 3 Muffler body clamp bolts 17 1.7 12 4 Muffler body mounting bolts and nuts 34 35 25 5 Crankshaft sensor cover bolts 11 1.1 Remarks 95
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    5-6 ENGINE TOP END Specifications Item Clean Air System: Vacuum switch valve closing pressure: Camshafts: Cam height: Exhaust Inlet Camshaft journal, camshaft cap clearance Camshaft journal diameter Camshaft bearing inside diameter Camshaft runout Cylinder Head: Cylinder compression Open → Close 45
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    ENGINE TOP END 5-7 Specifications Item Valve/valve guide clearance (wobble method): Exhaust Inlet Valve seat cutting angle Valve seating surface: Width: Exhaust Inlet Outside diameter: Exhaust Inlet Valve spring free length: Exhaust Inlet Cylinder, Piston: Cylinder inside diameter Standard 0.09 ∼
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    5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge: 57001–221 Valve Seat Cutter, 32° 57001–1119 28: Valve Spring Compressor Assembly: 57001–241 Valve Seat Cutter, 32° 57001–1120 30: Piston Pin Puller Assembly: 57001–910 Valve Seat Cutter, 60° 57001–1123 30: Valve Seat Cutter, 45°
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    ENGINE TOP END 5-9 Special Tools and Sealant Valve Spring Compressor Adapter, 57001–1202 22: Valve Seat Cutter Holder, 57001–1330 4.5: Spark Plug Wrench, Hex 16: 57001–1262 Valve Guide Reamer, 57001–1333 Fork Oil Level Gauge: 57001–1290 Valve Seat Cutter, 60° 57001–1334 Compression Gauge Adapter,
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    5-10 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: (see Fuel System (DFI) chapter) Fuel Tank Connector [A] (from Clamp [B]) Air Suction Valve Cover Bolts [C] and Clamp Air Suction Valve Cover [D] Air Suction Valve Air Suction Valve Installation air suction valve [A] • Install
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    ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Test • Remove: (see Fuel System (DFI) chapter) Fuel Tank • Vacuum Switch Valve Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001–1290 Air Flow [C] the
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    5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: (see Fuel System (DFI) chapter) Fuel Tank Vacuum Switch Valve and Hoses Stick Coils (see Electrical System chapter) Air Suction Valve Covers [A] • Remove the cylinder head cover bolts [A] and take off the cover. Cylinder
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    ENGINE TOP END 5-13 Cylinder Head Cover • Install the washer [A] with the metal side faces upward. • Tighten: Torque - Cylinder Head Cover Bolts [B]: 10 N·m (1.0 kgf·m, 87 in·lb)
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    5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the
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    ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: (see Fuel System (DFI) chapter) Fuel Tank Stick Coils (see Electrical System) Cylinder Head Cover (see Cylinder Head Cover Removal) Pickup Coil Cover #1, 4 • Position the crankshaft4atPistonspiston TDC. [A] TDC mark for #1, [B]
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    5-16 ENGINE TOP END Camshaft, Camshaft Chain cam parts and journals. • Apply engine oil to all be used, apply a thin coat of molybIf a new camshaft is to • denum disulfide grease to the cam surfaces. NOTE ○The exhaust camshaft has a 030 EX mark [A] and the inlet camshaft has a 030 IN mark [B]. Be
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    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove: Chain Guide Camshaft • • • Camshaft Cap Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. Measure each clearance between the camshaft
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    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankshaft/Transmission chapter). • Remove the camshaft chain [A] from the crankshaft sprocket.
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    ENGINE TOP END 5-19 Cylinder Head Cylinder Compression Measurement NOTE ○Use the battery which is fully charged. up the engine • Warmthe engine. thoroughly. Stop • Remove: • Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Stick Coils Spark Plugs Owners Tool - Spark Plug Wrench,
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    5-20 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Cooling System chapter). • Remove: Pipes (see Exhaust Pipe Removal) Exhaust Coolant Drain Bolt [A] (cylinder) • Remove: Head Cover (see Cylinder Head Cover ReCylinder moval) Camshaft Position Sensor (see Electrical
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    ENGINE TOP END 5-21 Cylinder Head • Install: Camshaft Chain Guide [A] Front • O-ring [B] Collar [C] Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) • Install: Camshaft Chain Guide
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    5-22 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the
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    ENGINE TOP END 5-23 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installation. the area • Heat°C (248 ∼around the valve guide hole to about 120 ∼ 150 302 °F). Drive the valve guide in from the top of the head using the • valve guide arbor. The flange stops the
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    5-24 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). the valve [B] valve seating • Check the seat [C]. surface [A] between and valve ○Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small,
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    ENGINE TOP END 5-25 Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. 3. Do not
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    5-26 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range. Widened Width [A] of engagement by machining with 45° cutter
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    ENGINE TOP END 5-27 Valves If the seat width is too wide, make the 60° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 60° angle until the seat width is within the specified range. ○To make the 60° grind,
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    5-28 ENGINE TOP END Valves
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    ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Head (see Cylinder Head Removal) Cylinder • Water Hose [A] Remove the cylinder [B]. Cylinder Installation NOTE ○If a new cylinder is used, use new piston ring. the pins [A] • Install engine oil toand new cylinder gasket [B]. the
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    5-30 ENGINE TOP END Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001–910 [A] • Remove the pistons. the ring opening your thumbs and • Carefully spreadthe opposite side ofwith ring [A] to remove then push up on the • it. Remove the 3-piece oil ring with
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    ENGINE TOP END 5-31 Cylinder, Pistons NOTE ○If a new piston is used, use new piston ring. the piston with its hollow facing • Installnew piston pin snap ring into theforward.the piston side of Fit a • so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○Apply
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    5-32 ENGINE TOP END Cylinder, Pistons Piston Ring Groove Width groove width. • Measure the piston ringseveral points around the piston. caliper at ○Use a vernier Piston Ring Groove Width Standard Top [A] 0.83 ∼ 0.85 mm (0.0327 ∼ 0.0335 in.) 0.82 ∼ 0.84 mm Second [B] (0.0323 ∼ 0.0331 in.) Service
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    ENGINE TOP END 5-33 Throttle Body Holder Throttle Body Holder Installation install • Be sure toclampsthe O-rings [A]. so that its hole fit on [B] as shown • Install the [C] of the holder. and the projection • Tighten: Torque - Throttle Body Holder Bolts [D]: 12 N·m (1.2 kgf·m, 104 in·lb) Throttle
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    5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Muffler Body Removal • Remove:Body Clamp Bolts [A] Muffler Muffler Body Mounting Bolts [B] Muffler Body [C] Exhaust Pipe Removal • Remove:Body
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    ENGINE TOP END 5-35 Muffler ○Install the muffler body clamp bolts as shown. [L] Upper Side [M] Inside [N] Connection Part Detail up the engine, wait until the • Thoroughly warmretighten all the bolts and nuts. engine cools down, and
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    CLUTCH 6-1 Clutch Table of Contents Exploded View........................................................................................................................ Specifications
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    6-2 CLUTCH Exploded View
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    CLUTCH 6-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Clutch lever clamp bolts 7.9 0.8 69 in·lb 2 Clutch cover bolts (L = 32 mm) 11 1.1 95 in·lb 3 Clutch cover bolts (L = 45 mm) 11 1.1 95 in·lb 4 Clutch cover bolts (L = 30 mm) 11 1.1 95 in·lb 5 Clutch cover bolts 11 1.1 95 in·lb 6 Oil
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    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) - - - Clutch plate assembly 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 in.) - - - Friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.4 mm (0.094 in.) Friction and steel plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012
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    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: 57001–143 Clutch Holder: 57001–1243 Kawasaki Bond (Silicone Sealant): 56019–120
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    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Adjust Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Adjust Inspection in the Periodic Maintenance chapter. Cable Removal • Slide the dust cover [A] at
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    CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Remove:Oil (drain, see Engine Oil Change section in the Engine Periodic Maintenance chapter) Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B] Clutch Cable Bracket [C] release lever [A] toward • Turn thethe clutch cover [B]. the rear as shown,
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    6-8 CLUTCH Clutch Cover [A] • Fit the springfrom as shown. [B] Viewed Rear [C] Release Shaft [D] Clutch Cover Clutch Cover Disassembly • Remove: [A] Oil Seal Needle Bearings • Remove:[A] Circlip Special Tool - Inside Circlip Pliers [B]: 57001–143 • Remove: Gauge [C] Oil Level Clutch Cover Assembly
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    CLUTCH 6-9 Clutch Clutch Removal • Remove:Oil (drain, see Engine Oil Change section in the Engine Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) • Remove: Plates, Steel Plates
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    6-10 CLUTCH Clutch ○Install the spacer [A] so that the tapered side [B] faces inward. ○Install the washer [A] so that the OUT SIDE mark faces outward. ○Replace the clutch hub nut with a new one. ○Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001–1243 Torque -
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    CLUTCH 6-11 Clutch • Apply molybdenum disulfide grease to the pusher ends [A] and install the pusher [B]. the • Apply engine oil to[D]. needle bearing [C] and install it. Install the washer • of the clutch • Align the mark [A]clutch hub. spring plate [B] with the groove [C] of the • Install the
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    6-12 CLUTCH Clutch Clutch Plate Assembly Adjustment then re• Inspect the clutch plate assembly length, andwithin the steel plate(s) which brings the length place the • • specified range. Remove: Spring Bolts Spring Holders Springs Spring Plate Replace the following steel plate(s). Part No.
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    ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Engine Oil Flow
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    7-2 ENGINE LUBRICATION SYSTEM Exploded View
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    ENGINE LUBRICATION SYSTEM 7-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Oil filler plug 1.5 0.15 13 in·lb 2 Engine drain plug 20 2.0 14.5 3 Oil filter (cartridge type, P/No. 16097–1070) 26 2.7 20 EO, R 3 Oil filter (cartridge type, P/No. 16097–0002) 31 3.2 23 EO, R 4 Oil cooler
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    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart
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    ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Oil Passage Hole in Alternator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Filter 7. Oil Cooler 8. Oil Pressure Switch 9. Oil Pipe 10. Oil Pump 11. To Drive Shaft
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    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level
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    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Kawasaki Bond (Silicone Sealant): 56019–120 Oil Pressure Gauge Adapter, PT3/8: 57001–1233 Oil Filter Wrench: 57001–1249
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    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection the engine oil • Check that[B]
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    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove:Oil (drain, see Periodic Maintenance chapter) Engine Muffler (see Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] ○Remove the oil pipe [A], oil pressure relief valve [B] and oil screen [C] as necessary. Oil Pan Installation the
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    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection if the valve [A] smoothly when push• Check to see wooden or otherslidesrod, and
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    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Drain: (see Periodic Maintenance chapter) Coolant • Engine Oil (see Periodic Maintenance chapter) Remove: Water Hose [A] Water Pipe Fitting Bolts [B] Water Pipes [C] • Remove: Cover Bolts [A] Water Pump Clamp [B] Water Pump Cover [C] •
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    7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Fit the pin [A] of the oil pump cover [B] into the hole [C] in the crankcase. • Install:[A] Pins Water Pump Body [B] • Install: [A] and Bolt [B] Impeller • Tighten: Torque - Water Pump Impeller Bolt: 10 N·m (1.0 kgf·m, 87 in·lb) • Install:[C] Pins Water
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    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Removal • Remove:(see Clutch chapter) Clutch Oil Pan (see Oil Pan Removal) Circlip [A] and Washer [B] Oil Pump Drive Gear [C] Oil Pump Drive Gear Installation molybdenum disulfide oil solution • Apply[A] on the oil pump gear shaft [B].to
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    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: (see Periodic Maintenance chapter) Coolant • Engine Oil (see Periodic Maintenance chapter) Remove: Oil Filter (see Periodic Maintenance chapter) Water Hose [A] Oil Cooler Mounting Bolt [B] and Washer Oil Cooler [C] and Water Hose
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    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement oil passage • Remove the[B] to the plugplug, and attach the adapter [A] and gauge hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pressure Gauge Adapter, PT 3/8: 57001–1233 the engine and warm up
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    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove:Oil (drain, see Periodic Maintenance chapter) Engine Switch Cover [A] Switch Terminal [B] Oil Pressure Switch [C] Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressure
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    ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Special Tools
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    8-2 ENGINE REMOVAL/INSTALLATION Exploded View
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    ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Adjusting collar locknut 49 5.0 36 S 2 Upper engine mounting bolts 44 4.5 32 S 3 Rear engine bracket bolts 25 2.5 18 S 4 Front engine bracket bolts 44 4.5 32 S 5 Middle engine mounting nut 44 4.5 32 S 6
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    8-4 ENGINE REMOVAL/INSTALLATION Special Tools Carburetor Drain Plug Wrench, Hex3: 57001–1269 Engine Mount Nut Wrench: 57001–1450
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    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand [A]. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It
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    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Hose Clamp [A] (Loosen) Radiator Radiator Hose [B] Oil Cooler Water Hose Clamp [C] (Loosen) Oil Cooler Water Hose [D] Radiator Bolt [E] (Loosen) Radiator Bracket Bolt [F] • Disconnect Sensor Lead Connector (see Electrical
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    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Position Sensor Connector [A] Camshaft Injector Harness Connector [B] Coolant Reserve Tank [A] (see Cooling System chapter) Air Cleaner Housing Bolt [B] Vacuum Switch Valve Hose [C] • Remove: Switch Valve Tube [A] Vacuum Inlet
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    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation engine with a suitable stand [A]. • Support the[B] onto the suitable stand for engine balance. ○Put a plank • Remove: Left Engine Upper Mounting Bolts [A] Right and Front Engine Bracket Bolts [B] Front Engine Bracket [C] • Remove the
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    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation adjusting collar [A] • Using the HexagontoWrench, turn thebetween the engine counter clockwise mark the gap and flame adjusting collar. • Remove the drive chain [A] from the output shaft [B]. • Down the rear portion of the engine a little
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    8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation engine • Install theinstallingmounting bolts and nuts, following the specified sequence. ○First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○Second, insert the lower
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    ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○Ninth, temporarily install: Front Engine Bracket [A] Front Right Engine Mounting Bolt [B] ○Tenth, tighten the rear bracket bolts. Torque - Rear Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) ○Eleventh, tighten securely: Middle Engine
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    CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Crankcase Splitting............................ Crankcase Splitting
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    9-2 CRANKSHAFT/TRANSMISSION Exploded View
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    CRANKSHAFT/TRANSMISSION 9-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Breather plate bolts 10 1.0 87 in·lb L 2 Crankcase bolts (M9, L=81 mm) 42 4.3 31 MO,S 3 Crankcase bolts (M9, L=95 mm) 49 5.0 36 MO,S 4 Crankcase bolts (M8) 27 2.8 20 S 5 Crankcase bolts (M7) 20 2.0 14.5 S 6
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    9-4 CRANKSHAFT/TRANSMISSION Exploded View
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    CRANKSHAFT/TRANSMISSION 9-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Shift pedal mounting bolt 34 3.5 25 2 Gear positioning lever bolt 12 1.2 104 in·lb 3 Shift shaft return spring pin 29 3.0 22 L 4 Shift drum cam holder bolt 12 1.2 104 in·lb L 5 Footpeg bracket bolts 34 3.5 25 L
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    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankshaft, Connecting Rods: Connecting rod bend Standard Service Limit --- Connecting rod twist --- Connecting rod big end side clearance TIR 0.2/100 mm (0.008/3.94 in.) TIR 0.2/100 mm (0.008/3.94 in.) 0.58 mm (0.023 in.) 0.11 mm (0.0043 in.) 34.97
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    CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard TIR 0.02 mm (0.0008 in.) or less Crankshaft runout Crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.) main journal diameter: 32.984 ∼ 33.000 mm Crankshaft (1.2986 ∼ 1.2992 in.) Marking None 32.984 ∼ 32.992
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    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: 57001–135 Kawasaki Bond (Silicone Sealant): 56019–120 Bearing Puller Adapter: 57001–317 Kawasaki Bond (Silicone Sealant): 92104–1063
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    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). engine on a • Set thewhile parts areclean surface and hold the engine steady being removed. Remove: • Crankshaft Sensor (see Electrical System chapter) Clutch (see
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    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting liquid gasket to the breather plate mating • Applyto 1.5 mm (0.04 to 0.06 in.) thick, and thensurface [A] 1 install the breather plate. Sealant - Three Bond: 1207B non-permanent • Apply athe bolts [A]. locking agent to the threads and tighten Torque
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    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting gasket • Apply liquidhalf. [A] to the mating surface of the lower crankcase Sealant - Kawasaki Bond (Silicone Sealant): 92104–1063 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. • Fit the lower
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    9-12 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal Crankcase Splitting). • Split the crankcase (see[A]. the crankshaft • Remove Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts
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    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods grease outer sur• Applyofmolybdenum disulfidethe inner[A] to theof the conface the upper insert and surface necting rod big end. Apply molybdenum disulfide oil [B] to the inner surfaces of upper and lower bearing inserts. ○The molybdenum
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    9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution. • WARNING Clean
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    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are
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    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend the connecting rod big end bearing • Removethe connecting rod big end cap. inserts, and reinstall the connect• Select an arbor [A] ofinsertsame diameter as the connecting rod big end, and the arbor through the • • • ing
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    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [B] clearance with plastigage [A]. ○Tighten the big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○Do not move the
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    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 38.000mm ∼ 38.008mm (1.4961 ∼ 1.4964 in.) 38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: “
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    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear • Using a plastigage (press gauge) [A], measure the bearing insert/journal [B] clearance. NOTE ○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○Do not turn the
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    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods bearing inside diameter, • Measure the mainhalf in accordance with theand mark the upper crankcase inside diam- • eter. Crankcase Main Bearing Inside Diameter Marks : " " or no mark. Tighten the crankcase bolts to the specified torque (see
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    CRANKSHAFT/TRANSMISSION 9-21 Starter Motor Clutch Starter Motor Clutch Removal/Installation Rotor • Refer to the Alternatorchapter.Removal and Installation in the Electrical System Starter Motor Clutch Assembly install the one-way clutch • Be sureintothe holder recess [C]. [A] so that its flange
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    9-22 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal shift [B] on the shift • Mark [A] the position of thelater inlever same position. shaft it can be installed the so that • Remove: Bolt [C] Shift Lever Shift Lever • Remove: Bracket Bolts [A] Footpeg Muffler Mounting Bolt [B] Footpeg
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    CRANKSHAFT/TRANSMISSION 9-23 Transmission footpeg bracket [A]. • Install thenon-permanent locking agent Apply a • bracket bolts [B]. • Tighten: to the footpeg Torque - Footpeg bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffler Mounting Bolt and Nut [C]: 29 N·m (3.0 kgf·m, 22 ft·lb) • Install the
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    9-24 CRANKSHAFT/TRANSMISSION Transmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Collar and spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] • Collar [C] Bolt [D] Tighten: Torque - Gear Positioning Lever Bolt:
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    CRANKSHAFT/TRANSMISSION 9-25 Transmission Transmission Shaft Removal (see Crankcase Splitting). • Split the crankcaseshaft [A] and output shaft [B]. • Remove the drive Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place. drive • Install the half.
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    9-26 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001–135 [B] Bearing Puller Adapter: 57001–317 [C] • Discard the bearing. Transmission Shaft Assembly engine oil the sliding surfaces on the transmis• Applyshafts, gearstoand
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    CRANKSHAFT/TRANSMISSION 9-27 Transmission NOTE ○When the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [B] of the toothed washer [28]. ○Fit the steel balls
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    9-28 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (Top) Gear 7. Toothed Washer, 31 mm (1.22 in.) 8. Thrust Washer, 30 mm (1.18 in.) 9. Circlip 10. Circlip 11. Bushing 12. Bushing 13. Needle Bearing 14. Needle Bearing 15. Bearing Outer Race
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    CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Drum and Fork Installation the shift rods • Installare identical. [A], noting the groove position. The rods shortest ears [B] shaft • Position the one withthe center grooveon the drive drum and place the pin in in the shift [C]. ○The two forks [D] on
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    9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear the thickness of the • Measurewidth [B] of the gearshift fork ears [A], and meagrooves. sure the If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness
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    WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................................................................................................................ Specifications
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    10-2 WHEELS/TIRES Exploded View
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    WHEELS/TIRES 10-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Front axle clamp bolt 20 2.0 15 2 Front axle 127 13 94 3 Rear axle nut 127 13 94 G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant. Remarks
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    10-4 WHEELS/TIRES Specifications Item Wheels (Rims): Rim runout: Axial Radial Standard ----- Axle runout/100 mm (3.94 TIR 0.05 mm (0.0020 in.) or less in.) Wheel balance Balance weights Tires: Air pressure: (when cold) Front Tread depth: Front Rear 10 g (0.35 US oz) or less 10 g (0.35 US oz), 20 g
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    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: 57001–1129 Bearing Remover Head, 57001–1346 25 × Jack: 57001–1238 Bearing Remover Shaft, 57001–1377 13: 28:
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    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] • Loosen: Axle Clamp Bolt [A] Right Side Axle [B] • Raise the front wheel off the ground. Special Tool - Jack: 57001–1238 • Pull out the axle to the right and drop the front wheel out of the forks.
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    WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the axle. Torque - Front Axle: 127 N·m (13 kgf·m, 94 ft·lb) tightening the bolt the fork • Beforethe front fork upclampdownon or 5right frontallowleg, pump and 4 times to the right front fork leg to seat on the front axle. NOTE ○Put a block in front of the
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    10-8 WHEELS/TIRES Wheels (Rims) • Remove:Mounting Bolts [A] Caliper Caliper [B] • Remove the drive chain [A] from the rear sprocket toward the left. the rear • Movecaliper. wheel back and remove the wheel from the rear • Remove the rear wheel. CAUTION Do not lay the wheel on the ground with the
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    WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result. the drive • Adjustchapter). chain slack after installation (see Final Drive • Check the rear
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    10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. are 100 in.) [A] • Place the axle in V blocks that[B] on themm (3.94 a point apart, and set a dial gauge axle at halfway between the blocks. Turn [C]
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    WHEELS/TIRES 10-11 Wheels (Rims) (b) When the tire is on the rim. Pry [A] the balance weight off the rim flange using a regular tip screwdriver as shown in the figure. ○Insert a tip of the screwdriver between the tire bead [B] and weight blade [C] until the end of the tip reaches the end of the
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    10-12 WHEELS/TIRES Wheels (Rims) (0.71 oz), in• When required total weight exceeds 20 gflange USshown. stall balance weight at both sides of rim as Required Total Weight: g (US oz) One Side [A] Other Side [B] 20 (0.71) 10 (0.35) 10 (0.35) 30 (1.06) 20 (0.71) 10 (0.35) 40 (1.41) 20 (0.71) 20 (0.71)
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    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Periodic Maintenance chapter. Tire Inspection • Refer to the Tire Inspection in the Periodic Maintenance chapter. Tire Removal • Remove:(see Front Wheel Removal, Wheel • Rear Wheel
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    10-14 WHEELS/TIRES Tires valve in • Install a newvalve cap,the rim. the stem seal with a soap lubricate ○Remove the and water solution or rubber lubricant, and pull [B] the valve stem [A] through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum
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    WHEELS/TIRES 10-15 Tires [A] • Check to see that the rim lines rim on both sides of the tire sidewalls are parallel with the flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. Lubricate the rim flanges and tire beads. Install the valve core and inflate
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    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars • Coupling (out of rear hub) Grease Seals Circlips Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage
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    FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................................................................................................................ Specifications
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    11-2 FINAL DRIVE Exploded View
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    FINAL DRIVE 11-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Engine sprocket cover bolts 9.8 1.0 87 in·lb 2 Engine sprocket nut 127 13 94 3 Rear sprocket nut 59 6.0 43 4 Engine sprocket cover damper bolts 6.9 0.7 61 in·lb L 5 Speed sensor bolt 6.9 0.7 61 in·lb L 6 Rear axle nut 127
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    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain: Chain slack 20 ∼ 30 mm (0.8 ∼ 1.2 in.) 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) - - 323 mm (12.7 in.) Standard chain Make ENUMA - - - Type EK525UVXL2, Endless - - - Link 112 links - - - Sprockets: Rear sprocket warp
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    FINAL DRIVE 11-5 Special Tools Bearing Driver Set: 57001–1129 Jack: 57001–1238
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    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment Wheel
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    FINAL DRIVE 11-7 Drive Chain EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] it • Grind [A] pin head to make [B]flat. shown. Set cutting and riveting pin as • touches chain pin. • Screw pin
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    11-8 FINAL DRIVE Drive Chain • Set plate holder (A) [A] and plate holder (B) [B] on the body. holder (A) to link plate. • Fit plate holder by hand until plate holder (B) touches the Turn pin • other link plate. wrench clockwise • Turn pin holder byof plate holder (A).until two pins of link come
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    FINAL DRIVE 11-9 Drive Chain • Turn wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. for the other link pin. • Some work • After staking, check the staked area of the link pin for cracks. diameter [A] of the link pin and link • Measure the outside[B]. plates outside width
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    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove:Sensor [A] Connector Speed Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor • Flatten out the bended washer [A]. and washer. • Remove the engine sprocket nut [B] NOTE ○When loosening the engine sprocket
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    FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). CAUTION 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. • Remove
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    11-12 FINAL DRIVE Sprocket, Coupling the grease seal with a one. • Replace the grease seal so thatnew seal surface is flush Press in the • with the end of the hole. ○Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set : 57001–1129 Coupling Installation • Grease
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    FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection). [A] Worn Tooth (Engine Sprocket)
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    BRAKES 12-1 Brakes Table of Contents Exploded View................................... Specifications .................................... Special Tool ....................................... Brake Lever, Brake Pedal.................. Brake Lever Position Adjustment. Brake Pedal Position Inspection
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    12-2 BRAKES Exploded View
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    BRAKES 12-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Front caliper mounting bolts 25 2.5 18 2 Brake hose banjo bolt 25 2.5 18 3 Bleed valve 7.8 0.80 69 in·lb 4 Front caliper assembly bolts 22 2.2 16 5 Front brake pad pin bolt 17 1.7 12 6 Brake lever pivot bolt 1.0 0.10 9 in·lb 7 Brake
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    12-4 BRAKES Exploded View
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    BRAKES 12-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Rear master cylinder push lod locknut 18 1.8 13 2 Rear caliper mounting bolts 25 2.5 18 3 Brake hose banjo bolts 25 2.5 18 4 Bleed valve 7.8 0.80 69 in·lb 5 Rear master cylinder mounting bolts 25 2.5 18 6 Brake disc mounting bolts 27
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    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position 5-way adjustable (to suit rider) - - - Brake lever free play Non-adjustable - - - Pedal free play Non-adjustable - - - Pedal position About 47 mm (1.85 in.) below footpeg top - - - DOT4 - - - Brake
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    BRAKES 12-7 Special Tool Jack: 57001–1238
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    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever
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    BRAKES 12-9 Calipers Front Caliper Removal • Loosen the itbanjo bolt [A] at the brake hose lower end, and tighten loosely. mounting bolts [B], and detach the • Unscrew the caliperdisc. caliper [C] from the CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting
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    12-10 BRAKES Calipers Caliper Installation brake • Install the caliper andon eachhose lower end. with new the washers side of hose fitting ○Replace • ones. Tighten: Torque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf·m, 18 ft·lb) Caliper Mounting Bolts (Rear): 25 N·m (2.5 kgf·m, 18 ft·lb)
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    BRAKES 12-11 Calipers WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○Pull out the pistons by hand. the • Remove the dust seals [A] and fluid seals [B]. Remove bleed
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    12-12 BRAKES Calipers ones. • Replace the fluid seals [A] with new and install them into ○Apply brake fluid to the fluid seals, the cylinders by hand. Replace the dust seals [B] with new ones if they are damaged. ○Apply brake fluid to the dust seals, and install them into the cylinders by hand. •
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    BRAKES 12-13 Calipers Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) with a new one. •
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    12-14 BRAKES Calipers Caliper Piston and Cylinder Damage • Visually inspect the piston [A] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Front Caliper [B] Rear Caliper [C] Caliper Holder Shaft Wear The caliper body must slide smoothly on the
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    BRAKES 12-15 Brake Pads Front Brake Pad Removal • Remove: Bolts [A] Mounting • Remove: Bolt [A] Pad Pin Pad Spring [B] Brake Pads [C] Front Brake Pad Installation hand as • Push the caliper pistons in bystopperas far[A]. they will go. Apply silicone grease to the ring • Install: • Brake Pads Pad
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    12-16 BRAKES Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install: Pads Brake • Pad Pin Clip Install the caliper (see Caliper Installation). WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the
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    BRAKES 12-17 Master Cylinder Front Master Cylinder Removal brake • Disconnect the frontbolt [B] light switch connectors [A]. the banjo brake hose • Removemaster cylinder [C] to disconnect theRemoval/Infrom the (see Brake Hose • stallation). Remove the rear view mirror (see Steering chapter). the
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    12-18 BRAKES Master Cylinder Rear Master Cylinder Removal the brake hose banjo bolt [A] on the • Unscrew Brake Hose Removal/Installation). master cylinder (see the reservoir hose • Pull offfluid into a container. lower end [B], and drain the brake cylinder • Loosen the master pin [D]. mounting
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    BRAKES 12-19 Master Cylinder Rear Master Cylinder Disassembly NOTE ○Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position adjustment. • Remove the rear master cylinder (see Rear Master Cylinder Removal). dust cover • Slide thethe circlip. on the
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    12-20 BRAKES Brake Disc Brake Disc Removal Wheels/Tires • Remove the wheel (seebolts, and take chapter). the mounting off the disc. • Unscrew Brake Disc Installation brake • Install the out. disc on the wheel so that the marked side [A] faces locking agent to the threads of • Apply a non-permanent
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    BRAKES 12-21 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Maintenance chapter. Brake Line Bleeding • Refer to the Brake Line Bleeding in the Periodic Maintenance
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    12-22 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately with wet cloth. removing the brake hose, take care • When fluid on the painted or plastic parts. not to spill the brake
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    SUSPENSION 13-1 Suspension Table of Contents Exploded View........................................................................................................................ Specifications
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    13-2 SUSPENSION Exploded View
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    SUSPENSION 13-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb Front fork clamp bolts (Upper): ZR1000–A2 ∼ 13 1.3 113 in·lb Front fork clamp bolts (Lower) 20 2.0 15 Front fork clamp bolts (Lower): ZR1000–A2 ∼ 30 3.1 22 3 Front fork top plugs 35
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    13-4 SUSPENSION Exploded View
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    SUSPENSION 13-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Rear shock absorber nuts (upper and lower) 34 3.5 25 2 Swingarm pivot shaft nut 127 13 94 3 Swingarm pivot shaft locknut 98 10 72 4 Rocker arm nut 34 3.5 25 5 Tie-rod nuts 59 6.0 43 G: Apply or add grease. Remarks
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    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube outside diameter 41 mm (1.61 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound damper setting 1 turns out from the fully clockwise position (only right fork leg) Fork spring preload setting (Usable
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    SUSPENSION 13-7 Special Tools Oil Seal and Bearing Remover: 57001–1058 Fork Piston Rod Puller, M10 × 1.0: 57001–1298 Bearing Driver Set: 57001–1129 Front Fork Spring Compressor: 57001–1338 Jack: 57001–1238 Socket Wrench: 57001–1370 Front Fork Oil Seal Driver: 57001–1288 Hook Wrench: 57001–1539 Fork
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    13-8 SUSPENSION Front Fork Rebound Damping Force Adjustment (Only Right Fork Leg) the rebound damping force, • To adjust adjuster [A] on top of the rightturn the rebound damping front fork leg to the desired position. ○The standard adjuster setting for the average-build rider of 68 kg (150 lb) with
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    SUSPENSION 13-9 Front Fork Front Fork Removal (each fork leg) • Remove: (see Wheels/Tires chapter.) Front Wheel Front Fender (see Frame chapter.) Windshield and Bracket (see Frame chapter.) Inner Cover (see Frame chapter.) Fairing and Bracket (see Frame chapter.) Loosen the upper fork clamp bolts
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    13-10 SUSPENSION Front Fork Fork Oil Change the front fork • Remove spring preload(see Front Fork Removal). until adjuster [A] counterclockwise ○Turn the • the fully position. Unscrew the top plug [B] out of the inner tube. • Avoiding the pins [A], set the front fork spring compressor set [B] on
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    SUSPENSION 13-11 Front Fork fork oil • Drain thethe fork into a suitable container. Remove spring [A]. • Pump the piston rod [B] up and down at least ten times to ○ expel the oil from the fork. tube upright, • Hold the fork the way down.press the inner tube and the piston rod all • Pour in the type
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    13-12 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: Right fork leg 62 ± 2 mm (2.44 ± 0.08 in.) Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.) (from the top of the outer tube) NOTE ○Fork oil level may also be measured using the fork oil level gauge. Special Tool - Fork Oil
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    SUSPENSION 13-13 Front Fork the O-ring • Checkdamaged. on the top plug and replace it with a new one if right fork distance [C] between the • For the end [A] ofleg, check theand rebound damping adbottom the top plug juster [B] with a pair of vernier caliper. [C] 20 mm (0.79 in.) a • Holding the top
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    13-14 SUSPENSION Front Fork ○Holding the inner tube [A] by hand, pull the outer tube [B] several times to pull out the outer tube. tube bushing tube • Remove the innerwasherguideoil seal [D][A], outer inner guide bushing [B], [C], from the tube. Front Fork Assembly • Replace the following parts
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    SUSPENSION 13-15 Front Fork the cente ring • Install the cente ring plate on the cylinder unit. a set into Insert • the inner tube. plate and cylinder unit as • • Cylinder Unit [A] and Center Ring Plate [C] for Right Fork Leg Cylinder Unit [B] and Center Ring Plate [C] for Left Fork Leg Hold the
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    13-16 SUSPENSION Front Fork Spring Tension becomes shorter as it weakens, check its • Since a spring to determine its condition. [A] free length If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining
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    SUSPENSION 13-17 Rear Shock Absorber Rebound Damping Force Adjustment the rebound • To adjustadjuster [A] todamping force, turn the rebound damping the desired position. ○The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories 3/4 turns out of
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    13-18 SUSPENSION Rear Shock Absorber Special Tools - Hook Wrench: 57001–1539 [A] Spring Adjustment Adjuster Position 193.4 mm (7.61 in.) ↑ ↓ 183.4 mm (7.22 in.) Damping Force Weak ↑ ↓ Strong Setting Load Road Speed Soft Light Good Low ↑ ↓ Hard ↑ ↓ Heavy ↑ ↓ Bad ↑ ↓ High Rear Shock Absorber Removal
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    SUSPENSION 13-19 Rear Shock Absorber • Remove the shock absorber [A] from upside. Rear Shock Absorber Installation • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Inspection the rear shock absorber. • Removeinspect the following items. Visually •
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    13-20 SUSPENSION Swingarm Swingarm Removal • Remove the muffler bodies (see Engine Top End chapter.) • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001–1238 • Remove: (see Wheels/Tires chapter.) Rear Wheel Chain Cover (see Final Drive chapter.) Mud Guard (see Frame
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    SUSPENSION 13-21 Swingarm Swingarm Installation of grease ball bearing, needle bearings • Apply plentyseals, andto theplenty of grease to the grease and grease add • nipple. Install the collars [A]. ○Place the right collar [A] on the • • • stopper [B] inside the frame [C]. Insert the pivot shaft
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    13-22 SUSPENSION Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal and Bearing Remover: 57001–1058 [A] Swingarm Bearing Installation • Apply plenty of grease to the ball bearing and needle bearings. the • Install faceneedle bearings so that the manufacturer’s marks in.
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    SUSPENSION 13-23 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the muffler bodies (see Engine Top End chapter.) chapter.) • Remove the side stand (see Frame off the ground. Using the jack, raise the rear wheel • Special Tool - Jack: 57001–1238 • Squeeze the brake lever slowly and hold it with a band
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    13-24 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation grease of the needle bearings • Applylips, and to the insideto the grease nipple. and oil add grease seal • Tighten: Torque - Rocker Arm Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nut: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Nut:
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    STEERING 14-1 Steering Table of Contents Exploded View........................................................................................................................ Special Tools
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    14-2 STEERING Exploded View
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    STEERING 14-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Steering stem nut 27 2.75 20 2 Steering stem head bolt 108 11 80 3 Front fork clamp bolts (Upper) 8.8 0.90 78 in·lb Front fork clamp bolts (Upper): ZR1000–A2 ∼ 13 1.3 113 in·lb Front fork clamp bolts (Lower) 20 2.0 15 Front fork
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    14-4 STEERING Special Tools Steering Stem Nut Wrench: 57001–1100 Steering Stem Bearing Driver: 57001–1344 Bearing Driver Set: 57001–1129 Steering Stem Bearing Driver Adapter: 57001–1345 Jack: 57001–1238
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    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Maintenance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Maintenance chapter.
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    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: and Bracket (see Frame chapter.) Windshield Inner Cover (see Frame chapter.) Fairing and Bracket (see Frame chapter.) Front Wheel (see Wheels/Tires chapter.) Handlebar (see Handlebar Removal.) Steering Stem Head Bolt Plug Steering
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    STEERING 14-7 Steering Stem the bearing outer races • To remove[B], insert a bar [A] into the [C] pressed into the head pipe recesses [D] of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE ○If either steering stem bearing is damaged, it is recommended
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    14-8 STEERING Steering Stem • Apply grease the lower ball bearing [A] and install it onto the stem. • Apply grease to the upper ball bearing [B] and inner race [C]. [A] head • Install the stem andthrough the[C] on pipe and install the ball bearing [B] inner race it. Install the stem cap [D] and
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    STEERING 14-9 Steering Stem NOTE ○Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolts. Torque - Steering Stem Head Bolt : 108 N·m (11 kgf·m, 80 ft·lb) Front Fork Clamp Bolts (Upper): 8.8 N·m (0.90 kgf·m, 78 in·lb) 13 N·m (1.3 kgf·m, 113 in·lb):
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    14-10 STEERING Handlebar Handlebar Removal • Remove:Lever Assembly [A] Clutch • Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right Handlebar Switch Housing [D] Handlebar Holder Bolts [E] Remove the handlebar holders [F] and then pull out the handlebar [G]. cotter pins [A]. •
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    STEERING 14-11 Handlebar Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to remove the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (Adapter) [B] with a pair of spanners. Disassembly of this area is Not
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    FRAME 15-1 Frame Table of Contents Exploded View........................................................................................................................ Seats
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    15-2 FRAME Exploded View
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    FRAME 15-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Footpeg holder bolts 34 3.5 25 2 Muffler mounting nuts 29 3.0 22 3 Side stand bolt 44 4.5 33 4 Side stand switch bolt 8.8 0.9 78 in·lb G: Apply grease. Remarks
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    15-4 FRAME Exploded View
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    FRAME 15-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Windshield screws 0.35 ∼ 0.50 0.035 ∼ 0.050 3 ∼4 in·lb 2 Front fender bolts 3.9 0.4 34.7 in·lb Remarks L
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    15-6 FRAME Exploded View
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    FRAME 15-7 Seats Rear Seat Removal ignition switch key into the seat [A], • Insert thecounterclockwise, pulling up on lock rearturning the key the of the seat [B], and pulling the seat backward. WARNING The muffler surface is hot once the engine has been started. When operating the seat lock be
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    15-8 FRAME Side Covers Side Cover Removal the • Removeside bolt [A]. evenly outward to clear the stop• Pull the cover [B] pers. Side Cover Installation • Insert the tabs [A] into the holes [B]. • Install the bolt.
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    FRAME 15-9 Fairings Windshield Removal • Remove: Bolts [A] Windshield [B] Windshield Installation • Windshield Installation is the reverse of removal. Torque - Windshield Screw: 0.35 ∼ 0.50 N·m (0.035 ∼ 0.050 kgf·m, 3 ∼ 4 in·lb) Inner Cover Removal • Remove: Screws [A] (both side) Inner Cover Inner
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    15-10 FRAME Fairings • Remove:Mounting Bolts [A] (both side) Fairing Headlight Connectors Fairing Installation • Fairing installation is the reverse of removal. Faring Bracket Removal • Remove:(see Fairing Removal) Fairing Turn Signal Lights (see Electrical System chapter) Meter Unit [A] (see
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    FRAME 15-11 Seat Covers Seat Cover Removal • Remove: Seats Screws [A] • Push the central pin, and then remove the quick rivets [A]. the [A] of the seat cover • Pull thenfront portionsseat cover backward. outside [B], and remove the Seat Cover Installation • Installation is reverse of removal. • Put
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    15-12 FRAME Mud Guard Mud Guard Removal • Remove: (see Final Drive chapter) Chain Cover Bolt [A] Clamp [B] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Installation • Put the projections [A] into the grommets [B].
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    FRAME 15-13 Fenders Front Fender Removal • Remove: Clamps [A] Brake Hose • Bolts [B] (both side) Remove the front fender [C]. Front Fender Installation • Install the brake hose clamps to the front fender holes. Rear Fender Rear Removal • Remove: Seats Seat Cover Canister (California model only)
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    15-14 FRAME Fenders • Remove: [A] Quick Rivets Rear Fender Rear [B] Rear Fender Rear Installation • Put the projection [A] into the hole [B]. into the holes • Put the projections [A]of removal. [B]. Installation is reverse •
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    FRAME 15-15 Frame Cover Frame Cover Removal • Remove: Bolts [A] Frame Cover [B] (both side)
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    15-16 FRAME Battery Case Battery Case Removal • Remove: Seats • Seat Cover Rear Fender Assy Side Covers Battery Left Side Screw [A] (with reserver tank) Pull out the battery case [B] backward [C]. Battery Case Installation the battery • Putthe frame. case attachments [A] at the projections [B] on
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    FRAME 15-17 Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove:(both side) Muffler Exhaust pipe Side Stand Switch Bolt [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Installation the [B] • Apply grease
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    15-18 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
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    ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location.................................... Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Wiring Diagram (U.S.A. and Canada) Wiring
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    16-2 ELECTRICAL SYSTEM Fan Motor Inspection ................... Meter, Gauge, Indicator Unit.............. Meter Unit Removal ..................... Meter, Gauge Disassembly.......... Electronic Combination Meter Unit Inspection .......................... Switches and Sensors .......................
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    ELECTRICAL SYSTEM 16-3 Parts Location [A] Starter Lockout Switch [B] Camshaft Position Sensor [C] Radiator Fan Switch [D] Starter Motor [E] Alternator [F] Speed Sensor [G] Neutral Switch [H] Side Stand Switch [I] Water Temperature Sensor [J] Battery [K] Junction Box [L] Front Brake Light Switch [M]
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    16-4 ELECTRICAL SYSTEM Exploded View
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    ELECTRICAL SYSTEM 16-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Meter mounting screws 1.2 0.12 11 in·lb 2 Tail/brake light mounting screws 1.2 0.12 11 in·lb 3 License plate light mounting screws 1.2 0.12 11 in·lb 4 Front brake light switch screw 1.2 0.12 11 in·lb 5 Starter locknut switch
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    16-6 ELECTRICAL SYSTEM Exploded View
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    ELECTRICAL SYSTEM 16-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Water temperature sensor 25 2.5 18 2 Spark plugs 13 1.3 115 in·lb 3 Alternator lead holding plate bolts 11 1.1 95 in·lb 4 Starter motor mounting bolts 11 1.1 95 in·lb 5 Stator motor coil bolts 11 1.1 95 in·lb 6
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    16-8 ELECTRICAL SYSTEM Exploded View
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    ELECTRICAL SYSTEM 16-9 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Regulator/rectifier bolts 6.9 0.7 62 in·lb 2 Fuel level sensor bolts 6.9 0.7 62 in·lb 3 Side stand switch bolt 8.8 0.9 78 in·lb 4 Neutral switch 15 1.5 11 5 Speed sensor bolt 6.9 0.7 62 in·lb L 6 Speed sensor cover
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    16-10 ELECTRICAL SYSTEM Specifications Item Battery: Type Capacity Voltage Charging System: Type Alternator output voltage Stator coil resistance Charging voltage (regulator/rectifier output voltage) Ignition System: Crankshaft sensor resistance Crankshaft sensor peak voltage Camshaft Position
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    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: 57001–1394 Rotor Puller, M16/M18/M20/M22 × 1.5: 57001–1216 Flywheel Puller, M38 × 1.5: 57001–1405 Flywheel and Pulley Holder: 57001–1343 Rotor Holder: 57001–1543 Needle Adapter: 57001–1457 Lead Wire-Peak Voltage Adapter: 57001–1449
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    16-12 ELECTRICAL SYSTEM Wiring Diagram (U.S.A. and Canada)
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    ELECTRICAL SYSTEM 16-13 Wiring Diagram (U.S.A. and Canada)
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    16-14 ELECTRICAL SYSTEM Wiring Diagram (Australia)
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    ELECTRICAL SYSTEM 16-15 Wiring Diagram (Australia)
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    16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)
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    ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)
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    16-18 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)
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    ELECTRICAL SYSTEM 16-19 Wiring Diagram (Malaysia)
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    16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○Always check battery
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    ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B]
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    16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean
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    ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the ECU (Electronic Control Unit). Never reverse the connections of the battery, this could damage the ECU. • Remove:
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    16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] sealing the filler ports [B] until just before use. no peeling, • Check to see that there isthe battery. tears or holes in the seal sheet on the top of battery • Place thethe seal on a level surface. Remove sheet. •
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    ELECTRICAL SYSTEM 16-25 Battery seal [A] tightly the filler ports until the • Fit theare atcapssame levelinto the top of the battery. seal caps the as NOTE ○Do not hammer. Press down evenly with both hands. CAUTION Once you installed the seal caps after filling the battery, never remove it, nor add
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    16-26 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping–up No topping–up is necessary in this battery until it ends its life under normal use. Forcibly prying off the sealing plug to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn
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    ELECTRICAL SYSTEM 16-27 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if a sealed
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    16-28 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.6 V Standard Charge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery Terminal Voltage (V) [A] Charge Time (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do
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    ELECTRICAL SYSTEM 16-29 Charging System Alternator Cover Removal • Remove:Cover Bolts [A] Frame Left Frame Cover [B] Clamp (open) [A] Alternator Lead Connector [B] For California model, remove the separator. ○ container under • Place a suitable cover bolts [B]. the alternator cover [A], and remove
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    16-30 ELECTRICAL SYSTEM Charging System Stator Coil Installation a • Applyandnon-permanent locking agent to the stator coil tighten it. bolts Torque - Stator Coil Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) the alternator • Secure the bolt. tighten lead with a holding plate, and ○Apply a non-permanent
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    ELECTRICAL SYSTEM 16-31 Charging System gear [A]. • Install the starter crankshaft tapered portion [B] and dry Again, clean the • there. woodruff key • Fit thebefore installing[C] securely in the slot in the crankshaft the alternator rotor. • Install the alternator rotor [A] while turning [B] the
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    16-32 ELECTRICAL SYSTEM Charging System a disulfide grease • Apply[A],thin coat of molybdenum idle gear [B]. to the shaft and install it and starter • Install the alternator cover (see Alternator Cover Installation). Alternator Inspection There are three types of alternator failures: short, open
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    ELECTRICAL SYSTEM 16-33 Charging System • If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. Using the
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    16-34 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test: ○Connect the test light and the 12 V battery to the regulator/rectifier as shown. ○Check BK1, BK2, and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If the
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    ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection the battery condition (see Battery section). • Check up the engine to obtain actual alternator operating • Warm conditions. seats (see Frame chapter). • Remove thethe ignition switch is turned off, and connect Check that • the hand
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    16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. To Starter Circuit Relay 3. Alternator 4. Regulator/Rectifier 5. Joint Connector C 6. Battery 12 V 8 Ah 7. Main Fuse 30A 8. Load
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    ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical
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    16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation the crankshaft sensor lead correctly (see • Routeand Hose Routing in Appendix chapter). Cable, Wire, • Tighten: Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.6 kgf·m, 53 in·lb) sealant [A] to the • Apply silicone crankcase halves
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    ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Resistance: 375 ∼ 565 Ω range of the tester, measure • Using the highest resistancecrankshaft sensor leads and the resistance between the chassis ground. Any tester reading less than infinity (∞) indicates a short, necessitating replacement
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    16-40 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal • Remove: (see Fuel System (DFI) chapter) Fuel Tank Camshaft Position Sensor Lead Connector [A] (disconnect) ○Push the tongue [B] upside and take out the connector from the bracket. • Remove: Position Sensor Bolt [A] Camshaft
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    ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Position Sensor Peak Voltage Inspection • Remove: (see Fuel System (DFI) chapter) Fuel Tank • • Camshaft Position Sensor Lead Connector [A] (disconnect) Set the hand tester [B] to the 10 V DC range. Connect the peak voltage adapter [C] to the hand
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    16-42 ELECTRICAL SYSTEM Ignition System • Remove the stick coil harness [A] from the bracket. • Remove: Connector #4 [B] (disconnect) Stick Coil Stick Coil #4 [C] Stick Coil Connector #3 [D] (disconnect) • Disconnect: Water Temperature Sensor Connector [A] • Left Switch Housing Connector [B] Pull
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    ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see this chapter). as follows. the primary winding resistance • Measure the hand tester between the coil[A] terminals. ○Connect ○Set the tester to the × 1 Ω range,
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    16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. ignition switch and the engine stop • Turn the the starter button, turn the engine 4 switch ON. Pushing 5 • with the transmission in neutral to measure
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    ELECTRICAL SYSTEM 16-45 Ignition System Interlock Operation Inspection • Remove: Frame chapter) Seats (see Junction Box (see this chapter) ○Do not disconnect the connectors. 1st Check Measure the terminal voltage of the G/BK lead in the junction box connector [A] in accordance with the following
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    16-46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○The IC Igniter is built in the ECU [A]. the Interlock Operation Inspection, Ignition • Refer toTroubleshooting Chapter and Fuel System (DFI) System chapter for ECU Inspection.
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    ELECTRICAL SYSTEM 16-47 Ignition System
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    16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Stick Coils 6. Side Stand Switch 7. Crankshaft Sensor 8. Camshaft Position Sensor 9. Throttle Sensor 10. Neutral Switch 11. Junction Box 12. Ignition Fuse 10A
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    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. the mounting bolts • Removethe starter motor [B].[A]. • Pull out [A]. • Slide back the rubber cap terminal nut [B]. Remove the
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    16-50 ELECTRICAL SYSTEM Electric Starter System ○The brush plate [A] and brushes come off with the right–hand end cover [B]. [A] bolt [B], • Remove the terminal locknut the and terminal [C] from and then remove the brush with brush plate the right–hand end cover. Starter Motor Assembly brush plate
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    ELECTRICAL SYSTEM 16-51 Electric Starter System the • Align[B]. line [A] marked on the yoke with the through bolt hole Brush Inspection the [A] of each • Measureworn lengthto the servicebrush.replace the carbon If any is down limit, brush holder assembly [B] and the terminal bolt assembly [C].
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    16-52 ELECTRICAL SYSTEM Electric Starter System NOTE ○Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still
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    ELECTRICAL SYSTEM 16-53 Electric Starter System hand • Connect the [C] as tester [A] and 12 V battery [B] to the starter relay shown. Special Tool - Hand Tester: 57001–1394 If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: Criteria: × 1
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    16-54 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and have a headlight relay in the junction box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is
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    ELECTRICAL SYSTEM 16-55 Lighting System Headlight Bulb Replacement • Remove: Connector [A] Headlight Headlight Bulb Dust Cover [B] • Remove: Hook [A] Headlight Bulb [B] CAUTION When handling the quartz–halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil
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    16-56 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] with the arrow mark upward onto the bulb [B] firmly as shown. • Good [C] Bad [D] Arrow Mark [E] After installation, adjust the headlight aim (see this chapter). Headlight Removal/Installation • Remove:(see Frame chapter) Fairing
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    ELECTRICAL SYSTEM 16-57 Lighting System • Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. • Replace the bulb with a new one.
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    16-58 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit (US, CA, AS) Headlight/Tail Light Circuit (Other than US, CA, AS) US: United States of America CA: Canada AS: Australia 1. Ignition Switch 2. Meter Ground 3. Alternator 4. Headlight Diodes 5. Taillight Fuse 10A 6. Headlight Fuse
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    ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Light Circuit US: U.S.A. model CA: Canada model MY: Malaysia model 1. Joint Connector D 2. Meter Unit 3. Right Turn Signal Indicator Light (LED) 4. Left Turn Signal Indicator Light (LED) 5. Front Right Turn Signal Light 6. Front Left Turn Signal
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    16-60 ELECTRICAL SYSTEM Lighting System • Push and turn the bulb [A] counterclockwise and remove it. by aligning its upper and lower • Insert the new bulb [A]lower grooves [C] in the socket,pins [B] with the upper and and turn the bulb clockwise. ○Turn the bulb about 15° degrees. For the U.S.A. and
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    ELECTRICAL SYSTEM 16-61 Lighting System by aligning its upper and lower • Insert the new bulb [A]lower grooves [C] in the socket,pins [B] with the upper and and turn the bulb clockwise. CAUTION The front turn signal/running position lights use a vibration resistant bulb. Replacement of the front
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    16-62 ELECTRICAL SYSTEM Lighting System the bolts [A]. • Unscrewthe bolts [B]. Loosen • the mounting screws [A]. • Unscrew the tail/brake light (LED) [B]. Remove • Pull out the mount portion [C]. ○ Tail/Brake Light (LED) Installation • Tighten the tail/brake light mounting screws. Torque -
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    ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan System Circuit Inspection • Disconnect the lead connector [A] from the radiator fan switch. • Using an auxiliary wire [A], connect the radiator fan switch leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the
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    16-64 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Joint Connector A 4. Joint Connector D 5. Meter Ground 6. Frame Ground 7. Joint Connector B 8. Junction Box 9. Fan Fuse 10A 10. Main Fuse 30A 11. Battery 12 V 8 Ah
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    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: (see Frame chapter) Wind Sealed Slide the dust cover [A] and remove the wiring connector • [B]. the meter unit • Removethe washers. by taking off the mounting screws [C] with CAUTION Place the meter or gauge so that
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    16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A]. [1] Ignition [2] Fuel Reserve Switch [3] Unused [4] Fuel Level Sensor [5] Neutral Indicator Light (LED) Ground (–) [6] FI Indicator Light (LED) Ground (–) [7] Tachometer
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    ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit MODE AND RESET BUTTON Operation Check: Connect the 12 V battery and terminals in the same manner as specified in the "Liquid Crystal Display (LCD) Segments Check". Check that the display change to the ODO, TRIP, and CLOCK displays each time the
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    16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit HOUR setting mode, press • In the the MINUTE setting mode. the RESET button to effect ○The minute display flashes on the display. • Press the MODE button to set the minute. press • In the MINUTE setting mode, settingthe RESET button to return to
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    ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit • If the oscillator is not available, the speedometer can be checked as follows. ○Install the meter unit. ○Raise the rear wheel off the ground, using the jack. ○Turn on the ignition switch. ○Rotate the rear wheel by hand. ○Check that the
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    16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Water Temperature Meter Check: Connect the 12 V battery and terminals in the same manner as specified in the "Liquid Crystal Display (LCD) Segments Check". Connect the variable rheostat [A] to the terminal [8] as shown. Check that the number of
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    ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit Fuel Level Gauge Inspection: Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”. Connect a variable rheostat [A] to terminal [4] and [9] as shown. Check that the number of
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    16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • If the oscillator is not available, the tachometer can be checked as follows. ○Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Segments Check". ○Using an auxiliary wire, quick open
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    ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Right and Left Turn Signal Indicator Light (LED): For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14] High Beam
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    16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Right Turn Signal Indicator Light (LED) 2. High Beam Indicator Light (LED) 3. Neutral Indicator Light (LED) 4. Oil Pressure Warning Indicator Light (LED) 5. FI Indicator Light (LED) 6. Odometer/Trip Meter/Clock/Fuel Indicator 7.
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    ELECTRICAL SYSTEM 16-75 Switches and Sensors Brake Light Timing Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection hand to • Using a showntester, checkhavesee that only the
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    16-76 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the connector [A]. • Remove the fan switch [B]. a container coolant • Suspend the switch [A] inprojection andofthreaded so that the temperature–sensing portion • are submerged. Suspend an accurate thermometer [B] in the coolant so that the
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    ELECTRICAL SYSTEM 16-77 Switches and Sensors of that • Suspend the sensor [A] in a container andcoolant so porthe temperature-sensing projection [E] threaded • tion [E] are submerged. Suspend an accurate thermometer [B] in the coolant. NOTE ○The sensor and thermometer must not touch the container
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    16-78 ELECTRICAL SYSTEM Switches and Sensors • Remove: Bolts [A] Speed Sensor Cover • Remove: Bolt [A] Take out the speed sensor [B]. • sensor connector the battery • Connect the speed[C] and hand tester[A] withshown. [B], 10 kΩ resistor [D] as • Set the tester to the DC 25 V range. Special Tool -
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    ELECTRICAL SYSTEM 16-79 Switches and Sensors Fuel Level Sensor Inspection • Remove: (see Fuel System (DFI) chapter) Fuel Tank Open the clamps [A]. • Remove: • Bolts [B] Fuel Level Sensor [C] the float moves down smoothly • Check thatshould go downup and its own weight. without binding. It under If
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    16-80 ELECTRICAL SYSTEM Switches and Sensors test light [A] (12 V socket with • Connect thethe 12 V battery [B]3.4 W bulb alevel sensor leads) and to the fuel connector [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) → Blue Lead Terminal Battery (–) → BK/Y
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    ELECTRICAL SYSTEM 16-81 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box [A]. connectors box [B]. • Pull off the all connector[A] from
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    16-82 ELECTRICAL SYSTEM Junction Box Starter Circuit/Headlight Relay Inspection • Remove the junction box (see Junction Box Fuse Circuit Inspection). • Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the junction box as shown. ○Refer to
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    ELECTRICAL SYSTEM 16-83 Junction Box Diode Circuit Inspection • Remove the junction box.following pairs of terminals. • Check conductivity of the Diode Circuit Inspection Tester Connection 13–8, 13–9, 12–11, 12–14, 15–14, 16–14 The resistance should be low in one direction and more than ten times
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    16-84 ELECTRICAL SYSTEM Fuse 30A Main Fuse Removal • Remove: Cover (see Frame chapter) Right Side • 30A Main Fuse Connector [A] Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse Removal the seats Frame • Removethe hook to(seeup the lidchapter). Unlock lift
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    APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. Troubleshooting Guide ...........................................................................................................
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    17-2 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Fixes by the left side clamp of the tank. 2. Tank drain hose passes the side cover installation under the bracket. 3. Air cleaner drain hose 4. Fuel tank drain hose 5. Cooling reserve tank hose 6. Fixes by the swingarm clamp 7. Fuel level sensor 8.
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    17-4 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch cable 2. Meter ground 3. Clamp (Ignition switch connector) 4. Ignition switch connector 5. Inlet air pressure sensor 6. To ignition coil 7. Fan motor connector (Connect the connector on the inlet air pressure sensor.) 8. Clamp 9. To fuel pump
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    17-6 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Ignition switch connector 4. Meter ground (with thermostat) 5. Engine harness (Connect the harness on the cross pipe.) 6. Water
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    17-8 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Tail light 2. Clamp 3. Atmospheric pressure sensor 4. To ECU fuse 5. Junction Box 6. To self-diagnosis indicator terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10. To inlet air temperature
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    17-10 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp all the wires as shown in the encircled area. 2. Meter 3. Take out the lead of the meter from the right side of the tie lap to connect with the meter. 4. Clutch cable 5. Starter cable 6. To front left turn signal light (Run the harness above the
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    17-12 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Clamp 2. Brake hose 3. Punch mark 4. Run the brake hose through the inside of the frame. 5. Tight the bolt to the specified torque with the stopper (for turning prevention) applied.
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    17-14 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head to secure the coupler.) 2. Radiator fan switch lead (Run the lead through into the water hose.) 3. Cap 4. Catch cable (Run the cable through forward the water hose.) 5.
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    17-16 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Run the lead end till it touches the boss of the crankcase. 4. Install the exterior of the lead with staking area facing downward.
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    17-18 APPENDIX Cable, Wire, and Hose Routing
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    APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Run the hose (cap – reserve) through upside of the throttle cable. 2. Run the hose (white) through into the throttle cables. 3. Run the throttle body harness throttle upside of the hose (white) and hose (throttle – fitting). 4. Run the harness through
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    17-20 APPENDIX Troubleshooting Guide NOTE ○Refer to the Fuel System chapter for most of DFI trouble shooting guide. ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common
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    APPENDIX 17-21 Troubleshooting Guide Air cleaner duct loose Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head warped Cylinder
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    17-22 APPENDIX Troubleshooting Guide Muffler overheating: For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running (Request the nearest service facility to correct it) For KLEEN, do not push-start with a dead battery (Connect another full-charged battery with jumper
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    APPENDIX 17-23 Troubleshooting Guide Abnormal Engine Noise: Knocking: IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston
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    17-24 APPENDIX Troubleshooting Guide Handling and/or Stability Unsatisfactory: Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent
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    MODEL APPLICATION Year Model 2003 ZR1000–A1 2004 ZR1000–A2 Beginning Frame No. JKAZRCA1□3A000001 ZRT00A–000001 JKAZRT00AAA000001 JKAZRCA1□ 4A015001 JKAZRT00AAA015001 ZRT00A–015001 □:This digit in the frame number changes from one machine to another. Part No.99924-1310-03 Printed in Japan
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